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NEEPCO (North Eastern Electric Power Corporation) Government of India Enterprise under the ministry of India was set up on the 2nd of April, 1976 to plan, investigate, design, construct, generate, operate & maintain operations in North Eastern region of India. NEEPCO has an installed capacity of 1130 MW which is 50% of the total installed capacity of the north east region. With its headquarters in the hilly town of Shillong, the capital of Meghalaya, NEEPCO is a power sector enterprise with its plants in various states of North East India.NEEPCO is entrusted with the responsibility to supply power to North Eastern States of India. The projects of NEEPCO that have been commissioned & are presently under operation are 275 MW KOPLI HYDRO PROJECT 291 MW Assam Gas Based Power Plant 84 MW Agartala Gas Turbine Project 75 MW Doyang Hydro Electric Project 405 MW Ranganadi Hydro Electric Project
AGTP
This project is located in West Tripura District Of Tripura near the capital town of Agartala.This project runs on an Open Cycle and it consists of 4 Gas turbines of 21MW each of European Gas Turbine make operating on natural gas which is supplied by GAIL in the vicinity of this project. This project is financed by Deutsche Bank, Germany. This project was completed on 1997-98 and currently in commercial operation supplying electric power to the households, industries, hospitals etc. in Agartala and adjoining districts. Talks are going on to couple a steam turbine power plant with the Gas Turbine Plant here in Agartala thus using a combined cycle for producing electric power. This will create a closed cycle and is anticipated that the combined cycle will generate power more efficiently as compared to the power generated by the Gas Turbine Plant alone. This will not only benefit the state of Tripura but also its adjoining states in North Eastern India. NEEPCO for a better living and achievement.
another. When the hot air mixture attains the right temaperature and pressure, it is passed to a two stage turbine where it passes from a low pressure region to a high pressure region. The impact force of the products of combustion chamber is just sufficient to run the turbine at 5100 rpm. In India we generally supply electrical power at a frequency of 50 Hz. So for a 2 pole machine, the synchronous speed accordingly is 3000rpm ( as we know from the formulae N=120f/p where N=synchronous speed , f=frequency and p=no. of poles of the generator). So in order to reduce the speed from 5100 rpm to 3000 rpm a gear system is used. When the generator begins to run at the rated speed it produces an output voltage of 11 kV which is stepped up to 132 kV. So from here 3 phase current is supplied to the grid for transmission.
STARTING SYSTEM
GENERAL
Before the gas turbine can be fired and started it must be rotated or cranked by accessory equipment. This is accomplished by a diesel engine operating through a torque converter to provide the cranking torque and speed required by the turbine for its start up. Diesel motor system components include: the diesel engine, the torque converter with ratcheting mechanism, starting jaw clutch and a hydraulic ratchet mechanism. In addition there are several supplementary components required for sequencing and operation of the turbine starting system.
FUNCTIONAL DESCRIPTION
During the starting sequence, the gas turbine is driven through accessory gear by a starting motor, torque converter, output gear and the starting clutch. The starting clutch assembly and the engagement cylinder are mounted on accessory gear assembly. The accessory gear is permanently coupled to the compressor shaft by a flexible coupling. The torque converter transmits the diesel engine output torque to the gas turbine accessory gear through a reversing gear. The charge pump driven by the diesel engine provides a supply from the lube oil system and primed by an adjustable pressure valve.
Oil is initially supplied to the torque converter charge pump from the lube oil header through the charge pump primer. After the charge pump builds up operating pressure, it drains its oil supply from the turbine lube oil tank through a filter. Oil is then returned to the turbine lube oil tank through drains.
output gear. The pump rotor requires rated engine horsepower at rated speed., independent of the output load. Power absorption of the pump is directly proportional to the cube of the input speed. The hydraulic ratchet mechanism is a rack and pinion type rotary actuator connected through a roller ramp type one way clutch to the input shaft of the output gear. The output gear unit connects ratchet mechanism and the output side of the torque converter to the starting clutch.
Engagement is done through the transmission of torque through the electronic control panel. Once in every 3 minutes the mechanism is operated through one complete cycle. The cycle is terminated in forward stroke position to lock the clutch in engaged position
COMPRESSOR SECTION
GENERAL
The type of compressor used is axial type and has 17 stages. It consists of a compressive rotor, casing, variable inlet guide vanes and exit guide vanes. Air is confined between stator and rotor blades and is compressed in stages which comprises of alternate series of rotor and stator (which are air foiled shaped blades). Stator blades guide the air such that air may enter the rotor stages at a desired angle. Air from the compressor is used in combustion chamber and also for turbine cooling and bearing lube oil sealing
ROTOR
Compressor assembly has 16 blades and wheel assembly and one blade and stub shaft assembly. Both assemblies are bolted concentrically around rotor axes. Stub shafts are machined to provide the forward and thrust forces and journal for bearing assembly. Compressor rotor assembly is dynamically balanced before being assembled to the pre-balanced turbine assembly. The whole completed assembly is dynamically balanced.
STATOR
The stator portion of the compressor is divided into 4 sections namely inlet section, the forward section, aft section and the discharge section
INLET CASING
In the inlet section direct atmospheric air from outside is directed to the compressor blading. It contains the variable inlet guide assembly, the no.1 bearing assembly and low pressure air seals.
FORWARD CASING
It contains the stator blading for 0 to 3. Air from 4th rotor can be extracted four ports which are located at the aft section of the compressor casing.
BLADING The stator blades have dovetail shaped bases that fit into dovetail
shapes opening in two piece semi-circular ring. The rotor blades have dovetail bases of a wide angle design which fits into the matching dovetail opening in the wheels.
6. Fuel gas stop valve 7. Stop ration valve control servo-valve 8. Gas control valve 9. Pressure transmitter
FUNCTIONAL DESCRIPTION
Fuel gas is first cleaned by passing through a strainer as it comes from the supply piping prior to flowing through the gas valve and into the gas manifold piping. The fuel gas is metered and controlled by the gas valve to supply the required flow to the gas turbine system The fuel gas stop ratio and control valve consists of two independent valves (a stop ratio valve and control valve) combined into one housing assembly. Both the gas stop ratio valve and gas control valve are single action electro hydraulically operated. The fuel gas control valve is activated by a SPEEDTRONIC control signal to admit the proper amount of fuel required by the turbine for a given load or speed. The fuel gas stop ratio valve is used to shut off fuel flow to the turbine whenever required. It also controls the pressure ahead of the fuel gas control valve. This enables the gas control valve to control fuel flow over wide range required under turbine starting and operating conditions.
servo valve controlled by hydraulic cylinder to provide the required inter-valve pressure The gas stop ratio valve function in the fuel gas system is to provide a positive fuel shut-Off when either required by either normal or emergency situation. A fuel gas stop is operated by control oil pressure acting on the piston end of a spool. When the control oil pressure is normal the fuel gas trip valve is held in a position that allows the hydraulic oil to flow between control servo valve and hydraulic cylinders. In this position the normal control of the stop ration valve is allowed. In event of a drop in control oil pressure below a predetermined limit spring in the stop valve shifts the spool to interrupt the flow path of oil between the control servo-valve and the hydraulic cylinder. Hydraulic oil is sumped and the stop ration valve closed, shutting of the fuel gas flow to the turbine assembly.
GAS STRAINER
A fuel gas strainer is installed in upstream of a turbine base fuel inlet connection to facilitate site maintenance requirement. Connection to the fuel gas supply is made at the purchasers connection in the supply ahead of the gas strainer. Foreign particles that may be in the incoming fuel gas is remover by the strainer. A blow down connection on the bottom of the strainer provides the periodic cleaning of the strainer screen. Frequency of the cleaning will depend upon the quality of the fuel gas used. The strainer has to be cleaned after the turbine attains the full load for the first time and after any deassembly of the purchasers of the fuel gas line
PROTECTIVE DEVICES LOW GAS PRESSURE SWITCH A low gas pressure switch is installed in the gas piping ahead of the gas sop/speed ratio and control valve assembly provides a protection should the gas pressure drops below the switch setting. An alarm is indicated in the annuator (Annuciator) panel in the control counter. FUEL GAS VENT VALVE
A solenoid operated valve is installed in the vent piping from the casing of the combination gas stop speed ratio and gas control valve. When the turbine is shutdown any fuel gas that might accumulate in the compartment between the stop/speed ratio and control valve, vents to atmosphere through the piping PRESSURE TRANSMITTER Pressure transmitter are installed in the fuel system on the fuel gas discharge side of the stop/speed ratio to provide the operational pressure feedback signal of the SPEEDTRONIC control system. PRESSURE GAUGES Pressure gauges are provided in the fuel gas piping. The upstream gauge measures the pressure of the fuel gas entering the stop/speed ratio valve, the intermediate gauge measures the pressure as it leaves the valve and the downstream gauge measures the pressure of the gas leaving the gas control valve and flowing to the gas manifold.
COMBUSTION SECTION
GENERAL
The combustion chambers consist of combustion chamber, the fuel nozzles, flame detection equipments, spark plug and the transition pieces. The combustion chambers are arranged concentrically around the compressor discharge section. Air from the compressor is fuelled in the combustion chamber for burning process to take place.
COMBUSTION CHAMBER
In the combustion chamber the air under high pressure enters and flows forward. A portion of air reaches the forward or head section of the combustion chamber and enters the lower cap and vortex generator nozzle Air which enters the combustion chamber has three functions: To oxidize the fuel To cool the adjoining metal parts. To adjust the extremely hot combustion products to the desired inlet gas turbine temperature. They are designed in such a way as to eliminate any exhaust air pollution. This is achieved by a process known as thermal soating which ensures that any soot which may be present in the exhaust gas is completely burned down due to combustion. During this Dilution of combustion products is delayed to allow the complete combustion of the soot There is no injection of air into the liner until the air reaches the downstream end of the combustion chamber.
SPARK PLUGS
Spark plugs used in combustion chambers have retracing electrodes. Power required for producing spark in the plug in received from the ignition transformer. Among the 10 combustion chambers present, only 2 of them have spark plugs installed in them, other 8 combustion chambers are ignited by devices called crossfires UV FLAME DETECTOR The function of the UV FLAME DETECTOR is to detect the presence or absence of flame in the combustion chamber. It consists of a flame sensor and a container which is filled with gas. Gas present inside the container is sensitive to the presence of ultraviolet radiations emitted by the hydrocarbon flame. DC voltage is applied across the
detector terminals. Whenever the flame is present, ionization of gas in the detector takes place which allows the conduction of current through the terminals which in turn activates the in-built electronics to give a output defining flame.
FUEL NOZZLE
The function of the fuel nozzle is that it releases a metered amount of fuel in the combustion chamber at a regular interval of time.
CROSSFIRE TUBES
The 10 no. of combustion chambers are interconnected by means of crossfire tubes. This enables the flame to travel from the fired chambers to the unfired chambers.
TRANSITION PIECES
Before the compressor discharges oxygen rich air to the combustion chamber it must first of all pass through the transition pieces. This encounter allows heat cooling the transition pieces and also preheating of the combustion chamber.
GAS TURBINE
GENERAL
The G537PA single shaft machine is mounted on a single platform or base which supports the basic gas turbine and the accessory equipments. In addition to this, the base also supports the gas turbine inlet and exhaust plenums. The forward end of the base, under the accessory compartment also functions as a lube oil storage tank. The air inlet end is called the forward end and the discharge end is called the aft end.
WORKING
The gas turbine functions when the high temperature gases from the combustion chamber are converted into shaft horsepower. The power required to drive the load package and the turbine compressor is provided by a 2 stage rotor. The first stage is a high pressure wheel while the second stage is a low pressure wheel. The 4th stage extraction from the compressor is piped to cool the shell and then discharged at the aft end of the shell to cool the aft surface of the second stage turbine wheel.
INLET SYSTEM
GENERAL
Gas turbine performance and reliability is a function of quality and cleanliness of the inlet air entering the turbine. Atmospheric air is to be treated to filter out any contaminants. The inlet system with specially designed equipment ensures modification of the quality of air under various temperature, humidity and contamination situations and makes it more suitable for use in the unit. Hot exhaust gases from the combustion chambers are cooled in the exhaust system ducting before being released to the atmosphere. These exhaust emissions must meet certain environment standards of cleanliness and acoustic level depending on site location The noise produced during the process is reduced by absorptive material and devices for built into the inlet and exhaust sections which dissipate or reduce the acoustical energy to an acceptable level
EXHAUST SYSTEM
GENERAL
In the exhaust system the gases which have used to power turbine wheels are redirected and released to the atmosphere. Hot exhaust gases pass through the sound reducing silencer modules before being vented. One component of the system is the exhaust plenum on which is mounted a transition duct. Exhaust thermocouples are mounted in the aft wall of the exhaust plenum and sense the exhaust temperature and input those values to the control system
PLENUM
The exhaust plenum configuration is that of a box open on one side and open at the top ad welded to an extension of the turbine base. It encloses the turbine exhaust frame, diffuser and turbine vanes
The cooling water system is designed to accommodate the heat dissipation requirement of the turbine and generator lubrication system, the diesel engine cooling system and generator cooling system
FUNCTIONAL DESCRIPTION
Cooling water system acts as a cooling medium to cool several turbine generator components & maintain the lubricating fluid at acceptable lubrication system temperature levels. The system normally operates at a pressure level which results when the liquid in the system expands with the increase in temperature during the operation. The system however does not require pressurization to ensure proper operation. Cooling water circulates through the lube fluid heat exchanger to keep the lubricant system at the required temperature setting for effective lubrication of the turbine and generator bearings. It is also circulated through the diesel engine heat exchanger. The coolant circuit for the lube oil heat exchanger actuated, three way valves and a two way valve respectively installed in the coolant inlet line to the heat exchanger. Lube oil feed header temperature are sensed by the bulb associated to control the flow of coolant through the heat exchanger and maintain the lube oil temperature at the predetermined temperature. The valves automatically control flow of the medium passing through the heat exchanger by responding to the temperature changes affecting the bulb. Pressure thus generated in the bulb is transmitted through the capillary tube to the bellows which positions in the disc to control the flow of coolant through the heat exchanger.
TECHNICAL DATA
COMBUSTION SECTION TYPE 10 simple combustors, reverse flow design
CHAMBER ARRANGEMENT FUEL NOZZLES
2,ultraviolet type Light desitilate, natural gas 2 electrode type, spring injected , self-retracing
BEARING ASSEMBLIES
QUANTITY LUBRICATION NO.1 BEARING ASSY(LOCATED IN INLET CASING ASSY) JOURNAL INACTIVE THRUST NO.2 BEARING ASSY( LOCATED IN COMPRESSOR DISCHARGE CASING
Two Pressure lubricated Active and inactive thrust and journal all contained in one assembly Elliptical, active thrust Tilting pad, self-equalizing Journal, elliptical
AUXILLARY GEAR
TYPE SHAFT SPEED OF HYDRAULIC OIL PUMP MAIN OIL PUMP(INTEGRATED IN GEAR CASING)
FUEL SYSTEM
G5371(PA) 572 390-572420 Generator drive Simple 1 Counter clockwise 21600 KW 14100 KW/KWh 506 degree Celsius 3000 rpm Speedtronic MARK V Over speed, over temperature, vibration and flame detection Acoustic enclosures, inlet and outlet silencers to meet requirements 24.6 m above sea level 1013 hPa 27 degrees
COMPRESSOR SECTION
NO OF STAGES COMPRESSOR TYPE CASING SPLITTING
SPEED
5100 /min
TURBINE SECTION
NO OF STAGES CASING SPLIT NOZZLES FIRST STAGE SECOND STAGE
OIL CONSUMPTION AUXILLARY GEAR ACCESORY COUPLING BEARING ASSY NO,1 LOAD GEAR LOAD COUPLING BEARING ASSY NO.2
140L/min 18.9 L/min 257.4 L/min 565 L/min 26 L/min 64.4 L/min
It is a three phase induction motor driven vertical, submerged, centrifugal sample type
DELIVERY PRESSURE PUMP SPEED
Fuel flow Dual with transfer valve 5-micron filtration, pleated paper
MAIN HYDRAULIC SUPPLY PUMP RATED FLOW SPEED HYDRAULIC FILTER QUANTITY HYDRAULIC FILTER PAPER THICKNESS
Axial piston pump, accessory gear driven 62 L/min at 82.7 bar 1300 rpm Dual with transfer valve microns
PG 5371A
DRIVEN EQUIPMENT STARTING DEVICE DESIGNED FOR FUEL CONTRACT CONTROL SYSTEM FURTHER DETAILS
Generator Diesel engine Natural gas Speedtronic mark V Low-NOX water injection On and offline compressor washing system