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    1ST Chapter EPG

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    Pravin Gauda

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    Thermal Power Plants (Coal, Gas, Diesel and Nuclear Based) 015880 Layout and working of a typical thermal power plant with steat ~ Properties of conventional fuels used in the energy conversion equipment used in thermal power plants : Coal, Gas/diesel, Nuclear fuels — fusion and fission action im turbines and electric generators. Sale practices and working of various thermal powerplants: coal-based, gas-based,desel-ased, uclear-hased, Functions of the following types of thermal power plants and their major auniiavies: (2) Coalfired boilers: fre tube and water tube _(b) Gasidiesel based combustion engines (©) Types of nuctear reactors: Disposal of nuclear wasto and nuclear shielding — Thermal power plants in Maharashtra, o wy oy 11 Introdu ‘This is also a thermal conversion and called as nuclear ower plant, ‘There are various types of generating stations which convert, In this chapter students will lear all these 4-power plants. ‘one form of energy into another form (ie. electrical energy). (One line diagram of powedenery conversion int electricity. Particularly heat energy is finally converted into electrical Electrical ‘energy and such plants of conversions are called as thermal energy output ower plants, eel > }ource of ‘Heat is produced by burning coal inthe boiler which contains ‘ong # Generator ‘water. Water converted into steam and high pressure steam is (lnput) : impinged on steam turbine which produce mechanical me energy and rotates the generator and generator converts mechanical energy into electrical energy. This plant is thermal (steam plant). Fig 114 Part 1 - Thermal Power Plant 1.2 Thermal Power Station (Steam Power Station) Another form of conversion is gas. Heat energy of gas rotates the gas turbine and this mechanical energy is utilized to rotate the coupled generator for production of electrical energy. This is gas thermal plant, in | 12:1 Most Important Points of Site Selection ‘Thermal energy can be produced from diese! oil buming in oil engine which drives the generaior. is plant is also a ‘thermal-Diesel engine plant. ‘A wemendous heat is obtained by nuclear fission which is used to heat the water to form steam which drives steam turbines to which generator is coupled and thus electrical nergy is obtained, D> MSBTE - 5-14, W-14,$-15, w-16, $17) 424 What are the points. to bo considered whit Selecting” site for @- steam (thermal) power| station ? Explain any four points in detail. (Refer Section 1.2.1): BP etecticat Power Generation (MSBTE) “Thermal Power Plants (Coal, Gas, Diesel & Nuclear Baseg 1-2 The 2.1.2.2 State any six factors governing selection of site for thermal stations and explain each in bic. (Refer Section 1.2.1) State any four factors on which selection of site| for a thermal power plant depends. (Reter Section 1.2.1) SSERCSRAHTEE State the various factors governing selection of site for thermal power station, 1.2.4 (Refer Section 1.2.1) State any, four factors for selection of hydro Power plant site. ¥ : (Reter Section 1.2.1) For any type of power plant, site selection is most important. (Most important points of site selection) 125 Site Selection for Thermal Power Plant {) Location of the power plant ] (il) Cost of the tana (il) Ash disposal facility (iv) Large quality of water (¥) Cost of fuel at cheaper rate i (vi) Quality of tana (vil) Away from populated area (vil) Labour availablity Fig. 1.2.1: Site selection for thermal power plant > @ Location of the power plant ‘The site should so selected such the plant is atthe load centre. ‘This means, electricity is to be distributed in the nearing areas. If the power station is too away from this area then cost of ‘transmission line will be very high which will be un-economical. ‘The second important thing is the transportation cost of coal, from the coal mines to power plant, So it will be economical if the plant is located near to ggg it can be transported by roads and railing. mine areas so that may be made available. ; Most of the thermal power plants are located jg Maharashtra -Vidharbh, Khandes, Marathwada, where coq) | transportation distance is less. > Gi) Costof the land i the city areas ; Cost ofthe land is much lesser in rural areas than the city areas 'A large ‘space is required for thermal power plant (The estimated figure is about 4 to 6 acres per megawatt genera ower). ~ Theland is required for @ Project Gi) Coal storage (Gi) Ash handling Gv) Staff quarters Water ete. ‘The cost of land should be reasonable and much in quantity and also bé available for future expansion. PGi) Ash disposal faciity Ash storage and ash disposal is also a problem in coal fired ‘thermal power plants. It requires much more space. ‘The ash can be sold in the industries where it is required, > (iv) Large quality of water "alu is about 550 x 10" kg of water requirement for burning ie Per fone of coal and converted into stem of drive steam turbine, G ‘This suggests that the site for thermal power plant be selected near river (running throughout the ‘year, or near water oul or near da), ! which ost, from plant is to be re-used providing cooling towers require additional space as much more constructional c > (©) Costot fuel at cheaper rate Main fuel is coal, Its cost may be cheaper or moderate ‘quires in much more quantity, as [EP exectrical Power Generation (MSBTE) 4-3 _ Thermal Power Plants (Coal, Gas, Diesel & Nuclear Based) > (so Quality of lana A good quality land is required for foundation ofthe plant and for other so many accessories = Rocky land will involve blasting for foundation and marshy land will require pile foundation. Both such types of land «quality makes the constructional cost much more. So a good quality land is needed to duce the cost of construction, (sil) Away from populated area - Buming of coal produces smoke, fumes, ash particles. The nearby area is therefore polluted which is not desirable = Sosuch power station is located avoiding populated areas, (vil) Labour availability Lot of Iabour is required in such plants s0 it should be available all the 24 hours of a day, as the plant runs all the 24 hours of a day. Labour should be available st cheaperfreasonable rates, (x) Industries near by A large quantity (MW) of electricity is produced. So small, medium and large scale industries should be in the nearby area which roquires electicity, 1.2.1(A) Fuels and their Properties (In Thermal Plant) Fuels used in thermal plant may be solid, liquid or gaseous, Fels may be natural or prepared fuels. ‘Common fuels for such plants are coal, oil or gas. Coal is most commonly used fuel Oil is used where iis available in bulk and at cheaper rte. ~ Gaseous fuel is rarely used, ‘Various form of coal - Natural coal from mines. This is formed in the earth as a result of decomposition of vegetation ‘sccumulation. Contents of coal - Moisture, Sulphur, Carbon, Hi, Nitrogen, Oxygen and ash. — In increasing value of coal are - Peat, lignite, sub-bituminous, semi-bituminous, semi anthracite, super anthracite coal. = Selection of type of coal for plant depends on its calorific value, weather ability, sulphur content, ash contents, particle size, grind ability index and caking properties. Syllabus Topic : Layout and Working of Typical Thermal Power Plant with Steam Turbines and Electric Generators 1.2.2 Layout of Typical Power Plant (Coal Fired Steam Plant and its Working) Iwith steam turbine and Generator] ‘D> (MSBTE - W-13, W-14, S-15, W-15, S-16, W-16, S-17) [2.1.2.6 Drew schematic block diagram of thermal power station and indicate following circuit in diagram| clearly. () Fusland ash circuit ) (i) Airand tue gas circuit (®) Cooling water circuit. Feed water and steam circuit (Reter Section 1.2.2) 10.4.2.7 Draw and explain the working of cooting tower in 2 thermal power station, (Reter Section 1.2.2) DEE }Q. 1.2.8 Draw a neat layout of thermal power station and label it = (Refer Section 1.22) MEE RUBTRRTEES| Draw a complete block diagram of a thermall ower plant, (Refer Section 1.2.2) Draw the flue gas flow diagram of thermal power} plant and label ell parts. (Refer Section 1.2.0) gram of eval, fred Draw a labelled schematic block diagram of thermal power plant showing ail the components| Of the plant, (Refer Section 1.2.2) 129 a. 4.2.10 Draw a schematic block dia P.S. label each block. (Reter Section 1.2.2) JO. 1.2.42 Ss EP exectical Power Generation (MSBTE) ‘© Working of thermal plant 2 Coal is brought from coal storage. It is fed to the boiler for bbuming. At the lower portion water is fed to boiler. Heat | ~ Produced by buming of coal heats the water. Steam is formed. Z ‘From the boiler steam is coming out (which is wet). From the boiler flue gases are also coming-out (Hot). - Hot gases has large amount of heat energy which can be Utilized at various stages prior to send them out into the chimney for exhausting in air. ~ Steam coming out from boiler is wet. It is superheated in | ~ supetheater (see the layout diagram) (supetheater receives heat of flue gases), : jesel & Nuclear Baseg) 4-4 Thermal Power Plants (Coal. Gas. Diss S Base ‘such sopereated and dry stam is fed through main valve tp the turbine. ‘Turbine is assembly of Blades fited on the shaft. Shaft of the turbine is fee to rotate. Superhested “high pressure” steam is impinged on turbine bades and hence turbine sha starts rotating. “Through coupling the turbine shaft is connected fo shat the “Altemator", Altemator is 2 AC generator. It stans rotating and converts mechanical eneray into electrical _ energy (Faraday’s law of electromagnetic induction). Exciter supplies the necessary magnetic flux to the alternator (students know the working of alternator). ; : 4 i ; ‘ Atemator handing Plont Flue gases Boile feed @ Water cycle Baioeed ® @ Aircycle mee @ Ast-handiing @ Five gas outlet system Condensate pump © Cooling water circuit 2 LEP etectical Power Generation (MSBTE) © Energy conversion ‘Thermal energy > Mechanical energy ~> Electrical energy Electricity is generated at the voltage of 6.6 KV or 11 KV. Itis to be stepped up to 132 kV or 220 KV by a step up transformer shown in the Fig, 1.2.2. Isolators and circuit breakers are connected in the circuit and high voltage transmission line starts from this point. Water cycle ‘Afier the work done by the steam, its pressure decrease, the outlet steam from turbine is taken into condenser. Condenser condenses the steam (condensate). Its then forced to the low pressure feed water heater. Here the temperature is raised by the heat from the bled steam the steam extracted from the lowest extraction point of the turbine). Feed water is pumped through deaerator to high pressure feed water heater where it gets heated by the heat from bleed extracted from suitable point of turbine. (Function of deaerator is to reduce dissolved oxygen content in the condensate (i.e. in the feed water)). ‘This water is pumped up to economiser. Economiser receives heat of flue gases and hence the water is heated up and hot water goes to boiler. ‘To make up the water, some water is added up by makeup water tank, Air supply to boiler (Air eyele) For combustion of coil air is required. It is taken from atmosphere with force by force draft fan. ‘The air goes to air preheater. In the preheater this ar is heated by the heat of flue gases. This heated air goes to boiler. In the lst stage the flue gases are taken up from ait preheater and by induced draft fan it goes to chimney from where the fue gases are expelled in the air at very high height (Due to chimney). 3 5. Step 1: by -rail, road, ships etc, 1-5 _ Thermal Power Plants (Coal, Gas, Diesel & Nuclear Based) Ash handling system After complete combustion of fuel the ash is collected at the back of the boiler and itis removed by ash conveyors to the ash storage. * Fine gas outlet system Gas after burning of coal from the boiler is called as flue gas. It passes via superheater for superheating the steam (dry tobe sent to turbine tint Then’ forward joumey of gas heats the inlet water in economize. Then onthe way prior to be exhausted inthe sit through chimney it heats the inlet air tobe sent to boiler. Cooling water circuit ‘Ample quantity of cooting water is required to condense the steam ffom turbines in the condenser and maintaining low pressure init If river or canal is nearby, cooling water may be taken from the upper side of the river or canal and after passing it through the condenser may be discharged tothe lower side of the river or canal; such a system will be possible only when ample water i flowing through the river or canal throughout the year. When sufficient quantity of water isnot available, water from the condenser may be used citer in cooling pond or cooling towers and reused. The quantity of water reduced inthe eyele is made up by other sources of water. 1.2.3 Coal Handling (Steps) > (MSBTE - W-15) 1.1.2.5 Show with the help of schematic diagram coal handling unit in steam power plant. (Refer Seotion 1.2.5(8) and Fig. 1.2.2) Delivery of coal Coal is brought from the coal mines. Transportation may be [€2F etectical Power Generation (MSBTE) Step2: Un-loading of coal at site For this purpose either ) Coal shakers or accelerators are used. Gi) Rotary car dumpers or wagon tipplers are used or Gi). Grab buckets are used, ‘Step 3: Unloading to dead storage For this purpose either @ Beltconveyors or —_(ii)Serew conveyors (ii) Bucket elevators (iv) Skip hoists may be used. ‘Step 4 : Preparation of coal suitable size for feeding to boiler ‘The coal is of random and big size pieces which cannot be directly used for firing in the boiler with the help of (Crushers, Gi) Sizers or ii) Dryers. or Gv) Magnetic separators itis cut to usable size Step5: Transfer . ‘The suitable size coal is now transferred using-conveyor. belts, scrip hoists or flight convers to the storage side from this place itis discharge to firing equipments. Step6: Outdoor (Dead) storage ‘The storage of coal is generally coal required for a month and it is laid directly on the ground, Step7: Indoor (Live) storage With the help of buakers and coal ins the coal is made available for a day consumption, Step 8: Implant handling ties This is the process of coal handling between the final storage to the firing equipment. Step 9: Coal weighing This is generally done at the unloading point to ascertain correct weight, expected quality et. Step 10: Furnace firing Coal is caried into the furnace for combustion. Ash formed affer buming the coal is discharged at particular place from where 71 itis sre .as, Diesel & Nuctear ' —— .al Power Plants (Coal G: Syllabus Topic : Coal Fired Boilers and Types z — 1.2.4 Boiler Thor: D (MSBTE -W-13, S44) 1.213 plan the funtion of Pole: (Peter Salon 12-4) la.1.214 Whatis p= () Fire tube boiler - (ay Water tube boiler: Also ae pressure, capacity and one eam | ‘each type (Refer Section 1.2. a(t) and 2: la. 2.15 Whats boiler? What is iis f “(Refer Section 1.2.4) = Boiler is @ major and very important component of the ‘thermal power plant in which thermal energy produced by : bbuming the coal is used to convert water into steam to drive steam turbine. = There are two main types of boilers, Types of Boller i 1. Fite tube boiler —————E 2. Water tube boilers Fig. 1.2.3 : Types of boiler Fire tube boiler In such types the heat transfer is as follows - Hot gases are passed in the tubes and water surrounds this tube. A shell supports these tubes, [& ctectrical Power Generation (MSBTE) 4-7 _‘Thermal Power Plants (Coal, Gas, Diesel & Nuclear Based) & Advantages of fire tube boiler 4248) Chimney 1. Cheaper in cost a > (wseTe- w-13) 2. Very compact : 7 function of chimney: 3, ‘The great advantage is that the fluctuations in steam demand i be very easily met. ‘The function of chimney is to release the flue gases at the higher level into the atmosphere. 1, Steam formed is not that dry but somewhat wet. cr 1.2.4(C) Superheater © Disadvantages (drawbacks) of fire tube boller ‘Time required for large steam formation is much more, > (MSBTE - W-19, S-15) Steam pressure is low. 4, Output of fire tube boiler is small and limited. = . Due to these drawbacks this type of boiler is not used in large ‘capacity thermal plants. <9 2. Water tube boilers = ° ‘The steam produced in the boiler is not dry but.it is wet containing some moisture. With the help of flue gas heat = Weight of metal is therefore less and rare possibility of ‘makes the steam dry to be supplied towards turbine. = These boilers have smaller drums and tubes. oe . = Thusit helps in increasing the efficiency of the plant. = Steam pressure produced is very high (125 kg/cm’) and ae js 300°C to 575°Ciis possible. 4.2.5 Some other Important Paris their Working, Function and Process Heat transfer is through walls of tube and drum. = For proper burning of coal ir is supplied through FD. | * Economizer Fans. > (MSBTE - S-16, S-17, W-17) function of economizer. 4.2.4(A) Comparison of Fire Tube Boiler and Water Tube Boiler . 1. | Capacity Smaller Bigger — As seen in the block diagram this component is placed in the ‘way of flue gases and the water inlet to the boiler. 2, | Suitability For small plant | For big plants. = Its fonction is to make use of heat energy of fle gases 19 3, | Steam pressure | Very low ‘Very high 300 to {ncrease the inlet water tobe fed to oiler. 175kglem? | 575kplem = By this provision rate of producing steam in the boiler 4. | Output ‘Small and ‘Output is large. 5 limited increases. 5. | Use Rarely used | Commonly wed. || 7 ‘Economizer can be called as heat exchanger. : The schematic diagram of economizer is shown in Fig. 12.4. 6. | Steam formed | Not that dry | Completely dry. but wet. [&2P crectical Power Generation (MsBTE) Flue gas (out) ttt Feed water outlet to boiler i Feed wator inte oe Fig. 1.2.4 = Construction > For medium pressure boilers economizer is made of cast iron case. ~ For high pressure boilers itis made of steel tubes. ~The loops form by continuous tubes. Fins are provided to economizer fins on the gas side, — Design of economizer is such that gas conies in contact with entire heating surface area, ~ To avoid accumulation of dust the surface is polished. - Si is compact and easy for maintenance. — Gas velocity is maintained constant throughout the passage. ‘The passage is straight. = Advantages of Economizer () It improves boiler efficiency per 5°C rises in feed water temperature efficiency increases by 1%. Gii) It reduces temperature stresses. 2. Condensers > (MSBTE - W-13, S-15, S-17) IQ. 1.2.21. Describe the construction of surface condenser] with the help of diagram. (Refer Section 1.2.5(2)) Explain working of condenser. (Refer Section 1.2.5(2)) lO, 1.2.22 SHEE State the different types of condensers used in} thermal power station. Z 8 STnEee la.1.2.23 (Refer Sect tion 1.2.5(2)) 4-8 Thermal Powor Plants (Coal, Gas, Diesel & Nuclear Based portant component in the thermal power system fy It is an imy steam from turbine, is located near turbine to receive exhaust In the condenser exhaust pressure of steam is decreased below the atmospheric pressure. es Condenser condenses the steam. It is cooled by the cold wate and the same is fed back to the boiler through economizer, So, this is good and pure fed water tothe boiler. “This helps in increasing the efficiency of the power plant “This also helps in reducing the capacity of water softening plant [Also it removes air and non-condefsable gases from steam when passes through condense. is taken from river Water required for cooting the condenser is ta source of by the use of cooling tower. Following are the two types. () det Condenser 4 Ale suation Pump for steam circulation > Hot wel = From cooling pond cold water is pumped in the condenser. ‘Steam exhausted from turbine enters into the condenser and ” cooled dam to form condenser. It is sent to feed water heater: to economizer-to boiler, (il) Surface Condensers Surface condensers’ are universally uses in steam turbine power plants o Types (@) Single pass, two pass condensers. (©) Down flow, central flow regenerative condensers [FP etoctrical Power Generation (MSBTE) 1-9 Thermal Power Plants (Coal, Gas, Diese! & Nuclear Based) © Construction @ Castiron shel. - - Cooling water oul @Brass tubes @esnavst soar rom engine oom aR @ Plate —| © Battle pate © coating water 1 = Itconsists of a cast iron shell in circular shape (1). The two ends are covered by cover plates (2). A nest of brass tubes Q)is fixed to the two tube plates (4) atthe ends. — The spaces betweén the tube plate and cover plates are known, ‘as water boxes (5). —Onvof the two water boxes has a baffle partioning ©). = The cooling water is passed through the lower half section tubes (7). It comes out through the upper half section tubes ®. = Exhaust steam from turbine enters the shell at the top (9). = It flows downwards surrounding the cold water tubes. ~The steath first. comes in contact with tubes containing comparatively hot water which has been progressively heated by the condensing steam. = And it then passes down and is effectively condensed by the cold water in the tubes before being removed by the extraction pump and sent to water heaters and then to economizer to feed boiler. 3. Cooling towers > (MSBTE - S-14, W-14) 0.1.2.24 State the function of Natural, Mechanical, Forced and Induced draught systems. (Refer Section 1.2.5(3)) Condensate to extraction pump i > (0. 1.2.25 Draw and explain the working of inlet Fig. 1.2.6 : Surface condenser cooling tower in| a thermal power station. (Refer Section 1.2.5(8)) When river, or continuous water supply for cooling the condenser is not available, then cooling towers are essential in the plant. Cooling of condensed water from the condenser is carried out in the cooling towers. () Natural draught cooling tovier | q Fig. 1.2.7 : Types of cool (i) Forced draught cooling tower ing tower (Natural draught cooling towers ‘Small capacity plants use (a) Rectangular timber tower as shown in Fig. 12.8. (©) Reinforced concrete hyperbolic type as shown in Fig. 129. a [& etectrical Power Generation (MSBTE) Hurdles Fig. 1.2.8: Rectangular timber tower Hot air outot Fig. 1,2.9 : Reinforced concrete cooling tower @ Advantages of reinforced concrete cooling tower (@ Better circulation of air. Gi) Wide variation of load is possible as much larger ‘amount of water per hour can be cooled. ii) Maintenance costis less. Gv) No fire hazard. =B (ii) Forced draught cooling towers “High capacity plant requires large amount of cooling air provided by fans. @& Construction ‘Main components - Motor, fans, spray nozzles, hurdles, catch tin, ater inet-outlet sytem. ‘Tey ae bial natural rag coting overs exept th vor dven fan is aso provided at de base, When impeller is used atthe top of the cooling tower it is called ss induced draught cooling tower: 4-10 Thermal Power Plants (Coal 1, Gas, Diesel & Nucloar Base “The forced dravght cools towers have horizontal shaft fan oon the side ofthe cooling tower. r wards the back of tower and thn baffles. In the process it cools the order of 100 rpm are used, ‘This fan discharges ait is turned upwards by means © Fan speeds o the falling water. for tis purpose- The induced draught 0 capacity installations. They Use "B® rocatd at te top of the rowers, ad IMeY from the sides of the cooling tower pe cooling towers ae used for le fans with vertical shaft pall air upwards pray. Si Hot air out gjiminator ye spray ADAAASAA AAAAAA Hurdles — Hot water init t from condenser AAAAAAS s sala slot AAAAAAA - Motor Motor ‘driven fan Catch basin Fig, 1.2.10 : Forced draught cooling tower ‘The warm airs exhausted at a considerable velocity upwards - after cooling the water on its way. Itrequires low speed fans. For increasing efficiency of towers, water flow should be uniformly distributed and divided into fine droplets, a large weted area shouldbe used, In order to increase air contact time a series of baffles, shelves etc. should be used to obstruct the flow of air. Disadvantages of forced draught cooling tower €) The dssitation of ir over the whole are sd due to high velocity from impellers, (Open type top of cooling towers with low humidity conditions produce a great load on the spray eliminator. 4 Gi) Du to les height, low discharge velocity along with light winds may cause recirculation ofthe heated ai. Eloctiical Powor Gonoration (MSBTE) Hig. 1.2.11 shows the Hine diagram of encrgy conversion, Sonn Five gasos 1.2.7 Advantages and Disadvantages of Thermal Power Plant > (mspir-c. 15, W-15, 8-17) J0.1.2.26 Stato any two advantagos of thormal powor| station, (Rofor Soction 1.2.7) EXERAMIET| Ja. 1.2.27 Whlto any four morita ond four domorits of a thormal powor plant, (Rotor Soction 1.2.7) AERA Wiito any four morits of stoam powor plant, advantagoa disadvantagoa of thormal powor plant. ESAT 2.2 (Rofor Section 1.2.7) 1, 1.2.29 Wito any four and four] (Rofor Soction 1.2.7) Advantages (W) Space required is lesser as compared with Hyuro electric plant, (i) I'we compare fuels in diesel plant and nuclear plants the fuel is cheaper in cost, id) Anita cost of plant is lesser than otter types of plants iv) Steam engines and tusbines are capable to withstaal over toads. (8) AF compared with hydro-plants, the thermal plants cam be mission Hine cost, located in tond centers which waves (vi). Cost of energy produced per kWh is less if we compare with diesel, as diesel Is 0 costly fuel, (vii) Power generating capacity is much more (Bulk). ttt Sloan tuibine Wig. 1.2.11 ¢ Line dlageam of energy conversion Thormal Powor Planta (Coal, Gas, Dioaal & Nucloar 830d) 6 Roprosont tho Powor Production by Thormal Systom of a Line Diagram Rotational ‘mochenical energy Exhaust ‘loam, “ Dinndvantagos 0 di) Gli) Operating cost, tabour cost and maintenance cost is much now, (iv) Coat transportation, toading, difficult and costly task, (9) Axle storage needs much space and thus disposal is difficult task, (vi) Area is polluted due to noise, heat, smoke, ash particles ete (vii) Station erection time is much more, (vii) Starting time is much more 6 t0 7 hrs, Hence this station is not «ult in fe systems as a peak load power station, Syllabus Tople : Dotalls of Thermal Power Plants In Ditferont States of India 1.2.8 Dotalls of Thermal Power Plants In Difforent States of India D (MSBTE - 5-14, W-14, S-15, W-15, S-16, S-17) IQ. 1.2.20, Namo any two thormal powor stations In Maharashtra with thott capacity, (Rotor Soction 1.2.8) Stato any four thonnal powor plants in} Matiarashtra with tholr capacitios. (Rotor Soction 1.2.8) 1. 1.2.32 List out thormal powor stations Ja Maharashtra and wito thoir gonorating capactos: (Rotor Section 128 seer 1 Plants (Coal, Gas, Diesel & Nuctea Pr 4-12_Thermal Powe! [BT crcctical Power Gonoration (MSBTE) Tee | ase and | state on sc | state Place | Numberand ating | Total : ae No. ofsets Installed No. - ‘capacity : 7 vat | Dhuvaran | 1x6350 1. | Maharsnes | Kos | 4x tzomw oom |} a7, | oa Eacuanrel 12004 ae 2x 210M ta. | Hayana | Favidabad | 1%15.001 2. | teharsta | ask 2x 40M siomw 155 MW (V plan) 3x2i0ntw <5 MW 49, | TamilNadu | Neyvel . 3 | Mebarasa | shucawal | 1 e6254W ees Aon al 2x210Mt 2x 100 MW (IV plan) Maharastra | Paras 1x62 anv e25nW 3x30 MW 5. | Maharastra | Para 2x30MW 680 MW ak | Madhya 7 al 0 ax210MW || | Prados — a & | moenova |e | evasoune —| wna do MW ee | 21. | Madhya | Amarkantak [2290 MW |_2-y-warsashira | Chandrapur | 4 x 210MW HOM Pradesh 2x60MW ae 3x 500MW on Pa 2 | wadrya | sapua | 5x00 @VPlan 8. | Maharashtra | Uran G.T. ‘3x60MW 12M a 2 | (Gas Tune) | 4x 108 MW pases 8. | Manarastia | wasteteat | 2x 120,W 2ioww 2 | Tamitnadu | Emo {2x60 MW ere 3110 MW (IV Plan) as Tun J a 24. | Orissa Talcher 463.5 MW 10, | Maharastve | Tromtay | 2x s00mw reson ; (Bombay) | 1x 150 MW 2. | Uttar Harduaganj |3x20Mw2x50 MW] son Leon and 2x55 MW (WV plan) | 210M i ew 3.) vir ‘Kanpur 2x32 MW enw. 11, | Matarastta | panarw —_[ax2s0mw sco. Pradesh tad 12 | Anda | Ramagundam | 3% 12507 75M 2 | tar Obra SxsoMW 4 x | 16251 (V Pan) | 625nN Pratsn — | cap) zou | 3100 MW (lv Pian) | SOOT 18. | Andna | Kutagudam | 4x60 mW 210M aes cone f 1 near Singareni | 2x<210MW end ot | 220 MW 28. | west oengar een {V Plan) § coal Pin ‘pur | 2x30 mw 235 NW! 414, | Assam Guahat 1x 125 MW 125 MW Sx75 MW SOM aE f recoumeree bm [IV [wate {asaya || ae pent | Bander | si 46. | Bihar Barun 3x15 MW “su | we axe2smw | sso f fate | santa ab 2x60 MW (V Plan) | 100%W a1 | eharana S120 6H (Plan) | 4a0Mw " Pamodar [pe pd 2 3x | 16, | Bhar 98 2xsoMw ‘aonw MestBenga | Vatoy souw zu | 2x5 MW (VPIen) | 300KW = leq re | fest | ————___| ‘ 2100 mW 5 2 Ber Chand z, | eee 3 140 Mw Seni Electrical Power Generation (MSBTE) 1-19 _Thermal Power Plants (Coal, Gas, Diesel & Nuclear Based) state Blase | Munberand tng | Ton fates Instat cxpacty je Durgapur (faxc75mW Bengal [xc womw ut Dati rajgnat } [160m 2054 1 (MsBTE-w-17) Ei ea] 1.2.33 State why Pificiency of thermal power station is about 24%. (Retbr Section 1.2.9) } MERA ‘There ae four faain equipments in he system, namely (i) Generatol (ii) Turbine (ii) Condens Gv). Boiler. Generator eff ciency is about 97% that of steam turbine is low. Air pret éater 60%, condenser 60%, Boiler efficiency is 50%. So some erfiergy is lost at every step is the complete cycle of power pf eneration and effective efficiency of the plant is, not more f hat 30 to 35 %. .2.10 Provsisions in the System to Improve The{rmal Efficiency > (usBTE-W-13) Ihdge oF eeonomiser, supathester, preheater, jActeases thermal efficiency of the thermal | power station.” Jusiy the statement. [. (Refer Section 1.2,10) See ne block diagram shown in Fig, 1.2.2. ‘As Jaeeady discussed, the steam produced by the boiler is wet abe net of x gases is made used inthe super heater 1 «vl speseat the steam tobe fd to turbine in dry condition, ~The water from condenser cycle is fed to the boiler again. While passing this water through the route the step of ‘economiser heats the water taking advantage of heat of flue gases hence help in utilising waste heat of fue gases. = Airspreheater: The airs sucked from the atmosphere to be fed to the boiler to help coal combustion, passes through aicpreheater wher it is heated by flue gases and thus helps in increasing efficiency. (Efficiency increases to suitably make ‘use of waste energy). 1.2.11 Gas Flow Diagram of Thermal Plant > (usete-s-17) Ja.1.2.35 Draw the labelled diagram of flue gas flow related to thermal povter plant Fig. 1.2.12 shows the gas flow diagram of thermal plant. © — aa oo [Super heater Economist Fig. 12.12 1.242 Safe Practices in Thermal Plants = Power plant has two locations where safety is important - = On both locations the safety is important. Field workers are at more risk because they have to work in hazardous locations. — ‘The accidents may take place due to ~ i) Direct contact with electricity fires ii) Explosions of boiler equipment iii) Contact with hazardous chemicals = The National Thermal Corporation Limited (NTPC) has laid down several clauses for safety. This mainly includes i. Electricity AcvRules ii, Boiler AcvRules/Regulations Explosives AcURules iv. Petroleum AcURules ¥. Motor Vehicles ActRules LEP etectical Power Generation (sere) vi, Dangerous Machines (Regulation) Act Mines Environment ‘AcuRules AcURules, etc. A safety officer is appointed to look after the safety issues. ‘The safety officer monitors the overall plant safety. Several vii, (Protection) safety awareness drives, safety trainings are conducted (0 improve the overall awareness about safety aspect. Safety management audits are conducted for assessing the overall picture of the quality and effectiveness of safety activities. ‘The safety management eudits includes i) i) iti) 13 Review of documented safety policies and programs. Manager, safety specialist and supervisor interviews, Workplace inspections and Workplace observations A detailed safety audit report is subn ted by the author after safety audit survey work is complete Action plan in case of accidents “The reporting of accidents is necessary. Every notice given for fatal accidents shall be followed by a written report tothe concemed statutory authorities and the engineer in-charge in schedule, under the specified form annexed as acknowledgement. ‘After this phase, the investigation of accidents and dangerous ‘occurrences is done, The flaw in safety if any is found and concerned department/person has to give explanation about the same. Part 2 - Gas Turbine Power Plant Introduction of Gas Turbine Power Plant Gas turbine is similar in action as steam turbine used in thermal power station. Gas turbine plant is also in many respects similar as thermal ‘Power plant Instead of steam a hot gas is used. In steam power plant the working medium is steam formed ‘rom water heated by burning the coal 4.3.1 Selection of Site for Gas Power Plant for the plant 1.3.2 Fuels used in Gas Turbine Power Plant 4-14 Thermal Powor Plants (Coal. Gas, Diosol & scented In gas plant the working medium is either & mixture of ‘combustion products and air or heated air ata certain pressure and higher initial temperature. Following factors are taken into account for deciding the site Availability of fuels : It should be easily available at reasonable price. ‘Transportation ; Transportation facilities should be easily available by road, railways. In onder to reduce transmission and distribution of electric the station should be planned at the load centre. ‘To locate at load centre, the land required should be easily available at low cost. This reduces capital cost and reduces energy cost ‘The location of plant shall be away from the populated area because the operation of plant is noisy and disturbs the day to day activities of the people. ‘The plant requires strong foundation. So the quality of land soil shall withstand the vibrations of working plant due to compressors and turbine operations. Syllabus Topic : Fuels used in Gas Turbine Power Plant Precaution is taken mot to damage the gas turbine blades by the use of fuels. So products of combustion shall contain a minimum of matter which way get deposited on turbine-blades. Fuels may be inthe form of solid, tiquid or gas Due to coal handling and ash disposal problems, generally coal is not the ble solid fuel to be used in Gas-turbi plant, ‘The other alternative is to use liquid fuels. 1-15 Thermal Power Plants (Coal, Gas, Diesel & Nuclear Based) Electrical Power Generation (MSBTE) ‘These liquid fuels are (@ Petroleum oit Gi) Kerosene Gil) Gas oit Gv) Diesel oil (8) Residual oil ‘These are most suited liquid fuels to be used in gas turbine plants. Bot the limitation is due to their high cost. So their use is limited. So mostly used fuels are natural gas (Methane) having higher calorific value. Petroleum fuels ar also used now-a-days. ‘The composition of natural gs is: 80% - Methane 20% - Smal factions of other gases Natural gas is very easy to burn and it mixes with sir very easily, tean be easily transported by pipe lines. But itis difficult to be stored in large quantity. Natural gas is clean, and ecofriendly fuel. Natural gas has very low content of sulphur, from atmosphere 1.3.3 Types of Gas Power Plant ‘There are two types of gas power plant - 1, Open cycle gas turbine plant 2. Closed cycle gxs turbine plant. 1.3.4. Layout and Working of Gas Turbine Power Plant Layout of gas turbine plant = Main components such as compressor, gas turbine, alternitor |. motor, combustion chamber, ar filter are connected as shown, in Fig. 13.1. = Turbine Tt is reaction type non-condensing turbine. ~ Compressor : It sucks the ar through filter from atmosphere then compresses the air and pressure increased. It has rotary blades and stationary blades. Compressor is driven by the turbine as it is connected tothe shaft of turbine. Compressor is rotary type. Combustion chamber: It consists of a vessel. In the vessel, air at high pressure comes inform compressor unit. Fuel is, injected into the combustion chamber and burnt i it. = Alternator : It is a 3-phase synchronous generator having ‘exciter and two ends ofits shaft is coupled to gas turbine one side and starting motor on the other side. Motor is also ‘connected to altemator for intial start of compressor. Circuit, Bus bar breaker => Feat? 39 4? Isolator : 2983 [EP cxoctical Power Generation (MSBTE) 4-16 Thermal Power Plants (Coal, Gas, Vest o nuuwar © = Working of simple gas turbine plant = Motor is started which rotates compressor (before starting turbine), Once the system stats the further running is by ‘urbine, $o motor is disconnected. Air is sucked from the atmosphere through filter by the compressor. Filter filters dirt dust from air. ~The rotary blades of compressor push the air between the stationary blades to raise its pressure to 4 to 5 atmosphere. available at the output of = This air at high pressure compressor. = Combustion takes place in the combustion chamber by fuel bbumt due high pressure stream of air supplied by compressor. = Part ofthe air is delivered ahead of burning fuel for cooling the not combustion products from 1650? to 800° wiich do not damage turbine blades in first rows. High pressure, high temperature gases pass through the turbine, they expand and turbine starts rotating. = Pressure and temperature of gas decreases and gas is exhausted from turbine to atmosphere. = Alternator coupled to turbine, starts rotating and converts ‘mechanical (rotational energy into electrical energy). Voltage of electricity is increased by step-up transformer. _ — Through protective circuit breakers, isolator as shown in the Fig. 1.3.1 the electric ci completed and electrical ‘energy is fed to transmission line / bus-bars and sent for use through transmission and distribution lines. ‘One-point is to be noted here that complete mechanical power = developed by the turbine isnot fully sent to alternator rotation but some major power is used to drive the compressor, 5 portion of mechanical energy is sent for compressor the output is lesser and efficiency of the plant is much less plants. ‘as compared with steam or water turbit = As noted, the gas turbine has to drive (1) Altemator and also (2)Compressor. In such arrangement itis difficult to keep the speed (synchronous speed) constant for the alternator as the speed is adjusted for the compressor according to output ‘The arrangement is shown in Fig. 1.3.1. 4.3.5 Advantages and Disadvantages of Open Cycle Gas Turbine = Advantages (Very sinple design. i) Small size ii) Less space required} So costis less Gv) Light in weight (Wy No need of warm up time. (vi) No cooling water required (vii) Self contained (viii) Combustion chamber can be designed to use any type of fuel | even solid fuel. = Disadvantages (@ Higher air rate in combustion to other prime movers. Due to dit, dust deposition on compressor blades efficiency | reduces. ii) Deposition of carbon, other foreign depositor on_ turbines, combustion chamber and regenerator affects performance. (Gv) Erosion “and corrosion of turbine blades is more so maintenance. 1.3.6 Layout Diagram of Gas Turbine Power. Plant efficiency of the plant, 1. Regenerator 2. Imer cooler 3. Reheater ‘improving performance of the plant. gcteal Powor Gonoration (MOBTE} 47 Thormmal Powor Plants (Cont, Gap, Diovol & Hucton Based) cram tub rahe me f Tansomar Coupting ‘counting [rm ir toks tom ats Rgsnoraioy — Cuunimati Components + LP, Compressor comb + Combustion ch IC & Imer cooler WT Pt UT = Lt RIL ~ Reheater AL = Alt M - Motor Tr ~ Transformer CH = Circuit breaker BB Bus bar © + Couplings Regenorator ‘This component is used in the system to improve the effi ney of the pl Ttconsists of shell and tubes. TLuses heat of exhaust gases from LP turbine. Ttusex heat of exhaust gases from LP turbine. Exhaust gases flows inside the nest of tubes and air flows outside the tubes the shell in the counter flow and heated up by exhaust gaves Ws compressed sir form compressor is heated before it is 110 combustion chamber. Geanbustion (B) Eshaust gnvos| fiom habiow Hig, 1.3.2.3 Open cycle power plant with regenerator, Intercooler and re-heater Due to this heating by exhaust yaves the advantage are : 2, Imiproveseycte thermal efficiency eat transfer from regenerator in improved by + (4) Increasing surface area but initial cost in inereavedd Gi) Increasing the flow of turbulence but it increases pressure drop. So the designer has to find best compromive. Intercooler Inter cooling means removal of heat from compressed air between the stages of compression, For this, two compressors are needed : (1) Low pressure compressor 2) igh pressure compressors. So we get two stagen of compression, Inter cooler cools the partly compressed air in order to reduce volume and increases density, Intercooler iv thus a ‘Heat Exchanges’, Inter cooler therefore (i) Improves thermal efficiency, Gi) Improves air rate, Gil) Improve work ratio, ue to use of inter cooler the size of turbine and size of ‘compressor is reduced which reduces cost, space etc. (©) Reheater = Reheater in between the iwo turbines i.e. between HP. turbine and LP. turbine, = Combustion gases (High pressure) come in turbine and ‘expand there. Here two turbines are used HP and LP. — The exhaust gases from HP turbine come out and go to reheater. — Gases reheated and enter into LP turbine and expand in it doing mechanical work of turning turbine shafts. — — Reheating improves the output from the turbines due 0 multiple heating. = Cést increases due to the additional fuel heat exchanger are therefore also employed. 1.3.8 Gas Turbine Power Plants in India plant of Gas Turbine Plant 1.3.7 Applications 1, Tousen peak loads in team ‘and hydropower plants, nary standby power plats 2. Used as station ing auxiliaries in other plans, 1 3, Asastartng plant for dvi 4 ‘asa base Toad power pant where fuel oll OF natal pi at cheap rate and easily available and wher thn available Jess water available in the area. | ‘Can be used in parallel with tidal power plants, Place (tate 1. | Deni 2x 104.6 + 1x 121.2 2. | Jamma and Kashmif | 3x25+4%25 ” 3. | Rajasthan 3x88,1%149 1x3, 1355, 1x37.5, 137.8, 3 x 110, 4,” | Uttar Pradesh (U.P) 4x 110, 2x 106 4x 131,2 x 146.5 5. | Haryana 2x 143, 1x 144 6. | Gujarat 1 x 675, 1 x 38.77, 1 x 72.51, 1 x 39.34, 3 x 30, 1x45, 1 228, 3 x32, 149, 1x 111, 1x54 4x 106, 2x 1105,3% 131 1x 255, 2325, 1235 3x 3825, 3x 110, 1 x 185 3x92,3x 135, 1250 5258.87 4x 108.2,2.% 120 1120, 160 1x 598, 1x323 1x 74.1, 138.80 430, 1x70, 138.88 1x 64,137, 1x61, 134 630.19 | [= EEF erectical Power Generation (MSBTE} = 1-20 _ Thermal Power Plants (Coal, Gas, Diesel & Nuclear Ba: a es@ Siencer Fuel da; g Spas, 7 tank tank {A Exhaust_—> _* ‘Water pump [Fuel injection pump Jacket ‘water as > Starting air tL Generator oil il cooler o™ 2 Staring ait Transfer untcatina ‘compressor oil Tank pump ‘Overfiow Straiter @ Fuel tank AUX. oi © Working of Diesel Electric Power Station (Function of main components) Diesel engine > (MSBTE -w-17) ‘State the function of diesel engine system. (Refer Section 1.4.1(1)) ‘This is the main component of the power plant which develops power. The diesel engines employed for diesel cleettic power plants may be four or two stroke engines. In 4-stroke engine the complete cycle of operations are performed in four strokes namely, suction, comipression, ~ expansion, and exhaust strokes and two revolutions of the engine. In the case of a two-stroke diesel engine all the four operations are completed within two stroke of the piston or during one revolution of the crank shaft - the power and exhaust operations are completed during the travel of the piston in backward direction (ie. toward crank end of the ot pump Fig. 1.4.1 : Block diagram of diesel electrical power plant oll purifier cylinder) while intake and compression ope ‘completed during the forward travel of the piston. A two-stroke engine is rugged and.compact in construction, simple in mechanical design, easily reversible, cheaper cost and develops more power for the same speed and piston displacement because of elimination of two idle strokes. Flywheel required is also smaller one development of more uniform torque, However, a fourstroke engine has lower specific fuel consumption and more effective lubrication, more flexibil less noisy exhaust, simple” and better cooling, beter ‘scavenging and higher efficiency than a two-stroke engine. Engine air intake including air filters, ducts and supercharger (Integral) with the engine > (MSBTE - S-17, W-17) Explain air intake system in diesel electric power} plant. (Refer Section 1.4.1(2)) State the function of air intake system. (Refer Section 1.4.1(2)) 0. 1.46 IP “owor Generation (MSBTE) 1-21_ Thermal Power Plants (Coal, Gas, Diesel & Nuclear Based) je power plants are considerable at 4-8 m? per kWh). drawn from outside the engine room and delivered the inlet manifold through ducts or pipes and filters, In old season, the intake air is heated by the heat for exhaust before injection. ‘The filters are to be cleaned periodically. Superchargers are ‘usually in between the engine and the intake since the noise may be transmitted back to the outside air via the air intake system. “There should minimum pressure loss in the air intake system, “otherwise specific fuel consumption will increase and the engine capacity will be reduced. Engine fuel system including fuel storage tanks, | fuel transfer pumps, strainers, heaters and connecting pipe work D> (MSBTE - W-14, S-15, W-16, S-17) Describe: the fuel systom of a diesel power} station. (Refer Section 1.4.1(0) DEERE Explain fuel system in diesel electric power (3)) plant. (Refer Section 1.4.1 State the function of fuel system of diosel power station. (Refer Section 1.4.1(3)) required to iransfer fuel from aly Fuel transfer pumps are = delivery point to storage tank and from storage tanks 10 ‘consumption tanks and then to engine. jded to remove suspended impurities and 4 season, The fuel oil is supplied at the plant site by rail or road. The fuel cil is stored in bulk storage tanks which are usually situated outdoor for safety. ‘The fuel oil is transfered from these tanks to the small storage tanks called day tanks daily or at suitable intervals by ‘means of transfer pumps through filters. From the day tank the fuel oil is passed through the strainers and fired into the engine through fuel filter and fuel injection pump. ‘The capacity of the daily consumption tank should be atleast the 8 hour requirement of the plant. Engine exhaust system Including silencers and connecting ducts D (WSBTE - W-14, S-16, WA7) la. 1.4.10 Describe the exhaust system of a diesel powor| 4.4.11. State the function of exhaust system in diesel station. (Rieter Section 1.4.1(4)) anos electric power plant. (Riefer Section 1.4.1(4)) red to heat the oil specially during winter | Heaters are requit ‘This system is provided to discharge the engine exhaust to the atmosphere outside the building, ‘The exhaust manifold connects the engine cylinder exhaust {0 with a muffler to reduce pressure in jnate most of the noise which may result the exhaust pipe pr cexhaust line and if the waste gases were discharged directly into the atmosphere. ‘As the temperature of the exhaust gases is sufficiently high, therefore, the heat of these gases is utilized in heating oil or to the engine. air suppl tn case of diesel electric generating units installed in steam power plants exhaust system also includes water heaters and steam boilers in order to utilize the heat of waste gases. Engine cooling system It is known that the heat generated by the burning off!” the engine cylinder is partially converted into sets! ¥oF “The remainder is wasted as heat in the outgoing <=b0U5 FSS and in heating the engine, and if mot removed mY (usBTE- W-15, $17, W-17) i gine starting system in. diesel power plant with neat diagram. | (Refer Section 1.4.1(7)), plant (Refer Section 14:17) la. 1.4.14 State function of engine starting system. Tosmp <4 (Refer Section 1.4.1(7)) = This system is provided to rotate the engine initially while = starting until the firing starts and the unit runs under its own power smal sets are usually started manually by handles but for sets of large capacity, say above 75 KW, the compressed sir system is mostly employed for stating diesel engines. = Battery driven motors can also the used for starting the diesel engine sets. In compressed air system of starting the” compressed air from a tank, ai high pressure (say 20 atmospheric pressure) is admitted to a few of the engine cylinders making them to act as reciprocating air motors to tum the engine shaft. = The ful is admitted to the remaining cylinders which causes the ‘engine to start under its own power. A motor driven compressor is employed for supply of air to be compressed air tank. 8s oe 7A I S = Solenoid, SS_= Starting switch B = Battery, M_ = Motor (for starting) E = Earthing, © HC = Holding P = Pullin coil, SMP = Starting Motor Pinion Shaft Fig. 14.2 : Diesel engine starting system (Electrical) ~ Battery supplied electric power to the motor through starting ‘switch. Motor is large current, low voltage series motor. — This inotor is linked with engine flywheel through gears and ‘tates the engine to stat it. Once the engine is started itis

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