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PROJECT
DOC. TITLE
EPC POWER
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
steam flow
pressure
temperature
torque
speed
voltage
amperage
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
EPC POWER
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
Combined Cycle
Figure shows a combination of both the cycles Topping with Braytons Cycle and &
Bottoming with Rankines Cycle.
Major Components:
1. The air compressor to compress the air for combustion of natural gas,
2. The burner to produce high temperature and high pressure gas by burning
natural gas,
3. The gas turbine which rotates the generator by the thrust of combustion
gas,
4. The HRSG (Heat Recovery Steam Generator) that produces steam by
recovered heat from exhaust gas discharged from the gas turbine,
5. The steam turbine driven by the steam produced by HRSG and
6. The condenser
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
EPC POWER
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
turbines are installed and operated in the simple-cycle mode during the
steam-cycle equipment installation, enables the user to generate power and
revenue in as little as a year from order date.
6. High Reliability/Availability High reliability operation results from
evolutionary design development that improves parts and components, and
quality manufacturing programs that offer operational factory testing. High
availability is achieved through development of sound operation and
maintenance practices, which reside principally with the user. Manufacturer
experience and recommendations also contribute to this feature.
7. Reduced Emissions and Fuel Consumption - Combined cycle plants
use less fuel per kWh and produce fewer emissions than conventional
thermal plants, thereby reducing the environmental damage caused by
electricity production. Compared with a coal-fired plant installed with the
latest clean coal technology, the burning of natural gas in combined cycle
plants is much cleaner. Combined cycle plants produce no sulphur and
virtually no particulate matter; they reduce nitrous oxide emissions by up to
90 percent and carbon dioxide by 60 percent.
Efficiency
The ratio between the earned electrical power of the generator of the steam
turbine Pel and the heat input by the fuel Qin is defined as efficiency of a
conventional steam power plant
Qin
Pel
QCW
Pel
= electrical output in kW
= loss in KJ/sec
Considerable parts of the heat input are lost (stack loss, moisture loss, radiation loss,
etc Qv) and a large amount of heat is taken away by the cooling water QC .
W
PROJECT
DOC. TITLE
EPC POWER
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
flux
electric loading
magnetic flux
flow
magnetic
electric loading
loading
electric
B D L
AD
rotor
rotor length
air-gap induction
electric loading
DC
L
B
A (extent)
PROJECT
DOC. TITLE
EPC POWER
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
Excitation System
Exciter installations are designed to supply the rotor winding of the
generators under all operating conditions with direct current so that the
exciter magnetic field can be constantly maintained and properly controlled.
This is why the safety of exciter current supply has to fulfill high
requirements. To maintain the operability of the generator also during power
system faults, the exciter installation should be designed such that the
voltage of the exciter installation is not influenced by system voltage faults.
Controllable exciter installations are needed for the
preparation of the generator for synchronization
reactive power control
grid operation in an interconnected power system
Figure below shows different circuitry possibilities that are available for the
solution of the problem:
actual value
Circuitry possibilities
Synchronization:
For connection of three-phase synchronous generators to the grid or in
parallel to the grid, it is necessary to synchronize the generator with the
grid, i.e. voltage, frequency and phase position of the voltage generated in
the generator have to be matched to the corresponding values of the grid.
The following is to explain the manual synchronizing process for a generator:
the generator is sped up, driven by the turbine (3000/rpm in case of 2pole generators);
then, the exciter installation is switched on and the excitation current is
increased until the voltage of the generator matches the system voltage
(comparison by means of double voltmeter);
the frequency of the generator is now matched to the system frequency
by means of the turbine speed governor;
the synchronoscope is switched on to test the phase position of the
generator and the system. The phase position of the generator voltage is
matched to the system voltage by means of the turbine speed governor.
PROJECT
DOC. TITLE
EPC POWER
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
Transformers
Transformers are used for the transformation of electric alternating current
powers or three-phase current powers from one voltage step to another. It
is also possible to say that transformers connect the electrical systems of
different voltage levels and provide for the necessary power flow.
power plant area
system area
380-kV-grid
crest voltage
330 MVA
(300)
220-kV-grid
high
voltage
industry
110-kV-grid
10...40 MVA
industry
10...20-kV-grid
medium
voltage
up to 1,6 MVA
industry
0,4-kV-grid
low voltage
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
A power transformer carries power, and transforms that power from one
voltage level to another. The voltage-levels are-related by the turns-ratio.
The insulation of current-transformer (CT) insulates the secondary from the
voltage of the primary; a current transformer is used so that the current
flowing in a high voltage circuit can be measured and read safely on an
instrument ammeter that is insulated only for low voltage / low current. The
ratio of the secondary current to the primary current is determined by the
turns-ratio; most current transformers have a single-turn primary winding.
A potential transformer (PT) transforms the voltage from a high voltage to a
low voltage so that the voltage can be measured and read on a voltmeter
that is insulated only for low voltage.
Basic Insulation Level (BIL) defines the ability of equipment and its
insulation system to withstand transitory voltage surges - such as lightning
surges.
Power transformers are rated in kilo-volt-amperes (kVA) of output; the
rating of the primary is equal to the rating of the secondary plus the losses.
The kVA rating of a transformer is based on the temperature rise of the
windings (usually 55oC) in operation. Transformer windings are usually (an
alloy of) copper, although aluminium is used in the smaller sizes.
Transformer tank
The shape of the oil tank of the transformers is determined by the type of
cooling and the transport possibilities.
It is necessary to dissipate the heat of the transformer losses and a variety
of ways of cooling are used. In a self-cooled dry-type transformer, air
circulates by natural convection from the room through openings in the
lower part of the housing, up around the coils and out to the room through
openings in the upper part of the housing. Such a transformer must be
located in a clean, dry, place, with a clear space around it for air circulation.
The transformer also gives off heat (is cooled) by radiation and convection.
More than 95% of high-capacity power plant transformers are liquid-cooled.
The coolant almost exclusively used in practice is oil. The remaining
transformers are dry-type and encapsulated-winding dry-type transformers.
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
Bus Duct
The basic purpose of bus duct is to conduct electrical power from a source to
a load. Bus, in one type or another, is generally considered where the
application involves currents of approximately 1200 amperes or more. At
these current levels, bus is usually more economical than a cable and
conduit installation and it avoids the physical problems of terminating many
large cables per phase at the equipment at the ends of the cable. Simply,
bus consists of heavy copper or aluminium conductors mounted on
insulators, in an enclosure. The most widely used types of bus ducts are
isolated phase bus and non-segregated phase bus.
Isolated phase bus is one in which each phase conductor is enclosed in an
individual metal housing. Air spaces separate adjacent phase conductor
housings. Isolated phase bus is particularly suited to handling large amounts
of power; hence in power station, this type of bus is used for the electrical
connection between the main generator and the main power transformer.
Isolated phase buses are available in ratings from 14,400 volts, 1200
amperes continuous for a typical 25-MW unit to 25,000 volts, 30,000
amperes continuous for a 1100-MW generating unit. On the larger
installations, certain sections of isolated phase bus may be required to
withstand momentary fault currents of 600,000 amperes rms asymmetrical
or higher.
The basic feature that distinguishes non-segregated phase bus from
segregated phase bus construction is the absence of interface barriers in
non-segregated phase bus. As in most types of bus construction, conductor
enclosure and insulator arrangement can vary between manufacturers and
with current or voltage ratings.
Non-segregated phase bus is generally used where the amount of electric
power to be conducted is considerably below the capabilities of isolated
phase bus, but above the power levels conveniently and economically
handled by insulated cables.
Standard voltage ratings for nonsegregated phase are 415, 3600, 7200, and
12000 volts; continuous current ratings generally range from 1200 to 6000
amperes. This category of bus may be required to withstand momentary
currents as high as 80,000 amperes. In power station application, bus of this
type is suitable for connecting unit auxiliary, station auxiliary and reserve
auxiliary transformer outputs to the main auxiliary system switchgear.
Nonsegregated phase bus can be also used to interconnect sections of
metal-clad switchgear.
Switching Equipment
The station auxiliary power system comprises the auxiliary transformers, the
cables or bus connecting these to the auxiliary switchgear, the cables
connecting the switchgear to the motors and other electrical equipment. The
switching of major equipment is done by switches assembled in groups,
called switchgear.
Switchgear, regardless of size or the auxiliary equipment which it serves or
the voltage system on which it operates, performs some or all of the
following functions:
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
It provides a means for starting or stopping the motor at the will of the
operator, either locally or from a remote location.
It provides a means for starting or stopping the motor automatically in
response to a definite quantity; e.g., it might be controlled by a liquid level.
It provides a means for interlocking the motor with other equipment, so that
it can be run only under the proper conditions. For instance, pulverizer mill
motors that supply fuel to a furnace are commonly interlocked with draft-fan
motors, so that the mill motors can run only when the fan motors are
running.
It provides a means for disconnecting and isolating the motor and driven
equipment so that they can be safely worked upon by the maintenance
personnel.
It provides a means for protecting the motor and power supply system for
the destructive effects of a sustained short circuit.
It provides a means for protecting the motor against damage resulting from
a prolonged overload.
A typical switchgear assembly will consist of a group of from 10 to 20 units
in sheet steel enclosures constructed on suitable structural steel
frameworks.
Electric Motors
In a modern steam power station practically all of the auxiliary devices, such
as pumps, fans, coal pulverizers, conveyors, etc., are driven by electric
motors. In addition, there are a great many small ventilating fans, small oil
pumps, and many other similar applications.
To provide suitable electric motors for these various applications, it is
necessary not only to select motors of the proper speed or horsepower
rating but also to take into account other factors, such as voltage rating,
phase, frequency, starting torque requirements, type of bearings, type of
motor enclosure, whether constant or variable speed, and any other special
requirements that may be necessary for the particular application.
Although there are many variations in motor designs to meet specific
requirements, the majority of the motors used in power plants may be
classified into a few basic types, namely, the synchronous motor, the
squirrel-cage induction motor, the wound rotor motor, and the direct current
motor. The most common type is the squirrel-cage induction motor.
Batteries and Chargers
Batteries
The lead-acid storage battery is the most common battery type used in
power stations today. A battery, as it is usually found in a power station, is
composed of a rack containing several rows of cells.
Most power station batteries are nominally rated at 120 or 240 volts. The
storage capacity of a battery is determined by the size of each cell - how
many, plates in the cell and the area per plate. Storage capacity is the
primary battery "size" parameter and is usually expressed in the units of
ampere-hours.
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER
cooling water through the plate type heat exchangers back into the
circulating water line downstream of the condenser.
The CCW pumps, the ACW pumps and the plate type heat exchangers are
located in the STG building. Make-up to the CCW system is through the CCW
expansion tank located on the roof of the STG building.
A minimum flow recirculation line for CCW pumps through an automatic
recirculation cum non return valve or an automatic flow control valve
controlled by a differential pressure switch on a flow element is provided in
the common discharge line.
In the ACW system a control valve is provided to maintain a constant
pressure differential between the main supply and return headers. This will
bypass flow to maintain a constant return header pressure to compensate
for fluctuation in coolant flow to the plate heat exchangers.
Principal components of the ACW/ CCW system are:
Two 100% ACW / CCW plate type heat exchangers
Three 50% CCW pumps (2W + 1S)
Three 50% ACW pumps (2W + 1S)
Chemical dosing system in the closed loop DM water circuit.
2 100% self cleaning type debris filter (1W + 1S)
CCW expansion tank,
Associated piping, valves and controls required to circulate cooling water
through the various heat exchangers.
The CCW system will be treated with suitable chemical dosing in the closed
loop DM water circuit to control pH and the iron level.
The CCW/ ACW Systems perform the following task:
The auxiliary cooling water system will take cooling water from CW supply
header to ACW / CCW heat exchanger where it will pick up the heat released
by CCW system and will return to CW hot return header which will lead to
the cooling tower return system.
The closed cooling cycle system will provide cooling of various heat loads
such as GTG coolers STG coolers, lube oil coolers, sample coolers, HRSG and
auxiliaries, HP/IP BFP coolers, air compressor coolers. The closed cooling
water will be passivated by DM water which is circulated through the primary
side of ACW / CCW heat exchanger. DM water will also be used as a make
up water to the system. The secondary side will circulate auxiliary cooling
water.
Raw Water Pre-Treatment System
This system consists of raw water reservoir, clariflocculators, clarified water
storage tank and chemical dozing system.
The function of the raw water pre-treatment system is to treat raw water
available from river water intake system and supply the clarified water for
various plant consumptive uses like makeup to the cooling water system,
fire protection system, service water system (air-conditioning & ventilation
system and miscellaneous services) and to supply the clarified water to the
water treatment (DM) plant which in turn will meet the filtered water and DM
water requirements of the plant.
.
Water Treatment (DM Plant) System
This system consists of Filtration system and DM System. The function of the
DM Plant is to provide the demineralized water for the plant DM water
requirement. The treatment will be done in two stages filtration and
demineralization. The filtered water serves as an influent to the DM Plant
and will also be used as plant potable water.
PROJECT
DOC. TITLE
TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.
EPC POWER