Bataan Peninsula State University

Department of Mechanical Engineering

College Of Engineering and Architecture

BATAAN PENINSULA STATE UNIVERSITY

Main Campus, Balanga City, Bataan

College of Engineering and Architecture

Department of Mechanical Engineering

Power Plant Design Study

A Final Report submitted to the Faculty of Mechanical Engineering Department College of Engineering and Architecture

In Partial Fulfillment of the Requirements for the Subject MEPD- 523 Power Plant Design with a title of DESIGN OF A 220-MW COAL-FIRED STEAM POWER PLANT

By: MICHAEL LAO DIZON

BSME-5B

MARCH 2, 2013
Date Submitted

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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

LETTER OF TRANSMITTAL
March 02, 2013

Engr. Alfredo D. Valentos, PME Faculty, College of Engineering and Architecture BPSU (Main Campus) Balanga City, Bataan

Dear Sir: In accordance with your instruction and in partial fulfillment of the subject ME 525 (Power Plant Design), I am submitting to you this design study. This study contains essential elements in designing a coal-fired steam power plant with a rated active power of 220MW. Accompanying with this are the important elements of a steam power plant namely: Furnace, Steam Boiler, SuperHeater, Economizer, Steam Reheater, Stack, Steam Turbine, Deaerator, Condenser, Piping, Cooling Tower and Pumps. Inclusive with this designs are the specification of Major Equipment.

Respectfully yours, Michael Lao Dizon Student no. 08-00620 BSME 5B Approved by: Engr. Alfredo D. Valentos, PME Instructor, ME Department

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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

PREFACE
The study of Power plant is a basic part of s a Mechanical Engineering course. Since it deals with important element in Steam Power Plant it necessarily deals with sciences and mathematical computations. It is very significant specifically for mechanical engineering students. The said subject is very broad but on this text, the topics are those more related to mechanical engineering.

Designing of a Coal- Fired Power plant teaches the most proper way of using a certain material upon the production of successful machines and structural designs. Using its concept; correct sizing, number of mechanical parts, sufficient load and pressure and exact fittings can be determined theoretically.

This book is good for students studying this subject, newly or graduated students reviewing for the board exam, even those professionals who forgot the concepts and also for interested people who are curious about it.

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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

ACKNOWLEDGEMENT
This piece of work will never be accomplished without our Almighty God for his manifold blessings and His power that work in me and also without the people behind my life for inspiring, guiding and accompanying me through thick and thin. I specially want to thank our instructor, Engr. Alfredo D. Valentos, PME, for his guidance during our thesis work. In addition, he was always accessible and willing to help his students with their research. As a result, thesis will become smooth and rewarding for me. To my colleagues, friends, cousins and my family thanks for the encouragements and support. Specially Neil, Chanu, Lester, Keane, Ryan, Miko, Zadam and those who are willing to help. Mr. Marty Dizon my father, Mrs. Jacqueline Dizon my mother, deserve special mention for their inseparable support and prayers and for their invaluable assistance, financial, moral, and spiritual support to fulfill this design study. And mostly I would like to thank Ms. Lyndsay Ann Mateo Herrera for giving me her moral support and for being my inspiration to finish my Design.

Michael L Dizon

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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

INTRODUCTION
A Power Plant is a complex of structures, machinery, and associated equipment for generating electric energy from another source of energy, such as nuclear reactions or a hydroelectric dam. It is also called a powerhouse, or PowerStation.

Coal power plants work by using several steps to convert stored energy in coal to usable electricity that we find in our home that powers our lights, computers, and sometimes, back into heat for our homes. In a coal-fired steam station water is turned into steam, which in turn drives turbine generators to produce electricity.

In this design it is necessary that the designer do have actively studied or become acquainted with subjects related to Elementary Heat Power and Applied

Thermodynamics or the likes.

This Power Plant Design includes computations based on the given design values. For better understanding, figures, schematic, diagrams, illustrations and tables were added including the specification of equipment designed.

Although carefully computed, prepared and reviewed, this design may contain errors of typography, mathematics or statement. Any report of this error will be very humbly welcomed by the author.

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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

Table of Contents
TITLE PAGE LETTER OF TRANSMITTAL PREFACE ACKNOWLEDGEMENT INTRODUCTION TABLE OF CONTENTS LIST OF TABLES LIST OF ILLUSTRATIONS AND FIGURES CHAPTER I Coal-Fired Steam Power Plant Schematic Diagram Thermal Power Station Process of Coal Fired Power Station Definition of Terms I II III IV V VI VIII IX 1 2 4 6 8 17 18 23 47 48 50 60 66 71 72

CHAPTER II Power Plant Data Design Condition Stage Efficiency

CHAPTER III Power of Steam Turbine Quality of Steam Percent Extraction

CHAPTER IV Heat Balance Energy In Energy Out

CHAPTER V Design of Furnace

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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

CHAPTER VI Design of Steam Turbine CHAPTER VII Design of Steam Boiler CHAPTER VIII Design of Super Heater CHAPTER IX Design of Economizer CHAPTER X Design of Steam Reheater CHAPTER XI Design of Air Preheater CHAPTER XII Design of Stack CHAPTER XIII Design of Deaerator CHAPTER XIV Design of Condenser CHAPTER XV Design of Heat Exchanger CHAPTER XVI Design of Piping System CHAPTER XVII Design of Cooling Tower CHAPTER XVIII Design of Pumps CHAPTER XIX Design of Valves APPENDIX REFERENCES

83 91 101 115 127 134 149 163 174 193 231 271 279 291 300 315

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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

List of Tables
Tables Table 1: Quality of Steam Table 2: Chemical Reaction Table 3: Energy In Table 4: Energy Out Table 5: Specification and Tabulation of Furnace Design Table 6: Specification and Tabulation of Turbine Design Table 7: Summary and Tabulation of Boiler Specifications Table 8: Specification and Tabulation of Super Heater Design Table 9: Specification and Tabulation of Economizer Design Table 10: Specification and Tabulation of Steam Reheater Table 11: Specification and Tabulation of Air Pre-Heater Design Table 12: Stacks Specification Table 13: Specification and Tabulation of Stack Design Table 14: Specification and Tabulation of Deaerator Design Table 15: Specification and Tabulation of Condenser Design Table 16: Low Pressure Heater 2 Specifications Table 17: Low Pressure Heater 1 Specifications Table 18: High Pressure Heater 2 Specifications Table 19: High Pressure Heater 1 Specifications Table 20: Pipe Specification and Insulation Table 21: Specification and Tabulation of Cooling Tower Design Page No. 58 63 66 71 82 90 100 114 126 133 148 157 162 173 192 203 212 221 230 270 278

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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

List of Illustrations and Figures

Illustrations 1. Schematic Diagram of Steam Power Plant 2. Steam Power Plant 3. Final Feed Water Temperature 4. Temperature Difference , 5. Enthalpy and Entropy 6. From Psychrometric Chart (h26 and h27) 7. Final Temperature of Flue Gas 8. Furnace Cut-away Illustration 9. Furnace 10. Finding L and W 11. Pelton Turbine 12. Francis Turbine 13. Kaplan Turbine 14. Steam Turbine 15. Boiler Illustration 16. Fire Tube Boiler 17. Water Tube Boiler 18. Steam Boiler 19. Super Heater 20. Illustration of Super Heater 21. Schematic Diagram of Super Heater 22. Center-to-Center Distance 23. Cross flow/counter flow (t3 and t1) 24. Economizer 25. Illustration of Economizer 26. Cross Flow/Counter Flow (t20 and t28) 27. Heat loss 28. Steam Reheater 29. Illustration of Steam Reheater 30. Tubular Air Preheaters 31. Rotating Air Preheaters Page Number 2 4 19 21 24 64 69 73 75 78 84 85 85 87 92 93 94 97 102 103 103 107 109 116 118 119 124 128 129 135 136
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Bataan Peninsula State University

Department of Mechanical Engineering
College Of Engineering and Architecture

32. Stationary Air Preheaters 33. Air Preheater 34. Cross Flow/Counter Flow (t27 and t26) 35. Number of tubes 36. Total Number of Tubes 37. Center Distance between Tubes 38. Illustration of Air Preheater 39. Stacks 40. Velocity ( ) vs. H x ( ) 41. Tray-Type Deaerator 42. Spray-Type Deaerator 43. Mixture of Steam 44. Pipe 45. Condenser 46. Size of tube 47. Total Number of Condenser 48. Cross flow/counter flow (t10 and t11) 49. Low Pressure Heater 2 50. Parallel Flow (LPH2) 51. Low Pressure heater 1 52. Parallel Flow (LPH1) 53. High Pressure Heater 2 54. Parallel Flow (HPH2) 55. High Pressure Heater 1 56. Parallel Flow (HPH1) 57. Piping 58. Cooling Tower 59. Pump

137 138 139 142 143 144 145 152 160 164 165 166 168 178 179 181 182 195 196 204 205 213 214 222 223 232 273 281

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