power plant basics
DESCRIPTION
Power Plant basicsTRANSCRIPT
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POWER GENERATIONPROCESS BASICS
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BOILER / STEAM TURBO-GENERATORUTILITY PLANT
Boiler
100% Fuel
Air
Stack
Steam
Steam Turbine Generator
20%
Lake
6% Aux. Power + Losses
Steam Condenser40%
34% Electricity
THERMAL EFFICIENCY - 34%
Transmission
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BOILER / STEAM TURBINE-GENERATORINDUSTRIAL CO-GENERATION
Boiler
Fuel100%
Air
Stack
15%
Steam Turbine Generator
15% Electricity
Transmission
Steam 5% Aux. Power + Losses
Process Steam65%
Process Plant
THERMAL EFFICIENCY - 80%
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SIMPLE CYCLE COMBUSTION (GAS) TURBINE
Air
100% Fuel
Compressor Turbine Generator
Combuster
Stack
57-62%
3% Aux Power + Losses
35-40% Electricity
Transmission
THERMAL EFFICIENCY - 35-40%
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Air
Compressor TransmissionGenerator
GAS TURBINEINDUSTRIAL CO-GENERATION PLANT
Turbine
100% Fuel
Combuster Exhaust Gas
20%
StackStack
Process PlantProcess Steam
Supplementary/AuxiliaryFuel (Optional)
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Air
Compressor TransmissionGenerator
GAS TURBINECOMBINED CYCLE POWER PLANT
20%
Stack
100% Fuel
Combuster Exhaust Gas
Stack
Turbine
Steam Turbine
Steam
GeneratorTransmission
Steam Condenser
Lake
28%
6% Aux. Power + Losses
12-15% Electricity
35-40% Electricity
SupplementaryFuel (Optional)
Thermal Efficiency - 45-55%
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UTILITY PLANT - FUNCTIONAL BLOCK DIAGRAMSwitch Yard System Station Electrical System
Boiler Feed Pumps & Deaerator System
Turbine Bypass System
BOILER
TURBINE-GENERATOR
UNIT#2
DM Plant Fuel Handling System Station Miscellaneous Systems
Turbine Miscellaneous Systems
Turbine Steam System
HP & LP Heaters System
Turbine Supervisory & ControlSystem
Generator & Electrical System
Boiler Steam & Water System
Air & Flue Gas System
Fuel Preparation System
Fuel Firing System
Boiler Miscellaneous Systems
Ash Handling System
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CAPTIVE POWER PLANT - FUNCTIONAL BLOCK DIAGRAM
Switch Yard System Station Electrical System
DM Plant Fuel Handling System Station Miscellaneous Systems
BFP’s & Deaerator System
UNIT#2 UNIT#3
BOILER
TG
Steam & Water
Air & Flue Gas
Fuel Preparation
Fuel Firing
Steam
HP & LP Heaters
Supervisory & Control
Generator & Electrical
Miscellaneous Systems
Ash Handling System
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BOILER FUNDAMENTALS
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BASIC DIAGRAM OF A BOILER
Steam / Water System
Furnace
Heat TransferSurface
Mixing ofFuel & Air
Water
Fuel
Air
Steam
Flue Gas
Ash
Blowdown
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SALIENT FEATURES OF MODERN INDUSTRIAL& UTILITY BOILER
• STEAM BOILER
• WATER TUBE
• SUPERHEATED STEAM
• HIGH PRESSURE
• WATER COOLED FURNACE
• WATER CIRCULATION
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COMBUSTION REQUIREMENTS
3 T’s of Combustion
CombustionTimeTemperatureTurbulence
SufficientCombustion Air
Fuel isGasified
Mixing withinFlammableRange
TemperatureaboveIgnition Point
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BASIC COMBUSTION CHEMISTRY
Complete
O2 +H2C
Heat
(Air) Oxygen Fuel
ProductsH2OCO2
Incomplete
+
Heat
O2
H2C
Oxygen Fuel
Flue Gas
Flue Gas
ProductsH2OCO2COH2C
• Other Combustibles - Sulphur to Sulphur Oxides• Non-combustible - Nitrogen to Nitrogen+Nitrous Oxides• Ash
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BOILER WATER & STEAM SYSTEM
Furnace
Water WallRisers
Drum
DownComers
EconomiserFeed Water
PrimarySuperHeater
FinalSuperHeater
PrimaryReHeater
Final ReHeater
PlatenSuperHeater
Attemperator
SprayWater
SprayWater
Main Steam
Hot ReheatSteam
ColdReheat Steam
Bottom Ring Header
Simplified Process Diagram
Flue Gas
Flue GasOut toAir Heater
Attemperator
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BOILER WATER & STEAM SYSTEM
Process Performance Highlights
• Heat Transfer by Radiation and Convection
• Boiler Water Circulation - Natural or Controlled
• Heat Transfer depends on Heat Transfer Area & Time
• Heat Transfer is affected by Fouling, Boiler Pressure, Boiler Water Quality and % MCR Load
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BOILER WATER & STEAM SYSTEM
Major Equipment
• Economiser - Pre-heats Boiler Feed water
• Boiler Drum - Separates water from steam and reduce solids in steam
• Water Walls - Absorb heat from flue gas to evaporate boiler water
• Superheaters - Heat up steam coming from boiler drum
• Reheaters - Heat up steam coming from High Pressure turbine
• Attemperators - Reduce superheat from steam
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BOILER WATER & STEAM SYSTEM
Process Regulation
• Drum Level - Regulation of Feed Water flow
• Drum Water Quality - Blow down / Chemical Dozing
• Fouling of Heat Transfer Surfaces - Blowdown / Soot Blowing
• Main Steam Temperature - Attemperation / Burner Tilt
• Hot Reheat Steam Temperature - Burner Tilt / Attemperation
• Main Steam Pressure - Regulation of Combustion
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AIR & FLUE GAS SYSTEM
Simplified Process Diagram
Chimney
ID Fan A
ID Fan B
ESP A
ESP B
AH A
AH B
FD FAN A
FD FAN B
PA FAN A
PA FAN B
To ColdPA Header
To HotPA Header
ECO
LTSH
FURNACERH
PTNSH
FINSH
WINDOX A
WINDBOX B
FromFD Fans
To Air CooledGuns
Scanner Air Fans
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AIR & FLUE GAS SYSTEM
Process Performance Highlights
• Generation of Draft - Natural / Induced / Forced / Balanced
• Supply of Air for Transport of Pulverised Coal
• Pre-heating of Air
• Distribution of Air in Combustion Chamber
• Recirculation of Gas
• Fan capacity depends on Flow, Density & System Resistance
• Fan performance is affected by temperature, density, barometric pressure and speed
• Flue Gas Cleaning
• Gas flow is restricted by ash deposits on boiler surfaces
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AIR & FLUE GAS SYSTEM
Major Equipment
• Air Path - Forced Draft Fans, Steam Coil Air Pre-heater, Regenerative Air Pre-heater & Wind-box
• Gas Path - Induced Draft Fans and Stack
• Gas Recirculation - Gas Recirculating Fans
• Flue Gas Cleaning - Mechanical Precipitator, Electrostatic Precipitator and Gas Scrubber
• Dampers
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AIR & FLUE GAS SYSTEM
Process Regulation
• Furnace Draft - ID Fan Inlet Vane Control and/or Variable Speed
• Secondary Air Flow - FD Fan Variable Pitch Control
• PA Header Pressure - PA Fan Inlet Vane Control
• RAPH Cold End Temperature - SCAPH Control
• Gas Recirculation - Damper Control
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FUEL PREPARATION SYSTEM - COAL
Simplified Process Diagram
Hot PA
Cold PAMill A
Raw Coal Bunker
Coal Feeder
Coal+Airto Burners
Seal Air FansTo Other Mills
To Mill DischargeValves
ToOtherMills
To OtherMills
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FUEL PREPARATION SYSTEM - GAS/OIL
Simplified Process Diagram
Fuel GasSupply To Burners
PRV’s
FCV FGTV
FUEL GAS
FUEL OIL
Fuel OilSupply
PCV
Fuel Oil Pumps
To BurnersOil Heater
Steam
FCV FOTV
Fuel OilReturn
ShortRecirc
LongRecirc
AtomisingSteam/Air
PCV
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FUEL PREPARATION SYSTEM
Process Performance Highlights
• Coal Pulverizing - Direct / Indirect Firing
• Coal Transport and Drying
• Fuel Gas Pressure Regulation
• Fuel Oil Pumping & Filtering
• Fuel Oil Pressure & Viscosity Regulation
• Gas Pressure & Oil Pressure/Temperature affect Boiler Load
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FUEL PREPARATION SYSTEM
Major Equipment
• Coal Mills - Tube Ball / Bowl / Impact
• Raw Coal Feeders - Chain / Belt / Rotary / Gravimetric
• Coal / Air Dampers, Gates & Discharge Valves
• Fuel Oil Pumps & Heaters
• Seal Air Fans
• Coal Bunkers
• Vapour Fans
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FUEL PREPARATION SYSTEM
Process Regulation
• Coal Flow - Raw Coal Feeder Speed
• Coal/Air Temperature & Flow - Cold & Hot PA Flows
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FUEL FIRING SYSTEM
Typical Corner Arrangementfor a Tangentially Fired System
Front Wall
Plan(Corner Designation)
(1)
(2) (3)
(4)
AA
A
AB
B
BC
C
CD
D
DE
E
EF
F
FF
Air Damper
OFA
OFA Over Fire Air
OFA
EA
EA End Air
FA
FA Fuel Air
AA
AA Aux. Air
Coal Burner
Fire Ball Scanner
LFO?HFO Burner
HFO Burner
Oil Flame Scanner
HEA Igniter
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FUEL FIRING SYSTEM
Process Performance Highlights
• Fuel Firing - Front / Tangential
• Fuel Oil Atomisation - Mechanical / Air / Steam
• Flame Ignition
• Air Distribution
• Fuel Combustion
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FUEL FIRING SYSTEM
Major Equipment
• Burners
• Ignitors
• Flame Scanners
• Burner Tilt Mechanism
• Wind Box
• Dampers
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FUEL FIRING SYSTEM
Process Regulation
• Furnace to Wind Box Differential Pressure
• Fuel Air Flows
• Fuel Firing
• Emergency Shutdown
• Flame Monitoring
• Oil Support for Coal Flame Stability
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BOILER MISCELLANEOUS SYSTEMS
Boiler Auxiliary Cooling Water System
• Ensures continuous supply of cooling water to Boiler & it’s auxiliaries
• Consists of Overhead Tank, Pumps & Heat Exchangers
Chemical Dosing System
• Prepares & supplies chemicals for treatment of Boiler Water
• Consists of Preparation Tanks, Mixers & Metering Pumps
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DEAERATION & FEED PUMPING SYSTEM
Simplified Process Diagram
Deaerator
Feed Storage Tank
M
Discharge Valve
RecirculationValve
Boiler Feed Pumps
To HPHeaters
To HP BypassSpray
T o APRDSSpray
HydrazineDosing
AmmoniaDosing
Aux. SteamforPegging
HP Heater Drains
Condensate from LP Heater
Aux. Steam
CRH Steam
IPT ExtractionSteam
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DEAERATION & FEED PUMPING SYSTEM
Process Performance Highlights
• Boiler Water pre-heating & air removal
• Maintain positive Suction Pressure for Feed Pumps
• Feed Water Pumping to Boiler
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DEAERATION & FEED PUMPING SYSTEM
Major Equipment
• Boiler Feed Pumps
• Hydraulic Coupling
• Deaerator
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DEAERATION & FEED PUMPING SYSTEM
Process Regulation
• Deaerator Pressure
• Deaerator Level
• BFP Minimum Recirculation
• Feed Pump Speed
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STEAM TURBINE FUNDAMENTALS
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LAWS OF THERMODYNAMICS
• Conservation of Energy - Heat may be converted in to work and work may be converted in to heat, in accordance with a certain natural proportionality constant (ENERGY CAN NOT BE DESTROYED)
• Not all of a given quantity of Heat can be converted in to useful Work, because of irreversbility in the process (ENTROPY OF THE UNIVERSE IS INCREASING)
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BASIC RANKINE CYCLE
T
S
Unavailable Heat
Heat Availablefor Work
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IMPROVING RANKINE CYCLE
• Superheating
• Increased Pressure
• Decreased Exhaust Pressure
• Regenerative Feed Heating
• Reheating
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STEAM TURBINE TYPES
• Condensing Turbine
• Back Pressure Turbine
• Regenerative Turbine
•Controlled Extraction
• No. of Cylinders
• Speed - Constant / Variable
• Single / Double Flow
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TURBINE STEAM SYSTEM
Simplified Process Diagram
Condenser
HPTurbine
IPTurbine LP Turbine
ExtractionSteam
MainSteam
ColdReheatSteam
HotReheatSteam
ESV CV
IV CV
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TURBINE STEAM SYSTEM
Major Equipment
• Turbine - Casing, Rotor & Blades
• Emergency Stop Valves
• Control Valves
• Condenser
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TURBINE STEAM SYSTEM
Process Regulation
• Steam Admission
• Emergency Shutdown
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REGENERATIVE FEED HEATING SYSTEM
Simplified Process Diagram
From BFPDischarge
ToBoiler
HPHTR
HPHTR
CRHSteam
To Deaerator
IPTExtrn.Steam
Condenser
Hotwell
Condensate ExtractionPump
LPHTR
LPHTR
HPFlashTank
LPFlashTank
ToDeaerator LPT
Extraction Steam
LPTExtraction Steam
MinimumRecirculation
LPHTR
DrainCLRGSC
ToCondenser
ToCondenser
GlandLeakoffSteam
LPT Extraction
Makeup
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REGENERATIVE FEED HEATING SYSTEM
Process Performance Highlights
• Pumping of Condensate from Hotwell to Deaerator
•Gradual Heating of Feed Water Temperature
• Minimise Heat Loss from the Cycle
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REGENERATIVE FEED HEATING SYSTEM
Major Equipment
• HP Heaters
• LP Heaters
• Drain Cooler
• Condensate Extraction Pumps
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REGENERATIVE FEED HEATING SYSTEM
Process Regulation
• Hotwell Level
• Heater Level
• Minimum Flow through CEP & GSC
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TURBINE GOVERNING & CONTROL SYSTEM
Functional Block Diagram
GlandSteamSystem
LubricatingOil
System
GoverningOilSystem
TurningGear
JackingOilSystem
CondenserVacuumSystem
TurbineDrainSystem
OIL SYSTEMS VACUUM SYSTEM WARM UP SYSTEM
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TURBINE GOVERNING & CONTROL SYSTEM
Process Performance Highlights
• Shaft & Bearing Protection
• Electro-hydraulic Governing
• Maintain Vacuum in Condenser
• Supply Steam to Turbine Glands
• Warming up of Turbines and their Valves
• Emergency Shutdown in case of Unsafe Conditions
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TURBINE GOVERNING & CONTROL SYSTEM
Major Equipment
• Oil Pumps, Turning Gear & Jacking Oil Pump
• Hydraulic Actuators for Turbine Valves
• Vacuum Pumps
• Gland Steam Pressure Regulator
• Oil Coolers & Temperature Regulator
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TURBINE GOVERNING & CONTROL SYSTEM
Process Regulation
• Speed / Load / Frequency Control
• Gland Steam Pressure Control
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TURBINE MISCELLANEOUS SYSTEMS
Condenser Cooling Water System
• Supplies Cooling Water Condensation of Turbine Exhaust Steam
Turbine Auxiliary Cooling Water System
• Ensures continuous supply of cooling water to Turbine & it’s auxiliaries
• Consists of Overhead Tank, Pumps & Heat Exchangers
Chemical Dosing System
• Prepares & supplies chemicals for treatment of Condensate
• Consists of Preparation Tanks, Mixers & Metering Pumps
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TURBINE MISCELLANEOUS SYSTEMSCondenser Cooling Water System
Simplified Process Diagram
CoolingTower
CWSump
CWMakeupWater
Condenser A
Waterbox B
CirculatingWater Pumps
ToUnit#2
CW Return Header
CW Supply Header
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TURBINE MISCELLANEOUS SYSTEMSCondenser Cooling Water System
Major Equipment
• Cooling Towers• CW Pumps
Process Performance Highlights
• Steam Condensation• Cooling of Condenser CW - Cooling Tower / Lake
Process Regulation
• Condenser Tube Cleaning - Online / Back flushing
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TURBINE BYPASS SYSTEM
Simplified Process Diagram
MainSteam
CRH
To HPT
From HPT
To IPTHRH
FeedWater PRV
SprayControlValve
BlockValve
Condenser
Condensate
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TURBINE BYPASS SYSTEM
Process Performance Highlights
• Enable Boiler Operation for Quick Re-start after Boiler Trip and during Turbine Start-up
• Control MS Pressure after Turbine Trip or Sudden Load Throw-off
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TURBINE BYPASS SYSTEM
Process Regulation
• MS Pressure Reduction & Desuperheating
• HRH Steam Pressure Reduction & Desuperheating
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GENERATOR FUNDAMENTALS
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WORKING PRINCIPLE
• Converts Mechanical Energy in to Electrical Energy
• Based on Electro-magnetic Induction E = 4.44 O FN volts E - e. m. f. O - Strength of Magnetic Field F - Frequency N - No. of Turns in a Stator Winding Coil
F = Pn/120
P - No. of Poles n - Revolution per second of Rotor
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GENERATOR EFFICIENCY & LOSSES
• Efficiency = Output Electrical Energy Input Mechanical Energy
• Losses - Bearing Loss, Copper Loss & Iron Loss
• Typically Efficiency is 90-97%
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GENERATOR & UNIT ELECTRICAL SYSTEM
Generator Functional Block Diagram
UnitAuxiliaryTransformer
FieldExcitationSystem
GeneratorSynchronisingSceme
Generator Transformer
Metering &ProtectiveRelays
StatorCooling WaterSystem
HydrogenCoolingSystem
SealOilSystem
ELECTRICAL SYSTEMS MECHANICAL SYSTEMS
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GENERATOR & UNIT ELECTRICAL SYSTEM
Key One Line Diagram
132 KV Bus I
132 KV Bus II
Isolator
Circuit Breaker
GT
Generator
UnitAuxiliaryTransformer
FromStationBus
FromStationBus
6.6 kV Unit Bus B6.6 kV Unit Bus A
11 kV
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GENERATOR & UNIT ELECTRICAL SYSTEM
Process Performance Highlights
• Conversion of Mechanical Energy in to Electrical Energy
• Field Excitation
• Stator Winding Cooling by Distillate / Air
• Rotor Winding Cooling by Hydrogen / Air
• Hydrogen Sealing by Oil
• Synchronisation & Voltage Transformation
• Emergency Shutdown in case of Unsafe Conditions
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GENERATOR & UNIT ELECTRICAL SYSTEM
Major Equipment
• Generator - Stator, Rotor, Armature Windings, Field Windings
• Field Excitation - Exciter (DC/AC), Static Rectifying Unit & AVR
• Bus Ducts & Transformers
• Circuit Breakers & Protective Relays
• H2 Cooling - Fans, Dryers & Coolers
• Stator Water Cooling - Pumps, Coolers & Overhead Tank
• Seal Oil - Pumps, Coolers & Differential Pressure Regulator
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GENERATOR & UNIT ELECTRICAL SYSTEM
Process Regulation
• Field Excitation
• Generator Synchrinisation
• Voltage Regulation
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POWER PLANTOPERATION & MAINTENANCE
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OPERATION & MAINTENANCE
Efficiency Calculations
• Boiler Efficiency - Direct / Heat Loss Method
• Turbine Heat Rate - Total Heat Supplied/ KWHR
• Plant Heat Rate - Heat Supplied/ KWHR
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Factors Affecting Plant Performance• Flue Gas Exit Temperature
• Excess Air
• Unburnt Fuel
• Steam Temperature
• Condenser Back Pressure
• FW Temperature at Eco Inlet
• Auxiliary Power Consumption
• Make up Water Flow
• Optimum Loading
OPERATION & MAINTENANCE
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OPERATION & MAINTENANCE
• Start-up & Shutdown Monitoring
• Trip Analysis - Boiler / Turbine / Generator
• Equipment Run-Hour Monitoring
• History Trending
• Alarm Management
• Division of Operational Responsibilities
• Economic Load Allocation & Load Shedding (CPP)
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POWER PLANTAUTOMATION &
CONTROL
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POWER PLANT AUTOMATION & CONTROL
Burner Management System
• Furnace Purge Supervision
• Secondary Air Damper Modulation, On/Off Control and Supervision
• Light/Heavy Oil On/Off Control and Supervision
• Pulveriser and Feeder On/Off Control and Supervision
• Flame Scanning
• Overall Boiler Flame Failure Protection
• Boiler Trip Protection
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POWER PLANT AUTOMATION & CONTROL
Soot Blower Sequential Control
• Wall Blowers
• Long Retractable Blowers
• Air Heater Blowers
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POWER PLANT AUTOMATION & CONTROL
Automatic Turbine Run-up System
• Oil Supply Control - Turning Gear, Auxiliary Oil Pumps, Emergency Oil Pump, Jacking Oil Pump and Lube Oil Temperature
• Condensate & Evacuation Control - Condensate Extraction Pumps, Gland Steam Pressure, Vacuum Pumps and Vacuum Breaker Valve
• Turbine Control - Steam & Metal Temperature Matching, Warming up of HP ESV & CV, Steam Rolling & Acceleration and Auto Synchroniser
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POWER PLANT AUTOMATION & CONTROL
Turbine Stress Evaluator
• Calculation of Actual and Permissible Thermal Stress Values
• Comparison of Actual with Permissible Stress Values and Computation of Available Margin
• Optimize Start up, Operation and Shut down
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POWER PLANT AUTOMATION & CONTROL
Automatic Turbine Tester
• Safety Devices - Remote Trip, Over-speed, Low Vacuum and Thrust Bearing
• HP/IP Valves - HP Stop and Control Valves, and IP Stop and Control Valves
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POWER PLANT AUTOMATION & CONTROL
Electro-hydraulic Governing System
• Speed Control
• Load Control
• Load Shedding
• Initial Pressure Control
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CRITICAL CLOSED LOOPS
• CMC - Boiler Follow / Turbine follow / Coordinated (Utility)
• Header Pressure Control (CPP)
• Combustion - Fuel / Air Flow
• Steam Temperature
• Drum Level
• Furnace Draft
AUTOMATION & CONTROL
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AUTOMATION & CONTROL
OPEN LOOP CONTROL
• Interlocking - Safe Startup / Shutdown
• Protection - Emergency Shutdown (Trip)
• Sequencial Control - Efficient Startup / Shutdown
CRITICAL OPEN LOOPS
• ID/FD /PA Fans
• BFP
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POWER PLANTINSTRUMENTATION
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POWER PLANT INSTRUMENTATION
• Temperature - T/C & RTD
• Pressure
• Level - DP / Displacement / Hydra Step Drum Level Indicator
• Flow - DP / Annubar / Mag-flow
• Turbine Supervisory - Vibration/ Expansion/ Axial Shift/ Eccentricity
• Steam & Water Analysers - Conductivity/ pH/ DO2/ Silica
• Gas Analysers - O2/ CO2/ CO (in Flue Gas) Pollution Monitor H2 Purity (in Generator)