INTERNSHIP REPORT

RAJIV GANDHI COMBINED

CYCLE POWER PLANT-NTPC
LTD.
Guided by
Mr. M.S DINESH KURUP
Sr.MANAGER (MTP)
RGCCPP-KAYAMKULAM
By
SREESANKAR.J
M.E THERMAL ENGINEERING
S.N.S COLLEGE OF TECHNOLOGY
COIMBATORE-35

ABOUT NTPC LIMITED

 NTPC Limited (formerly known as National Thermal Power

Corporation Limited) is a Central Public Sector Undertaking
(CPSU) under the Ministry of Power, Government of India,
engaged in the business of generation of electricity and allied
activities. It is a company incorporated under the Companies Act
1956 and a "Government Company" within the meaning of the
act.
The headquarters of the company is situated at New Delhi.
NTPC's core business is generation and sale of electricity to
state-owned power distribution companies and State Electricity
Boards in India. The company also undertakes consultancy and
turnkey project contracts that comprise of engineering, project
management, construction management and operation and
management of power plants. The company has also ventured
into oil and gas exploration and coal mining activities.
It is the largest power company in India with an electric power
generating capacity of 42,964 MW. Although the company has
approx. 18% of the total national capacity it contributes to over
27% of total power generation due to its focus on operating its
power plants at higher efficiency levels (approx. 83% against the
national PLF rate of 78%).

It was founded by Government of India in 1975, which held 75%

of its equity shares on 31 March 2013 (after divestment of its
stake in 2004, 2010 and 2013).
In May 2010, NTPC was conferred MAHARATANA status by the
Union Government of India. It is listed in Forbes Global 2000 for
2014 at 424th rank in the world.

ABOUT RAJIV GANDHI COMBINED CYCLE

POWERPLANT, KAYAMKULAM
The Rajiv Gandhi Combined Cycle Power Plant (also known
as Rajiv Gandhi CCPP Kayamkulam or NTPC Kayamkulam) is
a combined cycle power plant located at Choolatheruvu
in Alappuzha district, Kerala, India.
The power plant is owned by NTPC Limited. The power plant is
fueled by imported and indigenous naphtha. Source of the cooling
water is Achankovil River. Total installed capacity of the plant is
350MW.
The plant is a combined cycle power plant comprising of two Gas
Turbines and one Steam Turbine of capacities 115MW (2), and
120MW respectively. Unite 1 was commissioned on 1998
November, Unite 1 on February 1999 & Unite 3 on October 1999.
HSD (High Speed Diesel), Naphtha are used as fuels.

THERMODYNAMIC CYCLES
CARNOT CYCLE
RANKINE CYCLE
BRAYTON CYCLE

A.

CARNOT CYCLE

The Carnot cycle is a theoretical thermodynamic

cycle proposed by Nicolas Lonard Sadi Carnot in 1824 and
expanded by others in the 1830s and 1840s.
It can be shown that it is the most efficient cycle for converting
a given amount of thermal energy into work, or conversely,
creating a temperature difference (e.g. refrigeration) by doing
a given amount of work.
Every single thermodynamic system exists in a particular
state. When a system is taken through a series of different
states and finally returned to its initial state, a thermodynamic
cycle is said to have occurred. In the process of going through
this cycle, the system may perform work on its surroundings,
thereby acting as a heat engine.
A system undergoing a Carnot cycle is called a Carnot heat
engine, although such a "perfect" engine is only a theoretical
limit and cannot be built in practice.

B.

RANKINE CYCLE

The Rankine cycle is a model that is used to predict the

performance of steam engines. The Rankine cycle is an
idealized thermodynamic cycle of a heat engine that converts heat
into mechanical work. The heat is supplied externally to a closed
loop, which usually uses water as the working fluid. The Rankine
cycle, in the form of steam engines, generates about 90% of all
electric power used throughout the world, including virtually
all biomass, coal, solar thermal and nuclear power plants. It is
named after William John Macquorn Rankine, a
Scottish polymath and Glasgow University professor.

C.

BRAYTON CYCLE

The Brayton cycle is a thermodynamic cycle that describes the

workings of a constant pressure heat engine. Gas
turbine engines and air breathing jet engines use the Brayton
Cycle. Although the Brayton cycle is usually run as anopen
system (and indeed must be run as such if internal combustion is
used), it is conventionally assumed for the purposes
of thermodynamic analysis that the exhaust gases are reused in
the intake, enabling analysis as a closed system.
The engine cycle is named after George Brayton (18301892),
the American engineer who developed it, although it was
originally proposed and patented by Englishman John Barber in
1791.[1] It is also sometimes known as the Joule cycle.
The Ericsson cycle is similar to the Brayton cycle but uses
external heat and incorporates the use of a regenerator. There
are two types of Brayton cycles, open to the atmosphere and
using internal combustion chamber or closed and using a heat
exchanger.

COMBINED CYCLE
In electric power generation a combined cycle is an assembly
of heat engines that work in tandem from the same source of heat,
converting it into mechanical energy, which in turn usually
drives electrical generators.
The principle is that after completing its cycle (in the first engine),
the working fluid of the first heat engine is still low enough in its
entropy that a second subsequent heat engine may extract energy
from the waste heat (energy) of the working fluid of the first engine.
By combining these multiple streams of work upon a single
mechanical shaft turning an electric generator, the overall net
efficiency of the system may be increased by 50 60 percent.
That is, from an overall efficiency of say 34% (in a single cycle) to
possibly an overall efficiency of 51% (in a mechanical combination
of two (2) cycles) in net Carnot thermodynamic efficiency. This can
be done because heat engines are only able to use a portion of the
energy their fuel generates (usually less than 50%). In an ordinary
(non combined cycle) heat engine the remaining heat (e.g., hot
exhaust fumes) from combustion is generally wasted.
Combining two or more thermodynamic cycles results in improved
overall efficiency, reducing fuel costs. In stationary power plants, a
widely used combination is a gas turbine (operating by the Brayton
cycle) burning natural gas or synthesis gas from coal, whose hot
exhaust powers a steam power plant (operating by the Rankine
cycle).
This is called a Combined Cycle Gas Turbine (CCGT) plant, and
can achieve a thermal efficiency of around 60%, in contrast to a
single cycle steam power plant which is limited to efficiencies of
around 35-42%. Many new gas power plants in North America and
Europe are of this type. Such an arrangement is also used for

marine propulsion, and is called a combined gas and

steam (COGAS) plant. Multiple stage turbine or steam cycles are
also common.

 Combined Cycle consists of

A.Topping cycle
B.Bottoming cycle

DIFFERENT SYSTEMS IN THE PLANT

o Condensate System
o Feed Water System
High Pressure Feed Water System
Low Pressure Feed Water System
o Condensate Recirculation System
o Cooling water System
o Cooling Tower System
o Steam Circuit
High Pressure Circuit
Low Pressure Circuit
o Fuel Oil System
HSD (High Speed Diesel)
Naphtha
o Seal Steam System
o Turbine Oil System (Steam Turbine/Lub Oil
System)

 CONDENSATE SYSTEM
The steam after condensing in the condenser known as
condensate, is extracted out of the condenser hot well by
condensate pump and taken to the deaerator through ejectors,
gland steam cooler and series of LP heaters
Condensate Extraction Pump : To pump out the condensate to D/A
through ejectors, GSC and LPH

Gland Steam Condenser: To increase the temperature of

condensate.

Condensate polishing unit: To remove cat-ion and an-ion from the

condensate.

FEED WATER SYSTEM

Feed water system serves three purposes in the power plant.
They provide efficiency gains in the steam cycle by increasing the
initial water temperature to the boiler, so there is less sensible heat
addition which must occur in the boiler,
They provide efficiency gains by reducing the heat rejected in the
condenser, and they reduce thermal effect in the boiler.
Steam is extracted from selected stages in the turbine to shell and
tube heat exchangers or to open feed water heaters where the
steam and feed water are in direct contact.

HP FEED WATER SYSTEM

Located downstream of boiler feed pump. Typically, the tube side

sign pressure is at least 100 KG/CM2, and the steam source is high
ssure turbine.

LP FEED WATER SYSTEM

Located (with regard to the feed water flow) between condensate pump
d either boiler feed pump. It normally extracts steam from the low
ssure turbine.

CONDENSATE RECIRCULATION SYSTEM

o Condensate Pumps
o The function of these pumps is to pumps out the condensate
to the deaerator thru' ejectors, gland steam cooler, and L.P.
heaters. These pumps have FIVE stages and since the
suction is at a negative pressure, special arrangements have
been made for providing sealing.
o The pressure build up in 5 stages as suction is at negative
pressure.
o Recirculation
o It is done when the de aerator level controller trips in order to
prevent cavitations.
o Boiler Feed Pump
o To give the required pressure to the feed water before entering
into boiler
o Horizontal barrel type multi stage pump.

COOLING WATER SYSTEM

Cooling water system is the system that handles various cooling needs
he power plant.
Cooling water is used in condenser to remove heat from the steam.
The cooled water from the condenser is send to the Cooling tower
tem for further cooing purpose.
Cooling water system for turbine designed to accommodate the heat
sipation requirement of the turbine and the generator lubrication system,
erator cooling system.
CW system is a closed loop system which gets CW from cooling water
dule. It pumps CW to GT and generators which receives heat from GT
generators components.

DMCWS [DEMINERALISED COOLING WATER SYSTEM]

DMCWS supplies cooling water to equipment when ever its necessary.

DMCWS supplies CW to HPBFP (High Pressure Boiler Feed Pump),
PBFP (Low Pressure Boiler Feed Pump), CPHRCP etc.
DMCWS consists of a closed loop circuit that consists of a DMCWS
ver head tank which is an expansion tank (Constant level of water is
maintained always)
Two plate type heat exchangers, and ACWS (Auxiliary Cooling Water
ystem) which is used to cool down the water coming from DMCWS.
ACWS gets the cold water from the CW sump.

COOLING TOWER SYSTEM

Remove heat from the water discharged from the condenser so that the
er can be discharged to the river or re circulated and reused.

Air can be circulated in the cooling towers through natural draft and
chanical draft.

At RGCCPP there are induced draft type cooling towers.

STEAM CIRCUIT
High Pressure Circuit
Low pressure Circuit
Steam circuit is the circuit that involves all steam handling in the plant.
The hot exhaust from the gas turbine is passed to the HRSG with a
perature of 521oC, 50.45 KG, 166.65T/Hr.
HIGH PRESSURE CIRCUIT
High pressure circuit handles the high temperature high pressure
process that leads to the HPT (High Pressure Turbine) in the steam
cycle.
The circuit includes HP Drum, HPBP (High Pressure Boiler Pump), HP
Turbine.

LOW PRESSURE CIRCUIT

Low pressure circuit handles the low temperature high pressure
process that leads to the LPT (Low Pressure Turbine) in the steam cycle.
The circuit includes LP Drum, LPBP (Low Pressure Boiler Pump), LP
Turbine.

GAS TURBINE
Gas turbine model series: MS 9001
Shaft Relation: Counter Close Wise
Turbine Shaft Speed: 3000RPM
Control: SPEEDTRONIC MARK V Solid state electronic control
system.
Air In: 28oC
Fuel: Natural Gas, Naphtha, HSD.
Power turbine Stages: 3

Functional Description

The MS9001 is a Simple cycle, single-shaft gas turbine with 14

combustion, reverse flow combustion system. The Ms9001 gas turbine
assembly consists of 6 major sections:
Air Inlet
Compressor
Combustion System
Turbine
Exhaust
Support System
o Compressor Section
Rotor
Stator
Inlet casing
Forward compressor casing
After compressor casing
Compression Discharge Casing
o Combustion System
Combustion Wrapper
Combustion Chambers(no.14)
Spark Plugs
Ultraviolet flame Detectors
Fuel Nozzle
Cross Fire Tubes
o Turbine Section
Turbine Rotor
Turbine Casing Exhaust Frame
Exhaust Diffusers
Nozzle
GAS TURBINE FLAME DETECTION SYSTEM

 The Honeywell flame mounting system describes are designed to

detect the ultraviolet radiations emitted by a hydrocarbon flame and
provide either a logic signal [System YG 150Aol] a relay contact
closure to indicate flame in a gas turbine.

AUXILIARY UNITE FOR A GAS TURBINE

The auxiliary unite of this type are specially designed for compact
turbo alienate unites with:
To drive the Turbo axillaries at appropriate speed.
To drive the turbine through its starting device in the starting
process.
They are equipped with integral oil pumps
The gear is of single helical type.
Casing
Gearing
Lub oil pumps

ARTING SYSTEM

ming power is supplied by the starting system during gas turbine starting
d stopping.

ECTRIC STARTING MOTOR

e prime motor is a 4 pole, 6600VAC, 50Hz, 1750HP motor. The motor

erates in the single speed to produce the necessary horse power to start
he gas turbine.

BRICATION OIL SYSTEM

brication of the gas turbine and generator is fulfilled by a common forceed lubrication system
stem consists of:
Tank
Pumps
Coolers
Protection devices
Hydrocarbon based lubrication oil (recommended for the gas turbine)

EL SPECIFICATION OF BHEL/GE

ing temperature: 1600oF [870oC] or Higher

el Used: HSD (High Speed Diesel)
Naphtha: A highly volatile fuel with a boiling range between
gasoline and light distillate. The low flas point and high volatility
require special safety considering its very low viscosity may
result in poor lubricity.
HSD is used in the starting stage of the turbine and when it reaches
00 RPM the fuel switches to Naphtha.

RGING AIR SYSTEM

rging is the process of removing unburned fuel and air before the turbine
arts.
the starting stage of the GT there is a 15 second purging stage that is
een automatically performed by the control system.
the stage some amount of HSD is supplied in to the combustion
hamber and burned and is purged out.

DRAULIC SUPPLY SYSTEM

draulic fluid of a high pressure is provided by the hydraulic supply

ystem to operate control of the GT.
gh Pressure Hydraulic oil controlling the GT start/stop and control valve
ssembly fuel oil by pass valve assembly and variable Inlet Guide vanes
GV) mechanism.
ajor system compounds include:
Main hydraulic supply pump
Auxiliary supply pump
System filter
Transfer valves
The accumulator manifold assembly

P OIL SYSTEM

It is the primary protection interface between the gas turbine control

anel and the component as the turbine which shut off.

AL STEAM SYSTEM

Seal steam system is a system that seals the HPT & LPT preventing
e turbine from leaking the steam during work done.
The shaft and turbine consists of a annular grooves that reduce the
essure so as to prevent the wastage.
LPT sealing system will prevent air coming in, as the pressure inside
e turbine is low as compared to atmosphere.
The steam collected from leak steam is used for GSC (Gland Steam
ondenser)

E PROTECTION SYSTEM

e CO2 fire protection system for the gas turbine unites extinguishing the
e by reducing the oxygen.
reduce the oxygen content, a quantity of Co2 greater than 34% a
ompared by volume is discharged in to the combustion chamber, when
xposed to high temperature.

ER SPEED PROTECTION SYSTEM

nder normal operation the speed of the shaft is under the control of
peed loop or temperature loop.
e over speed protection system consists of a primary electronic system.
e primary electronic over speed protection system senses the turbine
peed, speed detection software and associated circuits.
echanical over speed protection system is a backup for electronic over
peed protection system failure.

ER TEMPERATURE PROTECTION SYSTEM

e over temperature protection system protects the GT from possible

mage caused by over firing. It is a backup system which operates only
er failure of the speed and temperature over ride loops.
ontrol of turbine is done mainly by start up speed acceleration,
nchronization and temperature controls

mperature, speed, vibration, flame and compressor operation limits over

mperature and over speed systems are provided as independent backup
stem for temperature control and speed control systems.
bration detections and protection is activated by abnormal turning
bration amplitude.
ame Diction and protection system is activated if flame is not established
ring start up or if it is lost during operation.

WORKING OF THE PLANT

Combined cycle power generation combines 2 cycles for operation,

namely the gas turbine cycle and the vapor power (or steam turbine)
cycle.
In a gas turbine power plant, the turbine starts with HSD (High Speed
Diesel) and when it reaches 2000 RPM the fuel switches to Naphtha and
compressed air undergo combustion.
The resultant high pressure gas drives the gas turbine which in turn
produces electricity.
Although it is clean and fast in starting up, the gas turbine power plant
suffers from low thermo efficiency of about 25 to 30%.
Much of the energy is wasted in the form of gas turbine exhaust.
The combined cycle power generation makes use of the merits of the
high temperature (1100 to 1650C) gas turbine cycle and the lower
emperature (540 to 650C) steam turbine cycle.
The hot exhaust gas from the gas turbine, instead of being released as
waste, is captured and channeled to the steam turbine where steam is
heated by the exhaust to drive the turbine.
A combined cycle power plant consists of two main parts: the gas
urbine plant and the steam turbine plant.
In the gas turbine plant, atmospheric air enters through the compressor
and into the combustor (or combustion chamber) where fuel (usually
natural gas) is added.

Combustion takes place and the hot gas drives the turbine, which in
urn drives the generator and produces electricity.
The hot flue gas from the gas turbine enters a heat exchanger,
sometimes known as Heat Recovery Boiler or Heat Recovery Steam
Generator [HRSG], where it is used to heat up the steam.
The superheated steam is then used to drive the steam turbine which in
urn drives the generator to produce electricity.
The exit steam from the steam turbine goes through a condenser and
hen back to the heat exchanger where the cycle repeats itself.

ELECTRICAL SYSTEM

The power production in RGCCPP-Kayamkulam by two 115MW Gas

Turbines and one 120MW Steam Turbine unite is supplied to the
customers through two buses of 220KV.
Power evacuation lines are to 4 places:
Edappon
Kundara
Pallom 1
Pallom 2
Produced current 115MW current is stepped up to 220KV by using a
step up transformer and is uploaded to the 220KV Bus.
A Unite Auxiliary Transmission (UAT) line of 1.66KV bus is also
available for the plant use.
A Bus coupler is used to separate the two lines of GTPP. This keeps
wo plants isolated.
The plant also consists of a Black Start Diesel Generator (BSDG). In
case of any plant black out.

BACK CHARGING

Back charging is the process of taking required amount of power back

om the main power line when the plant is not running.