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A
STUDY REPORT
ON
COMBINED CYCLE POWER PLANT
AT HAZIRA, SURAT


Submitted by: VIRAL J. PATEL
Department Of Mechanical Engineering.
Govt. engineering college,
valsad, Gujarat.


ACKNOWLEDEMENT
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We find it most difficult part of the entire project to record
our gratefulness to various persons to extended us more than the
necessary quantum of co-operation & help in this project. The words that
follow are merely the formal expression of are deep sense of
indebtedness that is better treasured in thoughts that said in words.
It is pleasure giving verbal expressions to our
feeling of deepest gratitude towards Mr.Anil Matoo (Head HR dept.) ,
Mr.Nishith Dayal, !" #$aintenance% & Mr. Sandip Sinha&!"
#"urchase% and our project guide also who guided and encouraged us
during the entire training period .
We would also li'e to express our gratitude to Mr.
Raesh Reddi, Mr. Moresh!ar "anjari, Mr. Shailendra sah,, Mr.
S.#oothalinga,
Mr. Sandip Goel, Mr. Nilesh $arasada, Mr. Alan De Sar%ar,Mr. D.
&atel of mechanical department also Mr. Gulshan Rana&() *epartment
for their unreserved co-operation& constant guidance and constructive
criticism.
We are very than'ful to +ssar ,roup for giving us
this golden opportunity to complete our training from a renowned industry.

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'(N)*N)
-. .bout +ssar
/. +ssar 0ombined 0ycle power plant
1. imple and 0ombined 0ycle
2. ,as Turbine and auxiliaries
3. (eat )ecovery team ,eneration
4. team turbine and auxiliaries
5. Water Treatment "lant
often "lant
*$ "lant
*SSAR &("*R
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"owering .head6
'(M&AN+ ($*R$,*"7
The +ssar group is one of India8s largest corporate
houses. Its interests span the manufacturing and service sectors in both
the old and new economies9 in steel& telecom& shipping& oil& power and
construction.
Its massive investments over the past decade have created compelling
tangible and intangible assets that have now begun to release value.

*SSAR &("*R7
substantially& giving us one of the lowest costs of production in India.
The government has notified +ssar "ower as an infrastructure company&
giving us the advantage of lower interest charges.
+ssar power is a significant force on India8s private
power generating landscape. It set up India8s first new generation
independent power plant at (a:ira& ,ujarat& after the government open
the power generation to private participation in the early -;;<8s. It has
consistently set new standards of excellence in the Indian power sector
and meets the highest operating benchmar's. It supplies around 5= of
the ,ujarat state8s power needs.
. >eing India?s first multi-fuel plant& it can operate simultaneously
on naphtha and gas& which will be a major advantage once @A,
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becomes freely available. >y switching over to @A,& our variable costs
have fallen
+ssar "ower @imited has an immaculate trac' record of
safety. The 0ompany has been consistently winning safety awards from
various institutions. This award has been
conferred on +ssar "ower @imited for maintaining excellent record in
safety and successfully
maintaining the incident rate far lower than that of national standards of
B.C. and also striving for the continuous improvement in (ealth and
afety standards. +arlier it had received this award in the year -;;D and
-;;;.
-ey value drivers.
- 3-3$W plant& which is India8s first independent power plant and first
multi fuel plant.
- World-class plant design and construction& equipment from ,eneral
+lectric& iemens and (oneywell.
- (ighly automated& with India8s lowest manpower to megawatt ratio.
- Ene of the few companies to receive the Fword of (onour8 from the
>ritish safety council.
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- Ene of India8s best technical teams& capable of setting up varied
power plants and of acting as operation and maintenance contractors.
- "lanning projects totaling over 1<<<$W of new capacity.
SIMPLE CYCLE The gas turbine operating itself is called as simple
cycle. The simple cycle is a constant flow cycle with a constant addition
of heat energy .It is commonly referred to as the >rayton cycle& after
,eorge >rayton .This cycle is plotted on temperature entropy co-
ordinates .The constant pressure line diverge with increasing
temperature and entropy. This divergent of constant pressure line ma'es
the simple cycle gas turbine possible.
The term >rayton cycle has more recently been given to
the gas turbine engine .This also has three components7
. gas compressor
. burner#combustion chamber%
.n expansion turbine
.ir is compressed from state -#atmospheric pressure% to
state/ in an axial flow compressor& while heat is added between states /
and 1 in a combustor .Wor' is then derived from expansion of hot
combustion gases from states 1 and 2.ince the expansion from states 1
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/ro (ther
#oilers




to 2 yield more wor' than that required to compress the air from state -to
/& useful wor' is produced to drive a load such as generator. The
efficiency of simple cycle is 1/=.

COMBINED CYCLE:

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/ro (ther
#oilers




The electricity generated in combined cycle by using
both gas turbine generator and steam turbine generator. ,as turbine
wor's on >rayton 0ycle and (eat )ecovery team ,enerator #(),%
wor's on )an'ine cycle.
. simple )an'ine cycle is consist of 2 components the
boiler #steam generators %&a turbine& a condenser and a boiler feed pump
.The simple cycle is shown on T- diagram .Aote that this boiler has a
super heater thus the steam temperature at the entrance of the turbine is
above the saturation temperature.
The first process in )an'ine cycle 1-2 is the increase in
pressure of the condensate from the condenser using boiler feed pump.
The second )an'ine cycle process represented by line 2-- is addition of
heat to water entering the boiler& the conversion of water from liquid to
steam and superheating of steam .This process is assumed to occur at
constant pressure. The steam is then expanded and cool as it passes
through the the turbine as represented by line --/.The last process in
)an'ine cycle is condensation of steam that exhausts from the turbine&
represented by line /-1.
The heat required to ma'e the )an'ine cycle wor' is
determined by the area under the curve 28-- and the heat lost from cycle
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Air
Gas Gas
)ur0ine )ur0ine
'opressor 'opressor
/uel
'o0ustion
Syste
*1haust
Alternator
#oiler
Stea Stea
)ur0ine )ur0ine
Alternator
'ondenser
'ooling "ater
#oiler /eed
&up(s)
'ondensate
*1traction
&up(s)
Deareator
)o other
#oilers
/ro (ther
#oilers




is under the curve 18-/.The area between the curve represents the heat
which is converted into useful mechanical wor'.
The efficiency of this cycle is about 3<=.

E!!AR COM"INED C#CLE POWER PLANT
Name ! t"e Cm#a$y : E%%a& #'e& (td
Ty#e ! t"e P(a$t : Cmbi$ed
)y)(e #'e& #(a$t
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0apacity 7 3-3$W
0onfiguration of the "lant 7 1 ,as turbine generator of
--<$WG11<$W
- team Turbine ,enerator of
-D3$W
Types of Huels used 7 A,@IAaphthaIAatural ,as I(*

@ocation of the "lant 7 (a:ira& /5 Cm from urat& 5Cm from
urat airport
*ate of 0ommissioning 7 ,TJ- 7 -2.<D.-;D3
,TJ/ 7 -3.<D.-;D3
,TJ1 7 -1.--.-;;5
T, 7 /4.<2.-;;5
Water ource 7 Wariv pump house at Tapi river #-3Cm from
surat%
*AS TURBINE
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$-;<<< gas turbine includes the compressor& combustion chamber&
turbine& the turbine casing exhaust frame& exhaust diffusers etc.
$odel 7 ",;-5-+
haft 7 -
peed 7 1<<<rpm
$aximum firing
Temperature 7 --/1.Ddeg 0
+xhaust temperature 7 33<deg 0
Hlow 7 2-/.;CgIs
)echnology 2eatures7
(igh reliability
(igh efficiency - imple cycle 1/= and 0ombined cycle 3<=
$ulti-fuel capability
$odular design
@ow-installed cost
(igh application flexibility
En-site maintenance capability
>uilt to operate in remote & hostile environments
+mergency start features
)he ajor constructional 2eatures are.
-5 stage axial compressor
!ariable inlet guide vanes for optimum efficiency
"ressure lubricated 1-bearing system
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0ombustion system consisting of -2 nos. reverse flow chambers
1-stage turbine & air cooled first and second stage no::les an
buc'ets
Hactory pac'aged and tested accessory base for easy installation
tarting through motor
A''*SS(R+ '(M&AR)M*N):
$ost of the mechanical and electrical auxiliary
equipment necessary for starting and operating the gas turbine is
contained within the accessory compartment.
There are many systems involved in operation of
turbine. everal of these systems have accessory devices& mechanisms&
located in the accessory section. These may include the starting& fuel&
lubrication& hydraulic& cooling water and atomi:ing air system. everal
major components of the accessories compartment include the starting
means& the torque converter and the accessory drive gear.
A''*SS(R+ *34,&M*N)

#AS* M(4N)*D A45,6,AR,*S + .ll turbine auxiliaries are base K
mounted to save installation costs and facilitate factory reliability tests of
the complete system
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A45,6,AR,*S (,6 &4M&S+ . variety of oil pumps and drives and
available to meet individual requirements.
S)AR),NG D*$,'*$ >efore the gas turbine can be fired and brought
to operating speed it must be first be rotated or cran'ed by the
accessory equipment. This is accomplished by an .0 induction motor.

GA4G* &AN*6S + Instrument grouped in centrali:ed location for
operator convenience.
)(R34* '(N$*R)*R,The starting motor drives the torque
converter through a flexible coupling. It provides the cran'ing torque and
speed required by the turbine or starter. It is coupled to the accessories
gear. This same equipment continuous to rotate the turbine rotor at slow
speed for cool down purpose. "rovides torque multiplication for starting
function.
A''.G*AR #(5 $The accessory drive gear is the gearing assembly
coupled directly through a flexible coupling to the turbine rotor. Its main
function is to drive each gas turbine accessory at its proper speed and to
connect the turbine to its starting device. "rovides auxiliary drives for
main lube oil pump& main atomi:ing air compressor& main hydraulic
supply pump& the liquid fuel pump and the water pump.

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Driven Accessory7
Torque 0onverter 7 1<<<rpm
.tomi:ing .ir 0ompressor 7 44<<rpm
(ydraulic upply "ump 7 -2/3rpm
@ube Eil "ump 7 -2/3rpm
(,6 '((6*RS AND /,6)*RS + .ll lubricant pumped from lube oil
reservoir to the bearing header flows through *ual lube fluid heat
exchanger to remove excess heat.
Two #*ual% filters are used with a transfer valve
installed between the filters to direct oil flow through either filter and into
the lube oil header. Enly one filter will be in service at a time.
/4*6 /6(" D,$,D*R + The flow divider equally distributes input fuel
flow to the -2 combustion no::les. It consists of -2 gear pump element
in a circular arrangement having a common inlet with a single timing
gear. .s the fuel enters the flow divider each pair of gear elements
distributes one-fourteenth of the fuel flow into each of the fuel lines
going to the fuel no::le.
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0E$")+E)
The axial flow compressor consists of
compressor rotor and the enclosing casing. The compressor casing
includes the inlet guide vanes& the -5 stages of rotor and stator blading
and the exit guide vanes.
In the compressor& air is compressed in stages
by a series of alternate rotating #rotor% and stationary #stator% airfoil
shaped blades. The rotor blades supply the force needed to compress
the air and the stator blades guides the air. 0ompressed air exit through
compressor exit casing. .ir is extracted from the diff. stages of
compressor is used for sealing and pulsation control.
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o $anufacturer 7 ,eneral +lectric 0ompany
o Type 7 $ulti-tage& .xial Hlow
o 0ompressor 7 --7-
o Eperating peed 7 1<<<rpm
o Inlet ,uide !ane 7 !ariable-$odulating Type

The main components of compressor are explained below7
R()(R7
The compressor rotor is an assembly of -5 individual wheels&
two stub shafts and compressor rotor blades. +ach wheel and the wheel
portion of each stub shaft have slots broached around its periphery& the
rotor blades are inserted into theses slots.

S)A)(R.
The stator casing composed of four sections
Inlet casing
Horward compressor casing
.fter compressor casing
0ompressor discharge casing

,N6*) 'AS,NG.
The inlet casing is located at the forward end of the gas
turbine. Its prime function is to uniformly direct air into compressor .It also
supports the no. - bearing housing.
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/(R"ARD 'AS,NG7
The forward compressor casing contains the first
2compressor stator stages. It also transfers the structural loads from the
adjoining casing to the forward support.
A/)*R 'AS,NG:
The after compressor casing contains the fifth through
tenth compressor stages. +xtraction ports in the casing permit removal
of fifth and eleventh stage compressor
air. This air is used for cooling and sealing function and also used for
pulsation control.
D,S'HARG* 'AS,NG:
The compressor discharge casing is the final portion of
the compressor section. The function of the compressor discharge
casing is to contain the final seven compressor stages to form both the
inner and outer valves of the compressor diffuser& and to join the
compressor and turbine stators.
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0E$>BTIEA LT+$
The combustion system is of the reverse flow type with
-2
th
combustion chamber arranged around the periphery of the
compressor discharge casing. This system also includes fuel no::les&
spar' plug ignition system& flame detectors and crossfire tubes.
(igh pressure air from compressor discharge is
directed into the combustion chamber liner& around the transient pieces.
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This air enters the combustion :one for proper fuel combustion through
metering holes and to cool the combustion liner through slots. Huel
supply is through no::le.
0ombustion chambers are numbered counter
cloc'wise when viewed loo'ing downstream and starting from the top of
the machine.
'(M#4S),(N "RA&&*R:
The combustion wrapper is a fabricated casing that
encloses the combustion area and provides a support surface for the
combustion chamber assembly. The plenum is formed in which the
compressor discharge air flow is directed to the combustion 0hamber.
'(M#4S),(N 'HAM#*R7
*ischarge air from the compressor flows upstream
along the outside of the combustion liner towards the liner cap. This air
enters the combustion chamber through the fuel no::le& swirl tip&
metering holes in both cap and liner and combustion holes in the forward
half of the liner. .dditional air is mixed with the combustion in a dilution
:one through metering house. .long the length of the combustion liner
and liner cap are openings to provide a film of air for cooling the walls of
liner and cap.
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N(776*S.
+ach combustion chamber consists of a fuel no::le.
,aseous fuel is
admitted directly into each chamber through metering holes located in
the outer valve of the gas swirl tip. The liquid fuel is atomi:ed with air
and then spread in the combustion :one. The action of the swirl tips
imparts a swirl to the combustion air for proper combustion.
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'R(SS/,R* )4#*S.
.ll combustion chambers are interconnected with the
help of crossfire tubes. These tubes propagate flame from the fired
chambers to the unfired chambers.
S&AR- &64G.
Two high voltage retractable electrodes spar' plug are
installed in adjacent combustion chamber for initiating the combustion.
/6AM* D*)*')(RS7
*uring the starting sequence it is essential that an
indication of the presence or absence of flame be transmitted to the
control system. Hor this reason& flame monitoring system is used
consisting of two sensors which are installed on two adjacent
combustion chambers.
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)4R#,N* S*'),(N
In the three stage turbine section the energy in the form of high
temperature pressuri:ed gas& produced by the compressor and
combustion sections& is converted into mechanical energy.
)4R#,N* R()(R7
This assembly is consists of two wheel shafts9 the first&
second and third stage turbine wheels with buc'ets9 and two turbine
spacer. The journal for the no./ bearing is a part of the forward wheel
shaft similarly after wheel shaft includes the no.1 bearing journal. The
turbine rotor assembly is arranged so that the buc'ets can be replaced
without unstac'ing the wheels& spacers and wheel shaft assemblies-
#4'-*)S.
The turbine buc'ets increases in si:e from the first to the
third stage. >ecause of the pressure reduction from energy conversion in
each stages& and increased annulus area is required to accommodate
the gas flow9 thus necessitating increasing the si:e of the buc'ets.
S)A)(R.
The $-;<<< gas turbine stator structure internally
supports the turbine no::les& shrouds& no.1 bearing and turbine exhaust
diffuser.
N(776*.
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There are three stages of stationary no::les which
direct the high velocity flow of the expanded hot combustion gas against
the turbine buc'et causing the turbine rotor to rotate. >ecause of the
high pressure drop across these no::les& there are seals at both the
inside and the outside diameter to prevent loss of system energy by
lea'age.
There are mainly three stages of no::les9 first stage no::les&
second stage no::les and third stage no::les. ince theses no::les
operate in the hot combustion gas flow they are subjected to thermal
stress hence needed to be cooled.
SHR(4DS7
The turbine buc'et tips run against annular curved
segments called turbine shrouds. It provides a cylindrical surface for
minimi:ing buc'et tip clearance lea'age. It acts as a high thermal
resistance between the hot gases and the comparatively cool shell.
*5HA4S) /RAM* ASS*M#6+7
+xhaust frame assembly consist of the exhaust frame and
exhaust diffuser. The exhaust frame is bolted to the after flange of the
turbine shell. The exhaust diffuser& located at the extreme after end of the
gas turbine& bolts to& and is supported by& the exhaust frame.
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GAS )4R#,N* A45,6,AR+ S+S)*MS
/,6)*RS.
Hilters are the primary component of gas turbine. The purpose
of filter is to filter out the dust particle at the si:e of / micron. These
particles if allowed in may cause severe
erosion of compressor and turbine blades. There are three ban's of
filters and there are in all -/D< filters. The types of filter used are cartridge
cylindrical filter. +. fine dust holding capacity is 33/3gm.
&46SA),(N.
These filters are self cleaning filters. These filters are self
cleaned by reverse pulse of high pressure air through filters. This reverse
cleaning process is called as pulsation. The pulse frequency is one pulse
per minute. .t a time 2 filters get the pulsation. The air used for pulsation
is bled off from the --
th
stage of compressor.

M**/(G S+S)*M7
The efficient temperature is -3deg.0. >ut specially in
summer it goes beyond -3deg 0 and ultimately the efficiency drops. To
low down the temperature of atmospheric air water at pressure 5CgIcm/
is sprin'led on the filtered air. This system is called as the $++HE,
system.

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,N6*) D4') S'R**N7
Inlet screens are provided immediately upstream of the
initial filters to prevent the entry of leaves& twigs papers and other similar
objects. These screens must be 'ept free from any excess accumulation
of such debris to ensure free air flow.

)4R#,N* S)AR),NG S+S)*M.
The starting motor is used for rotating or cran'ing turbine
before it can be fired and started. Typically& the ,as turbine becomes
self sustaining at 4< = speed after which the starting motor is
withdrawn. The starting system consists of an induction motor and
torque converter coupled to accessory gear. . motor driven torque
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adjustor drive forms an integral part of the torque converter system
which provides means for adjusting torque output within specified
ranges.
)4R#,N* 8G*N. 64#R,'A),NG (,6 S+S)*M.
The lubricating oil is used for main turbine bearings&
generator bearings& accessory gears and the @ube oil circuit also feeds
the (ydraulic oil & Trip oil circuits. It is also used as hydraulic fluid in
starting means torque converter.
ystem components7
-. $ain lube oil pump #haft driven from acc. gear%
/. .uxiliary lube oil pump #.0 motor driven submerged centrifugal
pump%
1. +mergency lube oil pump #*0 motor driven sub merged
centrifugal pump%
2. @ube oil reservoir in .ccessory >ase approx. -< C@ capacity.
The .ux. lube oil pump provides oil during gas turbine startup
and when main pump cannot supply adequate pressure for safe
operation.. The .ux. Eil pump cuts off at the ,as turbine speed of
;3=. *uring full speed operation the shaft driven main oil pump is
capable of delivering oil for all the above functions . +mergency
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lube oil pump supplies lube oil during emergency conditions e.g. @oss of
.0 power & avoids damage to the bearings.
)4R#,N* )R,& (,6 9 H+DRA46,' S+S)*M.
The gas turbine protection system is designed to provide
for a safe shutdown of gas turbine . The protections are strictly for
abnormal and emergency operating condition requiring immediate
shutdown of the Turbine. The (ydraulic oil is the high pressure oil
required to operate the fuel valves & the I,!8s as per the command
from the peedtronic mar' !.
The Trip oil is the primary interface between the turbine
control and protection system circuits #"++*T)EAI0 control system%
and the Huel valves on the turbine which admit or shut off fuel. In the
event of a trip initiation & the trip oil drains out causing the
(ydraulic oil circuit to be depressuri:ed . This results in the fuel
valves to close.
A)(M,S,NG A,R S+S)*M.
@iquid fuels require to be bro'en into particles by high-
pressure atomi:ing air& which increases surface area& and hence
complete and proper combustion is achieved. .ir for this purpose is
ta'en from last stage of the compressor& and the pressure is
increased before delivery to the no::le.
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ystem components7
-. $ain atomi:ing air compressor.
/. >ooster air compressor.
1. .tomi:ing air heat exchanger.
*uring turbine start up& atomi:ing air is supplied by motor
driven booster compressor& because accessory gear driven main
compressor does not deliver sufficient pressure at low turbine speed.
>ooster compressor shutdown at ;3= turbine speed during startups.
Hor maintaining a uniform inlet temperature to the atomi:ing air
compressor& air ta'en from the atomi:ing air extraction is passed
through air-to-water heat exchanger.
'((6,NG AND S*A6,NG A,R S+S)*M.
The air drawn from the compressor fifth stage is
used for feeding air to the cooing and sealing air system . This
system provides necessary air flow to the parts of the rotor and stator for
-. 0ooling of Internal turbine parts subjected to high temperature li'e
shrouds in the stator.
/. ealing of Turbine exhaust side & 0ompressor inlet side bearings.
)4R#,N* $*N),6A),NG S+S)*M.
!entilating system is provided in turbine& accessory and
load compartment for ventilating hot air & for removing the fuel oil
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fumes from the turbine I accessory compartment which can be a
safety ha:ard. The vent fans& driven by an .0 motor pulls air into
accessory compartment and after circulating& exhaust the heated air out
through vertical stac'. In turbine compartment-cooling air is brought in
through six ventilating louvers and heated air is exhausted through vent
fans located on turbine compartment roof. 0ooling air for load
compartment is brought in through two ventilation openings and heated
air is exhausted through vent fan.

'(M&R*SS(R "A)*R "ASH S+S)*M.
,as turbines can experience a loss of performance
during operation as a result of deposits of atmospheric components
such as dirt& insects& dust and hydrocarbon film on compressor parts
which occur with the ingestion of air. $ost of these can be removed by
inlet air filtration however& the dry components that pass through the
filters as well as wet contaminants &have to be removed periodically
by washing with a water and detergent solution followed by a water
rinse. Water wash may be performed both on - line as well as off - line.
GAS /4*6 S+S)*M.
,as fuel system is designed to deliver gas fuel to
turbine combustion chamber at the proper pressure and flow rates to
meet all of the starting& accelerating and loading of gas turbine. ,as
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comes through the scrubbers where it loses the condensates and
passes through the filters where the dust is removed.
The filtered gas is delivered to the gas turbine
where a stop ratio valve maintains the pressure of the gas at
desired value . The gas quantity fed into the gas turbine is
controlled by a control valve which is controlled by peedtronic $'
! . ,as is supplied to each combustion chamber from a ring which
equally divides the gas in to -2 parts and is supplied to the can through
individual lines.
6,34,D /4*6 S+S)*M.
EHH->.+ fuel system consists of fuel tan's&
forwarding pumps and fuel selection s'id. The pumps provide the fuel at
required pressure to the fuel selection s'id where it gets filtered
through Eff-base filters and after metering it goes to En-base filters

in accessory compartment.
EA-base liquid fuel system consists of hydraulically
operated stop valve& filters& gear driven screw pump& and flow divider.
Huel after filtration & is supplied equally to -2 no::les of combustion
chambers by flow divider at required pressure and flow rate&
provided by shaft driven screw pump . In the event of turbine tripping
hydraulic oil gets drained and stop valve closes. ince A,@ and
A."T(. have very low lubricating property lube oil is added to through
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lubricity injection module where (itec is added to the fuel with the help
of pumps at the required rate. @ubricator pump provides forced
lubrication to the bearings of the main fuel oil pump .
6,34,D /4*6 S+S)*M (HSD).
(* is used as the start up liquid fuel. .fter the ,as
Turbine starts generating power& the fuel is changed over to Aaphtha.
To remove entrapped naphtha from combustion system during gas
turbine startup and shut down & also in the event of a trip& (* is used
as the draining medium and procedure is called as Aaphtha draining.
.fter draining has been accomplished fuel is
pumped bac' to the storage tan' by an .0 driven pump. This system is
'nown as waste fuel drainage system.
GAS )4R#,N* A45,6,AR+ '((6,NG "A)*R S+S)*M.
The cooling water system is a closed system
designed for cooling the Turbine and generator lube oil& the atomi:ing air
and Turbine supports. It consists of both on -base and Eff-base
mounted components. The En-base components include
-. @ube fluid heat exchangers in .ccessory base.
/. Turbine support legs.
1. Hour Aos. (eat exchangers of generator hydrogen cooling system.
2. Hlow regulation valves orifices.
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The off base system comprises cooling towers & .0W circulation
pumps.

)4R#,N* S4&&(R)S.
The gas turbine is mounted to its base by vertical
supports at three locations9 the forward supports at the lower half vertical
flange of the forward compressor casing and the after two on either side
of the turbine exhaust frame. The outer surface of each after support leg
is a water jac'et. 0ooling water is circulating through the jac'ets is to
minimi:e thermal expansion of the support legs and assist in maintaining
alignment between the turbine and the generator.
The support legs maintain the axial and vertical
position of the turbine& while a gib 'ey coupled with the turbine support
legs maintains its lateral position.
#*AR,NGS.
The $-;<<< ,T unit contains three main journal bearing
used to support the gas turbine rotor.
Ao -bearing7 It is located in the center of the inlet casing assembly
and contains three bearings active thrust bearing& inactive thrust bearing
and journal bearing.
Ao. / bearing7 It is located in the center of the inner cylinder of the
compressor discharge casing.
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Ao. 1 bearing7 It is located at the after end of the turbine shaft in the
center of the exhaust frame assembly.
H*A) R*'($*R+ S)*AM G*N*RA),(N
,N)R(D4'),(N.
In the simple cycle the temperature of the exhausted
gas leaving a gas turbine can be high as --<<degH.(igh temperature
gas represents a source of heat energy .ome of which are recovered if
there is any alternative to do so .>y recovering the waste heat the output
and efficiency of power plant can be increased .
The function of (), is to recovery the waste
heat available in exhaust gases and transfers it to the water and steam.
The heat recovered is used to generate steam at high pressure and
temperature ..dditional power in a steam turbine driven generator is
generated from the steam .(), provides the critical lin' between the
gas turbine and )an'ine cycle in the combined cycle plant.
(&*RA),(N.
The condensate from gland steam condenser passes
through condenser preheated #0"(% and then to deaerator. In deaerator
the excess gases are removed .In feed water tan' #HWT% the steam is
ta'en from @" mean steam header which is called as pegging .To
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increase the temperature to the saturation temperature#--Ddeg0% at a
pressure of -./bar which increases the rate of oxygen release. Then this
*$ water in pump through three individual @" and (" feed water
system.
H,GH &R*SS4R* "A)*R 8 S)*AM /6(" &A)H
.fter passing through the feed water regulating
valve the water flows through high pressure low
temperature#("@T%economi:er &then the water flows through the high
pressure intermediate temperature# ("IT % economi:er and passes
through high pressure high temperature#("(T% economi:er.
.fter leaving ("(T economi:er& the water enters ("
steam drum through feed water inlet no::le and continuous to the ("
evaporator .Aatural circulation is maintained
in the (" evaporator by means of two down comers which feed the
water to the lower evaporator headers. The steam is generated and
flows upward in the evaporator tubes .The saturated water steam
mixture is conducted from the upper (" evaporator to the (" drum
through /2 risers .The saturated steam separated from the saturated
water steam mixture by the drum internals and then exit through two
saturated steam outlets.
The saturated steam leaving the drum passes through
the ("@T I( .The
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steam then flows through ("I" I(& then through the desuperheater
where small portion of water is tapped from the HWT and used as spray
water for (" I( desuperheater to minimi:e the temperature and then
pass through ("(T I( .The steam leaving the ("(T I( is combined
into the (" outlet steam header.
.s there are three gas turbines connected to three
(),& three ("(T I( outlets are connected to main (" steam header
6(" &R*SS4R* "A)*R 8S)*AM /6(" &A)H
The water from HWT is pumped through three @" HW"
and passes through the feed regulating value. The @" feed water enters
the (), at the @" economi:er. The water flow through @" economi:er
enter the @" steam drum through the feed water inlet no::le and
continuous on the @" evaporator. Aatural circulation is maintained by
means of two down comers. team is generated and flows upward in the
evaporator tubes. The saturated water steam mixture is conducted to the
@" steam drum through -2 risers. The saturated steam separated and
exit through two saturated steam output. The saturated steam outlet
direct the @" saturated steam to the single stage @" I( and combines
with the @" steam outlet header.
.s there are three (),& three @" I( outlets are
connected to the @" common header.
GAS S,D* /6(" &A)H
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The exhaust passes through the diverter damper and
then will pass by the pressure section in the following order.
("(T I( --- ("IT I( --- ("@T I( --- ("
+!."E).TE)---("(T +0EAE$I+) --- ("IT +0EAE$I+) --- @"
I( --- @" +!."E).TE) --- ("@T +0EAE$I+) --- @"
+0EAE$I+) --- 0EA*+A.T+ (+.T+) .

The exhaust gas will leave condensate heater and exit the
(), through the main exhaust stac'.

H& AND 6& #+&ASS S+S)*M
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The (" and @" steam bypass is a primary safety device for
(), against over pressuri:ation. In the event of steam turbine trip & the
entire steam production of (), is diverted through the condenser by
means of (" and @" bypass valve. The steam dumped to the condenser
is mixed with the desuper rating water spray to avoid high temperature in
condenser.
The bypass steam also allows steam generator to gradually
buildup the pressure and temperature of (" and @" during start up.
This system enables hot restarting of unit and warming up
steam line.
DR4M
The main function of drum is to reduce the moisture content of
saturated steam leaving the drum by mechanical means.
The feed water is fed to the drum through the feed water
no::le. The water then enters the down comers and the steam water
mixture enters through risers. The steam water mixture is collected in the
internal compartment the saturated steam travels through turbo
separators which is also called as centrifugal separators as it wor's on
the principle of centrifugal action. When the steam water mixture enters
the turbo separators due to the spinning action& the centrifugal force act
on the steam water mixture. The saturated steam at high velocities there
by loses most of its entrained water and enters the corrugated plate
driers. The drier directs the steam and forces any remaining entrained
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water against the corrugated plates since the velocity is relatively low&
this water can not be pic'ed up again and runs down the corrugated
plates and returns to the lower part of drum.
(" operating pressure 7 D2.3CgIcm/
(" operating temperature 7 /;D.1deg0
@" operating pressure 7 4CgIcm/
@" operating temperature 7 -42.2deg0

'(),N4(4S #6(" D("N 6,N* ('#D).
0>* line controls the concentration of the soluble solids in
the boiler water because it constantly removes a small portion of solids
and their by maintains relatively constant concentration in the boiler
water.
,N)*RM,))*N) #6(" (// 6,N* (,#D).
I>* should always be used to free a boiler of sediment &
when the boiler is being shut down .The should be blow down at least
once every /2 hour or more often during commissioning if the water is of
inferior quality or the amount of ma'e is large .
SA/*)+ $A6$*.
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It serves to protect pressure vessels from overpressure on
I( outlet .They serve the additional purpose of protecting the I( from
over heating in the event of sudden interruption in the steam
consumption.
"A)*R 6*$*6 ,ND,'A)(R.
The main function of the water level indicator is to indicate
the water level inside the drum& which should be at normal set value.
'H*M,'A6 D(S,NG.
Trisodium phosphate is used for maintaining the p( of
the water inside the drum .The p( is maintained at ;.3.
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S)*AM )4R#,N* AND G*N*RA)(R
team turbine coverts heat energy of steam to mechanical
energy .team turbine consists of two section (igh pressure and @ow
pressure. (" steam is supplied from common main steam header from all
three (), the @" steam is supplied from the common @" main
steam header through one stop and control valve. @" steam enters after
last stage of (" turbine where it mixes with (" steam which has already
done its wor'. Then finally it enters the @" turbine through crossover pipe.
Type 7 Impulse Turbine
)ating 7 -D4.-$W
peed 7 1<<<rpm
(" steam flow 7 3/4.34TIhr
@" steam f low 7 4<4.1TIhr
(" Throttle Temperature 7 3/<deg 0
(" Throttle "ressure 7 54CgIcm/
@" Throttle Temperature 7 /<3deg0
@" Throttle "ressure 7 3.-CgIcm/
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(" turbine stages 7 --
@" turbine stages 7 -4
,enerator uses hydrogen as cooling medium .There
are 2 Aos. of water cooled heat exchanger for cooling hydrogen. The hot
water is then cooled in Induced draught cooling tower #I*0T% for further
recirculation.

,enerator parameter
Type 7 (ydrogen cooled
!oltage 7 /2<32< C!.
.mpere 7 ;/3D .
Eutput 7 -3 C!
'(ND*NS*R S+S)*M
The condenser helps in converting the exhaust system into
water thus allow recycling of *$ water .The condensate system consist of
condensate system and extraction system.
0ondensation of @" exhaust steam from by pass system
and all the drain are connected to the condenser. 0ondenser is of surface
type and condensation of steam ta'es place at the surface of the tubes
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which are cooled by cooling water flowing inside them. This cooling water
gets heated up due to the heat transfer. This hot water is then sent to the
I*0T for cooling process with the help of -D induced draught fans.
S)*AM )4R#,N* A45,6,AR+ S+S)*MS
G*N*RA)(R '((6,NG S+S)*M.
The generator is cooled by hydrogen due its higher heat
transfer coefficient the hydrogen is then cooled by the cooling water
system. . 1< psi of (ydrogen pressure is maintained within the
generator and the gas is circulated within the generator housing with
the help of fans fixed on the rotor .The gas absorbs heat from the
generator windings . To maintain the purity of hydrogen continuous
scavenging is done. (ydrogen is sealed in the turbine with the help of
the seal oil which is derived from lube oil at little higher pressure than
the (/ pressure. In the event of loss of seal oil pressure or very low
purity of the hydrogen automatic emergency purging of hydrogen ta'es
place. The (ydrogen& in such cases is purged with the help of 0E/
which is supplied from the 0E/ s'id.
'((6,NG "A)*R S+S)*M.
To cool the lube oil& ,enerator and the .uxiliaries& cooling
water system is provided which consists of 2 x 11= .0 motor driven
pumps and 2 M 11 = I*0T fans .*uplex filters are provided to filter
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dirt out of the cooling water . The cooling water chemistry is
maintained by means of chemical treatment.
/,R* &R()*'),(N7
Hire protection is provided for @oad & Turbine & compressor
0ompartment. In the event of detection of fire& solenoid valve of 0E/
tan' gets operated.
The 0E/ fire protection system extinguishes fire by reducing the
E/ content of the air in the compartment from an atmospheric normal of
/-= to less than -3 =& an insufficient concentration to support
combustion. To reduce E/ content& a quantity of 0o/ equal to or greater
than 12= of compartment volume is discharged into the compartment in
one minute& and recogni:ing the reflash potential of combustibles
exposed to high temperature metal it provides an extended discharge to
maintain an extinguishing concentration for a prolonged period to
minimi:e the li'elihood of a reflash condition.
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"A)*R )R*A)M*N) &6AN)
/4N),(NS.
To minimi:e the amount of corrosion products such as oxides of iron&
copper and nic'el .These oxides invariably plate out on heat transfer
surface which must be periodically remove.
To minimi:e the hardness causing impurities such as magnesium&
0alcium& silicon .This impurity causes hard adherent scale formation
which results in tube failure.
To remove organic impurities& suspended solids& floating impurities
from raw water.
"A)*R )R*A)M*N) &R('*D4R*.
Ra! !ater.
)aw water source for +.) "@.AT is from warior pump
house situated on Tapi river located -3 Cm from (a:ira.
If there is any discontinuity in raw water inlet from warior&
then there is another substitute where in the raw water inta'es from
water sump located at +.) teel plant.
The raw water is stored in the raw water sump. The water
level in the sump is indicated with the help of -< steps which are
counted from top. If the water level reaches -.3 the inta'e of water stops
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and if the level reaches the step 4 the water inta'e is started. >y any
reason the water level reaches the ;
th
step then there is difficulty in
suction hence the plant trips.
'6AR,/6('46A)*R.
Dosing.
.lum is added as a coagulant& which helps in coagulating the
suspended particle from the raw water.
.mount of alum added G/.3CgNhr
0hlorine act as anti bacterial chemical ."olyelectrolyte is
added as a catalyst which increases the rate of reaction..
The water is brought up in the mixing chamber& where it
mixes properly for the increase in the rate of reaction.
Then the water from mixing chamber is divided into two
0larifloculator which consist of two circular concentric tan's. In central
tan' there is a moving body which moves at the rate of 1<minNrev.
In the clarifloculator& the raw water undergoes
sedimentation& coagulation& flocculation& chlorination.Then it is
accumulated in water storage tan'
Type of clariflocculator 7 vertical centrifugal
0apacity 7 -/<<m1Nhr
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S(/)*N "A)*R &6AN).
The water from clarified water storage tan' is pump
with the help of clarified water pump to the soften plant .In soften plant
the water is sampled and accordingly the sodium sulphite is added which
is then pass through pressuri:ed sand filter #"H%."H is the tan'
containing layer of sand and is also pressuri:ed.
The water from "H is divided into two& ;3= is sending
to soften tan' which is completely filled with resin and 3= is stored in the
filter water tan'.
The ;3= water coming out from soften plant is sent to
induced cooling tower #I*0T% fore bay and gas turbine cooling tower
#,T0T%.
)-Aa O0a0E1 )-0a OAa0E1
)-Aa O$gE2- )-$gOAaE2
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WATER TREATMENT PLANT
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D*M,N*RA6,S,NG &6AN)
The 3= water from "H which is stored in filter water tan'
is allowed to pass through the activated carbon filter #.0H% and then it is
used for two purposes.
-*rin'ing
-*$ water
N**D (/ DM &6AN).
The *$ water is used in T,& ,T, and in condenser for cooling and
ma'e up purpose .this water should be mineral free or else these
mineral
react with metal pipe lines and cause the damage.
The *$ water is also used in generator usually to cool the hydrogen
gas used for cooling purpose.
DM &6AN) &R('*SS
The water from .0H is treated in *$ plant as follows7
:. SA' (Strong Acid 'ation).
When water is pass through .0 the cations are removed
from the water as follows7
)-(
O
O 0a0E1 )-0a O (0E1
)-(
O
O 0a0l )-0a O (0@
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)-(
O
O $gE2 )-$g O (/E2
)-(
O
O Aa0@ )-Aa O (0@
)-(
O
O 0aE2 )-0a O (/E2
;. D*GASS*R7
In degasser the water is allowed to fall from particular
height and the gas is blown just below that of water fall by a degasser
pump as a result all the gases especially 0E/ removed from the water.
(0E1
-
O E/ 0E/ O (/E
%. S#A(Strong #ased Anion).
When the gas is passed through all the
anion are removed as follows-
)-E(
-
O (0@ )-0@ O (/E
)-E(
-
O (/E2 )-E2 O (/E
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<. M,5*D #*D.
When the cations and anions which are not being
removed in .0 and >. are removed by passing through mixed bed
which contain .0 as well as >. resin.
R*G*N*RA),(N.
.fter some time& the ability of .0 and >. resin to
exchange cations and anions gets exhausted and so regeneration is a
necessary process.
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The regenerate (0l is used in case of .0 and caustic
soda is used in case of >. .In $> both (0l and caustic soda is used.
The reactions are given below.
S'A7
)-0a O (0l )-( O 0a0l
)-$g O (0@ )-( O $g0l
)-Aa O (0l )-( O Aa0l
S#A.
)-0l O AaE( )-E( O Aa0l
)-E2 O AaE( )-E( O AaE2
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, had an e1treely eora0le e1perience here !ith personas li%e
Mr. =ay &atel (*&o6.), Mr. Gaurav &unj (*&o6.), Mr. $ive% Ma%ode
(#&o6.), Mr. Mithul &atel (#&o6.) and last 0ut surely not the least
Mr. Raesh Reddy (H(D, echanical departent).
, a also very grate2ul to the *ssar 2aily 2or lending out such
supporting hands to the young engineers li%e us.
)he !or%ing conditions here are such that it !ill ta%e the 0est out
o2 you, no atter !hat.
, a sincerely in de0t to the other heads o2 various departents 2or
0eing so cooperative and understanding and also the 0ac% 0one o2
this organi>ation? the technicians@ they !ere o2 great support and
too% a great interest in us.
, pay all o2 you sincere than%s.