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Abstract
The report is about my internship tenure which made me learn the basics of a combined cycle power
plant. There are ten Gas turbines and 10 HRSGs and 5 steam turbines (one steam turbine with every two
gas turbines) thus successfully following energy economy policy. The auxiliary systems with the main
units are extremely efficient at KAPCO.A very passionate management / a highly skilled and disciplined
man power and most importantly their mutual coordination makes KAPCO known all
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Acknowledgement
Thanks to Almighty ALLAH WHO gave me the strength and will to go out in search of knowledge and
WHO is always our greatest well wisher.
I would thank Engr. Mahmood Rahim & Engr. Arif Mahmood who has assisted me throughout my
internship tenure. Besides his engineering skills and knowledge they are thoroughly a well disciplined
personality. I would always remember their ditch efforts to make me and my fellows entangled in
discussions that ultimately proved to be very fruitful .It was a real feast being with him.
I am very obliged to all the personalities who were always there whenever I asked for help. It was really
a very good experience to be at KAPCO.
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TABLE OF CONTENTS
KAPCO: AN INTRODUCTION
Machining: An Introduction
COMBINED CYCLE POWER PLANT
Introduction
Functional Description
GAS TURBINE & ITS WORKING PRINCIPLE
Main components of gas turbine Working
Principle (BRAYTON CYCLE)
TURBINE WASHING
General Description
Pre washing
Washing
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LUBRICATION SYSTEM
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KAPCO: AN INTRODUCTION
Shareholding Structure:
On June 27, 1996, following international competitive bidding by
the Privatization Commission Government of Pakistan (the
"Privatization Commission"), the management of KAPCO was
transferred to National Power (now International Power) of the
United Kingdom, which acting through its subsidiary National
Power
(Kot
Addu)
Limited
("NPKAL"),
bought
shares
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Kot Addu Power Company Limited ("KAPCO") was incorporated in 1996 with the purpose to
contribute economical power to the national grid. KAPCO has shown exceptional results in the
area of plant maintenance, availability, quality standards and financial performance. In April
2005 KAPCO was formally listed on all the three Stock Exchanges of Pakistan. KAPCO is
committed to contributing to Pakistan's economy by powering the lives of its people by
continuously improving its performance through efficient systems, capable workforce and good
governance.
POWER PLANT TECHNOLOGY
KAPCO is Pakistan's largest Independent Power Producer (IPP) with a name plate capacity of 1600
MW. The Power Plant comprises of 10 multi fuel fired gas turbines and 5 steam turbines installed in 5
phases between 1985 and 1996. These turbines are divided into 3 energy Blocks with each Block
having a combination of gas and steam turbines. The Power Plant's combined cycle technology enables
KAPCO to use the waste heat from the gas turbine exhaust to produce steam in the Heat Recovery
Steam Generator, which in turn is used to run the steam turbines thereby resulting in fuel cost efficiency
and minimum wastage.
The Power Plant is a multi-fuel gas-turbine power plant with the capability of using 3 different
fuels to generate electricity, namely: Natural Gas, Low Sulphur Furnace Oil and High Speed Diesel to
generate electricity. The Power Plant is also the only major plant in Pakistan with the ability to self start
in case of a country wide blackout.
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Block-1
GT 1,2 and ST 9,10
Manufacturer
Capacity of Gas turbine
Capacity of Steam turbine
Siemens Germany
2*97MW = 194 MW
100 MW with 2 HRSGs
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5
1600MW
BRYTON CYCLE
1541MW
GENERATION
RANKINE
CYCLE
LOAD ACC TO IDC TEST (1996) LOAD
1345MW
1360MW
FEEDERS
6 x 132 KV
6 x 220 KV
35,667MWh
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order to achieve high efficiency, the temperature difference between the input and output heat levels
should be as high as possible. This is achieved by combining the Rankine (steam) and Brayton
An open circuit gas turbine cycle has a compressor, a combustor and a turbine. In this type of cycle, the
input temperature to the turbine (the firing temperature), is relatively high (900 to 1,400 0c). The output
temperature of the flue gas is also high (450 to 650 0c). 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 (HR5G) with a live steam temperature between 420
and 580 0c. 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.
Combined cycle plants are usually powered by natural gas, although fuel oil, synthesis gas, Furnace Oil,
High speed Diesel or other fuels can be used. The supplementary fuel may be natural gas, fuel oil,
Working
principle of a
combined
cycle power
plant
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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 O( 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%.
COMBINE
CYCLE
TURBINE
GAS
TURBINE
GAS
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A gas turbine, also called a combustion 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. (Gas turbine may also refer to just the turbine element.)
Energy is added to the gas stream in the combustor, where air is mixed with fuel and ignited. Combustion
increases the temperature, velocity and volume of the gas flow. This is directed through a nozzle over the
turbine blades spinning the turbine and powering the compressor.
Energy is extracted in the form of shaft power compressed air and thrust in any combination
and used to power generators
.
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Turbine
The turbine section converts the thermal and kinetic energy of the combustion gases into
rotational mechanical energy. Gas turbines like steam turbines have three or four stages of rotating and
stationary blades. However; because gas turbines work with lower initial inlet pressures, they have fewer
stages and less change in blade height from inlet to exhaust. Turbines normally consist of combination of
impulse and reaction types. The gas turbine also differs from the steam turbine in;
0 the type of blading material used
1 the lower ratio of blade length to wheel diameter
2 less number of turbine stages
Flue gases flow to the turbine with a very high velocity v of about 80 mjs (288 km/hr). It means it
has high kinetic energy. The kinetic energy of flue gases is converted to mechanical energy when flue gas
is expanded in the stages of turbine transferring its energy to the turbine rotor.
The volume of flue gases is increased by expansion and thus temperature is decreased and at the exhaust
it is about 500C
The turbine parts which are mechanically stressed are at the same time subject to very high
temperature, so that these parts are designed with special material and cooling paths are provided for
cooling air to flow.
Exhaust diffuser
It diverts the de-energized (but still hot) flue gases into the ambience to complete the cycle. It is
fitted with filter and silencer.
Bearings:
Bearing are used to lift the shaft, to make the vibration of rotor as small as possible and to make
the friction during the movement of the shaft. As shaft is connected with bearing, this shaft is lifted by oil
flowing in the bearing. The main purpose of using oil in these bearings is cooling of bearings which are
heated because of running of the shaft. Friction is also reduced when we use oil in the bearing.
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TURBINE WASHING
Why is it necessary?
After every 250 hours, when the GAS turbine is being operated at Low Sulphur Furnace Oil (LSFO) it is
recommended to carry out water wash of turbine blades.Actually there accumulates sulphur on blades
surfaces which is present in the furnace oil.This accumulation of sulphur on blades surface causes a
decrease in their efficiency.Therefore it is required to carry out washing after every 250 hours when
machine being operated at LSFO.
PRE-Washing Procedure:
While the turbine is in full operation the temperature of the burning gases inside turbine is about 1100 to
1150 C and cooling of the turbine blades is always required to have a proper function and for the safety
of blades. To keep them cool blowers are available and a discharge line is also taken out from compressor
to the rotor for the cooling purpose.
The wheel space temperature is the temperature of Blades space of rotor and stator blades.Its about 380
C to 480 C.
.
0 Before washing turbine unit is shutdown and transferred to turning gear motor.
1 The speed of Turning Gear Motor is 110 rpm.
2 The spead of the rotating rotor gradually slows down from 2900 /3000 rpm and when it reaches
110 rpm its automatically transferred on Turning Gear Motor.
3 After 6 to 7 hours the wheel space temperature reaches 150 C.
4 This time limit is usually for summers and for winters this time is comparatively less.
WASHING:
0 Then Turbine is given Crank start at crank speed of 475 rpm with the help of starting motor.
1 Then Washing Pump is started simultaneously.
2 Hot water at a temperature of 80c is used to wash turbine blades
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STEAM TURBINE
GENERAL DESCRIPTION:
A Steam turbine is a turbine that works with the help of superheated steam that has no moisture. We need
moisture free steam because of certain reasons. For example the moisture may cause rust and the surface
of blades corrodes. The blades of a turbine are very expensive and there replacement causes wastage of
huge sum of money and time which increase cost of energy production and this renders a huge loss to the
company.
A combined cycle employs gas and steam turbines. Its called a combined cycle because the exhaust gases
obtained by utilizing gas in the gas turbine after its combustion in the combustion chamber. The
temperature of these hot exhaust gases is very high ranging from about 480 to 510 C. Instead of
wasting such a huge amount of energy into the atmosphere this energy of exhaust gases are used in steam
turbine to produce superheated steam to run a steam turbine.
At KAPCO a steam turbine is installed with every two gas turbines. The exhaust gases of each gas
turbine are utilized in HEAT RECOVERY STEAM GENERATOR (HRSG) which is a nonconventional boiler. A complete description of HRSG is discussed later.
Two HRSG boilers produce superheated steam that runs a steam turbine. The efficiency of combined
cycle is higher than a closed cycle. Its about 35 % to 40 %.whereas the efficiency of a gas turbine is
25 % to 30 %.Although the efficiencies may vary depending upon the designs of particular gas turbines
and steam Turbines. Here these Efficiencies are for SIEMENS gas turbine and steam turbine. SIEMENS
is Turbine manufacturer based in germany.
When a single Gas Turbine is functioning then only one HRSG system works for that gas turbine and
therefore load of steam turbine is halved.
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1. BOILER (HRSG):
The exhaust gases of a gas turbine are at a high temperature and such hot gases are utilized in Heat
Recovery Steam Generator (HRSG) . The efficiency of HRSG is relatively higher than conventional
boilers i.e. 40% to 45 % whereas the efficiency of conventional boilers is about 35 0/0 and that of
Burners Boiler is 32% to 40 %.
1- LP Evaparator:
The LP Evaporator is basically a Heat Exchanger (
parallel flow ) consisting of a bundle of tubes
confined in a large shell or cylinder.
3 Pump
Now they are discussed in detail separately along with their auxiliaries and other components:
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The hot water coming from hot well passes through these tubes.The hot water at a temperature of about
125 C to 130 C from feed water tank at low pressure than atmospheric pressure flow through these
tubes.The water flows trough these tubes with the help of Low Pressure Pumps at Feed Water Pumps
Building where these pumps pick hot water from feed water tank and make it flow through LP Evaporator
tubes by first bringing it in LP DRUM that is connected with LP Evaparator.LP Drum maintains low
pressure saturated steam in it ..
The LP Evaporator is the top most stage a of vertically designed HRSG.The exhaust gases of a gas
turbine reach LP Evaporator at the last when the temperature of these gases has been utilized in first three
stages. The temperature of these gases at this stage is about 180 C.When these gases passes across the
water containing tubes it goes through a phase change where water is converted into steam with a little
increase in temperature. The Latent heat is added in water due to which it is converted in steam by
maintaining its temperature.
About 1/5th volume of water in LP Drum is converted into saturated steam and rest of the water keep
flowing in cycle through tubes or LP Evaporator until it is also converted into saturated steam.The level
of LP Drum is maintained at certain level which is controlled through automatic level detectors. These
send electrical signals to Central Control Room where the readings are viewed on computer screen.
Now the low pressure saturated steam produced in LP Evaporator going through LP Drum that is used for
the purpose of Dearation in DEARATOR.
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2- HP ECONOMIZER:
20
High Pressure (HP) Economizer is also a heat exchanger (counter flow) consisting of a bundle of tubes.
High Pressure Feed water Pumps placed in the Feed Water Pumps Building take water from Feed Water
Tank placed below Dearator and make it flow through HP Economizer. High pressure is developed with
the help of High Pressure Feed Pumps. Here at steam turbines 11 & 12 impeller type Centrifugal pumps
are being used for this purpose(Pump has been viewed in detail). High pressure is developed so that
maximum heat can be absorbed in the economizer by water at higher pressure (The boiling point of a
liquid increase with an increase in pressure).
The flue gases exchange heat to hot water in the tubes of HP Economizer and raise its temperature to
about 140 CAt this heat exchanger there is a sensible heat addition where there is an increase in
temperature of water in the tubes instead of phase change (steam). This high temperature water flows
down to HP Drum.
3- HP EVAPORATOR:
High Pressure Evaporator is also another heat exchanger (Parallel Flow) consisting of a bundle of tubes
through which hot water coming from second stage of the HRSG flows at high pressure.
As discussed before that water comes in HP Drum from Economizer. Then this high temperature water
from HP Drum is taken from suction pump and made flown through HP Evaporator where there is Latent
Heat Addition into the water.
The water is converted into high pressure saturated steam. This steam then goes again in HP Drum where
it maintains high pressure in which high pressure steam is present over a certain level of water. This HP
steam whose temperature is about 270 C flows through the last stage of HRSG called superheater whereas
water that has not been converted into steam in the HP Evaporator is brought again into HP Drum by
Reciprocating Pump.
.
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4- SUPERHEATER:
Superheater is another type of heat exchanger (counter flow) consisting of a bundle of thin walled tubes
for the maximum rate of heat exchange.
ThisOF
partPLANT
of the HRSG is located directly in front of the exhaust
FUELING
section where flue gases at a temperature ranging from 480 C to 500 C are coming out. Superheater
utilizes the maximum temperature of hot flue gases and there is a sensible heat addition in the saturated
steam coming from HP Drum; thus increasing temperature of steam in the tubes and making saturated
steam superheated and moisture free. The temperature of this superheated steam is about 480 C to 500 C.
This superheated steam at pressure of about 35 Bars then runs the steam turbine
CONDENSER:
GENERAL ARRANGEMENT:
The Condenser consists of a hotwell and a shell of rectangular shape, on which is placed a pyramidal
neck which is connected to the turbine exhaust hood by means of the expansion joint and the rectangular
neck.
The condenser is placed directly on concrete foundations with no flexible suspensions ( or springs) or
counter reaction devices.
Connection between the condenser hotwell and the condensate extraction pumps is provided by means of
pipings. Each of the four tube bundles is fed through an inlet and outlet waterbox which is bolted together
to the tube sheet. The water boxes are specially designed to uniformly distribute the cooling water flow in
all tubes. The four tube Bundles are identical.
The following main circuits are placed in the condenser shell :
Drain issuing from the flash tank
Air and Non-condensable gases extraction device.
Make-up water.
Main Components/Parts:
Water Boxes
Bundles
Tube Bundles
Air coolers
Tube sheets
Exhaust Neck
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Since the plants at kapco run on combined cycle which utilizes basically two types of fuels i.e. Liquid &
Gaseous.
The liquid fuels are:
Furnace oil
High Speed Diesel Oil (HSD)
While Gaseous Fuel is purely the Natural
Gas. Obtaining of the fuel:
Liquid Fuel is obtained from two sources:
i)
Pakistan State Oil is the major contractor for providing Low Sulphur Furnace Oil (LSFO) to Kapco.
This FO is untreated and raw form. The oil reaches the plant through two ways:
2. Pipe Line from Mahmood Kot Oil Depot.
3. Oil Tankers
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Untreated FO is mixed
with water in the
drum at a specific temperature. The water soluble salts get
TREATMENT
OF FURNACE
OIL:
mixed with water and +ive and -ive ions are formed. For example in case of NaCI two ions are formed
Treatment of LSFO is quite necessary before it can be used in the combustion chambers because it may
i.e. Na+ & CI- When electrodes are connected to power supply of high voltage, these ions move to their
contain a no. of impurities in the form of water soluble salts ,oil soluble salts and compounds, and
respective electrode. Thus these salts are thus removed from the electrodes later on.
suspended
particles.
These
impurities can is
cause
a considerable
damage
to combustion
chambers,
Turbine
Now a chemical
called
DEMULSIFIER
added
into the oil+water
mixture.The
function
of Demulsifier
blades
and other
necessary
verydroplets.It
expensive makes
and these
impurities
lower
the overall
is to make
the oil
dropletsequipment
separate that
fromare
water
water
dropletsthus
larger
in terms
of its
efficiency
and
increase
the
maintenance
costs.
Generally
these
impurities
are
classified
in
three
types:
diameter due to which its surface area increases and due to gravity water droplets settle down and drained
nd
Water water
Soluble
( Na,K
other
group
elements) WATER. Thus this treated Oil is obtained and
to. effulant
tanks.
Thisand
water
is 2called
EFFULANT
. Oil Soluble
(Pb, Ni , Co ,V etc)
pumped
to treated oil tanks.
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The lubricating requirements for the gas turbine are furnished by a common forced-feed
lubrication system. Lubricating fluid is circulated to the three main turbine bearings, generator
bearings, reducing gear, accessory gear, as hydraulic oil in torque converter and also as control,
trip oil, high pressure hydraulic oil & generator seal oil.
Such a system must supply cool, clean and pressurized oil to bearing. This lub. system includes
the following.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Storage tanks
There are total no.of 27 tanks to store untreated FO, treated FO,HSD and effluent water. one tank has the
capacity to store 8000cm3 oil. steam heating is carried out in tanks to keep oil temperature 80 c so that it
can be easily flow through pipes
The distribution of oil tanks is as follows
. For untreated oil, 11 tanks
. For treated oil, 11tanks
. For HSD,
5 tanks
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Main Oil Pump - positive displacement pump mounted on & driven by the accessory gear, rated
2725 lpm & 7 bar.
Auxiliary Oil Pump - submerged centrifugal pump driven by AC motor (88QA-1), rated 2460 lpm
& 7.5 bar.
o Higher pressure for torque converter during slow roll & start-up. Starts when speed drop
below 14HS (90% rated speed) stop when turbine attains 95% rated speed.
Also when 63QA-1 sense a drop below 4.83 bar.
Emergency Lub. Oil Pump - submerged centrifugal pump driven by a DC motor (88QE-1).
Rated at 1590 lpm & 1.4 bar. Back-up for AOP when 63QT-2A & 2B below 0.55 bar.
Generator
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