Electrical Lecture 1 - Basic of Power Plant

Basics of Power Generation Plant
Electrical Department Internal Lectures (2nd SEPTEMBER 2010) Presented by: Rajat Roy & Selvi
CONTENTS
Contents
I I. II. III. IV. V. VI. VII. VIII VIII. IX. X. XI. XII. XIII XIII. Purpose Definition Design Philosophy Design Consideration List of Major Equipment in Power Plant Types of Power Generation Plant Brief Detail of Thermal Energy Based Power Plant Brief Detail of Combustion Engine Based Power Plant Brief Detail of Diesel Engine Based Power Plant Brief Detail of Combined Cycle Power Plant Brief Detail of Cogeneration Power Plant Balance of Plant System El Electrical i l System S
INTRODUCTION
I. PURPOSE
PURPOSE
In Technip Technip, our main area of engineering design work is Oil & Gas projects wherein most of the projects (Offshore/ Onshore) engineering design scope includes a power generation facility i th in the range of f3 3- 10 MW MW. But there is an increasing trend of projects that include scope of large capacity captive power generation plant to support completely the power requirement of the process plant.
PURPOSE
Recently we have worked in some industrial and process plant projects also, where the power plant size is very big- viz- in Dung Quat Refinerytotal p power is aprox. p 110MW( ( 4*27MW STG+ 1.6MW EDG) ) and in Koniambo Nickel Project total power is approx. 360MW (2*131MW STG+ 2*46MW CTG+ 2*3.5MW EDG). Purpose of this Lecture is to provide some basic idea and generalized view of large g capacity p yp power g generation Plant to all design g staffs in our department and create great interest among them about big size power generation plant.
INTRODUCTION
II. DEFINITION
DEFINITION
A power station (also referred to as a generating station, power plant, or powerhouse) is an industry facility for the generation of electric power.
Called as energy center
DESIGN PHILOSOPHY
III. DESIGN PHILOSOPHY

General
i i. Categories ii. Classes
Reliability
i. Without failure ii Operate correctly ii.
Maintenance
i. Monitoring ii. Testing iii. Upgrading, Modifying, Repair
DESIGN PHILOSOPHY
III DESIGN PHILOSOPHY III.

Safety y
i. Operation ii. Personal iii. Environmental
DESIGN CONSIDERATION
IV DESIGN CONSIDERATION IV.

Electrical Load Capacity Configuration g Environmental Consideration Site Selection & Space limitation Plant Design Life Voltage Level
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DESIGN CONSIDERATION
Cost Cost-Maximum Maximum return from minimal expenditure for the working life of the station D Design i must t provide id cheap; h reliable li bl and d continuous service Future Growth
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MAJOR EQUIPMENT
V LIST OF MAJOR V. EQUIPMENT Q USED IN POWER PLANT
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1. BOILER
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OIL FIRED WATER BOILER
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COAL FIRED BOILER
Boiler
i Heat water/ fluid i.
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2. STEAM TURBINE
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STEAM TURBINE
Steam Turbine
i Mechanical device i. ii. Extract thermal energy to rotary motor
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3. GAS TURBINE
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GAS TURBINE
Gas Turbine
i. Rotary engine ii. Extract energy from flow of g combustion gas
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4. HEAT RECOVERY STEAM GENERATOR
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HRSG
Heat Recovery Steam Generator

i. Energy recovery heat exchanger
ii Steam used in process/ drive ii. turbine
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5. DEAERATOR
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DEAERATOR
Deaerator
i. Removal of air + dissolved gases
ii. From feedwater to boiler iii 2 type iii.
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6. SURFACE CONDENSER
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SURFACE CONDENSER
S f Surface C d Condenser
i. Heat exchanger ii. Condense exhaust steam
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7. BOILER FEED WATER PUMP
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BOILER FEED WATER PUMP
Feed Water Pump

i. Pump feedwater into steam generating boiler
ii F ii. Fresh h water/ t / condense d steam
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8. FEED WATER HEATER
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FEED WATER HEATER
Feed Water Heater

i i. Pre heat water Pre-heat ii. Improve thermodynamic efficiency
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TYPE & CONFIGURATION
VI. TYPES OF POWER GENERATION PLANT & CONFIGURATION

1 Thermal 1. Th l Steam St t bi turbine 2. Gas Engine- Based 3. Diesel Engine- Based 4 Nuclear (Not common) 4. 5. Renewable Energy Based
*Type 1, 2 & 3 are the primary intent of this lecture
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THERMAL POWER PLANT
VII. BRIEF DETAIL of THERMAL ENERGY BASED POWER PLANT
31
DESIGN
1. Definition: Fuel type (Coal/Oil/Agricultural Waste) 2. Steam Conditions: Pressure/ Temperature 3 Condensing/ Reheat Turbines 3. 4. Plant Function & Purpose 5. Steam Power Cycle Economy 6 Cogeneration Cycle 6.
32
FEATURES
1. Steam/ thermal p power station- used heat energy 2. Used to produce large amount of Electrical energy 3 Slow to start 3. 4. Cannot be used to cater peak loads 5. Keep running very close to full efficiency for 24 hours
33
MODEL FLOW
34
PROCESS FLOW
1. STAGE 1: COAL & ASH PLANT

i. Entrance and exit of fuel (coal) ii. Handling treatment & storage of coal iii. Final handling & disposal of ash
2. STAGE 2: STEAM GENERATING PLANT

i. Energy loss stage i ii. Steam creation by heat
3. STAGE 3 & 4: STEAM TURBINE & ALTERNATOR

i. Energy conversion stage ii. Steam turbine covert steam to rotational mechanical energy iii Alternator/ generator convert mechanical to electrical energy iii.
35
PROCESS FLOW
4. STAGE 5: FEED WATER & COOLING

i. Recycling stage ii. Steam used in boiler chamber is condensed back to water to re-use
36
STEAM TURBINE
37
STG LAYOUT
38
ADVANDAGES VS DISADVANTAGES
ADVANTAGES
1. Cheap p coal 2. Can be installed anywhere near fuel & water supply 3. Less construction space 4. Cost for generation less 5. Used for base power station
DISADVANTAGES
1. 2. 3. 4. 5. More Layout y Space p Air pollution Cost more to run Low overall efficiency Very high start-up/ shutdown time
39
COMBUSTION POWER PLANT
VIII. BRIEF DETAIL of COMBUSTION ENGINE BASED POWER PLANT
40
DESIGN
1. Use prime mover to generate electrical energy 2. Generally used to produce limited amount of electrical energy 3. Used as p peaking g power p stations 4. Applications:
i. For large g p power requirementsq space p limitation ii. Peak shaving iii. Combined cycle or cogeneration power plant- waste heat iv. Emergency power- starting time
41
OPERATION
Draw in air at front of the unit
Compress p
mechanical energy into electrical energy
Mix with fuel
Shaft turns
Ignite mixture at high pressure
Expand through turbine blades
Hot gas release

42
ADVANTAGES
1. Simple p design g & construction 2. Much smaller at same capacity 3. Lower operation cost 4. Less water (no condenser) 5. Maintenance cost low 6. Start quickly 7. No standby losses
DISADVANTAGES
1. 2. 3. 4 4. Problem with starting- compressor need power to operate Not output low- greater power used to drive compressor Overall efficiency low- exhaust gases contain heat Temperature of combustion chamber high- lower life
43
DIESEL POWER PLANT
IX. BRIEF DETAIL of DIESEL ENGINE BASED POWER PLANT
44
DESIGN
1 Higher 1. Hi h th thermal l efficiency ffi i 2. Fuel Selection 3. Used as emergency power supply source 4 3 general categories: 4.
i. Class A- continuous at full nameplate kW rating ii. Class B- Standby basis for extended period of time iii. Class C- Emergency basis for short period of time
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ENGINE OPERATION
1. Starting system 2 Fuel Supply & Injection System 2. 3. Lubrication System & Oil Cooling 4. Primary Cooling System (Engine) 5. Speed Control System (Governor) 6. Instrumentation Requirement
46
ADVANTAGES
1. Simple p design g & layout y 2. Less space & is compact 3. Start-up fast & pick up load in short time 4. Less water for cooling 5. Better thermal efficiency 6. Overall cheaper cost 7 No 7. N standby t db losses l
DISADVANTAGES
1. 2. 3. 4. 5. High g running g charges g due to diesel price Does not work efficiently under prolonged overload conditions Generates small amount of power Lubrication cost very high Maintenance charges high
47
COMBINED CYCLE
X. BRIEF DETAIL of COMBINED CYCLE POWER PLANT
48
DEFINITION
A combined cycle is characteristic of a power producing engine or plant that employs more than one thermodynamic cycle. Combining two or more cycle such as the Brayton cycle and Rankine cycle results in improved overall efficiency. efficienc
49
COMBINE CYCLE
1. Combination of- GTG (s)+ turbine exhaust waste heat+ STG 2. Maximum efficiency- hot exhausted gas from gas turbine raise steam
50
DESIGN
1. Operating Differences: i. Turndown ii. Exhaust gas flows iii.Feedwater temperatures 2. Varying loads 3. Boiler Design 4. Combined Cycle Controls
51
PROCESS FLOW
52
THERMAL POWER PLANT
XI COGENERATION POWER XI. PLANT
53
DEFINITION
Cogeneration (also combined heat & power, power CHP) is the use of power station to simultaneously generate both electricity and useful heat.
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TYPE
1. Steam Combined Generation

= Steam Boiler + Steam Turbine
2. Gas Combined Generation

= Gas Turbine + Heat Recovery Steam Generator
3. Steam Steam- Gas Combined Generation

= Gas Turbine + Steam +HRSG
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SIMPLE CYCLE
56
BOP
XII BALANCE OF PLANT XII. SYSTEM
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1. COAL PREPARATION & HANDLING PLANT
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COAL HANDLING PLANT
Coal Preparation
i. Prepare coal to make it usable for furnace and necessary y handling/ g storage ii. Main component: Stacker Reclaimer Stacker, Reclaimer, Crusher, Screen, Conveyor, etc
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2. LIMESTONE PROCESSING PLANT
60
LIMESTONE PLANT
Limestone
i. To make coal sulfur free ii. Reduce Sox iii. Main Component: Feeder, Crusher, Sizer, Conveyor, Rotary Feeder, Bucket Elevator, Cyclone, etc
61
3. FUEL STORAGE & HANDLING
62
FUEL STORAGE & HANDLING
Fuel Storage & Handling

i. Storage capacity at max load ii. Major Component: Storage tanks Unloading/ tanks, Forwarding Pumps
63
4. COMPRESSED AIR SYSTEM
64
COMPRESSOR
Compressed Air System

i. Service Air ii. Boiler Soot Blowing iii. Instrument Air
65
5. COOLING TOWER
66
COOLING TOWER
67
COOLING PROCESS
Steam pass through heat exchanger
Heat up of water
wind blow (constant) ( )
Cooling process by spaying water
Water drip down
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SYSTEM
6. Combustion Air Intake & Exhaust System

i. ii. Deliver clean combustion air to engine Min loss of performance
7. Heating, Ventilation & Air Condition System

i. ii. Removal of heat from Buildings/ Area & Cooling/ Heating Major Component: Air Condition, Supply Air Fan, Exhaust Fan, Filters, etc
8. Ash Removal & Handling System
69
THERMAL POWER PLANT
XIII. ELECTRICAL SYSTEM
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SYSTEM
1. Rating & System 2. Generator 3. Circuit Breaker 4. Power Transformer/ Distribution Transformer 5. MV/LV SWG, MCC, Fixed Panel 6 AC/ DC UPS S 6. System t 7. Earthing System 8. Raceway System 9 Lighting System 9.
71
SYSTEM
9. Electrical Control, Protection & Metering System 10 Instrumentation & Control System 10.Instrumentation
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1. RATING & SYSTEM
73
FREQUENCY
i.
RATING & SYSTEM
Operation Condition - Steady-state - Sustained - Harmonics
ii.
Frequency
- Ranges % - Duration Stability Study - Load shedding - Over-speed trip Limit Frequency Variation - Point of Common Coupling p g - Within the plant system
iii.
iv.
74
FREQUENCY CONTROL
Objective:
i. To control electrical output of generators ii. To control power balance between generators iii. To control export & import of electrical power iv To maintain frequency within certain bandwidth iv. v. To maintain balance in active power output
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RATING & SYSTEM
VOLTAGE
i. Operation Condition - Steady-state Stead state - Sustained - Harmonics ii. Voltage
- Ranges %
- Duration iii. Limit voltage variation - Point of Common Coupling - Transient T i t Voltage V lt
76
VOLTAGE CONTROL
Objective:
i. To maintain the voltage g constant within certain bandwidth
ii. Under normal operation conditions, the supply voltage range should not differ from the nominal voltage system (10% or define by utilities)
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2. GENERATOR
78
GENERATOR
79
3. CIRCUIT BREAKER
80
CIRCUIT BREAKER
81
PLANT LAYOUT
82
4. POWER TRANSFORMER
83
POWER TRANSFORMER
84
5. MV/ LV SWG, MCC, FIXED TYPE
85
SWITCHGEAR
86
6. AC/ DC UPS SYSTEM
87
UPS
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CONTROLS
7. Electrical Control 7 Control, Protection & Metering g System y

i. Electrical Control panels ii. Protection Panel iii.Metering iv.Electrical SCADA
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CONTROLS
8. Instrument & Control 8 System y

i. Control panels ii. Automatic control system, DCS, etc iii.Monitoring instruments iv.Alarm system v. Auxiliary system (Blower, heater, filter, air fan, fire fighting,
etc) )
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9. 9 10. 11.
Earthing System Raceway y System y Lighting System
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THE END
Thank You!!!
92

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Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

Called as energy center

Basics of Power Generation Plant

III. DESIGN PHILOSOPHY

III DESIGN PHILOSOPHY III.

Basics of Power Generation Plant

IV DESIGN CONSIDERATION IV.

Basics of Power Generation Plant

Basics of Power Generation Plant

V LIST OF MAJOR V. EQUIPMENT Q USED IN POWER PLANT

Basics of Power Generation Plant

Basics of Power Generation Plant

OIL FIRED WATER BOILER

Basics of Power Generation Plant

COAL FIRED BOILER

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

4. HEAT RECOVERY STEAM GENERATOR

Basics of Power Generation Plant

Heat Recovery Steam Generator

ii Steam used in process/ drive ii. turbine

Basics of Power Generation Plant

Basics of Power Generation Plant

ii. From feedwater to boiler iii 2 type iii.

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

7. BOILER FEED WATER PUMP

Basics of Power Generation Plant

BOILER FEED WATER PUMP

Feed Water Pump

ii F ii. Fresh h water/ t / condense d steam

Basics of Power Generation Plant

8. FEED WATER HEATER

Basics of Power Generation Plant

FEED WATER HEATER

Feed Water Heater

Basics of Power Generation Plant

TYPE & CONFIGURATION

VI. TYPES OF POWER GENERATION PLANT & CONFIGURATION

THERMAL POWER PLANT

VII. BRIEF DETAIL of THERMAL ENERGY BASED POWER PLANT

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

1. STAGE 1: COAL & ASH PLANT

2. STAGE 2: STEAM GENERATING PLANT

3. STAGE 3 & 4: STEAM TURBINE & ALTERNATOR

Basics of Power Generation Plant

4. STAGE 5: FEED WATER & COOLING

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

Basics of Power Generation Plant

COMBUSTION POWER PLANT