Amit Prakash1 POWER GENERATION PROCESS BASICS

Amit Prakash2 BOILER / STEAM TURBO-GENERATOR UTILITY PLANT Boiler 100% Fuel Air Stack Steam Steam TurbineGenerator 20% Lake 6% Aux. Power + Losses Steam Condenser 40% 34% Electricity THERMAL EFFICIENCY - 34% Transmission

Amit Prakash3 BOILER / STEAM TURBINE-GENERATOR INDUSTRIAL CO-GENERATION Boiler Fuel 100% Air Stack 15% Steam TurbineGenerator 15% Electricity Transmission Steam5% Aux. Power + Losses Process Steam 65% Process Plant THERMAL EFFICIENCY - 80%

Amit Prakash4 SIMPLE CYCLE COMBUSTION (GAS) TURBINE Air 100% Fuel CompressorTurbine Generator Combuster Stack 57-62% 3% Aux Power + Losses 35-40% Electricity Transmission THERMAL EFFICIENCY %

Amit Prakash5 Air Compressor TransmissionGenerator GAS TURBINE INDUSTRIAL CO-GENERATION PLANT Turbine 100% Fuel CombusterExhaust Gas 20% Stack Process Plant Process Steam Supplementary/ Auxiliary Fuel (Optional)

Amit Prakash6 Air Compressor TransmissionGenerator GAS TURBINE COMBINED CYCLE POWER PLANT 20% Stack 100% Fuel CombusterExhaust Gas Stack Turbine Steam Turbine Steam Generator Transmission Steam Condenser Lake 28% 6% Aux. Power + Losses 12-15% Electricity 35-40% Electricity Supplementary Fuel (Optional) Thermal Efficiency %

Amit Prakash7 UTILITY PLANT - FUNCTIONAL BLOCK DIAGRAM Switch Yard System Station Electrical System Boiler Feed Pumps & Deaerator System Turbine Bypass System BOILER TURBINE- GENERATOR UNIT#2 DM Plant Fuel Handling System Station Miscellaneous Systems Turbine Miscellaneous Systems Turbine Steam System HP & LP Heaters System Turbine Supervisory & Control System Generator & Electrical System Boiler Steam & Water System Air & Flue Gas System Fuel Preparation System Fuel Firing System Boiler Miscellaneous Systems Ash Handling System

Amit Prakash8 CAPTIVE POWER PLANT - FUNCTIONAL BLOCK DIAGRAM Switch Yard SystemStation Electrical System DM Plant Fuel Handling System Station Miscellaneous Systems BFP’s & Deaerator System UNIT#2UNIT#3 BOILER TG Steam & Water Air & Flue Gas Fuel Preparation Fuel Firing Steam HP & LP Heaters Supervisory & Control Generator & Electrical Miscellaneous Systems Ash Handling System

Amit Prakash9 BOILER FUNDAMENTALS

Amit Prakash10 BASIC DIAGRAM OF A BOILER Steam / Water System Furnace Heat Transfer Surface Mixing of Fuel & Air Water Fuel Air Steam Flue Gas Ash Blowdown

Amit Prakash11 SALIENT FEATURES OF MODERN INDUSTRIAL & UTILITY BOILER STEAM BOILER WATER TUBE SUPERHEATED STEAM HIGH PRESSURE WATER COOLED FURNACE WATER CIRCULATION

Amit Prakash12 COMBUSTION REQUIREMENTS 3 T’s of Combustion Combustion Time Temperature Turbulence Sufficient Combustion Air Fuel is Gasified Mixing within Flammable Range Temperature above Ignition Point

Amit Prakash13 BASIC COMBUSTION CHEMISTRY Complete O2 + H2 C Heat (Air) OxygenFuel Products H2O CO2 Incomplete + Heat O2 H2 C OxygenFuel Flue Gas Products H2O CO2 CO H2 C Other Combustibles - Sulphur to Sulphur Oxides Non-combustible - Nitrogen to Nitrogen+Nitrous Oxides Ash

Amit Prakash14 BOILER WATER & STEAM SYSTEM Furnace Water Wall Risers Drum Down Comers Economiser Feed Water Primary Super Heater Final Super Heater Primary Re Heater Final Re Heater Platen Super Heater Attemperator Spray Water Spray Water Main Steam Hot Reheat Steam Cold Reheat Steam Bottom Ring Header Simplified Process Diagram Flue Gas Out to Air Heater Attemperator

Amit Prakash15 BOILER WATER & STEAM SYSTEM Process Performance Highlights Heat Transfer by Radiation and Convection Boiler Water Circulation - Natural or Controlled Heat Transfer depends on Heat Transfer Area & Time Heat Transfer is affected by Fouling, Boiler Pressure, Boiler Water Quality and % MCR Load

Amit Prakash16 BOILER WATER & STEAM SYSTEM Major Equipment Economiser - Pre-heats Boiler Feed water Boiler Drum - Separates water from steam and reduce solids in steam Water Walls - Absorb heat from flue gas to evaporate boiler water Superheaters - Heat up steam coming from boiler drum Reheaters - Heat up steam coming from High Pressure turbine Attemperators - Reduce superheat from steam

Amit Prakash17 BOILER WATER & STEAM SYSTEM Process Regulation Drum Level - Regulation of Feed Water flow Drum Water Quality - Blow down / Chemical Dozing Fouling of Heat Transfer Surfaces - Blowdown / Soot Blowing Main Steam Temperature - Attemperation / Burner Tilt Hot Reheat Steam Temperature - Burner Tilt / Attemperation Main Steam Pressure - Regulation of Combustion

Amit Prakash18 AIR & FLUE GAS SYSTEM Simplified Process Diagram Chimney ID Fan A ID Fan B ESP A ESP B AH A AH B FD FAN A FD FAN B PA FAN A PA FAN B To Cold PA Header To Hot PA Header ECOECO LTSHLTSH FURNACE RHRH PTNSHPTNSH FINSHFINSH WINDOX A WINDBOX B From FD Fans To Air Cooled Guns Scanner Air Fans

Amit Prakash19 AIR & FLUE GAS SYSTEM Process Performance Highlights Generation of Draft - Natural / Induced / Forced / Balanced Supply of Air for Transport of Pulverised Coal Pre-heating of Air Distribution of Air in Combustion Chamber Recirculation of Gas Fan capacity depends on Flow, Density & System Resistance Fan performance is affected by temperature, density, barometric pressure and speed Flue Gas Cleaning Gas flow is restricted by ash deposits on boiler surfaces

Amit Prakash20 AIR & FLUE GAS SYSTEM Major Equipment Air Path - Forced Draft Fans, Steam Coil Air Pre-heater, Regenerative Air Pre-heater & Wind-box Gas Path - Induced Draft Fans and Stack Gas Recirculation - Gas Recirculating Fans Flue Gas Cleaning - Mechanical Precipitator, Electrostatic Precipitator and Gas Scrubber Dampers

Amit Prakash21 AIR & FLUE GAS SYSTEM Process Regulation Furnace Draft - ID Fan Inlet Vane Control and/or Variable Speed Secondary Air Flow - FD Fan Variable Pitch Control PA Header Pressure - PA Fan Inlet Vane Control RAPH Cold End Temperature - SCAPH Control Gas Recirculation - Damper Control

Amit Prakash22 FUEL PREPARATION SYSTEM - COAL Simplified Process Diagram Hot PA Cold PA Mill A Raw Coal Bunker Coal Feeder Coal+Air to Burners Seal Air Fans To Other Mills To Mill Discharge Valves To Other Mills To Other Mills

Amit Prakash23 FUEL PREPARATION SYSTEM - GAS/OIL Simplified Process Diagram Fuel Gas Supply To Burners PRV’s FCVFGTV FUEL GAS FUEL OIL Fuel Oil Supply PCV Fuel Oil Pumps To Burners Oil Heater Steam FCVFOTV Fuel Oil Return Short Recirc Long Recirc Atomising Steam/Air PCV

Amit Prakash24 FUEL PREPARATION SYSTEM Process Performance Highlights Coal Pulverizing - Direct / Indirect Firing Coal Transport and Drying Fuel Gas Pressure Regulation Fuel Oil Pumping & Filtering Fuel Oil Pressure & Viscosity Regulation Gas Pressure & Oil Pressure/Temperature affect Boiler Load

Amit Prakash25 FUEL PREPARATION SYSTEM Major Equipment Coal Mills - Tube Ball / Bowl / Impact Raw Coal Feeders - Chain / Belt / Rotary / Gravimetric Coal / Air Dampers, Gates & Discharge Valves Fuel Oil Pumps & Heaters Seal Air Fans Coal Bunkers Vapour Fans

Amit Prakash26 FUEL PREPARATION SYSTEM Process Regulation Coal Flow - Raw Coal Feeder Speed Coal/Air Temperature & Flow - Cold & Hot PA Flows

Amit Prakash27 FUEL FIRING SYSTEM Typical Corner Arrangement for a Tangentially Fired System Front Wall Plan (Corner Designation) (1) (2) (3) (4) AA A AB B BC C CD D DE E EF F FF Air Damper OFA OFA Over Fire Air OFA EA EA End Air FA FA Fuel Air AA AA Aux. Air Coal Burner Fire Ball Scanner LFO?HFO Burner HFO Burner Oil Flame Scanner HEA Igniter

Amit Prakash28 FUEL FIRING SYSTEM Process Performance Highlights Fuel Firing - Front / Tangential Fuel Oil Atomisation - Mechanical / Air / Steam Flame Ignition Air Distribution Fuel Combustion

Amit Prakash29 FUEL FIRING SYSTEM Major Equipment Burners Ignitors Flame Scanners Burner Tilt Mechanism Wind Box Dampers

Amit Prakash30 FUEL FIRING SYSTEM Process Regulation Furnace to Wind Box Differential Pressure Fuel Air Flows Fuel Firing Emergency Shutdown Flame Monitoring Oil Support for Coal Flame Stability

Amit Prakash31 BOILER MISCELLANEOUS SYSTEMS Boiler Auxiliary Cooling Water System Ensures continuous supply of cooling water to Boiler & it’s auxiliaries Consists of Overhead Tank, Pumps & Heat Exchangers Chemical Dosing System Prepares & supplies chemicals for treatment of Boiler Water Consists of Preparation Tanks, Mixers & Metering Pumps

Amit Prakash32 DEAERATION & FEED PUMPING SYSTEM Simplified Process Diagram Deaerator Feed Storage Tank M Discharge Valve Recirculation Valve Boiler Feed Pumps To HP Heaters To HP Bypass Spray T o APRDS Spray Hydrazine Dosing Ammonia Dosing Aux. Steam for Pegging HP Heater Drains Condensate from LP Heater Aux. Steam CRH Steam IPT Extraction Steam

Amit Prakash33 DEAERATION & FEED PUMPING SYSTEM Process Performance Highlights Boiler Water pre-heating & air removal Maintain positive Suction Pressure for Feed Pumps Feed Water Pumping to Boiler

Amit Prakash34 DEAERATION & FEED PUMPING SYSTEM Major Equipment Boiler Feed Pumps Hydraulic Coupling Deaerator

Amit Prakash35 DEAERATION & FEED PUMPING SYSTEM Process Regulation Deaerator Pressure Deaerator Level BFP Minimum Recirculation Feed Pump Speed

Amit Prakash36 STEAM TURBINE FUNDAMENTALS

Amit Prakash37 LAWS OF THERMODYNAMICS Conservation of Energy - Heat may be converted in to work and work may be converted in to heat, in accordance with a certain natural proportionality constant (ENERGY CAN NOT BE DESTROYED) Not all of a given quantity of Heat can be converted in to useful Work, because of irreversbility in the process (ENTROPY OF THE UNIVERSE IS INCREASING)

Amit Prakash38 BASIC RANKINE CYCLE T S Unavailable Heat Heat Available for Work

Amit Prakash39 IMPROVING RANKINE CYCLE Superheating Increased Pressure Decreased Exhaust Pressure Regenerative Feed Heating Reheating

Amit Prakash40 STEAM TURBINE TYPES Condensing Turbine Back Pressure Turbine Regenerative Turbine Controlled Extraction No. of Cylinders Speed - Constant / Variable Single / Double Flow

Amit Prakash41 TURBINE STEAM SYSTEM Simplified Process Diagram Condenser HP Turbine IP Turbine LP Turbine Extraction Steam Main Steam Cold Reheat Steam Hot Reheat Steam ESVCV IVCV

Amit Prakash42 TURBINE STEAM SYSTEM Major Equipment Turbine - Casing, Rotor & Blades Emergency Stop Valves Control Valves Condenser

Amit Prakash43 TURBINE STEAM SYSTEM Process Regulation Steam Admission Emergency Shutdown

Amit Prakash44 REGENERATIVE FEED HEATING SYSTEM Simplified Process Diagram From BFP Discharge To Boiler HP HTR HP HTR CRH Steam To Deaerator IPT Extrn. Steam Condenser Hotwell Condensate Extraction Pump LP HTR LP HTR HP Flash Tank LP Flash Tank To Deaerator LPT Extraction Steam LPT Extraction Steam Minimum Recirculation LP HTR Drain CLR GSC To Condenser To Condenser Gland Leakoff Steam LPT Extraction Makeup

Amit Prakash45 REGENERATIVE FEED HEATING SYSTEM Process Performance Highlights Pumping of Condensate from Hotwell to Deaerator Gradual Heating of Feed Water Temperature Minimise Heat Loss from the Cycle

Amit Prakash46 REGENERATIVE FEED HEATING SYSTEM Major Equipment HP Heaters LP Heaters Drain Cooler Condensate Extraction Pumps

Amit Prakash47 REGENERATIVE FEED HEATING SYSTEM Process Regulation Hotwell Level Heater Level Minimum Flow through CEP & GSC

Amit Prakash48 TURBINE GOVERNING & CONTROL SYSTEM Functional Block Diagram Gland Steam System Lubricating Oil System Governing Oil System Turning Gear Jacking Oil System Condenser Vacuum System Turbine Drain System OIL SYSTEMS VACUUM SYSTEMWARM UP SYSTEM

Amit Prakash49 TURBINE GOVERNING & CONTROL SYSTEM Process Performance Highlights Shaft & Bearing Protection Electro-hydraulic Governing Maintain Vacuum in Condenser Supply Steam to Turbine Glands Warming up of Turbines and their Valves Emergency Shutdown in case of Unsafe Conditions

Amit Prakash50 TURBINE GOVERNING & CONTROL SYSTEM Major Equipment Oil Pumps, Turning Gear & Jacking Oil Pump Hydraulic Actuators for Turbine Valves Vacuum Pumps Gland Steam Pressure Regulator Oil Coolers & Temperature Regulator

Amit Prakash51 TURBINE GOVERNING & CONTROL SYSTEM Process Regulation Speed / Load / Frequency Control Gland Steam Pressure Control

Amit Prakash52 TURBINE MISCELLANEOUS SYSTEMS Condenser Cooling Water System Supplies Cooling Water Condensation of Turbine Exhaust Steam Turbine Auxiliary Cooling Water System Ensures continuous supply of cooling water to Turbine & it’s auxiliaries Consists of Overhead Tank, Pumps & Heat Exchangers Chemical Dosing System Prepares & supplies chemicals for treatment of Condensate Consists of Preparation Tanks, Mixers & Metering Pumps

Amit Prakash53 TURBINE MISCELLANEOUS SYSTEMS Condenser Cooling Water System Simplified Process Diagram Cooling Tower CW Sump CW Makeup Water Condenser A Waterbox B Circulating Water Pumps To Unit#2 CW Return Header CW Supply Header

Amit Prakash54 TURBINE MISCELLANEOUS SYSTEMS Condenser Cooling Water System Major Equipment Cooling Towers CW Pumps Process Performance Highlights Steam Condensation Cooling of Condenser CW - Cooling Tower / Lake Process Regulation Condenser Tube Cleaning - Online / Back flushing

Amit Prakash55 TURBINE BYPASS SYSTEM Simplified Process Diagram Main Steam CRH To HPT From HPT To IPTHRH Feed Water PRV Spray Control Valve Block Valve Condenser Condensate

Amit Prakash56 TURBINE BYPASS SYSTEM Process Performance Highlights Enable Boiler Operation for Quick Re-start after Boiler Trip and during Turbine Start-up Control MS Pressure after Turbine Trip or Sudden Load Throw-off

Amit Prakash57 TURBINE BYPASS SYSTEM Process Regulation MS Pressure Reduction & Desuperheating HRH Steam Pressure Reduction & Desuperheating

Amit Prakash58 GENERATOR FUNDAMENTALS

Amit Prakash59 WORKING PRINCIPLE Converts Mechanical Energy in to Electrical Energy Based on Electro-magnetic Induction E = 4.44 O FN volts E - e. m. f. O - Strength of Magnetic Field F - Frequency N - No. of Turns in a Stator Winding Coil F = Pn/120 P - No. of Poles n - Revolution per second of Rotor

Amit Prakash60 GENERATOR EFFICIENCY & LOSSES Efficiency = Output Electrical Energy Input Mechanical Energy Losses - Bearing Loss, Copper Loss & Iron Loss Typically Efficiency is 90-97%

Amit Prakash61 GENERATOR & UNIT ELECTRICAL SYSTEM Generator Functional Block Diagram Unit Auxiliary Transformer Field Excitation System Generator Synchronising Sceme Generator Transformer Metering & Protective Relays Stator Cooling Water System Hydrogen Cooling System Seal Oil System ELECTRICAL SYSTEMSMECHANICAL SYSTEMS

Amit Prakash62 GENERATOR & UNIT ELECTRICAL SYSTEM Key One Line Diagram 132 KV Bus I 132 KV Bus II Isolator Circuit Breaker GT Generator Unit Auxiliary Transformer From Station Bus From Station Bus 6.6 kV Unit Bus B6.6 kV Unit Bus A 11 kV

Amit Prakash63 GENERATOR & UNIT ELECTRICAL SYSTEM Process Performance Highlights Conversion of Mechanical Energy in to Electrical Energy Field Excitation Stator Winding Cooling by Distillate / Air Rotor Winding Cooling by Hydrogen / Air Hydrogen Sealing by Oil Synchronisation & Voltage Transformation Emergency Shutdown in case of Unsafe Conditions

Amit Prakash64 GENERATOR & UNIT ELECTRICAL SYSTEM Major Equipment Generator - Stator, Rotor, Armature Windings, Field Windings Field Excitation - Exciter (DC/AC), Static Rectifying Unit & AVR Bus Ducts & Transformers Circuit Breakers & Protective Relays H2 Cooling - Fans, Dryers & Coolers Stator Water Cooling - Pumps, Coolers & Overhead Tank Seal Oil - Pumps, Coolers & Differential Pressure Regulator

Amit Prakash65 GENERATOR & UNIT ELECTRICAL SYSTEM Process Regulation Field Excitation Generator Synchrinisation Voltage Regulation

Amit Prakash66 POWER PLANT OPERATION & MAINTENANCE

Amit Prakash67 OPERATION & MAINTENANCE Efficiency Calculations Boiler Efficiency - Direct / Heat Loss Method Turbine Heat Rate - Total Heat Supplied/ KWHR Plant Heat Rate - Heat Supplied/ KWHR

Amit Prakash68 Factors Affecting Plant Performance Flue Gas Exit Temperature Excess Air Unburnt Fuel Steam Temperature Condenser Back Pressure FW Temperature at Eco Inlet Auxiliary Power Consumption Make up Water Flow Optimum Loading OPERATION & MAINTENANCE

Amit Prakash69 OPERATION & MAINTENANCE Start-up & Shutdown Monitoring Trip Analysis - Boiler / Turbine / Generator Equipment Run-Hour Monitoring History Trending Alarm Management Division of Operational Responsibilities Economic Load Allocation & Load Shedding (CPP)

Amit Prakash70 POWER PLANT AUTOMATION & CONTROL

Amit Prakash71 POWER PLANT AUTOMATION & CONTROL Burner Management System Furnace Purge Supervision Secondary Air Damper Modulation, On/Off Control and Supervision Light/Heavy Oil On/Off Control and Supervision Pulveriser and Feeder On/Off Control and Supervision Flame Scanning Overall Boiler Flame Failure Protection Boiler Trip Protection

Amit Prakash72 POWER PLANT AUTOMATION & CONTROL Soot Blower Sequential Control Wall Blowers Long Retractable Blowers Air Heater Blowers

Amit Prakash73 POWER PLANT AUTOMATION & CONTROL Automatic Turbine Run-up System Oil Supply Control - Turning Gear, Auxiliary Oil Pumps, Emergency Oil Pump, Jacking Oil Pump and Lube Oil Temperature Condensate & Evacuation Control - Condensate Extraction Pumps, Gland Steam Pressure, Vacuum Pumps and Vacuum Breaker Valve Turbine Control - Steam & Metal Temperature Matching, Warming up of HP ESV & CV, Steam Rolling & Acceleration and Auto Synchroniser

Amit Prakash74 POWER PLANT AUTOMATION & CONTROL Turbine Stress Evaluator Calculation of Actual and Permissible Thermal Stress Values Comparison of Actual with Permissible Stress Values and Computation of Available Margin Optimize Start up, Operation and Shut down

Amit Prakash75 POWER PLANT AUTOMATION & CONTROL Automatic Turbine Tester Safety Devices - Remote Trip, Over-speed, Low Vacuum and Thrust Bearing HP/IP Valves - HP Stop and Control Valves, and IP Stop and Control Valves

Amit Prakash76 POWER PLANT AUTOMATION & CONTROL Electro-hydraulic Governing System Speed Control Load Control Load Shedding Initial Pressure Control

Amit Prakash77 CRITICAL CLOSED LOOPS CMC - Boiler Follow / Turbine follow / Coordinated (Utility) Header Pressure Control (CPP) Combustion - Fuel / Air Flow Steam Temperature Drum Level Furnace Draft AUTOMATION & CONTROL

Amit Prakash78 AUTOMATION & CONTROL OPEN LOOP CONTROL Interlocking - Safe Startup / Shutdown Protection - Emergency Shutdown (Trip) Sequencial Control - Efficient Startup / Shutdown CRITICAL OPEN LOOPS ID/FD /PA Fans BFP

Amit Prakash79 POWER PLANT INSTRUMENTATION

Amit Prakash80 POWER PLANT INSTRUMENTATION Temperature - T/C & RTD Pressure Level - DP / Displacement / Hydra Step Drum Level Indicator Flow - DP / Annubar / Mag-flow Turbine Supervisory - Vibration/ Expansion/ Axial Shift/ Eccentricity Steam & Water Analysers - Conductivity/ pH/ DO2/ Silica Gas Analysers - O2/ CO2/ CO (in Flue Gas) Pollution Monitor H2 Purity (in Generator)