Module 4 PDF

Power Plant Engineering
Module 4- Diesel and Gas turbine Power plants
by
Dr. Mukesh Sharma
Assistant Professor
Department of Mechanical Engineering
Birla institute of Technology Mesra, Ranchi
Diesel Power Plants
25-10-2018
Diesel Engine Power plant
Power Plant Engineering Dr.Mukesh Sharma

Diesel Power Plants
25-10-2018
Overview
 The oil engines and gas engines are called Internal Combustion Engines.
 In IC engines fuels burn inside the engine and the products of combustion form the
working fluid that generates mechanical power.
A typical oil engine has:
 Cylinder in which fuel and air are admitted and combustion occurs.
 Piston, which receives high pressure of expanding hot products of combustion and the
piston, is forced to linear motion.
 Connecting rod, crankshaft linkage to convert reciprocating motion into rotary motion
of shaft.
 Connected Load, mechanical drive or electrical generator.
 Suitable valves (ports) for control of flow of fuel, air, exhaust gases, fuel injection, and
ignition systems.
 Lubricating system, cooling system.

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Diesel Power Plants
Applications of Diesel power plants
 Supply of coal and water is not available in desired quantity.

 Where power is to be generated in small quantity for emergency services.
 Standby sets are required for continuity of supply such as in hospital,
telephone exchange.
It is an excellent prime mover for electric generator capacities of from 100 hp

to 5000 hp.

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Diesel Power Plants
Types of Diesel Engines
2 Stroke Engines
4 Stroke Engines
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Diesel Power Plants
2 Stroke Engines
Exhaust
port

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Diesel Power Plants
2 Stroke Engines

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Diesel Power Plants
4 Stroke Engines

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Diesel Power Plants
4 Stroke Engines

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Diesel Power Plants
4 Stroke Engines

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Diesel Power Plants
Advantages of Diesel power plants
 Very simple design also simple installation.

 Limited cooling water requirement.
 Low fuel cost.
 Quickly started and put on load.
 Smaller storage is needed for the fuel.
 Layout of power plant is quite simple.
 There is no problem of ash handling.
 Less supervision required.
 For small capacity, diesel power plant is more efficient as compared to steam power
plant.
 They can respond to varying loads without any difficulty.

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Diesel Power Plants
Disadvantages of Diesel power plants
High Maintenance and operating cost.
Fuel cost is more, since in India diesel is costly.
The plant cost per kW is comparatively more.
The life of diesel power plant is small due to high maintenance.
Noise is a serious problem in diesel power plant.
Diesel power plant cannot be constructed for large scale.

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Diesel Power Plants
General layout of Diesel power plants

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Diesel Power Plants

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Diesel Power Plants

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Diesel Power Plants- Fuel Supply Systems
 Depending upon the location of the pumps and injectors, and the
manner of their operations, injection systems may be further
classified as follows:
 Common Rail System

 Individual Pump and Nozzle System
 Distributor System

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Common rail system
In this system, a high-pressure pump supplies fuel to a fuel header as shown.

The high-pressure in the header forces the fuel to each of the nozzles located in
the cylinders. At the proper time, a mechanically operated (by means of push
rod and rocker arm) valve allows the fuel to enter the cylinder through nozzle.

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Individual pump system  In this system, each cylinder is provided with one
pump and one injector.
 This type differs from the unit injector in that the
pump and injector are separated from each other,
i.e., the injector is located on the cylinder, while the
pump is placed on the side of the engine.
 Each pump may be placed close to the cylinder, or
may be arranged in a cluster.
 The high-pressure pump plunger is actuated by a
cam, and produces the fuel pressure necessary to
open the injector valve at the correct time.
 The quantity of fuel injected is again controlled by
the effective stroke of the plunger.
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Distributor system
 Here, the pump which pressurizes the
fuel also meters and times it.
 The fuel pump after metering the
required quantity of fuel supplies it to a
rotating distributor at the correct time for
supply to each cylinder.
 Since there is one metering element in
each pump, a uniform distribution is
ensured.
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Diesel Power Plants- Lubricating Systems
Main functions of lubricant
 To reduce friction and wear between the parts having relative motion by
minimizing the force of friction and ensures smooth running of parts.
 To seal a space adjoining the surfaces such as piston rings and cylinder liner.
 To clean the surface by carrying away the carbon and metal particles caused by
wear.
 To absorb shock between bearings and other parts and consequently reduce
noise.
 To cool the surfaces by carrying away heat generated due to friction.

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The various parts of an engine requiring lubrication are;
1. Cylinder walls and pistons.

2. Main crankshaft bearings.
3. Piston rings and cylinder walls.
4. Big end bearing and crank pins.
5. Small end bearing and gudgeon pin bearings.
6. Main bearing cams and bearing valve tappet and guides
7. Timing gears etc.
8. Camshaft and cam shaft bearings.
9. Valve mechanism and rocker arms.

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Types of Lubrication system
Wet Sump system
Dry sump system
Mist lubrication system

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Wet sump system
Splash system
Semi pressure system
Full pressure system

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Splash system  This system is used on some small four strokes,
stationary engines.
 In this case the caps on the big ends bearings of
connecting rods are provided with scoops which,
when the connecting rod is in the lowest position,
just dip into oil troughs and thus directs the oil
through holes in the caps to the big end bearings.
 Due to splash of oil it reaches the lower portion of
the cylinder walls, crankshaft and other parts
requiring lubrication.
 Surplus oil eventually flows back to the oil sump.
 Oil level in the troughs is maintained by means of
an oil pump which takes oil from sump, through a
filter.
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Semi- pressure system  This method is a combination of splash and
pressure systems.
 It incorporates the advantages of both. In this case
main supply of oil is located in the base of crank
chamber.
 Oil is drawn from the lower portion of the sump
through a filter and is delivered by means of a gear
pump at pressure of about 1 bar to the main
bearings. The big end bearings are lubricated by
means of a spray through nozzles.
 Thus oil also lubricates the cams, crankshaft
bearings, cylinder walls and timing gears.
 An oil pressure gauge is provided to indicate
satisfactory oil supply.
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Full pressure system
 In this system, oil from oil sump is pumped under
pressure to the various parts requiring lubrication.
 The oil is drawn from the sump through filter and
pumped by means of a gear pump.
 The pressure pump at pressure ranging delivers oil
from 1.5 to 4 bar.
 The oil under pressure is supplied to main bearings
of crankshaft and camshaft.
 Holes drilled through the main crankshafts bearing
journals, communicate oil to the big end bearings
and also small end bearings through holes drilled
in connecting rods.
 A pressure gauge is provided to confirm the
circulation of oil to the various parts.
 A pressure-regulating valve is also provided on the
delivery side of this pump to prevent excessive
pressure.

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Dry sump system
 In this system, the oil from the sump is
carried to a separate storage tank outside the
engine cylinder block.
 The oil from sump is pumped by means of a
sump pump through filters to the storage
tank.
 Oil from storage tank is pumped to the engine
cylinder through oil cooler.
 Oil pressure may vary from 3 to 8 kgf/cm2.
 Dry sump lubrication system is generally
adopted for high capacity engines.
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Diesel Power Plants- Cooling Systems
Air-cooling is used in small engines and portable engines by providing fins on the
cylinder.
Big diesel engines are always liquid (water/special liquid) cooled.
Cooling system
Open cooling system
Natural cooling system
Forced cooling system

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Natural cooling system  The system is closed one and designed so that the water
may circulate naturally because of the difference in
density of water at different temperatures.
 It consists of water jacket, radiator and a fan. When the
water is heated, its density decreases and it tends to
rise, while the colder molecules tend to sink.
 Circulation of water then is obtained as the water heated
in the water jacket tends to rise and the water cooled in
the radiator with the help of air passing over the radiator
either by ram effect or by fan or jointly tends to sink.
 Arrows show the direction of natural circulation.

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Forced cooling system
 The system consists of pump, water jacket in the
cylinder, radiator, fan and a thermostat.
 The coolant (water or synthetic coolant) is
circulated through the cylinder jacket with the help
of a pump, which is usually a centrifugal type, and
driven by the engine.
 The function of thermostat, which is fitted in the
upper hose connection initially, prevents the
circulation of water below a certain temperature
(usually upto 85°C) through the radiation so that
water gets heated up quickly.

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Gas Turbine Power Plants
Open cycle Gas Turbine Power Plants
Closed cycle Gas Turbine Power Plants

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 A simple open cycle gas turbine consists of a compressor, combustion chamber

and a turbine.
 The compressor takes in ambient air and raises its pressure. Heat is added to the
air in combustion chamber by burning the fuel and raises its temperature.
 The heated gases coming out of combustion chamber are then passed to the
turbine where it expands doing mechanical work. Part of the power developed by
the turbine is utilized in driving the compressor and other accessories and
remaining is used for power generation.
 Since ambient air enters into the compressor and gases coming out of turbine are
exhausted into the atmosphere, the working medium must be replaced
continuously.
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GAS TURBINE POWER PLANT

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 Closed cycle gas turbine plant was originated and developed in Switzerland. In
the year 1935, J. Ackeret and C. Keller first proposed this type of machine and
first plant was completed in Zurich in 1944.
 In closed cycle gas turbine plant, the working fluid (air or any other suitable gas)
coming out from compressor is heated in a heater by an external source at
constant pressure.
 The high temperature and high-pressure air coming out from the external heater
is passed through the gas turbine.
 The fluid coming out from the turbine is cooled to its original temperature in the
cooler using external cooling source before passing to the compressor.
 The working fluid is continuously used in the system without its change of phase
and the required heat is given to the working fluid in the heat exchanger.
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Elements of Gas Turbine Power Plants
Compressors
Centrifugal compressor
Axial Flow Compressor

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Centrifugal compressor

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Axial Flow compressor

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Cycle with Intercooler

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Cycle with Intercooler
 In Intercooling a heat exchanger is used to cool the compressor gases at the time
of compression process.
 When the compressor involves the high and low pressure unit in it, the intercooler
could be installed between them to cool down the flow.
 This cooling process will decrease the work needed for the compression in the high
pressure unit.
 The cooling fluid can be water , air. In marine gas turbines the sea water is used to
cool the fluid.
 It is observed that a successful implementation of the intercooler can improve the
gas turbine output.

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Gas Turbine Cycle with different arrangements
Cycle with Reheat

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Cycle with Reheat
 Reheating is applied in a gas turbine in such a way that it increases the

turbine work without increasing the compressor work or melting the
turbine materials.
 When a gas turbine plant has a high pressure and low pressure turbine
a reheater can be applied successfully.
 Reheating can improve the efficiency up to 3 % .
 A reheater is generally is a combustor which reheat the flow between
the high and low pressure turbines.

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Cycle with Regeneration

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Cycle with Regeneration
 Regeneration process involves the installation of a heat exchanger in the gas

turbine cycle.
 The heat-exchanger is also known as the recuperator.
 This heat exchanger is used to extract the heat from the exhaust gas .
 This exhaust gas is used to heat the compressed air.
 This compressed and pre-heated air then enters the combustors.
 Regenerated Gas turbines can improve the efficiency more than 5 % . Regenerated
Gas Turbine work even more effectively in the improved part load applications.

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Combined cycle power plant

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25-10-2018 Comparison between Diesel and Gas turbine Power plant
ITEM DIESEL GENERATOR SET GAS TURBINE GENERATOR SET
Start up time Start up within 10 sec Start up within 40 sec

(Impossible to start within 10 sec)
Efficiency 50 to 70%kW out put of rated capacity If uniaxial, 100% output possible. If biaxial, 70 -
possible 100% output is
possible
Maximum possible 110% load of rated capacity up to No overload capacity
output 1 hour is possible
Indoor outdoor Up to 500kVA class, external installation is Enclosed cabinet type is standard and can be
installation possible. However, over this size, due to installed either as internal or external.
the noise, an enclosed installation is
Roof/basement Due to heavy vibration and the Water cooling is not required, and with only
installation requirement of cooling water, installation slight vibrations, installation on building roof is
of high roof top is not practical. possible.
If installed in the basement, exhaust piping
required is larger than for a similar size diesel
unit
Cold region Insulation to prevent water pipe freezing is With no cooling water, support is simple. Fuel
installation required. Same for fuel oil pipes. pipes however need insulation to prevent
freezing.

Comparison between Diesel and Gas turbine Power plant
Possible fuel types Diesel & "A" type fuel and for Kerosene, Diesel, ship oil, "A"
short operating runs type fuel and LNG are all usable
Cooling water consumption If radiator cooling is used only top up water is Air cooled system.
required. If cooling water is used a large scale No cooling water is necessary.
water resevoir is required.
Cooling water Several major equipments related No cooling water
equipment required to the cooling system are required facilities/equipment are required
Air in take required With the increase in size, the air intake In comparison to a similar size Diesel
increases in direct proportion. unit, the amount of air intake is
much smaller.
Ventilation required With the increase in size, the amount of In comparison to a similar size Diesel
ventilation increases in proportion. unit, the amount of air intake is
much smaller.
Comparison between Diesel and Gas turbine Power plant
Exhaust required Smaller than for the gas turbine Larger than for the diesel
Temperature About 250 About 350

Vibration It is reciprocating facility, and big It is rotary machine, and small
vibration. vibration.
Vibration With anti-vibration device, turn No vibration absorption is
prevention the vibration down. necessary.
requirements
Maintenance/in As facilities construction is simple, overhaul a As facilities construction is complicated,
spection machine is possible at the site. factory rebuilt is necessary.
Overall rating It is advantage that the body is It is advantageous to install gas turbine
inexpensive than gas turbine, and is on the roof as it does not
easy to reserve water. require cooling water though is costs
more than diesel.

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Power Plant Engineering

Module 4- Diesel and Gas turbine Power plants

Diesel Engine Power plant

Power Plant Engineering Dr.Mukesh Sharma

A typical oil engine has:

Power Plant Engineering Dr.Mukesh Sharma

 Supply of coal and water is not available in desired quantity.

It is an excellent prime mover for electric generator capacities of from 100 hp

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

 Very simple design also simple installation.

Power Plant Engineering Dr.Mukesh Sharma

High Maintenance and operating cost.

Fuel cost is more, since in India diesel is costly.

The plant cost per kW is comparatively more.

The life of diesel power plant is small due to high maintenance.

Noise is a serious problem in diesel power plant.

Diesel power plant cannot be constructed for large scale.

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

 Common Rail System

Power Plant Engineering Dr.Mukesh Sharma

In this system, a high-pressure pump supplies fuel to a fuel header as shown.

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

The various parts of an engine requiring lubrication are;

1. Cylinder walls and pistons.

Power Plant Engineering Dr.Mukesh Sharma

Wet Sump system

Dry sump system

Mist lubrication system

Power Plant Engineering Dr.Mukesh Sharma

Semi pressure system

Full pressure system

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Open cooling system

Natural cooling system

Forced cooling system

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Open cycle Gas Turbine Power Plants

Closed cycle Gas Turbine Power Plants

Power Plant Engineering Dr.Mukesh Sharma

Open cycle Gas Turbine Power Plants

Power Plant Engineering Dr.Mukesh Sharma

 A simple open cycle gas turbine consists of a compressor, combustion chamber

Power Plant Engineering Dr.Mukesh Sharma

Axial Flow Compressor

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Power Plant Engineering Dr.Mukesh Sharma

Cycle with Reheat

Power Plant Engineering Dr.Mukesh Sharma