Classifications of Power Plants Fossil fuel or thermal Coal fired/ oil fired/ gas fired Hydel Nuclear Renewable Solar/ Wind turbines/GeothermalPower Plant Engineering Text Book by P K Nag Power plant engineering by Black and Veatch Boilers: A practical reference by Kumar Rayaprolu Training manual by NTPC, NPTI, BHEL CEGB handbookLeading Industries in India Metal producing industries such as steel making or aluminium making industries Power Plants both captive and utility type Automobile Industries Chemical Industries/refineries Textile industries Equipment making industries such as pumps, turbine, machine tools etc. Electrical equipment & accessories industries for motor, switchgear & controls Aerospace industriesNational Thermal Power Corporation (2020) NTPC Vindhachal 4670 MW NTPC Rihand 3000 MW NTPC Talcher 3000 MW NTPC Sripat 2980 MW NTPC Korba 2600 MW Total 70 power stations with installed capacity of 62,900 MW. 25,000 MW under construction and installation.Power plants need expertise from diverse areas of science and technology Thermodynamics and Heat transfer Fluid mechanics and Fluid machines Metallurgy, welding and heat treatment Solid mechanics and design, specifically pressure vessel design technology (HT, FEM, Fracture Mech.) Electrical machines Rotor dynamics and Vibration Chemistry Control systemsPower plants in India as on Sept. 2013 Total power generation 2,28,722 MW Private sector(Tata Power, CESC etc): 72,927 MW Central (NTPC, NHPC, NPCIL) : 65,733 MW State ( State electricity boards) : 90,062 MW Total generation capacity: 3,70,106 MW in 2020 Recent growth is only through private companies such as Adani, Reliance power etc.Break up of Renewable sources in INDIA (Total 87027.68MW) Sourecs Type Capacity in MW Small Hydro Power 4683.16 Wind Power 37,693.75 Bio-power 10,023 Solar Power 34,627.82All India Installed Capacity was 2,28,722 MW on Sept., 2013 Thermal “Coal: 1,34,388 MW *Gas : 20,380 MW “Oil : 1,199 MW 1,55,969 MW (68.2%) Hydro electric: 39,788 MW (17.4%) Nuclear : 4,780 MW (2.1%) Renewable : 28,184 (12.3%) (Solar, wind, bio-mass) Source: CEALeading power generating states (2013) Maharashtra: 31,934 MW Gujrat: 26,126 MW Tamil Nadu: 20,112 MW Andhra Pradesh: 17,175 MW Uttar Pradesh: 14,079 MW* As per the data published by Central Electricity Authority (CEA), NTPC Korba (2600 MW) in Chattisgarh has emerged as the top performing thermal power plant in India with 97.42% Plant Load Factor (PLF) between April to July 2020. * Further, two 200 MW units, Unit 4 & Unit 1 of NTPC Singrauli in Uttar Pradesh commissioned way back in January 1984 & June 1982 respectively, achieved highest PLF in the country with 99.90% and 99.87% respectively from April to July’20World electricity generation — Coal 40.6% —NaturalGas 22.2% — Hydro 16% — Nuclear 12.9% — Oil 4.6% — Others 3.7%Northern |Western | Southern | Eastern Region Region Region Region Thermal 60,801 85,282 54,510 27,385 Hydel 20,086 7,622 11,775 4,639 Nuclear 1,620 1,840 3320000 |-—- Renewable | 16,868 25,874 42,407 1,497 Total 99,375 1,20,618 112,012 | 33,521 * Total generation capacity: 3,70,106 MW in 2020Break up of overall power generation in INDIA 2020 Generation in MW eens ures in 2013) Thermal 2,30,600 (1,55,969) 62.3% (68.2 %) Hydel 45,700 (39,788) 12.3 % (17.4 %) Nuclear 6,780 (4,780) 1.83 % (2.1%) Renewable Energy 87,028 (28,184) 23.57 % (12.3 %) SourcesGlobal Power Generation ScenarioNuclear Power (2013) USA 1,01,000 MW 30.4% France 63,000 MW 15.6% Japan 49,000 MW 10.4% Russia 24,000 MW 6.2% Germany 20,000 MW 5.1% Korea 18,000 MW 5.4% Canada 13,000 MW 3.3% UK 11,000 MW 2.2% India 4,780 MW 2%Per capita consumption (KWh/year) Canada 16,473 USA 13,246 South Korea 10,162 Japan 7,848 France 7,292 Germany 7,081 Russia 6,486 UK 5,472 China 3,296 India 684* Selection factors for a particular type of power plant* First electricity generation started in Calcutta in 1894, the company is still there today known as CESC (Calcutta Electric Supply Corporation)Common abbreviations NTPC: National Thermal Power Corporation NHPC: National Hydro-Power Corporation NPCIL: Nuclear Power Corporation of India Limited CPRI: Central Power Research Institute CEA : Central Electricity Authority EIA : Environmental Impact Assessment PLF : Plant Load Factor CEGB, EPRI, BEI,fatyoro | 508 clear* Advantages and dis-advantages of each power plant typeLocation is generally unrestricted for thermal plants. Can be any where even away from coalfields. Only thing is that there should be some water source such as river or pond/lake nearby and railway line for coal transportation. Hydel power plants can only be near a dam or high catchment area Nuclear power plant is most restricted in location. It has to be far away from human habitation/cities or villages.Project Cost of Installation for thermal Power plant is 6 crore per MW. It is costlier for hydel and nuclear power plant Project time: 4 years for thermal power plant and at least ten years for Nuclear power plant, six years for hydel plant Social acceptability: It is important for hydel as affected villagers need to be relocated. It is a serious issue for nuclear power plant to convince population staying in near by areas. Fuel cost: Nil for hydel plant. Same for nuclear but availability of quality grade is important. Fuel cost is nominal for thermal power plant, the cost is mainly due to transportation cost.Environment pollution. Nil for hydel, ash particle pollution in thermal power plant and waste fuel disposal problem in nuclear plants. Maintenance problem Almost Nil in hydel power plant, nominal in nuclear but serious problem in thermal power plant due to ash particle erosion and high temperature stresses. Availability: Power is available throughout the year for Thermal and nuclear power plants, but only during monsoon months in Hydel power plants. Same problem is with solar and wind power plants also.Hydel Power Plant No fuel cost, no maintenance and no air pollution Quick start and stop within an hour Can operate at part load Power can only be generated in Monsoon months Location has to be specific and not anywhereGas turbine power plant * Natural gas and oil is used near sea shore oil refineries * Brayton cycle efficiency around 40% * Combustion product is working medium * Noash pollution and maintenance problem is minimum * Capital cost is lower than thermal plant Problem is location and continued availability of gas Maximum temperature is 1000 degree at turbineCoal based Thermal Power Plant Rankine cycle, cycle efficiency max. 44% Combustion product is not working medium Maintenance is high Ash disposal is a big problem and costly Part load below 70% operation is not recommended for efficiency drop and furnace combustion stability problem Can be installed anywhere but preferably close to coal and water sources.Diesel Engine Power Plant Can be installed any where Can start immediately. Quick start and stop Capital cost is lower Easy to meet transient demand spikes Generation cost is high Maintenance is high, Air and noise pollution Generally used as back up power sourceWind Mills Need location where wind velocity is available of the order of 13-40 kmph at 50m height. Capital cost is high No fuel cost, maintenance is minimum. But generation fluctuates with wind speed variation. Best for local use and not fit for grid power.Nuclear Power Plant High capital cost, project time is long, nearly 10 years and social acceptance of site. Safety problem as an accident can be very very dangerous (Chernobil in 1986, Fukiyama in 2012) Waste fuel disposal problem Availability of fuel grade uranium or thorium Generation cost is nominal Maintenance is less than thermal power plant. Large power plant at one siteNuclear Power Plants in INDIA Rajasthan Atomic Power Plant (RAPP) KAIGA in Karnataka Kalapakkam near Chennai Narora in UP Kakrapar near Surat Tarapore near Mumbai Kudankulam in Tamilnadu near KanyakumariSolar power plant * No fuel cost, minimal maintenance and no air pollution ¢ High capital cost and power can be generated only in daytime.Abbreviated terms ¢ Abbreviations are very common in Power Plants. There are more than 100 abbreviated terms commonly used by Engineers. In interview such terms are often asked like what do you mean by TTT. * Let us get acquinted with some common abbreviations. Many more will come during future discussions*A SHORT OVERVIEW OF THERMAL POWER PLANTSPower plant rating Less than 25 MW Stoker fired boiler 25/30 MW Pulverised Fuel fired boiler 60/67 MW PF fired 110/120MWw PF fired 210/230 MW PF fired 500 MW PF fired/CFB boiler 660 MW Supercritical with CFBC 1360 MW Supercritical with CFBC For nuclear power plants ratings are 250 MW, 500 MW, 1000 MW etc.QUESTION? What is critical pressure and temperature for water to steam conversion When a boiler is called super critical? Why we don’t require a boiler drum in super critical boiler? Coal fired power plants can not be near by of an airport why? Why most of power in Maharashtra is generated around NagpurT. Tuer Neycle = 3600 Heat Rate = —— kJ/KWh n 3600 Steam Rate = kg/KWh netAbbreviation used in power plants TIT : Time Temperature Turbulence FSSS: Furnace Safety Supervisory System CHP APH ESP CBD BFP FGD ESV MOP AOP TDF TTD IGV NDCTIncrease superheat * It has the advantage that turbine last stage steam quality improves (quality is close to 1) * But we can not increase superheat as much we want, why? 4 te. How to increase cycle efficiency? Te Ter Neycle = a) Increase mean effective temperature i) Increase super heat ii) Increase boiler pressure iii) Add reheater iv) Add regenerative feed water heater b) Decrease condenser temperatureRankine Cycle Mean Effective Temp. of Heat addition (Tmer) Neycle = 1- Tyer* CEA has recommended heat rate norm for 200MW-500MW units in INDIA as 3600 kj 3600 kCal Heat Rate = = ar Nplant KWh 4.17 * Nplant KWh * 0 - 10 years: 2515 kCal/kWhr * 10 - 20 years: 2540 kCal/kWhr * Above 20 years: 2670 kCal/kWhr* Boiler efficiency is net heat added divided by product of fuel mass flow rate and Higher Heating Value (HHV) _ Net heat added Tit x HHV * Plant Efficiency = Cycle efficiency (39-44%)* Boiler efficiency (88-92%)*Turbine efficiency (92- 95%) *generator efficiency (95%) . = 1/heat rateIncreasing boiler pressure * Disadvantage: Turbine expansion in last stages are in low quality zone, less than recommended value of .9. Why this is considered as a serious disadvantage? * This disadvantage is overcome by adding reheaterThermal power plants uses modified Rankine cycle Increase in superheat Condenser in vacuum Increase in Boiler pressure Introduction of reheater Introduction of regenerative feed water heatingIncrease in superheat * Mean effective temperature of heat addition increases and thus efficiency increases. * Higher superheat temperature requires special steel material (chrome molybdenum alloyed steel, which can withstand 540 degree). This temperature is often called metallurgical limit temperature of steel. At high temperature steel fails by creep and creep resistance is given by Chrome molybdenum alloying. * Heat transfer in superheater is most challenging as both the media are in gaseous phaseIncrease in Boiler pressure * Mean effective temperature of heat addition increases and thus efficiency increases. * But turbine exhaust stages are in more wet zone bad for blades due to moisture droplet impinging and resulting metal loss. * High pressure means better design of tubes and pressure partsWhat should be re-heater pressure? * Ina power plant cycle, boiler pressure is 150 bar, superheat temp is 500 degree and condenser vacuum is 0.1 bar absolute. Find efficiency of simple cycle. * Find efficiency with re-heater for re-heater pressure at 120 bar, 90 bar, 60 bar, 30 bar and 20 bar. * What do you learn from these efficiency values ?We have already pointed out that superheat is limited to 540 degree. Similarly boiler pressure also is not recommended above 160-170 bar why? The increase in mean effective temperature is not significant Higher boiler pressure increases tube failure chances Natural circulation does not work, forced circulation has to be provided.Metallurgical temperature limitation of Steel * Carbon steel 350 degree * Chrome-molybdenum steel 540 degree * What is the name of material property that is improved by Chrome molybdenum steel?Rankine cycle with Re-heaterIncreasing condenser vacuum It means decreasing absolute pressure inside condenser which is well below gauge pressure of 1 ata (760 mm of Hg). Condenser vacuum is often given in terms of mm of mercury (it is usually kept at 76mm Hg = 0.1 bar abs.). But increasing vacuum means decreasing turbine last stage steam quality, which is not good.ey 10 a ae 09 | 427 3 8 | 316 5 0.7 (205 3 S shit i 0 a2)| 4 ag yor | ee) 2 G3 | le | B 0 01 02 03 04 05 06 07 08 09 10 & Reheat pressure/initial pressure (mn!) * Pic taken from Text book by P K NagIntroduction of Reheater * It increases turbine exhaust stages steam quality ( should not be less than .9). Hence high boiler pressure can be adopted. * Increases mean effective temperature of heat addition and efficiency * More turbine work is done from same steam flow. Steam rate improves.In a Rankine cycle with reheater, boiler pressure is 162 bar, superheater outlet and reheater outlet temperature both are 540 degree. Condenser vacuum is 0.1 bar absolute. Find the cycle efficiency for following reheater pressures i) 20, 40, 50, 60, 80, 100 bar ii) 25, 35, 45, 60,90,120 bar iii) 30, 45, 55, 70, 100 , 120 bar lv) 20, 35, 45, 55, 80, 100 bar Then draw cycle efficiency Vs reheater pressure curve and find which pressure gives highest efficiencyRegenerative Feed water Heating * Increases efficiency, but also increases steam rate, which needs bigger boiler for same power generation. * High capital cost. * Todays power plants employ six to seven regenerative heater6.2": Hg Vey 2 Sea “ ers mn BEES 3 38 & 36 = 470°C 0 20 40 60 80 100 120 140 160 py bar & 2.14 Effect of inlet steam pressure (p;) and condenser on Rankine efficiency with constant inlet steam of 470°C me : Pic taken from Text book by P K Nag* Re-heater increases cycle efficiency and also reduces specific steam consumption (kg/sec per kW) or (ton/hr per MW). * However, It needs additional space in boiler, boiler becomes bigger. Additional high pressure piping from turbine back to boiler and again back to turbine. This requires advanced piping engineering design. This pipe line also introduce pressure loss.Regenerative feedwater heatingRegenerative feedwater heating increases cycle efficiency but also increases specific steam consumption. It reduces condenser loading as all steam does not go to condenser But feedwater heaters are very costly. The additional cost must be offset by improvement in efficiency.* How vacuum is created and maintained in a condenser? * We can not decrease condenser pressure below 0.1 bar why? * Why cycle efficiency varies from summer to winter?Three modes of heat transfer (feed water to steam) Feed water is ultra pure, it is demineralised. Cooling water for condenser and oil cooler is chemically treated but not demineralised Sensible Heat: Regenerative feed heater, Economiser Latent Heat: Riser tubes/water wall tubes inside boiler furnace Super heat: Primary superheater, Secondary super heater, Reheater As boiler pressure goes up, sensible heat and super heat proportion increases but latent heat proportion decreasesDuring 1950s, unit power generation was around 30 MW, during 1970s it increased to 210 MW, during 1980s it became 500 MW and during 2005 it grew up to 660 MW. What is advantage of bigger unit size? ¢ Advantage * Boiler efficiency increases * Project cost/MW decreases, generation cost/MW decreases * Land area required/MW decreases * Operational and maintenance cost/MW decreases * Disadvantage of big unit size * If demand is insufficient, there will be loss and furnace combustion problem in running at part load