Power Plant Engineering

This text-cum-reference book has been written to meet the manifold requirement and achievement of the students and researchers. The objective of this book is to discuss, analyses and design the various power plant systems serving the society at present and will serve in coming decades India in particular and the world in general. The issues related to energy with stress and environment up to some extent and finally Read more... Abstract: This text-cum-reference book has been written to meet the manifold requirement and achievement of the students and researchers. The objective of this book is to discuss, analyses and design the various power plant systems serving the society at present and will serve in coming decades India in particular and the world in general. The issues related to energy with stress and environment up to some extent and finally find ways to implement the outcome Electrical Engineering, Electronics Engineering Preface 6 Contents 8 Chapter 1. Fundamental of Power Plant 22 1.1 Introduction 22 1.2 Concept of Power Plant 22 1.3 Classification of Power Plants 23 1.4 Energy 24 1.5 Types of Energy 25 1.6 Power 26 1.7 Power Development in India 26 1.8 Resources for Power Generation 28 1.9 Present Power Position in India 30 1.10 Future Planning for Power Generation 30 1.11 Power Corporations in India 32 1.11.1 National Thermal Power Corporation 32 1.11.2 National Hydro-Electric Power Corporation 32 1.11.3 Rural Electrification Corporation 33 1.11.4 Damodar Valley Corporation 33 1.11.5 North-Eastern Electric Power Corporation Limited 33 1.11.6 Bhakra Beas Management Board and Beas Construction Board 34 1.11.7 Power Engineers Training Society (Pets) 34 1.11.8 Central Power Research Institute (Cpri), Bangalore 34 1.11.9 Nathpa, Jhaicri Power Corporation Limited 34 1.12 Review of Thermodynamics Cycles Related to Power Plants 35 1.13 Classification of Power Plant Cycle 36 1.13.1 Carnot Cycle 36 1.13.2 Rankine Cycle 36 1.13.3 Reheat Cycle 37 1.13.4 Regenerative Cycle (Feed Water Heating) 37 1.13.5 Binary Vapour Cycle 38 1.13.6 Reheat-Regenerative Cycle 38 1.13.7 Formula Summary 39 1.14 Fuels and Combustion 39 1.15 Steam Generators 39 1.16 Steam Prime Movers 40 1.17 Steam Condensers 40 1.17.1 Surface Condensers 41 1.17.2 Jet Condensers 43 1.17.3 Types of Jet Condensers 43 1.18 Water (Hydraulic) Turbines 44 1.18.1 Impulse and Reaction Turbines 44 1.19 Science Vs. Technology 46 1.19.1 Scientific Research 46 1.19.2 Science and Technology Infrastructure 47 1.20 Facts Vs. Values 47 1.21 Atomic Energy 47 1.22 Highlights of the Nuclear Power Programme 48 1.23 Nuclear Power Corporation of India Limited 48 1.24 Ocean Engineering Applications 49 Chapter 2. Non-Conventional Energy Resources and Utilisation 54 2.1 Introduction 54 2.2 Energy Science 54 2.3 Various Energy Science 54 2.4 Energy Technology 56 2.5 Energy Technology and Energy Sciences 57 2.6. Law of Conservation of Energy 58 2.7 Facts and Figures about Energy 58 2.8 Indian and Global Energy Sources 59 2.8.1 The Sun 59 2.8.2 Petroleum 60 2.8.3 Natural Gas 64 2.8.4 Coal 65 2.8.5 Nuclear Energy 66 2.8.6 Lpg (Liquefied Petroleum Gas) 67 2.8.7 Alcohol 67 2.8.8 Gasohol 67 2.8.9 Hydro Power 67 2.9 Energy Exploited 67 2.10 Energy Demand 69 2.11 Energy Planning 70 2.12 Introduction to Various Sources of Energy 72 2.12.1 Conventional Sources of Energy 72 2.12.2 Non-Conventional Sources of Energy 72 2.13 Introduction to Various Non Conventional(Renewable) Sources of Energy 73 2.14 Bio-Gas 74 2.14.1 Aerobic and Anaerobic Bio-Conversion Process 74 2.14.2 Raw Materials 76 2.14.3 Properties of Bio Gas 77 2.14.4 Bio Gas Plant Technology 77 2.15 Wind Energy 79 2.15.1 Wind Machine Fundamentals 80 2.15.2 Aerofoil Design 81 2.15.3 Wind Power Systems 83 2.15.4 Economic Issues 84 2.15.5 Selection of Wind Mill 85 2.15.6 Recent Developments 86 2.16 Solar Energy 87 2.16.1 Solar Radiations 88 2.16.2 Solar Thermal Power Plant 89 2.16.3 Solar Energy Storage 91 2.16.4 Recent Developments in Solar Power Plants 93 2.17 Electrochemical Effects and Fuel Cells 94 2.17.1 Reversible Cells 94 2.17.2 Ideal Fuel Cells 95 2.17.3 Other Types of Fuel Cells 96 2.17.4 Efficiency of Cells 97 2.18 Thermionic Systems and Thermionic Emission 99 2.18.1 Thermoionic Conversion 100 2.18.2 Ideal and Actual Efficiency 101 2.19 Thermoelectric Systems 103 2.19.1 Principle of Working 103 2.19.2 Performance 104 2.20 Geo Thermal Energy 107 2.20.1 Hot Springs 108 2.20.2 Steam Ejection 108 2.20.3 Site Selection 109 2.20.4 Geothermal Power Plants 109 2.20.5 Advanced Concepts 116 2.21 Ocean Energy 118 2.21.1 Power Plants Based on Ocean Energy 119 2.22 Other Technology 122 2.22.1 Liquid Fuel 122 2.22.2 Fuel Cell Technology 124 2.22.3 Hydrogen Energy 125 2.22.4 Hydrogen Energy Technology 125 2.22.5 Battery Operated Vehicles 127 2.22.6 Bio Fuel Technology 128 2.22.7 Hydroelectric Power 128 2.22.8 Innovative Heat Exchanger to Save Energy 129 Chapter 3. Power Plant Economics and Variable Load Problem 141 3.1 Terms and Factors 141 3.2 Factor Effecting Power Plant Design 143 3.3 Effect of Power Plant Type on Costs 143 3.3.1 Initial Cost 143 3.3.2 Rate of Interest 144 3.3.3 Depreciation 144 3.3.4 Operational Costs 145 3.3.5 Cost of Fuels 146 3.3.6 Labour Cost 146 3.3.7 Cost of Maintenance and Repairs 146 3.3.8 Cost of Stores 146 3.3.9 Supervision 147 3.3.10 TAXES 147 3.4 Effect of Plant Type on Rates(Tariffs or Energy Element) 147 3.4.1 Requirements of a Tariff 147 3.4.2 Types of Tariffs 147 3.5 Effect of Plant Type on Fixed Elements 150 3.6 Effect of Plant Type on Customer Elements 150 3.7 Investor’s Profit 150 3.8 Economics in Plant Selection 151 3.9 Economic of Power Generation 152 3.10 Industrial Production and Power Generation Compared 153 3.11 Load Curves 153 3.12 Ideal and Realized Load Curves 154 3.14 Effect of Variable Load on Power Plant Design 154 Chapter 4. Steam Power Plant 163 4.1 Introduction 163 4.2 Essentials of Steam Power Plant Equipment 163 4.2.1. Power Station Design 165 4.2.2. Characteristics of Steam Power Plant 165 4.3 Coal Handling 166 4.3.1 Dewatering of Coal 170 4.4 Fuel Burning Furnaces 171 4.4.1 Types of Furnaces 171 4.5 Method of Fuel Firing 172 4.5.1 Hand Firing 172 4.5.2 Mechanical Firing (Stokers) 174 4.6 Automatic Boiler Control 177 4.7 Pulverized Coal 178 4.7.1 Ball Mill 179 4.7.2 Ball and Race Mill 180 4.7.3 Shaft Mill 182 4.8 Pulverised Coal Firing 182 4.9 Pulverised Coal Burners 184 4.9.1 Cyclone Fired Boilers 187 4.10 Water Walls 187 4.11 Ash Disposal 188 4.11.1 Ash Handling Equipment 189 4.12 Smoke and Dust Removal 193 4.13 Types of Dust Collectors 193 4.13.1 Fly Ash Scrubber 195 4.13.2 Fluidised Bed Combustion (Fbc) 196 4.13.3 Types of Fbc Systems 197 Chapter 5. Steam Generator 200 5.1 Introduction 200 5.2 Types of Boilers 200 5.3 Cochran Boiler 202 5.4 Lancashire Boiler 204 5.5 Locomotive Boiler 206 5.6 Babcock Wilcox Boiler 208 5.7 Industrial Boilers 210 5.8 Merits and Demerits of Water Tube Boilers over fire Tube Boilers Merits 210 5.9 Requirements of a Good Boiler 211 5.10 High Pressure Boilers 211 5.10.1 La Mont Boiler 212 5.10.2 Benson Boiler 212 5.10.3. Loeffler Boiler 213 5.10.4. Schmidt-Hartmann Boiler 214 5.10.5. Velox-Boiler 214 Chapter 6.Steam Turbine 216 6.1. Principle of Operation of Steam Turbine 216 6.2. Classification of Steam Turbine 217 6.3. The Simple Impulse Turbine 221 6.4. Compounding of Impulse Turbine 222 6.5. Pressure Compounded Impulse Turbine 223 6.6. Simple Velocity-Compounded Impulse Turbine 224 6.7 Pressure and Velocity Compounded Impulse Turbine 225 6.8. Impulse-Reaction Turbine 226 6.9 Advantages of Steam Turbine over Steam Engine 227 6.10. Steam Turbine Capacity 227 6.11 Capability 228 6.12 Steam Turbine Governing 228 6.13 Steam Turbine Performance 228 6.14 Steam Turbine Testing 229 6.15 Choice of Steam Turbine 229 6.16 Steam Turbine Generators 229 6.17 Steam Turbine Specifications 230 Chapter 7. Fuels and Combustion 238 7.1 Introduction 238 7.2 Coal 238 7.3 Coal Analysis 240 7.3.1 Proximate Analysis 240 7.3.2 Ultimate Analysis 240 7.3.3 Heating Value 240 7.4 Coal Firing 242 7.5 Mechanical Stokers 243 7.6 Pulverized-Coal Firing 245 7.7 Cyclone Furnaces 251 Chapter 8. Diesel Power Plant 255 8.1 Introduction 255 8.2 Operating Principle 257 8.3 Basic Types of IC Engines 257 8.3.1 Two-Stroke, Spark Ignition Gas Engines/Petrol Engines 258 8.3.2 Diesel Engines/Heavy Oil Engines 258 8.3.3 Duel Fuel Engines 258 8.3.4 High Compression Gas Engines 259 8.4 Advantage of Diesel Power Plant 259 8.5 Disadvantage of Diesel Power Plant 259 8.6 Application of Diesel Power Plant 259 8.7 General Layout of Diesel Power Plant 260 8.8 Performance of Diesel Engine 260 8.8.1 Indicated Mean Effective Pressure (Imep) 260 8.8.2 Indicated Horse Power (Ihp) 260 8.8.3 Brake Horse Power (B.H.P.) 261 8.8.4 Frictional Horse Power (F.H.P.) 261 8.8.5 Indicated Thermal Efficiency 261 8.8.6 Brake Thermal Efficiency (Overall Efficiency) 261 8.8.7 Mechanical Efficiency 261 8.9 Fuel System of Diesel Power Plant 262 8.10 Lubrication System of Diesel Power Plant 263 8.10.1 Liquid Lubricants or Wet Sump Lubrication System 265 8.10.2 Solid Lubricants or Dry Sump Lubrication System 267 8.10.3 Mist Lubrication System 267 8.11 Air Intakes and Admission System of Diesel Power Plant 267 8.12 Supercharging System of Diesel Power Plant 268 8.12.1 TYPES OF SUPERCHARGER 269 8.12.2 ADVANTAGE OF SUPERCHARGING 270 8.13 Exhaust System of Diesel Power Plant 270 8.14 Cooling System of Diesel Power Plant 271 8.14.1 OPEN COOLING SYSTEM 272 8.14.2 NATURAL CIRCULATION SYSTEM 272 8.14.3 FORCED CIRCULATION COOLING SYSTEM 272 8.15 Diesel Plant Operation 273 8.16 Efficiency of Diesel Power Plant 274 8.17 Heat Balance Sheet 276 Chapter 9. Gas Turbine Power Plant 288 9.1 Introduction 288 9.2 Classification of Gas Turbine Power Plant 288 9.2.1 Open Cycle Gas Turbine Power Plant 289 9.2.2 Closed Cycle Gas Turbine Power Plant 290 9.3 Elements of Gas Turbine Power Plant 293 9.3.1. Compressors 293 9.3.2. Intercoolers and Heat Exchangers 294 9.3.3 Combustion Chambers 295 9.3.4. Gas Turbines 297 9.4 Regeneration and Reheating 297 9.4.1 Regeneration 297 9.4.2 Reheating 299 9.5 Cogeneration 300 9.5.1 Cogeneration — Why 300 9.5.2 Cogeneration Technologies 301 9.6 Auxiliary Systems 303 9.6.1 Starting Systems 303 9.6.2 Ignition Systems 304 9.6.3 Lubrication System 304 9.6.4 Fuel System and Controls 306 9.7 Control of Gas Turbines 307 9.7.1 Prime Control 307 9.7.2 Protective Controls 308 9.8 Gas Turbine Efficiency 310 9.8.1 Effect of Blade Friction 312 9.8.2 Improvement in Open Cycle 312 9.9 Operations and Maintenance Performance 313 9.9.1 Operation 313 9.9.2 Maintenance Performance 314 9.10 Troubleshooting and Remedies 315 9.11 Combined Cycle Power Plants 316 9.12 Applications of Gas Turbine 317 9.13 Advantages of Gas Turbine Power Plant 317 9.14 Disadvantages 318 Chapter 10. Nuclear Power Plant 328 10.1 Introduction 328 10.2 General History and Trends 329 10.2.1 Major Events 329 10.2.2 What Might Change the Current Situation? 330 10.2.3 Technical History and Developments 332 10.2.4 Developments after WW-2 332 10.3 The Atomic Structure 333 10.4 Summary of Nuclear Energy Concepts and Terms 335 10.4.1 Summary of Features 335 10.4.2 Fission 335 10.4.3 Critical Mass 336 10.4.4 Alpha Radiation 336 10.4.5 Beta Particles 336 10.4.6 Gamma Particles 336 10.4.7 Uranium Fission 336 10.4.8 Half Life, T 337 10.5 Ethical Problems in Nuclear Power Regulation 337 10.6 Chemical and Nuclear Equations 337 10.7 Nuclear Fusion and Fission 338 10.8 Energy from Fission and Fuel Burn Up 341 10.9 Radioactivity 341 10.10 Nuclear Reactor 343 10.10.1 Parts of a Nuclear Reactor 343 10.10.2 Nuclear Fuel 343 10.10.3 Moderator 345 10.10.4 Moderating Ratio 345 10.10.5 Reflector 346 10.10.6 Reactor Vessel 346 10.10.7 Biological Shielding 347 10.10.8 Coolant 347 10.10.9 Coolant Cycles 347 10.10.10 Reactor Core 347 10.11 Conservation Ratio 348 10.12 Neutron Flux 348 10.13 Classification of Reactors 348 10.14 Cost of Nuclear Power Plant 348 10.15 Nuclear Power Station in India 349 10.16 Light Water Reactors (LWR) and Heavy Water Reactors (HWR) 352 10.16.1 Importance of Heavy Water 353 10.17 Site Selection 354 10.18 Comparison of Nuclear Power Plant and Steampower Plant 355 10.19 Multiplication Factor 355 10.20 Uranium Enrichment 355 10.21 Reactor Power Control 357 10.22 Nuclear Power Plant Economics 357 10.23 Safety Measures for Nuclear Power Plants 358 10.24 Site Selection and Commissioning Procedure 359 10.25 Major Nuclear Power Disasters 359 10.26 Chernobyl Nuclear Power Plant 360 10.26.1 Reactor Design : Rbmk-1000 361 10.26.2 Control of the Reactor 361 10.26.3 Chernobyl Reactor Operations 361 10.26.4 Accident\Safety Plans 361 10.27 Safety Problems in Chernobyl Reactor Design 361 10.27.1 System Dynamics 361 10.28 Other, Earlier, Soviet Nuclear Accidents 362 Chapter 11. Hydro-Electric Power Plants 364 11.1 Introduction 364 11.2. Run-Off 366 11.3. Hydrograph and Flow Duration Curve 368 11.4. The Mass Curve 368 11.5. Selection of Site for a Hydro-Electric Power Plant 369 11.6. Essential Features of a Water-Power Plant 370 11.7. Calculations of Water Power Plants 372 11.8. Classification of Hydro-Plant 373 11.8.1 STORAGE PLANTS 373 11.8.2. RUN-OF-RIVER POWER PLANTS 375 11.8.3. PUMPED STORAGE POWER PLANTS 375 11.9 Power House and Turbine Setting 376 11.9.1. Advantages and Disadvantages of Underground Power-House 380 11.10 Prime-Movers 383 11.11. Specific Speed of Turbine 388 11.12 Draft Tubes 391 11.12.1 METHODS TO AVOID CAVITATION 396 11.12.2 Types of Draft Tubes 396 11.12.3 DIFFERENT TYPES OF DRAFT TUBES 398 11.13 Models and Model Testing 399 11.14. Selection of Turbine 402 Chapter 12. Electrical System 407 12.1 Introduction 407 12.2 Generators and Motors 407 12.2.1 Rotors 408 12.2.2 Stators 410 12.2.3 Ventilation 411 12.2.4 High-Voltage Generators 413 12.3 Transformers 413 12.3.1. Constructional Parts 414 12.3.2. Core Constructions 414 12.4 Cooling of Transformers 423 12.4.1 Simple Cooling 424 12.4.2 Mixed Cooling 424 12.4.3 Natural Oil Cooling 424 12.4.4 Forced Oil Cooling 426 12.4.5 Internal Cooling 427 12.5 Bus-Bar 430 12.5.1 Single Bus-Bar System 430 12.5.2 Single Bus-Bar System with Sectionalisation 430 12.5.3 Duplicate Bus-Bar System 431 12.6 Busbar Protection 432 12.6.1 Differential Protection 432 12.6.2 Fault Bus Protection 433 Chapter 13. Pollution and its Control 435 13.1 Introduction 435 13.2 Environment Polllution due to Energy Use 435 13.3 Environment Pollution due to Industrial Emissions 436 13.4 Environment Polllution due to Road Transport 436 13.5 Harmful Effects of Emissions 436 13.5.1 BUILDING AND MATERIALS 437 13.5.2 SOIL, VEGETABLE AND ANIMAL LIFE 437 13.5.3 HUMAN BEINGS 437 13.6 Steps Taken so far and their Impact 437 13.7 Noise Pollution and Its Control 438 13.8 Green House Gases and their Effects 439 13.9 Fossil Fuel Pollution 440 13.9.1 Urban Air Pollution 440 13.9.2 Acid Rain 441 13.9.3 Global Climate Change 441 13.9.4 Stratospheric Ozone Depletion 441 13.9.4 Acid Fog 441 13.10 Pollution due to Combustion of Fuel 442 13.10.1 Gas Fuel 442 13.10.2 Methane 442 13.10.3 Alkanes 443 13.11 Pollution due to Gas Combustion 443 13.11.1 Unburned Hydrocarbons (UHCS) 443 13.11.2 Carbon Monoxide (CO) 443 13.11.3 Nitric Oxide (NOx) 443 13.11.4 Soot 445 13.12 Pollution due to Liquid Fuel 445 13.12.1 Atomization 445 13.12.2 Vaporization 445 13.12.3 Modes of Combustion 445 13.13 Pollution due to Solid Fuel 446 13.14 Air Pollution by Thermal Power Plants 449 13.15 Water Pollution by Thermal Power Plants 449 13.16 Environment Concerns and Diesel Power Plants 450 13.17 Nuclear Power Plant and the Environment 452 13.17.1 The Fuel Cycle 453 13.17.2 Wastes 454 13.18 Radiations from Nuclear-Power Plant Effluents 455 13.19 Impact on Pollution Load and Air Quality in Delhi 455 13.19.1 Environmental Concerns 456 13.19.2 Pollution Levels 456 13.19.3 Measures to Combat Pollution 457 13.20 Method for Pollution Control 461 13.21 Control of Marine Pollution 462 Appendix 464 Glossary 466 Bibliography 476 Index 483 This Book Being Pilot Project Of The Authors Specially In The Area Of Conventional Power Plant Will Satisfy The Engineering Scholars As Well As Researchers In The Field Of Direct Energy Conversion Devices. In The Present Book The Syllabi Enclosed Has Been Covered In The Most Lucid Manner From Power Plant Point Of View To Avoid The Unnecessary Bulkiness And To Reduce The Cost Of The Price For The Benefit Of Our Beloved Students Of Engineering In Particular And Others In General.