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

1. BOILER & AUXILIARIES. 
2. TURBOGENERATOR & AUXILIARIES.
3. FUEL PREPARATION & HANDLING SYSTEM.
4. ASH HANDLING SYSTEM.
5. COOLING WATER SYSTEM.
6. DE-MINERALIZATION PLANT & FEED WATER SYSTEM.
7. CONDENSATE SYSTEM.
8. PLANT ELECTRICAL DISTRIBUTION SYSTEM.
9. HV & EHV SYSTEM.
10. 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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