Captive Power Plant An Overview

Power Plant

A power plant is an industrial facility for the generation of electric power It primarily consists of steam generator (boiler), turbine and generator. There are other auxiliary equipments to support the power generation

Power Plant: Classification

Based on Fuel

Thermal Power Plant (Coal Based) Nuclear Power Plant Solar Based Wind Based Hydro Based Geothermal Steam turbine based Gas turbine based Combined Cycle Based

Based on Prime Mover

Power Plant: Classification based on Fuel

Solar Power Wind Power

Hydropower

Geothermal Power

Nuclear Power

Thermal Power Plant: Process Diagram

Process Diagram of a Thermal Power Plant, showing different equipments

Thermal Power Plant: Main Equipments

Boiler Turbine Generator Ash Handling System Coal Handling System Water Treatment Plant DM Plant Instrumentation Electrical Safety

Boiler
A boiler or steam generator is a device used to create steam
by applying water to heat energy.
There are mainly two types:
Fire Tube Boiler A fire-tube boiler is a type of boiler in which hot gases from a fire pass through one or more tubes running through a sealed container of water. The heat energy from the gases passes through the sides of the tubes by thermal conduction, heating the water and ultimately creating steam. Water Tube Boiler

A water tube boiler is a type of boiler in which water circulates in tubes heated externally by the fire. Water tube boilers are used for highpressure boilers. Fuel is burned inside the furnace, creating hot gas which heats water in the steam-generating tubes

Boiler

Boiler furnace and steam drum A steam drum is a standard feature of a water-tube boiler. It is a reservoir of water/steam at the top end of the water tubes. The drum stores the steam generated in the water tubes and acts as a phaseseparator for the steam/water mixture

Superheater

A superheater is a device used to convert saturated steam or wet steam into dry steam used for power generation or processes.
There are three types of superheaters namely: radiant, convection, and primary

Reheater

Boiler

Turbine
A turbine is a rotary engine that extracts energy from a fluid flow and converts it into useful work. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process. The simplest turbines have one moving part, a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades, or the blades react to the flow, so that they move and impart rotational energy to the rotor Speed regulation The control of a turbine with a governor is essential, as turbines need to be run up slowly, to prevent damage while some applications (such as the generation of alternating current electricity) require precise speed control

Turbine

Generator
In electricity generation, an electric generator is a device that
converts mechanical energy to electrical energy.

The source of mechanical energy may be a reciprocating or

turbine steam engine, water falling through a turbine, an internal combustion engine, a wind turbine, a hand crank, compressed air or any other source of mechanical energy.

Generator
The two main parts of a generator or motor can be described in either
mechanical or electrical terms:

Mechanical: Rotor: The rotating part of an electrical machine Stator: The stationary part of an electrical machine Electrical: Armature: The power-producing component of an electrical machine. In a generator, alternator, or dynamo the armature windings generate the electrical current. The armature will be on the rotor in case of hydro and in stator in case of thermal.

Field: The magnetic field component of an electrical machine. The magnetic field of the dynamo or alternator can be provided by either electromagnets or permanent magnets mounted on the stator in hydro and in rotor in thermal sets..

Generator

Ash Handling System

Dry Ash System Ash Slurry System

Bottom ash system Ash water system

Ash Handling System

Coal Handling System

The coal received at site may be of different sizes. The railway cars are unloaded at site by rotary dumpers or side tilt dumpers to tip over onto conveyor belts below. The coal is generally conveyed to crushers which crush the coal to about inch (6 mm) size. The crushed coal is then sent by belt conveyors to a storage pile. Normally, the crushed coal is compacted by bulldozers, as compacting of highly volatile coal avoids spontaneous ignition. The crushed coal is conveyed from the storage pile to silos or hoppers at the boilers by another belt conveyor system

Coal Handling System

DM Plant

Hardness in the make-up water to the boiler will form deposits on the tube water surfaces which will lead to overheating and failure of the tubes. Thus, the salts have to be removed from the water, and that is done by a water demineralising treatment plant (DM). A DM plant generally consists of cation, anion, and mixed bed exchangers. Any ions in the final water from this process consist essentially of hydrogen ions and hydroxide ions, which recombine to form pure water.

Very pure DM water becomes highly corrosive once it absorbs

oxygen from the atmosphere because of its very high affinity for oxygen.

DM Plant

Water Treatment Plant

Instrumentation

MEASUREMENTS IN POWER PLANTS Electrical measurements current, voltage, power, frequency, power-factor etc., non-electrical parameters flow of feed water, fuel, air and steam with correction factor for temperature steam pressure and steam temperature-drum level measurement radiation detector smoke density measurement dust monitor ANALYZERS IN POWER PLANTS Flue gas oxygen analyser analysis of impurities in feed water and steam dissolved oxygen analyser chromatography PH meter-fuel analyser pollution monitoring instruments. CONTROL LOOPS IN BOILER Combustion control air/fuel ratio control furnace draft control drum level control main steam and reheat steam temperature control super heater control attemperator deaerator control distributed control system in power plants-interlocks in boiler operation. TURBINE-MONITORING AND CONTROL Speed, Vibration, shell temperature monitoring and control-steam pressure control lubricant oil temperature control cooling system.

Electrical
The Electrical System in Power Plant comprises of the following parts:

Switchyard Transformer Generator, complete with its auxiliaries Control and Relay Panels for Generator. Synchronizing panel for Generator with auto synchronizer. HV bus ducts. Turbine MCC, Turbine valve MCC, Boiler MCC, Boiler valve MCC, Soot blower MCC, ESP MCC, ESP PCC, Emergency MCC, Distribution board. DC starter panel for DC motors associated with Boiler and Turbine package. HT and LT motors associated with Boiler and Turbine package. Power and Control cables. Above ground earthing for all BTG equipment/structures. Lightning protection system for Turbine, Boiler, ESP, and other areas. Electric actuators with integral starters. UPS Elevator for Boiler.

Electrical

Single Line Diagram (SLD) for Power Plant

Safety

Why Safety? Safety Measures in Power Plant

PP Equipments like Safety helmets, safety shoes, safety belts, goggles, hand-gloves etc. Interlocking and cut-offs for warnings of extremes conditions

Environment
Why do we need to take care of Environment?

Thermal Power Plants will have these environmental factors:

Air Pollution Water Pollution Noise Pollution Influence on Flora and Fauna around

Environment

Layout of ESP

Project Highlight
The highlight of the project will be: Boiler- Rated (1185 T/hr of Superheated steam at 166.7 bar, 537C) 100% coal fired Sub-critical type Inlet feed water temperature- 278.5C

Have two pass design, radiant, single reheat, balanced draft, semioutdoor type.
Turbine- Rated ( 350 MW) Three cylinder reheat extraction and condensing type

Throttle condition: Steam at 166.7bar, 537C

Project Highlight
Generator- Rated (350 MW, at 20kV, 50Hz, 0.85 power factor) Water cooled stator windings

Hydrogen cooled stator core and rotor

Stack 220 m ( 1 no.) Concrete type ESP- Designed at emission limit of 50 mg/Nm3 Cooling System-Re-circulating closed cooling with sea water as medium for condenser cooling. Comprise of Induced draft cooling tower, circulating water pumps and cooling water pipes Ash Generation- 55 T/hr 20% will be bottom ash to be disposed off in the ash dyke using HCSD system 80% will be fly ash to be disposed off in the ash dyke using HCSD system

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