Study of Combined Gas Cycle Power Plant

and Modernization of Siemens V94.2

A report based on internship at NTPC, Faridabad

Submitted by:

Bhushan Maskay

Department of Mechanical Engineering

INDIAN INSTITUTE OF TECHNOLOGY, GUWAHATI

GUWAHATI- 781039, ASSAM
June-July, 2010
 Preface
This report is a summary of the study done at NTPC Limited (Formerly National
Thermal Power Corporation) based on 2 months (June-July 2010) training at its gas
based power plant in Faridabad. During the project I was introduced to the various
departments and their workings in the plant. I was also introduced to the various
components involved in the generation of electricity, their running parameters and
the necessary precautions taken to prevent their damage. During this training I
enhanced my engineering knowledge as I developed an entire concept of combined
gas cycle power generation from scratch.

There are three parts of this report: (I) Introduction to NTPC (II) Faridabad Gas
based power plant (III) Mechanical Design .

Part I covers the history of NTPC and its growth through the years. It also gives an
insight into its upcoming projects, joint ventures and other key data related to the
company.

Part II introduces the details of the Faridabad plant. It provides the particulars of the
components used and the procedure used in power generation. It also briefs on the
working of the major departments of the plant and their workings.

Part III deals mainly with the gas turbine design, and also includes the latest
modernization products from Siemens V94.2 (also known as SGT5-2000E).
 Acknowledgement

I owe thanks to a great many people who helped and supported me during the
training period at NTPC.

My deepest thanks to Mr. Niranjan for guiding the training and arranging the lectures
timely. I express my thanks to Mr. K K Sharma (Sr Manager, Chem.), Mr. S K
Bhargava (MTP), Mr. V K Garg(Operations), Mr. Manoj Agarwal (Mechanical
Maintenance), Mr. Rohit Sharma (C & I) and Mr. S K Baliyan (Electrical
Maintenance).

I extend my gratitude to Mr. Amit Tyagi (Mechanical Maintenance) for his guidance
and support during the period.

Thanks and appreciation to all the helpful people at NTPC Limited for their support.

I would also thank my institution and my faculty members for developing in me a

basic understanding of the concepts without which this report would have been a
distant reality.
 Index
1. Part I: Introduction to NTPC
1.1. About the company
1.2. Evolution of NTPC
1.3. NTPC group
1.4. Power Generation
1.5. NTPC Operations
1.6. Turnaround Capability
1.7. NTPC Strategies
1.8. International Cell
1.9. Ecological Monitoring Programme
2. Part II: Faridabad gas based power plant
2.1. Overview
2.2. Combined Cycle Gas Turbine (CCGT) power plant
2.3. Water treatment
2.3.1. Pre-Treatment(PT) plant
2.3.2. De-Mineralization(DM) plant
2.4. Components
2.4.1. Air Filter
2.4.2. Compressor-Gas Turbine- Generator
2.4.3. Diverter-Damper
2.4.4. Heat Recovery Steam Generator (HRSG)
2.4.5. Steam Turbine Generator
2.4.6. Main Control Room (MCR)
2.4.7. Cooling tower
2.5. Switchyard
2.6. Major Departments
2.6.1. Human resources (HR)
2.6.2. Maintenance Planning (MTP)
2.6.3. Operation & Maintenance: Mechanical (O&M- MM)
2.6.4. Operation & Maintenance: Electrical (O&M- EMD)
2.6.5. Operation & Maintenance: Control & Instrumentation (O&M- C&I)
2.6.6. Operation & Maintenance: Chemical (O&M-Chem)

3. Part III: Gas Turbine Design and Modernisation

3.1. Introduction to Siemens V94.2
3.2. Auxiliaries
3.2.1. Lube oil system
3.2.2. Lube oil cooling system
3.2.3. Fuel oil system
3.2.4. Purge water system
3.2.5. Hydraulic system
3.2.6. Ignition Gas system
3.2.7. Filter Housing
3.2.8. Turbine
 3.2.9. Generator
3.2.10. Generator cooling system
3.2.11. Exhaust
3.3. Overview of GT Modernistation Products
3.3.1. Turbine Inlet Temperature Upgrade(TT1+) and Extended Maintenance
interval (41 MAC)
3.3.2. Compressor Mass Flow Upgrade(CMF+)
3.3.3. Dry- Low- NOX (DLN) Upgrade using HR3-burner
3.3.4. Performance Boost with Wet Compression (WetC)
3.3.5. Humidity I & C Module for GT control system
3.3.6. Fuel Conversion Upgrade
3.3.7. Siemens innovative 3-D Turbine Blades & vanes
3.3.8. Lifetime Extension
3.4. SGT5-2000E adjustment to site conditions
3.5. Configuration after Modernization
Bibliography
1.1 About the company
Corporate Vision:
“A world class integrated power major, powering India’s growth, with increasing global
presence”

Corporate Mission:
“Develop and provide reliable power, related products and services at competitive prices,
integrating multiple energy sources with innovative and eco-friendly technologies and
contribute to society.”

Core Values: BCOMIT

B-Business Ethics
C-Customer Focus
O-Organizational & Professional pride
M-Mutual Respect and Trust
I- Innovation & Speed
T-Total quality for Excellence

India’s largest power company, NTPC was set up in 1975 to accelerate power
development in India. NTPC is emerging as a diversified power major with presence in
the entire value chain of the power generation business. Apart from power generation,
which is the mainstay of the company, NTPC has already ventured into consultancy,
power trading, ash utilization and coal mining. NTPC ranked 317th in the 2009’s Forbes
Global Ranking of the World’s biggest companies.

The total installed capacity of the company is 31,704 MW (including JVs) with 15 coal
based and 7 gas based stations, located across the country. In addition under JVs, 3
stations are coal based & another station uses naptha/LNG as fuel. By 2017, the power
generation portfolio is expected to have a diversified fuel mix with coal based capacity
of around 53000 MW, 10000 MW through gas, 9000 MW through Hydro generation,
about 2000 MW from nuclear sources and around 1000 MW from Renewable Energy
Sources (RES). NTPC has adopted a multi-pronged growth strategy which includes
capacity addition through green field projects, expansion of existing stations, joint
ventures, subsidiaries and takeover of stations.
NTPC has been operating its plants at high efficiency levels. Although the company
has 18.10% of the total national capacity it contributes 28.60% of total power
generation due to its focus on high efficiency.

In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25%
as fresh issue and 5.25% as offer for sale by Government of India. NTPC thus became a
listed company in November 2004 with the government holding 89.5% of the equity
share capital. The rest is held by Institutional Investors and the Public. The issue was a
resounding success. NTPC is among the largest five companies in India in terms of
market capitalization.
At NTPC, People before Plant Load Factor is the mantra that guides all HR related
policies. NTPC has been awarded No.1, Best Workplace in India among large
organisations and the best PSU for the year 2009, by the Great Places to Work
Institute, India Chapter in collaboration with The Economic Times.

The concept of Corporate Social Responsibility is deeply ingrained in NTPC's culture.

Through its expansive CSR initiatives, NTPC strives to develop mutual trust with the
communities that surround its power stations.
1.2 Evolution of NTPC
· 1975
o Incorporated on November 7.

· 1976
o On December 8, the Government of India cleared NTPC's first pithead
super thermal power project at Singrauli in Uttar Pradesh.
o The authorised share capital of the Company was Rs. 125 crore.

· 1977
o NTPC acquired the first patch of land at Singrauli in September.
o The first major contract of Rs. 57.5 million was awarded for site leveling
work at Singrauli in June.

· 1978
o Implementation of Korba and Ramagundam Projects cleared by the
Government of India in January and February respectively.
o Late Shri Morarji Desai, the then Prime Minister of India, laid the
foundation stone for Ramagundam Project on November 14th
o Construction of the first transmission network Singrauli-Kobra-Kanpur
of 400 KV system started

· 1979
o Government of India approved the implementation of Farakka Project in
March
o The authorised share capital of the Company rose from Rs.125 crore to
Rs. 300 crore

· 1980
o Former Soviet Union offered to assist in setting up of power stations.
Vidhayachal was identified as the first project for such assistance.
o The authorized share capital was raised from Rs. 300 crore to Rs. 800
crore in June.

· 1981
o Farakka Super Thermal Power Project in West Bengal was the fourth
among the first series of four super thermal power projects taken up by
NTPC. On December 29, late Smt. Indira Gandhi, the then Prime
Minister of India, laid the foundation stone for the Project.
 o On December 25, the fifth and last unit of 210 MW at Badarpur Thermal
Power Station was synchronised by NTPC, marking the completion of
the 720 MW project

· 1982
o The first 200MW unit at Singrauli was commissioned
o The first direct foreign currency borrowing for NTPC- a consortium of
foreign banks led by Standard Chartered Merchant Bank extended a loan
of GBP 298.41 million for the Rihand project.
o Power Management Institute, Delhi, a centre for education established.
o On November 12, Late Smt. Indira Gandhi, the then Prime Minister of
India laid the foundation stone for Vindhyachal Super Thermal Power
Project in Madhya Pradesh.

· 1983
o On March 1, the first 200 MW unit of Korba Super Thermal Power
Project was commissioned in a record time of 48 months after the
placement of order for the main plant equipment
o Another significant achievement was the supply of uninterrupted power
from Badarpur during Asian Games and Non-Aligned Meet held at
Delhi.
o Ramagundam became operational on November 26 by commissioning
its first 200 MW Unit.
o In the very first year of its commercial operation, NTPC earned a profit
of Rs. 4.51 crore in the financial year 1982-83

· 1984
o The transmission line based on HVDC (High Voltage Direct Current)
technology, commissioned for power transmission from Rihand to Delhi.
o Singrauli project received a World Bank loan of USD 150 million through
the Government of India

· 1985
o This year marked the completion of a decade (1975-1985) of NTPC's
existence. NTPC achieved a generating capacity of 2200 MW by
commissioning 11 units of 200 MW each at its various projects in the
country.
o In December '85, the Government of India approved the setting up of
three gas-based combined-cycle projects by NTPC at Kawas in Gujrat,
Auraiya in Uttar Pradesh and Anta in Rajasthan. For these projects, the
World Bank agreed to provide US$ 485 million, which was the largest
single loan in the history of the bank.
· 1986
o Synchronisation of its first 500 MW unit at Singrauli.
o NTPC launched its maiden public issue of Bonds and raised a total of Rs.
163.37 crore. This issue was over-subscribed by 63 percent.

· 1987
o Crossed the 5000 MW installed capacity mark.
o Korba also entered the 500 MW phase by synchronizing its first 500 MW
unit on May 31

· 1988
o Rihand entered the Operational phase by commissioning its first 500
MW unit on March 31.
o The first 500 MW unit of Ramagundam was commissioned on June 26.

· 1989
o Consultancy division launched.
o First unit (88 MW) of first gas based combined cycle power plant at
Anta, Rajasthan commissioned

· 1990
o Total installed capacity crossed 10000 MW

· 1991
o Vindhyachal recorded completion of stage I activities by synchronising
its sixth and last 210 MW unit in February.
o The first unit of NCPP (Dadri) was commissioned on December 21.

· 1992
o Acquisition by the Company of Feroze Gandhi Unchahar Thermal Power
Station (2x210MW) from Uttar Pradesh Rajya Vidyut Utpadan Nigam of
Uttar Pradesh.
o Pursuant to legislation by the Parliament of India, the transmission
systems owned by the company was transferred to Power Grid
Corporation of India Limited.

· 1993
o For the first time, IBRD extended direct loan of USD 400 million under
time slice concept for its projects.
· 1994
o Crossed 15000 MW of installed capacity.
o Declared a dividend of Rs. 65 crore for the first time.
o Jhanor-Gandhar (Gujarat) becomes the first thermal power station to
have commissioned an integrated Liquid Waste Treatment Plant
(LWTP)

· 1995
o NTPC celebrated 20 years (1975-1995) of its existence. A new logo was
adopted.
o On June 3rd, NTPC formally took over the 460 MW Talcher Thermal
Power Station from Orissa State Electricity Board
o On July 25th, the new campus of Power Management Institute (PMI)
was inaugurated.

· 1996
o Continuous running of sixth unit (210 MW) of Ramagundam for 406
days for the first time in India.
o PLF of Talcher Thermal reached 43.7 % from 18.7 % at the time of
takeover

· 1997
o Identified by the GOI as one of the Navratna public sector undertakings
o Achieved 100 billion units generation in one year.
o A consortium of foreign banks led by Sumitomo Bank, Hong Kong
extended foreign currency loan of 5 billion Japanese Yen for the first
time without GOI guarantee.

· 1998
o Commissioned the first Naphtha based plant at Kayamkulam with a
capacity of 350 MW

· 1999
o Dadri Thermal Power Project, Uttar Pradesh adjudged the best in India
with a PLF of 96.12%
o Dadri, Uttar Pradesh certified with ISO-14001 on October 7""

· 2000
o Commenced construction of a first hydro-electric power project of
800MW capacity in Himachal Pradesh
· 2001
o Main plant turnkey package of Rihand Stage-II (2x500MW) and
Ramagundam Stage-Ill (IX 500 MW) were awarded to BHEL in August
· 2002
o Three wholly owned subsidiaries of NTPC viz. NTPC Electric Supply
Company Limited, NTPC Hydro Limited and NTPC Vidyut Vyapar
Nigam Limited incorporated
o Crossed the 20000 MW installed capacity mark

· 2003
o Raised funds through bonds (Series Xlllth & XlVth) for prepayment of
high cost GOI loans

· 2004
o Awarded contract for the first Super Critical Thermal Power Plant at
Sipat NTPC's Feroze Gandhi Unchahar Thermal station achieved a
record PLF of 87.43% in current year, up from 18.02% in February' 92
when it was taken over by NTPC
o LIC extended credit facility of Rs.70 billion. Rs.40 billion was in the form
of unsecured loans and Rs.30 billion in the form of bonds
o NTPC made its debut issue of euro bonds amounting to USD 200 million
in the international market

· 2005
o NTPC received the International Project Management Award, 2005 for
its Simhadri project at the International Project Management
Association World Congress. NTPC became the only Asian Company to
receive this award
o NTPC was ranked as the Third 'Great Place to work for in India' for
second time in succession by a survey conducted by Grow Talent and
Business World 2005.
o The Company's name changed to NTPC Ltd.

· 2006
o For the fourth consecutive year, NTPC continued to realize 100% of
current bills
o On June, 1, the Badarpur Thermal Power Station with an installed
capacity of 705 MW was transferred to NTPC by the Government of
India
o Another 740 MW was added through its Joint Venture, Ratnagiri Gas
and Power Private Limited, Dabhol. Thus taking installed capacity of the
NTPC group to 27904 MW
 o MOA with Govt. of Sri Lanka and Ceylon Electricity Board for
development of 2 x 250 MW Coal based power project at Trincomalee in
Sri Lanka
o Energy Technology Centre set up with the mandate of being a world
class research institute
· 2007
o Ministry of Coal, Government of India granted in-principle approval for
allocation of a new coal block, namely, Chhati Bariatu South to NTPC,
subject to the conditions stipulated in the approval letter. The share of
reserves was indicated as 354 million tonnes
o Tripartite agreement signed with the Government of Assam, Assam
Power Generating Co. Ltd., and NTPC for transfer of existing plant at
Bongaigaon and to set up a new plant of 750 MW with 3 units of 250
MW each
o 765 KV switchyard transmission system energised at Sipat, the largest in
the country
o MOU signed between NTPC and Ministry of Energy, Federal
Government of Nigeria(FGN) for Energy cooperation
o Vindhyachal Super Thermal Power Project became the largest power
station in the country with an installed capacity of 3260 MW

· 2008
o Joint Venture Company under the name "National Power Exchange
Limited" was incorporated on 11th December 2008 with NHPC Ltd., PFC
Ltd., and TCS Ltd., to operate Power Exchange at national level
o NTPC was ranked Number 1 in the 'Best Work places for Large
Organisations' and Number 8 overall for the year 2008 by Great Places to
Work Institute's, India chapter in collaboration with the Economic
Times

· 2009
o 500 MW Unit VI of Sipat brought under commercial generation
o NTPC has achieved the highest ever single day generation of 655.22 MUs
on 2nd March, 2009 with highest ever single day coal based generation
of 579.02 MUs

· 2010
o Installed capacity reaches 31,704 MW (including 2864 MW under JVs).
o 17,830 MW under construction at 17 locations.
o New national benchmark: Dadri Unit-5 (490 MW) begins commercial
operation in 39 months from zero date.
o Generation increased by nearly 6% to 218.84 BUs compared to 3%
generation growth achieved in 2008-09; Exceeded the MoU ‘Excellent’
target of 217 BUs.
1.3 NTPC Group
· One of the three largest Indian companies with market cap of Rs.1778 billion
· Ranks 126th on the basis of market Cap globally (Forbes 2009 data)
· Has a net worth of Rs. 574 billion
· Owns total assets of Rs. 1052 billion

Subsidiaries(6)

Generation Services Power Trading

NTPC Hydro Ltd. NTPC Electric `NTPC Vidyut

Supply Company Vyapar Nigam
(100%) Ltd. (100%) Ltd. (100%)

Kanti Bijlee
Utpadan Nigam
Ltd. (51%)

Bhartiya Rail
Bijlee Company
Ltd. (74%)

Pipavav Power
Development Co
Ltd (100%)*
 Joint Ventures (15)

Equipment
Generation Services Coal Acquisition Power Trading
Manufacturing

Aravali Power NTPC BHEL Power International Coal `National Power

Utility Powertech Ltd
Company Pvt Ltd Projects Pvt Ltd Ventures Pvt. Ltd Exchange Ltd
(50%)
(50%) (50%) (14.29%) (16.67%)

NTPC Tamil Nadu NTPC Alstom Power NTPC SCCL Global

BF NTPC Energy
Energy Company Ltd Services Pvt Ltd Ventures Pvt Ltd
Systems Ltd (49%)
(50%) (50%) (50%)

Nabinagar Power National High Power Transformers and

Generating Company Test Laboratory Pvt Electricals Kerala
Pvt. Ltd (50%) Ltd (25%) Ltd.(44.6%)

Meja Urja Nigam Pvt.

Ltd (50%)

NTPC SAIL Power

Company Pvt Ltd
(50%)

Ratnagiri Gas and

Power Pvt Ltd
(28.33%)
1.4 Power Generation
Be it the generating capacity or plant performance or operational efficiency, NTPC’s
Installed Capacity and performance depicts the company’s outstanding performance
across a number of parameters.

NO. OF PLANTS CAPACITY (MW)

NTPC Owned
Coal 15 24,885
Gas/Liquid Fuel 7 3,955
Total 22 28,840
Owned By JVs
Coal & Gas 5 2,864
Total 27 31,704

Regional Spread of Generating Facilities

REGION COAL GAS TOTAL

Northern 7,525 2,312 9,837
Western 6,360 1,293 7,653
Southern 3,600 350 3,950
Eastern 7,400 - 7,400
JVs 924 1,940 2,864
Total 25,809 5,895 31,704

1.4.2 Coal Based Power Stations

With 15 coal based power stations, NTPC is the largest thermal power generating
company in the country. The company has a coal based installed capacity of 24,885
MW.
COAL BASED STATE COMMISSIONED
(Owned by NTPC) CAPACITY(MW)
1. Singrauli Uttar Pradesh 2,000
2. Korba Chhattisgarh 2,100
3. Ramagundam Andhra Pradesh 2,600
4. Farakka West Bengal 1,600
5. Vindhyachal Madhya Pradesh 3,260
6. Rihand Uttar Pradesh 2,000
7. Kahalgaon Bihar 2,340
 8. NCTPP, Dadri Uttar Pradesh 1,330
9. Talcher Kaniha Orissa 3,000
10. Feroze Gandhi, Unchahar Uttar Pradesh 1,050
11. Talcher Thermal Orissa 460
12. Simhadri Andhra Pradesh 1,000
13. Tanda Uttar Pradesh 440
14. Badarpur Delhi 705
15. Sipat-II Chhattisgarh 1,000
Total 24,885

Coal Based Joint Ventures:

COAL BASED (Owned by STATE COMMISSIONED

JVs) CAPACITY
1. Durgapur West Bengal 120
2. Rourkela Orissa 120
3. Bhilai Chhattisgarh 574
4. Kanti Bihar 110
Total 924

1.4.3 Gas/Liquid Fuel Based Power Stations

The details of NTPC gas based power stations is as follows

GAS BASED STATE COMMISSIONED

(Owned by NTPC) CAPACITY(MW)
1. Anta Rajasthan 413
2. Auraiya Uttar Pradesh 652
3. Kawas Gujarat 645
4. Dadri Uttar Pradesh 817
5. Jhanor-Gandhar Gujarat 648
6. Rajiv Gandhi CCPP Kerala 350
Kayamkulam
7. Faridabad Haryana 430
Total 3,955
Gas Based Joint Ventures:

COAL BASED (Owned STATE COMMISSIONED

by JVs) CAPACITY
1. RGPPL Maharashtra 1940
Total 1940

1.4.4 Hydro Based Power Projects (Under Implementation)

NTPC has increased thrust on hydro development for a balanced portfolio for long
term sustainability. The first step in this direction was taken by initiating investment
in Koldam Hydro Electric Power Project located on Satluj river in Bilaspur district of
Himachal Pradesh. Two other hydro projects under construction are Tapovan
Vishnugad and Loharinag Pala. On all these projects construction activities are in full
swing.

HYDRO BASED STATE APPROVED

CAPACITY(MW)
1. Koldam (HEPP) Himachal Pradesh 800
2. Loharinag Pala (HEPP) Uttarakhand 600
3. Tapovan Vishnugad (HEPP) Uttarakhand 520
Total 1,920

1.4.5 Renewable & Distributed Generation

Renewable Energy
Renewable energy (RE) is being perceived as an alternative source of energy for
“Energy Security” and subsequently “Energy Independence” by 2020. Renewable
energy technologies provide not only electricity but offer an environmentally clean
and low noise source of power.

Objectives
NTPC plans to broad base generation mix by evaluating conventional and non-
conventional sources of energy to ensure long run competitiveness and mitigate
fuel risks.

Portfolio of Renewable Power

NTPC has also formulated its' business plan of capacity addition of about 1,000
MW through renewable resources.
 Sl. No. RENEWABLE ENERGY SOURCES CAPACITY
1. Wind energy Farms 650 MW
2. Small Hydro Project 300 MW
3. Solar PV Power Project 5 MW
4. Solar Thermal 10 MW
5. Biomass Power Project 15 MW
6. Geothermal Power Project 30 MW
Total 1,010 MW

1.4.6 Distributed Generation

India’s ambitious growth plans require inclusion of all sectors, especially the rural
sector where two third of our population lives. Such economic development
cannot be achieved without availability of energy and subsequently efficient energy
management which is crucial for rural development. As per census 2001, about
44% of the rural households do not have access to electricity. Some of the villages
are located in remote & inaccessible areas where it would be either impossible or
extremely expensive to extend the power transmission network.

Objective
· Implementation of distributed generation projects using locally available
renewable resources such as biomass, wind, solar, micro hydel, bio-fuel etc.

· Training & capacity building of local community to enable them to

independently manage, operate & maintain the plant • To ensure viability
and long term sustainability of DG projects

· Integrated growth & development of rural areas by enhancing employment

education, income generation & livelihood opportunities

· To ensure implementation of various technologies as demo/pilot project

1.5 NTPC Operations

In terms of operations, NTPC has always been considerably above the national
average. The availability factor for coal based power stations has increased from
89.32% in 1998-99 to 91.76% in 2009-10, which compares favourably with international
standards. The PLF has increased from 76.6% in 1998-99 to 90.81% during the year
2009-10.
The table below shows that while the installed capacity has increased by 62.15% in the
last twelve years the generation has increased by 99.84%.

Description Unit 1998-99 2009-10 % of Increase

Installed Capacity MW 17,786 28,840 62.15
Generation MUs 1,09,505 2,18,840 99.84
* Excluding JVs and Subsidiaries

The table below shows the detailed operational performance of coal based stations
over the years.

OPERATIONAL PERFORMANCE OF COAL BASED NTPC STATIONS

Year Generation(BU) PLF(%) Availability Factor(%)
2009-10 218.84 90.81 91.76
2008-09 206.94 91.14 92.47
2007-08 200.86 92.24 92.12
2006-07 188.67 89.43 90.09
2005-06 170.88 87.52 89.91
2004-05 159.11 87.51 91.20
2003-04 149.16 84.40 88.79
2002-03 140.86 83.57 88.70
2001-02 133.20 81.11 89.09
2000-01 130.10 81.80 88.54
1999-00 118.70 80.39 90.06
1998-99 109.50 76.60 89.36
1.6 Turnaround Capability
NTPC has played an extremely important role in turning around sub-optimally
performing stations. The phenomenal improvement in the performance of Badarpur,
Unchahar, Talcher and Tanda by NTPC make them our big success stories.

Badarpur (705 MW)

The expertise in R&M and performance turnaround was developed and built up by
NTPC with the operational turnaround of Badarpur TPS through scientifically
engineered R&M initiatives. The PLF of the power station improved from 31.94% at the
time of the takeover to 86.46% for the year 2007-08.

Unchahar (420 MW)

The Feroze Gandhi Unchahar Power Station was taken over by NTPC whereby the
cash strapped UPSEB was rescued by the turnaround expertise of NTPC.
The remarkable speed and extent of the turnaround achieved can be seen in the table.
Talcher (460 MW)
An even more challenging turnaround story was being scripted at the OSEB's old
power plant at Talcher. Taken over in June 1995, the table indicates the dramatic gains
in the performance of the power plant as a result of NTPC’s expertise.

Tanda (440 MW)

Tanda Thermal Power Station was taken over by NTPC on the 15 January 2000.The
PLF of the power station improved from 21.59% at the time of the takeover to 91.66%
for the year 2007-08.

While NTPC bettered PPA commitments, from the viewpoint of capital requirements,
turning around such old units is a low cost, high and quick return option. This
unprecedented success helped the concerned SEBs and the entire nation in terms of
economy and power availability.
1.7 NTPC Strategies

1.8 NTPC International Cell

Towards the end of last century, many countries started structural changes in their
infrastructure sectors. Many countries decided to un-bundle their hitherto
government controlled power sector. Further, in order to meet the growing demand
for power, privatization of power projects emerged as the most outstanding choice.
These actions of many progressive governments resulted in a number of opportunities
for private players in power sector. These include development of power projects as
Independent Power Producers (IPP).
Keeping its proactive tradition, NTPC launched a separate International Cell to meet
the varied needs of IPPs and other International clients who are looking for a world
class service in power sector. The International Cell is fully backed by NTPC’s three
decades of experience and expertise. The Cell is especially tuned to meet the
requirements of International clients in terms of quick response, flexible service
options and to deliver value for money.

1.8.1 Rich International Experience

NTPC has a rich experience of executing power sector related projects abroad. Some of
the projects are:

· Turnkey supply and installation of 400 kV & 132 kV Transmission lines for
Dubai Electricity & Water Authority, Dubai
· Turnkey supply and installation of 132 kV Sub-stations for Dubai Electricity &
Water Authority, Dubai
 · Turnkey execution of 21 sub-stations for Asian Development Bank assisted 7th
Power Project for Nepal Electricity Authority, Nepal.
· Feasibility Studies for Mchuchuma Mining-cum-Power Project of about 400
MW for National Development Corporation, Tanzania.
· Preparation of Procurement plan for IDA funded National HIV / AIDS
Prevention Project of Ministry of Health, Nutrition & Welfare, Govt. of Sri
Lanka.
· Executive training to ALBA Engineers for ALBA Bahrain
· Training to Technical personnel of Oman Refinery Company for Petroleum
India International (PII).
· Deputation of experts to Nigeria to act as shift charge engineers for gas fired
project AFAM at Nigeria from Steag encotec, India.
· Status assessment of Kipevu Power Station of KenGen. Kenya.
· Energy audit of power plants of Saudi Electricity Company in Kingdom of Saudi
Arabia from YBAK of Saudi Arabia.
· Deputation of Metallurgical expert to Mangalore and USA for technical
discussion with M/s General Electric in connection with failure of one of the
Barge mounted Gas turbine belonging to GMR Energy Ltd. in India.
· Deputation of expert for assistance in due diligence of 683 MW Sidi Krier
Power project Egypt.
· Review of design engineering of 4 Nos. 132/33kV substations in Dubai for
DEWA, Dubai Investment Park & Tajera town.
· Experts’ services for supervision of commissioning and materials management
at 800MW Az Zour Gas Power Plant in Kuwait.
· Review of protocol document and performance data sheet at home office and
attending meeting at Kuwait and review of PG test calculation for 252 MW
open cycle gas plant at Shuwaikh, Kuwait.
· Analysis of root cause for internal corrosion in HRSG tubes in Fujairah
Independent water and power project, UAE.

Pursuing Business Opportunities In:

Bahrain Bangladesh China Egypt

Indonesia Iran Jordan Kazakhstan
Malaysia Nigeria Saudi Arabia Sri Lanka
Thailand UAE Vietnam Yemen
1.9 Ecological Monitoring Programme

NTPC has undertaken a comprehensive Ecological Monitoring Programme through

Satellite Imagery Studies covering an area of about 25 Kms radius around some of its
major plants. The studies have been conducted through National Remote Sensing
Agency (NRSA), Hyderabad at its power stations at Ramagundam, Farakka, Korba,
Vindhyachal, Rihand and Singrauli. These studies have revealed significant
environmental gains in the vicinity areas of the project as a result of pursuing sound
environment management practices. Some of these important gains which have been
noticed are increase in dense forest area, increase in agriculture area, increase in
average rainfall, decrease in waste land etc. In general, the studies, as such, have
revealed that there is no significant adverse impact on the ecology due to the project
activities in any of these stations. Such studies conducted from time to time around a
power project have established comprehensive environment status at various post
operational stages of the project.
2.1 Overview
The natural gas-fired combined cycle gas turbine (CCGT) based power plant and
associated transmission and transformer facilities (T&T facilities) is located in an area
of 324.58 acres in the village of Mujhedi, Neemka, Faridabad district, Haryana State, in
India’s Northern region, targeting the elimination of supply deficits and contributions
to living standard improvements and industrial development within the region.

*A indicates location of the plant

A yen loan of 56,154 million was extended from OECF (Overseas Economic
Cooperation Fund) Japan to the President of India / National Thermal Power
Corporation Ltd. (NTPC) and Powergrid Corporation of India Ltd. (POWERGRID) to
cover the power plant and T&T facilities costs, excluding the land acquisition costs,
project management costs, taxes and part of the costs for the switchyards, however,
the portion necessary for the works to be undertaken by the end of FY95 (23,536
million yen) was in fact provided.
Outline of Loan Agreement
Loan Amount 23,536 million yen
Loan Disbursed Amount 19,937 million yen
Exchange of Notes December 1993
Loan Agreement January 1994
Terms and Conditions
-Interest Rate 2.6%
-Repayment Period (Grace 30 years (10 years)
Period)
-Procurement General untied
Final Disbursement Date March (10 years)
2001
Initially the entire Northern region was established as the project’s beneficiary area,
and plant output was projected to be around 800MW so as to be capable of supplying
an adequate volume of power. However, an 800MW output scale was found to be
excessive in terms of securing fuel. In addition, with the exception of Haryana State,
all other states in the region expressed reservations about future purchases of power
from the plant, citing high fuel costs, thus a proposal was made to the Haryana State
government regarding the conclusion of a power purchase contract, on condition that
the entire volume of power produced at the Faridabad Power Station be supplied to
the state. This proposal was accepted by NTPC and approved by the central
government, in consequence of which the project’s beneficiary area was narrowed
down from the entire Northern region to Haryana State alone.

The “Flare Gas Reduction Project” and "HBJ (Hazira-Bijaipur-Jagdishphur) Gas

Pipeline Reinforcement Project” that were instituted as external requirements (the
drilling for and supply of natural gas) for the establishment of this plant were
respectively completed in 1999 and 1998. Both projects were jointly funded by JBIC
and the World Bank as well as the Asian Development Bank (ADB), and their
completion was also a precondition of gas supplies to the Faridabad Power Station.
The projects were divided into a number of components; these dates indicate
completion of the final components.

Power Plant Output

Due to the comparatively favorable nature of the terms for generation facilities
stipulated by the winning contractor, plant output was fixed at 430MW*6. Switchyard
facilities were also changed from the initial 400kV to 220kV compatibility since with
the reduction in plant scale (800MW→400MW) and hence the plant was connected to
220kV power lines.

Transmission & Transformer Facilities

Since the plant turned out to be connected to the 220kV system, the construction /
expansion of 400kV substations and the construction of incoming 400kV transmission
lines were omitted, and two 220kV transmission line routes were constructed from the
plant to existing substations.

Implementation Schedule
(1) Power Plant
The power plant was completed in July 2000, two years and seven months behind the
initially planned date (December 1997). This delay was caused by approval procedures
accompanying the changes to output scale and so on, however, as Table 3 illustrates,
construction of the plant per se progressed extremely smoothly.

Construction Schedule for Key Power Plant Components

Component Initial schedule Actual
No. 1 Gas turbine generator 30 months 23 months
No. 2 Gas turbine generator 32 months 27 months
Steam turbine generator 42 months 36 months
(2) Transmission & Transforming Facilities
For the same reason as cited above, construction started three years behind schedule,
but was completed in 16 months, which was essentially as per the plans (14 months).
The delays occurring prior to construction are believed to have been the product of
limitations in NTPC’s ability to deal, unassisted, with the numerous state governments
and related organizations involved in the process. However, given the fact that debate
over the changes in output scale linked to hold ups in the approval process, it might
have been possible to confirm / verify the prospects for power purchase by each of the
states in advance, thereby reducing the duration of the delays. However, it would be
beneficial to evaluate how the construction work was completed in less time than
initially projected under such circumstances.

Contribution of the plant in Haryana State

The Faridabad Power Station commenced on-grid generation in 1999 and all power
produced (100%) at the plant is being supplied to Haryana State. Assuming that the
plant had not existed in FY99, the supply deficit in the state would have deteriorated
from 2.3% to 9.0%*11. Moreover, in a trial calculation for the following year, FY00, the
supply deficit would worsen from 2.8% to 15.8%. In fact, the peak supply deficit
dropped from 8.3% in FY98 to 3.3% in FY00, a circumstance to which the Faridabad
Power Station is believed to making a certain contribution*12. The net electric energy
production had reached approximately 2,797MWh in FY01. This is roughly equivalent
to 16% of total power consumption in Haryana State (17,856MWh). Further, peak
demand (FY01) was 3,004MW with the plant supplying 12.7% of the demand during
peak times. In summary, the plant has attained the initially set targets.
Environmental Impacts

NTPC periodically measures effluent and atmospheric concentrations of

environmental pollutants including nitrogen oxide (NOx) and sulfur oxide (SOx), as
well as the quality of effluent and water in the river into which said effluent is
discharged (suspended particulate matter, heated effluent, etc.). All results to date
have been in conformity with the standards governing emissions and the environment
established by the national government, and there have been no specific reports of
adverse environmental impacts.

Power produced at the Faridabad Power Station is purchased by Haryana Vidyut

Prasaran Nigam Ltd., (HVPNL), the distribution company that came into being as the
result of the unbundling of Haryana State Electricity Board (HSEB).

Item Plan Actual

1) Project Scope
1) Gas turbine generators, 1) Gas turbine generators, 137MW
Power station 140MW × 2 ×2
Transmission / 2) Steam turbine generators, 2) Steam turbine generators, 156
transformer 130MW × 1 MW × 1
facilities 3) Heat recovery steam gas 3) As planned
boiler × 2
4) Monitoring /control 4) As planned
equipment, water treatment
facilities, etc.
5) Switchyard and related 5) Changed from 400kV to 220kV
facilities
1) 400kV Dadri-Ballabgarh 1) 220kV Faridabad-Samaypur
transmission line transmission line
2) 400kV Ballabgarh-Jaipur 2) 220kV Faridabad-Palla
transmission line transmission line
3) Construction and expansion 3) Only 220kV bay constructed
of substation facilities
2) Dec. 1994 - Dec. 1997 Jan. 1998 - Jul. 2000
Implementation Aug. 1995 - Sep. 1996 Aug. 1998 - Dec. 1999
schedule
Power plant Aug. 1994 - Sep. 1996 Aug. 1998 - Dec. 1999
Transmission
lines
Substations
2.2 Combined Cycle Gas Turbine (CCGT) plant
A combined cycle is characteristic of a power producing engine or plant that employs
more than one thermodynamic cycle. Heat engines are only able to use a portion of
the energy their fuel generates (usually less than 50%). The remaining heat (e.g., hot
exhaust fumes) from combustion is generally wasted. Combining two or more
thermodynamic cycles, such as the Brayton cycle and Rankine cycle, results in
improved overall efficiency.

In a combined cycle power plant (CCPP), or combined cycle gas turbine (CCGT) plant,
a gas turbine generator generates electricity and the waste heat is used to make steam
to generate additional electricity via a steam turbine; this last step enhances the
efficiency of electricity generation.

Design Principle
In a thermal power station water is the working medium. High pressure steam
requires strong, bulky components. High temperatures require expensive alloys made
from nickel or cobalt, rather than inexpensive steel. These alloys limit practical steam
temperatures to 655 °C while the lower temperature of a steam plant is fixed by the
boiling point of water. With these limits, a steam plant has a fixed upper efficiency of
35 to 42%.

An open circuit gas turbine cycle has a compressor, a combustor and a turbine. For gas
turbines the amount of metal that must withstand the high temperatures and
pressures is small, and lower quantities of expensive materials can be used. In this type
of cycle, the input temperature to the turbine (the firing temperature), is relatively
high (900 to 1,400 °C). The output temperature of the flue gas is also high (450 to
650 °C). This is therefore high enough to provide heat for a second cycle which uses
steam as the working fluid; (a Rankine cycle).
In a combined cycle power plant, the heat of the gas turbine's exhaust is used to
generate steam by passing it through a heat recovery steam generator (HRSG) with
a live steam temperature between 420 and 580 °C. The condenser of the Rankine
cycle is usually cooled by water from a lake, river, sea or cooling towers. This
temperature can be as low as 15 °C.

Typical size of CCGT plants

For large scale power generation a typical set would be a 400 MW gas turbine coupled
to a 200 MW steam turbine giving 600 MW. A typical power station might comprise of
between 2 and 6 such sets.

Efficiency of CCGT plants

By combining both gas and steam cycles, high input temperatures and low output
temperatures can be achieved. The efficiency of the cycles add, because they are
powered by the same fuel source. So, a combined cycle plant has a thermodynamic
cycle that operates between the gas-turbine's high firing temperature and the waste
heat temperature from the condensers of the steam cycle. This large range means that
the Carnot efficiency of the cycle is high. The actual efficiency, while lower than this,
is still higher than that of either plant on its own.
Supplementary firing and blade cooling
The HRSG can be designed with supplementary firing of fuel after the gas turbine in
order to increase the quantity or temperature of the steam generated. Without
supplementary firing, the efficiency of the combined cycle power plant is higher, but
supplementary firing lets the plant respond to fluctuations of electrical load.
Supplementary burners are also called duct burners.
More fuel is sometimes added to the turbine's exhaust. This is possible because the
turbine exhaust gas (flue gas) still contains some oxygen. Temperature limits at the
gas turbine inlet force the turbine to use excess air, above the
optimal stoichiometric ratio to burn the fuel. Often in gas turbine designs part of the
compressed air flow bypasses the burner and is used to cool the turbine blades.

Fuel for combined cycle power plants

Combined cycle plants are usually powered by natural gas, although fuel oil, synthesis
gas or other fuels can be used. The supplementary fuel may be natural gas, fuel oil, or
coal. Bio-fuels can also be used. Integrated solar combined cycle power stations
combine the energy harvested from solar radiation with another fuel to cut fuel costs
and environmental impact.

Configuration of CCGT plants

The combined-cycle system includes single-shaft and multi-shaft configurations. The
single-shaft system consists of one gas turbine, one steam turbine, one generator and
one Heat Recovery Steam Generator (HRSG), with the gas turbine and steam turbine
coupled to the single generator in a tandem arrangement on a single shaft. Key
advantages of the single-shaft arrangement are operating simplicity, smaller footprint,
and lower startup cost. Single-shaft arrangements, however, will tend to have less
flexibility and equivalent reliability than multi-shaft blocks. Additional operational
flexibility is provided with a steam turbine which can be disconnected, using an SSS
Clutch, for start up or for simple cycle operation of the gas turbine.
Multi-shaft systems have one or more gas turbine-generators and HRSGs that supply
steam through a common header to a separate single steam turbine-generator. In
terms of overall investment a multi-shaft system is about 5% higher in costs.
Single- and multiple-pressure non-reheat steam cycles are applied to combined-cycle
systems equipped with gas turbines having rating point exhaust gas temperatures of
approximately 540 °C or less. Selection of a single- or multiple-pressure steam cycle for
a specific application is determined by economic evaluation which considers plant
installed cost, fuel cost and quality, plant duty cycle, and operating and maintenance
cost.

Multiple-pressure reheat steam cycles are applied to combined-cycle systems with gas
turbines having rating point exhaust gas temperatures of approximately 600 °C.
The most efficient power generation cycles are those with unfired HRSGs with
modular pre-engineered components. These unfired steam cycles are also the lowest
in cost. Supplementary-fired combined-cycle systems are provided for specific
application.

The primary regions of interest for cogeneration combined-cycle systems are those
with unfired and supplementary fired steam cycles. These systems provide a wide
range of thermal energy to electric power ratio and represent the range of thermal
energy capability and power generation covered by the product line for thermal energy
and power systems.

2.2 Water treatment

Raw water for steam turbine generation (STG), use as circulating water (CW) and
other purposes is taken from the Agra canal through an extensive piping system. The
water is contaminated with various minerals and other impurities which readily
dissolve in it. They have to be removed from the raw water before it can be used for
any industrial applications. For this purpose water is treated first by a Pre-Treatment
(PT) plant and then by a De-Mineralization (DM) plant.

2.2.1 Pre-treatment (PT) plant

Pre-treatment plant consists mainly of clarifiers, chemical house, gravity filter,
pressure filter and Chlorine dozing. A Cooling Water (CW) clarifier caters water
requirement of CW makeup, HVAC makeup, fire fighting and auxiliary water
requirements. For back washing gravity filters, blowers have been provided. Sand in
the form of quartz, free from clay, fine particles and soft grains is used in the gravity
filters with sizes ranging between 0.45 to 0.70 mm.

The nature and concentration of impurities and objectionable constituents of water

determine the methods to be employed for the treatment of water. Different
techniques are used for removal of mechanical impurities, Clayey turbidities,
Colloidal, dissolved impurities, organic matter, detergents, polycyclic aromatics,
colouring substances, oils and aliphatic hydrocarbons etc. which impart taste or
odour, polyvalent heavy-metal compounds, germs and bacteria.

The water is given an initial dose of chlorine when it is in the raw water tank. This
water is pumped by three CW pumps for use as circulating water while other three
pump this water for further processing as described below:

1. The pumped water is passed to an Aerator, which oxidizes soluble iron in the
Raw Water (RW) from Ferrous to Ferric State.
2. Water flows to the Stilling Chamber to break the turbulence.
3. Water is then taken into the Flash Mixer for intimate mixing of chemicals with
the raw water.
4. The raw water is dosed with Alum or PAC (Poly Aluminium Chloride), Lime
and Polyelectrolyte to coagulate and flocculate the suspended / colloidal matter
and form floc of higher nuclei thereby enhancing the efficiency of
sedimentation.
5. Chemically dosed raw water is then fed into the clariflocculator unit wherein
flocculation and clarification of raw water takes place.
6. The sludge generated in the clariflocculator is bled via Telescopic Bleeds to an
underground Sludge Pit. The sludge collected from the plant is finally pumped
out.
7. Clarified water is collected in the launder of the clarifier located on the top
periphery from where it flows to the clarified water reservoir.

The clearified water is then pumped to the De-Mineralisation (DM) plant for
removing inorganic impurities and making the water suitable for use in Heat Recovery
Steam Generator (HRSG) and Steam Turbine (ST).
2.2.2 De-Mineralisation (DM) plant
Demineralisation is the process of removing the mineral salts from water by ion-
exchange. Impurities that remains dissolved in water dissociate to form positive and
negative charged particles known as ions. These impurities or compounds are called
electrolytes. Generally, all natural water has electrolytes in varying concentrations. An
ion-exchange vessel holds ion-exchange resin of the required type through which
water is allowed to pass. The selective ions in the water are exchanged with ions or
radicals loosely held by the resin. In this way, the water is passed through several
vessels or a mixed bed vessel so that both positive and negative ions are removed and
water is demineralised. The DM plant at Faridabad gas power plant (FGPP) was
provided by Ion Exchange (I) Ltd (Mumbai), over a period of 20 months on 30-03-
2000.

The demineralization plant is a two stream plant having a normal treatment capacity
of 100 m3/hr. Each demineralising chain comprises of following units:

a) ACF : Activated Carbon Filter

b) WAC :Weak Acid Cation Exchanger
c) SAC :Strong Acid Cation Exchanger
d) DG & DGWT :Degasser Tower and Degassed Water Storage Tank
e) WBA :Weak Base Anion Exchanger
f) SBA : Strong Base Anion Exchanger
g) MB :Mixed Bed Exchanger

Apart from the above a hot water tank is provided for heating “power water” required
for regeneration of SBA/WBA unit & when residual silica at outlet is high.

Each exchanger is mounted with several instruments for local and/or panel indication,
control or alarm to monitor the various parameters for smooth running of the plant.
Each exchanger is mounted with flow instrument (Rotameter) at the service inlet,
pressure gauge at inlet and outlet, and resin trap at the outlet.

The plant has predominantly DOPC diaphragm valves mounted on the service inlet,
backwash inlet and outlet, bleed and air release, Service outlet and regenerant valves
are DOPO diaphragm valves. The block valves open and close with the regenerant
inlet valve while the bleed valves open and close when the block valves and regenerant
inlet valves open and close respectively. Needle valves are used for transmitter, pH
sample, pressure indicator isolation, drain and sample while ball valves are used for
flow indicator and flow switch isolation, inter connecting valves between service outlet
header of two streams of two streams are manually operated butterfly valves.

Carbon filters are provided upstream for residual chlorine reduction and organic
removal in the water supply to the demineraliser. Downflow service and upflow
regeneration is employed for the primary Cation and Anion exchangers. The mixed
bed is designed with simultaneous regeneration of cation and anion resin. For anion
resin, the caustic dilution system is designed with on-line hot caustic regeneration.
The WAC and SAC remove the cationic inorganic impurities while the WBA and SBA
remove the acidic inorganic impurities present in water.

Feed Water

ACF WAC SAC

Degasser

WBA SBA
MB CST

2.4 Components
2.4.1 Air filters
Ambient air can be contaminated by solids, liquids, or gases. Of these three,
contamination by solids is the most common, and usually the most serious situation.
When account is taken of ’the large flow rates of gas turbines, it is evident that the
total quantity of dust which is ingested can be appreciable when summed over
hundreds or thousands of fired hours. Therefore, Inlet air filtration systems are
essential on any gas turbine. Some of the consequences of poor inlet filtration are
fouling, erosion, and corrosion.
Five basic filtration mechanisms are described below:
The first filtration mechanism is inertial impaction. This type of filtration is applicable
to particles larger than 1 micron in diameter. The inertia of the large heavy particles in
the flow stream causes the particles to continue on a straight path as the flow stream
moves to go around a filter fiber. The particulate then impacts and is attached to the
filter media and held in place as shown in the top picture of figure .This type of
filtration mechanism is effective in high velocity filtration systems.
The next filtration mechanism, diffusion, is effective for very small particles typically
less than 0.5 microns in size with low flow rates. These particles are not held by the
viscous forces in the fluid and will diffuse within the flow stream along a random path
(second picture). The path the particle takes depends on its interaction with nearby
particles and gas molecules. As these particles diffuse in the flow stream, they collide
with the fiber and are captured. The smaller a particle and the lower the flow rate
through the filter media, the higher probability that the particle will be captured.

The next two filtration mechanisms are the most well known; interception and
sieving. Interception occurs with medium sized particles that are not large enough to
leave the flow path due to inertia or not small enough to diffuse. The particles will
follow the flow stream where they will touch a fiber in the filter media and be trapped
and held. Sieving is the situation where the space between the filter fibers is smaller
than the particle itself, which causes the particle to be captured and contained.

Another type of filtration mechanism which is not shown in Figure is viscous

impingement. This type of mechanism uses the inertial impaction mechanism to
capture particles. What makes this mechanism unique is that the filter is covered with
a thin layer of oil which causes the captured particles to adhere to the filter surface,
thus preventing them from being released downstream. The amount of particles
captured is maximized by creating a torturous path for the air. This results in a filter
with many changes in flow direction. This filtration mechanism is effect for medium to
large size particles.

The last filtration mechanism is electrostatic charge. This type of filtration is effective
for particles in the 0.01 to 10 micron size range. The filter works through the attraction
of particles to a charged filter. In gas turbine applications, this charge is applied to the
filter before installation during the manufacturing process. Filters always lose their
electrostatic charge over time because the particles captured on their surface occupy
charged sites, therefore neutralizing their electrostatic charge. As the charge is lost,
the filter efficiency for small particles will decrease. However, it should be noted that
as the filter is loaded, the filtration efficiency increases. This will offset some of the
loss of filtration efficiency due to the lost charge. Figure below shows a comparison of
a filter’s total efficiency based on the various filtration mechanisms that are applied.
2.4.2 Compressor-Gas Turbine- Generator
A gas turbine is a rotary engine that extracts energy from a flow of combustion gas. It
has an upstream compressor coupled to a downstream turbine, and a combustion
chamber in-between. Energy is added to the gas stream in the combustor, where fuel
is mixed with air and ignited. In the high pressure environment of the combustor,
combustion of the fuel increases the temperature. The products of the combustion are
forced into the turbine section. There, the high velocity and volume of the gas flow is
directed through a nozzle over the turbine's blades, spinning the turbine which
powers the compressor and drives the generator.

Before starting the turbine, compressor has to be started. For this purpose, an electric
motor is mounted on the same shaft as that of the turbine. The motor is energised
externally. Upon reaching 20% of the rated rpm the gas turbine is ignited. It is speeded
up higher and takes the system to approximately 50% or its rated rpm. From this
point on, any further increase in speed is accomplished by the gas turbine and the
motor is disconnected. Once the unit starts, a part of the mechanical power of the
turbine drives the compressor and there is no need of the motor.

Faridabad plant is equipped with two gas turbines provided by Siemens (V94.2 model
3) with a capacity of 137.6 MW. Each turbine consists of a 16 stage compressor and a
four stage turbine mounted on a single shaft with four bearings as shown in figure.

Generator Compressor Turbine

Thrust Bearing

Journal Bearing
2.4.3 Diverter-Damper
Since the gas turbine has two options; one is to run in open cycle i.e. by passing HRSG
or waste heat recovery boiler (WHRB) and second (normal) mode in which HRSG is in
circuit, hence a damper has been provided on the path of flue gas. This damper will
close the path either towards HRSG or towards the by-pass stack.

.
Movement of the damper is 900 and it is basically rectangular shaped plate which seats
perfectle on its seal provided at the two places. Blade of diverter damper is made off
carbon steel supported on suitable modification on both sides to resist temp of 5400C
and sudden cooling and heating during operation.

2.4.4 Heat Recovery Steam Generator (HRSG)

Faridabad gas power project, popularly known as FGPP, is equipped with two HRSGs
of 277 t/hr each. A heat recovery steam generator or HRSG is an energy recovery heat
exchanger that recovers heat from a hot gas stream. It produces steam that can be
used in a process or used to drive a steam turbine. HRSGs consist of three major
components. They are the Evaporator, Superheater, and Economizer. The different
components are put together to meet the operating requirements of the unit. In
horizontal type HRSGs, exhaust gas flows horizontally over vertical tubes as shown in
figure.

Direct Benefits:
Recovery of waste heat has a direct effect on the efficiency of the process. This is
reflected by reduction in the utility consumption & costs, and process cost.

Indirect Benefits:
a) Reduction in pollution: A number of toxic combustible wastes such as carbon
monoxide gas, sour gas, carbon black off gases, oil sludge, Acrylonitrile and other
plastic chemicals etc, releasing to atmosphere if/when burnt in the incinerators serves
dual purpose i.e. recovers heat and reduces the environmental pollution levels.
b) Reduction in equipment sizes: Waste heat recovery reduces the fuel consumption,
which leads to reduction in the flue gas produced. This results in reduction in
equipment sizes of all flue gas handling equipments such as fans, stacks, ducts,
burners, etc.
c) Reduction in auxiliary energy consumption: Reduction in equipment sizes gives
additional benefits in the form of reduction in auxiliary energy consumption like
electricity for fans, pumps etc.

Flue gas from the combustion turbine enters the HRSG at a temperature of around
5400C and is reduced in temperature by the superheater, reheater, dram evaporative
surfaces, and economizer before it enters the stack. Condensate from the combined
cycle condenser enters the deaerator, and flows through the economizer to the drum.
Steam from the drum flows to the superheater and then to the high pressure turbine.
Steam from the high pressure steam turbine flows through the reheater and then to
the intermediate pressure turbine.
Pinch points and approach temperatures are important HRSG design parameters.
Reducing these temperatures will increase cycle efficiency.
2.4.5 Steam Turbine-Generator

The Faridabad gas power plant is equipped with BHEL 156 MW steam turbine. The
heat energy in the steam from HRSG is converted to mechanical energy in the steam
turbine. The turbine uses the mechanical energy from the steam to turn the generator
which then converts the mechanical energy to electrical energy.

The steam expands and cools in the energy conversion in the steam turbine. A small
fraction of the steam condenses in the steam turbine and appears as small water
droplets. The mixture of steam and water exhausts from the steam turbine to the
condenser where the remaining steam is condensed into water, usually referred to as
condensate. The heat required to change the state between steam and water, called
the heat of vaporization, is rejected to the circulating water through heat transfer in
the condenser. The condensate is then pumped back to the HRSG through heat
exchangers designed to capture more heat through heat transfer. The process is then
repeated.

Bearing and Lubication:

Two types of bearings are used to support and locate the rotors of steam turbines:
Journal bearings are used to support the weight of the turbine rotors. A journal
bearing consists of two half-cylinders that enclose the shaft and are internally lined
with Babbitt, a metal alloy usually consisting of tin, copper and antimony; and Thrust
bearings axially locate the turbine rotors. A thrust bearing is made up of a series of
Babbitt lined pads that run against a locating disk attached to the turbine rotor.
High-pressure oil is injected into the bearings to provide lubrication. The oil is
carefully filtered to remove solid particles. Specially designed centrifuges remove any
water from the oil. Shaft Seals The shaft seal on a turbine rotor consist of a series of
ridges and groves around the rotor and its housing which present a long, tortuous
path for any steam leaking through the seal. The seal therefore does not prevent the
steam from leaking, merely reduces the leakage to a minimum. The leaking steam is
collected and returned to a low-pressure part of the steam circuit.

Turning gear:
Large steam turbines are equipped with "turning gear" to slowly rotate the turbines
after they have been shut down and while they are cooling. This evens out the
temperature distribution around the turbines and prevents bowing of the rotors.
2.4.6 Main Control Room (MCR)
The control room is the heart of the processing system. It is the core of the plant and
the main part of the supervision is carried out here. Working as an operator involves
many hours in front of computer screens. A pleasant and appropriate surrounding
enhances the work spirit and stamina.

An interface provides the operator with the general following information:

· After initiating an action within a system the operator is clearly informed of the
result of their action.
· If there is a delay in the system that prevents the operator from being informed
of the result of his/her action, the system informs the operator of this fact.
· If an action is made in error then it is possible to reverse such an action where
it would not be detrimental to plant safety to do so.
· The system informs the operator of any deviations from safe operating levels,
through alarms.

For large plants, control rooms are likely to be situated in separate buildings away
from the process plant which they serve. For medium or small plants control rooms
may be within the plant building or control panels may be located local to the plant.

2.4.7 Cooling tower

Induced Draft Cooling Tower of 29000 m3/hr capacity has been built to cool the hot
water coming out of condenser of steam turbine. It is capable to reduce water
temperature by 110.
The primary task of a cooling tower is to reject heat into the atmosphere. This heat
rejection is accomplished through the natural process of evaporation that takes place
when air and water are brought into direct contact in the cooling tower. The
evaporation is most efficient when the maximum water surface area is exposed to the
maximum flow of air, for the longest possible period of time.

Cooling towers are designed in two different configurations, counter flow and cross
flow. The specific configuration indicates the direction of air flow through the tower
relative to the direction of the water flow.

Induced draft cooling towers are constructed such that the incoming circulating water
is dispersed throughout the cooling tower via a spray header. The spray is directed
down over baffles that are designed to maximize the contact between water and air.
The air is drawn through the baffled area by large circulating fans and causes the
evaporation and the cooling of the water.

The heat exchanger media in the cooling tower is PVC fills packed in box form after
gluing each other suitably at the top of the cooling tower. Placed just below the
propeller fans drift eliminator, PVC fills (grey coloured) are cross corrugated with
minimum sheet thickness of 0.2 mm and minimum sheet spacing is 17 mm.

Drift Eliminator:
It is placed between propeller fan and PVC fills boxes. The purpose of drift eliminator
is to arrest carry over of minute water particles form air so that drift loss is a minimum
of .05% of total water circulation. Drift eliminator is nothing but closely packed PVC
sheet arrangements.
2.5 Switchyard
A Switchyard or Substation, consisting of large breakers and towers, is located in an
area close to the plant. The substation is used as the distribution center where:
· electrical power is supplied to the plant from the outside, and
· electrical power is sent from the plant
Often there are at least 2 main Buses. The generated power at FGPP is transmitted as
220 kV to the grid thorugh four output lines: 2 to Samaipur (ballabgarh) and 2 to palla(
faridabad), where other substations step down the voltage for distribution to
households.
The switchyard at FGPP was erected by Power Grid Corporation Of India Ltd. (NR) in
1998.
2.6 Major Departments
Departments are the entities organizations form to organize people, reporting
relationships, and work in a way tht best supports the accomplishment of the
organization's goals. Departments are usually organized by functions.

2.6.1 Human resources (HR)

The human resource department is devoted to providing effective policies, procedures,
and people-friendly guidelines and support within companies. Additionally, the
human resource function serves to make sure that the company mission, vision, values
or guiding principles, the company metrics, and the factors that keep the company
guided toward success are optimized. It focuses on recruitment of, management of, and
providing direction for the people who work in the organization.

2.6.2 Maintenance Planning (MTP)

The MTP department increases the Maintenance department’s ability to complete
work orders. Work plans avoid anticipated delays, improve on past jobs, and allow
scheduling. Advance scheduling allows supervisors to assign and control the proper
amount of work. A work crew is ready to go immediately to work upon receiving a
planned and scheduled assignment because all instructions, parts, tools, clearances,
and other arrangements are ready. The required jobs are ready to go.

2.6.3 Operation & Maintenance: Mechanical (O&M- MM)

Mechanical Maintenance is a support service department that caters to the
maintenance needs of the refrigeration and mechanical sections of the plant. It does
works at an approximate rate of 6 jobs per day. They facilitate uninterrupted working
of the plant, including getting the spares as scheduled by the MTP department.

2.6.4 Operation & Maintenance: Electrical (O&M- EMD)

The EMD department takes care of electrical repairs of all types including primary as
well as the secondary systems. It continuously monitors the output of the plant and
takes necessary steps of efficient working of the plant. It also works with
POWERGRID, the transmission company, and caters to the requirements of the grid
with respect to plant capacity.

2.6.5 Operation & Maintenance: Control & Instrumentation (O&M- C&I)

Control & Instrument Department(C&I) is responsible for the operation and
maintenance of all the electronic sensors, actuators and controllers. It takes care of the
following functions: Maintenance of all existing systems, Procuring related Spares and
In-House Modification. It monitors the various parameters of the plant and notifies
the concerned department if case of any problems.

2.6.6 Operation & Maintenance: Chemical (O&M-Chem)

This department looks after the chemical maintenance of the DM plant and the PT
plant. It continuously monitors the pH values, pressures, storages, concentration of
chemicals, etc and takes measures accordingly as required for the healthy functioning
of the plant.
3.1 Introduction to Siemens V94.2
The gas turbine has a nominal generation capacity of 137 MW at site condition
(average temperature of about 30 degree C) and can be operated in open-cycle mode
as well as closed-cycle mode with either natural gas or Naptha as fuel. It generates at
10.5 kV, and transmits electrical power at 220 kV via a step-up transformer.
It is also equipped with black-start diesel engine generator to allow for total black-
start conditions (as an option).

The GT is a Siemens SGT5-2000E (formerly known as the V94.2) heavy-duty gas

turbine. It is of single-shaft, single casing design, equipped with 2 silo-type
combustion chambers, a 16-stage compressor and a 4-stage turbine. An air-cooled
generator, rated at 125 MVA and generating at 10.5 kV is driven from the cold
(compressor) end of the GT unit.

The unit is installed with dual fuel Siemens diffusion-type burners, capable of
operation on distillate-oil liquid and natural gas.

Other important features can be summarised as follows:

· 16-stage compressor, adjustable inlet guide vanes (IGVs), optionally fast-acting
for grid frequency stabilisation;
· two large external silo-type combustors equipped with 2x8 hybrid burners for
premix and diffusion mode operation with natural gas, fuel oil and special fuels,
such as heavy oil and refinery residues;
· hot casings weld-fabricated from Ni-based material, designed with single shell
for elbow-shaped mixing casings or double shell for inner casing;
· four-stage turbine with conventionally cast blading made of Ni-based material,
stages 1 and 2 having conventional cooling providing fuel flexibility (including
ash forming fuels, that cannot be burnt when film-cooled blading is used);
· built-up disc rotor with a self-centring radial Hirth serrations and one central
tie rod;
· four bearing design;
· generator drive at cold end;
· axial exhaust design;
· fast starting capability, a major advantage for peaking and black start
applications;
· compressor and turbine blades and vanes exchangeable with rotor in place;
· high availability due to long maintenance intervals; and
· Capability for hot-gas-path to be inspected without cover lift thanks to the
walk-in combustion chambers.

When looking at the silo-type combustor design, its robustness and simplicity become
evident:
· Flame tubes are lined with easily replaceable ceramic tiles; for ash-forming
fuels a specific flame tube option is available as well as for low-Btu gas
 · Walk-in combustion chamber design enables
minor walkthrough inspection without cover lift,
only one manhole is opened
· Hybrid burners in premix mode for dry low
NOx and low CO emissions (natural gas & fuel oil)
· Diffusion burners for special fuels, e.g. ash-
forming fuel oil or low-Btu gas such as synthetic gas
or coal gas used in V94.2 and V94.2K; these burners
have options for integrated water or steam injection
· The combustion chamber dome can easily be
modified when required for low-Btu gas diffusion
burners
· Turbine blading benefits from highly uniform
hot-gas temperature distribution due to the considerable mixing distance and
from non-exposure to flame radiation.

Compressor blades
· Variable pitch inlet guide vanes allow operation down to half load
while maintaining a constant exhaust temperature.
· All stationary and moving blades of the compressor and turbine
can be replaced individually without removing the rotor from the lower
casing.

Turbine blades
· Convective air-cooling of the first three stationary and first two
moving turbine blade rows protects the blade material against high
inlet temperatures. The first three stages of the turbine are protected
with a special coating.
· No film cooling is used to allow ash-forming fuel firing.
· The free-standing moving blades of the compressor and turbine
are tuned to permit continuous full load operation over a wide off-
frequency range.

Rotor
· The light, highly rigid rotor of disk design allows rapid start-ups.
· Internal air-circulation paths in the rotor minimize thermal
stresses.
· Hirth facial serrations at the outer perimeter of the disks ensure
self-centering of all the rotor components under steady and nonsteady-
state operating conditions.

These features make the V94.2 highly attractive for both continuous-duty combined
cycles as well as peaking applications.
During the tender process of choosing the technology, two dominant reasons led to
the selection of the Siemens V94.2 turbine over other competitors. Firstly, this
technology makes use of a dry-NOX system. This means that the amount of water
used by the turbine to keep the NOX levels within statutory requirements is minimal,
when compared to other machines. Secondly, these units are very robust and able to
absorb the stresses of frequent start-ups.

Standstill/Turning Gear to Generating

The units are very rarely at complete standstill. When not generating or in the
synchronous condenser operation (SCO) mode they are generally in “turning gear”.
The changes from standstill or turning gear modes to generating are very similar.

When a unit starts up, the generator initially acts as a motor, driving the rotor shaft
and therefore the compressor/turbine shaft. This function is performed by the static
frequency converter. The static frequency converter (SFC) draws power to drive the
shaft, via the start-up transformer, from the medium-voltage supply of the plant
auxiliary power supply system.

As the shaft speeds up the turbine also begins to play a role in accelerating the shaft as
the compressor blades begin to set up the vacuum effect which assists in driving the
machine. While the unit is still at these relatively low speeds, extra lube oil is pumped
into the bearings to provided additional lubrication and reduce the frictional forces
that the unit experiences.
When the speed of the unit is between 5.5 – 6.5 Hz the ignition gas system activates
and the gas is ignited by two spark plugs located near each burner. These receive their
energy from the ignition transformer. Hi- speed diesel is used to start the generator in
case the system has to run on Naptha.

Once the burners are running, the turbine begins to play the dominant role in
accelerating the shaft. When the shaft reaches approximately 36.5 Hz the ignition
transformer is switched off, the ignition gas valves close and diesel is pumped into the
burners. The unit now enters diffusion mode. During this mode only some of the fuel
is injected into the burners and the rest is returned via the return line to the storage
tanks. This means that there is an opportunity to influence the amount of fuel
entering the combustion chamber so that the process can be better controlled.
The benefit of diffusion mode is that it is very stable over the entire output range of
the machine. A negative, however, is that the emission levels are much higher when
the machine is run in diffusion rather than in premix mode.

The SFC continues to assist in the acceleration of the shaft until it turns at a speed
greater the 38.6 Hz. At this point the SFC is shut down and its external isolator is
opened. The turbine is now completely responsible for rotating the shaft.

Once the unit is ready to synchronize with the grid the generator breaker closes and
the static excitation equipment (SEE) begins to provide energy to the rotor so that the
generator can begin to produce power.
Once the unit reaches about 50 % of base load and an output temperature greater
than 500 ºC the unit switches to premix mode. In this mode the fuel enters the burner
at a different location which allows it to be mixed with air before the combustion
zone. This reduces both the fuel consumption and the emissions.

Standstill/Turning Gear to SCO

In SCO mode the generator is operated as a motor to either send out or absorb
reactive power from the grid. There are two options by which the generator can be
run-up to synchronize with the grid.

The first is to run the unit up using the SFC to a speed greater than 50 Hz. The SFC is
then switched off and the machine can synchronize with the grid as the machine slows
down naturally.

The second method is to run the unit up in the standard manner with the turbine and
then disconnect the turbine from the generator once the unit has linked with the grid.
The turbine, however, incurs superfluous equivalent operating hours (EOH). This
means that maintenance intervals are reached earlier and required more frequently,
which contributes to the running expenses of the unit.

Generation to Turning Gear/Standstill

Before the unit can be completely shutdown it is first de-loaded at 11 MW/ min to a
point below an 8MW output. Once it has reached this level it is further de-loaded
until zero MWs are sent out. The reason for de-loading in stages is that it allows the
other sub-systems on the unit to complete their own shutdown procedures. When the
generator reaches this stage it is disconnected from the grid and the turbine is
switched off. The shaft is then allowed to run down naturally until it reaches turning
gear speed at which it is rotated for 24 hours to ensure that the shaft and turbine cool
down uniformly and that no warping occurs. When the unit is not operating,
dehumidified air is circulated through both the turbine and the generator to ensure
that any corrosion is kept to a minimum. Ambient air is also prevented from entering
the turbine while it is not running so that it does not counteract the dehumidifying
system.

3.2 Auxilliaries
3.2.1 Lube Oil System
The Lube Oil System has four main functions. Firstly it provides lubricating oil to the
bearings along the shaft so as to minimize the friction within, and to remove heat
from, the bearings. The lube oil is continually circulated within the system and also
ensures that any wear debris or solid contaminants are flushed from the bearings.

Secondly the lube oil is sprayed onto a single-stage hydraulic turbine which is
connected to the gas turbine shaft by gearing. This enables the shaft to turn at
approximately 2 Hz or 120 rpm at Turning Gear or Barring Speed. This is an important
function as it is vital that the shaft is rotated at this speed for 24 hours after being in
either synchronous condenser operation (SCO) or generation mode to ensure that the
turbine cools down uniformly so that the shaft does not warp.

Thirdly, the Lube Oil System is used to jack the shaft up slightly when the unit is first
activated after being at either a very low speed or standstill. The jacking oil is
necessary as, at these low speeds, the lube oil in the bearings is not sufficient to create
an adequate hydrodynamic lubricating film. The presence of the jacking oil, therefore,
helps to further reduce the friction in the bearings, ensuring that the inertia of the
shaft can be overcome with less force being required.

Fourthly, lube oil is used by the synchronous condenser clutch to operate its locking
control and output brake.

3.2.2 Lube Oil Cooling System

The lube oil cooling is completed in two stages. The lube oil itself is water cooled
through the plate-type heat exchangers that can be found on top of the lube oil skid.
This water is in turn air cooled via three fin fan coolers which release the heat into the
atmosphere. The system is a closed system, meaning that no additional water is
required unless a leak occurs. This system uses demineralised water to ensure that the
system is maintained in as new a condition as possible.

3.2.3 Fuel Oil System

The Fuel Oil System links the Fuel Forwarding System to the turbine to provide the
burners within the combustion chambers with fuel oil as well as to remove any fuel
that is not burnt. The fuel enters the system at a pressure of between 4 and 7 bar,
although it is generally maintained above 6 bar. The fuel is passed through a 10
micron duplex filter before entering the injection pump to remove any debris that
could influence the system. The injection pump is a 16-stage centrifugal pump which
increases the pressure of the fuel to approximately 80 bar which is required for
atomization to take place in the burners. There are three different fuel lines going to
and leaving the combustion chambers, namely the diffusion supply and return lines
and the premix supply line. Each of these lines has a control valve which ensures that
the correct amount of fuel is being injected into the burners.

The Fuel Oil System thus comprises the fuel injection pump, duplex filters and the fuel
lines. It also has a fuel oil leakage tank to collect any fuel from the various drain and
relief lines in the system.

3.2.4 Purge Water System

The Purge Water System uses demineralised (demin.) water from the DM plant on
site. The system supplies demin. water at the required pressure to the premix burners
whenever the unit changes from diffusion to premix mode or vice versa. The reason
for this flushing is to firstly cool off the premix burners before use and then to clean
the burners afterwards. This prevents coking and ensures that the nozzles stay clear.
The length of each flush on start-up Diffusion-Premix mode, lasts 10 seconds and uses
37,5 litres of water. On shutdown, the Premix-Diffusion mode flush lasts for 20
seconds and uses 75 litres of water.
3.2.5 Hydraulic System
The Hydraulic System provides pressurized hydraulic fluid for the operation of the
position actuators in the auxiliary systems. Predominant of these are the control
valves on the fuel lines in the Fuel Oil System. The condition of the hydraulic oil is
very important and must remain within the ISO 4406 specifications. For this reason
the oil is filtered continuously.

3.2.6 Ignition Gas System

The Ignition Gas System is responsible for the storage of the ignition gas as well as
supplying the gas to the combustion chambers. The gas used on site is 90 - 97 %
propane and is contained in two 6.5m3 tanks at a pressure of 9 – 15 bar. The tanks are,
however, only filled to 60 % of their capacity.

3.2.7 Filter Housing

The air enters the unit through the filter housing situated on the top of the unit. The
filter house includes weather hoods, bird screens, pre- and fine filters. The
measurement for these filters is 25 micron and 4 micron respectively. The air enters
the housing from three sides after which it is fed through silencers into the air intake
and then into the compressor.

3.2.8 Turbine
The turbine is viewed as the portion of the unit that incorporates the air intake,
compressor section, combustion chambers, turbine section and diffuser. It is 9.45 m
long and 4.1 m in diameter. The compressor section has 16 stages and converts
mechanical energy into the kinetic and potential energy of the compressed air. The
combustion chambers are silo type chambers and are found on either side of the
turbine, weighing approximately 6 tons each. There are eight individual hybrid
burners per chamber and both the liquid petroleum (LP) gas and fuel are fed into the
same burner, although at different locations. The flame cylinder at the top of each
combustion chamber is covered with ceramic tiles, similar to those of space shuttles,
to protect the structure from the heat as the temperature ranges from 10300C to
12000C. There are four sets of turbine blades after which the air passes through to the
exhaust. The turbine also incorporates three blow-off pipes which bleed air from the
compressor stages and release it via the exhaust to prevent surging in the turbine
during start up.

3.2.9 Generator
The generator is the heaviest single component on site, weighing 223 tons. The
generator has a rated output of 15.75 kV and 6 818 A at 3 000 rpm with a power factor
of 0.9.
The rotor conductors are made of copper with a silver content of approximately 0.1 %.
This combination increases the strength at higher temperatures to eliminate coil
deformation due to thermal stresses. The insulation between the individual turns is
made of layers of glass fibre laminate. The field winding consists of several coils
connected in series and inserted into the longitudinal slots of the rotor body. The
coils are electrically connected in series so that one north and one south magnetic
pole are obtained.
3.2.10 Generator Cooling System
The generators are not 100% efficient, a lot of energy being produced in the form of
heat. The generators are equipped with indirectly air cooled stator windings and a
radial direct air cooled rotor winding. The cooling air for the generator is drawn by
axial-flow fans arranged on the rotor via lateral openings in the stator housing. The
heat generated in the generator interior is dissipated through air. The rotor is directly
air-cooled with heat losses being transmitted directly from the winding copper to the
cooling air. Cooling air is supplied at a rate of 50 m3/s at 28°C .

3.2.11 Exhaust
The exhaust stack transfers the hot air from the turbine and releases it into the
atmosphere at a maximum temperature of 560 ºC. The stack is 30 m high and has a
diameter of approximately 10 m. The exhaust gas has a mass flow rate of around 520
kg/ s and a velocity of approximately 40 m/ s.
3.3 Overview of GT Modernization Products
A wide range of products which are either already available or currently under
development by modernization engineering is shown in Figure 13. The upgrade
packages can be grouped systematically in the following main categories:
· Efficiency -through increasing turbine inlet temperature, enhancing turbine
aerodynamics, advanced compressor cleaning system and wet compression /
Power –through larger compressor mass flow, water injection and wet
compression
· Combustion- reducing emissions and reducing fuel consumption,
diversification of fuels (by dry low NOx combustion, fuel conversion and water
injection)
· Increasing operational flexibility - through fuel diversification, grid frequency
stabilization, improved starting behavior
· Reliability and Availability - through I&C improvement, extended maintenance
intervals, reduced maintenance time.

3.3.1 Turbine Inlet Temperature Upgrade (TT1+) or Extended Maintenance

Interval (41MAC)
This upgrade product features attractive alternatives which increase either availability
or turbine inlet temperature. These consist of extending the inspection interval or
increasing the turbine inlet temperatures from 1060°C to 1075°C for base-load
operation.

Regarding the hot gas path starting in the combustion chamber the flame tubes,
mixing casings and inner casing are improved. In the mixing casings additional
horizontal guides are installed, which require a modification of the mixing casing as
well as of the combustion chamber pressure shell. The additional horizontal guides
minimize wear at the mixing casing/inner casing transitions and thus contribute to
longer inspection intervals for the GT.
The inner casing of the V94.2 GT is specially redesigned in response to inspection
findings encountered in recent years. The hub, the part of this casing most exposed to
thermal fatigue, is redesigned for higher thermo-elasticity and better cooling; this
feature and modifications made at other locations have already been discussed in
greater detail later.
An upgrade of the premix gas spider piping is also necessary for the maintenance
approach; other recommended features are recaulking of the inner compressor vane
shrouds at two locations and an upgrade of the manhole insert in the mixing casings.
A most important upgrade feature is enhanced protective coatings for the turbine
blading. The coating choice has been based on finite element structural analysis and
metallographic investigations of service-exposed blades. Representative McrAlY-
coated blades and vanes coming especially from fleet leader units at overhaul time
have been examined
· by visual inspection for cracks and oxidation
· by metallographic analysis for examining internal surfaces and distinctive
structural features (e.g. brittle phases)
· by metallographic investigation to estimate blade material temperatures by
means of the gamma-prime-coarsening criterion: the gamma-prime-coarsened
metal structure of the service blade is compared to a material structure catalog
containing reference structures for various temperatures.

The results were very useful tool for calibrating the heat transfer and structural stress
analysis. It should be emphasized that investigations for the upgrade discussed here
also require recalculation of the baseline blades and vanes using state-of-the-art stress
analysis tools. The original analyses performed many years ago are no longer
sufficient; the tools from that time have meanwhile been replaced by state-of-the-art
analysis tools. Over the past years Siemens has channeled considerable R&D effort
into validation and improvement of turbine blading. The associated calculations for
rotor blades include both static and dynamic component loading (creep strength and
low cycle fatigue (LCF)). It should also be mentioned at this point that the LCF
strength analysis is based on the latest insights gained. Validation of the LCF strength
analysis in particular is based on a comparison of calculated component strength with
crack indications revealed during standard inspections and refurbishing of GT blades;
in this case a crack propagation analysis has to be included.

Raising the turbine inlet temperature (TIT) in the operating regime from 1060°C to
1075°C or using extended maintenance requires specific protective thermal barrier
coatings to appropriately reduce the temperature gradients (hot gas side/cooling air
side), thus sufficiently reducing the static and dynamic loads on the blade to achieve
correspondingly long service lives. The protective coating systems must also ensure
optimum bonding between the less ductile thermal barrier coating (TBC) and the base
material. Specially developed bond coats are required for bonding the TBC to the base
material (Ni-based casting) because of the extreme differences in the physical
properties of these materials. These protective coatings (bond coats) must also provide
protection against high-temperature oxidation and corrosion.

Premature wall thinning due to internal oxidation in the cooling air channels is
prevented by aluminizing the cooling air side using a process developed by Siemens
that is known as Sicoat1411. Siemens design their components in such a way that this
internal coating does not require renewal over the entire service life of the blades used
in its V94.2 fleet.
This applies for turbine airfoils in the first three rows. Internal aluminizing is not
necessary for blade row #2 due to lower thermal loading. Stage-3 turbine vanes are
protected against oxidation by an McrAlY-type coating applied using HVOF (High
Velocity Oxygen Fuel Thermal Spray Process); refurbishment of this coating is not
necessary during the entire lifetime. Refurbishment of the blading is planned for the
other externally coated vanes #1 and #2, and blades #1 to #3.

The upgraded blading discussed here can be implemented according to the customer’s
needs to make the transfer to the operating and maintenance upgrade as smoothly as
possible:
· As a complete upgrade package of new parts to replace the original ones
· By using single upgraded rows of blades or vanes with the additional benefit of
longer component life and the option for transferring to the upgrade concept
at a later point in time when the package has been completed.
· Upgrading the coating of original service-exposed blades and vanes through
refurbishment to meet the new requirements.

In the latter case the service life of the blades which has already been utilized must be
known in order to precisely determine the subsequent operating cycle following
advanced refurbishment. This is done based on the rule of linear damage
accumulation and uses the results of the baseline calculation of the original blading as
well as the evaluation of the upgrade version.

Benefits
The Firing Temperature Increase modernization can be a highly cost effective means
for improving the performance of your gas turbine plant.
Benefits can include:
· Up to 6% power increase (simple cycle)
· Heat rate improvement
· Increased exhaust energy for cogen or combined cycle applications.

Scope of supply
The Siemens Firing Temperature Increase is just one of the many innovative
modernization packages available. The scope of this modernization includes:
 · Inner casing – new design
· Mixing casing modification – horizontal guides
· HR3 burners
· Upgraded turbine blading materials and coatings.

3.3.2 Compressor Mass Flow Increase Upgrade (CMF+)

An output upgrade with a certain increase in efficiency can be achieved by increasing
compressor mass flow. As this was not feasible by simply higher loading of the original
compressor blading, this was accomplished by redesigning the airfoils of the first four
compressor blade rows (including inlet guide vanes!) with new controlled-diffusion-
type airfoils (CDAs). The CDAs produce a controlled deceleration in the axial
direction. Figure 17 shows the velocity profile on blade#2 and inlet guide vane before
and after optimization. The new profile exhibits higher axial velocities with a uniform
velocity distribution and thus reduced flow separation compared to the original
design.
The calculated simple-cycle output gain is approximately 3.5% with an efficiency
increase potential of up to 1%. An output increase of up to 2.8% can be anticipated in
combined-cycle operation.

Benefits
The Compressor Mass Flow Increase upgrade can be a cost-effective means to help
improve the overall performance of your gas turbine and combined cycle power plant.
Benefits may include:
· Increased gas turbine power output of up to 3% in simple cycle duty
· Higher combined cycle power output and lower heat rate due to increased
exhaust mass flow.
The modified airfoil profile is state-of-the-art for new Siemens gas turbines of all V-
frames manufactured since July 2005.

Scope of Supply
The scope of this upgrade includes:
· State-of-the-art controlled diffusion airfoil profiles
· Replacement of the first four rows of blades and vanes
· Diaphragm (vane 1)
· Inlet guide vane modification
· Instrumentation and control modification for surge control.

3.3.3 Dry Low-NOx (DLN) Upgrade Using HR3 Burner

Since 1986 Siemens has supplied a hybrid burner for natural-gas dry low-NOx premix
firing producing NOx values below 25 ppm and CO values below 9 ppm in the load
range from 50% base load to 100% base load. Dry low-NOx fuel oil firing became
available in 1993 and since 1995 the HR3 burner design is available and used as the
standard equipment in new plants since. Lowered or even eliminated temperature
peaks in the combustion zone result in lower NOx emissions. The new diagonal
swirlers generate a higher outlet velocity with their optimized flow channel and thus
provide maximum flashback resistance.

In market we find the following business cases for modernizations using the HR3 fuel
gas burner:
· Installed diffusion burner can no longer meet the stricter regulations for
emissions of combustion products: this was the market driver for a recent
retrofit order for HR3 burners won for a power plant with four V94.2 units in
Singapore;
· Hand in hand with a gas conversion, the latest technology represented by the
HR3 design: this was the case for a gas conversion carried out at two V94.2
units in Yang Pu/China;
· Retrofitting of existing H burners with HR3 burners to protect against
flashbacks resulting from higher hydrocarbons in the fuel gas: a current order
for a power plant with six V94.2 units in Egypt was driven by this;
· Compared to the H burner design, further NOx reduction provides benefits in
connection with a turbine inlet temperature increase especially for sites in the
USA with 9-ppm-NOx requirements.

The latter aspect will now be analyzed more closely. An increase in turbine inlet
temperature always involves an increase in NOx emissions. One part of all HR3 burner
retrofits is a flame tube upgrade. This is because the increased flow velocity from the
new diagonal swirlers resulted in an increased angle in the flame cone which in turn -
compared to the H burner design - shifted the hotter recirculation zone within the silo
combustion chamber from the center more towards the upper region of the
combustion chamber. This shift is also evident from increased oxidation findings on
the metal tile holders in rows A1/A2 detected during inspections after operation with
HR3 burners. For H burners comparable findings were already known but less
distinctive. A subsequent computational fluid dynamics (CFD) analysis of the new
temperature distribution in the silo combustion chambers also verifies that the higher
temperatures now occur in the upper region of the combustion chamber. When
installing the HR3 burners, the A1/A2 tile rows need to be shifted from the upper
position to the center position with lower temperatures.

A gas premix spider-shaped pipe connects the diagonal swirler of each burner to the
central pear-shaped gas distributor. Originally welded from a ferritic steel though
located in the combustion chamber this part is subject to wet corrosion from the outer
surface because of condensing water on the cold fuel gas pipes. To date the ferritic gas
spider piping is subject to maintenance activities during hot-gas-path inspection and,
depending on the remaining wall thickness, replacement of individual pipes can be
necessary. In one case this maintenance work was neglected during the hot-gas-path
inspection and caused internal fire damage in the area above the flame tube bottom
plates. A redesign has been released to make the gas premix spider maintenance-free
over an interval of 123 kEOH using a wet-corrosion-resistant material instead of the
original material. This spider upgrade is also a requirement for the 41MAC upgrade.
NOx production and emissions depend on the combustion temperature which
increases due to a higher turbine inlet hot-gas temperature and increases when the
ambient temperature drops. To generate a customer benefit with our turbine inlet
temperature increase even in connection with strict environmental requirements, we
have developed a special GT NOx control concept. This concept enables adjustment of
the turbine inlet hot-gas temperature as a function of ambient temperature for a
specified constant NOx limit curve (e.g. 9 ppm). Looking at the low ambient
temperature of -8°C we find an allowable TT1-ISO = 1040°C. With increasing ambient
temperatures the turbine inlet temperature can be raised, thus achieving higher power
output and better efficiency. Doing so the diagram shows an output gain of 3.6% at
15°C and increases of up to 6.4% at 30°C based on a turbine inlet temperature of
1075°C. All these values are valid for constant NOx emissions of 9 ppm (@15% oxygen
in the exhaust).
Another relevant parameter is humidity. The operating curves shown here hold for
optimized cooling air losses, optimized pilot gas flow and precisely adjusted radial
blade clearances. These conditions prevail after a major inspection performed by the
OEM Siemens AG. This open-loop control function thus enables adjustment of the
entire turbine inlet temperature operating range and hence output and efficiency of
the plant based on the specified NOx values.

Benefits
The HR3 Burner Retrofit modernization can be a highly cost-effective means to help
improve the performance, reliability and availability of your gas turbine plant.
Benefits may include:
· Extended range of stable combustion fuel gas operation
· Protection against flame flash back
· Corrosion-free material of fuel gas distribution skid
· Decrease of NOx-emissions < 25 ppm (@ 15% O2, dry).

Scope of Supply
The Siemens HR3 Burner Retrofit is just one of the many innovative modernization
packages available.
The scope of this modernization includes new burner assemblies with the following
features:
· Improved F-Ring design to avoid overheating
· Improved impingement cooled tile holders reduce cooling air consumption by
2%
· Tile holder exchange from row A1/A2 to F.

3.3.4 Performance Boost with Wet Compression (WetC)

The different locations in a GT application where water can be used for performance
improvements are:
· evaporative cooling with water in the air filter house,
· fogging makeup water in the air intake
· wet compression with makeup water in the air intake
· makeup water injection (PAG operation) into the combustor

The following focuses on the particularly effective wet compression upgrade. After
Siemens and Westinghouse became one company, they were able to develop wet
compression in an R&D program for the V94.2 frames for both the 50-Hz and 60-Hz
fleet based on applications and operating experience with Westinghouse W501
engines.
In wet compression, atomized water is injected through a nozzle rack into the
compressor air intake. Part of the injected water evaporates in the air intake; the
remaining water enters the compressor in liquid form (droplets of approx. 20μm
diameter at 90% probability). This achieves an inter-cooling effect. The injected water
evaporates in the compressor stages. The energy required for evaporation is taken
from the compressed air mass flow, which is thus continuously cooled. This cooling,
coupled with the mass flow increase of the working fluid drawn in, results in a
significant performance gain in both output and efficiency. In the baseline wet
compression the performance gain is independent from ambient conditions.

During the development of this upgrade, the design criteria assembled were analyzed
and met, and validation tasks for first-time application were defined. For example, we
needed to ensure that water injection is homogeneous to prevent casing deformation
due to non-uniform temperature fields. The spray pattern in the intake duct was
therefore specified in advance on the basis of 3-CFD analyses and temperature field of
the casings measured during the validation run.

The amount of water is controlled by a mass flow control loop comprising the
injection pump, a variable-frequency drive (VFD) and a controller. In order to
maintain a desired mass flow the controller activates the VFD to set the appropriate
speed at the pump motor. The pump directly feeds the desired amount of water into
the feeding line. Thus an additional return line is no longer necessary. The entire
equipment is arranged on the high-pressure wet-compression skid.

As for thermodynamic performance a typical increase in the efficiency of the overall

gas turbine in an open GT cycle is up to 5%, with an output increase of up to 20%.
Before wet compression implementation, the GT was operated with power
augmentation (PAG), i.e. water injection in the combustion chamber, achieving an
output increase at a NOx limit of 9 ppm and a turbine inlet temperature of 1040°C.
When using just the wet compression system without simultaneous power
augmentation, the result was an efficiency increase of 6%, compared to an efficiency
loss of 5% in the case of water injection into the combustion chamber.
The measured output increase for a relative ambient humidity of approximately 90%
was around 13% at 17.5°C ambient temperature. In contrast to wet compression, inlet
cooling systems such as evaporative cooling or fogging coolers yield only a negligible
increase or no increase whatsoever in output or efficiency under ambient conditions
with high humidity or cold temperatures.

As for combustion performance at a turbine inlet temperature of 1040°C, NOx

emissions were reduced from 9 ppm to 6 ppm, making it legitimate to conclude that a
level of 9 ppm will not be exceeded at a turbine inlet temperature of 1060°C. Any
potential corrosion occurring on the compressor blades and vanes can be limited by
coating the compressor parts.

The first compressor stages must be monitored for erosion and corrosion during
inspections performed at the standard intervals. Vibration measurements of blade row
#1 of the first unit will be repeated after a sufficient number of wet compression
operating hours and compared to the initial testing in order to evaluate erosion effects
on the vibration behavior of the compressor rotor blading. This will be done at the
fleet leader in wet compression operation.

In addition an R&D program was started this year to provide new corrosion-resistant
compressor blade materials and protective measures against erosion in the near
future.

Experience gathered at a specific Siemens Westinghouse GT W501D5A after some

25,000 operating hours with wet compression demonstrated that GT maintenance
follows the standard inspection intervals. As is also the case for the implementation of
power augmentation, the water factor must be included in the calculation of
equivalent operating hours.
Benefits
Wet Compression can be an effective system for recovering power loss experienced at
high ambient temperature. The mutual occurrence of peak load electricity demand
and high ambient temperature make Wet Compression more beneficial and valuable.
Benefits can include:
· Power increase of up to 15% and potentially more depending on the frame and
operational requirements *
· Up to 3% gas turbine heat rate improvement *
· Higher exhaust energy for increased steam production
· Greater operational flexibility.
These benefits can lead to the ability to produce more power in peaking and base load
operation.
Wet Compression is largely independent of the ambient relative humidity. While
somewhat higher performance improvement can be available in a very hot dry climate,
Wet Compression can also be very effective at times of high humidity.

* Actual results may vary

Scope of supply
Besides a diligent original equipment manufacturer assessment of the gas turbine and
the involved power plant components, the scope of this modernization includes:
· Compressor inlet Wet Compression water distribution system with nozzles
· Inlet duct treatment
· Wet Compression pump skid
· Piping between pump skid and distribution system
· Compressor coating (where required by gas turbine frame and version
· Compressor upgrade (depending on gas turbine frame and version)
· Modification of existing control logic Gas turbine customization (e.g. axial trust
compensation and compressor drains where applicable).
Installation and commissioning of Wet Compression can require an outage from one
to three weeks depending on plant and gas turbine configuration.

3.3.5 Humidity I&C module for gas turbine control system

The turbine can be operated significantly closer to the thermodynamically correct
performance point if the humidity in the gas turbine control system is taken into
consideration. An I&C module makes this increase in performance possible at a
reasonable price.

Although humidity has frequently not been measured, it is relevant for calculation of
the corrected outlet temperature (ATK). Consequently the gas turbine is often
operated under suboptimal conditions, especially at locations with major day/night or
seasonal humidity fluctuations. This disturbed performance balance can be
significantly improved with the help of the humidity I&C module.

The humidity module takes the current humidity into account and automatically uses
the plant specific ambient conditions as the basis for thermodynamic control. A sensor
continuously records the changing values and transfers them to the control system.
This ensures that the gas turbine comes closer to its design point with less wear on
components.

The special benefit of this measure lies in the fast return on investment. The module
itself can easily be retrofitted and demonstrates its effectiveness from Day 1. There is a
significant increase in performance in the case of changing levels of humidity.

3.3.6 Fuel Conversion Upgrade

Siemens offers a Fuel Conversion upgrade designed to enable the plant to use many
types and grades of natural gas and liquid fuels.
The Fuel Conversion upgrade is designed to give you operational flexibility to use a
range of both gas and liquid fuel, thus
enabling you to benefit from different fuels,
whether it is the reduced emissions from
using a high-grade fuel or the economy of a
lower grade fuel.

Benefits
Depending upon the configuration and
interests of the customer, the Fuel
Conversion Upgrade offers several
important benefits that can include:
· Reduced emissions
· Increased output and efficiency due
to removal of firing temperature
restrictions
· Improved plant economics by
enabling the use of a less expensive fuel
· Being able to utilize many refinery
products, such as H2, ethane, propane or
LSWR
· Operating flexibility through fuel
availability
· Power increase and heat rate
improvement.

Outage time and lead time will vary depending on fuel types.

Scope of Supply
The scope of supply for implementing the Fuel Conversion Upgrade includes:
· Gas turbine interconnect piping and cabling
· Packaged fuel measurement and control equipment including high pressure gas
turbine (GT) supply pumps and control valves
· Fuel treatment equipment (as required)
· Pipe manifolds (as required)
· Purge air systems (as required)
· Drain system integration
· Control system modification
· Hydraulic system modification and expansion
· Water or steam control equipment (as required)
· Combustion system modifications or replacement (as required)
· BOP supply or design requirements.
3.3.7 Siemens Innovative 3-Dimensional Turbine Blades & Vanes
One of the innovative solutions offered by Siemens Energy to help you improve your
operating plant competitiveness and profitability are the Siemens innovative 3-
dimensional blades and vanes for the turbine stages.
 Siemens innovative 3-dimensional blades and vanes are characterized by an
aerodynamic blade and vane design with optimal efficiency as well as ability for
retrofitting during service life. This generation of turbine stages blades and vanes has a
new, optimized aerodynamic airfoil designed with enhanced material, coatings, an
improved cooling air path and a reduction of parasitic losses.

Benefits
Siemens innovative 3-dimensional turbine blades and vanes can include the following
benefits:
Turbine stages 1 and 2:
Schematic illustration of Siemens innovative 3-
dimensional blades and vanes on turbine
stages 1 and 2
· Increased gas turbine power up to 5
blades MW *)
· Increased gas turbine efficiency up to
0.8%-pts.*)
· Reduced life cycle costs
· Compatible with the Siemens 41,000
EOH maintenance concept upgrade.
·
Turbine stages 3 and 4:

Installation of Siemens innovative 3-

dimensional blades and vanes on turbine
stages 3 and 4
· Increased gas turbine power up to 2,5
MW *)
· Increased gas turbine efficiency up to
0.5 %-pts.*)
· Reduced life cycle costs
· Compatible with the Siemens 41,000
EOH maintenance concept upgrade.
Siemens innovative 3-dimensional blades and
vanes for turbine stages 1 and 2 are state-of-the-art for new Siemens gas turbines of the
SGT5-2000E (V94.2).
*) Actual results may vary

Scope of Supply
Siemens innovative 3-dimensional blades and vanes for the turbine stages
modernization include the following new designed profiles and additional turbine
parts:
Turbine stages 1 and 2:
· Turbine vane 1 (including riffle seals)
· Turbine blade 1
· Turbine vane 2 (including riffle seals and U-shaped seal ring segments)
· Turbine blade 2
· Cooling air throttle for vane 2
 · Control optimization of corrected turbine outlet temperature.
The upgrade includes execution of the following field work:
· Machining of the turbine vane carrier in vane 2 section inserting the cooling air
throttle.
Turbine stages 3 and 4:
· Turbine vane 3 (including riffle seals and U-shaped seal ring segments)
· Turbine blade 3
· Turbine vane 4 (including riffle seals)
· Turbine blade 4.
Siemens innovtive 3-dimensional blades and vanes can potentially be implemented in
a row-by-row replacement. A major outage for the installation of this modernization is
estimated. We offer a full range of field service capabilities to help you manage your
maintenance and outage schedules.

3.3.8 Lifetime Extension

Currently, there are two basic maintenance inspection concepts:

Minor Inspection (MI)

The minor inspection comprises the visual inspection of the accessible regions of the
ma-chine, the compressor and turbine inlet, the combustion chamber and the
exhaust.
Optionally, non-accessible regions may be examined using borescopes.
The minor inspection includes the examination of various external gas turbine
components.

Hot Gas Path Inspection (HGPI)

The turbine is opened for the hot gas path inspection. Based on the findings, the vanes
and blades of the turbine are inspected, refurbished or replaced based on the
maintenance concept.
Various non-destructive examinations (NDE) are performed to determine the
condition of the essential components.

Major Overhaul (MO)

At a major overhaul, the compressor casing is removed and all compressor blades are
in-spected, as necessary and according to the checklist. The coated compressor front
stages are refurbished. The compressor guide vane carrier and the inlet casing are
inspected as well.

Non-destructive examinations (NDE) and detailed visual inspections are performed,

the rotor is removed from the machine.

Major components of the Siemens V-frame gas turbines – especially components of

the hot gas path and rotor – are designed for a set operational duration. Our
experience shows that for gas turbines being operated beyond the components’
original design life, the risk of operational failure can increase substantially.
These measures have been developed based on our knowledge of the original design
parameters and our fleet operating experience as original equipment manufacturer.
Implementation of the V-frame Lifetime Extension measures can not only help reduce
operational risk to your unit, but can also help reduce potential downtime due to
unscheduled outages or maintenance activities. Also, power and efficiency, which
gradually decline during the first 100,000 equivalent operating hours (EOH) or 3,000
starts, can potentially be restored or even in some cases increased by implementing
new technologies developed since the time of installation.
Benefits
Benefits may include:
· Detailed unit specific engineering analysis of the operation and maintenance of
your gas turbine, taking into consideration the specific characteristics of your
gas turbine, such as operating mode and unit history, leads to tailored, cost-
optimized Lifetime Extension recommendations.
· Positioning your unit for operation up to another 100,000 EOH or 3,000 starts
· Reduction of the operational risk when operating your unit past 100,000 EOH
or 3,000 starts
· An opportunity to upgrade previous technology with Siemens improved
components.

Scope of Supply
The Lifetime Extension outage includes a detailed, unit specific engineering analysis of
the operation and maintenance of your gas turbine. We deliver unit specific
recommendations through:
· Consideration of unit’s available operational history, duty cycle, findings and
component sample investigations (unit specific investigation)
· Fleet operational history and frame specific modeling (frame specific
investigation).

The unit specific investigation includes an evaluation of:

· Rotor
· Compressor
· Turbine
 · Combustion section
· Burners.

The recommended scope of work to be performed, including modernization and

upgrade measures, will be defined with consideration of your long-term operating
requirements.

3.4 SGT5-2000E adjustment to site conditions

3.5 Configuration after Modernisation
Grid frequency (Hz) 50
Gross power output (MW) 168
Gross efficiency (%) 34.7
Gross heat rate (kJ/kWh) 10,366
Gross heat rate (Btu/kWh) 9,825
Exhaust temperature (°C/°F) 536/998
Exhaust mass flow (kg/s) 531
Exhaust mass flow (lb/s) 1,170
Pressure ratio 11.7
Length x width x height (m)*) 10x12x7.5**
Weight (t) 234**

* Standard design; ISO ambient conditions

** Dimensions and weight incl. combustion chambers

Bibliography
· www.energy.siemens.com
· www.ntpcindia.com
· www.wikipedia.org
· www.ionindia.com/
· www.jica.go.jp
· www.emea.donaldson.com
· www.bhel.com
· www.npti.in
· Handbook for cogeneration and combined cycle power plant by Meherwan P.
Boyce
· Combined-Cycle Gas & Steam Turbine Power Plants By Rolf Kehlhofer, Bert
Rukes, Frank Hannemann, Franz Stirnimann
· Other resources on the world wide web.