TRAINING REPORT

RAMGARH GAS THERMAL POWER PLANT

(RGTPP)
Rajasthan Vidhyut Utpadan Nigam Ltd. Jaisalmer
Submitted in partial fulfillment of the
diploma engineering of (BTER) Govt. Polytechnic College
Hanumangarh

Period of Training
8th June 2015 To 5th July 2015

GOVT. POLYTECHNIC COLLEGE

HANUMANGARH

Submitted To:Sh.Karmveer
H.O.D.
Mechanical Department
GPC Hanumangarh

Submitted By:Swai Singh

Diploma 2 nd Year
Mechanical Engineering
GPC Hanumangarh

ACKNOWLEDGEMENT

I would like to acknowledge the officers and

other staff member of Ramgarh Gas Thermal Power
Plant.
I express special thanks to
Chief Engineer :
Z.A ATTARY
Executive Engineer :
Assistant Engineer : DALA RAM CHOUDHARY
Assistant Engineer : TIKU RAM CHOUDHARY
for their valued time ,kind ,wise
and illuminating advise during training period.

Swai Singh
Diploma 2nd Year

Mechanical Engineering
GPC Hanumangarh

RAMGARH GAS THERMAL POWER PLANT

Ramgarh gas thermal power station is the first gas thermal power
plant of Rajasthan. The first stage was commissioned on dated 1511-1994

LOCATION
Ramgarh gas thermal power plant is situated near
village Ramgarh,60 km away from Jaisalmer . The first unit of 3
MW is not in operation now . The present installed capacity of the
plant is 270.50 MW
STAGE UNIT NO. CAPACITY COST (Rs.Crore) SYNCHORONISING DATE
|.
GT-1
35.5 MW
180
12.01.1996
||.
GT-2
37.5 MW
300
07.08.2002
ST-1
37.5 MW
25.04.2003
|||. GT-3
110 MW
640
20.03.2013
ST-2
50 MW
05.04.2014

OPERATIONAL PERFORMANCE OF PLANT

PARTICULARS

2006-2007
2007-2008
2008-2009
2009-2010
2010-2011
2011-2012
2012-2013
2013-2014

GROSS
PLANT LOAD
AUX.POWER
GAS
GENERATION(LU) FACTOR(%)
CONSUMPTION(LU) CONS.(1000SCM)
4041.440
4141.153
3486.782
3539.44
3028.85
5367.94
4979.06
6733.195

41.75%
42.78%
36.00%
36.57%
31.29%
55.30%
51.44%
52.92%

268.179
551.61
333.116
279.029
161.452
95.796
90.245
607.423

240483
248876
209782
213635
183482
297151
272967
398509

INTRODUCTION ABOUT RAMGARH GAS THERMAL POWER PLANT

(RGTPP)
RGTPP is located near Ramgarh town at about 60 km from
district head quarter , Jaisalmer (Rajasthan) , which is largest district
of the state . Its installed capacity is 270.50 MW . This plant is
located in largest state of India, based on area .
There are problem in maintaining desired quality
standards in electric supply to Jaisalmer on account of excess losses
because of longer transmission lines . To rectify above problem and
to utilize available natural gas in this area RGTPP was established in
this border district whose existing capacity is 270.50 MW .
seeing the increasing demand of electricity in this
region for various purpose like for providing drinking water in desert
area , flood lighting on INDO-PAK border fencing etc. , the State Govt
.found it essential to raise the capacity of RGTPP and therefore
Rajasthan Vidhyut Utpadan Nigam Ltd. established here four more
units in third and fourth stage of the project . In third stage , one gas
turbine of 110 MW and one steam turbine of 50 MW capacities
were installed . Fourth stage is under planning . In fourth stage , one
gas turbine of 110 MW and one steam turbine of 50 MW capacities
were installed .

FIRST STAGE :
This unit is capable inn electric generation using
both gas and diesel as fuel . In power plant 12 underground tanks
are constructed for storage of diesel having total capacity of 2520
KLt . Necessary equipments for this power plant were supplied by
BHEL(Bharat Heavy Electrical Ltd. ),and building construction was
carried out by Rajasthan State Bridge Construction Corporation.
in this stage only gas turbine (GT-1) is used which
includes a single unit of 35.5 MW .

SECOND STAGE :
First unit of this power plant is being operated by open
cycle system , resulting in higher cost on electricity generation .
Reduction in cost is only possible when first unit is operated on
Combined Cycle System . So under expansion programming of this
project , work of installation of a gas turbine and a steam turbine is
taken in hand . In this system , electricity will be generated by a
steam turbine utilizing heat obtained from exhaust of gas turbines
through a Heat Recovery Boiler . Thus ,no additional fuel will be
required for operating Stem Turbine . Under stage-||, one Gas
Turbine Unit (37.5 MW) was commissioned and synchronized with
the grid on 07-08-2002 . The Steam Turbine Unit (37.5 MW) was also
commissioned and synchronized with the grid on 25-05-2003 and
thus the plant has been made operational in Combined Cycle mode
with a total capacity of 110.5 MW .

THIRD STAGE :
Under stage -|||, one gas unit of 110 MW commissioned
on 20.03.2013 and the steam unit of 50 MW has been synchronized
on dated 05.04.2014.At present activities for the COD of the 50 MW
STG unit is under way.

FOURTH STAGE :
160 MW stage-\\/ Gas Thermal Power Project is under planning
stage . Under stage- \\/ , one Gas Unit of 110 MW and one Steam
Unit of 50 MW capacities is under way .

Gas Transportation System :

ONGC and IOCL are engaged in exploration of oil and natural gas deposits
in western Rajasthan . GAIL (Gas Authority Of India Ltd.) laid down
12diameter and 35 km long pipe line for supply of gas from Gamnewala
based gas collection plant to Ramgarh , which has been further extended
up to Dandewala gas field of Oil India Ltd. Total distance of Dandewala
gas Terminal is approximately 67 km from Ramgarh Terminal . This pipe
line is being maintained by GAIL .
GAS , which is use in plant ,is mixture of different gas . Perchantage of
gas is as follows :

GAS

PERCENTAGE

NITROGEN

31.9064 %

METHANE

48.5668 %

CARBON DIOXIDE

18.8793 %

ETHANE

0.5009 %

PROPANE

0.0333 %

ISO- BUTANE

0.0285 %

N- BUTANE

0.0513 %

ISO- PENANE

0.0185 %

N- PENANE

0.0130 %

HEXANE

O.OOOO %

TOTAL

100 %

Availability of Water :
Requirement of water for power plant is supplied through Sagar Mal
Gopa branch of IGNP (Indira Gandhi Nahar Project) . For this a 27
kmlong ,5.4 cusec capacity pipe line is laid from RD- 190 of Sagar
Mal Gopa branch to power plant . For ensuring proper electric
supply requirements ,a sub station of capacity 2*250 KVA ,33/0.4 KV
,and a pumping station has been established at RD-190 in addition
to construction of water storage tank of capacity 77000m3 at power
plant .

Electricity Transmission System :

To ensure efficient transmission of electricity generated in the power
plant , a 215 km long Ramgarh - Jaisalmer -Barmer line of 132 KV has
been laid .

Expected System Operation :

In spite of unfavourable geographical conditions and availability of
lower quality gas than required , expected electricity is being
generated in this power plant .
The details of total energy generated from this power station during
last fifteen years are as under : Year

Energy Generated(MU)

1999-00

228

2000-01

229

2001-02

120

2002-03

221

2003-04

238

2004-05

361.13

2005-06

435.62

2006-07

404.14

2007-08

414.11

2008-09

348.67

2009-10
2010-11
2011-12
2012-13
2013-14
2014-15

BRIEF INTRODUCTION OF PLANT OPERATION

At RGTPP Gas to the turbines is being supplied through GAIL
from oil wells of ONGC and OIL ,which are the attached to discover
oil and natural gas recourses in Western Rajasthan . The quantity of
the gas is 6-8 Lac SCM per day . FROM GAIL Terminal gas is supplied
to Gas Booster Compressor(GBC motor)at pressure of 10-15 kg/cm2
and quantity of the gas is 6-8 Lac SCM per day . There are -----two------GBC motor in RGTPP . The work of the GBC motor is to compress
gas and to supply required quantity of gas for power production . In
compressing process by GBC the pressure of the gas increases from
10-15 kg/cm2 to 18-23 kg/cm2 . The output of the GBC motor is first
merged and then is divided further , before blowing into the
Combustion Chamber . There are three gas turbine in GTPP ,GT1,GT-2 and GT-3 . The blowing pressure is 18-23kg/cm2 .
Combustion Chamber is a place where ignition of fuel mixed
with air occurs with the help of the sparkplugs , the voltage on ----both-------- of the sparkplugs 15000V DC . On combustion ,the gas
gets mixed with air than the gas will expand and air pressure
increases . The air exhaust on the gas turbine fans gas turbine starts
to rotate . There are three generators of 35.5 MW, 37.5 MW and 110
MW attached with GT-1 , GT-2 and GT -3 respectively, mounted on
the same shaft as the turbine .so GT-1 , GT-2 , and GT -3 Produces
35.5 MW ,37.5 MW and 110 MW electricity respectively .
The exhaust of GT is flue gases .the temperature of the flue
is near about 500deg C . This exhaust may also be relived into the
atmosphere with help of controlled valves . But this exhaust is taken
in use to produce electricity . So this power plant is called Combined
Cycle Power Plant . This exhaust (flue gas) of the gas turbine is
further passed into the Heat Recovery Steam Generator (HRSG).

It is boiler . Water circulating in drum is superheated with the

help of flue gases . This superheated steam runs the Steam Turbine
Generator , so it is called unfired combined cycle .
The generator is mounted on the same shaft as of the ST-1 and ST-2
, produce 37.5 MW and 50 MW electricity . The steam which is
blowing on the gas turbine should be superheated .
Steam should be superheated so that
1. No Corrosion will occur ,
2. Enthalpy drop will be less .
Power generation is also done at low voltage because of the
insulation problem . If the power generation is done at high voltage
then there are following disadvantages
1. Losses will be more
2. Wire may burn out
3. High insulation will be required which is very costly .

POWER PLANT CYCLE

Ramgarh Gas Thermal power Station is Combined Cycle Power Station .

Open Cycle :
When Gas Turbine (GT) exhaust is diverted into the
atmosphere due to no provision of HRSG (Heat Recovery Steam
Generator) or non availability of HRSG then it is called is running in
open cycle . In open cycle as a gas turbine high exhaust gas is not
utilized for heat transfer in boiler so its efficiency will come down .

Combined cycle :
When Gas Turbine exhaust is diverted to HRSG in which high
temperature Gas Turbine exhaust gas passes through HP Super
Heater , HP Economizer , LP Evaporator ,LP Economizer , and
Condenser Pre-Heater (CPH) thus heat of gas turbine exhaust get
absorbed by above series of tanks located inside the HRSG and
temperature of Gas Turbine exhaust which is about 570 deg C will
come down to 135 deg C .
By utilizing the heat of Gas Turbine exhaust HRSG (Boiler) generates
Steam which is used to run Steam Turbine Generator (STG) .
Thus we can generates an additional power (about 50 % of gas
turbine) generation in Steam Turbine Generator without any extra
fuel cost . Thus we can get 30 % extra efficiency by running the gas
turbine in combined cycle . As gas turbine is operated on Brayton
Cycle principle and steam turbine is rotated on Rankine Cycle
principle that is why it is called Combined Cycle .

Advantage Of Combined Cycle Process :

Decreases in capital cost per MW installed
High overall efficiency i.e. 48 %
Compact in size
Low man power required for its operation and maintenance
Low water requirement
Pollution Free atmosphere and clean works place
Low installation time
High reliability and flexibility of the plant

INTRODUCTION TO PLANT EQUIPMENTS

Combined cycle power plants are installed now days at many places
in our country .

1.0 GAS TURBINE EQUIPMENTS :1.1 Compressor :

The atmosphere air is compressed to the 17 stage compressor and
before it passes through the filter . The compressor ratio is 10 and
this is routed to the combustors .

1.2 Combustors :
The fuel (gas) is provided to ten equal flow lines ,each terminating at
a fuel nozzle centered in the end plate of a ten separate combustion
chamber and prior to being distributed to the nozzles ,that fuel is
actually controlled at a rate consistent with the speed and load
requirements of gas turbine . The nozzle introduces the fuel into the
combustion chambers where it mixes with the combustion air and is
ignited by the spark plugs . At instant when fuel is ignited in one
combustion chamber , flame is propagated through connecting
crossfire tubes to all other combustion chamber .

1.3 Transition pieces :

The hot gases from the combustion chambers expand into the ten
separate transition pieces and from there to the three stage turbine
section of the machine .

1.4 Turbine :
There are three stage of the turbine and each consists of row of fixed
nozzles followed by a row of rotating turbine buckets . In each
following row of the jet is increased with an associated pressure
drop and in each following row of a moving buckets , a portion of
the kinetic energy of the jet is absorbed as useful work on the
turbine rotor .

1.5 Exhaust :
After passing through the third stage buckets , the gases are directed
into the exhaust hood diffuser which contains a series of turning
vanes to turn the gases from an axial direction , thereby minimizing
exhaust hood losses . The gases then pass into the exhaust plenum
and are introduced to atmosphere through the exhaust stack or to
the HRSG .

2.0GAS TURBINE SUPPORT SYSTEM AND THEIR EQUIPMENTS :

2.1 Starting System :
2.1.1 Diesel Engine :
Diesel engine / starting motor /main generator with static frequency
converter . Diesel or starting motor with torque convertor or main
generator with SFC is used as a starting device for gas turbine . We
have Detroit make diesel engine of 590 hp for starting purpose .

2.1.2 Torque Converter :

It transfers torque for DG to Gas Turbine . It is a hydraulic coupling
which transfers torque from zero speed to self sustaining speed of
Gas Turbine (i.e. about 60 % speed) .

2.1.3 Accessory gear Box :

It accommodates following equipments

Main tube oil pump ,

Main hydraulic pump ,

Main fuel oil pump ,

Atomizing air compressor.

2.1.4 Hydraulic Ratchet :

It rotates the turbine shaft when gas turbine is on cool down . It also
helps while break away of Gas Turbine during starting . It consists of
a ratchet mechanism operated by hydraulic device . Oil is supplied by
a DC driven positive displacement pump .

2.1.5 Jaw Clutch Mechanism :

It transmits power from Diesel Engine or Ratchet Mechanism to Gas
Turbine through Torque Converter.

2.2 Lubricating Oil System :

Major equipment of the system are :-

2.2.1 Oil Reservoir :

The capacity is 3300 gallons . The total system requirement is 3500
gallons .

2.2.2 Lubricating Pump :

Main lube oil pump is accessory gear driven. also for starting a/c
power driven lube oil pump of 175 m head and 460gpm flow is
provided . For emergency purpose DC pump of 910m head and
250gpm flow is provided . During emergency pump in service filter
remain by pass .

2.2.3 Heat Exchanger :

Two coolers are provided for cooling oil each of 100% capacity .

2.2.4 Gas Skid :

The function of the gas conditioning skid is to supply gas to gas
Turbine free from condensate and gas particles .

2.2.5 Scrubber :
The function of the scrubber is to remove condensate from gas by
centrifugal action by the use of no. parting plates within the
scrubber itself . There is provision of solenoid operated drain valve
for removal of condensate which is sensed by a level switch .

2.2.6 Filter :
The function of filter is to remove any foreign particles from the gas
and to supply totally clean gas . This filters are of cartridge type and
replaceable if D.P. across the filter increases .

2.2.7 Pressure Control Valve :

The function of the pressure control valve is to regulate down steam
pressure up to 22 kg/cm2 if upstream pressure is more . This is the
designed value for inlet the gas stop ratio control valve.

2.2.8 Condensate Tank :

All the condensate collected at the bottom of the scrubber is routed
to the tank through drain piping . For this is level controller on the
scrubber which will operate on maximum and minimum level
scrubber

Air Intake System :

Filters :
There are 396 no. of filters connected in different rows . These filters
are made of cellulose fiber .

Filter Cleaning :
Reverse pulse self cleaning system is provided for cleaning of these
fibers . Processor air is used for these pulsations . Each row is given
reverse pulse at fixed time interval and in predefined rotation .

Air Processing Unit :

Air from the compressor output is taken to finned tube cool it and is
passed through the dryer for removing moisture .

2.3 Cooling and Sealing Air System :

Air for the bearing sealing is extracted from the 5th stage of the
compressor. Centrifugal removes dust and other foreign particles
.Two centrifugal blowers are provided for turbine shell cooling .

2.4 Ventilating System :

Being a closed system , air circulation is provided by following

ventilating fans in different compartments :
Accessory and gas turbine compartment vent fan-2 no .
Load gear compartment -2 no.
Gas valve compartment vent fan -1 no.
Load gear oil vapors fan -1 no.

2.5 Gas Turbine and Compressor cleaning system :

Compressor washing skid consists of :

Water tank with heaters

Water pump

Detergent pump

Water wash valve (electrically operated)

Rice hoper is provided at compressor suction for solid compound
cleaning of compressor .

3.0 RREDUCING GEAR BOX :

Gas Turbine speed is 5100 rpm , but generator speed is designed as
3000 rpm ,so
reducing gear box is provided to reduce speed to
3000 rpm.

4.0 H.R.S.G. AND STEAM TURBINE EQUIPMENT :

4.1 H.R.S.G :
HRSG is a horizontal , natural circulation ,bid rum ,dual pressure
unfired water tube boiler . It is designed to generate HP steam at 62
kg/cm2 pressure and 483 deg C temperature with 59.9 t/hr steam
flow .LP steam is generated at 5 kg/cm2 pressure and at saturated
temperature with 10.9 t/hr steam flow . These HRSGs are having
facilities of HP and LP bypass system 100% for both the circuits to
match the rated parameters (pressure and temperature) while
starting the HRSGs and to minimize the losses of water and heat
while shutting down the m/c . These are also useful when STG trips
and to keep boiler in service .
Major equipment of recovery boilers are :

Diverter damper and its seal air fan ,

Super heater ,

Evaporator (HP & LP) ,

Economizer (HP-1 ,HP-2 & LP) ,

CPH ,

Stack (height) .

4.2 Steam Turbine :

The HP Steam Turbine is drawn from HP steam header of HRSG 1 & 2.
The HP Steam parameters of the HP steam are 60 kg/cm2 pressure and
480 deg C temperature . The LP steam to turbine is drawn from LP steam
header of HRSG 1 & 2 . The LP steam parameters of LP steam are 4.3
kg/cm2 and 148 deg C temperature .

4.3 Condensate Circuit Equipment :

It consists of condensers , ejectors ,extraction pumps ,gland steam
condenser .

4.3.1 Condenser :
It is a two pass condenser having 9084 no. of tubes having cooling
surface area of 3070 m2 . It has steam condensing capacity of 137 t/hr
,cooling water flow of 7050 m3/hr .

4.3.2 Ejectors :
Two no. of two pass ejectors are provided each having a capacity of
handling 15 kg/hr dry air 49 kg/hr air- water vapor mixture . One
starting ejector is also there of 220 kg/hr of dry air handling capacity
at a suction pressure of 0.33 atmosphere .

4.3.3 Extraction Pumps :

Two no. of pumps each of 100 % capacity in the system . Each has a
capacity of 95 m head and 186 m3/hr flow .

4.3.4 Gland Steam Condenser :

Steam leaking from turbine glands is used to raise the temperature
of the condensate by GSC . Two no. of fans are provided for
extracting steam .

4.4 Feed Water Circuit :

It consists of the feed water tank ; HP & LP feed water pumps .

4.4.1 Feed Water Tank :

It is mounted mounted at elevation of 9 m so it is provides a net
positive suction head to the boilers feed pumps . It is also has a
dearator at the top of the tank for mechanical dearation of the feed
water .

4.4.2 HP Feed Pumps :

Three feed pumps of 50 % duty are provided to feed H.P. water to the
boiler . Each is a KSB make , multistage pump with discharge head of
925 m and 75 m3/hr .

4.4.3 LP Feed Pumps :

Three feed pumps of 50 % duty are provided to feed L.P. water to the
boiler . Each is a Beacon water make , multistage pump with
discharge head of 117 m and 11.5 m3/hr

5.0 COMMON SUPPORT SYSTEM FOR GT AND ST :

5.1 CW and ACW System :
There are three CW pumps each of 50 % capacity of 23 m head and
3850 t/hr flow . The circulate water in steam turbine condenser and
ST oil cooler . There are three ACW pumps each of 50 % capacity of
34 m head and 576 t/hr flow . They circulate water in following gas
turbine auxiliaries :

Diesel engine ,

Lube Oil coolers ,

Generator air coolers .

It also circulates in feed pump bearing , coolers of AC plant ,air
compressors ,ADU s and boilers water sample coolers .

5.2 Air Compressors :

Air is required for the following purposes :

For pneumatic operations of all control valves ,

At different maintenance work places for cleaning ,

If required it can be used for GT filter cleaning .

There are three kirlosker make horizontal, balanced opposed piston
compressor each of 8.1 kg/cm2 head and 253 Nm cusec/hr air flow.
Air from the receiver tank is directed to air drying unit to moister

5.3 Raw Water System :

Three no. of bore wells supply raw water reservoir from which is
transferred to water treatment plant by use of raw water pumps
each of 125 t/hr flow capacity. Each bore wells is of @ 125 to 150
t/hr flow capacity . Daily raw water consumption of the plant is
around 40000 t.

5.4 Laboratory :
Any power plant requires soft water and dematerialized water in
large quantity. There are soft water plant (capacity7.2 t/hr*2) which
is used in the boiler water circuit. Apart from that, a continuous
watch is kept of water chemistry of HRSG water to keep its
parameters (such as ph and conductivity) within a specified range.

5.5 Fire Protection System :

It includes no. of water pumps, hallon & co2 bank, nozzle and piping
net work, flame and smoke detectors and emulsifies. There are three
types of water pumps :

Hydrant pump (Motor and DE operated) ,

HVWS pump ,

Jockey pump.

5.6 Black Start D.G Set :

In thee event of total power failure, GT can be started with the help
of diesel generating set (500 KVA, 680Amp. max) which is capable of
supplying power to the bare minimum requirement of the
auxiliaries of one gas turbine. Later, other auxiliaries can be started
with the help of running gas turbine.

CONSTRUCTION DETAILS OF GAS TURBINE

1. COMPRESSOR SECTION

General :
The axial-flow compressor consist of the compressor rotor and the
enclosing casing. The inlet guide vanes, the seventeen stage of the
rotor and stator balding and the two exit guide vanes are included
with in the compressor casing.
In compressor, air is confined to the space between the rotor and
stator balding where it is compressed in stage by a series of
alternate rotating (rotor) and stationary (stator) aerofoil-shaped
blades. The rotor blades supply the force needed to compress the air
in each stage and the stator blades guide the air so that it enters the
following rotor stage at the proper angle. The compressed air exits
through the compressor discharge casing to the combustion
chambers. Air is exerted from the compressor for turbine cooling
bearing sealing and , during start-up, for pulsation control.

Rotor :
The compressor rotor is an assembly of fifteen wheels two-stub
shaft, through bolts, and the compressor rotor bulkhead. The first
stage rotor blades are mounted on the wheel portion of the forward
stub shaft.

Stator :

a)
b)
c)
d)
e)

The stator (casing) area of the compressor section is composed of

five major sections :
Inlet Casing
Inlet Guide Vanes
Forward Compressor Casing
Aft Compressor Casing
Compressor Discharge Casing

2. COMBUSTION SECTION :
General :
The combustion system is the reverse flow type and comprises ten
combustion chambers with liners, flow sleeves, transition pieces and
crossfire tubes. Flame detectors, crossfire tubes, fuel nozzle and
spark plug igniters are also part of the complete system. Hot gases,
generated fro the burning of fuel in the combustion chambers, are
used to drive the turbine.

Combustion Chambers :
Discharge air from the axial-flow compressor enters the combustion
chamber from cavity at the center of the unit. The air flows
upstream along the outside of the combustion liner towards the 1
inner cap. This air enters the combustion chamber reaction zone
through the fuel nozzle swirl tip (when fitted) and through metering
holes in the both the cap and liner. When the nozzles supplied are
not of the type fitted with a swirl tip, the combustion chambers are
fitted with a tabulator system.
The hot combustion gases from the reaction zone pass through a
thermal soaking zone and then into a dilution zone where additional
air is mixed with a combustion gases. Metering holes inn the dilution
zone allows the correct amount of air to enter and cool the gases to
the required temperature. Opening located along the length of the
combustion liner cap provide a film of air for cooling the walls on the
liner and cap. Transition pieces direct the hot gases from the liners
to the turbine nozzles.

3. Spark plugs :
Combustion is a initiated by means of high-voltage, retractableelectrode spark plugs installed in two of the combustion chambers.
This spring-injected and pressure-retracted plugs receive their
energy from ignition transformers. At the time of firing, a spark at
one or both of these plugs ignites the combustion gases in a
chamber. The gases in the remaining chambers are ignited by
crossfire through the tubes that interconnect the reaction zones of
the remaining chambers. As rotor speed increases, chamber
pressure causes the spark plugs to retract and the electrodes are
removed from the combustion zone.

RATING OF GAS TURBINES:

GAS TURBINE-1
(GT-1)
GAS PRESSURE ( kg/cm2 )

22 kg/cm2

HYDRAULIC OIL PRESSURE ( kg/cm2 )

80 kg/cm2

GENERATOR BEARING PRESSURE ( kg/cm2 )

0.5 kg/cm2

RATIO VALVE GAS PRESSURE ( kg/cm2 )

16 kg/cm2

LUBE OIL PRESSURE ( kg/cm2 )

2 kg/cm2

GAS TEMPERATURE ( deg C)

120 deg C

LUBE OIL TANK TEMPERATURE ( deg C )

50-60 deg C

GENERATOR rpm

3000 rpm

GENERATOR TURBINE rpm

5000 rpm

GENERATOR VOLTAGE ( kilo volt )

11 KV

TURBINE MW

35.5 MW

GAS TURBINE-2
( GT-2 )
GAS PRESSURE ( kg/cm2 )

22 kg/cm2

HYDRAULIC OIL PRESSURE ( kg/cm2 )

80 kg/cm2

GENERATOR BEARING PRESSURE ( kg/cm2 )

0.5 kg/cm2

RATIO VALVE GAS PRESSURE ( kg/cm2 )

16 kg/cm2

LUBE OIL PRESSURE ( kg/cm2 )

2 kg/cm2

GAS TEMPERATURE ( deg C)

120 deg C

LUBE OIL TANK TEMPERATURE ( deg C )

50-60 deg C

GENERATOR rpm

3000 rpm

GENERATOR TURBINE rpm

5000 rpm

GENERATOR VOLTAGE ( kilo volt )

11 KV

TURBINE MW

37.5 MW

GAS TURBINE-3
( GT-3 )
GAS PRESSURE ( kg/cm2 )

22 kg/cm2

HYDRAULIC OIL PRESSURE ( kg/cm2 )

80 kg/cm2

GENERATOR BEARING PRESSURE ( kg/cm2 )

0.5 kg/cm2

RATIO VALVE GAS PRESSURE ( kg/cm2 )

16 kg/cm2

LUBE OIL PRESSURE ( kg/cm2 )

2 kg/cm2

GAS TEMPERATURE ( deg C)

120 deg C

LUBE OIL TANK TEMPERATURE ( deg C )

50-60 deg C

GENERATOR rpm

3000 rpm

GENERATOR TURBINE rpm

5000Rpm

GENERATOR VOLTAGE ( kilo volt )

11 KV

TURBINE MW

110 MW

STEAM TURBINE GENERATOR

INTRODUCTION :
Rajasthan Gas Thermal Power Plant Steam Turbo
Generator (STG-1) is of the capacity of 37.5 MW and STG runs in
Combined Cycle mode utilizing waste heat of exhaust of GT-1 (
capacity of 35.5 MW) and GT-2 ( capacity of 37.5 MW). Steam Turbo
Generator (STG-2) is of the capacity of 50 MW and STG runs in
Combined Cycle mode utilizing waste heat of exhaust of GT-3 (
capacity 110 MW).
In such Combined Cycle Power Plant higher thermal efficiency is
achieved as compared to coal based thermal power plant. Brief
introduction of the parts/equipment of the STG power plant is as
follows :

1. Turbine :
The function of the turbine is to drive the generator at a
speed of 3000 rpm. The heat energy of steam (enthalpy) is
converted in mechanical energy as steam expands in turbine. Before
entering the main stream in turbine it passes through emergency
stop valve and control valve located at turbine floor, there are 53
stage in turbine, one stage consists of a set of fixed blade mounted
on inner casing and rotary blade mounted on turbine shaft. LP
injection is connected after 43 stage of turbine. The turbine shaft is
supported by the front bearing (Journal and thrust bearing) and the
rear bearing (Journal bearing). The axial thrust produced in the
moving blades is balanced by balancing drum located in the front
side of turbine. The residual thrust forces of turbine that have not
been compensated by balancing piston are taken up by the front
thrust bearing. The rear bearing of turbine houses the oil hydraulic
turning device used for running the turbine on bearing gear. Turbine
gland sealing is done to avoid air entry initially at both gland ends at
in running to seal the LP end gland. When turbine is running sealing
is done through turbine leak steam itself and balance steam flows to
condenser.

1.1

Turbine Oil System :

1.1.1 Main Oil Tank (MOT) :

MOT is located on 5 m. it serves for storing the oil volume required
for governing and Lubrication system. Oil vapor in oil tank are
vented out by an oil vapor exhaust fan installed at the top of MOT.
The MOT is provided with oil centrifuge inlet connection at bottom
and the oil centrifuge return is connected back to oil tank. The oil
centrifuge cleans the oil stored in MOT.

1.1.2 Main Oil Pump (MOP) :

Lubrication oil needed for turbine bearing, governing oil system and
barring gear is supplied by MOP. The bearing Lubrication oil is
supplied after cooler and duplex filter but governing oil and barring
gear oil flows directly from the MOP discharge header.
Discharge Pressure
- 10.2 kg/cm2
Flow
- 150 m3/hr
Motor rating
- 55 KW, 93A
Standby pump comes inn service at header pr. Below - 6.5 kg/cm2

1.1.3 Emergency Oil Pump (EOP) :

In the case of tripping/non availability of MOP, EOP server for
supplying oil for bearing cooling. The emergency oil pumps cuts in
automatically when oil header pressure falls below 0.9 kg/cm2 in the
event of further pressure fall in header, Oil shell be fed from an
overhead oil tank placed about 6.5 m over the turbine.
Turning operation is to be continued till the turbine rotor cools off.
When AC power fails then turning operation is done by hand wheel,
but EOP and JOP must be started at that time.

1.1.4 Jacking Oil Pump :

In the case of start up and shut down, on bearing
gear it is necessary to supply the high oil pressure to lift the shafting
system slightly so as to avoid metal to metal contact. Friction
between shaft and bearing. For this purpose two nos. JOPS are
provided; one is AC-JOP and another is DC-JOP.
Discharge Pressure
- 120 kg/cm2
Flow
- 50 l/m
Motor rating
- 18.9 KW, 33A (AC-JOP)

1.1.5 Turbine Design Rating :

Rated output
- 38.7 MW
Maximum output
- 44.4 MW
Specified inlet steam pressure
- 76.0ata
Max. permissible inlet steam pressure - 90.0ata
MS inlet temperature
- 518 deg C
Max. permissible inlet steam temp.
- 526.3 deg C
Exhaust pressure
- 0.1ata or (-) 0.9kg/cm2 vacuums

1.1.6 Turbine Tripping :

Turbine over speed operated - 3300 rpm
Bearing temperature very high 120 deg C

2. Heat Recovery Steam Generator (HRSG) :

-------------- Two----------------- numbers of HRSG are established;
one each for steam generation utilizing waste heat of exhaust gases
of ----------GT-1, GT-2--------------respectively. HRSG is natural
circulation Unfired Steam Generator Feed water coming from BFP
discharge passes through the tube bunches of different modules of
heat transfer surface and gets heated by gas turbine exhaust flowing
in surrounding duct.

1.
2.
3.
4.
5.
6.
7.

HRSG has seven heat transfer surface as mentioned below :

High Pressure Super Heater
HP-Evaporator including HP drum
HP-Economizer for preheating the feed water entering in drum.
These are three in nos.
LP- Super Heater
LP- Evaporator including LP drum
LP- Economizer
Condensate preheated (CPH) for heating condensate water before
flowing to Deaerotar.

HRSG Tripping :

a.
b.
c.
d.
e.

HRSG Tripping means closing of diverter damper and closing of MS

(main supply) stop valve (MS 138 in case of HP steam and MS 23 in
case of LP steam).
It is tripped due to following reasons :
HP drum level very low (-) 512 mm
HP drum level very high (+) 175 mm
LP drum level very low (-) 438 mm
LP drum level very high (+) 175 mm
Pushing of both emergency trip push buttons from annunciation
panel.

3. Generator :
MW 40.8
Stator volt 11 KV
Pf 0.80
Stator Current 2677 A
MVA 51
Rotor volt 246 V
Rotor amp 717 A
Cooling air (which is further cooled by ACW water in air cooler
located at 0 m.)

4. Water & Steam Cycle Equipment :

The water is store in water storage tank from Sagar Mal Gopa branch
of India Gandhi Nahar Project. Then water is supplied by pump or
pipe. The following equipments are used :

(a) Deaerator :
It is two parts; one is Deaerating column where
Deaeration takes place in spray valve cum tray chamber and
another is Feed water storage tank, which is used, as water
reservoir tank with capacity of 27.5 m3. whole assembly is known
as Deaerator. Stream pegging is also done in Deaerator to increase
Deaeration, feed water temperature and BFP suction pressure.
Condensate discharge through CPH (condensate preheater) comes
here in a chamber with 12 spray valve and 9 tray S and Deaeration
takes place. Air comes out of the vent and water flows down in
reservoir feed water storage tank.

(b) HP BFP :
High Pressure Boiler Feed Pumps are in no. and two are
continuously running for full load operation. Its full load parameter
is as follows :Discharge pressure 133.5 kg/cm2
HP BFP trips at 120 kg/cm2 discharge pressure.

(c) LP BFP :
LP BFPs are similar in constructions and operation as HP BFP
mentioned above but with very low capacity as compared to the
HP BFP. Its full load parameter are as follows :
Discharge Pressure 15.28 kg/cm2
LP BFP trips at 14kg/cm2 discharge pressure.

(d) Condenser :
Turbine exhaust is connected to condenser. Condenser here used is
surface condenser. Circulating water pump discharge water flows
through condenser tubes & cools steam in surrounding areas
coming out of turbine. Hot wells is bottom part of condensate
resulting from condensation of steam is collected and we can add
make up water here to compensate line losses of closed water
cycle. The pressure at outlet of condensate is negative.
Condensate pressure (-) 0.9 kg/cm2
Condensate cooling water temperature 33 deg C

(e) Condenser Extraction Pumps :

Condensate Extraction Pump (CEP) are three in nos. and out of
them two pumps run for full load operation. These vertical pumps
are used to facilitate pumping the condensate back to deaerator.
Now condensate extracting out of CEP is heated injector gland
steam cooler, condensate preheated, deaerator and in economizer
before reaching to steam generator so as temperature is increased
up to 140 deg and thermal efficiency is improved.
Discharge Pressure 14.8 kg/cm2
Flow
107 m3/hr
Full load current 123 A
Motor rating
75 KW

(f) Ejector :
Ejectors are used to create vacuum in condenser. Starting ejector is
charged initially to create fast vacuum. Starting Ejector basically
consist of a nozzle through which pressure energy of incoming
auxiliary steam is converted in kinetic energy and passing through
high velocity it entails air from condenser and the exhausted air
and steam flows to the atmosphere.

Whereas in main ejector auxiliary steam accelerating through

nozzle is also being utilized in heating CEP discharge condensate
and the condensed steam flows to condenser through manual
valves in stead of being exhausted to atmosphere as in case of
starting ejector.

(g) Condensate Preheater :

Condensate preheater (CPH) is located as a last heat transfer
surface in exhaust gas path before flowing to 70 m high stacks.
Condensate water flowing in CPH tubes heated through exhaust
gas.
CPH inlet water temperature 48 deg C
Outlet water temperature
94.7 deg C

5. HP bypass and LP bypass (HP BP & LP BP):

HPBP and LPBP are used to bypass the turbine rolling parameter is
achieved. HPBP line is tapped off from individual HRSG MS line
and valves are located at 5 m in front of condenser. Similarly LPBP
line is tapped off from individual from HRSG (LP system) and one
valve is located in the front of condenser at 5 m and is behind the
condenser at separate platform. HPBP & LPBP dumps MS directly
to condenser after reducing pressure. Downstream temperature
are reduced in case of HPBP by spraying BFP discharge water.
HPBP / LPBP control valves on following protections
(1) HPBP / LPBP downstream pr. High 6 kg/cm2
(2) Condenser pr. (Vacuum) low
0.6 kg/cm2
(3) Condenser wall temperature high 200 deg C

HRSG Section :
High Pressure Boiler Feed Pump (HP-BFP) :
SUCTION PRESSURE (kg/cm2)

3 kg/cm2

DISCHARGE PRESURE (kg/cm2)

120 kg/cm2

DP ACROSS SUCTION PRESSURE (MMWC)

800MMWC

BALANCE LINE PRESSURE (kg/cm2)

3 kg/cm2

A.C.W SUCTION PRESSURE (kg/cm2)

3.5 kg/cm2

A.C.W DISCHARGE PRESSURE (kg/cm2)

3.2 kg/cm2

A.C.W INLET TEMPERATURE (deg C)

32 deg C

A.C.W OUTLET TEMPERATURE (deg C)

32 deg C

MOTOR WINDING TEMPERATURE (deg C)

50 deg C

MOTOR BEARING TEMPERATURE (deg C)

50-70 deg C

Rpm

2972 rpm

KW

600 KW

Low Pass Boiler Feed Pump (LP-BFP) :

SUCTION PRESSURE (kg/cm2)

2.5 kg/cm2

DISCHARGE PRESSURE (kg/cm2)

20 kg/cm2

FEED WATER TEMPERATURE INLET (deg C)

100 deg C

FEED WATER TEMPERATURE OUTLET (deg C)

95 deg C

D.P. ACROSS STRAINER (MMWC)

4000 MMWC

KW

20 KW

RPM

2930 rpm

STEAM TURBINE GENERATOR - 1(STG-1) :

HEADER PRESSURE (kg/cm2)

8.8 kg/cm2

LUBE OIL TANK TEMPERATURE (deg C)

50 deg C

AUXILIARY STEAM PRESSURE (kg/cm2)

11.2 kg/cm2

AUXILIARY STEAM TEMPERATURE (deg C)

180 deg C

CONDENSER VACUUM VALVE (kg/cm2)

-0.92 kg/cm2

SEAL STEAM PRESSURE (kg/cm2)

0.3 kg/cm2

SEAL STEAM TEMPERATURE (deg C)

120 deg C

CEP HEADER PRESSURE (kg/cm2)

15 kg

CEP MOTOR CURRENT (amp)

95 amp

HPCV POSITION

0-100 %

LPCV POSITION

0-100 %

CONTROL OIL PRESSURE (kg/cm2)

8 kg/cm2

TRIP OIL PRESSURE (kg/cm2)

9kg/cm2

BEARING OIL PRESSURE (kg/cm2)

0.35 kg/cm2

BEARING OIL TEMPERATURE (deg C)

55 deg C

STEAM TURBINE rpm

3000 rpm

GENERATOR rpm

3000 rpm

GENERATOR VOLTAGE (KV)

11 KV

TURBINE MW

37.5 MW

STEAM TURBINE GENERATOR 2 (STG-2) :

HEADER PRESSURE (kg/cm2)

8.8 kg/cm2

LUBE OIL TANK TEMPERATURE (deg C)

50 deg C

AUXILIARY STEAM PRESSURE (kg/cm2)

11.2 kg/cm2

AUXILIARY STEAM TEMPERATURE (deg C)

180 deg C

CONDENSER VACUUM VALVE (kg/cm2)

-0.92 kg/cm2

SEAL STEAM PRESSURE (kg/cm2)

0.3 kg/cm2

SEAL STEAM TEMPERATURE (deg C)

120 deg C

CEP HEADER PRESSURE (kg/cm2)

15 kg

CEP MOTOR CURRENT (amp)

95 amp

HPCV POSITION

0-100 %

LPCV POSITION

0-100 %

CONTROL OIL PRESSURE (kg/cm2)

8 kg/cm2

TRIP OIL PRESSURE (kg/cm2)

9kg/cm2

BEARING OIL PRESSURE (kg/cm2)

0.35 kg/cm2

BEARING OIL TEMPERATURE (deg C)

55 deg C

STEAM TURBINE rpm

3000 rpm

GENERATOR rpm

3000 rpm

GENERATOR VOLTAGE (KV)

11 KV

TURBINE MW

50 MW

6. Auxiliaries :
6.1 Circulating Water Pump (CW Pump) :

These are three in nos. and located in pump house. These pumps
are used for circulating water through condenser tubes so as to
condense the turbine exhaust steam
Discharge pressure 2.5 kg/cm2
Flow 4500 m3/hr
Full load Current 43 A
Motor rating 400 KW, 6.6 KV

6.2 Auxiliary Cooling Water Pump (ACW Pump) :

These are two nos. and also located in pump house. These pumps
are used for following purpose :
i.
BFG brig and seal water-cooling
ii.
Generator air cooling
iii.
Compressor lube oil cooling
iv.
Turbine bearing oil cooling
v.
In GT area gas booster compressor and atomizing air cooler ACW
pumps along with CW pumps take suction from pump located
underground beneath them and return is cooled by cooling towers.

Discharge pressure 4.5 kg/cm2

Flow 655 m3/hr

Full load current 215 A

Motor rating 125 KW, 415 V

WATER FEED SYSTEM TO HP & LP BOILERS

Temperature = 100- 150 deg C
Pressure = 13.41 kg/cm2

Deaerator

From DM- Water Plant

Feed Water Tank

HP-BFP Motors

To HP Boiler
Pressure = 132.05 kg/cm2
Temperature = 130.07 deg C

LP-BFP Motors

To LP Boiler
Pressure = 19.81 kg/cm2
Temperature = 121.02 deg C

COOLING SYSTEM FOR CONDENSING STEAM

Air Out
Cooling
Tower

35 deg C
C.W. Pump

25 deg C
Make up
Line
C.E.P Pump

To CPH
Section

RE-HEATINGOF CONDENSED STEAM FOR REUSE IN CYCLE

CPH Section

CPH Section

Gas Turbine
Last Exhaust

CPH 1

CPH 2

From CEP
Discharge

100-150 deg C
13.41 kg/cm2

Deaerator

Temperature =90.95deg C
Pressure
= 13.59 kg/cm2

DATA CONTROL SYSTEM

STEAM SUPPLY SYSTEM FOR POWER GENERATION
To Atmosphere
505 deg C
SHP STEAM
44 kg/cm2

2 kg/ cm2
LP INJECTION
STEAM

Pr. = -0.88 kg/cm2

Temp.= 146 deg C

185 deg C
CW Inlet

CW Inlet

CW Output

CW Output

GENERATION OF SUPERHEATED STEAM FROM

LP BOILER
Pressure = 3.03 kg/cm2
Temp. = 121.02 deg C
From
LP-BFP

Boiler

Pressure = 2.95 kg/cm2

Temp. = 187.39 deg C
Flow = 8.8 t/hr
To Steam
Turbine

Flue Gases
From GT
Exhaust

NOTE : The exhaust temperature of superheater varies from 480 to

520 deg C and pressure varies from 45-48 kg/cm2.
Flue gases path in :
LP Boiler LP Superheater LP Evaporater LP Economizer

GENERATION OF SUPERHEATED STEAM FROM

HP BOILER
Pressure = 52.13 kg/cm2
Temp. = 130.73 deg C
From
HP-BFP

Boiler

Pressure = 45.50 kg/cm2

Temp. = 506.94 deg C
Flow=35.35t/hr
To Steam
Turbine

Flue Gases
From GT
Exhaust

NOTE : The exhaust temperature of superheater varies from 480 to

520 deg C and pressure varies from 45-48 kg/cm2.
Flue gases path in :
HP Boiler HP Superheater HP Evaporater HP Economizer