JUNE - JULY

2009
Industrial Training Report

SUBMITTED BY:
DIGVIJAY SINGH
MECHANICAL (FINAL YR.)
ROLL NO. 0621640015
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 INDUSTRIAL TRAINING REPORT
ON
‘ NTPC DADRI’
GAS POWER PLANT

National Thermal Power Corporation Limited

National Capital Power Station - Dadri
P.O. Vidyut Nagar, District Gautam Budh Nagar - 201 008 (UP)

“NTPC was set up in the central sector in the 1975.Only PSU to achieve excellent
rati ng in respect of MOU targets signed with Govt. of India each year. NTPC Dadri
stati on has also bagged ISO 14001 certi fi cati on.
Today NTPC contributes more than 3 / 5th of the total power generati on in India.”

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 CONTENTS

S.NO. DESCRIPTION PAGE NO.

(1) OVERVIEW OF NTPC 3

(2) SATION AT A GLANCE 5

(3) INTRODUCTION TO GAS POWER PLANT 6

(4) GAS TURBINE STARTING SYSTEM 17

(5) FUEL SYSTEM 19

(6) GAS PLANT OPERATION 26

(7) HOW DOES A COMBINED-CYCLE POWER PLANT WORK? 30

(8) TRANSMITTED OF GENERATED POWER ONTO GRID

(9) AUTOMATION AND CONTROL 46

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(1) OVERVIEW OF NTPC

NTPC was set up in the central sector in the 1975 in response to widening demand & supply
gap with the main objective of planning, promoting & organizing an integrated development to
thermal power in India. Ever since its inception, NTPC has never looked back and the
corporation is treading steps of success one after the other. The only PSU to have achieved
excellent rating in respect of MOU targets signed with Govt. of India each year. NTPC is poised
to become a 40,000 MW corporation by the end of XI plan i.e. 2012 AD. Lighting up one fourth
of the nation, NTPC has an installed capacity of 19,291 MW from its commitment to provide
quality power; all the operating stations of NTPC located in the National Capital Region &
western have acquired ISO 9002 certification. The service groups like Engineering, Contracts,
materials and operation Services have also bagged the ISO 9001 certification. NTPC Dadri,
Ramagundam, Vindhyachal and Korba station have also bagged ISO 14001 certification.

Today NTPC contributes more than 3 / 5th of the total power generation in India.

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(2) STATION AT A GLANCE

NTPC dadri is model project of NTPC . also it tit the best project of NTPC also known as NCPS
( National capital power station ). Situated 60 kms away from Delhi in the District of gautam
budh Nagar, Uttar Pradesh. The station has an installed capacity of 1669 MW of power – 840
MW from Coal based units and 829 MW Gas Based Station . the station is excelling in
performance ever since it’s commercial operation . consistently in receipts of meritorious
projectivity awards, the coal based units of the station stood first in the country in terms of
PLF for the financial year 1999 – 2000 by generating an all time national high PLF of 96.12 %
with the most modern O & M Practices. NTPC – Dadri is committed to generated clean and
green Power. The Station also houses the first HVDC station of the country (GEP project) in
association with centre for power efficiency and Environment protection (CENEEP) – NTPC &
USAUID. The station has bagged ISO 14001 & ISO 9002 certification during the financial year
1999 – 2000, certified by Agency of International repute M/s DNV Netherlands M/s DNV
Germany respectively.

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(3) INTRODUCTION TO GAS POWER PLANT

3.1 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 sec tor 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 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 consists of gas turbine generating units waste heat recovery boilers, steam
turbo generator, ancillary electrical and mechanical equipments. The power generated at this
power station is fed over 220 KV AC transmission system associated with this project to distribute
the power in the various Regions.
In the Power Sector, gas turbine drive generators are used.

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

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3.2 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.

3.3 BRAYTON CYCLE

Gas Turbine plant-operate on Brayton Cycle in which air is compressed this compressed air is
heated in the combustor by burning fuel combustion produced is allowed to expand In the
Turbine and the turbine is coupled with the generator.

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 0C.

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:

th = Energy at GT shaft
Chemical Energy of fuel

= (Q Input. Q output )/ Q Input

= 1 — Q Output/ Q Input

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 Fig. (1)

3.4 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 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 0C to 550 0C at the inlet of the turbine.

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 Fig.2

3.5 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 0C and in Rankine Cycle heat is required to generate steam at the
temperature of 500-550 0C. 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.

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%.

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3.6 TYPES OF COMBINED CYCLE

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

3.6.1 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.

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 0C.

UNFIRED COMBINED CYCLE

FIG-3

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.

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3.6.2 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:

BOILER REPOWERING SYSTEM EXHAUST HEAT EXCHANGER

Fig. 4

Heat contained in exhaust gas is used to heat feed water to a desire 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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3.7 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 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.

3.8 ADVANTAGES OF COMBINED CYCLE PLANTS

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

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

2. 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.

3. 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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(4) 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 hy draulic 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.

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.

4.1 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.

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(5) FUEL SYSTEMS

5.1 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

5.1.1 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.

5.1.2 NAPHTAHA PRESSURING 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 m
easurements 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.

5.1.3 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.

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5.2 MODES OF FIRING

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

5.3 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.

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 off-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 veloc ity 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. The filter separators must have
minimum of two stages of separation. The initial stage being utilised 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.

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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.

5.4 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.

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(6) GAS PLANT OPERATION

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.

6.1 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.

6.2 OUTLINE OF EACH START UP

• NORMAL START UP MODE

This mode is two unit (2G/T’s + 2WHRB’s +1 S/T) combined cycle start up mode which, after
starting up one each of G/T and WHRB, starts up the 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 initial load is achieved, the pressure
control of HP/LP by-pass valves of both WHRB’S 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 WHRB’S is changed to
the common pressure control.

• RAPID START UP MODE

This is a mode of starting up both G/T’s and WHRB’S at the same time, changing the pressure
control of HP/LP by-pass valves of both WHRB’S 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).

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• 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 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 WHRB’s and detecting pressure before HP/LPCV so that HP/LP steam pressure of
both WHRB’S 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.

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(7) HOW DOES A COMBINED CYCLE POWER PLANT WORKS?

POWER GENERATION

7.1 AIR INLET

 The amount of air needed for combustion is 800,000 cubic feet per minute. This air is
drawn though the large air inlet section where it is cleaned, cooled and controlled, in
order to reduce noise.

7.2 TURBINE-GENERATOR:
 The air then enters the gas turbine where it is compressed, mixed with natural gas and
ignited, which causes it to expand. The pressure created from the expansion spins the
turbine blades, which are attached to a shaft and a generator, creating electricity.
 Each gas turbine produces 185 megawatts (MW) of electricity.
 The blades are attached to a rotor, which spins the generator, and makes electricity.
Think of a generator as a huge spinning magnet inside a coil of wire. As the magnet
spins, electricity is created in the wire loops.

7.3 HEAT RECOVERY STEAM GENERATOR (HRSG)

 The hot exhaust gas exits the turbine at about 1100 degrees Fahrenheit and then passes
through the Nooter Erickson, Heat Recovery Steam Generator (HRSG).
 In the HRSG, there are 18 layers of 100-foot tall tube bundles, filled with high purity
water. The hot exhaust gas coming from the turbines passes through these tube bundles,
which act like a radiator, boiling the water inside the tubes, and turning that water into
steam. The gas then exits the power plant through the exhaust stack at a much cooler
180 degrees, after having given up most of its heat to the steam process.

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7.4 STEAM TURBINE

 The steam turbine is a Siemens Westinghouse KN Turbine Generator, capable of

producing up to 240 MW. It is located on top of the condenser, across from the cooling
tower.
 Steam enters the turbine with temperatures as high as 1000 degrees Fahrenheit and
pressure as strong as 2,200 pounds per square inch. The pressure of the steam is used to
spin turbine blades that are attached to a rotor and a generator, producing additional
electricity, about 100 megawatts per HRSG unit.

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  After the steam is spent in the turbine process, the residual steam leaves the turbine at
low pressure and low heat, about 100 degrees. This exhaust steam passes into a
condenser, to be turned back into water.
 By using this “combined-cycle” process, two gas turbines and one steam turbine, we can
produce a total of about 600 megawatts of electricity.

7.5 EMISSION CONTROL

SELECTIVE CATALYTIC REDUCTION (SCR)

 To control the emissions in the exhaust gas so that it remains within permitted levels as
it enters the atmosphere, the exhaust gas passes though two catalysts located in the
HRSG.
 One catalyst controls Carbon Monoxide (CO) emissions and the other catalyst controls
Oxides of Nitrogen, (NOx) emissions.

AQUEOUS AMMONIA
 In addition to the SCR, Aqueous Ammonia (a mixture of 22% ammonia and 78% water) is
injected into system to even further reduce levels of NO x.

BEST AVAILABLE CONTROL TECHNOLOGY (BACT)

 Our annual average concentration of NOx is only 2 parts per million, which is considered
the “best available control technology” or BACT by the Air Board.
 As exhaust gas passes out of the exhaust stack, it is continuously sampled and analyzed,
assuring that permit limits are being met.
 With this kind of clean, modern technology, the exhaust stack is only 145 feet high,
compared to 500 feet, the height required by older power plants that use less efficient
emission technology.
 Environmental and health organizations recognize this technology as a benefit to the
community.

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(8) TRANSMISSION OF GENERATED POWER ONTO GRID

8.1 TRANSFORMERS

 The Gas Turbine and Steam Turbine generators produce power at 13,000 volts.
 The transformers take the generated 13,000 volts and “transform” them to 230,000
volts, which is the required voltage needed for transmission to the nearby tower that
sends power to the substation.
 A small amount of generation is directed to “Auxiliary transformers” which “transform”
the generated voltage to a lower voltage, so it may be used by the plant to power our
own pumps, fans, and motors. The Metcalf Energy Center requires 12 – 15 megawatts
to operate.
8.2 SWITCHYARD
 From each transformer, the power passes underground into our switchyard. The power
from all of the generators comes together there, where it is measured, metered and
directed onto the grid.
 The proximity of the site to a large, existing PG&E substation makes it a good place to
build a power plant and the nearest transmission tower is only about 200 feet away.
8.3 CONDENSOR AND COOLING TOWER
 The purpose of the condenser is to turn low energy steam back into pure water for use
in the Heat Recovery Steam Generator.
 The purpose of the cooling tower is to cool the circulating water that passes through the
condenser. It consists of ten cells with large fans on top, inside the cone-like stacks, and
a basin of water underneath.
 We process and treat the Title 22 recycled water after receiving it from the City, before
using it in our cooling tower. The cool basin water absorbs all of the heat from the
residual steam after being exhausted from the steam turbine and it is then piped back to
the top of the cooling tower.

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 As the cool water drops into the basin, hot wet air goes out of the stacks. Normally, hot
moist air mixes with cooler dry air, and typically a water vapor plume can be formed, one
that may travel hundreds of feet in the air and be seen from miles away. The California
Energy Commission considered this visually undesirable in this community so we added
a “Plume-Abatement” feature, louvers along the topsides of the tower that control the
air flow.
 The cooling tower evaporates about three-fourth of the processed, recycled water, then
we send about one-fourth of it back through the sewer lines for re-treatment by the City.
 The Metcalf Energy Center purchases 3 to 4 million gallons per day of recycled water
from the City of San Jose. Evaporation of this water assists the City in adhering to their
flow cap limits and helps to protect the sensitive saltwater marsh habitat of the San
Francisco Bay environment from receiving too much fresh, recycled water.

8.4 WATER TANKS

 The largest tank is the Service Water tank. It contains 470,000 gallons of water to be
used for drinking, fire fighting and for the high purity water train. The water from the
service water tank is pumped to the water treatment building where it then passes
through a reverse osmosis unit, a membrane decarbonater, and mixed resin bed
demineralizers to produce up to 400 gallons per minute of ultra pure water.
 The pure water is then stored in the smaller 365,000-gallon tank until it is turned into
steam for making electricity.

8.5 NATURAL GAS

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  Natural gas fuels the combustion turbines. Each turbine can consume up to 2,000
MMBTU per hour.
 The fuel comes from the major high pressure natural gas pipeline that runs along the
east side of Highway 101, less than 1 mile to the east of our site.
 During construction, “Horizontal Directional Drilling” was utilized with careful
coordination with many local authorities. The pipeline was built 60 feet underground
and passed under highways, creek, train tracks, and environmentally sensitive areas.
 The pipeline enters the site just behind the water tanks, where equipment regulates and
measures the natural gas composition, flow and pressure.
 Gas compressors pump the natural gas though the facilities’ fuel gas system where it is
delivered to the gas turbine and the HRSG duct burners at the proper temperature,
pressure and purity.

8.6 CONTROL ROOM

 From the control room, the plant operators monitor and operate the facility, via the
plant’s “Distributed Control System”, with the click of a mouse, viewing graphic
representations of all MEC systems on various screens.
 The system gives operators both audible and visual signals to keep them informed of
plant conditions at all times and to determine when preventative maintenance is
required.

(9) AUTOMATION AND CONTROL SYSTEM

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9.1 AUTOMATION: THE DEFINITION

The word automation is widely used today in relation to various types of applications, such as
office automation, plant or process automation.
This subsection presents the application of a control system for the automation of a process /
plant, such as a power station. In this last application, the automation actively controls the plant
during the three main phases of operation: plant start-up, power generation in stable or put
During plant start-up and shut-down, sequence controllers as well as long range modulating
controllers in or out of operation every piece of the plant, at the correct time and in coordinated
modes, taking into account safety as well as overstressing limits.

During stable generation of power, the modulating portion of the automation system keeps the
actual generated power value within the limits of the desired load demand.

During major load changes, the automation system automatically redefines new set points and
switches ON or OFF process pieces, to automatically bring the individual processes in an
optimally coordinated way to the new desired load demand. This load transfer is executed
according to pre- programmed adaptively controlled load gradients and in a safe way.

9.2 AUTOMATION: THE BENEFITS

The main benefits of plant automation are to increase overall plant availability and efficiency.
The increase of these two factors is achieved through a series of features summarized as
follows:

 Optimisation of house load consumption during plant start- up, shut-down and
operation, via:

 Faster plant start-up through elimination of control errors creating delays.

 Faster sequence of control actions compared to manual ones. Figures 1 shows the
sequence of a rapid restart using automation for a typical coal-fired station. Even a

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 well- trained operator crew would probably not be able to bring the plant to full load
in the same time without considerable risks.
 Co-ordination of house load to the generated power output.

 Ensure and maintain plant operation, even in case of disturbances in the control system,
via:

 Coordinated ON / OFF and modulating control switchover capability from a sub

process to a redundant one.
 Prevent sub-process and process tripping chain reaction following a process
component trip.

 Reduce plant / process shutdown time for repair and maintenance as well as repair
costs, via:

 Protection of individual process components against overstress (in a stable or

unstable plant operation).
 Bringing processes in a safe stage of operation, where process components are
protected against overstress

9.3 PROCESS STRUCTURE

Analysis of processes in Power Stations and Industry advocates the advisability of dividing the
complex overall process into individual sub-processes having distinctly defined functions. This
division of the process in clearly defined groups, termed as FUNCTIONAL GROUPS, results in a
hierarchical process structure. While the hierarchical structure is governed in the horizontal
direction by the number of drives (motorised valves, fans, dampers, pumps, etc.) in other words
the size of the process; in the vertical direction, there is a distinction made between three
fundamental levels, these being the: -

 Drive Level

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  Function Group Level
 Unit Level.

To the Drive Level, the lowest level, belong the individual process equipment and associated
electrical drives.

The Function Group is that part of the process that fulfils a particular defined task e.g., Induced
Draft Control, Feed Water Control, Blooming Mill Control, etc. Thus at the time of planning it is
necessary to identify each function group in a clear manner by assigning it to a particular
process activity. Each function group contains a combination of its associated individual
equipment drives. The drive levels are subordinate to this level. The function groups are
combined to obtain the overall process control function at the Unit Level.

The above three levels are defined with regard to the process and not from the control point of
view.

9.4 CONTROL SYSTEM STRUCTURE

The primary requirement to be fulfilled by any control system architecture is that it be capable
of being organized and implemented on true process-oriented lines. In other words, the control
system structure should map on to the hierarchy process structure.

BHEL’s PROCONTROL P®, a microprocessor based intelligent remote multiplexing system, meets
this requirement completely.

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9.5 SYSTEM OVERVIEW

The control and automation system used here is a micro based intelligent multiplexing system
This system, designed on a modular basis, allows to tighten the scope of control hardware to
the particular control strategy and operating requirements of the process

Regardless of the type and extent of process to control provides system uniformity and integrity
for:

 Signal conditioning and transmission

 Modulating controls

9.6 CONTROL AND MONITORING MECHANISMS

There are basically two types of Problems faced in a Power Plant

 Metallurgical
 Mechanical

Mechanical Problemcan be related to Turbines that is the max speed permissible for a turbine is
3000 rpm , so speed should be monitored and maintained at that level
Metallurgical Problem can be view as the max Inlet Temperature for Turbile is 1060 oC so
temperature should be below the limit.

Monitoring of all the parameters is necessary for the safety of both:

 Employees
 Machines

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So the Parameters to be monitored are :

 Speed
 Temperature
 Current
 Voltage
 Pressure
 Eccentricity
 Flow of Gases
 Vaccum Pressure
 Valves
 Level
 Vibration

9.6.1 PRESSURE MONITORING

Pressure can be monitored by three types of basic mechanisms

 Switches
 Gauges
 Transmitter type

For gauges we use Bourden tubes : The Bourdon Tube is a non liquid pressure measurement
device. It is widely used in applications where inexpensive static pressure measurements are
needed.

A typical Bourdon tube contains a curved tube that is open to external pressure input on one
end and is coupled mechanically to an indicating needle on the other end, as shown
schematically below.

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 Typical Bourdon Tube Pressure Gages

Transmitter types use transducers (electrical to electrical normally) they are used where
continuous monitoring is required. Normally capacitive transducers are used.

9.6.2 TEMPERATURE MONITORING

We can use Thernocouples or RTDs for temperature monitoring. Normally RTDs are used for low
temperatures.
Thermocouple selection depends upon two factors:
 Temperature Range
 Accuracy Required

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 RTDs are also used but not in protection systems due to vibrational errors. We pass a
constant curre t through the RTD. So that if R changes then the Voltage also changes
RTDs used in Industries are Pt100 and Pt1000
Pt100 : 0 0C – 100 Ω ( 1 Ω = 2.5 0C )
Pt1000 : 0 0C - 1000Ω
Pt1000 is used for higher accuracy
The gauges used for Temperature measurements are mercury filled Temperature gauges.
For Analog medium thermocouples are used And for Digital medium Switches are used which
are basically mercury switches.

9.6.3 FLOW MEASUREMENT

Flow measurement does not signify much and is measured just for metering purposes and for
monitoring the processes.

9.6.4 ROTAMETERS

A Rotameter is a device that measures the flow rate of liquid or gas in a closed tube. It is
occasionally misspelled as 'rotometer'.
It belongs to a class of meters called variable area meters, which measure flow rate by allowing
the cross sectional area the fluid travels through to vary, causing some measurable effect.
A rotameter consists of a tapered tube, typically made of glass, with a float inside that is pushed
up by flow and pulled down by gravity. At a higher flow rate more area (between the float and
the tube) is needed to accommodate the flow, so the float rises. Floats are made in many
different shapes, with spheres and spherical ellipses being the most common. The float is
shaped so that it rotates axially as the fluid passes. This allows you to tell if the float is stuck
since it will only rotate if it is not.

For Digital measurements Flap system is used.

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For Analog measurements we can use the following methods :
 Flowmeters
 Venurimeters / Orifice meters
 Turbines
 Massflow meters ( oil level )
 Ultrasonic Flow meters
 Magnetic Flowmeter ( water level )
Selection of flow meter depends upon the purpose , accuracy and liquid to be measured so
different types of meters used.
Turbine type are the simplest of all.
They work on the principle that on each rotation of the turbine a pulse is generated and that
pulse is counted to get the flow rate.

VENTURIMETERS :

Referring to the diagram, using Bernoulli's equation in the special case of incompressible fluids
(such as the approximation of a water jet), the theoretical pressure drop at the constriction
would be given by (ρ/2)(v22 - v12).
And we know that rate of flow is given by:

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Flow = k √ (D.P)
Where DP is Differential Presure or the Pressure Drop.

9.6.5 CONTROL VALVES

A valve is a device that regulates the flow of substances (either gases, fluidized solids, slurries,
or liquids) by opening, closing, or partially obstructing various passageways. Valves are
technically pipe fittings, but usually are discussed separately.
Valves are used in a variety of applications including industrial, military, commercial,
residential, transportation. Plumbing valves are the most obvious in everyday life, but many
more are used. Some valves are driven by pressure only, they are mainly used for safety
purposes in steam engines and domestic heating or cooking appliances. Others are used in a
controlled way, like in Otto cycle engines driven by a camshaft, where they play a major role in
engine cycle control.
Many valves are controlled manually with a handle attached to the valve stem. If the handle is
turned a quarter of a full turn (90°) between operating positions, the valve is called a quarter-
turn valve. Butterfly valves, ball valves, and plug valves are often quarter-turn valves. Valves can
also be controlled by devices called actuators attached to the stem. They can be
electromechanical actuators such as an electric motor or solenoid, pneumatic actuators which
are controlled by air pressure, or hydraulic actuators which are controlled by the pressure of a
liquid such as oil or water.

So there are basically three types of valves that are used in power industries besides the handle
valves. They are :
 Pneumatic Valves – they are air or gas controlled which is compressed to turn or move
them
 Hydraulic valves – they utilize oil in place of Air as oil has better compression
 Motorised valves – these valves are controlled by electric motors

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