POWER GENERATI ON

PROCESS BASI CS
BOILER / STEAM TURBO-GENERATOR
UTILITY PLANT
Boiler
100%
Fuel
Air
Stack
Steam
Steam Turbine Generator
20%
Lake
6% Aux. Power + Losses
Steam Condenser
40%
34% Electricity
THERMAL EFFICIENCY - 34%
Transmission
BOILER / STEAM TURBINE-GENERATOR
INDUSTRIAL CO-GENERATION
Boiler
Fuel
100%
Air
Stack
15%
Steam Turbine Generator
15% Electricity
Transmission
Steam 5% Aux. Power + Losses
Process Steam
65%
Process Plant
THERMAL EFFICIENCY - 80%
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%
Air
Compressor
Transmission Generator
GAS TURBINE
INDUSTRIAL CO-GENERATION PLANT
Turbine
100% Fuel
Combuster Exhaust Gas
20%
Stack
Stack
Process Plant
Process Steam

Supplementary/
Auxiliary
Fuel (Optional)
Air
Compressor
Transmission Generator
GAS TURBINE
COMBINED CYCLE POWER PLANT
20%
Stack
100% Fuel
Combuster Exhaust Gas
Stack
Turbine
Steam Turbine
Steam
Generator
Transmission
Steam Condenser
Lake
28%
6% Aux. Power + Losses
12-15% Electricity
35-40% Electricity
Supplementary
Fuel (Optional)
Thermal Efficiency - 45-55%
UTILITY PLANT - FUNCTIONAL BLOCK DIAGRAM
Switch 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 & Control
System
Generator & Electrical System
Boiler Steam & Water System
Air & Flue Gas System
Fuel Preparation System
Fuel Firing System
Boiler Miscellaneous Systems
Ash Handling System
CAPTIVE POWER PLANT - FUNCTIONAL BLOCK
DIAGRAM
Switch Yard System Station Electrical System
DM Plant
Fuel Handling System
Station Miscellaneous Systems
BFPs & 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
BOI LER FUNDAMENTALS
BASIC DIAGRAM OF A BOILER
Steam / Water System
Furnace
Heat Transfer
Surface
Mixing of
Fuel & Air
Water
Fuel
Air
Steam
Flue Gas
Ash
Blowdown
SALIENT FEATURES OF MODERN INDUSTRIAL
& UTILITY BOILER
STEAM BOILER

WATER TUBE

SUPERHEATED STEAM

HIGH PRESSURE

WATER COOLED FURNACE

WATER CIRCULATION
COMBUSTION REQUIREMENTS
3 Ts of Combustion
Combustion
Time
Temperature
Turbulence
Sufficient
Combustion Air
Fuel
is
Gasified
Mixing within
Flammable
Range
Temperature
above
Ignition
Point
BASIC COMBUSTION CHEMISTRY
Complete
O2
+
H2
C
Heat
(Air) Oxygen Fuel
Products
H2O
CO2
Incomplete
+
Heat
O2
H2
C
Oxygen Fuel
Flue Gas
Flue Gas
Products
H2O
CO2
CO
H2
C
Other Combustibles - Sulphur to Sulphur Oxides
Non-combustible - Nitrogen to Nitrogen+Nitrous Oxides
Ash
BOILER WATER & STEAM SYSTEM
Furnace
Water Wall
Risers
Drum
Down
Comers
Economiser
Feed Water
Primary
Super
Heater
Final
Super
Heater
Primary
Re
Heater
Final
Re
Heater
Platen
Super
Heater
Attemperator
Spray
Water
Spray
Water
Main Steam
Hot Reheat
Steam
Cold
Reheat
Steam
Bottom Ring Header
Simplified Process Diagram
Flue Gas
Flue Gas
Out to
Air Heater
Attemperator
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
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 Cold
PA Header
To Hot
PA Header
E
C
O
L
T
S
H
FURNACE
R
H
P
T
N
S
H
F
I
N
S
H
WINDOX A
WINDBOX B
From
FD Fans
To Air Cooled
Guns
Scanner Air Fans
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
Simplified Process Diagram
Hot PA
Cold PA
Mill A
Raw Coal Bunker
Coal Feeder
Coal+Air
to Burners
Seal Air Fans
To Other Mills
To Mill Discharge
Valves
To
Other
Mills
To
Other
Mills
FUEL PREPARATION SYSTEM - GAS/OIL
Simplified Process Diagram
Fuel Gas
Supply
To Burners
PRVs
FCV FGTV
FUEL GAS
FUEL OIL
Fuel Oil
Supply
PCV
Fuel Oil Pumps
To Burners
Oil Heater
Steam
FCV FOTV
Fuel Oil
Return
Short
Recirc
Long
Recirc
Atomising
Steam/Air
PCV
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
Typical Corner Arrangement
for 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
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
Simplified Process Diagram
Deaerator
Feed Storage Tank
M
Discharge Valve
Recirculation
Valve
Boiler Feed Pumps
To HP
Heaters
To HP Bypass
Spray
T o APRDS
Spray
Hydrazine
Dosing
Ammonia
Dosing
Aux. Steam
for
Pegging
HP Heater Drains
Condensate from LP Heater
Aux. Steam
CRH Steam
IPT Extraction
Steam
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
S
Unavailable Heat
Heat Available
for Work
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
Simplified Process Diagram
Condenser
HP
Turbine
IP
Turbine
LP
Turbine
Extraction
Steam
Main
Steam
Cold
Reheat
Steam
Hot
Reheat
Steam
ESV CV
IV CV
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
Simplified Process Diagram
From BFP
Discharge
To
Boiler
HP
HTR
HP
HTR



CRH
Steam
To
Deaerator
IPT
Extrn.
Steam
Condenser
Hotwell
Condensate Extraction
Pump
LP
HTR
LP
HTR
HP
Flash
Tank
LP
Flash
Tank
To
Deaerator
LPT
Extraction Steam
LPT
Extraction Steam
Minimum
Recirculation
LP
HTR
Drain
CLR
GSC
To
Condenser
To
Condenser
Gland
Leakoff
Steam
LPT Extraction
Makeup
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
Functional Block Diagram
Gland
Steam
System
Lubricating
Oil
System
Governing
Oil
System
Turning
Gear
Jacking
Oil
System
Condenser
Vacuum
System
Turbine
Drain
System
OIL SYSTEMS
VACUUM SYSTEM WARM UP SYSTEM
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
Simplified Process Diagram
Cooling
Tower
CW
Sump
CW
Makeup
Water
Condenser
A
Waterbox
B
Circulating
Water Pumps
To
Unit#2
CW Return Header
CW Supply Header
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
Simplified Process Diagram
Main
Steam
CRH
To HPT
From HPT
To IPT HRH
Feed
Water
PRV
Spray
Control
Valve
Block
Valve
Condenser
Condensate
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
Generator Functional Block Diagram
Unit
Auxiliary
Transformer
Field
Excitation
System
Generator
Synchronising
Sceme
Generator
Transformer
Metering &
Protective
Relays
Stator
Cooling Water
System
Hydrogen
Cooling
System
Seal
Oil
System
ELECTRICAL SYSTEMS MECHANICAL SYSTEMS
GENERATOR & UNIT ELECTRICAL SYSTEM
Key One Line Diagram
132 KV Bus I
132 KV Bus II
Isolator
Circuit Breaker
GT
Generator
Unit
Auxiliary
Transformer
From
Station
Bus
From
Station
Bus
6.6 kV Unit Bus B 6.6 kV Unit Bus A
11 kV
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
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
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
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
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)