Gama power plant -- An overview (2018)

This is a presentation on the overview of my father's powerplant, GAMA Infraprop Pvt Ltd (GIPL) located in Kashipur, Uttarakhand and powered by German Power Generation Company Steag GmbH. This powerplant was established as one of the three earlier proposed units by kashipur. There were three units of power plant as proposed by Govt. of Uttarakhand: The "Alpha" unit, the "Beta" unit and the "Gamma" unit. Out of these three, the first and the last runs while the middle one doesn't due to some technical issues and because of the fact that the equipments installed in the powerplant "Beta" were outdated, thus prior to the commence of the operation of the same, the project "Beta" was cancelled. Coming to the "Gamma" plant which is also spelled as "Gama", it is powered by Natural Gas supplied by IGL (Indraprastha Gas Limited). It is working under two gas turbines certified by GE energy service, a US electrical power generation company, and a "steam" turbine. Three of the turbines equally generate 75kW, ie, power outputs of the three are summed up to 225kW. Remaining information is written in this presentation. Powerplant photos here are just schematic, provided to give a clear image it. Have Fun!!!

1. GAMA Power Plant 225 MW CCPP GAMA project run by STEAG. Presented By : Indraneel Bhattacharya Submitted to : Vishnimurthi .

2. What is Power Plant? A power plant is a station where power is generated from the required resources. It consist of a Generator and a Prime mover to rotate it. Power plants can be built in various locations depending upon its characteristics. Introduction

3. Power Plant

4. Thermal Power Plant Gas Power Plant Hydroelectric Power plant Nuclear Power Plant Wind Power Plant Solar Power Plant Tidal Power Plant Geothermal Power Plant Biogas Power Plant Types of Power Plant

5. What is CCPP? A CCPP (or Combined Cycle Power Plant) is a power generating plant or power generating station where the power generated from it consist of a combination of two or more Heat cycle processes. It can involve Nuclear power, Gas power, etc. CCPP

6. CCPP CCPP Heat Cycle

7. The current plant is Gas Power Plant. It comprises main components/zones like: Gas Skid. Two Secondary Gas Skids Two Gas Turbines 75 MW each. PEECC Fire Extinguishing Chamber. 2 HRSGs. One Steam Turbine 75 MW. DM Plant. Air-Cooled Condenser. Cooling Towers Transformers. Unit Auxiliary transformers. Switchyard, etc. Diesel Generator. DCS. Control room. SCADA. It is a 225 MW project and this power output is the sum of individual power outputs from three generators. About the plant

8. A gas Skid is a gas-based power plant zone where gas is received and conditioned for the usage of Gas Turbines. It has step by step methods to process and filter the gas and it takes place in different zones. The gas supplied to the gas skid is below our body temperature but above the melting point of water (normally at the atmospheric pressure). Gas Skid

9. Gas Skid

10. Gas Skid

11. A Gas Turbine is a turbine that is just like a jet engine of an airplane however it is meant for power generation. Unlike the airplane turbine that has a curvilinear housing, Gas turbines have a cuboid -shaped housing provided with a 3-stage air filter and a fuel distribution system which is housed separately. Gas Turbine

12. Gas Turbine Internal Design of a Gas Turbine

13. PEECC or Packaged Electronic/Electrical Control Compartment is a major discipline within the field of electrical engineering and includes a wide variety of technologies. It refers to enclosures and protective features built into the product itself, and not to shipping containers. It applies both to end products and to components. Packaging of an electronic system must consider protection from mechanical damage, cooling, radio frequency noise emission, protection from electrostatic discharge, maintenance, operator convenience, and cost. PEECC

14. PEECC Visualization of PEECC

15. Packaging materials for PEECC: Sheet metal Cast metal Machined metal Molded plastic Potting Porosity sealing or impregnation Liquid filling Conformal coating Glop-top Hermetic metal/glass cases Hermetic ceramic packages Printed circuit assemblies Design considerations: Hazards to be protected against: mechanical damage, exposure to weather and dirt, electromagnetic interference, etc. Heat dissipation requirements Tradeoffs between tooling capital cost and per-unit cost Tradeoffs between time to first delivery and production rate Availability and capability of suppliers User interface design and convenience Ease of access to internal parts when required for maintenance Product safety, and compliance with regulatory standards Aesthetics, and other marketing considerations Service life and reliability PEECC

16. It is typically a chamber consisting of CO 2 cylinders that is meant to light out fire from any kind of leakages in the Gas Turbine. It is coloured Red for the purpose of safety or First Aid. It Comprises Three plugs in its housing (each plug for each zone—zone 1, 2 & 4) to be released at the time of fire accident, Sensors to sense the fire in the Gas Turbine and signal it to the circuit boards in the Chambers so as to automatically release the CO 2 to the Turbine Fire Extinguishing Chamber

17. Fire Extinguishing Chamber

18. The HRSG (or Heat Recovery Steam Generator) is a zone where the steam is generated from water by recovering the heat of the GT exhaust. It is coupled with the Gas Turbine. The Exhaust of the gas turbine pass through the HRSG over the pipelines through which water from the DM plant pass to form steam. HRSG Comprises three drums: HP (high pressure), IP (intermediate pressure), LP (low pressure); two chimneys and a series of pipelines. It is much similar to the Boiler, however it is characterized as a hollow chamber through which the GT exhaust pass and heat up the water in the pipeline unlike the boiler which is stored in a container that is heated up to form steam. HRSG

19. HRSG

20. The temperature of the gas inlet to the HRSG is about 650˚C. This gas is cooled down by using the pipelines within the HRSG Housing. There are three stage pairs of the pipelinings : HP pipelinings (HP Superheater + HP Economizer+HP Evaporator). IP pipelinings (IP Superheater + IP Economizer+IP Evaporator). LP pipelinings . Each of the pipelines have a specific function. Besides that the LP Drum (De-aerator) pipelines supply heated water to IP Drum and HP Drum then IP linings supply steam to the HP Drum. Temperature and pressure of the steam liberated from the HP pipelining is about 535˚C and 95 kgf /cm 2 respectively. The two chimneys of HRSG are meant to draw the GT exhaust out for separate occassions – one for drawing the exhaust out without utilizing its heat and the other one for drawing the same however utilizing its heat. HRSG

21. Steam turbines are the turbines driven by Steam that come out from the HRSGs It has three main components: HP turbine, IP turbine, LP turbine. The Size of each components of Steam turbines increase with decrease in steam pressure. Decrease in steam pressure in turbine takes place step by step. Steam Turbine

22. Steam Turbine HP steam turbine IP steam turbine LP steam turbine

23. Diesel Generators are provided in power plant so that if there is any power failure in the plant, emergency equippments in the plant can be run. Diesel Generator

24. DM plant (or De-Mineralization plant) is an area of power plant where the water taken out from the underground is purified to a degree in which there is an absense of any minerals that could harm the plant components. Most of the water from it is send to HRSGs so that the heat from the Gas Turbine exhaust is absorbed to form high pressure steam to run the turbine. DM Plant

25. DM Plant

26. It is a chamber or a compartment where the high pressure steam coming from the turbine is Cooled down to the normal state of water. It comprises series of narrow pipelines within the housing and several fans on and under the housing and a CST (Condensed Storage Tank). High pressure steam passing through the pipelines are cooled down by the fans pulling air either from above or from below. The condensed water is thus stored in the CST. Condenser

27. Condenser

28. It’s a heat rejection device that releases waste heat to the atmosphere through cooling of water stream to a lower temperature. They may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or, in the case of  closed circuit dry cooling towers , rely solely on air to cool the working fluid to near the  dry-bulb air temperature. Cooling towers vary in size from small roof-top units to very large hyperboloid structures that can be up to 200 metres (660 ft) tall and 100 metres (330 ft) in diameter, or rectangular structures that can be over 40 metres (130 ft) tall and 80 metres (260 ft) long. The hyperboloid cooling towers are often associated with nuclear power plants, although they are also used in some coal-fired plants and to some extent in some large chemical and other industrial plants. Although these large towers are very prominent, the vast majority of cooling towers are much smaller, including many units installed on or near buildings to discharge heat from air conditioning. There are 3 kind of classifications of Cooling tower By Build By Heat Transfer By Air Flow Generation By Use By Air-to-water flow Cooling Tower

29. There are types of cooling towers based on their build: Package type Field erection type There are types of cooling towers based on their Heat Transfer: dry cooling towers wet cooling towers (or  open circuit cooling towers )  fluid coolers (or  closed circuit cooling towers ) There are types of cooling towers based on their Air Flow Generation: Natural draft. Mechanical draft Fan assisted natural draft There are types of cooling towers based on their Air-to-water Flow: Crossflow . Counterflow . There are types of cooling towers based on their Use: Heating, ventilation and air conditioning (HVAC) Industrial cooling towers Cooling Tower

30. A transformer is a device that transfers power by either stepping up the voltage and stepping down the current or stepping down the voltage and stepping up the current. There are two types of transformers – Step up and Step Down. It comprises a Laminated soft iron core, Primary coil(s) and secondary coil(s), cooling tubes, conservation tank, low voltage bushes, main tank (housing), tank cover, drain off, cooling oil. Transformers

31. Transformers

32. There are certain limitations to the transformer while transferring power, i.e., loss of power. It includes: I 2 R Loss. Copper Loss Hysteresis loss Eddy current loss, etc. Magnetic flux loss. Such losses can be avoided by using proper material as m-flux transferring medium like laminated soft iron core, using thick wires for the transformer coils, proper cooling system, etc. Transformers

33. They are other kind of transformers that are paired parallel with the output lines of the Gas Turbine Generators. They step down the generator output voltage to the required voltage to run the power plant, unlike the main transformers that step up the generator output and send it to switchyard. The same precautions are to be taken For UATs as that of Ordinary transformers in order to avoid losses. Unit Auxiliary Transformers

34. Switchyard is a substation which operate at a single voltage level (for the current plant). Here the switching action takes place between the Power distribution and power collection takes place. Switchyard

35. There are several components of switchyard: Insulator Isolator Bus lining Bus Coupler Current Transformer (CT) Capacitive voltage Transformer (CVT) PLCC (Power Line Carrier Communication) Line Trap (Wave Trap) Switchyard

36. DCS or Distributed Control System is a computerized control system for a process or plant usually with a large number of control loops. Autonomous controllers are distributed throughout the system, but there is central operator supervisory control. The DCS concept increases reliability and reduces installation costs by localising control functions near the process plant, with remote monitoring and supervision. DCS

37. DCS Pictorial layout of DCS

38. A control room, a.k.a. operation center or operation control center, is a room serving as a central space where a large physical facility or physically dispersed service can be monitored and controlled. Control room

39. SCADA or Supervisory control and data acquisition is a control system architecture that uses computer, networked data communication and GUI (Graphical User Interface) for high-level process supervisory management, but uses other peripheral devices such as programmable logic controllers and discrete PID controllers to interface with the process plant or machinery. SCADA

40. There are five functional manufacturing levels implemented by SCADA as follows Level 0 contains the field devices such as flow and temperature sensors, and final control elements, such as control calves. Level 1 contains the industrialised input/output (I/O) modules, and their associated distributed electronic processors. Level 2 contains the supervisory computers, which collate information from processor nodes on the system, and provide the operator control screens. Level 3 is the production control level, which does not directly control the process, but is concerned with monitoring production and targets. Level 4 is the production scheduling level. SCADA

41. SCADA

42. Why need Safety? We need safety in every aspects of our lives in order to have a better living, to stay sane and stay safe from any kind of perils. What is Accident? An  accident , also known as an  unintentional injury , is an undesirable, incidental, and unplanned event that could have been prevented had circumstances leading up to the accident been recognized, and acted upon, prior to its occurrence. Sources of accident: Human activities (88%) System malfunctioning (2%) Nature (10%) Safety

43. Safety in plant : The Basic Requirement of safety in plant is from the fire and that to the workers from any kind of the reckless activities. Safety requirements: Helmet Safety shoes Safety belt Goggles Earplugs/Earmuffs Safety Gloves. Apron. Safety

44. Sources of Fire: There are only three main sources of fire— Oxygen (Air) Heat Energy Fuel (Inflammable at low ignition temp). Safety

45. Classes of fire: There are six classes of fire— Class A (Wood fire, paper fire) Class B (Petroleum fire or fire from reactive materials) Class C (Burning flammable gases’ fire) Class D (Fire from combustible metals) Class E (Electrical fire) Class F (Kitchen fire/Fire from cooking fat and oil) Types of fire extinguishers to safeguard from each class of fire: Water and foam (Class A) CO 2 (Classes B, C and E) Dry Chemical (Classes A, B, C and E) Wet Chemical (Class F) Dry Powder (Class D) Water Mist (Classes A, C & E) Clean Agent (Classes B, C & E) Catridge -Operated Dry Chemical (Classes A, B, C & E) Safety

46. Thank You Genuine ©Copyright Indraneel Blattacharya 2018. All rights Reserved