ZCPP VT Project Report

PROJECT REPORT

Certificate

This is to certify that Mr. Rajarshi Bhattacharya has successfully completed four weeks training in Reliance Industries Limited, Jamnagar. The project entitled, ‘Overview of SEZ CPP and Detailed Study of Gas Turbine’ is an authentic work carried out by him under my supervision and guidance.

Subham Ghanta Nayan Manavadaria(Plant Training Coordinator, ZCPP) (Mechanical Lead, SEZ CPP)

Overview of SEZ CPP and Detailed Study of Gas Turbine 1

RAJARSHI BHATTACHARYADEPARTMENT OF MECHANICAL ENGINEERING

JALPAIGURI GOVERNMENT ENGINEERING COLLEGEJALPAIGURI, WEST BENGAL

Acknowledgement

The internship opportunity I had with Reliance Industries Limited was a great chance for learning and professional development. Therefore, I consider myself as a very lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people and professionals who led me though this internship period.

Bearing in mind previous, I am using this opportunity to express my deepest gratitude and special thanks to Mr. Mukesh Ruparelia (Plant Maintenance Manager, SEZ CPP) and Mr. Sandip A Sharma (Plant Head, SEZ CPP) who in spite of being extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct path and allowing me to carry out my project at their esteemed organization and extending during the training.

I express my deepest thanks to Mr. Nayan Manavadaria (Mechanical Lead, SEZ CPP) for taking part in useful decision & giving necessary advices and guidance and arranged all facilities to make life easier. I choose this moment to acknowledge his contribution gratefully.

I would like to thank my mentor Mr. Subham Ghanta for his technical guidance throughout my training period. I would also like to thank other engineers of the plant Mr. Jainish Jain, Mr. Amit Mandora, Mr. Sravankumar Pulikam, Mr. Hitesh Munjapara, Mr. Anurag Ajudiya and Mr. Viral Mehta for sharing their experiences and knowledge which has really helped in solving my doubts and concepts.

I perceive this opportunity as a big milestone in my career development. I will strive to use these gained skills and knowledge in the best possible way and will continue to work on their improvement, in order to attain desired career objectives. Hope to continue cooperation with all of you in the future.

Sincerely,Rajarshi BhattacharyaPlace: JamnagarDate: 15th July 2015


CONTENTS 1. Company Profile

2. Business Overview

3. Introduction to Captive Power Plant

3.1 CPP Process Flow Diagram

3.2 Major Equipment

4. Equipment Description

4.1 Gas Turbine

4.1.1 Introduction

4.1.2 Advantages

4.1.3 Combined Cycle or Co-Generation Mode

4.1.4 Construction Features

4.2 Heat Recovery Steam Generator

4.2.1 Introduction

4.2.2 Rankine Cycle

4.2.3 Major Parts

4.2.4 Functional Description

4.3 Steam Turbine

4.3.1 Introduction

4.3.2 Pressure Reducing and Desuperheating System (PRDS)

4.4 Auxiliary Boiler

4.4.1 Introduction

4.4.2 CPP Boiler Design Parameter

4.4.3 Auxiliary Boiler Functional Description

4.5 Balance of Plant

4.5.1 Introduction


4.5.2 Equipment Details

5. Detail study of Gas Turbine in SEZ CPP

5.1 Machine Description

5.2 Machine Specification

5.3 Schematic Diagram

5.4 Part Description

1. COMPANY PROFILE

Reliance Industries Limited (RIL) is India’s largest private sector company, with a consolidated turnover of Rs. 3, 88,494 crore (US$ 62.2 billion), cash profit of Rs. 36,291 crore (US$ 5.8 billion) and net profit of Rs. 23,566 crore (US$ 3.8 billion) for the year ended March 31, 2015. It is an Indian conglomerate holding company headquartered in Mumbai, Maharashtra, India. The company operates in five major segments: exploration and production, refining and marketing, petrochemicals, retail and telecommunications.

RIL is the first private sector company from India to feature in Fortune’s Global 500 list of ‘World’s Largest Corporations’ and continues to be featured for the 11th consecutive year, currently ranking 114th in terms of revenues and 155th in terms of profits. RIL ranks 194th in the Financial Times’ FT Global 500 2014 list of the world’s largest companies. As per Newsweek’s Green Rankings 2014, RIL is India’s greenest and most environment-friendly company, ranking 185th among the world’s largest 500 companies.

RIL is the second-largest publicly traded company in India by market capitalization and is the second largest company in India by revenue after the state-run Indian Oil Corporation.

The company's petrochemicals, refining, and oil and gas-related operations form the core of its business; other divisions of the company include cloth, retail business, telecommunications and special economic zone (SEZ) development. In 2012–13, it earned 76% of its revenue from Refining, 19% from Petrochemicals, 2% from Oil & Gas and 3% from other segments.

In July 2012, RIL informed that it was going to invest US$1 billion over the next few years in its new aerospace division which will design, develop, manufacture, equipment and components, including airframe, engine, radars, avionics and accessories for military and civilian aircraft, helicopters, unmanned airborne vehicles and aerostats. In July 2012, RIL informed that it was going to invest US$1 billion over the next few years in its new aerospace division which will design, develop, manufacture, equipment and components, including airframe, engine, radars, avionics and accessories for military and civilian aircraft, helicopters, unmanned airborne vehicles and aerostats.


2. BUSINESS OVERVIEW Jamnagar Refinery and Petrochemical Complex is situated on the western coast of India in the state of Gujarat about 30km from the city of Jamnagar in Saurashtra region. This Complex consists of two large refineries, one of which falls in the DTA and the other in SEZ. This refinery complex is the world’s largest Crude Processing Site with a combined capacity of 1.24 million barrels per day.

The Jamnagar Complex is among the most complex refineries in the world. Each refinery has the capability to process 29 and 24 API crude. The capital cost of the refinery is one of the lowest compared to other new Indian and International refineries. It achieves the highest value addition per unit of capital investment.

UOP from the USA, the world leader in refinery technology has provided the basic engineering and license for the project. Foster Wheeler, EMRE/KBR, Pritchard, Linde & Dow are the other renowned licensors who have supplied know-how for various units such as Coker, Clean Fuels Complex, Alkylation Complex, Cold Bed Adsorption, Sulfur, Hydrogen and Polypropylene, etc.

The products from this refinery can meet the most stringent quality management for all products, mainly ATF, Gasoline and Diesel. The clean fuels complex makes it possible for Jamnagar to consistently deliver Euro-4 and Euro-5 grade Gasoline and Diesel that have lowest sulfur specifications and helps in a long way in meeting environmental regulations of current days and future.

On 25 December 2008, Reliance Petroleum Limited (RPL) announced the commissioning of its refinery into a Special Economic Zone in Jamnagar, Gujarat, India. The completion of the RPL refinery has enabled Jamnagar to emerge as a ‘Refinery Hub’, housing the world's largest refining complex with an aggregate refining capacity of 1.24 million barrels (197,000 m3) of oil per day, more than any other single location in the world.[2]

The globally competitive RPL refinery was commissioned in 36 months. RPL contracted several companies having expertise in engineering construction and refining like Bechtel, UOP LLC and Foster Wheeler amongst others. There are plans for the pipeline to process High Pour Point crude oil extracted at Barmer, Rajasthan in the near future. This would require an electrically heat traced pipeline to be set up from Barmer to Jamnagar.

The entire complex as of 2013; consisting of manufacturing and allied facilities, utilities, off-sites, port facilities and a township (415 acres of land) with housing for its 2,500 employees, results in over 7,500 acres (3,000 ha; 11.7 sq. mi) = 30,000,000 m2. This area, if overlaid on


Mumbai or London, would cover more than one-third of either city's landmass. If all of the pipes used in the refinery were laid out, one after another, they would connect the whole of India from north to south.

3. INTRODUCTION TO CAPTIVE POWER PLANT (CPP)

Electricity Act, 2003 defines “ captive generating plant ” as a power plant set up by any person to generate electricity primarily for his own use and includes a power plant set up by any co-operative society or association of persons for generating electricity primarily for use of members of such cooperative society or association;

Industries, which consume a large chunk of the power generated & distributed by the utilities and also provide the larger portion of the revenue, have to compete in the global market for their products and services. Non-availability, poor quality and reliability of grid power along with exorbitantly high tariffs have a significant impact on the competitiveness of the industry. This led to the emergence of captive generation. Captive power today accounts for at least 20 per cent of the total installed capacity in the country.

The high cost (because of the cross-subsidy element) and the abysmal quality of the power were the primary reasons driving industry towards investing in captive generation facilities. Some of process industries like chemical, aluminum, cement etc. the need for uninterrupted quality power was a necessity rather than a requirement.

Moreover, with advancing technologies, it was realized that the many of the power generation technologies have symbiotic relationship with the manufacturing process itself. For example the heat loss consequential to certain chemical processes could be used for power generation, or the need for steam (in the manufacturing process) besides power could be supported with highly efficient power generation technologies. The advantage of setting up captives to the industry accrued in the form of assured power supply, reduced wastes, fuel flexibility, and lower tariff.

CPP produces and distributes power, steam and process boiler feed water for Jamnagar Export Refinery Project. All these products are distributed to the different units of refinery as per process requirements. CPP consists of Gas Turbines and Steam Turbines for power generation and Heat Recovery Steam Generators and Auxiliary Boilers for steam generation. Design power generating capacity of CPP is 752 MW. It consists of 6 nos. of gas turbines and 2 nos. of steam turbines. Design capacity of each Gas Turbine is 116 MW and steam turbine is 28 MW. The installed steam generating capacity of CPP is 2990 TPH and is met by 6 nos. of HRSGs and 4 nos. of Auxiliary Boilers. HRSGs and Auxiliary Boilers are designed to generate 315 TPH & 275 TPH of steam respectively at 43.2+/-1 kg/cm2g pressure and 391oC+/-5oC temperature. Power distribution to the refinery plants is done at 33 KV level. In normal


operation it is expected that Reliance power system will operate in islanded mode. One Emergency Diesel generator (EDG) having design generating capacity of 4.2 MW, supply emergency power to the CPP critical equipment in case of power failure. Internal power distribution in CPP is done at 6.6 KV and 415 V levels. Feed water for steam generation is made available through 7 nos. of de-aerators in CPP (3 nos. for CPP, 3 nos. for Process & 1 no. Common for maintenance purpose). Capacity of each de-aerator is 750 TPH. Process feed water is distributed at HP, MP and LP pressure levels to the refinery. Each level has 3 nos. of pumps with 1 no. turbine driven & 2 nos. motor driven. The installed capacities of HP, MP& LP process feed water is 2249 TPH, 575 TPH & 507 TPH respectively. Process steam to refinery is supplied at three pressure levels, namely HP, MP& LP. There are process steam generators in the refinery complex also. All consumers and producers of steam are connected to a common header at each level of pressure. HP and MP steam from CPP are normally in the export mode and while LP steam can be in import or export mode. All header pressures are monitored and maintained by CPP on continuous basis. HP steam generated is used in back pressure Steam Turbine (HP to MP). CPP gets Fuels from other refinery units. DM water, Instrument air, Plant air, Nitrogen, Utility water and potable water are supplied by Utility plant. Dedicated air compressors at CPP end supply instrument air for CPP in normal case. However CPP air system is connected to the refinery air system so as to receive instrument air if required. Liquid fuels are supplied by RTF. Refinery fuel gas is received from Refinery. Natural Gas supply provision is made through GSPL pipe line which will be used as normal fuel for CPP.


3.1 CPP PROCESS FLOW DIAGRAM


3.2 MAJOR EQUIPMENT

a) Gas Turbine

GE Frame 9E machines supplied by GE, France GT 3 & 4 has “Black Start” capabilities From cold start GT can be synchronized within 16.5 minutes and fully loaded within

28 minutes Fuel : Distillate/Gas Oil and Natural gas (Dual fuel nozzles) Inlet guide vanes provided to support part load operation Inlet air system designed for minimum inlet air pressure drop Compressor section on-line and off-line water wash possible Power output at ISO Condition = 126 MW 30 Deg C = 112.7 MW 43 Deg C = 102.3 MW

b) Back Pressure Steam Turbine

Supplied by MAN TURBO, Germany Back Pressure type with HP steam inlet and MP steam as exhaust Maximum steam flow through each steam turbine is 543 TPH

c) Heat Recovery Steam Generator

6 nos. supplied by Thermax, Pune Capacity : 315 TPH, 49.6 kg/cm2 & 396 0C + 50C At GT base load & unfired mode : 200-210 TPH Supplementary firing mode MCR : 315 TPH Ramp up rate : 32 TPH per min Number of Burners : 06 Heat input : 236.8 GJ/Hr. (Supplementary firing) Supplementary firing : Liquid fuel & gas fuel firing facility HRSG performance and efficiency optimized at the predicted gas turbine part load

point. DM Water preheater sections provided in each HRSG in order to maintain stack

temperatures < 1100C when firing natural gas. The preheater sections can be by passed when firing liquid fuels to maintain stack

temperatures above the acid dew point to avoid corrosion. Total Heat Transfer Area : 68,150 m2 Overall Cogeneration Efficiency (GT + HRSG) : 86.6 %


d) Auxiliary Boiler

4 nos. supplied by Thermax, Pune Capacity : 275 TPH, 49.33 kg/cm2, 397 +/- 5⁰C Ramp up rate : 38 TPH per min Number of Burners : 6 Heat input @ MCR : 776.63 GJ/Hr. (15.88 TPH) Liquid fuel & gas fuel firing facility Auxiliary boilers are designed to operate during power failure to supply steam to

refinery plants for safe shutdown Drum coil pre-heating provided for flexibility of firing CSO fuels Total Heat Transfer Area : 9,499 m2 Thermal Efficiency : 94.4%

e) Balance of Plant

7 nos. of Deaerators : 03 for CPP, 03 for Process and 01 common 5 nos. of CPP HP boiler feed water pumps, 9 nos. (3 HP Process FW, 3 MP Process

FW, 3 LP Process FW) of Process feed water pumps. 2 nos. of dedicated Instrument air compressors & drier package 2 nos. of DM water

tanks and 9 nos. Deaerator feed pumps (6 for CPP Deaerator and 3 for Process Deaerator)

4 nos. of GT-HRSG fuel tanks, 2 nos. of FO tanks Close Cooling Water system with 4 nos. of pumps and 6 nos. of Plate Type Heat

Exchangers


4. EQUIPMENT DESCRIPTION

4.1 GAS TURBINE

4.1.1 INTRODUCTION

Gas Turbine is a Modern Power generating equipment.It takes the air from atmosphere compresses it to sufficiently high pressure, same

pressurized air is then utilized for combustion, which takes place by in combustion chamber by addition of fuel, there by hot combustion products are generated which are expanded in the turbine where Heat energy of hot combustion products is converted in to mechanical energy of shaft which in turn utilized for generating power in Generator.

Compression is carried out by Axial Flow compressor, Heat addition is done by Fuel in combustion chambers, Expansion of hot combustible gases is carried out in Turbine and Burnt Gases are exhausted to atmosphere or utilized for steam generation in GTs. All of these four processes are carried out in only one Factory assembled Unit which is called Gas Turbine. Drawing shows the Typical Brayton cycle and also shows the components of Gas


Turbine. Gas Turbine operates on Brayton Cycle. Brayton cycle is having divided in four segments namely Compression, Heat addition, Expansion and Exhaust.

Process is explained in following diagram on T-S curve.

4.1.2 ADVANTAGES

Capital cost is less. Fewer auxiliaries. Less erection time. Less area. Higher thermal efficiency when operated in combined cycle mode. Quick start. Fuel flexibility ( Liquid / Gas ) Very compact system. Black start facility. Suitable for Base load / Peak load / Part load operation. No/Less environmental Hazards. Control reliability.

4.1.3 COMBINED CYCLE OR CO-GENERATION MODE

In modern days Gas Turbine Based power plants are becoming more and more popular mainly because of its higher efficiency, Reliability, Quick response.

In the modern Power Plants Gas Turbine Exhaust is connected to Heat Recovery Steam Generator where the steam is generated from hot gases and Steam is utilized for running the Steam Turbine such system is known as combined cycle power plants and where steam is utilized for various processes such system is called as Co-generation system


Normally combined cycle power plant efficiency is around 48-50 % and co-generation system efficiency is around 80 % depending up on application.

Reliance Petroleum Limited at Jamnagar has combination of these both combined cycle and co-generation system.

Reliance Petroleum Limited has 756 MW captive power plant, which we can call a Combined Cycle Power Plant consists of

6 x 126 MW Frame-9E (GE France) supplied by GE Energy Products France 2 x 30 MW MAN TOURBO (Germany) make back pressure, non-condensing steam

Turbines.

Gas Turbine operates on Brayton Cycle and Steam Turbine works on Rankine cycle, in combined cycle both these cycles are combined hence such power plants are called combined cycle power plant.

Typical combined cycle diagram is explained in drawing.

4.1.4 CONSTRUCTION FEATURES

Gas Turbine mainly divided in three sections:

Compressor: The axial flow compressor is consisting compressor rotor and the enclosing casing. The compressor casing consisting of Inlet Guide Vanes, 17 stages of rotor and stator balding, and 2 exit guide vanes.Air is extracted from the compressor for turbine cooling, bearing sealing and during start-up pulsation control.


Combustion system: The combustion system is the reverse flow type which includes 14 combustion chambers having the components like:a) Combustion Linersb) Flow Sleevesc) Transition Piecesd) Cross fire Tubese) Flame Detectorsf) Fuel Nozzlesg) Spark Plugs

Hot gases generated from burning the fuel in combustion chambers, are used to drive the Turbine. Fuel is supplied to each combustion chamber through a nozzle that functions to disperse and mix the fuel with proper amount of combustion air.

Turbine: The three stage turbine section is the area in which energy in the form of high energy, pressurized gas produced by compressor and combustion section is converted in to mechanical energy.

4.2 HEAT RECOVERY STEAM GENERATOR

4.2.1 INTRODUCTION

Heat Recovery Steam Generators are located in the downstream of GTs and produces HP steam utilizing the GT exhaust gases. These HRSGs can be run with or without supplementary firing according to the steam demands. The total generating capacity of each HRSG from 50% to base load of GT with supplementary firing is 315 TPH of HP steam at


Location of spark plugs

Location of flame detectors

Location of flame detectors

3960C temperature and 49.3-kg/cm2 pressure. These are horizontal, natural circulation, single drum, single pressure, duct fired water tube type HRSGs. The capacity of each HRSG in unfired mode at base load of GT is 218 TPH of steam at above specified pressure and temperature. Rated steam temperature in unfired mode is achievable above 60% of GT load, at the expected steam generation of about 142TPH. Additional steam demand is met by introducing Supplementary Firing (SF) in the duct. HRSGs are supplied by M/S by M/S TBW.

4.2.2 RANKINE CYCLE

The basic thermodynamic cycle in a combined cycle operation is given by Rankine cycle, which is shown in the diagram. The water from the deaerator is pressurized in a feed pump and then taken to the boiler is shown by d-e-a. Constant pressure heat addition is shown by a-b. The Isentropic or adiabatic expansion in a steam turbine is given by b-c. The condensation process is shown by c-d. The output from the adiabatic expansion is more in the case of superheated steam than that of the saturated steam as shown in the figure. So the steam outlet from HRSGs given at a high degree of superheat helps to increase the mechanical output of steam turbines.


4.2.3 MAJOR PARTS

Economiser: Economizer in a steam-generating unit is to absorb heat from the flue gases and to add this as the sensible heat to the feed water before the water enters the evaporative circuit of the boiler. In modern boilers economizers are mainly used to increase the efficiency of the unit and the feed water temperature.

Evaporator: Water to steam phase change is taking place in the evaporator by absorbing the latent heat of evaporation from the gases. Evaporator tubes are fed from the bottom through feed distribution pipes. As the water goes up the phase transformation takes place. So at higher elevations the percentage of steam vapor keeps on increasing in the water – steam mixture. The amount of water, which is converted to steam just before it enters the drum it determined by the circulation ratio of the boiler and this, is a design aspect. The temperature in evaporator zone will remain constant with respect to the operating pressure.

Superheaters: The dry saturated from the drum (evaporator) is further heated in super heaters. Here the temperature of the steam will increase and the degree of super heat is controlled by the process requirements. To have the desired temperature at the outlet, attemperators are introduced in between the super heater modules. Here the feed water at high temperature is sprayed into the stream of steam for fine control of the final temperature. The metallurgy of these tubes should be able to withstand this high thermal stresses and high temperature failures like creep. Usually these tubes are made of alloy steels of different grades. (Material details are given in the section – ‘equipment description’)

4.2.4 FUNCTIONAL DESCRIPTION


RANKINE CYCLE

BOILERPRIMEMOVER

POWEROUTPUT

CONDENSER

CW IN

CW OUT

FEED PUMP

da

b

c

(e)

RANKINE CYCLE

BOILERPRIMEMOVER

POWEROUTPUT

CONDENSER

CW IN

CW OUT

FEED PUMP

da

b

c

(e)

RANKINE CYCLE ON p-v DIAGRAM

P1

P2

d

e,a b

c

Adiabatic Expansion

V

RANKINE CYCLE ON p-v DIAGRAM

P1

P2

d

e,a b

c

Adiabatic Expansion

V

P1

P2

d

e,a b

c

Adiabatic Expansion

V

The HRSG generates steam utilizing the energy in the exhaust flue gas from the GT. Recent trends in the HRSG design include multiple pressure units for maximum energy recovery, the use of high temperature SH and auxiliary firing for efficient steam generation. The quality and quantity of steam generates from HRSG depend on the flow and temperature of the entering exhaust gas from GT.

GT can be run in open cycle with venting the exhaust gases to atmosphere through the chimney but In this case the efficiency of the system is very less and a lot of useful heat energy is wasted to the atmosphere. So HRSGs are introduced at the down streamside of GT. This mode of operation is called Co-generation mode (Fig. 1). In co-generation mode steam generated is mainly used for process requirements. But if the steam generated is used for further power generation via Steam turbine then that cycle is called Combines cycle operation (Fig. 2).

Each HRSG consists of preheater, economizers, evaporator, Drum and Super heaters as major components. DM water before entering in to the dearator pass through the preheater where it is pre heated. Feed water from the boiler feed pump enters to economizers, flow through economizer will increase the water temperature and this results in a lower temperature at the stack inlet. The water then goes to the drum, from drum flows to a down comer. At the bottom of the down comer there are distribution pipes, which connect to all modules of evaporator. The water in the evaporator will rise and change its phase from water to vapor form and finally reaches the drum. In the drum this saturated steam is separated from the water with the help of cyclone separators. Strainers are also provided in the upper part of the drum to prevent water droplets entering the super heater. Saturated steam is then passing through super heaters in series with attemperator in between. Attemperation is done through boiler feed water itself. Other accessories of boiler include safety valves, soot blowers, and blow down drum, emergency blow-down system, and continuous blow down system, S0x/ N0x monitoring system and steam & water analysis system.


COGENERATION MODE

COMBINED CYCLE MODE


COGENERATION MODE

COMPRESSOR GAS TURBINE

CC

FUEL

GENERATOR

HRSG

HHP STEAM

FEED WATER

STACK

AIR


CC

FUEL

HRSG

FEED WATER

STACK

AIR

STG

EXTRACTION CONDENSATE

GENERATOR

GENERATOR HHP STEAM


CC

FUEL

HRSG

FEED WATER

STACK

AIR

STG

EXTRACTION CONDENSATE

GENERATOR

GENERATOR HHP STEAM

4.3 STEAM TURBINE

4.3.1 INTRODUCTION

Captive Power Plant has 6 identical steam turbines. Steam turbine is single shaft, axial flow, single cylinder and condensing type impulse reaction turbine with two stage extractions at different pressure. The turbine has three sections called HP section, MP section and LP section. HP section has 7 stages of rotating blades, MP section has 8 stages of rotating blades and LP section has 16 stages of rotating blades. All the three sections are housed in a single cylinder. Maximum flow limit is given to protect the steam turbine against overloading. Extraction pressure high and low trips are provided to protect turbine against overloading. To ensure the blade cooling of different sections of the turbine, required minimum flow through each of the turbine section blades must be maintained. The turbine is having single shaft supported by two journal bearings at each end and held axially by double acting tilting type thrust bearing. The bearings are forced feed lubrication type. The turbine casing is horizontally split and via two brackets integrally cast to the casing top part, rests on the bearing housing. The bearing housing rests on supports and is guided axially by longitudinal keys on the foundation such that to allow thermal expansion in axial direction. The turbine exhaust end is bolted to condenser. An expansion bellow is provided between turbine and condenser to take care of the thermal expansion. The exhaust steam casing rests on laterally arranged bracket supports to which it is axially fixed such that transverse expansion is not restricted. Drawing shows line diagram of turbine with design values.

28MW


543 TPH HP steam (Max)Pr: 43.2 Kg/CM2 @ 391 Deg C

543 TPH MP Steam (Max)Pr: 17.85 Kg/CM2 @ 290 DegC

4.3.2 PRESSURE REDUCING AND DESUPERHEATING SYSTEM (PRDS)

Six pressure reducing / de-superheating stations are provided to supply HP, MP & LP steam for the refinery process plants. One pressure reducing / de-superheating station is provided for initial startup of the HRSGs / Aux. Boilers. The PRDS system is sized to provide redundancy for meeting refinery steam demand for limited failure or non-availability of the steam turbine. The PRDS is sized to meet the demand normally met by two steam turbines on the basis that one trips while another is out of service for the maintenance. All let down stations and de superheating stations are located adjacent to the north wall of steam turbine building.


4.4 AUXILIARY BOILER

4.4.1 INTRODUCTION

There are four auxiliary boilers in Reliance Jamnagar JERP CPP. They are supplied by M/S Thermax India Ltd. They have a capacity of supplying 275 t/hr. of steam at 49.3 kg /cm 2 and 397 + / - 5 OC. These boilers will normally be operated at 90 t/hr. load and ready to ramp up to MCR (Maximum Continuous Rating) in case of disturbance in steam supply. The auxiliary boilers are designed for the combustion of fuel oil and refinery fuel gas (dual fuel). These boilers are mainly designed to supply steam for the safe shut down of the refinery in the event of total power failure. So it is imperative that the boiler operation not only be efficient but also reliable. The support system of the boiler has to be equally reliable to face such an eventuality (meaning, turbine drives for fuel oil pumps, forced draft air fan and emergency instrument air supply).

The Auxiliary Boiler here is a water tube, forced draft, natural circulation, bottom supported, bi drum and four pass boiler.

Boilers can be classified as a water tube or a fire tube boiler depending upon whether the flue gas or water is passing through the boiler tubes. In a fire tube boiler the flue gas passes through the boiler tubes and water surrounds the tubes. Hence the name fire tube boilers. The locomotive engine is a fine example of this. But these boilers are not available in the higher capacity ranges owing to their design limitations. Whereas in the water tube boiler, the water passes through the tubes and the flue gas envelopes the water tubes. And hence the name water tube boilers. Owing to their design the water tube boilers are available.


FIGURE 1: FORCED DRAFT BOILER

BOILER

FORCEDDRAFT FAN

WIN

D B

OX

STA

CK

In higher capacities of pressures and steam flow. The JERP Auxiliary boiler is a water tube boiler. The flue gases in the auxiliary boilers pass through an enclosure of water tube panels that is called the furnace.

Boiler can be classified as induced, forced or balanced depending upon the nature of admission of air and exit of flue gasses in the boiler. In a forced draft boiler the fan that supplies air to the boiler is located in the up-stream direction of the boiler. The figure 1 gives a clear indication of the forced draft system. It is termed as forced draft as the air is forced into the system (boiler). The induced draft boilers have a fan at the downstream end of the boiler. In this the air and flue gases are induced in and out of the boiler respectively. The balanced draft boiler have both, the forced draft fan that forces air into the boiler and induced draft fan that induces or sucks out the flue gases from the boiler and throws them in to the stack. Boilers burning solid fuel and of higher capacities are of balanced type (mainly because, in solid fuel firing boilers the Increment in flue gas volume is higher as compared to gas fired or oil fired boilers). Induced draft type boilers are of lower capacity. As the auxiliary boiler burns liquid and gas fuel the forced draft system in it is adequate enough to force in the air required for combustion and force out the flue gases after combustion.

Boilers can be either supported at the top or bottom. The water walls of top supported boilers are hung or suspended from the top. These types of boilers expand downwards. The structures for these types of boilers are heavier and hence higher initial cost is incurred. The bottom-supported boiler expands upwards. The membrane walls are not hung (supported) from the top but are supported at the bottom. The Auxiliary boiler is a bottom supported type. The initial cost, as compared to that of the top supported boiler is lesser owing to lighter supports.

The water circulation in the boiler is either natural or forced. Meaning, the circulation is based upon the density difference arising due to the heat generated from burners. The water that is in the tubes located away from the burner zone is colder and hence is heavier. They are heavier in comparison to the water in the tubes that is closer to the burner zone. It shows Natural circulation in a boiler. (Arrows represent direction of water flow).The illustration clearly indicates that the water wall that is furthest away from the burner is colder. Hence the water in it is heavier. This causes a downward flow. Whereas the water wall that is closer to the burner is hotter and hence the water in it is lighter. Hence the upward flow is established. In this way owing to density difference there is natural circulation of water from the drum and back to the drum. This type of circulation is termed as natural circulation. But this density difference ceases for boilers operating at pressures greater than 220.9 atmospheres, At this pressure the difference in density (between water vapor and water) is zero. For circulation of water in such boilers an external energy in the form of a pump is required to establish circulation within the boiler. Such boilers are called forced circulation boilers. The auxiliary boilers at CPP are of “natural circulation type.

Auxiliary boiler is a bi-drum boiler if it has two drums namely Steam drum and Mud drum or bottom drum. The bi-drum boilers cannot ramp as fast as the single drum. This is because the drums are directly in the flue gas path. Because of this, they undergo a lot of thermal stress during ramping. The single drum boilers ramp up faster because, the single drum is outside the flue gas path and hence lesser thermal stresses. The time taken for alkali boil out for a bi-drum boiler is lesser as compared to the single drum boiler. Because most of the


debris to be removed after alkali boil out is done by opening the mud drum manholes in case of a bi-drum boiler.

The boiler is a water tube boiler, forced draft, bi-drum, bottom supported, and natural circulation type of boiler. It is a water tube type of boiler as the water is in the tube and the flue gasses are outside it. The boiler is forced draft because there is a positive draught in the furnace and the exit of the flue gases is dependent on the draught created by the temperature differences of flue gas and air and also because of the height of the chimney. The boiler is supported at the bottom and therefore the expansion of the boiler is upwards i.e. vertical. The main advantage of such a (bottom supported) design is the reduction in the capital cost needed towards the heavier support structure which would have been needed if the boiler was to expand downward (as in case of top supported or freely hanging boilers) direction. The water circulation in the boiler is natural meaning no external force is required for inward movement or travel in the boiler.

4.4.2 CPP BOILER DESIGN PARAMETER

The boiler has been designed for site conditions having a maximum dry bulb temperature of 43 deg. C and maximum wet bulb temperature of 28 deg. C. The design surface temperature is at 65 deg. C. the boiler is designed for a max. RH (Relative Humidity) of 92.8 % and a minimum RH of 27 %.Evaporation capacity of the boiler is 275 t/hr. Out let superheated steam at a pressure of 49.3 kg / cm sq. and 397 + / _ 5 O C. The total surface area of the boiler is 9499 sq. meters. The auxiliary boiler has been designed for earthquake of class three type. The boiler has six burners which are mounted in the front wall of the furnace. These burners are of dual type as they are capable of burning fuel oil and fuel gas. The boiler has a turn down ratio of 1: 4. The boiler being a forced draft one has two forced draft fans (2 x 100 %). It also has two scanner fans (2 x 100 %) which help in sealing and cooling peep holes, soot blowers and scanners. Two phosphate dosing pumps help in maintaining the water quality of the boiler. The boiler has three super heaters. The super heaters help in increasing the temperature of steam from saturation point. There is a single attemperator that helps in controlling the steam outlet temperature at any load. The attemperator is of a spray type.

The super heater has three passes. The attemperator is situated between the second and the third pass. The boiler consists of two economizers 1A and 1B. The economizers boost up the feed water temperatures by absorbing heat from the flue gases. There is also a drum coil preheater (DCPH), situated in the mud drum, which plays an important role in control of flue gas exit temperature.

Soot blower is a device for removing the soot that is deposited on the furnace tubes of a boiler during combustion. There are twenty seven numbers of soot blowers of which three


are located in the super heater zone, twelve in the convective bank or generating bank zone and twelve in the economizer zone. The boiler consumes HP steam to the tune of around 5.5 TPH in the turbine driven FD fan, MP steam in soot blowers and burners for atomizing steam (1.4 t/hr. – 10.6 t/hr.). The boiler also consumes LP steam for oil tracing. The boiler uses dry air at a pressure of 7 – 8 kg/cm sq. for pneumatic valves and for emergency cooling of scanners in case of total power failure. The boiler motor driven fan consumes a maximum of around 325 KW power at 6.6 KV.

4.4.3 AUXILIARY BOILER FUNCTIONAL DESCRIPTION

The Boiler is divided into a furnace section and a second pass by a division membrane wall. The furnace section is made by tube walls and refractory wall. The furnace comprises of the furnace side wall, roof, floor & rear walls and the front refractory wall. The furnace side, roof and floor, rear walls are of membrane panel construction. The furnace front wall is of refractory construction. The second part comprise the super heater, convection bank tubes. The second pass is enclosed by the rear wall & boiler side wall. Entire array of tubes in the furnace and second pass is designed for convective heat transfer and is fully drainable. Feed water from plant is admitted to the drum coil heater and then to the economizer through a feed water control station. The feed water is then feed led to the steam drum. Steam is generated in the convective bank tubes. In the riser tubes partial evaporation takes place due to heating. The resulting water stream mixture returns drum where the separation of the steam from water takes place. The saturated steam is led to the super heater and then through the main steam stop valve to the process plant.

Combustion of fuel takes place in the furnace with the help of the burner mounted on the furnace front refractory wall. Combustion air is sucked from the plant environment by the FD fan. Flue gases generated are passed through the convection bank and is led to the economizer through the flue gases duct and finally through the steel stack into the atmosphere. Six burner are provided on the burner front wall in three elevations for burning fuel oil and gas. The starting and stopping are monitored by the PLC based burner management system. DCS based controllers are provided by the contractor for the control loops. Six long retractable and nine rotary soot blowers are provided in the second pass and twelve short retractable soot blower are provided for economizer to periodically clean the soot and other deposits which may accumulate in the super heater, boiler tanks and economizer surface when the burner are in service. Soot blowing is done to keep up the heat transfer efficiency at maximum level. Safety walls have been provided in the drum and in the main stream line of the boiler. Suitable insulation around the drum and the membrane panels, steam lines, feed water lines, hot air and flue ducts have been provided to minimize heat loss and for operators safety.

4.5 BALANCE OF PLANT

4.5.1 INTRODUCTION

The balance of plant system of the CPP consists of the following parts:


Compressed Air System Demineralized Water (DM Water) System Deaerator System Feed Water System Chemical Dosing System Nitrogen System

4.5.2 EQUIPMENT DETAILS

Compressed Air System: CPP has an instrument air system which provides both instrument and plant air. All air supply will be oil free. Plant air is distributed from the receiver dried to the various Utility Stations.a) Compressed Air System Design:

Air Compressor: 2 Nos.Capacity: 2421 Nm^3/hr.Discharge Pressure Temperature: 10.2 kg/cm^2, 36 deg CelsiusDriver: 380 kW, 6.6kV

Plant Air Receiver: 1 No.Capacity: 20 m^3Design Pressure/Temperature: 15 kg/cm^2, 65 deg Celsius

Instrument Air Dryer Skid: 1 No.Pressure/Temperature: 15kg/cm^2, 65 deg CelsiusNormal Flow Rate: 1600 Nm^3/hr.Operating Pressure/Temperature: 10kg/cm^2, 40 deg Celsius

Instrument Air Receiver: 2 Nos.Capacity: 60m^3 eachDesign Pressure/Temperature: 15kg/cm^2, 65 deg Celsius

b) Compressed Air System Functional Description:Both the compressors are Screw compressors of non-lubricated type. Compressor skid consists of a lube oil pump and its cooler within the base plate limit. Compressors are of two stages with an intercooler in between in order to get high compression ratio and efficiency. A motor driven auxiliary startup pump is provided for each unit .Its operation is a part of the startup sequence such that compressor drive motor is only energized once the compressor oil pressure has reached the required setting. There are two dryers installed for drying of wet air discharged from compressor packages. Each compressor package outlet air goes through the respective dryer and the common outlet is routed to Instrument air receivers. Both air dryers are of adsorption type. Dryers can operate either on timer or dew point control. In a two stage compressor about 45% of the energy is lost in the after cooler. This energy is used as a source of hot air in adsorption air drying system. In an adsorption dryer there are two factors to be considered, one is adsorption and the other is regeneration. In adsorption the air goes through an activated bed where moisture is adsorbed and air goes out in regeneration we bring the desiccant back to


its original adsorption capacity so that it can be reused in the next cycle by flowing a stream of hot air through the bed.

Demineralised Water TankEach Demineralised Water Storage Tank will be supplied with three 100% pumps (one motor and one turbine driven operating, one motor driven standby), making up the feed to the CPP deaerators via the HRSG condensate Preheater sections. The DM water tanks receive DM water from utility on continuous basis. Apart from DM water deaerator feed pumps spill back also comes back to DM water tanks. The deaerator feed pumps supply DM water to deaerators. Demineralised water is produced in the Water Treatment Plant (WTP) portion of the refinery Utility Block. Output from the WTP will be pumped to the CPP Demineralised Water Storage Tanks. Two tanks will be provided for the CPP demand. This provides the required minimum level of capacity to allow for upset conditions or problems in reaching water spec. within the WTP. The principle requirement is high purity low conductivity water suitable for use in the CPP high pressure boilers and for water injection into the Gas Turbines for NOx

control.

DM water tanks (2 Nos.)Size: - 36 M x 20 M heightGross capacity: - 20350 M3 (each)Operating temperature: - 450cDesign pressure and temperature: - 18.1 kg/cm2, 65 ocHydro test Pressure: - 29.1 kg/cm2

Deaerator Feed pumps (9 Nos.)Normal flow: - 587.9m3/hr.


Pump discharge pressure: - s 15.7 kg/cm2 abs. Rated suction pressure: - 1.1kg/cm2NPSH required: - 3.5 meter of waterWorking temperature Normal: - 45 deg CMaximum temperature: - 65 deg c Minimum continuous flow: - 225 m3/hr.Pump speed: - 1480 rpmHydraulic power: – 308 kWDriver motor: - 371.77 kWDriver: -1500 rpm

Demineralised Water System Functional Description:

DM Water TankThe DM water tanks are vertical cylindrical with truss supported cone roof type of tanks. On tank overflow line of 24 inch diameter is also provided which extends to ground level. Two atmospheric vents of 8 inch diameter are provided to protect the tank from pressurization and vacuum. The pumping IN and pumping OUT rate of the tank is 2300 m3/hr. Each tank will be provided with nitrogen blanketing to limit and control the amount of dissolved oxygen in the Demineralised water. The nitrogen for blanketing will be provided from the refinery utilities block.

Deaerator Feed PumpsTo supply DM water to deaerators, each DM tank is provided two motor driven and one turbo driven deaerator feed pumps. Process deaerator feed pumps are connected with both the tanks through a common header. So there are total nine deaerator feed pumps each of capacity 794m3/hr design flow. The DM water from utility is supplied to both tanks, DM water level control valves LV410 and LV420 maintains the DM water tank levels , normally 18.00meters as the set point is given by panel engineer. However on both these controllers, 10% minimum open locking is provided to protect the utility DM water supply pump operating against shut off pressure.

Deaeration SystemThere are 3 deaerators each sized for 750 TPH. The deaerators receive feed water makeup from the Demineralised Water Storage Tanks. Prior to the deaerators, the feed water is routed through the condensate preheater sections of the HRSGs. The pre heater serves to preheat the feed water, reducing the amount of LP steam required for deaeration and improving cycle efficiency. A spare deaerator is located between the deaerators and the Process deaerators that serve the refinery process feed water system. This swing deaerator can be valve into service on either the side or the Process Feed water to allow inspection, maintenance or repair of a deaerator without impacting operation of either system. There are 3 process deaerators each sized for 750 TPH. The process deaerators receive feed water from the process condensate by utility. Located at the same elevation and alongside the deaerators


are three further deaerators which have no function for CPP but are dedicated to supply of feed water to the refinery process. The deaerators are installed at a suitable location to ensure the minimum NPSH requirement of the BFP's is achieved. The deaerators serving the refinery are to be mounted adjacent to the deaerators and are to be of similar size. The spare deaerator is a common spare. Selection of this location rationalizes steam pipe routing and minimizes cost by permitting use of a single spare deaerator to cover removal from service of either a CPP or Process Deaerator. This arrangement avoids the need to construct separate supporting steelwork and assists in lying out and support of the pump suction and discharge manifolds. The Process boiler feed water system is ideally isolated from the feed water supply to prevent potential contamination of feed water. However, a cross connection will be provided to allow Demineralised water to feed the process deaerators under upset conditions. Similarly, a separate cross connection will be provided to allow condensate return to feed the deaerators under upset conditions, but only if the condensate returns is of Demineralised water quality.


Deaeration System Functional Description:Deaeration is process to remove non condensable gases from the water. To remove non-condensable gases from water, the water temperature must be raised to the boiling point. The solubility of the gases is dependent upon the temperature of the water. When the temperature of the water is at the boiling point for the operating pressure, the solubility of the gases is zero. In order to escape insoluble gases from the mass of the water, the gas must diffuse through the surface film surrounding the particle of the water. Repeated agitation and breaking up of the water by passing it through spray and over trays and through a steam atmosphere causes rapid diffusion and elimination of the gases. Deaerator is an equipment used for the Deaeration of the boiler feed water. DM water is supplied to deaerator through deaerator feed water pump. LLP steam is used for the deaeration, which is taken through heat recovery system and by desuperheating the LP steam to 1.2-1.5 kg\cm2. Process deaerator get the feed water from the process condensate from utility.


Feed Water System:The conceptual design includes for common boiler feed water pumps and deaerators for supply of feed water to all HRSGs and Auxiliary Boilers. It is intended to utilize 3 deaerators and 3 BFWPs sized to meet the full boiler feed water flow requirements. Boiler feed water is also supplied to the HP/MP and MP/LP Pressure Reducing Stations and all boiler attemperators for desuperheating. The design basis for sizing the deaerators and BFP's is the requirement that there should be no boiler trip leading to interruption in steam output during transients caused by an upset condition resulting in tripping of a BFP or deaerator. The transient upset condition will be of relatively short duration as the control system will automatically start the standby pump. Process heat developed in various refinery units is utilized to generate steam. For steam generation, process units required feed water at different condition. The design basis of the BOP - CPP is developed for overall summary of refinery requirement for power, steam, process feed water, condensate, desalination water, and cooling water. Three dedicated Process Condensate Deaerators are provided within the CPP. Three sets of BFWP (i.e. HP, MP and LP pressure levels) are provided to pump feed water back to the Refinery. In order to ensure safe shutdown of the FCC and other critical process units, two of the BFW pumps are turbine driven, the others are motor driven. Normal operation would be with two turbine pumps in service with one electric if demand warranted running a


third pump. This combination provides the advantage of rapid run up characteristic of an electric pump, following the trip of any running pump. All CPP deaerators and pumps are manifold together under normal service conditions.

Feed Water System Functional Description

A centrifugal pump is one of the simplest pieces of equipment in any process plant. Its purpose is to convert energy of a prime mover (an electric motor or turbine) first into velocity or kinetic energy and then into pressure energy of a fluid that is being pumped. The energy changes occur by virtue of two main parts of the pump, the impeller and the volute or diffuser. The impeller is the rotating part that converts driver energy into the kinetic energy. The volute or diffuser is the stationary part that converts the kinetic energy into pressure energy. The process liquid enters the suction nozzle and then into eye (center) of a revolving device known as an impeller. When the impeller rotates, it spins the liquid sitting in the cavities between the vanes outward and provides centrifugal acceleration. As liquid leaves the eye of the impeller a low-pressure area is created causing more liquid to flow toward the inlet. Because the impeller blades are curved, the fluid is pushed in a tangential and radial direction by the centrifugal force. This force acting inside the pump is the same one that keeps water inside a bucket that is rotating at the end of a string.


5. DETAIL STUDY OF GAS TURBINE IN SEZ CPP

5.1 MACHINE DESCRIPTION

Gas Turbine Vendor: GE France Model: Frame PG 9171 E

o PG: Package Generatoro 9: Frame 9o 17: 17 * 10,000 HPo 1: Single Shafto E: Machine Series

Open Cycle Efficiency: 35% Cogeneration Mode Efficiency: 89% Compressor: 17 Stage; 3000rpm Turbine: 3 Stage; 3000rpm Fuel Type: Natural Gas and Distillate Fuel

5.2 MACHINE SPECIFICATION

ISO conditions = 1.01325 Bar atm pressure (MSL) = 15 oC


= 60 % RH

ISO Rating of Frame 9171 Gas Turbine= 126 MW

5.3 SCHEMATIC DIAGRAM

5.4 PART DESCRIPTION

Cranking Motor: It is used as the initial power source for starting the Gas Turbine. After the turbine reaches rated speed, the turbine itself drives the compressor

Turning Gear: It is used during starting and shut down of the Gas Turbine. When starting after a long time, the machine has a huge

downward force due to its own weight. Therefore running it directly at 3000 rpm may cause damage to the equipment. Hence it is initially rotated at a slow speed for at least 2 hours.

During complete shutdown of the equipment; the casing being in contact with the atmosphere loses heat more quickly and easily as compared to the turbine inside the casing. Hence this results to the casing cooling and contracting faster than the turbine inside the casing. This results in reduction of the turbine and casing clearance which is as less as 3-4mm and thus may cause damage to the equipment. To prevent this; the turbine is rotated at a slow speed for some time so as it loses heat along with the turbine.

Torque Convertor: It transmits and regulates the torque between the turning gear shaft and the compressor shaft.

Inlet Guide Vanes (IGV): IGV controls the combustion air which comes into the compressor. It is controlled by a hydraulic system which controls the rack and pinion mechanism which opens and closes so as to regulate the amount of air that is taken in.

Fuel Nozzle: Each combustion chamber is equipped with a fuel nozzle that emits a metered amount of fuel into the combustion liner. Gaseous fuel is admitted directly


Turning Gear

Torque Convertor

Cranking Motor

Combustion Chamber

C T

into each chamber through metering holes located at the outer edge of the swirl plate. When liquid fuel is used, it is atomized in the nozzle swirl chamber by means of high pressure air. The atomized fuel/air mixture is then sprayed into the combustion zone. Action of the swirl tip imparts a swirl to the combustion air with the result of more complete combustion and essentially smoke free operation of the unit.

Cross Fire Tubes: The 14 combustion chambers are interconnected by means of cross fire tubes, these crossfire tubes propagate the flame to other combustion chambers.

Spark Plugs: Combustion is initiated by means of the discharge from two high voltage, retractable electrode spark-plugs installed in adjacent combustion chambers. These 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 the chamber, the gases in the remaining chambers are ignited by cross-fire through the tubes that interconnect the reaction zones of remaining chambers. As rotor speed increases, chambers pressure causes the spark plugs to retract and the electrodes are removed from the combustion zones. The spark plugs are located at the combustion chamber 14 and 15.

UV Flame Detector: During the starting sequence, it is essential that an indication of the absence of flame to be transmitted to control system. For this reason, a flame monitoring system is used consisting of four sensors which are installed on tow adjustment combustion chambers and an electronic amplifier which is mounted in the Turbine control panel.

The ultraviolet flame sensor consists of flame sensor, containing a gas filled detector. The Gas within this flame sensor detector is sensitive to the presence of ultraviolet radiation which is emitted by a hydrocarbon flame. A DC voltage, supplied by amplifier, is impressed across the detector terminals. If flame is present, the ionization of gas in the detector allows conduction in the circuit which activates the electronics to give an output defining flame. Conversely, the absence of flame will generate an opposite output defining “No flame ".

The four flame detectors are located in the combustion chamber No 4, 5, 10, and 11 out of total 14 combustion chambers.


Turbine Nozzle: In the turbine section, there are three stages of stationary nozzles which direct the high velocity flow of the expanded hot combustion gas against the turbine buckets, causing the rotor to rotate. Because of the high pressure drop across these nozzles, there are seals at both the inside diameters and the outside diameters to prevent loss of system energy by leakage. Since these nozzles operate in the hot combustion gas flow, they are subjected to thermal stresses in addition to gas pressure loadings.

Diaphragms: Attached to the inside diameters of both the second and third stage nozzle segments are the nozzle diaphragms these diaphragms prevent air leakage past the inner sidewall of the nozzles and the turbine rotor. The high/low, labyrinth-type seal teeth are machined into the inside diameter of the diaphragm. They mate with opposing sealing lands on the turbine rotor. Minimal radial clearance between stationary parts (diaphragm and nozzles) and the moving rotor are essential for maintaining low interstage leakage; this results in higher turbine efficiency.

Shrouds: Unlike the compressor balding, the turbine bucket tips do not run directly against an integral machined surface of the casing but against annular curved segments called turbine shrouds.The primary function of the shrouds is to provide a cylindrical surface for minimizing tip clearance leakage. The secondary function is to provide a high thermal resistance between the hot gases and the comparatively cool shell. By accomplishing this function, the shell cooling load is drastically reduced, the shell diameter is controlled, the shell roundness is maintained, and important turbine clearances are assured. The shroud segments are maintained in the circumferential position by radial pins from the shell. Joints between shroud segments are sealed by interconnecting tongues and grooves.

Overview of SEZ CPP and Detailed Study of Gas Turbine 35Turbine first stage nozzle

18 cast nozzles (18*2)= 36

Turbine first stage nozzle

CONCLUSION

As stated in my report the SEZ CPP is the power hub of JERP. It is capable of supplying sufficient power to this plant as well as to DTA plant. It incorporates both, the generation and the distribution systems of the plant.

The plant has the most advanced world class systems as per the needs. It has been designed with the environmental sustainability and protection in mind. The well maintenance and proper protection of the machines is always taken care of. The safety is always considered the first priority in RIL.

I have gained a lot of knowledge in the field of industrial applications. I’m very much thankful to the finest industrial systems and the friendly and most organized working environment in RIL which has transformed my mere theoretical knowledge into solid understanding which is sure to be helpful throughout my life.


Stage 3 Nozzle

Stage2 nozzle3rd stg nozzle

16*4=64

Stage 2 Nozzle

Stage 2 Shroud Stage 1 Shroud

Stage 2 DiaphragmStage 3 Diaphragm

ZCPP VT Project Report

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Transcript of ZCPP VT Project Report