General Layout of Modern Steam

Power Plant

Prepared by
Ankur Sachdeva
Assistant Professor, ME
 Introduction to Thermal Power Plant
• Steam is an important medium of producing mechanical energy.
• Steam has the advantage that, it can be raised from water which is available in abundance it does not
react much with the materials of the equipment of power plant and is stable at the temperature required in the
plant.
• Steam is used to drive steam engines, steam turbines etc.
• Steam power station is most suitable where coal is available in abundance.
• Thermal electrical power generation is one of the major method.
• Out of total power developed in India about 60% is thermal.
• For a thermal power plant the range of pressure may vary from 10 kg/cm2 to super critical pressures and
the range of temperature may be from 250°C to 650°C.
 Essentials of Steam Power Plant
• A steam power plant must have the following equipment:
(a) A furnace to burn the fuel.
(b) Steam generator or boiler containing water. The heat generated in the furnace is utilized to convert water into
steam.
(c) Main power unit such as an engine or turbine uses the heat energy of steam and performs work.
(d) Piping system to convey steam and water.
• In addition to the above equipment, the plant requires various auxiliaries and accessories depending upon the
availability of water, fuel, and the service for which the plant is intended.
Layout of Steam Power Plant
 Components of Steam Power Plant
A steam power plant using steam as a working substance works basically on the Rankine cycle. Steam is generated
in a boiler, expanded in the prime mover and condensed in the condenser, and fed into the boiler again.
• The different types of systems and components used in a steam power plant are as follows:
(a) High-pressure boiler
(b) Prime mover
(c) Condensers and cooling towers
(d) Coal handling system
(e) Ash and dust handling system
(f) Draught system
(g) Feed water purification plant
(h) Pumping system
(i) Air preheater, economizer, super-heater, feed heaters
 Working of Steam Power Plant
• Coal received in the coal storage yard of the power station is transferred to the furnace by the coal
handling unit.
• Heat produced due to the burning of coal is utilized in converting water contained in the boiler drum into
steam at suitable pressure and temperature.
• The steam generated is passed through the superheater.
• Superheated steam then flows through the turbine.
• After doing work in the turbine the pressure of steam is reduced. The steam leaving the turbine passes
through the condenser which is maintained the low pressure of steam at the exhaust of the turbine.
• Steam pressure in the condenser depends upon the flow rate and temperature of cooling water and on the
effectiveness of air removal equipment.
• Water circulating through the condenser may be taken from various sources such as rivers, lakes or seas.
• If a sufficient quantity of water is not available the hot water coming out of the condenser may be
cooled in cooling towers and circulated again through the condenser. Bled steam taken from the turbine at
suitable extraction points is sent to low-pressure and high-pressure water heaters.
 Working of Steam Power Plant
• Air taken from the atmosphere is first passed through the air pre-heater, where it is heated by flue gases.
The hot air then passes through the furnace.
• The flue gases after passing over the boiler and superheater tubes, flow through the dust collector and then
through the economizer, air pre-heater, and finally, they are exhausted to the atmosphere through the
chimney.
• Steam condensing system consists of the following :
(a) Condenser

(b) Cooling water

(c) Cooling tower

(d) Hot well

(e) Condenser cooling water pump

(f) Condensate air extraction pump

(g) Air extraction pump

(h) Boiler feed pump

(i) Make up water pump.

 Circuits in Steam Power Plant
1. Coal and ash circuit
2. Air and flue gas circuit
3. Feed water and steam circuit
4. Cooling water circuit
Coal and Ash Circuit
• Coal and Ash circuit in a thermal
power plant layout mainly takes care
of feeding the boiler with coal from
the storage for combustion.
• The ash that is generated during
combustion is collected at the back of
the boiler and removed to the ash
storage by scrap conveyors.
• The combustion in the Coal and Ash
circuit is controlled by regulating the
speed and the quality of coal entering
the grate and the damper openings.
Air and Gas Circuit
• Air from the atmosphere is directed into
the furnace through the air preheated by
the action of a forced draught fan or
induced draught fan.
• The dust from the air is removed before
it enters the combustion chamber of the
thermal power plant layout.
• The exhaust gases from the combustion
heat the air, which goes through a heat
exchanger and is finally let off into the
environment.
Feed Water and Steam Circuit
• The steam produced in the boiler is
supplied to the turbines to generate
power.
• The steam that is expelled by the prime
mover in the thermal power plant layout
is then condensed in a condenser for re-
use in the boiler.
• The condensed water is forced through
a pump into the feed water heaters
where it is heated using the steam from
different points in the turbine.
• To make up for the lost steam and water
while passing through the various
components of the thermal power plant
layout, feed water is supplied through
external sources.
Cooling Water Circuit
• The quantity of cooling water required to cool
the steam in a thermal power plant layout is
significantly high and hence it is supplied from
a natural water source like a lake or a river.
• After passing through screens that remove
particles that can plug the condenser tubes in a
thermal power plant layout, it is passed through
the condenser where the steam is condensed.
• The water is finally discharged back into the
water source after cooling.
• Cooling water circuit can also be a closed
system where the cooled water is sent through
cooling towers for re-use in the power plant.
• The cooling water circulation in the condenser
of a thermal power plant layout helps in
maintaining a low pressure in the condenser all
throughout
Characteristics of a Steam Power Plant
• The desirable characteristics of a steam power plant are as follows:
(i) Higher efficiency
(ii) Lower cost
(iii) Ability to burn coal, especially of high ash content, and inferior coals
(iv) Reduced environmental impact in terms of air pollution
(v) Reduced water requirement
(vi) Higher reliability and availability
Advantages of a Steam Power Plant
• The fuel (coal) is relatively inexpensive.
• The less initial investment is required compared to other generating stations.
• Thermal power plants can be found anywhere there are coal and water.
• Fuel can be transported by rail or road to the plant.
• Compared to hydroelectric power stations, it requires less space. As a result,
thermal plants are able to respond to load demand more effectively and support the
performance of the electrical grid.
• There are steady supplies of coal, oil, and natural gas at this plant, so it is less
expensive than a diesel power plant to generate electricity
Disadvantages of a Steam Power Plant
• As a result of coal combustion in a thermal power plant, there is a large amount of
smoke and fumes resulting in pollution and increasing carbon footprints.
• Large amounts of water are required for the condensation of steam. The steam
power plant has high running costs compared to hydroelectric power plants.
• Handling coal and disposing of ash takes up a great deal of space.
• Coal is used as fuel, which is an exhaustible natural resource. Steam power plant
maintenance is complex.
• A power plant’s starting time is quite long compared to other plants.
• Efficiency is around 30 to 35 percent less than other power plants.