For restricted Circulation Only

GAS PLANT
FAMILIARISATION






Power Management Institute
Noida



CONTENTS

S. No. Description Page No.
1. Introduction to Gas Power Plant 1
2. Gas Turbine Starting System 10
3. Fuel System 12
4. Fire Detection and Protection System 17
5. Salient Features NTPC Gas Based Power Projects 22
6. Modern large size Gas Turbine 25
7. Gas Turbine Compressor 50
8. Waste Heat Recovery Boiler 67
9. Gas Turbine Generator 82
10. Excitation System 92
11. Gas Plant Operation 103
12. Protection & Interlock 156
13. Spare Part Management 177
14. Data Sheet for Gas Projects 194

PMI,NTPC 1
1. Introduction To Gas Power Plants


Introduction

The development of the sector in the country, since independence has been
predominantly through the State Electricity Boards. In order to supplement the
effects of the states in accelerating power development and to promote power
development on a regional basis to enable the optimum utilisation of energy
resources, the Government of India decided to take up a programme of
establishment of large hydro and thermal power stations in the central sector on
a regional basis. With this in view, the Government set up the National Thermal
Power Corporation Ltd., in November 1975 with the objective of planning,
construction, commissioning, operation and maintenance of Super Thermal and
Gas Based Power projects in the country.

The availability of gas in a large quantity in western offshore region has opened
an opportunity to use the gas for power generation, which is an economical way
and quicker method of augmenting power generating capacity by natural gas as
fuel in combined cycle power plant in a power deficit country like ours. With this
intention in mind the Government has asked NTPC to take up the construction of
Kawas, Auraiya, Anta, Dadri and Gandhar Gas Power Project along the HBJ Gas
pipe line.

The power plant will consist of gas turbine generating units waste heat recovery
boilers, steam turbo generator, ancillary electrical and mechanical equipments.
The power generated at this power station will be fed over 220 KV AC
transmission system associated with this project to distribute the power in the
various Regions.

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In the Power Sector, the use of gas turbine drive generators has just started and
will go a long way in meeting the countrys requirements.

Gas turbines range in size from less than 100 KW up to about 140.000 KW. The
gas turbine has found increasing application due to the following potential
advantages over competive equipment.

Small size and weight per horsepower
Rapid loading capability
Self-contained packaged unit
Moderate first cost
No cooling water required
Easy maintenance
High reliability
Waste heat available for combined cycle application.
Low Gestation Period
Low Pollution Hazards

The function of a gas turbine in a combined cycle power plant is to drive a
generator which produce electricity and to provide input heat for the steam cycle.
Power for driving the compressor is also derived from gas turbine.

Combined Cycle

Combined Cycle power plant integrates two power conversion cycles namely.
Brayton Cycle Gas Turbines) and Rankin Cycle (Conventional steam power
plant) with the principal objective of increasing overall plant efficiency.




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Brayton Cycle

Gas Turbine plants-operate on Brayton Cycle in which air is compressed
(process 1-2, in P-V diagram of Figure-1), this compressed air is heated in the
combustor by burning fuel combustion produced is allowed to expand In the
turbine (process 3-4) and the turbine is coupled with the generator.

Without losses the theoretical cycle process is represented by 1 2 3 4

In the actual process losses do occur. Deviation from the theoretical process,
results from the fact that compression and expansion are not performed
isentropically but polytropically which is conditioned by heat dissipation
(expansion) and heat supply (Compression) caused by various flow and fraction
by losses.

In the combined cycle mode, the Brayton Cycle is chosen as the topping cycle
due to the high temperature of the exhaust of the gas turbine (point 4 in the P.V
diagram). In modern gas turbines the temperature of the exhaust gas is in the
range of 500 to 550
o
C.

Reference to the T.S. diagram may indicate the amount of heat that is produced,
converted into mechanical energy and extracted from this process. For the
evaluation of the cyclic process, two parameters are of greatest importance;

1) Thermal efficiency 2) Process working capacity

Thermal efficiency is obtained from chemical binding energy of the fuel and
mechanical energy available at the shaft of the gas turbine. Thermal efficiency
(
th
) as follows:


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th

=

Energy at GT shaft
Chemical Energy of fuel



=

Q Input. Q output 1

Q Output
Qinput Q Input

Working capacity is also obtained from the difference between the amounts of
heat supplied and removed. This is achieved by increasing P
2
that is increasing
gas inlet temperature T
3.




BRAYTON CYCLE
FIG-1

Rankine Cycle

The conversion of heat energy to mechanical energy with the aid of steam is
carried out through this cycle. In its simplest form the cycle works as follows
(fig.2).

The initial state of the working fluid is water (point-3) which, at a certain
temperature is compressed by a pump (process 3-4) and fed to the boiler. In the
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boiler the compressed water is heated at constant pressure (process 4-5-6-1).
Modern steam power plants have steam temperature in the range of 500
o
C to
550
o
C at the inlet of the turbine.




COMBINE CYCLE
FIG-2

Combining two Cycles to Improve Efficiency

We have seen in the above two cycles that gas turbine exhaust is at a
temperature of 500 550
o
C and in Rankine Cycle heat is required to generate
steam at the temperature of 500-550
o
C. so, why not use the gas-turbine exhaust
to generate steam in the Rankine cycle and save the fuel required to heat the
water ? Combined Cycle does just the same.
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The efficiency of Gas Turbine cycle alone is 30% and the efficiency of Rankine
Cycle is 35%. The overall efficiency of combined cycle comes to 48%.

Types of Combined Cycles

It is basically of two types, namely Unfired Combined cycle and Fully Fired
combined cycle.

Unfired combined Cycle

The basic system is shown in figure- 3. in this system the exhaust gas is used
only for raising steam to be fed to the steam turbine for power generation.

The conventional fossil fuel fired boiler of the steam power plant is replaced with
a Heat Recovery Steam Generator (HRSG). Exhaust gas from the gas turbine is
led to the HRSG where heat of exhaust gas is utilised to produce steam at
desired parameters as required by the steam turbine.


UNFIRED COMBINED CYCLE
FIG-3

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However, non-reheat steam turbine is the preferred choice for adopting this type
of system as usually the live steam temperature for HRSG will be solely
controlled by the gas turbine exhaust temperature which is usually around 500
o
C.

In recent development, with the introduction of Dual Pressure Cycles more heat
is recovered in the HRSG and steam with higher pressure and temperature can
be generated. But higher capital investment and sometimes necessity of
supplemental firing system makes the system complex and costly.

Fully Fired Combined Cycle

Fig 4 shows the basic schematic of this cycle. In this system the heat of
exhaust gas from gas turbine is used for two purposes as described below:

Heat contained in exhaust gas is used to heat feed water to a desired
temperature at the inlet to the boiler. This leads to the reduction or elimination of
the extraction steam requirement from the steam turbine. In case, the steam
turbine has a larger steam swallowing capacity to generate more power the
amount of steam which is being extracted from steam turbine for regenerative
feed heating could be made to expand in the turbine to increase its base load
capacity and improve the overall efficiency. In case the steam turbine does not
have the capacity to swallow extra steam available due to cutting down of
extraction, the fuel being fired in the boiler can be cut down to generate less
steam by an amount equivalent to steam required for extractions and thus
improving the overall efficiency due to less consumption of fuel.

Gas turbine exhaust contains about 14 to 16 % oxygen (by weight) and can be
used as hot secondary air in the conventional fossil fired furnaces. So the heat
required to heat the secondary air will be saved and can be used for other
purposes. FD fan power consumption will also be reduced to a great extent.

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BOILER REPOWERING SYSTEM EXHAUST HEAT EXCHANGER
Fig 4

Fuels

Gas turbines are capable of burning a range of fuels including naptha, distillates,
crude oils and natural gas. Selection of fuel (s) depends on several factors
including fuel availability, fuel cost and cleanliness of fuel.

Natural gas is an ideal fuel because it provides high thermal efficiency and
reliability with a low operation and maintenance cost. Liquid fuels, particularly
heavy oils, usually contain contaminants, which cause corrosion and fouling in
the gas turbine. Contaminants, which cannot be removed from the fuel, may
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leave deposits in the gas turbine, which reduce performance and add
maintenance costs.

Dual fuel systems are commonly used, enabling the gas turbine to burn back-up
fuels when the primary fuel source is not available. Dual fuel systems can also be
designed to fire both fuels simultaneously.

Advantages of Combined Cycle Plants

Apart from the higher overall efficiency, the combined cycle power plants have
following advantages:

Low installation Cost: power from a combined cycle power plant is approximately
70% of a conventional coal based power plant of same capacity.

Low Gestation Period: Power from a combined cycle power plant can be
obtained in two phases, i.e. two third power, obtainable from gas turbines, is
available within 16-18 months and the balance in next 1 month. This is much
lower than the gestation period for conventional thermal power plants, which is
around 48-60 months.

Better Reliability: Combined cycle power plants are considered to be highly
reliable with the reliability factor of 85-90% as compared to 60-65% for
conventional coal Fired Power Plants.







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2. Gas Turbine Starting System


The function of the starting system is to crank the gas turbine upto the required
speed until : it becomes self sustaining.

One method of starting large gas turbine is by using a motor driven hydraulic
starting system. Alternatively, the GTG can be started by using a frequency
converter to rotate the generator which drives the turbine for starting.

A typical hydraulic starting system for each gas turbine consist of the following:

Starting motor, electric AC induction motor

Hydraulic torque converter

Auxiliary Gear

Couplings

The electric starting motor drives the hydraulic torque generator through a
coupling. The hydraulic torque converter consists of an impeller, which forces the
fluid against hydraulic starting motor. The hydraulic torque converter is coupled
to the accessory gear, which is connected to the gas turbine shaft. The torque
converter receives hydraulic fluid from hydraulic and lube oil reservoir during
operation. When gas turbine reaches self-sustaining speed the starting device is
disconnected and shut down. To break the inertia of the starting motor and
reduce the starting current a pony motor is provided. Gas turbines of GE and WH
designs are provided with starting motor system for cranking purpose.

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The static frequency converter serves the same function of starting, accelerating
running at preset speed by starting the generator as a synchronous motor by
feeding variable frequency current drawn from the connected grid. Gas turbines
of ABB and SIEMENS make are provided with frequency converter s for the GT
cranking and normally 2 * 100% static converters are provided for the power
station.

Black Start System

To start a gas turbine in the event of AC-power failure an emergency black start
system is provided. It also helps in safe coasting down of the gas turbine and its
auxiliaries following a trip in the event of grid collapse. The black start system
consist of a separate diesel engine or a gas turbine driven synchronous
generator connected to station switch gear bus. It can be operated manually from
local or remote and also it automatically comes into operation following a black
out condition. Capacity of the black start unit should be such that it can supply
the total auxiliary power required to start a gas turbine from standstill condition.

The NTPCs Auraiya project gas turbine is provided for emergency black-start
purpose and all other projects are provided with diesel generator set for the same
duty.










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3. Fuel System


Fuel System of Gas Turbine

The function of the fuel system is to deliver fuel to the combustion chamber(s) of
a gas turbine at quantity and pressure as required by the control system

Liquid fuel system

The liquid fuel system consists of the liquid fuel storage and handling system.
The liquid fuel storage and handling system provides means for unloading ,
storage and distribution of the fuel oil within the plant and typically composed of
the following major components:

Fuel oil unloading pumps
Fuel oil transfer pumps
Fuel oil storage tanks
Flow meter
Strainers
Pressure and Level control stations.
Distribution piping

The number and size of equipments is site dependant. The storage facility is
dependant on such factors as the location of the site, proximity of the oil supply
and the reliability of the oil supply. Fuel oil may be supplied to the plant by a
pipeline, oil barriages, oil tankers, rail/road or high way trucks. Fuel oil unloading
pumps may not be required if the oil arrives by a pipeline, an oil barge, or an oil
tanker since they have their own pumps.

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Naphtha Pressurising System

By the forwarding pumps,Naptha is pumped upto the GTs and kept under
recirculation. For firing the naphtha is the GT,separate pressurising system with
high pressure pump, allied filters and measurements and recirculation system is
used. This pressurising is required because in the naphtha burner this fuel is
mechanically atomised. There is no other medium like air, etc are used for
atomisation.

Naphtha drain system

Since the flash/fire point of this fuel is very low it is designed to drain the oil from
the piping burner etc when the system is stopped. Separate drain tanks are kept
at pumping stations, which will collect these naphtha and pump back to the main
storage tanks.

Mode of firing

It is provided to fire natural gas or naphtha or in mixed mode of the fuel in the GT
Combustion Chamber.

FUEL GAS SYSTEM

The purpose of the fuel gas system is to take gas fuel from the custody transfer
point, process it to the quality and pressure conditions required by the gas
turbine and to distribute it and monitor its use. Fuel gas system consists of the off
base system and the on base system.


PMI,NTPC 14
Off base fuel gas System

The off-base fuel gas system is typically composed of the following major
components:

An emergency stop valve at the gas inlet to the plant knock out drum
Filters
Pressure-control station
Distribution piping

Optional Components are

Gas metering station
Gas Heaters

The need for any of the optional components is dictated by the conditions
specific to each individual application. The final supply pressure required at gas
turbine is a function of the gas turbine compression ratio and the control valve
and nozzle pressure drops. Large gas turbines typically require a gas supply
pressure of about Kg/cm2 with pressure regulated with in +10 percent of set
point.

The emergency stop valve at the in let to the station is provided to completely
shut off the gas supply in an emergency. The gas fuel then goes through a
knockout drum. A knock out drum will remove the free liquid and some solids
from the gas stream. However, it will not separate out much of the entrained
liquids. The liquids separation from gas stream takes place by decreasing the
gas velocity in its transit through the drum. Impurities collect at the drum bottom
and are periodically automatically purged A level controller opens a drain valve
which allows the waste to Adrian tank vented to the atmosphere.

PMI,NTPC 15
The filter separators must have minimum of two stages of separation. The initial
stage being utilised for removal of large liquid droplets and the final stage for
mist separation . Any solid particles carried with the gas stream are separated
in the first stage . The first stage elements consist of hollow tubes of glass
fibers through which gas flows radially from outside. The separation of carried
solids and liquid particles is by interception, diffusion and/or inertial impaction of
the droplets on the fibers. The liquid droplets coalesced on the surface drain on
to the shell and from there to the drain pot. The second stage mist separator is
preferably of the vans type in which liquid separation takes place by subjecting
the gas path to multiple changes of direction.

The gas analysis is carefully checked from the stand point these point of hydrate
formation or icing at the pressure reducing station under the worst ambient
temperatures prevalent at each site. If there is any tendency for the above, a
suitably, rated gas fired indirect heater is provided ahead of the pressure
reducing station. The gas heater ensures a gas temperature sufficiently high
such that the after pressure reduction the gas temperature is at least 20 C
higher than hydrate forming temperature or the gas dew point whichever is
higher. The heater normally utilises natural gas for firing. Heat from the fire tube
be utilised to heat a water bath in which the U tubes for carrying the gases to be
heated are immersed. The control system ensures constant temperature of the
outlet gas for gas flows ranging from zero to full gas flow. A full capacity bypass
is provided so as to enable operation of the fuel gas system is designed to
deliver gas fuel to the gas turbine combustion chamber(s) at the proper pressure
and flow rates to meet all the starting, acceleration and loading requirements of
gas turbine operation.


PMI,NTPC 16
Naphtha forwarding system

The forwarding system is mainly remote controlled from the GT LCR and CCR.
Although there is a possibility to control the main devices locally by a switching
the selector switch on local position in the local panel.

By means of three way valves a tank selection is possible. To ensure the standby
position of the lines keep the value open. The pumps are protected by the
automatic recirculating valves. The condition of the strainers as well as of the
filters is monitored by the differential pressure indicators and switches. The
safety valves protect the line against the line against over pressure.




















PMI,NTPC 17
4. Fire Detection And Protection System


The combined cycle power station represents a large capital investment in high
technology plant and equipment, the loss of which would entail disruption to the
power system and a larger reduction revenue. It is necessary to protect this
investment against fire damage and to this effect an elaborate fire detection and
protection system is being provided throughout the power plant.

The areas to be protected by fire detection and protection system in a combined
cycle gas project are

1. Power house building consisting of gas turbine generator and its
auxiliaries, steam turbine and its auxiliaries and waste heat recovery boiler
equipment and its auxiliaries.

Gas regulating station

Liquid fuel storage and unloading area

Cable galleries/spreader room

Transformer switchyard and other transformers located in the plant
area

Various control rooms

Administrative office and other auxiliary equipment buildings

Covered and uncovered stores
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The various fire detection and protection system are :

Hydrant System

The Hydrant System essentially consists of larger network of pipes both
underground and over ground which feeds pressurized water to number of
hydrant valves which are located throughout the power station at strategic
locations. In addition, monitors are provided to protect gas reducing station and
WHRB. Hydrant system is designed considering the plant as ORDINARY
HAZARD

High Pressure Water Spray System

The high pressure water spray system applies water in the form of a conical
spray consisting of droplets of water travelling at high velocity. The automatic
operation of flow control/deluge valve can be through wet Detection or Dry
detection-Initiation System.

Separate 2x100% capacity pumps and header is provided for H.V.W. spray
system.

This system is provided to protect transformer and gas reducing station (for
indoor installations) and lub oil storage tanks.

Medium velocity Water spray system

The medium velocity water system applies water in finely divided droplets
travelling at medium velocity to control the fire and the same time renders
adjacent areas safe by cooling action. This system is operated manually and
protect tanks containing flammable/combustible liquid such as Naptha. The
discharge density shall not be less than 10.2 litres per minutes per sq. metre.
PMI,NTPC 19
Sprinkler System

The sprinkler system consists of a pipe work array filled with water having
sprinkler needs at laid down intervals which operates at a predetermined
temperature. Conventional cable galleries are not provided in the combined cycle
power plant, however the spreader rooms where power cable are is protected by
sprinkler system.

Detection of fire in cable spreader room is through combination of smoke
detectors i.e. Ionisation type and optical type detectors fully cross-zoned.
Beside this, linear thermal sensors are also used. The discharge density for this
system shall not be less than 12.2.Ipm/sq.M

Foam Injection System

To extinguish the fire inside tanks containing flammable/combustive liquids, foam
is produced by mixing foam concentrate with water in the required proportion and
aerating the resultant solution. Low expansion floroprotein in foam concentrate is
used as foam concentrate. Foam injection is carried out manually only. Foam
extinguishing system is provided for floating roof tanks storing Naptha, tank car
unloading manifold and the dyke area surrounding the tanks.

Halon System

In NTPCs earlier gas project, automatic inert gas extinguishing system using
Halon 1301 was used to protect electrical and electronic equipments. However,
recent scientific researches have indicated that man chemicals such as Halon
and Chlorofluorocarbon deplete stratospheric ozone layer. In view of adverse
Environmental impact, NTPC has stopped using Halon flooding as well as Halon
extinguishers for all future projects.

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CO2 Extinguishing System

After deflected of halon extinguishing system for all future NTPC projects,
modular CO2 extinguishing system is envisaged in control panels, fuel gas
control block of Gas turbine (under sound proof enclosure), GT sound proof
enclosure, bearing housing within exhaust diffuser and the cable space below
electronic equipment room. This system is designed to achieve 34%
concentration by volume in the areas to be protected and are equipped with
optical type and ionisation type smoke detectors. Temperatures detectors are
installed in the bearing housing within exhaust diffuser.

Fire Alarm System

An automatic fire detection system is provided for an early warning throughout
the power plant area. This system detects the outbreak of fire at the inception
stage and facilities to take remedial action at the initial stage to prevent/reduce
damage of costly equipments. Since Combined cycle plant operation is simpler
as compared to thermal power plant and the manpower required is less, the
computerized early warning system is preferred than the conventional fire alarm
system. Computerized addressable type early warring system which have
following advantages:

i) The system has provision for automatic sensitivity compensation

ii) Each detector is individually addressed

iii) The system has facility for complete data logging.

iv) The system is on modular basis and can be expanded at a later date.

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v) The interface units are provided for connecting open type alarm initiating
devices such as pressure switches, potentials free contracts etc.

vi) Exact location of fire can be known from the fire alarm control panel.


Potable Extinguishers

Portable pressurised water type and CO
2
type extinguishers are provided at
strategic locations inside the entire power station area. For 600 MW combines
cycle power plant, approx. 75 nos. water type and 100nos. of CO
2
type portable
extinguishers are provided.



















PMI,NTPC 22
5. Salient Features Of NTPC Gas Projects


A. ANTA GBCCPP STAGE I (413 MW)

The plant is located near Anta Town of District Kota in Rajasthan. The
nearest railway station is that of Anta which is approximately 1 km.from
plant site. The branch offline of HBJ pipeline is approximately 15 kms.from
the site, from where a tap offline is taken. The Kota right main canal which
is the source of plant water requirements, runs along the plant boundary.

In the main plant block, the gas-turbines and the steam-turbine are
housed in separate buildings. There are 3 GTs in are one hall and one ST
in another building, with GT hall towards the west. In the extension stage
of the project, the mirror image of stage I is anticipated and after
completion it shall have 2 GT, halls with 3 GTs on each side of the ST hall
having 2 STs. The extension is planned towards the east of stage I. The
GTs are placed transversally. The control building is adjacent to ST
building. Each GT is having one local control centre located towards south
of GT hall. The transformer yard is towards south of turbine hall and
switchyard is further south.

B. KAWAS GBCCPP.STAGE I ( 640 MW )

The plant is located near village Kawas in District Surat of Gujarat. The
nearest railway station is that of Surat which is approximately 19 kms.
From site.

In the main plant block two modules each consisting of 2 GTs and ST
have been provided. The turbine building houses two pairs of GTs at the
east and west ends with 2 ST in the middle. Here all GTs and STs are
PMI,NTPC 23
placed longitudinally. The common control building is located adjacent to
the ST hall towards north.

Each WHRB is located towards south of the respective gas turbine. Each
GTG is having one local control room which is located towards north,
below the inlet air filter. The transformer yards is in north of turbine hall
and switch yard further north.

C. AURAIYA GBCCPP-STAGE I (650MW)

The plant is located in Etawah District of Uttar Pradesh. The plant site is
approximately 2.5 kms. from the nearest railway station of phaphund.

In the main plant block, two no of STGs are located in between 2 pairs of
GTs. GTGs are placed transversally. The central control room with 220 KV
switchyard control room is located close to STG-I. Local control panel of
each GTS is located near the GT pedestal itself.

The water pre-treatment plant and DM plant are located adjacent to both
the power house and CW pump house.

Induced draft cooling towers have been located considering the proper
flow of cooling water, nearness to main power house & convenient routing
of open return channel to CW pump house. The 200/400 KV switchyard
has been located in front of the power station.

PMI,NTPC 24
D DADRI GBCCPP-STAGE I (817MW)

General Layout Plan

In the main plant block two modules, each consisting of two GTGs placed
on each side of 2 STGs. The central control room is located towards west
of the ST hall. The transformer yard Is on the western side of the turbine
hall, with switchyard further down west.

Induced draft cooling towers have been located considering the proper
flow of cooling water. Nearer to main power house & convenient routing of
open return channel to CW pump house. The 220/400 KV switchyard has
been located in front of the power station.

The 220 KV switchyard control room is accommodated in the central
control room itself. Space has been kept for liquid oil installation and oil
unloading facilities.

The GAIL terminal for receiving gas is located within boundary of plant
site.











PMI,NTPC 25
6. The Modern Large Size Gas Turbine, Type
GTI3


The main feature of this gas turbine is the simple design, one compressor, one
combustion chamber with one burner, a 5- stage turbine arranged on a common
shaft with the 17- stage compressor, the shaft being mounted on two journal
bearings, the axial thrust absorbed by one thrust bearing as well as an exhaust
gas diffuser which permits an easy connection to a waste heat boiler.

With the increasing operational experience the coupling output of this type could
be considerably raised by gradually increasing the gas turbine inlet, temperature.
This was made possible by cooling the blades of the 1
st
and 2
nd
stationary and
rotating blade rows or total, with the typical gas turbine, by
cooling the first three stages and by an intensified cooling of the rotor and the
gas turbine blade carrier.

The positive results expected by these measures such as higher power, higher
efficiency and lower specific cost have been fully confirmed by the experience
gained in operation.

The single combustion chamber was mounted at the side of the gas turbine, and,
via a U-shaped double piping, connected to the gas turbine. In the course of the
further development of this type it was possible, in spite of the higher gas turbine
inlet temperature, to reduce the size of the combustion chamber so that it is now
arranged directly above the gas turbine. A dual fuel burner makes it possible,
simultaneously or alternately, to use gaseous or liquid fuels at improved
combustion conditions.

PMI,NTPC 26
The separation of flow surging, during partial speeds, may be prevented also with
the aid of several adjustable stationary blade rows. Today,, economic reflections
lead to the blow off solution or to combined system with blade readjustment and
blow off facilities in the case of industrial gas turbines.

INTAKE AND EXHAUST SYSTEM

A typical intake & exhaust system for an industrial gas turbine, comprise the
following components:

a) Intake system (i) Inlet Air filter
(ii) Inlet air silencer
(iii) Inlet Duct

b) Exhaust system (i) Exhaust duct
(ii) Expansion joint
(iii) Dampers
(iv) Exhaust silencer
(v) By pass stack

Design, construction and operating principle of the above components are
described in the following paragraphs.

Inlet Air Filtration

The need for filtration on gas turbine inlet arises because of four phenomena:
foreign object damage erosion, fouling and corrosion.

Foreign object damage is usually defined as the resultant blade damage caused
by the ingestion of an object of suitable mass and hardness to create physical
destruction.
PMI,NTPC 27
Erosion is typically defined as the actual removal of material by collision with a
moving object. It is often observed on the compressor blades of a gas turbine
due to the exposure to larger sized contaminant particles.

Fouling is defined as the deposition of smaller particles on the compressor
blades, there by changing the blade shape and degrading the performance of
the compressor. It is usually not a permanent situation and can be corrected by
cleaning of the compressor section.

Corrosion is the loss of material in the hot sections due to chemical reaction. It is
typically observed in off shore and near shore environments and is attributable to
small salt practices and heavy metals.

Design/ Construction and operating principles various type of filtration systems
are described as follows:

No Filtration

In the early days of stationary turbine application, it was widely believed that inlet
filtration was not needed, that the turbine could ingest almost anything as long as
it was not a large object. Many early units were only provided with a simple
screen on the inlet to prevent entry of animals, birds, and any other large object.

Moving Media

The first major problem undertaken was to deal with the larger particles which
caused erosion of the compressor blades. By experience and past history, it is
generally accepted that a 10 micro metre particle is a size of sufficient mass and
inertia to cause actual removal of the metal in a compressor blade. Two of the
earliest designs selected were the roll-type and the travelling screen filters.

PMI,NTPC 28
The roll-type filter utilizes a roll of dry viscous treated filter material inserted at the
top, fed down through a passageway to take-up reel on the bottom.

This material is advanced either on demand via the increasing pressure drop
across it or automatically on a time basis.

The travelling screen filter utilizes an endless belt of metal elements which
passes through a through of viscous oil, removing the accumulated contaminants
and replenishing the viscous treatment. The visors treatment itself is the medium
for tapping the airborne particle. The travelling screen type has many of the same
operating parameters as the roll-type (efficiency, pressure drop) with one unique
potential disadvantage, that of oil carry-over contamination.

Both the roll-type with viscous impingement and the travelling screen type
depend upon one primary mechanism to trap the airborne contaminants, an oily
surface to which the particle will adhere. If the oil is not present or has been
covered over with particles, the removal efficiency will drop off markedly.

Both of these types have been used throughout the world with limited success.
Today they are both basically obsolete.

Inertial Separators

Because of the shortcomings of the moving media types, in terms of large
particle protection, the search turned to the inertial separator as a likely
candidate for dealing with the larger particles. Inertial separators today are in
basically two forms, the vane type and the spin-tube types. The vane type
operates in two dimensions and the spin-tube type operates in three.

Both use the principle of accelerating the particle and using its own inertia to
remove it from the main air stream.
PMI,NTPC 29
The primary advantage with an inertial separator is its low maintenance cost and
relatively trouble free operation, making it very suitable for remote locations. The
need for a secondary power source for the scavenge blower is occasionally a
disadvantage, however, the restriction across the inertial separator does not
increase with operating time and remains constant under normal conditions. The
inertial separator does have proven quite successful in terms of dealing with the
larger particles and have gone a long way in reducing significantly the typical
erosion problem with turbines. One major shortcoming has been in areas of
extremely heavy dust conditions such as desert where the percentage of
particles that do pass the inertial separator can still be harmful.

High Efficiency Media Filter

While the previously described inertial separators proved quite effective in
dealing with the larger particles sizes, they lack the necessary separation
efficiency when confronted with the smaller particles (under 10 micrometers).
The advances in design and materials of gas turbines necessitated that fouling
and corrosion effects be considered; hence the need arose for the high efficiency
media filter.

The majority of high efficiency media filters in use today are composed of
randomly oriented small filters, either of cellulose or a synthetic material.

Such filters depend upon the contaminant particle contacting a fiber by one or a
combination of three mechanisms: Inertia Impaction, Interception and Diffusion.

Multi-Stage Filters

While the high efficiency filters do an excellent job of protecting the turbine, they
typically have a rather low dust holding capacity and are subject to frequent
PMI,NTPC 30
servicing. The solution to this has been to use some form of filtration ahead of
the high efficiency filter to extend its useful life.

In multistage filters a number of different concepts have been applied. All operate
on the basic principle of having one or more stages of some type of device ahead
of the high efficiency filter elements to help extend the useful life of the high
efficiency elements.

Self-Cleaning Filters

The self-cleaning or Pulse-Cleaning Filter represents the latest technology in gas
turbine filtration.
The need for it arose when user experience indicated shortcoming in multi-stage
systems, namely their finite dust holding capacity. Regions such as the Middle
East experienced the problems of excessive filter servicing, turbine damage, lack
of proper maintenance, etc., all due to the fixed limit every conventional system
has with regard to its dust capacity. The Pulse Cleanings system effectively
eliminates the finite limit.

The concept of the Pulse-Cleaning filter is relatively straight-forward, a high
efficiency filter which, after loading with dust, is automatically back flushed with
compressed air and effectively renewed. The Pulse-Cleaning system operation is
described here with reference to a basic module or collection of high efficiency
filters, cylindrical cartridges.

The high efficiency filter cartridges are attached to the bottom of a horizontal
plate and hang vertically downward: Above each filter cartridge, in the clean air
plenum, is a venture flow nozzle. During normal operation, ambient air flows
upward, radically inward through the cartridges and then upward through the
venture and finally to the turbine. Up to this point the device is operating basically
as just a high efficiency filter. Each cartridge is rated for 500-600 cfm at an initial
PMI,NTPC 31
pressure drop of 1.2-1.8 inches of water, hence the total number of cartridges
required for any installation is controlled by this operating range. Skirts are
suspended around the exposed sides of the cartridges to protect them from
damage and to force the incoming air to travel upward.

As the contaminants build up on the surface of the cylindrical cartridges, the
pressure drop across the cartridges will continually increase. When the pressure
drop reaches a preset limit (typically 2.2-2.8 inches of water above the new and
clean initial pressure drop) the automatic Pulse-Cleaning sequence is activated.

A pressure switch senses that this upper limit has been reached and activates
the timer/sequencer. The timer/sequencer signals the solenoid value to open,
releasing the pressure holding the pneumatic air valve. The release of the air
valve (typically for only 50-100 milliseconds) allows a blast of compressed air
(80-100 psig) to leave the air manifold and proceed out through the blow pipe.
Above each venture is an outlet hole in the blowpipe. This blast of compressed
air exist through the hole, enters the venturi, induces a secondary flow into the
venturi and effectively closes off the flow through the cartridge for a fraction of a
second. The compressed air pressure wave continues down into the cartridge
and then radically outward, blowing the accumulated dust off the cartridge. In
another fraction of second, the cartridge is back in service. A row of cartridges is
pulsed at one time. Then 10-20 seconds later the timer/sequencer chooses
another row of cartridges and the Pulse-Cleaning procedure is repeated. The
timer/sequences continues to sequence the cleaning operation through out the
elements until the overall pressure drop reaches a preset lower limit, at which
time the cleaning process ceases until called upon again by a high-pressure drop
reading. The number of elements cleaned at any instant and the time interval
between are chosen so that no significant distortion of the airflow is presented to
the turbine.


PMI,NTPC 32
Since the pulse-cleaning filter renews it self as needed, the old concept of how
much dust a filter can hold no longer applies. The system will maintain the
average pressure within its upper and lower limits virtually independently of the
ambient dust concentration.

Augmented Self clearing system

American air filter company has introduced an augmented self cleaning air
filtration system (ASC) In which self-cleaning principle is combined with inertial
separation, and the separated dust is taken out from the operational area by an
exhaust system.

Dust laden air enters the ASC intake system and is cleaned by passing through
the panel pack filter elements with in the housing. The clean filtered air exit
through the ventures in to the clean air plenum and on to the turbine in take.
However, by means of the integral secondary air cleaning circuit about 75% by
weight of the dust is removed from the incoming air by inertial separation before
it reached the panel pack filter elements.

The inertial separated dust together with a small amount of scavenge air is
conveyed into the secondary cleaning air circuit where the secondary air fan
exhausts air fan exhausts it to the atmosphere at any desired point of discharge.

The reverse air cleaning cycle is controlled by a solid state printed circuit timer
which is housed in a control panel assembly. The timer sequentially energizes
the solenoid valves that activate air valves to admit sharp bursts of compressed
air through vertical blowpipes located in the clean air plenum. Orifices located in
the blowpipes direct the compressed air horizontally through the ventures into the
filter chamber. The momentary pressurization and reversal of air flow dislodges
the accumulated particulate from the filter elements, automatically reconditioning
the filter for continued uninterrupted services. The dislodged dust is immediately
PMI,NTPC 33
sucked into the secondary cleaning air circuit together with the scavenge air. In
this manner there is no re entrainment of the dislodged dust back into the filter
elements.

Entrance to the secondary air circuit is through a strategically located slot at the
apex of the V formed by two adjoining panel pack filter elements. This
secondary air slot leads into a vertical metal secondary air duct that conveys the
particulate to a horizontal dust chute and exhaust fan.

Pulse-Cleaning Filters

The pulse-cleaning concepts represents the heavy-weight in the air filtration
industry and is the closest idea so far to a universal filtration system. They are
presently in use in the arctic, heavy deserts, off-shore, rural areas, industrial
areas, major cities, etc.

If there is one thought to keep in mind on turbine filtration, it is to add in favour of
better filtration, not lesser,. Considering the cost of a modern gas turbine, the
cost of ownership of a more expansive filtration system can be an excellent
investment.

Silencer

A silencer is needed to attenuate the noise while allowing the medium to
continue to flow in a duct pipe with least possible hindrance. Silencers work
either in absorption principle or in resonance principle

In a absorption silencer sound energy when comes in direct contact with
acoustically absorbent material, the air molecules oscillate freely in the medium
and thus sound energy is transformed into heat energy by molecular friction. The
abortive material is therefore covered with acoustically transparent perforated
PMI,NTPC 34
sheeting. If the surface of absorption material is covered with an impermeable
layer of dirt, the effectiveness of the silencer reduces. Thus the draw back of
these type of silencers is their susceptibility to soiling.

Resonator silencer attenuate noise by principle of resonance/interference. These
silencers are not affected by loose non sticky dust unlike absorption type
silencers. However, because of their effectiveness is limited to a narrow bank of
frequency, much larger silencer volume is required attenuate same noise levels
as compared to absorbent type silencers. This entails in increase pressure drop
& increased cost of material.

In gas turbine inlet and exhaust system adsorption silencers with splitter or baffle
type arrangement are provided. To optimise pressure drop, and to attenuate
noise levels over a range of frequency baffle/splitter are arranged in staggered
form. Normally baffles are made of perforated stainless sheets filled with mineral
wool felts and pads.

Inlet & Exhaust Dust

The GT engine, by its very nature, requires a considerable mass flow of air per
KW delivered than other conventional engines. Thus, the duct sizes will be
larger, if conventional power plant criteria for ducts, gas velocities are used. Of
course smaller duct sizes require higher velocities & resulting greater pressure
loss. Design consideration or pressure loss. Design considerations or pressure
loss influences depends on Fluid dynamic and geometric consideration.

The detailed producers for calculation of pressure loss in inlet and exhaust
system is not presented here & standard literature on the subject may be referred
in case it is required.

PMI,NTPC 35
Normally, when a GT unit is supplied on a turnkey basis, GT manufacture
optimises the pressure loss in the inlet & exhaust system to maximize output &
heat rate of the engine. However, in case GT inlet & exhaust system are ordered
are ordered separately, the GT manufacturer specifies corresponding maximum
losses in inlet & exhaust system respectively, at which output & heat rate of the
machine are guaranteed. Accordingly allowable pressure drop in the dusting
system is decided, taking into account pressure losses in other system
components.

COMBUSTION CHAMBER

Introduction

In the combustion chamber the air delivered and compressed by the compressor
is brought to the necessary process temperature by the combustion of liquid fuel
(e.g. fuel oil) and/or gaseous fuel (e.g. natural gas). The simple combustion
chamber is vertically arranged on the thermal block. Cooling air required for
cooling of the hot gas turbine parts is bypassed.

Design Features

The combustio9n chamber is an all-welded sheet structure fig-5 and essentially
consists of these outer acket with combustion chamber cover, the bottom and
top combustion chamber liners. The complete finned segments insert and the
burner with swirl insert fixed in the burner cover.

PMI,NTPC 36


GAS TURBINE UNIT
Fig . 5

The combustion chamber outer jacket consists of a creep resistant, low-alloy
ferrite sheet steel. A specific BBC structure (patented) is the ribbed body linear
with the welded finned segments which has proved a successful design for more
than 20 years. The finned segments insert encloses the hottest zone of the
combustion chamber, the actual combustion zone, and consists of five rows of
welded metal finned segment also called brick, the carrier, the lifting device and
the intermediate jacket.

Owing to the high thermal stresses of these parts, a special design and carefully
selected material are required to ensure a long operating life. They have proven
very successful for a long time. The finned segments (bricks) made of a highly
heat resistant material are, on the fire side, connected by a cladding and
protected from the hot flame.
PMI,NTPC 37

FINNED SEGMENTS
figure. 6

Convective cooling of the finned segments is carried out on the rear side but
cooling air flowing between the ribs, and open the fire side by a cooling air film
which escapes on from the bottom side on the end of the bricks and is passed
over the row located beneath. The finned segments can be easily replaced with
the aid of a special lifting device.

The upper combustion chamber inert consist of the outside unit and the double-
wall interior unit is made of heat-resistant sheet metal welded together.

The lower combustion chamber insert is a double-jacket structure made of
crimped, non-scaling sheet metal, and is composed of an inner part and an outer
part. It is connected to the finned segment insert. By means of the gimbal
suspension the lower combustion chamber insert can expand freely . Outer and
inner parts are centred against each other by a three-point mounting.

For the observation of the combustion zone during operation, several sight glass
units are mounted on the combustion chamber. Moreover, there is an automatic
flame monitoring devices on the combustion chamber cover. The whole
PMI,NTPC 38
combustion chamber is fitted with a thermal- acoust insulation and encapsulated
with galvanized sheet steel.

For maintenance and checking purpose, the combustion chamber is equipped
with a platform, which the access is ensured via a ladder or spiral staircase.

Advantages of the Combustion Chamber

1. Burner

- A burner for the gas turbine in Contrast to gas turbines with many
combustion chamber, no measure for an accurate distribution of
fuel and air are required to obtain a good temperature distribution.

- Can be applied for any liquid or gaseous fuels.

- Standard burner for oil and/or natural gas, consequently suited also
for mixed operation.

- Special burners are available in this field.

- For liquid low-calorific value fuels such as ethanol or methanol
standard burners can be used which only differ the oil burners by
the size of their jet diameters.

- The burner itself can be removed and checked which ensures easy
maintenance.

- The design ensure a good ensures a good atomising of the fuel and
consequently, optimum evaporation and mixing with the air which is
PMI,NTPC 39
essential to good combustion. The combustion efficiency amounts
to > 99.58, under full load > 99.98.

- Since there is only one fuel jet, it has relatively larger openings so
that it is less prone to contamination.

- One ignition for the whole system easier, i.e. higher ignore on
reliability than with multiple combustion chamber systems.

Combustion Space

The whole dimensioning of the combustion space results in the following
advantages.

No flame contact with the wall, which means that no combustion takes
places near the wall and, consequently, the film cooling air cannot be
misused as combustion air (this danger exists with small size chamber
chambers).

No oil spraying on the flame tube possible.

Combined cooling of convective cooling and film cooling by special cooling
elements provided with ribs (ribbed bodies ), which form the flame tube.

Thus the flame tube does not consist of one ring, but is formed by
individual elements. Therefore, no stability problems (dents) of the
combustion wall as is the case with flame tubes.

Long dwell time ensure burning out of the fuel (the emission of CO and
non-burnt hydrocarbons is practically zero).

PMI,NTPC 40
Flame radiation independent of the fuel since E of the flame (desire of
emission) is nearly 1.0 (black body).

The combustion chamber is laid out for easy maintenance since it is
possible, after removal of the further including swirl insert, to enter the
combustion chamber, so that it can be checked in a very simple manner.
Also the hot-gas housing and the first gas turbine stage are easily
accessible. (See fig.7)



















COMBUSTION CHAMBER
Fig.7


PMI,NTPC 41
Burner Combustion

a) General description of the duel burner.

The dual burner with its auxiliary facilities is used for the supply of gaseous and
liquid fuels to the combustion chamber. Simultaneously, mixing of the fuel with
the primary air is achieved with this burner, while the flame is stabilized by an
appropriate air supply.

b) Constructional features (fig.8)
- Burner cover
- Swirl inset
- Fuel supply with fuel nozzle
- Servomotor for liquid fuel
- Gas burner jacket with inner jacket
For the supply of the gaseous fuel
- Nozzle cap
- Igniter

c) Combustion

The air arriving from the compressor enters the combustion chamber from
the bottom and flows upwards. Approximately 30% of the air between
combustion chamber outer jacket and other part of the lower combustion
chamber liner flow as secondary air via the mixing jets to the combustion
chamber inner space while the remainder flows further upwards between
inner and outer part. Further distribution takes places at the funnel shaped
outlet of the lower combustion chamber outlet.

Via an orifice on the lower end of the intermediate jacket another 30% of
the air are branched off for cooling the finned segments. This air then is
PMI,NTPC 42
dispersed on the partition walls and flows between the cooling ribs
downwards into the combustion space, while a layer of protective cooling
air is formed on the flame side of the ribs which protects the ribbed bodies
from adverse heating.

The remaining 40% flow as primary air i.e. as oxidizing agent for the
combustion, into the swirl insert in the air enters the combustion space in
a turbulent state. This ensures a very good mixing with the fuel. Moreover,
the swirl insert is used for a good stabilization of the flame.

Another portion of the primary air flows through four orifices in the gas
burner jacket into the annuls between inner jacket and inner wall of the
gas burner jacket and enters the combustion space directly at the fuel
nozzle with a turbulence caused by the inner swirl insert. By this type of air
guide a very intensive mixing with the fuel is attained which ensures a
complete and rapid combustion. The ignition of the fuels during starting is
effected by the igniter with a propane flame.


PMI,NTPC 43
After ignition of the fuel, the hot combustion gases flow downwards. Before they
enter the turbine, these gases are well mixed with the secondary air, coming from
the mixing orifices and brought of a temperature admissible for the turbine.

Figure-9 shows a schematic diagram of the streamlines.



The air enters with swirl to the combustion space through the primary air inlet
(swirl insert). Due to this flow scheme (cyclone principle), a back flow to the
burner jet is produced. This reduces the flame front speed, which ensures a
stable flame. The cyclone effect is terminated by the inflowing cooling air at the
mixing orifices (D).

Fig-10 shows a fuel jet liquid fuel is injected at a very high pressure and finely
atomized.



PMI,NTPC 44

FIG-10

TURBINE

In the gas turbine, the power for driving both the compressor and the generator
is produced. The energy is supplied to the turbine in the form of the hot gases as
they come from the combustion chamber. The kinetic energy of the gases is
transferred to the rotor in the turbine by means of the rotating blades. In the
following this process is explained with the example of a gas turbine stage.

The combustion gases, coming from the combustion chamber or from the
preceding stage, are accelerated in the stator blade to the speed C while,
PMI,NTPC 45
simultaneously, the inlet pressure is reduced. By vectorial addition with the
circumferential speed the relative speed w is obtained.

Depending on the degree of reaction this speed is accelerated to W2 in the
rotating blades row (fig.11). On the other hand the absolute speed C2 is
obtained by the addition of W2 and U2: The pulse change of m.W1(mass by
speed) into m.W2 generates the driving power acting on the blade.


TURBINE BLADES
FIG.-11

P
T
= P
V
+P
N
= m
R
. h
t
.

P
t
= Gas turbine power in KW

P
v
= Compressor driving power in KW

P
n
= Generator effective power in KW

M
s
= mass flow in kg/sec

PMI,NTPC 46
ht = Isentropic turbine gradient in kj / kg

= effective efficiency,
e
=
it
.
m

it = internal turbine efficiency, approximately 0.80 to 0.87

it = mechanical efficiency, approx. 0.99

Example with partial data of the GT 13 D2

m = 372kg/sec; P
1
= 11.6bar t
1
= 990
o
C

P
2
= 1 bar t
2
= 490
o
C

h
t
= 680 kj/kg for fuel oil

Hu = 42000kj/kg


PT = 372 kg/sec; 680 kj/kg; 0.83 = 212.5 MW

PN = P
T
- P
V
= 212.5-124.5=88.0MW.

DESIGN FEATURES

Talking into account its thermal load the turbine housing made of creep-resistant
ferrite mater raise as welded structure or steel casting. On the exhaust gas side
the inner cone of the turbine housing is connected to the outer wall by ribs.
Inner cone and outer wall form in this area the annuals for the escaping exhaust
gas. Because of the relatively high exhaust gas temperatures the walls and ribs
of this duct in the gas turbine housing are cladding with a sheet metal lining. The
PMI,NTPC 47
sheet metal lining is made of a temperature resistant material and fastened in
the turbine outer housing allowing for thermal motion. The bearing housing
made of cast steel for the reception of the journal bearing on the exhaust gas
side is suspended allowing for thermal motion in the inner cone of the outer
housing bottom part.

The stationary blade carrier made of alloyed ferrite cast steel is cooled with the
aid of compressor air which enters through appropriate holes and air inlets.

To keep the thermal flux and the temperature stresses in the stationary blade
carrier(fig.12) low also during start-up and shutdown of the machine the side
exposed to hot gas is provided with heat shields which are radically suspended.














BLADE CARRIER
Fig-12

The turbine blading consists of five stationary and five rotating blades. Because
of the continuously increasing turbine inlet temperature the number of cooled
PMI,NTPC 48
stages is increased(from a stage at the beginning with 13D2stages on 13D2to
3stages on the 13Etype).

The cooled blades are manufactured of nickel-base alloys in a precision casting
process.

Different types of blade cooling methods (fig.13)










BLADE COOLING
Fig-13

In convection cooling air flows through holes smooth or ribbed ducts (figure 14)
and absorbs part of the quantity of heat transferred by the hot gas into the
blades. Depending on the design, the heated cooling air is mixed to the hot gas
on the blade trailing edge, on the blade tip and or an the blade.







PMI,NTPC 49











GUIDE VANE CONNECTING COOLING Fig-14
DEFLECTOR COOLING- which also called jet cooling is also type of convection
cooling. However, the cooling air is passed through the sheet metal deflector
plates. These deflector inserts are provided with holes so that the cooling air
bounces as jets on the blade wall to be cooled.














TURBINE COOLING SYSTEM FIG-15
PMI,NTPC 50
7. Gas Turbine Compressor


General

The characteristic feature of this turbine generator set is the use of a single,
composite welded shaft for the compressor and turbine gas rotor, carried in only
two bearings. This enables the complete compressor/turbine assembly to be of
very compact construction and ensures good shaft stability with a simple bearing
arrangement of two journal bearings and one thrust bearing.

The welded rotor concept has been in use for many years in the steam turbine
field and this design has also proved superior for the gas turbine. In comparison
to a rotor comprising several disc held together by a tie rod. The welded rotor has
several important advantages: the welded discs have o holes in highly stressed
areas, especially in the center, and dangerous stress concentrations are
therefore avoided. The welding joins the discs together into a single shaft without
mechanical joins in which misalignments caused by centrifugal force or thermal
expansion cannot occur. This is particularly important with large shafts. The
commonly- observed heavy vibrations caused by rapid acceleration and load
application are completely avoided. The welded designs avoids all the problems
which can otherwise occur due to the above- mentioned mechanical joins. In
addition, this design guarantees maintenance free service of the rotor.

The compressor and turbine casing consist of several sections which are joined
together to form a single unit.

Design and function of Individual Components of the Compressor/Turbine
Assembly


PMI,NTPC 51
Air Intake connection

The air intake connection has a horizontal air inlet, and is situated axially in front
compressor. It is a welded, solid steel plate construction split horizontally and
held together with hexagon bolts and nuts. The attachment to the compressor
casing is effected by two guide flanges welded on to the connection which locate
in the appropriate slots turned in the compressor casing. Sealing tubes made of
synthetic material are laid in these slots and form a seal against the environment.
The air intake connection has four feet which are bolted with adjusting belts to
steel plates embedded in the foundations. These bolts allows the height to be
adjusted to that of the rest of the compressor/turbine assembly.

Compressor casing

The compressor casing, which is horizontally spilt as axis height is made of
spheroidal graphite cast iron. This material possesses high tensile strength and
good expansion qualities and for this reason is well suited to the stresses and
high temperatures in the pressure and caused by the compression process.

The upper and lower halves of the compressor casing are provided with robust
flags and are held together by expansion studs with sockets head nuts.

To bearing housing for the intake end journal bearing and thrust bearing is
integrally cast with the help of the compressor casing. The bearing cover
is bolted on to the bearing housing. The oil glass for the thrust bearing and the
axial shaft position monitor are mounted on the. The flanges of the bearing cover
and housing are sealed with an oil resistant jointing

The bearing cover and housing incorporate all the necessary grilling for lube oil
purpose, for the sealing air of the intake end shaft seal and for temperature
monitoring.
PMI,NTPC 52
The lower half of the compressor casing is also fitted with paws for the fixed
supports at the intake end and for the pin-ended supports at the pressure end, as
well as the flange for the king pin which is situated at the intake end and
determines the fixed point form the complete compressor/turbine assembly.

The compressor casing has three integrally- cast circular ducts, which are
connected to the blade duct behind the fourth, seventh, and tenth rows of fixed
blades. These ducts are closed to the outside by four blow-off values flanged
directly to the upper half of the compressor casing. the blow-off values are
controlled pneumatically and are open at lower speeds,i.e.up to approx 90%of
the rated speed, so that a certain amount of the compressor output can be blown
off. the air blown off flows into the machine room through the blow-off valve
bonnet arranged around the valves and a silencers in that order. these blow-off
valves enable a consideration reduction to be made in the external power input
requirements during start-up, and they also avoid undesirable and dangerous
flow conditions in the compressor which result in rotating stall and pumping
effects.

Turbine outer casing

The outer casing is split into two halves the same as the compressor casing. the
turbine and compressor casing are bolted together at a radial flange with
expansion bolt. the casing parts are centered by means of eight round wedges in
the circumference.

The turbine casing is made of heat-resisting ferrite steel in order to withstand the
thermal stresses, and is of welded construction. the upper and lower halves are
bolted together at the horizontal flanges with expansion studs, expansion sleeves
and socket head nuts. The horizontal flanges are of solid construction and are
slotted at the drilled holes so as to avoid high thermal stresses. Horizontal and
radial flanges of the turbine and compressor are metal-to- metal joints.
PMI,NTPC 53
The inner cone and outer wall of the turbine casing are joined together by ten ribs
at the exhaust end, and the resulting ring duct between the two constitutes the
flow passage for the exhaust gas from the turbine. Due to the relatively exhaust
gas temperature, the walls and ribs of the ring duct are lined with a special
plating to prevent the temperature differences between various parts of the
casing walls and therefore, the thermals stresses during transitional operating
phase (e.g. starting up and shutting down); from exceeding the allowable limits.
The planting is manufactured from temperature resistant materials and is
attached to the turbine outer casing in such a way as to accommodate thermal
expansion.

A cast steel bearing housing is mounted in the inner cone of the lower half of the
outer casing and provides the support for the exhaust end journal bearing. The
housing is free to thermally expand. The bearing housing is retained in the
turbine outer casing by means of integrally cast guide at axis height and by a key
collar bolts are provided to prevent lifting.

The reaction forces of the journal bearing are transmitted through the lower half
of the inner cone and the above-mentioned ribs to the turbine outer casing. From
here are transmitted through the pin-ended supports to the unit support.

The trip and mechanism for the two over speed trips, which are mounted at the
rotor are installed on the bearing housing. The oil supply line mounted on a cover
on the hearing housing enables the over speed trips to be checked while the
turbine is operating by supplying oil pressure to the underside of the over speed
bolts. Ventilation and oil wiper rings are inserted in the bearing cover and bearing
housing and also in the intake end bearing housing and cover to prevent the
escape of oil. Two air deflector plates are welded in to the lower half of the outer
casing to stabilize the flow. In addition two paws are cast integrally with the lower
half of the turbine outer casing, and the pin-ended supports of the exhaust end
are bolted to these paws.
PMI,NTPC 54
The vertically arranged combustion chamber is mounted on a horizontal flange
welded on to the upper half of the outer casing. In addition, the outer casing has
a circumferential coller for the blade carrier.

Blade carrier

The blade carrier for the turbine fixed blade is a ferrite steel alloy casting and is
axially spilt the same as the compressor/turbine casing. It is bolted together with
expansion bolts, expansion sleeves and hexagon socket head nuts. The blade
carrier is fluxed axially by a collar in the turbine outer casing, which fits in to a salt
around the blade carrier circumference. Paws are integrally cast with the parting
flange of the lower half of the blade carrier at the same level as the outer
circumferential salt. These paws have hardened pads fixed to them and together
with the corresponding support surfaces in the turbine outer casing they form the
vertical support for the blade carrier. An axial salt, is machined in the lower half of
the blade carrier at the same level as the circumferential slot , and the guide pin
fitted in the lower half of the turbine outer casing locates in this axial slot hold the
blade carrier in its lateral position. The external pressure of the compressed
combustion air on the blade carrier causes it to be pressed against the support
collar and forms a metal-to-metal seal to the exhaust end. This air also cools the
blade carrier at the same time. A more intensive cooling of the blade carrier is
achieved by allowing a small amount of air to flow through the appropriate holes
and circular ducts. This air flow results fro the relatively small differential pressure
between the compressor exhaust and turbine Intel and is sufficient to maintain
the temperatures within the allowable limits. This air stream reenters the hot gas
flow channel before the first row of fixed blades.

Radically supported heat storage segments are fitted between the rows of fixed
blades in the areas exposed to the gas flow, similar to the heat shield of the
turbine end of the rotor. These segments contain the heat flow and thermal
stresses within the blade carrier at a low level during start-up and shut-down.
PMI,NTPC 55
Owing the absence of centrifugal stresses these segments can be mounted in
the blade carrier more simply than on the rotor.

The cooling air deflectors fitted to the upper half of the blade carrier are to
improve the cooling of the corresponding inner casing walls.

Combined compressor- turbine rotor

The combined compressor and turbine rotor comprises the individual discs which
are welder together to form the compressor and turbine blading. The eleven
discs constituting the body of the shaft are centralized with one another by
circumferential recesses and connected together by a special welding process.

The complete shaft comprises seven compressor discs, and a center drum
connecting the two section made of a ferritic forged steel alloy. The end discs
have forged journals, and the one at the compressor end is fitted with a coupling
flange and thrust bearing caller. The complete shaft is stress-relieved after
welding. The blade rotor is then over speeded to 20% above the rated speed and
balanced.

The compressor turbine rotor is carried by two journal bearings which are
force-lubricated and cooled. The bearings are each held by four fitted plates and
are each prevented from rotating by a solid pin. The bearing are lined with white
metal and the radial clearance is approx 1.5%. A lubricating oil film is formed by
the pressurized oil, which enters the bearing from both ends and is forced in to
two lube oil groves. The lower halves of the journal bearing are connected to
jacking oil pumps which deliver high pressure oil to the bearing to lift the
compressor- turbine rotor from the lower shells thereby reducing the initial
breakaway torque.


PMI,NTPC 56























COMPRESSOR TURBINE ASSEMBLY
Fig-16

The axial thrust of the rotor is taken up by the thrust bearing situated at the
compressor end. This bearing is of the pad type and is also lubricated and cooled
by pressurized oil. Since the thrust on the turbine balding is in opposition to that
compressor balding the resulting differential axial thrust remains small. Moreover,
this thrust always acts in the same direction, i.e. against the gas flow and
PMI,NTPC 57
towards the generator. The thrust bearing also fixes the axial position of the rotor
in the casing. Both expand in the same direction since the fixed point is given by
the king pin for the complete casing and is situated in the area of the thrust
bearing. A shaft monitor is provide which measures the axial displacement. This
gives an alarm in the event of abnormal displacement and then gives a trip
signals for the unit when a maximum value is reached. The axial clearance
required can be adjusted at the bearings.

The surface of the rotor between the rows of turbine blades is protected against
excessively high temperatures by heat storages segments. These subdivided the
hot upper surface of the rotor into small rectangular zones. They can expand
freely in all directions independently of the exhaust end of the shaft. In this way
the major part of the heat which enters the rotor from outside is conducted away
just below the surface of the rotor, so that the amount of heat reaches the actual
body of the shaft remains small. This results in a relatively slow warm-up of the
shaft body and therefore high thermal stresses cannot occur. A similar effect is
experienced during shutting down when the flame is extinguished and a relatively
cold air stream flows through the machine while it slows down. The lifespan of
the rotor is extremely good with this method or construction.

The cooling air required for the turbine part of the rotor, the feet of the turbine
rotor blades and the first and second rows or rotor blades is taken directly from
the compressor flow at the diffuser after the last row of fixed blades. The air flows
through the channels between the compressor diffuser and the shaft cover to a
ring nozzle, and then to the turbine part of the rotor. Here it passes through
drilling in the projecting shoulder of the rotor and flows through the cooling air
ducting system between shaft and heat storage segments and also around the
blade feet.

After the fourth rotor blade row the cooling air exhausts into the gas steam from
the rotor. It then flows over the feet of the last row of rotor blades and leaves with
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the exhaust gases. Part of this cooling air flow is used to cool the rotor blades in
the first and second rows. The cooling air flow is monitored by measuring the
pressure difference across the ring nozzle of the nozzle of the compressor
diffuser. The sealing air for the shaft seal cools the end of the rotor at the
exhaust end. Shaft seals are formed by thin sheet metal strips caulked into
grooves in the rotor by means of caulking wire, operating at a small running
clearance with either the shaft seal shell or the corresponding part of the casing,
respectively relatively few sealing strips are required to give an adequate seal
since the pressure difference at the shaft seal is small. The exhaust end shaft
seals prevent the gas from escaping to atmosphere. Those at the intake end
prevent the ingress of oil laden or otherwise contaminated air from the bearing
regions into the flow duct/ both these shaft seals have a sealing air supply taken
from the blow off duct after the fourth row of fixed blades in the compressor. At
the exhaust end draft seal the sealing air supply comes through the shaft seal
shell, thus cooling the rotor end as well as explained above. The shaft seal at the
air intake end is divided into two groups of sealing strips. Here the sealing air
enters the annular space between two groups via the appropriate ducts and
holes in the compressor casing. The shaft seals situated between the
compressor and turbine prevent the leakage of too much cooling air.

Pressure tapping are located before and after the sealing strips of the shaft seal
directly below the first row of turbine fixed blades. These are used to measure
the pressure difference, which is necessary to monitor the correct functioning of
the shaft sealing.

Compressor balding

The compressor balding is designed as reaction balding and consists of eighteen
stages with one additional inlet guides row. The inlet guide row serves to correct
the flow direction for the first row of rotor blades. The blades of the eighteen rotor
and nineteen fixed rows are manufactured from high tensile ferric chrome steel.
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They are either precision forged or machined, and fit into slots which are turned
in the shaft and compressor casing. The blades are separated from one another
by spacers. The blades of the first seven rows are rooted directly in the shaft,
those of the remaining rows are inserted in intermediate pieces.

Turbine Blading

The turbine blading is also of the reaction type, and consists of five rotor and five
fixed rows of blades. Due to the high temperature of the incoming gas, the first
and second rows of the rotor and fixed blading are cooled with air from the
compressor.

The cooling air is fed to the first and second rows of fixed blades through holes
drilled in the blade carrier and to the first and second rows of rotor blades
through drilling in the shaft and through the passage underneath the heat storage
segments. After entering the blade foot, the air passes along several parallel
ducts into the blade proper. Each air stream changes direction several times
inside the blades in the first and second fixed blade rows and before finally
blowing out through a number of slits in the trailing edge of the blade.

Part of the cooling air in the first row of rotor blades and the second row of fixed
blades and the entire cooling air flow in the second row of rotor blades is blown
out through the blade tips. The first row of fixed blades is film- cooled as well,
whereby the air leaves the blades through numerous small holes and forms a
protective film over the blades surface. This method of cooling ensures that the
leading and trailing edges of the blades in particular are thoroughly cooled,
thereby avoiding cracks induced by thermal stresses.

These cooled blades and the fixed and rotor blades of the other rows are
precision cast in a nickel based alloy. The fourth and fifth rows of rotor blades
and the fifth row of fixed blades are precision drop-forged.
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The first row of fixed blades sits in an axial slot in the carrier segments, which are
in turn fitted into a slot in the blade carrier. The specially-formed ends of these
blades are supported in the shroud segments which are mounted in a radial slot
in the compressor diffuser, which extends as far as this point.

The remaining fixed blades have rhombic shaped feet which fit into the
appropriate slots of the blades carrier.

The first row of rotor blades are fitted into radial double. T slots in the rotor
while the fifth row fits into angled fir tree slots.

The so-called super materials: and high alloy steels used in the turbine blading
are all resistant to extremely high temperatures and to scale. Their anticipated
service life is calculated on the respective prevailing temperature and resulting
stresses. An additional protective measure has been taken to counteract
corrosion in the form of a specially applied chrome layer on the first rows of
blade. This increases the service life of the blades considerably.

Compressor Diffuser

The main function compressor diffuser is that of flow device, namely reducing
the relatively high velocity of the combustion air from the compressor blading
while keeping losses to a minimum, and ensuring a favorable flow into the turbine
outer casing and combustion chamber connection.

The compressor diffuser is branched into a radial and an axial section, so giving
a favourable flow distribution which produces uniformly intensive cooling of the
entire inner casing surface. The shaft cover and the inner shell of the compressor
diffuser together form the annular duct for the cooling air for the turbine section of
the rotor. The nozzle segments are fitted in circumferential slots in the diffuser at
the outlet of this annular duct. These nozzle direct the cooling air flow with
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minimum losses to the rotor. At the inlet to the turbine blading, the end shroud
segments of the first row of fixed blades and the inlet segments together form a
heat shield for the wall of the compressor diffuser. Both segment types are
inserted in circumferential slots in the compressor diffuser.

The compressor diffuser and the shaft cover are heat resistant spheroid graphite
iron castings. They are both splits horizontally, the same as the rest of the
casings in the compressor/turbine assembly. The top and bottom section of the
compressor diffuser are bolted together at the parting flange with expansion
bolts.

The complete compressor diffuser is flanged at the front end to the lower half
only of the compressor casing, and is cantered by a collar on the front flange
which fits into a corresponding recess turned in the compressor casing.

Inner Casing

The inner casing guides the hot gases coming from the combustion chamber to
the turbine blading. It is a relatively thin walled welled construction made of heat
resistant chrome nickel austenitic alloy. The outside of the inner casing is cooled
by the combustion air coming from the compressor diffuser. It rests on supports
in the turbine outer casing is split axially, and is held together by expansion bolts
made of high temperature resistant materials. All flanges bolts of the inner casing
are secured by special locking devices so that they cannot become loose during
operation.

The inner casing is supported by two flange rings at its outlet which fit into
corresponding recesses turned in the blade carrier and compressor diffuser. This
prevents axial movement and at the same time guarantee good separation
between the hot gas and compressed combustion air in the turbine casing. A
drain connection is arranged in the lower half of the inner casing which is used
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for draining fuel which has not burnt due to ignition failure (only with oil or dual
fuel operation). Special equipment and the associated guide bolts must be used
when fitting or removing the inner casing, and the instructions must be followed
implicitly.

Exhaust Diffuser

The exhaust diffuser is a single unit of welded steel plate construction to the
turbine outer casing by two radial flanges forming metal to metal joints, and
guides the relatively hot exhaust gases into the exhaust gas system. Expansion
bolts with hexagon head nuts are used to bolt the diffuser to the turbine outer
casing. The inner part of the exhaust diffuser, which is annular in shape, is
essentially held by three oval- shaped, hollow plate ribs. These serve at the
same time to permit access to the diffuser up the exhaust end bearing, for the
installation of pipe- work, and also for ventilation purposes. The sheet metal
cover of the thermal installation on the inside of the diffuser is welded over a third
of its circumference to make it oil tight and so prevent smouldering which might
occur as a result of oil leakage. A leakage drain is fitted to the lowest point of the
diffuser unit.

A traveling hoist can be fitted to one of the rails inside the exhaust diffuser and
this assists in the assembly and disassembly of the exhaust end bearing during
erection and overhauls so that bearing parts can be lifted in and out through the
upper hollow rib. The exhaust diffuser is supported on the foundations through
two adjustable spring supports. These take up small relative movements
between the exhaust gas system, exhaust gas diffuser, and machine
foundations.

PMI,NTPC 63
Support

The complete compressor/turbine assembly is supported on both sides at axis
height by four pin-ended supports and two fixed supports: These rest on the unit
supports that are bolted to the anchor plates which are in turn cast into the
machine foundations.

The casing rests on two fixed supports at the intake end between which is a solid
king pin which fixes the position of the compressor/turbine assembly laterally and
longitudinally.

The king pin, which is situated below the machine in line with the central axis,
takes up the forces which are transmitted by the exhaust gas system.
Longitudinal movement of the compressor/turbine assembly is guided by the
guide key below the turbine flange.

In general, all supports are principally of welded construction.

Insulation

The complete outer surface of the compressor/turbine assembly is thermally
insulated by two layers of lagging mats. These are made of mineral fibre cloth
with a sewn in mineral wool insult ant and are laid on the casings in a staggered
pattern attached to one another by books and eyes. The method allows easy and
non-destructive removal during overhauls.

The exhaust gas diffuser is thermally insulated and soundproofed with the
special insulating material consisting of several layers. This is covered with the
galvanized steel sheet. Insulation of the air intake connection is similar to the
exhaust gas diffuser. The enclosure over the compressor/turbine assembly, ie.
the gas turbine unit, is free-standing on the machine foundation and can be
PMI,NTPC 64
walked on for access purposes. It reduces the noise level and protects the
insulation from damage. It also improves the appearance of the unit.

Compressor Section

Compressors for gas turbines may be centrifugal or axial flow type, but all large
gas turbine use axial flow compressors. Gas turbine compressors are multistage
design and consists of individual discs or wheels mounted on a shaft. Each disc
holds the compressor blades which extend rapidly. This complete assembly is
called the compressor rotor and is enclosed in the compressing casing. The
casing holds stationary blades which direct the air flow against the rotating
blades. The stationary assembly is called the stators. As the blades force air
through the compressor, the casing area decreases and air is compressed
through each successive stage.

Early axial compressor designs were almost all based upon constant axial
velocity over the length of the compressor. This constraint simplified some flow
analysis and together with other arbitrary assumptions such as constant inner
diameter or constant diameter enables analytical and design team to cope with a
complex engineering problem. The large investment made in such design
approaches has resulted in their persistence in present day gas turbines. Over
time, the body of

Knowledge of the processes actually occurring in axial compressors grew and
economic factors related manufacturing costs became more important. Also,
manufacturing processes and materials advances gave more freedom to
compressor designers, and thus a different approach to design was taken. The
results of this different and more sophisticated approach are axial compressors
with variable axial velocity distributions and variable inner and outer diameters.
Such compressors are generally capable of providing superior performance
characteristics with fewer stages than earlier compressor. However, design of
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gas turbine compressor design is fixed for a particular machine by the
manufacturer. It is not an option to be selected; rather it is part of an overall piece
of equipment. The compressor must be designed and operated so as to avoid
compressor surge. The surge characteristic of compressor is a complex function
of many compressor design features. It can also be affected by compressor
deterioration and blade fouling in operating units. In order to avoid compressor
surge, each stage of the compressor must maintain its overall flow situation.
When a breakdown of this overall flow situation occurs in any one stage, the
result is usually disruptive to the flow situation in subsequent stages and surge
occurs. Under such conditions, intermittent flow and conditions such as puffing
or rotating stall(in which only a part of one ore more stages is in surge while the
remainder is in steady flow ) can occur . In such conditions are found to occur at
rotational speeds high enough to pose the danger of mechanical damage to the
combustion turbine unit, the situation can be alleviated by :1) providing inter
stage relief valves at one or more points along the compressor or 2) equipping
or more stages of is based on years of research and development and the
compressor stationary blade rings with variable geometry provisions. The first
method maintains a viable axial velocity distribution by relieving axes flow from
the later stages of the compressor . The second method controls the flow
produced by the variable geometry stages to be within the capacity of the later
stages of the compressor.

The method of surge control is inherent to the design of each particular gas
turbine and is left to the manufacturer.

Combustion Chamber (Combustor)

In large industrial type gas turbine, two types of combustion chambers are used.
With an annular type combustors, combustion occurs in numerous combustion
chambers located radially around the compressor discharge casing. Some
manufacturers use a single or dual silo type combustor, which is a large
PMI,NTPC 66
chamber, mounted on top of the turbine. Each combustion chamber includes fuel
nozzles, and ignition system and flame detectors. Each combustor is enclosed in
a casing and liner for support and insulation. Compressor discharge bleed air is
used to cool the combustor.

There are advantages and disadvantages to silo-type combustors when
compared to multiple in-line type combustors. Silo-type combustors provide
better combustion when using liquid fuel. Nox emissions are not easily controlled
with a silo-type combustor. However, external silo-type combustors have greater
pressure drop than then in-line type combustor arrangement.

Turbine Section

The turbine expands the hot gases from the compressor and combustor and
drives the compressor and generator. The turbine is constructed similar to the
compressor. Turbines are multistage design and consist of individual discs or
wheel mounted on a shaft. Each disc holds the turbine blades (buckets), which
extend radially from the shaft. This complete assembly is called the turbine rotor
and is closed in the casing. The casing holds stationary nozzles, which direct the
gas, flow against the turbine blades causing the rotor to rotate.

Generator Assignment

The generator can be located either at the hot and (exhaust) or the cold
end(inlet) of the gas turbine. With a hot end generator, the exhaust system
becomes more complicated and direct axial exhaust into the HRSG is not
possible with a hot end arrangement. Using a cold end generator arrangement
may complicate the air inlet system. It may also complicate arrangement of the
starting drive and/or accessory gear. Either arrangement is acceptable and the
location is the manufacturers choice based on his experience.

PMI,NTPC 67
8. Waste Heat Recovery Boiler


INTRODUCTION

What is waste heat? It is heat that is discharged in to the atmosphere without
recovering the available energy that might be economically converted in to useful
purposes. Then what is wastes heat recovery system? it is a system of heat
exchangers which converts this heat in to a more usable form of energy.

The utilization of the wastes heat recovery system in combine cycle power plants
with gas turbines is a relatively recent development brought by the development
in the field of gas turbines resulting in gas turbines becoming larger in size and
output, the large volume of heat available form gas turbine exhaust and rising
fuel costs.

One of the main features of the gas turbine is the high mass flow of air used over
the stoichiometric quantity of air. Typically volume of [excess air factor] for gas
turbine combustion lies between 3 to 4. this means there is more than sufficient
oxygen to support secondary combustion, if required. This high mass flow in turn
makes the gas turbine exhaust an ideal candidate for heat recovery steam
generation.

Description

The basic wastes heat recovery boiler (WHRB) consists of an evaporator which
is the basic steam generator, and an economizer which heats the incoming feed
water to the evaporator. Super heaters are also furnished, and condensate
preheaters (low pressure feed water heaters/ are sometimes used depending on
need and circumstances.)

PMI,NTPC 68
A complete wastes heat recovery boiler would also include an inlet gas by-pass
damper, with by pass stack and silencer, exhaust stack with monitoring
provisions and all interconnecting ducting between the gas turbine and exhaust
stack. Other WHRB accessories include the drum level sight glasses and level
controls, pressure gauges, continuous blow down control and sampling stations.

The WHRB evaporator consists of a steam drum, interconnecting unheated down
comer tubes, interconnecting heated riser tubes, enclosures casing and
accessories. The evaporator receives the incoming heated feed water from the
economizer and generates saturated steam which is taken form the top of the
steam drum, the evaporator will operator at constant saturation temperature
corresponding to the drum operating pressure. The steam drum is locked at the
top of the evaporator to enable natural circulation to take place water steam level
will be maintained in the steam drum during operation.

The economizer is a feed water heater operating at the steam drum pressure
utilizing the heat left in the exhaust gas after the gas leaves the evaporator. The
economizer will heat the incoming feed water to the evaporator

Super heaters are basically steam heater receiving saturated steam from the
steam drum and producing superheated steam. Super heater are located ahead
of the evaporator in the WHRB exhaust gas flow stream in order to develop
required superheated steam temperatures.

Low pressure feed water heaters also called condensate perheaters are
sometimes used on combined cycle units to heat the desecrator feed water thus
the cycle required less desecration steam making it more efficient.

WHRB exhaust gas by pass are commonly provided to isolate the WHRB form
its heated source. If furnished this isolation will permit running the gas turbine at
times whens steam is not required or when WHRB is not available. Normally the
PMI,NTPC 69
by pass dampers will have a straight open/close function though some designs
can also provide degree of modulation. A by pass stack complete with silencer is
required and provided when by-pass dampers are used

Duct burners can be used to raise the temperature of the exhaust gas to produce
more steam. However, duct burners are generally not used on combined cycle
plants due to the low rankine cycle efficiency as compared to higher combined
cycle efficiency.

Design considerations

a) Number of steam cycle pressures:

The general design philosophy of the WHRB is to exhaust heat form the
gas to the fluid at the highest temperature difference available. This can
best be accomplished by making the gas and the fluid [steam or water]
temperature gradients as nearly parallel to each other as possible. With a
single pressure level boiler, the choice is very limited since the super
heater, evaporator and economizer have to be placed in descending fluid
temperature along the gas path, in a multi pressure level unit this general
order is maintained, but various section may be interchanged so that a
nearly parallel relation between the temperature gradients can be
achieved.

In a single pressure boiler there is a limited amount of heat that can be
extracted, because the exhaust gas temperature cannot be reduced below
the steam saturation temperature. However, with a multipressure system
the recoverable heat range can be extended by extracting heat at various
levels, as the saturation temperatures are lower at each successive
pressure.

PMI,NTPC 70
However each successive pressure level adds to the plant cost and
complexity, which may make them uneconomical for most combine cycle
applications. Due to this reason dual pressure WHRBs are commonly
used particularly in combined cycle application where moderate and low
pressure steam is required. Dual pressure WHRBs are basically two
WHRBs utilizing the same gas stream. The high pressure section of the
WHRB would consist of an HP evaporator complete with HP economizer
and HP super heater interconnected to produce HP superheated steam.

The LP section would consist of LP evaporator with LP economizer
interconnected to produce lp saturated steam. Both WHRBs would be
built in to the same gas steam and would normally take feed form a
common condensate heating system. The hot gas path would be HP
super heater, HP evaporator HP economizer, LP evaporator, LP
economizer and condensate preheater, splitting the HP economizer in to
section and the cooler section downstream of the LP evaporator can
provide far more efficient utilization of the heat source.

By Pass Stack And Pass Damper

In an open cycle GT plant requirement of damper does not arise. In a combined
cycle plant provision of bypass stack and bypass require to be examined:

The major advantage a bypass damper and stack can offer are

i) To phase out the installation schedule of the GT open cycle and combined
cycle module, and

ii) The capability of running the G when the GT open cycle and obtained
cycle module, and generator is out of service for scheduled maintenance
or repair.
PMI,NTPC 71
In the case of the steam turbine down, it is possible to run a GT without a bypass
stack if the steam can be used elsewhere or dumped. For combined cycle
applications however, the use for the steam else where is generally nonexistent
and dumping the steam involves sizing the condenser to take the full load steam
in a steady state condition, running steam and circulation water cycles in an
unproductive heat-dump mode of operation. Alternatively, the WHRB is required
to be suitable for dry running. A further advantage the bypass damper offers is
the provision to control, to a limited extent, the heat input into the WHRB and the
quantity of steam produced partially bypassing the particularly important and
useful during cold startup operations.

Another distinct advantage of the bypass damper is the ability to isolate the
WHRB from the GT during the initial preoperative GT testing, when the repeated
stop-start operating of the GT can otherwise cause condensation to occur
throughout the WHRB.

A further possible advantage, dependent on circumstances, is the ability to
isolate the WHRB from the GT is burning sulfurous fuel.

Disadvantages in using a bypass duct and damper include the initial equipment
cost, maintenance costs on the bypass dampers and the constant heat loss
through both direct exhaust gas leakage and heat loss through the dampers.

A value can be derived for the GT operating time gain utilizing the bypass on
consideration of the expected WHRB and steam turbine down times which can
be compared to the value of the expected constant heat and gas leakage losses,
maintenance costs, and equipment costs. In summary, however there is no
general position on this subject and the same should be evaluated specifically for
each site conditions.


PMI,NTPC 72
Type of dampers

The major choice lies between utilizing a single diverter damper or two isolating
type dampers one for the WHRB duct and one for the bypass stuck. The two
damper concept offers the greater selection of damper types that can be used
but has the disadvantage that should both dampers close at the same time the
ducting would become over pressurized. In turn this necessities the installation of
relief panels or pressure relief type dampers, in addition to the electrical interlock
to prevent such situation. In the event of malfunctioning/ failure of the above
provisions a mechanical linkage system ensures that both the dampers are not
closed at the same time, as a foolproof system.

By pass dampers are prone to high leak rates. losses from the dampers include
both sealing losses through leakage and heat losses through the blade(s).For
combined cycle application involving large gas turbines. Damper types cover a
range including,multi louver type, diverter type and flap type dampers.

The advantages and disadvantages of each type and the suitability for a
particular application very with the application.

The multi louver type damper normally has external linkage actuating all the
louvers simultaneously and is good for regulating flow. However it will not be as
good on sealing as the single blade type damper. Further more, any pressure
differential would tend to force one part of the louver seating open, and would not
assist the sealing. The losses from this damper would therefore be greater and
furthermore, differential expansion on the linkage brings to question the
possibility of linkage binding.

The diverter valve offers the advantage that the duct cannot be closed off and
would be open to either the bypass stack or the WHRB. Sealing is generally
effective and the damper can be appropriately insulated to minimize heat losses.
PMI,NTPC 73
Flap damper have the same kind do flap operation and sealing action as the
diverter but are single application operating only as a single isolation type
damper. They offer an advantage on extremely large ducts by utilizing a seating
grid in the damper and breaking the damper into two or more individual flaps of
a smaller easier handled size. Disadvantages would be the pressure drop across
the seating grid. Pressure relief type flap dampers are also available and offer
the advantage of incorporating an over pressure relief flaps and avoiding the
additional costs of adding the relief panels elsewhere in the ducting. Normally
they are associated with multi louver dampers.

Generally the diverter and the louver type dampers can be set to a partially open
position to control heat for or start-up. However the dampers are generally not
suitable for continuous modulation such as load following, due to the size. All the
dampers, of course will utilize either motor drive or hydraulic power for operation.

Seals on the dampers are particularly important. Metal seals utilize the pressure
differential in the duct together with a built in spring action to help seat the thin
flexible metal seals against the seats. Normally the seals are attached to the
flaps and the seat area is built into the fixed frame.

Multi blade dampers have a greater seal footage than other types, and only part
of the seal is helped by the differential pressure. Other parts of the seal must seal
against the differential pressure. Because of this multi blade dampers tend to
have a higher leakage rate than the flap or guillotine type dampers. Sealing
efficiencies of 99.95% should be specified for metal in seals without air sealing.
Dual seals are often provided to obtain a greater sealing efficiency. Air seals use
a fan to create a small positive air pressure to help seal the metal seals.
Efficiencies of 100% should be specified for the seals if air sealing is utilized.

Several factors must be considered when selecting by pass dampers the value of
thermal losses, safety considerations cost and operation and maintenance costs.
PMI,NTPC 74
Normally the diverter is preferred for the GT by-pass application, however the
actual losses for each particular application must first be considered.

Heat losses through the damper is an extremely important consideration and
insulation of the damper or louver to minimize the heat loss is an important
consideration. Heat losses will vary departing on the insulation material used,
type of damper and temperature of exhaust gas. Manufacturers should be asked
to specify the minimum heat loss through the insulated dampers they
manufacture.

The particular design and type of damper selected will vary with the application.
For example, if air sealing is used. The cost of supplying the constant air supply
must be considered and compared to the additional sealing savings.

By Pass Stack

The height of stack, if not restricted by local regulations, will be based on
economic considerations of the stack construction costs compared to the value
of the gain in stack draft.

Stack construction cost will increase with stack height, due to weight to be
supported, increased wind loads, increased material costs, and increased
handling cost and maintenance costs.

The gain in stack draft will be the theoretical stack draft gain less the stack gas
pressure drop and its value will be obtained from the value of the increased
electrical output from the GTC due to less back- pressure.

A theoretical stack draft effect will be produced for each meter of stack height
due to the difference in the weight of the external air at atmospheric
temperature.
PMI,NTPC 75
Stack gas pressure drop will be the friction loss plus the stack exit loss.

Stack diameter will require selection prior to the determination of the pressure
drop. In selecting the stack diameter a velocity between 2,000 to 5,000 ft/min
should be assumed and pressure drops determined accordingly.

In certain circumstances discharging the gasses at a height sufficient to disperse
and dilute the exhaust may be a consideration.

The wind load on a stack is a major consideration, and a high stack may often
require a large diameter or other special provisions at the base for stability.

The bypass stack construction could be of fabricated carbon steel [outer shell]
with internal insulation and stainless steel liner. Otherwise it could be made of
stainless steel with external insulation and aluminum/GT cladding. Differential
expansion for the complete system is taken care by provision of an Expansion
joint, normally of flexible [fabric] type. In some design, exhaust side silencer is
located in the by pass stack upstream of the damper.

Pinch Point and Approach Temperature

These are two factors which affect the cost and effectiveness of WHRB. Pinch
point is the differences between the gas temperature leaving the evaporator
section of the system and the saturation temperature corresponding to the steam
pressure in that section.

Approach temperature is the difference between the saturation temperature of
the fluid and the inlet temperature of the fluid . Figure-17 makes the definition
more clear. These two factors and the desire on the part of the engineer to keep
them as low as practical cause more concern to the system designer than any
other factors in the design of WHRB.
PMI,NTPC 76
As a general rule, lowering the pinch point results in an increase in the total heat
recovered in that section. However, lowering the pinch point will require more
heat exchange surface and a subsequent increase in cost and gas side draft
loss. Multiple computations are required to select the most economical optimum.
Another possible penalty which must be evaluated in lowering . then pinch point
excessively is unstable operation. The very low design pinch point may indicate
more heat recovery but if all other factors are not realized, it may result in poorer
performance when steam production is critical.

Lowering the approach temperature can result in more steam production at that
pressure level as with a lower pinch point, this can only be realized at a higher
cost and same increase in draft loss. Higher approach temperature would result
in design stability. The higher approach temperature would increase the surface
in the evaporator section and assure a higher level of stability. Al low load the
gas turbine exhaust temperature will help drop but mass flow of the gas may not
drop signification depended on type of gas turbine and intent vane range. The
quantity of steam generates in the evaporator will drop. The economizer, will see
nearly the constant gas temperature. Conditions but will have to heat a reduced
fed water flow. The reduction in mass flow of the gas is not great as the reduction
in feed water flow. This could cause steaming and water hammer problem in the
economizer.
PMI,NTPC 77

Path of Flow
Fig. 17

In an economiser section a higher approach temperature will reduce the
probability of steaming at lower loads or during. Start up a design feature that
could prevent this problem of seaming at lower load is to located the feed
regulating station on the downstream of the economizer rather then the
traditional location upstream of the economizer . This will have the effect of
maintaining an economizer pressure higher then evaporator steam drum
pressure particularly during the economizer low flow situations when the value
would be party closed with a corresponding high pressure drop.
PMI,NTPC 78
Types of Circulation

Circulation of the water through the evaporator tubes can be forced utilizing
circulation pumps or can be natural utilizing gravity and density difference
between water and steam to obtain circulation. Both types of WHRB s are
common with combined cycle power plants.

Natural circulation boilers must have vertical or inclined to the vertical tubing and
will normally have higher initial costs. Forced circulation WHRB s using a
water/steam drum normally use horizontal tubing pump pressure to circulate the
water/ steam through the evaporator tubes. The advantages with horizontal tube
design is the lower cost of the tube bundles and potential for lower cost of section
renewal if request in later years. However, due to horizontal tube design used
with this type of boilers there will be lack of tolerance. Pressure drops through the
horizontal evaporator tube banks must be balanced and often require restriction
on some of the tubing in order to achieve this balance. This increases the
pressure drop through the system and water tend to separate to separate easily
leading to further problem and minimum velocity through the tubes must be
maintained to avoid this separation. If separation does occur, the bottom of the
tube will have a steam surface and heat transfer through the top of the tube will
not be as effective as heat transfer through the bottom of the tube. The top of the
tube will become hotter, setting up thermal stresses in the tube leading to
sagging and in some cases out right tube failure due to overheating the tube.

Thermal inertia of the forced circulation WHRB is less then the natural circulation
WHRB which facilitates faster loading and unloading of the WHRB. The table
below gives the summary of advantages and disadvantages associated with
each type of design.



PMI,NTPC 79
Summary Forced circulation Vs National circulation

Function forced Circulation Natural Circulation
Position Adv. Dis. Position Adv. Dis.


Circulation pump purch and inst. Costs REQD X NOT REQD X
Circulation pump operating costs REQD X NOT REQD X
Balanced tube side press drop REQD X NOT REQD X
Potential for tube failure HIGH X LOW X
Potential for steam/ water separation HIGH X LOW X
Initial cost LOWER X HIGHER X
Replacement cost LOWER X HIGHER X
Tolerance to changed conditions LOWER X HIGHER X
Sensitivity to adverse conditions HIGHER X LOWER X
Faster startup and shutdown FASTER X SLOWER X
(Less thermal inertia)


Unfired or fired Whrb

As stated gas turbine at high excess air. Hence, the exhaust gases have very
high oxygen content of the order of 16 to 20% which is sufficient to support if any
fuel firing desired in the WHRB or its duct.

A WHRB designed to recover only the heat available in the exhaust gases is
termed as unfired WHRB. Where are heat in the exhaust gases is supplemented
PMI,NTPC 80
by firing of additional fuel in the WHRB duct, the WHRB is termed as a fired
WHRB.

It must be recognized that the overall combined cycle plant efficiency will drop
when duct firing due to the fact that Rankine cycle efficiency is lower than then
combined cycle efficiency especially when the steam is used in a relatively low
pressure induction type steam turbine. However the cost of installing a duct
burner is extremely small and other equipment costs are nonexistent. Ducts
burning can be advantageously used in combined cycle units where a need
exists for peaking capacity. For evaluation of duct burner firing for peaking in a
combined cycle value of additional KW produced by the steam turbine should be
compared to the cost of generating the steam. Costs of additional steam turbine
generator capacity should be added, if applicable.

Choice on Condensates Pre-heater

Decision about adding a condensate pre-heater is dependent on the being
available in the back end of the WHRB,the requirement for heat to be added to
the condensate return and economic justification. In most HRSGs the back end
heat is usually available and justification for the heater is based on need due to
the temperature of the return condensate and economic justification.

Economic justification for a condensate pre-heater should evaluate and compare
all the costs associated with the installation of a condensate pre-heater against
the value of the steam saved by the utilization of the condensate preheater. The
steam saved by utilization of a condensate preheater will be the difference
between the steam used by deaerator operating with the condensate preheater
and without the condensate preheater. Without the condensate pre-heater
additional deaerator steam would be used to heat the incoming condensate (feet
water) to the saturation temperature required for dearerator operation.

PMI,NTPC 81
Condensate pre-heaters are subject to similar low load problems as experienced
by the economizer. The problem is aggravated in the condensate pre-heater,
however by a temperature rise in the exhaust gas at low load as the economizer
will use less heat front the gas with the reduced feed water flow. The
condensate pre-heater will therefore be subject to hotter gas together with
reduced condensate flow which can cause severe steaming and steam hammer
in the heater. In many cases the chosen solution to the condensate pre-heater
low load problems is a planned by-pass of the condensate preheater during the
infrequent low load operations permitting the condensate preheater torn day.
Alternate solutions to this problem, dependent on the excepted frequency of low
load operation would include running a full flow feed through the pre-heater at all
times and dumping the surplus heated water to the condenser.
PMI,NTPC 82
9. Gas Turbine Generator


Synchronous Generator

The air cooled generator Type WY 18 L is of simple but robust construction. The
generator and the gas turbine 13D are placed on a common and plain concrete
foundation, with the same center line level for both the gas turbine and the
generator rotor. Therefore, the space below the active part could be used to
house the four cooler sections. The outline drawing shows the principle design
and the main dimensions.

Generator Design

The generator is built in compliance with the latest standards of the IEC, ANSI
and VDE, and is designed to operate continuously at rated load but also it
withstand a wide range of abnormal operating conditions, including short circuits.

Stator casing and Iron core

The horizontally spilt stator casing of the active part consists of two welded sheet
steel constructions, which are screwed together. Inside the casing sheet, steel
ribs are arranged as guide plates for optimum cooling air distribution to the active
sections. The four identical air recooling elements inserted into the casing below
the active part can be withdrawn horizontally.

The low-loss core segments are punched from silicon alloyed electric sheets.
They are carefully deburred and are given several coats of a heat resistant
varnish which can withstand temperatures much higher than the normal
operating temperature. By this manner, the individual segments are dependably
PMI,NTPC 83
insulated from each other, so that even after many years; operations no short
circuits or even hot sports can occur.

After stacking the core segments outside the casing, vibrations and inseased
temperatures are applied when the core is compressed between heavy press-
plates. The press-plates are made of low-loss non-magnetic material and press
by special fingers the whole cross section of the core. The resulting core remain
rigid over its whole length, especially the highly stressed end parts, even if
subjected to varying load conditions or daily multiple starts.

Distance profits are welded to thicket segments, so that in constant distances
radial slots are formed for flowing through of the cooling air. The would core will
be inserted as a ready unit into the casting and will be welded with the casing
upper part by use of adjusting pieces.



OUTLINE DRAWING OF ALTERNATOR
Figure-18

PMI,NTPC 84
Stator-Winding Bars and Installation of Bars

The mechanical energy generated by the turbine is converted to electrical energy
by the generator and appears in the stator winding in the form of current and
voltage. The winding is capable of withstanding all thermal and mechanical
stress arise from normal operating or from external faults, with a generous
factory of safety.

The stator winding consists of individual bars installed in rectangular slots
distributed uniformly along the inside circumference of the stator core. Each
winding bars consists of solid conductors, insulated from each other. The
conductors are first wound with resin-impregnated glass fiber, then assembled
together and pressed in heated modulus to form compact bars. During bar
assembly, the conductors positions in the bar are transposed, or twisted, so that
each conductor occupies each possible position once in the straight part of the
bar. Thus, the same amount of current appears in each couch and no
unnecessary losses occur. The bars so formed are called Roentgen bars, after
their inventor.

The main bar insulation is built up following the Micadur (R) system, which was
developed by BBC and which has been successfully used for many years. In this
system, the bars are continuously wound, in an automatic tape winding machine,
with the required number of layers of mica-coated glass-fabric tape.
PMI,NTPC 85

STARTOR SLOT CROSSECTION
Fig.-19

The straight part of each bar is pressed to size, the bars then are dried in an
oven, then they are impregnated in vacuum, by a special epoxy resin, and
hardened in an oven by means of circulating air. The finished insulation complies
with the Insulation Class F specifications of the IEC, ANSI and VDE standards.
PMI,NTPC 86

ENDWINDING SUPPORT
FIG-20

Terminals

The winding connections and the terminals are connected by means of flexible
copper strips. The flexible strips absorb possible relative motions between casing
and winding which may be caused by different heating of casing and winding.

The terminals are designed to withstand forces in case of a short circuit at he
terminals. The insulation is designed fir the 1.5-fold test voltage of the generator,
and consists of impregnated mica-glass strips.

Both ends of the terminals have two parallel connecting plates, inside the
generator for connecting of the flexible strips, and outside for the connection to
the bus bars to the star point, respectively.



PMI,NTPC 87
Rotor Body

The rotor balances the torque of the gas turbine. It leads the magnetic flux, and
carries the field winding and the necessary parts for conducting the field current.

The rotor body is a single forging of heat-treated alloy steel having very good
mechanical and magnetic properties. After heat treatment, the rotor body is
tested using the most up-to-date methods to ensure that the required properties
have been obtained. As an example, the rotor is subject to ultrasonic testing over
its complete length and cross-section. Therefore, a central bore for testing
purposes is not required.

Longitudinal slots are milled in the two winding zones of the rotor surface to carry
the field winding. The different slot shapes in the pole zone and winding cause
different moments of inertia relative to the direct and the quadrature axis. In order
to achieve uniform bending of the rotating rotor relative to these two axes,
transverse slots are milled in the pole zones. This acts to reduce the amplitude of
the double-frequency flexural vibration in a smooth-running rotor.

The driven shaft end of the rotor is provided with an integrally-forged coupling
flange for connecting the turbine shaft.

At both ends of the rotor are seats for the fans and also journals for the bearings,
the ends of the rotor body are machined to take the retaining rings. The non-
driven shaft ends has a central bore to take the rotor filed current lead, while
radial holes are drilled for the lead studs which connect the rotor leads with the
field winding.




PMI,NTPC 88
Rotor Winding

The rotor winding is composed of hollow conductors which carry the excitation
current required to produce the armature field. The conductors are made of
drawn silver containing oxygen-free copper having high-grade properties.

In the active region, the hollow conductors are insulated from each other and
from the rotor iron by Nomex, a polyamide paper, fulfilling class F requirements.


ROTOR WINDING
FIGURE-21

The rotor winding is directly cooled by air howing from both ends of the rotor
through all the conductors. At all the air inlets and outlets, the creepage (leakage)
PMI,NTPC 89
paths between the bare copper and the rotor mass are rather long. This ensures
goods dielectric strength of the winding even after long operation time.

The filed current is conducted from the slip rings to the rotor windings by means
of two half-round copper lead bars fitted in the shaft bore. At one end of the lead
bars, connection is made to the slip rings by two leads studs and flexible-plate
connectors. At the other end, connection is made to the rotor winding by similar
lead-studs and flexible-plate connectors located under the retaining ring. At each
end, one stud is provided for each polarity. The stud is made of flexible-plate
connections compensate all mechanical and thermal stresses.

Retaining Ring

Retaining rings which carry the centrifugal forces of the rotor end windings are
fitted at each end of the active part of the rotor.

Each retaining ring has a cylindrical section and disc-shaped cap end.

The retaining rings are shrunk onto the rotor ends and maintained in their axial
position by means of a bayonet attachments. A special key prevent any
movements of the rings in the tangential direction under short circuit conditions.

A special feature is the insensibility of the used steels against stress corrosion.

Cooling System

The axial fans at both ends of the motor provide for two cooling circuits. The air
which cools the rotor enters the end-coil space between the end bells and the
shaft. In the vicinity of the slots it flows through slits into the hollow conductors,
where the air flow is being divided. One flow path is through the hollow
conductors in the slots, entering the air-gap at the middle of the rotor through
PMI,NTPC 90
radial passages in the windings and slot wedges. The other one leads through
the hollow conductors in the end-coils, finally leaving the space under the end-
bells through slots n the rotor body and entering the air-gap.


AIR FLOW SCHEME OF THE ALTERNATOR
FIG-22

Some of the air which cools the stator is led straight into the air-gap. Together
with the cooling air from the rotor end-coils, it leaves this region through radial
passages in the frame. From there the air returns via the coolers to the fans. The
rest of the air cools the stator end-coils and flows through axial channels into the
second frame chamber. From there it flows through the laminations towards the
air-gap where it splits up again. One half flows back through further slots into the
first frame chamber, the other half mixes with the air coming from the rotor at the
middle of the machine. From there the air passes through the laminations to the
third frame chamber, the coolers and aging to the fans.

Each of the cooling elements consists of a finned tube bundle and two water
chambers. The materials for the coolers will be selected depending on the quality
of the water. The coolers can be cleaned easily with brushes.
PMI,NTPC 91
Bearings

The generator is equipped with two journal bearings. The bearing at the driven
end is part of the immediate block of the gas turbine. The bearing on the non-
driven end is insulated to prevent shaft currents. The rotor is earthed via earthing
brushes. The bearings are connected to the lub and jack in oil systems of the
turbine.

Slipring Unit

The equipment for conducting the excitation current (direct current) into the
rotating rotor in order to produce the magnetic field in the rotor winding is located
in the slipring unit at the non-driven end of the generator. It consists mainly of two
slip rings shrunk onto the shaft (but insulated from it), a set of carbon brushes in
contact with the slip rings and carried in replaceable holders, and the brush-
holder supports. The actual transfer of current takes place between the brush
surfaces and the slipring surfaces. The constant pressure required between the
surfaces is provided by rolled-strip springs on the brushes.

The heat generated in the slip rings and brush gear is removed by a dual exhaust
fan which draws cooling air through each side of the unit. During operation, the
brush gear can be inspected through safety-glass windows provided in the
casing.

Temperature Monitoring

Temperature sensors are provided in the stator winding and the cooling air
circuit. The connecting wires to the sensors are brought out through bushings to
the instruments terminal box.
PMI,NTPC 92
10. Excitation System


General Description

The synchronous generator is shunt excited. The power required for the
excitation is taken from the generator terminals and fed to the field winding
through the excitation transformer and the thyristor-controlled rectifier units. The
thyristor-controlled by the voltage regulator through the grid control unit and
pulse amplifier stages, so that the generator voltage is held almost constant from
no load to rated load. A fully-controlled 3ph AC bridge circuit is used for the
rectifier circuitry. This permits reversing of the polarity of the excitation voltage
during rectifier operations ensuring rapid control during build-up or discharge of
the field.

A three phase AC auxiliary gird is required for field flashing for the generator
excitation which is supplied via the transformer and the field flashing circuit
breaker until the generator is excited to such an extent that the excitation
equipment can operate automatically. When a fault occurs, the generator can be
deenergized quickly with the field circuit breaker and the voltage dependent
resistor. The short circuit device protects the excitation equipment and the
thyristors from excess voltage by short circuit the field windings through the
limiting resistor.

Description of Operation

Automatic Voltage regulator (A.V.R)

Regulator rack

PMI,NTPC 93
The actual value and set point are compared in the Unitrol Section and the
difference between the two is amplified in the control amplifier. The output
voltage of the amplifier is limited to a value set by an internal potentiometer. The
generator is controlled as follows below the cut-off frequency F. the control
voltage is proportional to the frequency, and above this the voltage is held
constant to a set value (see fig. 23)


Figure-23

The cut-off frequency can be adjusted by an internal potentiometer. The set point
adjustment is made using a reference value transmitter Unitrol, which is installed
in the regulatory rack.

Adjusting elements allow the level and range of the voltage regulator to be
selected (see fig. 24)

Figure 24
PMI,NTPC 94
Adjustable compound resistances are connected in the circuit to ensure the
required reactive load distribution during parallel operation with other generators.
The resistors allow the regulator drop to be changed. AP. I.D. feedback filter and
a differential amplifier are used for stabilizing, which permits optimum matching
of the controlled generator. A power pack supplies a stabilized voltage to the set
point potentiometers.

Grid control unit automatic channel and manual channel the output signal of the
regulator rack or manual control potentiometer is fed to the input of the grid
control unit Unitrol together with a 3ph A.C. voltage from the filter Unitrol which is
synchronous with and has the same phase as the supply for the power rectifier.
From this, 6 phase voltages are formed, which are compared with the regulator
or hand control signal (see Fig. 25). The differences is formed into square wave
form voltages by an operational amplifier with controlled limits. Six trigger pulses
are thus formed at 60 (electrical) intervals by the change in polarity.


Figure-25

The trigger pulses can be shifted depending on the size of the AC and DC
voltage. For safety reasons, adjustable limits are provided for full rectifier or DC-
AC converter operation. The weak pulses of the grid control units 1001c-P are
PMI,NTPC 95
amplified in the pulse stages of Unitrol. Control relays in the unit allow the pulses
to be suppressed, i.e. blocked, or to be reversed in DC-AC converter operation.

Pulse end stages

The output pulse of the grid control unit are fed to the parallel-connected pulse
end stages of Unitrol. These end stages are designed to control up to a
maximum of 8 thyristors in parallel per branch by means of the appropriate pulse
gradient and power level, i.e. a 3ph AC bridge with up to 48 thyristors can be
controlled. The pulse of every end stage can be suppressed by means of a
blocking relay. The corresponding thyristors therefore remain isolated.

Current rectifiers

Three current rectifiers unit are fitted in section of the lead rectifier cabinet. The
thyristors are directly fitted to the heat sinks. The current strips are connected to
the DC AC busbars, the auxiliary and control cables are lead to the appropriate
terminal blocks. Each unit is ventilated by its own fan. The fans are supplied
through the fuses, which are directly connected to the secondary voltage of the
excitation transformer, the transformer, and the protection circuit breaker. The air
flow from the fans is monitored by a wind vane relay.

Regulator limit rack

Limit criteria

All limits act equally in that they influence the voltage control and alter the
excitation accordingly.

The criteria are :

PMI,NTPC 96
Too large a stator current

Too large rotor current

Too larger a load angle for stability

In the over-excited range, the rotor or stator current limiter reduces the excitation
and in the under-excited range the load angle limiter increases the excitation.
The rotor or stator current limiter acts through a time delay and integrator to
maintain both good regulation in the event of load changes, and also the dynamic
behavior of the generator when intermittent grid faults occur. This allows the
protective system to operate selectively.

Load angle limiter Unitrol

The load angle, the angle between the generator longitudinal axis the grid
voltage vector, can be determined by forming a vector diagram of the generator
and the external reactance. The generator voltage and current are fed to the
input of the load angle control limiter. The quardrature reactance xq of the
generator is the determining parameter, and can be adjusted between 0.5 and
3.0 p.u. While the external; reactance xe can be adjusted between 0 and 3.0 p.u.
by means of potentiometer: The two voltages so formed enclose an angle
between them which corresponds to the load angle. This angle is transformed in
a transducer to a DC voltage signal. This angle is transformed in a transducer to
a DC voltage signal. This signal is compared to an adjustable set point. When the
measure value exceeds the set point, the limiter comes into operation and acts
upon the voltage regulator. The excitation is then increased until the load angle
corresponds to the adjusted set point. Despite increasing generator voltage, the
voltage regulator remains ineffective.
PMI,NTPC 97
Rotor current limiter Unitrol

This limiter protects the rotor winding from thermal overload. The excitation
current is measure on the AC side at the supply to the controlled rectifier units,
and converted into a current proportional DC voltage within the limiter. This is
then compared with an adjustable set point, amplified and fed to the input of the
voltage regulator. The limiter acts with a time delay, so that the dynamic control
is not affected in cases of fault.

Stator current limiter Unitrol

The stator current is converted by a transducer into an equivalent DC voltage
which is polarized positively or negatively according to the over-or under-excited
operating condition. This forms the actual value for the regular in which the
comparison with the adjustable set point is carried out the difference signal first
amplified. The output of the amplifier for limiting the stator current influences the
regulation of the voltage in such a way as to reduce he excitation.

Temperature-dependent current limiter

The temperature-dependent current limiter is used to protect the generator
winding against thermal overload, should the ambient air temperature exceed 40
deg. C. The current limiter, by an appropriate reduction in excitation current,
prevents the windings from overheating. On gas turbine systems, on which the
limiter is used, the active power of the turbine decreases with increasing air
intake temperature, and the limits given by the generator are always in the
specified range. Thus any effect on the active power nominal value is not
necessary. The current limiter includes supervision, which incase of irregularities
such as nominal/actual deviations, gives a command signal to shut down the
turboset.

PMI,NTPC 98
Basically the system consists of two units :

(a) Nominal value formation and nominal/actual value supervision of the
stator current.
(b) Nominal value formation and nominal/actual value supervision of rotor
current.

Excitation the system consists of two units:

Excitation with field flashing

The supply for power rectifier is from the 3ph excitation transformer which
receives its power from the generator. Before excitation takes place at rated
speed, there is only the residual voltage of the generator available. This is
insufficient for starting the excitation equipment. The thyristors of the controller
remain blocked. An auxiliary voltage of 414 V, 50 Hz is available for field flashing,
which supplies sufficient excitation current through the matching transformer and
diode bridge for 35% of the generator voltage. The on command is given by the
start-up automatic, or from the control room, via the decontic control. The
command is only given when the criterion ready for connection is fulfilled. The
field breaker is switched on.

At 70% generator voltage the voltage relay switches the field flashing breaker off.
Switching off must take place within 20s, otherwise the time supervision switches
the field breaker off. The excitation process will be interrupted.

De-excitation

De-excitation can follow through the following criteria :

PMI,NTPC 99
(a) By the command Excitation off via the contactor from the automation or
from the control room.
(b) By a fault within the excitation equipment.
(c) By the generator protection.

The field breaker is immediately opened and the field discharges through the
voltage dependent resistor. The excitation circuit must not be broken as long as
current is flowing, since this can cause high voltages which would damage the
thyristors or the rotor winding. When the filed breaker is switched off, a contact
switches the resistors in, parallel with the rotor winding. A second contact breaks
the supply from the rectifier. The resistor is sized so that the over voltage of the
filed breaker. The resistor is designed as nonlinear and voltage-dependent,
whose resistance decreases with increasing voltages. In this way the de-
energizing time constant becomes shorter. The blocking voltage of the thyristors
lines above this cut-off overvoltage.

The overvoltage short-circuit device, parallel to the rotor winding, offers additional
protection as undesired break in the rotor circuit occur during operation. When
the short circuit device acts, the limiting resistor is switched in parallel to the rotor
winding. It acts between the allowable switching voltage of the field breaker and
the cut-off overvoltage, so that it is only activated when a fault occurs.

Power supply

Automatic Voltage Regulatory (AVR)

Automatic voltage regulator and manual voltage control have two independent
power supply units each, one AC-DC converter and one DC-AC converter. The
AC-DC converters Unitrol are connected to the secondary side of the excitation
transformer via transformer. The DC-AC converters Unitrol are fed from the 220
PMI,NTPC 100
V DC distribution AC-DC converter Unitrol connected to the 220 DC distribution
serves for power supply for the protection.

Control Voltage

The 220 V DC supply voltage in the control cabinet is provided by a 220 V DC
distribution Systems.

The control voltage is monitored by, which gives a signal the voltage is low.

Every function has its own control circuit, so that when failure occurs, only a part
of the system is out of operation. When a failure occurs in the circuit it must be
decided whether the excitation equipment can remain in operation or not,
according to the importance of the faulty circuit. The faulty control circuit must be
brought back into operation again as soon as possible. The protection switches
are monitored by the built-in auxiliary contacts. When a protection switch cut out,
the alarm Protection switches Voltage is illuminated in the control cabinet and in
the electrical control room the excitation warning signal is given. Normally only a
small amount of power is taken from the battery for the controls. Switching
process require approx. 10 KW for a short period.

Method of operation of the complete equipment

When the generator is stationary the circuit diagram shows that field breaker is
open. The generator must be brought up to rated speed before it can be put into
operation. Above 95% rated speed, the excitation process can be started by
switching on the field breaker. The generator is excited up to 35% rated voltage
by the filed flashing. Above this value the electronics function reliably, and the
regulator takes over the control of the generator voltage. At 70% generator
voltage the field flashing is switches off by the field flashing breaker. The set
point is compared to the actual value. During the excitation process the generator
PMI,NTPC 101
voltage is low. The control amplifier Unitrol 2010 gives a higher signal to the grid
control unit Unitrol.

At first a celling voltage of approximate. 40% of max. excitation voltage at rated
generator voltage is present. The generator voltage and thereby the exciter
voltage continually rise. As soon as the output voltage of the voltage transformer
reaches the adjusted set point, the control pulses to the thyristors are pushed
back until set point and actual generator voltage are equal.

When manual control has been selected, then the firing angle of the thyristors
can be adjusted with the hand potentiometer, which corresponds to a certain
exciter voltage. The actual value of the generator voltage has no influence on the
firing angle-in contrast to the automatic control-since with manual control, there is
no closed control circuit. When the potentiometer is changed as a result.

The changeover to manual channel can be made at any time. However the pulse
difference between the output of the grid control unit automatic channel and the
grid control unit manual channel must be zero. The pulse difference can be read
off on the comparative voltmeter via the measurement Unitrol 0040, comparator
Unitrol and measuring converter. The comparison is made in the control room via
the contractor by adjusting the potentiometer. When zero voltages is shown on
the comparative voltmeter, a smooth changeover can be made to manual control.

Protection and Monitoring equipment

The excitation equipment is monitored and protected by various protective relays,
motor protection relays, and various monitoring equipment. The function
description=MKC01..MKC05 gives information about the monitoring equipment
provided, and the result when a fault occurs.


PMI,NTPC 102
Alarms

The signals for the excitation equipment are shown on the circuit diagrams. They
are illuminated in bottom for acknowledgment, lamp test, functional test and lamp
reset.

Protection of the excitation equipment and the excitation transformer

Electronic inverse time overcurrent relay type IKC 062 delay trip (change-over to
manual), instantaneous trip.

Electronic short circuit relay type Unitrol.

Temperature protection with PTC-Resistors fitted to the excitation transformer.
PMI,NTPC 103
11. Gas Plant Operation


Gas Turbine, WHRB, Steam Turbine Starting Modes

Basic conditions for plant operation are as follows:-

Start up or shut down of G/T, WHRB and S/T of each module is performed
separately from the other module (except for S/T gland steam back-up
and heating steam back up systems).
Start up/shut down mode is selected freely form among those mentioned.

The start up/shut down procedure for WHRB and S/T here mainly describes
operating procedure for G/T by-pass damper, WHRB inlet damper and remote
operated valve necessary for start up and shut down from G/T exhaust gas
admission to WHR till rated load operation of S/T. For detail operating procedure
for G/T WHRB, S/T auxiliaries and remote operated valve following procedures
are followed.

Start up Mode

The start up mode of G/T, S/T and WHRB shall be selected from among the
following as a rule through various other start up modes are conceivable
according to power demand and operating principle.

Outline of each start up

Normal start up mode

This mode is two unit (2G/Ts + 2WHRBs +1 S/T) combined cycle start up
mode which, after starting up one each of G/T and WHRB, starts up the
PMI,NTPC 104
other G/T and WHRB and brings the output of G/T and S/T the target
output of the module. In this mode, S/T is loaded with one each of G/T and
WHRB in operation, and after the intial load is achieved, the pressure
control of HP/LP by-pass valves of both WHRBS is changed to common
pressure control and then S/T is loaded up.

The timing of starting up the other G/T and WHRB is left to the discretion
of the operator, and S/T is kept stand by at the initial load until the
pressure control of both WHRBS is changed to the common pressure
control.

Rapid start up mode

This is a mode of starting up both G/Ts and WHRBS at the same time,
changing the pressure control of HP/LP by-pass valves of both WHRBS
to the common pressure control, then loading up and brining G/T the
output of and S/T to the target output of the module is achieved.

This mode is used only for start up after right stop or hot start up (with
vacuum).

In other start up modes; in which the time from G/T start up to S/T loading
is long, simultaneous startup is not made to reduce heat lose at start up.

G/T/WHRB additionally start up mode

This is a mode of starting up the other G/T and WHRB one until combined
cycle of G/T, WHRB and S/T is in operation. In this mode, the HP Steam
pressure and temperature of the other G/T and WHRB are raised up those
of G/T and WHRB in operation, and then the pressure control of HP/LP
PMI,NTPC 105
by-pass valves is changed to the common pressure control, and S/T is
loaded up.

Single G/T/WHRB start up mode

This is a combined cycle start up mode of starting up S/T with only one
each of G/T and WHRB in operation. The other G/T and WHRB remain
stopped.

Individual pressure control

Individual pressure control means pressure control made automatically by
using HP/LP by-pass valves of both WHRBs and detecting pressure
before HP/LPCV so that HP/LP steam pressure of both WHRBS will be
the same and constant respectively.

Loading of S/T

S/T loading rate after HP/LP by-pass are fully closed and HP/LPCV are
fully opened is determined by the load change rate of G/T, namely S/T
load change rate increases as G/T load change rate increase. (Except for
G/T/WHRB additionally start up mode).

S/T unloading rate too is determined by G/T load change rate under
HP/LP by-pass valves are fully closed and HP/LPCV are fully opened.

STARTUP PROCEDURE

Normal start up mode

Cold start up
PMI,NTPC 106

The condition in which HP turbine rotor temperature is below 120 degC is
called cold condition.

In cold start up, the HP turbine rotor needs warming, which is performed to
raise the rotor temperature above the transition temperature of the rotor
material 120deg.C and prevent brittle fracture in high speed operation to
achieve this heat sock is done by holding rotor speed at 2000 rpm during
start up of the steam turbine. The time of heat soak varies with rotor
temperature before steam admission. Heat soak time of 2 hours is given
on the assumption that the rotor is at the ambient temperature.

Heat soak is performed with one G/T in operation to reduce start up loss
and the other G/T shall be stared up just before that soak is completed.

At cold start up, WHRB outlet steam temperature must be below 43
0
C
because of temperature limitation at steam admission to S/T. Therefore,
WHRB inlet exhaust gas temperature must also be limited accordingly.

WHRB and S/T shall be started up after G/T load is held at a load (about
30%) at which boiler outlet steam temperature can be kept below 430
0
C.

Start up conditions

Turbine vacuum Without vacuum
Gland steam supply conditions 2.5t/h x 200
0
C x 3kg/cm
2
above
Steam admission conditions 60t/h 300
0
C-430
0
C x 39kg/cm
2

WHRB inlet damper initial opening 100%
Steam evaporation at G/T 30% load 25t/h
SH outlet below valve capacity 35t/h x 29kg/cm
2

Time required for pressure About 40 minutes
PMI,NTPC 107
Rise (0-29 kg/cm
2
) (at G/T 30% load)
WHRB temperature rise rate 400
2
C/h
S/T speed rate 300 rpm/min
S/T load up rate
(Before HP by-pass valve full close) 1%/min.
(After HP by-pass valve full close) 2.5%/min.

Start up procedure

Preparation for start up
- Start up the following common equipment which is necessary for
start up of G/T, S/T and WHRB.

a) Raw water pump system (clarifier, pretreatment plant and
water treatment plant)
b) DM water transfer pump system.
c) Compressed air system.
d) Compressed air system.

- Fill up condenser and deaerator with water.
- Start up circulating water system CWP Condenser-cooling tower
CWP
- Start up chemical injection system.
- Start up seal air fan.
- Make sure that all preparations for start up have been completed.

WHRB start up

- Start up HP BFP and LP BFP
- All manual operation
PMI,NTPC 108
- Start up boiler circulating pump
- Make sure that by-pass damper is full open and WHRB inlet
damper is full shut.
- Start up G/T after all preparation for G/T start up have been
complete.
- Start turning S/T
- Open HP/LP drum air vent valves and SH outlet air vent valves.
- When WHRB inlet damper is open, automatically open HP steam
pipe drain valve and LP steam pipe below valve.
- After synchronizing G/T, fully open WHRB inlet damper. By-pass
pre-heater and fully open HP/LP economizer re-circulation value.
- Start up G/T up to 30% load and hold that load.
- When HP steam pressure reaches 2 kg/cm
2
, automatically close
HP/LP drum air vent valves and SH outlet air vent valve.
- When HP steam pressure reaches 3kg/cm
2
x 200
0
C. Open the Hp
steam stop valve and HP turbine inlet pipe drain valve to start
warming of HP turbine inlet pipe.
- After warming is over, start up gland condenser exhaust fan, and
open gland steam stop valve to start gland steam supply
- Start up vacuum pump after gland steam has been established.
- Until HP/LP by-pass valves are put into operation, open SH outlet
blow valve, HP steam pipe drain valve and LP steam pipe blow
valve, and steam is blown into the WHRB blow down tank and S/V
flush pipe.
- At that time, opening of SH outlet blow valve and LP steam blow
valve is automatically adjusted according to HP/LP steam pressure
at start up of WHRB.
PMI,NTPC 109
- Opening HP steam pipe drain valve is automatically adjusted
according to HP steam temperature at start up of WHRB.
- After vacuum has been established (550 mm Hg), open turbine
drain valves and open HP/LP by-pass valve inlet stop valves to put
HP/LP turbine by pass system is individual pressure control.
- Open HP by-pass valve to start individual pressure control so that
HP steam pressure will be constant of 29 kg/cm
2
.
- Open LP by-pass valve to start individual pressure constant so that
LP steam pressure will be constant of 5kg/cm
2
.
- When HP/LP by-pass valves are put in operation, fully close by-
pass damper.
- After HP/LP by-pass valves have been put in operation and SH
outlet blow valve HP steam pipe drain valve and LP steam pipe
blow valve.
- When LP by-pass valve is put in operation open LP steam stop
valve and LP turbine inlet pipe valve and LP steam pipe blow valve.
- When LP by-pass valve is put in operation open LP steam stop
valve and LP turbine inlet pipe drain valve to start warming of LP
turbine inlet pipe.
- After warming is over, open deaerator heating steam supply valve
to start heating of deaerator.
- At the same time, open condenser pre-heater re-circulating valve
by the specified degree (at gas firing only)
- When boiler evaporation is established and drum level control is
switched to 3-factor control, admit rate to pre-heater and fully close
HP/LP economizer re-circulation valves.


PMI,NTPC 110
S/T start up

- Make sure that all preparations for S/T start up have been
completed
- Make sure of turbine steam admission conditions 29kg/cm
2
x 300
0

C (below 430
0
C).
- After steam admission conditions have been completed, HP/LP
turbine inlet pipe drain valves are fully closed.
- Start steam admission to turbine (DEH on)
- Start accelerating. Accelerate at 300 rpm/min. up to target of 2000
rpm. Make rub checks as necessary during acceleration.
- Make heat soak at 2000 rpm for 2 hours.
(Heat stocks time depends on mismatch temperature difference of
turbine)
- Startup the other G/T just before heat sock is completed and hold it
at 30% load, increase steam temperature and pressure of the other
WHRB and when HP/LP steam pressure reached 27/cm
2
and
4.5/cm
2
respectively, put HP/LP by-pass valves in operation.
(To start up the other G/T and WHRB, follow the startup procedure
described earlier).
- After heating soak, accelerate up to 3000 rpm/min.
- Check that preparations of generator have been completed.
- Loading.
- Maintain 5% initial load for 10 minutes.


PMI,NTPC 111
Load up

- Put HPCV and LPCV (Governor valve) in upstream pressure
control and sequentially close HP/LP by-pass valves so that the S/T
load up rate will be 1% min. at this time, HP/LPCV automatically
following up in pressure control. As a result, steam goes to S/T.
- When S/T load reaches 20% full close all turbine drain valves.
- When HP by-pass valve is fully closed, shift HP by-pass valve to
backup mode.
- When LP by-pass valve is fully closed, shift LP by-pass valve to
back up mode.
- Fully close HP main steam stop valves for other WHRB adjusting
temperature and pressure differences.
- Fully close LP main steam stop valve for other WHRB, adjusting
temperature and pressure differences, fully close LP turbine by-
pass valve according to the predetermined programme and then
switch to back-up control
- When HPLP by-pass valves are fully closed, adjust G/T output to
achieve target plant output.
- At this time, adjust G/T load up rate so that the S/T load up rate will
be 2.5% min. (GT load up rate will be approx. 2.9% min.)

Warm Startup

The condition in which HP turbine rotor temperature is between 120
0
C
and 140
0
C is called warm condition.

PMI,NTPC 112
Because of thermal stress, heat soak from 0 to 40 minutes is required,
depending on the steam turbine rotor temperature. Startup procedure is
basically the same as is cold start up. When making a weekend shut down
of the plant, if a normal shutdown is made, the steam turbine rotor can be
held at a relatively high temperature, and so heat sock time can be
shortened.

If, rotor metal temperature is above 300 C, and heat sock is not required.

Because of temperature limitation at steam admission to S/T, WHRB
outlet steam temperature must be below 430
0
C. Therefore hold G/T load
at a load (about 30%) at which WHRB outlet stream temperature can be
kept below 430
0
C, and then start up WHRB and S/T.

Start up conditions

Turbine vaccum Without vacuum
Gland steam supply conditions 2.5t/h x 200
0
Cx.3kg/cm
2
above
75t/hx300
0
C-430
0
Cx29kg/cm
2

(10% initial load)
WHRB inlet damper initial opening 50%
Steam evaporation at G/T 30% load. 25t/h/
SH outlet blow valve capacity 35t/h x 20 kg/cm
Time required for pressure rise at About 25 minutes (at
G/T 30% load. G/T 30% load)
WHRB temperature rise rate 400
0
C/hr
S/T speed rate 300 rpm/min.
S/T load up rate (Before HP by-pass 2.5% min.
Valve full close) 3.0% min. (Corresponding to the
C/T load up rate of 30%/min.)

PMI,NTPC 113
Star up Procedure

- Preparation for Start up

Start up the following common equipment which is necessary for
start up of GT, S/T and WHRB.

a) Service water pump system or clarified water pump system.
b) Compressed air sytem.

Start up circulating water system-CWP-Condenser-Cooling Tower
CWP)
Startup cooling water and condensate systems.
Start up chemical injection systems.
Start up seal air fan.
Make sure that all preparations for start up have been completed.

WHRB start up

Start up HP BFP and LP BFP.
Fill up HP/LP DRUM with water up to normal water level.
Start up boiler circulating pump.
Keep WHRB inlet damper fully shut
G/T start up have been completed.
Start turning S/T
After G/T is loaded, open WHRB inlet damper upto 30% opening.

Note : *Manual operation

Start up G/T up to 30% load and hold that load.
PMI,NTPC 114
Start drain blow Opening HP steam pipe drain valve and LP steam
pipe blow valve.
When HP steam pressure reached 3kg/cm
2
x 220
0
C. Open the HP
turbine inlet pipe drain valve to start warming of HP turbine inlet
pipe.
After warming is over start gland steam supply.
Start up vacuum pump after gland steam has been established.
Open SH outlet blow valve, HP steam pipe drain valve and LP
steam pipe blow
Valve and steam is blown into the WHRB blow tank down tank and
S/T flush pipe.
At that time, opening of SH outlet blow valve and LP steam blow
valve is automatically adjusted according to HP/LP steam pressure
at start up of WHRB.
HP steam pipe drain valve is automatically adjusted according to
HP/LP steam temp. at start up of WHRB.
After vacuum has been established (550 mm Hg.), open turbine
drain valves and open HP/LP by-pass valves inlet stop valves to
put HP/LP turbine by-pass system in individual measure control
mode.
Open HP by-pass valve to start individual pressure control so that
HP steam pressure will be constant of 29kg/cm
2
g.

- When HP/LP by-pass valves are put in operation, full open WHRB
inlet damper and full close by-pass damper.

PMI,NTPC 115
- After HP/LP by-pass valves have been put in operation, shut SH
outlet blow valve, HP steam pipe drain valve and LP steam pipe
blow valve.

- After HP/LP by-pass valves have been put in operation, shut SH
outlet blow valve, LP steam pipe blow valve.

- When LP by-pass valve is put in operation, open LP steam stop
valve and LP turbine inlet pipe drain valve to start warming of LP
turbine inlet pipe.

- After warming is over, open deaerator heating steam supply valve
to start heating of deaerator. (Deaerator set pressure at 0.3
kg/cm
2
g)

At the same time, open condenser pre-heater re-circulating valve
by the specified degree (at gas firming only).

S/T Start up

Make sure that all preparations for S/T start up have been
completed.
Make sure of turbine steam admission conditions 29 kg/cm
2
g x
300
0
C (below 4300
0
C).
After steam admission conditions have been completed HP/LP
turbine inlet pipe drain valves are fully closed.
Start steam admission to turbine (DEH on).
PMI,NTPC 116
Start accelerating. Accelerate at 300 rpm/min. upto target speed of
3000 rpm. Make rub checks as necessary during acceleration.
Start up the other G/T just before steam admission is completed,
and hold it at 30% load, increase steam temperature and pressure
of the other WHRB and when HP/LP by-pass valves in operation.
Loading.
Maintain 10% initial load for 10 minutes.
After initial load operation is over, open HP/LP steam stop valve of
the other WHRB, and change pressure of the other WHRB and
when HP/LP by-pass valves in operation.
Loading.
Maintain 10% initial load for 10 minutes.
After initial load operation is over, open HP/LP steam stop valve of
the other WHRB, and change pressure control of HP/LP by pass
valves to common pressure control.

Load up

Put HPCV (governor valve) in upstream pressure control
sequentially close HP/LP by pass valves so that the S/T load up
rate will be 2.5% min. at this time, HP/LPCV automatically following
up in pressure control. As a result, steam goes to S/T.
When S/T load reaches 20% full close all turbine drain valves.
PMI,NTPC 117
When LP by pass valves is fully closed, shift LP by-pass valve to
back up mode.
When HP by pass valves is fully closed, shift HP by-pass valve to
back up mode.
After HPCV is fully opened, restore deaerator set pressure to
normal pressure of 3kg/cm
2
, and put condensate pre-heater re-
circulation control back to automatic mode. (at gas firing only)

Rapid start up mode (Hot start up)

The condition in which The HP turbine rotor temperature is above 400
0
C is
called hot condition. In a hot start up, the turbine rotor temperatures is
high enough, so the operating procedure required is to load and speed up
the turbine in a shortest possible time using high temperatures team to
minimize the mismatch temperature. Therefore hold G/T load at 40 MW at
which this condition can be satisfied, and then start up WHRB and S/T. It
is assumed that vacuum of condenser is maintained inlet condition.

Startup conditions

Turbine vacuum With vacuum

Gland steam supply conditions Gland steam being supplied from
WHRB by remaining steam
pressure.

Steam admission conditions 110t/h x 400
0
C above x 20 kg/cm
2

(15% initial load)

WHRB inlet damper initial opening 100%
PMI,NTPC 118
Steam evaporation at G/T 50% load 25t/h

SH outlet blow valve capacity 35t/h x 29 kg/cm
2


Time required for pressure rise About 10 minutes

(10-2kg/cm
2
) (at G/T 50% load)

WHRB temperature rise rate 400
0
C/hr.

S/T speed rise rate 300 rpm/min.

S/T load up rate 2.5%/min.

(Before HP by-pass valve full close)

(After HP by-pass valve full close)

Start up procedure

Preparation for start up
Startup the following common equipment which is necessary for
start up of GT, S/G and WHRB.
a) Raw water pump system clarifier, pretreatment plant and
water treatment plants.
b) Service water pump system or clarified water pump system.
c) DM water transfer pump system.
d) Comp ressed system
PMI,NTPC 119

- Start up chemical injection system.
- Start up seal air fan.
- Make sure that all preparations for start up have been completed.

WHRB startup
- Start up HP BFP and LP BFP
- Start up boiler circulating pump
- Make sure the by-pass damper is full open and WHRB inlet damper
is full shut.
- Start up G/T After all preparations for G/T start up have been
completed.
- Make sure of S/T turning.
- Open HP main steam stop valve and establish vacuum, supplying
vacuum gland steam by remaining steam pressure of WHRB.
- After G/T is loaded, open WHRB inlet damper upto 100% opening.
Note : * Manual Operation
- Start up G/T up to 40% load and hold that load.
- At boiler start up fully open LP main steam stop valve and HP/LP
by-pass stop valves in operation automatically by individual
pressure control.
PMI,NTPC 120
- At that time, opening of SH outlet blow valve and LP steam blow
valve is automatically adjusted according to HP steam pressure at
start up of WHRB.
- Hp steam pipe drain valve main automatically adjusted according to
HP steam temperature at start up of WHRB.
- Open HP by-pass valve to start individual pressure control so that
HP steam pressure will be constant of 2kg/cm
2
.
- Open LP by-pass valve to start individual pressure control so that
HP steam pressure will be constant of 5kg/cm
2
.
- When HP/LP by-pass valves are put in operation, fully close by-
pass damper.
- Open the turbine drain valve.
S/T start up
- Make sure that all preparations for S/T start up have been
completed.
- Make sure of turbine steam admission conditions 2 kg/cm
2
x 400
0
C
above.
- After steam admission conditions have completed HP/LP turbine
inlet pipe drain valves are fully closed.
- Start steam admission in turbine.
- Start accelerating. Accelerate at 300 rpm/min. upto target speed of
3000 rpm.
- Check that preparations of generator have been completed.
- Loading.
PMI,NTPC 121
- Maintain 15% initial load.
- After initial operation is over, full shut turbine drain valves.

Load up
Put HPCV and LPCV (governor valve) in upstream pressure control
and sequentially close HP/LP by-pass valves of both WHRBS that
the S/T load up rate will be SH/min. At this time HP/LP by-pass
valves automatically following up in pressure control.
As a result steam goes to S/T.
When HP by pass valve is full shut, shift HP by-pass valve to
backup mode.
When LP by pass valve is fully closed, shift LP by-pass valve to
backup mode.
When HP/LP by-pass valves are fully closed, adjust G/T output to
achieve target plant output.
At this time, G/T load up rate will be 3.6% min.

G/T, WHRB additionally start up mode

While the plant is in partial load operation, the number of G/Ts in operation is
changed in some cases to increase efficiency of plant operation. When
starting up G/T and WHRB in such case, the start up procedure must be such
that minimize the temperature difference between high pressure steam of the
plant in operation and high pressure steam in G/T and WHRB to be started
up.


PMI,NTPC 122
Start up conditions

- Conditions of G/T and WHRB in operation

1. G/T load 100%
2. WHRB steam condition ..29kg/cm
2
x 495
0
C
3. S/T load .. about 40t

- Condition of WHRB to be started up Cold condition.

Startup procedure

WHRB startup

- Startup HP BFP and LP BFP.
- Startup boiler circulating pump.
- Make sure that by-pass damper is full open and WHRB inlet
damper is full shut.
- Startup G/T after all preparations for G/T startup has been
completed.
- Open HP/LP drum air vent valves and SH outlet air vent valve.
- When WHRB inlet damper is open automatically open HP steam
pipe drain valve LP steam pipe blow valve.
- After G/ is loaded, open WHRB inlet damper up to full opening.
- G/T is 40% load hold on.
PMI,NTPC 123
- When HP steam pressure reaches 2kg/cm2g, automatically close
HP/LP drum air vent valves, and SH outlet air vent valve.
- Until HP/LP by-pass valves are put n operation, open SH outlet
blow valve, HP steam pipe drain valve and LP steam pipe blow
valve, and steam is blown not the WHRB blow down tank and ST
flush pipe
- At that time, opening of SH outlet blow valve and LP steam blow
valve is automatically adjusted according to HP/LP steam pressure
at startup of WHRB.
- After HP steam temperature reaches above 400
0
C, open HP/LP by-
pass valve inlet stop valves to put HP/LP turbine by-pass system in
individual pressure control mode.
- Open HP by-pass valve to start individual pressure control so that
HP steam pressure will be constant at 27kg/cm
2
.
- Open LP by-pass valve to start individual pressure control so that
LP steam pressure will be constant of 4.5kg/cm
2
.
- When LP/HP by-pass valves are put in operation, fully close by-
pass damper.
- After HP/LP by-pass valves have been put in operation, shut SH
outlet flow valve,
- HP steam pipe drain valve and LP steam pipe blow valve.
- When HP by-pass valve is put in operation, equalize pressure and
temperatures of both WHRBs, open the HP steam stop valve.
- When LP by-pass valve is put in operation, equalize pressure of
both WHRBs and open LP steam stop valve.
PMI,NTPC 124
Load up

Put LPCV (Governor valve) in upstream pressure control and
sequentially close LP by-pass valve so that S/T load up rate will
be 2.5% min.
When by-pass valve is fully closed, shift LP by-pass vale to
backup made.
Put HPCV (governor valve) in upstream pressure control and
sequentially close HP by-pass valve so that the S/T load up rate
will be 2.5% min.
When HP by-pass valve is fully closed, shift HP by-pass valve to
backup mode.
When HP/LP by-pass valves are fully closed, adjust G/T output
to achieve target plant output.

WHRB SHUTDOWN PROCEDURE

Normal shut down mode

Normal shutdown is mode used as planned shut down of both WHRBs. In
this steam turbine has to the taken out first since we have to shutdown
both WHRBs. The following steps are adopted in WHRB shut down.

- Start reducing GTs loads at the of 3.8% min.
- Maintain GT load such that the HP steam tem. Is 480
0
C.
- Put HP/LP turbine by-pass of both WHRBs in individual mode.
PMI,NTPC 125
- Bring down S/T load to 15% by opening the HP/LP by pass valve of
both WHRBs
- Take LP steam of both WHRBs in out of service.
- Open steam turbine breaker and strip S/T manually.
- Open the by-pass damper of both GTs.
- When ST speed is less than 400 RPM. Close WHRB inlet damper
of both WHRBs.
- Close the HP and LP Turbine by-pass stop valves of both WHRBs
after closing of the by-pass control valves.
- Break condenser vacuum when condenser vacuum is less than-
100 mm Hg.
- When the HP/LP drum pressure become less than2kg/cm
2
open
HP/LP drum air vents.
- Stop one each CWP, LP & HP BFP.
- Confirm that HP & LP economizer recalculation valve are opened
and condenser preheater is by-passed.
PMI,NTPC 126
UNIT I UNIT-II

GT LOAD DOWN START GT LOAD DOWN START
H P STEAM TEMP. HP STEMA TEMP.
480
0
C 480
0
C
HOLD GT LOAD HP HOLD GT LOAD
HP/LP TB BYPASS HP/LP TB BYPASS
INDV. MODE INDV. MODE
LP STEAM OUT OF SERVICE HP STEAM OUT OF SERVICE

DEA HEATING STEAM VALVE DEA HEATING STEAM VALVE CLOSED
CLOSED
ST MAIN BRKAR OPEN
AND ST TRIP

GT BYPASS DAMPER OPEN GT BY PASS DAMPER OPEN
ST SPEED ^400RPM

WHRB INLET DAMPER CLOSE WHRB INLET DAMPER CLOSE

HP/LP TURBINE BYPASS CLOSE HP/LP TURBINE BYPASS VALVE
CLOSE

CONDENSER VACUUM
BREAK COND. VACCUUM
<-100 mm of hg
Gland steam Group off

HP STOP V/V CLOSE HP STOP V/V CLOSE
HP DRUM PR.<2kg/cm
2
HP DRUM PR <2kg/cm
2
open
open HP drum air vents HP drum air vent
LP DRUM PR <2 kg/cm
2
open LP DRUM PR Less then <2 kg/cm
2
LP drum air vent LP drum air vents
STOP ONE CWP ONE LP7 HP BFP
PMI,NTPC 127
WHRB out off shut down

In this shut down only WHRB is taken out of service. ST will be in service
with second WHRB. Corresponding GT may be stopped as per the
situations.

The following steps are adopted in the shutdown.

Reduce the GT load 30% of the corresponding WHRB which is to be taken
out of service.
- Change HP and LP by-pass to individual mode.
- Change LP turbine by-pass to main and open gradually (ST load
down rate should be 2.5% min.
- When LP boiler pressure, PB is less than LP turbine inlet pressure,
close LP steam stop valve.
- Change LP turbine bypass to individual mode.
- Change HP turbine bypass to manual. Open gradually, ST load
down rate 2.5%/min.
- PB less than PT is when the shutdown boiler HP stream pressure is
less than the turbine inlet HP steam pressure close HP stop valves.
- Change HP turbine bypass to individual mode.
- Open GT bypass damper.
- After stabilizing HP/LP drum level close WHRB inlet damper.
- GT shut down as per the situations.

PMI,NTPC 128
CONFIRM HP CV CONFIRM LP CV
SET 29 KG/CM
2
SET IN 5 KG/CM
2


SHUT DOWN SIDE WHRB GT LOAD=30%
CHANGE HP TB CHANGE LP TB
BYPASS TO IND. MODE BYPASS INDV. MODE

CHANGE LP BYPASS LOAD
DOWN (ST) TO MANUAL & GRADUAL RATE
2.5 min. OPEN

PB< PT PB: BOILER PRESSURE
PT TB: INLET PRESSURE

LP STEAM STOP VALVE

CHANGE HP TB BYPASS INDIVIDUAL>MODE

CHANGE HP TB BYPASS TO MANUAL ST load down rate
AND GRADUALLY OPEN 2.5%/min.
PB<PT PB BOILER PR PT TB INLET PR>

HP STEAM STOP VALVE CLOSE
CHANGE HP TB BYPASS IND MODE
GT BYPASS DAMPER OPEN

STABILISE HP/LP DRUM LEVEL

WHRB INLET DAMPER CLOSE

GT SHUTDOWN IF REQUIRED
PMI,NTPC 129

MALFUNCTION AND REMEDIES

ABNORMALITY CAUSES REMEDY
a. Malfunctioning of level
controller
1. Change over the level
Controller into manual
Mode and drop the water
Level.
b. Sudden increase in
load
2. Re adjustable of the level
Controller.
1. High Drum Level
LP or HP drum
3. Closed the corresponding
HP/LP Stop valve if both
WHRBs are in service to
avoid tripping of ST while
avoid carry over of water
to steam turbine.
a. Malfunctioning of drum
level controller
1. Change over the level
Controller into manual
Mode and normalise the
drum level
b. Trouble of feed water
pump
2. Start the standby feed
water pump
c. In sufficient quantity of
feed water
d. Boiler tube leakage
2. Drop in drum
level (LP drum or
HP drum)
e. Sudden decrease of
load
3. Re adjustable of level
controller


a. Too much of exhaust
gas
flow
1. Investigate the gas turbine

b. Too high temp. of feed
water
2. Reduce the temp. of feed
water
3. Too high temp. of
flue gas
c. Fouling of heating
surface


PMI,NTPC 130
SHUT DOWN PRODECURE

- Except in an emergency shut-down, load must be reduced gradually.

- At approximately 15% of rated load, open all turbine drains.

- When all load been removed, shut-down the unit by tripping either
manually or remotely.

This closes all the turbine HP steam and LP steam valves and
disconnects the generator from the line.
- Make sure that the auxiliary oil pumps starts when the bearing oil pressure
drops below 0.85+0.05 kg/cm
2
.
- Refer to the generator instruction book for information on the water
supplied to the hydrogen coolers.
- In order that the turning gear will be remotely engaged, be sure that the
rotor speed is below the turning speed before the control switch is turned
to the START position. This will also supply oil to the turning gear.
- Shut-down the auxiliary oil pump and make sure that the turning gear oil
pump starts when the bearing oil pressure drops below 0.75+0.05 kg/cm
2
.
- Open the vacuum breaker when the turbine speed reaches about 400
rpm. Shut down the air removal equipment.
- When the vacuum has reached zero shut-off sealing steam from the HP
steam header to the gland steam control value and shut down the gland
steam condenser exhauster.
- Shut - down the condensate pumps.
- Shut - down the circulating water pumps.
PMI,NTPC 131
- Regulate water to the oil cooler to maintain the temp. of the oil leaving
the coolers between 35
0
C and 38
0
C, if possible.

Loss of Electrical Load to the System

In the event of a complete or partial loss of electrical load, the following
procedure should be noted:

- Since the governor is in such a position that the no load speed is higher
than 3,000 rpm, the speed will rise will suddenly at a rate proportional to
the electrical load lost.

- This sudden speed rise will cause the acceleration response feature of the
governor momentarily to assume control of the turbine, and close the both
HP and LP control valves rapidly.

- With the both LP and HP control valves closed, the speed of the unit will
decrease at a rate depending on the residual load left on the gtenerator.

- If desired, the unit may now be resynchronized. If it is decided not to put
the unit back on the line, the normal shut down procedure outlined
above should be followed.

- If the cause of the load dump cannot be determined, resulting in a delay in
resynchronizing, the unit should be tripped automatically after a specified
time, the shut down procedure described below under Loss of Pressure
or Temperature should then be followed.


PMI,NTPC 132
Loss of Pressure or Temperature

If the initial pressure regulating system is cut out or inoperative the following
procedure will apply:

- The operator will begin to reduce load in an attempt to maintain pressure
above 80% of normal or temperature drop to not more than 83
0
C.

- If the pressure falls below 80% of normal or temperature drops 83
0
C,
reduce the load and trip the unit.

- Place unit on turning gear, note power input to turning gear motor and
listen for rubs. If everything is normal, follow standard starting procedure
to bring unit up to speed and synchronize.

- For the case where the pressure can be held above 80% of normal and
temperature to less than 83
0
C drop, bring the unit up in normal manner
after temperature and pressure have been restored to normal.

- If the unit trips from a known cause resulting from testing, etc. or if the
vacuum is lost, let the unit come to rest and place on turning gear.

- Check the rotor for truth. If everything is normal follow Normal Starting
Procedure.

- Where vacuum and speed can be held, reset overspeed trips and proceed
with synchronizing the unit.

- For the case where vacuum is lost and the low vacuum trip mechanism
trips the load and unit, let the unit come to rest and place on turning gear.

PMI,NTPC 133
- Clear vacuum trouble and follow Normal Starting Procedure.

Protective Devices Function

- This unit is equipped with protective devices, which trip the unit in the
event of low vacuum. Low bearing oil pressure and axial shift.
- In addition, the unit can be tripped, either with the trip solenoid or with
hand trip lever.
- The situation can also arise where by the unit is inadvertently tripped in
the process of testing the protective devices if the overspeed trip test lever
is released prematurely.
- In the event the unit is tripped as noted in above and the trouble has been
recognized, cleared and the vacuum maintained, relatch the unit and
proceed to synchronize.
- If in the even of a trip and the vacuum is lost let the unit come to rest,
following the normal shut-down sequence. After the trouble is corrected,
restart the unit in accordance with the normal starting sequence.

Shut Down of Steam Turbine
CHECK

ST OIL GROUP
GROUP GROUP ON
ST TURNING GROUP
GROUP GROUP ON
ST DRAIN GROUP
GROUP GROUP ON
CONDENSATE PRE HEATER IN AUTO HP 2
nd

PMI,NTPC 134
Economizer and LP economiser Recirculation valve
on auto.

1
st
GT 2
nd
GT
GT Load Down from UCD or UCP DT Load Down form UCD or UCP
If GT Load = 50% If GT Load = 50%
Take HP TB PC coned. Take HP TB PC coned
INDIVID INDIVID
Take HT TB PC coned. Take HP TB PC coned
INDIVID INDIVID

Check GT & ST should not be in APR

Decrease HPNTB P/C set Decrease HP TB P/C SV to 10
Valve to 10kg/cm
2
/(g) kg/cm2 (g) gradually at the rate of
gradually at the rate of let1.5 kb/cm
2
min.
1.5 kg/cm
2
min

Decrease LP RB P/C SV to 2kg/cm2 Decrease LP RB P/C SV to 2kg/cm
2


If LPTB bypass open=50%

Class LPSSV, IV Close LPSSV IV check LP check
Check LP steam inlet D/V; IV open LP steam inlet D/V; IV open

Continue GT Load decrease in unit mode or UCP up to 20% to 30%
ST load 15% open generator, breaker from UCB
HAND TRIP ST from UCP
Check (i) HPCV close, HPSV close
(ii) HPCV close, HPSV close
(iii) Turbine Drains open
PMI,NTPC 135
OPEN GT BYP ASS DAMPER OPEN GY BYP ASS DAMPER
HP and LP drum level will go
down. Increase SV to + 50mm as
after 10 min closing the inlet
damper the drum Level will min.
and go further down.

CLOSE WHRB INLET DAMPER GO FOR GT ETOP CLOSE
WHRB INLET DAMPER
As gland steam will bead be
available for 15 to 20 min

Close HP TB bypass, I/V Close HP TB bypass, I/V
Close HP TB bypass, I/V Close HP TB bypass, I/V

If ST SPEED 400 RPM

Condenser Vacuum Group see (i) condenser vacuum pump stop
OFF (ii) Vacuum breaker open

If condenser vacuum 100 of Hg
Gland steam Group Off See (i) Gland steam condenser
Exhaust fan stop
(ii) Gland steam supply close

- Close deaerator Heating steam supply Close HP SSV
- See turning motor run and turning gear engaged. (Check at local also)
- Check condensate PH bypass B/P value open and inlet close.
- HP and LP economizer re-circulation value open.
- START TOP and STOP AOP
PMI,NTPC 136
- Keep only one see each of the following auxiliaries, and stop if more than
one running.

i) Circulating water pump CWP For one module
ii) HPO Boiler feed pump HPBSAP One set
iii) LP Boiler feed pump LP BFP One set
iv) Condensate extraction pump CEP One set

Some Important Alarm/Trip Set Value

Bearing Vibration Hi HI 125 (P-P) Alarm

Bearing oil pressure low, 0.75+0.05 kg/cm
2

Alarm low, 0.52 kg/cm
2
Trip

Turbine speed High, 3240 RPM alarm HI HI,
3330 RPM Trip

Condenser vacuum low, 635 mm Hg Alarm Low,
550 mm Hg Trip

Axial shift Trip 5.6 kg/cm

2

GT No load trip: if generator breaker of Both GT ( of the Module of which
ST is opened then ST of that module will trip on GT NO LOAD TRIP

HP main steam pressure high > 70 kg/cm
2

HP Main steam Temperature High > 525
0
C
HP main steam Temperature low < 150
0
C
HP exhaust Temperature High < 175
0
C

PMI,NTPC 137
LP main steam pressure high > 7 kg/cm
2

LP Main steam Temperature High > 175
0
C
LP main steam Temperature low < 150
0
C
LP exhaust Temperature High > 80
0
C

Condenser Hot well level abnormal
Low NWL 150mm
High NWL +150 mm
ST Parameters
ST Eccentricity High 0.0750mm
Axial Shift Low 1.100mm 2.10+2.0kg/cm
2

High +0.700mm

HP Differential expansion
Low Low -2.30mm
Low -1.70mm
High +4.70mm
High High +5.70mm

LP Differential expansion Low Low -2.30mm
Low +2.90mm
High +5.10mm
High High +5.90mm

HP TB by pass spray water pressure low 9kg/cm
2

- HP bypass valve outlet temperature High 190
0
C
- HP steam to condenser temperature High 200
0
C

Thrust bearing temperature high 99
0
C
- Bearing temperature High 107
0
C

PMI,NTPC 138
- Lubricating Oil temperature High 50
0
C
- HP Oil pressure low 16kg/cm
2

- Main oil tank level low FL +2165mm

Deaerator level Low NWL 300mm
- Low Low NWL 60mm
- High WL+300mm
- Deaerator pressure High 3.2kg/cm
2

- Condensate flow low 100t/hr

Oil pump auto start :
- Auxiliary oil pump auto start 0.85kg/cm
2

- Bearing oil pressure low alarm 0.75kg/cm
2

- Turing oil pump auto start 0.75kg/cm
2

- DC Emergency oil pump auto start 0.52kg/cm
2

- Bearing oil pressure Low Low Trip 0.52kg/cm
2


ST Run Back

Run Back on ST will operate automatically if ST load > 50% and its load will
come down to 45% in the following cases.

i) Out of the 2 running CEP one trips and 3
rd
one does not starts on auto.
ii) Out of the 2 running HP BFP one trips and 3
rd
one does not starts on
Auto.
iii) Out of the 2 running LP BFP one trips and 3d one does not starts on Auto.
iv) STG transformer winding temperature High


PMI,NTPC 139
Soaking Time in Warm Start (in minutes (M.T.)

S = 5 + 8T = 9M} {P {3 x 2 + 14}
50 200

Where T = steam inlet temperature in
0
C
M = 1
st
stage metal temperature in
0
C
P = Intel steam pressure in kg/cm
2


For conservative time estimation last term can be neglected which is negative
(and negligible)

S = 5 + 8T = 9 M Minuets
50

Exhaust Hood Spray

This spray will start if exhaust hood temp. 70
0
C
This will close when turbine load 15% and exhaust hood temp 70
0
C
Exhaust hood temp. high alarm at 80
0
C

Curtain spray

Certain spray will start when CEP is running and any of HP & LP. TB By pass
valve i/v and control valve open.

It will close when HP & LP by pass control valve close

System Alarm/Trips

The following alarm./trips are provided to safe guard the operation of steam
turbine.
PMI,NTPC 140
Main oil tank level high FL + 2565 mm
Main oil tank level low FL + 2165 mm
Thrust bearing wear alarm 2.10+0.2kg/cm
2

Thrust bearing wear trip 5.3-5.6kg/cm
Bearing oil pressure low alarm 0.75+0.05 (bearing oil) kg/cm
2

Bearing oil pressure low trip 0.52 kg/cm
2

Turning oil pump auto start 0.75+0.05 (bearing oil) kg/cm
2

Emergency oil pump auto start 0.65+kg/cm
2

HP oil pressure low alarm 18.0 kg/cm
2

Aux. oil pump auto start 0.85+0.05 (bearing oil) kg/cm
2

Oil cooler outlet oil temp. high 50
0
C at 900 rpm to rated
40
0
C turning to 900 rpm
Axial shift alarm at 2.1+0.2kg/cm
2
(trip control oil)
Turbine trip indication 3.0+0.2kg/cm
2
(auto control oil)
Turbine reset indication 6.0+0.2 (auto stop oil)
Turbine trip test indication on 3.0+0.2kg/cm
2
(at trip test)
Turing gear interlock 0.3kg/cm
2
(bearing oil)
Journal bearing metal temp alarm 107
o
C
journal bearing metal trip 113
o
C
thrust bearing metal alarm 99
o
C
thrust bearing metal trip 107
o
C
bearing oil drain tem alarm 77
o
C

Main oil transfer pump takes suction from bottom of main oil tank and transfers
the oil to the dirty oil storage tank. From dirty oil storage tank the dirty oil is fed to
plant oil purifier and after purification oil is stored in clean oil storage tank. From
clean oil storage tank the oil is transferred back to main oil tank by clean oil
transfer pump.

Main oil transfer pump, plant oil purifier, dirty oil storage tank clean oil storage
tank and clean oil transfer pump are common for both modules.
PMI,NTPC 141
Turbine Gear Operation During Shut-Down

In order to facilitate starting, the turning gear should be in operation and should
preferably have been in operation through-out the shut-down period

Even after the turbine is comparatively cool, this offers minimum time lost in
starting and an assurance of safety in the even of any leakage of steam in to the
turbine during the shut-down period.

When it can be arranged without delaying work schedules, the turning gear and
the oil circulation system should be kept in operation for not less then 48hours
after shut-down.

In the event that continuous rolling during shut-down is not practical, the turning
gear should be started again at least an hour before rolling the turbine with
steam. It should remain in operation sufficient length of time be fore admitting
steam to the turbine to allow the rotor to become straight with in the limits noted
in the section on Limit son operation.

Recognizing that tha preceding schedule may not be practical in case repairs or
adjustments are to be made to the turbine, the following schedules are
recommended as the absolute minimum periods considered satisfactory under
various circumstances.

The turbine is to be dismantled.

The turning gear should be kept in operation until the dismantling
programme requires that it should be stopped.


PMI,NTPC 142
If an emergency necessities it, the turning gear may be shut down
immediately. However, it must be recognized that this may subject the
rotor to a severe bow. It must not be used for continuous rolling unless
the bearing lubrication system is operating.

Bearing oil circulation must be maintained after shut down to protect the
bearing against overheating.

The minimum circulation period should be 24 hours after shut-down.
During this period oil temperature leaving the coolers should be held
below 35
o
C. If possible

Shut down of extensive repair or adjustment

Both the turning and bearing oil circulation systems are to be kept in
operation for a minimum of 12 hours; oil temperature from the cooler
should be maintained below 35
o
C. if possible.

Both the turning gear and the oil circulation may then be shutdown. If
operation of the unit is to be resumed before the turbine is thoroughly
cooled, the turning gear should be started 3-4 hours before rolling the
unit with steam.

Shut-down for minor repair or adjustment

Depending upon the nature of the work to be done, the following shedule
may be adopted.

Keep the turning gear and the oil circulation systems in operation for a
minimum of 3 hours. Both systems may then be shut off for a period of
PMI,NTPC 143
not more than 15 minutes; if practical, however, oil circulations should be
maintained.

Immediately thereafter roll the turbine on turning gear for at least 2
hours. Both turning gear and oil circulation may then be stopped for not
over 30 minutes; however. 15 minutes after stopping, the rotor is to be
turned 180
o
with the gear.

This 180
o
turn may be made without oil circulation, if avoidable.

Following the 30 minute shut down period as above, the turbine should
again be rolled on turning gear with oil circulation for a minimum of 2
hours.

The system may then be shut down indefinitely, provided that at 30
minute intervals for the next 6 hours the rotor is turned 180
o
Deg. Turns
may again be made without oil circulation if necessary.

In any case, if the turning gear has been disengaged, it should be put in
operation a sufficient time before admitting steam to the unit to allow the
rotor to become straight within a limit of approximately 0.025mm on the
truth indicators or within a limit of approximately 0.05mm on the
eccentricity recorder indications.

System Alarms

The following alarms and shutdown point are provided for gas turbine protection.

- Hand trip - Alarm/Shutdown
- Fire - Alarm/Shutdown
- Lube oil Pressure Low - Alarm
PMI,NTPC 144
- Lube oil Temperature High - Alarm
- Lube oil tank level Abnormal - Alarm/shutdown
- Inlet Air Filter Abnormal - Alarm
- Vibration high - Alarm
- Vibration high - Alarm/shutdown
- Exhaust gas temperature - Alarm/Shutdown
- Gas Pressure Supply Pressure Low - Alarm/Shutdown
- Liquid fuel Main Pump Trip - Alarm/Shut down
- Gas Leakage - Alarm
- Liquid Fuel Drain Tank Level Hi - Alarm
- Over speed - Alarm/Shut down
- Exhaust Gas Pressure Hi - Alarm
- Exhaust Gas Pressure Hi - Alarm/Shut down
- Flame Out - Alarm/Shut down
- Flame Detector Abnormal - Alarm
- Blade Path Temperature Spread Hi - Alarm
- Disc Cavity Temperature Hi - Alarm
- Turning Gear Trouble - Alarm
- Bleed Value Abnormal - Alarm/Shut down
- Acceleration Rates Insufficient - Alarm/Shut down
- Auxiliary Motor Abnormal - Alarm
- SW Position Wrong - Alarm
- Inst. Air Pressure Low - Alarm
- Electrical Fault - Alarm/Shut down

Emergency Operation

The Gas Turbine System can be operated in an emergency during the following
conditions:

- Operation of the turbine with a control or lube oil system leak.
PMI,NTPC 145
- Immediately tighten nuts, bolts or fasteners, if leak cannot be stopped the
gas turbine must be shut down and repairs made.

- Operation with a turbine with a fuel leak.

- If a fuel leak occurs prompt action must to taken to contain and repair the
leak. If the leak cannot be controlled the gas turbine must be shut down.

- Operation of a gas turbine with abnormal vibration.

- Many factors affect vibration, the cause of any abnormal vibration must be
found and corrected. Unsteady blade path temperature, high bearing
temperatures, turbine rotor rubbing against the turbine casing, speed and
load will all directly or indirectly affect the amount of vibration.

- Alarm and trip devices will shut down the unit if vibration exceed 0.200
mm (Peak to Peak).

- Operation of a turbine during compressor surging.

- If the gas turbine speed exceed its specified low frequency operating
range, compressor surging can occur. If surging occurs the unit must be
shut down immediately and inspected for damage.

- Operation of a gas turbine in a under frequency condition.

- If the unit is to run in under frequency mode particular attention should be
paid to turbine blade resonance and compressor surging. If the turbine
compressor enters a surge condition it must be tripped immediately.


PMI,NTPC 146

Turbine blade resonance is produced by blade conditions above or below the
blades normal operating frequency range. Turbine blade resonance is a main
concern of low frequency operation. When operating below Hz the unit must be
monitored for abnormal noise and vibration. If unit frequency falls below 47.5 Hz
for more than 15 seconds or falls below 47.0 Hz it will automatically trip.

System Trouble Shooting

Dependable, economic operation over long periods of time is only possible if the
equipment is maintained and operated according to the manufacturers
instructions. If problems develop, they should be traced and corrected as soon as
possible.

The following is a list of potential problems, possible causes and suggested
checks to be performed by the plant equipment operator.

Potential Problem - Gas turbine starting motor will not start when
GTSTART push button is depressed.

Possible Causes - Unit auxiliaries not running, starting motor circuit not
operating Properly.

Operator Action - check all switch positions at unit auxiliary motor
control centers, check starting motors breaker for
standing switch gear alarms at breaker.

Potential Problem - Gas turbine trips at ignition and light off sequence.

Possible Causes - Fuel On FLM2,FLM3 out of control sequence,
CSO and main fuel oil pump discharge pressures are
PMI,NTPC 147
out of adjustment (liquid fuel firing only), blade path
temperatures during light off abnormal.

Operator Action - Check Fuel ON FLM2 and FLM3 lamp sequence
and compare to previous operation, check for any
extreme difference between FLM2 and FLM3 lamp
sequence, check CSO and main pump discharge
pressure, check blade path temperature
spread.

Abnormal Operation

The response characteristics of turbine-generator units and their auxiliaries to
power system emergencies and the procedures to follow during such periods are
of particular interest to the operating utility.

In general, question may arise concerning the following:

- Low-frequency operation
- Maintaining low auxiliary load on the unit
- Steam turbine motoring

Low Frequency Operation

Limits for operating frequency and time at frequency are given for the protection
of the turbine and generator during under-frequency over-frequency operation.

For the turbine prevention of resonant operation of the tuned blades is the major
consideration. Operating limits have been developed form engineering analysis
coupled with laboratory testing and extensive field telemetry testing.

PMI,NTPC 148
Time limits are based on fatigue life consideration and have been apportioned to
the more prevalent under-frequency operating mode. For specific blading styles,
more conservative off-frequency operation limits have been imposed than
previously published. Generator operating limitations are also presented which
must be observed during off-frequency situations in order to prevent undesirable
thermal excursions of generator components.

The primary consideration in operation of a steam turbine under load at other
than the synchronous frequency is the protection of the long tuned blading in the
low pressure (L.P) turbine element.

In the design and design verification process, great care is taken to properly tune
the tapered and twisted blades that constitute the last several stages in the L.P.
turbine element.

Operation of these stages under load, at a speed that causes a coincidence of
blading natural frequency in a lower mode and multiple of the actual turbine
running speed frequency, will lead to blading fatigue damage and ultimately
blading failures.

Auxiliary Load Operation

Most turbine generator units are designed to withstand complete isolation from
the system and remain in service at no load or at an auxiliary load level.

However, it should be recognized that some of the larger plants now in operation,
and under construction, have plant control interlocks which automatically trip the
complete plant in the event of load separation.

PMI,NTPC 149
The transient stress in the turbine rotor is a factor to be considered when
suddenly dropping from full power out to auxiliary load and the subsequent
rapid application of load after the connection to the system is reestablished.

The immediate affect is an instantaneous drop in first stage temperature of
about 120 degree c.

This drop in stage temperature produces a peakstress in 10to 15 minutes
after initiation of the transient which decays slowly to zero in about one
hour, if auxiliary load is maintained for an hour or more, the rotor is force-
cooled to new equilibrium state.

The subsequent reloading should then be performed at a moderate rate in
order to avoid a large thermal stress in the opposite direction. To minimize
the accumulation of rotor fatigue damage, it is recommended that auxiliary
load operation following an electrical out occur only when the system
conditions make it absolutely necessary.

Steam turbine motoring

Motoring occurs when the steam supply to the turbine is shout while the
generator is still On the line.

Since there is no steam energy available to supply the turbine-generator
losses, the generator will act as a synchronous motor and drive the turbine.

Although this condition is generally defined as generator motoring, the
protection is not for the generator, but to prevent overheating low pressure
turbine or high pressure turbine blade. Monitoring can caused by closing steam
valves without taking the unit off the line. This can be done by.

PMI,NTPC 150
- Closing all governor valves during shut- down operation.

- Tripping the turbine while not tripping the generator breaker.

Our general policy in connection with motoring of a turbine generator unit is as
follows:

- Closing all governor valves during shut-down operation.

- Tripping the turbine while not tripping the generator breaker.

- Operation with high density steam entrapped within a high pressure
casing may result in a rapid temperature rise of the steam and internal
turbine parts.

- A turbine- generator unit should not be motored for any extended period
without ventilating steam being admitted to all turbine elements.

- It is recommended that such operation be limited to not less than one
minute.

- It is recommended that the opening of the generator circuit breakers for
the purpose of avoiding or limiting a motoring condition be controlled by
the closing of the main valves.

Interlock for turbine motoring is installed to protect turbines from the damaging
effects caused by motoring and lack of ventilating system.

PMI,NTPC 151
Emergency Operations

Black out (Grid Failure)

Main Control Broad is connected to the grid with two 200 KV lines terminating
220KV and two 400 KV lines terminating at 400 KV. At Main Control Broad
the interconnection between 220 KV and 400 KV Buses is through two ICTs
each of 325 MVA capacity.

Black out condition may occur when all the four lines trip or there is failure of
supply at both 220 KVS/S and 400 KV S/S. In case both 220 KV lines trip
and 220 KV side breakers of ICTs also get opened then a circuit called
House Load Circuit gets triggered. This will cause tripping of both STs and
desynchronization of all the GTs except one reselected GT which will supply
House Load of Gas Plant. In all other conditions units at Gas Plant will trip on
high frequency or low frequency (Grid sinking).

In case of total power supply failure Gas Plant provision has been made of
Emergency Gas Turbine (EGT) to run essential auxiliaries and to start one
Gas Turbine. One Emergency D.G.Set has also been provided to keep the
units on turning gear in case of non-availability of EGT.

Following operation shall be carried out in the condition of black out (i.c.,when all
the efforts to save one of the GTs for House Load have failed ):-

- Ensure that DC Lub. Oil pumps and DC Seal Oil Pumps have started in
auto, if not start manually.

- Ensure the starting of EGT in Auto/ Manual.

PMI,NTPC 152
- Charge Station 6.6 KV SW/GR (one bus only) from EGT and charge
auxiliary transformers one by one. Put on sufficient lights

- Start cooling Water Circulating Pumps (110 KW) for GTs and then one
IAC.

- Ensure starting of AC Lub. Oil pumps of GTs and TG Oil Pumps of STs.
Then stop DCLub. Oil Pumps. Start AC Seal Oil Pumps of all the units and
then stop DC Seal Oil Pumps.

- Ensure starting of turning gear of all the units.

- In case EGT is not available then Emergency D.G. Set shall be started.
Other restorations are to be done only after power Supply is made
available from the grid. IOCC and 220 KV S/S shall be contacted for
restoration of grid supply, so that start up power can be made available to
the Gas Plant.

- Start Raw Water Pumps and Clarified Water Pumps.

- Start6 on PAC.

- Line up one of the Gas Turbines for start up.

- Start the selected Gas Turbine and keeping both 220 KV lines and ICTs
out of service charge one 220 KV Bus (In case Grid supply has not been
restored till that time).

- Take one Station Transformer into service (which can feed to the other
dead 6.6 KV Bus)and transfer station auxiliaries load to this transformer.

PMI,NTPC 153
Following shall be attempted only if Grid Supply has not been normalized.

- After getting a load of 7 MW on gas turbine, by starting station auxiliaries,
one of the 220 KV lines shall be charged from Gas Plant end with proper
communication to 220 KV S/S and they shall be advised to load the line at
the rate of 5 MW/minute.

- Start one more gas turbine and keep it ready for synchronization. This
units can also be brought on bar if the previously running gas turbine has
crossed a load of 20 MW. Then further load can be increased at the rate
of 10 MW/minute.

- After the grid condition are normalised EGS can be stopped. Get the other
220 KV line charged from the grid end and synchronize at Plant end.
Similarly synchronize the 400 KV lines, Bring the combined cycle into
service.

Tripping of one of the 220 KV lines(Station Load full)

Normally when both the 220/400 KV ICTs are available, tripping of the 220KV
lines shall not pose much problem. However it shall be ensured that the other
220 KV lines and ICTs are not getting overloaded. To reduce the station load one
of the gas turbines can be desynchronized temporarily. If the overloading is
minor, then station load can be reduced slowly.

In case only one ICT is in service then changes of overloading 220 KV lines/ICT
are high and one or two gas turbines can be desynchronized temporarily,
depending on the amount of overload, to control the station the station load.

After ascertaining the healthiness of the line units can be normalized.

PMI,NTPC 154
Tripping of both 220 KV lines (Station Load Full)

Normally when both ICTs are available tripping of both 220 KV lines will overload
the ICTs slightly. The amount of overloading will depend on the reactive power
flow through ICTs. Depending on requirement, one of the gas turbines can be
desynchronized temporarily or the load on all the units can be reduced gradually
to a safe level. However , if only one ICTs is available at the time of tripping of
both the 220 KV lines, immediately two GTs shall be desynchronized, load on
remaining GTs shall be reduced and load on STs shall be reduced by operating
HP/LP bypass valves. If fast action is taken ICT will also trip on over load causing
House Load Circuit triggering. Another course of action can be, opening of 220
KV Bus coupler breaker. This action may however trip the units connected to the
bus, where 220 KV lines were connected earlier.

After ascertaining the healthiness of the line units can be normalized.

Tripping of one of the ICT s {Station Load full}

Same action as in above point no. 2 will have to be taken depending on the
loading of remaining ICT and 220 K V LINES.

Tripping of both ICT s {Station load full}

Same action as above will have to be taken to avoid overloading of the 220 K V
lines.

High Frequency Operation

At a Frequency of 51.2 Hz there is provision for GT s to run back to 60 MW. In
case Frequency remains above 51.5 Hz for more than 2 minutes both GTs of a
module will get automatically desynchronized causing the ST to trip on GT
PMI,NTPC 155
NO load ST Trip. Before this happens efforts can be made to bring down the
frequency by desynchronizing of the GTs manually and reducing be made load
on remaining GT. Simultaneously IOCC shall be contacted to control the
frequency. During this process HP/LP stop values of the out of service WHRB
shall be kept closed to a void tripping of ST on WHRB HP/LP Drum level High .
If the frequency comes down the GT shall be synchronized and WHRB shall be
taken into service immediately to avoid drop in outlet temperatures of WHRB.

If all the efforts fail the remaining GT will also get desynchronized and ST will trip
on GT No Load ST Trip. During this time efforts shall be made to keep the
WHRB s in steady operating condition by controlling the drums level and
operating the HP/LP bypass valves suitably. When frequency comes, GT s can
be synchronized and ST rolling can started to bring ST into service .




PMI,NTPC 156
12. Protection And Interlock


General Philosophy Regarding Protection Electrical Equipment

All electrical equipment must be protected against internal and external faults, as
well as abnormal conditions which may endanger the equipment or the system.
Appropriate relays and devices have to be provided, to detect the faults and
potentially dangerous conditions and to isolate the concerned equipment cost the
earliest in order to minimize the damage.

The basic requirements of sensitivity and speed have to be met by provisions of
carefully selected relays and relaying schemes, since failure of a protection
operate cannot be ruled out, and it need lead to damage of costly equipment, it is
necessary to provide back up in the form of redundancy of relays, local or
upstream back up relays etc. however, continuity of power generation is also of
utmost importance and it dictates that the risk of tripping (due to mal-operation of
the protection) when a tripping is not really necessary be minimized. This risk is
related directly to the number of relays and other elements in the protection
scheme must be made as simple as possible. Redundancy and back ups must
also be minimised and tendency of over protection checked.

The protective relays must be connected to automatically isolate the endangered
equipments if the damage is imminent or short circuit has already occurred.
However, in cases where the equipment or system is not immediately
endangered and can continue in service for some more time, the protective
devices should be connected to initiate only an alarm. This would enable the
plant operator to take corrective steps and prevent a tripping or to prepare the
outage of an equipment (by changing over the stand by provisions or bringing
down the unit load).

PMI,NTPC 157
It is also important that the control room operator is not burdened or confused
with too many alarms. The alarm facial on the unit control board (UCB) are
therefore to be used for annunciating only those abnormal conditions for which
the UCB operator has to take some distinct preventive or restorative action. It is
generally adequate and/or with hand reset flags on protective and auxiliary relays
panels or switchgear.

Protection of Generator & General Bus Against Bus Duct Against internal
Fault

The generator bring very costly and critical items in a power plant, should be
protected by duplicate protections. Phase to Phase Faults are to be covered by
differential relays 87G and 87GT. In case of CGB scheme 87 GT covers up to
CGB generator is not protected by87GT. In such a case voltage controlled over
current protection is provided as back up. The stators earth faults would be
covered by 64 G1 & 64G2. the earth faults in the stators winding close to natural
are generally remove, however the chances of such faults can not be ruled out. It
is therefore proposed to have at least one stators earth fault relay to detect faults
anywhere in stators winding including neutral terminal. The relay 64G1 therefore,
should be capable of detecting earth faults anywhere in the stators winding but
64 G2 may cover only 95% of the stators winding.

There are various type of relays available which operate on different principles to
detect earth faults close to neutral (64G1).

One of the type has there elements built in. One element detects rise of the
fundamental frequency voltage across the neutral grounding resistor and protects
the generator winding about 95% (relay element similar to 64G2). Second
element detects collapse of third harmonic voltage present on neutral and
thereby detects the earth fault close to neutral. Third element which supervises
PMI,NTPC 158
the voltages, prevents the tripping command to exist during generator shutdown
period. ASEA relay type RAGEA operates on as principle.

Relays type PVMM, manufactured by English Electric Co., works on a more or
less similar principle, except that the second element compares the third
harmonic voltage element protects the entire generator stators winding except for
a blind zone in the middle of the winding. Another principle to inject a low
frequency signal (ariybd .01 pu) which biases the generator neutral point to earth.
Through a minimal amount of current flows continuously due to generator and
lead capacitance, any drastic increase in the current indicates the existence of a
ground fault. BBC relay type GIX 103 ir GIX 104 & SIEMENS relay type 7UE22
are examples of relays working on this principle.

Any one the above described type of relays can be considered for 100% stators
earth fault protection. The relays are time delayed by about one second to
prevent mal operation during transformer KHV side ground faults currents is
limited to about 10A.
The earth fault relay 62 G4 shall be voltage operated inverse time relay
connected across the open delta winding of an auxiliary voltage transformer 9
(VT) on generator terminal.

The generator bus ducts has an isolated phase construction throughout and
hence cannot have a direct phase to phase fault. Their coverage by one 87GT
(and partly by 87G also in case of GCB scheme) for short circuits is therefore
considered sufficient. Earth faults in the generator bus ducts are however
covered by two protections 64G and 64 G2.

The configuration transverse differentials protection (50G) is proposed to be
provided for generator internal fault protection.

PMI,NTPC 159
In case generators have only three terminals brought out in line as well as neutral
sides (even if the stators winding is double star) it would not be possible to apply
the conventional transverse differential protection for internal faults. The inter turn
fault protection is not considered very essential since such faults are very unlikely
in single turn coil construction adopted for the large generators.

For earth fault protection of the generator rotor circuit a two stage relays (64F)
working on the principle if insulation resistance measurement of rotor is
provided. The first stage of the relay shall be connected for alarm in UCB.
Further fall in insulation resistance of the rotor circuit initiate operation of the
relay second stage which is recommended to trip the unit. However it is
recommended that the machine be shut down for detection of fault location and
rectification as early as possible on occurrence of first stage alarm because a
second earth fault at another location could be quite harmful.

Protection of Generator Transformer & EHV connection

Provisions of duplicate instantaneous (main) protection is mandatory for all 220
KV/400KV elements. Accordingly the overhead EHV connections between
generator transformer and switchyard would be covered by two differential
protection 87GT and 87Tl each of would detect all type of short circuits. 87GT
and 87LT would also cover HV side earth faults, HV/LV winding would be
covered by generator earth fault relays 64G1 and 64G2.

In addition to the above differential protections, the generator transformer would
have the usual Buchholz relay (63T), winding temperature indicator and oil
temperature indicator, each of these would have alarm and trip contacts. Winding
temperature indicators would be connected to as repeater dial on the unit control
board, and would also be used for transformer cooler control.
PMI,NTPC 160
Transformer would also have oil level indicator with alarm contact, and devices to
detect abnormal, ties in coolers control.

Protection of Generator and Generator Transformer Against External Faults
and Abnormal Operating Conditions

As the large-generator have a very limited capacity to withstand and negative
sequence currents (caused by unbalanced loading, opening of phase, and
uncleared system fault etc.) a precise negative sequence protection 46 G must
be provided. It should have an 12 element to give a time delay alarm in case of a
persistent negative sequence current exceeding the generator continuous 12
capability and 12t unit to initiate generator tripping before generator 12 2t
capability limit has been reached.

While the generator has a certain overload capacity, continued operation at a
load higher than its rated current can lead to overheating and consequent
insulation failure. The protection against stators over heating would be provided
by the generator temperature monitoring system.

No protection or separate temperature monitoring for bus ducts is necessary
since they would have a naturally cooled rating slightly higher than the generator
rating.

A three-phase single zone impedance relay (21G) is to be provided for the back
up protection of generator against external three phase and phase to phase
faults in the EHV system, which may be hanging on due to failure of their own
system primary protection, The zone of 21G should be extend beyond the EHV
switchyard. It should be connected to trip the generator after a time delay of 1.0
to 1.5 seconds so that the generator is tripped only if the EHV line protection has
not cleared the fault even in second zone.

PMI,NTPC 161
The back up protection against resisting earth faults in the EHV system is
provided by an over current relay 51 NT connected to the current transformer
(CTs) in generator transformer HV neutral. Local breaker backup (or breaker
failure) protection 50Z is to be provided for the generator breaker EHV as well as
GCB). It would facilitate fast back up isolation of faults not cleared by the
instantaneous primary protection.

Loss of excitation protection 40G is provided as per universally accepted
practice. In case steam turbines ratings high (<=200MW), a Pole slipping
protection is also provided to cover the protection against instability in EHV
system.

The generator can develop high over voltages in the even of mal operation of
automatics voltage regulator, or a load thrown off while generator excitation is
under manual control. An over voltage relay 59G set at 110% is to be provided to
detect its condition and give an alarm in case it persists for 2-3 seconds. The
severe over voltage would be covered by over fluxing protection which is
explained in next clause.

Over fluxing of the generator transformer and unit transformer can occur due to
over voltage on generator terminals, or due to excitation application while turbo
generator is at lower speed. Its persistence can cause gradual over heating and
damage to the generator and transformer. An over fluxing protection 99T is to be
provided to protect the generator and transformer against the condition. The
generators to be tripped if voltage/frequency remains above 1.2 p.u. for about 2-3
seconds. Time delays necessary in order to allow AVR to correct the situation. In
case of GCB scheme separate over fluxing relays need to be provided for
generator and generator transformer.
PMI,NTPC 162
Motoring of the turbine generator can occur due to storage of steam/fuel supply.
While it does not affect the generator, it can cause gradual over heating of
turbine blade. The low forward power relay 37GA along with a time delay is used
for detecting this conditions.

While reserve power relays have conventionally been used for this protection, a
low forward power relay (LFPR) is proposed to be used since both are equally
effective for this purpose. In fact LFPR is better, since turbine blade over heating
would occur even if the unit is in generating mode at a load at which LFPR
operates about 0.5% of rated output.

Any other electrical protection which have to be provided for turbine safety is the
under frequency protection. The turbine manufacturers normally stipulate
stringent limitations regarding under frequency operation of turbine, and it would
be safer to trip the unit whenever the frequency tends to drop to a value
dangerous for turbine operation.

A multi stage relay is proposed to be used for under frequency protection (81G)
the first stage of the relay gives an alarm in unit control board indicating that the
system is operating in an under frequency regime. The operator should inform
the Regional Load Dispatch Centre regarding this so that they can take timely
action by way of load shedding to improve the frequency.

The second stage will stage will again give an alarm permit operation for a set
time after which the machine will be tripped. The third stage when reached will
instantaneously trip the machine. These levels of operation are normally defined
by the turbine manufacturers. Relay are also available which have df/dt functions.
However it would also be beneficial to work out am overall operation strategy,
during under frequency conditions, in association with the Region Load Dispatch
Centre and other utilities in the region.

PMI,NTPC 163
Monitoring of generator VT fuses would also be provided to give an alarm in
UCB, in the even of fuse failure. VT fuse failure may maloperate back up
impendence stators earth fault (64G2), low forward relays and under frequency
relays therefore these protections would be blocked on VY fuse failure.

Besides the above electrical protections, the generator and its auxiliary systems
(hydrogen cooling, bearing lubrications, seal oil, gas etc.) would be protected in
accordance with manufacturers recommendation.

Fire protection system shall be provided for generator transformer and its contact
shall be give for class A tripping.

Generator have certain MW/MVAR capabilities which are indicated in capability
curve. The operation beyond its capability is harmful to the generator. In order to
give a clear picture to the operator about the actual operation of the generator
with references to its capability, it is proposed that DDC MIS should have a
facility to show the actual operating point to generator plotted on the generator
capability curve.

Protection of Unit Auxiliary Transformer

The unit auxiliary would have separate differential protection (87UT) as their
main electrical protection against phase-to-phase faults. 87UT shall also have set
instantaneous element. Earth fault bt their HV winding be covered by 64G1 and
64G2 and the earth faults in each LV winding shall be covered by restricted earth
fault protection 64 RUT. Back up to 64RUT and HT system earth faults shall be
provided by earth fault 51 NUT connected to a CT in transformer neutral. Backup
to 87 UT for transformer faults and to HT incoming breaker protections for HT
system faults would be provided by overcurrent relays 51UT with a definite time
delay to coordinate with down stream protection. Besides the above electrical
protections, the transformers would have the usual protective devices like
PMI,NTPC 164
buchholz relay with alarm and trip contacts, winding and oil temperature
indicators with alarm and devices to detect cooler abnormality. Winding
temperature indicators would have a repeater dial on UCB and will also be used
for cooler control. The H.T. bus ducts between the unit auxiliary transformer and
the associated H.T. Switchgears would also be protected by the transformer
protections 87UT, 51UT, 64NUT.

Unit auxiliary transformer is so designed that they would not normally get
overloaded. However, winding temperature indicator (WTI) and oil temperature
indicator (OTI) are provided alongwith alarm contact to detect any overloading
and annunciate.

Fire protection system shall be provided for unit auxiliary transformer and its
contact shall be given to class A tripping.

Generator Tripping Logic

Scheme without GCB

In the absence of any circuit breaker on generator on terminals, the generator
and associated transformer become one integral unit as far as their protection in
concerned. In case of short circuit anywhere in the generator bus ducts,
generator transformer, EHV connections upto the circuit breakers, unit auxiliary
transformer and H.T. bus ducts it is necessary to immediate isolate and H.T. unit
incoming breaker instantaneously. This is commonly known as class A tripping
and the following protections must be connected to initiate the same: 87G, 87GT,
87LT, 87UT, 63UT, 95G, 51UT, 64G1, 64G2, 64RUT, and 51NUT.

Tripping of the circuit breakers as mentioned above would suffice for electrical
isolation of the fault, the tripping of the turbine is not necessary. However, the
electrical fault which caused the tripping would require investigation, and tripping
PMI,NTPC 165
of the turbine would be required subsequently in any case. Therefore, there is no
point in trying to keep the turbine in operation after a class trip and it can also be
tripped alongwith the circuit breakers in case of class A trips. Besides the risk of
dangerous turbine over speeding upon disconnection of generator from the grid
is higher when turbine is not tripped. This risk is considerably reduced when
turbine is tripped simultaneously with circuit breakers.

Scheme with GCB

In case generator or circuit breakers are provided on generator terminals, EHV
and 6.6 KV auxiliary breakers should not be tripped for generator faults/trouble
since 6.6 KV supply needs to be retained for running of steam turbine. It is
therefore, required that following protections need only be connected to tripping
of generator circuit breaker, field breaker and turbine (class A1): 87G, 95G,
64G1, 64G2.

However, the protections which covers generator transformer, UATs and
associated systems beyond GCB upto EHV breaker such as: 87G, 87UT, 63UT,
51UT, 64RUT, 51NUT need to be connected to trip EHV breaker, field brenker,
UAT LV brenker and turbine alongwith GCB (Class A2).

Protections 64G, 21G, and 51NUT require isolation of the generator from a
persisiting external fault, for which tripping of the EHV breakers alone would
normally be sufficient. However, the fact that these ultimate back, up time
delayed protections have operated indicates a serious failure of EHV switchgear
or relays, since they would operate only if all the normal back ups EHV system
(i.e. second main protection, second zone of distance relays and local breaker)
has already failed to open (after having received a tripping command from the
bus bar differential protection or local breaker back up), in which case there
would be no point in giving another tripping impulse to the same breaker.
PMI,NTPC 166
Considering all these aspects, it is proposed that the back up protections under
consideration (46G, 21G & 51NT) be connected to initiate class A/Class A2 trip.

In case of over-fluxing, ideally only the generator excitation need to be rapidly cut
back. Since this is not feasible when AVR is not functioning properly (which is
evident from the very fact that 99T has operated), tripping of the excitation
becomes necessary. However, this would lead to loss of excitation condition
unless the generator is completely tripped at the same time. Therefore, in effect,
over-fluxing protection (99T also have to be connected to initiate tripping of all
generator circuit breakers. Considering the fact that serious abnormality in the
excitation system is indicated, and generator back in service, it is proposed that
turbine also be tripped simultaneously. 99T would therefore initiate class A/class
A2 trip.

The generator would work as an induction machine and there is a loss of
excitation. The turbine generator speed would rise, the MW output would come
down due to governor action and the generator would start drawing a large
MAVR from the grid. While the generator can sustain this condition for a short
time at much reduced active load, it is nevertheless to keep such an abnormal
condition in which severe torque oscillations are produced, current are induced in
the rotor core and overheating takes place. Since the protection operation
indicates major failure in excitation systems protection should also be connected
to class A/class A2 trip.

Pole slipping of provided on steam turbine proposed to be connected for class A
tripping since it is a condition in which turbine generator may have suffered
mechanical damage and the unit has to be brought back only after careful
checking.



PMI,NTPC 167
Unit Tripping Logic

As mentioned earlier, most of the electrical protection of generator transformer
unit have to connected for class A mode of tripping, where all circuit breakers
and turbine are tripped simultaneously, as soon as the fault has been detected
by protective relay.

The electrical fault in the generator transformer are comparatively rare, and most
of the unit tripping take place due to other causes generally related to problems
in boiler, turbine take place due to other causes generally related to problems in
boiler, turbine and their auxiliaries. For such problems, it is not necessary to trip
the generator breakers instantaneously. Infact, it is desirable to delay their
tripping, as explained below:

In a class A trip, the turbine-generator gets instantaneously disconnected the
power system, stops delivering power and is then free to accelerate. The turbine
emergency stop valves take a finite time to close and some steam enters the
turbine even after initiation of a trip. This steam alongwith the steam which is
already present in the turbine expands to energy in accelerating the turbine.
There after the turbine would start slowing down if the steam Valves have closed
fully and there is a case all the valves have not closed fully and there is a
leakage through any of the valves, the turbine may not slow down but start
accelerating further. The dangerous possibility is now widely recognized and a
sequential trip (also known as class B trip) the turbine valves are allowed to close
first. When the steam inside the turbine has exhausted, the power output of the
turbine generator comes to zero. This condition is verified by sensitive LFP, and
then only the generator circuit breakers are tripped. This kit is insured that the
turbine does not over speed. Another advantage of class B trip is that grid suffers
the loss of generation as a cramp down over a few seconds, and not as a step.
Two LFPR are provided to provide backup to each for the purpose.

PMI,NTPC 168
However in case of Gas turbines, since a large compressor load is connected on
its shaft such dangerous over speeds are not expected and as such no
necessity of all the protection are connected to trip electrical breakers as well as
turbine simultaneously.

The trip contacts of WTI and OTI of generator transformer (49T), the excitation
system troubles if not urgent, and all abnormalities in generator auxiliary system
(hydrogen cooling, bearing lubrications, seal oil, gas etc.) which require unit
tripping should follow class B mode. Excitation system troubles which require
immediate tripping of excitation would initiate class A tripping. In OTI of the unit
transformer would be connected for tripping only associated H.T. circuit breakers
(but not de-enrgising the transformer.

Two separate hand reset lockout relays 86G and 186G would be provided for
class A/Class A1/Class A2 tripping. They would operate in parallel but on
separately fused 220VDC supplies, the various protections would be distributed
on these two DC supplies such that even if one of the supplies, faults. The VT
supplies, DC supplies and healthiness of lockout relays would also be monitored.

Protection of Station Transformer

The station transformers would have differential protection (87) as main electrical
protection against phase to phase faults, 87 shall have one instantaneous high
set element. Since EHV system is solidly grounded, the HV winding earth fault
shall also be covered by 897. However, a restricted earth fault protection. Back
up to incoming breaker protection for H.T. system faults would be provided by
definite time delay over current relay (51) on all three phases on HV side of
transformer.

For earth faults in LV winding, restricted earth fault relays (64RST) shall be
provided, Backup to this and H.T. system, earth fault shall be provided by a
PMI,NTPC 169
definite time delay really (51N) connected to a CT in transformer neutral, which
shall be connected to trip EHV breaker.

Besides the above electrical protection, the transformer would have the usual
protective devices like Buchholz relay with alarm and trip contacts, winding and
oil temperature indicators with alarm and the contact, oil level, indicator with
alarm and devices to detect cooler abnormality. Winding temperature, indicator
would have a repeater dial in central control room and also be used for cooler
control.

Station transformer are so designed that they would not normally get overloaded.
However, WTI & OTI are provided alongwith alarm contact in order to detect any
over loading and annunciate.

Fire protection system shall be provided for station transformers and its contact
shall be connected to trip its EHV breaker.

Local breaker back up (or breaker failure) protection 50Z is proposed to be
provided for the EHV breaker in the HV side of the station transformer.

Protection of H.T. Motors

Very divergent practices are adopted by different organizations in this respect.
On one extreme, CTs are provided on only two phases and just one single
element relay is provided for short circuit protection. Overload protection is
provided only for those motors which have a distinct possibility of getting
overloaded and not for every motor. The other extreme, CTs are provided on all
phases as well as on the cable, separate short circuit elements are provided for
each phase, overload protection is provided on all the phases as a general rule
(whether the motor has a possibility of getting overloaded or not), stalling
PMI,NTPC 170
protection is provided for all motors, and a sensitive earth fault protection is
provided using the core balance CT on the cable.

A moderate approach should however be adopted. Low resistance natural
grounding is being adopted for the HT system. CTs are to be provided on all
phases, Proposed provision of relays would be as described below, the guiding
philosophy being provision of some back up but a voidance of superfluous
elements. For example, only balanced three phase overloading is expected for
which provision of overload relays on one phase would be sufficient. However,
for backing up against relay failure, overload relays proposed to be installed on
two phases. Protection of overload relay on the third phase is considered
absolutely redundant and has therefore been avoided.

Selection of the types relays would be based on their reliability record and ability
to work satisfactory under the prevailing environmental conditions.

For protection against phase fault, all motors up to 2000KV rating should have
instantaneous high set over current relay (50) having low transient over reach to
avoid mal operation due to DC component in motor starting current on all
phases. The motor rated above 2000KW need to be protected by high speed
differential relay (87), which would be connected to H.T. switchgear CTs on one
side and the CTs on motors natural bushings on the other side in order to have
better sensitive of the protection. Provisions of relays on all phases would give
inherent instantaneous back up for relay failure.

For protection against earth faults, all HT motors should have sensitive earth fault
relay (560N) connected o core balance (zero sequence) current transformer to
be put in H.T. switchgear. CBCT is recommended in order to have better
sensitivity of the protection for the cases where earth fault current is linked (low
resistance or high resistance grounding).

PMI,NTPC 171
For overload protection, all motors would have inverse time over current relays
(51) on two phases, and their Characteristics would be adjusted selected to lie
between the hot withstand curve and the starting curve of the motors.

The stalling or locked rotor protection will be provided only for those motors
which do not have sufficient gaps between their hot withstand and starting curves
or which have a distinct possibility of stalling. It will comprise of an over current
relay (50/LR) having plan adjustable definite time delay, which would operate in
conjunction with speed switch with adjustable setting on motor shaft.

One more over current relay (50/OL) will be provided for overload alarm, for all
motors, it would alert the operator in advance, so that corrective action may be
taken or preparations made before a motor is tripped out by the over load relays
(51) Provision of 51 on two phases and 50/OL on the third phase would provide
inherent back up against relay failure as well protection against faults near the
motor neutral which may not be detected by the other protections.

Single phasing protection is not necessary for motors controlled by circuit
breakers having a common operating mechanism for the three poles. Negative
sequence current protection is also not considered necessary for power plant
auxiliary motors since the supply voltage would always be balance in the close
proximity of generators.

The large motors lasted above 1000KW would be having winding temperature
monitoring, with automatic scanning by the embedded RTDs. These would be
connected for alarm only winding temperature monitoring is not considered
necessary for smaller motor, which would normally be self cooled with little
possibility to overheating as long as they are not overloaded. However, adequate
monitoring of the cooling system shall be provided where water coolers are
involved.

PMI,NTPC 172
The proposed provision of CTs and connection of relays for the motors rated up
to 2000KW and for motor above 2000KW are shown in fig. 3&4 of annex-C
respectively in enclosed sketch.

Composite relays are also available which have all the features as mentioned
above. These relay are static and/or microprocessor based having built in on line
testing facilities, and have thermal memory for overload protection of motor. Such
relays, when employed, should meet the environmental conditions at their
location. Transient overreach requirement for short circuit protection and the
initial cost are some of the additional factors needing attention.

Protection of Auxiliary Transformers (6.6 KV/0.433KV)

The H.T. feeders to auxiliary transformers would have instantaneous high set
overcurrent relays (50) on all phase for protection against phase to phase fault.
The LT transformers rated above 5 MVA, if any, shall be provided with differential
protection instead of short circuit protection (50). Definite time delayed low set
overcurrent relays (51) would be provided on all phases for protection against LV
side faults. The latter would also provide backup protection against faults in the
LV system. Inverse time overcurrent relays are not proposed to be used since
time varies with the fault current and low intensity faults are cleared after a
considerable time delay. Use of overcurrent relays with a definite adjustable time
delay for 51 would provide clearance of all type of faults in less than one second
(Ref. Annexure-D).

For protection against HV side earth faults, all LT transformers would have an
instantaneous earth fault relay connected to core balance CTs for all the LT
transformers.

For protection against LV side earth faults, 6.6KV/0.433KV transformer would
produce current of the same magnitude as the faults (since the neutral is solidly
PMI,NTPC 173
grounded) and would recover by overcurrent relays 51 mentioned in cl. No.
11.1.0. for the protection against earth faults inside the LV winding, a definite
time delayed earth fault relay is proposed which should be connected to a CT in
transformer LV neutral side. This earth faults relay shall be fully coordinated with
maximum fuse resting of outgoing motor feeders.

Besides the above electrical relays, the liquid filled LT transformers would have
Buchhloz relays (63) with alarm and trip contacts, winding and/or oil temperature
indicators with alarm and trip contacts. Dry type indoor transformers would have
only winding temperature indicator, with necessary contacts for alarm and trip.

The LT transformers normally so sized that they are not over loaded. However,
winding temperature and oil temperature are monitored and alarms are given for
temperature high in case of any overheating.

Protection of LT Motors

The 415 V motors rated above 125 KW would be controlled through circuit
breakers. They would be protected against phase-to-phase faults either with
instantaneous short circuit released in the circuit breakers, or with instantaneous
high-set over current relays (50), provided on all phases. For a sensitive earth
fault protection these motors would have instantaneous overcurrent relay (50) in
the residual CT connection.

For overload protection, the breaker controlled motors would have inverse time
overcurrent relay (51) on two phases for tripping and a definite time overcurrent
relay (50/OL) on the third phase for alarm. The arrangement would be similar to
that described earlier for the H.T. motors.

The smaller 415 V motors (rated upto 125 KW) would be controlled by
contactors. They would be protected against phase-to-phase and earth faults by
PMI,NTPC 174
HRC fuses. The fuse would be selected as not to be affected by repeated motor
starting. The overload protection would be provided with three phase thermal
(bilmetallic) overload relays.

Single phasing protection should be provided for all contactor controlled motors
which are protected by fuses. It would be ensure that this protection is not too
sensitive to negative sequence current, and is adequately stable during motor
starting, normal voltage unbalance etc.

Undervoltage protection is proposed to be provided on all the H.T. and L.T.
breaker controlled motors in order to avoid spurious tripping of reverse supply
breaker (due to drawl) of starting current of all the motors connected on particular
bus), when it is closed on a dead bus. The under voltage protection would be
connected on bus VT and would trip all the motors connected on the bus VT and
would trip all the motors connected on the bus after a time delay. Time delay is
provided in order to allow the changeover to take place on up stream switchgear
and voltage dip due to the fault anywhere in the system.

Protection of Auxiliary Supply System

For phase to phase faults on H.T. bus and back up protection for outgoing feeder
on these buses, a definite time delay over current relay need to be provided in all
phases on H.T. tie and incoming breakers.

Earth faults on H.T. bus and backup to all outgoing feeders on unit/station bus
would be covered by a definite time delay overcurrent relay need to be provided
in all phases on H.T. tie and incoming breakers.

For phase to phase faults on 415V incomes & buscoupler breakers. Tie to 415V
MCCs/boards, if controlled by breakers, shall also have short circuit release
fitted in the breaker. The releases shall be definite time delayed magnetic/solid
PMI,NTPC 175
state type. Definite time delayed over current relays as real so acceptable in
place of releases, Earth fault current in the 415V system would produce currents
on same magnitude as for phase to phase faults, and therefore would be covered
by phase faults relays. Earth fault protection therefore is not necessary to be
provided in incomes, buscouplers and tie feeders to MCC/board.

Time graded protect as detailed above, results in a very high operating times
(about 1.0 sec.) for relays located at income. Through switchgear have one
second through faults withstand capability, they can not be expected to withstand
internal faults for such long time without serious damage. It is therefore
recommended to adopt a reverse blocking principle to cut down the grading
times. For this arrangement all the relays as described above located on ties, bus
coupler, income, shall have instantaneous (with a short delay of about 100as)
and delayed (coordinated with downstream) stages with the instantaneous stage
of up stream blocked by all the down stream protection current element. With this
arrangement a faults last any point in the system can be detected within
100m.sec.

Protection of Emergency Diesel/Gas Turbine for Black Start Facility

For phase to phase fault protection three phase high impedance differential
protection should be provided for these generators. This protection shall be
extended upto 6.6KV breaker so as to protect 6.6KV cables also, For6.6 KV bus
phase to phase faults and back pup to out-going feeders protection, voltage
controlled overcurrent relays should also be provided. Voltages control over
current relays are recommended for back protecting because fault current form
generator would reduce considerably owing to its very high steady state
impedance.

Since emergency diesel generator neutral is kept undergrounded, in a single
earth fault only capacitive current would blow. Earth fault in this case shall be
PMI,NTPC 176
detected by the voltage relay provided in the neutral VT which shall be connected
for an alarm in the central control room. Above arrangement would facilitate the
diesel generator operation under emergency conditions even if a simple earth
fault exists in the system.

Though necessary interlocks shall be provided to avoid motoring of the diesel
generators, possibility of such occurrence cannot be ruled lout. Single phase
reverse power relays are therefore proposed to be provided for diesel
generators.

Protection, described above shall be connected to trip 6.6 KV breaker as well as
diesel engine fuel solenoid valve since only tripping of 6.6KV cable fault. Interlock
shall be provided so as too allow the engine to be restarted only after manual
resetting of tripping relay located at diesel generator control panel. The reverse
power relay shall be connected only to trip diesel generator 6.6KV breaker.
















PMI,NTPC 177
13. Spare Parts Management


Spare parts management is an important aspect for trouble free operation and
minimum breakdowns or shut down time in a plant. For optimizing power
generation, availability of required number of quality spare parts is of paramount
importance. While quality is normally ensured, availability is mostly poor
because of inadequate planning, Selection of spares in right quantity is equally
important, otherwise the plant may have high inventory of spares, still may not
have a needed spares. In case of NTPC; due to diversity of equipment and use
of highly abrasive coal, a large variety of spares are to be stocked. Unavailability
of even a small item could cause a total or partial unavailability of the units,
resulting into huge loss of generation and consequential industrial loss.

The process of spare parts management is governed by number of factors, e.g.
maintenance planning equipment history and behaviors, spare parts planning,
forecasting, procurement policy and procedures etc. Efforts have been made
here to dwell upon some of the important aspect and present them as a
recommendatory system of NTPC power stations which may be taken as general
guidelines. The stress is on the maintenance planning, spare forecasting,
planning, stocking and inventory control.

Procurement of Initial Spares

A provision equivalent to 4% of the equipment cost is made towards the purchae
of initial spares in our feasibility reports and detailed project reports. These initial
spares include consumable spare parts, unit replacements and insurance spare.
The spare parts are recommended by Operation Services based on past O & M
experience, manufactures recommendation and potential indigenous
development of such items.

PMI,NTPC 178
The provision of 4% of equipment cost of initial spares have been found to be
inadequate and as a result, the quantity of initial spares are restricted to the
provisions made by CEA, Even though the prices quoted by vendors for
mandatory and recommended spares are very competitive since they are
subjected to bid evaluation were are not able to procure sufficient quantity of
initial spares due to financial constraints.

Mandatory and Recommended Spares

During initial periods, the spares parts were procured based on the
recommendations of the manufacturers who were quoting very exorbitant prices
as their virtual monopoly over these prices which were not subjected to any
evaluation.

In NTPC, to obtain, more competitive prices of spare parts, it was considered
desirable to prepare a list of spare parts which will normally be required and
procured along with the main equipment and are independent of equipment
order. These lists include some of he high value insurance items and unit
replacement assemblies. Such spares which are included in technical
specifications as part of supply are known as Mandatory Spares. The prices of
these spares have to be competitive as they are subjected to evaluation.

Once the order is placed on the successful bidder, he is asked to submit a
detailed list of spares which will be required for day-to-day operation and
maintenance of initial period of 3 years as well as any other special and high
valued items not included in mandatory spares, the list of recommended spares
including mostly fast moving consumable type of items like bearing,
liners, gaskets, HRC fuses, contractors etc. This list is subjected too rigorous
scrutiny and spare parts 3 year O & M are recommended


PMI,NTPC 179
Since the total cost of mandatory and recommended spares has to be within the
provisions of 4% of the total equipment cost as per CEA guideline, this causes
resource constraints which result in either reduction of quantity of spares of
enhanced expenditure on spare parts.

Basic for Procurement of Initial Spares

The initial spare included essential insurance items, unit replacement and
consumable of 3 years. The period of 3 years has been chose because of non
availability of O & M personnel at site at the time of placement of order for main
equipment and long lead time associated with imported spare parts. Also no
consumption is worked out on the basis of past experience of similar equipment
and the manufactures recommendations. Any period less than 3 years of
procurement of initial spares could lead to undesirable situation of stock out.

The system of thorough review of manufactures recommendation has helped
NTPC to avoid the common pitfalls of lending up with the high inventories of
those items which are normally not required and not having the items,
unavailability of which could case total or partial outage of the equipment.

While deciding upon the adequate quantities of consumables spares of 3 years
consumption, the following kept in view:-

- Anticipated or known failure rate
- Succeptability of he items to loss/ damage
- Self Life
- Manufactures recommendation
- Interchangeability with other similar spares
PMI,NTPC 180
- Development potential
- Operating condition and environment
- Total installed quantity (Population)
- Accessibility of skills, tools, time and other facilities of repair
- Wear life of components
- Sub assembly replacement and repair at later date
- Consumption rate
- Fast technology developments of items of imported origin specially C&I
items

The above considerations have helped in proofing down the quantities of
various slow moving items. It is observed that space parts recommended by
vendor needs to be reviewed judiciously, so as to optimize the recommended
list of spares of procurement in respect of number and type of item and such
review has helped in cutting down our inventory at least by 20-30% of the
original recommendation.

The actual values of spares for all the packages considered together as per
past experience, works out to be in the range of 5.5 to 6% for 200MV stages
and similar trend is emerging for 500 MW sets where relatively fewer orders
have been placed so far. Since the initial spares that are being ordered
includes Insurance Spares, unit assemblies and consumable spares for
3years, it has not been possible to limit the value of initial spares within the
stipulated provision of 4% given by CEA.

NTPC being committed to high plant load factor and considering the isolated
location long lead time, multiplicity of make and type of equipment,
PMI,NTPC 181
sophisticated control & instrumentation and operational aids. The spares
ordered initially exceed the provision to have a sufficient stock of spares, to
avoid shortages and stock-out situations.
Based on the above experience & judicious review of initial spare parts
requirement, it has been proposed to CEA that the provision for initial spares
procurement should be as follows for both 200 MW & 500 units.

Mech.
Packages
Elect.
Package
C& I
Package
% to total
Equipment
Cost Indigenous Plants 6% 4% 8-10% 6%
Imported Plants 6-8% 4-5% 12-15% 8%

The matter is under consideration with CEA and it is hoped that as a special case
of NTPC, the provision of initial spares may be suitably enhanced.

Spare Parts Planning, Forecasting & Procurement

In order to ensure availability of spares at the minimum inventory carrying cost, a
systematic approach is necessary to be evolved on forecasting planning and
procurement of spares. The main objectives of this approach are as follows:

- To ensure availability of spare parts whenever needed so that plant
availability is not affected.
- To achieve optimum inventory turnover into i.e., consumption and
purchase of spare parts be so matched that capital blocked in inventory is
minimum.
- To procure the spare parts at the lowest individual and lowest total cycle
cost with consistency is quality.

PMI,NTPC 182



Maintenance Planning

Spare parts planning is dependent on the maintenance planning function. The
behavior pattern/ history of the equipment is available from the past operational
feed back which helps in preparing maintenance and capital overhauling
schedules. Requirement of spares for all type of maintenance. i.e. preventive,
break down and capital repair & overhauling, can be planned accordingly in the
following manner.

Preventive Maintenance

Scheduling of preventive maintenance of various equipment in the power station
is done as per the norms worked out on the basis of experience of power station
maintenance engineers or as per recommendations of the manufacturers. A
detailed weekly preventive maintenance programme for all the equipment is
finalized in advance and is strictly adhered to by the maintenance personnel.
Certain fast wearing type of items like glands, gaskets, packing etc. are
necessarily to be changed during these preventive maintenance and hence can
be planned for availability.

Capital Repair & Overhauls

During capital repairs and major overhauls, many items are required to be
changed depending upon the wear and tear, failure and past history of the
equipment. Theses items are normally long lead items and hence a
comprehensive planning for such spares should be done at least 2-3 years in
advance to meet the overhauling requirements. 5year rolling plans for stations
should be prepared, updated and reviewed every year for the purpose of
PMI,NTPC 183
ascertaining the need of spares, depending upon the plan condition and
equipment behaviour.

Break-down Maintenance

It is very different to predict the requirement of spares for such jobs as the
pattern of breakdown occurrence is uncertain. However based on regular
condition monitoring predictions can be made Regarding residual life of the
equipment. Accordingly, requirement of spares can be worked out for future
period depending upon past history and failures.

Spare planning & Inventory Control

Maintenance Planning will indicate the schedule of maintenance and quantity of
spares required to meet schedules. These quantities are to be cumulated for total
quantity of spares required to meet the schedules. These quantities are to be
cumulated for total quantity and analysed for deciding the order quantities
keeping the current stocks, quantity due in against pending orders and lead
period. The inventory for the consumable spares should be such that it meets the
management objectives of no stock outs and minimum inventory holding.

Since there is always some gap between the time when order is placed and the
spare is actually reviewed, the role of spares planning is very vital. The planning
cycle and inventory level fixation depends upon various factors.

Location of the plant The location of the plant effects the lead
time & local source development. NTPC
plants located at remote place have to
carry high inventory of spares.

PMI,NTPC 184
Nature of spares Proprietary items or imported spares
which calls for cumbersome import
procedure, have high lead periods and
should be planned well in advance.

Lead Time The time elapsed between indent raising
and availability of spare part for use is
an important factor which governs the
stocking policy: This time comprises
internal lead time of indent processing &
placement order, apart from the
manufacturers delivery period.

Equipment history and The equipment behaviour and failure
rate usage rate determines the usage
rate. It provides the guidelines for
inventory stocks. However, usage rate
varies with the age of plant.

Organization and Budgeting Spare parts planning set up for
identification Budgeting and placement
of orders for spares help in
curtailinadministrative and procedural
delays. Similarly adequate Budget
provisions and availability of funds for
spares leads to optimum inventory
stocks.

PMI,NTPC 185
Analysis and Classification

For the purpose of planning, it is necessary to conduct an analysis of spares with
respect to consumption; critically movement and their availability etc.

F.S.N. Analysis The spares are classified into Fast, Slow and
non moving categories based on the movement rate.

Fast Moving Items which have moved at least once in 1-2 years
Slow Moving Items which moved at least once in 2-4 years.
Non Moving Items which have not even once in 4-5 years.

Type of Spares:

Insurance Spares The spares which normally not required but are
vital for the equipment as in case of any miss hope or
accidents non availability of these items will lead to
long out ages. For example turbine rotors exciters etc.

Unit Replacement In order to reduce equipment down time complete
assembly is replaced. This assembly/sub assembly
can be repaired later on and can be used again.

Consumable Spares These are fast wearing out items and have reduced
life. These spares are replaced.

ABC Analysis Based on the annual consumption or usage values,
spares are replaced a new when found worn out.

Non-Moving Items

PMI,NTPC 186
A. Contributing to 60-80% of total spares consumption. Industrial annual
consumption Of more than 50 thousand.

B. Covering about 25% items contributing to 15-30% of total usage value.
Industrial consumtion between 5000-50000/-.

C. Annual usage value of each spares less than 5000/-.

Criticality Analysis The spares categories according to their criticality of
usage In the plan.

Vital Spares which cause complete stoppage of plant and
service risk in operation are vital like control value
speed governors load limiters.

Essential In absence of such spares, the plant can run but
perhaps at substandard performance level like spares
of ID fan, mills etc.

Desirable These are the spares whose non-availability may not
Adversely affect the plant performance but may
increase down time later on.

SDE Analysis Categorization depending upon sources and lead-
time of procurement:

Scarce Normally proprietary or imported spares with long
lead time.

Difficult Special efforts are to be put in the for procurement of
these items. They are high tech. Items.
PMI,NTPC 187

Easy These items can be procured from standard suppliers
in a short lead time.

Inventory Control

To meet the objective of spares planning, inventory levels should be so optimised
that stock out as well out stocking are minimum. The inventory cost include
carrying cost and ordering cost. Optimisation is to be achieved so as to minimise
the total cost by controlling how much to order and when . To achieve this, it is
necessary to classify the spares into above categories such as ABC, VED, and
FSN and expected life. On the basis of these classification , Inventory levels
safety stocks & recording level can be decided for each and every items.

Based on the VBC and ABC analysis, a confidence level matrix have been
adopted to determine the safety stock of the spares.

Confidence matrix
A B C
V 85% 95% 99%
K=1 K=1.7 K=2.5
E 75% 85% 95%
K=0.75 K=1.0 K=1.7
D 70% 76% 80%
K=0.7 K=0.75 K=0.8

Periodic Review System

The spare parts planning and forecasting is proposed to be done on fixed review
period basis. It is envisaged that all the consumables spares will be reviewed
only once in a years. A calendar for the review of spares have been prepared
which provides review of spares segregated into seven packages such as SG,
TG, Elect., C&I, Off-sites etc. Apart from these, high consumption critical spares
PMI,NTPC 188
of Bowl mills, coal handling plant and ash handling plants will be reviewed on
quarterly basis.

The maximum inventory level has been fixed on the basis of consumption rate,
lead time and safety stock.

1. Average consumption = total population
during lead period ______________ x Lead period
Expected life


2. Average consumption = total population
during review period ------------------------- x Review per
Expected life

A. Lead period
i) BHEL spares = 1.5 years 2 years
ii) Other than BHER = 1 year


B. Review period = 1year


3. Safety stock

Safety stock = K M
where K = face or depending upon ABC /VED analysis
M = consumption during lead period

4. maximum Level
= lead period consumption stock + review period Safety Stock

5. Reorder quantity

Reorder quantity = Maximum level (present stock quantity due).



PMI,NTPC 189
N.B in case the present stock is less than lead period consumption , recorder
quantity should be taken equal to review period consumption only.

The identification of consumable spares, their classificatication schwas VED,
ABC, FSN and expected life havebeenentrusted to site Ormond the fixation of
maximum in vent ore safety stock etc. have been entrusted to Operation
Services. The periodic annual review of spare will be carried out by Site O&M
Planning &Materials Deptt.

The objective of the spare development is to make a systematic effect to develop
the spare parts indigenously or in house for all categories of spares whether
Indian or Imported so as to achieve the following objectives.

Cost reduction
Alternative source
Import substitution
Availability
Reduction in Lead time

It has been proposed that items which are common to 2 or more than projects or
which have a annual consumption value of more than 10 lakhs will be taken up
for developments from Corporate Centre while the items having less
consumption value or particular to individual projects will be taken up for
development by project itself. The responsibility of preparation of drawings and
technical specification will be O&M planning at Sites and COS at Corporate
Centre while replacement of order will be the responsibility of site materials
Deptt. And Materials department at projects and Coordinate Centre respectively.
Once the source standardisation is done, projects can place order on these
parties for their annual requirements.

PMI,NTPC 190
Already the jobs of spare parts developments has been taken up by all the
projects & coordinate Centre with encouraging results and the number of spare
parts developed will increase with the availability of drawings and material
specification of spares which is a very elaborate process.

Vender development

The spares being im ported by the plant can be boradly as

- Spares for which there is not enough capacity witmn the country though
the required specifications are available

- Spares for which there no specification is available but capacity is a
vailable within the country (most of these are propriety nature spares
imported as per suppliers part numbers).

A study conducted shows that the category(b) constitutes about 80% of the
total import budget of spare and thus requires special attention towards import
substitution drive. We had developed in our project many of the spares which
would lead to foreign exchange savings to the tune of several lack per annum.

The interesting feature of this development management is that ones
specifications of an item is established, the item will go out of the import-list for
all time to come leading to saving foreign exchange over a number of years.

Dependence on continued import and indigenous proprietary procurement is not
only expensive but also very time consuming and leads to long delivery per
period and available inventory as well. The development spares required
continuous efforts right from identification of spares for development to the trial
runs, assessment of performance of the spares supplied by the vendors and
PMI,NTPC 191
accordingly enlisting successful vendors for such development items and
continue to explore new competent sources.

Identification for Spares for Development

Spare parts be identified for development purpose on the following criteria:

(a) Spare of imported origin.

(b) Spare of indigenous proprietary origins.
Spare of vital/ essential in nature. Long/ irregular delivery period from
original equipment manufacturer/ Oes and not of high tech-components.
Spare common among various NTPC projects.
Spares generally bought out items and only assembled by OEM/OES.
High consumption spares.
High value spares and not of very sophisticated technology involved.

Identification of Sources

Press advertisements, Exhibitions, State wise yellow pages, DGTD.
Manufactures/ trade and NSIC directories and users/ other projects past
experience.

Introductory letters received from vendors and advertisements published in
leading newspaper journals.

Information obtained from DGTD regarding items licensed for same/ allied
items.

PMI,NTPC 192
Magazines like Industrial /Electronic product finders, Computers Todays,
Industrial Equipment News, National Product News, Telemetric India, etc.

Registration of Vendors

The vendors shall be required to furnish the details such as technological
expertise, financial soundness, manufacturing/ testing facilities and past
performance with regard to supply and quantity of same/similar items in the
prescribed Performa.

Screening committee consisting of representatives from Finance, Material,
O&M, QA not below the level of Manager/ Supdt. At Site/OS will finalize the
list of verdors for undertaking the development of items, based on their
capability and capacity. Suppliers work may be visited if necessary.

Vendors registered with DGTD/NSIC and known to NTPC site/OS need not
be reassessed

Enquiries

Enquiries can be floated for spare development to all the registered vendors for
similar items. In case more than one vendor is not available in the approved
vendor list for a particular item, enquiry can also be floated even to single vendor
with approval.

Placement of Development Order

The negotiation/Tender committee (as per DOP) places the development
orders. The original price or spares/ items, estimated costs, specific
investment and infrastructure by the vendors will be considered

PMI,NTPC 193
The committee can propose to issue more than one PO against single item in
case of multiple offers (all being L1).

Negotiation committee can recommend issuing of more purchase order for
single items at different rates to different vendors.

PMI,NTPC 194
14. Date Sheet for Gas Projects

S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR

1. a) Net plant capacity, Base 413.3 652.56 645. 36 817.48 648.6
load (MW) at design condition
(i.e. 27
0
C ambient temp.
60xRM, 32
0
C CW temp.
at site elevation)

b) Combined Cycle net heat 1796 1796 1771 1748 1834
rate at base load design (This figures are with DM
condition of 15 kg/sec. Water injection turbine)
per Gas (K cal/KWhr.)

2. Fuel & its Source Natural Gas Natural Gas Natural Gas Natural Gas Natural Gas From
tapped from tapped from /NGL Natural from BHEL Gandhar Gas Basin.
HBI pipeline HPI pipeline Gas is supplied pipeline.
From HBJ
3. Gas Requirement 1.75 MCMD 2.25 MCMD 2.25 MCMD 3MCMD 1.5MCMD
(Annual Average) (Annual Average) (Annual Average) (Annual Average) (Annual Average)
4. Water Source Kota right main Etawah branch Hazira Branch Net Canal Wareada river
canal canal canal
5. Condenser cooling system Hybrid (Closed Closed circuit Closed Circuit Closed Circuit Closed Circuit
circuit/once through)
6. Mode of operation of plant Base load and/or Base load and/or Base load and/or Base load and/or Two shift operation
two shift or peak- two shift or peaking shift or peaking or two shfit or
ing duty depending duty depending on duty depending peaking duty
on technical and/ technical and/ on technical and/ depending on
economic conside- economic economic technical and/
rations consideration consideration economic
consideration.
7. Main Plant awarded on ABB, West MHI Japan GEC-Alsthom Siemen AG, West Marubani,
Germany on on 03.09.90 France on Germany Corporation
20.8.87 05.03.90 on 26.3.92
8. Orientation of GT Exhaust Axial Axial Axial Axial Axial

PMI,NTPC 195
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR

GAS TURBINE AND AUXILIARIES

9. Design Conditions 27
0
C asb. Temp. 27
0
C asb. Tmep. 60% 27
0
C asb. Tmep. 60% 27
0
C asb. Tmep 27
0
C asb. Tmep.
60% RH 253 M RH, 140M above sea 60% RH, 5.5 M above 60% RH 210 M 60%RH, 23.25M
above seal level, Level, 32
0
C CW temp. sea level, 32
0
C CW above sea 32
0
C above seal level,
32
0
C CW temp. temp. CW temp. 32
0
C temp.
10. Manufacturer ABB, Germany MHI, Japan Eropean Gas Turbine Siemens AG, ABB, Germany
France Germany.
11. ISO base rating at 98.9 121.51 116.9 142.42 147.8
12. Net O/C base output of GT 89.25 111.76 105.62 131.31 131.36
at design condition (MW)
13. Net O/C heat rate at base 2770 2623 2697 2692 2617
load and design conditions
(K cal/Kg. Hr.)
14. Net efficiency of GT (%) 31 32.78 31.9 31.95 32.8
(O/C, at base load, design
conditions)
15. Natural gas consumption 6.76 8.2 7.8 9.6 9.4
(O/C, base load design
condition kg/sec, assuming
cal value of gas as 8700
K cal/m
3
and density of gas
As 0.856 kg/m
3

16. Turbine speed (rpm) 3000 3000 3000 3000 3000
17. Compression 12.4 13 12 10.2 14.3
18. Air bass flow (O/C base 370 412 388 462 500
19. Exhaust gas temp. (
0
C) 505 513 540 560 525
PMI,NTPC 196
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR

20. Ignition of speed of the 600 600 510 400 600
shaft (RPM)

21. Self sustaining speed of 1500 2100 1950 2100 2000
the shaft

22. start-up mechanism frequency Converter Starting motor Starting motor Frequency Converter Frequency converter

DESIGN FEATURES

23. No. of compressor stages 18 19 17 16 21
24. No. of turbine stages 5 4 3 4 5
25. No. of air cooled stage
i) Guide 2 2 2 2 3
ii) Rotating blades 3 2 2 2 3
26. GT Generator Rating MVA 125 141.08 171.875 165.5
27. GT Generator Cooling by Air Hydrogen Air Air Air
TYPE OF AIR FILTER
28. Type of Air Rating MVA Self cleaning Self cleaning Self cleaning Self cleaning Self cleaning
system. Cartridge type Cartridge type Cartridge type Cartridge type Cartridge type

BYPASS DAMPER

29. Type Diverter type Diverter Louver Diverter type Diverter Louver Diverter type

WHRB

30. Type Forced circulation/ Forced circulation/ Forced circulation/ Forced circulation/ Natural circulation/
Dual Pressure Dual Pressure Dual Pressure Dual Pressure Dual Pressure
PMI,NTPC 197
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR

31. Manufacturer Wanger Biro/Austria MHI. Japan CMI. Belgium BHEL, India KHI, Japan (with
(with Wagener Henry vogt design)
Biro design)
a) HP Super heater
Out let temp. (
0
C) 485 495 520 530 504.5
Outlet pressure (bar) 63.97 60 70 65 76.9

b) LP Drum/Super heater
Out temp. (
0
C) 210 158.1 193.2 200 220
Outlet Pressure 5.91 bar 7 kg/cm
2
7 bar 5.7 bar 6.1 bar

STEAM TURBINE
32. Make ABB, Germnay MHI, Japan ALSTHOM, France BHEL, India ABB, Germany

33. Type Tandem compound Tandem compound Tandem compound Tandem compound Tandem compound
Dual pressure Dual pressure Dual pressure Dual pressure Dual pressure
Condensing type Condensing type Condensing type Condensing type Condensing type

34. Mode of Operation Sliding Pressure Sliding Pressure Sliding Pressure Sliding Pressure Sliding Pressure

35. HP CYLINDER Single flow Single flow Single flow Double flow Single flow
25 Stages 25 stages (Impulse) 13 Stages 24 Stage (Reaction) Single flow
Impulse

36. LP CYCLINDER Double Flow Double Flow Double Flow Double Flow Double Flow
6 stage (Reaction) 6 stages (Reaction) 5 stage (Reaction) 7 stage (Reaction)

37. Rated Speed 3000rpqm 3000rpm 3000rpm 3000rpm 3000rpm

38. Based load out put at 153.28 MW 109.3MW 116.1 MW 154.51 MW 227 MW
PMI,NTPC 198
S. NO. DESCRIPTION ANTA AURIYA KAWAS DADARI GANDHAR

39. Make ABB MHI DELASWAER BHEL ABB

40. Condenser back pr. At 100 bar 72mm hg abs 92 a bar 0.1122 kg cm
2
100a bar
load and design condition.

41. Cooling water flow 29700 M
3
/hr 23340M
3
/hr 23061 M
3
/hr 25000 M
3
/hr 37728 M
3
/hr

42. Design Cooling water temp. 32
0
C 32
0
C 32
0
C 32
0
C 32
0
C

DEAERATOR

43. No. of Deaerator/module one (1) one (1) one (1) one (1) one (1)

FEED WATER PUMP

A. HP FEED WATER WATERPUMP

44. MAKE SULZER TORISHIMA SULZER BHEL
JAPAN
45. No. of HP feed water 3x50% 3x50% 3x50% 3x50%

46. Capacity 307.3m
3
/hr 210 T/hr 182.2 M
3
/hr 290 M
3
/hr

47. TDM 94.3 bar 80 kg/cm
2
110 bar 107 bar

B. LP FEED WATER PUMP

48. MAKE SULZER TORIHIMA SULZER KSB
JAPAN
49. No. of LP feed water 3x50% 3x50% 3x50% 3x50% 3x50%