BY

MANOJ KUMAR (DGM- Opn)

DGPS

Rly-1 Rly-2

ICT-4

ICT-3
Interconnection to
Thermal

220 KV BUS BAR

Gen

Gen

Gen

Gen

Gen

Gen

GT-1

GT-2

ST-1

ST-2

GT-3

GT-4

130.19 MW 130.19 MW

154.51 MW

154.51 MW

130.19 MW 130.19 MW

TOTAL GENERATING CAPACITY : 829.78 MW

DADRI GAS POWER STATION

DADRI GAS POWER STATION

STATION SALIENT FEATURES :

Type of Station

Combined cycle power plant

Station Capacity

829.78 MW(2(130.19 x 2+154.51))

Main- Natural Gas

Fuel

Alternative - HSD

Gas transportation

Hazira Through HBJ Pipe Line / RIL

P/L

Consumption

4 MCMD

Cooling Water Source

Upper Ganga Canal

:100% MCR

HP/LP bypass capacity (for steam turbine only )

Open cycle - 32%

Efficiency

Combined cycle - 48.33%

STATION SALIENT FEATURES :

GAS TURBINE
Make
:Siemens AG, Germany
Type
:V94.2
Yr. Of Mfr.
:1990
Capacity
:130.19 MW
Gross Power
:284.2 MW at 27 C and
987 mbar
Turbine efficiency
:32.7%
Design inlet Temp
:1060 C
Rated Speed
:3000 rpm
Critical Speed of turbine
:1750 rpm
Self sustaining Speed :2100 rpm
Starting Device
i) Type
:Starting Frequency

INPUTS FOR GAS STATION

Fuel Natural gas (Primary) HSD (Alternate fuel)

Source of gas- APM, PMT:ONGC/RIL/BRITISH
GAS
PMT
RLNG :GAIL, IOCL, GSPCL.
KG-D6 : RIL
TRANSPORTATION :From GAIL through HBJ Pipeline
& RGTL.
. Source of HSD : IOCL, HPCL, BPCL through Rly. rakes.

BENEFECIARIES
State / Union Territory

Share (%)

Share from
Station(In MW)

U.P.

29.60

246

Delhi

10.96

91

Rajasthan

9.28

77

J&K

6.75

56

Punjab

15.90

132

Haryana

4.94

41

Uttarakhand

3.41

28

H.P.

3.01

25

Chandigarh

0.61

Unallocated

15

129
Railways gets 8.43 % ( 70 MW ) from unallocated power of DGPS.

Commissioning Dates of DGPS

CC

COMP

GAS
TURBINE

GUILOTINE DAMPER

S
T
A
C
K

H
R
S
G

DIFFUSER

INTERFACE OF GT WITH HRSG

OVERVIEW OF COMBINED CYCLE

OPERATION

HPD

WHRB

GT1
Gas Turbine Unit-1

LPD
BP
DUCT

LP STEAM (5 KSC, 210C)

HPD

HP STEAM (61 BAR, 530C)

BP
DUCT

LPD

HP

LP

ST1
CW

Condenser
Steam Turbine Unit-1

WHRB

GT2

CEP
Gas Turbine Unit-2

To Dearator

FILTER
WASHING
HOUSE

WORKSHOP
BLDG

SYD BLDG
COMPRESSOR HOUSE

NEW DG SET

CHLORINATION
PLANT

GT#3

2
T#
C

RHOMBAK
FILTER

SWAS
ROOM

GT#4

PARK

H2
FILLING
STATION

1
T#
C

WHRB#2

WHRB#1
MAKEUP
P/H

GT#3

STACK

H2
FILLING
STATION

SWAS
ROOM

ICT#4B

UAT#4 UT#4

STACK

WHRB#3

CW P/H

CT SWGR

WHRB#4

GT#4

ST#2

UT#6

CCR
ST#1

STACK

STACK

GT#2

UAT#3 UT#3

UT#5

GT#2

UAT#2 UT#2

GT#1

UAT#1 UT#1

GT#1

PARKING SHED
PARKING SHED

ICT#4Y

S
W
I
T
C
H
Y
A
R
D

ICT#4R

ICT
SPAIR

ICT#3B

ICT#3Y

ICT#3R
OLD DG
STATION

CANTEEN

STORE

MAIN COMPONENTS OF GAS TURBINES POWER

GENERATING PLANT
Starting system
Air intake system
Fuel supply system
Compressor
Combustion chamber
Gas turbine
Gas turbine exhaust diffuser/Diverter damper/Chimney
Lub oil supply system
Control oil supply system
Turbo generator
Generator circuit breaker
Generator transformer
Control and instrumentation system

GAS TURBINE

Single Silo & Single Burner :- ABB 13D2/13E1/8C/11N

BURNER

TYPE 13 E
COMBUSTION CHAMBER

TURBINE
AIR
GENERATOR

EXHAUST DIFFUSER

COMPRESSOR

Double Silo with Multiple Burners :- SiemensFUEL

V 94.2/84.2
SUPPLY SYSTEM
COMBUSTION
CHAMBER

TURBINE

COMPRESSOR

SECTIONAL OVER VIEW SIEMENS V 94.2

131 MW

LUB OIL SYSTEM

GENERATOR

TURBINE

ADVANTAGES OF GAS TURBINE

Environment

Friendly
Less installation Period
High Efficiency.(60% )
Less manpower requirements
Quicker response time
Faster Acceleration/deceleration
Modular replacement
Less vibrations
Less area required
No by Product like ash.

DISADVANTAGES OF GAS TURBINE

High cost of maintenance

High frequency of inspection/overhauling
Hot gas path components under high thermal
stress
Variation in out put due to external factors like
ambient pressure, temp, relative humidity ,Grid
Frequency
Running on secondary fuel or frequent start stop
reduces the components life.

The

gas turbine works on

the principle of BRAYTON
CYCLE.

Joule Brayton Cycle

THE IDEAL BRAYTON CYCLE IS MADE UP OF

FOUR INTERNALLY REVERSIBLE
PROCESSES :

1-2

Isentropic compression (in a

compressor)
2-3 Constant pressure heat addition
3-4 Isentropic expansion (in a turbine)
4-1 Constant pressure heat rejection

BRAYTON CYCLE
Compressor draws

air from the atmosphere

Air passes through the compressor, and the pressure
increases and the volume decreases
Combustion occurs at constant pressure-air heats upvolume increases
The gases pass through the turbine rotor
The rotor turns Kinetic Energy and Thermal Energy to
Mechanical Energy.
Gases are released through the exhaust stack to the
atmosphere or sent to waste heat recovery boiler.

Rankine Cycle

Combined Cycles

Combined Cycles Efficiencies

cc = B + R - B*R
If
Gas turbine efficiency =
40%,
Rankine cycle efficiency =
30%,
then Combined cycle efficiency is . ?

Combined Cycle Heat Flow

OUTPUT
30 %

100% FUEL
INPUT

GT

3% MISC
LOSSES

OUTPUT
16 %

67%

HRSG
+
ST

34%
CONDENSER
LOSSES

14% TO
STACK

3%
MISC
LOSSES

GAS POWER STATIONS IN OPERATION IN NTPC

Sl
No

Station

Capacity(GT+ST)

Make

Model

Fuel

ANTA

3*88+1*149

ABB

13D2

NG/NAPTHA

AURIYA

4*112+2*102

MHI

701D

NG/NAPTHA

DADRI

4*131+2*146.5

SIEMENS

V94.2

NG/HSD

KAWAS

4*105+2*110.5

EUROPEAN
GAS TURBINE

PG-9161E

NG/NAPTHA

GANDHAR

3*131+1*224.49

ABB
(ALSTHOM)

13E

NG

FARIDABAD

2*143+1*129

SIEMENS/BHEL

V94.2

NG/NAPTHA

KAYAMKULAM

2*115+1*144

GE,USA/BHEL

FRAME9171E

NAPTHA

Module Concept
1 GT + 1 HRSG + 1 ST ]
2 *[ GT + HRSG ] + 1 ST ]
3 *[ GT + HRSG ] + 1 ST ]
4 *[ GT + HRSG ] + 1 ST ]
Single shaft system

2 GT + 1 ST

2 GT + 1 ST
Fuel

106 MW
HRSG
G
Steam
GT-1

116 MW

Exhaust gas

Air

Air

Exhaust gas

ST-1

GT-2
G
106 MW
Fuel

2 X 106 + 1 X 116 = 328 MW

2 GT + 1 ST
Fuel

255 MW
G
Steam
GT-1

276 MW

Exhaust gas

Air

Air

Exhaust gas

ST-1

GT-2
G
255 MW
Fuel

2 X 255 + 1 X 276 = 786 MW

2 * [2 GT + 1 ST]
4 GE 7FA gas
turbo-generator
units [60 Hz,
183 MW each]
and 2 GE D11S
steam turbines.,
totaling 1135
MW in two
modules.

Tamazunchale Combined Cycle Power Station (Mexico)

3 GT + 1 ST
Fuel

G
GT-1

Air

Exhaust gas

Fuel

Steam

G
GT-2

Air

G
Exhaust gas

ST-1

Fuel

G
GT-3

Air

Exhaust gas
3 X 140 + 1 X 230=650 MW

4 GT + 1 ST

Single Shaft Arrangements

STARTING SYSTEM

THE INITIAL ROLLING OF GAS TURBINE IS DONE BY

TURBO GENERATOR WORKING AS MOTOR.
THE ELECTRICAL POWER IS FED IN TO THE TURBO
GENERATOR THRU STATIC FREQUENCY CONVERTER.
THE SPEED OF TURBINE ROTOR IS INCREASED IN A
REGULATED MANNER THRU FREQUENCY CONVERTER
UP TO 600 RPM AND THE IGNITION OF FUEL GAS TAKES
PLACE IN COMBUSTION CHAMBER.
THE FLUE GAS PRODUCED IN COMBUSTION CHAMBER
IS INJECTED INTO THE GAS TURBINE.

 The

starting equipment The rotor of gas

turbine is driven by the combined torque
produced by the gas turbine and starting
equipment ( turbo generator working as
motor) up to the rotor speed 2100 RPM.
The starting system gets disconnected at
2100 RPM and the rotor is driven further up
to 3000 rpm by the torque developed by
the gas turbine.
The gas turbine can be also started by an
electric starting motor connected to gas
turbine generator shaft thru torque
converter.

AIR INTAKE FILTER CARTIDGE

COMPRESSOR

Air is sucked in to the compressor thru air filter cartridges

installed in air intake system and air inlet duct.
The air intake system consists a nos of filter cartridges installed
in air filter house.
The incoming air is compressed to high pressure and directed
to combustion chamber.
Major Part of compressed air is used for cooling of combustion
chamber and turbine blades.
The inlet air to compressor is regulated by changing opening of
compressor inlet guide vanes.
The axial flow compressor is having stator and rotor .
The stator of compressor consists diaphragm in a nos of rows
attached to the casing .The compressor diaphragm consists of a
no of fixed vanes.
The rotor of compressor consists rotating blades in a no of rows
attached to the rotor.

COMBUSTION CHAMBER

The compressed air discharged by the compressor is directed to the

combustion chamber
The fuel is supplied to the combustion chamber thru burner/nozzle
and is burnt in the combustion chamber in presence of compressed
air.
The flue gas produced at high pressure and high velocity in the
combustion chamber is directed to gas turbine blades.
The temperature of the gas in the combustors and entering the turbine
can reach up to 1350 C.
Special heat resistant materials (such as ceramics) are used to line the
inside walls of the combustors.
Water or steam can be injected into the combustors to reduce the
concentration of NOx (oxides of nitrogen) in the exhaust gas (by
reducing the temperature of the flame).
Special burners (usually called "dry low NOx burners") are used to
reduce the concentration of NOx in the exhaust gas to less than 25
ppm at full load, without the use of water or steam injection

FUELS USED IN GAS TURBINES COMBUSTION CHAMBER

1.

Natural Gas

2.

Wellhead Gases

3.

Landfill Gas

4.

Sewage Gas

5.

High Hydrogen Gases

6.

Diesel

7.

Kerosene

8.

LPG (liquid and gaseous)

9.

Naphtha

10.

Wood or Synthetic Gas

11.

Coal Mine Gas

12.

Coke Oven Gas

45

Natural Gas Composition

MethaneCH4 72-90%
EthaneC2H6 0-20%
PropaneC3H8ButaneC4H10Carbon DioxideCO2 0-8%
OxygenO2 0-0.2%
NitrogenN2 0-5%
Hydrogen sulphideH2S 0-5%
Rare gases, He, Ne, Xetrace

46

Natural Gas Composition-Processed

MethaneCH4 77%
EthaneC2H6 9%
PropaneC3H8ButaneC4H10 10%
Carbon DioxideCO2 2%
NitrogenN2 2%

47

PANNA-MUKTA-TAPTI OIL & GAS

FIELDS
APM-PMT

RLNG
RGTL

Gadimoga
Near
Kakinada, AP
KGD6

DADRI GAS SUPPLY SYSTEM

DGPS

Vertical Silo
Combustion
Chamber
Gas Control
Station

HBJ Pipeline

GAIL
Term.

36 to 20
Pr Reducing
Station

Rhommback
Filter

FIltan
Filter

GT-1

Natural Gas Firing in Gas Turbine

Comb
Stop
Valve

Control
Valve
Comp

Drain

Turb

Gen

Air

GT-1

50

TURBINE BLADES

COMPRESSOR
BLADES

TURBINE BLADE COOLING HOLES

The flue gas produced at high

pressure and high velocity in the
combustion chamber is injected to the
gas turbine blades.
The kinetic energy and thermal
energy of flue gas is converted in to
mechanical energy by the gas turbine
.
The gas turbine works as prime
mover of compressor and turbo
generator .
The discharge of gas turbine is fed in

SUB LEVEL COMPONENTS

Cooling air passage

Outer wall
COOLING HOLES

Partition

Inner wall

GT Blades: Internal Cooling Passage

GT Blades: Internal Cooling Passage

TURBINE EXHAUST

BURNER

THE POWER OUTPUT/E EFFICIENCY FROM THE GAS

TURBINE MAY BE INFLUENCED BY

The energy used by the air compressor - if less

energy is used to compress the air, more energy is
available at the output shaft.
The temperature of the hot gas leaving the
combustors - increased temperature generally
results in increased power output.
The temperature of the exhaust gas - reduced
temperature generally results in increased power
output.

The mass flow through the gas turbine - in general,

higher mass flows result in higher power output.

The drop in pressure across the inlet air

filters,
silencers and ducts - a decrease in
pressure loss increases power output.

 The drop in pressure across the exhaust

gas silencers, ducts and stack - a decrease

in pressure loss increases power output.
Increasing the pressure of the air entering
or leaving the compressor - an increase in
pressure increases power output.
Cooling the inlet air - mainly used
in hot weather conditions

 Inject steam or water into the combustors or

turbine

Wash or otherwise clean the fouling from

the blades of the air compressor at regular
intervals

Combinations of the above methods

Effect of Temperature on Capacity of Gas

Stations

Effect of Frequency on Capacity of Gas

Stations

For a

Gas Turbine, approximately 60% of

the total work produced in the turbine is
consumed by its axial compressor.
Consequently, maintaining a high
compressor efficiency is important for the
plants revenue stream.

Depending upon the weather conditions,

the entry of impurities from air into the
Gas Turbine compressor can have the
effects of Erosion, Fouling & / or
Corrosion.
Performance losses on these
accounts could be either
recoverable (fouling) or nonrecoverable (erosion & corrosion)
.

COMPRESSOR FOULING
FOULING IS THE SOILING OF BLADES :

The formation of deposits on the blades can alter the shape

of blades.
TYPICALLY IT IS FORMED BY
Airborne salt
Industrial pollutions: Fly Ash,Hydrocarbons,etc .This
Causes a grimy coating on the early stages and can
backed on in later stages.
Ingestion on lub oil vapors
Internal Gas Turbine oil leaks from axial bearing front
bearing (Oil mixed with dirt in gestation cause heavy
fouling on blades.
Coal Dust spray paint, fumes .

Black deposition on blades.

Fouling responsible for 70-85% of all

performance losses in Gas Turbines.
(Estimate)
Output losses have also been
estimated between 2-15% (from
favourable to unfavourable
conditions).
An axial compressor is a machine
where the aerodynamic performance
of each stage depends on that of the
earlier stages. Thus when fouling
occurs in the inlet guide vanes and
the first few stages, drop in

IGV

IGV
IGV
IGV

IGV

The first five to six stages of the

compressor tend to foul and the
degree of fouling tends to
decrease from the first to the last
stage of compressor.

Good filtration must be coupled with

a carefully planned online and offline
washing regime to minimize salt
deposits on compressor airfoils.
Air tightness is a must for any GT
inlet system as even the most efficient
filtration system will be useless if
unfiltered airflow leaks in and enters
the
compressor.
Bypass
door leakage, Poor
gaskets and seals at flanges &
Modifications made on the inlet

CONTROL OF FOULING
BY COMPRESSOR WASHING

HIGH QUALITY AIR FILTRATION SYSTEM

COMPRESSOR WASHING
Two different techniques are used .
OFFLINE and ONLINE CLEANING.
Hand washing of the IGVs may have
to be done for effectiveness

OFF- LINE CLEANING

Off-line washing when performed correctly can
restore up to 80% percent of the lost power
output and efficiency attributed to compressor
fouling.

However, disadvantage of off-line washing

is the requirement of shut down of gas
turbines.
The objective of online washing is to
maintain the cleanliness of a
compressor after offline washing.

Compressor Wash Pump Skid

Mixing Tank
Control system
High pressure pump
Pnuematic 12 tyres

Dust Deposit on cooling Holes

All filters to be properly installed

leaving no gaps in between rubber
gasket and sealing gap to be checked.

LATEST DEVELOPMENT IN GAS TURBINE TO ACHIEVE

INCREASE IN POWER OUTPUT
Using

the exhaust gas to heat the air from the

compressor (mainly used in cold weather
conditions)

Divide

the turbine into two parts and reheat the

gas between the two parts by passing the gas
through additional burners and combustors
located between the two parts

In gas turbines, Cooling air is replaced

with steam, which enhances cycle
performance in efficiency, and significantly
increases the gas turbine output, since all
the compressor air can be channeled
through the turbine flow path to do useful
work.

Variable Cost after New Gas

Rate
FC FOR 2013-14
Rs 1.20/-

Type of
Gas
PMT
APM
RLNG
1 MMBtu= 26.25
SCM
#GCV9600KCAL/SCM

Before
01/04/2014

After
01/04/2014

Gas
Gas
Rate=$4.2/MMB Rate=$8.4/MM
TU
BTU

Rs/UNIT
2.835
2.835
9.675
Current PLF is 43.52%
$=59/-Rs

Rs/UNIT
5.103
5.103
9.675

After New Gas Rate PLF

will be ? %