1m2_overview of steampower plants

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MODULE-1

Presentation Overview Steam Power Plants

Plant Layout Training Series

April-07Protection notice / Copyright notice

SPEL /Gurgaon / PMR.SridharPlant Layout Training SeriesOverview of Steam Power Plants

2. Overview of Steam Power Plants

1. Introduction to Coal fired thermal power station; coal handling, steam generation, power conversion, circulating water and post-combustion cleanup systems.

2. Introduction to steam turbine, generator, heat exchangers, condenser, main pumps

3. Introduction to planning of Steam Turbine building in a Reference Power Plant

Contents



Conventional Power Plant, Sea Location

Coal Yard

SteamGenerators

Electro-chlorinating

Staff Amenities and Administration Building

Demineralisation plant

Steam TurbineBuilding

Switch GearBuilding in between

Workshop andStores Building

Stack

Ash Silos

Fuel Oil Tanks

Circulation Water Pump Building

Jetty

Circulation Water Out-Fall



Coal Handling System

TRAIN UNLOADING

UNLOADING CONVEYORSTOCKOUT/RECLAIM CONVEYOR

ACTIVE PILE

RESERVE PILE

RECLAIM

RECLAIM CONVEYOR

CRUSHER

CONVEYOR

SILO FILL

CONVEYOR

TRANSFER BUILDING

CRUSHER BUILDING

UNIT SILOS



Systems of Power Island

POST-COMBUSTION CLEANUP SYSTEM

PULVERZER(S)

UNIT SILOS

FE

ED

ER

(S)

PRIMARY AIR FAN(S)FORCED

DRAFT FAN(S)

AIR HEATER

Scrubber solids & fly ash to landfill

ST

AC

K

INDUCED DRAFT

FAN(S)

PARTICULATE REMOVAL SYSTEM

SO2 REMOVAL SYSTEM

STEAM DRUM

WALL TUBES

SUPER HEATER

REHEATER

ECONOMIZER

STEAM GENERATOR

Hot Reheat Steam

Superheated Steam

Cold Reheat Steam

HP IPLP

CONDENSER

CEP

LP

BFP

HP

FEEDWATER HEATER(S)

DEAERATOR

GENERATOR

~

Extraction steam

STEAM GENERATION SYSTEM

POWER CONVERSION SYSTEM

COOLING TOWER(S)

CWP

Make up



Rankine Cycle with superheat, reheat and regeneration

s

T

isentropic expansion

heat rejection

compression

heat addition

1

2

4

3b3a

pump

Condenser

Turbine

BoilerQ1

Q2Wp

Wp

Q1

Q2

1

2 3

4

3

Superheater

Heat addition at multiple pressures; latent and sensible heat addition with superheat and reheat to working medium

Higher is the temperature/pressure at source, greater is the work done in turbine

Lower the sink temperature, greater is the work done in turbine

Feedwater heating regeneration to reduce load on boiler and increase cycle efficiency

Wa

4a

4b

Wb

reheater

Wa Wb

4a 4b

HeatersWp

1’

Heaters



Schematic of a Coal fired Power Plant



Principles of Steam Power Plant

Operates on combined Superheat, reheat and regeneration cycle

Uses Coal as primary fuel in a conventional Steam Generator

Recovers heat by means of economizers and regenerative air heaters.

Optimizes the heat rate and cycle efficiency by means of regenerative feedwater heaters

Efficiencies in the order of 35%



Major Equipment in a Power Plant

1. Steam Turbine

2. Generator

3. Condenser

4. Heat Exchangers

5. Pumps

Power Plant Components



Steam Turbines – Product Range Overview



Product Range application



Turbo-Generator set (HMN series)



Steam Turbine

CROSS OVER PIPE

IP TURBINE

HP TURBINE

COMBINED HP STOP AND CONTROL VALVE

COMBINED IP STOP AND CONTROL VALVE

COOLING WATER IN AND OUT

ONE COMMON CONDENSER FOR BOTH LP TURBINES. CW FLOWS IN 2 PATH AND IS DIVIDED

COMBINED LP BYPASS STOP AND CONTROL

VALVE

LP TURBINE



HP turbine



IP Turbine



LP Turbine

DOUBLE FLOW LOW PRESSURE TURBINE



Generators-Product Range



Air/Hydrogen Cooled Generators



Generator (Air Cooled)



Tasks of a Condenser



Classification of Condensers

Circulating Water System



Condenser Types



Feed water Heater

Drain cooling Zone

Extraction steam inlet

Feedwater outlet

Feedwater inletSteam phase Condensate phase

Possible condensate

level

Vents

Steam cooling Zone

Tube sheet



Horizontal LP Feedwater Heater with Drain Cooling Zone

Drain cooling Zone

Extraction steam inlet

Feedwater outlet

Feedwater inletSteam phase Condensate phase

Possible condensat

e level

Vents

Steam cooling Zone

Tube sheet

Beside of an economic Pipe Routing sufficient space for Insulation and access has to be considered while placing the heaters.



Comparison of horizontal and vertical heaters



Gland Steam Condenser



External drain cooler (for Heater A1 and A2)

2

1

4 3

A

ÆB

D C

1 Drains Inlet 2 Drains Outlet 3 Main Condensate Inlet 4 Main Condensate Outlet

For WGQ ca. 7,2 m

For WGQ ca. 1m



Deaerator and Feedwater Tank

Separate Deaerator tank mounted on the Feedwater tank is less costly than a STORK sprinkler deaerator

Objectives:1. Feed water heating (direct)2. Collector for condensates3. Storage overhead tank for BFP4. Used for balancing during operation



Deaerator and Feedwater Tank



Main Pumps

Feedwater pump

Condensate extraction pump

Circulating water pump



Boiler Feedwater Pump Design

Ring Section Type Barrel Type

• less invest costs • faster and easier assembly/disassembly

• no cutting of connecting pipes



Boiler Feedwater Pump (Barrel Type)

DruckgehäuseSauggehäuse

Laufrad Leitrad

Welle



Stufengehäuse

Boiler Feedwater Pump (Ring Section)

Verbindungsschraube



Classification by mode of Control

1. Variable Frequency drive

2. Constant Frequency drive with different control methods

Bypass operation

Throttling

Speed control

Turbo-coupling

Thyrister

Boiler Feedwater Pumps



Flow Control methods



Hydro-Coupling (Voith)



Economics of Speed Controlled Pumps

Design Features Design Features

• Donaustadt, Austria• Köln-Niehl, Germany

Advantage

• Speed control by adjusting the scoop tube position to vary the hydraulic oil flow rate

• Power transmission via hydraulic oil from pump wheel which is driven by the motor to turbine wheel

Advantages

References CCPP

MM

Hydro Coupling Frequency Converter

Reference CCPP

• General principle: transformation of the incoming alternating voltage to a direct voltage and then back to an alternating voltage of the required motor frequency

• Varying the motor frequency by thyristor

• Cottam, UK• King‘s Lynn, UK• Pulau Seraya, Singapore

• Highest full and part load efficiency• Low I&C effort• Low space requirement

Remarks

• Inadmissible harmonics may occur• Operating ambient temperature < 35°C



Condensate Extraction Pump



Condensate Extraction PumpIskenderun

Flow 215 l/sTDH 311 mLength 7,5 mDiameter 0,95 mWeight 4,4 tMaterial Cr-steel (impeller)

cast steel (bowl,stage casing)



Can for Condensate Extraction PumpIskenderun


SPEL /Gurgaon / PMR.SridharPlant Layout Training SeriesOverview of Steam Power Plants Quelle: KSB

Dr. Wehinger / September 2003

Motor Stool

Adjusting NutThrust Bearing

Discharge cover

Delivery Supension

Pipe

Radial Bearing

Column Pipe

Diffuser

Wear Ring

Impeller

Bellmouth

Discharge Elbow

Coupling

Disc Coupling, Rigid

Shaft

Coupling

Adjusting NutThrust Bearing

Discharge Elbow

Disc Coupling, Rigid

Radial Bearing

Column Pipe

Diffuser

Wear Ring

Impeller

Bellmouth

Shaft

pull-out type non-pull-out type

Circulating Water Pumps (Tubular Casing)



Circulating Water PumpIskenderun

Flow 15,35 m³/sTDH 18,3 mLength 11 mDiameter 3,3 mMaterial Duplex

(X2CrNiMo 22.5)



Coal Fired Thermal Power Plant



Steam Turbine Building



Steam Turbine Building Longitudinal Section

Steam TurbineGenerator

Exciter

Compressed Air Unit

Condensate PumpsCondenser Inlet/OutletClosed CW Heat ExchangerClosed CW Pumps

CondensatPolishingPlant

Seal Oil Unit



Condenser

Steam Turbine

Steam Turbine Building Cross Section View

Main Transformer

Main Cooling Water Piping

Generator Circuit Breaker

Main Machine Set Foundation

Boiler Feed Pump

LP Heaters

Feed Water Tank

Turbine Crane

Auxiliary Transformers



Turbo-set Arrangements

Paiton II – Indonesia2x 670 MW sub-critical

167 bar, 538°C / 538°C(2422 psi, 1000°F / 1000°F)Operation - 2000

Iskenderun – Turkey2x 660 MW sub-critical

177 bar, 538°C / 538°C

(2567 psi, 1000°F / 1000°F)Operation - 2003




Schwarze Pumpe – Germany2x 813 MW supercritical

260 bar, 547°C / 565°C(3770 psi, 1016°F / 1049°F)Operation - 1997/1998

Boxberg – Germany1x 908 MW supercritical

258,4 bar, 541°C / 578°C(3748 psi, 1006°F / 1072°F)Operation - 2000




Isogo – Japan

1x 600 MW ultra Supercritical

251 bar, 600°C / 610°C

3,640 psi , 1,112°F / 1,130°F

Two flow LP

Operation - 2002

1m2_overview of steampower plants

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