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Introduction to Power Plant Engineering

Name: Introduction to Power Plant Engineering
Author: Amitava Sarkaar
ISBN: 9789367133705

by Amitava Sarkaar

January 2025

Beginner

800 pages

24h 26m

English

Pearson India

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Cover
About Pearson
Title Page
Dedication
Contents
Foreword
Preface
Acknowledgements
About the Authors
Chapter 1: Energy and Economics of Power Generation
1.1 Energy Defined1.2 Classifications of Energy1.3 Introduction to the Energy System1.4 Quantification of Energy1.5 Energy Flow Diagrams1.6 Reference Energy Systems (RES)1.7 Power Plant Economics1.7.1 Definition of Standard Factors1.7.2 Basic Economics of Power Generation1.7.3 Plant Net Heat Rate1.7.4 Economic Operation of Power System1.7.5 Unit Commitment1.8 A Few Words About Energy Demand Management1.8.1 Load ManagementAppendixReferencesShort QuestionsNumerical Problems

Chapter 2: Review of Thermodynamics
2.1 Introduction2.2 Some Basic Definitions2.2.1 Work and Heat2.3 First Law of Thermodynamics for Closed System2.3.1 Expansion and Compression Work2.3.2 Ideal Gas Law2.3.3 Thermodynamic Cycle2.4 First Law of Thermodynamics for Open System2.5 Second Law of Thermodynamics2.5.1 Reversible and Irreversible Processes2.5.2 External and Internal Irreversibilities2.6 Clausius Statement of the Second Law2.6.1 Heat Engines2.7 Carnot CycleReferencesShort QuestionsNumerical Problems
Chapter 3: Vapour Power Cycles
3.1 Introduction3.2 Carnot Cycle3.3 Ideal Rankine Cycle3.3.1 Water as the Working Fluid3.4 Methods for Improving the Thermal Efficiency/Net Work of Rankine Power Cycle3.4.1 Superheating3.4.2 Reheating3.5 Qualitative Difference Between the Carnot and Rankine Cycle3.5.1 An Ideal Regenerative Cycle3.6 Combination of Reheat and Regenerative Cycle3.7 On the Placement of Feed Water Heaters in a Power Cycle3.8 Advanced Rankine Cycle Steam Plants3.9 Cogeneration3.9.1 Types of Cogeneration3.10 Alternative Working Fluids for Vapour Cycles3.11 Binary Vapour CyclesReview QuestionsNumerical Problems
Chapter 4: Gas Power Cycles
4.1 Introduction4.1.1 An Ideal Gas Turbine Plant4.2 Combined Cycle Gas Turbine (CCGT) Power Plants4.2.1 Energy Distribution in a Typical CCGT Plant4.3 Introduction to Reciprocating Internal Combustion Engines4.3.1 Engine Performance4.3.2 Losses in an Engine4.3.3 Engine Performance Curves4.4 Supercharging and TurbochargingReferencesShort QuestionsNumerical Problems
Chapter 5: Fossil Fuels
5.1 Introduction5.2 Coal5.2.1 Types of Coal5.3 Analysis and Tests of Coal5.3.1 Classification of Coal By Rank5.3.2 Important Tests on Coal5.3.3 Hardgrove Grind-Ability Index (HGI)5.3.4 Abrasion Index5.3.5 Swelling Index5.3.6 Weatherability5.3.7 Spontaneous Combustion5.3.8 Burning Profile Technique5.3.9 Ash Softening Temperature5.4 Petroleum5.5 Fuel Oil Properties5.5.1 API Gravity of Oils5.5.2 Heating Values of Fuel Oils5.5.3 Viscosity of Fuel Oils5.5.4 Sulphur Content5.5.5 Flash Point5.5.6 Cloud and Pour Point5.5.7 Cleanliness and Stability5.6 Natural Gas5.7 Synthetic Fuels5.7.1 Coal Gasification5.7.2 Coal Liquefaction5.7.3 Stoichiometric Calculations5.7.4 Excess Air5.7.5 Composition of Flue Gas and Its Determination5.8 Introduction to Fuel Combustion5.8.1 Enthalpy of Reaction and Heating Values5.8.2 Adiabatic Flame Temperature5.9 Combustion of Solid Carbonaceous Fuels5.9.1 Heating of Coal Particles5.10 Devolatilization5.10.1 Combustion of Volatiles5.10.2 Influence of Devolatilization on Ignition5.11 Char Combustion5.12 Char De-Activation5.13 Combustion of Cloud of Particles5.14 Prospects of Coal Blend as Fuel in Utility Boilers5.15 Introduction to the Combustion of Liquid Fuels5.15.1 An Isolated Liquid DropReferencesReview QuestionsNumerical Problems
Chapter 6: Fossil Fuel Based Utility Steam Generators
6.1 Introduction6.2 Classification of Boiler6.2.1 Cochran Boiler6.2.2 Babcock and Wilcox Boiler6.3 Methods of Coal Firing6.3.1 Stoker Firing Systems6.3.2 Travelling Grate Stoker Firing6.3.3 Flow Diagram of a Typical Pulverized Coal Fired Boiler Plant6.4 Water Circulation in Steam Generators6.4.1 Circulation Ratio6.4.2 Natural Circulation6.4.3 Pump-Assisted Circulation6.4.4 Once-Through Circulation6.4.5 Once Through Type with Superimposed Pumped Re-Circulation6.5 Supercritical and Sub-Critical Pressure Operation6.6 Furnace6.6.1 Furnace Requirements6.6.2 Structure of Furnace Bottom6.6.3 Characterization of Furnace6.6.4 Furnace Water-Walls6.6.5 Furnace Profile6.6.6 Release of Heat in Furnace6.6.7 Furnace Shape Factor6.6.8 Leakage of Air into the Furnace6.6.9 Furnace Exit Gas Temperature (FEGT)6.6.10 Furnace Mass Balance6.6.11 Furnace Implosion and Explosion6.7 Burners for Pulverized Coal Fired Boilers6.7.1 Classification of Pulverized Coal Burners6.7.2 Arrangement of Burners6.8 Fans6.8.1 Types of Fans Used for Utility Applications6.8.2 Fan Types6.8.3 System Resistance6.8.4 Fan Laws6.8.5 Fan Characteristics6.8.6 Drive System for Fans6.8.7 Fan Control6.8.8 Variable Speed Drives6.9 Draft6.9.1 Natural Draft6.9.2 Mechanical Draft6.10 Pulverization Systems6.10.1 Closed Pulverization Systems6.10.2 Open Pulverization Systems6.11 Steam Drum6.11.1 Drum Connections6.11.2 Separation of Steam from Steam-Water Mixture6.11.3 Priming and Foaming Processes in Drum6.11.4 Carryover6.11.5 Size and Manufacturing Aspects of Steam Drums6.12 Low Temperature Heating Surfaces6.12.1 Arrangements of Low Temperature Heating Surfaces6.12.2 Air Heaters6.12.3 Economizer6.13 Superheaters and Reheaters6.13.1 Classification of Superheaters6.13.2 Load Characteristics of Superheaters6.13.3 Location of Super Heaters6.13.4 Vertical and Horizontal Superheaters6.13.5 Fixing of Horizontal and Vertical Super Heaters6.13.6 Use of Fins in Superheaters/Reheaters
6.14 High Pressure Boilers
6.14.1 Sub-Critical Versus Supercritical Pressure Boilers6.14.2 Advantages of Supercritical Boilers6.14.3 Terminal Steam Conditions6.14.4 Pump Work and Specific Coal Consumption6.14.5 Furnace for Supercritical Boilers6.14.6 Types of Operations of Supercritical Boilers6.14.7 Variable Pressure Operation Versus Constant Pressure Operation6.15 Fluidised Bed Boilers6.15.1 Theory of Fluidization6.15.2 Pressure Drop in the Bed6.15.3 General Features of FBC6.15.4 The BFBC Combustor6.15.5 Circulating Fluidized Bed Combustion (CFBC)6.15.6 Pressurized Fluidized Bed Boilers6.16 Boiler Efficiency6.16.1 Input Output Method6.16.2 Loss Due to Incomplete Combustion6.16.3 Loss Due to Moisture6.16.4 Unburnt Carbon Loss6.16.5 Physical Heat of Slag6.16.6 Radiation and Convection Loss6.16.7 Dry Gas Heat LossReferenceAppendix-1: Interaction of Jets from Stack of BurnersShort QuestionsNumerical Problems
Chapter 7: Soot Blowers and Boiler Feed Pump
7.1 Soot Blowers7.1.1 Soot Blower Action Areas7.1.2 Types of Soot Blowers7.1.3 Soot Blowing Medium7.1.4 Soot Blower Induced Boiler Tube Erosion7.1.5 When to Use Soot-Blowers?7.1.6 Effect of Fuel Switching on Soot Blower Performance7.2 Boiler Feed Pump7.2.1 Principle of Operation of Boiler Feed Pumps7.2.2 Specific Speed of Pump7.2.3 Important Hydraulic Considerations7.2.4 Selection of Design Point of BFP7.2.5 Arrangement of Boiler Feed Pump in Feed Circuit7.2.6 Drives for BFP7.2.7 Noise in Boiler Feed Pump7.2.8 Erosion in Boiler Feed Pumps7.2.9 Thrust Reduction in Boiler Feed PumpsReferenceReview QuestionsNumerical Problems
Chapter 8: Pulverization of Coal and Some Ash Related Issues
8.1 Introduction8.2 Necessity of Pulverized Coal8.2.1 Reasons for and Against the Use of a Pulverized Coal Plant8.3 Important Properties of Coal for Pulverization8.3.1 Volatility8.3.2 Grindability8.3.3 Fineness8.3.4 Moisture8.3.5 Abrasion8.3.6 Pulverizer Design Coal8.4 Drying of Pulverized Coal8.4.1 Mill Inlet and Exit Temperature8.5 Coal Dust Characteristics8.6 Classification and Layout of Pulverization Plant8.6.1 Layout of a Central or Bin System8.6.2 Layout of a Direct-Fired System8.7 Types of Pulverization Mills8.7.1 Ball and Tube Mill8.7.2 Ball and Race Mill8.7.3 Unit Turndown8.7.4 Ignitors and Warmup Burners8.8 Pulverizer Plant Auxiliaries8.8.1 Coal Crushers8.8.2 Coal Feeders8.8.3 Dust Classifier8.8.4 Cyclones8.8.5 Dust Bunkers8.8.6 Dust Feeders8.9 Coal Pipes8.9.1 Coal Roping8.9.2 Branching Out of Main Coal Pipe8.9.3 Corrosion and Erosion Problems in Coal Pipes8.10 Coal Pipe Network8.11 Ash: Its Constituents, Formation Mechanism and Removal8.11.1 What is Ash?8.11.2 Ash Constituents8.11.3 Disturbing Aspects of Ash8.11.4 Ash Formation in Pulverized Coal Fired Boiler8.11.5 Ash Deposition8.11.6 Formation of Slag Layer8.11.7 Formation of Deposits Due to Fouling8.11.8 Shedding of Deposits8.11.9 Role of a Soot Blower8.12 Monitoring of Ash Fouling and SlaggingReferencesReview Questions
Chapter 9: Condenser, Cooling Tower and Feed Heaters
9.1 Introduction9.2 Condensers9.2.1 Direct Contact Type Condensers9.2.2 Surface Condensers9.2.3 Deaeration in Condenser9.2.4 Surface Condenser Calculations9.2.5 Calculation of Air Leakage9.2.6 Steam Jet Air Ejector (SJAE)9.2.7 Performance of Condensers9.2.8 Factors That Affect Condenser Performance9.2.9 Measurements for Performance Testing of Condensers9.3 Cooling Towers9.3.1 Types of Cooling Towers9.3.2 Some General Features of Cooling Towers9.3.3 Revisit to Psychometry and Cooling Tower Calculations9.3.4 Thermal Analysis of Cooling Tower9.4 Circulating Water Systems9.4.1 Circulating Water System Components9.5 Feedwater Heaters9.5.1 Open Type Feed Heaters9.5.2 Closed Type Feed HeatersReferenceReview QuestionsNumerical ProblemsAppendix-1 (A Brief Introduction to Condensation Heat Transfer)Appendix-2 (Recirculation and Interference in Cooling Tower)
Chapter 10: Water Treatment
10.1 Introduction10.2 On the Use of Water in Thermal Power Plants10.3 Some Basic Definitions in Connection with Water Chemistry10.4 Scale Deposit and Corrosion10.4.1 Scale Deposits10.4.2 Corrosion10.5 Water Treatment ProcessesReferencesReview Questions
Chapter 11: Steam Turbines
11.1 Introduction11.2 Principle of Operation of Steam Turbine11.3 Classification of Turbines11.3.1 The Impulse Principle11.3.2 Steam Nozzles11.4 Impulse Turbines11.4.1 Simple Velocity Compounded Impulse Turbine11.4.2 Pressure Compounded Impulse Turbine11.4.3 Pressure Velocity Compounded Impulse Turbine11.5 The Reaction Principle11.5.1 Reaction Turbine11.5.2 Degree of Reaction11.5.3 Condition Curve of a Compound Turbine11.5.4 Combined Impulse and Reaction Turbine11.6 Axial Thrust in Steam Turbines11.7 Twisted Blades in Steam Turbines11.8 Turbine Losses11.8.1 Fluid Friction Losses11.8.2 Residual Velocity Loss11.8.3 Gland Leakage Losses11.8.4 Heat Transfer Losses11.8.5 Partial Admission Losses11.9 Turbine Arrangements11.10 Governing of Steam Turbine11.10.1 Throttle Governing11.10.2 Nozzle Control Governing11.10.3 Bypass Governing11.11 Introduction to Steam Turbine Components and Materials11.11.1 Turbine Casings11.11.2 Types of Steam Turbine Rotors11.11.3 Rotor Discs11.11.4 Diaphragms11.11.5 Some Features of Low-Pressure Turbines11.11.6 Labyrinth Gland Seals11.11.7 Couplings for Steam Turbines11.11.8 Barring Gears of Turbine11.11.9 Bearings and Lubrication Systems11.12 Critical or Whirling Speed of a RotorReferencesShort QuestionsNumerical Problems
Chapter 12: Plant Control
12.1 Introduction12.2 Basic Control Actions12.3 Basic Definitions and Concepts12.3.1 Closed Loop Control Versus Open Loop Control12.3.2 Transient Response and Steady State Response12.3.3 Elements of Control12.3.4 Feedback, Feed Forward Control12.3.5 Monitoring Functions12.4 Use of Computer in the Implementation of Control and Monitoring Function12.4.1 Some Applications of ON-OFF Control Systems12.4.2 Sequential Control Logic12.4.3 Modulating Control Applications12.4.4 Condition Monitoring12.4.5 Model Based Control Applications12.5 Control System Elements12.5.1 Sensors12.5.2 Control Valves12.5.3 Actuators12.5.4 Control System Hardware and Software12.6 The 21st Century Control Room12.6.1 Human–Machine InterfacesReferencesReview Questions
Chapter 13: Hydel Power Plants
13.1 Introduction13.2 Sites for Hydel Stations13.3 Dams and Barrages13.3.1 Reservoir Projects13.3.2 Run-of-River Project13.4 Important Components of a Hydel Power Plant13.4.1 Penstock13.4.2 Control Gate13.4.3 Surge Tank13.5 Water Turbines13.5.1 Impulse Turbines13.5.2 Reaction Turbines13.5.3 Plant AuxiliariesReferencesShort QuestionsNumerical Problems
Chapter 14: Diesel Power Plants
14.1 Introduction to Reciprocating Internal Combustion Engines14.2 Diesel Engines14.2.1 Principal Components of a Diesel Engine14.2.2 Auxiliary Systems14.2.3 Layout of a Typical Diesel Power Plant14.3 Fuel Admission System in Diesel Engines14.3.1 Individual Pump System14.3.2 Plunger Geometry14.3.3 Role of Control Rack14.3.4 Operation14.3.5 Common Rail Fuel Injection System14.4 Supercharging and Turbo-Charging14.4.1 Need for Exhaust Gas Bypass in Turbochargers14.5 Lubrication in Engines14.5.1 Lubricating Systems in Engines14.6 Cooling of Large Engines14.6.1 Direct or Non-Return System14.6.2 Thermo-Syphon Water Cooling System14.6.3 Pump/Forced Circulation System14.7 Noise14.7.1 Sources of Noise in an Engine14.7.2 Intake and Exhaust System Noise14.8 Tests on Engines14.9 Governing of Diesel Engines14.10 Fuels for Diesel Engines14.10.1 Knocking Quality14.10.2 Volatility14.10.3 Viscosity14.10.4 Impurities14.10.5 Flash Point14.10.6 Sulfur Content14.10.7 Cloud and Pour Point14.10.8 Cleanliness and StabilityReferencesShort QuestionsNumerical Problems
Chapter 15: Gas Turbines
15.1 Introduction15.2 Thermodynamic Fundamentals15.2.1 Rankine Cycle and Brayton Cycle Compared15.3 Gas Turbine Cycle15.3.1 Analysis of the Ideal Gas Turbine Plant15.3.2 Methods of Increasing the Work Output15.3.3 Cycles with Intercooled Compression15.4 Differences Between Ideal and Actual Cycles15.5 Stagnation Properties15.6 Polytropic Efficiency15.6.1 Actual T-S Diagram of an Open Gas Turbine Cycle15.7 Gas Turbine Components15.7.1 Inlet Air System15.7.2 Compressor15.7.3 Centrifugal Compressor15.7.4 Impeller15.7.5 Diffuser15.7.6 Axial Flow Compressor15.7.7 Gas Turbine Combustion Chamber15.7.8 Combustor Requirements15.8 Combustor Types15.8.1 Pressure Loss in the Combustion Chamber15.9 Turbines15.9.1 Elementary Theory of Axial Flow Turbine15.9.2 Mean Diameter Treatment15.10 Exhaust System15.11 Starting of Gas Turbines15.12 Auxiliary Systems15.13 Gas Turbine Fuels15.14 NOx ControlReferencesShort QuestionsNumerical Problems
Chapter 16: Nuclear Power
16.1 Introduction16.2 Fundamentals of Nuclear Power16.2.1 The Atomic Structure16.2.2 Mass Defect16.2.3 Chemical and Nuclear Reactions16.2.4 Energy from Nuclear Reactions16.3 Nuclear Fuels16.4 Nuclear Processes16.4.1 Fusion16.4.2 Fission16.4.3 Radioactivity16.5 Nuclear Reactors16.5.1 Nuclear Criticality16.5.2 Critical Mass of a Reactor16.5.3 Reactor Control16.5.4 Classification of Reactors16.5.5 Types of Thermal Reactors16.5.6 Breeding Ratio16.6 Nuclear Waste Disposal16.7 Fusion ReactorReferenceShort QuestionsAppendixNumerical Problems
Chapter 17: Energy Storage
17.1 Why Energy is Needed to be Stored?17.2 Some Definitions in Connection with the Energy Storage Systems17.2.1 Energy Storage Systems17.3 Mechanical Energy Storage17.3.1 Pumped Hydro Systems17.3.2 Gravity Energy Storage (GES)17.3.3 Compressed Air Energy Storage Systems (CAES)17.3.4 Energy Storage By Fly Wheels17.4 Electrical Energy Storage System (EES)17.4.1 Superconducting Magnetic Energy Storage17.4.2 Capacitors17.5 Electrochemical Storage Systems17.5.1 Lead Acid Batteries17.5.2 Lithium Ion Batteries17.5.3 Other Batteries17.5.4 Hydrogen Energy17.6 Thermochemical Energy Storage (TES)17.7 Thermal Energy Storage17.7.1 Sensible Heat Storage (SHS) Method17.7.2 Latent Heat Energy StorageReferencesReview QuestionsNumerical Problems
Chapter 18: Renewable Energy
18.1 Introduction18.2 Solar Energy18.2.1 Sun - the Source18.2.2 Sites for Solar Power Generation18.2.3 Methods for Harnessing the Solar Energy18.2.4 Solar Thermal Power Generation18.2.5 Photovoltaic Cell18.3 Wind Power18.3.1 Locating a Wind Power Site18.3.2 Important Features of a Wind Mill18.3.3 About the Turbine18.3.4 Principles of Wind Power18.3.5 Influence of Some Other Forces on a Wind Turbine Rotor18.3.6 Control of Wind Turbines18.3.7 Layout of a Typical Wind Power Plant18.4 Pumped Hydro Energy Storage18.5 Geothermal Energy18.5.1 Geothermal Fields18.5.2 Geothermal Fluids18.5.3 Sites for Geothermal Plants18.5.4 Collection and Transmission of Geothermal Fluids18.5.5 On the Utilisation of Geothermal Fluids for Power Generation18.6 Tidal Energy18.6.1 Simple Single Pool Tidal SystemAppendix: Introduction to Micro GridReferencesReview QuestionsNumerical Problems
Chapter 19: Environmental Aspects of Power Generation
19.1 Introduction19.2 Combustion Generated Pollutants19.3 Formation of NOx and Its Control19.3.1 NOx Control19.3.2 Reduction of NOx During Combustion Process19.4 Particulate Matters19.4.1 Methods of Ash Removal19.4.2 Electrostatic Precipitator19.5 Removal of Sulfur19.5.1 Removal of Sulphur During Combustion Process19.5.2 Flue Gas Desulphurization19.5.3 Wet Scrubbing Process19.5.4 Dry Scrubbing Process19.6 Carbon Capture Systems (CCS)19.6.1 Post-Combustion CO2-capture19.7 Greenhouse Effect19.7.1 Acid Precipitation19.7.2 Acid Rain and Acid Snow19.7.3 Dry Deposition19.7.4 Acid Fog19.8 Pollution from Nuclear Power Plants19.8.1 Definition of Curie19.8.2 Sources of Pollution from Nuclear Power Plants19.8.3 Thermal Pollution19.8.4 Nuclear Fuel Cycle19.8.5 Nuclear Power Plant Effluents19.8.6 Nuclear WastesReferencesShort QuestionsNumerical Problems
Chapter 20: Review of Electrical Systems
20.1 Introduction20.2 Fundamentals20.2.1 Phasor20.2.2 Poly Phase Systems20.3 Electromagnetic Machines20.3.1 Law of Induction20.3.2 Law of Interaction20.3.3 Generator and Motor Actions20.4 Transformers20.4.1 Basic Transformer Theory20.4.2 Losses in a Transformer20.4.3 Efficiency of a Transformer20.4.4 Transformer Taps20.4.5 Internal Forces in Windings20.4.6 Transformer Rating20.4.7 Transformer Cooling20.4.8 Transformer Oil20.5 Conservator20.5.1 Buchholz Relay20.6 Types of Cooling20.6.1 Oil-Filled – Self-Cooled Transformers20.6.2 Forced-Air and Forced-Oil-Cooled Transformers20.7 Transformer Sealing Systems20.7.1 Free Breathing Type20.7.2 Pressurised Breathing20.8 Transformer: Construction20.8.1 Core Construction20.8.2 Windings20.8.3 Bushings20.9 Current Transformer20.10 Three Phase Transformers20.10.1 Advantages of Using 3-Phase Transformer Over Three Single Phase Transformers20.10.2 Three-Phase Transformer Windings20.11 Balanced and Unbalanced 3 Phase System20.11.1 Connections20.11.2 3-Phase Transformer Construction20.12 Faults in Transformer20.13 Introduction to Rotating Machines20.14 Generator20.14.1 Stator20.14.2 Rotor20.15 Synchronous Generator20.16 Induction Machines20.16.1 Rotating Magnetic Field20.16.2 Operation of Polyphaser Induction Machine20.16.3 Operation of Induction Machine as Induction Motor20.17 Protection System20.17.1 Impedance Relays20.17.2 Differential Relays20.18 Switchyard Configurations20.18.1 Radial Bus20.18.2 Double Bus20.18.3 Ring Bus Configuration20.18.4 Infinite Bus20.19 Electrical Power Transmission20.20 Transmission Lines20.20.1 Some Unavoidable SituationsReferencesShort QuestionsNumerical Problems
Index
Copyright

Content preview from Introduction to Power Plant Engineering

CHAPTER 9 Condenser, Cooling Tower and Feed Heaters

9.1 Introduction

Steam turbine based electric power plants work on the principle of heat engines. They reject a significant amount of heat into the environment. Some of that heat is added to the environment by the condensing system in a steam cycle, and the rest is added by the discharge to the atmosphere of the hot flue gas vented through the smoke stack. The heat removed from the steam, to complete the cycle, is achieved in the condenser.

The circulating cooling water of the condenser, in turn, rejects its heat to the atmosphere by means of a cooling tower or to a nearby surface water. In absence of a nearby river, the cooling of circulating cooling water is achieved in a closed loop by incorporating ...

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CHAPTER 9