Beruflich Dokumente
Kultur Dokumente
INTRODUCTION
Mymensingh Power Station
Rural Power Company Limited (RPCL)
context the river water has significantly reduced and as a result the barge plant is now hard to be
differentiated from a land one. In the year 2000, the Phase - II was commissioned with capacity of
another 70 MW (2x35 MW Gas turbine). And to utilize the waste gas rather than to leave it to the
atmosphere, a 70 MW steam turbine was commissioned in the year 2007.
Table.1 Phases of MPS
Phase
Commissioning year
Type
Capacity
Phase I
1999
Gas Turbine
35 x 2 = 70 MW
Phase II
2000
Gas Turbine
35 x 2 = 70 MW
Phase III
2007
Steam Turbine
70 MW
Gas Turbine
Generators
ABB, Sweden
Plant design includes multiple layers of backup control levels to ensure high availability.
Plant Control is state of art with computerized generation control and a complete
monitoring system of all significant data.
Steam Turbine
Generator
Boiler (HRSG)
Organogram
Plant Manager
HR & Administration Division
SSI division
Deputy Plant Manager
Operation
Division
Mechanical
Maintenance
Division
Electrical
Maintenance
Division
I&C
Maintenance
Project
Division
Division
Manager (1)
Chapter
GAS TURBINE
A package power plant, as furnished for most installations, is comprised of the single shaft, simple
cycle and heavy duty gas turbine unit driving a generator. Fuel and air are used by the gas turbine
unit to produce the shaft horsepower necessary to drive certain accessories and ultimately the
driven load generator.
The turbine unit is composed of a starting device, support systems, an axial flow compressor,
combustion system components, a three stage turbine. Both compressor and turbine are directly
connected with an in line single-shaft rotor supported by two pressure lubricated bearings. The
inlet end of the rotor shaft is coupled to an accessory gear having integral shaft that drive the fuel
pump, lubrication pump and other system components.
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turbine buckets. In each nozzle row, the kinetic energy of the jet is increased, with an associated
pressure drop, and in each following row of moving buckets, a portion of the kinetic energy of the
jet is absorbed as useful work on the turbine rotor. After passing through the 3rd stage buckets, the
exhaust gases are directed into the exhaust hood and diffuser which contains a series of turning
vanes to turn the gases from the axial direction to a radial direction, thereby minimizing exhaust
hood losses. Then, the gases pass into the exhaust plenum. The resultant shaft rotation is used to
turn the generator rotor, and drive certain accessories. By definition, the air inlet of the gas turbine
is the forward end, while the exhaust end is the aft end. The forward and aft ends of each
component are determined in like manner with respect to its orientation within the complete unit.
The RIGHT and LEFT sides of the turbine or of a particular component are determined by standing
forward and looking aft.
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(a)
(b)
(c)
Fig. 2.2 Conical cylindrical filter (a) one unit (b) assembly (c) pocket filter
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Inlet casing
These sections, in conjunction with the turbine shell and exhaust frame form the primary structure
of the gas turbine. They support the rotor at the bearing points and constitute the outer wall of the
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gas path annulus. The casing bore is maintained to close tolerances with respect to the rotor blade
tips for maximum efficiency.
The inlet casing is located at the forward end of the gas turbine. Its prime function is to uniformly
direct air into the compressor. The inlet casing also supports the n 1 bearing housing, a separate
casting that contains the n 1 bearing. The n 1 bearing housing is supported in the inlet casing on
machined surfaces on either side of the inner bell mouth of the lower half casing. To maintain axial
and radial alignment with the compressor rotor shaft, the bearing housing is shimmed, doweled
and bolted in place at assembly.
The inner bell mouth is positioned to the outer bell mouth by eight airfoil-shaped radial struts that
provide structural integrity for the inlet casing. The struts are cast into the bell mouth walls.
2.3.3 Variable inlet guide vanes:
Variable inlet guide vanes are located at the aft end of the inlet casing. The position of these vanes
has an effect on the quantity of compressor air flow. Movement of these guide vanes is
accomplished by the inlet guide vane control ring that turns individual pinion gears attached to the
end of each vane. The control ring is positioned by a hydraulic actuator and linkage arm assembly.
to this compressor casing's forward flange. The forward compressor casing is equipped with two
large integrally cast trunnions which are used to lift the gas turbine when it is separated from its
base.
2.3.5 Aft casing:
The aft compressor casing contains the fifth through tenth compressor stages. Extraction ports in
the casing permit removal of 5th and 11th stage compressor air. This air is used for cooling and
sealing functions and is also used for starting and shutdown pulsation control.
2.3.6 Discharge casing:
The compressor discharge casing is the final portion of the compressor section. It is the longest
single casting. It is situated at the midpoint between the forward and aft supports and is, in effect,
the keystone of the gas turbine structure.
The functions of the compressor discharge casings are to contain the final seven compressor stages,
to form both the inner and outer walls of the compressor diffuser and to join the compressor and
turbine stators. They also provide support for n 2 bearing, the forward end of the combustion
wrapper, and the inner support of the first-stage turbine nozzle. The compressor discharge casing
consists of two cylinders, one being a continuation of the compressor casings and the other being
an inner cylinder that surrounds the compressor rotor. The two cylinders are concentrically
positioned by twelve radial struts. These struts flair out to meet the larger diameter of the turbine
shell, and are the primary load bearing members in this portion of the gas turbine stator. The
supporting structure for bearing is contained within the inner cylinder. A diffuser is formed by the
tapered annulus between the outer cylinder and inner cylinder of the discharge casing. The diffuser
converts some of the compressor exit velocity into added pressure.
2.3.7 Blading:
The compressor rotor and stator blades are airfoil shaped and designed to compress air efficiently
at high blade tip velocities. The blades are attached to their wheels by dovetails arrangements.
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The dovetail is very precise in size and position so as to maintain each blade in the desired
position and location on the wheel.
liners,
Flow sleeves,
Transition pieces
Flame detectors,
Hot gases, generated from burning fuel in the combustion chambers are used to drive the turbine.
In the reverse flow system, high pressure air from the compressor discharge is directed around the
liner wall and impinges against rings that are brazed to the liner wall. This air then flows right
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toward the liner discharge end and forms a film of air that shields the liner wall from the
combustion gases. Fuel is supplied to each combustion chamber through a nozzle. Combustion
chambers are numbered counterclockwise when viewed looking down stream and starting from
the top of the machine. The ten combustion chambers are interconnected by means of crossfire
tubes. These tubes enable flame from fired chambers containing spark plugs to propagate to the
unified chambers.
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maintaining alignment between the turbine and the generator. The support legs maintain the axial
and vertical positions of the turbine, while a key coupled with the turbine support legs maintains
its lateral position.
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The three stage turbine buckets are attached to their wheels by straight, axial entry, multiple tang
dovetails that fit into matching counts in the rims if the turbine wheels. The turbine rotor assembly
is arranged so that the buckets can be replaced without unstacking the wheels, spacers and wheel
shaft assemblies.
In the turbine section, there are threestages of stationary nozzles which direct the highvelocity flow
of the expanded hot combustion gas against the turbine buckets, causing the rotor to rotate. Because of
the high pressure drop across these nozzles, there are seals at both the inside diameters and the outside
diameters to prevent loss of system energy by leakage. Since these nozzles operate in the hot combustion
gas flow, they are subjected to thermal stresses in addition to gas pressure loadings.
First stage nozzle: The firststage nozzle receives the hot combustion gases from the
combustion system via the transition pieces. The transition pieces are sealed to both the outer and
inner sidewalls on the entrance side of the nozzle minimizing leakage of compressor discharge
air into the nozzle. The 18 cast nozzle segments, each with two partitions (or airfoils) are contained
by a horizontally split retaining ring which is center line supported to the turbine shell on lugs at
the sides and guided by pins at the top and bottom vertical center lines. This permits radial growth of
the retaining ring, resulting from changes in temperature while the ring remains centered in the
shell. The aft outer diameter of the retaining ring is loaded against the forward face of the first
stage turbine shroud and acts as the air seal to prevent leakage of compressor discharge air
between the nozzle and shell. On the inner sidewall, the nozzle is sealed by U shaped seal
segments installed between the nozzle and the first stage nozzle support ring bolted to the
compressor discharge casing. The nozzle is prevented from moving forward by four lugs welded
to the aft outside diameter of the retaining ring at 45 degrees from vertical and horizontal center
lines. These lugs fit in a groove machined in the turbine shell just forward of the first stage shroud
Thook. By removing the horizontal joint support block and the bottom center line guide pine,
the lower half of the nozzle can be rolled out with the turbine rotor in place. The first stage
nozzle partitions are internally cooled by compressor discharge air.
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pins from the shell into axial slots in the nozzle outer side-wall. The second stage nozzle
partitions are cooled with compressor discharge air.
Thirdstage nozzle :
The thirdstage nozzle receives the hot gas as it leaves the second stage buckets, increases its
velocity by pressure drop and directs this flow to impinge against the third stage buckets. The
nozzle consists of 16 cast segments, each with four partitions (or airfoils). It is held at the outer
sidewall forward and aft sides in grooves in the turbine shrouds in a manner identical to that
used on the second stage nozzle. The third stage nozzle is circumferentially positioned by radial
pins from the shell.
the wide range required under turbine starting and operating conditions. The fuel gas control valve is
activated by a SPEEDTRONIC control signal to admit the proper amount of fuel required by the
turbine for a given load or speed.The gas control valve part of the gas stop/ratio and control valve
provides a gas fuel metering function to the turbine in accordance with its speed and load requirements.
The position of the gas control valve (hence fuel gas flow to the turbine) is a linear function of a variable
control voltage (FSR) generated by the SPEEDTRONIC control. The control voltage generated acts to
shift the electrohydraulic servo valve to admit oil to or release it from the hydraulic cylinder to position
the gas control valve so that the fuel gas flow is that which is required for a given turbine speed and a
load situation.
The gas stop ratio valve is similar to the gas control valve. Its plug, however, has a steeper taper to
provide the high gain necessary to maintain good pressure control. The ratio function of the stop ratio
valve provides a regulated inlet pressure for the control valve as a function of turbine speed. The
SPEEDTRONIC pressure control loop generates a position signal to position the stop ratio valve by
means of a servo valve controlled hydraulic cylinder to provide required intervalve pressure.
The gas stop ratio valve functions in the fuel gas system to provide a positive fuel shutoff when required
by either normal or emergency conditions. A gas fuel trip valve is operated by trip oil pressure acting
on the piston end of a spool. When the trip oil pressure is normal the gas fuel trip valve VH 5 is held
in a position that allows hydraulic oil to flow between the control servo valve and the hydraulic cylinder.
In this position, normal control of the stop ratio valve is allowed. In event of a drop in trip oil pressure
below a predetermined limit, a spring in the trip valve shifts the spool to interrupt the flow path of oil
between the control servo valve and the hydraulic cylinder. Hydraulic oil is dumped and the stop ratio
valve closes, shutting off fuel gas flow to the turbine.
2.6.3 The cooling and sealing air system:
Provides the necessary air flow from the gas turbine compressor to other parts of the gas turbine
rotor and stator to cool these parts during normal operation. When the gas turbine is operating, air
is extracted from the two stages of the axial flow compressor as well as from the compressor
discharge. It is used to provide the following cooling and sealing functions:
Specially designed air passages are fabricated in the turbine casing, turbine nozzles and rotating
wheels. Functional description Air extracted from the fifth stage and eleventh stage of the axial
flow compressor and from the compressor discharge is used for sealing the bearings and cooling
internal turbine parts. It is also used after filtration to provide a clean air supply for air-operated
control valves of other systems. Bearing sealing air is extracted from the fifth and eleventh stage
of the compressor. Internal cooling air, identified as sixteenth-stage extraction air, is extracted
from the compressor discharge. It provides an internal flow of cooling air through the center of the
turbine rotor. Air used as the operating air supply for the air-operated extraction valves is extracted
from the discharge of the compressor. Besides, two motor driven centrifugal blowers mounted
external to the turbine itself, supply cooling air for the turbine shell, then the exhaust frame and its
support struts, and the aft side of the third stage turbine wheel.
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Chapter
20
Heat recovery steam generator or HRSG is an energy recovery heat exchanger that recovers heat
from a hot gas stream. They can be operated in either Co-generation mode or the combined cycle
mode. In the Co-generation mode, steam produced from the HRGS is mainly used for process
application, whereas in combined cycle mode, power is generated via steam generator. In the
combined cycle mode, the efficiency of the combined gas turbine and HRSG system can reach
55%-60%. Heat Recovery Steam Generator (HRSG) boiler is very useful to improve efficiency of
fuel that is used in gas turbine unit, which will further drive steam turbine unit.
Fig.3.1 Exhaust gases from the gas turbine passes through the HRGS to produce steam
Figure 3.1 shown above describes the basic process of steam and Power generation. The HRGS
generates steam utilizing the energy in the exhaust from the gas turbine.
In a Combined Cycle power plant Gas turbine and Steam turbine is used for power production.
Steam turbine uses steam to produce power. HRGS is the major parts of the steam system. It is
used to produce steam.. It produces steam that can be used to drive a steam turbine. The exhaust
gas temperature from a Gas Turbine is about 580 C.
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Super Heater
Evaporator
Economizer
Pre-heater
Drum
3.1.4 Pre-heater
Pre-heater is one of HRSG components that serves as initial heater of water which is pumped
from condenser before enter into feed water tanks. In the HRSG system, pre-heater serves to raise
temperature before enter feed water tanks which later will be forwarded to economizer.
(a)
(b)
(c)
The power plant has 4 heat recovery steam generator. Each Heat recovery steam generator
produces two types of steam-high pressure steam and low pressure steam. High pressure steam
enters in one common header which is called high pressure line. Similarly Low pressure steam
enters in one common header which is called Low pressure line. Adding Additional pressure level
in the HRSG can increases the amount of heat that can be recovered from the exhaust gas. So, in
order to extract more energy from exhaust gas, both HP and LP steam are produced. HRSG can be
classified in many ways, such as exhaust gas flow, the number of pressure levels or whether the
flue gases or water passes through the tube, etc. The HRGS used in this power plant is vertical and
water tube and dual pressure boiler. The tubes contain water and are surrounded by the high
temperature exhaust gases. The HRSG consists of 2 HP super heater, 2 HP Economizer, 1 HP
Evaporator,1 LP superheater,1 LP Economizer and 1 Evaporator. There are 3 pumps used for
supplying water to the Economizer. Among the three, 2 of them are always running. Another one
is kept standby. There are 3 types of tank named HP drum, LP drum and Feed water tank. Blow
down is done periodically by blow down vessel. Boiler blow down is water intentionally wasted
from a boiler to avoid concentration of impurities during continuing evaporation of steam. The
water is blown out of the boiler with some force by steam pressure within the boiler. Bottom blow
down used with early boilers caused abrupt downward adjustment of boiler water level and was
customarily expelled downward to avoid the safety hazard of showering hot water on nearby
individuals.
HRSG can supply steam at 520 degree Celsius. If by chance steam temperature rises above 520
degree Celsius water is sprayed in steam to reduce temperature. The water sprayed is supplied
from
Economizer. The material used for the heat recovery steam generator should be able to
withstand high temperature and pressure. The material should have high strength. The feed water
used in HRSG should be properly treated. Water treatment unit is used for these purposes. In this
power plant there are a sophisticated, specialized water treatment unit which ensures better quality
water supplied to the HRSG. This leads to increase in HRSG life.
A schematic diagram of HRSG has been shown in Figure 3.4 which has been obtained from mark5
console.
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Pre-Treatment System
Demineralization System
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Deep Well
Water
Aeration
Tank
PAC
Dosing
Multimedia
Filter
NaOCl
Dosing
Filtered
Water Tank
Cation
Exchanger-1
Anion
Exchanger2
CO2 degasify-1
Filtered
Tank
Intermediate
Tank
Cation
Exchanger-2
Anion
Exchanger2
CO2 degasify2
Ultra-filtration
Rack-1
Ultra-filtrate
Tank
Ultra-filtration
Rack-2
Mixed-bed
Filter 1 & 2
Demi Water
Tank
Condensate
Tank
Boiler
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Waste
Water
Coagulation
Tank
Flocculation
Tank
Lamella
Separator
Filter
Press
pump
Environment
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acidic water is then passed through an Anion exchange where the anions such as sulfates chlorides
etc. are removed by Hydroxyl (OH-) ions.
Demineralization system consists of Cation Exchanger (1 & 2), Anion Exchanger (1 & 2), CO2
degasify (1 & 2), Intermediate Tank, Ultra filtration Rack (1 & 2) and Ultra-filtrate Tank. The pH
of filtrated water is about 7 (6.9 - 7.1) which is neutral. When this water passes through Cation
exchanger, Cations like Ca2+, Mg2+, Na+, K+, NH4+ and traces of heavy metals are exchanged
through Cation resin decreasing the value of pH 4 5. When water passes through Anion
exchanger, Anions like SO42-, NO3-, Cl-, PO4- and dissolved SiO2 are exchanged through anion
resin and pH of water then becomes about 7. The conductivity and pH is continuously checked in
an automated system. Maximum allowable conductivity 1.20 S/cm. Above this limit,
regeneration of resin have to operate. 20% H2SO4 is used for Cation resin and 50% NaOH is used
for anion resin for regeneration. CO2 degasify is used for removing carbon dioxide from the water
after being processed in Ion Exchanger. Then the water is collected in a tank named Intermediate
Tank. The most fantastic Water Treatment part of Mymensingh Power Station (MPS) is the
Ultrafiltration which is the process of separating colloidal silica from water coming from
intermediate tank by means of ultrafiltration membranes. After every 2 hour ultrafiltration rack
goes to backwash where 10th backwash is caustic backwash. 50% NaOH use for caustic backwash.
After the treatment from the Ultrafiltration Tank the water is stored in Ultra filtrate Tank. Cation
and Anion resin remain in mixed condition in Mixed Bed Filter. The remaining ions that are not
separated by the previous processes are exchanged here from water coming from Ultra-filtrate
Tank. 20% H2SO4 is used for Cation resin and 50% NaOH is used for anion resin for regeneration
of resin in the Mixed Bed Filter. Then Demi water whose pH is 7 is produced and stored in the
Condensate Tank.
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Chapter
31
The turbine is a condensing turbine with normal main steam parameters, an inlet casing with an
overall dimension of 90 and an exhaust steam casing with and overall dimension of 3.2 m2 with
axial exhaust flow.
The main steam expands in the turbine and flows axially into the condenser where it condenses.
The turbine itself is a subcomponent of the overall turbine-generator unit, which includes other
components such as oil supply unit, condensing plant, generator and the I&C system.
The Steam turbine consists of:
Steam Turbine
Rotor
Shaft Glands
Control System
Instrumentation
Lifting oil system with lift oil pump and lift oil filter
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Accessories
Seal-steam condenser
Generator
Voltage regulator
24 V DC power supply
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The steam passes through sealing shells that seal off against internal excess pressure from
the inside to the outside. Through the slits in the sealing shell body. leaking steam is
sucked out of the shell after the inner area. A small amount of steam passes through the
middle area into the subsequent collecting space and, from there, through the opening
in the top shell and the connected vapor line into the atmosphere.
Sealing shells that are intended to ensure a partial vacuum in the turbine casing must
prevent the ingress of ambient air into the casing. This is why sealing steam with a slight
excess pressure is passed through the slits in the sealing shell body. The sealing steam
splits into two portions. Corresponding to the larger pressure gradient. The main portion
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flows towards the inside, while a lesser portion passes through the middle area into the
steam collecting space and further through the vapor line into the atmosphere. If required,
steaming of the sealing shell can be adjusted according to the quantity of emerging vapor
steam.
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controlled turbines which have no control stage. All the blade rows are designed with shroud.
Stainless Cr steel is employed exclusively for the entire blading.
4.2.6 Control Stage
The control stage comprises nozzles and moving blades. The nozzles for the inner casing (steam
chamber) with horizontal casing split are milled in one piece and inserted in slots. Single-piece
inner casings are equipped with a three-piece nozzle ring, which consists of a centre, outer and
inner ring. Using an electro-chemical process, profile-formed openings are created in the centre
ring, into which the corresponding formed profile material is inserted. The centre ring is connected
to the inner and outer ring by electron-beam welding. The moving blades of the control stage
together with the blade shroud and the straddle root are milled in one piece. A two-tongue or threetongue straddle root is employed depending on the blade loading. In special cases the blades are
machined directly from the rotor material employing an electro-chemical process. The straddle
roors are inserted into slots of the control stage disk and are secured by means of axial taper pins.
4.2.7 Drum Blading
The guide blades are manufactured from extruded rod stock. They have a hook-type root and are
held apart at the specified pitch in the slot by means of milled spacers inserted into the blade
groove. The spacers are secured by means of taper pins at the joint planes of the guide blade carrier.
The shrouds are riveted to the guide blades. They join a number of guide blades to form sets of
blades. The moving blades of the drum blading together with the inverted 1-root and the blade
shroud are milled in one piece. The inverted t-roots are inserted in slots in the turbine rotor and are
caulked from below using sectional material of brass The form of the blade roots is such that the
contiguously arranged blades have the specified throat openings. The insertion opening of the
blade groove is closed by a locking blade per row. These blades are secured to the turbine rotor by
means of stud screws. Consequently, there is thus neither a gap in the blade ring nor a spacing
deviation.
The radial free clearance between the guide and moving blades fitted with gap shrouds is of the
order of millimeters. Contact between the stationary and moving parts over a large area, e.g. on
deflection of the turbine rotor or of the casing, is thus obviated. This large radial gap is sealed by
means of seal strips in order to reduce the tip clearance losses to a minimum. In the case of the
guide blades, the seal strips are caulked into the turbine rotor, and. in the case of the moving blades,
into the guide blade carrier. The thin seal strips leave a clearance of a few tenths of a millimeter
between the shroud and the turbine rotor on the one hand and between the shroud and the guide
blade carrier, on the other hand.
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CONCLUSION
I remembered seeing it and it was this metallic turbine and I thought it was beautiful. I had
never been in a power plant before, but I felt, without being overly dramatic, compelled to make
photographs of this for myself- was the impression of John Sexton, an American professor and
educator, on his first ever visit to a power plant. It remains to be a universal feeling that resonates
with everyone having his first exposure to the enormity of life-line these modern civilizationpower plants. Power plants are modern marvels that harness the energy from natural resources
and convert them to the most suitable of forms electric energy. Mymensingh Power Station is
no different. On the bank of river Bramhaputra the power station stands firm as a symbol of hope
and excellence for the locality and the country as a whole, both literally and figuratively. Instead
of being mere switching practices or knob twiddling manipulation, harmonic operations of the
machines have transcended to rather metaphorical communication with them as we experienced
it from the spontaneity of the workforce involved to run the colossal activity in the power station.
It was an experience most necessary for us to know the real world of work where theories meet
implementation, where unforeseen problems pop-up every now and then. We were enriched and
now have a better understanding of our duties as our dreams are better shaped in the daylight of
real engineering. The whole training ushered us to new alleyways of knowledge and whispered
in our hearts that learning never stops.
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ACKNOWLEDGEMENT
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REFERENCES
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