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DOC. TITLE

EPC POWER

TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

IBDC/ L&T/ VCCPP/ 02


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Combined Cycle Power Plant


Fundamental
Introduction to Combined Cycle Power Generation
Conventional Steam Power Plant: The fundamental task of a Thermal
Power Plant is to convert the chemical energy in fossil fuels like lignite, coal,
oil or gas into electrical energy.
In a conventional Steam Power Plant the following processes take place
1. By means of combustion with air in the furnace, the chemical energy of the
fuel is converted into thermal energy of hot flue gases.
2. The flue gases are cooled down at the heating surfaces of the steam
generator and transfer their thermal energy to water and steam. At the
heating surfaces, the water entering the steam generator is evaporated
and superheated, and thus receives thermal energy.
3. In the turbine, the thermal energy of the steam is converted into
electromagnetic energy which can be tapped at the generator terminals.

The energy flow is determined by


fuel flow
type
composition

flue gas flow


temperature
composition

steam flow
pressure
temperature

torque
speed

voltage
amperage

Energy Conversion in a steam power plant


The following schematic view shows a simplified flow diagram and the process
characteristic curve in an entropy/temperature diagram to indicate the
thermodynamic evolution of the process (Rankines Cycle).

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Basic thermodynamic process of a thermal power plant


Gas Turbine and Combined Cycle Power Plant: During the last three
decades, the development of gas turbines has made a lot of progress. Also
due to environmental legislation, gas, as a relatively low-pollutant fuel,
encourages the gas turbine manufacturers to specially adapt gas turbines to
power plant requirements and to improve their thermal efficiency.
The modern power gas turbine is a high-technology package that is comprised
of a compressor, combustor, power turbine, and generator, as shown in the
figure "Simple-Cycle Gas Turbine".

Gas Turbine Configuration


In a gas turbine, large volumes of air are compressed to high pressure in a
multistage compressor for distribution to one or more combustion gases from
the combustion chambers power an axial turbine that drives the compressor
and the generator before exhausting to atmosphere. In this way, the
combustion gases in a gas turbine power the turbine directly, rather than
requiring heat transfer to a water/steam cycle to power a steam turbine, as in
the steam plant.
The figure below represents the thermo-dynamic cycle in a gas turbine power
pant (Braytons Cycle).

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PROJECT
DOC. TITLE

EPC POWER

TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

IBDC/ L&T/ VCCPP/ 02


Page 3 of 22

Gas Turbine Cycle


Combined Cycle Power Plant: When two thermal cycles are combined in a
single power plant, the efficiency that can be achieved is higher than that of
one cycle alone. Normally, when two cycles are combined, the cycle operating
at higher temperature level is called the topping cycle. The waste heat it
produces is then used in a second process that operates at a lower
temperature level and is therefore called the bottoming cycle.
The flue gas leaving the gas turbine after expansion in an open process still
contains a lot of thermal energy which should be used efficiently. This can be
done by installing a water/steam circuit with a steam turbine downstream of
the gas turbine process.
The Combined Cycle Power Plant (CCPP) utilizing the Brayton Cycle gas
turbine and the Rankine Cycle steam system with air and water as working
fluids achieve efficient, reliable, and economic power generation. The
combination of the gas turbine Brayton Cycle and the steam power system
Rankine Cycle complement each other to form efficient combined-cycles. The
Brayton Cycle has high source temperature and rejects heat at a temperature
that is conveniently used as the energy source for the Rankine Cycle. Other
working fluids (organic fluids, potassium vapor, mercury vapor, and others)
have been applied on a limited scale.
Air and water as working fluids have achieved widespread commercial
application due to:
1. High thermal efficiency through application of two complementary
thermodynamic cycles.
2. Heat rejection from the Brayton Cycle (gas turbine) at a temperature that
can be utilized in a simple and efficient manner.
3. Working fluids (water and air) are readily available, inexpensive, and
nontoxic.
Combined Cycle Fundamental Theory and Operation
In combined cycle power generation systems, the gas turbine is driven by high
temperature gas produced by combustion of fuels such as natural gas, and the
steam turbine turned by steam produced by the exhaust heat of the
combustion. The generator is driven by the combined power of these two sub
systems to generate power.

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388.5 MW Combined Cycle Power Plant
DOC No.
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EPC POWER

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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

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EPC POWER

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Schematic Diagram of basic Combined Cycle Power Plant


In this system Gas dampers are often provided so the gas turbine exhaust
can bypass the heat recovery boiler allowing the gas turbine to operate if the
steam unit is down for maintenance.
Sometimes as many as four gas turbines with individual boilers may be
associated with a single steam turbine. The gas turbine, steam turbine, and
generator may be arranged as a single-shaft design, or a multi-shaft
arrangement may be used with each gas turbine driving a generator and
exhausting into its heat recovery boiler with all boilers supplying a separate
steam turbine and generator.

Combined Cycle Shaft Arrangement

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The single shaft arrangement in a combined cycle power plant functions in


the same way as the multiple shaft arrangement. The most important
difference is the application of self shifting and synchronizing (SSS) clutch. It
permits the Steam Turbine to be accelerated and to be connected to the
Alternator, already being driven by the GT.
The SSS clutch engages automatically as soon as the torque from the ST
shaft becomes positive, that is as soon as the rotational speed of the ST
tends to over table that of the alternator. It disengages automatically as
soon as the torque of the ST shaft becomes negative.
Cycle Parameters and the Impact upon Performance
The first and second generation combined-cycles were configured using gas
turbine designs that were optimized for simple-cycle output and efficiency.
Specific power (i.e., output per pound of airflow) is important since the
higher the value, the smaller the gas turbine required for design power
output. The importance of thermal efficiency is obvious since it directly
impacts the operating fuel cost.
1. Where simple-cycle efficiency is the goal, high pressure ratio is desirable.
2. Where combined-cycle efficiency is the objective, more modest pressure
ratios are selected.
3. Firing temperature has a greater impact on combined-cycle efficiency than
simple-cycle efficiency.

The GE F Technology gas turbine designed in the 1980s, with pressure


ratio of about 14:1 and 2400F firing temperature was the result of a design
effort aimed at optimization for combined cycle peak efficiency rather than
simple cycle peak efficiency.
Gas turbine development has had the greatest impact on improved
combined cycle efficiency due primarily to the increase in firing temperature
made possible through the development of high-temperature oxidation/

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DOC No.
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corrosion-resistant metals and coatings, and advanced metal surface cooling


techniques.
Another important factor is that the gas turbine contributes about two-thirds
of the combined cycle plants power.
Advances in steam system technology have also contributed to improved
combined-cycle efficiency.
Steam Cycle Parameters Selection:
Because fuel constitutes 50 to 70 percent of the cost of electricity from a
combined cycle plant, cycle efficiency has historically been the single most
dominant variable in selecting a plants thermodynamic configuration. Thus,
a triple pressure reheat cycle has become the industry standard for
achieving higher efficiency. With the increased firing temperatures and the
attendant higher gas exhaust temperatures from the GTs, the main steam
pressures have steadily increased over the years. Today, 124 bar (1,800
psig) cycle in the unfired mode is considered the industry norm.
Benefits of Combined Cycle
The combined-cycle system provides flexibility with features that include:
1. High Thermal Efficiency Combined cycle thermal efficiency is higher
than that of other conventional power generation systems.
2. Low Installed Cost - Combined-cycle equipment is pre-engineered and
factory packaged to minimize installation time and cost. All major equipment
(gas turbine generator, heat recovery steam generator [HRSG], and steam
turbine generator) is shipped to the field as assembled and tested
components.
Auxiliary equipment, such as condensers, can be shipped factory-tubed and
hydro-tested.
This greatly reduces the inventory of parts that must be managed in the field
and minimizes installation cost. Though combined-cycle equipment cost is
higher than that for conventional steam plants due to pre-engineering,
combined-cycle plant installation costs are significantly lower, resulting from
the reduced installation cycle.
3. Fuel Flexibility - Combined-cycle plants operate efficiently by burning a
wide range of fuels, ranging from clean natural gas and distillate oil fuels to
ash bearing crude oil and residual oil fuels.
Operation with coal-derived gas fuels has been applied in many commercial
sized, combined-cycle systems (IGCC).
4. Flexible Duty Cycle - Combined-cycle systems provide flexibility in
operation for both base load and mid-range duty with daily startup. Gas
turbines in multi-shaft, combined-cycle configuration can be started quickly,
bringing about two thirds of plant power on-line, typically in less than 60
minutes. Combined-cycle plants also provide efficient operation at part load,
particularly for multiple gas turbine combined-cycle systems. Modulating
compressor inlet guide vanes are standard features of many gas turbine
models, enabling high efficiency operation at part load through reduction in
turbine airflow. This is accomplished at nearly constant turbine exhaust
temperature, so that design steam conditions and low stack loss can be
maintained to provide excellent part-load efficiency.
5. Short-Installation Cycle Combined cycle plants can be installed and
operated in less time than that required for conventional steam plants.
Again, this is primarily due to the pre-engineering and packaging of major
components in the factory. Phased installation of the plant, when gas

LARSEN & TOUBRO LIMITED

PROJECT
DOC. TITLE

EPC POWER

TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

IBDC/ L&T/ VCCPP/ 02


Page 8 of 22

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

Qin = thermal power input from fuel,


in KJ/sec

output balance: Qin = Pel + QCW . QV

Pel

= electrical output in kW

QCW = thermal power removed with cooling


water, in KJ/sec
QV

= loss in KJ/sec

Efficiency = Pel / Qin

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

Compared to the conventional steam power plants, the efficiency of a


combined cycle plant is better, due to the double use of fuel energy in the
gas turbine part and in the water/steam part.
Efficiency = PelGT + PelST / Qin
Here PelGT and PelST are the electrical power output in kW of GT and ST
respectively and Qin is the thermal power input in kJ/s

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PROJECT
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TRAINING MANUAL
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Major Electrical Equipment


Generator:
A generator is a device that converts mechanical energy into electrical
energy. The basic principle of any generator is the relative motion between
electrical conductors and a magnetic field. The magnetic field structure may
be stationary and the electrical conductors (armature) revolve; or the
electrical conductors may be stationary (stator) and the magnetic field
structure (rotor) may revolve. The former normally applied to dc machines
and the latter to ac machines.
The rotor winding is used to produce the magnetic field for the generator. It
receives its DC power from an exciter through either slip or collector rings on
the rotor shaft or by insulated conductors through the rotor shaft. The fact
that the rotor is a relatively low voltage, low power circuit is one reason for
building the generator with a rotating field instead of a rotating armature. It
is considerably more difficult to conduct the higher ac voltage out through a
set of collector rings and brushes.

flux

electric loading

output magnetic flux electric loading speed

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)

the result consequently is: S D2LB An

Generator and its output


The function of the stator core is to provide a return path for the lines of
magnetic flux from the field (rotor), and at the same time support the coils
of the stator winding. The resistance of the magnetic path is determined by
the material through which they pass; air forms a high resistance and
magnetic steel forms a low resistance. Rotation of the field causes flux to
sweep around the stator. For a given point, this amounts to a rapidly
reversing direction of the lines of flux in the stator core; this dictates that
the stator core be laminated, in contrast to the solid body of the rotor
(rotating field).
Generator Cooling
Generators may be Air Cooled, Water Cooled or Hydrogen Cooled depending
upon its rating. Hydrogen cooled generators are used in typical 250 MW
power plants. For rating below 100 MW generally water is used as cooling
medium for the generators.

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CCPP Fundamental
Page No.

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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

a) generator with external excitation and stationary converter


b) generator with rotating excitation

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.

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It may be necessary to readjust the excitation current, i.e. the generator


voltage has to be matched to the grid voltage.
If the synchronoscope slowly turns clockwise, the switch-on impulse can
be given to the generator if the pointer position lies between about 3 to 5
min before 12 h. Due to the existing constant dead times of the break
distance (mechanical delay of relays and switches), the generator will
then be connected to the system at approx. 12 h.

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

Power system levels with transformers


In a power station, the Generator Transformer (GT) steps the voltage up
from the generator-voltage to the transmission system voltage; the Unit
Auxiliary Transformer (UAT) steps the voltage down from the generator
voltage to the auxiliary-bus voltage, and the Startup or Reserve Auxiliary
Transformer (RAT) steps the voltage down from the transmission system
voltage to the auxiliary-bus voltage.
The main power transformer is usually located near the turbine-generator
building, on the side nearest the high-voltage switchyard. The unit auxiliary
transformers) and the startup auxiliary transformer are often in the same
general area, to minimise the costs of bus duct or cable connections.

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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.

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Distribution transformer with and without expansion tank and a


capacity of up to 4 MVA and voltages of up to 30 kV
The simplest type of transformer is referred to as "self-cooling" (ONAN). In
case of self-cooling, transformers with a higher capacity can not dissipate
their heat loss via the tank surface (radiators) because the tank sizes grow
beyond transportability.
In case of the ONAF cooling type the air flow is forced, i.e. the radiators are
ventilated by fans which are either switched on by the oil temperature or by
a current relay. Thus, the dissipation of heat is increased. The radiators may
also be separately installed - radiator or cooler bank - under special
conditions or in case of transformers with an even higher capacity. Then, the
oil has to be supplied to this cooler bank by oil circulating pumps. The types
of coolers which can be used are oil-to-air coolers as well as oil-to-water
coolers with the OFAF or OFWF cooling type.
Fire Protection
Power transformers are usually provided with fire-protection in the form of
water spray, actuated by the transformer sudden-pressure relay or
differential relay. An oil-water separator is provided on a plant-site to catch
the oil and water from the crushed-rock or gravel fill that is placed around
the transformer base.

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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:

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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.

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The ampere-hours capacity of a battery is the amperes which can be


provided for a certain period (without dropping below a specified minimum
voltage) multiplied by the length of that period in hours. Thus a battery cell
which can provide 50 amperes for 10 hours without the cell voltage dropping
below 1.75 volts has a capacity of 500 ampere-hour (AH).
Chargers
The battery-charger is a highly regulated rectifier with automatic current
limit. In most power station applications the charger is operated in a floating
configuration, which is to say, the battery and charger are continuously
connected in parallel. In this configuration, the charger provides the
following functions:

It supplies the necessary current to the station dc loads during normal


conditions when ac power is available.
It supplies continuous charging current to the battery to keep it fully charged
during normal conditions when ac power is available.
It supplies recharging current to the battery after the battery becomes
discharged after an ac power outage.
It supplies an equalising charge as periodically required.

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TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

EPC POWER

IBDC/ L&T/ VCCPP/ 02


Page 17 of 22

The Vemagiri Combined Cycle Power Plant:

A Schematic representation of Vemagiri Combined Cycle Power Plant


At Vemagiri, we have the following major components:
1. One Gas turbine and Generator, Type GE PG 9351(FA), 50 HZ, Heavy Duty
industrial with 232.54 MW output at generator terminal with power factor
of 0.85 lagging.
2. One Supplementary-fired, triple pressure, reheat, vertical HRSG with
assisted circulation system (HP & LP are assisted circulation and IP is
natural circulation), sliding pressure.
3. Separate stand alone Deaerator
4. One Condensing Steam Turbine & Generator, Type Horizontally split,
sliding pressure, two cylinder type (HP and combined IP-LP) axial
exhaust system with 155.96 MW output at generator terminal. This is in
multi-shaft arrangement with the gas turbine.
The different systems and their tasks
Steam System
Steam is generated in the HRSG by using heat of the exhaust gases of the
Gas Turbines and supplementary firing. The Steam System is further
categorized as High Pressure (HP), Reheat (Cold Reheat (CR) and Hot
,Reheat (HR)) and Low Pressure (LP) Steam Systems which operate at the
three pressure levels at which the HRSG generates steam.
The steam system performs following tasks:
1. Routes HP, LP superheated steam from each Heat Recovery Steam
Generator (HRSG) superheater outlet to the steam turbine where thermal
energy of the steam is converted to mechanical energy. The Reheat Steam
system routes steam from the HP steam turbine outlet to the HRSG reheater
(Cold Reheat) and from the reheater to the IP steam turbine inlet (Hot
Reheat.) Intermediate Pressure steam from the HRSG intermediate pressure
superheater is mixed with the cold reheat steam prior to the HRSG reheater.

LARSEN & TOUBRO LIMITED

PROJECT
DOC. TITLE

TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

EPC POWER

IBDC/ L&T/ VCCPP/ 02


Page 18 of 22

The system is designed such that it is capable of operating continuously in


sliding pressure or constant HP pressure mode of operation in conjunction
with the steam turbine.
2. A 100% cascading steam bypass system is provided. This system
bypasses
HRSG steam to the condenser so that the HRSG can be operated with the
steam turbine offline to facilitate start-up of HRSG and steam turbine
generator of the combined cycle plant and to improve the operational
flexibility. The bypass line is closed during the normal operation of the steam
turbine and the system is operated automatically during start-up or in the
event of a steam turbine trip or load throwoff.
Feed Water System
The HP/IP& LP feed water system consists of Two (2) 100% electric motor
driven HP/IP feed water pumps with an inter-stage tap-off for IP feedwater
and Two(2) 100% electric motor driven LP feed water pumps. The BFPs are
provided with 10% margin on Flow & 10% margin on equipment and piping
loss over the normal requirement (100% MCR i.e. 388.5 MW), which is
generally adequate for the purpose. The HP BFP is provided with a variable
speed Hydraulic coupling which will adjust the speed of the pump
corresponding to the load / capacity.
The Feed Water system performs following tasks:
Takes suction from the deaerator.
Provides feed water from the HP/IP feed water pump discharge to HRSG
HP/IP economizers with an inter-stage tap-off for IP feed water and LP feed
water pump discharge to HRSG economizer.
Provides feed water from the feed water pump HP discharge to the HRSG
superheater attemperator,
Provides feed water from the feed water pump IP discharge to the HP
bypass valve attemperator,
Provides feedwater from the feedwater pump IP discharge to the HRSG
reheater attemperator,
Routes boiler feed pump minimum recirculation flow back to the
deaerator,
Condensate System
The Condensate system consists of two 2 x 100% capacity Condensate
extraction pumps which take suction from the Main condenser hot well and
supply condensate to the Deaerator through the Gland steam condenser. 2 x
100% capacity hot well makeup pumps take suction from the Condensate
storage tank, where DM water makeup is stored, to the condenser hot well
for supply cycle makeup and to control hot well level.
The suction side vent of each condensate extraction pump is individually
connected to condenser. Discharge side vent of each condensate extraction
pump have its own solenoid valve operated, together with break down orifice
and connected individually to condenser.
The initial sealing water for the condensate extraction pumps is taken from
hot well make-up system and during normal operation from condensate
extraction pump discharge.
Excess condensate dump system dumps the excess condensate in condenser
hot well to the condensate storage tank through an excess condensate dump
line downstream of condensate extraction pump discharge. The excess
condensate dump line is provided with an excess condensate dump control
valve sized for not less than 10 percent steam turbine MCR flow.

LARSEN & TOUBRO LIMITED

PROJECT
DOC. TITLE

TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

EPC POWER

IBDC/ L&T/ VCCPP/ 02


Page 19 of 22

Minimum flow recirculation system is provided for maintaining minimum flow


through the condensate extraction pumps. Minimum recirculation line at the
outlet of the gland steam condenser is led to the condenser hot well.
Provision is made for dosing Ammonia at the CEP discharge for pH
correction.
The Condensate system performs following tasks:
Pump the condensed steam (condensate) from the surface condenser hot
well to the Condensate Pre-Heater (CPH) of the HRSG through the gland
seal steam condenser.
Provide cooling water flow to the gland seal steam condenser.
Provide excess condensate dump to the condensate storage tank.
Inject amine into the condensate water for pH control.
In addition, the condensate system supplies condensate to the following
equipment:
o Steam turbine exhaust hood spray system (if required)
o HR and LP bypass attemperator
o Vacuum pump seal water makeup (if required)
o Condenser vacuum breaker seal (if required)
o Gland seal steam emergency spray (if required)
o Valve gland sealing (if required)
Condenser Air Evacuation System:
The CA system comprises of two (2) 100% vacuum pump skids with
associated motors, seal water heat exchangers, seal air/water separators
and with associated pipes, valves, instruments and controls for connecting
skid mounted components.
The air is drawn from the condenser through the vacuum pump air intake
piping. The air and non-condensable gases are removed and discharged
outside the building through the air exhaust piping. The pumps are of two
stage liquid ring without air ejector. The control system is such that the
entire operation from hogging through holding can be carried out
automatically.
The water flow to the vacuum pump liquid ring is monitored by a flow switch
with an alarm provision.
The Condenser Air Evacuation system performs the following task:
Continuous venting of non-condensable gases from the main condenser
steam space (holding).
Creates the initial condenser vacuum before steam turbine start-up
(hogging).
Changes from hogging to holding operation.
Breaks condenser vacuum quickly by use of vacuum breaker valve to
reduce steam turbine roll down time.
Fuel Gas System
Natural gas fuel is supplied at the plant boundary by the Gas supplier (GAIL)
at a pressure of minimum 34 bar (g) at minimum site ambient temperature.
Downstream of the gas suppliers terminal point the gas will be conditioned
to meet the requirement of gas turbine and HRSG fuel specification.
The Gas Conditioning System performs the following task:
Conveys natural gas from the Owner's terminal point to the terminal
point of gas turbine and HRSG duct burners meeting all the specific
requirement of each consumer.
Removes liquid droplets & particulate matters in knock-out drum and
horizontal filter separators before pressure reduction & control station
(PRCS).

LARSEN & TOUBRO LIMITED

PROJECT
DOC. TITLE

TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

EPC POWER

IBDC/ L&T/ VCCPP/ 02


Page 20 of 22

Two independent pressure reduction cum control stations are provided


downstream of dew point heater. One is for GTG and the other is for
HRSG. Dew point heaters are indirect fired water bath gas heaters to
provide 300C superheat over hydrocarbon dew point in the gas during
start-up of the gas turbine.
After pressure reduction for gas turbine gas is further heated in a
water/gas shell and tube heat exchanger (Performance Heater) to
improve the cycle efficiency during normal operation of combined cycle.
Downstream of performance heater, gas is passed through coalescing
filter for final removal of solid and liquid particles from the gas prior to
the inlet of the gas turbine.
Provides connections for sampling gas.

Circulating Water (CW) System


A recirculating type of circulating cooling water system with one number
Induced Draft Cooling Tower (IDCT) and three 60% (2W + 1S) circulating
water pumps have been provided. The circulating water make-up will be by
gravity flow of water from the clarified water storage tank.
The CW system returns the hot circulating water to hot water return header,
which goes to the cooling tower, where the heat absorbed by the circulating
water is released to the atmosphere. A tap-off from the CW discharge
header is taken to the side stream filters. 2 x 100% Side stream filter of
dual media / pressure sand filter /auto valve less gravity filter type, will be
provided to control the circulating cooling water turbidity. The side stream
filter will be sized based on 1% CW system flow. The side stream filters will
have manual back washing facility with proper valves and back washing
water supply and disposal arrangement. The outlet filtered water is
discharged in the CW fore bay. The CW pumps are located indoor inside the
CW pump house.
Principal components of the CW system are:
Three 60% vertical circulating water pumps (2W + 1S)
One mechanical Induced draft cooling tower
Two (2) x100% Side stream filters with back washing facility.
Two (2) x100% Blowdown Pumps
Cooling Tower make-up system
Associated piping, valves and instruments & controls required to
circulate the water through the main condenser.
The CW system is treated by dosing suitable chemical in the cooling
tower basin for prevention of biological growth, scale/corrosion
inhibitors and pH control.
The circulating water System performs the following task:
Dissipate the thermal load of steam turbine by providing a continuous supply
of cooling water to the main condenser, vacuum pump coolers, motive water
requirement for chlorination system and for the ACW pumps to meet the
requirement of ACW Heat exchanger open circuit.
Auxiliary Cooling Water (ACW) & Closed Cooling Water (CCW)
System
Three CCW pumps of 50% (2W+1S) capacity circulate the DM water in a
closed loop system through plate type heat exchangers (ACW / CCW heat
exchanger). 3 ACW pumps of 50% (2W+1S) capacity are provided to
circulate cooling water on the secondary side of the plate type heat
exchangers. In the secondary loop the ACW pumps draw suction from tapoff from main circulating water pump discharge header and circulate the

LARSEN & TOUBRO LIMITED

PROJECT
DOC. TITLE

TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

EPC POWER

IBDC/ L&T/ VCCPP/ 02


Page 21 of 22

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.

LARSEN & TOUBRO LIMITED

PROJECT
DOC. TITLE

TRAINING MANUAL
388.5 MW Combined Cycle Power Plant
DOC No.
CCPP Fundamental
Page No.

EPC POWER

IBDC/ L&T/ VCCPP/ 02


Page 22 of 22

The demineralized water from DM Plant will be stored in DM water storage


tank and will be used for HRSG feed cycle make-up in the condenser, makeup in gas turbine compressor water wash skids, CCW make-up, initial filling
of HRSG and boiler feed chemical solution preparation. It is also used in
hydro-testing, chemical cleaning, displacement flushes after cleaning and
wet storage of HRSG during commissioning.
The system boundary for Demineralization (DM) plant starts from DM Plant
clarified water storage tank and ends at the DM water storage tank (inlet)
including all plant and equip
Effluent Water Treatment System
The function of the effluent treatment system is to collect and treat the
liquid effluents generated from various sources (like DM plant regeneration
waste, oily effluents from various areas, cooling tower blow down, HRSG
blow down, etc.) and bring the quality of effluent to permissible level as per
regulation at the central monitoring basin (Guard pond).
The effluents will be treated at source as much as possible and will be
pumped to a two-compartment guard pond, where effluents will be mixed
for equalization. Acid or alkali will be dosed if necessary for pH correction.
The quality of combined effluent will be tested and analyzed to verify
whether the same meets the level of different parameters as stipulated in
pollution control board guidelines (APPCB).
When the quality meets the desired norms, the treated effluent will be
reused for plant washing and gardening and any excess will be pumped to
the Kadiyan Ava drain.
In addition to the above there are a number of utility systems like
Compressed Air System, Fire Protection and Detection System, Power Cycle
Chemical Feed System, EOT Cranes and Hoists, Ventilation and Air
Conditioning System, etc, which constitute the support system to the major
organs for an efficient running of the Power Plant.

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