Working as an operator involves many hours in front of computer screens. A pleasant and appropriate surrounding enhances the work spirit and stamina. For large plants, control rooms are likely to be situated in separate buildings away from the process plant which they serve.
For medium or small plants control rooms may be within the plant building or control panels may be located local to the plant.
It is capable to reduce water temperature by The primary task of a cooling tower is to reject heat into the atmosphere. This heat rejection is accomplished through the natural process of evaporation that takes place when air and water are brought into direct contact in the cooling tower.
The evaporation is most efficient when the maximum water surface area is exposed to the maximum flow of air, for the longest possible period of time. Cooling towers are designed in two different configurations, counter flow and cross flow. The specific configuration indicates the direction of air flow through the tower relative to the direction of the water flow. Induced draft cooling towers are constructed such that the incoming circulating water is dispersed throughout the cooling tower via a spray header.
The spray is directed down over baffles that are designed to maximize the contact between water and air. The air is drawn through the baffled area by large circulating fans and causes the evaporation and the cooling of the water. The heat exchanger media in the cooling tower is PVC fills packed in box form after gluing each other suitably at the top of the cooling tower.
Placed just below the propeller fans drift eliminator, PVC fills grey coloured are cross corrugated with minimum sheet thickness of 0.
The purpose of drift eliminator is to arrest carry over of minute water particles form air so that drift loss is a minimum of. Drift eliminator is nothing but closely packed PVC sheet arrangements. The generated power at FGPP is transmitted as kV to the grid thorugh four output lines: 2 to Samaipur ballabgarh and 2 to palla faridabad , where other substations step down the voltage for distribution to households.
NR in Departments are usually organized by functions. Additionally, the human resource function serves to make sure that the company mission, vision, values or guiding principles, the company metrics, and the factors that keep the company guided toward success are optimized. It focuses on recruitment of, management of, and providing direction for the people who work in the organization.
Work plans avoid anticipated delays, improve on past jobs, and allow scheduling. Advance scheduling allows supervisors to assign and control the proper amount of work.
A work crew is ready to go immediately to work upon receiving a planned and scheduled assignment because all instructions, parts, tools, clearances, and other arrangements are ready.
The required jobs are ready to go. It does works at an approximate rate of 6 jobs per day. They facilitate uninterrupted working of the plant, including getting the spares as scheduled by the MTP department. It continuously monitors the output of the plant and takes necessary steps of efficient working of the plant. It takes care of the following functions: Maintenance of all existing systems, Procuring related Spares and In-House Modification. It monitors the various parameters of the plant and notifies the concerned department if case of any problems.
It continuously monitors the pH values, pressures, storages, concentration of chemicals, etc and takes measures accordingly as required for the healthy functioning of the plant. It generates at It is also equipped with black-start diesel engine generator to allow for total black- start conditions as an option. It is of single-shaft, single casing design, equipped with 2 silo-type combustion chambers, a stage compressor and a 4-stage turbine.
An air-cooled generator, rated at MVA and generating at The unit is installed with dual fuel Siemens diffusion-type burners, capable of operation on distillate-oil liquid and natural gas. The first three stages of the turbine are protected with a special coating.
These features make the V During the tender process of choosing the technology, two dominant reasons led to the selection of the Siemens V Firstly, this technology makes use of a dry-NOX system. This means that the amount of water used by the turbine to keep the NOX levels within statutory requirements is minimal, when compared to other machines. Secondly, these units are very robust and able to absorb the stresses of frequent start-ups.
The changes from standstill or turning gear modes to generating are very similar. This function is performed by the static frequency converter.
The static frequency converter SFC draws power to drive the shaft, via the start-up transformer, from the medium-voltage supply of the plant auxiliary power supply system. As the shaft speeds up the turbine also begins to play a role in accelerating the shaft as the compressor blades begin to set up the vacuum effect which assists in driving the machine.
While the unit is still at these relatively low speeds, extra lube oil is pumped into the bearings to provided additional lubrication and reduce the frictional forces that the unit experiences. When the speed of the unit is between 5. These receive their energy from the ignition transformer. Hi- speed diesel is used to start the generator in case the system has to run on Naptha. Once the burners are running, the turbine begins to play the dominant role in accelerating the shaft.
When the shaft reaches approximately The unit now enters diffusion mode. During this mode only some of the fuel is injected into the burners and the rest is returned via the return line to the storage tanks.
This means that there is an opportunity to influence the amount of fuel entering the combustion chamber so that the process can be better controlled.
The benefit of diffusion mode is that it is very stable over the entire output range of the machine. A negative, however, is that the emission levels are much higher when the machine is run in diffusion rather than in premix mode. The SFC continues to assist in the acceleration of the shaft until it turns at a speed greater the At this point the SFC is shut down and its external isolator is opened.
The turbine is now completely responsible for rotating the shaft. Once the unit is ready to synchronize with the grid the generator breaker closes and the static excitation equipment SEE begins to provide energy to the rotor so that the generator can begin to produce power. In this mode the fuel enters the burner at a different location which allows it to be mixed with air before the combustion zone. This reduces both the fuel consumption and the emissions.
There are two options by which the generator can be run-up to synchronize with the grid. The first is to run the unit up using the SFC to a speed greater than 50 Hz. The SFC is then switched off and the machine can synchronize with the grid as the machine slows down naturally. The second method is to run the unit up in the standard manner with the turbine and then disconnect the turbine from the generator once the unit has linked with the grid.
The turbine, however, incurs superfluous equivalent operating hours EOH. This means that maintenance intervals are reached earlier and required more frequently, which contributes to the running expenses of the unit.
Once it has reached this level it is further de-loaded until zero MWs are sent out. The reason for de-loading in stages is that it allows the other sub-systems on the unit to complete their own shutdown procedures. When the generator reaches this stage it is disconnected from the grid and the turbine is switched off. The shaft is then allowed to run down naturally until it reaches turning gear speed at which it is rotated for 24 hours to ensure that the shaft and turbine cool down uniformly and that no warping occurs.
When the unit is not operating, dehumidified air is circulated through both the turbine and the generator to ensure that any corrosion is kept to a minimum. Ambient air is also prevented from entering the turbine while it is not running so that it does not counteract the dehumidifying system.
Firstly it provides lubricating oil to the bearings along the shaft so as to minimize the friction within, and to remove heat from, the bearings. The lube oil is continually circulated within the system and also ensures that any wear debris or solid contaminants are flushed from the bearings. Secondly the lube oil is sprayed onto a single-stage hydraulic turbine which is connected to the gas turbine shaft by gearing.
Thirdly, the Lube Oil System is used to jack the shaft up slightly when the unit is first activated after being at either a very low speed or standstill. The jacking oil is necessary as, at these low speeds, the lube oil in the bearings is not sufficient to create an adequate hydrodynamic lubricating film. The presence of the jacking oil, therefore, helps to further reduce the friction in the bearings, ensuring that the inertia of the shaft can be overcome with less force being required.
Fourthly, lube oil is used by the synchronous condenser clutch to operate its locking control and output brake. The lube oil itself is water cooled through the plate-type heat exchangers that can be found on top of the lube oil skid. This water is in turn air cooled via three fin fan coolers which release the heat into the atmosphere. The system is a closed system, meaning that no additional water is required unless a leak occurs. This system uses demineralised water to ensure that the system is maintained in as new a condition as possible.
The fuel enters the system at a pressure of between 4 and 7 bar, although it is generally maintained above 6 bar. The fuel is passed through a 10 micron duplex filter before entering the injection pump to remove any debris that could influence the system.
The injection pump is a stage centrifugal pump which increases the pressure of the fuel to approximately 80 bar which is required for atomization to take place in the burners. There are three different fuel lines going to and leaving the combustion chambers, namely the diffusion supply and return lines and the premix supply line. Each of these lines has a control valve which ensures that the correct amount of fuel is being injected into the burners.
The Fuel Oil System thus comprises the fuel injection pump, duplex filters and the fuel lines. It also has a fuel oil leakage tank to collect any fuel from the various drain and relief lines in the system. The system supplies demin. The reason for this flushing is to firstly cool off the premix burners before use and then to clean the burners afterwards. This prevents coking and ensures that the nozzles stay clear. The length of each flush on start-up Diffusion-Premix mode, lasts 10 seconds and uses 37,5 litres of water.
On shutdown, the Premix-Diffusion mode flush lasts for 20 seconds and uses 75 litres of water. Predominant of these are the control valves on the fuel lines in the Fuel Oil System. The condition of the hydraulic oil is very important and must remain within the ISO specifications.
For this reason the oil is filtered continuously. The filter house includes weather hoods, bird screens, pre- and fine filters. The measurement for these filters is 25 micron and 4 micron respectively. The air enters the housing from three sides after which it is fed through silencers into the air intake and then into the compressor.
It is 9. The compressor section has 16 stages and converts mechanical energy into the kinetic and potential energy of the compressed air. The combustion chambers are silo type chambers and are found on either side of the turbine, weighing approximately 6 tons each. There are eight individual hybrid burners per chamber and both the liquid petroleum LP gas and fuel are fed into the same burner, although at different locations. The flame cylinder at the top of each combustion chamber is covered with ceramic tiles, similar to those of space shuttles, to protect the structure from the heat as the temperature ranges from C to C.
There are four sets of turbine blades after which the air passes through to the exhaust. The turbine also incorporates three blow-off pipes which bleed air from the compressor stages and release it via the exhaust to prevent surging in the turbine during start up. The generator has a rated output of The rotor conductors are made of copper with a silver content of approximately 0. This combination increases the strength at higher temperatures to eliminate coil deformation due to thermal stresses.
The insulation between the individual turns is made of layers of glass fibre laminate. The field winding consists of several coils connected in series and inserted into the longitudinal slots of the rotor body. The coils are electrically connected in series so that one north and one south magnetic pole are obtained. The generators are equipped with indirectly air cooled stator windings and a radial direct air cooled rotor winding.
The cooling air for the generator is drawn by axial-flow fans arranged on the rotor via lateral openings in the stator housing.
The heat generated in the generator interior is dissipated through air. The rotor is directly air-cooled with heat losses being transmitted directly from the winding copper to the cooling air. The stack is 30 m high and has a diameter of approximately 10 m.
Regarding the hot gas path starting in the combustion chamber the flame tubes, mixing casings and inner casing are improved. In the mixing casings additional horizontal guides are installed, which require a modification of the mixing casing as well as of the combustion chamber pressure shell.
The inner casing of the V The hub, the part of this casing most exposed to thermal fatigue, is redesigned for higher thermo-elasticity and better cooling; this feature and modifications made at other locations have already been discussed in greater detail later. An upgrade of the premix gas spider piping is also necessary for the maintenance approach; other recommended features are recaulking of the inner compressor vane shrouds at two locations and an upgrade of the manhole insert in the mixing casings.
A most important upgrade feature is enhanced protective coatings for the turbine blading. The coating choice has been based on finite element structural analysis and metallographic investigations of service-exposed blades.
The results were very useful tool for calibrating the heat transfer and structural stress analysis. It should be emphasized that investigations for the upgrade discussed here also require recalculation of the baseline blades and vanes using state-of-the-art stress analysis tools.
The original analyses performed many years ago are no longer sufficient; the tools from that time have meanwhile been replaced by state-of-the-art analysis tools. The associated calculations for rotor blades include both static and dynamic component loading creep strength and low cycle fatigue LCF. It should also be mentioned at this point that the LCF strength analysis is based on the latest insights gained.
Validation of the LCF strength analysis in particular is based on a comparison of calculated component strength with crack indications revealed during standard inspections and refurbishing of GT blades; in this case a crack propagation analysis has to be included. The protective coating systems must also ensure optimum bonding between the less ductile thermal barrier coating TBC and the base material.
Specially developed bond coats are required for bonding the TBC to the base material Ni-based casting because of the extreme differences in the physical properties of these materials. These protective coatings bond coats must also provide protection against high-temperature oxidation and corrosion.
Premature wall thinning due to internal oxidation in the cooling air channels is prevented by aluminizing the cooling air side using a process developed by Siemens that is known as Sicoat Siemens design their components in such a way that this internal coating does not require renewal over the entire service life of the blades used in its V This applies for turbine airfoils in the first three rows.
Internal aluminizing is not necessary for blade row 2 due to lower thermal loading. Refurbishment of the blading is planned for the other externally coated vanes 1 and 2, and blades 1 to 3. In the latter case the service life of the blades which has already been utilized must be known in order to precisely determine the subsequent operating cycle following advanced refurbishment.
This is done based on the rule of linear damage accumulation and uses the results of the baseline calculation of the original blading as well as the evaluation of the upgrade version. Benefits The Firing Temperature Increase modernization can be a highly cost effective means for improving the performance of your gas turbine plant. Scope of supply The Siemens Firing Temperature Increase is just one of the many innovative modernization packages available. As this was not feasible by simply higher loading of the original compressor blading, this was accomplished by redesigning the airfoils of the first four compressor blade rows including inlet guide vanes!
The CDAs produce a controlled deceleration in the axial direction. Figure 17 shows the velocity profile on blade 2 and inlet guide vane before and after optimization.
The new profile exhibits higher axial velocities with a uniform velocity distribution and thus reduced flow separation compared to the original design. The calculated simple-cycle output gain is approximately 3. An output increase of up to 2. Benefits The Compressor Mass Flow Increase upgrade can be a cost-effective means to help improve the overall performance of your gas turbine and combined cycle power plant.
The modified airfoil profile is state-of-the-art for new Siemens gas turbines of all V- frames manufactured since July Dry low-NOx fuel oil firing became available in and since the HR3 burner design is available and used as the standard equipment in new plants since.
Lowered or even eliminated temperature peaks in the combustion zone result in lower NOx emissions. The new diagonal swirlers generate a higher outlet velocity with their optimized flow channel and thus provide maximum flashback resistance. The latter aspect will now be analyzed more closely.
An increase in turbine inlet temperature always involves an increase in NOx emissions. One part of all HR3 burner retrofits is a flame tube upgrade. For H burners comparable findings were already known but less distinctive. A subsequent computational fluid dynamics CFD analysis of the new temperature distribution in the silo combustion chambers also verifies that the higher temperatures now occur in the upper region of the combustion chamber. A gas premix spider-shaped pipe connects the diagonal swirler of each burner to the central pear-shaped gas distributor.
Originally welded from a ferritic steel though located in the combustion chamber this part is subject to wet corrosion from the outer surface because of condensing water on the cold fuel gas pipes. To date the ferritic gas spider piping is subject to maintenance activities during hot-gas-path inspection and, depending on the remaining wall thickness, replacement of individual pipes can be necessary. In one case this maintenance work was neglected during the hot-gas-path inspection and caused internal fire damage in the area above the flame tube bottom plates.
A redesign has been released to make the gas premix spider maintenance-free over an interval of kEOH using a wet-corrosion-resistant material instead of the original material. This spider upgrade is also a requirement for the 41MAC upgrade. NOx production and emissions depend on the combustion temperature which increases due to a higher turbine inlet hot-gas temperature and increases when the ambient temperature drops.
To generate a customer benefit with our turbine inlet temperature increase even in connection with strict environmental requirements, we have developed a special GT NOx control concept. This concept enables adjustment of the turbine inlet hot-gas temperature as a function of ambient temperature for a specified constant NOx limit curve e. With increasing ambient temperatures the turbine inlet temperature can be raised, thus achieving higher power output and better efficiency.
Doing so the diagram shows an output gain of 3. Another relevant parameter is humidity. The operating curves shown here hold for optimized cooling air losses, optimized pilot gas flow and precisely adjusted radial blade clearances. This open-loop control function thus enables adjustment of the entire turbine inlet temperature operating range and hence output and efficiency of the plant based on the specified NOx values.
Benefits The HR3 Burner Retrofit modernization can be a highly cost-effective means to help improve the performance, reliability and availability of your gas turbine plant. The following focuses on the particularly effective wet compression upgrade. In wet compression, atomized water is injected through a nozzle rack into the compressor air intake.
Part of the injected water evaporates in the air intake; the remaining water enters the compressor in liquid form droplets of approx. This achieves an inter-cooling effect. The injected water evaporates in the compressor stages.
The energy required for evaporation is taken from the compressed air mass flow, which is thus continuously cooled. This cooling, coupled with the mass flow increase of the working fluid drawn in, results in a significant performance gain in both output and efficiency.
In the baseline wet compression the performance gain is independent from ambient conditions. During the development of this upgrade, the design criteria assembled were analyzed and met, and validation tasks for first-time application were defined.
For example, we needed to ensure that water injection is homogeneous to prevent casing deformation due to non-uniform temperature fields. The spray pattern in the intake duct was therefore specified in advance on the basis of 3-CFD analyses and temperature field of the casings measured during the validation run.
The amount of water is controlled by a mass flow control loop comprising the injection pump, a variable-frequency drive VFD and a controller. In order to maintain a desired mass flow the controller activates the VFD to set the appropriate speed at the pump motor.
The pump directly feeds the desired amount of water into the feeding line. Thus an additional return line is no longer necessary. The entire equipment is arranged on the high-pressure wet-compression skid. It may not display this or other websites correctly.
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