Coal-Fired Thermal Power Plant

Coal Fired Thermal Power Plant
Systems and Operation
Presented by: Jonas Belitor, ME, MEng

Objectives For Today
To have a basic idea on Coal Fired Thermal Power Plants
Be able to identify the basic systems that comprises a Coal Fired Thermal Power Plants
To have a better understanding of the operations of a CFB power plant.

Course Outline
I. Coal Fired Thermal Power Plant
A. Basic Concepts on Coal Fired Thermal Power Plants
B. Coal Fired Thermal Power Plant Systems

1. Boiler Systems
2. Turbine Systems
3. Material Handling System
4. Balance of Plant
C. Functions and Basic Operations
3
Basic Concepts
4
History of Coal Fired Thermal Plants
The first coal fired power

plant was constructed in
London in 1882 by
Thomas Edison’s Edison
Electric Light Company
Holborn Viaduct Power

Stations
5
Worldwide there are over

2,400 Coal Fired Power
totaling over 2,000
Gigawatts in capacity.
Coal Fired Power Plant

generate about a third of
the World’s electricity
6
Jackson RB, et al. (2022). "Global fossil carbon emissions

rebound near pre-COVID-19 levels"
7
Philippine Energy Situationer
Installed Generating Capacity, by Source in MW
Excerpt from : Department of Energy KES
8
Installed Generating Capacity, by Source in MW
9
Power Generation, by Source and Grid in GWh
10
Power Generation, by Source and Grid in GWh
11
Philippine Coal Production, by Source in MMT at 10,000 BTU/lb
12
Coal Importation, by Country of Source in MMT at 10,000 BTU/lb
13
Known Coal Fired Thermal Plants in the Country
List of existing coal-fired power plants in the Philippines(Greenpeace.org, 2016)
14
Known Coal Fired Thermal Plants in Mindanao
GNPower Kauswagan, a 4x154 MWg PC Coal Fired

Power Plant
15
FDC Misamis Power Corporation- a 3x135 MWg CFB

Coal Fired Power Plant
16
STEAG State Power Inc., a 2x105g MW PC Coal Fired

Power Plant
17
SMCGP Malita Power Plant – a 2x150 MWg CFB Coal

Fired Power Plant
18
What is a Coal Fired Thermal Plant?
Coal power plant is a thermal

power station which burns coal to
generate electricity.
19
Coal Power Plant as a Venue of Energy Conversion
Chemical Kinetic Mechanical Electrical

Energy Energy Energy Energy
Coal Steam Turbine Generator
20
Coal Power Plant as a Venue of Energy Conversion
Carbon/Energy Content of Coal High
High Moisture Content of Coal
Low Rank Coal High Grade Coal
Largely power Power generation Power generation Manufacture of Domestic/industrial

generation Cement manufacture Cement manufacture iron and steel including smokeless
Industrial uses Industrial uses fuel
21
Ranks of Coal
 Lignite Coal
 Is the youngest form of coal;
 coal with least carbon ;
 high ash and moisture content &
low heating value
 Sub-Bituminous Coal
 Coal has a higher HV than Lignite, typically contains 35-45%
carbon, compared to 25-35% for lignite, at least 100 million
years old.
 best suited for use in steam generators due to abundance and
low cost
 Anthracite Coal
 it is the hardest coal;
 very slow to ignite, but burns very bright at
a high temperature.
 Contains 86-97% carbon, and has the highest HV among coal.
22
Coal Power Plant and the Rankine Cycle
23
Coal Power Plant in Simple Process Diagram
Turbine Generator
Boiler Steam
Coal Electricity to Customers
Silo
COAL Condenser
Cooling Water Line
Feed Water Seawater
BOILER FEED Demi Water Tank

PUMP CONDENSATE PUMP
24
Coal Power Plant in Simple Process Diagram
If a power plant is
basically this simple why
are complex plants built? C Y .
I C IEN
sEFF
e r i
e answ
Th
What is Efficiency?
Ideally, the objective is

to produce the most
kilowatt-hours of
electricity with the least
amount of fuel.
25
PC vs CFB
1.1.2 Difference Between PC Boiler and

CFBC Boiler
Pulverized Coal Plant (PC) Circulating Fluidized Bed

Boiler Coal Plant (CFBC) Boiler
26
PC vs CFB
1.1.2 Difference Between PC Boiler and

CFBC Boiler
Circulating Fluidized Bed

Pulverized Coal Plant (PC)
Coal
Boiler
Plant (CFBC) Boiler
1. Smaller Coal size (below 5 mm)
2. Operating furnace temp around 1400 1.Bigger Coal size (10 mm above)
-1600 C 2.Operating furnace temp. around
3. Employs Secondary Gas Desulfurizer 800 – 950 C
(SGD) to neutralized SOX 3.Uses limestone injection at
4. Uses pulverizer furnace to limit SOX
4.Uses cyclone separator to
circulate unburnt coal
27
Systems
28
Coal Power Plant Systems
29
Coal Plant
Boiler System Turbine System MH System BOP System
30
Boiler System Turbine System MH System BOP System
1. Air and Gas

System 1. ST Lube Oil System 1. Coal Handling 1. Water Treatment
2. STEAM and 2. Jacking Oil System System System
WATER System 3. Rotor Train Monitoring 2. Oil Fuel Hadndling 2. Air Compressor
3. Fuel System System System System
4. Soot Blower 4. Control Oil System 3. Bottom Ash System 3. Wastewater System
System 5. Gland Sealing System 4. Limestone Feeding
5. Boiler Blowdown 6. LP Hood Spray System System
and Drain System 7. Turbine Drain System 5. Fly Ash System
8. Vacuum Breaking
System
31
Boiler Systems
32
Air and Flue Gas System
1. Air and Flue Gas System
Primary and Secondary Air Fan extract air from the

environment to be used for combustion. Air enters the
Air Preheater to increase temperature and efficiency
then goes to the furnace for combustion.
HP Blowers fluidized the seal pot to maintain circulation
of the bed materials back to the furnace.
Combustion of air-fuel (coal) takes place at the furnace
and flue gas exchange heat energy with the tubes.
Exhaust Flue gases from backpass passes though the
Electrostatic Precipitator (ESP) to remove dust.
33
1. Air System
FAB
PRIMARY AIR FANS (PAF):

2 x 50%
Centrifugal Type
SECONDARY AIR FANS (SAF):

2 x 50% SAF & PAF
Centrifugal Type
FLUIDIZING AIR BLOWERS (FAB)

3 sets
Constant Volume Type
34
1. Air System
35
1. Flue Gas System
INDUCED DRAFT FANS

(IDF):
2 x 50%
Centrifugal Type
Variable Frequency Drive
Option or Damper Control
ELECTROSTATIC
PRECIPITATOR (ESP):
1 set, 120m
Double Chamber and Four
Field Type
36
37
Steam and Water System
2. Steam and Water System
The system covers up the steam production thru boiler and
water usage of the boiler.
Water enters the boiler steam drum through economizer

and circulates to the evaporator tubes naturally (natural
circulation). Saturated steam leaves the drum to be further
heated to the superheaters and to be used by the HP turbine
Exhaust steam by the HP turbine is reheated back to the boiler

reheater to be use again by the IP/LP turbine.
38
2. Steam System Steam – working fluid of the system
Provides high temperature and high
pressure good quality steam to the
Turbine at a rated steam capacity
Steam is superheated to expand
isentropic process at the turbine
Equipped with Primary SH
Desuperheater (for coarse control),
Secondray SH Desuperheater (for
fine tune temperature) and Reheater
Desuperheater (for transition and
emergency)
PROCESS OVERVIEW:
Steam Drum – Backapass four
Wall Corners SH– Middle Wall
SH – Wingwall LT SH –
Wingwall MT SH – Final SH –
HP Turbine.
39
2. Water System “Natural Circulation” for equal
temperature distribution and prevent
overheating of tubes.
Continuous supply of water to the boiler
aids the steam consumption that is being
used by the turbine.
Chemical Dose:
Phosphate Dosing (Na3PO4) – at
Steam Drum
Hydrazine (N2H4) & Ammonia (N2OH) –
at Deaerator
Ammonia (N2OH) – at Condensate
PROCESS OVERVIEW:
Feed Water System – Economizer – Steam
Drum – Steam System
40
Fuel System
3. Fuel System
Provides crushed coal to the furnace as
fuel
COAL BUNKERS
4 sets
430 m3
Capable of 6 hours Continuous Operation
at BMCR per Bunker
COAL FEEDERS
4 sets
42 T/H Max Capacity
Gravimetric Type
ACCESSORIES:
Air Blasters/Canon, Pnuematic Valve,
Motorized Knife Gate Valve, Emergency
Discharge Line
41
Fuel System
3. Fuel System
42
Fuel System
Fuel System
Provides diesel oil to

the furnace as fuel for
start-up ignition
IGNITION GUNS
4 guns
FLAME SCANNER
4 set
43
Sootblower System
Removes soot and ash deposits
from the tubes of the backpass
area
SOOT BLOWER
34 sets
Two types: Long Retractable
Half Retractable
Blowdown and Drain System
Maintains the Quality and Quantity of Steam in the
Drum
Two Types of Blowdown
1.Continuous Blowdown
2.Periodic Blowdown
CONTINUOUS BLOWDOWN FLASH TANK:

1 set
PERIODIC BLOWDOWN TANK:
1 set
PERIODIC BLOWDOWN SUMP:
1 set
BLOWDOWN SUMP PUMP:
2 sets
Turbine Systems
47
Turbine System
1. Lube Oil System
System Components:
•Lube oil tank

•Vapor extractor
•Pumps (main, auxiliary, emergency)
•Constant pressure valve
•Cooler
•Temperature controller
•Filter
•Supply lines and orifices
•Return lines
•Oil purifier
•Instrumentation and controls
•Air filter .
48
Turbine System
Oil Tank
The tank is mainly used to store the lube oil. Also most system components
are
mounted on it. It is designed and sized to allow a sufficient deaeration
(removing of entrained air bubbles in the returning lube oil flow from the
bearings).
49
Turbine System
1. Lube Oil System
Vapour extractors
The lube oil vapor extractor maintains a slight vacuum in the lube oil tank,
oil drain pipes and bearing pedestals. This not only removes oil vapor from
the tank, but also prevents oil from leaking through the oil scrapers of the
bearing pedestal. A butterfly valve upstream from the vapor extractor is
used to adjust the vacuum in the tank. Ventilation with fresh air is provided
via the air filter.
50
Turbine System
1. Lube Oil System
Pumps:
Main Oil Pump
The main lube oil pump is a gear pump (volumetric pump type), driven by
the turbine shaft. It provides oil as soon as the shaft begins to turn, but
reaches its design data already at approximately 80 % of nominal shaft
speed.
51
Turbine System
1. Lube Oil System
Auxiliary Pump
At low turning speeds during start-up, shut-down and turning gear

operation, the main oil pump delivers insufficient oil and the required lube
oil is then supplied by the auxiliary lube oil pump (centrifugal pump with
AC motor). The auxiliary pump is designed for the full pressure and a
flow rate of the required maximum (100 %).
52
Turbine System
1. Lube Oil System
Emergency Lube Oil Pump
The emergency lube oil pump is a centrifugal, DC motor-driven back-up

pump. It is powered by batteries and runs only for test purposes or if the
main and auxiliary lube oil pumps fail. To limit the DC power consumption,
the emergency oil pump is designed with pressure and flow parameters
below the required maximum at rated speed. The capacity is sufficient to
ensure safe rundown of the turboset and cooling of the bearings if an AC
power failure occurs. The discharge of the emergency oil pump is located
after the coolers and filters for two reasons:
• Oil can be delivered to the system when these components are blocked.
• Elimination of the pressure loss from these components allows the DC
pump to be designed for a lower discharge pressure and less power
consumption.
53
Turbine System
1. Lube Oil System
Constant pressure valve
To fit the oil supplied to the oil consumption of the bearings and to avoid an
overpressure in the system induced by the gear pump, a constant pressure
valve is installed, which guides the excessive oil before the filter back to the
tank. To compensate for the variable pressure loss depending on the
cleanliness of the filter, the pressure feedback signal for the valve is taken after
the filter.
54
Lube Oil System
Coolers and AMOT Valve – Oil Temperature Control
Lube oil temperature is regulated by the inline lube oil cooler and a
thermostatic valve.
Downstream from the cooler, the thermostatic valve maintains the oil
temperature at a constant value by passing part of the oil around the
cooler.
• Hot oil from the pump and the cold oil from the cooler are mixed in the
internally-sensed thermostatic valve.
• A cartridge with the expanding (controlling) medium moves the control
cylinder to open either the cold or hot oil supply.
55
Lube Oil System
Coolers and AMOT Valve – Oil Temperature Control – Process Diagram
56
Lube Oil System
Filters.
The lube oil filter consists of two 100 % filters. Differential pressure over
the filter (an indication of the amount of dirt in the cartridge) is supervised
continuously by a differential pressure switch, with remote and local
indication. The filters, which can be changed over during operation, are
equipped with vent valves.
57
Lube Oil System
Controls and Instrumentation
Lube oil upstream from the bearings is supervised by three pressure

transmitters whose outputs are processed in a 2-out-of-3 logic for turbine
safety purposes. If rated lube oil pressure at the shaft level drops to below
a minimum value, the turbine is tripped. The lube oil pumps cannot be
switched off until the shaft is at standstill.
58
Lube Oil System
Lube Oil Purifier
Purpose of the system:
•Dirt sucked into the bearing pedestal.
•Water from the gland seals.
•Particles from erection or overhaul.
•Sludge from erosion of materials.
59
Lube Oil System
Lube Oil System Block Diagram
60
Lube Oil System
Lube Oil System Emergency Protection
The lube oil system is one of the most important auxiliary systems for the
steam turbine. Without a sufficient supply of lube oil to the bearings, the
machine will be seriously damaged and may be out of service for weeks.
Therefore the supply pressure (2 out of 3 pressure measurement) in the
distribution system is ensured as follows:
• AC auxiliary lube oil pump starts below 90 % nominal rotor speed.
• AC auxiliary lube oil pump starts below 60 % nominal lube oil pressure
without delay.
• DC emergency lube oil pump starts below 60 % nominal lube oil pressure
with a delay of 15 seconds.
• DC emergency lube oil pump starts below 40 % nominal lube oil pressure
without delay. .
61
Jacking Oil & Turning Gear System
Jacking Oil
The jacking oil system performs the following purposes:
• Prevents metal to metal contact in the journal bearings by producing a

hydrostatic oil film when the rotational shaft speed is too low to create a
continuous hydrodynamic oil film.
• Reduces the break away torque during run-up of the steam turbine rotor.
The following components are needed as a minimum:
• Jacking oil pump

• Pressure limiting valve
• Flow control valves
• Forwarding and distribution piping
• Lube oil tank
62
Jacking Oil Pump
Pressure limiting Valve
63
Flow Control Valves
64
Turning Gear System
The turning gear system performs the following functions:

• Continuously turns the rotor at low speed before start up and after shut
down.
• Ventilation, caused by the blades, prevents bending due to temperature

differences between top and bottom, caused by natural convection after
stand
still of the hot turbine.
• Avoids the rubbing of blading and sealstrips due to rotor bending during
restart.
65
Turning Gear System

STEP
1
STEP
3
66
Turning Gear System
STEP 2
67
Rotor Train Monitoring System
The turbine supervisory instrumentation (TSI) includes those

measurements which monitor the speed, vibrations, axial position and
differential expansion of the turbo set.
For monitoring of the turbine supervisior instrumentation Benlty Nevada

System is used.
For speed monitoring Jaquet System is used.
68
Turbine Speed
The turbine speed is measured by three probes MAD20CS001/2/3 which are

wired directly to the speed acquisition modules in the steam turbine control
and protection system. The trip limit of the Speed is generated in the speed
acquisition module
Shaft Position
The axial displacement (shaft position) is detected by three eddy

current probes MAD20CY011/012/013 located on thrust bearing MAD20.
The signals from these probes are routed to the associated monitor via
the proximitors. The limit values for the alarms are generated in the monitor.
Absolute Expansion
To measure the absolute expansion of the LP/IP casing, atransducer

MAD20CY004 is installed at the thrust bearing MAD20 to measure the LP/IP
turbine expansion.
69
Differential Expansion
The differential expansion of the HP and LP turbines is determined

via current probes MAA10CY011/012 and MAC10CY011/012
respectively. The displacement is measured on a conical portion of the
shaft. By this measurement, one of the probes measures a displacement
perpendicular to the conical section while the second probe measures the
radial compensation. In the associated monitor the net difference in axial
displacement is calculated and the alarm limit values are generated.
70
Shaft Eccentricity
The measure of the amount of bow in the rotor (eccentricity), is

determined via an eddy current probe MAD20CY005. The probe is
positioned between theIP casing and the thrust bearing. Rotor bow in this
case is caused by uneven thermal heating, the non-contact eddy current
probe will provide peak to peak eccentricity (min and max gap) for
eccentricity monitoring.
71
Vibration Supervision
The following description for the monitoring of vibrations is given for

the example of bearing MAD20, but applies accordingly to the other
bearings.
Bearing MAD20 is equipped with eddy current probes MAD20CY021 and
MAD20CY022 which monitor the relative vibration of the shaft in two
directions.
The eddy current probes are first routed to the associated proximitors, and
then to the relative vibration monitor. In the monitor the alarm and trip limit
values are processed accordingly. In order to determine the phase angle of
the relative shaft vibration, key phasor MAD20CY025 (eddy current probe)
with the associated proximitor is provided. Additionally all bearings are
equipped with eddy current probes, which monitor the absolute
vibration at the bearing pedestals.
72
Control Oil System
The hydraulic oil supply system performs the following function:
• Supplies hydraulic oil to various consumers, mainly for control purposes.
This is achieved by the following:
• Maintaining a constant hydraulic oil pressure throughout all operating

situations.
• Maintaining a constant hydraulic oil temperature.
• Filtering hydraulic oil.
• Guiding hydraulic oil to consumers.
• Returning hydraulic oil from consumers.
• Deaerating hydraulic oil.
• Storage of hydraulic oil at sufficient temperature.
73
Control Oil System
The following components are needed:
• Hydraulic oil tank.
• Hydraulic oil pumps (main and standby).
• Constant pressure valve.
• Duplex filter.
• Hydraulic oil accumulator with safety valve.
• Supply and return lines.
• Instrumentation and controls.
74
Control Oil System
Hydraulic Oil Tank
Normally, the lube oil is used as hydraulic oil; therefore the same standards
regarding properties and cleanliness are applicable.
This setup requires only one common tank for the lube oil- and the
hydraulic oil
system. The components required to operate the hydraulic oil system are
then also mounted on the lube oil tank. The main differences between the
lube oil system and the hydraulic oil system are the operating pressure and
the required voluminous.
75
Control Oil System
Hydraulic oil pumps (main and standby).
Screw-type hydraulic pumps with AC motors supply the oil to the

consumers. One pump covers the full demand while the other remains on
stand-by. A check valve downstream of each pump prevents back flow
during stand-by mode.
76
Control Oil System
Constant Pressure Valve
The required hydraulic oil system pressure is kept at the operating value by
a
constant pressure valve installed in the feed line before the filter.
77
Control Oil System
Duplex Filter
The hydraulic oil passes through one of the change-over duplex filters. To
avoid air being passed into the hydraulic oil system, the filters feature vent
lines back to the hydraulic oil tank. The filter cartridges are of the high
pressure type with bypass, disposable and can be exchanged during
operation.
78
Control Oil System
Hydraulic oil accumulator with safety valve
The accumulator is charged with nitrogen. It smoothens pressure

fluctuations in the hydraulic oil supply system and maintains for a short
time the supply pressure if large hydraulic oil volumes are required, or
when switching over from the pump unit in-service to the stand-by unit.
79
Control Oil System
Control Oil System Instrumentation
80
Control Oil System
Process Block Diagram
81
Safety System
The system protects the turbo set from possible damage that could result
from inadmissible operating conditions. All trips are initiated through the
electronic steam turbine protection system, which is based on a 2 out of 3
voting principle, normally energized. The three independent channels are
connected with three trip solenoid valves on the electro hydraulic trip unit.
82
Safety System
The safety system operates on binary logic and has only two operational
states:
OFF or ON, i.e. no or full hydraulic oil pressure. The safety system contains
of the following:
• 2 out of 3 trip unit.
• Sequence valve.
• Central system discharge amplifier.
• Discharge amplifiers on each steam admission and extraction valve

actuator.
83
Safety System
Safety Block
84
Safety System
Safety Block
85
Safety System
Trip Sequence for different operational situations:
Case A: Hydraulic oil supply pipe to steam turbine valves breaks

→pressure loss →trip initiation by first closing with spring force of all stop –
and control valves.
Case B: The emergency system is depressurized by the mechanical over

speed
(optional) →discharge amplifier opens →fast closing of all stop and control
valves.
Case C: The trip unit is tripped by the DCS trip signal (2 out of 3) →same
sequence follows as case B.
86
Safety System
Machanical overspeed device
87
Safety System
HP Control and Stop Valves
88
Safety System
IP Control and Stop Valves
89
Safety System
Safety System
Stop Valves
The stop valves are controlled directly by the pressure in the safety system.
As soon as the hydraulic oil pressure rises to the normal value, the stop
valves open directly (no electric opening command!). When the safety
system is depressurized, the discharge amplifier drains the hydraulic oil
quickly and the spring force closes the valve. The discharge amplifier
reduces the closing time of the stop valve
90
Safety System
Contro Valves
The pressure in the safety system supplies the control valves via electro
hydraulic converters. The control valve position is specified by the steam
turbine control system. The valve can take up any position between closed
and open. When the safety system is depressurized, the discharge amplifier
quickly drains the hydraulic oil and the spring force closes the valve.
As soon as the hydraulic oil pressurizes to the normal value, the stop valves
open directy (no electric opening command!).
Electro-hydraulic converter
91
Gland Steam System
The steam turbine gland steam system fulfils the following functions:
• Seals the steam turbine prior to start-up to enable condenser evacuation.
• Seals the steam turbine during operation to prevent steam losses on

casings operating under overpressure.
• Seals the steam turbine during operation to prevent air leaks into turbine
sections running operating under vacuum.
92
Gland Steam System
• Providing external steam into the system prior to and during start-up of
the
turbine to all seals.
• Removing excess steam out of the system during higher load operation.
• Maintaining a constant gland steam pressure throughout the entire
operating range.
• Limiting gland steam temperatures to match steam turbine materials
properties.
• Avoiding air leaks into the turbine sections running under vacuum
conditions.
• Removing leak steam out of each seal and discharging it safely to the
atmosphere.
• Removing leak steam out of each seal and condensing it in the gland
steam
condenser (optional). Components Therefore the following components are
needed as a
93
Gland Steam System
The proper functioning of the Gland Steam System is achieved with the
help of two subsystems:
•First,
the suction steam system MAW30 with a pressure slightly below the
atmospheric pressure;
•Second,the sealing steam system MAW10/15 with a pressure slightly

above the atmospheric pressure.
94
Gland Steam System
Therefore the following components are needed as a minimum:
• Gland steam supply line.
• Gland steam shut-off valve (motorized).
• Gland steam admission control valve.
• Gland steam dump control valve.
• Gland steam attemperation station with spray nozzle and condensate

injection control valve.
• Gland steam supply lines to all gland seals.
• Vacuum system with steam exhaust fan (optional: stand-by unit).
• Gland steam condenser (optional).
95
Gland Steam System
Gland steam admission control valve.
96
Gland Steam System
Gland Steam Admission Valve Controller
97
Gland Steam System
Gland Steam Water Injection Valve
98
Gland Steam System
Gland Steam Water Injection Shut off Valve
99
Gland Steam System
Gland Steam Condenser
100
Gland Steam System
Gland Steam Dumping Valve
101
Gland Steam System
Sealing System
The pressure in the sealing steam system is maintained by supplying gland

steam through gland steam control valve MAW10AA011 during low load
operation.
Self Sealing System
During high load operation the admission control valve MAW10AA011

will close fully and the gland steam dump control valve MAW15AA012
will take over to maintain the pressure in the gland steam header,
which is supplied by the leaking steam from the HP- and the IP-
Turbine glands.
102
Gland Steam System
Sealing System Temperature Control
The sealing steam for some of the seals must be cooled due to material
properties, especially in the LP turbine section. An attemperation station
with spray nozzle and condensate injection control valve maintains the
desired temperature in the sealing system.
103
Gland Steam System
Gland Steam System – Process Diagram
104
LP Hood Spray Water System
The LP turbine hood spray system performs the following function:
• Prevents inadmissible temperature of the LP last stage blading during no-

load
and low-load operation. The injected water absorbs the heat.
• Injection of condensate into the LP turbine exhaust section.
• Condensate supply line.
• Water injection valve.
• Spray lines in the LP turbine exhaust casing with multiple spray nozzles.
105
Water Injection System
106
To prevent overheating due to ventilation, water is injected into the exhaust

of the LP turbine. This water absorbs the heat. The water injection ensures
the effective cooling without spraying water directly onto the blading.
The control of the injection valve is dependent on the mass flow through
the LP turbine and the turbine speed. When the flow is less than 10% and
the turbine speed is greater than 50% and high LPT ventilation and
exhaust temperatures the injection valve is open. When this flow is greater
than 10% or the speed is less than 50%,the injection valve is closed.
Temperature setpoint is : 83 ˚C.
107
LP Hood Spray Water System - Process Diagram
108
Drain System
The drain system fulfils the following functions:
• Removes condensate from steam lines to prevent water hammer during

start-up.
• Removes condensate from the steam turbine to prevent thermal stress

during start-up.
• Removes condensate to protect the turbine and heat exchangers from

water
damage.
• Removes condensate from steam systems that forms during normal

operation.
• Guides condensate to the appropriate collection vessels.
• Handles flashing of condensate in the collection vessels.
• Separates steam and condensate in the collection vessels.
• Desuperheats flash-steam to desired temperature levels.

109
Drain System
This functions are implemented by performing the following tasks:
• Providing start-up drains equipped with pneumatically actuated shut-off

valves.
• Providing continuous drains equipped with steam traps and/or drain

orifices
• Providing a vacuum drain collection vessel for drains out of systems,

which may run under vacuum conditions
110
Drain System
Two thirds of all mechanical damage to steam turbines is related to inappropriate

and malfunctioning drain systems. The steam turbine drain system may look non
important and small, which is however a dangerous misinterpretation.
Drain systems need continuous attention and supervision in order to properly

discharge dirt and foreign particles from the steam system during start-up. This
cleaning function is very important due to the following:
• To prevent damage on components, i.e. turbine blading.

• To prevent malfunction of equipment, i.e. valves.
• To quickly reach good water chemistry conditions after a start-up.
111
Drain System
Start up drains
The start-up drains are equipped with pneumatic actuated valves that are
automatically closed during normal operation. Start up drains open / close
depending on the steam turbine load.
The valves are “fail safe open”, which means in case of power failure
(electric or
pneumatic) the valves will open.
Continuous drains
Continuous drains are always open. The flow is limited by an orifice

installed at the very end of the drain line towards the drain vessel.
112
Drain System
Arrangement of the drains at the flash tank
113
Drain System
Drain System Block Diagram
114
Vacuum Breaking System
The vacuum breaking system performs the following functions:
• Partial vacuum breaking in case of a turbine shut-down in order to slow-

down
through the critical speed ranges more quickly.
• Full vacuum breaking in case of an emergency.
This is reached by the following:
• Admitting ambient air to enter the condenser through a valve.
115
• Vacuum breaker valve

• Sealing water line
• Drain line
• Instrumentation and controls
116
117
118
Material Handling System
119
Coal Handling System
SYSTEM FUNCTION
THE COAL HANDLING SYSTEM UNLOADS
COAL DELIVERY FROM BARGE OR SHIP,
TRANSFER THE COAL FOR STACKING IN THE
COAL YARD AND RECLAIMING AND THE FILL
COAL FUEL TO THE SILOS TO SUPPORT
PLANT OPERATION
COAL HANDLING SYSTEM

MAJOR EQUIPMENT
SHIP UNLOADER
STACKER/RECLAIMER
BELT CONVEYORS
COAL CRUSHER
VIBRATION SCREEN
SELF CLEANING MAGNETIC SEPARATOR
BAG FILTER
DEDUSTING VENT FANS
TWO WAY SEPARATOR


SHIP UNLOADER

SHIP UNLOADER OPERATIONS

BELT CONVEYOR

BELT CONVEYOR MATERIAL

STACKER/RECLAIMER

STACKER/RECLAIMER SPECS

COAL CRUSHER

BAG FILTER

MODES OF OPERATION

MODES OF OPERATION

MODES OF OPERATION

Limestone Feeding System
Pressure transmitter
Level transmitter
Level transmitter
Limestone Feeding System
Sulfur Capture:
SO2 is captured from gas phase and transformed to solid phase (CaSO4).
Sulfur Reaction:
Step 1: S combustion to SO2
S + O2 ----> SO2 (high temperature needed)
Step 2: Sulfur Capture Reaction
Heat + CaCO3 (limestone) ----> CaO (lime) + CO2
SO2 + 2CaO ----> CaSO4 (gypsum)
Lime - Strictly speaking, lime is calcium oxide or calcium hydroxide. It is also the name of
the natural mineral (native lime) CaO which occurs as a product of coal seam fires and in
altered limestone xenoliths in volcanic ejecta.
Gypsum - is a soft sulfate mineral composed of calcium sulfate dihydrate, with

the chemical formula CaSO4·2H2O. It can be used as a fertilizer, is the main
constituent in many forms of plaster and is widely mined.
Bottom Ash System
r
Co ol e
w
c re
hS
Asc
Drag Chain Conveyor
Fly Ash System
ESP Hoppers
Fly Ash Transmitter
Balance of Plant System
138
Water Treatment System
Desalination
A process that removes minerals and salts from saline water
Demineralization
A process of removing ions in water
Desalination
Demineralization
ION is an atom or molecule with a net electric charge due to the

loss or gain of one or more electrons
Cations Anion
Calcium Chloride
Magnesium Bicarbonate
Sodium Nitrate
Potassium Carbonate
1
4 5
2 3
Industrial water tank

INDUSTRIAL WATER
TANK
receives and stores the permeate or

product water from the 2nd RO
unit
Mixed bed Feed Pump

delivers the industrial water
from the industrial water tank
to the carbon filter units
Carbon filter
removes undesirable odor
and color in industrial
water using activated
carbon and sand as filter
media
Demi mixed bed

processes the water from
the carbon filters to
produce ultrapure or
demineralized water with
low silica content by
passing through a mixture
of anionic and cationic
resins
Demi Tank
stores the ultrapure or
demineralized water for
boiler feedwater make-up
and other purposes
Waste Water Treatment System
Air Compressor System
Air
Dryer
Compressor
D – 0206A
C – 0201A Plant Air
Tank
Air
Dryer T - 0208
Compressor
C – 0201B D – 0206B
Air
Compressor Dryer Instrume
C – 0201C D – 0206C nt Air
Tank
Air T - 0207
Dryer
Compressor
D – 0206D
C – 0201D
Basic Operation
151
1. Drum Filling
2. Sand Injection
3. Draft System
a. IDF
b. FAB
c. SAF
d. PAF
4. Purging Process Drum
5. Diesel Firing
LIMESTONE to Turbine
6. Coal Firing Finishing SH
7. Limestone Feeding
8. Saturated Steam Low Temp. SH
Vortex
Wing
9. Superheated Steam wall
Finder
10.Auxilliary Steam
Economizer
11. Gland Steam Seal
Economizer
from HPH
SAND
COAL
FA
B SAF
Wind-box
PAF
Smoke stack
Continuous Emission Monitoring System (CEMS)
24/7 Monitoring
SOx – NOx - PM10 – CO - O2 - Temp

Drum
Back Pass
Electrostatic Precipitator ( ESP )
Cyclone
Furnace
IDF
Bottom Fly Wet Type

Ash Ash Ash Pond
Silo Silo
Ash
Pond
Cement/
Batching Plant
Dry Type
P= 126 Kg/cm2
Main T= 538 OC
Steam
from
Boiler
Electric generation 75%

50%
25% MW
8.37MW
Sea Water
Main Condenser Cooling
From S/B Aux. Hot Well
Heating
Steam
Deaerator
Gland Steam
LPH2 Condenser
Condensate
Boiler By-pass tank
HPH1 HPH2 BFP D/A Storage Demi

LPH1 Demi Water
Tank
MWP
Explanation of Boiler Water
Steam (126kg/cm2 g - 541oC)
Drum
300 T/H CFB Boiler Turbine Generator
SH
Furnace
ELECTRICITY
to Customers
Back Pass
Condenser
Return Eco. (Turbine ext. # 1)
Leg
Hotwell
(Turbine ext. #2)
Sea Water
Feedwater
Condensate
(Turbine ext. # 3)
By-pass
Tank
(Turbine ext. # 4) CP
Deaerator (Turbine ext. # 5)
HPH 1 LPH 1 LPH 2

HPH 2
Deaerator
Tank
BFP Demineralized
WaterTank
MWP
The Electric Power Industry
POWER TRANSMISSIO DISTRIBUTION Electricity

GENERATIO N LINES Users
N LINES
ANYONE FROM THE GROUP?
Albert Einstein

Coal-Fired Thermal Power Plant

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Coal-Fired Thermal Power Plant

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Coal Fired Thermal Power Plant

Systems and Operation

Presented by: Jonas Belitor, ME, MEng

To have a basic idea on Coal Fired Thermal Power Plants

To have a better understanding of the operations of a CFB power plant.

I. Coal Fired Thermal Power Plant

A. Basic Concepts on Coal Fired Thermal Power Plants

B. Coal Fired Thermal Power Plant Systems

C. Functions and Basic Operations

The first coal fired power

Holborn Viaduct Power

Worldwide there are over

Coal Fired Power Plant

Jackson RB, et al. (2022). "Global fossil carbon emissions

Installed Generating Capacity, by Source in MW

Excerpt from : Department of Energy KES

Installed Generating Capacity, by Source in MW

Excerpt from : Department of Energy KES

Power Generation, by Source and Grid in GWh

Excerpt from : Department of Energy KES

Power Generation, by Source and Grid in GWh

Excerpt from : Department of Energy KES

Philippine Coal Production, by Source in MMT at 10,000 BTU/lb

Excerpt from : Department of Energy KES

Coal Importation, by Country of Source in MMT at 10,000 BTU/lb

Excerpt from : Department of Energy KES

List of existing coal-fired power plants in the Philippines(Greenpeace.org, 2016)

GNPower Kauswagan, a 4x154 MWg PC Coal Fired

FDC Misamis Power Corporation- a 3x135 MWg CFB

STEAG State Power Inc., a 2x105g MW PC Coal Fired

SMCGP Malita Power Plant – a 2x150 MWg CFB Coal

Coal power plant is a thermal

Chemical Kinetic Mechanical Electrical

Coal Steam Turbine Generator

Carbon/Energy Content of Coal High

High Moisture Content of Coal

Low Rank Coal High Grade Coal

Largely power Power generation Power generation Manufacture of Domestic/industrial

Feed Water Seawater

BOILER FEED Demi Water Tank

Ideally, the objective is

1.1.2 Difference Between PC Boiler and

Pulverized Coal Plant (PC) Circulating Fluidized Bed

1.1.2 Difference Between PC Boiler and

Circulating Fluidized Bed

Boiler System Turbine System MH System BOP System

1. Air and Gas

Primary and Secondary Air Fan extract air from the

PRIMARY AIR FANS (PAF):

SECONDARY AIR FANS (SAF):

FLUIDIZING AIR BLOWERS (FAB)

INDUCED DRAFT FANS

Water enters the boiler steam drum through economizer

Exhaust steam by the HP turbine is reheated back to the boiler

Provides diesel oil to

CONTINUOUS BLOWDOWN FLASH TANK:

•Lube oil tank

Main Oil Pump

At low turning speeds during start-up, shut-down and turning gear

The emergency lube oil pump is a centrifugal, DC motor-driven back-up

Lube oil upstream from the bearings is supervised by three pressure

Purpose of the system:

•Dirt sucked into the bearing pedestal.