MTV 420 THERMAL AND FLUID MACHINES

Nicola Kotz

THERMAL MACHINES

Alumni of Tuks Honours Professional Engineer Fossil Fuel Refining and Power Generation Experience

Ryno Nell

FLUID MACHINES

MTV 420 THERMAL AND FLUID MACHINES

What to expect from me
Industry based experience Patience and understanding Respect

What I expect from you

To work hard in my class and be prepared To be on time To participate in class discussions

MTV 420 THERMAL AND FLUID MACHINES

The STUDY GUIDE
Course layout Thermal up to Spring Day Textbooks Practicals Groups 30 July 2012 and ECSA Teaching Assistants

LETS GET STARTED

KOMATI POWER STATION

HOW DOES IT WORK?

COMPONENTS OF A POWER STATION

Turbine Plant
Turbine centre line LP, IP and HP Turbine SIZE?

Generator
Condenser Extraction Pumps Cooling towers/Fans

ARNOT POWER STATION TURBINE HALL (www.eskom.co.za)

Auxiliary Plant Regenerative feedwater heat exchangers

COMPONENTS OF A POWER STATION

Boiler Plant
Boiler Boiler drum Pumps and Pipes
Mills and mill feeders Grinding media Coal Bunkers Draft Group Fans

COMPONENTS OF A POWER STATION

Common Plant

Water Treatment Plant and distribution Chemistry Coal and Ash Handling Coal and Ash Storage Compressed Air Smoke Stack Effluent Handling Fire Systems Civil Structures Air conditioning Fuel Oil Plant

COMPONENTS OF A POWER STATION

Electrical Switchgear Transformers

Motors
Control and Instrumentation Instrumentation Brain of the Power Station

SIMPLIFIED VIEW
REF: Wikipedia

WHY STEAM POWER?

So now you know what a Steam Power Plant is Source fuel? Why does South Africa primarily use Steam Power for Electricity Generation?
Komati Power Station

Any significance?

CRITICAL TAKE HOME POINTS

Coal
Low calorific value: = low carbon = less energy = need to burn more coal = more ash = more $$ High ash content: = more ash = bigger ash plant = bigger ash dump = more $$ Abrasiveness: = wear on your grinding media = more $$ Hardgrove index: = milling requirements = more $$

Quality
Calorific value Ash content Abrasiveness Hardgrove index

So why dont we burn the best coal RSA can offer?

CRITICAL TAKE HOME POINTS

Coal Handling Coal Stockyard, Stacker/Reclaimer, Feeders, Conveyor Belts, Storage Silos, Bunkers Maximum stockpile, flexibility, belt tensioning, silo and bunker design What are key factors that affect your design? Quality of coal Mill capacity Bunker Capacity Required MW!

CRITICAL TAKE HOME POINTS

Ash Handling Wet Ash System Dry Ash System Ash Dam Ash Dump Sluice water Dust Suppression Pumps Pneumatic Handling: Pressure Vessels, Pipes Compressors, Airslides Valves Conveyor Belts, scrapers Blockages, wear, scale Ash conditioning

What types of Ash do you get?

Anything special that we can do with it??

EXAMPLE OF AN ASH DAM COMPLEX

CRITICAL TAKE HOME POINTS

Environmental Considerations ZLED ZERO LIQUID EFFLUENT DISCHARGE Ash Dam Complex Ground water contamination Cooling towers Is it pollution? Storm Water Friend or foe? Smoke Stack Height Distribution of particulates (90m vs 220m) Smoke Stack Emissions SO3 Conditioning

CRITICAL TAKE HOME POINTS

Boiler Construction of a Boiler Height: 120 m Tube material Types of Mills Mill Feeders Grinding Media Boiler tube leaks

Boiler Dosing and Sampling

Boiler blow through

BOILER BLOW THROUGH

CRITICAL TAKE HOME POINTS

Turbine Demin (??!!) Water Jacking oil Bearing oil Vibrations Oil analysis Temperature probes

Blades and vanes Is it catastrophic if a blade breaks?

CRITICAL TAKE HOME POINTS

Electrical
What is switchgear? DOL Bulk supply Starting current? Motor protections Control And Instrumentation

Heart of a power station Controls and Monitoring

Reduces man power requirements Pneumatic control instruments DRY AIR

STEAM POWER THERMODYNAMICS!

Major Components of the Steam Power Cycle
Turbine (Centreline) Condenser Pump Boiler

THE IDEAL RANKINE CYCLE

THE IDEAL RANKINE CYCLE

THE IDEAL RANKINE CYCLE

THE IDEAL RANKINE CYCLE

1 (1) 2 (2): Isentropic expansion of the Turbine, throttled conditions 2 3: Outflow of heat in the Condenser, constant pressure Isentropic pumping of condensate to Boiler, feedwater

3 4:

4 1 (1):

Inflow of heat in the Boiler, constant pressure

LETS DO AN EXAMPLE
Determine the thermal efficiency of an ideal Rankine cycle using steam as a working fluid. The condenser pressure is 5kPa, the boiler pressure is at 3.5MPa. Saturated vapour enters the turbine inlet.

BUT IS THE REAL WORLD IDEAL?

Piping Losses Friction causes a pressure drop Is the pressure of the water entering a boiler the same as the steam pressure exiting the boiler? Turbine Losses Heat transfer to surroundings neglected Turbine =

The efficiency is a known parameter of a turbine (OEM)

BUT IS THE REAL WORLD IDEAL?

Pump Losses Work lost due to irreversibility (energy in energy out) Heat transfer to surroundings neglected Pump = =

Pump efficiency Function of the pump characteristic curve

Condenser Losses Negligible

DEVIATIONS FROM THE IDEAL

LETS DO ANOTHER EXAMPLE

Determine the thermal efficiency of a real world steam power plant. The steam enters the turbine at 3.5MPa, 350C where it expands to 7.5kPa, 40C. It is then pumped up to 5.2MPa before entering the boiler at 5MPa, 39C. Steam leaves the boiler at 4MPa, 400C. The pump efficiency is 82% and the turbine efficiency is 87%. Discuss where other losses occur and why.

REHEAT
Bleed off steam from the HP turbine and reheat in the Boiler before expanding in LP turbine Advantages Improve LP exhaust quality (moisture and turbine blades) NB!! Increased net work = lower steam flow rate Smaller plant components = Capital cost lower Thermal efficiency increases/decreases dependant on when where you bleed off the steam
=

REHEAT

REHEAT

A REHEAT EXAMPLE
Consider a reheat cycle. Steam exits the boiler in a throttled state of 4.5MPa, 400C. After expansion in the turbine to 450kPa, the steam is reheated to 400C and then expanded to 7.5kPa before entering the condenser. Determine the efficiency of the cycle.

REGENERATION
Heat the feedwater return with bleed steam from the turbine via a heat exchanger

Feedwater heaters Open: changes due to mixing Closed: stays constant Constant pressure mixing

Steam Extraction Fraction??

Energy = money Hypothesis: Energy required heat demin from ambient vs FWH Temperature? Thermal Efficiency improved Avoid thermal shock in your boiler tubes Reduce irreversibilities

Airheaters another example of regeneration

REGENERATION 1 CLOSED FWH

Mass flows???

REGENERATION

REGENERATION A REALISTIC VIEW

Ref: Pg 365; Fig 11.12; Sonntag, Borgnakke and Van Wylen, Fundamentals of Thermodynamics , 5th Edition

A REGENERATION EXAMPLE
A power plant with 1 closed FWH has a condenser temperature of 45C, a maximum boiler pressure of 5MPa and a boiler exit temperature of 900C. Extraction steam at 1MPa to the FWH condenses and is pumped to the 5MPa feedwater line where all the water goes to the boiler at 200C. Find the fraction of the extraction steam flow and the two specific pump work inputs.

QUESTIONS?