Material On Steam Power Plants

1
WORKING PRINCIPLE OF STEAM POWER PLANT

The main components of power plants are boiler-generating steam of more or less parameters of a
steam turbine and an electrical generator having mutual shaft line with turbine that is connected to
a transformer to an electrical grid of power system.
First the coal delivered is unloaded in to the storage piles, then conveyed to the plant, crushed into
pieces of approximately 1" and brought to coal silo.
From the coal silo it is sent to mill, where it is pulverized.
The forced drought (draft) fan supplies the mills with the hot air, heated in the boilers air-heater.
The hot air is mixed with the pulverized coal and forwarded through the boiler burners in to the
furnace, a chamber where fuel is burned. The burned fuel forms fire jets with temperature s over
1500o C (2730oF ) as a might source of radiant and heat energy.
Some of the water is lightly reheated in economizer. In these tubes feed water is heated and
partially evaporated.
Then exits so called drum type boiler, where drum is used for separation of water and steam.
Steam flow go into the boiler super heater, where steam temperature and consequently heat energy
is rise. High parameter steam is brought through the main steam lines in to the turbine.
Expanding the steam works and makes the turbine rotate together with the generator coupled with
the turbine .In this mechanical energy is converted in to the electrical energy.
After the furnace and super heater, the furnace flue gas passes the economizer tubes.
The fuel gas comes in to the air heater where gas temperature reduces to 140-160oC.
The down steam the air heater, the fuel gas directed in to the stack with the help of the induced
draught fans. The precipitates, installed in this way, have to catch the dry fly ash from the gas.
THERMAL POWER PLANTS
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Steam and Drain System In Power Plants

Turbines:
Auxiliary Steam PRDS(Pressure Desuperheating System):
Auxiliary steam system is intended to provide steam to turbine auxiliaries, during start up, low
loads and also during normal operation.
From the main steam line to turbine line , a tap-off is taken for Aux. steam PRDS. The steam is
tapped from main and reduced required pressure with the pressure control valve and the temparature is
reduced to the required temperature through a de-superheating station (by cooling it with spray water
taken from boiler feed pump discharge and pressure of spray water is reduced through the pressure
control valve(PCV) and flow is controlled by a temperature control valve(TCV). A safety valve (PSV) is
provided to protect the downstream system against excessive pressure rise.
The system provides the steam to the following utilities:
Turbine Gland Sealing
Steam jet ejectors
Deaerator
Process
Parameters:
Flow
Temperature
Pressure
: During start up and low loads

: To create vaccum
:when turbine extractions is not available
Pegging Steam is used and during the startup conditions initial heating is done.
: To use for some external purpose. (not cupulsary)
Tone Per Hour (TPH)

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ATA
EXTRACTION STEAM:
The turbine is a single cylinder machine which offers the following extractions
Extraction I
: Uncontrolled Extraction to LP Heater
Extraction II : Uncontrolled Extraction to Deaerator

Extraction III : Uncontrolled Extraction to HP Heater
Extraction I :
The steam is extracted from turbine casing and connected to LP Heater. Where the condensate can
be heated at some required parameters and send to the LP heater. The turbine extraction line is provided
with a two non return valves (QCNRV(Hydralic operated valve) & other one is flap NRV) connected at
the turbine end and a Motorised isolating valve connected at LP Heater end.
Extraction II :
The steam is extracted from turbine casing and connected to Deaerator. In the extraction line there
are two non return valves(hydraulic operated valves) at the end of the turbine. A motorized operated valve
are also provided in the extraction line at the deaerator end. When the extraction steam is not taken then
deaerator is supplied steam from auxiliary steam.
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Extraction III :
The steam is extracted from turbine casing and connected to HP Heater. Where the condensate can
be heated at some required parameters and send to the BFP via. Boiler,So that the efficiency of boiler
increases. The turbine extraction line is provided with a two non return valves (QCNRV(Hydralic
operated valve) & other one is flap NRV) connected at the turbine end and a Motorised isolating valve
connected at HP Heater end.
The power assisted check valves are hooked up to the turbine governing system to make them
close with every trip of the turbine.
These nrv and motorized operated valve closes under interlock action when the water level
reaches High-High level set point in Heaters.
To safeguard the turbine against water ingress into turbine which may cause lot of damage to
turbine we use non return valves.
The drains are mainly connected inbetween NRVs and Motorised isolating valve. During the start
up of the turbine, entire extraction steam piping up to the isolation valve is to be drained. The drain valves
are closed only after extablishing steam flow through the line.
Parameters:
Flow
Temperature
Pressure
Tone Per Hour (TPH)

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ATA
EXHAUST DRAINS SYSTEM

GLAND STEAM:
From the clearance between rotor and turbine glands the steam tries to escape, So inorder to seal
this glands we use gland steam (from the main steam a tap-off is taken and set at required parameters).
The purpose of the gland steam system is to seal the inner compartments against the atmosphere by
admitting the steam to front and rear glands at a pressure slightly above atmosphere.If the glands are not
sealed the air tries to enter through the glands and this may lead to loss of vaccum and thereafter vaccum
cannot be established in the condenser. So, it is necessary to seal the glands.
Pressure and temperature indications are provided on the balance piston leak-off line to known
the excessive leakages through the glands. Whenever these are exceeding the valves mentioned in first
commissioning report, the glands is to be replaced after taking shut-down.
The steam is supplied through a control valve(PCV) at a constant pressure of 1.1 ata from the
Auxiliary steam header.
During running of turbine the excess leakage from the turbine glands is dumped to condenser
through control valve(PCV).
GSC bypass to atmosphere is provided which will be used when GSC is taken out for
maintenance.
Parameters:
Flow
Temperature
Pressure
Tone Per Hour (TPH)

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ATA
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GLAND STEAM CONDENSER
The excess leakage from the turbine glands and the steam used for gland sealing is removed from
the front and rear glands of the turbine and connected to the gland steam condenser where the gland steam
is condensed using condensate as cooling medium. This shall prevent steam oozing out from the glands
and heating the bearings pedestrals.Gland steam ejectors are used to create vaccum in the condenser.
VACCUM BREAKER
In case of turbine trip, vaccum is deliberately broken in the condenser by admitting air into the
condenser through a motor operated valve. This shall shorten the coasting down time of turbine.
Parameters:
Flow
Temperature
Pressure
Tone Per Hour (TPH)

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ATA
EXHAUST HOOD SYSTEM

It is necessary to run the turbine in no load conditions for prolonged period. During this period,
the exhaust hood temperature rises beyond the safe limit, especially in material point of view. Hence it is
necessary to limit the temperature by spraying the condensate through nozzles (the solenoid valve) fitted
in the exhaust hood. The spray water is taken from condensate extraction discharge pump. The solenoid
valve opens automatically when the temperature switch exceeds the preset value and when temperature
returns to safe limit the solenoid valve closes automatically thus stopping the spray water supply.
Parameters:
Flow
Tone Per Hour (TPH)
Temperature
C
Pressure
ATA
TURBINE DRAINS
All drains from the turbine are connected to surge pipe arranged adjacent to the condenser which
are under high pressure and temp. The top of the surge pipe is connected to steam space and bottom to the
hotwell of the condenser. The hot drains may thus flash out in the surge pipe without endangering the
condenser tubes.
The inlet of the surge pipe must be minimum of 250mm above the max. water level in the
condenser. The HP drain lines should be connected nearer to hotwell and LP drain lines should be
connected nearer to steam space on the surge pipe.
MOTOR OPERATED GATE VALVE
The gate valve is provided in the live steam line to isolate the turbine during the shut-down period.
BY-PASS VALVE:
During startup , steam is admitted steadily through the bypass valve for warming up the pipe line.
After attaining the required parameters the motor operated gate valve is opened and by pass valve is
closed.
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WET STEAM WASHING SYSTEM:
This system is envisaged to clean unwanted salts deposited on the turbine blades. A pressure
measurement is provided in the wheel chamber zone which helps in knowing about the salt deposited on
turbine blading during the course of turbine running.
EMERGENCY STOP VALVE:
To stop the live steam entering into the turbine when a problem arises in turbine.
Governing Valve
: The function of the valve is to control the steam inlet of the turbine.
Balance piston leak off
: It control the excess enlargement of rotor near the thrust bearings by
extracting the steam and this steam is connected to the controlled
extractions.
Check valves (QCNRV)
: These check valves are located on the extractions that are taken from the
turbine in order to stop the back flow from the concerned equipments.
QCNRV(Quick Control Non Return Valve)
Steam trap
:To discharge condensate
PCV
: used to control the pressure
TCV
: used to control the temperature.
Flow element
: to measure the flow
Drains are provided in the valve block(emergency valve and governing valve) and turbine casing which
will be opened during stratup and closed only after warming up period, these valve shall be kept opened
during the shut-down period.
Condensate System In Power Plants

The condensate systeam is used to condense the steam. (This works under the principle of shell and tube
On the shell side steam enters from the turbine ie to be condensed and on tube side waters acts as the
coolant to condense the steam. The coolant is taken from cooling water tank . The cooling water is
pumped with high pressures and connected to the condenser. The pump is designed is such a way that it
should recover all the losses and pr. Drop). The condensate is drawn from the main condenser hotwell by
one of the two 100% extraction pumps. In case of pump failure, the standby pump comes into existence
automatically. The pump is designed in such a way that it can recover the overall pressure drop
(sjae+gsc+lp+deaerotor+losses). From the pump discharge the condensate passes through the ejector
condenser, GSC, LP and deaerator where it is employed as cooling medium. From the deaerator it is
unruffled to BFP there after it is unperturbed to the HP via boiler with required pressure from the BFP.
HOT-WELL:
From the hotwell, the condensate is send to the concerned equipments as the cooling medium.
Normal level in the hotwell is maintained by recirculating the minimum flow requirements to the
concerned equipments. An LCV is positioning in the hotwell. When the level exceeds the normal level,
the dump control valve opens to increase the flow from the hotwell and maintains the constant level in the
hotwell.
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CONDENSATE EXTRACTION PUMPS:
The condensate is drawn from the main condenser hotwell by one of the 2 x 100% extraction
pumps. In case of pump failure, the standby pump comes into existence automatically .
a)
The following shall be ensured for starting of the pump:

Suction valve is open
Hot level should not be low
Minimum recirculation valve should be fully open
When pressure at the discharge of the pump is more than a preset value, the following shall be done
Opening the discharge valve
standby condensate pump shall be switched ON automatically when level in the hotwell rises to
HIGH LEVEL or the discharge pressure of pump falls below a preset valve.
pump shall trip when any of the following conditions exists:
hot well level falls below a preset very low level.
Motor protection circuit operated.
Bypass valves for cep discharge valves are provided only for initial priming of system. These valves
are kept normally closed.
AIR EJECTOR SYSTEM:

The air ejector system is used to create the vaccum in the condenser. It consists one hogging
ejector and two main ejectors one in working condition and other as standby. To create vaccum
during starting in the short time, hogging ejector is used when the vaccum reaches 500-550mm of
the column and after stabilization of main ejector, hogging ejector shall be manually stopped.
Motive steam for the starting ejector & running ejector is taken from auxiliary steam header.
To create vaccum during startup in the short time, hogging ejector is put into service by first
opening the steam side valve (to create vaccum in the ejector) and then the air side valve (which is
above the atmospheric pressure ). Limit switch in the valve shall be used to ensure that the valve is
open before the ejector is put into service.
When condenser vaccum reaches 500mm hg, one of the two ejectors is brought into service by
opening the respective steam side valve.
When the condenser reaches 600mm hg, starting ejector is taken out of services by first closing the
air side valve and then closing steam side.
CONTROL AND INTERLOCKING FUNTIONS:

HOT-WELL LEVEL CONTROLS :
For initiating alarms, interlocks, controls and actions following are provided on the hot well.
VERY LOW LEVEL (LSLL):
Two level switches in 1 out of 2 logic shall be annunciated in the control room and condensate
pump shall trip under interlock action.
LOW LEVEL (LSL):
One level switch shall annunciated in the control room
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HIGH LEVEL (LSH):
One level switch shall annunciated in the control room and standby pump shall be started
automatically.
LEVEL TRANSMITTERS (LT):
Two level transmitters to select the average level in the hot well.
HIGH HIGH LEVEL (LSHH):
One level switch annunciated in the control room.
NORMAL LEVEL:
This shall be used for START PREMISSIVE for condensate extraction pump.
Normal level in the hot well is maintained by hot well level controlled by positioning the excess dump
control valve(LCV1) and make up control valve(LCV2). As the hot well level rises, the dump control
valve opens to increase the flow from the hot well and maintains the constant level in the hot well. When
the hot well level falls, the make up control valve opens to maintain the constant level in the hot well.
MINIMUM RECIRCULATION CONTROL:
Minimum recirculation control valve(LCV1) along the deaerator level control valve(LCV2) maintains a
minimum flow of condensate through CEP at all modes of operation. Two flow transmitters installed
across the flow orifice downstream of GSC in one of the two mode to feed signal to controller which
modulates minimum recirculation control valve.
Here the control valves(LCV1 &LCV2) is operated by flow controller.
FEED WATER SYSTEM IN POWER PLANTS:
The feeding heating system consists of one LP heater, one Deaerator, One HP heater.
LP HEATER :
The LP heater is condensing heater with an external drain cooler. The header and drain cooler are
horizontally designed. An extraction is taken from the turbine and connected to the shell side to heat the
condensate and condensate is taken from the hotwell. Normal drains of LP heater are cascated to
condenser. Afer passing through the LP heater it enters the deaerator feed storage tank via deaerator.
DEAERATOR:
Deaerator is used to remove the air bubbles in the condensate so that no oxide are formed in the
condensate. Deaerator is designed to operate under constant pressure mode Heating system bled from
turbine. During the startup conditions intial heating process is done by taking from an external source i.e
auxiliary steam header at required parameters. When turbine extraction is not available, deaerator is
pegged from an external source i.e, auxiliary steam header through deaerator pegging control station. A
nrv is used to stop the back flow.
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BOILER FEED PUMP
The condensate is drawn from the Deaeratorl by one of the 2 x 100% extraction pumps. In case of
pump failure, the standby pump comes into existence automatically .
a) The following shall be ensured for starting of the pump:
Suction valve is open
b) When pressure at the discharge of the pump is more than a preset value, the following shall be done
Opening the discharge valve
Standby condensate pump shall be switched ON automatically when discharge pressure of pump
falls below a preset valve.
Pump shall trip when any of the following conditions exists:
When Deaeratorl level falls below a preset very low level.
Motor protection circuit operated.
HP HEATER:
HP heater is condensing heater with a flash tank(under high level conditions,the alternative path
provided on heater diverts the drains directly to the flash tank). The header and drain cooler are
horizontally designed. An extraction is taken from the turbine and connected to the shell side to heat the
condensate and condensate is taken from the hotwell. Normal drains of LP heater are cascated to
condenser. Afer passing through the LP heater it enters the deaerator feed storage tank via deaerator.
CONTROL AND INTERLOCKING FUNTIONS:
DEAERATOR LEVEL CONTROL :
For initiating alarms, interlocks, controls and actions following are provided on the hot well.
VERY LOW LEVEL (LSLL):
Three level switches shall be annunciated in the control room and boiler feed pump shall trip under
interlock action.
LOW LEVEL (LSL):
One level switch shall annunciated in the control room
HIGH LEVEL (LSH):
Highlevel in the feed storage tank shall be shall annunciated in the control room.
One level switch at 50mm above HIGH LEVEL(LSH) for deaerator overflow valve
open interlock and annunciated in the control room.
One level switch at 50mm below HIGH LEVEL(LSH) for deaerator overflow valve closes
interlock and annunciated in the control room.
LEVEL TRANSMITTERS (LT)
:
Two level transmitters to select the average level in the Deaerator.
HIGH HIGH LEVEL (LSHH):
One level switch annunciated in the control room.
Closing the motor operated valve and then the qcnrv & nrv that are located on the steam supply
line from deaerator to turbine.
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Closing of deaerator pegging control valve(PCV) located on the steam supply line to deaerator
from auxiliary steam header.
Repeatedly opening the motor operated drain valve.
Closing the motor operated valve on incoming condensate to deaerator.
NORMAL LEVEL:
This shall be used for START PREMISSIVE for Boiler Feed Pump.
Lubrication System In Power Plants

Through there are many rotating equipments in a power plant the heart of a power plant is lube oil
system. The oil system is so designed that each bearing under consideration is supplied with oil to the
required parameters of pressure, temperature and flow and the outlet oil from all the bearings is drained
properly back to the system so that the lubrication system shall be a closed cut lubrication system.
Oil from the Main oil tank will b pumped by the main oil pump (driven by a.c) to the bearings in
the system through coolers and filters. Thus cool and filtered oil will enter into the bearings in the
required/designed qualities at the designed pressure.
This oil will form as a wedge/hydrodynamic oil film in between and the shaft on which the shaft
rotates, thus eliminating metal to metal contact.
The oil after taking away the heat in the bearings will flow in between bearings and comes back to
the main oil tank, making the system as a closed circuit one.
Since a highly reliable and continuous lubricatin of the bearings is of the utmost importance,
sufficient redundancy is provided in the lubricating system. In case of any problem with Main oil pump/
Auxiliary oil pump will take over and in case auxiliary oil pump also develops problem. Emergency oil
pump (run by dc) will come into operation. However emergency oil pump operation is only to ensure
proper lubrication during the coasting down period. If Emergency oil pump also fails., which is last
possible than oil from over head oil tank will be supplied to the bearings for coasting down period.
In certain cases when rotor are heavy jacking oil is provided . It ensure that during startup to lift
the rotor rating metal to metal contact. The jacking oil pump will stop as soon as the film is formed.
Jacking oil is required for all the cases. It will be used where the bearings specific pressure is high
MAIN OIL TANK
The oil tank is located on the ground.
The oil tank serves for storing the oil volume required for governing and lubricating system. It
allows the impurities to be deposited at the bottom of the tank along with the oils sludge. A
gradient is provided at the bottom of the tank to enable the impurities to be collected for easy
drain-off. Baffle plates are provided to give a longer time in the tank, so that the entrapped air is
effectively released. Level gauge and level transmitter indicate the level in the tank.
The oil vapor extraction tanks mounted on the oil tank top plate evacuate oil vapors accumulated
in the oil tank. The exhaust is led to safe location outside the hall.
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The oil tank is provided with connection for oil centrifusion. The oil centrifuge inlet connection
provided in the oil tank is of loop configuration in order to prevent entering of the oil. Tank in case
of leakage in the oil purification circuit. The top of the loop is in line with minimum oil level in
the oil tank. If the oil level in the tank falls below min. level, flow to centrifuge circuit is
interrupted as air enters into the loop through the hole provided at the top of the loop. The low and
high levels, are annunciated in the control room. When ever the level falls below minimum oil
level, the level shall be raised to normal operating level by adding clarified oil. Mostly we use
servo prime 46 as the lubricating oil.
LUBE OIL PUMP
The lube oil pump is a single stage centrifugal pump driven by A.C motor. The delivers the total
oil required for governing and lubricating oil system. The oil which flows through the governing system is
known as leak oil and the oil which flows through the coolers side is known as lube oil. Tap-off for
governing circuit is taken immediately after pump discharge. For lubricating purpose, oil is taken down
stream the oil cooler after suitable pressure reduction using an adjustable throttle.
MAIN OIL PUMP AND AUXILIARY PUMPS
The main oil pump is invariably ac motor driven centrifugal pumps to ensure maximum reliability
.It may also provide high pressure oil for the relay system at a pressure of 150kg/cm2. By raising
all the oils to this pressure, the lubricating oil being drain off through a reduction valve. Although
this method is often adopted because of its
simplicity and because the relays automatically
close the stop valve, if the lubricating oil supply falls it is wasted of pumping energy.
The quantity of oil used makes it economically to incorporate a centrifugal pump driven directly to
the bearings. It is self priming and requires oil ejector to over come the suction head both when starting
and during running a governing hydraulic systems is used. The pumps may be mounted directly in the
main oil tank with their inlets submerged below the oil level thus obviating the need for an oil ejector.
Note:
The auxiliary pump is automatically brought into operation by a relay when the oil pressure falls
below a certain value.
A check valve in the pump discharge ensures safety of the pump against reverse rotation when the
pump is kept as stand by.
If the pump discharge pressure falls below 6.5kg/cm2, the stand by pump will be started through
pressure switch.
If the stand by pump also fails, the turbine will be tripped set at 0.8kg/cm2.
EMERGENCY OIL PUMPS

During coasting down of turbine, when lube oil pump is not available, lubricating oil is provided
by emergency oil pump. The emergency oil pump is driven by D.C. motor.
The E.O.P. will cut in automatically by lube oil pressure switch set at 0.7kg/cm2. In order to ensure
positive supply of oil to the bearings, this pump is connected directly to the lube oil with out going
through cooler and filter.
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JACKING OIL PUMP
A positive displacement pump unit provides the supply of high-pressure oil to the bottom side of
the individual shaft journal, an oil pump unit is provided. The pump is driven by A.C motor and from the
pump the lifting oil passes to the various bearings and from the bearings the oil returns to the drain header.
When a turbine is started up the shaft journal are in contact with the white metal of the bearings
due to the weight of the rotor. The low pressure of the lubricating oil supply when the set is stationary is
insufficient to stop the metal to metal contact between journal and bearing shells. So the starting and
stopping in the presence of metal to metal contact would result in increase to wear of the white metal
surface. So in order to prevent the metal to metal contact between journal and bearings shells during
startup and shutdown, an oil pocket machine into the bottom shell of the journal bearing is supplied with
oil under high pressure. This lifts the shafting the shafting system slightly and it floats on a film of the oil.
Only a small volume of oil is needed to perform the lifting of the shaft.
The lifting oil pressures required are set individually with the throttling valves at each bearing. Pressure
gauges provided down stream of these throttles shall be referred for setting the throttle position.
The check valves fitted between the throttling valves and the bearings prevent oil from the bearings
flowing back into the jacking oil system when the turbine is running and jacking oil system has been
shutdown.
OIL COOLERS:
Twin coolers shall be provide and shall be piped in a parallel arrangement using a continuous flow
transfer valve.The main factor of the cooler is to freeze the water and an oil-bypass line around the cooler
being included to regulate the oil supply temperature. To regulate lube oil temperature the control valves
are provided to by-pass around the cooler. The control valve shall be sized to handle all oil flow passing
through the cooler with a pressure drop equal to or less than the pressure drop in the cooler. The coolers
are usually mounted vertically for easy removal of the tubbiest and water passing upwards through the
tubes ensures complete flooding at all times. Oil enters at the top and passes across the tubes in a zigzag
manner, guided by the fins. The oil and water passes are arranged in counter flow. The arrangement
reduces the amount of sludge precipitation. In the cooler as the hot oil entering the cooler does not strike
the coldest part of the cooler tube.
In the coolers the efficiency of a centrifugal pump may be of the order of 55% and the remaining
45% of the pump input energy generates heat in the oil. The oil absorbs a large amount of heat from the
bearing friction and shaft conduction. To remove this heat the oil is passed through coolers which reduces
the temperature to that required for the bearings.
Both the water side and the oil side of the cooler shall be self-venting and self-draining or shall be
completely drainable.
Each cooler are divided into three types, They are:
Water cooled
Shell and tube
Air cooled
A removable bundle design is required for shell and tube coolers. Removable bundle coolers are
constructed with a removable channel cover.
Note:
To prevent the oil from being contaminated if coolers fails, the oil side operating pressure shall be higher
than the water side operating pressure.
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SPECIFICATION:
OIL FILTER:
Twin full flow filters with replaceable elements or cartridges with filtration of 10microns nominal
or finer shall supplied. The filter shall be located down stream of the coolers and shall be piped in a
parallel arrangement using a continuous flow transfer valve. Filter cases and heads shall be suitable for
operation at the maximum discharge pressure. The filter shall not be equipped with relief valves are other
valves which can cause by-pass of unfiltered oil around the filter elements.
The pressure drop for clean filtered elements are cartridges shall not exceed 15% of the total allowable
dirty pressure drop at an operating temperature of 38C.
FEATURES:
Oil flow from the outside inward towards the centre of the filter element.
Adequate support of the filter elements to prevent them from rupturing or to prevent unfiltered
oil from bypassing the elements and reaching the equipment.
Minimum exposure of non stainless steel filter casing surface to the oil down stream of the filter
elements.
Adequate support and maintainable alignment of staged filter cartridges.
Proper sealing at the ends of the cartridges, including cartridges to casing sealing and sealing
between stacked cartridges.
The ability to completely drain oil from the filter housing while avoiding contamination of the
downstream side with unfiltered oil during replacement of the filter elements.
Consideration of the use of guard elements to capture debris in case of filter element deterioration
or failure.
OVER HEAD OIL TANK:
When E.O.P. also fails, as a last resort to protect bearings, an over head oil tank is provided. The
tank is kept at an elevation of 6.5m to provide lubricating oil by gravity.
The tank is filled using lube oil pump during initial startup. Overflowing oil through flow glass
indicates the oil filling completion. Once the tank is full, the inlet valve is closed and a small amount of oil
is allowed to continuously over flow through the tank.
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EQUIPMENT-LAYOUT
In a power plant station the equipment are arranged as shown in the figure.
In the 15MW TG power plant the length of TG hall is 47000 mm and TG hall span is 27000mm.
The ground floor elevation is 0.0m.
The mezzanine floor elevation is 4.0m.
The operating floor elevation is 9.0m.
The de-aerator floor elevation is 14.0m.
GROUND FLOOR: In the floor the following equipments are placed. They are
BFPS.
CEPS.
Boiler house.
Oil tank.
Oil coolers.
Oil filters.
Oil pumps.
Oil Centrifuse.
Condensers.
Flash tank.
Generator air cooler elements.
NGR.
MEZZANINE FLOOR: It is the floor lie in between the ground floor & operating floor. The following
equipments were kept on this floor.
Steam jet air ejector.
Gland steam condenser.
HP heater (Horizontal).
LP heater (Horizontal).
OPERATING FLOOR: This is above the mezzanine & ground floors.
The following equipments were placed on the TG deck at operating floor elevation.
Turbine.
Gearbox.
Generator.
The control room is adjacent to TG hall were turbine control panel, generator control panel are
placed. Above control room the de-aerator is placed on the de-aerator floor.
While placing the equipment care is to be taken that sufficient walk around space is available.
At the time of operation or maintenance this is very much required for all equipments. The
equipments are arranged in logical manner so that when the piping is done there is no back tracking
or criss crossing of pipes.
The tube removal of equipments shell is also marked in the equipment layout so that no piping
or equipment come in that space earmarked for maintenance. All the equipments shall be kept on
a pedestal.
The equipment layout for 15MW STG is enclosed.
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PUMP: In general pump may be defined as a mechanical device which when interposed in a
pipe line, converts the mechanical energy into hydraulic energy and transfers the same to the
liquid through the pipe line, there by increasing the energy of the flowing fluid.
EXTRACTION
PUMPS: The most important function in extraction pump design is the avoidance
of the excess of oxygen into the condensate system .This can be carried out in a number of ways ,
they are
Two stage extraction pumps
Two stage extraction pump with internal bearing .
Three stage extraction pump alternative arrangements.
In Two stage design the gland at the left hand side adjacent to the first stage impeller is
under vacuum ,when the pump is in service .The gland is therefore scaled by leading a condensate
supply to it from the second stage discharge pipe ,care must be taken to ensure that the gland
connections to the stand by pump are isolated from the pump in operation . This results in a somewhat
complicated small board piping system with the necessary operational requirements of changing
over the sealing connections when bringing the stand by pump into service. The water being rotated
by the action of the shaft when the pump is in use, forming a helix . The air then leaks into the
pump between the water streams which form the helix.
One partial solution is to fit an internal bearing at the suction end of the
Pump. But this bearing must be water lubricated and may ,therefore ,be damaged by suspended
matter. The vertical spindle arrangement is particularly vulnerable to this damage during the
commissioning or after the overhaul period.
Probably the best arrangement , where the hydraulic characteristics allow is
to mount the first stage impeller on the shaft between two impellers running in parallel on a two stage
design and in series for a three stage duty. The arrangement is slightly more expensive ,but it does
ensure positive pressure on the pump glands.
Recently we used reentry type extraction pumps. The extractions pumps become integrated
with the generator coolers and auxiliary cooler system .This limits maximum design pressure
needed for the auxiliary coolers.
FEED PUMP:The feed pump is a pump which is used to deliver feed water to the boiler. It is a
desirable that the quantity of water supplied should be at least equal to that evaporated and
supplied to the engine. Two types of pumps which are commonly used as feed pumps are
1.Reciprocating pump
2.Rotory pump
The reciprocating pump consists of a pump cylinder and a piston. Inside the cylinder
reciprocates a piston which displaces water.
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The reciprocating pump may be of two types. They are
1.SINGLE ACTING PUMP:
In a single acting pump , the water is displaced by one side of the piston
only and so the water is discharged in alternate strokes.
2.DOUBLE ACTING PUMP:
In a double acting pump, the water is discharged in each stroke ofthe piston, since the water
is displaced by both the sides of the piston.
The reciprocating feed pumps are continuously run by steam from the the same boiler to
which water is to be fed.
In a double direct acting steam pump, there are two single steam cylinders placed side by
side. Slide valves distribute the steam in each cylinder
The slide
valve in each cylinder steam chest is operated by the crosshead on the piston
rod of the opposite cylinder, through, an arrangement of rods and rocker arms. The feed pump
is generally double acting. On each side of the pump plunger there are suction and
discharge valves. The pumps work alternately and consequently continuous flow of water is
maintained double feed pump is commonly employed for medium size boilers.
Rotary feed pumps are of centrifugal type and are commonly run either by a small steam
turbine or by an electro motor. A rotary pump consists of a casing and a rotating element
known as impeller, which is fitted over a shaft. It utilizes the centrifugal force of the rotating
impeller for pumping the liquid from one place to the other.
BOILER FEED PUMP: Boiler feed pumps are used for pumping hot feed water from de aerators to boilers
of thermal power stations and constitutes one of the most essential equipment for uninterrupted
power supply. Every increasing steam parameters in modern power stations have resulted in
fast development of boiler feed pumps and today these pumps are highly sophisticated equipment
in thermal power stations.The function of the feed pump is to deliver feed water from de aerator
to the
boiler drum at a required pressure and temperature. The water with the given operating
temperature flows from the de aerator to the pump continuously it passes through suction branch
into the intake spiral and from there it is desired in to the first impeller. After leaving the
impeller it passes through the diffuser where the kinetic energy is converted into potential
energy. Then it flows over to the guide vanes to the inlet of the next impeller eye. This process
is separated from one stage to another till it passes through the last impeller and the end
diffuser. Thus the feed water at outlet of the last stage attains the required discharge head.
About 50% of the feed water is taken off from the space behind the last impeller for automatic
balancing axial thrust produced. The feed water passes through the balancing device and comes,
into the space behind the balancing disc. Water is taken from space to the suction or to the feed
water tank.
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ELEMENTS OF BOILER FEED PUMP: The boiler feed pumps at highly sophisticated equipment in thermal power stations
and in fact represent the heart of a power station. Very high technical skill sophisticated
materials and rigid quality control are employed in the production of these pumps. These
pumps operate at high rotational speed and therefore require very accurate balancing. The pump
is of robust construction and does not require any warm up.
The pump consists of:
1.Casing
2.Shaft
3.Shaft sleeves
4.Impeller
5.Diffuser
6.Ring sections
7.Suction cover
8.Discharge cover
9.Stuffing box assembly
10.Balance drum
11.Pump half coupling
12.Bearings and housings.
BOILER FEED BOOSTER PUMP: For efficient and reliable operation of the boiler feed pump, even under adverse suction
conditions and constrained layouts without provision for adequate net positive suction
head , it is often pressed to provide a booster pump to boost the suction head to the required
levels.
HEAT EXCHANGERS: A heat exchanger is any device used for effecting the process of heat
exchange between two fluids that are at different temperatures. A heat exchanger in which two fluids
exchange heat by coming in to direct contact is called a direct contact heat exchanger. Example of this
type are open feed water heaters, de super heaters and jet condensers. The wall may be simple
plane wall or a tube or a complex configuration involving fins, baffles and multiple passes of tubes.
These units are called surface heat exchangers, are more commonly used because they can be
constructed with large heat heat transfer surfaces in a relatively small volume and are suitable for
heating cooling, evaporating or condensing applications.A periodic flow type of heat exchanger is called a
regenerator. In this type of heat exchanger, the same space is alternately occupied by the hot and cold
gases between which heat is exchanged. Regenerators find their application in pre heaters for steam
power plants, blast furnaces, oxygen producers etc.
TYPES OF HEAT EXCHANGERS:Heat exchangers may be classified in several ways. One classification is
according to the fluid flow arrangement or the relative direction of the hot and cold fluids. The fluids
may be separated by a plane wall but more commonly by a concentric tube(double pipe)
arrangement. If both the fluids move in the same direction, the arrangement is called a
parallel flow type. In the counter flow arrangement, the fluids move in parallel but in opposite
directions. In a double pipe heat exchanger, either the hot or cold fluid occupies the annular space and
the other fluids moves through the inner pipe. Since both fluids streams traverse the exchanger only
once, this arrangement is called single pass heat exchanger.
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Another flow configuration is one in which the fluids move at right angles to each other
through the heat exchanger. This type of arrangement is called a cross flow type. When large quantities
of heat are to be transferred, the heat area requirement of the exchanger also becomes large. In this case
multiple pass arrangements can be used.
FEED WATER HEATING EQUIPMENT:Feed water heating is accomplished in one string for the low pressure heating, while
in two strings for the high pressure heating in order to improve the reliability of operation.
Such joints in the construction of the high pressure feed water heater as between the tube and
baffle and between the water box and shell etc is setup by welding to assure prevention of leakage.
The main condensate in most of the power plants returns to the steam generator as feed water. Some
makeup water may be added to replace in the cycle. In a few plants the boiler feed water may be 100%
makeup, in this case the plant turbines exhaust at backpressures above atmospheric to supply steam for
other purpose. Feed water is heated by bleeding steam to heaters as in a regenerative cycle from the main
turbine, or by using exhaust steam from auxiliary drive turbine, or by byproducts steam from processes.
Feed water heaters may be classified as follows:
1. Open (or) contact heaters.
2. Tray type
3. Jet type.
4. Closed (or) surface heaters.
Heated feed water enables steam generators to produce more Kg of steam and avoids severe thermal
stressing by cold water entering a hot drum. Pre heating feed water also causes scale forming dissolved
salts to precipitates outside the boiler and removes dissolved O2 &CO2 which corrode boiler material.
OPEN HEATERS:1) Tray type: -The construction of an open heater employs a shell of rolled steel plates welded along the
longitudinal steam. Dished steel ends are joined to the shell at two ends through welding. In the tray type
heater the upper half of the shell contains two tray sections and the spray distributor, while the lower half
is mostly empty and serves as storage for heated water. Above the shell is placed a vent condenser. Feed
water after passing through the vent condenser flows into the spray distributor from where it cascades over
the staggered trays, Exhaust steam from auxiliaries or low pressure steam from a suitable point in the
turbine is passed into the heater, entering into opposite the tray sections and flowing upward counter to the
direction of water, through the heating section. The flow of two liquids through the heater, thus results in
thorough mixing up so that heat of steam is transferred to water, the steam itself also being condensed O2,
CO2 & NH3 are also removed by this type of heaters.
In addition to the heating of feed water, the contact type heater is often
construction for de aerating action. The only difference between the simple heater and a de aerating open
heater is in the addition of a suction of air removing trays below the heating trays. After the water has
been heated in heating section, it is made to pass over the air separating trays, which provide a complete
separation of air and water, Water
then flows down while air and non-condensable gasses together with water vapour pass to the top of the
shell and from there to the vent condenser. The vent condenser is a small surface condenser of U-type.
The vapour went to the atmosphere. The interior of the shell of de aerating as also the trays is made of
corrosion resistance material such as stainless steel.
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JET TYPE OPEN HEATERS:In this type of de aerating contact heater spring loaded spray valves
atomize the feed water coming from the vent condenser spray it up words against the baffle. The low
pressure steam enters a conical steam jacket fitted in the upper part of shell, and is allowed to
expanding the same direction as the water spray, mixes with water and mixture falls down to the
lower part of the shell which serves as the storage. The non-condensing gases travel upwards as in
the tray type heater and are passed on the vent condenser. It is mainly used in marine where tray
type heaters do not work well due to the pitching & rolling of the vessel. They can handle water
containing scaling impurities and are lighter in weight. These heaters do not work well at low
pressures special at sub atmospheric pressure.
CLOSED(OR)SURFACE FEED HEATERS:These heaters usually have shell and tube construction and may be made
horizontal and vertical. The construction of a closed heater and a surface condenser are identical except
that the heater is design for higher temperatures and pressures and has greater than the condenser .
It consists of a shell which has a welded longitudinal steam. To each end of the shell
is welded a steel flange for fitting the covers , and top and bottom connections are provided for
inlet of steam and exit of condensate . A baffle plate is provided below the steam inlet to spread
the steam evenly over the tubes. The water tubes are admiralty brass or other suitable material are
stretched between two end sheets of muntz metal or soft steel ,one of these being fixed and the
other floating to take up extraction strain in tubes, The floating tube sheet is covered with a head
cover bolted on to it and prevents the leakage of water into space.
The heater may have single pass or the water box may be divided to give pass basin. A pair of
air pockets provided at bottom of the shell permits the with drawn of air.
The flow of steam and water through the heater is usually counter to each other low pressure
heaters may use the steam under vacuum high pressure heaters at pressure above 40 bars. Steam
and water need not beat the same pressure and one pump may push water through several heaters
in series. Water pressure may be as high as 250 bars. For good performance heaters must be
drained and vented.
L .P. HEATERS:These heaters are usually constructed of mild steel tube plates and shells
with tubes of 90/10 cupronickel or admiralty brass expanded into the tube plate for a depth
of approximately 1 1/2inch. The usual procedure when testing for leaks in L.P heater tube nests
is by filling the steam space with water and applying a pressure not in excess of the design
pressure of the body when leaking expansions and tubes are readily shown up.
When leaking tube expansions exits a further light rolling is usually necessary
to stop the leakage , unless the severity of the leak is sufficient to erode the tube plate ,in
which case plugging may be necessary leaking tubes are normally plugged off when the
incidence of failure is slight , but there is an obvious limit to this procedure. The location of the
leaking tube in the tube plate is of some consequence with u-tube heaters .
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H.P HEATERS:It is similar to L .P . heaters. The essential difference is that the tubes must with
stand the full pressure of the feed pumps However if a booster pump is employed upstream
of the heater, the feed pump pressure can be reduced.
The tubes may be of 70/30 cupronickel , with some iron alloyed ,and the shells of
forged steel. The water box is bolted down with bolts drilled down the axis to facilitate electric
bolt heating .The bolt heating is done by passing current through carbon rods in the central
holes of the bolts .This method of bolt tightening ensures tight, joints even at the high pressure
and temperature en counted in the last one (or) two heaters which receive super heated steam
from the high pressure stages of turbine.
H.P heaters too are equipped with gauge glasses steam and water spring loaded relief
valves as well as body air vents .The body air vents and vents on the incoming and out going
feed pumps are led to an open turn dish to enable observation of air release ,thence to a drain
tank ,and finally to a separates flash box ,and onto the condenser.
DE- AERATOR HEATER:It was a conventional practice of designing the de-aerator , so that the storage tank
has a capacity sufficient enough to contain the feed water for about 15 min running at a rated
output.
Reduced capacity of the storage tank has been found successful in realization of
uniform temperature distribution of the feed water in the tank,prevention of flashing in the
suction pipe of the feed water pump as well as economization of the frame work of the
building ,resulting from reduced weight of the tank. The distillate pump is to be operated only
for filling up the boiler drum and not to make up the de aerator when the units in operation.
In a de-aerating heater entering water spills over trays (or) sprays through nozzles
to make it present a maximum surface, for heat transfer to the atmosphere of steam filling
the heater. This also removes all dissolved O2 in excess of 0.03 ml per 1 from the water .A unit
that reduces the O2 to 0.005 ml is a de-aerator.
Adding Na2 So3 to the feed water or boiler reduces any remaining dissolved O2 to a
tolerable minimum. De- aeration may takes place at any pressure or vacuum. Heating releases the
gas from the water in minute bubbles that tend to stray entrained. These can removed by
agitation (or) stirring the water turbulently. The de-aerating heater and de-aerator mix steam and
water to heat the water to saturation temperature, they also agitate the boiling water to remove
entrained gases and vent them to atmosphere .The most heaters have a storage tank below with
controls to add make up water as needed to maintain feed water flow. The heating steam may
be main turbine feed steam (or) may
be from other sources.
OTHER EQUIPMENTS:Other equipments required for steam power plant are:
Glands & Sealing systems.
generator.
Drains.
Drain flash tank.
Safety valves.
Steam nozzles
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GLANDS& SEALING SYSTEMS:Glands and sealing systems are used on turbines to prevent
(or) reduce the leakage of steam (or)air between rotating and stationery components that have a
pressure difference across them.. e .g. where the turbine shaft is extended through the cylinder end
walls to the atmosphere . When the cylinder pressure is higher than atmosphere will be a
general steam leakage outwards whilst if the cylinder contains steam below atmosphere pressure
there will be leakage of air inwards and a sealing system must be used to prevent the air
from entering the cylinder and the condenser.
As most of the steam leakage from glands does not pass through the turbine stages , a
loss of power output is involved and every effort is made to reduce this power loss by an
efficient arrangement of seals and glands. Three types of glands and seals are in general use on
steam turbines , the carbon ring gland and the water seals. The first two glands act as restrictors
to steam and air leakage ,whilst the water seal will prevent all leakage of steam and air.
Pump glands are generally of the mechanical type .Clean water flushing is provided
to reduce the heavy wear that would otherwise occur on startup after a lengthy shutdown.
Conventional soft packing glands are used on the older smaller cooling water pump design.
AIR JET EJECTORS: The operating medium of an air ejector can be either high pressure gas or liquid. This is passed
through a nozzle and the pressure energy is converted into velocity energy. The high velocity fluid
aspirates the air and non condensable gases and the mixture is projected into a diffuser which
reconverts the velocity energy into pressure energy. Steam is a suitable operating medium and is
used in the steam jet air ejector.
The steam consumption is controlled by the compression ratio of the and this factor influences
the decision to adopt either single or multiple stage ejectors for a particular condition. To meet the
requirements when raising vacuum a starting ejector is provided. This is a high capacity high steam
consumption ejector, of single stage and with out an after condenser.
A main air ejector with stand by unit is usually provided for normal operation. The heat in
the operating system is partially recovered in the condensate which flows through the inter and after
coolers.
If an installation is to operate with a direct cooling system, as is provided by the sea or
river, vacuum as high as 29.2 in HG would be expected during the winter months. A two stage
ejector is generally only capable o f maintaining a vacuum of 29.0 in HG even at zero flow ,but
three stage ejector will hold up to 29.4 in HG and would there fore be used.
Further advantage here is that for a comparable duty the three stage ejector shows a slight saving
in steam consumption over the two stage ejector.
GENERATOR:Generator is used to produce electricity. The turbine and generator are connected
by a shaft. In the generator the field system will always be the rotating member and is called
the rotor while the armature assembly, comprising armature winding and magnetic iron core
will be stationary and is called the stator. In the generator the mechanical energy obtained in the
turbine is converted into electrical energy. Generator air cooler is used in order to cool the
generator.
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GEAR BOX:The use of very large circulating water pumps with low rotational speeds has
necessitated the use of an intermediate gearbox .How speed motors of the size required are
very expensive and it is economically justifiable to sacrifice 1 to 2% in efficiency by
introducing a step down gearbox between pump and motor. The gear ratio can be set to allow a
motor with an economic running speed to be selected. In practice a 4000 h. p .c pump unit
running at 200 rev/min will require a 5:1 step down gear box ,permitting the use of a 1000
rev/min motor. The gear boxes may be of 2 basic types ,either parallel shaft offset(or) co axial.
LUBRICATION SYSTEMS:Oil is required by the bearing in order to provide a continuous oil wedge on
which the shaft revolves , this requires only a small quantity of oil .
However shaft conductivity , surface friction and turbulance set up in the oil produces
considerable,amount of heat and in order to keep the bearing temperature constant at the desired
level a further quantity of oil is required to remove this heat.
Oil is supplied to the bearing at a pressure from 5 to 25 lb/in2 gauge. This pressure is
required to ensure that the pressure in the upper part of the bearing does not below atmosphere ,in
which case discontinuities in the oil film would form .On the other hand if the pressure is too
high the oil be sprayed out from the end of the bearing at a high velocity &will become finally
atomized. In the conditions the oil may easily escape from the bearing house. The temperature of
oil must be kept within certain limits. If the oil temperature entering the bearing is too low , in
sufficient bearing lubrication will occur due to high velocity of the oil , whilst if the oil
temperature on leaving the bearings too high, this will lead to deterioration of oil due to high
rates of oxidation.
This temperature of oil leaving the bearing is limited to 1600F .So that the maximum
temperature with the bearings not more than 1600F and required leaving temperature is achieved
by adjusting the supply of oil to each bearing .
OIL PUMPS:Types of oil pumps;
1. Main oil pump
2. Auxiliary oil pump
3. Jacking oil pump
4. Emergency oil pump
MAIN OIL PUMP:The main oil pump is invariably driven from the turbine shaft, either directly
or through gears , to ensure maximum reliability .It may also provide high pressure oil for the
relay system at a pressure of from 50 to 2000 lb/in2 usually by raising all the oil to this
pressure , the lubricating oil being drain off through a reduction valve .Although this method is
often adopted because of its simplicity and because the relays automatically close the stop
valve, if the lubricating oil supply falls it is wasted of pumping energy. Some turbines use a
double gear pump having high and low pressure outputs, but on large turbines it may be
advantageous to employ to separate pumps.
The normal type of pump used on turbines has been the gear pump. This requires no
priming and provides positive oil displacement but must be driven from the shaft through reduction gear at
about 400 RPM. The pump has two or three meshing gears.
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On large turbines the quantity of oil used makes it economically to incorporate a centrifugal
pump driven directly from turbine shaft. It is not self priming and requires oil ejector to over come the
suction head both when starting and during running. When a separate governing hydraulic systems is used
the oil lubricating system may be simplified by the adoption of ac motor driven centrifugal pumps. The
pumps may be mounted directly in the main oil tank with their inlets submerged below the oil level thus
obviating the need for an oil ejector.
AUXILLIARY PUMP:It is used for starting, stopping, and emergencies. It is sometimes driven by a
steam turbine, but for some years the tendency has been to use a motor driven auxiliary pump feed with
supply. The auxiliary pump is automatically brought into operation by a relay when the oil pressure falls
below a certain value.
EMERGENCY OIL PUMP:It is invariably provided as a stand by the auxiliary pump. In the event of
a fault interrupting the normal station or unit supply the d. c. pump which is fed from the station battery
circuits in, thus ensuring the safety of the bearing whilst the turbine is brought to rest.
JACKING OIL PUMP:Supply of very high pressure oil provided by a small capacity positive
displacement. Jacking oil is fed into the base of the bearings in sufficient quantity to establish each oil
film on which the heavy rotors may float at very low speed of rotation, when the normal oil wedge would
not be formed. The presence of jacking oil film whilst the machine reduces the torque required by the
turbine motor and prevent the metal to metal contact damaging the bearings.
OIL VALVES:As the pumps are constant speed types, a uniform quantity oil will be delivered. Surplus
oil must be blend continuously and this process through the spring loaded relief valves generally ground
together in a valve box. Filled to both the main and
Auxiliary pumps are relief valves which limit the delivery pressure each pump is fitted with a non return
valve in the discharge valve branch which prevents oil flowing back through the idle pump units.
OIL COOLERS: The efficiency of a centrifugal pump may be of the order of 55% and the remaining
45% of the pump input energy generates heat in the oil. The oil absorbs a large amount of heat from the
bearing friction and shaft conduction. To remove this heat the oil is passed through coolers which reduces
the temperature to that required for the bearings.
Coolers are designed to have the maximum surface area for heat transfer compatible with small
pressure drop between entrance and exit.
STRAINERS:These are used for removing the dust particles. It consists of cylindrical wire mesh are
interposed between the returning drains and drain tank. In addition ,filters of the duplex (or) auto dean
types are usually inter posed. In the pump delivery pipe to protect the bearing and relay system from
foreign particles. These filters can be cleaned while in service.
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STEAM CONDENSER: A steam condenser is a device or an appliance in which steam condenses and
heat released by steam is absorbed by water. It serves the following purposes;
1) It maintains a very low back pressure on the exhaust side of the piston of the steam engine or turbine
,in available heat energy for converting into mechanical work. The shaded are in the given fig. Shows
the increase in work obtained by fitting a condenser to non-condensing engine. The thermal efficiency
of a condensing unit is higher than that of non-condensing unit for ,the same available steam.
2) It supplies to the boiler pure and hot feed water as the condensed steam which is
discharged from the condenser and collected in a hot well can be used as feed water
for the boiler..
Organs of a steam condensing plant .
A steam condensing plant mainly consists of the following organs / elements :
1) condenser (to condensate the steam)
2) supply of cooling (or injector)water
3)wet air pump(to remove the condensed steam ,the air &uncondensed water vapour and gases from
the condenser ; separate pumps may be used to deal with air and condensate).
4) Hot well (where the condensate can be discharged and from which the boiler feed water is taken ).
5) Arrangement for re cooling the cooling water incase surface condenser is employed.
CLASSIFICATION OF CONDENSERS: 1. Jet condensers
2. Surface condenser
In Jet condensers ,the exhaust steam and water come in direct contact with each
other and temperature of the condensate is the same as that of cooling water leaving
the condenser. The cooling water is usually sprayed into the exhaust steam to cause
rapid condensation.
In surface condensers , the exhaust steam and water do not come into direct contact.
The steam passes over the outer surface of tubes through which a supply of cooling
water is maintained .There may be single pass or double pass. In a single pass condenser
, the water flows in one direction ,only through all the tubes ,while in two pass
condenser the water flows in one direction through the tubes and returns through the
remainder.
A Jet condenser is simpler and cheaper than a surface condenser .It should be installed
when the cooling water is cheaply and easily made suitable for boiler feed or when a cheap source
of the boiler and feed water is available is not thrown as a waste but returned to the boiler.
ASH HANDLING SYSTEMS:A huge quantity of ash is produce in central stations, sometimes
being as much as 10 to 20% of the total quantity of coal burnt in a day. Hundreds of tonns
of ash may have to be handled every day in large power stations.
Handle of ash includes Its removal from the furnace.
Loading on the conveyers and delivery to the fill or dump from where it can be disposed off by
sale.
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The commonly used equipment for ash handling are
bucket elevator
bucket conveyor
belt conveyor
pneumatic conveyor
hydraulic equipment
rail cost
The modern ash handle systems are
mechanical system
hydraulic system
pneumatic system
steam jet system
DRAUGHT: The small pressure difference which causes a flow of gas to take place is termed as
draught. The function of it is to force air to the fire and to carry away the gaseous products
are combustion.
The draught may be classified as
Forced draught
Induced draught
Balanced draught
Steam jet draught
FORCED DRAUGHT:This draught is produced by a fan. In this draught system a fan is installed
near or at the base of the boiler to forced the air through the cool bed and other passages
through the furnace, flues, air pre heater & economizer.
INDUCED DRAUGHT:In this system a fan is located at or near the base of the chimney. The
pressure over the bed is reduced below that of the atmosphere . By creating a partial vacuum
in furnace and flues , the products of combustion are drawn from the main flue and they pass
of the chimney.
BALANCED DRAUGHT:It is a combination of the forced and induced systems. In this system,
the forced draught fan over comes the resistance in the air pre heater and chain grate stoker
while the induced draught fan over comes draught losses through boiler, economizer, air pre
heater and connecting flues.
STEAM JET DRAUGHT:This system produces the artificial draught. It may be of forced or
induced type depending upon where the steam jet to produce draught is located.
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AIR - PREHEATER:The function of air pre heater is to increase the temperature of air before it
enters the furnace. It is generally placed after the economizer. So the flue gases pass through
the economiser and then to the air pre heater.
An air pre heater consists of plates or tubes with hot gases on one side and
air on the other. It pre heats the air to be supplied to the furnace. Pre heated air accelerates the
combustion and facilitate the burning of coal.
Degree of pre heating depends on
type of fuel
type of fuel burning equipment
rating at which the boiler and furnace are operated
FUEL OIL STORAGE & HANDLING SYSTEM:Oil fuels are costly to store not only because of the capital cost of fuel lying in to the
store, but because the tanks necessary to hold the oil are expansive. Tank which need a piled
foundation are about 40% more expensive than those which do not.
Fuel oils are delivered at temperature which give good handle ability and this presents some
advantage to the customer when the turn over of his stock is rapid. For exit is very useful in
cold weather to have gas diesel oil delivered at about ambient temperature because the user
does not usually providence heating for his equipment. B S classed fuel can be stored and fired
at ambient temperature but provision could be advantage be made to see that the temperature does
not fall below 00 C this can be effected by a small tank out flow heater, since it is the fuel handle system
which requires protection against extreme cold. Residual fuel oils should be stored and handled at
temperatures well above their pour points.
It is necessary to provide trace heating logging for all pipe lines, filters and valves etc.
handle residual fuel oils. It is particularly important that pressure gauges and other instruments
using the fuel oil as a control fluid should be either heated or filled with a suitable buffer fluid
such as gas oil. The heating may be effected by means of steam or hot water or it may be electrical
.Even after the boiler fuel ring main circulating oil is pre heated to atomizing temperature There can
be sufficient cooling in branches to burners which are shut down to make lagging and trace heating
necessary.
The oil in store should never be raised in temperature to its closed flash point
because this would increase the fire hazards
temperature
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STEAM GENERATOR: It is the part of the steam heat engine in which the chemical energy of a
fuels liberated and is partially transferred from the products of the combustion to the working
substance of the cycle is properly called the steam generator. The transfer of energy in the steam
generator should be accomplished with a minimum of loss both in quality and availability.
The basic components of a steam generator are fuel burning equipment,
heater, air heater surface and steam re super heating surface may also be add as
thermodynamic need and economic justification dictate .The ASME test code for stationary steam
generating units defines steam generator heating surface as follows. If that portion of the
surface of the heat transfer apparatus exposed on
the one side to the gas(or)refractory being cooled and on the other to the fluid being heated,
measured on the side receiving heat. In the boiler in which vaporization
of the working substance takes place. Feed water enters the boiler at a temperature equal to or less
than saturation temperature at boiler pressure and after being, heated
to saturation temperature, it is vaporized super heated steam cannot be formed in the boiler because
of the immediate presence of saturated water with which the steam tends to be in equilibrium.
In this steam water mixtures must pass from the risers to cyclone by the
separating force of gravity. The steam free water is desired down ward to the
drum and dry steam passes upward to the steam outlets. Scrabbers are used to remove the last
traces of moisture.
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PIPING SYSTEMS
GENERAL: The design of the steam plant piping will be in accordance with the ASME. Gas piping will
be in accordance with ASME.
OTHER CODES
Alberta Safety Codes Acts and Codes of Practice
NEPA Codes (National Electrical Protection Association)
NFC - NFPA Codes (National Fire Code / National Fire Protection Association)
CSA Standards (Canadian Standards Association)
MSS Standard Practices (Manufacturers Standardization Society.)
API (American Petroleum Institute)
ASTM (American Society for Testing and Materials)
PIPING MATERIAL SELECTION:
Material is selected based on:Characteristics of operating fluid
For condensate, steam and water applications based on operating temperature material can be Carbon
Steel (CS), Alloy Steel (AS), or Stainless Steel (SS) .
For corrosive fluids stainless steel is normally preferred.
For brackish and sea water CS piping with rubber or FRP lining is used.
DESIGN TEMPERATURE:Up to 4120c carbon steel (A 106 Gr B) can be used.
From 4120c to 5100c A 335 Grade P11 material is used.
From 5100c to 5900c A 335 Grade P22 material is used.
From 5400c to 6350c P91 material is used.
AIR JET EJECTORS:
The operating medium of an air ejector can be either high pressure gas or liquid.
This is passed through a nozzle and the pressure energy is converted into velocity energy. The high
velocity fluid aspirates the air and non condensable gases and the mixture is projected into a diffuser
which reconverts the velocity energy into pressure energy. Steam is a suitable operating medium and
is used in the steam jet air ejector. The steam consumption is controlled by the compression ratio of the air
and this factor influences the decision to adopt either single or multiple stage ejectors for a particular
condition. To meet the requirements when raising vacuum a starting ejector is provided. This is a high
capacity high steam consumption ejector, of single stage and with out an after condenser.
A main air ejector with stand by unit is usually provided for normal operation. The heat in the
operating system is partially recovered in the condensate which flows through the inter and after
coolers.
If an installation is to operate with a direct cooling system, as is Provided by the sea or river,
vacuum as high as 29.2 in HG would be expected during the winter months. A two stage ejector is
generally only capable o f maintaining a vacuum of 29.0 in HG even at zero flow ,but three stage
ejector will hold up to 29.4 in HG and would there fore be used. Further advantage here is that for a
comparable duty the three stage ejector shows a slight saving in steam consumption over the two stage
ejector.
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EXTRACTION PUMPS:
The most important function in extraction pump design is the avoidance of the excess of oxygen
into the condensate system .This can be carried out in a number of ways , they are
Two stage extraction pumps
Two stage extraction pump with internal bearing .
Three stage extraction pump alternative arrangements.
In Two stage design the gland at the left hand side adjacent to the first stage impeller is under
vacuum ,when the pump is in service .The gland is therefore scaled by leading a condensate supply
to it from the second stage discharge pipe ,care must be taken to ensure that the gland connections
to the stand by pump are isolated from the pump in operation . This results in a somewhat
complicated small board piping system with the necessary operational requirements of changing
over the sealing connections when bringing the stand by pump into service. The water being rotated
by the action of the shaft when the pump is in use, forming a helix . The air then leaks into the
pump between the water streams which form the helix.
One partial solution is to fit an internal bearing at the suction end of the Pump. But this
bearing must be water lubricated and may ,therefore ,be damaged by suspended matter. The
vertical spindle arrangement is particularly vulnerable to this damage during the commissioning or
after the overhaul period.
Probably the best arrangement , where the hydraulic characteristics allow is to mount the first
stage impeller on the shaft between two impellers running in parallel on a two stage design and in
series for a three stage duty. The arrangement is slightly more expensive ,but it does ensure positive
pressure on the pump glands.
Recently we used reentry type extraction pumps. The extractions pumps become integrated
with the generator coolers and auxiliary cooler system .This limits maximum design pressure
needed for the auxiliary coolers.
FEED WATER HEATING EQUIPMENT:Feed water heating is accomplished in one string for the low pressure heating, while in two strings for
the high pressure heating in order to improve the reliability of operation.
Such joints in the construction of the high pressure feed water heater as between the tube and
baffle and between the water box and shell etc is setup by welding to assure prevention of leakage.
The main condensate in most of the power plants returns to the steam generator as feed water. Some
makeup water may be added to replace in the cycle. In a few plants the boiler feed water may be 100%
makeup, in this case the plant turbines exhaust at back pressures above atmospheric to supply steam for
other purpose. Feed water is heated by bleeding steam to heaters as in a regenerative cycle from the main
turbine, or by using exhaust steam from auxiliary drive turbine, or by byproducts steam from processes.
Feed water heaters may be classified as follows:
Open (or) contact heaters.
Tray type
Jet type.
closed (or) surface heaters.
Heated feed water enables steam generators to produce more Kg of steam and avoids severe thermal
stressing by cold water entering a hot drum. Pre heating feed water also causes scale forming dissolved
salts to precipitates outside the boiler and removes dissolved O2 &CO2 which corrode boiler material.
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OPEN HEATERS:1) Tray type: -The construction of an open heater employs a shell of rolled steel plates welded along the
longitudinal steam. Dished steel ends are joined to the shell at two ends through welding. In the tray type
heater the upper half of the shell contains two tray sections and the spray distributer, while the lower half
is mostly empty and serves as a storage for heated water. Above the shell is placed a vent condenser. Feed
water after passing through the vent condenser flows into the spray distributer from where it cascades
over the staggard trays, Exhaust steam from auxiliaries or low pressure steam from a suitable point in the
turbine is passed into the heater, entering into opposite the tray sections and flowing upward counter to the
direction of water, through the heating section. The flow of two liquids through the heater, thus results in
thorough mixing up so that heat of steam is transferred to water , the steam itself also being condensed
O2,CO2 & NH3 are also removed by this type of heaters.
In addition to the heating of feed water , the contact type heater is often construction for de
aerating action. The only difference between the simple heater and a de aerating open heater is in the
addition of a suction of air removing trays below the heating trays. After the water has been heated in
heating section, it is made to pass over the air separating trays which provide a complete separation
of air and water, Water
then flows down while air and non-condensable gasses together with water vapour pass to the top of the
shell and from there to the vent condenser . The vent condenser is a small surface condenser of U-type.
The vapour went to the atmosphere. The interior of the shell of de aerating as also the trays is made of
corrosion resistance material such as stainless steel.
JET TYPE OPEN HEATERS:In this type of de aerating contact heater spring loaded spray valves atomize the feed water
coming from the vent condenser spray it up words against the baffle. The low pressure steam enters
a conical steam jacket fitted in the upper part of shell, and is allowed to expanding the same
direction as the water spray, mixes with water and mixture falls down to the lower part of the shell
which serves as the storage. The non-condensing gases travel upwards as in the tray type heater
and are passed on the vent condenser. It is mainly used in marine where tray type heaters do not
work well due to the pitching & rolling of the vessel. They can handle water containing scaling
impurities and are lighter in weight. These heaters do not work well at low pressures special at
sub atmospheric pressure.
CLOSED(OR)SURFACE FEED HEATERS:These heaters usually have shell and tube construction and may be made horizontal
and vertical. The construction of a closed heater and a surface condenser are identical except that the
heater is design for higher temperatures
and pressures and has greater than the condenser .
It consists of a shell which has a welded longitudinal steam. To each end of the shell
is welded a steel flange for fitting the covers , and top and bottom connections are provided for
inlet of steam and exit of condensate . A baffle plate is provided below the steam inlet to spread
the steam evenly over the tubes. The water tubes are admiralty brass or other suitable material are
stretched between two end sheets of muntz metal or soft steel ,one of these being fixed and the
other floating to take up extraction strain in tubes, The floating tube sheet is covered with a head
cover bolted on to it and prevents the leakage of water into space.
The heater may have single pass or the water box may be divided to give pass basin. A pair of
air pockets provided at bottom of the shell permits the with drawn of air.
The flow of steam and water through the heater is usually counter to each other low pressure
heaters may use the steam under vacuum high pressure heaters at pressure above 40 bars. Steam
and water need not beat the same pressure and one pump may push water through several heaters
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in series. Water pressure may be as high as 250 bars. For good performance heaters must be
drained and vented.
L .P. HEATERS:- These heaters are usually constructed of mild steel tube plates and shells
with tubes of 90/10 cupronickel or admiralty brass expanded into the tube plate for a depth
of approximately 1 1/2inch. The usual procedure when testing for leaks in L.P heater tube nests
is by filling the steam space with water and applying a pressure not in excess of the design
pressure of the body when leaking expansions and tubes are readily shown up.
When leaking tube expansions exits a further light rolling is usually necessary
to stop the leakage , unless the severity of the leak is sufficient to erode the tube plate ,in
which case plugging may be necessary leaking tubes are normally plugged off when the
incidence of failure is slight , but there is an obvious limit to this procedure. The location of the
leaking tube in the tube plate is of some consequence with u-tube heaters
H.P HEATERS:- It is similar to L .P . heaters. The essential difference is that the tubes must
with stand the full pressure of the feed pumps However if a booster pump is employed
upstream of the heater, the feed pump pressure can be reduced.
The tubes may be of 70/30 cupronickel , with some iron alloyed ,and the shells of
forged steel. The water box is bolted down with bolts drilled down the axis to facilitate electric
bolt heating .The bolt heating is done by passing current through carbon rods in the central
holes of the bolts .This method of bolt tightening ensures tight, joints even at the high pressure
and temperature en counted in the last one (or) two heaters which receive super heated steam
from the high pressure stages of turbine.
H.P heaters too are equipped with gauge glasses steam and water spring loaded relief
valves as well as body air vents .The body air vents and vents on the incoming and out going
feed pumps are led to an open turn dish to enable observation of air release ,thence to a drain
tank ,and finally to a separates flash box ,and onto the condenser.
DE- AERATOR HEATER:It was a conventional practice of designing the de-aerator , so that the storage tank has a
capacity sufficient enough to contain the feed water for about 15 min running at a rated output.
Reduced capacity of the storage tank has been found successful in realization of uniform
temperature distribution of the feed water in the tank,
prevention of flashing in the suction pipe of the feed water pump as well as economization
of the frame work of the building ,resulting from reduced weight of the tank. The distillate
pump is to be operated only for filling up the boiler drum and not to make up the de aerator
when the units in operation.
In a de-aerating heater entering water spills over trays (or) sprays
through nozzles to make it present a maximum surface, for heat transfer to the
atmosphere of steam filling the heater. This also removes all dissolved O2 in excess of 0.03 ml
per 1 from the water .A unit that reduces the O2 to 0.005 ml is a de-aerator.
Adding Na2 So3 to the feed water or boiler reduces any remaining dissolved O2 to
a tolerable minimum. De- aeration may takes place at any pressure or vacuum. Heating releases
the gas from the water in minute bubbles that tend to stray entrained. These can removed by
agitation (or) stirring the water turbulently. The de-aerating heater and de-aerator mix steam and
water to heat the water to saturation temperature, they also agitate the boiling water to remove
entrained gases and vent them to atmosphere .The most heaters have a storage tank below with
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controls to add make up water as needed to maintain feed water flow. The heating steam
may be main turbine feed steam (or) may
be from other sources.
OTHER EQUIPMENT :
Other equipments required for steam power plant are;
Glands & Sealing systems.
Generator.
Drains.
Drain flash tank.
Safety valves.
Steam nozzles
GLANDS& SEALING SYSTEMS:Glands and sealing systems are used on turbines to prevent (or) reduce the leakage
of steam (or)air between rotating and stationery components that have a pressure difference across
them.. e .g. where the turbine shaft is extended through the cylinder end walls to the atmosphere .
When the cylinder pressure is higher than atmosphere will be a general steam leakage outwards
whilst if the cylinder contains steam below atmosphere pressure there will be leakage of air
inwards and a sealing system must be used to prevent the air from entering the cylinder and
the condenser.
As most of the steam leakage from glands does not pass through the turbine stages , a
loss of power output is involved and every effort is made to reduce this power loss by an
efficient arrangement of seals and glands. Three types of glands and seals are in general use on
steam turbines , the carbon ring gland and the water seals. The first two glands act as restrictors
to steam and air leakage ,whilst the water seal will prevent all leakage of steam and air.
Pump glands are generally of the mechanical type .Clean water flushing is provided
to reduce the heavy wear that would otherwise occur on startup after a lengthy shutdown.
Conventional soft packing glands are used on the older smaller cooling water pump design.
GENERATOR:Generator is used to produce electricity. The turbine and generator
are connected by a shaft. In the generator the field system will always be the rotating member
and is called the rotor while the armature assembly, comprising armature winding and magnetic
iron core will be stationary and is called the stator. In the generator the mechanical energy
obtained in the turbine is converted into electrical energy. Generator air cooler is used in order
to cool the generator.
GEAR BOX:The use of very large circulating water pumps with low rotational speeds has necessitated the
use of an intermediate gearbox .How speed motors of the size required are very expensive and
it is economically justifiable to sacrifice 1 to 2% in efficiency by introducing a step down
gearbox between pump and motor. The gear ratio can be set to allow a motor with an economic
running speed to be selected. In practice a 4000 h. p .c pump unit running at 200 rev/min will
require a 5:1 step down gear box ,permitting the use of a 1000 rev/min motor. The gear boxes
may be of 2 basic types ,either parallel shaft offset(or) co axial.
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PLANT LAYOUT:Plant layout is concerned with the logical and economical use of space and the relation ship of
one piece of plant with another. Suitable factors of prejudice and taste play their part and
sometimes have a powerful influence particularly in the early stages when the relationship
between the boiler and the turbine is fixed.
Three types of flows are involved in the plant layout are
Energy flow
Regenerative flow
Waste flow
An efficient layout of plant minimizes the losses and hence running costs
in each stream but vitally in the energy flow stream. Ideally plant should be close together
connected to each other in short straight paths, This approach to design could be termed the
datum philosophy and is used to asses the practical achievement with its necessary deviations and
compromises to evaluate new ideas and to reject what is bad(or) un necessary.
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HEAT EXCHANGERS:
A heat exchanger is any device used for effecting the process of heat exchange between two
fluids that are at different temperatures. A heat exchanger in which two fluids exchange heat by coming in
to direct contact is called a direct contact heat exchanger. Example of this type are open feed water
heaters, de super heaters and jet condensers. The wall may be simple plane wall or a tube or a complex
configuration involving fins, baffles and multiple passes of tubes. These units are called surface heat
exchangers, are more commonly used because they can be constructed with large heat heat transfer
surfaces in a relatively small volume and are suitable for heating cooling, evaporating or condensing
applications. A periodic flow type of heat exchanger is called a regenerator. In this type of heat
exchanger, the same space is alternately occupied by the hot and cold gases between which heat is
exchanged. Regenerators find their application in pre heaters for steam power plants, blast furnaces,
oxygen producers etc.
TYPES OF HEAT EXCHANGERS:
Heat exchangers may be classified in several ways. One classification is according to the
fluid flow arrangement or the relative direction of the hot and cold fluids. The fluids may be separated
by a plane wall but more commonly by a concentric tube(double pipe) arrangement. If both the
fluids move in the same direction, the arrangement is called a parallel flow type. In the counter
flow arrangement, the fluids move in parallel but in opposite directions. In a double pipe heat
exchanger, either the hot or cold fluid occupies the annular space and the other fluids moves through
the inner pipe. Since both fluids streams traverse the exchanger only once, this arrangement is called
single pass heat exchanger.
Another flow configuration is one in which the fluids move at right angles to each other
through the heat exchanger. This type of arrangement is called
a cross flow type. When large quantities of heat are to be transferred, the heat area requirement of the
exchanger also becomes large. In this case multiple pass arrangements can be used.
SUPERHEATER
The steam produced in the boiler is nearly saturated .This steam should not be used in the
turbines. Because the dryness fraction of the steam is low .This causes the turbine blades get a
corrosion. For eleminating the moisture in the steam super heater is used .
It consists of several tube circuites in parallel with one or more return bends connected
between headers. The superheater tubes range from 1 to 2 inch of diameter .The superheater supply
steam at constant temperature at different loads the use of superheated steam increases turbine
efficiency.
There are three types of super heater
1 .Convective super heater.
2. Radient super heater .
3. Combination of the two
Convective super heater will heat the steam by convective with the help of gases.
Radient super heater is placed in the furnance and walltubes and
burning fuel through radiation process.
recieves heat from the
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According to location the superheaters are classified as follows:
1. Overdeck.
2. Enterdeck.
3. Entertube.
4. Inte ank.
COOLING TOWERS:
In power plants the hot water is cooled in cool in water,so that it can be reused in condenser for
condensation of steam. In a cooling tower water is made to trickle down drop by drop so that
it comes in contact with the air moving in the opposite direction. As a result of this some water
is evaporated and is taken away with air.In evaporation the heat is taken away from the bulk of
water, which is thus cooled.
FACTORS AFFECTING COOLING WATER IN A COOLING TOWER :
They are
1.Temperature of air.
2.Humidity of air.
3.Temperature of hot air.
4.Size and height of tower.
5.Velocity of air entering tower.
6.Accessibility of air to all parts of water.
7.Degree of uniformity in descending water.
8.Arrangement of plates in tower.
CLASSIFICATION OF COOLING TOWERS:
These are classified in many ways,
According to the material of which these are made, as follows:
(a)Timber
(b)Concrete(Ferro-concrete, multi deck concrete hyperbolic)
(c)Steel duct type.
A)TIMBER TOWERS:
These towers are rarely used due to the following
DISADVANTAGES:
(1)Due to exposure to sun, wind, water etc., timber rots easily.
(2)Short life.
(3)High maintenance charges.
(4)The design generally does not facilitate proper circulation of
water.
(5)Limited cooling capacity.
(B)CONCRETE TOWERS:
The concrete towers posses the following advantages:
(1)Large capacity sometimes of the order of 5000m3/h.
(2)Improved draft and air circulation.
(3)Increased stability under air pressure.
(4)Low maintenance.
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(C)STEEL DUCT TYPE:
Duct type cooling towers are rarely incase of modern power plants owing to their small
capacity.
The cooling towers may also be classified as follows:
(a)Natural draught cooling towers
(b)Mechanical draught cooling towers:
(1)Forced draught cooling towers
(2)Induced draught cooling towers.
(a)NATURAL DRAUGHT COOLING TOWERS:
In this type of tower, the hot water from the condenser is pumped to the nozzles situated
near the bottom . Through spray the water falls in the form of droplets into a pond situated
at the bottom of the water. The air enters the cooling tower from air opening provided near
the base, rises upward and takes up the heat of falling water.
(b)MECHANICAL DRAUGHT COOLING TOWERS:
In these towers the draught of air cooling the tower is produced mechanically by
means of propeller fans. These towers are usually built in cells or units, the capacity depending
upon the number of cells used.
FORCED DRAUGHT cooling tower is similar naturally draught tower as far as
interior construction is concerned, but the sides of the tower are closed and form an air and
water tight structure, expect of air and vapour. There are hoods at the base projecting from
the main portion of the tower where the fans are placed for forcing the air, into the tower.
Induced draught cooling towers, the fans are placed at the top of the tower and they draw the
air in through louvers extending all around the tower at its base.
DRY COOLING TOWERS: The necessity of using dry cooling towers has been felt
due to the following reasons:
(1) Natural water sources can be used for dissipating heat in power plants but thermal pollution
problem in this system.
(2) In evaporating cooling system due to continuous evaporation of water, the concentration of
impurities goes on increasing and so the disposal of tower blow down may become a serious
problem at some times. Besides this make up water tower use is Limited in some areas.
Thus the use of dry cooling towers in power plants is the only alternative. The dry system
rejects the heat directly to the atmosphere which is the largest heat sink available.
EQUIPMENT-LAYOUT
In a power plant station the equipment are arranged as shown in the figure.
In the 15MW TG power plant the length of TG hall is 47000 mm and TG hall span is 27000mm.
The ground floor elevation is 0.0m.
The mezzanine floor elevation is 4.0m.
The operating floor elevation is 9.0m.
The de-aerator floor elevation is 14.0m.
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SYSTEM DESCRIPTIONS:
MAIN STEAM:
The main steam system delivers steam from the boiler outlet connections to the process. The main
steam system consists of a primary superheater section, a desuperheater, and a secondary super heater.
LOW PRESSURE STEAM:
The low pressure steam system provides steam for use within the steam plant. These uses include
deaerator (DA) pegging steam, sootblowing steam, steam coil air preheaters, boiler feed pump turbine
drives, and feed water heaters. The low pressure steam system consists of steam pressure reducing station,
DA, sootblowers, steam coils turbine drives, feed water heaters, and interconnecting piping.
FEED WATER:
The feed water system collects returning process condensate, treats raw water for makeup to the
boiler, collects returning condensate makeup to the boiler, collects returning condensate from in plant
processes, conditions the condensate and makeup to remove corrosive gases, heats the water and delivers
it to the boiler economizer. The feed water system consists of water treatment equipment to condition raw
water for makeup to equipment to condition raw water for makeup to the boiler, a treated water and
condensate storage tank, treated water and condensate pumps to deliver water to the DA, a blow down
recovery heat exchanger, a DA to remove the entrained corrosive gases from the water boiler feed pumps
to increase the pressure of the water and deliver it to the boiler, feed water heaters to heat the water and
protect the boiler economizer against acid condensation of the flue gas at low loads, flow regulating
stations, and interconnecting piping.
FUEL GAS:
The fuel gas system reduces gas pressure from the suppliers pipeline, totalizers flow to the plant,
removes impurities from the gas, to the plant, removes impurities from the gas, allows manual isolation of
the plant from the supply, provides visual indication of plant gas pressure, and electrically isolates the
plant piping from the buried supply piping. FUEL OIL: The fuel oil system includes pumps to move oil
from outdoor storage tanks to the plant header. The functions performed by the fuel oil system are similar
to those listed for the gas system. Since oil is stored on site and since there is recirculation back to the fuel
oil storage tank, more than one totalizing flow meter is needed to calculate the amount of oil burned.
BLOW DOWN HEAT RECOVERY:
The blow down heat recovery system recovers part of the heat available in boiler blow down water
and discharges the unusable high solids content water. The blow down heat recovery system consists of:
blow down recovery heat exchanger, and interconnecting piping.
INSTRUMENT AIR:
The instrument air system supplies air to the pneumatic instruments and control devices
throughout the plant. The instrument air system consists of: instrument air compressors, after coolers, air
drying equipment, instrument air receiver, baghouse air receiver (when required), and interconnecting and
distribution piping.
PLANT AIR:
The plant air system supplies air for pneumatic tools, maintenance uses, and other uses throughout
the plant. Plant air may also be used for sootblowing and igniter atomizing purposes when required. The
plant air system consists of: plant air compressors, after coolers, oil separating equipment on crosstie to
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instrument air system, plant receiver, soot blower air receiver (when required), atomizing air regulating
station ( when required), and interconnecting piping.
BOILER VENTS AND DRAINS.
Boiler vents and drains provide the means by which the boiler is vented and drained during start up
and maintenance operations. The system consists of piping from the vent and drain connections on the
boiler to the appropriate disposal points.
DEARATOR VENT:
The DA vent piping provides the means by which the entrained gases removed by the DA are
vented to the atmosphere. The system will contain an orifice sized for the venting requirements
determined from operating conditions and DA design.
SAFETY VALVE VENTS:
Safety valve vent piping provides for the safe discharge of fluids from safety valves. Water safety
valves require piping from the safety valve outlet to drain. Air and gas safety valves outlet to atmosphere
or to a safe location. Steam safety valves require piping from the safety valve outlet to a safe location that
is outside the building. Steam safety valve vents also require provisions for removal of water condensed
under the safety valve seat and in the vent piping itself. Safety valve piping must be designed to pass the
required flow without adversely effecting safety valve operation.
MISCELLANEOUS WATER SYSTEM:

Miscellaneous water system include service and potable water and ash sluice water. The
service and potable water system will provide water for the various cooling requirements in the plant,
such as air compressor intercoolers and after coolers, and will provide water for personnel usages. The ash
sluice water system is required when a hydraulic bottom ash system is used. Ash sluice water provides the
water for ash jet pumps and bottom ash hopper filling and sealing water requirements.
MISCELLANEOUS GAS SYSTEM:
Miscellaneous gas systems include nitrogen system and coal bunker and pulverizer inerting
systems. The nitrogen system is used to fill any of the boilers with nitrogen when it is to be out of service
for an extended period. The system consists of nitrogen bottles, manifold, and interconnecting piping. The
coal bunker and pulverizer inerting system is used to fill coal bunkers and pulverizers with an inert gas,
usually 002 when fires are detected in the equipment or when the equipment is to be out of service for an
extended period. The system consists of gas bottles, manifold, and interconnecting piping.
IGNITER FUEL:
The igniter fuel system provides fuel for burner igniters. Igniters are used on gas, oil, pulverized
coal, and ACFB boilers. The ignition fuel may be oil, natural gas or liquefied petroleum gas based on the
type of igniters used. The system consists of pressure regulating stations and interconnecting piping.
CHEMICAL FEED:
The chemical feed system supplies maintain water quality. The system consists of chemical feed
tanks for mixing and storage of chemical solutions; [positive displacement metering type chemical feed
pumps; and stainless steel piping or tubing for interconnection of system components and the DA storage
tank.
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SAMPLES:
The samples system collects samples from various points in the plant for use in determining
chemical feed requirements based on water quality. Sample points will include boiler drum, feed water
and condensate. The system consists of sample coolers (boiler drum) and tubing from the sample point to
a central location when desired.
GENERAL:
All valves installed in piping system must be suitable for the pressure and temperature of the
piping system in which they are installed. Valves will be selected based on type of service (throttling or
isolation), type of process fluid (water, steam, air), and special conditions (corrosive or abrasive process).
Consideration must be given to material of construction and packing materials.
VALVE TYPES:
Numerous types of valves are available including globe, gate, butterfly, plug, ball and check
valves. Valves can be furnished with flanged, but welded, socket welded, or screwed end connections.
VALVE CONSTRUCTION:
Valves must be constructed of suitable materials for the pressures, temperatures, and fluids for
which they will be used.
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PIPING MATERIALS
STEAM SYSTEM:Main steam from main steam inlet to turbine
Aux steam upto desuperheater
From control station to turbine glands,dump to condenser
Gland steam upto vent
: P22
: P11
: P11
: P11
(SA335 P22)
( SA335 P11)
(SA335 P11)
( SA335 P11)
Desuperheater to control station

From vent to GSC
Extraction 1 (turbine to HP heater)
Extraction 2 (turbine to deaerator)
Extraction 3 (turbine to LP heater)
GSC ejector exhaust
GSC drains
: CS
: CS
: CS
: CS
: CS
: CS
: CS
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
: CS
: CS
: CS
: CS
: CS
: CS
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
: CS
: CS
: CS
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
: CS
: CS
: CS
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
: CS
: CS
(SA672 Gr B)
(SA106 Gr B)
CONDENSATE SYSTEM:CEP suction from pump upto level control valve outlet
CEP minimum recirculation
Air ecacuation system from condenser
Ejector and Gland steam drains
Vaccum breaker
Ejector exhaust
FEED WATER SYSTEM:From level control valve (After GSC)upto deaerator,
excess dump to DM tank
deaerator overflow to condensate
condensate normal drain and overflow drain
HEATER DRAIN AND VENT FLOW DIAGRAM:Hp heater drain to deaerator,
heater alternate drain to flash tank
Hp heater vent to deaerator
Lp heater drain to drain cooler via condenser
COOLING WATER SYSTEM:Cooling water (inlet/outlet)

Cooling water (inlet/outlet) to auxiliaries
Prepared By MANOJ
40
LUBE OIL SYSTEM:Mop/Aop/Eop suction
Mop/Aop discharge upto coolers via filters,
governing system upto valve
Oil from filters to header via bearings & OHT
Eop Discharge
From valve to governing system
Oil drains
Oil fans suction/discharge
Oil centrifuge
: CS
(SA106 Gr B)
: CS
: SS
: SS
: SS
: CS
: CS
: CS
(SA106 Gr B)
(SA 312 TP 304)
(SA 312 TP 304)
(SA 312 TP 304)
(SA106 Gr B)
(SA106 Gr B)
(SA106 Gr B)
Prepared By MANOJ

Material On Steam Power Plants

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1

WORKING PRINCIPLE OF STEAM POWER PLANT

THERMAL POWER PLANTS

Steam and Drain System In Power Plants

: During start up and low loads

Tone Per Hour (TPH)

: Uncontrolled Extraction to LP Heater

Extraction II : Uncontrolled Extraction to Deaerator

THERMAL POWER PLANTS

Tone Per Hour (TPH)

EXHAUST DRAINS SYSTEM

Tone Per Hour (TPH)

THERMAL POWER PLANTS

Tone Per Hour (TPH)

EXHAUST HOOD SYSTEM

THERMAL POWER PLANTS

Condensate System In Power Plants

THERMAL POWER PLANTS

The following shall be ensured for starting of the pump:

AIR EJECTOR SYSTEM:

CONTROL AND INTERLOCKING FUNTIONS:

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

Lubrication System In Power Plants

EMERGENCY OIL PUMPS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

recieves heat from the

THERMAL POWER PLANTS

THERMAL POWER PLANTS

THERMAL POWER PLANTS

MISCELLANEOUS WATER SYSTEM:

THERMAL POWER PLANTS

THERMAL POWER PLANTS

Desuperheater to control station

COOLING WATER SYSTEM:Cooling water (inlet/outlet)

THERMAL POWER PLANTS

THERMAL POWER PLANTS

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