Course Contents

Part –I Power Plant Overview

Part –II Power Plant Systems & Equipments
Part –III Power Plant Control Philosophy

Power Plant Overview

 Thermal
 Coal Fired
 Gas Fired
 Hydro
 Nuclear
 Non-conventional

Power Plant Overview

 Basic Principle
Basic principle in modern power plants is based on Rankine Cycle. It is applicable
for conventional coal fired steam turbine plant as well bottoming turbine for combine
cycle plants.

Power Plant Overview

 1-2 Saturated Liquid from condenser at state 1 is pumped isentropically to state 2
and into the boiler.
 2-3 Liquid is heated at constant pressure in the boiler to state 3 (Saturated Steam).
 3-4 Steam expands isentropically through the turbine to state 4, where it enters
condenser as wet vapors.
  4-1 Constant pressure transfer of heat in the condenser takes place to return the
steam to state 1 (Saturated Liquid).

Power Plant Overview

 Efficiency of Rankine cycle can be increased by superheating the steam in the

boiler.

 Efficiency of Rankine cycle can also be increased by Re-heating (4-5) the steam
in the boiler. The steam is expanded to some intermediate pressure in turbine and
then reheated in boiler. Following reheat the steam is expanded to the cycle
exhaust pressure in the turbine again.
 Efficiency of Rankine cycle can also be increased by Regeneration which
involves feed-water heaters. This cycle regains some of the irreversible heat lost
when condensed liquid is pumped into the boiler by heating feed-water through
heaters (Using extraction steam).
Gas Fired Power Plants

 Open Cycle
 Combined Cycle (With or without Supplementary Firing)
 Cogeneration (With or without Supplementary Firing)
Gas Fired Power Plants

 Basic thermodynamic cycle on which Gas Turbine is based is known as Brayton

Cycle. Work obtained by expanding gas at higher temperatures.

Air/Flue Gas Handling System

 All equipments required for providing combustion air and extracting flue gas are
included.
 All interlocks and protections related to individual Fans, Dampers, Air Pre-
Heaters are covered in this area.
 Normally includes Furnace Draft Fans, Induced Draft Fans, Primary Air Fans,
Secondary/Primary Air control Dampers, Air Pre-Heaters.
 Major function of this system to maintain furnace draft, provide combustion air
and perform proper heat exchange between air and flue gas.

Main Steam System

 All equipments required for providing superheated steam are included here.
  All interlocks and protections related to individual Super-heaters, Attemprators
are covered in this area.
 Normally includes Water-walls, Drum, Super-heaters, Attemprators, Main Steam
isolating valves.
 Major function of this system is to separate steam from water, superheat steam to
desired pressure and temperature and isolate boiler if steam is not required.

Reheat Steam System

 All equipments required for providing reheated steam are included here.
 All interlocks and protections related to individual Re-heaters, Attemprators are
covered in this area.
 Normally includes Re-heaters, Attemprators.
 Major function of this system is to provide reheated steam at desired pressure.

HP/LP Bypass System

 All equipments required for bypassing the HP and IP/LP turbine are included
here.
 All interlocks and protections related to individual Bypass valves, Attemprators
are covered in this area.
 Normally includes HP/LP bypass valves, Attemprators.
 Major function of this system is to maintain desired main steam/ HRH
pressure/temperature during turbine start-up and shutdown and bypass the
HP/IP/LP turbine during tripping.

Auxiliary Steam System

 All equipments required for providing auxiliary steam are included here.
 All interlocks and protections related to individual valves, Attemprators are
covered in this area.
 Normally includes auxiliary steam pressure control valves and attemprators.
 Major function of this system is to provide auxiliary steam for Soot-blowing,
Steam Coil Air-Preheating, Turbine Seal-Steam System, De-aerator Pegging, Fuel
Heating etc. during plant start-up and normal running

Extraction Steam System

 All equipments required for extracting steam from steam cycle are included here.
 All interlocks and protections related to individual non-return valves and isolating
valves covered in this area.
 Normally includes individual non-return valves and isolating valves.
 Major function of this system is to provide extraction steam for auxiliary steam
header, De-aerator Pegging, HP/LP Heaters during plant start-up and normal
running for overall improvement in plant efficiency.
Condensate System

 All equipments required for condensate extraction from hot-well are included
here.
 All interlocks and protections related to individual Condensate Extraction Pumps,
isolating valves, recirculation valves, make-up valves are covered in this area.
 Normally includes individual Condensate Extraction Pumps, isolating valves,
recirculation valves and make-up valves.
 Major function of this system is to extract condensate from hot-well, maintain the
condensate losses and maintain hot-well level.

Feed-water System

 All equipments required for feed-water are included here.

 All interlocks and protections related to individual Boiler Feed Pumps, isolating
valves, recirculation valves, drum level control valves are covered in this area.
 Normally includes individual Boiler Feed Pumps, isolating valves, recirculation
valves, drum level control valves.
 Major function of this system is to provide feed-water to drum and maintain its
level. Single, two or three element drum level control may be used depending
upon the plant requirements.

Circulating Water System

 All equipments required for circulating cooling water are included here.
 All interlocks and protections related to individual Closed Cycle Pumps, Open
Cycle Pumps, isolating valves, recirculation valves, level control valves are
covered in this area.
 Normally includes individual Closed Cycle Pumps, Open Cycle Pumps, isolating
valves, recirculation valves, level control valves.
 Major function of this system is to provide cooling water to plant equipments like
condenser, generator, HT motors, vacuum system etc.

Air Evacuation System

 All equipments required for Air Evacuation are included here.

 All interlocks and protections related to individual Vacuum Pumps/Ejectors,
System isolating valves, recirculation pumps, level control valves are covered in
this area.
 Normally includes individual Vacuum Pumps (and/ or) Ejectors, System isolating
valves, recirculation pumps, level control valves.
 Major function of this system is to vacuum in the condenser as per plant
conditions.
Drain & Vent System

 All equipments required for draining and venting boiler and turbine are included
here.
 All interlocks and protections related to individual drain and vent valves are
covered in this area.
 Normally includes drain and vent valves situated in different areas of boiler and
turbine.
 Major function of this system is to drain boiler and turbine steam lines as per
plant conditions. This system is an essential part of plant start-up and shut-down.

Lubrication Oil System

 All equipments required for providing lubrication to turbine/generator bearings

are included here.
 All interlocks and protections related to individual Auxiliary Oil Pumps,
Emergency Oil Pumps, Jacking Oil Pumps, Lube Oil Temperature Control Valves,
Lube Oil Tank, Lube Oil Coolers are covered in this area.
 Normally includes Auxiliary Oil Pumps, Emergency Oil Pumps, Jacking Oil
Pumps, Lube Oil Temperature Control Valves, Lube Oil Tank, Lube Oil Coolers .
 Major function of this system is to provide lubrication to turbine bearings through
out turbine barring gear operation, rolling of turbine , normal running and shut-
down of turbine.

Turbine Governing System

 All equipments required for controlling turbine throttle valves are included here.
 All interlocks and protections related to individual HP Control Valves, IP Control
Valves, HP Shut-off Valves, IP Shut-off Valves, Over-speed Trip, Vacuum Trip,
Manual Trip are covered in this area.
 Normally includes Electro-Hydraulic Converter, HP Control Valves, IP Control
Valves, HP Shut-off Valves, IP Shut-off Valves, Over-speed Trip, Vacuum Trip,
Manual Trip.
 Major function of this system is to regulate turbine control valves as per load/
throttle pressure requirement depending upon boiler follow or turbine follow
mode respectively.

Turbine Protection System

 All instruments required for protecting turbine are included here.

 All interlocks and protections related to turbine tripping are generated in this area.
 Normally includes trips due to vibrations, turbine expansions, axial shift, bearing
temperatures, low vacuum, fire protection, low lube oil level, generator
mechanical protection, high hot-well level, master fuel trip, high exhaust steam
temperatures etc.
  Major function of this system is to trip turbine due to above unsafe conditions
during start-up / running.

Turbine Stress Evaluator System

 All instruments required for supervising turbine thermal stresses are included
here.
 All interlocks and protections related to turbine thermal stresses are generated in
this area.
 Normally includes thermal stress measurements related to turbine Inner/outer
casing temperatures, turbine control/shut-off valves temperatures etc .
 Major function of this system is to guide operator and restrict loading/unloading
of turbine to avoid fatigue to turbine and turbine valves during start-up, running
and shut-down.

Turbine Supervisory System

 All instruments required for supervising turbine conditions are included here.
 All interlocks and protections related to turbine vibrations, turbine expansions,
axial shift, bearing temperatures are generated in this area.
 Normally includes turbine vibrations, turbine expansions, axial shift, bearing
temperatures .
 Major function of this system is to supervise turbine operating conditions during
start-up, running and shut-down.

Generator / Excitation/Electrical System

 All equipments required for Generator are included here.

 All interlocks and protections related to Generator Stator Cooling System, Gas
Cooling System, Seal Oil System, Exciter Cooling System are generated in this
area.
 Normally includes Generator Stator Cooling System, Gas Cooling System, Seal
Oil System, Exciter Cooling System.
 Major function of this system is to provide mechanical protection to the generator
during start-up, running and shut-down. All electrical protection are part of
generator/exciter electrical protection system.

Coal Handling System

 All equipments required for Off Site Coal Handling are included here.
 All interlocks and protections related to Wagon Tippler, Stack/Re-claimer,
Crushers and Conveyor are generated in this area.
 Normally includes Wagon Tippler, Stack/Re-claimer, Crushers and Conveyor
System.
 Major function of this system is to Unload coal from Wagons, Stack the coal,
convey the coal to crushers and from crushers to the coal bunkers
Ash Handling System

 All equipments required for Off Site Ash Handling are included here.
 All interlocks and protections related to Slurry Maker/Transfer system, if wet ash
removal system, Ash Silos, if dry ash removal system, are generated in this area.
 Normally includes Slurry Maker/Transfer system, if wet ash removal system, Ash
Silos, if dry ash removal system.
 Major function of this system is to remove ash from boiler (bottom ash hoppers,
ESP ash hoppers).

DM Water System

 All equipments required for Off Site DM water making are included here.
 All interlocks and protections related DM water making are generated in this area.
 Normally includes chemical treatment plant, DM water Storage Tanks, DM water
transfer pumps.
 Major function of this system is to provide DM water to the Main Power Plant
Area. Some of the equipments like generator require DM Water for its cooling
due conductivity reasons.

Water Cooling System

 All equipments required for Off Site water cooling are included here.
 All interlocks and protections related Cooling water pumps, Cooling Tower fans
are generated in this area.
 Normally includes Cooling water pumps, Cooling Tower fans, Cooling Towers.
 Major function of this system is to cool the water that got heated after heat
exchange in condenser and other coolers located in plant area, and can be re-used.

Power Plant Control Philosophy

Hierarchy of Controls

 AGC (Grid Level)

 CMC /UCC (Unit Level)
 Turbine Control (Plant Level)
 Boiler Controls (Plant Level)
 Balance of Plants Controls (Plant Level)
 Control Loops in Power Plant (System Level)
 Control Equipments in Power Plant (Equipment Level)

Automatic Generation Control

 Top Level Power Generation Control
 Remote Set-point send to different units
 Set-point based on Grid Demand (Load/Frequency)
 Set-point can be analog or Pulse from AGC
 Units must runs in UCC/CBF Mode for best results
 Unit Coordinated Control

 Unit Level Power Generation Control

 Remote Set-point from AGC is received here
 Depending upon the ramp rate set, the unit responds to AGC Demand
 Units runs in Remote/UCC/CBF Mode for best results
 All control loops are running in auto

Turbine Control (Plant Level)

 Turbine governing system receives MW demand from Turbine Master (UCC in

CBF Mode).
 Turbine Governing Valves modulates to match the demand.
 The demand is matched very fast, boiler is to response faster to avoid throttle
pressure deviation.
 All Control loops in turbine area working in auto.

Boiler Controls (Plant Level)

 Fuel Master receives Throttle Pressure demand from Boiler Master (UCC in CBF
Mode).
 As the turbine valves modulates to match the MW demand, disturbance will be
created in throttle pressure.
 Fuel Master increase or decreases fuel to maintain throttle pressure.
 All Control loops like fuel master, air master, feed-water master in boiler area
working in auto.

Balance of Plants Controls (Plant Level)

 Balance of plant controls are independent of UCC controls.

 The effect on these loops is indirect.
 Depending upon the unit ramping up or down these loops responds, but do not
have direct effect on unit.
 These loops must work efficiently to help proper and efficient plant operation
 Normally these loops includes, ash handling, coal handling, DM Water Plants,
Water Cooling System
Main Control Loops in Power Plant (System Level)

 Fuel Master (Feeder Speed Control)

 Controls Mills/Coal Feeders
 Air Master (Cross-Limiting and Secondary air Flow Control)
 Controls FD Fans and related control dampers and blade pitch
 Furnace Pressure Control
 Controls ID Fans and related control dampers and hydraulic coupling

 Steam Temperature Control (SH/RH)

  Controls de-superheating spray valves
Main Control Loops in Power Plant (System Level)

 Feed-water Master (Drum Level Control)

 Controls Boiler Feed Pumps and related control valves and hydraulic
coupling
 Condensate Control ( Hot-well Level Control)
 Controls Condensate Pumps and related control valves
 De-aerator Level Control
 Controls control valves
 HP/LP Heater Level Control
 Controls level control valves
 HP/LP Bypass Pressure and Temperature Controls
 Controls related pressure control valves de-superheating spray valves