1M2 - Overview of Steampower Plants

Plant Layout Training Series
MODULE-1
Presentation
Overview Steam Power Plants
For internal use only / Copyright Siemens AG 2006. All rights reserved.
Contents
2. Overview of Steam Power Plants
1. Introduction to Coal fired thermal power station;
coal
handling, steam generation, power conversion,
circulating water and post-combustion cleanup systems.
2. Introduction to steam turbine, generator, heat
exchangers, condenser, main pumps
3. Introduction to planning of Steam Turbine building in a
Reference Power Plant
Page 2
April-07
Overview of Steam Power Plants

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Plant Layout Training Series R.Sridhar
SPEL
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Conventional Power Plant, Sea Location
Stack
Jetty
Circulation
Water OutFall
Ash
Silo
s
Workshop and
Stores Building
Electrochlorinating
Fuel Oil
Tanks
Demineralisation
plant
Staff Amenities
and
Administration
Building
Circulation
Water Pump
Building
Page 3
Coal Yard
Steam
Generators
Switch Gear
Building in between Steam Turbine
Building
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Coal Handling System
TRAIN UNLOADING
TRANSFER
BUILDING
CRUSHER
BUILDING
L
FIL OR
O Y
SIL VE
N
CO
UNLO
ADIN
G CO
NVEY
STOC
OR
KOU
T/RE
CON
C
VEYO LAIM
R
HER
CRUS YOR
E
CONV
RE
CL
AIM
ACTIVE PILE
CO
NV
RECLAIM
EY
OR
RESERVE PILE
UNIT
SILOS
Page 4
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Systems of Power Island

Hot Reheat Steam
POWER CONVERSION SYSTEM
STEAM GENERATION SYSTEM
GENERATOR
HP
IP
LP
Extraction
steam
Cold Reheat Steam
FEEDER(S)
HP
REHEATER
STEAM
DRUM
ECONOMIZER
PRIMARY AIR FAN(S)
CEP
CWP
POST-COMBUSTION CLEANUP
SYSTEM
PARTICULATE
REMOVAL
SYSTEM
INDUCED
DRAFT
FAN(S)
AIR HEATER
PULVERZER(S)
April-07
DEAERATOR
SO2 REMOVAL
SYSTEM
WALL
TUBES
STEAM
GENERATOR
Make
up
CONDENSER
LP
BFP
FEEDWATER
HEATER(S)
SUPER
HEATER
Page 5
COOLING
TOWER(S)
Superheated Steam
STACK
UNIT
SILOS
FORCED
DRAFT FAN(S)
Scrubber solids &

fly ash to landfill

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Rankine Cycle with superheat, reheat and regeneration

heat addition
3
4b
Q1
2
Q1
3b
3a
Boiler
Wa
Super 3
heater
4a
Heaters
reheater
4b
Turbine
Wb
Wp
4a
compression
2
Wp
isentropic
expansion
Wa
pump
1
Wp
heat rejection
Q2
Heaters
Condenser
Q2
Heat addition at multiple pressures; latent and sensible heat addition with superheat
and reheat to working medium
Higher is the temperature/pressure at source, greater is the work done in turbine
Lower the sink temperature, greater is the work done in turbine
Feedwater heating regeneration to reduce load on boiler and increase cycle efficiency
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Wb

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Schematic of a Coal fired Power Plant
Page 7
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Principles of Steam Power Plant
Operates on combined Superheat, reheat and regeneration

cycle
Uses Coal as primary fuel in a conventional Steam Generator
Recovers heat by means of economizers and regenerative air
heaters.
Optimizes the heat rate and cycle efficiency by means of
regenerative feedwater heaters
Efficiencies in the order of 35%
Page 8
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Power Plant Components

Major Equipment in a Power Plant
1. Steam Turbine
2. Generator
3. Condenser
4. Heat Exchangers
5. Pumps
Page 9
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Steam Turbines Product Range Overview
Page 10
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Product Range application
Page 11
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Turbo-Generator set (HMN series)
Page 12
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Steam Turbine
CROSS OVER PIPE
IP TURBINE
LP TURBINE
ONE COMMON
CONDENSER
FOR BOTH LP
TURBINES. CW
FLOWS IN 2
PATH AND IS
DIVIDED
HP TURBINE
COMBINED IP STOP AND

CONTROL VALVE
COMBINED HP STOP AND
CONTROL VALVE
COMBINED LP BYPASS
STOP AND CONTROL
VALVE
COOLING WATER IN AND OUT
Page 13
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HP turbine
Page 14
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IP Turbine
Page 15
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LP Turbine
DOUBLE FLOW LOW PRESSURE TURBINE
Page 16
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Generators-Product Range
Page 17
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Air/Hydrogen Cooled Generators
Page 18
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Generator (Air Cooled)
Page 19
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Tasks of a Condenser
Page 20
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Classification of Condensers
Circulating Water System
Page 21
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Classification of Condensers
Circulating Water System
Page 22
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Condenser Types
Page 23
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Condenser Types
Page 24
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Condenser Types
Page 25
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Feed water Heater
Tube sheet
Extraction steam inlet
Vents
Feedwater outlet
Possible
condensate
level
Steam phase
Steam cooling Zone
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Condensate phase
Feedwater inlet
Drain cooling Zone

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Horizontal LP Feedwater Heater with Drain Cooling Zone
Tube sheet
Extraction steam inlet
Vents
Feedwater outlet
Possible
condensat
e level
Steam phase
Steam cooling Zone
Condensate phase
Feedwater inlet
Drain cooling Zone
Beside of an economic Pipe Routing sufficient space for Insulation and access has
to be considered while placing the heaters.
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Comparison of horizontal and vertical heaters
Page 28
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Gland Steam Condenser
Page 29
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External drain cooler (for Heater A1 and A2)
A
For WGQ
ca. 7,2 m
2
For WGQ
ca. 1m
1
D
1 Drains Inlet
Page 30
2 Drains Outlet
April-07
3 Main Condensate Inlet
4 Main Condensate Outle

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Deaerator and Feedwater Tank
Objectives:
1. Feed water heating (direct)
2. Collector for condensates
3. Storage overhead tank for BFP
4. Used for balancing during
operation
Separate Deaerator tank mounted

on the Feedwater tank is less
costly than a STORK sprinkler
deaerator
Page 31
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Deaerator and Feedwater Tank
Page 32
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Main Pumps
Feedwater pump
Condensate extraction pump
Circulating water pump
Page 33
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Boiler Feedwater Pump Design
Ring Section Type
less invest costs
Page 34
April-07
Barrel Type
faster and easier

assembly/disassembly
no cutting of connecting
pipes

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Boiler Feedwater Pump (Barrel Type)
Sauggehuse
Druckgehuse
Welle
Leitrad
Page 35
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Overview ofLaufrad
Steam Power Plants
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Boiler Feedwater Pump (Ring Section)
Stufengehuse
Verbindungsschraube
Page 36
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Boiler Feedwater Pumps

Classification by mode of Control
1. Variable Frequency drive
2. Constant Frequency drive with different control methods
Bypass operation
Throttling
Speed control
Turbo-coupling
Thyrister
Page 37
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Flow Control methods
Page 38
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Hydro-Coupling (Voith)
Page 39
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Economics of Speed Controlled Pumps

Hydro Coupling
Design Features
Speed control by adjusting the scoop tube
position to vary the hydraulic oil flow rate
Power transmission via hydraulic oil from
pump wheel which is driven by the motor to
turbine wheel
Design Features
General principle: transformation of the
incoming alternating voltage to a direct
voltage and then back to an alternating
voltage of the required motor frequency
Varying the motor frequency by thyristor
Advantages
Low I&C effort
Low space requirement
Advantage
Highest full and part load efficiency
References CCPP
Cottam, UK
Kings Lynn, UK
Pulau Seraya, Singapore
Page 40
Frequency Converter
April-07
Remarks
Inadmissible harmonics may occur
Operating ambient temperature < 35C
Reference CCPP
Donaustadt, Austria
Kln-Niehl, Germany

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Condensate Extraction Pump
Page 41
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Condensate Extraction Pump

Iskenderun
Flow
TDH
Length
Diameter
Weight
Material
(impeller)
215 l/s
311 m
7,5 m
0,95 m
4,4 t
Cr-steel
cast steel (bowl,
stage casing)
Page 42
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Can for Condensate Extraction Pump

Iskenderun
Page 43
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Circulating Water Pumps (Tubular Casing)

non-pull-out type
pull-out type
Motor Stool
Coupling
Adjusting Nut
Thrust Bearing
Discharge cover
Coupling
Adjusting Nut
Thrust Bearing
Discharge Elbow
Shaft
Discharge Elbow
Delivery
Supension
Pipe
Disc Coupling,
Rigid
Shaft
Radial Bearing
Disc Coupling,
Rigid
Column Pipe
Radial Bearing
Diffuser
Column Pipe
Wear Ring
Diffuser
Impeller
Wear Ring
Impeller
Bellmouth
April-07
Page Dr.
44Wehinger / September
2003
Bellmouth
Quelle: KSB
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Circulating Water Pump

Iskenderun
Flow
TDH
Length
Diameter
Material
15,35 m/s
18,3 m
11 m
3,3 m
Duplex
(X2CrNiMo
22.5)
Page 45
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Coal Fired Thermal Power Plant
Page 46
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Steam Turbine Building
Page 47
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Steam Turbine Building Longitudinal Section
Generator
Steam Turbine
Exciter
Condensat
Polishing
Plant
Compressed Air Uni
Closed CW Pumps
Closed CW Heat ExchangerCondenser Inlet/Outlet
Page 48
April-07
Seal Oil
Condensate Pumps Unit

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Steam Turbine Building Cross Section View
Turbine
Crane
Steam Turbine
Condenser
Main Cooling Water
Piping
Feed
Water
Tank
Generator Circuit
Breaker
LP
Heaters
Boiler
Feed
Pump
Main Machine Set Foundation
Page 49
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Main
Transforme
r
Auxiliary
Transformers

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Turbo-set Arrangements
Paiton II Indonesia
2x 670 MW sub-critical
167 bar, 538C / 538C
(2422 psi, 1000F / 1000F)
Operation - 2000
Iskenderun Turkey
2x 660 MW sub-critical
177 bar, 538C / 538C
(2567 psi, 1000F / 1000F)
Operation - 2003
Page 50
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Schwarze Pumpe Germany
2x 813 MW supercritical
260 bar, 547C / 565C
(3770 psi, 1016F / 1049F)
Operation - 1997/1998
Boxberg Germany
1x 908 MW supercritical
258,4 bar, 541C / 578C
(3748 psi, 1006F / 1072F)
Operation - 2000
Page 51
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Isogo Japan
1x 600 MW ultra Supercritical
251 bar, 600C / 610C
3,640 psi , 1,112F / 1,130F
Two flow LP
Operation - 2002
Page 52
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Plant Layout Training Series

Overview Steam Power Plants

Overview of Steam Power Plants

Conventional Power Plant, Sea Location

Overview of Steam Power Plants

Coal Handling System

Overview of Steam Power Plants

Systems of Power Island

POWER CONVERSION SYSTEM

STEAM GENERATION SYSTEM

Cold Reheat Steam

PRIMARY AIR FAN(S)

Scrubber solids &

Overview of Steam Power Plants

Rankine Cycle with superheat, reheat and regeneration

Overview of Steam Power Plants

Schematic of a Coal fired Power Plant

Overview of Steam Power Plants

Principles of Steam Power Plant

Operates on combined Superheat, reheat and regeneration

Overview of Steam Power Plants

Power Plant Components

Overview of Steam Power Plants

Steam Turbines Product Range Overview

Overview of Steam Power Plants

Product Range application

Overview of Steam Power Plants

Turbo-Generator set (HMN series)

Overview of Steam Power Plants

COMBINED IP STOP AND

Overview of Steam Power Plants

Overview of Steam Power Plants

Overview of Steam Power Plants

Overview of Steam Power Plants

Overview of Steam Power Plants

Air/Hydrogen Cooled Generators

Overview of Steam Power Plants

Generator (Air Cooled)

Overview of Steam Power Plants

Overview of Steam Power Plants

Overview of Steam Power Plants

Overview of Steam Power Plants

Overview of Steam Power Plants

Overview of Steam Power Plants

Overview of Steam Power Plants

Feed water Heater

Extraction steam inlet

Steam cooling Zone

Drain cooling Zone

Overview of Steam Power Plants

Horizontal LP Feedwater Heater with Drain Cooling Zone

Extraction steam inlet

Steam cooling Zone

Drain cooling Zone

Overview of Steam Power Plants

Comparison of horizontal and vertical heaters

Overview of Steam Power Plants

Gland Steam Condenser

Overview of Steam Power Plants

External drain cooler (for Heater A1 and A2)

3 Main Condensate Inlet

4 Main Condensate Outle

Overview of Steam Power Plants