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Basics of Power
Generation Plant
Lectures(2nd SEPTEMBER 2010)
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CONTENTS
Contents.
II. Definition
III. Design Philosophy
IV. Design Consideration
V. List of Major Equipment in Power Plant
VI. Types of Power Generation Plant
VII. Brief Detail of Thermal Energy Based Power Plant
.
IX. Brief Detail of Diesel Engine Based Power Plant
X. Brief Detail of Combined Cycle Power Plant
XI. Brief Detail of Cogeneration Power Plant
XII. Balance of Plant System
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XIII. Electr ical System
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INTRODUCTION
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PURPOSE
Recently we have worked in some industrial and process plant projects
also, where the power plant size is very big- viz- in Dung Quat Refinery-
total ower is a rox. 110MW 4*27MW STG+ 1.6MW EDG and in
Koniambo Nickel Project total power is approx. 360MW (2*131MW
STG+ 2*46MW CTG+ 2*3.5MW EDG).
Purpose of this Lecture is to provide some basic idea and generalized
view of large capacity power generation Plant to all design staffs in our
department and create great interest among them about big size power
generation plant.
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INTRODUCTION
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DESIGN
PHILOSOPHY
III. DESIGN PHILOSOPHY General
.
ii. Classes
i. Without failure
.
Maintenancei. Monitoring
ii. Testing
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iii. Upgrading, Modifying, Repair
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DESIGN
PHILOSOPHY
Safet
.
i. Operation
ii. Personal
iii. Environmental
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DESIGN
CONSIDERATION
.
Electrical Load Capacity
Confi uration
Environmental Consideration
Site Selection & Space limitation
Plant Design Life
Voltage Level
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DESIGN
CONSIDERATION
-
expenditure for the working life of the station
es gn mus prov e c eap; re a e an
continuous service
Future Growth
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MAJOR EQUIPMENT
.
E UIPMENT USED INPOWER PLANT
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1. BOILER
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OIL FIRED WATER
BOILER
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COAL FIRED
BOILER
Boiler
.
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2. STEAM TURBINE
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STEAM
TURBINE
Steam Turbine
.
ii. Extract thermal
energy to rotary
motor
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3. GAS TURBINE
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GAS TURBINE
Gas Turbine
i. Rotary engine
ii. Extract energy from flow of
combustion as
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4. HEAT RECOVERY STEAM
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HRSG
Heat Recovery SteamGenerator
i. Energy recovery heat
exchanger
.
turbine
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5. DEAERATOR
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DEAERATOR
Deaerator
i. Removal of air +
dissolved gases
ii. From feedwater to
boiler
.
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6. SURFACE CONDENSER
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SURFACE
CONDENSER
Surface Condenser
i. Heat exchanger
ii. Condense exhaust steam
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7. BOILER FEED WATER
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BOILER FEED WATER
PUMP
Feed Water Pump
.
steam generating
boiler
. res wa er con ense
steam
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8. FEED WATER HEATER
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FEED WATER
HEATER
Feed Water Heater
. -
ii. Improve thermodynamic
efficiency
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TYPE &
CONFIGURATION
VI. TYPES OF POWER
GENERATION PLANT &
. erma eam ur ne
2. Gas Engine- Based
3. Diesel Engine- Based
.
5. Renewable Energy Based
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*Type 1, 2 & 3 are the primary intent of this lecture
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THERMAL POWER
PLANT
VII. BRIEF DETAIL of THERMAL
ENERGY BASED POWER
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DESIGN
1. Definition: Fuel type (Coal/Oil/Agricultural
Waste)
2. Steam Conditions: Pressure/ Temperature
.
4. Plant Function & Purpose
5. Steam Power Cycle Economy
.
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FEATURES
1. Steam/ thermal ower station- used heat
energy
. energy
.
4. Cannot be used to cater peak loads
5. Keep running very close to full efficiency for
24 hours
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MODEL FLOW
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PROCESS FLOW
1. STAGE 1: COAL & ASH PLANTi. Entrance and exit of fuel (coal)
ii. Handling treatment & storage of coal
iii. Final handlin & dis osal of ash
2. STAGE 2: STEAM GENERATING PLANT.
ii. Steam creation by heat
. i. Energy conversion stage
ii. Steam turbinecovert steam to rotational mechanical energy
.
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PROCESS FLOW
4. STAGE 5: FEED WATER & COOLINGi. Recycling stage
ii. Steam used in boiler chamber is condensed back to water to re-use
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STEAM TURBINE
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STEAM TURBINE
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STG LAYOUT
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ADVANDAGES VS
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ADVANDAGES VS
DISADVANTAGES
ADVANTAGES DISADVANTAGES
1. Chea coal 1. More La out S ace
2. Can be installed anywhere near
fuel & water supply
2. Air pollution
3. Cost more to run
3. Less construction space
4. Cost for generation less4. Low overall efficiency
5. Very high start-up/ shutdown
5. Used for base power station time
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COMBUSTION
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COMBUSTION
POWER PLANT
VIII. BRIEF DETAILof
COMBUSTION ENGINE
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DESIGN
1. Use prime mover to generate electrical
energy
2. Generally used to produce limited amount ofelectrical energy
3. Used as eakin ower stations
4. Applications:i. For large power requirements- space limitation
ii. Peak shaving
iii. Combined cycle or cogeneration power plant- waste
iv. Emergency power- starting time
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ADVANDAGES VS
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ADVANDAGES VS
DISADVANTAGES
ADVANTAGES DISADVANTAGES
1. Sim le desi n & construction 1. Problem with starting- compressor
2. Much smaller at same capacity
3. Lower operation cost
need power to operate
2. Not output low- greater power used
to drive compressor
4. Less water (no condenser)5. Maintenance cost low
3. Overall efficiency low- exhaust gasescontain heat
6. Start quickly
7. No standby losses
.
high- lower life
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DIESEL POWER
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DIESEL POWER
PLANT
IX. BRIEF DETAIL of DIESEL
ENGINE BASED POWER
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DESIGN
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. g er t erma e c ency
2. Fuel Selection3. Used as emergency power supply source
.
i. Class A- continuous at full nameplate kW rating
ii. Class B- Standby basis for extended period of time
iii. Class C- Emergency basis for short period of t ime
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ENGINE OPERATION
1. Starting system
.
3. Lubrication System & Oil Cooling
4. Primary Cooling System (Engine)5. S eed Control S stem Governor
6. Instrumentation Requirement
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ADVANDAGES VS
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DISADVANTAGES
ADVANTAGES DISADVANTAGES
1. Sim le desi n & la out 1. Hi h runnin char es due to
2. Less space & is compact
3. Start-up fast & pick up load in
diesel price
2. Does not work efficiently under
short time
4. Less water for cooling
3. Generates small amount ofpower
5. Better thermal efficiency
6. Overall cheaper cost
4. Lubrication cost very high
5. Maintenance charges high
. o s an y osses
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COMBINED CYCLE
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COMBINED CYCLE
X. BRIEF DETAILof
COMBINED CYCLE
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DEFINITION
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A combined cycle is characteristic of a power producing
engine or plant that employs more than one
thermodynamic cycle.
Combining two or more cycle such as the Brayton
cycle and Rankine cycle results in improved overall
e c ency.
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COMBINE CYCLE
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1. Combination of- GTG (s)+ turbine exhaust waste heat+
STG
2. Maximum efficiency- hot exhausted gas from gasturbine raise steam
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DESIGN
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1. Operating Differences:
i. Turndown
ii. Exhaust gas flowsiii.Feedwater temperatures
3. Boiler Design
4. Combined Cycle Controls
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PROCESS FLOW
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THERMAL POWER
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PLANT
.
PLANT
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DEFINITION
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,
is the use of power station to simultaneously
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TYPE
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TYPE
1. Steam Combined Generation
2. Gas Combined Generation
= Gas Turbine + Heat Recovery Steam Generator
3. Steam- Gas Combined Generation
= Gas Turbine + Steam +HRSG
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SIMPLE CYCLE
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BOP
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.
Y TEM
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1. COAL PREPARATION &
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COAL HANDLING
PLANT
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PLANT
Coal Preparation
i. Prepare coal to make it
usable for furnace and
necessar handlin /storage
ii. Main component:
, ,
Crusher, Screen,Conveyor, etc
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2. LIMESTONE PROCESSING
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LIMESTONE
PLANT
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PLANT
Limestone
i. To make coal sulfur free
ii. Reduce Sox
iii. Main Component:
Feeder, Crusher, Sizer,
Conveyor, Rotary
Feeder, Bucket Elevator,
Cyclone, etc
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3. FUEL STORAGE & HANDLING
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FUEL STORAGE
& HANDLING
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Handling
. load
ii. Major Component: Storage
an s, n oa ng
Forwarding Pumps
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4. COMPRESSED AIR SYSTEM
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COMPRESSOR
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Com ressed Air
System
i. Service Airii. Boiler Soot Blowing
iii. Instrument Air
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5. COOLING TOWER
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COOLING
TOWER
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COOLING
PROCESS
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Heat up
of waterSteam pass through
heat exchanger
wind blowconstant
Cooling process by
Water drip down
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SYSTEM
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6. Combustion Air Intake & Exhaust System
i. Deliver clean combustion air to engine
ii. Min loss of performance
7. Heating, Ventilation & Air Condition System
.
ii. Major Component: Air Condition, Supply Air Fan, ExhaustFan, Filters, etc
8. Ash Removal & Handling System
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THERMAL POWER
PLANT
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XIII. ELECTRICAL SYSTEM
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SYSTEM
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2. Generator
3. Circuit Breaker
4. Power Transformer/ Distribution Transformer
5. MV/LV SWG, MCC, Fixed Panel
. ys em
7. Earthing System
8. Raceway System
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.
SYSTEM
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System
.
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1. RATING & SYSTEM
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RATING &
SYSTEM
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i. Operation Condition
- Steady-state
- Sustained
- Harmonics
ii. Frequency
- Ranges %
- Duration
iii. Stability Study- Load shedding
- Over-speed trip
iv. Limit Frequency Variation
- Point of Common Cou lin
- Within the plant system
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FREQUENCY
CONTROL
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Objective:
i. To control electrical output of generators
ii. To control power balance between generators
iii. To control export & import of electrical power
.
v. To maintain balance in active power output
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RATING &
SYSTEM
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VOLTAGE
i. Operation Condition
- ea y-s a e
- Sustained
- Harmonics
ii. Voltage
- Ranges %
-
iii. Limit voltage variation
- Point of Common Coupling
- rans en o age
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VOLTAGE
CONTROL
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Objective:
i. To maintain the volta e constant within certain bandwidthii. Under normal operation conditions, the supply voltage range should not
differ from the nominal voltage system (10% or define by uti lities)
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2. GENERATOR
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GENERATOR
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3. CIRCUIT BREAKER
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CIRCUIT
BREAKER
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PLANT
LAYOUT
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4. POWER TRANSFORMER
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POWER
TRANSFORMER
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5. MV/ LV SWG, MCC, FIXED
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SWITCHGEAR
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6. AC/ DC UPS SYSTEM
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UPS
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CONTROLS
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. ,
Protection & Meterin S stemi. Electrical Control panelsii. Protection Panel
iii.Metering
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CONTROLS
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.
S stemi. Control panelsii.Automatic control s stem DCS etc
iii.Monitoring instruments
v.Auxiliary system (Blower, heater, filter, air fan, fire fighting,etc
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.
10. Raceway System
11. Lighting System
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THE END
Thank You!!!
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