ME 6701

POWER PLANT ENGINEERING

UNIT I COAL BASED THERMAL POWER
PLANTS
UNIT 2 : DIESEL, GAS TURBINE AND
COMBINED CYCLE POWER PLANTS
UNIT 3 : NUCLEAR POWER PLANTS
UNIT 4 : POWER FROM RENEWABLE
UNIT 5 : ENERGY, ECONOMIC AND
ENERGY
ENVIRONMENTAL ISSUES OF POWER
PLANTS
1
 COURSE OBJECTIVE
•
Providing an overview of Power

Plants and detailing the role of

Mechanical Engineers
operation and in their
maintenance.

S.PALANIVEL ASSOCIATE PROF./MECH ENGG

2
KAMARAJ COLLEGE OF ENGG. & TECH.
 CO COURSE OUTCOMES
CO Statements
Learning
No. Level

Explain the basics of Thermal Power Plant and the working principle K2 -
C411.1 of various accessories Understand

Describe about the various diesel, gas turbine and combined cycle K2 -
C411.2 power plants. Understand

K2 -
C411.3 Illustrate the recent trends in Nuclear Power Generation. Understand

K2 -
C411.4 Know overall idea about power from renewable energy Understand

Analyse about the energy, economic and environmental issues of K2 -

C411.5 power plants Understand

S.PALANIVEL ASSOCIATE PROF./MECH ENGG

3
 MEASURING TOOL FOR COURSE OUTCOME EVALUATION

UNIT Slip Test Internal Test Assignment Seminar/Discussion/

Quiz/Others
I 20% 40% 20% 20% (CASE STUDY/
SEMINAR)
II 20% 30% 20% 30%
(QUIZ/SEMINAR)
III 20% 40% 20% 20% (CASE
STUDY/SEMINAR)
IV 20% 40% 20% 20%
(QUIZ/SEMINAR)
V 20% 40% 10% 30%
(QUIZ/MOODLE
TEST)

S.PALANIVEL ASSOCIATE PROF./MECH ENGG

4
KAMARAJ COLLEGE OF ENGG. & TECH.
 UNIT 1 : POWER PLANT ENGG.
•
• ELECTRICITY
• ENERGY
• EASY TO PRODUCE,
• TRANSPORT,
• USE & CONTROL
MOSTLY TERMINAL FORM OF ENERGY FOR
TRANSMISSION & DISTRIBUTION
•
IT HAS TO BE CONSUMED AT THE MOMENT
OF GENERATION
S.PALANIVEL ASSOCIATE PROF./MECH ENGG
5
 TYPES OF POWER PLANTS
•
THERMAL
•
HUDRAULIC
•
GAS TURBINE
•
NUCLEAR
•
GEO THERMAL

S.PALANIVEL ASSOCIATE PROF./MECH ENGG

6
BASIC FLOW DIAGRAM OF POWER PLANT

7
8
 POWER PLANT CIRCUITS
•
• STEAM CIRCUIT
CONDENSATE & FEED WATER CIRCUIT
•
COAL CIRCUIT
•
AIR CIRCUIT
•
ASH CIRCUIT
•
CIRCULATING WATER CIRCUIT
•
D.M. WATER CIRCUIT

9
 STEAM CIRCUIT
•
• Steam from Boiler drum ,
• further heated in super heaters,
fed into HP Turbine, outlet of turbine
HP
•
Reheaters, Temperature of steam increased
• goes to
fed into Intermediate pressure Turbine
•
then to LP Turbine
•
certain amount of stem extracted and used
to preheat Feedwater
10
 CONDENSATE & FEED WATER CIRCUIT
•
Exhaust of LP turbine condensed by circulating water
becomes condensate
•
Condensate heated in LP heaters
•
Preheated Condensate, further heated and its

dissolved oxygen are liberated at deaerator thro

• deaeration
Feed water and
stored in
• deaerator
From condenser till reaching Boiler drum it is kept as
pumped by
water
Boilerbyfeed
rising temp & pressure of water.
11
• COAL CIRCUIT
• Coal received thro rail/ship/Mines are stored in yard
Coal from yard transported to Coal handling
Receiving Bunkers ( capacity minimum 2days
of
• storage)
Coal from receiving bunkers crushed to a specified
size say upto 80 mm by crushers and fed into Boiler
Bunkers. To avoid entry of iron material, magnetic
separators are used.
•
From Boiler bunkers, coal fed into individual mills by
boiler feeders, Mills powdered the coal as minute
particles, pulversied coal fed into Furnace.
•
By varying the speed of the boiler feeders, coal input
S.
to Boiler is varied. 12
• AIR CIRCUIT
Air required for firing is drawn from
atmosphere thro forced draught fans.
•
Drawn air is preheated in Air preheaters,
preheated air is used for many purposes.
•
Combustible gas called flue gases are sucked
by Induced draught fans and let out to
atmosphere thro high rise stack after passing

• thro Electrostatic Precipitators.

Temp. of outlet Air is kept above 140 deg. C
to avoid cold end corrosion. 13
 ASH CIRCUIT
There are two types of ash generated in Boiler
as Botom ash and fly ash

Unburnt carbon materials are collected at the
botom ofthe furnace as botom ash in slag
conveyors and continuously removed thro
conveyors. Scrapped
scrapperbottom ash are collected in
 trucks and disposed off.
Fly ash coming out with flue gases are collected at
electro static precipators. Fly ash are collected at
Ash vessel at the bottom of ESP and transported to

 Ash Silo thro pneumatic conveying.

Ash from Ash silo are disposed off by trucks. 14
• CIRCULATING WATER CIRCUIT
Steam at the exhaust of the LP turbine is condensed by circulating
• water.
Cold circulating water pumped (or) drawn from sea /river into
• Condenser as inlet to condense the steam
Afer condensing the steam , the cold water gets heated and the
hot circulating water is taken from condenser outlet to Cooling
• tower
Hot circulating water will then enter into cooling tower and gets
cooled by air travelling in opposite direction to water flow. Cooled
• water gets collected at the cooling tower basin.
• Cold water pumped from cooling tower basin to condenser
In places where circulating water is taken from sea or river,
hot water either sent back to sea or river if it is permited
• by authorities or cooled at the cooling tower.
Certain quantity of water is added at the basin to make up
evaporation losses in cooSl.
15
 DM WATER CIRCUIT
•
Raw water taken from river or from bore water is firstly

• removed/ filtered of suspended solids /sediments

Filtered water will be processed in ION EXCHANGERS to
• remove unwanted salts
D.M. water will be made either thro Ion exchange process or

• distillation processes or reverse osmosis (RO) processes.

D.M water thus produced will be kept stored in condensate
• storage tanks.
From condensate storage tanks, DM water is added as make
up thro DM water make up pumps while the plant is running
• by taking signals from condenser level.
While starting up of unit or for filling up the Boiler , it can be
done by a dedicated lineS.PALANIVEL
fromASSOCIATE
DM PROF./MECH
makeENGG
up water pumps .
16
17
18
19
20
21
22
23
Natural
Draugh
t
Coolin
g
Tower

24
25
 POWER PLANT ENGG.
WHAT THESE WORDS REPRESENT?
ESP RESERVE FACTOR BOILER

MILL GENERATOR
HEAT RATE
LOAD CONDENSER
PEAK LOAD

STACK GRID DEAERATOR

HEATER FREQUENCY LOAD FACTOR

COOLING TOWER TURBINE PUMP

FAN BFP
MU TRANSFORMER

26
SFEE Steady Flow Energy Equation
SFEE for Boiler , h + Q 1 = h
4 1
Q1=h -h
1 4
SFEE for Turbine h 1 = WT + h2
SFEE for Condenser h = Q + h
2 2 3
SFEE for Pump h 3 27
Efciency of Rankine Cycle
=W (Net = (WT – WP)/Q1
)
Q1
Heat rate = Q1/(WT – WP)
Heat transfer to water in Steam Generator in 3 regimes :
1. Water heated in Economizer using sensible heat in

liquid phase from state 4 to state 5

2.
In Evaporator, there is a phase change as water into
steam from state 5 to state 6 by absorbing latent heat
3.
Saturated vapor at state 6 is further heated at const.
pressure in super heater to state 1 28
•
As the Live steam pressure increases , the
latent heat decreases , heat absorbed in the

evaporator decreases and the fraction heat

• absorbed in the super heater increases.
In High pressure Boilers, more than 40 % of
• total heat absorbed in super Heaters.
In Boilers operating above critical pressure
there is no Evaporator (Boiler Drum). There
is a transition zone where all the liquid on
being heated suddenly flashes into vapor. 29
•
Liquid leaving the pump (Boiler Feed Pump –

• BFP) > Turbine Inlet Pressure

Steam generator pressure > Turbine Inlet
• pressure
Too small pinch point temp diference
causes increase in surface area, large
• expensive more efficient
Large pinch point temp difference decrease in
surface area, inexpensive but with a reduced
efficiency 30
31
32
33
•
Efects of Super Heat
Increase in the Super heat
at constant pressure
increases the mean temp.
of heat addition , hence the
• Cycle efciency increases.
Increase in super heat, the
expansion line of steam in
the turbine shifts to the 1.Instead of T1 if the steam is further
super heated to T1’ – heat addition (T1’-
right, as a result the quality t1) & work done increased by 2-1-1’-2’
of steam of turbine exhaust 2. More over the expansion line 1-2 is
improves ie. Dryness shifted to right side as 1’-2’ , hence the
dryness fraction of steam at Turb.
fraction improves which Exhaust improves , hence the
increases the performance performance of turbine.
of Turbine. 34
 Effects of Inlet Pressure
•
Due to increase in pressure to p2,

ideal expansion line of steam shifts

to left and the moisture content of

• steam at exhaust stage of turbine

•
Max. temp. of stem is fixed on
metallurgical considerations.. It is
called metallurgical limit.
When the steam inlet pr. Increases
from p1 to p2, the mean temp. of heat
addition increases since Tm1
between stage 7 and 5 is higher than
stage 1 and 4, but inlet pr. Increases
to p2 from p1.
increases because x6 < x2
Steam with high moisture content
will erode the edges of last stage
blades.
Hence the maximum moisture
content in the steam should not
exceed 12% or the quality of
steam should not falll below 88 %.
35
 Efects of Reheat

In order to limit the quality of steam

at Turbine exhaust above 0.88,
reheating of steam has to be
adopted.
All the steam after partial
expansion is brought back to
Boiler , reheated by combustion
gases and then fed back to
turbine for further expansion
36
•
In the reheat cycle the and the remaining expansion of

expansion of steam from steam is carried out in LP Turbine

condenser
initial stateis1 carried
to the out in • (process 3-4 S).

one or more steps Had pressure p1 has been

without
be 1- 4’ Sreheat S the
- 5 -6 with lotcycle
of would
number of reheats
depending upon theused.
• moisture at turb. Exhaust. Having
In the first step, the steam steam quality of x 4’s. With the use
expands in HP turbine into .
s S
of
- 4’reheat . The
some intermediate S is added , net out put
).
S area under 2 -3- 4
• pressure (process 1-2 increases since (h 3 - h 4S ) is greater
Steam is reheated to super
than
heater temp. of HP turbine
• (h - h ). Reheating also
inlet at const. pressure 2s 4’S

(process 2 S -3) improves the quality of steam at

37
x 4’s to x 4s
38
 Efects of Regeneraton
•
• Increases the Cycle Efficiency
• Reduces heat rate and thus operating cost.
• Increases Steam flow rate (Bigger Boiler)
Reduces the flow to condenser (Small
• Condenser)
• Size of turbine small
If there is no change of Boiler output, Turbine

output drops.

39
40
 EFFICIENCIES IN A STEAM POWER PLANT
•
A STEAM POWER PLANT IS A BULK ENERGY CONVERTER
FROM FUEL TO ELECTRICITY
•
OVERALL EFFI. = ȠOA = POWER AT GEN. TERMINAL
RATE OF ENERGY RELEASE OF FUEL
= MWe X 103 (w f = FUEL RATE
w
f X C.V. C.V.= CALORIFIC VALUE)
EFFICI. OF BOILER = ȠBr = RATE OF ENERGY ABSORPTION BY WATER TO FORM STEAM
RATE OF BY ENERGY RELEASE FUEL
= wS (h 1 - h 4 ) (w s = STEAM RATE)
w
f X C.V

EFFICI. OF CYCLE = ȠCY = (h 1 - h 2 ) (PUMP WORK HAS BEEN NEGLECTED)

(h 1 - h 4 )
EFFICI. OF TURBINE = ȠTUR.mech. S=.PABLARNAIVKEEL AOSSUOCTIAPTUE = BRAKE OUTPUT 41
EFFICI. OF GENERATOR = ȠGEN.. = ELEC. OUTPUT AT GENERATOR= MWe X 103

BRAKE OUTPUT OF TURBINE BRAKEOUTPUT IN K.We

ȠOA = ȠBr X ȠCY X ȠTUR.mech X

ȠGEN
= wS (h 1 - h 4 ) X wS (h 1 - h 2 ) X BRAKE OUTPUT X MWe X 103
w
f X C.V wS (h 1 - h 4 ) wS (h 1 - h 2 ) BRAKE OUTPUT

ȠOA = MWe X 103 = ȠBr X ȠCY X ȠTUR.mech X

w
f X C.V. ȠGEN
ȠAUX. = Net Power Transmited by Generator
Gross Power produced by Plant
ȠOA = ȠBr X ȠCY X Ƞ TUR.mech X ȠGEN X

ȠAUX.

42
• Co-Generaton Plant
Paper mills, Textile mills, Chemical factories
•
require STEAM for heating

• Saturated Steam at the DESIRED TEMP. used

for heating.
• Apart from process heat, factory need
power to drive machines, lighting etc.
By modifying initial steam pressure and
power & make available required steam for
EXHAUST pressure, possible to generate
process work 43
•
Process heater replacing Condenser
•
Exhaust press. of the Turbine is the saturation
pressure corresponding to temp. desired in
the process heater. Such Turbine is called Back
• Pressure Turbine.
Plant producing both elec. Power and process
heat simultaneously is called as Cogeneration
• Plant.
Process Steam is basic need, power is
produced incidentally as a by-product,
cycle is called a by- product power cycle.
the
44
• W = Turbine output in kW.
T
• Q = Process heat reqd, in kJ/h
H
•
wS = Steam flow rate in kg/h
•
WT x 3600 = wS (h 1 - h 2)
•
QH = wS (h 2 - h 3 )
•
QH = WT x 3600 x (h 2 - h 3 ) kJ/h
(h 1 - h 2 )
Q1 is the total energy input as heat, WT is shaft work
converted into elec. Balance energy
Q1 – WT is utilized as process heat.
Cogeneration Plant Ef. ȠCO = WT + QH 45
•
Co generation is beneficial if the efciency of

the cogeneration plant is greater than of

• separate generation.
Back pressure Turbines are small w.r.t. power
• output because exhaust steam density high
They are single cylinder , it is cheaper in cost
per MW compared to condensing sets of
• same power.
They are used in process, petro chemical,
for driving compressors
desalination and Feed
of sea water, Pumps.heating,
domestic 46
•
A steam power plant with inlet steam to H.P. turbine

at 90 bar and 500 deg. C and condensation at 40 deg.

C produces 500 MW. It has one stage of
optimally placed which raises the steam temp. back reheat
to 500 deg C One closed feed water heater with
drains cascaded back to the Condenser receives bled
at the reheat pressure, and the remaining
steam
is reheated and then expanded in L.P. turbine.
The H.P. and L.P. turbines have isentropic eficiencies
steam
of 92 % and 90 % respectively. The isentropic
efciency of Pump is 75 %. Calculate a) the mass flow

rate of steam at turbine inlet in kg/s b) the cycle efi.

47
•
Inlet Steam press. & temp. = 90 bar, 500⁰C
•
Condenser Temp = 40 ⁰C : RH Temp = 500⁰C
•
Isent. Effi. HPT = 92 %, LPT=90% Pump=75%
•
TTD = - 1.6⁰C
Assume RH press= 20 % of HPTPr.= 0.2x90=18bar
h1 for 90 bar & 500 ⁰C =3386. 8 kJ/kg
s1 for 90 bar & 500 ⁰C =6.660 kJ/kg = s2S
h2S for 18 bar & 250 ⁰C = 2911 kJ/kg
h3 for 18 bar & 500 ⁰C =3469. 8 kJ/kg
S.PALANIVEL ASSOCIATE PROF./MECH ENGG 48
s4S = sf + x4s sfg (ref. S for 40 ⁰C )
x4s = 7.4825 – 0.572 = 0.8991
7.686
h4s = 167.5+ 0.8991 x 2406.9 2331.54 kJ/kg
=
h
h75 == 884.5
167.5kJ/kg
( ref. hf for
( ref. 4018⁰Cbar
h7 for ) )
WPs = ƪ vdp = 0.001008 x 90 x10 = 9.072 kJ/kg
H6s = 176.64 kJ/kg
h 1 - h 2 ȠHPT (h 1 - h 2s ) =0.92 (3386.8 -2911)
== 437.736 : h 2 = h 1 - 437.736=3386.8- 437.736=2949.06
S. 49
h 4 = 3469.8 – 1024.434 = 2445.366 kJ/kg
WP = ȠP (h 6 - h 5 ) = 9.072

h 6 - h 5 = 9.072/0.75 = 12.1
kJ/kg
Thsat6 =12.1+167.57 = 179.67 kJ/kg
at 18 bar = 207.1⁰C
T9 = 207.1 +1.6 = 208.7 ⁰C : h9 = 875 +(22.7x3.7/5)=891.8
1(h 9 - h 6 ) = m(h 2 - h 7 ) : m = 891.8 – 179.67 = 712.13
2949.06- 884.5 2064.56
= 0.3449 kg.
WT = (h 1 - h2 )+ (1-m) (h3 - h4 )=437.736 1024.434
+0.6551x S.
50
Wnet = WT - WP = 1108.8427- 12.1 = 1096.7427
wS = MWx 103 / Wnet = 500x1000/ 1096.7427
= 455.895 kg/s
Q1 = (h 1 – h9 )+ (1-m) (h3 – h2 )
= (3386.8 - 891.8)+0.6551 (3469. 8 -2949.06)
= 2495 + 341.137 =2836.137 kJ/kg
Ƞcy = Wnet / Q1 = 1096.7427/ 2836.137=0.3867=38.67 %
Work ratio = Wnet / WT = 1096.7427/ 1108.8427=0.989

51
•
An ideal steam power plant operates between 70 bar, 550 ⁰C

and 0.075 bar. It has seven feed water heaters. Find the
optmum pressure and temperature at which the heaters

operate
TB = Saturaton temp at 70 bar = 285.9 ⁰C

TC = Saturaton temp at 0.075 bar = 40.3 ⁰C

Temp.
Heater rise
1: t1/heater
= 285.9-= 30.7
(285.9-40.3)/(7+1)=30.7
=255.2⁰C: p1=43.246 bar⁰C
Heater 2: t2 = 255.2- 30.7 =224.5⁰C: p2=25.318 bar
Heater 3: t3 = 224.5 - 30.7 =193.8⁰C: p3=13.67 bar
Heater 4: t4 = 193.8- 30.7 =163.1⁰C: p4=6.714 bar
Heater 5: t5 = 163.1- 30.7 =132.4⁰C: p5= 2.906 bar
Heater 6: t6 = 132.4- 30.7 =101.7⁰C: p6= 1.08 bar
7: = 101.7- 30.7 =71⁰C: p7=0.32535 bar 52
•
A Textile factory requires 10 t/h of steam for process
heating at 3 bar saturated and 1000 kW of power,
for which a back pressure turbine of 70 % internal
efciency is to be used. Find the steam condition

required at the inlet of turbine.

If
w = mass flow rate of steam
W((h 1 - h 2s) = 1000 kW ;
(h 1 - h 2) =1000x3600/10,000 = 360 kJ/kg
For 3 bar h 2 =2724.7 kJ/kg : h 1 = 2724.7+360= 3084.7
h 1 - h 2s = 360/0.7= 514.286 kJ/kg
h 2s = 3084.7 -514.286 = 2570.414 = hf + x2s x2163.2
=561.47 + x2s x2163S..P2ALA:NIx2sA=SSO0CI.A9TE
VEL
53
s 2s =1.6718+ 0.9287 (6.9919-1.6718)=6.6125 kJ/kg = s1
Corresponding h 1 = 3085.3 kJ/kg and s 1 =6.6125
From Mollier diagram
P1= 37.3 bar and t1 =344 ⁰C

54