POWER GENERATION

PROCESS BASICS

BOILER / STEAM TURBO-GENERATOR

UTILITY PLANT
40%

Steam Condenser

20%

Stack
Lake

Steam
6% Aux. Power + Losses

34% Electricity

100%
Fuel
Air

Boiler

Steam Turbine

Generator

THERMAL EFFICIENCY - 34%

Transmission

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

THERMAL EFFICIENCY - 80%

Transmission

SIMPLE CYCLE COMBUSTION (GAS) TURBINE

57-62%

100% Fuel

Stack
Combuster

3% Aux Power + Losses

35-40% Electricity

Air

Compressor

Turbine

Generator

THERMAL EFFICIENCY - 35-40%

Transmission

GAS TURBINE
INDUSTRIAL CO-GENERATION PLANT
20%
Stack

Stack
Supplementary/
Auxiliary
Fuel (Optional)

Process Steam

Process Plant

100% Fuel
Combuster

Exhaust Gas

Air

Compressor

Turbine

Generator

Transmission

GAS TURBINE
COMBINED CYCLE POWER PLANT

28%

Steam Condenser
20%
Stack

Stack

Steam

Supplementary
Fuel (Optional)

Lake

100% Fuel
Steam Turbine
Combuster

Generator

Exhaust Gas

Air

6% Aux. Power + Losses

Compressor

Turbine

Generator

Thermal Efficiency - 45-55%

Transmission
12-15% Electricity

35-40% Electricity

Transmission

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

UNIT#2

Turbine Steam System

TURBINEGENERATOR

HP & LP Heaters System

Turbine Supervisory & Control
System
Generator & Electrical System
Turbine Miscellaneous Systems
Turbine Bypass System

DM Plant

Fuel Handling System

Station Miscellaneous Systems

CAPTIVE POWER PLANT - FUNCTIONAL BLOCK

DIAGRAM
Switch Yard System

Ash Handling System

Station Electrical System

Steam & Water

BOILER

Air & Flue Gas

Fuel Preparation
Fuel Firing
Steam

TG

UNIT#2

UNIT#3

HP & LP Heaters
Supervisory & Control
Generator & Electrical
Miscellaneous Systems

BFPs & Deaerator System

DM Plant

Fuel Handling System

Station Miscellaneous Systems

BOILER FUNDAMENTALS

BASIC DIAGRAM OF A BOILER

Steam

Water

Steam / Water System

Blowdown

Fuel

Flue Gas

Mixing of
Fuel & Air

Air

Furnace

Heat Transfer
Surface

Ash

SALIENT FEATURES OF MODERN INDUSTRIAL

& UTILITY BOILER
STEAM BOILER
WATER TUBE
SUPERHEATED STEAM

HIGH PRESSURE
WATER COOLED FURNACE
WATER CIRCULATION

COMBUSTION REQUIREMENTS

Sufficient
Combustion Air

Fuel
is
Gasified

Mixing within
Flammable
Range

Temperature
above
Ignition
Point

Combustion
Time
Temperature
Turbulence
3 Ts of Combustion

BASIC COMBUSTION CHEMISTRY

Complete
(Air) Oxygen

O2

Fuel

Flue Gas
Products
H2O
CO2

H2
C

Incomplete
Oxygen

O2

Fuel

Heat

H2
C

Other Combustibles - Sulphur to Sulphur Oxides

Non-combustible - Nitrogen to Nitrogen+Nitrous Oxides
Ash

Heat
Flue Gas
Products
H2O
CO2
CO
H2
C

BOILER WATER & STEAM SYSTEM

Drum

Spray
Water

Hot Reheat
Steam
Main Steam

Attemperator
Attemperator
Platen
Super
Heater
Down
Comers

Final
Re
Heater

Primary
Re
Heater

Flue Gas

Final
Super
Heater

Primary
Super
Heater

Economiser

Furnace
Flue Gas
Out to
Air Heater

Water Wall
Risers

Bottom Ring Header

Simplified Process Diagram

Spray
Water

Cold
Reheat
Steam

Feed Water

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

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

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

AIR & FLUE GAS SYSTEM

To Air Cooled
Guns

To Hot
PA Header

From
FD Fans

Scanner Air Fans

To Cold
PA Header

PA FAN A

PA FAN B

WINDOX A
AH A
FURNACE

WINDBOX B

P
T
N
S
H

R
H

F
I
N
S
H

L
T
S
H

ESP A

E
C
O

ID Fan A
Chimney
ID Fan B
AH B

ESP B

FD FAN A

FD FAN B

Simplified Process Diagram

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

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

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

FUEL PREPARATION SYSTEM - COAL

Raw Coal Bunker

To Mill Discharge
Valves
To
Other
Mills

Coal Feeder

Hot PA

Coal+Air
to Burners

Mill A

To
Other
Mills

To Other Mills

Seal Air Fans

Simplified Process Diagram

Cold PA

FUEL PREPARATION SYSTEM - GAS/OIL

Fuel Gas
Supply

To Burners
FCV

FGTV

PRVs

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

PCV
Fuel Oil
Supply

Long
Recirc

To Burners

Oil Heater
FCV
Fuel Oil Pumps

FOTV

Steam

FUEL OIL

Simplified Process Diagram

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

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

FUEL PREPARATION SYSTEM

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

FUEL FIRING SYSTEM

OFA
OFA
FF

EA

FA

EF

AA

(3)

(2)

OFA

E
DE
D
CD
C

Air Damper

Front Wall

EA

End Air

FA

Fuel Air

AA

Aux. Air

(4)

(1)

Over Fire Air

Plan
(Corner Designation)

Coal Burner
Fire Ball Scanner
LFO?HFO Burner

BC
HFO Burner

Oil Flame Scanner

AB
A

HEA Igniter

AA

Typical Corner Arrangement

for a Tangentially Fired System

FUEL FIRING SYSTEM

Process Performance Highlights
Fuel Firing - Front / Tangential
Fuel Oil Atomisation - Mechanical / Air / Steam
Flame Ignition
Air Distribution
Fuel Combustion

FUEL FIRING SYSTEM

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

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

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

DEAERATION & FEED PUMPING SYSTEM

Condensate from LP Heater
HP Heater Drains

Aux. Steam
CRH Steam

Deaerator
Aux. Steam
for
Pegging

To HP
Heaters

IPT Extraction
Steam
Feed Storage Tank

To HP Bypass
Spray

Hydrazine
Dosing

T o APRDS
Spray

Ammonia
Dosing

Recirculation
Valve
M

Discharge Valve

Boiler Feed Pumps

Simplified Process Diagram

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

DEAERATION & FEED PUMPING SYSTEM

Major Equipment
Boiler Feed Pumps
Hydraulic Coupling
Deaerator

DEAERATION & FEED PUMPING SYSTEM

Process Regulation
Deaerator Pressure
Deaerator Level
BFP Minimum Recirculation
Feed Pump Speed

STEAM TURBINE FUNDAMENTALS

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)

BASIC RANKINE CYCLE

T
Heat Available
for Work

Unavailable Heat

IMPROVING RANKINE CYCLE

Superheating
Increased Pressure
Decreased Exhaust Pressure
Regenerative Feed Heating
Reheating

STEAM TURBINE TYPES

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

TURBINE STEAM SYSTEM

Main
Steam
ESV

CV

HP
Turbine

IP
Turbine

LP

Turbine

Cold
Reheat
Steam
Condenser
Hot
Reheat
Steam

IV

CV

Extraction
Steam

Simplified Process Diagram

TURBINE STEAM SYSTEM

Major Equipment
Turbine - Casing, Rotor & Blades
Emergency Stop Valves
Control Valves
Condenser

TURBINE STEAM SYSTEM

Process Regulation
Steam Admission
Emergency Shutdown

REGENERATIVE FEED HEATING SYSTEM

To
From BFP
Boiler Discharge

CRH
Steam
To
Deaerator

To
Deaerator

LPT
Extraction Steam

LP
HTR

HP
HTR

LPT
Extraction Steam

IPT
Extrn.
Steam

LP
HTR

HP
HTR

To
Condenser

Minimum
Recirculation

Hotwell

Makeup

LPT Extraction

To
Condenser
HP
Flash
Tank

Condenser

Gland
Leakoff
Steam

GSC

LP
HTR

LP
Flash
Tank

Simplified Process Diagram

Drain
CLR

Condensate Extraction
Pump

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

REGENERATIVE FEED HEATING SYSTEM

Major Equipment
HP Heaters
LP Heaters
Drain Cooler
Condensate Extraction Pumps

REGENERATIVE FEED HEATING SYSTEM

Process Regulation
Hotwell Level
Heater Level
Minimum Flow through CEP & GSC

TURBINE GOVERNING & CONTROL SYSTEM

Governing
Oil
System
Turning
Gear

Jacking
Oil
System

Condenser
Vacuum
System

Lubricating
Oil
System
OIL SYSTEMS

Gland
Steam
System
VACUUM SYSTEM

Turbine
Drain
System

WARM UP SYSTEM

Functional Block Diagram

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

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

TURBINE GOVERNING & CONTROL SYSTEM

Process Regulation
Speed / Load / Frequency Control
Gland Steam Pressure Control

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

TURBINE MISCELLANEOUS SYSTEMS

Condenser Cooling Water System
CW Return Header

Cooling
Tower
CW
Sump

CW
Makeup
Water

To
Unit#2

CW Supply Header

Circulating
Water Pumps

Simplified Process Diagram

Condenser Waterbox
A
B

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

TURBINE BYPASS SYSTEM

Main
Steam

To HPT
Feed
Water

PRV
Block
Valve

Spray
Control
Valve

CRH

HRH

From HPT

To IPT

Condensate
Condenser

Simplified Process Diagram

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

TURBINE BYPASS SYSTEM

Process Regulation
MS Pressure Reduction & Desuperheating
HRH Steam Pressure Reduction & Desuperheating

GENERATOR FUNDAMENTALS

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

GENERATOR EFFICIENCY & LOSSES

Efficiency = Output Electrical Energy

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

GENERATOR & UNIT ELECTRICAL SYSTEM

Metering &
Protective
Relays

Generator
Transformer

Generator
Synchronising
Sceme
Unit
Auxiliary
Transformer

Field
Excitation
System

ELECTRICAL SYSTEMS

Seal
Oil
System
Hydrogen
Cooling
System
Stator
Cooling Water
System

MECHANICAL SYSTEMS

Generator Functional Block Diagram

GENERATOR & UNIT ELECTRICAL SYSTEM

Isolator

132 KV Bus I

132 KV Bus II
Circuit Breaker

Unit
Auxiliary
Transformer

GT

11 kV

From
Station
Bus
Generator

6.6 kV Unit Bus A

Key One Line Diagram

From
Station
Bus
6.6 kV Unit Bus B

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

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

GENERATOR & UNIT ELECTRICAL SYSTEM

Process Regulation
Field Excitation
Generator Synchrinisation
Voltage Regulation

POWER PLANT
OPERATION & MAINTENANCE

OPERATION & MAINTENANCE

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

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

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)

POWER PLANT
AUTOMATION &
CONTROL

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

POWER PLANT AUTOMATION & CONTROL

Soot Blower Sequential Control

Wall Blowers
Long Retractable Blowers
Air Heater Blowers

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

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

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

POWER PLANT AUTOMATION & CONTROL

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

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

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

POWER PLANT
INSTRUMENTATION

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)