GPPC Report

INDUSTRIAL TRAINNING REPORT
On
GSPC PIPAVAV POWER COMPANY
Submitted in partial fulfillment towards the degree of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
Prepared By
ANKIT PANDYA (MH003, 15MHUOS057)

SANDEEP BALDANIYA (MH006, 15MHUBS083)
DHRUVIT VALA (MH026, 16MHUBD020)
DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF TECHNOLOGY
DHARMSINH DESAI UNIVERSITY, NADIAD
APRIL 2019
I
BONAFIDE CERTIFICATE
Certified that the industrial training report titled “GSPC PIPAVAV POWER
COMPANY” is the bonafide work of ANKIT PANDYA (Roll No. MH-003),
SANDIP BALDANIYA (Roll No. MH-006) and DHRUVIT VALA (Roll
No. MH026) (Bachelor of Technology in Mechanical Engineering, Semester
VIII, 2018-19) who carried out the industrial training under our supervision.
Prof. (Dr.) G. D. Bassan Prof. N.A. Vora

HEAD SUPERVISOR
Mechanical Engineering Department Assistant Professor
Faculty of Technology Mechanical Engineering Department
Dharmsinh Desai University Faculty of Technology
College Road Dharmsinh Desai University
Nadiad – 387 001 College Road
Gujarat Nadiad – 387 001, Gujarat
Mr. Naresh Ukani

INDUSTRY SUPERVISOR
Designation - Manager (HR)
Company name – GPPC , Kovaya
Company Address – Kovaya, Tal. Rajula - 365560
II
ABSTRACT
A combined cycle as the name implies is the combination of two cycles
operating at different temperature, each of which could operate independently.
The heat rejected by the higher temperature cycle is recovered and is used by
lower temperature cycle to produce additional power to realize an improved
overall efficiency. For the combination the separate cycle must operate on
separate fluids.
The most effective way of increasing the efficiency of a gas turbine based
power plant is to turn it into a combined cycle plant. The most common
configuration of this type involves adding a steam turbine bottoming cycle to
the gas turbine. Hot gases from the exhaust of the gas turbine are used to raise
steam in a heat recovery steam generator and this steam is used to drive a steam
turbine. The best plants of this type can achieve an energy conversion efficiency
of over 60%. More versatile combined cycle plants can be created by adding
additional heating by burning more natural gas in the steam generator.
III
ACKNOWLEDGEMENT
It is our pleasure to be indebted to various people, who directly or

indirectly contributed in the development of this work and who influenced
our thinking, behavior, and acts during the course of study.
We express our sincere gratitude to GSPC Pipavav Power Company

Ltd., KOVAYA for providing us an opportunity to undergo vocational
training.
We are thankful to Mr. Darshan Desai for his support, cooperation,

and motivation provided to us during the training for constant inspiration,
presence and blessings.
We also extend our sincere appreciation to Mr. Naresh Ukani, Mr.

Parthiv Oza, Mr. Chirag Patel and Mr. Rajnikant Parmar who provided his
valuable suggestions and precious time in accomplishing our vocational
training.
Lastly, we would like to thank the whole staff of the Mechanical

engineers of GPPC PLANT for lending us the helping hand at every point in
our training.
IV
TABLE OF CONTENTS
NO. TITLE PG NO.
ABSTRACT .................................................................................................................... I
ACKNOWLEDGEMENT .......................................................................................... IV
LIST OF FIGURE ......................................................................................................... X
LIST OF TABLES .................................................................................................... XIII
ABBREVIATIONS................................................................................................... XIV
1 Introduction .................................................................................................................. 15
2 Sea Water Intake System ............................................................................................. 16
3 Pre-Treatment Plant .................................................................................................... 17
3.1 Introduction: .......................................................................................................... 17
3.2 Cascade Aerator: ................................................................................................... 17
3.3 Stilling Chamber: .................................................................................................. 18
3.4 Flash Mixer: .......................................................................................................... 19
3.5 High Rate Solid Content Clarifier:........................................................................ 20
3.6 Dual Media Filter: ................................................................................................. 21
3.7 Blow Down Pit: ..................................................................................................... 22
3.8 Sludge Thickener: ................................................................................................. 22
4 RO-DM Plant ................................................................................................................ 24
4.1 Introduction: .......................................................................................................... 24
4.2 Pressure Sand Filter: ............................................................................................. 25
4.3 Membrane Cartridge Filter: .................................................................................. 26
4.4 Sea Water Reverse Osmosis: ................................................................................ 27
4.4.1 Understanding Reverse Osmosis: ........................................................... 27
4.4.2 How does Reverse Osmosis Work?:....................................................... 30
4.4.3 SWRO HP Feed Pump:........................................................................... 30
V
4.4.4 Energy Recovery Device: ....................................................................... 31
4.4.5 SWRO System : ...................................................................................... 31
4.5 Brackish Water Reverse Osmosis: ........................................................................ 32
4.6 Strong Acid Cation : ............................................................................................. 33
4.7 Strong Base Anions :............................................................................................. 35
4.8 Mixed Bed: ............................................................................................................ 36
5 Heat Recovery Steam Generator (HRSG) ................................................................. 38
5.1 HRSG Function : ................................................................................................... 38
5.2 HRSG Design:....................................................................................................... 39
5.3 HRSG Components:.............................................................................................. 40
5.3.1 Economizer : ........................................................................................... 40
5.3.2 Evaporator :............................................................................................. 40
5.3.3 Steam Drum : .......................................................................................... 40
5.3.4 Superheater : ........................................................................................... 40
5.4 HRSG Blow down : .............................................................................................. 41
5.4.1 Intermittent Blow Down : ....................................................................... 41
5.4.2 Continuous Blow Down : ....................................................................... 42
6 Boiler Feed Pump Building.......................................................................................... 43
6.1 Introduction: .......................................................................................................... 43
6.2 Deaerator: .............................................................................................................. 43
6.3 Flow path of DM water: ........................................................................................ 44
6.4 Pump and its parameter: ........................................................................................ 46
6.5 Dozing: .................................................................................................................. 46
6.5.1 Phosphate dozing: ................................................................................... 47
6.5.2 Ammonia and Hydrazine dozing: ........................................................... 47
7 Air Filtration System .................................................................................................... 48
7.1 Introduction: .......................................................................................................... 48
7.2 Weather hood and Trash Screens: ......................................................................... 48

VI
7.3 Pulse filter: ............................................................................................................ 49
8 Gas Turbine .................................................................................................................. 51
8.1 Introduction: .......................................................................................................... 51
8.2 Gas Turbine Parts: ................................................................................................. 51
8.2.1 Compressor: ............................................................................................ 52
8.2.2 Combustion Chamber: ............................................................................ 53
8.2.3 Turbine: ................................................................................................... 53
8.3 Working: ............................................................................................................... 53
8.4 Gas Turbine Performance: .................................................................................... 54
8.5 Gas Turbine Parameter: ........................................................................................ 55
9 Steam Turbine .............................................................................................................. 56
9.1 Introduction: .......................................................................................................... 56
9.2 Working: ............................................................................................................... 56
9.3 Condenser: ............................................................................................................ 57
9.4 Vacuum pump: ...................................................................................................... 59
9.5 Condensate extraction pump: ................................................................................ 59
9.6 Steam turbine parameter: ...................................................................................... 60
10 Cooling Tower ............................................................................................................... 62
10.1 Components of cooling tower ............................................................................... 62
10.2 Types of cooling tower ......................................................................................... 64
10.2.1 Induced draft counter flow cooling tower............................................... 64
10.3 Performance parameters :...................................................................................... 65
10.4 Cooling Tower Losses : ........................................................................................ 66
10.4.1 Blow down losses: .................................................................................. 66
10.4.2 Drift loss: ................................................................................................ 66
10.4.3 Evaporation Loss: ................................................................................... 66
10.5 Design Specification: ............................................................................................ 66
11 Pump House .................................................................................................................. 68

VII
11.1 Centrifugal pumps : ............................................................................................... 68
11.2 Horizontal axial split casing pumps : .................................................................... 69
11.3 RO-DM Pump House ............................................................................................ 69
11.4 Service Water Pump House .................................................................................. 71
11.5 Cooling Water Pump House ................................................................................. 72
11.6 Fire Water Pump House: ....................................................................................... 72
11.7 Clarified Water Pump House ................................................................................ 73
11.8 DMCW Pump: ...................................................................................................... 74
12 Maintenance .................................................................................................................. 76
12.1 Introduction: .......................................................................................................... 76
12.2 Vibration Analysis: ............................................................................................... 78
12.2.1 Introduction:............................................................................................ 78
12.2.2 Positioning of Probe: .............................................................................. 78
12.2.3 Case Study: ............................................................................................. 80
12.3 Alignment: ............................................................................................................ 83
12.3.1 Introduction :........................................................................................... 83
12.3.2 Tools Used for Alignment: ..................................................................... 83
12.3.3 Case Study: ............................................................................................. 85
12.4 FRP Coating .......................................................................................................... 87
12.4.1 What Is FRP Coating? ............................................................................ 87
12.4.2 FRP Coating Applications ...................................................................... 87
12.4.3 Methods of applying FRP: ...................................................................... 87
12.4.4 FRP Lining Application Approach ......................................................... 88
12.4.5 Case Study: ............................................................................................. 89
12.5 Hydro test: ............................................................................................................. 92
12.5.1 Introduction:............................................................................................ 92
12.5.2 Equipment used: ..................................................................................... 92
12.5.3 Case Study: ............................................................................................. 95

VIII
12.6 Flame Cleaning: .................................................................................................... 95
12.6.1 Introduction:............................................................................................ 95
12.6.2 Case study: .............................................................................................. 96
12.7 Tube Cleaning: ...................................................................................................... 97
12.7.1 Introduction:............................................................................................ 97
12.7.2 Case Study: ............................................................................................. 98
13 Conclusion ..................................................................................................................... 99
REFERENCES ..................................................................................................................... 100
IX
LIST OF FIGURE
Figure 1-1 Gas based thermal power plant layout ................................................................... 15

Figure 2-1 Sea Water Intake Pump travelling water screen .................................................... 16
Figure 3-1 Overall PT Process ................................................................................................. 17
Figure 3-2 Cascade Aerator ..................................................................................................... 18
Figure 3-3 Stilling Chamber .................................................................................................... 18
Figure 3-4 Parshall Flume ........................................................................................................ 19
Figure 3-5 Flash Mixer ............................................................................................................ 19
Figure 3-6 Solid Content Clarifier ........................................................................................... 20
Figure 3-7 Solid Content Clarifier ........................................................................................... 20
Figure 3-8 Dual Media Filter ................................................................................................... 21
Figure 3-9 Blow Down Pit ....................................................................................................... 22
Figure 4-1 RO-DM Process Flow Diagram ............................................................................. 24
Figure 4-2 PSF - A ................................................................................................................... 25
Figure 4-3 PSF – D .................................................................................................................. 25
Figure 4-4 Membrane Cartridge Filter ..................................................................................... 26
Figure 4-5 Static Mixer ............................................................................................................ 27
Figure 4-6 Osmosis .................................................................................................................. 28
Figure 4-7 Reverse Osmosis .................................................................................................... 29
Figure 4-8 Working of Reverse Osmosis System .................................................................... 30
Figure 4-9 Energy Recovery Device........................................................................................ 31
Figure 4-10 SWRO System ..................................................................................................... 32
Figure 4-11 BWRO System ..................................................................................................... 33
Figure 4-12 Strong Acid Cation............................................................................................... 34
Figure 4-13 Strong Base Anion ............................................................................................... 35
Figure 4-14 Mixed Bed ............................................................................................................ 36
Figure 5-1 Heat Recovery Steam Generator (HRSG).............................................................. 38
Figure 5-2 HRSG Design ......................................................................................................... 39
Figure 5-3 Intermittent Blow down Tank ................................................................................ 41
Figure 5-4 Continuous Blow Down Tank ................................................................................ 42
Figure 6-1 Schematic Diagram of BFP Building ..................................................................... 43
Figure 6-2Deaerator ................................................................................................................. 44
X
Figure 6-3 Actual Deaerator .................................................................................................... 44

Figure 6-4 Hydraulic Coupling ................................................................................................ 45
Figure 6-5 Lube cooler and Working Oil Cooler..................................................................... 45
Figure 6-6 Booster pump ......................................................................................................... 46
Figure 6-7 Phosphate dozing tank............................................................................................ 47
Figure 6-8 Hydrazine Dozing Tank and Ammonia Dozing Tank ......................................... 47
Figure 7-1 weather hood .......................................................................................................... 48
Figure 7-2 Trash screen filter ................................................................................................... 49
Figure 7-3 Cylindrical and Conical pulse filter ....................................................................... 49
Figure 7-4 Cleaning of pulse filter ........................................................................................... 50
Figure 8-1 Brayton cycle ......................................................................................................... 51
Figure 8-2: Gas turbine basic parts .......................................................................................... 52
Figure 8-3 Gas Turbine Compressor........................................................................................ 52
Figure 8-4: Gas turbine Burner ................................................................................................ 53
Figure 8-5 Working of gas turbine........................................................................................... 54
Figure 9-1 Steam Turbine ........................................................................................................ 56
Figure 9-2 Rankine cycle ......................................................................................................... 56
Figure 9-3 Multistage Steam turbine ....................................................................................... 57
Figure 9-4 Condenser ............................................................................................................... 57
Figure 9-5 One shell Two tube type heat exchanger ............................................................... 58
Figure 9-6 Vacuum pump ........................................................................................................ 59
Figure 9-7 Condensate Extraction Pump ................................................................................. 60
Figure 10-1 Cooling Tower ..................................................................................................... 62
Figure 10-2 Nozzle .................................................................................................................. 63
Figure 10-3 Cold Water Basin ................................................................................................. 63
Figure 10-4 CT Fan .................................................................................................................. 63
Figure 10-5 Splash Fill Fins..................................................................................................... 64
Figure 10-6 Induced draft counter flow cooling tower ............................................................ 65
Figure 11-1 Centrifugal Pump ................................................................................................. 68
Figure 11-2 Horizontal Axial Split Casing Pump .................................................................... 69
Figure 11-3 RO-DM Pump House ........................................................................................... 70
Figure 11-4 Service Water Pump House ................................................................................. 71
Figure 11-5 CW Pump ............................................................................................................. 72
Figure 11-6 Hydrant Pump ...................................................................................................... 73
XI
Figure 11-7 Jockey Pump ........................................................................................................ 73

Figure 11-8 Clarified Water Pump .......................................................................................... 74
Figure 11-9 DMCW Pump....................................................................................................... 75
Figure 12-1 Vibrometer ........................................................................................................... 78
Figure 12-2 Measuring point of bearing stand ......................................................................... 79
Figure 12-3 Measuring point of inbuilt bearing ....................................................................... 79
Figure 12-4 Probe Positioning in pump and motor assembly .................................................. 79
Figure 12-5 Probe Positioning across three planes .................................................................. 80
Figure 12-6 Horizontally positioned probe .............................................................................. 81
Figure 12-7 Vertically Positioned Probe.................................................................................. 81
Figure 12-8 Axially Positioned Probe ..................................................................................... 82
Figure 12-9 Dial Gauge ........................................................................................................... 84
Figure 12-10 Horizontal Alignment Bolts ............................................................................... 84
Figure 12-11 Base Plates for Vertical Alignment .................................................................... 85
Figure 12-12 Positioning of Base Plate ................................................................................... 85
Figure 12-13 PSF Backwash Pump ......................................................................................... 86
Figure 12-14 Dial Gauge Values (Radial) ............................................................................... 86
Figure 12-15 Dial Gauge Values (Axial) ................................................................................ 86
Figure 12-16 Resin and FRP Mat ............................................................................................ 89
Figure 12-17 FRP Surface and Hardener ................................................................................. 89
Figure 12-18 Worker Applying Resin Mat Mixture ................................................................ 90
Figure 12-19 Worker applying FRP coatings to isolation gates. ............................................. 90
Figure 12-20 Loaders before Coating ...................................................................................... 91
Figure 12-21 Loaders after Coating ......................................................................................... 91
Figure 12-22 Triplex Plunger Pump ........................................................................................ 93
Figure 12-23 High Pressure Hose Pipe .................................................................................... 94
Figure 12-24 Nozzle Tip .......................................................................................................... 94
Figure 12-25 Oxy-Acetylene Flame ........................................................................................ 96
Figure 12-26 Cleaning of Strainer by Flame ........................................................................... 96
Figure 12-27 Bending of Strainer blade................................................................................... 97
Figure 12-28 After heating and hammering condition of blade ............................................. 97
Figure 12-29 Tube Cleaning of condenser............................................................................... 98
Figure 12-30 Tube Cleaning of Heat exchanger ...................................................................... 98
XII
LIST OF TABLES
Table 2-1 Sea Water Intake Pump Specifications.................................................................... 16

Table 3-1 HRSCC Description ................................................................................................ 21
Table 3-2 DMF Description ..................................................................................................... 22
Table 4-1 Turbidity change after pressure sand filter .............................................................. 26
Table 4-2 Turbidity change after MCF .................................................................................... 27
Table 4-3 Conductivity changes after SWRO ......................................................................... 32
Table 4-4 Conductivity changes after BWRO ......................................................................... 33
Table 4-5 Conductivity and PH changes after SAC ................................................................ 34
Table 4-6 Conductivity and PH changes after SBA ................................................................ 35
Table 4-7 Conductivity and PH changes after MB .................................................................. 36
Table 6-1 Pumps and their parameters..................................................................................... 46
Table 8-1 Gas Turbine Parameter ............................................................................................ 55
Table 9-1 Condenser design specifications.............................................................................. 58
Table 9-2 CEP parameter ......................................................................................................... 59
Table 9-3 Steam turbine parameter .......................................................................................... 60
Table 10-1 Design Specifications of cooling tower ................................................................. 66
Table 11-1 Specifications of RO-DM Pump House ................................................................ 70
Table 11-2 Specification of Service Water Pump House ........................................................ 71
Table 11-3 Specification of Cooling Water Pump House ....................................................... 72
Table 11-4 Specification of Fire Water Pump House .............................................................. 73
Table 11-5 Specification of Clarified Water Pump House ...................................................... 74
Table 11-6 DMCW Pump Specifications ................................................................................ 75
Table 12-1 Types of Maintenance Strategies........................................................................... 77
Table 12-2 Vibrational Velocity of DM Transfer Pump A...................................................... 82
XIII
ABBREVIATIONS
 DMST : Demineralized Storage Tank

 CWST : Cooling Water Storage Tank
 FWST : Filter Water Storage Tank
 DMF : Dual Media Filter
 PSF : Pressure Sand Filter
 SWRO : Sea Water Reverse Osmosis
 BWRO : Brackish Water Reverse Osmosis
 MCF : Micron Cartridge Filter
 HRSG : Heat Recovery Steam Generator
 BFP : Boiler Feed Pump
 GT : Gas Turbine
 ST : Steam Turbine
 CT : Cooling Tower
 PT : Pre-Treatment
 CST : Condensate Storage Tank
 CW : Cooling Water
 ACW : Auxiliary Cooling Water
 DMCW : Demineralized Cooling Water
 HRSCC : High Rate Solid Content Clarifier
 FM : Flash Mixer
 SC : Stilling Chamber
 PF : Parshall Flume
XIV
1 Introduction
GSPC Pipavav Power Company Ltd. (GPPC) is public limited company incorporated under
the Companies Act 1956. The company is jointly promoted by Gujarat State Petroleum
Corporation Ltd. (GSPC) and Gujarat Power Corporation Limited (GPCL) in year 2006.
Figure 1-1 Gas based thermal power plant layout [1]
GPPC is a 2x351.43 MW Combined Cycle Power Plant Using Natural Gas as Fuel, is located
at Kovaya village, a rural area, situated in Amreli District, Gujarat State, about 18 KM from
Rajula. A district road connecting the state highway no. SH 34 and running between Rajula
and Jafrabad is the main access road to site at present. The nearest National Highway is NH –
8E, running East – West from Porbandar on the coast to Rajkot. This is at a distance of about
6 km from the state highway. The site has about 125 hectares of land bank.
The installed generation capacity of the plant is 702.86 MW can be achieved through two
units of Gas turbine with 222 MW Capacity and a steam Turbine with 129.43W Capacity
each. The gas turbine is connected with Heat Recovery steam Generator (HRSG) and the
steam turbine put together is called “Combined Cycle”. The gas turbine is designed for firing
on fuel as Natural gas .The generated power is fed to the GETCO (Gujarat Energy
Transmission Company Limited) grid through the network system erected in the plant. For
Natural Gas there is no storage and the Gas, which is drawn through pipe lines by GSPL
(Gujarat State).
15
2 Sea Water Intake System
Sea water intake system draws water from the sea and supply to plant. Raw water is treated
and supplied for plant needs. Raw water is used in Cooling tower (CW system), CCW
system, ACW system, fire fighting system, DM Water plant, Service water etc.
Figure 2-1 Sea Water Intake Pump travelling water screen
Sea water intake pump house helps to flow water through pump from Arabian sea to pre-
treatment plant. There are two intake and one outlet line (4m depth and 1km away from pump
house) having Dia. 1200mm, from intake pipe line the water enters in the sump. From sump
the water enters in the travelling water screen which cleans the water by removing or
screening out any debris such as algae, sticks, leaves and aquatic life such as fish. For
removing such debris air spray system is used, in which flow of air in travelling water screen
is done in reverse direction. The water is then stored in the sump and from sump the pump
helps to flow water further towards pre-treatment plant. There are four vertical pump in the
pump house (two in operation and two in standby condition). The capacity of pump is 1900
cubic meter / hour.
Table 2-1 Sea Water Intake Pump Specifications [7]
SEA WATER INTAKE PUMP

DISCHARGE (m3/hr) HEAD (m) SPEED (RPM) POWER (KW)
1900 26 1478 200
16
3 Pre-Treatment Plant
3.1 Introduction:
The sea water in the Arabian Sea contains suspended solids as well as dissolved solids like
minerals, chemicals and micro particles which cannot be directly used as cooling water or
generating steam as it can damage the pipes carrying water. So, the water must be first treated
before using for the power generation process. Out of the Total Solids, the Pre-Treatment
Plant removes Suspended Solids from Water. PT Plant constitutes Cascade Aerator, Clarifier,
Stilling Chamber and Flash Mixer.
Figure 3-1 Overall PT Process
3.2 Cascade Aerator:
Aeration is the generally the first process in the Pre Treatment Plant. In this process, water is
allowed to mix with air in order to remove dissolved gases and metals. The Water enters to
the centre of the Aerator through the Sea Water Intake System with a flow of 3200 m3 /hr
through the motorized position controlled valve. The water is allowed to fall to different
circular trays as shown above. The dissolved gases present in water, are removed due to the
turbulence introduced in the process. The Oxygen present in air reacts with the dissolved
metals and forms metal oxides which can be removed in the subsequent processes.
17
Figure 3-2 Cascade Aerator
3.3 Stilling Chamber:
After aeration process, the water enters the Stilling Chamber for DM(1W) &
CW1/2(1W+1SB) where hypochlorite (Chlorine) is dosed for pre-chlorination. The Water
then enters the Parshall Flume which is similar to a Convergent-Divergent Nozzle as shown
in the figure below.
Figure 3-3 Stilling Chamber
18
Figure 3-4 Parshall Flume
The Parshall Flume is used as a rapid mixing device which increases flow rate and turbulence
for proper mixing of the chemicals in the subsequent steps.
3.4 Flash Mixer:
The water after coming out of the Parshall Flume is sent to the Flash Mixers where Lime
& FeCl3 (CW1/2) & FeCl3 (DM) solution is mixed with the sea water which helps to
coagulate water and thus increase the mass and size of suspended solids.
Figure 3-5 Flash Mixer
The Mixer contains a rotating fan which mixes different chemicals and water, it also contains
an air blower for proper mixing. The water is then passed to the Clarifier.
19
3.5 High Rate Solid Content Clarifier:
After passing through the Flash Mixer, the water containing coagulated particles is allowed to
rest in a large Tank known as High Rate Solid Content Clarifier.
Figure 3-6 Solid Content Clarifier
The water enters through the bottom of the Tank and fills the Tank. The turbo drive motor is
connected with a Fan which mixes the water properly. The heavy Coagulated Particles settle
at the bottom in the form of sludge and the light particles float at the top known as Scum. The
Sludge is not allowed to settle in the bottom of the tank with the help of Scrapper rotating at
a slow speed. With sludge at the bottom and scum in the centre top, the pure water enters
through the channel connected with a central hub as shown in the figure below.
Figure 3-7 Solid Content Clarifier

20
After passing through the clarifier, the turbidity of water is reduced from 50-100 to 10 NTU
and thus is stored in a storage tank known as Cooling Water Storage Tank (CWST) having
capacity of 9,800 m3. There are in total three HRSCC; two for CWST and one for DWST(De-
mineralised water storage Tank).
Table 3-1 HRSCC Description [7]
S.NO DESCRIPTION CAPACITY

1. Number of clarifier for CW stream. Two (1w + 1s)
2. Net Output Capacity Of each High Rate Solid Contact 2400 m3 /hr
Clarifier (HRSCC) For CW Stream.
3. Number of clarifier for DM stream. One (1w)
4. Net Output Capacity Of High Rate Solid Contact 732 m3 /hr
Clarifier (HRSCC) For DM Stream.
3.6 Dual Media Filter:
The Water from DWST is passed to the Dual Media Filter through two Centrifugal Feed
Pumps. There are total 6 Dual Media Filters out of which five are working and one is
standby. The Water enters from the top of the tank and is passed through dual media filter
layer consisting of anthracite coal and sand particles. The Filtered water enters to the Filtered
Water Storage Tank (FWST) having capacity of 12,500 m3.
Figure 3-8 Dual Media Filter

21
Table 3-2 DMF Description [7]
S.NO. DESCRIPTION CAPACITY

1. Total Number of Dual Media Filter 6(5W+1S)
2. Net Output Capacity Of Dual Media 750 m3 /hr (150× 5𝑊)
Filters For DM Stream
After passing through the Dual Media Filter, the Turbidity of water is reduced to 2 NTU.
3.7 Blow Down Pit:
The remaining sludge with water in HRSCC is pumped in the blow down pit. With the help
of blower (dual lobe type) air scoring in the blow down pit is done. From blow down pit the
water is send in the sludge thickener.
Figure 3-9 Blow Down Pit
3.8 Sludge Thickener:
This process involves the concentration of thin sludge to more dense sludge in special
circular tanks designed for this purpose. Its use is largely restricted to the watery excess
sludge from the activated sludge process. It may also be used to concentrate sludge to
primary tanks or a mixture of primary and excess activated sludge prior to high rate digestion.
The thickening tank is equipped with slowly moving vertical paddles built like a picket
fence. Sludge is usually pumped continuously from the settling tank to the thickener which
has a low overflow rate so that the excess water overflows and the sludge solids concentrate
22
in the bottom. A blanket of sludge is maintained by controlled removal which may be

continuous at a low rate. A sludge with a solids content of 8 -10 percent or more can be
produced by this method. A gravity thickener is similar to a conventional sedimentation tank
in design, but has a more steep floor slope. Tanks range from 6 – 20 m dia. & side water
depth (SWD) may vary from 3 – 4 m. Floor slope is varies from 1:4 to 1:6 depending upon
the type of sludge, time required for thickening & storage volume to absorb peak solids load.
23
4 RO-DM Plant
4.1 Introduction:
After removing the suspended solids from water and achieving turbidity level to 2 NTU , the
next step is to remove the dissolved solids in water which is achieved in the RO-DM Plant.
The purpose of RO (Reverse Osmosis) system is to further reduce turbidity and conductivity
to acceptable levels while the purpose of DM (Demineralisation) system is to remove the
cations and anions of various salts present in water and thus reduce hardness of water.
The Plant Consists of Mainly two sections:
RO Plant DM Plant
 PSF – Pressure Sand Filter  SAC – Solid Acid Cation
 MCF – Membrane Cartridge Filter  SBA – Solid Base Anion
 SWRO – Sea Water Reverse Osmosis  MB – Mixed Bed
 BWRO – Brackish Water Reverse Osmosis
Figure 4-1 RO-DM Process Flow Diagram
24
4.2 Pressure Sand Filter:

Water from the Filtrate Water Storage Tank is pumped to the PSF vessels with the help of
Filtrate Water Pump House. Like DMFs, PSFs are vertical vessels containing minute sand
particles on which water at high pressure enters from the top and low turbidity water is
obtained at the output. There are total 8 PSF out of which 6 are working and 2 are in standby
condition.
Figure 4-2 PSF - A
Figure 4-3 PSF – D
25
The enters from the input header as shown in the figure to the top of the PSF at a cumulative
flow rate of 330 m3 /hr. Output is taken from the bottom and is connected to the output header
which eventually leads water to the MCF for further process.
Table 4-1 Turbidity change after pressure sand filter [7]
INPUT OUTPUT
0.4 ppm 0.2 ppm
4.3 Membrane Cartridge Filter:

After coming from the PSFs, the water flow gets divided into three pipes which leads to three
Membrane Cartridge Filter as shown in the figure below.
Figure 4-4 Membrane Cartridge Filter
26
Each MCF contains 9 cartridge filters through which water enters from the sides and is
collected from the middle portion. The resulting output water has negligible turbidity and is
ready for the desalination process.
The water before entering into the SWRO, is sent to the static mixer where proper chemicals
are added for the purification of water and then through a common pipe, water is sent to
SWRO through HP pump.
Figure 4-5 Static Mixer
Table 4-2 Turbidity change after MCF [7]
INPUT OUTPUT
0.2 ppm 0.001 ppm
4.4 Sea Water Reverse Osmosis:

4.4.1 Understanding Reverse Osmosis:
Reverse Osmosis, commonly referred to as RO, where you demineralize or deionise

water by pushing it under pressure through a semi-permeable Reverse Osmosis
Membrane.
27
To understand the purpose and process of Reverse Osmosis you must first understand
the naturally occurring process of Osmosis.
Osmosis is a naturally occurring phenomenon and one of the most important processes
in nature. It is a process where a weaker saline solution will tend to migrate to a strong
saline solution. Examples of osmosis are when plant roots absorb water from the soil
and our kidneys absorb water from our blood.
Figure 4-6 Osmosis [8]
Above is a diagram which shows how osmosis works. A solution that is less
concentrated will have a natural tendency to migrate to a solution with a higher
concentration. For example, if you had a container full of water with a low salt
concentration and another container full of water with a high salt concentration and
they were separated by a semi-permeable membrane, then the water with the lower salt
concentration would begin to migrate towards the water container with the higher salt
concentration.
A semi-permeable membrane is a membrane that will allow some atoms or molecules

to pass but not others. A simple example is a screen door. It allows air molecules to
pass through but not pests or anything larger than the holes in the screen door. Another
28
example is Gore-Tex clothing fabric that contains an extremely thin plastic film into
which billions of small pores have been cut. The pores are big enough to let water
vapour through, but small enough to prevent liquid water from passing.
Reverse Osmosis is the process of Osmosis in reverse. Whereas Osmosis occurs

naturally without energy required, to reverse the process of osmosis you need to apply
energy to the more saline solution. A reverse osmosis membrane is a semi -permeable
membrane that allows the passage of water molecules but not the majority of dissolved
salts, organics, bacteria and pyrogens. However, you need to 'push' the water through
the reverse osmosis membrane by applying pressure that is greater than the naturally
occurring osmotic pressure in order to desalinate (demineralize or deionize) water in
the process, allowing pure water through while holding back a majority of
contaminants.
Below is a diagram outlining the process of Reverse Osmosis. When pressure is

applied to the concentrated solution, the water molecules are forced through the semi -
permeable membrane and the contaminants are not allowed through.
Figure 4-7 Reverse Osmosis [8]
29
4.4.2 How does Reverse Osmosis Work?:
Reverse Osmosis works by using a high pressure pump to increase the pressure on the salt
side of the RO and force the water across the semi-permeable RO membrane, leaving almost
all (around 95% to 99%) of dissolved salts behind in the reject stream. The amount of
pressure required depends on the salt concentration of the feed water. The more concentrated
the feed water, the more pressure is required to overcome the osmotic pressure.
The desalinated water that is demineralized or deionized, is called permeate (or product)
water. The water stream that carries the concentrated contaminants that did not pass through
the RO membrane is called the reject (or concentrate) stream.
Figure 4-8 Working of Reverse Osmosis System [8]
As the feed water enters the RO membrane under pressure (enough pressure to
overcome osmotic pressure) the water molecules pass through the semi -permeable
membrane and the salts and other contaminants are not allowed to pass and are
discharged through the reject stream (also known as the concentrate or brine stream),
which goes to drain or can be fed back into the feed water supply in some
circumstances to be recycled through the RO system to save water. The water that
makes it through the RO membrane is called permeate or product water and usually has
around 95% to 99% of the dissolved salts removed from it.
4.4.3 SWRO HP Feed Pump:
Going with the water circuit, the water coming from the MCFs enters into high pressure
SWRO feed pumps. The pumps are of multistage type which eventually provides an output
pressure of 30 bar and the water is sent to the SWRO for the desalination process. But, before
entering into SWRO, water enters into a device known as Energy Recovery device (ERD).
30
4.4.4 Energy Recovery Device:
As discussed above, SWRO rejects large amounts of concentrate which contains enough
pressure energy which can be used in the Reverse Osmosis process. The devices which
provides this energy is called Energy Recovery Device.
Figure 4-9 Energy Recovery Device
In simple words, an ERD is a device which contains a shaft whose one end is connected with
a turbine and the other is connected with an impeller. The concentrate water which is rejected
enters into the ERD from the turbine side and thus powers the impeller on the other side of
the shaft. The water coming from the SWRO HP Pump enters into the ERD from the impeller
side and thus gets pressurised even further providing the output pressure to approximately 49
bar from 30 bar.
Thus an ERD recovers waste energy which could have been otherwise rejected and thus
eventually improves performance and efficiency of the plant.
4.4.5 SWRO System :
Water with an effective pressure of 49 bar and a flow rate of 320 𝐦𝟑 /hr enters into a
network of RO Membranes as shown in figure 2-10. The water enters from the sides and the
permeate is collected from the centre. Permeate from each Membrane then enters into a tank
31
on the top of the structure known as Suck Back Tank. The water then enters into a final tank
known as SWRO Permeate Tank.
Figure 4-10 SWRO System
There are total three structures each containing a network of 31 Membranes as shown above.
The water enters at a flow rate of 320 𝐦𝟑 /hr, while the permeate flow rate at the output of
SWRO is 112 𝐦𝟑 /hr. Thus, the water recovery of the current system is 35 %.
Table 4-3 Conductivity changes after SWRO [7]
INPUT OUTPUT
50,000 µS/cm 1000 µS/cm
4.5 Brackish Water Reverse Osmosis:
The BWRO system is similar to the SWRO system, but it contains specialized brackish water
membranes designed to process water with higher salt concentrations and under higher
pressure than the membranes used for SWRO.
The Water after coming from the SWRO gets collected in the SWRO Permeate Tank, from
where it is sent to the BWRO system with the help of BWRO feed pump. The water after
32
reaching the BWRO system is pressurized further with the help of Vertical inline pumps and
is sent to the Membranes for the RO Process.
Figure 4-11 BWRO System
Table 4-4 Conductivity changes after BWRO [7]
INPUT OUTPUT
2000 µS/cm 50 µS/cm
The Water after coming from the BWRO is stored in the BWRO Permeate Tank.
4.6 Strong Acid Cation :
After reducing the salinity of water, now it needs to be de-ionised. Cations and anions of
various salts present in water like carbonates, nitrates of calcium, magnesium, etc. needs to be
removed to make the water usable for the power plant. Thus it is done step by step in the DM
Plant which starts with the SAC (Strong Acid Cation) system.
33
In SAC, the Calcium and Barium cations are exchanged with Sodium Cations when the water
flows through the cation resin bed inside the vessel. Thus the hardness of water is removed
with the help of SAC.
There are total two SAC vessels out of which one is working and one is in standby condition.
Figure 4-12 Strong Acid Cation
Table 4-5 Conductivity and PH changes after SAC[7]
INPUT OUTPUT
Conductivity - 50,000 µS/cm Conductivity - 1000 µS/cm
PH – 7.0 PH – 4.6
34
4.7 Strong Base Anions :
Once the specified conductivity is obtained, the water is directed towards Strong Base Anions
to remove the basic anions and other organics from water by passing it through SBA resin
bed in the vessel.
There are total two SBAs, out of which one is working and another is in standby condition.
Figure 4-13 Strong Base Anion
Table 4-6 Conductivity and PH changes after SBA [7]
INPUT OUTPUT
Conductivity - 70 µS/cm Conductivity - 3 µS/cm
PH – 4.2 PH – 5.6
35
4.8 Mixed Bed:
After passing through the SBA, and reaching the specified conductivity and PH levels, the
water is passed to the last stage of the DM process which is Mixed Bed.
Mixed Bed vessel contains both cationic and anionic resins which eventually removes the
final traces of cations and anions present in the water and thus completes the DM process.
There are total two MBs, out of which one is in standby and the other is in working condition.
Figure 4-14 Mixed Bed
Table 4-7 Conductivity and PH changes after MB [7]
INPUT OUTPUT
Conductivity – 3 µS/cm Conductivity – 1 µS/cm
PH – 5.6 PH – 5.5
36
Water after the DM process, is discharged and stored in two DMST tanks. The RO-DM
process is now complete and the water stored in DMST tanks is ready for use in the power
generation process. The water in the DMST is pumped to the CST with the help of three DM
Transfer Pumps.
37
5 Heat Recovery Steam Generator (HRSG)
Figure 5-1 Heat Recovery Steam Generator (HRSG)
5.1 HRSG Function :
The exhaust gas from the combustion turbine becomes the heat source for the Rankine cycle
portion of the combined cycle. Steam is generated in the heat recovery steam generator
(HRSG). The HRSG recovers the waste heat available in the combustion turbine exhaust gas.
The recovered heat is used to generate steam at high pressure and high temperature, and the
steam is then used to generate power in the steam turbine/generator.
The HRSG is basically a heat exchanger composed of a series of preheaters (economizers),

evaporator, reheaters, and super heaters. The HRSG also has supplemental firing in the duct
that raises gas temperature and mass flow.
This section is intended to provide turbine operators with a basic understanding of heat
recovery steam generator (HRSG) design and operation.
38
5.2 HRSG Design:

The heat is converted into usable steam by the heat transfer surfaces within the HRSG. The
usable steam is generated in three separate and different pressure levels for use in a steam
turbine (ST) generator set.
The pressure levels and their associated components are :
 High pressure (HP)

 Intermediate pressure (IP)
 Low pressure (LP)
 Reheat (RH)
 Feed water preheater (FWPH)
Since we are operating a triple-pressure system of HP, IP, and LP, we have these components
for each associated pressure. These components (except drum) are arranged in series in the
gas flow path within the HRSG. Essentially, this means that the heat transfer boiler circuits
are not in parallel with one another with respect to GT exhaust gas flow. The gas, after
having been used to heat the water/steam in the HRSG is released to the environment through
a stack.
Figure 5-2 HRSG Design [9]
39
5.3 HRSG Components:
There are main four parts in HRSG :
5.3.1 Economizer :
The first major HRSG circuit component is the economizer. An economizers function is to
increase water temperature to an "approach" temperature near the saturation temperature.
Approach temperature is carefully chosen to ensure maximum heat energy absorption
efficiency and operational flexibility
5.3.2 Evaporator :
Evaporator sections are where the boiling process or steam generation occurs. As heat energy
is absorbed by water from the gas stream, the water temperature increases. When water
reaches the boiling point or saturation temperature, some of the water evaporates or vaporizes
to steam. The evaporator sections are single-pass, two- and three-row modules. The single
pass is on the water side and is vertically up. The modules feed a steam/water mixture to the
riser pipes. The modules are fed with water from the down comer/feeder header assembly to
replace the water exiting as a steam/water mixture
5.3.3 Steam Drum :
In the steam drum, saturated steam is separated from the steam/water mixture. The separated
steam rises up through the drum as feed water enters the drum from the economizer. The
separated water from the steam/water mixture is then recirculated together with the feed
water to the heat absorbing evaporator tubes through the circulation loop. The steam/water
separation is done through a combination of gravity and mechanical components.
5.3.4 Superheater :
The last major component of a steam generator circuit is the superheater. The major function
of a superheater is to increase steam temperature above saturation. High steam temperature
minimizes the introduction of water as liquid to the steam turbine and improves steam cycle
efficiency. The superheater absorbs heat energy from the GT exhaust gas and transfers this
energy to the steam. The superheater sections typically have the highest metal temperatures in
the HRSG. Superheater sections are composed of extended or finned tube surface modules.
40
5.4 HRSG Blow down :

All dissolved and suspended solid with feed water entering on to the boiler remains in to the
boiler drum as steam is generated. With continuous supply of water, the concentration of
impurities increases. The control of concentration of impurities in the water when internal
treatment is used is obtained by blowing off some of the water. Draining of the water
containing excessive concentrated solid and replacing the same with new fresh water which
keeps the solid concentration within the limits. This process is known as blowing down and
discharge water is known as blow down.
There are basically two types of blow down:

5.4.1 Intermittent Blow Down :
In this, the blow down is carried out intermittently through the blow down valve located in
the lowest part of circulation system. This is done periodically after each and every 4 to 8 hrs.
It is useful for low capacity and low-pressure boiler having small blow down rate.
Disadvantages :
 There is waste of heat energy carried with blow down.
 The control of boiler water concentration is irregular
 The operator has to follow rigid schedule otherwise priming, foaming and
carryover may happen.
Figure 5-3 Intermittent Blow down Tank
41
5.4.2 Continuous Blow Down :
The continuous blow down system is adopted to overcome the disadvantage of intermittent
blow down process.
Figure 5-4 Continuous Blow Down Tank
42
6 Boiler Feed Pump Building

6.1 Introduction:
BFP (Boiler Feed Pump) Building is a place where numbers of pump are present. It
contains number of pump, flow control system and dozing tank. From BFP Building water is
supply to HP, IP and LP Drum. Schematic diagram of BFP Building is as shown below.
Figure 6-1 Schematic Diagram of BFP Building
6.2 Deaerator:
A deaerator is a device that removes oxygen and other dissolved gases from water.
43
Figure 6-2 Deaerator [3]
Dissolved oxygen in feed water will cause serious corrosion damage in boiler walls or
metal piping and other equipment and produce rust.
Figure 6-3 Actual Deaerator
Deaerator works on principal that as ‘temperature increases, the solubility of gas will
decrease’. As the temperature of water increase oxygen or any other dissolved gases are
separated from water and is escaped from vent provided on top.
6.3 Flow path of DM water:

As show in figure 3-1 water from hot well is supplied to deaerator by condensate
extraction pump, Then it feeds in to FWST. For compensating the losses, DM water is
supplied from CST (condensate storage tank) by using hotwell makeup pump.
From FWST, DM water is directly supplied to LP drum by using ‘LP BFP’, Flow is
controlled by flow control system. DM Water from FWST is also supplied to the Booster
pump. Outlet of booster pump feeds into ‘HP/IP BFP’. From HP/IP BFP water is supplied to
HP or IP Drum. Flow is controlled by control valve or flow control system.
44
Hydraulic coupling is used to connect motor and BFP pump shaft. Reason behind
that, is to transmit the power under fluctuation of load. Under variation of load it is able to
transmit power without break.
Figure 6-4 Hydraulic Coupling
There is no mechanical interconnection between the impeller and the rotor (i.e. the
driving and driven units) and the power is transmitted by virtue of the fluid filled in the
coupling. The impeller when rotated by the electric motor imparts velocity and energy to the
fluid, which is converted into mechanical energy in the rotor thus rotating it.
Oil is used as working medium in hydraulic coupling. During working condition

temperature of oil will increase. So, working oil cooler is used. It is a shell and tube type heat
exchanger in which heat transfer is done between oil and DM water.
Lube cooler is used to cool lubrication oil. Lubrication oil is used to transfer heat
generated in electric motor and hydraulic coupling. Heat absorbed by lube oil is transferred to
DM water by shell and tube type heat exchange or lube cooler.
Figure 6-5 Lube cooler and Working Oil Cooler

45
Booster pump and HP/IP BFP pump driven by same electric motor. Requirement of
booster pump is to increase the input head of HP/IP BFP pump.
Figure 6-6 Booster pump
6.4 Pump and its parameter:

Table 6-1 Pumps and their parameters [7]
Flow rate Head Speed

Type
(m3/hr) (m) (rpm)
HP/IP pump Centrifugal 420 2012 4970
LP pump Centrifugal 50 165 2960
Booster pump Centrifugal 420 103 1465

Hot well make
Centrifugal 30 40 145
Up pump
ACW pump HSC 2050 13 740
HRSG fill pump Centrifugal 250 90 1485
CP HRC pump Centrifugal 90 170 2970
6.5 Dozing:
Dozing is a part of internal water treatment in which adding of chemical to the boiler
either to precipitate the impurities and removing them in the form of sludge or to convert
them in to salt which remain in water in the harmless condition. Mainly phosphate, ammonia
and hydrazine dozing are done in to boiler water. Dosages and controls of chemicals are
affected by how and where they are fed. The reaction and residual part of the chemical
46
dosage calculation equation can affect control and results. Looking at the reaction percent
helps decide whether it will work.
6.5.1 Phosphate dozing:
To maintain required degree of alkalinity at high temperature and pressure, phosphate

dozing is used. Phosphate dozing is directly given to the boiler drum with chemical pump
because if introduce in to the suction pump or boiler feed pump, most phosphate react with
impurities of water and cause deposition in pump, pipe fitting, regulators and valves.
Figure 6-7 Phosphate dozing tank

6.5.2 Ammonia and Hydrazine dozing:
Ammonia - to maintain pH range in boiler feed water which further helps in stability of
protective layer inside boiler tubes, this protective layer prevents oxidation.
Hydrazine - also known as oxygen scavenger, as the name suggests, it helps in scavenging
out oxygen from boiler feed water, which further helps in prohibition of corrosion in tubes.
Figure 6-8 Hydrazine Dozing Tank and Ammonia Dozing Tank

47
7 Air Filtration System

7.1 Introduction:
Proper air filtration is important for overall performance and reliability of gas
turbines. Inlet air filtration systems are essential on any gas turbine. Filtration system remove
both solid or liquid particle present in atmospheric air. Filter house contain weather hood ,
guard filter, pulse filter or self-cleaning filter and at last evaporating cooling.
7.2 Weather hood and Trash Screens:
Weather hoods and trash screens are the most simplistic of the filtration mechanisms
but they are important in order to reduce the amount of moisture and particles which enter the
main filtration system.
Figure 7-1 weather hood
Weather hoods are sheet metal coverings on the entrance of the filtration system. The
opening of the hood is pointed downward so the ambient air must turn upwards to flow into
the inlet filtration system. The turning of the air is effective at minimizing rain. Weather
hoods is use on the majority of inlet filtration systems, and they are essential for systems
inareas with large amounts of rainfall.
48
Figure 7-2 Trash screen filter
Trash screen or say guard filter is a pre-filter which remove the dust present in air
having the higher size. Dust will not able to pass the guard screen. It required cleaning at
specific interval of time. Cleaning of guard is done buy compress air.
7.3 Pulse filter:

Pulse filter are the main filter stage where fine dust particle will remove from air.
Pulse filter is a conical in shape which contains number of layer.
Figure 7-3 Cylindrical and Conical pulse filter
49
Pulse filter is also known as self-cleaning filter. Pulse filter have advantage that high
filter effectiveness with lower space area requirement. Pulse filter have advantage that high
surface area, low-pressure drop and can be installed either horizontally or vertically.
Reverse flow of compressed air is done for cleaning of pulse filter. So, it also known as self-
cleaning filter. Cleaning of pulse is done one by one as show in figure 4-3
Figure 7-4 Cleaning of pulse filter
Air exit from pulse filter pass through evaporative cooling and mist separator. In
evaporative cooling air is cooled by using water. Cool air will improve the compressor
efficiency. During cooling moisture is absorb by air which is remove by mist sperator. Finally
air is supply to the gas turbine compressor.
50
8 Gas Turbine
8.1 Introduction:
The use of gas turbines is to generating electricity. In Gas turbines burning of an air-
fuel mixture produces hot gases that rotate a turbine to produce power. There is production of
hot gases during fuel combustion. Gas turbines can utilize a variety of fuels, including natural
gas, fuel oils, and synthetic fuels. In GPPC , Natural Gas is used. Gas turbine works on the
principal of brayton cycle.
Figure 8-1 Brayton cycle [4]
Ideal brayton cycle includes four processes as mention below:
1. Isentropic process (1→2) – ambient air is drawn into the compressor, where it is
pressurized.
2. Isobaric process(2→3)– the compressed air then runs through a combustion chamber,
where fuel is burned, heating that air—a constant-pressure process, since the chamber
is open to flow in and out.
3. Isentropic process(3→4) – the heated, pressurized air then gives up its energy,
expanding through a turbine. Some of the work extracted by the turbine is used to
drive the compressor.
4. Isobaric process(4→1) – heat rejection
8.2 Gas Turbine Parts:

Gas turbines are having three primary sections mounted on the same shaft: the
compressor, the combustion chamber and the turbine.
51
Figure 8-2: Gas turbine basic parts [4]
8.2.1 Compressor:
Figure 8-3 Gas Turbine Compressor
Axial flow compressor is used to compress the suction air. Axial flow compressors
are more common in power generation because they have higher flow rates and efficiencies.
Axial flow compressors are comprised of multiple stages of rotating and stationary blades (or
stators) through which air is drawn in parallel to the axis of rotation and incrementally
compressed as it passes through each stage. In GPPC the compressor consists of 18 stages
with an overall compressor pressure ratio of 15.4.
52
8.2.2 Combustion Chamber:
The combustion system is a multi-chamber (can annular) design in which combustion

chambers are arranged around the periphery of the compressor discharge casing. It consists
total 18 number of burners, 2 number of ignition torch and 4 number of flame monitor.
Figure 8-4: Gas turbine Burner
8.2.3 Turbine:
Multi stage Turbine having three stages issue. There is 2 rotating blade row and 1 static blade
row.
8.3 Working:
Air compressed by compressor, and fuel in the ratio of 55:1 is injected in combustion
chamber by nozzle. Then mixture of air-fuel is ignited by burner. Due to combustion, hot
gases are produced which imparts kinetic energy on turbine blade which causes rotation of
shaft. The rotation of the shaft drives the compressor to draw in and compress more air to
sustain continuous combustion. The remaining shaft power is used to drive a generator which
produces electricity. Power generated by gas turbine generator is 222MW.
53
Figure 8-5 Working of gas turbine [4]
8.4 Gas Turbine Performance:
The thermodynamic process used in gas turbines is the Brayton cycle. Two significant
performance parameters are the pressure ratio and the firing temperature. The fuel-to-power
efficiency of the engine is optimized by increasing the difference (or ratio) between the
compressor discharge pressure and inlet air pressure.
The temperature at which the turbine operates (firing temperature) also impacts
efficiency, with higher temperatures leading to higher efficiency. However, turbine inlet
temperature is limited by the thermal conditions that can be tolerated by the turbine blade
metal alloy. Gas temperatures at the turbine inlet can be 1200ºC to 1400ºC.
Because of the power required to drive the compressor, energy conversion efficiency
for a simple cycle gas turbine power plant is typically about 30 to 40 percent. A large amount
of heat remains in the exhaust gas, which is around 500 to 600ºC as it leaves the turbine. By
recovering that waste heat to produce more useful work in a combined cycle configuration.
54
8.5 Gas Turbine Parameter:
Table 8-1 Gas Turbine Parameter [7]
Parameter Unit Value

Make - GE
Flue type - Flue Gas
Electric Output MW 222
Speed rpm 3000
Compressor type - Axial
Compressor Stage Nos 18
Compressor Pr. ratio Bar 15.4:1
Air Fuel ratio Ratio 55:1
Number of turbine stages Nos 3
Number of rotating blade rows Nos 2
Number of stationary blade Nos 1
rows
Critical Speed rpm 1350/2450/6610
Type of combustor - Single can annular
Number of burners Nos 18
Type of burners - Dry Low NO, Can annular
Number of ignition torches Nos 2
Number of flame monitors Nos 4
Gross electrical efficiency % 36.90%
Gross heat rate KJ/KWH 1810
Exhaust gas flow Kg/Sec 564
Exhaust gas Temp. Deg C 510
55
9 Steam Turbine
9.1 Introduction:
A turbine is a device that converts chemical energy in mechanical energy. Steam

turbine available in GPPC is manufactured by BHEL(Bharat heavy Electricals Limited).
Exhaust of Gas turbine is use to convert water into super-heated steam. Then steam is
supplied to the turbine.
Figure 9-1 Steam Turbine
Steam turbine works on Rankine cycle principal. The Rankine cycle is an

idealized thermodynamic cycle of a heat engine that converts heat into mechanical work.
Figure 9-2 Rankine cycle [5]
9.2 Working:
Steam turbine has three stage HP(High pressure turbine),IP(Intermediate pressure
turbine),LP(Low pressure turbine). Steam at inlet of HP turbine is near around 530°C to
540°C. At the exit of HP turbine the temperature reduces to 346°C, then further it goes to
HRSG for reheating up to 540°C. Reheated steam goes to IP turbine and at exit the
56
temperature becomes 230°C. Steam exit from IP turbine, directly enters into the LP turbine.
Steam at nearly 46°C exits from LP turbine which is Condensed By shell and tube type
condenser. Turbine shaft is connected with generator shaft which produce electric power.
Power generated by steam turbine generator is 129MW.
Figure 9-3 Multistage Steam turbine [5]
9.3 Condenser:
Figure 9-4 Condenser
Steam exit from low pressure turbine is Condense by shell and tube type condenser in
which heat transfer is done between Axillary Cooling Water (ACW) and steam. Then
Condensate is store in Hot well.
Condenser is classified on the basis of tube pass and shell pass, such as one shell one
tube pass(1-1 exchanger), one shell two tube pass(1-2 exchanger) or two shell four tube
pass(2-
57
4 exchanger). Condenser used in plant is one shell two tube pass heat exchanger as shown in
below figure 2-5.
Figure 9-5 One shell Two tube type heat exchanger [5]
There are often baffles directing flow through the shell side so the fluid does not take
a short cut through the shell side leaving ineffective low flow volumes. These are generally
attached to the tube bundle rather than the shell in order that the bundle is still removable for
maintenance.
As name indicates, there is only one shell and tube bundle is separated in two parts as
shown in figure 2-5. The Cool ACW water come twice in contact with hot steam first in
upper part and other in lower part of shell as show in figure 2-5.
Table 9-1 Condenser design specifications [7]
Parameters Shell side Tube side

Medium Cooling water Steam
Design pressure(kg/cm2g) 3.5 1.05 & full vacuum
Design temperature(0C) 65 100
Hydro test pressure(kg/cm2) 6.5 Hydro fill
Working pressure(ATA) - 0.1
Flow rate 21,000 m3/hr 350.5TPH
Total nos. of tubes - 14124
58
9.4 Vacuum pump:
In condenser, the latent heat of steam is transferred between steam and ACW water
which results in the phase change of steam. Due to phase change from steam to water large
volume reduction occurs which results in high vacuum in condenser. This releases non
condensable gases like O2,CO2 etc. So, vacuum pump extracts non-condensable gases like
O2, CO2 and trapped air to maintain negative pressure at the outlet of LP turbine.
Figure 9-6 Vacuum pump
9.5 Condensate extraction pump:
The Function of CEP pump is to transfer condensate water from hot well to deaerator .
Table 9-2 CEP parameter [7]
Installed Qty. 2(1+1)

Make BHEL
Flow rate(m3/hr) 420
Head(m) 245
Speed(rpm) 1485
59
Figure 9-7 Condensate Extraction Pump
9.6 Steam turbine parameter:

Table 9-3 Steam turbine parameter [7]
Parameter Unit Details

Make - BHEL
Design Rating MW 129.0
Maximum Output MW 136.9
Turbine Speed rpm 3000
Steam Pressure
Initial steam ata 129.6
Before 1st HP drum stages ata 126.8
HP cylinder exhaust ata 35.3
60
IP cylinder stop valve inlet ata 33.3

LP steam ata 4.87
LP cylinder exhaust ata 0.10
Steam Temperature
Initial Steam °C 537.8
IP cylinder stop valve inlet °C 539.6
LP Steam °C 229.6
HP cylinder exhaust °C 346.2
LP cylinder exhaust °C 45.4
High Pressure Electro-
Turbine Governing System
Hydraulic Governing System
61
10 Cooling Tower
A cooling tower is a semi-enclosed device for evaporative cooling of water by contact with
air. It is a wooden, steel or concrete structure and corrugated surfaces or baffles or perforated
trays are provided inside the tower for uniform distribution and better atomization of water in
the tower.
The hot water coming out from the condenser is fed to the tower on the top and allowed to
tickle in form of thin sheets or drops. The air flows from bottom of the tower or perpendicular
to the direction of water flow and then exhausts to the atmosphere after effective cooling. To
prevent the escape of water particles with air, drift eliminators are provided at the top of the
tower.
In this plant, mechanical induced draft cooling tower is there in which there are total 20
towers (18 working and 2 standby). Each unit has 10 cooling towers. The flow of water and
air is counter, so this cooling tower is known as induced draft counter flow cooling tower.
Figure 10-1 Cooling Tower
10.1 Components of cooling tower
 Drift eliminators: capture droplets in air stream

 Air inlet: entry point of air
 Louvers: equalize air flow into the fill and retain water within tower
62
 Nozzles: spray water to wet the fill
Figure 10-2 Nozzle
 Cold water basin: receives water at bottom of tower
Figure 10-3 Cold Water Basin
 Fans: deliver air flow in the tower Frame and casing: support exterior enclosures
Figure 10-4 CT Fan
63
 Fill: facilitate heat transfer by maximizing water / air contact

 Splash fill
 Film fill
Figure 10-5 Splash Fill Fins
10.2 Types of cooling tower
Cooling tower
Natural draft Mechanical draft
Spray filled tower Packed type tower Hyperbolic Forced draft Induced
Cooling tower draft
10.2.1 Induced draft counter flow cooling tower
The induced draft cooling tower or mechanical draft tower comes with a fan at the discharge
end, which drives air upwards via the tower. The fan generates hot moist air out the
discharge. This generates high exiting and low entering air velocities, lessening the chance of
recirculation, in which, discharged air circulates back into the air intake.
 Extremely efficient comparing to forced draft cooling tower
 Employs 50% less energy while comparing to forced draft design
 Contains a fan located on the top, which drives the air via the fills
64
 An inlet fan is placed on the top of the cooling tower, which creates low pressure
Figure 10-6 Induced draft counter flow cooling tower [2]
10.3 Performance parameters :

1. Range: It is the difference between cooling water inlet and outlet temperature.
2. Approach: It is the difference between cooling tower outlet cold water temperature
and ambient wet bulb temperature.
3. Effectiveness: Cooling tower effectiveness (in percentage) is the ratio of range, to the
ideal range, i.e., difference between cooling water inlet temperature and ambient wet
bulb temperature, or in other words it is = Range / (Range + Approach).
4. Cooling capacity: Cooling capacity is the heat rejected in kCal/hr or TR, given as
product of mass flow rate of water, specific heat and temperature difference.
5. Cycles of concentration: Cycles of concentration (C.O.C) is the ratio of dissolved
solids in circulating water to the dissolved solids in makeup water.
6. Blow down losses: Blow down losses depend upon cycles of concentration and the
evaporation losses and is given by relation:
1. Blow Down = Evaporation Loss / (C.O.C. – 1)
7. Liquid/gas ratio: Liquid/Gas (L/G) ratio, of a cooling tower is the ratio between the
water and the air mass flow rates. Against design values, seasonal variations require
adjustment and tuning of water and air flow rates to get the best cooling tower
effectiveness through measures like water box loading changes, blade angle
adjustments.
65
10.4 Cooling Tower Losses :

10.4.1 Blow down losses:
During the cooling process of hot water in cooling tower, around 2% water evaporates. In the
long run, it increases the solid content in the circulating water. Some dust particles also come
from the environment and mix with circulating water. But the solid content of the cooled
water must be kept under a certain limit to avoid scaling or fouling on the heat exchange
equipment. A part of the circulating water is drained from the bottom of the cooling tower to
discard the deposited solids from the cooling tower. This is called blow down.
10.4.2 Drift loss:

Small droplets that are en-trained by the upward-flowing air stream are collected in a mist
eliminator, where they accumulate to form larger drops that are eventually returned to the fill.
In general, very little water in the form of droplets is carried along with the air, but those
droplets do results in water loss, called drift loss or windage loss. This drift water typically
contains dissolved solids and may cause stain, corrosion or damage to nearby buildings and
structures. Drift loss is usually about 0.1–0.3% of the circulation water rate
10.4.3 Evaporation Loss:

Evaporation loss is the water quantity evaporated for cooling duty and, theoretically, for
every 10,00,000 kCal heat rejected, evaporation quantity works out to 1.8 m3 .
10.5 Design Specification:
Table 10-1 Design Specifications of cooling tower [7]
Specification Unit Details

Make Gammon India
Qty. 2 (one of each unit)
No. of cells 9W+1SB
Rated cooling water flow m3/hr. 24,000
rate
o
Ambient design wet bulb C 28
temp.
o
Recirculation allowance C 0.5
o
Design inlet wet bulb temp. C 28.5
o
Cold water temp. C 33
66
o
Hot water temp. C 42.5
o
Cooling tower approach C 4.5
o
Cooling tower range C 9.5
Effectiveness % 67.9
Evaporation loss m3/hr. 310
Drift loss m3/hr. 1.2
Blow down loss m3/hr. 619
Total cooling tower losses m3/hr. 930
Overall size of cooling M×M×M 156×15×25.65
tower
Cell size (L×W×H) M 15.6×32×25.65
Flow per cell at design m3/hr. 2666.67
condition
Total water wetted surface M2 6084
per cell
Dry air flow rate per cell Kg/m2/hr. 7244.92
Ratio of water to air 1.57
Dry air flow rate per cell Kg/hr 1659313.29
o
Temperature of air leaving C 38.54
the stack
Type of air inlet Counter flow single inlet
Air inlet area per cell M2 73.32
Cooling tower fans
Manufacturer GTPL
Type, Model Axial, CD 10
Nos., Furnished One for each cell
Diameter M 10
67
11 Pump House
In GPPC basically there are two types of pumps which are mostly used that are :
 Centrifugal pumps
 Horizontal axial split casing pumps
11.1 Centrifugal pumps :

Centrifugal pumps are a sub-class of dynamic axisymmetric work-absorbing turbo
machinery. Centrifugal pumps are used to transport fluids by the conversion of rotational
kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically
comes from an engine or electric motor. The fluid enters the pump impeller along or near to
the rotating axis and is accelerated by the impeller, flowing radially outward into a diffuser
or volute chamber (casing), from where it exits.
Common uses include water, sewage, agriculture, petroleum and petrochemical pumping.
Centrifugal pumps are often chosen for their high flow rate capabilities, abrasive solution
compatibility, mixing potential, as well as their relatively simple
engineering. A centrifugal fan is commonly used to implement a vacuum cleaner. The reverse
function of the centrifugal pump is a water turbine converting potential energy of water
pressure into mechanical rotational energy.
Figure 11-1 Centrifugal Pump
68
11.2 Horizontal axial split casing pumps :

A type of centrifugal pump, in which the casing is split into two separate chambers. It’s
different from an end suction pump or inline pump, in which the casing, the suction nozzle,
and the discharge nozzle are all included in a single chamber. When the casing is split along a
vertical plane in relation to the impeller, it is known as a vertical split case pump; when it’s
on a horizontal plane, it is known as a horizontal split case pump. This type of casing design
is more economical for higher flow applications, and the impeller can be supported by
bearings on both sides, an advantage for larger, higher flow pumps and are used in fire
protection systems and mining, petroleum refineries, air-conditioning and refrigeration
systems.
The pump has the suction and discharge connections in the lower half of the casing, opposed
to each other. The impeller is mounted on a shaft which is supported by bearings on both
sides.
Figure 11-2 Horizontal Axial Split Casing Pump
11.3 RO-DM Pump House

In RO-DM there are many pumps used, whose functions are given below:
1. DM Transfer Pump : This pump helps to transfer DM water from DMST tank to
CST (condensate storage tank)
69
2. DM Regeneration Pump : This pump regenerates SAC and SBA using HCL and
NaOH
3. DM Feed Pump : This pump transfers water from permeate water tank to DM plant.
4. Flushing Pump : This pump flushes or cleans the membranes by flowing pressurized
water from feed water side.
5. BWRO Feed Pump : Transfers water from permeate water tank to BWRO.
6. SWRO CC pump : Transfers chemical (hydrochloric acid, hydrogen peroxide) from
chemical tank in the membrane for chemical cleaning process.
Figure 11-3 RO-DM Pump House
Table 11-1 Specifications of RO-DM Pump House [7]
PUMP DISCHARGE TDH SPEED MOC TYPE

(m3/hr.) (m) (RPM)
DM transfer pump Flow more ltd. C.F
40 35 1455
DM regeneration
pump 20 40 2000 KSB pumps ltd. C.F
DM feed pump 37 50 1460 KSB pumps ltd. C.F
Flushing pump 250 50 2955 Mather & Platt C.F

pumps ltd.
BWRO feed pump Mather & Platt C.F
43 27 1455 pumps ltd.
SWRO CC pump Mather & Platt C.F
140 55 2950 pumps ltd.
70
11.4 Service Water Pump House

Service water pump house is used to transfer water for daily use and for other purpose also :
1. HRSG Blow down Dilution Pump : Transfers water from service water tank to
HRSG blow down tank.
2. Service & Potable Water Pump :
3. HVAC Water Make-up pump : Transfers water from service water tank to various
cooling system as make-up water.
Figure 11-4 Service Water Pump House
Table 11-2 Specification of Service Water Pump House [7]
PUMP DISCH. TDH SPEED Capacity Power MOC TYPE

(m3/hr.) (m) (RPM) (m3/hr.) I/P
(KW)
HRSG blowdown Flowmore HSC
dilution pump 65 30 1455 55 6.61 ltd.
Service & potable 80 60 1460 65 15.34 Flowmore HSC
water pump ltd.
HVAC water 80 46 1455 25 6.60 Flowmore HSC
make-up pump ltd.
71
11.5 Cooling Water Pump House

Cooling water pump transfers cold water from cooling tower to the condenser for cooling the
steam. There are total 3 CW pumps in the plant (2W+1SB)
Table 11-3 Specification of Cooling Water Pump House [7]
Pump Head Discharge Pump I/P Imp. Dia. Speed MOC Type
(m) (m3/hr.) (KW) (mm – (rpm)
deg.)
CW 27.50 25000 2242.380 1300-12 425 Kirloskar HSC
pump pumps
Figure 11-5 CW Pump
11.6 Fire Water Pump House:

There are two pumps in fire water pump house whose functions are :
1. Hydrant Pump : Hydrant pumps are high pressure water pumps designed to increase
the firefighting capacity of a building by boosting the pressure in the hydrant service
when mains is not enough.
72
Figure 11-6 Hydrant Pump

2. Jockey Pump : A jockey pump is a small pump connected to a fire sprinkler system
to maintain pressure in the sprinkler pipes.
Figure 11-7 Jockey Pump
Table 11-4 Specification of Fire Water Pump House [7]
Head Discharge Imp. Dia. Speed Stage MOC Type

Pump
(m) (m3/hr.) (mm) (rpm)
Hydrant 88 410 515 1490 - Kirloskar HSC

pump pumps
Jocky pump 90 25 178 1490 9 Kirloskar Centrifugal
pumps
11.7 Clarified Water Pump House
Function of clarified water pump is to transfer water from CWST to the cooling tower for
make-up purpose. There are 3 pumps in the clarified water pump house having common
header.
73
Table 11-5 Specification of Clarified Water Pump House [7]
Pump Head Discharge Pump I/P Suction Capacity MOC Type

(m) (mm) (KW) (mm) (m3/hr.)
CT
Flowmore
make- 20 350 85.80 400 1350 HSC
pump ltd.
up
Figure 11-8 Clarified Water Pump
11.8 DMCW Pump:
DMCW pump circulates the water for cooling lubricating oil, passing through heat
exchangers. This pump is installed in close circuit in which initially water is filled in the pipe
line and as there is heat exchange process water gets evaporated and therefore make-up water
is to be supplied which is stored in surge tank (at 22m height). Hot water from lube oil cooler
enters in the DMCW pump. From DMCW pump, hot water enters in the plate type heat
exchanger and cools the water. Cold water is then supplied to various heat exchangers.
74
Table 11-6 DMCW Pump Specifications [7]
Pump Flow rate Head Speed MOC Type

(m3/hr.) (m) (RPM)
DMCW 1800 44 1487 Flow more HSC
Pump pumps ltd.
Figure 11-9 DMCW Pump
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12 Maintenance
12.1 Introduction:
Maintenance to most people is any activity carried out on an asset in order to ensure that the
asset continues to perform its intended functions, or to restore to its favourable operating
condition. The purpose of maintenance is to extend equipment lifetime, or at least the mean
time to the next failure the repair of which may be costly. Furthermore, it is expected that
effective maintenance policies can reduce the frequency of service interruptions and the many
undesirable consequences of such interruptions. Maintenance clearly impacts on component
and reliability; if too little is done ,this may result in an excessive number of costly failures
and poor system performance and therefore, reliability is degraded, done often, reliability
may improve but the cost of maintenance will sharply increase. In a cost effective scheme,
the two expenditures must be balanced.
Maintenance is just one of the devices for up keeping or if necessary improving the level of
reliability of components and systems. Over the years, many new strategies have been
implemented as maintenance strategies which are intended to overcome the problems which
are related to equipment breakdown. Some of the common maintenance strategies are as
follows.
1. Breakdown Maintenance
This is one of the earliest maintenance programs being implemented in the industry. The
approach to maintenance is totally reactive and acts only when equipment needs to be fixed.
This strategy has no routine maintenance task and it is also described as no scheduled
maintenance strategy. To rectify the problem, corrective maintenance is performed onto the
equipment. Thus, this activity may consist of repairing, restoration or replacement of
components. The strategy is to apply only the corrective maintenance activity, which is
required to correct a failure that has occurred or is in the process of occurring.
2. Preventive Maintenance
This is the time-based maintenance strategy where on a predetermined periodic basis,
equipment is taken off-line, opened up and inspected. Based on visual inspection, repairs are
made and the equipment is then put back on-line. Thus under this equipment maintenance
strategy, replacing, overhauling or remanufacturing an item is done at fixed intervals
regardless of its condition at the time.
76
Although this is a well-intended strategy, the process can be very expensive as typically 95%
of the time everything was alright. Nevertheless, some preventive maintenance is necessary
as some regulation such as DOSH regulation require that annual/bi-annual boiler inspection
to be conducted.
3. Predictive Maintenance
Predictive maintenance is a more condition-based approach to maintenance. The approach is
based on measuring of the equipment condition in order to assess whether an equipment will
fail during some future period, and then taking action to avoid the consequences of those
failures. This is where predictive maintenance technologies (i.e. vibration analysis, infrared
thermographs, ultrasonic detection, etc.) are utilized to determine the condition of equipment,
and to decide on any necessary repairs. Apart from the predictive technologies, statistical
process control techniques, equipment performance monitoring or human senses are also
adapted to monitor the equipment condition. This approach is a more economically feasible
strategy as labours, materials and production schedules are used much more efficiently.
4. Proactive Maintenance
Unlike the three type of maintenance strategies which have been discussed earlier, proactive
maintenance can be considered as another new approach to maintenance strategy. Dissimilar
to preventive maintenance that biased on time intervals or predictive maintenance concentrate
on the monitoring and correction of root causes to equipment failures. The proactive
maintenance strategy is also designed to extend the useful age of the equipment to reach the
wear-out stage by adaptation of a high mastery level of operating precision.
Table 12-1 Types of Maintenance Strategies
Maintenance Strategy Maintenance Approach Significance

Breakdown Maintenance Fix-it when broken Large Maintenance Budget
Preventive Maintenance Scheduled Maintenance Periodic Component
Replacement
Predictive Maintenance Condition-based Monitoring Maintenance decision based
on equipment
Proactive Maintenance Detection of Source of Monitoring and correcting
Failure. failing root causes
The Aspects of Maintenance used in GPPC Kovaya is Breakdown and Preventive

Maintenance.
77
12.2 Vibration Analysis:
12.2.1 Introduction:
Vibration monitoring of critical and auxiliary pumping systems helps improve machine
reliability, safety and production capability. Pumps produce vibrations indicative of running
condition, incipient faults and component failure. Vibration is an integral part of an effective,
predictive maintenance program, enabling the early detection of failure modes such as
impeller erosion, pump imbalance, shaft looseness, coupling problems and cavitation.
The tool used for measuring vibration is known as Vibrometer as shown in figure 3-1.
Figure 12-1 Vibrometer [10]
The device contains a probe which needs to be positioned at the point of the pump or motor
where vibration is to be measured. The output is displayed on the screen in terms of
displacement, velocity, acceleration or frequency depending on the mode of the device.
12.2.2 Positioning of Probe:
In order to get accurate vibration results, the probe must be positioned properly on the pump
motor assembly. Normally, Vibration is measured in all the three planes that is Horizontal,
Vertical and Axial. Probe must be situated at the front and back bearings of the pump and
motor as shown in the figure.
78
Figure 12-2 Measuring point of bearing stand [10]
Figure 12-3 Measuring point of inbuilt bearing [10]
Figure 12-4 Probe Positioning in pump and motor assembly [10]
79
Figure 12-5 Probe Positioning across three planes [10]
Vibration is measured in terms of displacement (mm peak to peak), velocity (mm/s),

acceleration (g) or frequency (hz). For measuring amplitude of vibration, vibrometer is set in
displacement mode. While vibration is most commonly measured in terms of velocity, for
high frequency vibration , acceleration mode is set in the vibrometer.
In order to pass vibration analysis, the device must produce vibration (velocity) less than a
pre-specified value. In GPPC, a pump is said to have passed vibration test if it produces
vibration less than 7 mm/s.
12.2.3 Case Study:
During our GPPC training, we collected and analysed the vibrational data using a vibrometer
for DM Transfer Pumps located in the RO-DM Pump House. As DM Transfer Pumps are
continuously in working condition, a little vibration may hinder the working of the power
plant.
Thus, it is necessary to periodically analyse vibration and correct it if went beyond the limits
for efficient working of a power plant.
The Probe was set on the following positions for correctly analysing the vibrational data.
 Pump input
 Pump output
 Motor input
 Motor output
Each Readings were taken in three different planes , Horizontal, Vertical and Axial.
80
Figure 12-6 Horizontally positioned probe
Figure 12-7 Vertically Positioned Probe
81
Figure 12-8 Axially Positioned Probe
Table 12-2 Vibrational Velocity of DM Transfer Pump A
Probe Position Plane Velocity Result

Horizontal 0.6 mm/s Safe
Motor Output Vertical 0.5 mm/s Safe
Axial 0.5 mm/s Safe
Motor Input Vertical 0.5 mm/s Safe
Axial 0.4 mm/s Safe
Pump Output Vertical 0.5 mm/s Safe
Axial 0.3 mm/s Safe
Pump Input Vertical 0.6 mm/s Safe
Axial 0.5 mm/s Safe
Thus, it is seen from the above data, that all the values are far less than the safe limit of 7
mm/s and thus needs no maintenance.
82
12.3 Alignment:
12.3.1 Introduction :
Misalignment is one of the main reasons of vibration and thus, a pump motor assembly must
be properly aligned. Motor-Pump alignment is the process of aligning shaft centrelines
between a motor and a pump. The motor is the prime mover, transferring power to the pump
by the use of a coupling. This is probably the most common configuration of coupled
machines in industry.
In this type of alignment, the motor is almost always the moveable machine, and the pump is
the stationary machine. In almost all cases, the pump is already piped up with suction and
discharge flanges, which means it can move only slightly, if at all.
Motors are normally easier to move, since the motor is not piped into a process system.
Proper shaft alignment is achieved by moving the motor. The motor is shimmed vertically to
achieve the proper elevation to align it to the pump, both parallel (offset) and angular. The
motor is them moved horizontally to achieve proper horizontal placement for aligning the
shaft centrelines, both parallel and angular. The motor is moved horizontally by the use of
jacking bolts, or by the use of pry bars, hammers, or other tools.
Motor-Pump alignment is critical for these reasons:

 It minimizes the forces of misalignment acting upon the bearings and seals of both
components.
 It minimizes wear of the coupling.
 It can help reduce energy costs.
 It maximizes the life of the machine components by minimizing wear, increasing time
between failures, and reducing vibration.
12.3.2 Tools Used for Alignment:
The most basic tool used for the alignment of pump motor assembly is Dial Gauge. The base
of the dial gauge is mounted on one coupling and the dial is pointed on the other coupling.
The Coupling is then rotated and the movement of Dial on the Gauge is noted. If the
misalignment is more than the pre-specified limit, it is corrected using Horizontal, Vertical or
Axial Alignment Methods according to the Company.
83
Figure 12-9 Dial Gauge [10]
Horizontal Alignment is done with the help of horizontal bolts provided at the base of the
motor. The motor can be moved horizontally with the help of these bolts. The movement
depends on the pitch of the bolt used. As shown in the figure, bolts are provided on both the
sides of the motor.
Horizontal
Alignment Bolts
Figure 12-10 Horizontal Alignment Bolts

84
Vertical Alignment is done with the help of base plates which are placed at the base of the
motor between the motor and the foundation. The plates are available in different sizes as
shown in figure 3-11, which is placed according to the vertical misalignment between the
motor and pump assembly.
Figure 12-11 Base Plates for Vertical Alignment [10]
Figure 12-12 Positioning of Base Plate [10]
+
In GPPC, misalignment of −
0.05 mm is permissible across all planes.
12.3.3 Case Study:
After undergoing vibrational analysis of PSF Backwash Pumps, it was found that the pumps
were misaligned and thus they were properly aligned with the help of horizontal bolts and
base plates. The dial gauge is placed on top of the coupling and is set zero. Then the coupling
along with the dial gauge is rotated and the misalignment is noted at 90° intervals. Whenever
85
the reading goes beyond 0.5 mm, it is corrected and examined again with the help of Dial
Gauge.
Figure 12-13 PSF Backwash Pump
-0.01 Radial -0.02
-0.03
Figure 12-14 Dial Gauge Values (Radial)
+0.0 +0.0
Axial
3 2
+0.0
5
Figure 12-15 Dial Gauge Values (Axial)

86
12.4 FRP Coating
12.4.1 What Is FRP Coating?
FRP Coatings & Linings (Fibreglass Reinforced Plastics), is a superior coating and lining
system formed by thermosetting resins and fiberglass to raise durability and safety by lining
inside of piping systems chemical storage tanks, cooling towers, and other types of industrial
process equipment.
In a lot of applications, FRP coating provides superior performance over other materials.
When a polyester resin is used in combination with fiberglass, the coatings lifetime becomes
longer and becomes much more corrosion resistant.
12.4.2 FRP Coating Applications
 FRP water tanks and acid Overlays

 Acid Cap GRP Skins
 Concrete floor and roof coatings
 Acid Ground FRP Overlays
 Treatment Plant Isolation
12.4.3 Methods of applying FRP:
There are two methods by which FRP tank lining systems can be applied. There is hand lay-
up and spray-up methods to install the FRP lining. Before either type of coating can be
applied sand blasting has to be done to remove any debris or corrosion. This provides a clean
and rough surface for the primer to be applied on. Adhesion of either system is dependent
upon having that rough and primed surface.
Spray-Up Method
Glass-chopper guns are used to apply the spray-up FRP linings. The glass-chopper gun mixes
to glass roving and resin components at the time of being sprayed. Dual head glass-chopper
guns allow very rapid rates of depositing the coating. The average thickness of the resin at the
tank bottoms are typically a quarter inch when the spray-up method is used.
Hand Lay-Up Method

While the spray-up method is quicker the hand lay-up method is the preferred method of
consistency. This method produces a more consistent, and uniform layer of coating. The
87
quality of the hand lay-up method does take more time, requires more labour, and longer time
for the resin gel to dry. While being more labour intensive this method does take less skill to
apply.
To apply the lining using the hand lay-up method a heavy layer of resin is applied with
brushes, rollers, or it is sprayed on. The next step is applying the glass mat to the wet resin
and ensuring it is fully saturated with the resin to make sure adhesion is strong. Lastly a seal
coat is applied on top of the resin and glass mat. This is only done after the resin saturated
material has gelled.
12.4.4 FRP Lining Application Approach
Quality FRP tank coatings rely on how the lining is applied. The standardized approach for
applying an FRP hand lay-up tank coating has 5 distinct phases that must be followed.
 Prepare The Surface

Organic contaminants build up in steel storage tanks and must be removed. Following this the
internal surfaces must be blasted with abrasive materials to prepare the inside of the tank for
the primer and resin.
 Applying The Primer

Immediately after the blasting is complete the dry film polyamide-cured epoxy primer is
applied at a thickness of 1 to 3 mils. It is applied to prevent any contamination of the bare
metal surface and to “hold” the tank in condition for the resin phase. Sharp angles in the tank,
especially those at the bottom are filled in with a putty type material which includes the fibres
and fillers. This putty material should of the same compound as the resin you will use for the
tank to ensure proper adhesion. Any deeply pitted tanks should be resurfaced with the same
fill material to create a smooth bottom.
 Resin Application & Fibre glass Reinforcement

Resin is applied in a heavy layer by brush, sprayer, or roller. While the resin is still wet the
fibre glass mat is laid into it and full saturation should be ensured.
 Final Coating
A finish coat that is a resin rich layer of polyester resin is applied as the seal coat. This
process helps prevent capillary action which causes wicking along the partially exposed glass
fibres that stick out of the resin. Paraffin wax aids in the curing process.
88
 Final Inspection
Before the tank is passed for use again an inspection should be carried out to ensure that the
FRP lining has been successfully installed. A magnetic dry film tester is used to check the
thickness of the dry film.
12.4.5 Case Study:
Under preventive maintenance, the loaders and isolation gates of HRSCCs were coated with
FRP to prevent corrosion and thus increase its life.
Before applying the coating, loaders were properly finished by grinding process. Then, a
mixture of resin, cobalt and hardener is mixed properly and applied to the loaders along with
mat as shown in the figure 3-20.
Figure 12-16 Resin and FRP Mat
Figure 12-17 FRP Surface and Hardener

89
Figure 12-18 Worker Applying Resin Mat Mixture
After applying Mat, the loaders are coated with resin surface mixture, to provide a smooth
surface. At last, loaders and gates are painted.
Figure 12-19 Worker applying FRP coatings to isolation gates.

90
Figure 12-20 Loaders before Coating
Figure 12-21 Loaders after Coating

91
12.5 Hydro test:
Hydro test involves a test which is performed with the help of water (which is why
this test is called hydro) passed through the pipelines or tanks or any fuel carrying vessels in
order to inspect any leakages in the material assembly. This test also helps in understanding
the pressure loss inside the pipeline system. This is done by shutting down the supply valve
and pressurizing the vessel at the required pressure. The liquid will flow inside the pipeline
and simultaneously the pressure loss inside the pipeline is observed.
Hydro test or hydrostatic test is one of the most common methods used for testing the
pressure vessels, pipelines, tanks, for any leakages and pressurization integrity of the system.
12.5.2 Equipment used:
1) Triplex plunger pump

2) High pressure Hose pipe with Nozzle
 Triplex plunger pump:
High Pressure Triplex Plunger Pumps are the most versatile, time effective and
economical solution for High Pressure Cleaning, Cutting, etc.
The High Pressure Reciprocating Triplex Plunger Pumps pumps are meant for high
pressure low volume application and are positive displacement type requiring a positive
suction head. Triplex plunger pumps give efficiency of more than 90 % which is very high in
comparison to centrifugal pumps.
The Triplex Plunger Pumps /Piston Pumps use a crankshaft mechanism where the rotary
motion is converted into a linear reciprocating motion. In the fluid end of the pump a fixed
volume of liquid is drawn per backward stroke through the suction valve and the same is
pushed through the discharge during the forward stroke through the discharge valve.
The suction & discharge valves are non-return type and the design varies depending on
type of application & liquid to be pumped. The flow rate of the pump is directly proportional
to the RPM (rotations per minute) of the pump / strokes per minute of the pump.
92
Figure 12-22 Triplex Plunger Pump [6]
The Triplex Plunger /Piston Pumps have three plungers reciprocating simultaneously
in synchronization 120° apart from each other. The High Pressure Triplex Plunger /Piston
Pumps have lesser flow pulsation as compared to single plunger pumps. Goma pumps are
available with various types of fluid end materials depending on abrasive and corrosive
nature of fluid, pressure rating, atmospheric conditions etc.
The High Pressure Unit Consist:
 High Pressure Reciprocating Triplex Pump

 Prime Move)r: Electric Motor / Diesel Engine
 Mounting: Base Plate / Trolley / Trailer
 Pulley set with belts and guard or Coupling with guard.
 Standard Accessories: Pressure Gauge, Pressure Regulating Valve, Safety Valve,
Strainer
 Cleaning Accessories (Optional
 High pressure Hose pipe and Nozzle:
High pressure hose pipe is flexible hollow pipe use to carry high pressure water from
one end to another.
93
Figure 12-23 High Pressure Hose Pipe [6]
Hose design is based on a combination of application and performance. Common

factors are size, pressure rating, weight, length, straight hose or coil hose, and chemical
compatibility.
A nozzle is a device designed to control the direction of a fluid flow (especially to
increase velocity) as it exits (or enters) an enclosed chamber or pipe.
Figure 12-24 Nozzle Tip [6]
As shown in above figure tip of nozzle have numbers of hole on its periphery so it is
easy to clean tube around its periphery.
Nozzles are used to control the rate of flow, speed, direction, mass, shape, and/or the
pressure of the stream that emerges from them. In a nozzle, the velocity of fluid increases at
the expense of its pressure energy.
94
12.5.3 Case Study:
i. Hydro test of Heat exchanger:

In shell and tube type heat exchanger hydro test done from the shell side in
which pressure of water is maintain up to certain level. Then each tube is check
individually. If water is come from any tube its means that there is some crake of
defect present inside the tube. Then tube is change by new one. There is not any
defect present in heat exchanger.
ii. Hydro test of HRSG:
During the hydro test of HRSG all the tubes of HP/IP/LP drums were filled
with high pressure water supply by the triplex plunger pump. Pressure of pump is
calculated by the equation mention as below.
Hydro test pressure = 1.5 * Working pressure
Or
Hydro test pressure = 1.25 * Design pressure
For HP boiler Hydro Test pressure = 205 Kg/cm2
IP boiler Hydro Test pressure = 65 Kg/cm2
LP boiler Hydro Test pressure = 13 Kg/cm2
There is no any problem present in HRSG is conclude by hydro test because there is
no any leakage of water is shown during hydro test.
12.6 Flame Cleaning:

Flame cleaning is the process of cleaning a structural steel surface by passing an

intensely hot oxy-acetylene flame over it. Mill scale and rust are removed by the flame. The
oxy-flame can work on assorted surface qualities and remove some of the hardest to clean
substances such as lubricants and grease. the function of cleaning can be thoroughly
accomplished, the general aesthetic look is damaged due to the burn marks by the oxy-flame.
Equipment used:
1) Oxygen cylinder
2) Acetylene cylinder
3) Welding torch
95
Figure 12-25 Oxy-Acetylene Flame
12.6.2 Case study:
Flame cleaning of self-cleaning strainer is done during the maintenance. Function of self-
cleaning strainer is remove suspended or foreign particle present in condenser cooling water
coming from cooling tower.
Figure 12-26 Cleaning of Strainer by Flame
96
There was also breakdown of strainer blade due to collision with hard foreign impurities. The
problem was solved by heating and hammering.
Figure 12-27 Bending of Strainer blade
Figure 12-28 After heating and hammering condition of blade
12.7 Tube Cleaning:

Reason behind tube cleaning is the erosion in metal and Fouling means The deposition of any
undesired material on heat transfer surfaces. Due to erosion and fouling heat transfer will
97
decrease. Cleaning of tube is done by using triplex plunger pump, Hose pipe and radial or
axial nozzle.
12.7.2 Case Study:
Under preventive maintenance of condenser and vacuum pump heat exchanger, the tubes
were cleaned with the help of triplex plunger pump, hose pipe and axial/radial nozzle.
Figure 12-29 Tube Cleaning of condenser [6]
High pressure water one by one passed through all the tubes via the nozzle. Pressure of the
pump was maintained between 1000 kgf/cm2 to 1200 kgf/cm2
Figure 12-30 Tube Cleaning of Heat exchanger
98
13 Conclusion
Our four months training at GPPC, Kovaya has given us a nice exposure to the working
environment in a power plant industry. It has gained us enough knowledge about the working
of a Gas based thermal power plant.
The various preventive and breakdown maintenance techniques which we have learned here
like Vibration analysis, Alignment, Hydrotest, Flame Cleaning and so on, has provided us
good practical knowledge about the steps and procedures of maintenance in any Plant. These
techniques have developed our practical approach towards machines which theoretically,
have been covered during our undergraduate course.
Various day to day activities like filling check sheets, supervising FRP coating, analysing and
correcting vibration of pumps, observing various processes in the power plant, taking
chemical samples, observing valve controls etc. has provide a boost to our confidence level
which will surely be useful to us during my lifetime.
Apart from these, we think that, it is easy to work with complex machines, but not with
people. The only chance an undergraduate has to have this experience is the industrial
training period. We feel we got the maximum out of that experience. Also we learnt the way
of work in an organization, the importance of being punctual, the importance of commitment,
and the importance of team spirit.
99
REFERENCES
1. www.ccsdualsnap.com
2. Power Plant Engineering, Arora, S.C. and Domkundwar, S., Dhanpat Rai & Co.
3. Power Plant Engineering, P.K. Nag, Tata McGrahill Co., Delhi
4. energyeducation.ca
5. www.mechanicaltutorial.com
6. highpressurepumpmanufacturer.com (Triplex)
7. Technical Data Sheet
8. puretecwater.com
9. www.myodesie.com
10. www.aptitudeexchange.com
100

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INDUSTRIAL TRAINNING REPORT

GSPC PIPAVAV POWER COMPANY

Submitted in partial fulfillment towards the degree of

ANKIT PANDYA (MH003, 15MHUOS057)

DEPARTMENT OF MECHANICAL ENGINEERING

COMPANY” is the bonafide work of ANKIT PANDYA (Roll No. MH-003),

SANDIP BALDANIYA (Roll No. MH-006) and DHRUVIT VALA (Roll

No. MH026) (Bachelor of Technology in Mechanical Engineering, Semester

Prof. (Dr.) G. D. Bassan Prof. N.A. Vora

Mr. Naresh Ukani

A combined cycle as the name implies is the combination of two cycles

operating at different temperature, each of which could operate independently.

lower temperature cycle to produce additional power to realize an improved

configuration of this type involves adding a steam turbine bottoming cycle to

additional heating by burning more natural gas in the steam generator.

It is our pleasure to be indebted to various people, who directly or

We express our sincere gratitude to GSPC Pipavav Power Company

We are thankful to Mr. Darshan Desai for his support, cooperation,

We also extend our sincere appreciation to Mr. Naresh Ukani, Mr.

Lastly, we would like to thank the whole staff of the Mechanical

LIST OF FIGURE ......................................................................................................... X

LIST OF TABLES .................................................................................................... XIII

2 Sea Water Intake System ............................................................................................. 16

3 Pre-Treatment Plant .................................................................................................... 17

3.1 Introduction: .......................................................................................................... 17

3.2 Cascade Aerator: ................................................................................................... 17

3.3 Stilling Chamber: .................................................................................................. 18

3.4 Flash Mixer: .......................................................................................................... 19

3.5 High Rate Solid Content Clarifier:........................................................................ 20

3.6 Dual Media Filter: ................................................................................................. 21

3.7 Blow Down Pit: ..................................................................................................... 22

3.8 Sludge Thickener: ................................................................................................. 22

4 RO-DM Plant ................................................................................................................ 24

4.1 Introduction: .......................................................................................................... 24

4.2 Pressure Sand Filter: ............................................................................................. 25

4.3 Membrane Cartridge Filter: .................................................................................. 26

4.4 Sea Water Reverse Osmosis: ................................................................................ 27

4.4.1 Understanding Reverse Osmosis: ........................................................... 27

4.4.2 How does Reverse Osmosis Work?:....................................................... 30

4.4.3 SWRO HP Feed Pump:........................................................................... 30

4.4.4 Energy Recovery Device: ....................................................................... 31

4.4.5 SWRO System : ...................................................................................... 31

4.5 Brackish Water Reverse Osmosis: ........................................................................ 32

4.6 Strong Acid Cation : ............................................................................................. 33

4.7 Strong Base Anions :............................................................................................. 35

4.8 Mixed Bed: ............................................................................................................ 36

5 Heat Recovery Steam Generator (HRSG) ................................................................. 38

5.1 HRSG Function : ................................................................................................... 38

5.2 HRSG Design:....................................................................................................... 39

5.3 HRSG Components:.............................................................................................. 40

5.3.1 Economizer : ........................................................................................... 40

5.3.2 Evaporator :............................................................................................. 40

5.3.3 Steam Drum : .......................................................................................... 40

5.3.4 Superheater : ........................................................................................... 40

5.4 HRSG Blow down : .............................................................................................. 41

5.4.1 Intermittent Blow Down : ....................................................................... 41

5.4.2 Continuous Blow Down : ....................................................................... 42

6 Boiler Feed Pump Building.......................................................................................... 43

6.1 Introduction: .......................................................................................................... 43

6.2 Deaerator: .............................................................................................................. 43

6.3 Flow path of DM water: ........................................................................................ 44

6.4 Pump and its parameter: ........................................................................................ 46