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Ankit Kamal Anurag Kamal

ABSTRACT

To meet the power demands of the country, it is required to set up new projects, time to time so that demand and generation gap may be narrowed but most important is to full utilization of existing capacity. This may be possible only by increasing the reliability, availability and maintainability of power generation units and by operating the units at its full capacity. This vocational training report is concerned with the overall operation of the plant, machines used in the plant, water treatment in the plant and thermodynamic cycles used in the NTPC, Auraiya Gas Power Plant.

CONTENT
INTRODUCTION TO NTPC TOTAL INSTALLED CAPACITY OF NTPC INTRODUCTION OF NTPC, AURAIYA GAS POWER STATION COMBINED CYCLE AND COMBINED CYCLE PLANT AIR COMPRESSOR AND COMBUTION CHAMBER FUELS TURBINES AND GAS TURBINE LAYOUT OF NTPC,AURIAYA BOILERS AND WASTE HEAT RECONERY BOILERS BOILER ECONOMISER AND WASTE HEAT RECOVERY WATER TREATMENT PLANT AND STORAGE STEAM TURBINE PASSOUT OR EXTRACTION TURBINES CIRCULATING WATER PUMPS AND DEAERATOR COOLING SYSTEM WATER SOURCES CONTROL SYSTEM OF THE PLANT ELECTRICAL AND SWITCHYARD DEPARTMENT DIFFERENT TYPE OF EQUIPMENT USED IN SUB STATIONS

 CONCLUSION

THE COMPANY

NTPC Limited is the largest thermal power generating company of India. A public sector company, it was incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the Government of India. At present, Government of India holds 89.5% of the total equity shares of the company and the balance 10.5% is held by FIIs, Domestic Banks, Public and others. Within a span of 30 years, NTPC has emerged as a truly national power company, with power generating facilities in all the major regions of the country. Based on 1998 data , carried out by data monitor UK, NTPC is 6th largest in terms of thermal power generation and the second most efficient in terms of capacity utilization amongst the thermal utilities in the world.

NTPC Ltd. IN INDIAN POWER SECTOR

NTPCs core business is engineering, construction and operation of power generating plant and also providing consultancy to power utilities in India and abroad. As on date the installed capacity of NTPC is 24,954 MW through its 14 coal based (20,685 MW), 7 gas based (3,955 MW) and 3 joint venture projects (314 MW). NTPC acquired 50% equity of the SAIL Power Supply Corporation Ltd. (SPSCL). This joint venture company operates the captive power plants of Durgapur(120 MW), Rourkela(120 MW) and Bhilai(74 MW). NTPCs share on 31 march 2006 in the total installed capacity of the country was 19.51% and it contributed 27.68% of the total power generation of the country during 2005-06. NTPC has set new bench marks for the power industry both in the area of power plant construction and operation. It is providing power at the cheapest average tariff in the country. With its experience and expertise in the power sector,

NTPC is extending consultancy services to various organizations in the power business.

INSTALLED CAPACITY
AN OVERVIEW Projects No. of Projects Commissioned Capacity(MW) 20,685 3,955 24,640 314* 24,954

NTPC OWNED COAL 14 GAS/LIQ FUEL 07 TOTAL 21 OWNED BY JVCS COAL 3 GRAND TOTAL 24 *Captive Power Plant under JV with SAIL

PROJECT PROFILE
Coal Stations Coal Based Singrauli Korba Ramagundam Farakka Vindhyachal Rihand Kahalgaon NTCPP Talcher Kaniha Unchahar Talcher Thermal Simhadri State Uttar Pradesh Chhattisgarh Andhra Pradesh West Bengal Madhya Pradesh Uttar Pradesh Bihar Uttar Pradesh Orissa Uttar Pradesh Orissa Andhra Pradesh Commissioned Capacity(MW) 2,000 2,100 2,600 1,600 2,260 2,000 840 840 3,000 840 460 1,000

Tanda Badarpur Total (Coal)

Uttar Pradesh Delhi

440 705 20,685

Gas/Liq. Fuel Stations

Gas Based State Commissioned Capacity(MW) 413 663 645 817 648 350 430 3,966

Anta Rajasthan Auraiya Uttar Pradesh Kawas Gujarat Dadri Uttar Pradesh Jhanor-Gandhar Gujarat Kayamkulam Kerala Faridabad Haryana Total (Gas)

Introduction of gas power station ntpc(Auraiya)

Auraiya gas power station is a gas based combined cycle power plant of NTPC. The plant is situated in Distt. Auraiya of Uttar Pradesh, on main railway track. It is 60 km from Kanpur. The plant has 4 Gas Turbines (GT) and 2 Steam Turbines (ST) with 4 Waste Heat Recovery Boilers (WHRB). Though the plant is normally operated on combined cycle but it may be operated on open cycle mode in case of any problem in WHRB. The plant is basically divided in two modules and each module has 2 GT, 1ST and 2WHRB. Their capacities are as follows:MODULE I: Gas Turbine Capacity Steam Turbine Capacity Total Module I Capacity MODULE II: Gas Turbine Capacity Steam Turbine Capacity : 2 X 111.19 MW : 109.3 MW : 331.68 MW : 2 X 111.19 MW : 109.3 MW

Total Module II Capacity

: 331.68 MW

TOTAL PLANT CAPACITY: 663.36 MW

THE BASIC DIAGRAM OF ARRANGEMENT OF UNITS IN AURAIYA GAS POWER PLANT

MODULE #1
2 X 111.19 + 109.3 = 331.68 MW

MODULE #2
2 X 111.19 + 109.3 = 331.68 MW

STATION CAPACITY
ST # 1
109.3 MW

663.36 MW

ST # 2
109.3 MW

WHRB #1

WHRB #2

WHRB #3

WHRB #4

GT # 1
111.19 MW

GT # 2
111.19 MW

GT # 3
111.19 MW

GT # 4
111.19 MW

GT - Gas Turbine ST Steam Turbine WHRB Waste Heat Recovery Boiler

Combined CYCLE
Combined Cycle is a term used when a power producing engines or plant employs more than one thermodynamic cycle. Heat engines are only able to use a portion of the energy their fuel generates (usually less than 30%). The remaining heat from combustion is generally wasted. Combining two or more cycles such as the Brayton cycle and Rankine Cycle results in improved overall efficiency.

Combined Cycle Plants

The combined-cycle unit combines the Rankine (steam turbine) and Brayton (gas turbine) thermodynamic cycles by using heat recovery boilers to capture the energy in gas turbine exhaust gases for steam production to supply a steam turbine as shown in the Combined Cycle Cogeneration Unit. Process steam can be also provided for industrial purposes. Fossil fuel-fired (central) power plants use either steam or combustion turbines to provide the mechanical power to electrical generators. Pressurized high temperature steam or gas expands through various stages of turbines, transferring energy to the rotating turbine blades. The turbine is mechanically coupled to a generator, which produces electricity.

Combined cycle operation of ntpc, Auraiya

Air compressor
An air compressor, as the name indicates, is a machine to compress the air and to raise its pressure. The air compressor sucks air from the atmosphere, compresses it and then delivers the same under the high pressure to a storage vessel. From the storage vessel it may be conveyed by the pipeline to the place where the supply of compressed air is required. Since the compression of the air requires some work to be done on it, therefore a compressor must be driven by some prime mover. There are total 5 compressors in the plant. 4 are used in GT and 1 is used in emergency GT. The compressor used in AUGPS is a 19 stage series compressor. Advantages of using multistage compressor are as follows It improves the volumetric efficiency for the given pressure ratio. It reduces the leakage cost considerably. It reduces cost of compressor. Compressor pressure ratio: - 6.9:1

COMBUSTION CHAMBER
In the combustion chamber the high pressure and temperature air burns the fuel and hot gases are generated. These hot gases are used for further work.

FUELS
Mainly two fuels are used in this gas power plant which are listed below Natural gas Naphtha The Natural gas is supplied by GAIL, Dibiyapur and is taken directly From the pipeline which goes from Hazira to Jagdishpur. The other fuel is supplied by IOC, Kanpur and Mathura.

STORAGE CAPACITY FOR NAPHTHA

There are two tanks for storing Naphtha fuel each having a capacity of 1500 KL. There are three transfer pumps for loading fuel from tankers. The two pumps work and the third is auxiliary. There are twelve unloading pipes, thus twelve trucks con be unloaded at a time. If a gas turbine is running at full load then it consumes 20 KL Naphtha fuel in one hour.

TURBINES
INTRODUCTION:Turbines are a rotary engine that converts the energy of a moving stream of water, steam or gas into mechanical energy. The basic element in a turbine is a wheel or rotor with paddles, propellers, blades or buckets arranged on its circumference in such a fashion that the moving fluid exerts a tangential force that turns the wheel and imparts energy to it. This mechanical energy is then transferred through a drive shaft to operate a machine, compressor, electric generator or propeller. Turbines are classified as Hydraulic or Water turbines, Steam turbines and Gas turbines. Today turbine powered generators produce most of the worlds electrical energy. There are total 6 turbines in NTPC, Auraiya Gas Power Plant; of which 4 are Gas turbines and remaining 2 are Steam turbines.

GAS TURBINE
Generally known as gas turbine engines, gas turbine is a type of internal combustion engine capable of generating either power or propulsive force by forcing a high temperature gas flow to turn a turbine (centrifugal impeller). Jet engines are the familiar type of gas turbine. MSC provides maintenance service for gas turbine used at power plants.

GAS TURBINE LAYOUT OF NTPC, AURAIYA

Jet engines are a familiar type of gas turbine.MSC provides maintenance services for gas turbines used at power plants. Gas turbines are well suited for use in generating electricity due to their combustion of small size and high output. Among the reasons gas turbines compare favorably to diesel engines (another type of internal combustion engine) are the ease with which nitrogen oxide (NOx) and hydrocarbons can be controlled and their relatively smaller size (when comparing engines with the same output).

In addition to traditional power generation applications, gas turbines are recently being employed as power sources for pumps used in emergency situations such as natural disasters, due to their short start-up times and for water jet propulsion systems (used in high-speed ships). In thermal power plants using gas turbines, there is a trend towards the use of combined cycle power generation systems. This technology takes advantage of the high temperature of the exhaust gases produced by gas turbines, passing the gases through a heat recovery steam generator to produce high- temperature steam. This steam is then routed through a steam turbine to generate additional electricity. The approach yields a greater thermal efficiency than is possible with a gas turbine alone, and recently some power plants, including the Higashi-Niigata Thermal Power Station, have surpassed 50% thermal efficiency. This level of efficiency is among the worlds best. As a means of increasing the thermal efficiency of gas turbines themselves, manufacturers are beginning to build turbines with high inlet temperatures.

Among the gas turbines manufactured by Takasago Machinery Works, Mitsubishi Heavy Industries Ltd. Are turbines with inlet temperatures in excess of 1,500C, also among the worlds best. The D type gas turbines which are being used in NTPC, Auraiya are supplied by M.H.I. Japan having turbines inlet temperatures of 1139C.

BOILER
Boiler is a device for heating water or generating steam above atmospheric pressure. All boilers consist of a separate compartment where the water can be evaporated into steam. NTPC, Auraiya Gas Power Plant has 4 WASTE HEAT RECOVERY BOILERS. All the 4 boilers are NON FIRED and WATER TUBE BOILERS.

WASTE HEAT RECOVERY BOILERS (WHRB):A WHRB consists of a super heater, a boiler, an economizer and a steam drum. Waste heat boilers may be horizontal or vertical shell boilers or water tube boilers. They could be designed to suit individual applications ranging through gases from furnaces, incinerators, gas turbines and diesel exhausts. The prime requirement is that the waste gases must contain sufficient usable heat to produce steam or hot water at the condition required. Some boilers may be dealt with by maintaining gas-exit at a predetermined level to prevent dew point being reached and others by soot blowing. Currently, there is a string interest in small combined heat and power (CHP) stations, and these will normally incorporate a waste heat boiler.

BOILER ECINOMIZER:A boiler economizer is a device that reduces the overall fuel requirements a boiler requires which results in reduced fuel costs as well as fewer emissions since the boiler operates at a much higher efficiency. Boiler economizers recover the waste heat from the boilers hot stack gas and transfer this waste heat to the boilers feed-water. Because the boiler feed-water is now at a higher temperature that it would have been without a boiler economizer, the boiler does not need to provide as much additional heating to produce the steam requirements of a facility or process, thereby using less fuel and reducing the fuel expenses. Boiler economizers also help improve a boilers efficiency by extracting heat from the flue gases discharged from the final super heater section of a radiant/reheat unit or the evaporation bank of a non-reheat boiler. Heat is transferred, again, back to the boiler feed-water, which enters at a much lower temperature than saturated steam.

WASTE HEAT RECOVERY:Many industrial processes generate large amount of waste energy that simply pass out of plant stacks and into the atmosphere or are otherwise lost. Most industrial waste heat streams are liquid, gaseous or a combination of the two and have temperatures from slightly above ambient to over 2000F. Waste heat recovery methods used with industrial process heating operations intercept the waste gases before they leave the process, extract some of the heat they contain, and recycle that heat back to the process. Common methods of recovering heat include direct heat recovery to the process, recuperators/regenerators, and waste heat boilers.

WATER TREATMENT PLANT & STORAGE

Since steam is taken out continuously and returned to the boiler, losses due to blow downs and leakages have to be made up for maintaining designed boiler water quantity by means of the level gauges provided on the boiler drum. For this, continuous make up water is added to the boiler water system. Since this make up requires pure water this quality water is obtained by a Demineralised (DM) water treatment plant. However some storage is essential as DM plant may be down for maintenance. For this purpose a storage tank is installed from which continuously DM water is drawn for boiler make up. The impurities in water input to this plant generally consist of calcium and magnesium salts imparting hardness to the water. These salts have to be removed from the water. If hardness is present in makeup water to the boiler, the salts not only form deposits on the tube surfaces but also lead to overheating in those localities resulting in tube failures. Therefore these have to be completely removed for use as boiler make up, this is done using DM water treatment plant which gives the purest form of water. This generally consists of cation, anion and mixed bed exchangers. The final water from this process consists generally of hydrogen ions and hydroxide ions which is the chemical combination of pure water. The DM water being very pure is highly corrosive, once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen absorption. The capacity of the DM plant is dictated by the type and quantity of salts in the raw water input. The storage tank for DM water is made from materials not affected by corrosive water, such as PVC. The piping and valves are generally of stainless steel.

STEAM TURBINE

Steam turbines are a type of external combustion engine capable of generating power or propulsive force by forcing high temperature steam generated outside the engine to turn a turbine (centrifugal impeller). Steam turbines have a long history and it is said that a Greek mathematician first described a body that would rotate under steam power some 2,000 years ago. The first ship powered by steam turbine was the product of the Industrial revolution in Europe. Compared to the steam reciprocating engines (engines that generate rotational power by forcing pistons to move back and forth), steam turbines are lighter and capable of producing higher output. Recently steam turbines have gained use in power plants and there are large numbers of nuclear plants that generate output in excess of 1,000 megawatts by

powering massive steam turbines with high temperature steam generated by a nuclear reactor. In order to increase the efficiency of steam turbines, Takasago Machinery Works, Mitsubishi Heavy Industries Ltd is using 3D design technology to shape rotor blades, developing and manufacturing larger rotor blades and designing methods to prevent the loss of steam throughput.

PASS OUT OR EXTRACTION TURBINES:-

The steam turbines that are used in NTPC, Auraiya are Pass out OR Extraction turbines. In these types of turbines steam is exhausted at different stages and used in heating the steam water for the boiler or processing work. The high pressure steam from the boiler enters the HP stage of turbine where it expands and the pressure is reduced to such a value that is required for processing work. A part of this low pressure steam leaving the high pressure stage is supplied to the processing work while the remaining steam expands further in the L.P. stage. The exhaust steam from the processing plant and the low pressure turbine steam is condensed in the condenser and pumped back to the boiler.

CIRCULATING WATER PUMPS

These pumps are used to pump water to the deaerator from where the water goes to boiler feed pump.

DEAERATOR
The deareators are used to deaerate the water before feeding it into BFP. This is done because HRB is a water tube boiler and the tubes containing water have very small diameter. There are some gases like CO2 if present in water they can create rusting or can choke the tubes. So these gases are removed in the deaerator. There are total four deareators in the NTPC, Auraiya one each for every WHRB.

WORKING OF WHRB:The feed water enters into steam drum through boiler economizer from where it goes into boiler and converted into steam. This steam further goes to super heater and at the output superheated steam at the temperature of 530 C is gained. This superheated steam is used to drive steam turbine to generate electricity as in the cycle.

COOLING SYSTEM
The majority of the electricity generated is produced by steam driven turbine generators. A very important step in this power generation process is the condensation of exhaust steam from the final, low pressure turbine when the steam condenses, the rapid decrease from vapor-to-liquid specific volume creates a vacuum at the turbine outlet (monitored as turbine backpressure) that increases power generation efficiency. Low turbine backpressures are achieved when the steam condensate temperatures are lower. Designing and operating a cooling system that can consistently and continually remove the heat of condensation at those low temperatures is essential. Therefore, the cooling system should be considered the integral part of power generation process that can have a major influence on the overall power plant performance and availability. The waste heat removed by the cooling system during the steam condensation step must ultimately be transferred to the surrounding environment. Having a high unit heat capacity, water has been the traditional transfer medium of choice because it has been readily available, relatively inexpensive and reusable up to a point. Wet cooling systems use water to absorb heat via indirect contact with steam in a condenser. The heated water is either discharged to a large surface water body such as lake or river (once through cooling) or passed through a cooling tower and recycled back to the condenser (recirculated cooling). Many of the plants built during the last decade are based on the combined cycle process of power generation. In the most common 2-on-1 arrangement, electricity is produced by two combustion turbine generators with the hot exhaust gas from these turbines used to produce steam in a heat recovery steam generator for a single steam driven turbine generator. Since the combustion turbines produce roughly two third of the overall electrical power and have no steam condensation step, a combined cycle plant requires only about one-third the amount of cooling needed by a conventional steam electric plant of equivalent capacity.

WET COOLING:Since the advent of steam-electric generation, wet cooling systems have been a de facto component of the power production process. Initially, once-through cooling was the favored approach. The large size of the source water guarantees cold cooling water temperatures with almost no daily variation and usually very modest seasonal variation. However in the early 1970s, new steam electric generation began using recirculated cooling. The wet cooling towers have a hot water distribution system that showers or sprays water evenly over a lattice work of closely set horizontal salts or bars called fill or packing. The fill thoroughly mixes the falling water with air moving through

the fill the water splashes down from one fill to the next by gravity. Outside air enters the towers via fans in the form of horizontal slats in the side of the towers. The slates usually slope downward to keep t water in. The intimate mix between air and water enhances heat and mass transfer (evaporation), which cools the water. Cold water is then collected in concrete basin at the bottom of the tower where it is pumped back to the condenser. The now hot, moist air leaves the tower at the top.

WATER SOURCES

CONTROL SYSTEM OF THE PLANT

There are three of controlling systems available in the plant and they are as follows: LOCAL CONTROL:In it the control commands are given to the machine from that place where machine is located. This system is rarely used. SWITCHYARD CONTROL:In it all controlling commands are given from switchgear room. REMOTE SYSTEM:This system is frequently used. In it all controlling commands are given from central computerized control room.

In the central computerized control room, there are two set of controlling devices. If one set is shut down for maintenance then commands are given by second set.

ELECTRICAL AND SWITCHYARD DEPARTMENT

Electrical energy management system ensures supply of energy to every consumer at all times at rated voltage, frequency and specified waveform at lowest cost and minimum environmental degradation. The switchgear, protection and network automation are integral parts of the modern energy management system and national economy. The modern 3-ph, 50 HZ, AC interconnected system has several conventional and non-conventional power plants, HV transmission network, substations, MV and LV distribution systems and connected electrical loads. The energy form is supplied to various consumers located in vast geographical area, instantly, automatically, and safely with required quality at all times. The service continuity and high quality of power supply have become very important. For fulfilling the foresaid purpose, a state of the art, scientifically and technologically advanced SUBSTATION is required. Sub-station is the load control centre of the thermal plant where power at rated voltage, frequency and waveform is exported/ imported as per requirements. The substation at NTPC, Auraiya has two switchyards, one of 220 KV and other of 440KV. There are two bus bars and one transfer bus for supplying electricity. After step up, the 220 KV output from the generator transformer is fed to either of two bus bars through relays and circuit breakers and these are connected to various feeders through various equipments. There are total 10 lines going out of NTPC, Auraiya for supplying electricity. Their descriptions are as follows:1. 2. 3. 4. 5. 2 lines of 220 KV to Agra. 2 lines of 440 KV to Agra. 2 lines of 220 KV to Maingaon, M.P. 2 lines of 220 KV to Railway. 2 lines of 220 KV to GAIL, Dibiyapur.

DIFFERENT TYPES OF EQUIPMENTS USED IN SUB-STATIONS:BUS-BARS:Bus bar is term used for main bar of conductor carrying an electric current to which may be made. These are mainly convenient means of connecting switches and other equipments into various arrangements. There are two bus bars and one transfer bus for supplying electricity. Both bus bars are used continuously and transfer bus is used in case of many repairing or maintenance.

LIGHTENING ARRESTORS:These are equipments designed to protect insulators of power lines and electrical installations from lightening surges by diverting the surge to earth and instantly restoring the circuit insulation to its normal strength with respect to earth.

INDICATING AND METERING INSTRUMENTS:Ammeters, voltmeters, watt meters, KWH meter and KVA meters are installed in sub-station to watch over the currents flowing in the circuit and voltages and power loads.

ISOLATORS:One of the cardinal measures for ensuring full safety in carrying out work on equipment in electrical installations is to disconnect reliably the unit or the section on which the work is to be done from all other live parts of the installation. To guard against mistakes, it is necessary that apparatus, which make a visible break in the circuit such as isolators, should do this.

Isolators do not have arc control devices therefore cannot be used to interrupt currents at which the arc will be drawn across the contacts. The open arc in these is very dangerous, in that it will not only damage the isolator or the equipment surrounding it but will also cause the flashover between the phase in other words, it will result in short circuit in the installation i.e. why isolators are used only for disconnecting parts after de-energizing them by opening their respective circuits by use of their circuit breakers. CIRCUIT BREAKERS:Circuit breakers are mechanical devices designed to close or open contact or electrical circuit under normal conditions. CB is equipped with a strip coil directly attached to relay or other means to operate in abnormal conditions such as over power etc. In NTPC, Auraiya Gas power plant SF6 CB is used. In sulphur puffer type SF6 CB is filled with SF6 gas at single pressure (4to6kgf/cm2). The pressure and gas flow required for arc extinction is obtained by piston action. In double pressure type SF6 CB the gas from high-pressure system is released to into low-pressure system over the arc during the arc quenching process. DUPLICATE BUS BAR ARRANGEMENT:The duplicate bus bar system provides additional flexibility, continuity of supply and permits periodic maintenance without total shut down. In the event of fault on one bus the other bus can be used. RELAYS:Relay is a device by means of which an electrical circuit (trip or alarm circuit) is controlled (closed) by change in the other circuit. Relays are automatic. The function of relay in power supply system is to recognize a start out and to initiate the operation of CB or other devices to isolate the defective elements with minimum disturbance to the normal power supply system.

CONCLUSION

Thus this vocational training report deals with overall operation of the NTPC plant in Auraiya. Also the report has a view of some parts used in plant. The depleting resources of oil, gas and coal (the conventional fuels) along with atmospheric pollution problems have drawn the attention of the scientists and engineers all over the world to find out other sources for the generation of electric power. These sources of energy are going to attain the nerve centre of the future power plants. Though atomic and nuclear power plants have been developed on conventional lines, but lot of work is yet to be done. Efforts are being made to convert atomic and nuclear energy directly into electric power with the help of magneto-hydrodynamic generator and other equipments.