Documente Academic
Documente Profesional
Documente Cultură
7/06/2010 to 3/07/2010
Submitted By:-
Rishabh Ladha
B.Tech 2nd year
VIT University
This is to certify that Rishabh Ladha(08BEE126), student of 2008-2012 Batch of Electrical
& Electronics Branch in 2nd Year of Vellore Institute of Technology, Vellore has successfully
completed his industrial training at Pragati Power Corp Ltd-PPCL, New Delhi for four weeks
from 7th june to 3rd july 2010. He has completed the whole training as per the training report
submitted by him.
Training Incharge
Pragati Power Corp Ltd.
New Delhi
Contents:
• Introduction
• Combined Cycle Power Plant
• Mechanical Equipment
• Electrical Equipment
• Protection and Switchgear
• Balance of Plant
• Bibliography
Introduction:
IPGCL-PPCL
INDRAPRASTHA POWER GENERATION COMPANY LIMITED
&
PRAGATI POWER CORPORATION LIMITED
(GOVT. OF NCT OF DELHI UNDERTAKINGS)
Their Vision:
“TO MAKE DELHI – POWER SURPLUS”
OUR MISSION
Ø To maximize generation from available capacity
Ø To plan & implement new generation capacity in Delhi
Ø Competitive pricing of our own generation
Ø To set ever so high standards of environment Protection.
Ø To develop competent human resources for managing the company with good standards.
Combined Cycle Power Plant:
Combined Cycle
Systems which are designed for maximum efficiency in which the hot exhaust gases
from the gas turbine are used to raise steam to power a steam turbine with both turbines being
connected to electricity generators.
To minimise the size and weight of the turbine for a given output power, the output
per pound of airflow should be maximised. This is obtained by maximising the air flow
through the turbine which in turn depends on maximising the pressure ratio between the air
inlet and exhaust outlet.
System Efficiency: Thermal efficiency is important because it directly affects the fuel
consumption and operating costs.
Combined Cycle Turbines It is however possible to recover energy from the waste
heat of simple cycle systems by using the exhaust gases in a hybrid system to raise steam to
drive a steam turbine electricity generating set. In such cases the exhaust temperature may be
reduced to as low as 140°C enabling efficiencies of up to 60% to be achieved in combined
cycle systems.
Thus simple cycle efficiency is achieved with high pressure ratios. Combined cycle
efficiency is obtained with more modest pressure ratios and greater firing temperatures.
Fuels One further advantage of gas turbines is their fuel flexibility. Crude and other heavy
oils and can also be used to fuel gas turbines if they are first heated to reduce their viscosity
to a level suitable for burning in the turbine combustion chambers.
• The Open Cycle efficiency of the plant is about 31%
• The Closed Cycle efficiency is around 49%
Mechanical Equipment:
The
HRSG at PPCL
Condenser
The surface condenser is a shell and tube heat exchanger in which cooling water is
circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell
where it is cooled and converted to condensate (water) by flowing over the tubes. Such
condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of
air and gases from the steam side to maintain vacuum
For best efficiency, the temperature in the condenser must be kept as low as practical
in order to achieve the lowest possible pressure in the condensing steam. Since the condenser
ο
temperature can almost always be kept significantly below 100 C where the vapour pressure
of water is much less than atmospheric pressure, the condenser generally works under
vacuum. Thus leaks of non-condensable air into the closed loop must be prevented. Plants
operating in hot climates may have to reduce output if their source of condenser cooling
water becomes warmer; unfortunately this usually coincides with periods of high electrical
demand for air conditioning. The condenser generally uses either circulating cooling water
from a cooling tower to reject waste heat to the atmosphere, or once-through water from a
river, lake or ocean.
A typical water cooled condenser Deaerator
Deaerator
A steam generating boiler requires that the boiler feed water should be devoid of air
and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the
metal. Generally, power stations use a deaerator to provide for the removal of air and other
dissolved gases from the boiler feedwater. A deaerator typically includes a vertical, domed
deaeration section mounted on top of a horizontal cylindrical vessel which serves as the
deaerated boiler feedwater storage tank.
Practical considerations demand that in a steam boiler/steam turbine/generator unit the
circulating steam, condensate, and feed water should be devoid of dissolved gases,
particularly corrosive ones, and dissolved or suspended solids. The gases will give rise to
corrosion of the metal in contact thereby thinning them and causing rupture. The solids will
deposit on the heating surfaces giving rise to localised heating and tube ruptures due to
overheating. Under some conditions it may give rise to stress corrosion cracking.
Cooling Towers:
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process heat
and cool the working fluid to near the wet-bulb air temperature or rely solely on air to cool
the working fluid to near the dry-bulb air temperature. Common applications include cooling
the circulating water used in oil refineries, chemical plants, power stations and building
cooling. The towers vary in size from small roof-top units to very large hyperboloid
structures (as in Image 1) that can be up to 200 metres tall and 100 metres in diameter, or
rectangular structures (as in Image 2) that can be over 40 metres tall and 80 metres long.
Smaller towers are normally factory-built, while larger ones are constructed on site.
Cooling Towers
Electrical Side:
GENERATORS:
The class of generator under consideration is steam turbine-driven generators,
commonly called turbo generators. These machines are generally used in nuclear and fossil
fuelled power plants, co-generation plants, and combustion turbine units. They range from
relatively small machines of a few Megawatts (MW) to very large generators with ratings up
to 1900 MW. The generators particular to this category are of the two- and four-pole design
employing round-rotors, with rotational operating speeds of 3600 and 1800 rpm in North
America, parts of Japan, and Asia (3000 and 1500 rpm in Europe, Africa, Australia, Asia, and
South America). At PPCL 3000 rpm, 50 Hz generators are used of capacities 122 MW. As
the system load demands more active power from the generator, more steam (or fuel in a
combustion turbine) needs to be admitted to the turbine to increase power output. Hence
more energy is transmitted to the generator from the turbine, in the form of a torque. This
torque is mechanical in nature, but electromagnetically coupled to the power system through
the generator. The higher the power output, the higher the torque between turbine and
generator. The power output of the generator generally follows the load demand from the
system. Therefore the voltages and currents in the generator are continually changing based
on the load demand. The generator design must be able to cope with large and fast load
changes, which show up inside the machine as changes in mechanical forces and
temperatures. The design must therefore incorporate electrical current-carrying materials (i.e.,
copper), magnetic flux-carrying materials (i.e., highly permeable steels), insulating materials
(i.e., organic), structural members (i.e., steel and organic), and cooling media (i.e., gases and
liquids), all working together under the operating conditions of a turbo generator.
An open Electric Generator at Power Plant Stator of a Turbo Generator
Since the turbo generator is a synchronous machine, it operates at one very specific
speed to produce a constant system frequency of 50 Hz, depending on the frequency of the
grid to which it is connected. As a synchronous machine, a turbine generator employs a
steady magnetic flux passing radially across an air gap that exists between the rotor and the
stator. (The term “air gap” is commonly used for air- and gas-cooled machines). For the
machines in this discussion, this means a magnetic flux distribution of two or four poles on
the rotor. This flux pattern rotates with the rotor, as it spins at its synchronous speed. The
rotating magnetic field moves past a three-phase symmetrically distributed winding installed
in the stator core, generating an alternating voltage in the stator winding. The voltage
waveform created in each of the three phases of the stator winding is very nearly sinusoidal.
The output of the stator winding is the three-phase power, delivered to the power system at
the voltage generated in the stator winding.
In addition to the normal flux distribution in the main body of the generator, there are
stray fluxes at the extreme ends of the generator that create fringing flux patterns and induce
stray losses in the generator. The stray fluxes must be accounted for in the overall design.
Generators are made up of two basic members, the stator and the rotor, but the stator and
rotor are each constructed from numerous parts themselves. Rotors are the high-speed
rotating member of the two, and they undergo severe dynamic mechanical loading as well as
the electromagnetic and thermal loads. The most critical component in the generator is the
retaining rings, mounted on the rotor.
These components are very carefully designed for high-stress operation. The stator is
stationary, as the term suggests, but it also sees significant dynamic forces in terms of
vibration and torsional loads, as well as the electromagnetic, thermal, and high-voltage
loading. The most critical component of the stator is arguably the stator winding because it is
a very high cost item and it must be designed to handle all of the harsh effects described
above. Most stator problems occur with the winding.
STATOR
The stator winding is made up of insulated copper conductor bars that are distributed
around the inside diameter of the stator core, commonly called the stator bore, in equally
spaced slots in the core to ensure symmetrical flux linkage with the field produced by the
rotor. Each slot contains two conductor bars, one on top of the other. These are generally
referred to as top and bottom bars. Top bars are the ones nearest the slot opening (just under
the wedge) and the bottom bars are the ones at the slot bottom. The core area between slots is
generally called a core tooth.
ROTOR
The rotor winding is installed in the slots machined in the forging main body and is
distributed symmetrically around the rotor between the poles. The winding itself is made up
of many turns of copper to form the entire series connected winding. All of the turns
associated with a single slot are generally called a coil. The coils are wound into the winding
slots in the forging, concentrically in corresponding positions on opposite sides of a pole. The
series connection essentially creates a single multi-turn coil overall, that develops the total
ampere-turns of the rotor (which is the total current flowing in the rotor winding times the
total number of turns). There are numerous copper-winding designs employed in generator
rotors, but all rotor windings function basically in the same way. They are configured
differently for different methods of heat removal during operation.
BEARINGS
All turbo generators require bearings to rotate freely with minimal friction and
vibration. The main rotor body must be supported by a bearing at each end of the generator
for this purpose. In some cases where the rotor shaft is very long at the excitation end of the
machine to accommodate the slip/collector rings, a “steady” bearing is installed outboard of
the slip-collector rings. This ensures that the excitation end of the rotor shaft does not create a
wobble that transmits through the shaft and stimulates excessive vibration in the overall
generator rotor or the turbo generator line. There are generally two common types of bearings
employed in large generators, journal” and “tilting pad” bearings. Journal bearings are the
most common. Both require lubricating and jacking oil systems. Jacking oil pumps and Lube
oil pumps are used for this purpose.
AUXILIARY SYSTEMS
All large generators require auxiliary systems to handle such things as lubricating oil
for the rotor bearings, hydrogen cooling apparatus, hydrogen sealing oil, de-mineralized
water for stator winding cooling, and excitation systems for field-current application. Not all
generators require all these systems and the requirement depends on the size and nature of the
machine. For instance, air cooled turbo generators do not require hydrogen for cooling and
therefore no sealing oil as well. On the other hand, large generators with high outputs,
generally above 400 MVA, have water-cooled stator windings, hydrogen for cooling the
stator core and rotor, seal oil to contain the hydrogen cooling gas under high pressure,
lubricating oil for the bearings, and of course, an excitation system for field current. There are
five major auxiliary systems that may be used in a generator. They are given as follows:
PROTECTION:
The protection system of any modern electric power grid is the most crucial function
in the system. Protection is a system because it comprises discrete devices (relays,
communication means, etc.) and an algorithm that establishes a coordinated method of
operation among the protective devices. This is termed coordination. The key function of any
protective system is to minimize the possibility of physical damage to equipment due to a
fault anywhere in the system or from abnormal operation of the equipment (over speed, under
voltage, etc.). Protective systems are inherently different from other systems in a power plant.
Electric power generators are most often the most critical electrical apparatus in any power
plant.
Protection systems can be divided into systems monitoring current, voltage (at the
machine’s main terminals and excitation system), windings, and/or cooling media
temperature and pressure, and systems monitoring internal activity, such as partial discharge,
decomposition of organic insulation materials, water content, hydrogen impurities, and flux
probes. Protective functions acting on the current, voltage, temperature, and pressure
parameters are commonly referred to as primary protection. The others are referred to as
secondary protection or monitoring devices. Secondary functions tend to be monitored real
time, or on demand. For instance, hydrogen purity is monitored on-line real time, while water
content (for water leaks) is not. Temperature detectors (RTDs or thermocouples) on bearings
(and sometimes in on windings) may be monitored on-line real time, or they may not.
Furthermore these functions may more often than not result in an alarm, rather than directly
trip the unit (e.g., core monitors).
To the primary protective functions monitoring currents, voltages, temperatures and
pressures, there can be added the mechanical protective function of vibration. Typically it
will alarm, but it can also be set to trip the unit. Protections function can also be divided into
shortcircuit protection functions. The short-circuit protection comprises impedance, distance,
and current differential protection.
TRANSFORMER:
SAFETY:
Safety is of primary concern when working around a transformer. The substation
transformer is usually the highest voltage item in a facility’s electrical distribution system.
The higher voltages found at the transformer deserve the respect and complete attention of
anyone working in the area. A 6.6 kV system will arc to ground over 1.5 to 2.5 in. However,
to extinguish that same arc will require a separation of 15 in. Therefore, working around
energized conductors is not recommended for anyone but the qualified professional. The best
way to ensure safety when working around high voltage apparatus is to make absolutely
certain that it is de-energized.
A properly installed transformer will usually have a means for disconnecting both the
primary and the secondary sides; ensure that they are opened before any work is performed.
Both disconnects should be opened because it is possible for generator or induced power to
back feed into the secondary and step up into the primary. After verifying that the circuit is
de-energized at the source, the area where the work is to be performed should be checked for
voltage with a “hot stick” or some other voltage indicating device.
ELECTRIC MOTORS
An electric motor uses electrical energy to produce mechanical energy. The reverse
process that of using mechanical energy to produce electrical energy is accomplished by a
generator or dynamo. Traction motors used on locomotives and some electric and hybrid
automobiles often performs both tasks if the vehicle is equipped with dynamic brakes.
SWITCHGEAR
The term switchgear, used in association with the electric power system, or grid,
refers to the combination of electrical disconnects, fuses and/or circuit breakers used to
isolate electrical equipment. Switchgear is used both to de-energize equipment to allow work
to be done and to clear faults downstream.
Oil-filled equipment allowed arc energy to be contained and safely controlled. By the
early 20th century, a switchgear line-up would be a metal-enclosed structure with
electrically-operated switching elements, using oil circuit breakers. Today, oil-filled
equipment has largely been replaced by air-blast, vacuum, or SF6 equipment, allowing large
currents and power levels to be safely controlled by automatic equipment incorporating
digital controls, protection, metering and communications.
Classification
Several different classifications of switchgear can be made:
By the current rating:
By interrupting rating (maximum short circuit current that the device can safely
interrupt)
Circuit breakers can open and close on fault currents
Load-break/Load-make switches can switch normal system load currents
Isolators may only be operated while the circuit is dead, or the load current is very
small.
By voltage class:
Low Tension (less than 440 volts AC)
High Tension (more than 6.6 kV AC)
By insulating medium:
Air
Gas (SF6 or mixtures)
Oil
Vacuum
By construction type:
Indoor
Outdoor
Industrial
Utility
Marine
Draw-out elements (removable without many tools)
Fixed elements (bolted fasteners)
Live-front
Dead-front
Metal-enclosed
Metal-clad
Metal enclose & Metal clad
Arc-resistant
High Tension Switchgear at a Power Plant
By IEC degree of internal separation:
No Separation
Bus bars separated from functional units
Terminals for external conductors separated from bus bars
Terminals for external conductors separated from functional units but not from each
other
Functional units separated from each other
Terminals for external conductors separated from each other
Terminals for external conductors separate from their associated functional unit
By operating method:
Manually-operated
Motor-operated
Solenoid/stored energy operated
By type of current:
Alternating current
Direct current
By application:
Distribution.
Transmission system
Contactor
Their functions are similar to the high-current switching mechanism, but they can be
used at higher rates. They have a high electrical endurance and a high mechanical endurance.
Contactors are used to frequently operate device like electric furnaces, high voltage motors.
They cannot be used as a disconnecting switch. They are used only in the band 30 kV to 100
kV.
Fuses
The fuses can interrupt automatically a circuit with an over current flowing in it for a
fixed time. The current interrupting is got by the fusion of an electrical conductor which is
graded. They are mainly used to protect against the short-circuits. They limit the peak value
of the fault current. In three-phase electric power, they only eliminate the phases where the
fault current is flowing, which is a risk for the devices and the people. Against this trouble,
the fuses can be associated with high-current switches or contactors.
They are used only in the band 30 kV to 100 kV.
Circuit Breaker
A high voltage circuit breaker is capable of making, carrying and breaking currents
under the rated voltage (the maximal voltage of the power system which it is protecting):
Under normal circuit conditions, for example to connect or disconnect a line in a power
system. Underspecified abnormal circuit conditions especially to eliminate a short circuit.
From its characteristics, a circuit breaker is the protection device essential for a high voltage
power system, because it is the only one able to interrupt a short circuit current and so to
avoid the others devices to be damaged by this short circuit. The international standard IEC
62271-100 defines the demands linked to the characteristics of a high voltage circuit breaker.
The circuit breaker can be equipped with electronic devices in order to know at any moment
their states (wear, gas pressure etc) and possibly to detect faults from characteristics
derivatives and it can permit to plan maintenance operations and to avoid failures. To operate
on long lines, the circuit breakers are equipped with a closing resistor to limit the
overvoltage. They can be equipped with devices to synchronize the closing and/or the
opening to limit the overvoltage and the inrush currents from the lines, the unloaded
transformers, the shunt reactance and the capacitor banks.
Switchyard:
Bus Coupler
Bus couplers are used in distribution system to provide better isolation and protection
from electrical arcs. They are used on Transformers to connect it to the distribution system. It
has it advantage over direct coupling w.r.t arc suppression as they provide greater impedance
to the path of the load. So, they provide better arc protection especially, during the transient
or switching period. Even if only one non-terminated coupler acts as the bus because all
devices (bus controller, remote terminals, etc.) are connected to the coupler’s stubs, the
external bus connections of the coupler must be terminated. A dual-terminated coupler (with
or without non-functional bus connectors) can be employed where the coupler acts as the bus
without other couplers.
Isolator/ Diconnector:
Isolators are devices used to isolate a certain portion of the circuit in case of a fault.
The isolator can clip off a certain portion of the circuit if it
Busbar:
In electrical power distribution, a busbar is a thick strip of copper or aluminium that
conducts electricity within a switchboard, distribution board, substation or other electrical
apparatus. Busbars are used to carry very large currents, or to distribute current to multiple
devices within switchgear or equipment. For example, a household circuit breaker panel
board will have bus bars at the back, arranged for the connection of multiple branch circuit
breakers. An aluminum smelter will have very large bus bars used to carry tens of thousands
of amperes to the electrochemical cells that produce aluminum from molten salts.
The size of the busbar is important in determining the maximum amount of current
that can be safely carried. Busbars can have a cross-sectional area of as little as 10 mm² but
electrical substations may use metal tubes of 50 mm in diameter (1,963 mm²) or more as
busbars.
A busbar may either be supported on insulators, or else insulation may completely
surround it. Busbars are protected from accidental contact either by a metal enclosure or by
elevation out of normal reach. Neutral busbars may also be insulated. Earth busbars are
typically bolted directly onto any metal chassis of their enclosure. Busbars may be enclosed
in a metal housing, in the form of bus duct or busway, segregated-phase bus, or isolated-
phase bus.
Busbars may be connected to each other and to electrical apparatus by bolted or clamp
connections. Often joints between high-current bus sections have matching surfaces that are
silver-plated to reduce the contact resistance. At extra-high voltages (more than 300 kV) in
outdoor buses, corona around the connections becomes a source of radio-frequency
interference and power loss, so connection fittings designed for these voltages are used.
Lightning arrester
Fuses
A fuse can automatically interrupt a circuit with an overcurrent flowing in it for a
fixed time. This is accomplished by the fusion of an electrical conductor which is graded.
Fuses are mainly used to protect against short circuits. They limit the peak value of the fault
current.
In three-phase electric power, they only eliminate the phases where the fault current is
flowing, which can pose a risk for both the malfunctioning devices and the people. To
alleviate this problem, fuses can be used in conjunction with high-current switches or
contactors.
Like contactors, high-voltage fuses are used only in the band 30 kV to 100 kV
Balance of plant:
Demineralised Water:
Purified water is water from any source that is physically processed to remove
impurities. Distilled water and deionized water have been the most common forms of purified
water, but water can also be purified by other processes including reverse osmosis, carbon
filtration, microporous filtration, • ultrafiltration, ultraviolet oxidation, or
electrodialysis. In recent decades, a combination of the above processes have come into
use to produce water of such high purity that its trace contaminants are measured in parts per
billion (ppb) or parts per trillion (ppt). Purified water has many uses, largely in science and
engineering laboratories and industries, and is produced in a range of purities.
Deionization
RODM: Reverse osmosis and De-minerelisation plant in PPCl is used to carry out the
conversion of soft water to DM water. DM water is expensive and is only used in critical
machinery
It should be noted that deionization does not remove the hydroxide or hydronium ions
from water; as water self-ionizes to equilibrium, this would lead to the removal of the water
itself.
Lime Softening Plant: Lime dosing to treat hard water and converting it to soft water.
Gravity Filters: Gravity filters separating out dust and dirt particles.
Deionized water which is also known as demineralized water (DI water or de-ionized
water; can also be spelled deionised water, see spelling differences) is water that has had its
mineral ions removed, such as cations from sodium, calcium, iron, copper and anions such as
chloride and bromide. Deionization is a physical process which uses specially-manufactured
ion exchange resins which bind to and filter out the mineral salts from water. Because the
majority of water impurities are dissolved salts, deionization produces a high purity water
that is generally similar to distilled water, and this process is quick and without scale buildup.
However, deionization does not significantly remove uncharged organic molecules, viruses or
bacteria, except by incidental trapping in the resin. Specially made strong base anion resins
can remove Gram-negative bacteria. Deionization can be done continuously and
inexpensively using electrodeionization.
DM Water is used in a closed-loop steam generation cycle to drive the turbines that
produce electricity. After passing through the turbine, the steam will eventually be condensed
into water to be fed back to the boiler to repeat the cycle. Demineralization will protect the
boiler from the formation of salt deposits on its inner surfaces
Bibliography:
• www.ipgcl-ppcl.gov.in
• www.google.com
• www.wikipedia.com
• www.wikipedia.org/wiki/University
• www.scribd.com
Thank you…