This is a presentation on the overview of my father's powerplant, GAMA Infraprop Pvt Ltd (GIPL) located in Kashipur, Uttarakhand and powered by German Power Generation Company Steag GmbH. This powerplant was established as one of the three earlier proposed units by kashipur. There were three units of power plant as proposed by Govt. of Uttarakhand: The "Alpha" unit, the "Beta" unit and the "Gamma" unit. Out of these three, the first and the last runs while the middle one doesn't due to some technical issues and because of the fact that the equipments installed in the powerplant "Beta" were outdated, thus prior to the commence of the operation of the same, the project "Beta" was cancelled. Coming to the "Gamma" plant which is also spelled as "Gama", it is powered by Natural Gas supplied by IGL (Indraprastha Gas Limited). It is working under two gas turbines certified by GE energy service, a US electrical power generation company, and a "steam" turbine. Three of the turbines equally generate 75kW, ie, power outputs of the three are summed up to 225kW. Remaining information is written in this presentation. Powerplant photos here are just schematic, provided to give a clear image it. Have Fun!!!

1. 225 MW CCPP GAMA project run by STEAG.
Presented By: Indraneel Bhattacharya
Submitted to: Vishnimurthi.

2.  What is Power Plant?
A power plant is a station where power is
generated from the required resources. It
consist of a Generator and a Prime mover to
rotate it. Power plants can be built in various
locations depending upon its characteristics.

4.  Thermal Power Plant
 Gas Power Plant
 Hydroelectric Power plant
 Nuclear Power Plant
 Wind Power Plant
 Solar Power Plant
 Tidal Power Plant
 Geothermal Power Plant
 Biogas Power Plant

5.  What is CCPP?
A CCPP (or Combined Cycle Power Plant) is a power
generating plant or power generating station where
the power generated from it consist of a
combination of two or more Heat cycle processes. It
can involve Nuclear power, Gas power, etc.

7.  The current plant is Gas Power Plant. It comprises main components/zones like:
1. Gas Skid.
2. Two Secondary Gas Skids
3. Two Gas Turbines 75 MW each.
4. PEECC
5. Fire Extinguishing Chamber.
6. 2 HRSGs.
7. One Steam Turbine 75 MW.
8. DM Plant.
9. Air-Cooled Condenser.
10. Cooling Towers
11. Transformers.
12. Unit Auxiliary transformers.
13. Switchyard, etc.
14. Diesel Generator.
15. DCS.
16. Control room.
17. SCADA.
 It is a 225 MW project and this power output is the sum of individual power outputs from three generators.

8.  A gas Skid is a gas-based power plant zone
where gas is received and conditioned for the
usage of Gas Turbines.
 It has step by step methods to process and filter
the gas and it takes place in different zones.
 The gas supplied to the gas skid is below our
body temperature but above the melting point of
water (normally at the atmospheric pressure).

9. Natural Gas Filter Separator IDBH
Pressure Reduction
and Controlling
System
Secondary gas skidGas Turbine inlet

11.  A Gas Turbine is a turbine that is just like a
jet engine of an airplane however it is meant
for power generation.
 Unlike the airplane turbine that has a
curvilinear housing, Gas turbines have a
cuboid-shaped housing provided with a 3-
stage air filter and a fuel distribution system
which is housed separately.

12. Internal Design of a Gas Turbine

13.  PEECC or Packaged Electronic/Electrical Control
Compartment is a major discipline within the field of
electrical engineering and includes a wide variety of
technologies.
 It refers to enclosures and protective features built into the
product itself, and not to shipping containers.
 It applies both to end products and to components.
 Packaging of an electronic system must consider
protection from mechanical damage, cooling, radio
frequency noise emission, protection from electrostatic
discharge, maintenance, operator convenience, and cost.

14. Visualization of PEECC

15.  Packaging materials for PEECC:
◦ Sheet metal
◦ Cast metal
◦ Machined metal
◦ Molded plastic
◦ Potting
◦ Porosity sealing or impregnation
◦ Liquid filling
◦ Conformal coating
◦ Glop-top
◦ Hermetic metal/glass cases
◦ Hermetic ceramic packages
◦ Printed circuit assemblies
 Design considerations:
◦ Hazards to be protected against: mechanical damage, exposure to weather and dirt, electromagnetic interference, etc.
◦ Heat dissipation requirements
◦ Tradeoffs between tooling capital cost and per-unit cost
◦ Tradeoffs between time to first delivery and production rate
◦ Availability and capability of suppliers
◦ User interface design and convenience
◦ Ease of access to internal parts when required for maintenance
◦ Product safety, and compliance with regulatory standards
◦ Aesthetics, and other marketing considerations
◦ Service life and reliability

16.  It is typically a chamber consisting of CO2
cylinders that is meant to light out fire from any
kind of leakages in the Gas Turbine.
 It is coloured Red for the purpose of safety or
First Aid.
 It Comprises Three plugs in its housing (each
plug for each zone—zone 1, 2 & 4) to be released
at the time of fire accident, Sensors to sense the
fire in the Gas Turbine and signal it to the circuit
boards in the Chambers so as to automatically
release the CO2 to the Turbine

18.  The HRSG (or Heat Recovery Steam Generator) is a zone where the steam
is generated from water by recovering the heat of the GT exhaust.
 It is coupled with the Gas Turbine.
 The Exhaust of the gas turbine pass through the HRSG over the pipelines
through which water from the DM plant pass to form steam.
 HRSG Comprises three drums: HP (high pressure), IP (intermediate
pressure), LP (low pressure); two chimneys and a series of pipelines.
 It is much similar to the Boiler, however it is characterized as a hollow
chamber through which the GT exhaust pass and heat up the water in
the pipeline unlike the boiler which is stored in a container that is heated
up to form steam.

20.  The temperature of the gas inlet to the HRSG is about 650˚C.
 This gas is cooled down by using the pipelines within the HRSG Housing.
 There are three stage pairs of the pipelinings:
◦ HP pipelinings (HP Superheater+ HP Economizer+HP Evaporator).
◦ IP pipelinings (IP Superheater+ IP Economizer+IP Evaporator).
◦ LP pipelinings.
 Each of the pipelines have a specific function. Besides that the LP Drum (De-
aerator) pipelines supply heated water to IP Drum and HP Drum then IP linings
supply steam to the HP Drum.
 Temperature and pressure of the steam liberated from the HP pipelining is about
535˚C and 95 kgf/cm2 respectively.
 The two chimneys of HRSG are meant to draw the GT exhaust out for separate
occassions – one for drawing the exhaust out without utilizing its heat and the
other one for drawing the same however utilizing its heat.

21.  Steam turbines are the turbines driven by
Steam that come out from the HRSGs
 It has three main components: HP turbine, IP
turbine, LP turbine.
 The Size of each components of Steam
turbines increase with decrease in steam
pressure.
 Decrease in steam pressure in turbine takes
place step by step.

22. HP steam turbine
IP steam turbine LP steam turbine

23.  Diesel Generators are provided in power plant
so that if there is any power failure in the
plant, emergency equippments in the plant
can be run.

24.  DM plant (or De-Mineralization plant) is an
area of power plant where the water taken
out from the underground is purified to a
degree in which there is an absense of any
minerals that could harm the plant
components.
 Most of the water from it is send to HRSGs so
that the heat from the Gas Turbine exhaust is
absorbed to form high pressure steam to run
the turbine.

26.  It is a chamber or a compartment where the high
pressure steam coming from the turbine is
Cooled down to the normal state of water.
 It comprises series of narrow pipelines within the
housing and several fans on and under the
housing and a CST (Condensed Storage Tank).
 High pressure steam passing through the
pipelines are cooled down by the fans pulling air
either from above or from below.
 The condensed water is thus stored in the CST.

28.  It’s a heat rejection device that releases waste heat to the atmosphere through cooling of water
stream to a lower temperature.
 They may either use the evaporation of water to remove process heat and cool the working
fluid to near the wet-bulb air temperature or, in the case of closed circuit dry cooling towers,
rely solely on air to cool the working fluid to near the dry-bulb air temperature.
 Cooling towers vary in size from small roof-top units to very large hyperboloid structures that
can be up to 200 metres (660 ft) tall and 100 metres (330 ft) in diameter, or rectangular
structures that can be over 40 metres (130 ft) tall and 80 metres (260 ft) long. The hyperboloid
cooling towers are often associated with nuclear power plants, although they are also used in
some coal-fired plants and to some extent in some large chemical and other industrial plants.
Although these large towers are very prominent, the vast majority of cooling towers are much
smaller, including many units installed on or near buildings to discharge heat from air
conditioning.
 There are 3 kind of classifications of Cooling tower
◦ By Build
◦ By Heat Transfer
◦ By Air Flow Generation
◦ By Use
◦ By Air-to-water flow

29.  There are types of cooling towers based on their build:
◦ Package type
◦ Field erection type
 There are types of cooling towers based on their Heat Transfer:
◦ dry cooling towers
◦ wet cooling towers (or open circuit cooling towers)
◦ fluid coolers (or closed circuit cooling towers)
 There are types of cooling towers based on their Air Flow Generation:
◦ Natural draft.
◦ Mechanical draft
◦ Fan assisted natural draft
 There are types of cooling towers based on their Air-to-water Flow:
◦ Crossflow.
◦ Counterflow.
 There are types of cooling towers based on their Use:
◦ Heating, ventilation and air conditioning (HVAC)
◦ Industrial cooling towers

30.  A transformer is a device that transfers power by
either stepping up the voltage and stepping
down the current or stepping down the voltage
and stepping up the current.
 There are two types of transformers – Step up
and Step Down.
 It comprises a Laminated soft iron core, Primary
coil(s) and secondary coil(s), cooling tubes,
conservation tank, low voltage bushes, main tank
(housing), tank cover, drain off, cooling oil.

32.  There are certain limitations to the transformer while
transferring power, i.e., loss of power. It includes:
◦ I2R Loss.
◦ Copper Loss
◦ Hysteresis loss
◦ Eddy current loss, etc.
◦ Magnetic flux loss.
 Such losses can be avoided by using
◦ proper material as m-flux transferring medium like
laminated soft iron core,
◦ using thick wires for the transformer coils,
◦ proper cooling system, etc.

33.  They are other kind of transformers that are
paired parallel with the output lines of the
Gas Turbine Generators.
 They step down the generator output voltage
to the required voltage to run the power
plant, unlike the main transformers that step
up the generator output and send it to
switchyard.
 The same precautions are to be taken For
UATs as that of Ordinary transformers in
order to avoid losses.

34.  Switchyard is a substation which operate at a
single voltage level (for the current plant).
 Here the switching action takes place
between the Power distribution and power
collection takes place.

35.  There are several components of switchyard:
◦ Insulator
◦ Isolator
◦ Bus lining
◦ Bus Coupler
◦ Current Transformer (CT)
◦ Capacitive voltage Transformer (CVT)
◦ PLCC (Power Line Carrier Communication)
◦ Line Trap (Wave Trap)

36.  DCS or Distributed Control System is a
computerized control system for a process or
plant usually with a large number of control
loops.
 Autonomous controllers are distributed
throughout the system, but there is central
operator supervisory control.
 The DCS concept increases reliability and
reduces installation costs by localising
control functions near the process plant, with
remote monitoring and supervision.

37. Pictorial layout of DCS

38.  A control room, a.k.a. operation center or
operation control center, is a room serving as
a central space where a large physical facility
or physically dispersed service can be
monitored and controlled.

39.  SCADA or Supervisory control and data
acquisition is a control system architecture
that uses computer, networked data
communication and GUI (Graphical User
Interface) for high-level process supervisory
management, but uses other peripheral
devices such as programmable logic
controllers and discrete PID controllers to
interface with the process plant or machinery.

40.  There are five functional manufacturing levels
implemented by SCADA as follows
 Level 0 contains the field devices such as flow and
temperature sensors, and final control elements, such
as control calves.
 Level 1 contains the industrialised input/output (I/O)
modules, and their associated distributed electronic
processors.
 Level 2 contains the supervisory computers, which collate
information from processor nodes on the system, and
provide the operator control screens.
 Level 3 is the production control level, which does not
directly control the process, but is concerned with
monitoring production and targets.
 Level 4 is the production scheduling level.

42.  Why need Safety?
◦ We need safety in every aspects of our lives in order to have
a better living, to stay sane and stay safe from any kind of
perils.
 What is Accident?
◦ An accident, also known as an unintentional injury, is an
undesirable, incidental, and unplanned event that could
have been prevented had circumstances leading up to the
accident been recognized, and acted upon, prior to its
occurrence.
 Sources of accident:
◦ Human activities (88%)
◦ System malfunctioning (2%)
◦ Nature (10%)

43.  Safety in plant: The Basic Requirement of safety
in plant is from the fire and that to the workers
from any kind of the reckless activities.
 Safety requirements:
◦ Helmet
◦ Safety shoes
◦ Safety belt
◦ Goggles
◦ Earplugs/Earmuffs
◦ Safety Gloves.
◦ Apron.

44.  Sources of Fire: There are only three main
sources of fire—
◦ Oxygen (Air)
◦ Heat Energy
◦ Fuel (Inflammable at low ignition temp).

45.  Classes of fire: There are six classes of fire—
◦ Class A (Wood fire, paper fire)
◦ Class B (Petroleum fire or fire from reactive materials)
◦ Class C (Burning flammable gases’ fire)
◦ Class D (Fire from combustible metals)
◦ Class E (Electrical fire)
◦ Class F (Kitchen fire/Fire from cooking fat and oil)
 Types of fire extinguishers to safeguard from each class of fire:
◦ Water and foam (Class A)
◦ CO2 (Classes B, C and E)
◦ Dry Chemical (Classes A, B, C and E)
◦ Wet Chemical (Class F)
◦ Dry Powder (Class D)
◦ Water Mist (Classes A, C & E)
◦ Clean Agent (Classes B, C & E)
◦ Catridge-Operated Dry Chemical (Classes A, B, C & E)

46. ©Copyright Indraneel Blattacharya 2018. All rights Reserved