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IntroductIon
IPGCL-PPCL
Indraprastha Power Generation Co. Ltd. (IPGCL) was incorporated on 1st July,2002
and it took over the generation activities w.e.f. 1st July,2002 from erstwhile Delhi Vidyut
Board after its unbundling into six successor companies. The main functions of IPGCL is
generation of electricity and its total installed capacity is 994.5 MW including of Pragati
Power Station. Its associate Company is Pragati Power Corporation Limited which was
incorporated on 9th January, 2001.
To bridge the gap between demand and supply and to give reliable supply to the capital City
a 330 MW combined cycle Gas Turbine Power Project was set up on fast track basis. This
plant consists of two gas based Units of 104 MW each and one Waste heat Recovery Unit of
122 MW. Gas supply has been tied up with GAIL through HBJ Pipeline. Due to paucity of
water this plant was designed to operate on treated sewage water which is being supplied
from Sen nursing Home and Delhi Gate Sewage Treatment plants.
Their Vision:
The Power demand in the Capital City is increasing with the growth of population as
well as living standard and commercialization. The unrestricted power demand in the
summer of year 2000 was 3000 MW and increasing every year @ 6 to 7%. In 2005-
2006, it is expected to be 4078 MW and by 2009-10 it will reach 5075 MW.
Erstwhile DVB's own generation from RPH, I.P. Station and Gas Turbine Power Station
had been around 350-400 MW and Badarpur has been supplying 600-700 MW and the
balance was met from the Northern Grid and other sources.
To bridge the gap between demand and supply and to give reliable supply to the Capital
City, Delhi Govt. had set up 330 MW Pragati Power Project on fast track basis. To cut
down the project cycle duration, turnkey contract was awarded to M/s BHEL in May
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The total capacity of this Station is 270 MW. The gas supply has been tied up with GAIL
through HBJ Pipeline. The APM gas allocation was not sufficient for maximum
generation from the power station. Subsequently with the availability of Regassified -
LNG an agreement was made with GAIL in Jan. 2004 for supply of R-LNG so that
optimum generation could be achieved. The performance of the station has improved
from 49 % in 2002-03 to 70.76 % in 2005-06.
Steam TurbIne
Steam turbines are devices which convert the energy stored in steam into
rotational mechanical energy. These machines are widely used for the generation of
electricity in a number of different cycles, such as:
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Rankine cycle
Reheat cycle
Regenerative cycle
Combined cycle
The steam turbine may consist of several stages. Each stage can be described by
analyzing the expansion of steam from a higher
pressure to a lower pressure. The steam may be
wet, dry saturated or superheated.
TurbIne EffIcIency
Impulse TurbInes
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ReactIon TurbInes
In the reaction turbine, the rotor blades themselves are arranged to form convergent
nozzles. This type of turbine makes use of the reaction force produced as the steam
accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by
the fixed vanes of the stator. It leaves the stator as a jet that fills the entire
circumference of the rotor. The steam then changes direction and increases its speed
relative to the speed of the blades. A pressure drop occurs across both the stator and the
rotor, with steam accelerating through the stator and decelerating through the rotor,
with no net change in steam velocity across the stage but with a decrease in both
pressure and temperature, reflecting the work performed in the driving the rotor.
When warming up a steam turbine for use, the main steam stop valves (after the
boiler) have a bypass line to allow superheated steam to slowly bypass the valve and
proceed to heat up the lines in the system along with the steam turbine. Also a turning
gear is engaged when there is no steam to the turbine to slowly rotate the turbine to
ensure even heating to prevent uneven expansion. After first rotating the turbine by the
turning gear, allowing time for the rotor to assume a straight plane (no bowing), then
the turning gear is disengaged and steam is admitted to the turbine, first to the astern
blades then to the ahead blades slowly rotating the turbine at 10 to 15 RPM to slowly
warm the turbine.
Problems with turbines are now rare and maintenance requirements are
relatively small. Any imbalance of the rotor can lead to vibration, which in extreme
cases can lead to a blade letting go and punching straight through the casing. It is,
however, essential that the turbine be turned with dry steam. If water gets into the
steam and is blasted onto the blades (moisture carryover) then rapid impingement and
erosion of the blades can occur, possibly leading to imbalance and catastrophic failure.
Also, water entering the blades will likely result in the destruction of the thrust bearing
for the turbine shaft. To prevent this, along with controls and baffles in the boilers to
ensure high quality steam, condensate drains are installed in the steam piping leading to
the turbine.
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Speed regulatIon
Gas TurbIne
A gas turbine, also called a combustion turbine, is a rotary engine that extracts
energy from a flow of combustion gas. It has an upstream compressor coupled to a
downstream turbine, and a combustion chamber in-between. (Gas turbine may also
refer to just the turbine element.)
Energy is added to the gas stream in the combustor, where air is mixed with fuel
and ignited. Combustion increases the temperature, velocity and volume of the gas flow.
This is directed through a nozzle over the turbine's blades, spinning the turbine and
powering the compressor.
Energy is extracted in the form of shaft power, compressed air and thrust, in any
combination, and used to power aircraft, trains, ships, generators, and even tanks.
Gas turbines are described thermodynamically by the Brayton cycle, in which air
is compressed isentropically, combustion occurs at constant pressure, and expansion
over the turbine occurs isentropically back to the starting pressure.
As with all cyclic heat engines, higher combustion temperature means greater
efficiency. The limiting factor is the ability of the steel, nickel, ceramic, or other
materials that make up the engine to withstand heat and pressure. Considerable
engineering goes into keeping the turbine parts cool. Most turbines also try to recover
exhaust heat, which otherwise is wasted energy. Recuperators are heat exchangers that
pass exhaust heat to the compressed air, prior to combustion. Combined cycle designs
pass waste heat to steam turbine systems and combined heat and power (co-
generation) uses waste heat for hot water/steam production.
More sophisticated turbines (such as those found in modern jet engines) may
have multiple shafts (spools), hundreds of turbine blades, movable stator blades, and a
vast system of complex piping, combustors and heat exchangers.
As a general rule, the smaller the engine the higher the rotation rate of the
shaft(s) needs to be to maintain top speed. Turbine blade top speed determines the
maximum pressure that can be gained, this produces the maximum power possible
independent of the size of the engine. Jet engines operate around 10,000 rpm and micro
turbines around 100,000 rpm.
Thrust bearings and journal bearings are a critical part of design. Traditionally,
they have been hydrodynamic oil bearings, or oil-cooled ball bearings. These bearings
are being surpassed by foil bearings, which have been successfully used in micro
turbines and auxiliary power units.
Systems which are designed for maximum efficiency in which the hot exhaust gases
from the gas turbine are used to raise steam to power a steam turbine with both turbines being
connected to electricity generators.
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To minimise the size and weight of the turbine for a given output power, the output
per pound of airflow should be maximised. This is obtained by maximising the air flow
through the turbine which in turn depends on maximising the pressure ratio between the air
inlet and exhaust outlet.
System Efficiency: Thermal efficiency is important because it directly affects the fuel
consumption and operating costs.
Combined Cycle Turbines It is however possible to recover energy from the waste heat of
simple cycle systems by using the exhaust gases in a hybrid system to raise steam to drive a
steam turbine electricity generating set. In such cases the exhaust temperature may be
reduced to as low as 140°C enabling efficiencies of up to 60% to be achieved in combined
cycle systems.
Thus simple cycle efficiency is achieved with high pressure ratios. Combined cycle
efficiency is obtained with more modest pressure ratios and greater firing temperatures.
Fuels One further advantage of gas turbines is their fuel flexibility. Crude and other heavy
oils and can also be used to fuel gas turbines if they are first heated to reduce their viscosity
to a level suitable for burning in the turbine combustion chambers.
MechanIcal EquIpments:
Superheater Section: The Superheater Section of the HRSG is used to dry the
saturated vapour being separated in the steam drum. In some units it may only be
heated to little above the saturation point where in other units it may be superheated
to a significant temperature for additional energy storage. The Superheater Section
is normally located in the hotter gas stream, in front of the evaporator.
The steam turbine-driven generators have auxiliary systems enabling them to work
satisfactorily and safely. The steam turbine generator being rotating equipment generally has
a heavy, large diameter shaft. The shaft therefore requires not only supports but also has to be
kept in position while running. To minimize the frictional resistance to the rotation, the shaft
has a number of bearings. The bearing shells, in which the shaft rotates, are lined with a low
friction material like Babbitt metal. Oil lubrication is provided to further reduce the friction
between shaft and bearing surface and to limit the heat generated.
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Condenser
The surface condenser is a shell and tube heat exchanger in which cooling water is
circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell
where it is cooled and converted to condensate (water) by flowing over the tubes. Such
condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of
air and gases from the steam side to maintain vacuum
For best efficiency, the temperature in the condenser must be kept as low as practical
in order to achieve the lowest possible pressure in the condensing steam. Since the condenser
temperature can almost always be kept significantly below 100 C where the vapour pressure
of water is much less than atmospheric pressure, the condenser generally works under
vacuum. Thus leaks of non-condensable air into the closed loop must be prevented. Plants
operating in hot climates may have to reduce output if their source of condenser cooling
water becomes warmer; unfortunately this usually coincides with periods of high electrical
demand for air conditioning. The condenser uses either circulating cooling water from a
cooling tower to reject waste heat to the atmosphere, or once-through water from a river.
Figure 8: A Typical Water Cooled Condenser
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Figure 9: Showing Exclusive Inside View of Tube Type Condenser Installed at IPGCL Gas Turbine Station
Deaerator
A steam generating boiler requires that the boiler feed water should be devoid of air
and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the
metal. Generally, power stations use a deaerator to provide for the removal of air and other
dissolved gases from the boiler feedwater. A deaerator typically includes a vertical, domed
deaeration section mounted on top of a horizontal cylindrical vessel which serves as the
deaerated boiler feedwater storage tank.
deposit on the heating surfaces giving rise to localised heating and tube ruptures due to
overheating. Under some conditions it may give rise to stress corrosion cracking.
CoolIng Towers
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process heat
and cool the working fluid to near the wet-bulb air temperature or rely solely on air to cool
the working fluid to near the dry-bulb air temperature. Common applications include cooling
the circulating water used in oil refineries, chemical plants, power stations and building
cooling. The towers vary in size from small roof-top units to very large hyperboloid
structures (as in Image 1) that can be up to 200 metres tall and 100 metres in diameter, or
rectangular structures (as in Image 2) that can be over 40 metres tall and 80 metres long.
Smaller towers are normally factory-built, while larger ones are constructed on site.
Figure 11: Fan of Induction Type Cooling Tower
Figure13: Inside Views of Cooling Tower Left Hand and Right Hand Respectively.
AUXILIARY SYSTEMS
All large generators require auxiliary systems to handle such things as lubricating oil
for the rotor bearings, hydrogen cooling apparatus, hydrogen sealing oil, de-mineralized
water for stator winding cooling, and excitation systems for field-current application. Not all
generators require all these systems and the requirement depends on the size and nature of the
machine. For instance, air cooled turbo generators do not require hydrogen for cooling and
therefore no sealing oil as well. On the other hand, large generators with high outputs,
generally above 400 MVA, have water-cooled stator windings, hydrogen for cooling the
stator core and rotor, seal oil to contain the hydrogen cooling gas under high pressure,
lubricating oil for the bearings, and of course, an excitation system for field current. There are
five major auxiliary systems that may be used in a generator. They are given as follows:
The technique operates on measuring pulse widths and detecting changes in the
patterns to determine the differential expansion of the shaft. A standard speed probe
can be utilised for the pulse measurement and with appropriate signal processing,
changes in the probe gap across the measuring range have no effect on accuracy, since it
is the shaft transitions that are measured. Therefore the measurement provides a true
differential expansion reading and requires no further allowances for movement in the
non-axial direction.
The technique has no real limit on the measurement range, being restricted only by the
plate dimensions. During commissioning a normalised range is calculated by moving the
probe across the required measurement window - determining the pulse width ratio at
each extreme (T2 and T3 with respect to d). The true differential expansion reading can
then be determined from the given formula.
While it is usual to implement a number of chevron patterns around the shaft, reality is
quite different. From experience the quantity can vary from one set of plates to many -
depending on the turbine engineer s preference. If an uneven distribution is selected it
is important the overall balance of the rotating shaft is maintained, with the addition of
opposing weights if necessary.
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The plate pattern is fitted at a position on the rotor section close to where the shaft fits
in to the bearing pedestal - this location allows straightforward access to the plate
pattern through the bearing cover. The turbine casing and pedestal are mechanically
joined in most circumstances, where the pedestal and casing movement is catered for
with a sliding base arrangement. At the HP, IP and LP3 locations a bracket assembly
fitted to the pedestal cover accepts a standard inductive proximity probe to generate
the timing waveforms.
Capacity : 34 MW
No. of stages : 50
Steam flow : 125 Tonne/hr.
Inlet temperature : 502°C
Inlet pressure : 40 Kg/cm2
Lube oil grade : SP 46
No. of journal bearings : 5
No. of thrust bearing : 1
Coupled Main Oil Pump (MOP) with turbine shaft
Exhaust steam pressure : 3.3 ata
Exhaust steam flow : 2.16 Tonne/hr.
Exhaust pressure : 0.105 Kg/cm2
Lube oil pressure : 9 Kg/cm2
Over speed trip : >3300 rpm
Differential expansion : +6 to -4
\
Gas TurbIne SpecIfIcatIons
Capacity : 30 MW
Gas pressure : 20 Kg/cm2
Speed : 5135 rpm
Generator speed : 3000 rpm
Generation at : 11 KV
Exhaust temperature : 560°C
Air flow : 490 Tonne/hr.
DIESEL ENGINE
1. Vibration on bearings.
2. Lube oil header temperature.
3. Lube oil header pressure.
4. Hydraulic oil pressure.
5. Hydraulic trip oil pressure.
6. Battery charger should be healthy. Battery voltage should >120V
7. Cooling water pressure.
8. Air sealing system.
9. TAD should < 170 mm.
10. GAD should < 150 mm.
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