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PROJECT REPORT
Guided By:
Mr. SRIKANTH KOLUKULA
Done By:
Mr.RAMANJANEYA
REDDY
Design Engineer
Mr.SHASHANK.B
Mr.GANESH.N
Hyderabad
DEPT. OF EEE
J.B.I.E.T
ACKNOWLEDGEMENT
I owe this profound acknowledgement to all those people who made this
project successful. I express my deep sense of gratitude to BHEL,
Ramachandrapuram, Hyderabad for permitting me work in their esteemed
organization.
I would like to thank Mr. B.Shyam Babu, Sr. Manager (Gas Turbine
Engineering ) and Mr. K.Srikanth, Design Engineer (Gas Turbine Engineering )
BHEL, R.C.Puram, Hyderabad for their kind co-operation without which the project
training would not have been completed.
I would like to extend my sincere thanks to Mr. K.Suresh, Dy. Manager (Gas
Turbine Engineering) and Mr. G. Nageshwer Rao, Design Engineer ( Gas Turbine
Engineering ) for their encouragement and constant support throughout the training.
I take the opportunity to thank our Head Of Department, Prof. Padmavathi
and also Prof.Sharma for their timely advice and guidance while pursuing this
project.
INTRODUCTION TO BHEL
BHEL is the largest engineering and manufacturing enterprise in India in the
energy-related/infrastructure sector, today. Established more than 40 years ago, BHEL
is ushering in the indigenous Heavy Electrical Equipment industry in India - a dream
that has been more than realized with a well-recognized track record of performance.
The company has been earning profits continuously since 1971-72 and paying
dividends since 1976-77.
BHEL, countrys premier engineering organization and one of the
NAVARATNA PSUs caters to core sectors of Indian economy viz Power Generation
and Transmission, Industry, Transportation, Oil & Gas, Renewable Energy. Having 14
Manufacturing Divisions, 08 Service Divisions, 15 Regional Offices, 04 Power Sector
Regional Centres and over 100 Project Sites spread all over the Country, BHEL
manufactures over 180 products under 30 major product groups. The financial
turnover during the year 2007-08 was Rs.21,401 Crores and Current Order Book is of
around Rs.1,20,000 Crores. BHEL plans to be a Rs.45,000 Crores Company by 201112 and a Rs.90,000 Crores Company by 2016-17. BHEL is the only PSU among the
12 Indian Companies to figure in Forbes Asian Fabulous 50 list. The Company to
promptly serve its customers and provide them with suitable products, systems and
services -- efficiently and at competitive prices. BHEL has a high level of quality &
reliability of its products due to the emphasis on design, engineering and
manufacturing to international standards by acquiring and adapting some of the best
technologies from leading companies in the world, together with technologies
developed in its own R&D centre.
BHEL has
Supplied traction electrics and AC/DC locos to power over 12,000 kms
railway network.
Supplied over one million valves to power plants and other industries.
Power Generation
Power Generation Sector comprises thermal, gas, hydro and nuclear power
plant business. As of 31.3.2008, BHEL- supplied sets account for 85,811 MW or
nearly 64% of the total installed capacity of 1,34,722 MW in the country.
Significantly, these sets generated an all-time high 456.12 Billion Units of electricity,
contributing 73% of the total power generated in the country. The cumulative capacity
of projects installed worldwide have crossed 1,00,000 MW.
BHEL has proven turnkey capabilities for executing power projects from Concept-to
Commissioning. The Company has introduced new rating thermal sets of 270 MW,
525 MW & 600 MW in subcritical range and possesses the technology and capability
to produce large capacity thermal sets with super critical parameters and, advancedclass gas turbine-generator sets. Co-generation and combined cycle plants have been
introduced to achieve higher plant efficiencies. To make efficient use of the high-ashcontent coal available in India, BHEL also supplies circulating fluidized bed
combustion (CFBC) boilers for thermal plants. The Company manufactures
Industries
BHEL manufactures and supplies major capital equipment and systems like
captive power plants, centrifugal compressors, drive turbines, industrial boilers and
auxiliaries, waste heat recovery boilers, gas turbines, pumps, heat exchangers,
electrical machines, valves, heavy castings and forgings, electrostatic precipitators,
ID/FD fans, seamless pipes etc. to a number of industries like, metallurgical, mining,
cement, paper, fertilizers, refineries & petro-chemicals, etc., other than power utilities.
BHEL has also emerged as a major supplier of controls and instrumentation systems,
especially distributed digital control systems for various power plants and industries.
Transportation
Most of the trains in Indian Railways, whether electric or diesel powered, are
equipped with BHELs traction propulsion system and controls. The systems supplied
are both with conventional DC drives and state of the art AC drives. Indias first
underground metro at Kolkata runs on drives and controls supplied by BHEL. The
Company also manufactures complete rolling stock i.e., Mainline 25 kV AC
locomotives up to 5000 HP, EMU coaches and Diesel Electric Shunting Locomotives
from 350 HP to 2600 HP. BHEL also undertakes retrofitting and overhauling of
rolling stock. In the area of Urban transportation, BHEL is geared up for turnkey
execution of electric trolley bus systems, light rail systems and metro systems. BHEL
Renewable Energy
BHEL has been manufacturing and supplying a range of Renewable Energy
products and systems. It includes Photo Voltaic modules and systems. BHEL has
supplied stand alone Power Plants of ratings up to 150 KW peak, usually used as
Distributed Power generation plants. The Company has capability to design and
execute grid connected MW sized PV plants. BHEL is actively associated with the
development and adoption of Wind Power and Concentrated Solar Power (CSP)
projects in India and abroad.
Transmission
BHEL supplies a wide range of products and systems for transmission and
distribution applications. The products manufactured by BHEL include power
transformers, instrument transformers, dry type transformers, shunt reactors,
capacitors, vacuum and SF6 switchgear, gas insulated switchgears, ceramic insulators,
etc. BHEL has developed and commercialized the countrys first indigenous 36 kV
Gas Insulated Substation (GIS) and has also developed 145 kV GIS which has
undergone successful field trials at Hyderabad. For enhancing the power transfer
capability and reducing transmission losses in 400 kV lines, BHEL has indigenously
developed and executed a number of fixed series compensation schemes. BHEL has
indigenously developed and commercialized state-of-the-art 400 kV Controlled Shunt
Reactor (CSR) for reactive power management of long transmission lines. With a
strong
engineering
base,
the
Company
undertakes
turnkey
execution
of
International Business
BHEL has, over the years, established its references in more than 70 countries
across all inhabited continents of the world. These references encompass almost the
entire range of BHEL products and services, covering Thermal, Hydro and Gas-based
turnkey power projects, Substation projects and Rehabilitation projects, besides a
wide variety of products like: Transformers, Compressors, Valves and Oil Field
Equipment, Electrostatic Precipitators, Photovoltaic Equipment, Insulators, Heat
Exchangers, Switchgears, Castings and Forgings etc. Some of the major successes
achieved by BHEL have been in Gas-based power projects in Oman, Libya, Malaysia,
UAE, Saudi Arabia, Iraq, Bangladesh, Sri Lanka, China, Kazakhstan; Thermal power
projects in Cyprus, Malta, Libya, Egypt, Indonesia, Thailand, Malaysia, Sudan, Syria,
Ethiopia, Senegal, New Caledonia; Hydro power plants in New Zealand, Malaysia,
Azerbaijan, Bhutan, Nepal, Taiwan, Tajikistan, Vietnam, Rwanda, Thailand,
Afghanistan; and substation projects & equipment in various countries. Execution of
these overseas projects has also provided BHEL the experience of working with
world-renowned Consulting Organizations and Inspection Agencies. The Company
has been successful in meeting demanding requirements of International markets, in
terms of complexity of the works as well as technological, quality and other
requirements viz., HSE requirements, financing packages and associated O&M
services, to name a few. BHEL has proved its capability to undertake projects on fasttrack basis. BHEL has also established its versatility to successfully meet the other
varying needs of various sectors, be it captive power, utility power generation or for
the oil sector. Besides undertaking turnkey projects on its own, BHEL also possesses
the requisite flexibility to interface and complement other International companies for
large projects, and has also exhibited adaptability by manufacturing and supplying
intermediate products. The Company is taking a number of strategic business
initiatives to fuel further growth in overseas business. This includes firmly
establishing itself in target export markets, positioning of BHEL as a regular EPC
contractor in the global market both in utility and IPP segments, and exploring various
opportunities for setting up overseas joint ventures etc.
system of the Indian Army, solar panels with 5500 watt output consisting of highefficiency multi-junction solar cells, satellite batteries for INSAT 4A, controlled shunt
reactor(CSR) for 400 kV transmission lines, Flexible AC transmission system
(FACTS) STATCOM, Phase Shifting Transformer (PST), 145kV gas insulated
Switchgear(GIS), micro-controller-based flame scanner, a more energy efficient
single cylinder non-reheat Steam turbine for 100-140 MW applications, IGBT-based
3-phase drive system for 700 HP Diesel Electric Locomotives, technology for
manufacture of 400kV long rod composite insulators with improved properties by
adding nano materials, performance analysis, diagnostic and optimization (PADO)
package for power plants, 91 Ton BHEL 280 Bowl Mill, etc. To meet its commitment
to clean environment, BHEL has developed design for an IGCC power plant and has
also signed an MOU for an IGCC plant at Vijayawada. The Company is also engaged
in research in futuristic areas like fuel cells for distributed environment friendly power
generation, clean coal technology applications, superconductivity applications in
transformers, generators/motors etc, thin film solar cells and nano technology for
various applications.
several
short-term
need-based
programmes
based
on
comprehensive
organizational research, enable its human resources to unearth and polish their
potential. HRDI is spearheading the HRD initiatives in the Company and focusing on
competency, commitment and culture building. The various types of programme
being conducted at HRDI are:- _ Core Programmes _ Extension Programmes _
Change of House Programmes _ Strategic Need-based Programmes _ Competency-
Gas turbines
BHEL - the largest Gas Turbine manufacturer in India, with the state-of-art facilities
in all areas of Gas Turbine manufacture provide complete engineering in-house for
meeting specific customer requirement. With over 100 machines and cumulative fired
hours of over four million hours, BHEL has supplied gas turbines for variety of
applications in India and abroad. BHEL also has the world's largest experience of
firing highly volatile naphtha fuel on heavy duty gas turbines. BHEL is one of the few
business associates of M/s. GE, USA and under its comprehensive Technical
Collaboration Agreement from 1986, (license to manufacture rotors and hot gas path
components) offers complete power plant engineering solutions. BHEL also
manufactures Gas Turbine under its ongoing Technical Collaboration Agreement with
M/s Siemens, Germany. Some specific features:
1. Capability to fire a wide range of gaseous and liquid fuels and a mix of such fuels
ranging from clean fuels like Natural Gas, Distillate Oil, Naphtha, LNG to heavy fuels
like LSHS, crudes, blends, etc. Fuel economy over a wide range of ambient
temperatures and loads.
2. Facilities like Black start, fast start and emergency start.
3. Suitable for power generation and mechanical drive application. Models below 100
MW suitable for 50 Hz and 60 Hz.
4. All matching equipment like generators, compressors, etc. manufactured in-house.
Design of combustion systems as per international emission norms. Machines
designed as per major international codes like API, etc.
5. Suitable for IGCC applications.
6. Suitable for indoor or outdoor locations.
7. Use of water or steam injection for abatement of NOX emissions and power
augmentation.
BHEL equipped with precision and sophisticated machine - tools like CNC
Broaching Machine, 5-Axis Milling Machine and over speed Vacuum Balancing
Tunnel offers Conversion, Modification and Up-gradation services - through joint
venture with GE for all existing Gas turbines. Services are also offered for all Field
support, Retrofits and repairs, inspections and Technical Consultancy on "Operation
& Maintenance of Gas Turbine Based Power Plants".
Steam turbines
technology
Which
is
Turbo generators:
Heat Exchangers:
Pumps:
Pulverizers:
BHEL manufactures mills for pulverized coal fired Thermal and Industrial
boilers. BHEL till date has manufactured over 1200 bowl mills and over 100 tube
mills, operating in different coal fired Thermal power stations in India. BHEL has
absorbed technology from world leader M/s. Combustion Engineering USA for bowl
mills. The specific range - 583 XRP/XRS to 1043 XRP covers the-state-of-the-art
mills required for the Indian market and are supplied as Industrial boilers as-well-as
Utility boilers of 60 MW, 110 MW, 120 MW, 210 MW, 250 MW & 500 MW capacity.
To meet the requirement of very high ash content coal with high moisture, BHEL in
collaboration with M/s Stein Industries, France of the ALSTHOM group,
manufactures Ball Tube Mills for Tower-type Boiler as-well-as conventional Boiler.
These are horizontal mills that grind coal by impact and attrition. They do not lose
any of their grinding characteristics with time, and provide constant fineness
throughout the service life of their wear parts. They are the only mills truly adapted to
both, very abrasive high -ash coals and very low volatile coals which require very fine
grinding.
Oil rigs:
and well servicing rigs to a well depth of 6100 meters. BHEL is authorized by the
American Petroleum Institute (API) for manufacturing products under specification
API 4F, API 7K and API 8A. BHEL also undertakes refurbishment, upgradation and
renovation of the existing rigs with the customers to provide better flexibility of
operation for faster drilling, and higher availability of rigs. BHEL, since the first order
for oil rigs in 1977, has manufactured and supplied 84 nos. drilling and well servicing
rigs to both M/s ONGC Ltd. and M/s Oil India Ltd. that are deployed for drilling and
well servicing operations. In addition BHEL has upgraded 3 nos. rigs by installing
Independent Rotary Drive system. BHEL offers services for refurbishment and
modernization of the rigs and rig equipment of both BHEL make and also others. This
includes:
-Total inspection of rig equipment
-Major overhauling of rig equipment
-Supply of spares (for BHEL make rigs)
-Refurbishment of rig equipment
-Repairs on mast and substructures and reassessment of the structure
-Upgradation of rigs
-Supply & installation of Independent Rotary Drive system on the
conventional drilling rigs.
TURBINES:
Theory of operation:
A working fluid contains potential energy (pressure head) and kinetic
energy (velocity head). The fluid may be compressible or incompressible.
Several physical principles are employed by turbines to collect this energy:
Impulse turbines
These turbines change the direction of flow of a high velocity fluid jet. The
resulting impulse spins the turbine and leaves the fluid flow with diminished kinetic
energy. There is no pressure change of the fluid in the turbine rotor blades. Before
reaching the turbine the fluid's pressure head is changed to velocity head by
accelerating the fluid with a nozzle. Pelton wheels and de Laval turbines use
this process exclusively. Impulse turbines do not require a pressure casement around
the runner since the fluid jet is prepared by a nozzle prior to reaching turbine.
Newton's second law describes the transfer of energy for impulse turbines.
Reaction turbines
calculation methods were used at first. Formulae for the basic dimensions of turbine
parts are well documented and a highly efficient machine can be reliably designed for
any fluid flow condition. Some of the calculations are empirical or 'rule of thumb'
formulae, and others are based on classical mechanics. As with most engineering
calculations, simplifying assumptions were made.
Types of turbines:
Shrouded turbine Many turbine rotor blades have a shroud at the top,
which interlocks with that of adjacent blades, to increase damping and
thereby reduce blade flutter.
Bladeless turbine uses the boundary layer effect and not a fluid
impinging upon the blades as in a conventional turbine.
Water turbines
o Pelton turbine, a type of impulse water turbine.
o Francis turbine, a type of widely used water turbine.
o Kaplan turbine, a variation of the Francis Turbine.
o Voith, water turbine.
Tide turbine
GAS TURBINES
A gas turbine is an internal combustion engine that extracts energy from a flow of gas.
Intake air is heated by burning after being mixed with some fuel source, and then
directed out an expanding nozzle, flowing past the turbine on the way. They are
continuous combustion engines that produce work by burning fuel. Gas turbines are a
versatile, cost effective source of electricity, mechanical power and propulsion.
The air is sucked from the surroundings and then squeezed to attain high pressures by
a series of compressor stages. The highly compressed air enters a combustion
chamber. It is here that fuel is mixed together with the air and burnt in a controlled
fashion.
Generally gas turbines can use both gas and liquid fuels or combination of both. The
burning of fuel causes rapid expansion of gases within the combustion chamber and
then passes through a series of turbine stages. This generates the power required to
drive the compressor stages and supply other needs. Once the past this stage, the
expanded gas then leaves the gas turbine at a high velocity.
COMPRESSOR SECTION
Combustion of the fuel and air mixture is initiated by the spark plugs
with retracting electrodes. The spark plugs, installed in two of the combustion
chambers, receive power from ignition transformers. The chambers without spark
plugs are fired with flame from the fired chambers through interconnecting crossfire
tubes.
During the starting sequence it is essential that
an indication of the presence or absence of flame be transmitted to the control system.
For this reason the flame monitoring system is used consisting of sensors, which are
installed, in adjacent combustion chamber and an electronic amplifier mounted on the
turbine control panel.
ULTRAVIOLET FLAME DETECTORS:
TURBINE SECTION:
In the turbine section, high temperature gases from the combustion section are
converted to shaft horsepower. The two-stage turbine rotor provides the power
required to drive the load package and the compressor. The first-stage, or highpressure wheel and the second stage, or low-pressure wheel is bolted together to make
up a single unit through which the first and second stage nozzles direct the flow of
combustion gases. These components, with associated air seals and deflectors, are
contained within the turbine shell.
The forward section of the turbine shell forms the casing for the shaft end of
the compressor discharge and the combustion sections. The shaft section of the shell
forms the casing for the first and second stage nozzle and the shrouds for the first and
second stage turbine rotors.
EXHAUST FRAME
The exhaust frame is bolted to the turbine shell. Structurally the frame consist
of an outer and an inner cylinder inter connected by a radial struts. The bearing is
supported from the inner cylinder. The exhaust diffuser is located between the outer
and inner cylinder. Gases exhausted from the third turbine stage enter the diffuser
where the velocity is reduced by diffusion and pressure is recovered at the diffuser
exit vanes to assist in directing the gases radial outward into exhaust plenum.
ACCESSORY BASE:
Most of the mechanical and electrical auxiliary equipment necessary for
starting and operating a gas turbine is contained with in the accessory base. The
major components of an accessory base are:
Starting System.
Lubricating System.
Cooling Water System.
Gas Fuel System.
Liquid Fuel System.
Atomizing System
Trip Oil System.
Starting system
Before the gas turbine can be fired and brought to operating speed it must be rotated
and cranked by accessory equipment. This is accomplished by starting device which
can be induction motor, a diesel engine etc operating through a turbine to start up.
Also at shutdown, this same equipment continues to rotate the turbine at low speed
for cool down purpose.
Lubrication system
The lubricating system requirements for a gas turbine power plant are furnished by a
common forced feed lubrication system. This lubrication system completes with
tanks, pumps, coolers, filters and various controls and protection device furnishes
normal lubrication and absorption of heat rejection load of turbine. Lubricating fluid
is circulated to the main turbine bearing and to the turbine accessory gear.
The main components include lube reservoir, main lube pump (driven by accessory
gear), emergency and auxiliary lube pump, and pressure relief valve, lube fluid heat
exchanger, lube filters and bearing header pressure regulator.
Cooling water system
Cooling water system is pressurized closed system designed to accommodate the
heat dissipation requirements of the turbine and the generator, atomizing air precooler and the turbine supports. The cooling water system is comprised of both onbase and off-base mounted components. The on-base components include the heat
exchangers in the turbine support legs, flow regulating valves, orifices and hand
valves. The off base components are customer supplied.
Gas fuel system
Gas fuel system is used to control the flow of gas fuel to turbine combustion
chambers at the proper pressure and flow rates to meet all of the starting,
accelerating and loading requirements of gas turbine operation. The major
components include gas valve with necessary inlet piping and strainers, fuel vent
valve, control servo valves, pressures gauges and distribution piping to the
combustion fuel nozzles.
Liquid fuel system
This system pumps and distributes fuel as supplied from the off-base source to the
nozzles of the combustion system. After being filtered, the fuel flow is divided into
equal parts for the distribution to the combustion chambers of required pressure and
flow rate. Controlling the position of the fuel pump, bypass valve regulates the
amount of fuel input to the turbine combustion system by varying the amount of the
bypassed fuel. The major Components of this system include low pressure fuel
strainers, fuel oil stop valve, liquid fuel pump, fuel pump discharge relief valve, false
drain valve and dual fuel system.
Atomizing air system
The atomizing air system provides sufficient pressure in the air-atomizing chambers
of fuel nozzle body to maintain the proper ratio of atomizing air pressure to the
compressors discharged pressure. The ratio is approximately 1.2 or greater over the
full operating range of the turbine. Since the output of the main atomizing air
compressor, driven by the accessory gear is low at turbine firing speed, and starting
atomizing air compressors provides a similar ratio during the firing and warm up
period of the starting cycle, and a portion of the accelerating cycle. The major
components include main atomizing air compressors, the starting atomizing air
compressors and atomizing air heat exchanger.
Trip oil system
The hydraulic trip oil system is the primary protection interface between the turbine
control and protection system circuits (speedtronic control system) and the
components on the turbine, which admit, or shut off fuel to the turbines lube fluid
system, is used in the are trip oil system.
Fire fighting system
A fire fighting system is the key element among the fire protection features of a gas
turbine. The CO2 fire protection system is designed to extinguish fire by reducing
the percentage of oxygen level. The major components include CO2 cylinders,
discharge pipes and nozzles, solenoid pilot valves, fire detectors and pressures
switches.