BASIC DESIGN OF POWER PLANTS
BASIC DESIGN ASPECTS OF POWER PLANTS AN OVERVIEW
TYPES OF PLANTS
•
CO-GENERATION PLANTS
•
CAPTIVE POWER PLANTS
•
DIESEL ENGINE BASED CPP
•
GAS TURBINE / COMBINED CYCLE
•
BIO MASS BASED CPP
•
WASTE HEAT BASED CPP
• COAL BASED CPP / IPP
SITE SELECTION
•
LOCATION / METROLOGICAL
•
TOPOGRAPHICAL / GEOLOGICAL FACTORS
•
SITE ACCESS
•
WATER AVAILABILITY
•
FUEL AVAILABILITY
•
GRID PROXIMITY
•
ENVIRONMENTAL CONSIDERATIONS
FUELS
•
COAL / LIGNITE
•
WASHERY REJECTS
•
CHAR
•
BIO MASS / MSW
•
BAGASSE
•
WASTE GASES (BFG, COKE OVEN CARBON BLACK TAIL GAS)
•
DIESEL /
FURNACE OIL
THE FUEL
The fuel
used in the captive power plant can be one or more of the following
|
FUEL |
STEAM / FUEL RATIO |
|
|
|
67/485 |
87/515 |
|
SPONGE KILN EXHAUST GAS kg/Nm3 |
- |
- |
|
COAL Kg/Kg |
4.45 |
4.38 |
|
COAL CHAR Kg/Kg |
2.51 |
2.47 |
|
COAL WASHERY REJECTS Kg/Kg |
2.45 |
2.41 |
|
RICE HUSK Kg/Kg |
3.60 |
3.54 |
|
COKE OVEN GAS Kg/Nm3 |
0.46 |
0.46 |
|
BFG Kg/Nm3 |
0.672 |
0.657 |
|
FUEL |
STEAM / FUEL RATIO |
|
|
|
42/440 |
67/485 |
|
COCONUT SHELL |
4.58 |
4.46 |
|
COTTON STALK |
4.59 |
4.48 |
|
CASTOR STALK |
4.62 |
4.50 |
|
GROUND NUT SHELL |
4.93 |
4.81 |
|
SABABUL ROOT |
5.28 |
5.15 |
|
SABABUL BARK |
4.63 |
4.50 |
|
CASURINA ROOT |
5.55 |
5.41 |
|
EUCALYPTUS BARK |
1.95 |
1.90 |
|
TUMMA WOOD |
4.62 |
4.50 |
BIOMASS FUELS
|
|
kcal/kg |
|
kcal/kg |
|
Bagasse |
2272 |
Palm fiber |
2800 |
|
Rice Husk |
3150 |
Corn cobs |
3727 |
|
Mustard
Husk |
4200 |
Groundnut
shell |
3620 |
|
Sunflower Husk |
4155 |
Palm shell |
4390 |
|
Cotton stalk |
3978 |
Coconut shell |
3900 |
|
Mustard stalk |
3900 |
Coir dust |
4180 |
|
Chilly stalk |
3850 |
Saw dust |
3396 |
|
Paddy stalk |
3500 |
Wood Chips |
4490 |
|
Cane Trash |
2880 |
Palm Empty
fruit bunch |
3400 |
STUDIES TO BE CONDUCTED FOR POWER PLANTS
•
Fuel survey (Like Biomass
assessment study)
•
Fuel collection and
transport logistics
•
Rapid Environment study
•
On site emergency plan
•
Pre-Feasibility/Feasibility
Report (Bankable)
•
Water survey and water
analysis
•
Ash utilization
•
Fuel / Ash analysis and
boiler design
•
Power evacuation system
study
PREFERRED TURBINE STEAM INLET CONDITION
CONSIDERING OPTIMUM UTILIZATION OF HEAT ENERGY
IN STEAM THE FOLLOWING TURBINE INLET PARAMETERS ARE RECOMMENDED AS PER IEC 45.
|
Pressure (ATA) |
Temperature (0C) |
|
32 |
435 |
|
41 |
455 |
|
62 |
485 |
|
86 |
510/538 |
|
103 |
538/565 |
HOW HIGHER PRESSSURE POWER CYCLES HELP?
EVERY 100 KG OF
BAGASSE WILL PRODUCE THE FOLLOWING
STEAM AND POWER FOR VARIOUS POWER CYCLES.
|
STEAM CYCLE PARAMETERS |
STEAM PRODUCTION |
POWER GENERATION |
|
ATA / DEG.C |
(KGS) |
WITH BP OF 2.5ATA(KW) |
|
21/340 |
250 |
22.73 |
|
32/380 |
243 |
28.60 |
|
42/400 |
240 |
31.30 |
|
45/440 |
233 |
32.80 |
|
67/480 |
227 |
37.80 |
|
87/510 |
224 |
40.00 |
|
105/520 |
223 |
41.30 |
MAJOR EQUIPMENT / SYSTEMS IN THE POWER PLANT
- BOILER & AUXILIARIES.
- TURBOGENERATOR & AUXILIARIES.
- FUEL PREPARATION & HANDLING SYSTEM.
- ASH HANDLING SYSTEM.
- COOLING WATER SYSTEM.
- DE-MINERALIZATION PLANT & FEED WATER SYSTEM.
- CONDENSATE SYSTEM.
- PLANT ELECTRICAL DISTRIBUTION SYSTEM.
- HV & EHV SYSTEM.
- PLANT INSTRUMENTATION & CONTROL SYSTEM
EQUIPMENT SELECTION
Ø BOILER &
AUXILIARIES
1. FIXED GRATE FIRED BOILER
2. TRAVELLING GRATE / STOKER BOILER
3. AFBC – CONVENTIONAL AND OPEN BOTTOM
4. CFBC
5. WASTE HEAT RECOVERY
Ø TURBINE
& AUXILIARIES
1. CONDENSING TURBINE
2. BACK PRESSURE TURBINE
3. CONDENSING EXTRACTION
4. EXTRACTION BACK PRESSURE
Ø CONDENSER
1. WATER COOLED CONDENSER
2. AIR COOLED CONDENSER
3. COMBINATION OF WATER AND AIR COOLED
Ø COOLING TOWER
1. INDUCED DRAFT
2. FORCE DRAFT
3. NATURAL DRAFT
PROJECT ENGINEERING - DESIGN BASIS
·
CONFIGURATION IS PLANT
SPECIFIC.
·
REALISTIC FUELAVAILABILITY
& NO. OF DAYS OF OPERATION TO BE TAKEN
IN CONCEPTUALIZATION.
·
BETTER TO DOWNSIZE THE PLANT
TO ENSURE GOOD PLANT LOAD FACTOR.
PLANT LAYOUT
•
CRITICAL FROM O&M POINT OF VIEW
•
OPTIMUM ROUTING OF PIPING,
CABLES & CONVEYORS.
•
COOLING TOWER LOCATION TO TAKE CARE OF WIND DIRECTION & DUST
NUISANCE
•
SWITCHYARD TO ENSURE
COMFORTABLE TRANSMISSION LINE ROUTING.
STATUTORY CLEARANCES REQUIRED
•
CLEARANCE FOR POWER
GENERATION FROM STATE GOVERNMENT
•
WATER AVAILABILITY FROM
IRRIGATION DEPARTMENT
•
POLLUTION CLEARANCE FROM
POLLUTION CONTROL BOARD
•
FOREST CLEARANCE FROM FOREST
DEPARTMENT
•
CIVIL AVIATION CLEARANCE FOR
CHIMNEY HEIGHT FROM NATIONAL AIRPORT AUTHORITY
•
REGISTRATION OF COMPANY FROM
REGISTRAR OF COMPANIES
•
POWER PURCHASE AGREEMENT
FROM ELECTRICITY BOARD
•
APPROVAL FOR TEMPORARY
CONSTRUCTION POWER LINES FROM CHIEF ELECTRICAL INSPECTORATE
•
LICENSE FROM LABOUR
COMMISSIONER FOR CONSTRUCTION LABOURS
FROM LABOUR COMMISSIONER
•
REGISTRATIONOF WORKERS FROM
LABOUR COMMISSIONIER
PERMITS AND LICENSES DURING CONSTRUCTION
•
BOILER AND OTHER PRESSURE
PARTS INCLUDING PIPES AND VALVES FROM CHIEF INSPECTORATE OF BOIELRS
•
FIRE FIGHTING / PROTECTION
SYSTEM FROM TARIFF ADVISORY COMMITTEE
•
ELECTRICAL PLANT AND
EQUIPMENT DESIGN / INSTALLATION WITH RESPECT TO BACK CHARGING CLEARANCE AND
SYNCHRONIZATION CLEARANCE FROM CHIEF ELECTRICAL INSPECTOR
•
APPROVAL FOR STACK
OBSTRUCTION LIGHT FROM NATIONAL AIRPORT
AUTHORITY
•
POST INSTALLATION APPROVAL
FOR BUILDING PIPE LAYOUT, CABLE ROUTES, ACID & OTHER CHEMICAL STORAGES FROM
CHIEF INSPECTOR OF FACTORIES
•
APPROVAL FOR BUILDING,
SEWERAGE FROM TOWN PANCHAYAT
PROBLEMS ASSOCIATED WITH BIO-MASS UTILIZATION
•
LABOUR INTENSIVE AND DISPERSED IN LARGE AREAS
•
SPECIFIC ENERGY CONTENT IS LOWER
•
LOCALIZED PRICE SENSTIVITY
•
HIGH MOISTURE CONTENT
•
AUTOMATIC FEED CONTROL IS REQUIRED BECAUSE OF ITS NON
FREE-FLOW NATURE
•
BIO-MASS HANDLING & COLLECTION; LARGE NETWORK
REQUIRED
•
LIGHT ASH - AN ATMOSPHERIC POLLUTANT
•
DUST AND OTHER HEALTH HARZARDS
•
TRANSPORTATION: BIOMASS OCCUPIES A LARGE VOLUME DUE TO
LOW BULK DENSITY (30 - 180 KG/M3)
•
SEASONAL AVAILABILITY
•
LARGE STORAGE SPACE IS REQUIRED DUE TO LOW BULK
DENSITY & SEAONSAL PRODUCTION
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Reviewed by Thermal Power Tech
on
June 17, 2024
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