Project for Gas Plant at NTPC Dadri

Project Report On Gas Plant At

NTPC Dadri

From: PRAVEEN PUROHIT

Branch: Electrical Engg.—3rd year

College: GNIT, GREATER-NOIDA

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 Project for Gas Plant at NTPC Dadri

PREFACE
National Thermal power corporation (NTPC) is India’s largest power
generating sector. NTPC alone generates about one fourth the power
generated in India. NTPC has many units all over India.

DADRI is National central power station (NCPS) of NTPC. NTPC Dadri

unit has total installed capacity of 1669.78 MW. It has both coal and gas
plant. Coal plant has total capacity of 840 MW and gas plant has total
capacity of 829 MW.

NTPC dadri has Asia’s largest switchyard. HVDC from Rihand is also
adding 1500 MW power in addition to power generated at thermal and
gas power plant.

Coal plant has four units which were commissioned one by one from
1991 to 1994. Each unit has a generation capacity of 210 MW . The coal
for the plant is sourced from the Piparwar mines of Jharkhand while the
upper Ganga canal acts as the water source.

The gas plant has six units which have a combined capacity of 829.78
MW. It has four gas turbine units which were commissioned in 1992
while the two steam turbine units were commissioned in 1994.The gas
turbine units have capacity of 130.19 MW each while the steam turbines
have a capacity of 154.51 MW each.

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ACKNOWLEDGEMENT

Practical training is one of the essential parts of electrical engineering. So

it is very important to select the right site or company for practical
training and BHEL is one of the best sites for training.

We want to thank the Engineers, Managers, workers of BHEL Bhopal to

give us their valuable time and attention to know the manufacturing and
working of hydro electric generators.

We want to thank Mr. P. CHAUDHARI (Sr.DGM HGE);

Mr. Ajay Kumar Gupta (DGM PLM)

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NTPC GAS PROJECTS

1. ANTA GBCCPP STAGE ONE (413 MW )

2. KAWAS GBCCPP STAGE ONE (640 MW)
3. AURAIYA GBCCPP STAGE ONE (650 MW)
4. DADRI GBCCPP STAGE ONE (817 MW)

General layout plan

In the main plant block two modules, each consisting of two GTG`s are
placed on each side of two STG`s. The central control room is located
towards west of the ST hall. The transformer (BHEL) yard is on the
western side of turbine hall, with switchyard further down west.

Induced draft cooling towers have been located considering the power
flow of cooling tower water, nearer to main power house and convenient
to CW pump house. The 220/400 KV switchyard is located in front of the
power station.

The 220 KV switchyard control room is accommodated in the control

room itself. Space has been kept for liquid oil installation and oil
unloading facilities.

The GAIL terminal for receiving gas is located within boundary of plant
site.

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PRINCIPLE OF OPERATION OF GAS

TURBINE PLANT

A gas turbine plant consists of a compressor, combustion chamber, gas

turbine and alternator. The compressor takes in atmospheric air,
compresses it and supply the pressurised air to the combustion chamber.
Fuel is injected into the combustion chamber and burnt in the stream of
air supplied by the compressor. The combustion rises the temperature of
air and increases its volume under constant pressure. The hot pressurised
gas expands in turbine, produces mechanical power and turns the rotor of
the turbine. Both the compressor and the alternator are coupled to the
turbine shaft. Due to the high temp of the products of combustion
chamber, the turbine output exceeds the input to the compressor. The
turbine therefore drives the compressor and the surplus power drives the
alternator. The products of combustion after expansion through the
turbine are finally exhausted to the atmosphere. Such plants are known as
open cycle gas turbine plants.

The gas turbine has to drive the compressor as well as the alternator.
Some times two turbines are used for these two purposes. A high pressure
turbine drives the compressor and a low pressure turbine drives the
alternator .This arrangement has the advantage that the speed of the
power turbine ( which drives the alternator ) can be kept constant at
synchronous speed while the speed of the turbine driving the compressor
can be varied depending on the required output .
The pressure ratio in the gas turbine plant is around five is to one .The
compressor compresses the air to about five times the atmospheric
pressure. The pressure at exhaust is nearly the atmospheric pressure .In
the combustion chamber the temperature constant is around 1600 degree
Celsius. The hot gas at this high temperature cannot be allowed to enter
the turbine directly because of a possible damage to the turbine blades. A
part of the air (from compressor) is delivered directly to the turbine,
ahead of the hot gas from combustion chamber; so that the hot gas may

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be cooled to a safe temp around 800 degree Celsius. The temperature

exhaust is around 500 degree Celsius.

GAS TURBINE PLANT

A gas turbine plant has three main units :-

1. Main plant
2. Switchyard
3. Electrical testing lab

GTP at NTPC Dadri:-

The plant receives gas through the HBJ pipeline, with the gas
originating at Hajira. The plant works on combined cycle which has
very high efficiency of 48.33% as opposed to 32% offered by open
cycle.
The main fuel is natural gas and the alternate being HSD. The upper
ganga canal head work provides a source of cooling water, during the
closure of the canal a network of tube wells serve the purpose.

Main Plant:-

 It is that area of plant which consists of compressors,

combustion chambers, gas turbine and alternators.
 The compressors takes in atmospheric air, compresses it and
supplies the pressurised to combustion chamber in which fuel
is injected.
 The hot pressurised gas is then made to expand in turbine to
which the alternator is coupled.
 Efficiency –
1. Open cycle ( gas ) - 32%
2. Combined cycle (gas) - 48%
3. Thermal - 37%

The efficiency of an open cycle plant is very low. This is

bear of the fact that about 65% of the mechanical power

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developed in the turbine is used to drive the compressor

.The fact that the hot gases from the combustion
chamber is cooled to a safe temperature before
admitting it to turbines also reduces the efficiency ,
because of the above reasons the efficiency rarely
exceeds 20%.

 In the open cycle the natural gas is compressed ignited. It is

used to drive the gas turbine which in turn a generator and
produces electricity. The left over gases which are at very
high temperature are exhausted. This cycle has efficiency of
32%.
 In the open cycle the gases left after ignition are further
driven into a boiler and is used to heat water to make steam.
This steam is then used to run steam turbine. Such system is
used in Dadri power station. The efficiency of the combined
cycle comes out to be very much improved (48%).

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GAS TURBINE COMPRESSOR

General-

The characteristic feature of this turbine generator set is the use of a

single composite welded shaft for the turbine, rotor, compressor carried in
only two bearings. This enables the complete assembly to be of very
compact construction and ensures good stability with a simple bearing
arrangement of two journal bearing and one thrust bearing.
The welded rotor concept has been in used for many years in the steam
turbine field and this design has also proved superior for the gas turbine.
The compressor and turbine casing consists of several sections
which are joined together to form a single unit.

Air intake connection –

The air intake connection has a horizontal air inlet, and is situated axially
in front of compressor. It is a welded, solid steel plate construction split
horizontally and held together with hexagon bolts and nuts.

Compressor casing-

The compressor casing which is horizontally split as axis height is made

of spheroidal graphite cast iron. This material posses high tensile strength
and good expansion qualities.

Support-

The complete outer surface of the compressor –turbine assembly is

supported on both sides at axis height by four pin ended supports and two
fixed pressure supports. These rest on the unit supports that are bolted to
the anchor plates which are in turn cost in to the machine foundation.

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Insulation-

The complete outer surface of the compressor – turbine assembly is

thermally insulated by two layers of lagging mats. These are made of
fibre cloth with swirl in mineral wool insulators, and are laid on the
casings in a staggered pattern attached to one another by books and eyes.
The method allows easy and non destructive removal during overhauls.

Compressor section-

Compressor for the gas turbine may be centrifugal or axial flow type, but
all large gas turbine use axial flow pressure compressors. Gas turbine
compressors are multistage design and consists of individual discs or
wheels mounted on a shaft. Each disc holds the compressor blades which
extend rapidly. This complete assembly is called compressor rotor and is
enclosed in compressor casing. This holds stationary blades which direct
the air flow against the rotating blades.

Combustion chamber-

In large industrial type gas turbine, two types of combustion chambers are
used. With an annular type combustor, combustion occurs in numerous
combustion chambers located radically around the compressor discharge
casing. Some manufacturers use a single or dual ‘silo’ type combustor
which is a large chamber mounted on top of the turbine. Each combustor
is enclosed in a casing and linear for support and insulation. Compressor
discharge bleed air is used to cooler the combustor.

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Turbine section-

The turbine expands the hot gases from the compressor and the
combustor and drives the compressor and generator. The turbine is
constructed similar to the compressor. Turbines are multistage design and
consist of individual discs or the wheels mounted on a shaft. Each disk
holds the turbine blades (buckets) which extend radically from the shaft.
This complete assembly is called the institute turbine rotor and is
enclosed in the casing. The easing holds stationary nozzles which direct
the gas flow against the turbine blades causing the rotor to rotate.

Generator arrangement-

The generator can be located at the hot end (Exhaust) or at the cold end
(Inlet) of the gas turbine. With a hot end generator, the exhaust system
becomes more complicated and direct axial exhaust into the HRSG is not
possible with a hot end arrangement. Using a cold end generator
arrangement may complicate the air in late system. It may also
complicate the arrangement of starting drive and accessories. Either
arrangement is acceptable or the location is the manufacturer’s choice
based on his experience.

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STARTING OF GENERATOR

Starting of generator from stand still to the running condition can be

divided into three stages mainly-
1. Standstill
2. Turning Gear
3. Running Condition

Initially for starting we give excitation and power supply so that

generator works as motor. Due to this as compressor is attached to the
same shaft, compresses the air and combustion starts up which further
rotates turbine. After acquiring 3000 rpm speed generator is
synchronised with output supply.

SPEED OPERATION

1. 120 Ready To Start

2. 650 Combustion On
3. 2150 SFC and Excitation OFF
4. 2850 Excitation On
5. 3000 Excitation on synchronisation

Power supply to generator is connected till it is working as motor.

During complete back out they use diesel generator set.

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SALIENT FEATURES

Type of station- Thermal

Station capacity-840 MW (4*210 MW)
Fuel- 100% coal or 100% oil.
Coal
 Source – Piparwar block of North Karnanpur coal fields in
Bihar ,about 1200 KM
 Transportation- Indian Railways by means of bottom discharge
wagons.
 Consumption-3.66 millions tonnes per year assuming 6500 hours
of operation

Cooling water
 Source – upper Ganga canal Dehra headwork’s, during closure of
UGC through networks of tube wells.
 Consumptions- 50 cusecs
 Methods- close cycle with natural cooling towers.

Start up power – through 3*167 MVA, 400/220/33 KV single phase auto

transformer.
Ash disposal - Dry ash disposal system.
Chimney- RCC multi flue chimney with steel flue 225 meter high.
Heat rate- 2600 MCAL /KWH
HP/LP by pass capacity –60% of MCR
Land requirement – 2200 acres

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COMPARISON OF GAS PLANT AND STEAM

PLANT
 The capital cost of a gas turbine plant is lower than that of a steam
plant of the same size.
 It has no standby losses.
 It requires lesser area than a steam plant of same capacity.
 It has less water requirement as compared to a steam plant .
 Its foundations and building are simple and cheap.
 They can be started and put on load more quickly than steam plant.
 A gas turbine plant can be located very near to the load even in
cities and town.
 The operating cost of a GTP is very high as compared to STP.
 GTP can be used in small sizes of about 50 MW or so.

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HVDC (500 KV,1500 MW)

NTPC Rihand generates power and sends it to NTPC Dadri’s

switchyard. Transmission of power from Rihand to Dadri is done by
HVDC. As DC can’t be generated at high voltage so generation is
done in form of AC and converted into DC for long distance
transmission as it is economic with DC.

Here ‘a’&’b’ are the terminal cost of HVDC and EHV

respectively.’c’ is the distance above which transmission with HVDC
is economic.Terminal cost for DC is higher than AC.At NCPS Dadri
DC is again converted into AC.Thyristors of rating 6.6 KV are used
for inverter process to convert 500 KV DC into AC.

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HVDC TERMINAL DATA

Rating 2*750 MW+- 500 KV

AC Voltage For performance 380-

420 KV ,for rating 360- 440 KV

AC side frequency For performance 48.5-50 HZ

,for rating 47.5 to 51.5 HZ

Overload Rating 1650 MW

Short time overload 1000 MW per pole (5 sec)

Thyristor Rating 6.5 KV,1565 Ampere ,watercooled

Convertor X-mer Single phase,3 WDG ,305 MVA

AC Filter 3*230 MVAR

DC Filter 2*(12th ,HP 24)

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HVDC LINE DATA

Line 815 Km

Number of towers 2142

Conductor/Pole 4

Conductor Sectional
Area 725 mm square

Line to Line clearance 12.75m

Line to ground clearance 12.5 meter

Height of way 46 meter

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