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INTERNAL GUIDE
B.KUMARA SWAMY
PROJECT MEMBERS
D.V.KIRAN PRIYA(09981A0209)B.SARAT CHANDRA PRABHU(09981A0202)
P.VENKATA RAO(09981A0227)
V.SRI RAM(08981A0264)
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1. OVERVIEW OF HPCL
2. CAPTIVE POWER PLANT(CPP)
i) Gas Turbine Generator
3. POWER DISTRIBUTION IN HPCL
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HPCL is a Government of India Enterprise with a Navratna Status
Its annual turnover is Rs. 1,32,670 Crores
HPCL operates 2 major refineries producing a wide variety of petroleum fuels
& specialties, one in Mumbai (West Coast) and the other in Visakhapatnam(East
Coast).
Different units at HPCL:
Crude Distillation Unit(CDU)
Fluidized Catalytic Cracking Unit (FCCU)
Propylene Recovery Unit(PRU)
Sulphur Recovery Unit(SRU)
Diesel Hydro De Sulphurization Unit(DHDS)
De Mineralization Unit(DM)
Bitumen Breaking Unit(BBU)
Merox Unit
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Straight run and cracking LPG unit
Vis Breaking Unit(VBU)
Gasoline/motor spirit merox
Kerosene merox
Effluent treatment plant(ETP)
HPCL also owns and operates the largest Lube Refinery in the India producing Lube
Base Oils
This Lube Refinery accounts for over 40% of the India's total Lube Base Oil production.
HPCL is also a leading jet fuel supplier in India
The refinery gets power from AP grid also. But due to uncertainty in power it is not
completely reliable due to regular power cuts. The need of continuous supply is
needed. So for this reason the captive power plant has emerged.
The refinery gets power from AP grid also. But due to uncertainty in power it is not
completely reliable due to regular power cuts. The need of continuous supply is
needed. So for this reason the captive power plant has emerged.
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Captive power plant meets the total power demand of HPCL
It uses naphtha as the fuel for the generation of the power which
is a bi product obtained after the extraction of petrol and othercomponents from the crude oil
This unit comprise of six gas turbine generators (GTG) Two with 9MW capacities (FRAME-3 Machines) each
Four with 25MW capacities (FRAME -5 Machines) each
Frame -3 Machine is a two shaft machine whereas Frame -5Machine is a single shaft machine
Distribution of the power to different parts of the plant aresupervised only from the CPP
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GENERATORS 1&2:
A 15 stage axial flow compressor type generator having two shaft one
driving the compressor and the other driving the generator. The
machine is rated for 11.2MVA at 0.8pF, 11Kv, 3-phase, 50Hz 4-pole
running at a speed of 1500rpm with 6 combustion chambers are called
Frame 3 machines.
GENERATORS 3, 4, 5&6:
A 17 stage axial flow compressor type generator rated at 27.388MVA at
0.8pF, 11Kv, 3-phase, 50Hz 2-pole machine running at a speed of
3000rpm with 10 combustion chambers are called Frame 5 machines.
This type of generator only has a single shaft
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Principle:The principle of a gas turbine power plant is that a turbo-
compressor compresses working medium to a high pressure and then it is
burnt in the combustion chamber where the combustion takes place at a
constant pressure and temperature of working medium is raised. This high
pressure and high temperature is then expanded in gas turbine coupled to
the alternator.
Gas turbine plants have the following applications:
To drive generators and supply peak loads in steam, diesel or hydro
plants.
To work as combination plants with conventional steam boilers
To supply mechanical drive for auxiliaries.
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Main Features Of The equipment Of GTG:
I. Compressor Section :
In this air is confined to the space between the rotor and stator
where it is compressed in stages by an alternate series of rotating
(rotor) and stationary (stator) air foil shaped blades
II. Turbine Section :In the turbine, the high pressure gases from the combustion
section are converted through shaft into horse power.
III. Turbine Rotor assembly :
There are two separate turbine rotors in the gas turbine.
First stage or high pressure turbine rotor.
Second stage or low pressure turbine rotor.
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IV. Accessory Drive :
The accessory drive gear located at the compressor end of Gas Turbine
is a gear assembly coupled to the turbine rotor through flexible
coupling
V. Turbine Support System :
This consists of Starting system, Fuel system , Lubrication system
VI. Heat Recovery Steam Generator (HRSG) :
HRGS are installed to recover heat from turbine exhaust gases. The
steam generated is utilized for downstream process use and co-
generation plant is optimized.
It consists of super heater , evaporator, economizer, condensate pre
heater, chimney, fuel gas flow controllers and fuel pumps
VII.Fuel system :
Fuel is pumped from tanks by fuel forwarding pumps to GTG.
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Major distribution system at HPCL consists of :
Substations
Double Bus Bar System
Transformers Switchgear
DISTRIBUTION TO DIFFERENT SUBSTATIONS
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The scheme envisages use of two identical bus-bars so that
each load may be fed from either bus; or the in feed and loadcircuit may be divided into two separate groups if neededfrom operational considerations. Also bus-bar may be takenout for maintenance and cleaning of insulators.
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Transformers :HPCL uses a wide range of transformers which are very important in thepower distribution systemHPCL has approximately 79 transformers in the entire refinery with the ratinglike 10MVA/11KVA, 11/33KVA, 3.3/1.1KVA, 1.1KVA/415VA and etc.
Switchgear :The switchgear is a combination of electrical disconnects, fuses and/or circuitbreaker used to isolate the electrical equipment.
Classification of switchgear is generally as follows :Low Tension (L.T)High Tension (H.T)Extra High Voltage (E.H.V)
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