Professional Documents
Culture Documents
LTD
GENCO-
GENCO-II
BY
KHALID AYAZ SOOMRO
INSTRUCTOR (INTERN ENGINEERS)
TPS, GUDDU
PRINCIPLE OF FIRE
1. Oxygen
2. Fuel
3. Heat
The flash point indicates how easy a chemical may ignite and
burn
FUEL
Fuels are any materials that store potential energy in forms that can
be practicably released and used for work or as heat energy.
OR
Types of Fuels
Ordinary combustibles
(e.g. trash, wood, paper, A Water; chemical foam
cloth)
Flammable liquids
Carbon dioxide (CO2); dry
(e.g. oils, grease, tar, B
chemical; film forming foam
gasoline, paints, thinners)
Electricity
(e.g. live electrical C CO2; dry chemical
equipment)
Dry powder (suitable for the
Combustible metals
D specific combustible metal
(e.g. magnesium, titanium)
involved)
Combustible gases
E A.B.C powder
(e.g. Natural Gas, Butane)
Combustible Cooking
Wet chemical (Potassium
(e.g. cooking oils; animal F or K
acetate based)
fats, vegetable fats)
Ensure you remain a safe distance from the fire and remove the
safety pin
Fire spreading vertically: Aim the hose at the base of the fire, slowly
moving the jet upwards following the direction of
the fire
Squeeze the lever slowly to begin discharging the extinguisher, as the fire starts
to diminish carefully move closer to it.
Ensure all the fire has been extinguished; try to focus on any hot spots that may
re-ignite.
1. Starvation
2. Smothering
3. Cooling
Starvation
Removing fuel from fire triangle is called elimination of fire starvation.
Smothering
Removing oxygen from fire triange is called smothering
Cooling
To decrease the temperature of fuel from ignition point is called
cooling
PRECAUTIONARY MEASURES
DUTIES OF WORKERS
All employees should follow safety rules and always try best to avoid
redundant situation regarding his own and other co-workers.
SAFETY CODE
The safety code contains all information and guideline to restrain
from accidents during job and further if any accident take place
then how the aftereffect can be minimized. Thus, safety code is used
to minimize the risk of accident for example: safety tags etc.
SAFETY FUNDAMENTALS
There are two major rules of safety
GOOD OPERATION
Good operation means to take necessary measures to safe
operation of all appliances at industry i.e. If you have to work on
breaker then it should be isolated, check its isolation and connect a
earth lead. The worker should take serious efforts on the following.
1. Missing Warning Sign.
Without warning sign any work on equipment can be very
dangerous and severe damage to life and equipment can take
place.
2. Improper Guarding
During work all safety gears should be wear i.e. gloves, safety shoes,
safety goggles etc.
3. Defective Material
Before starting work proper tools and safety gears should be used to
avoid any accident. It should be ensured that tools are made in
accordance with international laws and they have not been broken
nor have bad workmanship quality.
Causes of accidents
1. Hazards
Everything which came under hazards is dangerous. i.e. oil leakage,
cotton rags, and bad sanitation.
At work place harmful gases should not be gathered i.e. acid vapors
and dust. Thus, proper ventilation of air should be ensured.
4. Loose Cloths
SAFETY GEARS
Safety gears are used as prime substance to ensure safety to worker.
Thus, before working on electrical system this should be checked
and ensure according to rules and regulation of department.
1. Safety Helmet
It protect worker from head and eye injury, further it protects from
heat stroke and dust. Thus, this should be wear during work hrs.
Safety equipment
This protect human ear from excessive noise a work place which can
damage hearing efficiency. Normal noise level is 85~90db. Thus if the
noise exceed from above the ear muffs should be used.
3. Safety shoes.
5. Respirator mask
This should be wear, where industrial exhaust i.e. stacks or where any
other dangerous gases contacting human body. If respirators are
not used that this will bring deceases like i.e. chest infection and
allergies during respiration.
7. Safety gloves.
This safes the worker from fall down from height. Thus during work on
electrical pole or any place alike that, safety belt must be used.
Safety shoes
During welder a vital sparking light may cause an injury to eye. Thus,
to restrain such type of injury protection shield must be wear before
welding.
Faraday's iron ring apparatus. Change in the magnetic flux of the left
coil induces a current in the right coil.
The first public power station was the Edison Electric Light Station,
built in London, which started operation in January 1882. This was a
project of Thomas Edison, it was called JUMBO.
Energy Cycle
In water tube boiler, boiler feed water flows through the tubes and
enters the boiler drum. The circulated water is heated by the
combustion gases and converted into steam at the vapor space in
the drum. These boilers are selected when the steam demand as
well as steam pressure requirements are high.
In fire tube boiler, hot gases pass through the tubes and boiler feed
water in the shell side is converted into steam. Fire tube boilers are
generally used for relatively small steam capacities and low to
medium steam pressures.
Radiation zone:
Heat transfer takes place by radiation from the yellow flames. This
zone is located in the bottom and middle portion of the furnace
(1200~1400 0C). It consists of combustion chamber, water wall and
radiant super heaters.
Page : 33 of 105
PARTS OF BOILER
01 Boiler Drum
02 Boiler Furnace
03 Super Heaters
04 Re-heaters
06 Water economizer
09 Calorifier
10 I.D. Fan
11 F.D Fan
12 Chimney
15 Down comers
04 Contains pressure
DRUM INTERNALS
Baffle plates
OR
It converts feed water into small particles and when it passes through
feed water it separate rust & unsolvable gases which may remove
through boiler vent.
Steam Washer
Steam purifier
Steam Scrubber
Cyclone
Discharge lines
Flue Gases
During burning of fuel some gases are expelled which are called flue
gases.
Burners
Burner is a device, which helps to ignite fuel with the help of air. This
device is used for proper firing. Burner is a prime source to set right
the fuel and air mixture, pressure and firing location. Burner is also
called boiler operating parameter due to its importance for
calculating boiler efficiency.
1. De-super heater
a. Atompration
b. F.W injection
2. Gas recirculation fan
3. Fuel increased / decreased
4. Air flow control
5. Tilting of burner position
6. Soot blowing
7. Shot blasting
Re-
Re-heaters
Re-heater can also be termed as super heater. They can also be
called as intermediate super heaters. These are installed in flue gas
duct. The get heat through flue gases and rises wet steam
temperature. There is no temperature different in re-heater or super
heater. However due no decrease in steam pressure it is called re-
heater. The pressure decreases due to line resistance.
Duties of re-heaters
Tubes that come downward from boiler are called down comers.
These are located in unheated zone. They contain feed water.
Further due to less temperature of feed water it become heavy
comparison to steam, thus natural circulation of water occurs. The
feed water enters in boiler drum lower header. This is also called
thermal circulation of feed water.
Up riser
Duties of economizer
1. It increase the temperature of feed water
2. Receives heat from flue gases
3. Lower the temperature of flue gases
4. Reduces the size of boiler
5. Increase the efficiency of boiler upto 1% in terms of fuel
consumption
6. It is water heat recovery device.
This fan is installed in the 2nd zone of boiler, however sent the flue
gases to 1st zone from this cold reheat steam converts into hot reheat
steam and further increased the temperature upto 540 0C. This
steam is used in IP turbine. The GRC fan is only used whenever reheat
temperature did not arise.
Heating combustion air can raise boiler efficiency about 1% for every
40F in temperature increase. The most common way to preheat the
air is with a heat exchanger on the flue exhaust.
Air pre-heater is installed into flue gases duct. The heating element
get heat from flue gases and passes it to the air going into furnace,
so that temperature of combustion air increased. This helps for
proper fuel burning.
This is also called steam air heater. When the machine is operating of
fewer load, this device is used to increase the temperature of flue
gases to ensure not getting dew point in air pre heater and as well in
stack.
Duties of calorifier
Duties of ID Fan
1. It suck flue gases from furnace
2. It provides zero pressure in the furnace. (it slightly operates on
negative pressure)
3. The temperature of flue gases when exit from chimney should
not less than 150 0C
To generate steam several boiler use fuel as coal, gas, oil etc. When
firing occurs due to higher viscosity value of fuel comparison to air
some un-burnt particles remains and further deposit on the boiler
tubes is called soot.
The soot restrains heat transfer and to tackle this soot blowers are
installed, so that flue gases transfer maximum heat to superheater,
economizer and re-heaters etc. Further to improve the heat transfer
either steam or feed water tubes.
1. Water surface
1. Economizer 100%
2. Boiler drum partially
3. Down comers 100%
4. Generation tubes partially
(i) Heat stays in the flue gases path for maximum possible
time.
(ii) Different compenets placed in the flue gases path
absorb heat from the flue gases.
Natural draught
When the draught is generated with the help of the chimney only, it
is called natural draught.
OR
When air or flue gases flow due to the difference in density of the hot
flue gases and cooler ambient gases. The difference in density
creates a pressure differential that moves the hotter flue gases into
the cooler surroundings.
Artificial Draught
The draught produced by mechanical means like fans and blowers
is called artificial draught. Artificial draught is required because
natural draught will not be sufficient to generate enough static
draught (25 to 350mm of water column) as is quired by large steam
generation plants. Moreover natural draught depends upon climate
conditions.
Induced draught: When air or flue gases flow under the effect of a
gradually decreasing pressure below atmospheric pressure. In this
case, the system is said to operate under induced draught. The
stacks (or chimneys) provide sufficient natural draught to meet the
Balance: With both F.D and I.D fan whne used simultaneously
The F.D fan will supply the combustion air for proper and complete
combustion fuel and will overcome the fuel bed resistance I the
case of stoker grate.
The I.D fan will remove the flue gases in addition eliminate excess air
from the furnace , maintaining the pressure inside the furnace just
below the atmospheric pressure (slightly negative)
Boiler protections
• Loss of flame
Power
Plant
Types of CCPP
• Unfired CCPP
• Additional fired CCPP
HRSG
It is also called waste heat boiler (or) waste heat recovery steam
generator
The temperature of exhaust flue gases from gas turbine is 540 0C. This
has HHV higher heating value and thereafore these gases are used
in HRSG instead of ruined in atomopsheric air.
Arrangement of HRSG
1st of all super heater has been installed in HRSG to attain maximum
heat and to convert saturated steam into superheated steam,
thereafter evporator tubes are installed therein feed water converts
into saturated steam and in final stage economizer has been placed
therein feed water temp increased upto 250~270 0C.
Parts of HRSG
1. Feed water gate and regulator valve
2. Economizer
3. H.P Drum
4. Evaporator re-circulation pump
5. Evaporator
6. Super heater
7. By-pass damper
8. Isolation Damper
9. Weather damper / stack damper
Protection of HRSG
1. Drum level low low
2. Drum level high high
3. Live steam temperature > 540 0C
4. Evaporator circulation pump tripped.
5. G.T Tripped
6. HP Bypass station tripped
7. G.T flue gases pressure high (50mbar alarm…. 70 mbar trip)
8. Vacuum low
9. Pressure rising OR dropping at the rate >4 bar min (ramp rate)
Gas Turbine
Gas Turbine is the machine which converts hot gases kinetic energy
into mechanical energy or gas turbine is the device which operates
on hot gases energy. Gas Turbines are made with the special
material that can endure high heat.
1. Filter House
2. Axial Flow Compressor
3. Combustion Chamber
4. Gas Turbine
Filter House
It consists of 1200 approx. air inlet filter which cleans atmospheric air
for compressor. These filters are cartridge type and their use full life is
around 2 years further due to these air inlet filer hard particulars
cannot penetrate into compressor.
Gas turbine
Gas Turbines are operated on hot gases pressure. These hot gases
have been attained from combustion chamber. The temperature of
these gases on turbine inlet is 1060 0C. However on the outlet their
temperature decreases upto 540 0C. Gas Turbine is the main part
which converts heat energy into mechanical energy, so that
electrical output can be received.
Casing / cylinder
The casing contains rotor, blades, seals and bearings. All articles of
turbine contained in casing. This prevents to enter air and other
things this casing also balance the heat. This is also called stationary
part of turbine.
Turbine Rotor
This is rotational parts of turbine. Moving blades are installed in rotor
and their fuction is to rotate turbine rotor, so that generator rotor
may also accompany during rotation.
Shaft
Turbine blades are affixed on shaft. If HP, IP, LP rotors are coupled it is
called shaft.
Seals
Turbine seals are used where leakage of air or steam can occur. Due
to turbine improper sealing vacuum can be loss because LP has
works under negative pressure and that why air tries to enter in LP
turbine.
Types of sealing
1. Stuffing boxes
2. Carbon ring packing
3. Labyrinth seal
4. Water glands
These are also called diaphragm blades and their prime function is
to divert the steam toward moving blades. Steam pressure is much
higher on fixed blades as compare to moving blades. Hence they
divert high pressure steam to moving blades.
These are installed on the rotor surface and high pressure steam hits
them and movement starts. This rotates the turbine on constant
speed.
1. Reaction type
2. Impulse type
Impulse Turbine
Pressure drop & velocity increases in curtus wheel stage after this
pressure works in constant position (some lose) and velocity
decreased in every moving blade. In gas turbine 75% energy and
pressure used on 1st stage and the remaining i.e. 25 used on 2nd
stages.
These are also called emergency stop valve. Their prime function is
to protect the turbine in the event of emergency initiated through
protection system. These valves are also called protection operated
valves. These valves operate on hydraulic system.
F= p x n / 120
• Check vlv or non-return vlv, allows the fluid to pass in one direction only.
• Plug valve, slim valve for on/off control but with some
pressure drop.
• Sampling valves
• Safety valve
General Bearings
1. Upper half
2. Lower half
Thrust bearing
When turbine stops rotating then there is a vital chance that upper
half will be hotter than lower half casing. Thus, if shaft stops rotating a
difference will occur in-between upper and lower half of turbine
casing this will lead to shaft sag or bend. Thus, to prevent from sag
and bend turning gear rotates the shaft slowly on constant speed, so
that the temperature of shaft remain equal on both side i.e. upper
and lower half of turbine casing.
Kinds of gear
Supr gear
Helical gear
Bevel gear
Worm gear
Rack gear
Coupling
Kinds of coupling
Rigid coupling
Hydraulic coupling
Flexible coupling
Magnetic coupling
Jaw coupling
Spider coupling and SSS coupling
Bucket trap
Expansion trap
Float trap
Thermostatic trap
Tilting trap
Kinds of relays
Instantaneous relay
Electrostatic relay
Electromechanical relay
Time delay relay
Oil System
There is three kind of oil systems are used in thermal power plants.
This system is used to lubricate the bearing and has low pressure.
Another oil system is used for sealing of generator which has medium
pressure and the third one is control oil which is usually high pressure.
This pump operates through directly from turbine shaft. This provides
bearing lubrication and hydraulic pressure to governing system. In
big machine some centrifugal pumps are installed because their
discharge pressure is much higher, however priming shall be carried
out before taking into service.
This pump supply oil to turbine during startup and shutdown. This
pump has been installed over main oil tank.
The AC auxiliary pump is coupled with the turbine main oil pump,
however it decreases the discharge pressure for generator seals on
rare and front ends. When AC supply fails the DC lube oil pumps
starts automatically, so that hydrogen can’t expel or to prevent
hydrogen sealing.
Oil Coolers
Lubrication oil attains heat when gone through the bearings, thus to
decrease the temperature of lube oil “oil coolers” have been
installed. When hot lube oil passes through these cooler its
temperature become decreased.
1. Vacuum loss
2. Lube oil pressure low
3. Turbine bearing vibration high
4. Turbine over speed
5. Axial displacement
6. Minimum level of hot well
7. Maximum level of hot well
8. Relative expansion differential expansion
9. Wet steam protection
10. Lube oil temperature
Function of Condenser
Cleaning of condenser
1. Back washing
2. CW reverse flow partially
3. Brushes
4. Plugs
5. Rubber balls
6. Hard deposit removed by chemical treatment
7. Jet washing
Condensate Pump
These pumps take water from hot well and sent to feed tank through
LP heaters.
L.P Heaters
The condensate water flow into the tubes and gain heat from
bleeding steam and resultantly bleeding steam got condensate. This
condensate is supplied to hot well or feed tank.
Deaerator
This has been installed over the speed tank. Its prime function is to
remove non-solvable gases from condensate water. This has been
energized by using bleeding steam. A pipeline with small holes have
been installed wherefrom feed pump fall in shape of drops. The
baffle plates are inside under the pipe on which waterfalls.
Therefore, non solvable gases get eliminated and water emerges
into bottom of feed tank.
This has been installed under the deaerator. The condense sate
water is collected here without any gases. This water is also called
boiler feed water.
Feed Pump
This feed pumps drive water from feed tank and supply it to boiler
drum through H.P heaters and economizer
H.P Heaters
The feed water passes into tubes and take heat from bleeding
steam. In this process bleeding steam got condensed and heated
water goes toward feed water. The main aspect of H.P heater is to
improve turbine efficiency and to supply hot water to boiler drum.
This saves fuel consumption.
Condensate Cycle
Each unit has 03 feed pumps. Two remain in operation while the 3rd
one is on standby position.
The steam get out through super heater no. 4 and enters into HP
turbine at that time its pressure is 130 kg/cm2 and temperature is 540
0C and after exiting from HP turbine it becomes 370 0C with 32
Advantage of extractions
Alternator
Turbo Generator
Synchronous Generator
Synchronous Condenser
Parts of Generator
Stator
This is stationary part of generator and stator winding is nested in it,
this is coupled through bus bar to system.
Frame
Bearing
The bearing share load of generator rotor and prevent from excess
radial movement.
Exciter
This device supplies DC current to rotor, so that the generator can
work on the law of electromagnetic.
The rotating part is called rotor and stationary part is called stator.
Generator rotor field winding is energized through DC supply which is
called excitation this produce magnetism to rotor thus it generates
magnetic flux. When generator rotor starts rotating it cut then stator
winding reacts by cutting the flux.
This product Electromagnetic flux. The EMF excites the electrons for
movement and a flow of electrons starts. So, it is called terminal
voltage or generator voltage. This excitation plays main role for
generating voltage in generator i.e. 11kV, 15.75kV or 20~30kV.
Generator protections
1. Generator differential protection
2. Generator over current protection
3. Stator earth fault protection
4. Rotor earth fault protection
5. Under excitation protection
6. Reverse power protection generator motoring
7. Negative phase sequence protection… system unbalance
8. Over / under frequency protection
9. Breaker pole failure protection
10. Synchronous check protection “When you system supply is
dead and you are the 1st one in the system.. no need of
synchronization”
11. Over excitation
The coil in which the current is supplied called “Primary coil” and the
receiving coil is called “Secondary coil”. The transformer can be step
up or step down. Transformers are used to reduce of improve the
generator voltage which is further supplied to system.
Parts of Transformer
Buchhloz relay
Differential relay
Transformer Protection
Bus-bar
These are connecting bar which are connected to various local and
distribution feeders and also intact with supply sources.
OR
Those conductors that receive source supply and distribute to
different lines.
Bus Coupler
Double bus scheme, where two bus bars are installed a provision of
bus coupler has been provided. Therein a bus coupling circuit
breaker with two isolators is called bus coupler. Its prime function is to
substantiate the supply on any bus bar without disconnecting with
system.
Feeder
The feeder is used to connect the electricity to consumer. This has
vital role is power system
CT/PT (Current and potential transformer)
These are also called instrument transformer. These are used to
measure voltage and current of different high voltage lines.
Power Transformer
These are used for set up and set down of voltage
Breaker
This is an on load switching device. This can be opened or closed
while sharing load.
Lightening arrestor
A lightening arrester is a device to protect electrical equipment from
over-voltage transients caused by external (lightning) or internal
(switching) events. Also called a surge protection device (SPD) or
transient voltage surge suppressor (TVSS),
Importance of DC supply
1. Rectifier
2. Battery charger
3. Battery cell 24VDC or 220VDC
Kinds of batteries
Note: The charge battery has 11% water and 89% sulphuric acid and
when it discharged it become 15% sulphric acid and 15% water.
Parts of battery
Battery is consisting on many cells and each cell has negative and
positive plate. Thus more cells produce more current. The battery
power has been measured in Amp/hr.
Parts of battery
1. Plate
2. Group
3. Element
4. Separator
5. Cell connector
6. Vent plug
7. Body
8. Electrolyte
Structure
There a fan on the top of each cell of cooling tower and below the
fan (fiber) water tubes are placed which convert the water into
small particles. The titling edges are lay down on the side wall of
each cell which prevent the water from fall outside the basin. The
fan through the air outside the tower fan assembly and from this
action the process of evaporation or removing heat from water
occurs.
The water in the basin of each cell is called pit (hot basin) and
thereafter connected to cold basin (C.W pump suction). This cold
basin water is re-circulated through C.W Pumps. During this process
3% loss occurs which has been compensated / makeup through
tube wells.