INDUSTRIAL TRAINING

AT
DHOLPUR COMBINED CYCLE POWER PROJECT (DCCPP)

DHOLPUR (RAJ.)

(May 17, 2018 - July 16, 2018)

A
Practical Training Seminar Report
Submitted
in partial fulfillment
for the award of the Degree of
Bachelor of Technology
in Department of Mechanical Engineering
(With specialization in Mechanical Engineering)

(Batch 2015-19)
Supervisor Submitted by:
Mr. Ashwani kapoor GOPESH KUMAR MEENA
HOD 15ESDME030
Department of Mechanical Engineering
Poornima Group of Institutions, Jaipur (RTU)
 Candidate’s Declaration

I hereby declare that the Practical Training Seminar, entitled “Industrial training” is
being submitted in partial fulfillment for the award of Degree of “Bachelor of
Technology” in Mechanical Engineering. It is being submitted to the Department
of Mechanical Engineering, Poornima Group of Institutions, Rajasthan
Technical University, Kota and is compiled and prepared by me under the
supervision and guidance of Mr. Ratnesh Kumar Sharma Department of
Mechanical Engineering.
.
I have not submitted the matter presented in this Report anywhere for the award of
any other Degree.

GOPESH KUMAR MEENA

15ESDME030

Signed by
Mr. Ashwani Kapoor
Head of the Department of Mechanical Engineering
TRAINING CERTIFICATE
 ABSTRACT

As a part of the curriculum and for the partial fulfillment of the requirements for
compilation of the bachelor degree from Poornima Group of Institution, I
Gopesh kumar meena underwent an industrial training at Dholpur Combiend
Cycle Power Project, for 8 weeks during two months periods May 17, 2018 to
July 16
DCCPP is situated in the outskirts of Dholpur which is about 55Km. South West of
Agra In this Plant we interface with Gas Turbine & Heat recovery Steam
Generator. I learn about the working of these process and gain the knowledge
about these Turbine.
Under the guidance of Mr. RISHI BHARGAVA (Executive Engineer
mechanical Department), I got the opportunity to have exposed to work carried
out in this department of the Plant, and hence learned a good deal from them.
During the period of two months of industrial training, the work primarily assigned
was concerned with the finding of different defects of different products.
 INTRODUCTION

DHOLPUR COMBINED CYCLE POWER PROJECT.

DCCPP is situated in the outskirts of Dholpur which is about 55Km. South West of

Agra. Dholpur was considered an ideal location for setting up of a gas power plant

having regards to the availability of land, water, transmission network, proximity

to broad gauge railway , also well connected by roads (G.T. road passes through

this city) and being an important load center for eastern Rajasthan.

The total estimated cost of the plant is Rs. 1155 crore.The main equipments were

supplied by M/s BHEL and it was also the main contractor for erection, testing and

commsining of the plant. The BOP(Balance of plant) was given to M/s GEA

Energy System. The main fuel used for this plant is R-LNG(liquified natural gas)

which will be supplied by M/s GAIL. The gas required per day for both unit is

1.3MM SCM at 9000Kcal.

The unique feature of this plant is that waste heat from the gas turbine is recovered

by a heat recovery steam generator to power a conventional steam turbine in a

combined cycle configuration. And also a MARK- 6 control system has been

introduced for the first time in the northern region in INDIA.

GENERAL INTRODUCTION
Method for transforming other power in to electrical power :-
Rotating turbines attached to electrical generators produce most commercially
available electricity. Turbines may be driven by using steam. Water wind or other
fluids as an intermediate energy carrier. The most common usage is by steam in
fossil fuel power plants or nuclear power plants and by water in hydroelectric
dams. Alternately turbines can be driven directly by the combustion of natural gas.
Power plants are classified in the following categories according to the fuel used:
(a) Coal based thermal power plant
(b) Nuclear power plant
(c) Hydro electric power plant
(d) Solar power plant
(e) Wind power plant
(f) Gas power plant

Electricity From Natural gas :-

Power plant uses several methods to convert gas into electricity. One method is to
burn the gas in a boiler to produce steam, which is then used by a steam turbine to
generate electricity. A more common approach is to burn the gas in a combustion
turbine to generate electricity.
Another technology that is growing in a combustion turbine and used the hat
combustion turbine exhaust to make steam to drive a steam turbine. This
technology is called combined cycle and achieves a higher efficiency by using the
same fuel source twice.
COMBINED CYCLE POWER
GENERATION
Combined cycle electricity generation :-
Growth in gas fueled combined cycle system will take place,
because of the attractive economic environmental and operating characteristics of
this natural gas system . Combined cycle gas turbine plants generate electricity
more. Efficiently than conventional fossil to percent compares with 30 to 50
percent for typical now biological units.

Advantage of Combined Cycle Gas Power Plant

 High Thermal Efficiency
 Low water Requirement
 Environmental friendliness
 Fast start-up
 Low Gestation period
 Low Installation Cost

Disadvantage of Combined Cycle Gas Power Plant

 Low thermal Efficiency in Open cycle
 Higher Cost of Generation
 Higher Maintenance Cost

Classification of Combined Cycle Gas Power Plant

SIZE PLANT CAPACITY GT CAPACITY

SMALL UP-TO 100 MW 30-40 MW
MEDIUM 150-400 MW 60-120 MW
LARGE > 400 MW > 120 MW
Environmental effects of combined cycle electricity generation
(a). Natural-gas fueled combined cycle units are environmentally performable to
conventional coal system the gas combined cycle unit produces none of the solid
waste associated with coal units less than 1 percent of the sulfur dioxide and
particulate matter and about 85 percent less nitrogen oxide produces by a similarity
sized new coal unit equipped with pollution control equipments.

(b). cogeneration system :- cogeneration is use of a primary energy like natural gas
to sequentially produce heat and electricity. The concept is based on the recover
and use of waste heat produced daring the generation of electricity. In most electric
utility power plants. This waste heat is lost resulting in substantially lower
operating efficiencies than with cogeneration.
A variety of natural gas cogeneration technologies are currently being used.
Including small prepackaged units that incorporate all the necessary components
for a cogeneration system as well as high efficiency industrial gas turbines. These
natural gas cogeneration system are available in sizes ranging from as small as 202
kw to as larges as several hundred mega watts.

(c.) air emissions :- the average emissions rates in the united states from natural gas
fired generation are 1135 ibd/meh of carbon dioxide 0.1 ibs/mwh of sulfer dioxide
and 1.7 ibs/mwh of nitrogen oxide compared to the average air emissions from
coal fired generation natural gas produces as much carbon dioxide less than a third
as much nitrogen dioxide at the power plant in addition the process of extraction
 treatment and transport of the natural gas to the power plant generators additional
emissions.

(d) design principle :- in a gas turbine set composed primarily of a compressor

burner and the gas turbine proper. The input temperature to the gas turbine is
relatively high but the output temp of the fuel gas temperature is sufficient for
production of steam in the second steam cycle with live steam temperature in the
range of steam cycle depends on the ambient temperature and the methods of waste
heat disposal either by direct cooling by lake river or sea water or using cooling
towers.

(e) efficiency of ccgt plants :- the thurmel efficiency of a combined cycle power
plant is normally in termsof the net power output of the plant as a percentage fo the
lower heating value or net calorific value of the fuel. In the case of generating only
etc. criticity power plant efficiencies of up to 59% can be achieved in the case of
combined heat and power generation the efficiency can increase to about 85%.

PLANT DESIGN INPUTS

 AMBIENT TEMPERATURE RANGE
 AMBIENT AIR QUALITY
 FUEL SPECIFICATIONS
 ENVIRONMENTAL REQUIREMENTS
 PEAKING CAPABILITY
 OPERATIONAL FLEXIBILITY
 PLANT WATER QUALITY
 BLACK START FACILITY
 

FUEL SPECIFICATIONS
 NATURAL GAS/ LNG VS NAPHTHA
 NATURAL GAS SUPPLY PRESSURE
 BRIDGE FUEL - NAPHTHA/ HSD
 SULPHUR CONTENT - LOW PREFERRED

WORKING OF THE COMBINED CYCLE POWER PLANT

DCCPP located at Dholpur has an unique feature that the same energy source (i.e.
natural gas) is used to rotate both gas and steam turbine without wasting much of
energy. As the name implies it is a combined cycle i.e. waste heat from the gas
turbine is recovered by a heat recovery steam generator to power a conventional
steam turbine in a combined cycle configuration. Hence, the working of both gas
and steam turbine is discussed here.
GAS TURBINE
WORKING OF THE GAS TURBINE:

This machine has a single-stage centrifugal compressor and turbine, a

recuperator, and foil bearings.

A gas turbine extracts energy from a flow of hot gas produced by

combustion of gas or fuel oil in a stream of compressed air. It has an

upstream air compressor (radial or axial flow) mechanically coupled to a

downstream turbine and a combustion chamber in between. Gas turbine

may also refer to just the turbine element.

Energy is released when compressed air is mixed with fuel and ignited

in the combustor. The resulting gases are directed over the turbine's

blades, spinning the turbine, and, mechanically, powering the

compressor. Finally, the gases are passed through a nozzle, generating

additional thrust by accelerating the hot exhaust gases by expansion

back to atmospheric pressure.

 Energy is extracted in the form of shaft power, compressed air and

thrust, in any combination, and used to power aircraft, trains, ships,

electrical generators, and even tanks.

A gas turbine, also called a combustion turbine, is a rotary engine that extracts
energy from a flow of hot gas produced by combustion of gas in a stream of
compressed air. It has an upstream air compressor radial or axial flow
mechanically coupled to a downstream turbine and a combustion chamber in
between. Gas turbine may also refer to just the turbine element.

Energy is released when compressed air is mixed with fuel and ignited in the
combustor . The resulting gases are directed over the turbine's blades, spinning the
turbine, and, mechanically, powering the compressor. Finally, the gases are passed
through a nozzle, generating additional thrust by accelerating the hot exhaust gases
by expansion back to atmospheric pressure.

Energy is extracted in the form of shaft power, compressed air and thrust, in any
combination, and used to power electrical generators .

Theory of operation:

Gas turbines are described thermodynamically by the Brayton cycle , in which air is
compressed isentropically , combustion occurs at constant pressure, and expansion
over the turbine occurs isentropically back to the starting pressure.

In practice, friction, and turbulence cause:

a) non-isentropic compression: for a given overall pressure ratio, the compressor

delivery temperature is higher than ideal.
 b) non-isentropic expansion: although the turbine temperature drop necessary to drive
the compressor is unaffected, the associated pressure ratio is greater, which
decreases the expansion available to provide useful work.

c) pressure losses in the air intake, combustor and exhaust: reduces the expansion
available to provide useful work.

Gas Power Cycle :- although any cycle may in principle be used as a heat engine or as a
refrigerator and heat pump by just reversing the direction of the process in practice
there are big difference and the study is split between power cycle and refrigeration
cycle.
Many gas cycle have been proposed and several are currently used to model real
heat engines. From the academic point of view we will the brayton cycle.
brayton cycle :- the bray ton cycle nomad after the American engineer George
bray ton is a good model for the operation of a gas turbines engine. Now a days
used by practically all aircraft except the smallest once by fast boast and
increasingly been used for stationary power generation. Particularly when both
power and heat are of interest the ideal bray ton cycle in the T-S and P-V diagram
and the regenerative cycle.As with all cyclic heat engines, higher combustion
temperature means greater efficiency. The limiting factor is the ability of the steel,
nickel, ceramic, or other materials that make up the engine to withstand heat and
pressure. Considerable engineering goes into keeping the turbine parts cool. Most
turbines also try to recover exhaust heat, which otherwise is wasted energy. the
heat released from the exhaust gas has been absorbed by many kms of tubing
which line the boiler. Inside these tubes is water, which takes the heat and is
converted into steam at high temperature and pressure. The type of boiler is called
heat recovery steam generation (HRSG) This steam at high temperature and
pressure is sent to the turbine where it is discharged through the nozzles on to the
turbine blades. The energy of the steam striking on the blades makes the turbine to
rotate. Coupled to the turbine is the rotor of the generator. So when the turbine
rotates the rotor of the generator turns. The rotor is housed inside a stator having
heavy coils of copper bars in which electricity is produced through the movement
of magnetic field produced by the rotor. Electricity passes from stator winding to
the transformer, which increases its voltage level so that it can be transmitted over
the lines to far off places.

The steam, which has given away its energy, is changed back into water in the
condenser. Condenser contains many kms of tubing through which cold water is
continuously pumped. The steam passing over the tubes continuously loses heat
and is rapidly changed back into water. But the two waters i.e. the boiler feed
water and cooling water must never mix. Boiler water must be absolutely pure
otherwise the tubing of the boiler may get damaged due to the formation of salts
inside the tubes due to the presence of different impurities in water.
To condense large quantities of steam huge and continuous volume of water is
required. In some power stations same water has to be used again and again
because there is not enough water. So the hot water tracts are passed through the
cooling towers. The cooling towers are simply concrete shells acting as a huge
chimney creating a draught of air. The design of cooling towers is such that a
draught of air is created in the upward direction. The water is sprayed at the top of
the tower. As it falls down the air flowing in the upward direction cools it. The
water is collected in a pond from where the water is recirculated by the pumps to
the condenser. Inevitably, however some of the water is taken taken away by the
draught of water in the form of vapours and it is this water with familiar white
clouds emerging from the cooling towers.
HRGS (heat recovery steam generator)
SALIENT FEATURES OF HRSG

 Horizontal Natural Circulation Design.

 Steam generation at multiple pressure levels with or without reheaters.
 Modular construction with spiral finned tubes for compactness.
 Fully drainable heat transfer section
 Short installation time.
 Ease of operation.
 Supplementary Fuel firing system to meet specific customer requirements.
o -In duct firing/Furnace firing.
o Multiple Fuel firing (Oil/Gas).
 Low NOx and CO emission.
o Stand by fresh air firing with FD fan for uninterrupted steam supply (
FD Fan mode ).
 Unfired boiler.
 Exhaust gases are used to generate steam.
 500 c lower portion.
 High pressure circuit two.
 6H bar upper portin economizer.
 Low temperature portion.
 6 bar 202 c (ragging)
 Discharge pressure 1H bar steam
 Water tube boiler.
 Forced circulation boiler.
 Vertical boiler.
 At 100 c leaver boiler.
 Deareater feed storage tank
 Circuit feed regulating
 Economizer station controls
 Evaporator flow
  Super heater H.P. turbine and L.P. turbine
 Twin cyclender turbine.
 Tendon compound turbine.

HP STEAM (RATED PARAMETERS)

• PRESSURE : 78.2 Kg/Cm2.
• TEMPERATURE : 514+/- 5 Deg. C
• FLOW : 187.1 TPH.

LP STEAM (RATED PARAMETERS)

• PRESSURE : 5.0 Kg/Cm2.
• TEMPERATURE : 200 Deg. C
• FLOW : 39.8 TPH.
 ARRANGEMENT OF HRSG DHOLPUR CCPP
HP Main Steam LP
Line Fe
ed HP
Co
W Fe nd
HP Steam Drum LP Steam Drum at ed .
er W In/
at Ou
er t

GT Exhaust HP HP HP HP HP LP LP LP HP
SH-II SH-I
CPH
EVP-II EVP-I ECO-II SH EVP-II EVP-II ECO-I

DD GD DESH

Spray line
LP Main Steam
Line
STEAM TURBINE
Steam turbine auxiliary (STA) :-
1. H.P. & L.P. by pass system
2. shapt turning system
3. feed water system
4. air extraction water side.
5. cw make up and raw water system.
6. hub oil system.
7. tacking oil system.
8. hydrolic oil system.
9. glained steam system
(1) two glained steam
(a) fan
(b) cooler
(2) pressure can valve
10. cooling water circuit :-
to create low back pressure
11. cooling water pump :-
two pump are in service one is service & second is stained
12. cooling tower:-
fans is use in cooling.
13. lub water pump:-
3 pumps one is service of two is stained.
14. air extraction system:-
Steam side removes non condensable from steam turbine.
15.air ph system:-
 load on turbines is lers.
 We head up air.
  It’s density is reduce
 Mass flow is reduced

16. auxiliary raw cooling water com water:-

 Three pump 2.1
 Intermediate heat exchanger
17. feed water duration:-
(a) hat water line
(b) L.P. steam line
(c.) H.P. steam line
TURBO-GENERATOR AND
EXCITATION SYSTEM
An Turbogenerator is an electromechanical device that converts mechanical energy
to electrical energy, using a rotating magnetic field

THEORY BEHIND THE WORKING OF A TURBOGENERATOR

 An Turbogenerator generally includes a rotor that rotates within a stator core

to convert mechanical energy into electrical energy.

 A frame-supported stator core provides a high permeability path for

magnetic flux and a rotor assembly positioned to rotate continuously within
the stator core so as to induce electrical current.

 The resulting current is carried by high-current conductors through and out

from the power generator, to connectors that provide the current to a plant
bus for power distribution.

Main Components of Generator

• Stator
– Stator Frame (Fabrication & Machining)
• Core Assembly
– Stator Core, Core Suspension Arrangement
• End Shield
• Stator Winding Assembly
– Stator Winding , Winding Assembly, Connecting Bus bar, Terminal
Bushing
• Rotor
– Rotor Shaft, Rotor Wedges, Rotor Coils, Wound Rotor, Rotor
Assembly
• Completing Assembly
– Bearing Assembly, Shaft Seal Assembly, Oil Catchers, Insert Cover
etc
• Exciter
• Auxiliary Systems
•
FUNCTIONS OF EXCITATION SYSTEM

 GENERATION OF AIR GAP FLUX TO GET ELECTRICAL OUTPUT.

 TO GENERATE SYNCHRONISING TORQUE TO KEEP THE
MACHINE IN SYNCHRONISM.
 TO GENERATE REACTIVE POWER (MVAR)
 FAST RESPONSE TO SYSTEM DISTURBANCES.
 CAPABILITY TO GENERATE FIELD FORCING CONDITION FOR
PROMPT CLEARANCE OF FAULTS.

BRUSHLESS EXCITATION SYSTEM

 CONTACT LESS SYSTEM

 ELIMINATES ALL PROBLEM RELATED TO TRANSFER OF POWER
BETWEEN
 STATIONARY AND ROTATING ELEMENTS
 COMPLETELY ELIMINATES BRUSHGEAR ,
 SLIPRINGS, FIELD BREAKER .
 ELIMINATES THE HAZARD OF CHANGING
 BRUSHES ON LOAD
 BRUSH LOSSES ARE ELIMINATED
 RELIABILITY IS BETTER
 IDEALLY SUITED FOR LARGE SETS
RATING OF GENERATORS

Parameter GTG STG

TYPE TARI 1080 TARI108
ACTIVE POWER 112.46 126.46MW
MVA 132.3 148.47
SPEED/FREQUENCY 3000/50 3000/50
RPM/Hz
STATOR VOLTAGE 10.5 10.5 Kv
STATOR CURRENT 7275A 8164A
CONT. UNBALANCED CURRENT 10% 10 %
RATED POWER FACTOR 0.85 LAG 0.85 LAG
INNER CONNECTION OF
STATOR WINDING Y-Y Y-Y
RATED FIELD CURRENT 756 825A
RATED FIELD VOLTAGE 319 368V
INTERNAL COOLING AIR AIR
EXTERNAL COOLING MEDIUM AIR WATER
220 KV SWITCHYARD AND
TRANSFORMERS
220 KV SWITCHYARD AND DIFFERENT EQUIPMENTS INSTALLED AND
BUS SCHEMES.

BUS SCHEME
Main Function Of The Stations Is To Receive The Energy And Transmit It At The
Required Voltage Level With The Facility Of Switching.
At DCCPP Following Are The Bays:-
1 GTG-1
2 Bus coupler
3 Line-1
4 GTG-2
5 Line-2
6 Line-3
7 STG
Bus System
There Are Mainly Two Buses
1 Main Bus-1
2 Main Bus-2

SF6 GAS CIRCUIT BREAKERS:

In this type of breaker quenching of arc is done by SF6 gas. The opening and closing of
the circuit breaker is done by air.

TYPE DESIGNATION:-
E : S F 6 Gas Insulation
L : Generation
F : Out Door Design
SL : Breaker Construction
4 : Code BIL Rated Voltage 4 - 245 / 460 / 1050 kv
1 : No. of chamber
The high voltage circuit breaker type ELF SL 4-1 comprises 3 breaker poles, a
common control cubicle and a pneumatic unit (compressed air plant) a
breaker pole consists of :-
- SUPPORT (FRAME) - 40000
- POLE COLUMN - 41309 N
- PNEUMATIC ACTUATOR ( PKA) - 90200
The actuator is operated with compressed air.
A pneumatic unit ( 97200), an air receiver and a unit compressor is installed to
supply the compressed air. the compressed air stored in the air receiver is
distributor to the three actuator via pipe line.
The common control cubicle ( 96000), which is installed separately contains all
control devices and most of the monitoring instrumentation with the
exception of the density monitor 98005 mounted on the middle breaker pole.
the pressure switches are installed in the control cubicle. all three poles
columns are filled with insulating gas and interconnected by means of pipe
lines. the gas is monitored by a density monitor 98005 ( temp. compensated
pressure monitor )
If all the poles of the circuit breaker do not close simultaneously then the pole
discrepancy relay will operate and trip the breaker. Also at the time of
tripping, if all the breakers do not trip simultaneously, then again the
tripping command through the pole discrepancy relay will initiate to trip the
breaker and annunciation will appear in the sub station control room and the
UCB.
ISOLATORS:
Isolators are used to make or break the circuit on no load. They should never be operated
on load. The isolators installed in the sub station have a capacity of 1250 amperes.
They are double end break type, motor operated and can be operated from local as
well as remote.

CURRENT AND CAPACTIVE VOLTAGE TRANSFORMERS:

These are used for metering and protection. It should always be kept in mind that a CT
should never be open circuited and a PT should never be short-circuited.

LIGHTINING ARRESTOR AND ARC HORNS:

Protection against lightening.
Thank You