Inplant training report

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GAS TURBINE POWER STATION
URAN

INPLANT TRAINING PROJECT



PRESENTED BY : SAMIP SHRIKANT JOSHI

FINOLEX ACADEMY OF MANAGEMENT AND TECHNOLOGY
RATNAGIRI

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ACKNOWLEDGEMENT
We take this opportunity to express the our sincere gratitude to the people who have been
helpful in the successful completion of our industrial training .We would like to show our
greatest appreciation to highly indebted to them for their tremendous support and help during
the completion of our training and project.
We are grateful to Mr.Patil (Chief Engineer) G.T.P.S Uran, who granted us the permission of
industrial training in the power plant and Mrs.S.V.Kulkarni(Training Coordinator)G.T.P.S
Uran, who guided us throughout the training period .We would like to thank all those people
who directly or indirectly helped and guided us to complete our training and project in the
power plant.

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INDEX
SR.NO. CONTENT PG.NO.
1 INTRODUCTION 4
2 OVERVIEW 5
3 FILTER HOUSE 6
4 COMPRESSOR 7
5 COMBUSTION CHAMBER 8
6 GAS TURBINE 9
7 GENERATOR 11
8 WASTE HEAT RECOVERY PLANT 12
9 BOILER 13
10 STEAM TURBINE 15
11 AIR COOLED CONDENSER 17
12 TRANSFORMER 18
13 STARTING FREQUENCY CONVERTER 19
14 GAS SKID 20
15 FUEL MANAGEMENT 21
16 CONCLUSION 22

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INTRODUCTION
GAS TURBINE POWER STATION, URAN
Commissioned in- early 80’s
Gas Supplier –ONGC
Total Area of Power Plant-45.23 Hectares
• Power Station-21.50 hectares
• Colony-4.03 hectares
• Plant(new)-19.70 hectares
POWER GENERATION
• Stage 1(4*60Mw)-240MW(scrapped in 2011)
• Stage 2(4*108Mw)-432MW
• Stage 3(2*120Mw)-240MW
WATER REQUIREMENT-1500m3/day
WATER SOURCE-M.I.D.C. RANSAI DAM
FUEL SOURCE- Natural Gas
• ONGC-BOMBAY HIGH
• KGD6 RELIANCE
POWER EVACUATION-
• On 220 KV lines to APTA substation(4 lines)
• On 220KV lines to KHARGHAR substation (2 lines)
The speciality of the GTPS plant is, in INDIA ,it is the first air cooled condensing system so
as to save water requirement to run the plant.

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OVERVIEW OF POWER PLANT

The Uran power plant was built from 1982 until 1986 for peak load and mediun load
operation. It initially comprised four 60 MW gas turbine and four 108 MW gas turbine. Four
of the 108 MW gas turbine installed during this period were financed out of FC funds. The
power plant were designed in a such way that it could be upgraded later on to an integrated
gas and steam turbine plant for minimum load operation. The provision of more power was
assured through the expansion of the 220KV switchboard and corresponding overhead lines.
Simultaneously the grid in the western region was built up with the help of funds from the
World Bank. When gas delivery totaling 3 million cubic meters per day (MMCMD) were
promised to the Indian government in 1987,the MSEB decided to combine the four 108 MW
gas turbine with waste heat boiler and two turbogenerator in order to use the steam being
produced.This formed the basis for FC project ‘Steam Turbines with waste heat boiler’ that
was initiated in 1994 there was an urgent need to increase their economic life via renewal
measure in order to have another 100,000 equivalent hours of operation.
These measures were implemented under the follw-up project “Rehabilitation of Four
108MW Gas turbines”

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GAS TURBINE COMPONENTS

1. FILTER HOUSE

The main function of the filter house is to remove the impurities from the atmospheric air so
as to avoid consequences fouling ,erosion ,corrosion.
The filter house is consisting of three main filters-
• MOISTURE FILTER-
Removes the moisture from the atmospheric air
• PRE FILTER-
Removes the small particles from the air stream which increases the filter life.It
eliminates the particles upto 100 microns
• FINE FILTERS-
It eliminates particles from the air upto 10 microns
ATMOSPHERIC AIR PARAMETERS-
• Flow rate-1412750m3/hr
• Temperature-37 c
• Humidity-80%
• Pressure-1.01325 bar

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2. COMPRESSOR
A compressor is a mechanical device that increases the pressure by reducing its
volume.In this plant 16-stage axial flow type compressor is used.Axial flow
compressors are dynamic rotating compressors that use arrays of fan like air foils to
progressively compress the working fluid.It consist of IGV(inlet guide vanes) which
are used to control air flow according load.





COMPRESSOR PARAMETERS-
• Inlet pressure-1.01325bar
• Inlet temperature-37 c
• Outlet pressure-9.5bar
• Outlet temperature-350 c
• Mass flow rate-450kg/s
• Power consumed-200MW





3. COMBUSTION CHAMBER
A combustor is a component or area of gas turbine ,ramjet engine where combustion
takes place.it is also known as burner or flame holder.In GTPS one gas turbine is
having two combustion chambers ,each having 8 spark plugs and 8 burners. The

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combustion chamber is divided into two areas –the annular area which allows the
flow of air to the combustion chamber and the remaining area which carries the
products of combustion.





C.C.PARAMETERS-
• Inlet temperature of air-350 c
• Inlet pressure of air-9.5 bar
• Fuel-air ratio-1:57
• Outlet temperature of product-1300 -1500 c
• Material –Ceramic bricks

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4. GAS TURBINE-

Gas turbine is a prime mover which converts chemical energy into mechanical energy
by the expansion of gas. In GTPS a 4-stage gas turbine is used. Each stage consist of a
pair of stator and rotor. The turbine is connected to the shaft. The bombardment of
products of combustion rotates the turbine and ultimately the shaft.
Gas turbine works on BRAYTON’s CYCLE. It consist of four thermodynamic
processes-
• Isentropic compression-This is achieved with the help of compressor.
• Isobaric combustion-Heat is added at constant in combustion chamber .
• Isentropic expansion-This is achieved with the help of turbine and torque is
generated.
• Isobaric heat rejection-Heat is rejected via boiler or bypass chimney.



GAS TURBINE PARAMETERS-
• No. of stages-4

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• Temp. at inlet- 1010 c
• Temp. at oulet-520 c
• Speed of the shaft-3000 rpm
• Inlet Pressure to turbine-9.5 bar
• Outlet pressure -16mbar
FACTORS AFFECTING GT PERFORMANCE-
1. Ambient temperature
2. Ambient pressure
3. Relative humidity
4. Inlet air pressure loss
5. GT outlet pressure
6. Blade cleanliness in terms of running hours
7. Calorific value
8. Speed or frequency
9. Partial Load

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5. GENERATOR

It is a device which converts mechanical energy into electrical energy for use in an
external circuit.The source of mechanical energy vary widely from a handcrank to a
turbine. In this plant the generator is having two poles.This generator can also be used
as motor to drive the shaft in case of rolling.


PARTS-
• ROTOR-Rotating part
• STATOR-Stationary part
• ARMATURE-The power producing component of an electrical machine.The
armature winding generate the electric current.The armature can be on either
the rotor or the stator.
• FIELD-The magnetic field component of an electrical machine.The magnetic
field can be provided by either electro magnets or permanat magnets mounted
on either the rotor or the stator.

GENERATOR PARAMETERS-
• Manufacturer-SIEMENS AEG.
• Rating-10.5KV/8284Amp. In which synchronous breaker 10.5KV


6. WASTE HEAT RECOVERY PLANT(WHRP)-
Many power plant use this process for increasing the overall efficiency.Using this
system high temperature waste heat of waste gas ,gas turbine and this heat used in
boiler and to produce HP &LP steam.

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COMPONENTS:

• BOILER:
A boiler is basically a heat exchanger. The WHRP system used in GTPS
comprises of one boiler for each GT. The exhaust of GT is the inlet to boiler.
SPECIFICATIONS:
§ Make-Babcock-Wilcox
§ Type-water tube boiler
§ Circulation-forced
§ Externally fired
§ Horizontal type
§ Two pressure drum
§ Area – 1 lakh meter sq.
§ Height -25 to 26 m
§ Efficiency-76%

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SUPERHEATER:
The main function it is to raise the temp. of steam from the evaporator. Here in
case of HP super heater temp. is raised to 500 c & in LP super heater to 210 c.
This steam is then supplied to steam turbine for further generation.
EVAPORATOR:
It is used to change the phase of water to steam. The BCP’s are used to
facilitate the forced circulation of water into evaporator. This steam-water
mixture is collected in HP or LP drum where steam takes the upper half and
water lower one.
ECONOMISER:
As the name suggest it is used for increase the overall efficiency of boiler by
increasing the heat exchange. In GTPS only HP economiser is used.
Inlet temp.-166 c
Outlet temp.-271 c

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§ STEAM TURBINE:
It is a device that extracts thermal energy from pressurized steam and uses it to
do mechanical work on rotating shaft. In GTPS while starting of turbine first
turbine casing is heated then rotor is heated. Expansion of stator and rotor is
observed and with the help of anchor point the turbine is balanced and then the
steam is allowed to pass into the turbine.

COMPONENTS:
§ Grouting
§ Pedestral
§ Stator and rotor
§ Bearing
§ Lubrication
§ Governer
§ Seal steam

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SPECIFICATION:
§ No. of stages for HP-25
§ No. of stages for LP-6
§ HP turbine inlet pressure-70 bar
§ HP turbine outlet pressure-7 bar
§ LP turbine inlet pressure- 7 bar
§ LP turbine outlet pressure-0.280 bar
§ Flow rate of steam-500 tonnes/hr
§ Efficiency-34%

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AIR COOLED CONDENSER

It is used for condensing the steam into water for its reuse. Because the water
used is very expensive. It consist of distribution head where all the steam is
accumulated. Then it is passed through the tubes where it gets condensed into
water. The tubes used are made up of carbon steel and elliptical in shape. The
tubes are having rectangular type fins to increase heat exchange area.
Dephlegmator is used for condensing the inert and non-condensed gases.


SPECIFICATION:
§ Material-steel
§ Fan speed-100 or 50 rpm
§ No.of fans -20 per steam turbine
§ Fan blade tip angle-12.5 to 13 degree
§ Gear box-vertical helical spur
§ No. of tube bundles-256 per unit
§ Steam flow-500 tonnes/hr
§ Air flow-9078 m3/s

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TRANSFORMER


A transformer is an electric device that transfers energy between two or more circuit through
electromagnetic induction. A varying current in transformer primery winding creates a
varying magnetic flux in core and varying magnetic field impinging on the secondary
winding.This varying magnetic field at the secondary induces a varying Elecromotive force
(EMF) or voltage in secondary winding.Making use of Faraday’s Law in conjuction with
high magnetic permeability core properties,transformer can thus be designed to efficiently
changes AC voltage from one voltage level to another.

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STARTING FREQUENCY CONVERTER
~
~
=
=
Single line diagram: 2 SFC for 4 Gas Turbine Units
6.6 KV
Circuit breaker
GT5
Transformer
Rectifier
Choke
Inverter
Fuse
Disconnecting
switch
~
GT6
Fuse
Disconnecting
switch
~
~
~
=
=
~ ~
Transformer
Rectifier
Choke
Inverter
GT7
Fuse
Disconnecting
switch
GT8
Fuse
Disconnecting
switch
Bus Coupler
SFC 1 SFC 2
6.6 KV
Circuit breaker

Initial spinning by Frequency Converter
• Machine is always kept on barring speed (80-100 RPM) to avoid sagging of Shaft due
to self weight.
• We cannot fire fuel gas at barring speed as negligible air flow in CC.
• At least 700 RPM is required to establish sufficient air flow.
• Therefore Initially Generator works as Synchronous motor.
• Supply of controlled frequency (with help of Thyristers) is given to Frequency
Converter to increase the regulated speed slowly.
• At 700 RPM combustion of fuel gas is started in CC.
• From 700 RPM to 2100 RPM, Synchronous Motor power and Fuel Gas power in
combination spin the machine.
• At 2100 RPM Frequency Converter function is with drawn. Generator regain it’s
original role as Generator.
• From 2100 RPM to 3000 RPM Fuel power increase the speed.
• At 3000 RPM machine is synchronized.

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GAS SKID

This system is used to supply natural gas for 4 gas turbine plants.
There are 3 no. of gas streams are used.
Stream capacity is about 2.4MMCMD
Upstream side pressure is about 49BAR Max.
Downstream side prtessure is about 20BAR Max.
Control valve:Maintain gas pressure at 16.5BAR
Operated on Instrument air.
Air pressure require for its operation=0.2 to 1.4 BAR

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FUEL MANAGEMENT
Natural gas is gaseous hydrocarbon consisting mostly of methane with lesser amounts of
natural gas liquids, as well as other gases such as such as nitrogen, carbon dioxide, hydrogen
sulphide and water.
Once captured at producing wells, natural gas is transported via pipeline to gas processing
facilities where the natural gas liquids, carbon dioxide and other trace compounds are
removed.
India is the world’s seventh largest energy producer, accounting for 2.49% of the world’s
total annual energy production. Natural gas has emerged as the most preferred fuel due to its
greater efficiency and cost effectiveness. Natural gas is a scarce resource in India and Govt.
of India plays an important role in its allocation. The natural gas pricing scenario in India is
complex in nature.
PRESENT PRICE COMPARISON OF NATURAL GAS

Price For 1MMSCM gas, Exchange rate= Rs.62 and NCV 8500
Basic cost --> 4.20
USD/MMBTU
5.25
USD/MMBTU
4.66

USD/MMBTU
4.66
USD/MMBTU
Sr. No. APM NON APM APM NAPM
1 Basic cost 10333333 12916667 10948156 10948156
2 Rebate 1550000 1937500 0 0.00
3
Marketing margin (for
Non APM
rate/MMBTU)
200000 344385 200000.00 379801
4 Marketing margin
Rebate 30000 0 30000.00 0
5 Transportaion 59530 59530 63160.00 63160
6 Net cost (1+3+5-2-4) 9012863 11383082 11181316.93 11391118
7 Service Tax @ 12% on
(5) 7144 7144 7579 7579
8 Edu cess @ 3% on (7) 214 214 227 227
9 VAT @ 5% on(6)/ CST
@ 2% 450643 569154 559065.85 569555
10 Gross Price 9470864 11959594 11740383 11960674
11 Increase in Price 26.28% 23.96% 26.28%
12 Fuel cost in Rs./kWH 2.24 2.82 2.76 2.82

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CONCLUSION:
We thank once again the GTPS Uran for providing us such a wonderful opportunity by
giving permission for inplant training in the power plant. We are glad to thank all the staff of
GTPS Uran.
This inplant training provided us more deep technical knowledge about the power plant and
their working. Thus I conclude by thanking all the staffs who directly or indirectly helped us
to complete the inplant training successfully.