Neepco Avik
Neepco Avik
Neepco Avik
Submitted by
1. AVIK BAL
Department of Mechanical Engineering, NERIST, Itanagar-791109
2. UPAYAN DEBNATH
Department of Mechanical Engineering, NERIST, Itanagar-791109
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CANDIDATES DECLARATION
We certify that the work presented in this dissertation submitted in practical fulfillment of
vocational training in Agartala Gas Tubine Power Plant, NEEPCO is an accurate record of
our work carried out under the guidance of Engineers and officials of AGTP.
We hereby declare that all information in this document has been obtained and presented in
accordance with academic rules and ethical conduct. I also declare that, as required by these
rules and conduct, I have fully cited and referenced all material and results that are not
original to this work.
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CONTENTS
Cover Page
Certificate of Approval
Candidates Declaration
Contents
CHAPTER 1 INTRODUCTION
1.1 Overview
1.2 Mission
1.4.Human Resource
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3.6 Generators.
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3.8 A.C.Generators
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3.9 D.C.Generators.
3.10. Electric power transmission and distribution.
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CHAPTER 1 : INTRODUCTION
1.1. OVERVIEW
North Eastern Electric Power Corporation Limited (NEEPCO) , a Schedule "A"
Government of India Enterprise under the Ministry of Power was set up on the 2nd of
April, 1976 to plan, investigate, design, construct, generate, operate and maintain power
stations in the North Eastern Region of the country. NEEPCO has an installed capacity of
1130 MW which is 47% of the total installed capacity of the N.E Region. NEEPCO's
authorised share capital is Rs 5000 Crores at present and its net worth as on 31st
March 2012 is Rs 4780.01 Crores.
With its headquarters in the charming town of Shillong, the capital of Meghalaya,
NEEPCO is a power sector enterprise with projects located in the various states of the
North East.
1.2. MISSION
o
o
o
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To responsibly exploit the vast hydro & thermal power potential for sustainable
development of N.E Region
To undertake execution of new hydro/thermal schemes and undertake timely
renovation & modernization of existing old hydro and thermal plants.
To execute on-going hydro/thermal projects as per targets set, so as to achieve
commissioning of such projects as per schedule or ahead of schedule.
To ensure optimum utilization of installed capacity so as to achieve maximum
generation and optimum machine availability .
To improve the Quality Management System, NEEPCO is already registered as an
ISO: 9001:2008 Company, NEEPCO has also been accredited with OHSAS 18001
for occupational health and safety management systems and ISO 14001 for
environmental management systems.
To complete DPR of new schemes for hydro/thermal projects as per schedule or
ahead of schedule as and when estimated by Central Electricity Authority (CEA)
To promote industrial growth and prosperity of the N.E region by fulfilling the need
of supply of electricity thereby improving the quality of life of the region.
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1.5.COMPANY PROFILE
Authorised Share Capital
Installed Capacity
1130 MW
Projects Completed
Manpower
Certifications Received
ISO 9001:2008
ISO 14001:2004
ISO 18001:2007
Occupational
Health
and
Management Systems (OHSAS)
Very Good
2008 - 09
Good
2009 - 10
Very Good
2010 - 11
Good
2011 - 12
Good (Provisional)
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Safety
2.2.THEORY OF OPERATION
Gases passing through an ideal gas turbine undergo three thermodynamic processes. These
are isentropic compression, isobaric (constant pressure) combustion and isentropic
expansion. Together, these make up the Brayton cycle.
In a practical gas turbine, fresh air from ambient atmosphere are first accelerated in either a
centrifugal or axial compressor. The air is screened and filtered to remove all dust particles
and other impurities. These gases are then slowed using a diverging nozzle known as a
diffuser; these processes increase the pressure and temperature of the flow. In an ideal
system, this is isentropic. However, in practice, energy is lost to heat, due to friction and
turbulence.
Gases then pass from the compressor (or diffuser) to a combustion chamber, or similar
device, where heat is added. In an ideal system, this occurs at constant pressure (isobaric
heat addition). As there is no change in pressure the specific volume of the gases increases.
In practical situations this process is usually accompanied by a slight loss in pressure, due
to friction. Finally, this larger volume of gases is expanded and accelerated by nozzle guide
vanes before energy is extracted by a turbine. In an ideal system, these gases are expanded
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isentropically and leave the turbine at their original pressure. In practice this process is not
isentropic as energy is once again lost to friction and turbulence.
If the device has been designed to power a shaft as with an industrial generator or a
turboprop, the exit pressure will be as close to the entry pressure as possible. In practice it
is necessary that some pressure remains at the outlet in order to fully expel the exhaust
gases. In the case of a jet engine only enough pressure and energy is extracted from the
flow to drive the compressor and other components. The remaining high pressure gases are
accelerated to provide a jet that can, for example, be used to propel an aircraft.
Brayton cycle
As with all cyclic heat engines, higher combustion temperatures can allow for greater
efficiencies. However, temperatures are limited by ability of the steel, nickel, ceramic, or
other materials that make up the engine to withstand high temperatures and stresses. To
combat this many turbines feature complex blade cooling systems.
As a general rule, the smaller the engine, the higher the rotation rate of the shaft(s) must be
to maintain tip speed. Blade-tip speed determines the maximum pressure ratios that can be
obtained by the turbine and the compressor. This, in turn, limits the maximum power and
efficiency that can be obtained by the engine. In order for tip speed to remain constant, if
the diameter of a rotor is reduced by half, the rotational speed must double. For example,
large Jet engines operate around 10,000 rpm, while micro turbines spin as fast as 500,000
rpm. More sophisticated turbines (such as those found in modern jet engines) may have
multiple shafts (spools), hundreds of turbine blades, movable stator blades, and a vast
system of complex piping, combustors and heat exchangers. Thrust and journal bearings are
a critical part of design. Traditionally, they have been hydrodynamic oil bearings, or oilcooled ball bearings.
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number. Beyond about 5 stages or a 4:1 design pressure ratio, variable geometry is
normally used to improve operation. Axial compressors can have high efficiencies; around
90% polytropic at their design conditions. However, they are relatively expensive, requiring
a large number of components, tight tolerances and high quality materials. Axial-flow
compressors can be found in medium to large gas turbine engines, in natural gas pumping
stations, and within certain chemical plants.
In Agartala Gas Turbine Power Plant each unit employs a 17 stage axial gas
compressor.
3.3. Combustion Chamber: The combustion chamber in gas turbines and jet engines
(including ramjets and scramjets) is called the combustor.
The combustor is fed with high pressure air by the compression system, adds fuel and burns
the mix and feeds the hot, high pressure exhaust into the turbine components of the engine
or out the exhaust nozzle.
Different types of combustors exist, mainly:
Can type: Can combustors are self contained cylindrical combustion chambers.
Each "can" has its own fuel injector, liner,interconnectors,casing. Each "can" get an
air source from individual opening.
Cannular type: Like the can type combustor, can annular combustors have discrete
combustion zones contained in separate liners with their own fuel injectors. Unlike
the can combustor, all the combustion zones share a common air casing.
Annular type: Annular combustors do away with the separate combustion zones
and simply have a continuous liner and casing in a ring (the annulus).
3.4. Gas Turbine: A gas turbine, also called a combustion turbine, is a type of internal
combustion engine. It has an upstream rotating compressor coupled to a downstream
turbine, and a combustion chamber in-between.
The basic operation of the gas turbine is similar to that of the steam power plant except that
air is used instead of water. Fresh atmospheric air flows through a compressor that brings it
to higher pressure. Energy is then added by spraying fuel into the air and igniting it so the
combustion generates a high-temperature flow. This high-temperature high-pressure gas
enters a turbine, where it expands down to the exhaust pressure, producing a shaft work
output in the process. The turbine shaft work is used to drive the compressor and other
devices such as an electric generator that may be coupled to the shaft. The energy that is not
used for shaft work comes out in the exhaust gases, so these have either a high temperature
or a high velocity. The purpose of the gas turbine determines the design so that the most
desirable energy form is maximized.
3.5. Load Reduction Gear Box: The gear ratio of a gear train, also known as its speed
ratio, is the ratio of the angular velocity of the input gear to the angular velocity of the
output gear. The gear ratio can be calculated directly from the numbers of teeth on the gears
in the gear train. The torque ratio of the gear train, also known as its mechanical advantage,
is determined by the gear ratio. The speed ratio and mechanical advantage are defined so
they yield the same number in an ideal linkage. In Agartala Gas Turbine Power Plant each
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unit employs a load reduction gear box which reduces the speed from 5000 rpm to 3000
rpm to synchronize with the grid frequency (standard grid frequency for India is 50 Hz).
Generator:In electricity generation, an electric generator is a device that converts
mechanical energy to electrical energy. A generator forces electric current to flow through
an external circuit. The source of mechanical energy may be a reciprocating or turbine
steam engine, water falling through a turbine or waterwheel, an internal combustion engine,
a wind turbine, a hand crank, compressed air, or any other source of mechanical energy.
Generators provide nearly all of the power for electric power grids.
An induction generator or asynchronous generator is a type of AC electrical generator that
uses the principles of induction motors to produce power. Induction generators operate by
mechanically turning their rotor faster than the synchronous speed, giving negative slip. A
regular AC asynchronous motor usually can be used as a generator, without any internal
modifications. Induction generators are useful in applications such as mini hydro power
plants, wind turbines, or in reducing high-pressure gas streams to lower pressure, because
they can recover energy with relatively simple controls.
To operate an induction generator must be excited with a leading voltage; this is usually
done by connection to an electrical grid, or sometimes they are self excited by using phase
correcting capacitors.
The primary supply of all the world's electrical energy is generated in three phase
synchronous generators using machines with power ratings up to 1500 MW or more.
Though the variety of electric generators is not as great as the wide variety of electric
motors available, they obey similar design rules and most of the operating principles used
in the various classes of electric motors are also applicable to electric generators. The vast
majority of generators are AC machines (Alternators) with a smaller number of DC
generators (Dynamos).
Stand Alone (Island) Systems In smaller, stand alone systems particularly those
designed to capture energy from intermittent energy flows such as wind and wave
power the voltage and frequency control may be carried out electronically. In
principle these control systems are similar to Motor Controls and the the various
components are outlined in that section.
Grid Connected Systems In grid connected systems the generator voltage and
frequency are locked to the grid system. Changing the energy output from the prime
mover does not affect the frequency and voltage but will cause the output current to
increase resulting in an equivalent change in the generator output power. When
connecting a generator to the grid, it's speed should be run up so that it's output
frequency matches the grid frequency before the connection is made.
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In a stationary field generator, the stator in the form of fixed permanent magnets (or
electromagnets fed by DC) provides the magnetic field and the current is generated
in the rotor windings.
When the rotor coil is rotated at constant speed in the field between the stator poles
the EMF generated in the coil will be approximately sinusoidal, the actual
waveform being dependent on the size and shape of the magnetic poles. The peak
voltage occurs when the moving conductor is passing the centre line of the magnetic
pole. It diminishes to zero when the conductor is in the space between the poles and
it increases to a peak in the opposite direction as the conductor approaches the
centre line of the opposite pole of the magnet. The frequency of the waveform is
directly proportional to the speed of rotation. The magnitude of the wave is also
proportional to the speed until the magnetic circuit saturates when rate of voltage
increase, as the speed increases, slows dramatically.
o
The output frequency is proportional to the number of poles per phase and
the rotor speed in the same way as a synchronous motor.
The alternating current output generated in the rotor can be connected to external
circuits via slip rings and does not need a commutator.
The high speed generator needs fewer poles, simplifying the design and reducing
the costs.
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The power handling capacity of a brushed machine is usually constrained by the current
handling capability of the slip rings in an AC machine (or even more by the
commutator in a DC machine). Since the generator load current is generally much
higher than the field current, it is usually desirable to use the rotor to create the field and
to take the power off the generator from the stator to minimise the load on the slip rings.
By interchanging the fixed and moving elements in the above example a rotating field
generator is created in which the EMF is instead generated in the stator windings. In
this case, in its simplest form, the field is provided by a permanent magnet (or
electromagnet) which is rotated within a fixed wire loop or coil in the stator. The
moving magnetic field due to the rotating magnet of the rotor will then cause a
sinusoidal current to flow in the fixed stator coil as the field moves past the stator
conductors. If the rotor field is provided by an electromagnet, it will need direct current
excitation fed through slip rings. It does not need a commutator.
If instead of a single coil, three independent stator coils or windings , spaced 120
degrees apart around the periphery of the machine, are used, then the output of these
windings will be three phase alternating current.
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Classified as a constant speed generator, they have poor voltage regulation and
few are in use.
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Brushless Excitation
Rotating field machines are used for the high power generating plant in most of
the world's national electricity grid systems. The field excitation power needed
for these huge machines can be as much as 2.5% of the output power ( 25 KW
in a 1.0 MW generator) though this reduces as the efficiency improves with size
so that a 500 MW generator needs 2.5 MW (0.5%) of excitation power. If the
field voltage is 1000 Volts, the required field current will be 2500 Amps.
Providing such excitation through slip rings is an engineering challenge which
has been overcome by generating the necessary power within the machine itself
by means of a pilot, three phase, stationary field generator on the same shaft.
The AC current generated in the pilot generator windings is rectified and fed
directly to the rotor windings to supply the excitation for the main machine.
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Cooling
The efficiency of a very large generator can be as high as 98% or 99% but for a 1000
MW generator, an efficiency loss of just 1% means 10 Megawatts of losses must be
dissipated, mostly in the form of heat. To avoid overheating, special cooling
precautions must be taken and two forms of cooling are usually employed
simultaneously. Cooling water is circulated through copper bars in the stator windings
and hydrogen is passed through the generator casing. Hydrogen has the advantages that
its density is only about 7% of the density of air resulting in fewer wind age losses due
to the rotor churning up the air in the machine and its thermal capacity is 10 times that
of air giving it superior heat removal capability.
Smaller versions of both of the above machines can use permanent magnets to provide
the machine's magnetic field and since no power is used in providing the field this
means that the machines are simpler and more efficient . The drawback however is that
there is no simple way to control such machines. Permanent magnet synchronous
generators (PMSGs) are typically used in low cost "gensets" to provide emergency
power.
The voltage and frequency output of the permanent magnet generator are proportional
to the speed of rotation and though this may not be a problem for applications powered
by fixed speed mechanical drives, many applications such as wind turbines, require a
fixed voltage and frequency output but are powered by variable speed prime movers. In
these cases, complex feedback control systems or external power conditioning may be
required to provide the desired stabilised output.
Generally the output will be rectified and the varying output voltage fed through the DC
link to a buck - boost regulator which provides a fixed voltage coupled with an inverter
which provides a fixed frequency output.
Induction Generators
Induction generators are essentially induction motors which are run slightly above the
synchronous speed associated with the supply frequency. They have no means of
producing or generating voltage unless they are connected to an external source of
excitation. The squirrel cage construction is used for small scale power generation
because it is simple, robust and inexpensive to manufacture.
o
Fixed speed induction generators actually run over a small speed range
associated with the generator slip. They receive their excitation from the
electricity supply grid and can only be run in parallel with that supply. When
used on line, they are fine for returning power to the grid from which they
derive their excitation current but useless as standby generators when the
electric grid goes down. Their limited speed range restricts the possible
applications.
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Small scale electricity generating systems are quite often stand alone
applications, remote from the electricity supply grid, utilising widely fluctuating
energy sources such as wind and water power for their source of energy. The
fixed speed induction generator is not suitable for such applications. Variable
speed induction generators need some form of self-excitation as well as power
conditioning to be able to make practical use of their unregulated voltage and
frequency output.
Operation
Control
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The output voltage ripple can be minimised by using multipole designs. The construction of
a DC generator is very similar to the construction of a DC motor.The rotor consists of an
electromagnet providing the field excitation. Current to the rotor is derived from the stator
or in the case of very large generators, from a separate exciter rotating on the same rotor
shaft. The connection to the rotor is through a commutator so that the direction of the
current in the stator windings changes direction as the rotor poles pass between alternate
north and south stator poles. The rotor current is very low compared with the current in the
stator windings and most of the heat is dissipated in the more massive stator structure.In
self excited machines, when starting from rest, the current to start the electromagnets
working is derived from the small residual magnetism which exists in the electromagnets
and surrounding magnetic circuit.
3.9. Electric power transmission and distribution.
Electric-power transmission is the bulk transfer of electrical energy, from generating
power plants to electrical substations located near demand centers. This is distinct from the
local wiring between high-voltage substations and customers, which is typically referred to
as electric power distribution. Transmission lines, when interconnected with each other,
become transmission networks. These are typically referred to as "power grids" or just "the
grid."
Electricity is transmitted at high voltages (110 kV or above) to reduce the energy lost in
long-distance transmission. Power is usually transmitted through overhead power lines.
Underground power transmission has a significantly higher cost and greater operational
limitations but is sometimes used in urban areas or sensitive locations.
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A key limitation in the distribution of electric power is that, with minor exceptions,
electrical energy cannot be stored, and therefore must be generated as needed. A
sophisticated control system is required to ensure electric generation very closely matches
the demand. If the demand for power exceeds the supply, generation plants and
transmission equipment can shut down which, in the worst cases, can lead to a major
regional blackout. To reduce the risk of such failures, electric transmission networks are
interconnected into regional, national or continental wide networks thereby providing
multiple redundant alternative routes for power to flow should (weather or equipment)
failures occur. Much analysis is done by transmission companies to determine the
maximum reliable capacity of each line (ordinarily less than its physical or thermal limit) to
ensure spare capacity is available should there be any such failure in another part of the
network. Transmission efficiency is greatly improved by devices that increase the voltage,
(and thereby proportionately reduce the current) in the line conductors, thus allowing power
to be transmitted with acceptable losses. The reduced current flowing through the line
reduces the heating losses in the conductors. According to Joule's Law, energy losses are
directly proportional to the square of the current. Thus, reducing the current by a factor of 2
will lower the energy lost to conductor resistance by a factor of 4.
This increase of voltage is usually achieved in AC circuits by using a step-up transformer.
HVDC systems require relatively costly conversion equipment which may be economically
justified for particular projects such as submarine cables and longer distance high capacity
point to point transmission but are infrequently used at present.
A transmission grid is a network of power stations, transmission lines, and substations.
Energy is usually transmitted within a grid with three-phase AC. Single-phase AC is used
only for distribution to end users since it is not usable for large polyphase induction motors.
In the 19th century, two-phase transmission was used but required either four wires or three
wires with unequal currents. Higher order phase systems require more than three wires, but
deliver marginal benefits.
The price of electric power station capacity is high, and electric demand is variable, so it is
often cheaper to import some portion of the needed power than to generate it locally.
Because loads are often regionally correlated (hot weather in the Southwest portion of the
US might cause many people to use air conditioners), electric power often comes from
distant sources. Because of the economic benefits of load sharing between regions, wide
area transmission grids now span countries and even continents. The web of
interconnections between power producers and consumers should enable power to flow,
even if some links are inoperative.
The unvarying (or slowly varying over many hours) portion of the electric demand is
known as the base load and is generally served by large facilities (which are more efficient
due to economies of scale) with fixed costs for fuel and operation. Such facilities are
nuclear, coal-fired or hydroelectric, while other energy sources such as concentrated solar
thermal and geothermal power have the potential to provide base load power. Renewable
energy sources such as solar photovoltaics, wind, wave, and tidal are, due to their
intermittency, not considered as supplying "base load" but will still add power to the grid.
The remaining or 'peak' power demand, is supplied by peaking power plants, which are
typically smaller, faster-responding, and higher cost sources, such as combined cycle or
combustion turbine plants fueled by natural gas.
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