Power Plant Familiarization

By Avtar Singh
Control Design & Tuning
 Course Contents

Part –I Power Plant Overview

Part –II Power Plant Systems &

Equipments

Part –III Power Plant Control Philosophy

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Emerson Confidential
27-Jun-01, Slide 2
 Part –I Power Plant Overview

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Emerson Confidential
27-Jun-01, Slide 3
 Power Plant Overview

Types of Power Plants

 Thermal
 Coal Fired
 Gas Fired
 Hydro
 Nuclear
 Non-conventional

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27-Jun-01, Slide 4
 Power Plant Overview
 Basic Principle
Basic principle in modern
power plants is based on
Rankine Cycle. It is
applicable for conventional
coal fired steam turbine
plant as well bottoming
turbine for combine cycle
plants.

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27-Jun-01, Slide 5
 Power Plant Overview
 1-2 Saturated Liquid from
condenser at state 1 is pumped
isentropically to state 2 and into the
boiler.
 2-3 Liquid is heated at constant
pressure in the boiler to state 3
(Saturated Steam).
 3-4 Steam expands isentropically
through the turbine to state 4,
where it enters condenser as wet
vapors.
 4-1 Constant pressure transfer of
heat in the condenser takes place
to return the steam to state 1
(Saturated Liquid).
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27-Jun-01, Slide 6
 Power Plant Overview

 Efficiency of Rankine cycle

can be increased by
Superheating the steam in
the boiler.

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27-Jun-01, Slide 7
 Power Plant Overview
 Efficiency of Rankine cycle
can also be increased by
Re-heating (4-5) the steam
in the boiler. The steam is
expanded to some
intermediate pressure in
turbine and then reheated in
boiler. Following reheat the
steam is expanded to the
cycle exhaust pressure in
the turbine again.

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27-Jun-01, Slide 8
 Power Plant Overview
 Efficiency of Rankine
cycle can also be
increased by
Regeneration which
involves feed-water
heaters. This cycle
regains some of the
irreversible heat lost
when condensed liquid is
pumped into the boiler by
heating feed-water
through heaters (Using
extraction steam).
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27-Jun-01, Slide 9
 Power Plant Overview
Coal Fired Power Plants
 Drum Type Boiler
 Once Through Type Boiler

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Emerson Confidential
27-Jun-01, Slide 10
 Power Plant Overview
 Fluidized Bed Boiler

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27-Jun-01, Slide 11
 Power Plant Overview
 Steam Turbine Product Combinations

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27-Jun-01, Slide 12
 Power Plant Overview
Gas Fired Power Plants
 Open Cycle
 Combined Cycle (With
or without
Supplementary Firing)
 Cogeneration (With or
without Supplementary
Firing)

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27-Jun-01, Slide 13
 Power Plant Overview
Gas Fired Power Plants
 Open Cycle
 Combined Cycle (With
or without
Supplementary Firing)
 Cogeneration (With or
without Supplementary
Firing)

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27-Jun-01, Slide 14
 Power Plant Overview
Gas Fired Power Plants

ess
Open Cycle

oc


Pr
to
 Combined Cycle (With

m
ea
or without

St
Supplementary Firing)
 Cogeneration (With or
without Supplementary
Firing)

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27-Jun-01, Slide 15
 Power Plant Overview
Gas Fired Power Plants
 Basic thermodynamic
cycle on which Gas
Turbine is based is
known as Brayton Cycle.
Work obtained by
expanding gas at higher
temperatures.

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27-Jun-01, Slide 16
 Power Plant Overview
Gas Fired Power Plants
 T-S Diagram of a combined-cycle power plant with
single-pressure steam cycle

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27-Jun-01, Slide 17
 Power Plant Overview
 Plant efficiencies using different combination of Combined-
Cycles

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27-Jun-01, Slide 18
 Power Plant Overview
 Typical Overview of a Combined-Cycle Power Plant

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27-Jun-01, Slide 19
 Power Plant Overview

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27-Jun-01, Slide 20
 Power Plant Overview

Go
Go To
To Demo
Demo of
of Combine
Combine Cycle
Cycle Power
Power Plant
Plant

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Emerson Confidential
27-Jun-01, Slide 21
 Part –II Power Plant Systems &
Equipments

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Emerson Confidential
27-Jun-01, Slide 22
 Power Plant Systems &
Equipments
Major Power Plant On Site Systems Major Power Plant Off Site Systems
 Boiler/HRSG Protection System  Coal Handling System
 Fuel Handling System  Ash Handling System
 Air/Flue Gas Handling System
 Main Steam System
 DM Water System
 Reheat Steam System
 Water Cooling System
 HP/LP Bypass System
 Auxiliary Steam System
 Extraction Steam System
 Condensate System
 Feed-water System
 Circulating Water System
 Air Evacuation System
 Drain & Vent System
 Lubrication Oil System
 Turbine Governing System
 Turbine Protection System
 Turbine Supervisory System
 Turbine Stress Evaluator System
 Generator / Excitation /Electrical System

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Emerson Confidential
27-Jun-01, Slide 23
 Power Plant Systems &
Equipments
Boiler/HRSG Protection System
 All Interlocks and protections are wired up to this system
for supervising and safe operation of the Boiler/HRSG.
 The protection mainly includes Drum level, furnace
pressure, flame failure, fuel protections, major auxiliary
equipments trips etc.
 One out of two OR Two out of three combinations are
used for trips.
 Normally includes Master Fuel Trip, Purge and overall unit
logic.

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27-Jun-01, Slide 24
 Power Plant Systems &
Equipments
Fuel Handling System
 All equipments required for firing the fuel are included in
this system like Fuel burners, Mills, Coal Feeders etc.
 All interlocks and protections related to individual
burner/equipment are covered in this area.
 Normally includes Oil/Gas Stations, Burners at Oil/coal
Elevations, Mills, Coal Feeders, Atomization Air/Steam
Stations, Fuel Transfer Pumps.

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27-Jun-01, Slide 25
 Power Plant Systems &
Equipments
Air/Flue Gas Handling System
 All equipments required for providing combustion air and
extracting flue gas are included.
 All interlocks and protections related to individual Fans,
Dampers, Air Pre-Heaters are covered in this area.
 Normally includes Furnace Draft Fans, Induced Draft
Fans, Primary Air Fans, Secondary/Primary Air control
Dampers, Air Pre-Heaters.
 Major function of this system to maintain furnace draft,
provide combustion air and perform proper heat exchange
between air and flue gas.

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 Power Plant Systems &
Equipments
Main Steam System
 All equipments required for providing superheated steam
are included here.
 All interlocks and protections related to individual Super-
heaters, Attemprators are covered in this area.
 Normally includes Water-walls, Drum, Super-heaters,
Attemprators, Main Steam isolating valves.
 Major function of this system is to separate steam from
water, superheat steam to desired pressure and
temperature and isolate boiler if steam is not required.

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 Power Plant Systems &
Equipments
Reheat Steam System
 All equipments required for providing reheated steam are
included here.
 All interlocks and protections related to individual Re-
heaters, Attemprators are covered in this area.
 Normally includes Re-heaters, Attemprators.
 Major function of this system is to provide reheated steam
at desired pressure.

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 Power Plant Systems &
Equipments
HP/LP Bypass System
 All equipments required for bypassing the HP and IP/LP
turbine are included here.
 All interlocks and protections related to individual Bypass
valves, Attemprators are covered in this area.
 Normally includes HP/LP bypass valves, Attemprators.
 Major function of this system is to maintain desired main
steam/ HRH pressure/temperature during turbine start-up
and shutdown and bypass the HP/IP/LP turbine during
tripping.

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 Power Plant Systems &
Equipments
Auxiliary Steam System
 All equipments required for providing auxiliary steam are
included here.
 All interlocks and protections related to individual valves,
Attemprators are covered in this area.
 Normally includes auxiliary steam pressure control valves
and attemprators.
 Major function of this system is to provide auxiliary steam
for Soot-blowing, Steam Coil Air-Preheating, Turbine Seal-
Steam System, De-aerator Pegging, Fuel Heating etc.
during plant start-up and normal running.

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27-Jun-01, Slide 30
 Power Plant Systems &
Equipments
Extraction Steam System
 All equipments required for extracting steam from steam
cycle are included here.
 All interlocks and protections related to individual non-
return valves and isolating valves covered in this area.
 Normally includes individual non-return valves and
isolating valves.
 Major function of this system is to provide extraction steam
for auxiliary steam header, De-aerator Pegging, HP/LP
Heaters during plant start-up and normal running for
overall improvement in plant efficiency.

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27-Jun-01, Slide 31
 Power Plant Systems &
Equipments
Condensate System
 All equipments required for condensate extraction from
hot-well are included here.
 All interlocks and protections related to individual
Condensate Extraction Pumps, isolating valves,
recirculation valves, make-up valves are covered in this
area.
 Normally includes individual Condensate Extraction
Pumps, isolating valves, recirculation valves and make-up
valves .
 Major function of this system is to extract condensate from
hot-well, maintain the condensate losses and maintain hot-
well level.

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27-Jun-01, Slide 32
 Power Plant Systems &
Equipments
Feed-water System
 All equipments required for feed-water are included here.
 All interlocks and protections related to individual Boiler
Feed Pumps, isolating valves, recirculation valves, drum
level control valves are covered in this area.
 Normally includes individual Boiler Feed Pumps, isolating
valves, recirculation valves, drum level control valves .
 Major function of this system is to provide feed-water to
drum and maintain its level. Single, two or three element
drum level control may be used depending upon the plant
requirements.

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 Power Plant Systems &
Equipments
Circulating Water System
 All equipments required for circulating cooling water are
included here.
 All interlocks and protections related to individual Closed
Cycle Pumps, Open Cycle Pumps, isolating valves,
recirculation valves, level control valves are covered in this
area.
 Normally includes individual Closed Cycle Pumps, Open
Cycle Pumps, isolating valves, recirculation valves, level
control valves .
 Major function of this system is to provide cooling water to
plant equipments like condenser, generator, HT motors,
vacuum system etc.

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 Power Plant Systems &
Equipments
Air Evacuation System
 All equipments required for Air Evacuation are included
here.
 All interlocks and protections related to individual Vacuum
Pumps/Ejectors, System isolating valves, recirculation
pumps, level control valves are covered in this area.
 Normally includes individual Vacuum Pumps (and/ or)
Ejectors, System isolating valves, recirculation pumps,
level control valves .
 Major function of this system is to vacuum in the
condenser as per plant conditions.

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 Power Plant Systems &
Equipments
Drain & Vent System
 All equipments required for draining and venting
boiler and turbine are included here.
 All interlocks and protections related to individual
drain and vent valves are covered in this area.
 Normally includes drain and vent valves situated
in different areas of boiler and turbine.
 Major function of this system is to drain boiler and
turbine steam lines as per plant conditions. This
system is an essential part of plant start-up and
shut-down.

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 Power Plant Systems &
Equipments
Lubrication Oil System
 All equipments required for providing lubrication to
turbine/generator bearings are included here.
 All interlocks and protections related to individual Auxiliary
Oil Pumps, Emergency Oil Pumps, Jacking Oil Pumps,
Lube Oil Temperature Control Valves, Lube Oil Tank, Lube
Oil Coolers are covered in this area.
 Normally includes Auxiliary Oil Pumps, Emergency Oil
Pumps, Jacking Oil Pumps, Lube Oil Temperature Control
Valves, Lube Oil Tank, Lube Oil Coolers .
 Major function of this system is to provide lubrication to
turbine bearings through out turbine barring gear
operation, rolling of turbine , normal running and shut-down
of turbine.

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27-Jun-01, Slide 37
 Power Plant Systems &
Equipments
Turbine Governing System
 All equipments required for controlling turbine throttle
valves are included here.
 All interlocks and protections related to individual HP
Control Valves, IP Control Valves, HP Shut-off Valves, IP
Shut-off Valves, Over-speed Trip, Vacuum Trip, Manual
Trip are covered in this area.
 Normally includes Electro-Hydraulic Converter, HP Control
Valves, IP Control Valves, HP Shut-off Valves, IP Shut-off
Valves, Over-speed Trip, Vacuum Trip, Manual Trip.
 Major function of this system is to regulate turbine control
valves as per load/ throttle pressure requirement
depending upon boiler follow or turbine follow mode
respectively.

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 Power Plant Systems &
Equipments
Turbine Protection System
 All instruments required for protecting turbine are included
here.
 All interlocks and protections related to turbine tripping are
generated in this area.
 Normally includes trips due to vibrations, turbine
expansions, axial shift, bearing temperatures, low vacuum,
fire protection, low lube oil level, generator mechanical
protection, high hot-well level, master fuel trip, high
exhaust steam temperatures etc.
 Major function of this system is to trip turbine due to above
unsafe conditions during start-up / running.

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27-Jun-01, Slide 39
 Power Plant Systems &
Equipments
Turbine Stress Evaluator System
 All instruments required for supervising turbine thermal
stresses are included here.
 All interlocks and protections related to turbine thermal
stresses are generated in this area.
 Normally includes thermal stress measurements related to
turbine Inner/outer casing temperatures, turbine
control/shut-off valves temperatures etc .
 Major function of this system is to guide operator and
restrict loading/unloading of turbine to avoid fatigue to
turbine and turbine valves during start-up, running and
shut-down.

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27-Jun-01, Slide 40
 Power Plant Systems &
Equipments
Turbine Supervisory System
 All instruments required for supervising turbine
conditions are included here.
 All interlocks and protections related to turbine
vibrations, turbine expansions, axial shift, bearing
temperatures are generated in this area.
 Normally includes turbine vibrations, turbine
expansions, axial shift, bearing temperatures .
 Major function of this system is to supervise
turbine operating conditions during start-up,
running and shut-down.

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27-Jun-01, Slide 41
 Power Plant Systems &
Equipments
Generator / Excitation/Electrical System
 All equipments required for Generator are included here.
 All interlocks and protections related to Generator Stator
Cooling System, Gas Cooling System, Seal Oil System,
Exciter Cooling System are generated in this area.
 Normally includes Generator Stator Cooling System, Gas
Cooling System, Seal Oil System, Exciter Cooling System.
 Major function of this system is to provide mechanical
protection to the generator during start-up, running and
shut-down. All electrical protection are part of
generator/exciter electrical protection system.

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 Power Plant Systems &
Equipments
Coal Handling System
 All equipments required for Off Site Coal Handling
are included here.
 All interlocks and protections related to Wagon
Tippler, Stack/Re-claimer, Crushers and
Conveyor are generated in this area.
 Normally includes Wagon Tippler, Stack/Re-
claimer, Crushers and Conveyor System.
 Major function of this system is to Unload coal
from Wagons, Stack the coal, convey the coal to
crushers and from crushers to the coal bunkers.

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27-Jun-01, Slide 43
 Power Plant Systems &
Equipments
Ash Handling System
 All equipments required for Off Site Ash Handling are
included here.
 All interlocks and protections related to Slurry
Maker/Transfer system, if wet ash removal system, Ash
Silos, if dry ash removal system, are generated in this
area.
 Normally includes Slurry Maker/Transfer system, if wet
ash removal system, Ash Silos, if dry ash removal system.
 Major function of this system is to remove ash from boiler
(bottom ash hoppers, ESP ash hoppers).

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 Power Plant Systems &
Equipments
DM Water System
 All equipments required for Off Site DM water
making are included here.
 All interlocks and protections related DM water
making are generated in this area.
 Normally includes chemical treatment plant, DM
water Storage Tanks, DM water transfer pumps.
 Major function of this system is to provide DM
water to the Main Power Plant Area. Some of the
equipments like generator require DM Water for
its cooling due conductivity reasons.

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27-Jun-01, Slide 45
 Power Plant Systems &
Equipments
Water Cooling System
 All equipments required for Off Site water cooling are
included here.
 All interlocks and protections related Cooling water pumps,
Cooling Tower fans are generated in this area.
 Normally includes Cooling water pumps, Cooling Tower
fans, Cooling Towers.
 Major function of this system is to cool the water that got
heated after heat exchange in condenser and other
coolers located in plant area, and can be re-used.

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Emerson Confidential
27-Jun-01, Slide 46
 Part –III Power Plant Control Philosophy

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Emerson Confidential
27-Jun-01, Slide 47
 Power Plant Control Philosophy
Hierarchy of Controls
 AGC (Grid Level)
 CMC /UCC (Unit Level)
 Turbine Control (Plant Level)
 Boiler Controls (Plant Level)
 Balance of Plants Controls (Plant Level)
 Control Loops in Power Plant (System Level)
 Control Equipments in Power Plant (Equipment Level)

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27-Jun-01, Slide 48
 Power Plant Control Philosophy
Automatic Generation Control
 Top Level Power Generation Control
 Remote Set-point send to different units
 Set-point based on Grid Demand
(Load/Frequency)
 Set-point can be analog or Pulse from AGC
 Units must runs in UCC/CBF Mode for best
results

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27-Jun-01, Slide 49
 Power Plant Control Philosophy
Unit Coordinated Control
 Unit Level Power Generation Control
 Remote Set-point from AGC is received here
 Depending upon the ramp rate set, the unit
responds to AGC Demand
 Units runs in Remote/UCC/CBF Mode for best
results
 All control loops are running in auto

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 UCC – AGC Set-Point

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 UCC – Typical scheme (Emerson)

CBF

CTF

TF BF

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27-Jun-01, Slide 52
 Power Plant Control Philosophy
Turbine Control (Plant Level)
 Turbine governing system receives MW demand from
Turbine Master (UCC in CBF Mode).
 Turbine Governing Valves modulates to match the
demand.
 The demand is matched very fast, boiler is to response
faster to avoid throttle pressure deviation.
 All Control loops in turbine area working in auto.

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 Power Plant Control Philosophy
Boiler Controls (Plant Level)
 Fuel Master receives Throttle Pressure demand from
Boiler Master (UCC in CBF Mode).
 As the turbine valves modulates to match the MW
demand, disturbance will be created in throttle
pressure.
 Fuel Master increase or decreases fuel to maintain
throttle pressure.
 All Control loops like fuel master, air master, feed-water
master in boiler area working in auto.

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27-Jun-01, Slide 54
 Power Plant Control Philosophy
Balance of Plants Controls (Plant Level)
 Balance of plant controls are independent of UCC
controls.
 The effect on these loops is indirect.
 Depending upon the unit ramping up or down these
loops responds, but do not have direct effect on unit.
 These loops must work efficiently to help proper and
efficient plant operation
 Normally these loops includes, ash handling, coal
handling, DM Water Plants, Water Cooling System

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27-Jun-01, Slide 55
 Power Plant Control Philosophy
Main Control Loops in Power Plant (System Level)
 Fuel Master (Feeder Speed Control)
 Controls Mills/Coal Feeders
 Air Master (Cross-Limiting and Secondary air Flow
Control)
 Controls FD Fans and related control dampers and blade pitch

 Furnace Pressure Control

 Controls ID Fans and related control dampers and hydraulic
coupling
 Steam Temperature Control (SH/RH)
 Controls de-superheating spray valves

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Emerson Confidential
27-Jun-01, Slide 56
 Power Plant Control Philosophy
Main Control Loops in Power Plant (System Level)
 Feed-water Master (Drum Level Control)
 Controls Boiler Feed Pumps and related control valves and
hydraulic coupling
 Condensate Control ( Hot-well Level Control)
 Controls Condensate Pumps and related control valves
 De-aerator Level Control
 Controls control valves
 HP/LP Heater Level Control
 Controls level control valves
 HP/LP Bypass Pressure and Temperature Controls
 Controls related pressure control valves de-superheating spray
valves
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 s ?
i o n
es t
Qu

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 o u
k Y
ha n
T
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