A Summer training report ON Power Generation AT Steam Power Plant Chabbra Submitted as a partial fulllment of Bachelor of Technology

Session:2011-2012

Submitted To:Mr. Ajit Kumar Joshi H.O.D ME Department

Submitted By:Satish Chaudhary 08EMBME057 Final Year ME

M. L. V. Textile and Engineering College. (An Autonomous Engineering College of Govt. Of Rajasthan) Bhilwara(Rajasthan).

Preface
Summer practical training is an important part of the engineering curriculum. The B.Tech. course summer training helps a student in getting acquainted with the manner in which his knowledge is being practically used outside his institute and this is normally dierent from what he has learnt from books. Hence, when the student switches from the process of learning to that of implementing his knowledge, he nds an abrupt change.
A This repert has been developed in LTEX, a document preparation system. Tex is a sophisticted program designed to produce high-quality typesetting, especially for mathematical text. It takes a computer le, prepared according to the rules of Tex, and converts it to a form that may be printed on a high-quality printer, such as a laser writer, produce a printed document of publication quality.

The need of training arises for doing things yosurself, understanding its way. Practical exposure for doing things makes a person conversant to the technicalities involved in any job. To overcome the problem of prot and growth through the soundest utilization of human capacities eective recruitment and selection process in rst step. If it is not done well no amount of training, supervision or incentive make for it. In view of such benets, imparting of vocational training has been made as an integral part of any academic structure.

Acknowledgment
It is indeed a great pleasure and privilege for me to have training for 30 days at Combined Cycle Power Project(A unit of NTPC) , Dholpur (raj.) We would express appreciation to all individuals who assisted to me in one or another way. I wish to express my thanks to Mr.G.K.Tyagi, Pricipal of M.L.V.T.E.C.,Bhilwara for letting me use its infrastructure to complete this report work. I have furthermore to thank Mr. K.K. Chaturvedi last but not the least all members of RAJ. RAJYA VIDYUT UTPADAN NIGAM LTD. for respective stimulating support. I am deeply indebted to my mentor Ms. Upma Garg whose help, stimulating suggestions encouragement helped me in all the time during my industrial training. also thankful to our training incharge Mr. Ritesh Saraswat who helped us in providing all the information regarding NTPC. I also pay my sincere thanks and gratitude to our project and seminar guide Mrs. Abha singh And Co -guide Mr.Nagendra Bhadana for their advice, encouragement and support during training.

I am indebted to all my elders and friends for inspiring me to have my training with immense dedication.

Mukesh Kumar

Contents
1 Introduction 1.1 History of power development . . . . . 1.2 Intoduction of gas turbine power plant 1.3 Combined Cyle . . . . . . . . . . . . . 1.4 Power Generation . . . . . . . . . . . . 1.4.1 Air Inlet . . . . . . . . . . . . . 1.4.2 Heat Recovery Steam Generator 1.4.3 Steam Turbine . . . . . . . . . 1.4.4 Transformers . . . . . . . . . . 1.4.5 Condenser and Cooling Tower . 1.4.6 Control Room . . . . . . . . . . 2 Gas 2.1 2.2 2.3 2.4 Turbine Introduction . . . . . . . . . . Theory of Operation . . . . . Advantages of Gas Turbine . . Disadvantages of Gas Turbine 1 1 2 2 4 4 5 5 6 6 7 8 8 9 10 11

. . . . . . . . . . . . . . . . . . . . . . . . . (HRSG) . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

3 Steam Turbine 12 3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.2 Principle of working of steam turbine . . . . . . . . . . . . . . . . . . 12 4 Condensing Plant 4.1 Introduction . . . . . . . . . . . . . . . . 4.2 Circulating Water System . . . . . . . . . 4.3 Condenser . . . . . . . . . . . . . . . . . . 4.4 Condensate System . . . . . . . . . . . . . 4.5 Shaft Seal Steam System . . . . . . . . . 4.6 Process engineering functions of condenser 4.7 Components of the condenser . . . . . . . 16 16 16 17 17 17 17 18

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

4.8 4.9 4.10 4.11 5 HP 5.1 5.2 5.3 5.4 5.5 5.6 5.7

Vacuum Breaker . . . . . . . . . . . . . . . . . . Isolation valve downstream of the vacuum breaker Level Monitoring Equipment . . . . . . . . . . . . Information for operation maintenance . . . . . . Turbine General Arrangement . . . . . . . . . Steam Flow . . . . . . . . . . . . . . Double Shell Construction . . . . . . Admission Pipe Units . . . . . . . . . Attachment of the Inner Casing . . . HP turbine casing supports and guide HP turbine blading . . . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

18 19 19 19 20 20 20 20 21 23 23 24

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

6 LP Turbine 26 6.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 6.2 Stationary and moving blades . . . . . . . . . . . . . . . . . . . . . . 27 7 HP and LP Bypass(EHA Type) 29 7.1 Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 8 Turbo Generator 8.1 Working of turbo generator 8.2 Components of generator . . 8.3 Stator core . . . . . . . . . . 8.4 Stator winding . . . . . . . 31 31 31 32 32

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

List of Figures
1.1 1.2 2.1 2.2 2.3 3.1 3.2 5.1 5.2 5.3 5.4 8.1 8.2 8.3 Diagram : basic blocks of combined cycle . . . . . . . . . . . . . . . . Diagram : Control Section . . . . . . . . . . . . . . . . . . . . . . . . 4 7

Diagram : Gas Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Diagram : Gas Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Diagram : Operation of gas turbine. . . . . . . . . . . . . . . . . . . . 10 Diagram : Working of steam turbine. . . . . . . . . . . . . . . . . . . 13 Diagram : Ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Diagram Diagram Diagram Diagram : HP Turbine. . . . . . . . . . . . . . . . . : Admission Pipe Unit. . . . . . . . . . . . :HP Turbine casing supports and guide. . :HP Turbine Blading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 22 24 25

Diagram :HP Turbine Blading. . . . . . . . . . . . . . . . . . . . . . . 32 Diagram :Generator capacity vs Water Temp. Curve.. . . . . . . . . . 33 Diagram :Generator Capability Curve. . . . . . . . . . . . . . . . . . 33

Chapter 1

Introduction

Combined Cycle Power Projct ,Dholpur Rajasthan Rajya Vidyut Utpadan Nigam Limited (RVUN) has been entrusted with the job of development of power projects under state sector, in the state along with operation maintenance of state owned power stations. Government of Rajasthan constituted the Rajasthan Rajya Vidyut Utpadan Nigam Ltd. (RVUN) under Companies Act-1956 on 19th July, 2000. The Nigam is since playing lead role in giving highest priority to the power generation for manifold and rapid development of the state. The generating Stations of RVUN have acquired a distinctive reputation in the country for their ecient and economic power generation. RVUN has track record of completing the generation projects ahead of schedules. The present installed capacity of RRVUNL is 4097.35 MW... 1.1 History of power development

The history of power developemnt in Rajasthan goes back to the year 1949,when 19 princely states merged to form Rajasthan.At that time,electric power,was conned to very few towns,and electricity was considered a luxury.The total number of towns and villages electried at that time,did not exceed 42 and the installed gererating capacity was only 13.27 MW.However,with the formation of Rajasthan State Electricity Board on 1st july 1957,power sector in Rajasthan received priority and power projects began to mushroom all over State. Under new Power Reforms Undertaken by State Govt. RESB was unbundled into following ve Govt. Companies in July 2000. Present capacity of Dholpur combined cycle power plant (CCPP) is 330MW

1.2

Intoduction of gas turbine power plant

A gas turbine extracts energy from a ow of hot gas produced by combustion of gas or fuel oil in a stream of compressed air. It has an upstream air compressor (radial or axial ow) mechanically coupled to a downstream turbine and a combustion chamber in between. Gas turbine may also refer to just the turbine element. Energy is released when compressed air is mixed with fuel and ignited in the combustor. The resulting gases are directed over the turbines blades, spinning the turbine, and, mechanically, powering the compressor. Finally, the gases are passed through a nozzle, generating additional thrust by accelerating the hot exhaust gases by expansion back to atmospheric pressure. Advantage of Gas Turbine High thermal eciency(in combined cycle) Low water requirements Environment friendliness Fast start up Low gestation period Disadvantage of Gas Turbine Lower eciency in open cycle Higher cost of generation Higher maintenance cost 1.3 Combined Cyle

Combined cycle plants have both, a gas turbine red by natural gas a steam boiler and steam turbine which use the exhaust gas from the gas turbine to produce electricity. First step is the same as the simple cycle gas turbine plant. Burning of gas, the thrust rotating a gas turbine and the coupled generator produces Electricity. In the second step the hot gases leaving the gas turbine passes into boiler to produce steam. This boiler is called the Heat Recovery Steam Generator (HRSG). The steam then rotates the steam turbine and coupled generator to produce Electricity. The hot gases leave the HRSG at around 140 degrees centigrade and are

discharged into the atmosphere. steam condensing, and water recycling system is the same as in the steam power plant. The attached animation shows the working of the CCPP. First step is the same as the simple cycle gas turbine plant. Burning of gas, the thrust rotating a gas turbine and the coupled generator produces Electricity. In the second step the hot gases leaving the gas turbine passes into boiler to produce steam. This boiler is called the Heat Recovery Steam Generator (HRSG). The steam then rotates the steam turbine and coupled generator to produce Electricity. The hot gases leave the HRSG at around 140 degrees centigrade and are discharged into the atmosphere. The steam condensing, and water recycling system is the same as in the steam power plant. Even though this system is having the best eciency, it has limitations. The gas turbine can only use Natural gas or high grade oils like aviation or diesel fuel. Because of this the combined cycle can be operated only in locations where these fuels are available and cost eective. Combined cycle is mostly use rather than other such as individually(gas turbine, steam turbine)because it has high heat addition and very low heat sinking property comparatively others.thats why it is highly ecient,better performance In electric power generation a combined cycle is an assembly of heat engines that work in tandem o the same source of heat, converting it into mechanical energy, which in turn usually drives electrical generators. The principle is that the exhaust of one heat engine is used as the heat source for another, thus extracting more useful energy from the heat, increasing the systems overall eciency. This works because heat engines are only able to use a portion of the energy their fuel generates (usually less than 50The remaining heat (e.g., hot exhaust fumes) from combustion is generally wasted. Combining two or more thermodynamic cycles results in improved overall eciency, reducing fuel costs. In stationary power plants, a successful, common combination is the Brayton cycle (in the form of a turbine burningnatural gas or synthesis gas from coal) and the Rankine cycle (in the form of a steam power plant). Multiple stage turbine or steam cylinders are also common.

Figure 1.1: Diagram : basic blocks of combined cycle

1.4

Power Generation

As we Know that A power station (also referred to as a generating station, power plant, or powerhouse) is an industrial facility for the generation of electric energy.450 to 650 C). This is therefore high enough to provide heat for a second cycle which uses steam as the working uid; (a Rankine cycle). An open circuit gas turbine cycle has a compressor, a combustor and a turbine. For gas turbines the amount of metal that must withstand the high temperatures and pressures is small, and lower quantities of expensive materials can be used. In this type of cycle, the input temperature to the turbine (thering temperature), is relatively high (900 to 1,400 C). The output temperature of the ue gas is also high
1.4.1 Air Inlet

The amount of air needed for combustion is 800,000 cubic feet per minute. This air is drawn though the large air inlet section where it is cleaned, cooled and controlled, in order to reduce noise. The air then enters the gas turbine where it is compressed, mixed with natural gas and ignited, which causes it to expand. The pressure created from the ex-

pansion spins the turbine blades, which are attached to a shaft and a generator, creating electricity. Each gas turbine produces 185 megawatts (MW) of electricity. The blades are attached to a rotor, which spins the generator, and makes electricity. Think of a generator as a huge spinning magnet inside a coil of wire. As the magnet spins, electricity is created in the wire loops.
1.4.2 Heat Recovery Steam Generator (HRSG)

The hot exhaust gas exits the turbine at about 1100 degrees Fahrenheit and then passes through the Nooter Erickson, Heat Recovery Steam Generator (HRSG). In the HRSG, there are 18 layers of 100-foot tall tube bundles, lled with high purity water. The hot exhaust gas coming from the turbines passes through these tube bundles, which act like a radiator, boiling the water inside the tubes, and turning that water into steam. The gas then exits the power plant through the exhaust stack at a much cooler 180 degrees, after having given up most of its heat to the steam process. About 1 million pounds of steam per hour is generated in this way and sent over to the steam turbine through overhead piping
1.4.3 Steam Turbine

The steam turbine is a Siemens Westinghouse KN Turbine Generator, capable of producing up to 240 MW. It is located on top of the condenser, across from the cooling tower. Steam enters the turbine with temperatures as high as 1000 degrees Fahrenheit and pressure as strong as 2,200 pounds per square inch. The pressure of the steam is used to spin turbine blades that are attached to a rotor and a generator, producing additional electricity, about 100 megawatts per HRSG unit. After the steam is spent in the turbine process, the residual steam leaves the turbine at low pressure and low heat, about 100 degrees. This exhaust steam passes into a condenser, to be turned back into water. By using this combined-cycle process, two gas turbines and one steam turbine, we can produce a total of about 600 megawatts of electricity.

1.4.4

Transformers

The Gas Turbine and Steam Turbine generators produce power at 13,000 volts. The transformers take the generated 13,000 volts and transform them to 230,000 volts, which is the required voltage needed for transmission to the nearby tower that sends power to the substation. A small amount of generation is directed to Auxiliary transformers which transform the generated voltage to a lower voltage, so it may be used by the plant to power our own pumps, fans, and motors. The Metcalf Energy Center requires 12 15 megawatts to operate. From each transformer, the power passes underground into our switchyard. The power from all of the generators comes together there, where it is measured, metered and directed onto the grid. The proximity of the site to a large, existing PGE substation makes it a good place to build a power plant and the nearest transmission tower is only about 200 feet away.
1.4.5 Condenser and Cooling Tower

The purpose of the condenser is to turn low energy steam back into pure water for use in the Heat Recovery Steam Generator. The purpose of the cooling tower is to cool the circulating water that passes through the condenser. It consists of ten cells with large fans on top, inside the cone-like stacks, and a basin of water underneath. We process and treat the Title 22 recycled water after receiving it from the City, before using it in our cooling tower. The cool basin water absorbs all of the heat from the residual steam after being exhausted from the steam turbine and it is then piped back to the top of the cooling tower. As the cool water drops into the basin, hot wet air goes out of the stacks. Normally, hot moist air mixes with cooler dry air, and typically a water vapor plume can be formed, one that may travel hundreds of feet in the air and be seen from miles away. The California Energy Commission considered this visually undesirable in this community so we added a Plume-Abatement feature, louvers along the topsides of the tower that control the air ow.

 The cooling tower evaporates about three-fourths of the processed, recycled water, then we send about one-fourth of it back through the sewer lines for re-treatment by the City The Metcalf Energy Center purchases 3 to 4 million gallons per day of recycled water from the City of San Jose. Evaporation of this water assists the City in adhering to their ow cap limits and helps to protect the sensitive saltwater marsh habitat of the San Francisco Bay environment from receiving too much fresh, recycled water.
1.4.6 Control Room

Figure 1.2: Diagram : Control Section

From the control room , the plant operators monitor and operate the facility, via the plants Distributed Control System, with the click of a mouse, viewing graphic representations of all MEC systems on various screens. The system gives operators both audible and visual signals to keep them informed of plant conditions at all times and to determine when preventative maintenance is required.

Chapter 2

Gas Turbine

2.1

Introduction

This machine has a single-stage centrifugal compressor and turbine, a recuperator, and foil bearings. A gas turbine extracts energy from a ow of hot gas produced by combustion of gas or fuel oil in a stream of compressed air. It has an upstream air compressor (radial or axial ow) mechanically coupled to a downstream turbine and a combustion chamber in between. Gas turbine may also refer to just the turbine element.

Figure 2.1: Diagram : Gas Turbine

2.2

Theory of Operation

Figure 2.2: Diagram : Gas Turbine

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. In practice, friction, and turbulence cause: a) non-isentropic compression: for a given overall pressure ratio, the compressor delivery temperature is higher than ideal. b) non-isentropic expansion: although the turbine temperature drop necessary to drive the compressor is unaected, the associated pressure ratio is greater, which decreases the expansion available to provide useful work. c) pressure losses in the air intake, combustor and exhaust: reduces the expansion available to provide useful work. As with all cyclic heat engines, higher combustion temperature means greater eciency. 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. Mechanically, gas turbines can be considerably less complex than internal combustion piston engines 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 tip speed. Turbine blade tip speed determines the maximum pressure that can be gained, independent of the size of the engine. Jet engines operate around 10,000 rpm and micro turbines around 100,000 rpm. 2.3 Advantages of Gas Turbine

Very high power-to-weight ratio, compared to reciprocating engines (ie. most road vehicle engines) Smaller than most reciprocating engines of the same power rating Moves in one direction only, and doesnt vibrate, so very reliable Simpler design.

Figure 2.3: Diagram : Operation of gas turbine.

2.4

Disadvantages of Gas Turbine

Cost is much greater than for a similar-sized reciprocating engine (very highperformance, strong, heat-resistant materials needed) Use more fuel when idling compared to reciprocating engines - not so good unless in continual operation These disadvantages explain why road vehicles, which are smaller, cheaper and follow a less regular pattern of use than tanks, helicopters, large boats and so on, do not use gas turbine engines, regardless of the size and power advantages imminently available.

Chapter 3

Steam Turbine

3.1

Introduction

It has completely replaced the reciprocating piston steam engine invented by Thomas Newcomen and greatly improved by James Watt primarily because of its greater thermal eciency and higher power to weight ratio. Also, because the turbine generates rotary motion, it is particularly suited to be used to drive an electrical generatorit doesnt require a linkage mechanism to convert reciprocating to rotary motion. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic eciency to the use of multiple stages in the expansion of the steam (as opposed to the one stage in the Watt engine), which results in a closer approach to the ideal reversible process. A steam turbine extracts the energy of pressurized superheated steam as mechanical movement. 3.2 Principle of working of steam turbine

A steam turbine is a prime mover that derives its energy of rotation due to conversion of the heat energy of steam into kinetic energy as it expands through a series of nozzles mounted on the casing or the xed blades. Water is converted to steam by application of heat in the boiler, which makes the steam at specied pressure and temperature. To convert the steams energy into work, it must go through a thermodynamic cycle that combines expansion compression, heat input, and heat rejection.

12

The most ecient thermodynamic cycle for an ideal uid is Carnot cycle. It consists of an isothermal heat input, isentropic expansion, isothermal heat rejection, and an isentropic compression. Regardless of the combination, the eciency of the cycle, assuming constant mass ow is based on the dierence in the enthalpy and between the beginning and end of the cycle.

Figure 3.1: Diagram : Working of steam turbine.

Steam can be used as the working uid in the Carnot Cycle. But its properties adversely impact its usefulness. In this case the steam expansion process takes place completely in the moisture region. This requires compression of a vapour/moisture mixture to return to the cycles starting point. Moisture is an expansion process imposes large mechanical eciency losses. Also, vapour compression is inecient and consumes relatively large amounts of power. To avoid a two-phase vapour compression process, turbines are based on the Rankine cycle. It is similar to the Carnot Cycle, except that the initial pressure of the steam is raised and the condensation process that accompanies heat rejection

continues until the liquid saturation point is reached. At the end of the cycle, then, condensate is simply pumped back to the boiler to begin the cycle. The role of the steam turbine is to expand the steam from high pressure and temperature to lower pressure and temperature. Rankine cycle is a heat engine with vapor power cycle. The common working uid is water. The cycle consists of four processes:

Figure 3.2: Diagram : Ts.

1 to 2: Isentropic expansion(Steam turbine) 2 to 3: Isobaric heat rejection(Condenser) 3 to 4: Isentropiccompression (Pump) 4 to 1: Isobaric heat supply(Boiler) Several things can be done to steam to improve the Rankine Cycle eciency. Raise initial steam condition and reduce the amount of moisture near the end of expansion stage. The rst is accomplished by superheating the steam before it does any work. The second involves re- heating steam to near initial-conditions after it is partially expanded by directing it back to the heat source, then completing the expansion. In a combined cycle power plant (CCPP), or combined cycle gas turbine (CCGT) plant, a gas turbine generator generates electricity and heat in the exhaust is used to make steam, which in turn drives a steam turbine to generate additional electricity.

This last step enhances the eciency of electricity generation. Many new gas power plants in North America and Europe are of this type. Such an arrangement used for marine propulsion is called combined gas (turbine) and steam (turbine) (COGAS). In converting the thermal energy of steam into mechanical energy turbines takes advantage of this facts- as it expands or drops in pressure, through a small nozzle or opening, it accelerates and forms high-speed jet. Directing this momentum in a rotating blade provides mechanical energy.

Chapter 4

Condensing Plant

4.1

Introduction

The condensing forms the main heat sink of the power plant unit. The following systems are involved in the process engineering function: Circulating Water System PA Condenser MAG Condensate System LCA LCB Evacuation System MAJ Shaft Seal system MAW 4.2 Circulating Water System

The circulating water system, whose essential components are the circulating water pumps and pipings, has the function of supplying the condenser with circulating water for removing the heat of the vaporization of the condensed steam. The circulating for condenser must meet certain requirements i.e. it must be free of solid contaminants, which can be deposited in or in front of condenser tubes.The strainer system dosing equipment aid in maintaining circulating water requirements and also form part of the circulating water system.

16

4.3

Condenser

The steam expanded to condenser pressure in the steam turbine and / or bypass valve condenses in the condenser by removing the heat of the evaporation. 4.4 Condensate System

The condensate accumulating in the condenser is fed back into water-steam circuit by the condensate system pumps. The level controller has the function of maintaining constant level in the condenser. The control valves of the condenser level controller forms the part of the condensate system. The condensate system also provides: Injection water for bypass steam. Injection water for the ash tanks of the condenser. Seal water for glands of the valves Operating under vacuum. Cooling water for seal steam condenser

4.5

Shaft Seal Steam System

The shaft seal steam system supplies seal steam to the shaft seals of LP Turbine, through which air can ingress into the condenser due to negative internal pressure. The seal steam is either supplied directly or in the form of leako steam from the shaft seals of the other turbines.

4.6

Process engineering functions of condenser

The surface condenser has function of condensing steam expanded in the turbine and /or in the bypass valves.The steam or condensate from shaft seal system and the leako steam system are fed into the condenser.Condensate collecting in the hot-well of the condenser is drawn o by the condensate pumps and returned to water-steam cycle.

4.7

Components of the condenser

The condenser has following components: Vacuum Breaker MAG10AA001. Isolation valve downstream of vacuum breaker MAG10AA501. Level monitoring equipment with ID code in accordance with system diagram. 4.8 Vacuum Breaker

During turbine operation boundary conditions can arise under which the turbine generator coast down time during shut down should be as short as possible. On opening the vacuum breaker, air is admitted into the condenser, thereby increasing the condenser pressure. The windage in the blading slows down the speed of the rotor system and reduces the coasting down time. The vacuum breaker opens automatically when the turbine re protection is activated. Other criteria for opening of the vacuum breaker are: The limit value of one of the following parameters is reached: Shaft or bearing vibration. Bearing temperature. Casing distortion due to temperature dierences between top bottom halves of the casing. Shaft position in the thrust bearing. Vibration increases drastically when passing through critical speeds during coasting down of rotor system Air must not be drawn over the seat of the vacuum breaker. Hence, the seal water valve for the vacuum breaker must always be open so that some seal water ows out of the overow line.

4.9

Isolation valve downstream of the vacuum breaker

The isolation valve downstream of the vacuum breaker must be open during normal operation and should only be closed when the vacuum breaker opens spuriously. 4.10 Level Monitoring Equipment

The level monitoring equipment has the following functions: Output of a control signal for the condenser level controller, which is part of the condensate system Signaling an inadequate condenser level, which cause the condensate pumps to malfunction. Signaling an excessive condenser level. 4.11 Information for operation maintenance

Technical Data: The technical data contains the limit pressure setpoints of the condenser protection system Overpressure Protection Of Condenser The rupture discs of the LP turbine protect the condenser against excessive internal pressure. Condenser Protection System protects the condenser turbine against operation at inadmissible condenser pressure. Condenser Protection Against Excessive Steam Temperature Superheated steam, which is fed into the condenser through lance pipes, must be cooled in the ash tanks. Isolation valves in the condensate lines to the ash tanks must be opened

Chapter 5

HP Turbine

5.1

General Arrangement

The HP turbine has two stop valves and two control valves located on each side of the turbine casing. The valves are arranged in pairs with one main stop valve and one control valve in a common body (1). 5.2 Steam Flow

The main steam is admitted through the main steam pipe and passes rst the main stop valves and then the control valves. From the control valves the steam enters the turbine casing The shortlength of the admission pipes between the control valves and the casing results in a very low steam volume in this section, which gives the turbine excellent trip reliability. For easy maintainability, the steam inlet connection to casing top half is made through a anged joint . 5.3 Double Shell Construction

The casing of the HP turbine is split horizontally and is of double-shell construction. A single-ow inner casing is supported in the outer casing . The initial steam enters the inner casing from above and below through two admission branches. The provision of an inner casing connes the high- temperature and high-pressure steam inlet conditions to the admission section

20

of this casing, while the outer casing is subjected only to the lower pressure and temperature eective at the exhaust from the inner casing. This means that the joint ange of outer casing can be kept small and material concentrations in the area of the ange reduced to a minimum, thus avoiding diculties arising from deformation of a casing with ange joint due to non-uniform temperature rises, e.g,. on startup and shutdown. The joints of the inner casing are relieved by the pressure in the outer casing so that these joints only have to be sealed against the resulting dierential pressure.

Figure 5.1: Diagram : HP Turbine.

5.4

Admission Pipe Units

The Angle-ring form the connection of the admission pipe units to the inner casing (Detail D). One leg of the Angle-ring at such a connection engages behind the collar of the threaded ring in the admission pipe unit, while

the other ts into an annular groove in the inner easing. The threaded ring is tted in such a way that the short leg of the Angle-ring can slide freely between the collar of the threaded ring and the admission pipe unit. The steam pressure prevailing on the side forces the seal ring against the face of the admission pipe unit. The tolerances of the annular groove in the inner easing are dimensioned to allow the long leg of the Angle-ring to slide. The Angle-ring is exibly expanded by the pressure on the inside and its outer areas are forced against the annular grooves to provide the desired sealing eect. While providing a tight seal, this arrangement permits the inner easing to move freely in all directions. The admission pipe units are welded to the outer casing.

Figure 5.2: Diagram : Admission Pipe Unit.

5.5

Attachment of the Inner Casing

Due to the dierent temperatures of the inner casing relative to the outer casing, the inner casing is attached to the outer casing in such a manner as to be free to expand axially from a xed point and radially in all directions, while maintaining the concentricity of the inner casing relative to the rotor.

The steam admission connections are designed to avoid constraining thermal expansion in any way. The inner casing is attached to the outer casing in the horizontal and vertical plane. 5.6 HP turbine casing supports and guide

The turbine casing is supported in such a way so as to make allowance for thermal expansion. It is essential for the casing to retain concentric alignment with the rotor, which is supported independently. The turbine casing is supported by its two front and two rear palms on the palm supports of the bearing pedestals at the turbine center line level. This arrangement determines the height of the casing and also allows thermal expansion to take place in the horizontal plane by the casing palms sliding on the sliding pieces mounted on the bearing pedestals . To prevent lifting of the turbine casing the palms projecting into the corresponding recesses in the bearing pedestals are held by the clamping plate . When the turbine is erected, a clearance s is allowed between the palm projection of turbine casing and the clamping plate through screwed thrust bar , thus restricting the casing lift. In addition, the HP turbine casing support on front bearing pedestal joins the casing and the pedestal into a single unit in axial direction by means of sliding pieces . No such anchoring is there in casing rear, supported on the LP front bearing pedestal. This means that the axial expansion of HP turbine initiates from front bearing pedestal and is transmitted towards LP front pedestal .

Guides The transverse location of the turbine casing at right angles to the machine axis is provided by the guides shown in Detail-B.These guides allow

the turbine casing to expand freelly in vertical as well in axial direction, and restrict movement in transverse direction through sliding pieecs and parallel keys.

Figure 5.3: Diagram :HP Turbine casing supports and guide. .

(1) HP front bearing and pedestal (2) HP turbine and casing (3) LP front bearing and pedestal 5.7 HP turbine blading

The HP turbine blading consists of 28 drum stages. All stages are reaction stages with 50The stationary and moving blades of allstages are provided with inverted T-roots and integral shrouds.The moving and stationary blades are inserted into corresponding grooves in the shaft and inner casing and are caulked at bottom with caulkirig material . The insertion slot in the shaft is closed by a locking blade which is xed by taper pins or grub screws. Special end-blades which are locked with the joint plane by grub screws are used for the, inner casing. Gap Scaling: Sealing strips are cawked into the inner casing and the shaft to reduce leakage losses at the blade tips.

The surfaces have stepped diameters in order to increase the turbulence of the steam and this the sealing eect. Should an operational disturbance. cause the sealing strips to come into contact with opposite surfaces, they are rubbed away without any considerable amount of heat being generated. They can then easily be replaced at a later date to provide the specied clearance.

Figure 5.4: Diagram :HP Turbine Blading.

Chapter 6

LP Turbine

6.1

Construction

The LP turbine casing consists of a double ow unit and has a triple shell welded casing. The outer casing consists of the front and rear walls, the two lateral longitudinal support beams and the upper part. The front and rear walls as well as the connection areas of the upper part are reinforced by means of circular box beams. The outer casing is supported by the ends of the longitudinal beams on the base plates of the foundation The drum blading stages of the double ow L.P. turbine are reaction stages with 50 Stationary and moving blades:All stationary and moving blades are provided with integral shrouds which after installation form a continuous shrouding. All stationary and moving blades have t-roots which also determine the distance between the blades. They are inserted in mating grooves in shaft (6) and inner casing (1) and are caulked in place with caulking material (5). The Insertion slot in the shaft is sealed by means of a locking blade which is held in position by grub screw. The stationary blades are held in position in the grooves of grub screw that are screwed into the inner casing material and the blades lock from the joint surface. Gap Sealing:

26

In order to reduce blade tip losses, seal strips (7) are caulked into the inner casing (1) and turbine shaft (6). The seal strips are located opposite integrally machined seal-points on the blade shroud (Detail A). This design gives favourable radial clearance. In the event of rubbing due to a fault, the seal strips are worn away without generating much heat. They can then be easily replaced at a later date to restore the required clearances.

6.2

Stationary and moving blades

The last three stages of the LP turbine are designed as reaction stages. Each stage is made up of stationary and moving blades. The stationary blade rings are made by welding inner rings, blades and outer rings together into segments and bolting them to inner casing (5). The two nal stages have blades which are made of sheet steel and are hollow. Drainage slots are provided in the blade (6) of these rows. Through these slots any water impacting on these blades is drawn away to the condenser. When the stationary blade rings are installed in place, inner rings attached to these form a continuous ring of shrouding. The moving blades (3) have T-roots which are inserted into corresponding grooves in the turbine shaft and caulked with caulking material (2). The moving blades (7) inserted in axial grooves in the turbine shaft (1) have curved r-tree roots (see view B). These are attached with ller pieces (11) and secured against axial movement of the blades by retaining strips (10), the end segment of which are welded together at the joint. The objective of this control system is to maintain the drum level at normal water level of the drum at all loads. The three elements of this control loop are - Drum level, Feed water ow and Main steam ow. This conventional three element drum level control regulates the water supply to the drum through feed water control valve. Temperature compensated feed water ow signal is computed. A time lag f(t) has been included in the steam ow signal to keep the loop stable during sudden load changes resulting in either drum level swelling or shrinking. The drum level measured signal is compared with the drum level set point.

The error signal is processed in a proportional, integral and dierential drum level controller. This will be added with steam ow signal. Resultant is the feed water ow demand signal (set point for feed water ow). in turn is compared with feed water ow in the feed water PID controller. Controller output will be the position demand signal for feed water control valve. Auto/Manual switching facility has been provided for auto/manual selection and operation. Feed control valve position feedback signal is available on the DCS. At lower loads (30The drum level measured signal is compared with the drum level set point.

The error signal is processed in a proportional, integral and dierential drum level controller. This will be added with steam ow signal. Resultant is the feed water ow demand signal (set point for feed water ow). This in turn is compared with feed water ow in the feed water PID controller. Controller output will be the position demand signal for feed water control valve. Auto/Manual switching facility has been provided for auto/manual selection and operation. Feed control valve position feedback signal is available on the DCS. The temperature elements 1-TE-HMS-10, 1-TE-HMS-11, signal is compared with the set point. The error signal produced between the steam temperature measured signal and the set point will be processed in the proportional, integral and dierential steam temperature controller. controller output will be the position demand signal for the desuperheating spray control valve. Final temperature is maintained within desired limits of set point value by desuperheating thus minimising the error. Auto/manual switching facility is provided in the DCS for auto/manual selection and operation. Control valve position feedback signal is available on the DCS.

Chapter 7

HP and LP Bypass(EHA Type)

The function of the bypass control system within the combined cycle is to dump steam to the condenser via HP and LP bypass stations in the event of transient turbine operating conditions such as turbine trip, load rejection, start-up and shutdown. 7.1 Mode of operation

Each of the two-dual pressure steam generators (HP and LP) is provided with a dedicated bypass control of essentially identical design. Each stop valve (SV) and control valve (CV) of HP and LP bypass system is provided with its own Electro-Hydraulic Actuator (EHA). The EHA for each SV consists of an operating cylinder with control piston and disc springs and a control unit anged to the operating cylinder and limit switches to monitor the opening and closing of the actuator.

Each bypass controller consists of a pressure controller and a position controller. The opening and closing of the bypass SV is done over a pilot valve (solenoid operated) which is controlled in relationship with the pressure controller output signal. The pressure controller output also acts as a setpoint for the subordinate position controller. The position controller output acts on the servo-valve to open or close the bypass control valve. The analog position of the CV is fed back to the position controller by an

29

analog position transmitter. HP and LP bypass control system includes the necessary protective devices for the condenser and interlocks for the water injection system. These are as follows: Condenser vacuum too low. Water injection pressure too low. HPSU emergency OFF. HPSU:- Control oil pumps protection OFF (generated from pump discharge oil pressure) Manual initiation of bypass trip from Emergency OFF PB in the control room Note:- This is a general description of HP and LP Bypass system (EHA Type). HP and LP Bypass system (EHA Type) is supplied by M/S Bomafa Armaturen GMBH, Germany and O M manual supplied by vendor may please be referred for detail description.

Chapter 8

Turbo Generator

An Turbo generator is an electromechanical device that converts mechanical energy to electrical energy, using a rotating magnetic eld.

8.1

Working of turbo generator

An Turbogenerator generally includes a rotor that rotates within a stator core to convert mechanical energy into electrical energy. A frame-supported stator core provides a high permeability path for magnetic ux and a rotor assembly positioned to rotate continuously within the stator core so as to induce electrical current. The resulting current is carried by high-current conductors through and out from the power generator, to connectors that provide the current to a plant bus for power distribution. 8.2 Components of generator

Stator-Stator Frame (Fabrication Machining) Core Assembly-Stator Core, Core Suspension Arrangement End Shield Stator Winding Assembly-Stator Winding , Winding Assembly, Connecting Bus bar, Terminal Bushing RotorRotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor, Rotor Assembly Completing Assembly-Bearing Assembly, Shaft Seal Assembly, Oil Catchers, Insert Cover etc

31

Figure 8.1: Diagram :HP Turbine Blading.

8.3

Stator core

Made up of punched segments of thin sheets of ETS . Punchings coated by insulating varnish. Vent segments at designed intervals for ow of cooling gas. Compressed with tension bolts, pressure plate and clamping ngers. Stepped arrangement at the end for reduction in eddy current losses Stator winding

8.4

The Pre-insulated and pre-shaped bars are placed into the slots of the stator core.The Insulated bars in the slot section are covered with pre-fabricated glass fabric pads and locked by inserting slot wedges. Specially treated taps are applied to the bar portion just outside the slot to take care of corona discharges.

The micalastic post impregnation process insures a mechanically rm bond between all winding components

Figure 8.2: Diagram :Generator capacity vs Water Temp. Curve..

Figure 8.3: Diagram :Generator Capability Curve.

CONCLUSION

Hence we have analysed how to power generate and what are the basic building blocks of the power generation project such as compressor, combustion chambers, gas turbine, steam turbine and turbo generator.

How Power is supplied to the transmission line. We also observe construction of gas turbine,steam turbine, turbo generator etc.

Power generation plants are very ecient, reliable, highly performance and gives tremendous results. There are 8 plants working under the RAJASTHAN RAJYA VIDYUT UTPADAN NIGAM LTD.and present total installed capacity of rajasthan rajya vidyut utpadan nigam ltd. Is 4097.35 MW. Dholpur Combined Cycle Power Plant is 330 MW.

Some other power station are:Suratgarh TPS,Kota TPS,Chhabra super thermal power station,Ramgarh gas power plant,Mahi hydel,MMH schemes,Gir lignite TPS.

REFERENCES

Mannuals probided by CCPP Dholpur contains brief description about the control system, maintenance,technical data,protective device,fault tracing etc

www.rvunl.com

www.rajpower.com

some other sites like Wikipedia etc