POWER GENERATION PROCESS BASICS

Amit Prakash

BOILER / STEAM TURBO-GENERATOR UTILITY PLANT

Steam Condenser 40%

20%

Stack Lake Steam 6% Aux. Power + Losses 34% Electricity 100% Fuel Air

Boiler

Steam Turbine

Generator

Transmission

Amit Prakash THERMAL EFFICIENCY - 34%

BOILER / STEAM TURBINE-GENERATOR INDUSTRIAL CO-GENERATION

Process Steam 65% 15%

Process Plant Stack

Steam

5% Aux. Power + Losses 15% Electricity

Fuel 100% Air

Boiler

Steam Turbine

Generator

Transmission

THERMAL EFFICIENCY - 80% Amit Prakash

SIMPLE CYCLE COMBUSTION (GAS) TURBINE

57-62%

100% Fuel

Stack

Combuster

3% Aux Power + Losses

35-40% Electricity Air

Compressor

Turbine

Generator

Transmission

THERMALAmit EFFICIENCY Prakash - 35-40%

GAS TURBINE INDUSTRIAL CO-GENERATION PLANT

20% Stack

Stack Supplementary/ Auxiliary Fuel (Optional) 100% Fuel

Process Steam
Process Plant

Combuster

Exhaust Gas

Air

Compressor

Turbine

Generator

Transmission

Amit Prakash

GAS TURBINE COMBINED CYCLE POWER PLANT

Steam Condenser 20% Stack Supplementary Fuel (Optional) 100% Fuel Steam Turbine Combuster Exhaust Gas Generator Stack Steam Lake

28%

Transmission 12-15% Electricity

Air

6% Aux. Power + Losses

35-40% Electricity

Compressor

Turbine

Generator

Transmission

Thermal Amit Efficiency Prakash- 45-55%

UTILITY PLANT - FUNCTIONAL BLOCK DIAGRAM

Switch Yard System Ash Handling System Station Electrical System

Boiler Steam & Water System Air & Flue Gas System

BOILER

Fuel Preparation System Fuel Firing System Boiler Miscellaneous Systems Boiler Feed Pumps & Deaerator System Turbine Steam System

UNIT#2

TURBINEGENERATOR

HP & LP Heaters System Turbine Supervisory & Control System Generator & Electrical System Turbine Miscellaneous Systems Turbine Bypass System

DM Plant

Fuel Handling System Amit Prakash

Station Miscellaneous Systems

CAPTIVE POWER PLANT - FUNCTIONAL BLOCK DIAGRAM

Switch Yard System Ash Handling System Station Electrical System

Steam & Water Air & Flue Gas BOILER Fuel Preparation Fuel Firing

Steam

UNIT#2

UNIT#3

TG

HP & LP Heaters
Supervisory & Control Generator & Electrical

Miscellaneous Systems

BFPs & Deaerator System Fuel Handling System Amit Prakash

DM Plant

Station Miscellaneous Systems

BOILER FUNDAMENTALS

Amit Prakash

BASIC DIAGRAM OF A BOILER

Water Steam

Steam / Water System

Blowdown

Fuel Flue Gas

Mixing of Fuel & Air

Heat Transfer Surface Furnace

Air

Ash

Amit Prakash

10

SALIENT FEATURES OF MODERN INDUSTRIAL & UTILITY BOILER STEAM BOILER

WATER TUBE
SUPERHEATED STEAM

HIGH PRESSURE WATER COOLED FURNACE WATER CIRCULATION

Amit Prakash

11

COMBUSTION REQUIREMENTS

Sufficient Combustion Air

Fuel is Gasified

Mixing within Flammable Range

Temperature above Ignition Point

Combustion Time Temperature Turbulence 3 Ts of Combustion

Amit Prakash

12

BASIC COMBUSTION CHEMISTRY

Complete (Air) Oxygen Fuel

Heat
Flue Gas Products H2O CO2

O2

H2 C

Incomplete Oxygen Fuel H2 C

Heat
Flue Gas
Products H2O CO2 CO H2 C

O2

Other Combustibles - Sulphur to Sulphur Oxides Non-combustible - Nitrogen to Nitrogen+Nitrous Oxides Ash

Amit Prakash

13

BOILER WATER & STEAM SYSTEM

Spray Water Drum Attemperator

Hot Reheat Steam Main Steam

Attemperator Platen Super Heater Down Comers Final Re Heater Primary Re Heater Final Super Heater Primary Super Heater Cold Reheat Steam Spray Water

Flue Gas

Economiser

Feed Water

Furnace Flue Gas Out to Air Heater

Water Wall Risers

Bottom Ring Header

Simplified Process Diagram

Amit Prakash

14

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

Amit Prakash

15

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

Amit Prakash

16

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

Amit Prakash

17

AIR & FLUE GAS SYSTEM

To Air Cooled Guns Scanner Air Fans

From FD Fans

To Hot PA Header

To Cold PA Header

PA FAN A

PA FAN B

WINDOX A AH A P T N S H R H F I N S H L T S H E C O ESP A ID Fan A Chimney ID Fan B ESP B AH B WINDBOX B FD FAN A

FURNACE

FD FAN B

Prakash Diagram Simplified Amit Process

18

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
Amit Prakash 19

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

Amit Prakash

20

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

Amit Prakash

21

FUEL PREPARATION SYSTEM - COAL

Raw Coal Bunker To Mill Discharge Valves To Other Mills Hot PA

Coal Feeder

Coal+Air to Burners

Mill A

To Other Mills

Cold PA

To Other Mills

Seal Air Fans

Simplified Process Diagram

Amit Prakash

22

FUEL PREPARATION SYSTEM - GAS/OIL

Fuel Gas Supply FCV PRVs FGTV To Burners

FUEL GAS
Atomising Steam/Air PCV Fuel Oil Return PCV Short Recirc Long Recirc

Fuel Oil Supply

Oil Heater FCV Steam FOTV

To Burners

Fuel Oil Pumps

FUEL OIL

Simplified Process Diagram

Amit Prakash

23

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

Amit Prakash

24

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

Amit Prakash

25

FUEL PREPARATION SYSTEM

Process Regulation Coal Flow - Raw Coal Feeder Speed Coal/Air Temperature & Flow - Cold & Hot PA Flows

Amit Prakash

26

FUEL FIRING SYSTEM

OFA OFA FF F EF EA FA AA (2) (3) OFA EA DE D Front Wall CD C BC B AB A AA HEA Igniter HFO Burner Oil Flame Scanner (1) Plan (Corner Designation) (4) Coal Burner FA AA Air Damper Over Fire Air End Air Fuel Air Aux. Air

Fire Ball Scanner

LFO?HFO Burner

Typical Corner Arrangement for a Tangentially Fired System Amit Prakash

27

FUEL FIRING SYSTEM

Process Performance Highlights

Fuel Firing - Front / Tangential

Fuel Oil Atomisation - Mechanical / Air / Steam Flame Ignition

Air Distribution
Fuel Combustion

Amit Prakash

28

FUEL FIRING SYSTEM

Major Equipment Burners Ignitors Flame Scanners Burner Tilt Mechanism Wind Box Dampers

Amit Prakash

29

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

Amit Prakash

30

BOILER MISCELLANEOUS SYSTEMS

Boiler Auxiliary Cooling Water System Ensures continuous supply of cooling water to Boiler & its 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

Amit Prakash

31

DEAERATION & FEED PUMPING SYSTEM

Condensate from LP Heater HP Heater Drains Aux. Steam Deaerator Aux. Steam for Pegging CRH Steam IPT Extraction Steam Feed Storage Tank To HP Bypass Spray T o APRDS Spray Recirculation Valve

To HP Heaters

Hydrazine Dosing Ammonia Dosing

Discharge Valve

Boiler Feed Pumps

Prakash Diagram SimplifiedAmit Process

32

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

Amit Prakash

33

DEAERATION & FEED PUMPING SYSTEM

Major Equipment Boiler Feed Pumps Hydraulic Coupling Deaerator

Amit Prakash

34

DEAERATION & FEED PUMPING SYSTEM

Process Regulation

Deaerator Pressure
Deaerator Level BFP Minimum Recirculation

Feed Pump Speed

Amit Prakash

35

STEAM TURBINE FUNDAMENTALS

Amit Prakash

36

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)

Amit Prakash

37

BASIC RANKINE CYCLE

T
Heat Available for Work

Unavailable Heat

Amit Prakash

38

IMPROVING RANKINE CYCLE

Superheating Increased Pressure Decreased Exhaust Pressure Regenerative Feed Heating Reheating

Amit Prakash

39

STEAM TURBINE TYPES

Condensing Turbine Back Pressure Turbine Regenerative Turbine Controlled Extraction No. of Cylinders Speed - Constant / Variable Single / Double Flow

Amit Prakash

40

TURBINE STEAM SYSTEM

Main Steam ESV CV HP Turbine IP Turbine

LP

Turbine

Cold Reheat Steam Condenser Hot Reheat Steam IV CV Extraction Steam

Prakash Diagram SimplifiedAmit Process

41

TURBINE STEAM SYSTEM

Major Equipment

Turbine - Casing, Rotor & Blades

Emergency Stop Valves Control Valves

Condenser

Amit Prakash

42

TURBINE STEAM SYSTEM

Process Regulation Steam Admission Emergency Shutdown

Amit Prakash

43

REGENERATIVE FEED HEATING SYSTEM

CRH Steam To Deaerator To From BFP Boiler Discharge To Deaerator LPT Extraction Steam

HP HTR

LP HTR

IPT Extrn. Steam HP HTR

LPT Extraction Steam LP HTR

Condenser Gland Leakoff Steam Minimum Recirculation Makeup Hotwell

To Condenser HP Flash Tank To Condenser GSC LP Flash Tank

LPT Extraction LP HTR Drain CLR

Condensate Extraction Pump

Prakash Diagram SimplifiedAmit Process

44

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

Amit Prakash

45

REGENERATIVE FEED HEATING SYSTEM

Major Equipment HP Heaters LP Heaters Drain Cooler Condensate Extraction Pumps

Amit Prakash

46

REGENERATIVE FEED HEATING SYSTEM

Process Regulation

Hotwell Level
Heater Level Minimum Flow through CEP & GSC

Amit Prakash

47

TURBINE GOVERNING & CONTROL SYSTEM

Governing Oil System

Turning Gear

Jacking Oil System

Condenser Vacuum System

Lubricating Oil System

Gland Steam System

VACUUM SYSTEM

Turbine Drain System

OIL SYSTEMS

WARM UP SYSTEM

Functional Block Amit Prakash Diagram

48

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

Amit Prakash

49

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

Amit Prakash

50

TURBINE GOVERNING & CONTROL SYSTEM

Process Regulation

Speed / Load / Frequency Control

Gland Steam Pressure Control

Amit Prakash

51

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 & its 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

Amit Prakash

52

TURBINE MISCELLANEOUS SYSTEMS Condenser Cooling Water System

CW Return Header

Cooling Tower CW Sump

To Unit#2

Condenser Waterbox A B

CW Makeup Water

CW Supply Header

Circulating Water Pumps

Prakash Diagram SimplifiedAmit Process

53

TURBINE MISCELLANEOUS SYSTEMS Condenser 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

Amit Prakash

54

TURBINE BYPASS SYSTEM

Main Steam To HPT Feed Water Block Valve CRH From HPT Spray Control Valve

PRV

HRH

To IPT

Condensate Condenser

Amit Prakash Diagram Simplified Process

55

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

Amit Prakash

56

TURBINE BYPASS SYSTEM

Process Regulation

MS Pressure Reduction & Desuperheating

HRH Steam Pressure Reduction & Desuperheating

Amit Prakash

57

GENERATOR FUNDAMENTALS

Amit Prakash

58

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

Amit Prakash

59

GENERATOR EFFICIENCY & LOSSES

Efficiency = Output Electrical Energy Input Mechanical Energy

Losses - Bearing Loss, Copper Loss & Iron Loss Typically Efficiency is 90-97%

Amit Prakash

60

GENERATOR & UNIT ELECTRICAL SYSTEM

Metering & Protective Relays

Generator Transformer

Seal Oil System Hydrogen Cooling System

Generator Synchronising Sceme

Unit Auxiliary Transformer

Field Excitation System

Stator Cooling Water System

ELECTRICAL SYSTEMS

MECHANICAL SYSTEMS

Generator Functional Amit PrakashBlock Diagram

61

GENERATOR & UNIT ELECTRICAL SYSTEM

Isolator 132 KV Bus I

132 KV Bus II

Circuit Breaker

GT

Unit Auxiliary Transformer From Station Bus From Station Bus 6.6 kV Unit Bus B

11 kV

Generator 6.6 kV Unit Bus A

Amit Prakash Key One Line Diagram

62

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

Amit Prakash

63

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

Amit Prakash

64

GENERATOR & UNIT ELECTRICAL SYSTEM

Process Regulation

Field Excitation
Generator Synchrinisation Voltage Regulation

Amit Prakash

65

POWER PLANT OPERATION & MAINTENANCE

Amit Prakash

66

OPERATION & MAINTENANCE

Efficiency Calculations Boiler Efficiency - Direct / Heat Loss Method Turbine Heat Rate - Total Heat Supplied/ KWHR Plant Heat Rate - Heat Supplied/ KWHR

Amit Prakash

67

OPERATION & MAINTENANCE

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

Amit Prakash

68

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)

Amit Prakash

69

POWER PLANT AUTOMATION & CONTROL

Amit Prakash

70

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

Amit Prakash

71

POWER PLANT AUTOMATION & CONTROL

Soot Blower Sequential Control

Wall Blowers
Long Retractable Blowers Air Heater Blowers

Amit Prakash

72

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

Amit Prakash

73

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

Amit Prakash

74

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

Amit Prakash

75

POWER PLANT AUTOMATION & CONTROL

Electro-hydraulic Governing System Speed Control Load Control Load Shedding Initial Pressure Control

Amit Prakash

76

AUTOMATION & CONTROL

CRITICAL CLOSED LOOPS CMC - Boiler Follow / Turbine follow / Coordinated (Utility) Header Pressure Control (CPP) Combustion - Fuel / Air Flow Steam Temperature Drum Level Furnace Draft

Amit Prakash

77

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

Amit Prakash

78

POWER PLANT INSTRUMENTATION

Amit Prakash

79

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)

Amit Prakash

80