POWER PLANT

APPLICATIONS
A General Overview

-
 CONTENTS
• Power Plant Introduction, Types of Power Plants
• Flow diagram of a Conventional Power Plant
• Major Components of a Conventional Thermal
Power Plant
• List of valves used in a Conventional Power
Plant
• Typical Thermal Power Plant Schematic
• Combined Cycle Power Plant
• Introduction to Supercritical Power plants
 WHAT IS A POWER PLANT ?
A POWER PLANT
IS A FACILITY FOR
THE GENERATION
OF ELECTRIC
POWER.
 TYPES OF POWER PLANTS
• HYDROELECTRIC POWER PLANTS
Working fluid: Water, Energy Source: Water

• THERMAL POWER PLANTS

Working fluid: Steam, Energy source: Coal / Oil / Gas
- Conventional Single Cycle power plant
- Combined Cycle Power plant
• NUCLEAR POWER PLANTS
Working fluid: Steam, Source: Uranium/Plutonium
 TYPES OF POWER PLANTS
(Contd…)

•WIND MILLS
Working fluid: Wind

• GEOTHERMAL
ENERGY
HYDROELECTRIC POWER
PLANT
CONVENTIONAL COAL FIRED
THERMAL POWER PLANT
Generally a Power Plant can be divided into:

The Steam Supply System

(thermal heat source, eg Boiler)

Balance of Plant Systems (BoP)

(systems for power conversion
and distribution, which includes Heat
Transfer and conversion system incl
auxiliary systems)
 Major Components of a Power
Plant
BOILER

A boiler is a closed vessel in

which water is heated under
pressure and converted to
steam.
Boiler is a source for producing
high pressure / temperature
steam.
Fossil fuel (that is coal or oil) or
nuclear energy is consumed to
provide heat energy to the
boiler.
Principle of natural circulation
 Drum boiler / once-through boiler

To Turbine To Turbine
SH SH

Drum WS

EVA EVA

ECO
ECO
 Major Components of a Power
Plant
TURBINE

• The purpose of a
steam turbine is to
convert heat energy
contained in high
pressure and high
temperature steam
into mechanical
energy.
 Major Components of a Power Plant
CONDENSER
• The condenser is
essentially a heat-
exchanger and operated
at near vacuum
conditions on the steam
turbine side, to enhance
the pressure drop through
the steam turbine and
improved the efficiency of
condensing the low
pressure steam back into
liquid water.
 Major Components of a Power
Plant
• FEED WATER PUMP
The feedwater pump must
pump the liquid water that
was condensed in the
condenser from the low
pressure steam, back into
the boiler. The primary
working fluid must be
pumped at a slightly
greater pressure than the
boiler pressure to ensure
that the fluid enters the
boiler
 Major Components of a Power
Plant
DEAERATOR
Deaerators are mechanical
devices that remove
dissolved gases from boiler
feedwater. During the
deaeration process,
concentration of the dissolved
carbon dioxide and oxygen is
reduced to a level where
corrosion is minimized; hence
the steam generation system
is protected from the
harmful effects of corrosive
gases.
CONVENTIONAL THERMAL
POWER PLANT
 SCHEMATICS OF CONVENTIONAL POWER PLANT

To
Auxillaries

MAIN TURBINE REHEAT TURBINE

PRIMARY SECONDARY
SUPERHEATER SUPERHEATER

SH Spray valve
BOILER REHEATER

RH Spray valve

ECONOMISER DEAERATOR

Cond Recirc valve

BFP Recirc valve

CONDENSER

HP HEATER Feed Water BOILER LP Heater Deaerator CONDENSATE

Control valve FEED PUMP Level Control PUMP
valve
 LIST OF SEVERE SERVICE
VALVES IN A POWER PLANT
• Condensate Pump Recirculation valve
• Deaerator Level Control valve
• Boiler Feed Water Pump Recirculation
valve
• Boiler Feed Water Level Control valve
• SH & RH Spray control valve
• Soot Blower valve
• Turbine Bypass valve
 CONDENSATE PUMP
RECIRCULATION VALVE
• Application of Condensate
Recirc valve is to protect the
Condensate pump by ensuring
that the minimum flow of fluid
(water) is maintained so that the
pump does not dry, during start
up or turbine trip. Cond Recirc valve

• Due to high pressure drop

across the valve, the trim of this 35 bar
valve needs to be designed to
eliminate erosion caused due to CONDENSER
flashing / cavitation.
Deaerator CONDENSATE PUMP
• Valve is open in air fail position.

• Class V tight shut-off is

generally provided, as even
small leakage can cause wire
drawing effect.
 DEAERATOR LEVEL CONTROL
VALVE
• The application of this
valve is to maintain the
level of water in the
deaerator.
DEAERATOR
• This valve requires high Atm pressure

rangeability, as this valve 35 bar

sees a variation of low
flowrate to high flow rate LP Heater Deaerator CONDENSATE PUMP
Level Control
with variation in the inlet valve

pressure.
• Generally valve fail
position is stay put.
 BOILER FEEDWATER PUMP
RECIRCULATION VALVE
• The application of a BFP
Recirculation valve is to
protect the Boiler Feed
Pump by ensuring the min 5-8 bar
flow of water thro the
pump. This is a severe DEAERATOR
service valve that is critical
in a power plant.
• This valve encounters high BFP Recirc valve
pressure drop at low flows.
• Sizing and selection of this
valve is to eliminate the 220 bar
trim erosion due to the high
pressure drop and BOILER
cavitation. FEED PUMP
• Tight shut-off Class V /MSS
SP-61 recommended for
this valve to prevent wire
drawing effect.
• The valve is generally open
on air failure position.
 FEEDWATER (LEVEL)
CONTROL VALVE
• The application of the
Feedwater valve is to
ensure that the level
of water in the boiler
is maintained.
• This valve is designed
to have a high
rangeability, eliminate
trim erosion, provide
good controllability.
SH / RH SPRAY WATER
CONTROL VALVE
 SH / RH SPRAY WATER
CONTROL VALVE
• The application of these valves is to control the
temperature of steam prior to entry into the
steam turbine, by providing adequate quantity of
water that is sprayed into the steam line using
an attempertor.
• These valves need to meet the following
requirements.
- Tight Shut-off (Class V)
- Eliminate Cavitation and trim erosion due to
the high pressure drop.
- Must have high rangeability.
 SOOT BLOWER VALVES
• The application of the
Soot Blower valve is to
maintain suitable
pressure, while the
poppet valves are closed.
• This valve needs to meet
the following
requirements.
- Tight Shut-off
- Good rangeability due to
variation in steam flow
during a soot blower
cycle.
- Must take care of
thermal expansion.
- Ability to respond
immediately.
- Control the noise.
 TURBINE BYPASS VALVE
The Turbine Bypass valve is used for 3
purposes in a power plant
1) Start-up
Before minimum pressure, temperature
and flow are achieved to allow for flow
through the steam turbine, a bypass
valve is used to circulate the flow.
2) Turbine trip
When the turbine is stopped quickly, the
bypass valve opens to bypass the steam.
Depending on type of plant, fuel and use
of ventilation valve and/or safety valves,
the bypass is sized from 15 – 100%
capacity.
3) House load operation
Many plants are designed to produce the
power for internal consumption in case
the
outer electric grid fails in order to avoid
emergency trip and allow for quick
rephasing into external grid. The bypass
is in this case used to handle the excess
steam flow until the produced steam from
the boiler has been reduced.
 COMBINED CYCLE POWER
PLANT
• In a combined cycle
power plant (CCPP)
or combined cycle
gas turbine (CCGT),
a gas turbine
generator is
combined with a
steam turbine
generator with the
objective to increase
the efficiency of
electricity generation.
 COMBINED CYCLE POWER
PLANT

Heat recovery steam generator

Gas turbine plant Steam turbine plant

Electrical Air Fuel Life steam

energy
Electrical
6 5 1 2 3 10
energy
7 11
4

Exhaust gas 8
9
Cooling tower
Gas turbine plant: Steam turbine plant: Condensate 12
1 Air intake 7 Steam turbine
2 Compressor 8 Condenser Cooling
3 Gas turbine 9 Feeding pump air
4 Heat recovery 10 Generator
steam generator 11 Transformer
5 Generator 12 Circulating pump
6 Transformer Fresh water
GAS TURBINE
 HEAT RECOVERY STEAM
GENERATOR
HRSG generates steam
by use of exhaust
heat from gas turbine
and feed it to steam
turbine.
 STEAM TURBINE
A steam turbine is a
mechanical device
that extracts
thermal energy from
pressurized steam,
and converts it into
useful mechanical
work.
Single Shaft Combined Cycle Plant
Multi-Shaft Combined Cycle
Plant
Introduction to Supercritical
Power Plants
 What is a supercritical unit?
• The “critical” point in steam generation is
3206.2 psi (221 BAR) at 705.4 degF (374
degC)
– At this point there is no physical difference
between steam & water
– Operating at conditions above this point is
called “supercritical” while operation below is
“subcritical”
• A ‘supercritical’ unit is a unit designed to operate
above the critical point
• Turbine pressure is generally 3500 psi at 1000
degF (241 BAR @ 538 degC)
Effect of pressure on steam &
water density
POWER PLANTS IN INDIA