MAPÚA UNIVERSITY

658 MURALLA ST., INTRAMUROS, MANILA

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING

COAL-FIRED POWER PLANT

IN PARTIAL FULFILLMENT
OF THE REQUIREMENTS FOR POWER PLANT ENGINEERING
ME154-1P/A1

SUBMITTED BY:
AYALA, Arch Joseph V.
CRUZ, John Luke M.
DUQUE, Patrick Stephen L.
ESPAÑOLA, Jazer Mesha V.
SORETA, John Jerry B.
SUMILE, Ayran Danielle P.

SUBMITTED TO:
ENGR. IGMEDIO F. ISLA JR.

July 2019

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 TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION ...................................................................................... 1

1.1. FUNDAMENTAL KNOWLEDGE........................................................................ 1
1.1.1. BACKGROUND OF THE STUDY ............................................... 2
1.1.2. LOCATION SELECTION ............................................................. 3
1.1.3. LOAD CURVE AND PROFILE .................................................... 5
1.2. FUNDAMENTAL CONCEPT OF POWER PLANT ............................................ 8
1.2.1. THE ENERGY SOURCE CYCLE ................................................. 8
1.2.2. PRINCIPLES OF COAL-FIRED POWER PLANT .................... 15
1.2.3. ADVANTAGES AND DISADVANTAGES OF COAL-FIRED
POWER PLANT ................................................................................................... 17
1.2.4. CLASSIFICATION OF COAL-FIRED POWER PLANT .......... 20
1.2.5. SPECIFIC COAL-FIRED POWER PLANT ................................ 22
1.2.6. SYSTEM COMPONENTS OF COAL-FIRED POWER PLANT 23
CHAPTER 2: DESIGN AND COMPUTATIONS .......................................................... 34
2.1. ESTIMATIONS OF POWER REQUIRED TO THE PLANT............................. 34
2.2. ESTIMATIONS OF FUELS AND COMBUSTIONS ......................................... 35
2.2.1. CALCULATING THE HEATING VALUE OF COAL .............. 40
2.3. DESIGN AND CALCULATIONS OF STEAM TURBINES ............................. 40
2.3.1. CALCULATING THE MASS FLOW RATE OF STEAM ......... 40
2.3.2. 2.3.2. CALCULATING FOR THE TURBINE WORK .............. 45
2.4. DESIGN AND CALCULATIONS OF BOILEr .................................................. 46
2.4.1. CALCULATING the ASME EVAPORATION UNITS .............. 46
2.4.2. CALCULATING THE DEVELOPED BOILER HORSEPOWER
46
2.4.3. CALCULATING THE RATED BOILER HORSEPOWER ....... 47
2.4.4. CALCULATING THE HEATING SURFACE............................ 47
2.4.5. CALCULATING THE FACTOR OF EVAPORATION ............. 47
2.4.6. CALCULATING THE EQUIVALENT EVAPORATION ......... 48

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 2.4.7. CALCULATING THE OVERALL BOILER EFFICIENCY ...... 48
2.5. DESIGN AND CALCULATIONS OF CONDENSER ....................................... 48
CALCULATING THE LOG MEAN TEMPERATURE ................................................. 48
2.5.1. CALCULATING THE OVERALL HEAT TRANSFER
COEFFICIENT ..................................................................................................... 49
2.5.2. CALCULATING THE HEATING SURFACE AREA ................ 49
2.5.3. CALCULATING THE VOLUME OF COOLING WATER ....... 50
2.5.4. CALCULATING THE NUMBER OF TUBES ........................... 51
2.5.5. CALCULATING THE PUMP-MOTOR POWER....................... 53
2.6. DESIGN AND CALCULATIONS OF CHIMNEY ............................................. 55
2.6.1. CALCULATING THE MASS OF AIR ....................................... 55
2.6.2. Calculating the DENSITY OF AIR .............................................. 56
2.6.3. Calculating the DENSITY OF FLUE GAS .................................. 56
2.6.4. Calculating the HEIGHT OF CHIMNEY..................................... 56
2.6.5. Calculating the FLOW RATE OF FLUE GAS ............................ 57
2.6.6. Calculating the DIAMETER OF CHIMNEY ............................... 57
2.7. EQUIPMENT SELECTION ................................................................................. 58
2.7.1. 2.7.1 STEAM GENERATOR / BOILER ..................................... 58
2.7.2. 2.7.2 STEAM TURBINE ............................................................. 61
2.7.3. 2.7.3 CONDENSER...................................................................... 64
2.7.4. 2.7.4 GENERATOR ..................................................................... 67
2.7.5. 2.7.5 CONVEYOR ....................................................................... 69
2.7.6. 2.7.6. EMMISSION CONTROL SYSTEM .............................. 73
2.7.7. 2.7.7 CONTROL SYSTEM COMPONENTS .............................. 78
2.7.8. 2.7.7.1 Operator Station (OPS) Functions .................................... 78
2.7.9. 2.7.7.2 Accessory Station (ACS) .................................................. 79
2.7.10. 2.7.7.3 Engineering & Maintenance Station (EMS) ..................... 81
2.7.11. 2.7.7.3 DIASYS Netmation .......................................................... 82
2.7.12. 2.7.7.3 FEEDWATER HEATER.................................................. 83
CHAPTER 3: INSTALLATION AND COMMISSIONING .......................................... 85

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CHAPTER 4: OPERATION AND MAINTENANCE .................................................. 151
CHAPTER 5: ENVIRONMENTAL STUDIES ............................................................ 180
5.1. POTENTIAL IMPACTS OF THE PROPOSED PROJECT .............................. 180
5.1.1. Risks on the Air Quality ............................................................. 180
5.1.2. Risks on the Water Quality ......................................................... 182
5.1.3. Health Impacts ............................................................................ 183
5.2. PHILIPPINE ENVIRONMENTAL LAWS RELEVANT TO THE PROPOSED
PROJECT........................................................................................................................ 184
5.2.1. REPUBLIC ACT 9003 ECOLOGICAL SOLID WASTE
MANAGEMENT ACT OF 2000............................................................ 184
5.2.2. REPUBLIC ACT 9275 PHILIPPINE CLEAN WATER ACT OF
2004 184
5.2.3. REPUBLIC ACT 8749 PHILIPPINE CLEAN AIR ACT OF 1999
185
5.3. DENR Standards ................................................................................................. 185
REFERENCES: .......................................................................................................................... 187
APPENDIXI ...…………………………………………………………………………………168

APPENDIX II…..………………………………………………………………………………189

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 CHAPTER 1: INTRODUCTION

This chapter discusses the fundamental knowledge of the proposed coal power plant. The

goal of this study is to be able to design a coal power plant in Aurora, Zamboanga del Sur. The

power plant will provide the said municipality with a base load of 50 MW.

1.1. FUNDAMENTAL KNOWLEDGE

This section discusses the fundamental knowledge of the proposed power plant. This

includes the background of the study, location selection, as well as the load curve of the

municipalities in the selected location.

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1.1.1. BACKGROUND OF THE STUDY

Energy provides services to meet many basic human needs, such as electricity,

which in turn is used to power up different kinds of appliances that help us in our daily

lives. Such examples are lightings, air-conditioners, refrigerators, and many more that we

use daily. Energy is also essential in a nation’s economic development. Energy enables

countries to be able to use and provide more advanced services for its people to use.

Global demand for energy is rising continuously. Developed countries continue to

consume large amounts of energy while demand is increasing in developing countries.

Between 2005 and 2030, energy needs are projected to expand by 55 percent,

with demand increasing from 11.4 billion tons of oil equivalent to 17.7 billion. Between

2005 and 2030, energy consumption is expected to increase by 50 percent, with the bulk

of the demand coming from developing countries. A cause of this can be reflected upon

the increasing number of populations a country has.

With the increase in energy demand, the energy supply must be increased too. A

typical powerplant will provide the necessary energy to the consumers. Correspondingly,

there are several kinds of powerplant that uses non-renewable, such as coal, gas and

diesel, and renewable resources. In this paper, the powerplant that will be used is a coal-

fired powerplant.

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 Figure 2.1. Power Mix

Source: DOE Philippine Energy Plan

1.1.2. LOCATION SELECTION

According to Investment Opportunities in the Philippine Energy Sector, the ideal

locations where new powerplants may connect without the need for any significant

transmission reinforcement is shown in Figure 2.2. Thus, we picked the Aurora,

Zamboanga del Sur as the location of the 50 MW coal powerplant. Furthermore, there is

coal basin located in Zamboanga.

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 Figure 2.2. Ideal Locations of Powerplants in the Philippines

Source: DOE - Investment Opportunities in the Philippine Energy Sector

Aurora, officially the Municipality of Aurora, is a 2nd class municipality in the

province of Zamboanga del Sur, Philippines. According to the 2015 census, it has a

population of 50,755 people. It has a total area of 180 square kilometers. An estimated 42

barangays are consolidated in this municipality. The map of Aurora is shown in the

Figure 2.3.

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 Figure 2.3. Map of Aurora

Source: Google Maps

1.1.3. LOAD CURVE AND PROFILE

Figure 2.4. 2017 ZANECO’s Hourly Load Profile (MW)

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Source: Zamboanga Del Norte Electric Cooperative, Inc. (ZANECO)

Figure 2.5. 2017 ZANELCO’s Load Curve (MW)

Source: Zamboanga Del Norte Electric Cooperative, Inc. (ZANECO)

Figure 2.6. 2017 ZANECO No. of Customers

Source: Zamboanga Del Norte Electric Cooperative, Inc. (ZANECO)

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 Figure 2.7. Sample expected no. of customers in coming years

Figure 2.8. Sample expected demand (MW) in coming years

Figure 2.4 and Figure 2.5 contain data by and from Zamboanga Del Norte Electric

Cooperative, Inc (ZANECO). This data served as our basis in designing the proposed 50

MW coal-fired power plant located in the province of Zamboanga. Figure 2.4 shows the

load profile and curve of the municipalities to be powered by the proposed power plant.

Based on the 2017 load curve of ZANECO, the equivalent demand based on the 2017

peak demand of 39.078 MW is 16 MW for baseload, 8.9 MW for the peak load and 14

MW for the mid-merit load, which we then adjusted so that it can still support and

provide enough energy supply in the years to come. Thus, us deciding to have a design of

50 MW coal power plant.

In Figure 2.6, in the year 2017, we see that residential areas consume the largest

amount of electricity. This equates to around 91.48 % of the total consumers. Figure 2.7

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 and Figure 2.8 show sample data of what to expect in the coming years in terms of

number of customers as well as the expected demand with an increase in population. We

can see that a 50 MW coal power plant can sufficiently provide enough supply in the

following years.

1.2. FUNDAMENTAL CONCEPT OF POWER PLANT

1.2.1. THE ENERGY SOURCE CYCLE

Coal-fired power plant, also known as thermal power plant or steam

turbine is one of the most common and basic type of power plant that is producing energy

or electricity around the world. From the name itself, thermal power plant will make use

of the temperature difference present in the process and according to thermodynamic

properties and laws, a rise in temperature can cause a rise in pressure. To put it simply,

the power plant will be using temperature and pressure difference to run the process. The

common and major equipment found in a thermal power plant is the steam turbine,

generator, condenser, feedwater pump and a boiler. This are the parts that are needed in a

thermal power plant, otherwise it will not work.

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 Figure 2.9 Schematic Overview of a Typical Coal Fired Power Plant

Source: Water.usgs.gov
The working fluid for a steam turbine power plant or a Thermal power plant is

water. Using this working fluid, the steam turbine in a thermal power plant will revolve

due to high temperature and high pressure produced by the steam which is produced by

the boiler. This rotation or revolution produce by the turbine will be then turned into

electricity by means of a shaft connected to the generator from the steam turbine. When

the steam turbine is rotated by means of a high temperature and high-pressured steam, the

steam loses most of its energy. This is because most of the energy is given off to rotate

the turbine blades. This causes the temperature and pressure to be relatively low at the

steam turbine outlet. At this point onwards, the steam will expand and because there is no

heat addition nor heat rejection happening to the steam, the entropy of the steam will stay

the same and this process can be seen using a T-S diagram. The low pressure, low

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temperature can be then reverted into its original state which is high pressure, high

temperature steam. This will result to a continuous production of electricity.

Figure 2.10 Pressure and temperature drop of steam at point 3 to 4 Source:

www.learnengineering.org

When the turbine blades are rotated by high-pressure and high temperature

steam, it loses its energy which result in a low-pressure and low temperature steam at the

turbine outlet. In this process, the steam expands until the saturation point is reached.

Because there is no heat added or removed from the steam, the entropy of the steam

remains constant. This can be seen by using a P-V and T-S diagrams. If the low-pressure,

low temperature steam can be reverted to its original state, the generation of electricity

can be continuous.

The working fluid that will be used, which is water, will be then compressed

from its gaseous state but this requires a lot of energy. Therefore, it is convenient to

convert it back to its liquid form to compress it easily using a condenser. The heat will be

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rejected to the surrounding to convert the gaseous state to liquid state. There would be no

pressure change in the condenser due to the free moving motion of the fluid inside it.

This can be seen in the P-V diagram and T-S diagram.

Figure 2.11 Addition of condenser to convert the steam from its vapor phase to liquid
phase Source: Mass Engineers

At the outlet of the condenser, the gaseous state is now turned into liquid state by

means of rejecting heat to the surrounding. Due to the change in phase of the working

substance from gas to liquid, a feed water pump can now be used to increase the pressure

of the working fluid or the water to its original state and return it to the boiler for

continuous process.

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 Figure 2.12. Addition of pump to bring the liquid to its original pressure Source: Mass
Engineers

It is also noted that external heat will be added to the working fluid so that it can

return to its original temperature. This can be done with the use of the boiler. This

regains the lost temperature due to several processes. When the working fluid returns to

the boiler, the pressure will be constant all throughout the heat addition process and the

liquid working fluid will be then again converted into gas. This will regain not only its

temperature, but also its pressure. These four processes will complete the cycle called

Rankine Cycle.

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 Figure 2.13 Addition of boiler to bring the fluid to its original temperature
Source: Mass Engineers

Heat will be added in the boiler by using the boiler furnace. In this stage, the fuel

that is used will react with the air around it and therefore produce heat. There are

commonly two types of fuel that is being used in a power plant and those are nuclear and

coal. Coal can be easily produced and requires small of amount of money compared to

nuclear, but this type of fuel produces more pollutants compared to the nuclear. That is

why it is important to add certain machineries that can help reduce the pollutants produce

by the burning of coal before releasing it to the atmosphere. The most common type of

machineries that can do this stuff is the electro static precipitator or also known as ESP.

This machinery removes the fly ash from the leftovers of the burnt coal. This removes the

pollutants or segregates them before releasing it to the atmosphere to reduce the amount

of pollution being blown out by the exhaust.

To further explain the process of a coal powered power plant, the coal will be first

put into a conveyer where it will be pulverized there before feeding it to the boiler by

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means of using the boiler furnace. The water in the boiler will then change its pressure

from low pressure to a high pressure due to the burning of coal. From that point, the high-

pressured steam will then pass through a series of superheaters where it will be heated

even more or heated above its saturation point so that it may contain more energy before

entering the turbine. The superheater will also be used to further dry the coal or the steam

so that it may contain more gas than liquid. Liquid in the pipes can mean a lot of trouble

for the plant because it may cause stagnation in the pipes. This may cause the pipes to

rust faster than the expected time and may weaken it even further. Overall, this may

cause a drop in the efficiency of the plant. The next process will be the high-pressured

steam that pass through the superheater will then strike the blades of the steam turbine

resulting to a high velocity rotation of the steam turbine. The rotor or the shaft of the

steam turbine is directly coupled to a generator therefore, as the steam turbine rotates, the

generator will also rotate producing electricity. The generator which is directly coupled to

the steam turbine will rely on it in producing electricity. This process converts the

mechanical energy present in the steam turbine into electrical energy by means of a

generator. In other types of plants, an exciter is used to further increase the speed of the

generator and to further increase the amount of electricity being produced. After that

process, the superheated steam will then enter the condenser where it will be converted

into liquid. The steam that enters the condenser is being cooled by means of water

flowing in and out of the condenser which is connected to a cooling tower. The feedwater

pump will be then pressurized the liquid flowing through it which will then pass to the

economizer. The economizer will increase the amount of heat present in the liquid to

further increase the efficiency of the boiler. The exhaust gases released from the furnace

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 will pass through the economizer, superheater and in the air pre-heater. The reason for

this process is so that, they can maximize every bit of substance that flows in and out of

the system. The exhaust gases still contain heat in them which can be used to heat the

working fluid where it is needed before releasing it to the atmosphere. This will increase

the efficiency of the boiler and decrease the heat coming out of the stack. For the final

process, the fuel which is coal will be then transported into an ash handling facility which

in turn will transport them in to an ash storage.

1.2.2. PRINCIPLES OF COAL-FIRED POWER PLANT

Like it was said in the paragraph before, coal is the most used fuel for power plant

and it is also affordable and largest domestically produced source of energy. It can be

easily produced and almost all of the countries in the world can produce coal. However,

the problem lies in the after effect the coal fired power plant leaves to the environment.

The present challenge in the coal fired power plant nowadays is for it to become more

sustainable. There is a lot of station and sub stations are needed to convert and reduce the

amount of pollution being produced by a Coal-fired power plant before it can become

acceptable. Another problem arises from this solution. Coal-fired power plant becomes

more expensive due to additional machinery and apparatus due to the problem that it

needs to be cleanse further before releasing the exhaust to the environment. To

understand the complete process including the coal-fired power plant, a step by step will

be shown below.

 Heat is created

Pulverizing the coal that will be supplied will be the first step. It will be

pulverized until its fineness is of that of a talcum powder. This way it will be easier to

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 burn them, and ash deposits can be segregated quickly. The pulverized coal will be feed

into the firebox together with a hot air. The ratio of coal and air will provide a better and

complete combustion and will also result to a greater heat which will then produce more

energy.

 Water turns to steam

The working substance which is a highly purified water will be then feed into the

boiler by means of pipes connected to the boiler. This will turn the water into gas or the

liquid form into steam which has a higher energy. The temperature that can be measured

in the steam in this process can reach up to 1000 degrees Fahrenheit and a pressure equal

to 3,500 Psi. This steam will be then transferred into the steam turbine.

 Steam turns the turbine

The pressure present in the steam which can reach up to 3500 Psi will start to

push the gigantic blades located inside the steam turbine. This will convert it into

mechanical energy which will be then converted into electrical energy by means of a

shaft that is connected to the generator which will produce electricity.

 Steam turns back into water

The last process is to convert or revert the working substance to its original state.

The steam that passed through the steam turbine will then pass through a chamber or the

condenser which will be then cooled by means of using a cooled water that is from a

nearby source such as lake or river. This cooled water will pass through pipes inside the

condenser. The steam will be then condensed into liquid form and will be then transferred

through the feedwater pump to return it in the boiler.

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1.2.3. ADVANTAGES AND DISADVANTAGES OF COAL-FIRED POWER

PLANT

1.2.3.1. ADVANTAGES OF COAL-FIRED POWER PLANT

Some of its advantages include reliability, affordability, abundance,

known technologies, safety, and efficiency.

Reliability

The most unique characteristic and advantage of using a coal-fired power

plant is that it is reliable. In terms of emergency production of electricity, coal

fired power plant can produce it. However, it may take some time before

electricity is produced but nonetheless, it will produce electricity. Coal-fired

power plants reliability to produce power in peak hours is noticeable. This brings

out that advanced pulverized coal in a power plant can be used to support

shortages of electricity and can also be used to avoid blackouts.

Affordability

The electricity or energy that will be produced using this type of power

plant will be a lot cheaper compared to other types of power plant due to the fact

that the fuel, which is coal, is abundant. Coal is also easy to mine and not that

expensive and that is the reason that is price remains lows compared to other fuel

for power plants.

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Abundance

There is still a lot of coal that can be found in our world. Roughly, it will

take around 300 years for coal to reach critical level or economic coal deposits.

This makes it a reliable and power plant that can continuously produce electricity.

Known Technologies

The production of and use of coal is well and continuously monitored to

avoid unwanted circumstances and situations. Also, coal mining companies are

devising techniques that will help them mine more coal but still maintain the level

of coal supply.

Safety

Coal fired power plants is a much safer type of power plant compared to

other power plants like a nuclear power plant that can cause catastrophic events

such as meltdown. It only takes a mask and other PPE to keep the workers away

from harm. Additionally, the welfare and productivity of coal industry employees

has greatly improved over the years. In fact, injuries, time lost, and fatalities have

decreased significantly in the past years.

1.2.3.2. DISADVANTAGES OF COAL-FIRED POWER PLANT

On the other hand, there are also some significant disadvantages of coal

fired plants including Greenhouse Gas (GHG) Emissions, mining destruction,

generation of millions of tons of waste, and emission of harmful substances.

Greenhouse Gas Emissions

It is true that a coal fired power plant has a lot of benefits and advantages

but one of its major disadvantage is the pollutants it produces. The amount of

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pollutants it produced is so large that it need stations and sub stations to further

decrease it, but even using certain machinery, the pollutants is still pollutants. It

has amounted to a large pile of pollutants that it has further increase the global

warming.

Mining Destruction

Mining causes a lot of trouble not only for its environmental resources, but

also for the people as well. Active mining cause lands to erode quickly and not

only just the spot they’re working on. Mining in a certain place can spell doom for

the surrounding areas as well. This poses a problem for the people living near a

coal mining area because the land where their house is standing on can crumble

any moment due to the erosion of soil due to the mining of coal.

Generation of Millions of Tons of Waste

Tons and tons of waste products and harmful pollutants are produced by

Coal fired power plant and most of them are not convertible at our time. This

contributes to other waste products produced by factories and other

infrastructures.

Emission of Harmful Substances

Thermal power plants if not properly cleanse or exhausted properly can

emit and produce harmful chemicals and substances like sulfur dioxide, carbon

monoxide, mercury, selenium and arsenic. This is also the reason the rain is being

acidic. However, this disadvantage is slightly being overwhelmed by the

production of the coal-fired power plant. The reliability of the said plant is too

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 good to pass on and the fuel that requires to start the plant is very easy to make

and easy to find. That is the reason coal fired power plant is hard to let go.

1.2.4. CLASSIFICATION OF COAL-FIRED POWER PLANT

A coal fired power plant will be classified according to the way how they use the

coal serving as the fuel. The coal is used as the primary fuel in order to boil the water that

is available to the superheated steam that is then used for driving the steam turbine.

Steam turbine is then coupled to the alternate rotor whereas the rotation which would

result to the generation of the electric power. The different classifications of coal fired

power plant would depend on how the coal would be used and those are:

1.2.4.1. PULVERISED COAL-FIRED (PCF) POWER PLANTS

This type of power plants coal is grounded into a fine powder and will be

then feed into the boiler. The powder coal will now fuel the fire to heat the boiler

which will produce steam that turn or rotate the turbine and the generator. PCF

power plants are the most common and reliable type of power plant that is

currently operational. In fact, 90 percent of the electricity provided in the country

is because of the coal fired power plant and 38 percent of the worlds power is

generated through PCF.

However, using a lot of PCF also introduces a problem to use more coal

and this type of power plant is very inefficient in terms of power production.

About 32 percent of power is produced and almost 70 percent is wasted which is a

lot. This introduces a solution to use more coal to produce more power. However,

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 more coal means more CO2 and harmful substances will also be produced and

PCF power plants is also costlier compared to other type of power plants.

1.2.4.2. FLUIDISED BED COMBUSTION (FBC) PLANTS

In this type of power plant, air is mixed with the coal and other gases. This

can be done in either ambient temperature and pressure or a pressurized container

or under pressure and this power plant operates at a temperature lower compared

to that of a PCF. The main reason that they operate at low temperature is because

at this temperature, the amount of NOx produced will be similarly small. Also,

sulfur pollutants can be contained and captured inside the boiler.

However, the critical part here is that they only use low quality of coal and

if this will be put together with an inefficient type of power plant, this will

produce the same result. More coal and this means more harmful chemicals and

substances will be produced.

1.2.4.3. INTEGRATED GASIFICATION COMBINED CYCLE

(IGCC) PLANTS

Integrated Gasification Combined Cycle IGCC is a combination of two leading

technologies. The first technology is called coal gasification, which uses coal to create a

clean-burning gas (syngas). The second technology is called combined-cycle, which is

the most efficient method of producing electricity commercially available today. Coal

Gasification is the gasification portion of the IGCC plant produces a clean coal gas

(syngas) which fuels the combustion turbine. Coal is combined with oxygen in the

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gasifier to produce the gaseous fuel, mainly hydrogen and carbon monoxide. The gas is

then cleaned by a gas clean-up process. After cleaning, the coal gas is used in the

combustion turbine to produce electricity. Combined-cycle on the other hand has a design

consists of a combustion turbine/generator, a heat recovery steam generator, and a steam

turbine/generator. The exhaust heat from the combustion turbine is recovered in the heat

recovery steam generator to produce steam. This steam then passes through a steam

turbine to power another generator, which produces more electricity. Combined cycle is

more efficient than conventional power generating systems because it re-uses waste heat

to produce more electricity. The integration of these technologies provides the high

efficiency of the combined-cycle design with the low cost of coal for fuel.

1.2.5. SPECIFIC COAL-FIRED POWER PLANT

The group decided to design this coal-fired power plant for the chosen location

which is Kalamansig, Sultan Kudarat. This location was chosen by the group due to the

population, state of the municipality, large supply of water, low source of electricity and

it is close to the Moro Gulf which could be beneficial for importing coal and is suitable

for discharging large quantities of waste heat from the proposed power plant.

The group would design the specific components in a coal-fired power plant

basing from the load curves presented in the previous pages. The components which

capacities to be computed and types to be determined/analyzed for are boiler, condenser,

air fuel ratio, generator and turbine. Additional computations are for the feature or

characteristics of the mentioned components and circulation of water, steam and fuel.

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1.2.6. SYSTEM COMPONENTS OF COAL-FIRED POWER PLANT

1.2.6.1. AIR PREHEATER

The remaining heat of flue gases is utilized by air preheater. It is a device used in

steam boilers to transfer heat from the flue gases to the combustion air before the air

enters the furnace. Also known as air heater; air-heating system. It is kept at a place

nearby where the air enters in to the boiler. The purpose of the air preheater is to recover

the heat from the flue gas from the boiler to improve boiler efficiency by burning warm

air which increases combustion efficiency, and reducing useful heat lost from the flue. As

a consequence, the gases are also sent to the chimney or stack at a lower temperature,

allowing simplified design of the ducting and stack. It also allows control over the

temperature of gases leaving the stack (to meet emissions regulations, for example). After

extracting heat flue gases are passed to electrostatic precipitator.

1.2.6.2. BOILER

Now that pulverized coal is put in boiler furnace. Boiler is an enclosed vessel in

which water is heated and circulated until the water is turned in to steam at the required

pressure. Coal is burned inside the combustion chamber of boiler. The products of

combustion are nothing but gases. These gases which are at high temperature vaporize

the water inside the boiler to steam. Sometimes this steam is further heated in a

superheater higher the steam pressure and temperature the greater efficiency the engine

will have in converting the heat in steam in to mechanical work. This steam at high

pressure and temperature is used directly as a heating medium, or as the working fluid in

a prime mover to convert thermal energy to mechanical work, which in turn may be

23
converted to electrical energy. Although other fluids are sometimes used for these

purposes, water is by far the most common because of its economy and suitable

thermodynamic characteristics.

1.2.6.3. CHIMNEY STACK

A chimney is a system for venting hot flue gases or smoke from a boiler,

stove, furnace or fireplace to the outside atmosphere. They are typically almost

vertical to ensure that the hot gases flow smoothly, drawing air into the

combustion through the chimney effect (also known as the stack effect). The

space inside a chimney is called a flue. Chimneys may be found in buildings,

steam locomotives and ships. In the US, the term smokestack (colloquially, stack)

is also used when referring to locomotive chimneys. The term funnel is generally

used for ship chimneys and sometimes used to refer to locomotive chimneys.

Chimneys are tall to increase their draw of air for combustion and to disperse

pollutants in the flue gases over a greater area so as to reduce the pollutant

concentrations in compliance with regulatory or other limits.

1.2.6.4. COAL CONVEYOR

This is a belt type of arrangement. With this coal is transported from coal

storage place in power plant to the place nearby boiler.

24
1.2.6.5. CONDENSER

Steam after rotating steam turbine comes to condenser. Condenser refers

here to the shell and tube heat exchanger (or surface condenser) installed at the

outlet of every steam turbine in Thermal power stations of utility companies

generally. These condensers are heat exchangers which convert steam from its

gaseous to its liquid state, also known as phase transition. In so doing, the latent

heat of steam is given out inside the condenser. Where water is in short supply an

air-cooled condenser is often used. An air-cooled condenser is however

significantly more expensive and cannot achieve as low a steam turbine

backpressure (and therefore less efficient) as a surface condenser.

1.2.6.6. COOLING TOWER

The condensate (water) formed in the condenser after condensation is

initially at high temperature. This hot water is passed to cooling towers. It is a

tower- or building-like device in which atmospheric air (the heat receiver)

circulates in direct or indirect contact with warmer water (the heat source) and the

water is thereby cooled. A cooling tower may serve as the heat sink in a

conventional thermodynamic process, such as refrigeration or steam power

generation, and when it is convenient or desirable to make final heat rejection to

atmospheric air. Water, acting as the heat-transfer fluid, gives up heat to

atmospheric air, and thus cooled, is recirculated through the system, affording

economical operation of the process.

25
1.2.6.7. COOLING TOWER PUMP

Cooling Water Pump which may be engine driven or be a separate

electrically driven pump pushes the water around the circuit. After passing

through the engine, where it removes the heat from the cylinder liners, cylinder

heads, exhaust valves and sometimes the turbochargers, it is cooled by seawater

and then returns to the engine. The temperature of the cooling water is closely

controlled using a three-way control valve. If the water is allowed to get too cold,

then it will cause thermal shocking which may lead to component failure and will

also allow water and acids to condense on the cylinder bores washing away the

lubricating film and causing corrosion. If it gets too hot then it will not remove the

heat effectively causing excessive wear and there is a greater danger of scale

formation. For this reason the cooling water outlet temperature is usually

maintained at about 78-82°C. Because it is at a higher temperature than the

cooling water used for other purposes (known as the LT cooling), the water for

cooling the engine is known as the HT (High Temperature) cooling water

1.2.6.8. DEAERATOR

A Deaerator is a device that is widely used for the removal of oxygen and

other dissolved gases from the feed water to steam-generating boilers. In

particular, dissolved oxygen in boiler feed water will cause serious corrosion

damage in steam systems by attaching to the walls of metal piping and other

metallic equipment and forming oxides (rust). Dissolved carbon dioxide combines

26
with water to form carbonic acid that causes further corrosion. Most deaerators

are designed to remove oxygen down to levels of 7 ppb by weight (0.005 cm³/L)

or less as well as essentially eliminating carbon dioxide.

1.2.6.9. ECONOMIZER

Flue gases coming out of the boiler carry lot of heat. Function of an

economizer is to recover some of the heat from the heat carried away in the flue

gases up the chimney and utilize for heating the feed water to the boiler. It is

placed in the passage of flue gases in between the exit from the boiler and the

entry to the chimney. The use of economiser results in saving in coal

consumption, increase in steaming rate and high boiler efficiency but needs extra

investment and increase in maintenance costs and floor area required for the plant.

This is used in all modern plants. In this a large number of small diameter thin

walled tubes are placed between two headers. Feed water enters the tube through

one header and leaves through the other. The flue gases flow outside the tubes

usually in counter flow.

1.2.6.10. FEEDWATER HEATER

A feed water heater is a power plant component used to pre-heat water delivered

to a steam generating boiler. Preheating the feed water reduces the irreversibilities

involved in a steam generation and therefore improves the thermodynamic

efficiency of the system. This reduces plant operating costs and also helps to

27
avoid thermal shock to the boiler metal when the feed water is introduced back

into the steam cycle.

1.2.6.11. FORCED DRAFT FAN

Forced Draft (FD) fans purpose is to provide a positive pressure to a

system. This basic concept is used in a wide variety of industries but the term FD

Fans is most often found in the boiler industry. Fans for boilers force ambient air

into the boiler, typically through a preheater to increase overall boiler efficiency.

Inlet or outlet dampers are used to control and maintain the system pressure.

Typical fan arrangements are 3SI or 3DI which utilize a wheel center hung on the

shaft with integral inlet boxes

1.2.6.12. GENERATOR

An alternator is an electromechanical device that converts mechanical

energy to alternating current electrical energy. Most alternators use a rotating

magnetic field. Different geometries - such as a linear alternator for use with

Stirling engines - are also occasionally used. In principle, any AC generator can

be called an alternator, but usually the word refers to small rotating machines

driven by automotive and other internal combustion engines.

1.2.6.13. INDUCED DRAFT FAN

Induced Draft (ID) fans are used to create a vacuum or negative air

pressure in a system or stack. Our centrifugal blowers are used to maintain

elevated ventilation, resulting in increased system efficiency. Twin City Fan

28
can also supply extractor fans, which are typically heavy duty construction to

handle particulate in the airstream. In the boiler industry ID Fans are often

used in conjunction with FD fans to maintain system pressure which is slightly

lower than ambient.

1.2.6.14. LOW PRESSURE TURBINE

The low pressure turbine is designed to efficiently extract work out of

steam which is exhausting out of the high pressure turbine at a lower pressure. In

order to fully comprehend how this occurs, the student must grasp basic turbine

construction and design. Once basic construction and design is understood, the

conversion of thermal energy into mechanical energy will be more clearly

understood.

1.2.6.15. PULVERIZER

The coal is put in the boiler after pulverization. For this pulverizer is used.

A pulverizer is a device for grinding coal for combustion in a furnace in a power

plant.

1.2.6.16. PRECIPATATOR

It is a type of filter that uses static electricity to remove soot and ash from

exhaust fumes before they exit the smokestacks. This one common air pollution

control device. Most power stations burn fossil fuels such as coal or oil to

generate electricity for use. When these fuels undergo combustion, smoke is

29
produced. Smoke consists of tiny particles of soot that are suspended in hot, rising

air. These unburned particles of carbon are pulled out of the smoke by using static

electricity in the precipitators, leaving clean, hot air to escape the smokestacks. It

is vital to remove this unreacted carbon from the smoke, as it can damage

buildings and harm human health especially respiratory health.

1.2.6.17. PYLON

A power transmission tower is a structure that plays an important role in

bulk energy transfer systems. The basic role of this structure is to safely and

effectively accommodate transmission lines. Such a structure, which is generally

made of a metal such as galvanized steel, may also be referred to as a pylon.

Power can be transported overhead or underground. Overhead transport is

generally considered the better option because maintenance and repair is easier

and the costs are lower. Overhead transport can usually be identified when

electrical wires are seen running between tall metal structures. These wires are

known as transmission lines, or conductors. The metal structures which keep the

transmission lines off the ground are power transmission towers. These structures

help facilitate the transportation of energy from the generating source to the

substations where power is distributed.

1.2.6.18. REHEATER

Some of the heat of superheated steam is used to rotate the turbine where

it loses some of its energy. Reheater is also steam boiler component in which heat

30
is added to this intermediate-pressure steam, which has given up some of its

energy in expansion through the high-pressure turbine. The steam after reheating

is used to rotate the second steam turbine where the heat is converted to

mechanical energy. This mechanical energy is used to run the alternator, which is

coupled to turbine, there by generating electrical energy.

1.2.6.19. STOKER

The coal which is brought nearby boiler has to put in boiler furnace for

combustion. This stoker is a mechanical device for feeding coal to a furnace.

1.2.6.20. SUPERHEATER

Most of the modern boilers are having superheater and reheater

arrangement. Superheater is a component of a steam-generating unit in which

steam, after it has left the boiler drum, is heated above its saturation temperature.

The amount of superheat added to the steam is influenced by the location,

arrangement, and amount of superheater surface installed, as well as the rating of

the boiler. The superheater may consist of one or more stages of tube banks

arranged to effectively transfer heat from the products of combustion.

Superheaters are classified as convection, radiant or combination of these.

1.2.6.21. TRANSFORMER

It is a device that transfers electric energy from one alternating-current

circuit to one or more other circuits, either increasing (stepping up) or reducing

31
(stepping down) the voltage. Uses for transformers include reducing the line

voltage to operate low-voltage devices (doorbells or toy electric trains) and

raising the voltage from electric generators so that electric power can be

transmitted over long distances. Transformers act through electromagnetic

induction; current in the primary coil induces current in the secondary coil. The

secondary voltage is calculated by multiplying the primary voltage by the ratio of

the number of turns in the secondary coil to that in the primary.

1.2.6.22. STEAM TURBINE

Steam turbines convert heat energy from steam to mechanical energy.

Conversion is accomplished by accelerating steam through nozzles, then

transferring the energy of the flowing steam to moving blades. The moving blades

are attached to a wheel or disk and produce shaft rotation. Steam flows in the

axial direction, or parallel to the shaft, in most turbines. In some small turbines,

steam flows in the radial or tangential direction relative to the shaft. The first set

of nozzles is usually mounted in a nozzle block which is attached to the casing or

is a part of it. Other nozzles and fixed blades may be mounted in disks called

diaphragms. Diaphragms are mounted in the casing. Seals located where the shaft

passes through the diaphragms prevent steam from bypassing the nozzles. The

moving blades are known by various manufacturers as buckets, vanes or blades.

They are mounted on or are an integral part of wheels or disks.

32
 1.2.6.23. STEAM GOVERNOR

The Governor is considered as a feedback device. The use for this device will be

during or having the system to be subjected to the variable loading. Example would be

having the steam turbine based power plant that supplies the power to the specific city

where having the plant to be overloaded is prevented by the governor. The device used

to sense the load and even the supply of the fuel that will go to the engine accordingly

to keep the pace with load

33
 CHAPTER 2: DESIGN AND COMPUTATIONS

This chapter is focused on the design, computations, and selection of the components of

the coal fired power plant. Additional sections are added for the instrumentation of the engine

components.

2.1. ESTIMATIONS OF POWER REQUIRED TO THE PLANT

The estimation of the power consumption of Aurora is based on the given data of

ZENECO(Zamboanga Del Norte Electric Cooperative, Inc (ZANECO)). The Figure 2.1 shows

the location that the power plant is planned to install.

Figure 2.1: Map of Aurora

Source: Google Maps

34
 Figure 2.2 2017 ZANECO’s Hourly Load Profile (MW)

Figure 2.2 shows our basis for the load curve of our designed power plant

Figure 2.3 2017 ZANELCO’s Load Curve (MW)

Source: Zamboanga Del Norte Electric Cooperative, Inc. (ZANECO)

2.2. ESTIMATIONS OF FUELS AND COMBUSTIONS

This section is responsible for the design computations and selection of components to

satisfy the load curve of Aurora, Zamboanga del Sur which is approximately 25MW. The

35
following computations would determine the selection of components in the Steam power plant.

According to the Republic of the Philippines Coalbed Methane Assessment conducted by the

U.S. Geological Survey, Zamboanga Sibugay consists of semi-anthracite coal, which is one of

the highest ranking coal, with an ultimate/gravimetric analysis of: C= 82.87%, S= 0.74%, H₂=

3.67%, O₂=5.14%, N₂=2.38% with an assumed excess air to be 20%.

Figure 2. The Ultimate Analysis of Coal Resources in the Philippines

CALCULATING OF THE THEORETICAL OXYGEN RATIO

O 2 lbO2 lbC O2 lbO2 lbO2

= (2 ) (C ) + 8 (H2 − ) + 1 (S )
F 3 lbC lbfuel 8 lbfuel lbfuel

O 2 lbO2 lbC 0.0514 lbO2 lbO2

= (2 ) (0.8287 ) + 8 (0.0367 − ) + 1 (0.0074 )
F 3 lbC lbfuel 8 lbfuel lbfuel

O lbO2
= 2.4595
F lbfuel

36
CALCULATING OF ACTUAL AIR RATIO

A A O 1
= (1 + e) = ( ) (1 + e)
Fa Ft F 0.231 lbO2
lbfuel

lbO2
A 2.4595
=( lbfuel) (1 + 0.20)
Fa lbO2
0.231
lbfuel

𝐀 𝐥𝐛𝐚𝐢𝐫
= 𝟏𝟐. 𝟕𝟕𝟔𝟔
𝐅𝐚 𝐥𝐛𝐟𝐮𝐞𝐥

CALCULATING THE VOLUMETRIC ANALYSIS OF WET GAS

Gravimetric Analysis for Dry Gas:

2 lbCO2 lbC lbCO2

mCO2 = 3 (0.8287 ) = 3.0386
3 lbC lbfuel lbfuel

lbSO2 lbC lbSO2

mSO2 = 3 (0.0074 ) = 0.0148
lbS lbfuel lbfuel

lbN2 lbair lbN2 lbN2

mN2 = 0.0238 + 12.7766 (0.769 ) = 9.8490
lbfuel lbfuel lbair lbfuel

O lbO2 lbO2
mO2 = (excess) = 2.4595 (0.20) = 0.4919
F lbfuel lbfuel

lbCO2 lbSO2 lbN2 lbO2 lbdg

mdg = 3.0386 + 0.0148 + 9.8490 + 0.4919 = 13.3943
lbfuel lbfuel lbfuel lbfuel lbfuel

lbCO2
mCO2 3.0386
%GCO2 = ∗ 100% = ( lbfuel ) ∗ 100% = 22.6858%
mdg lbdg
13.3943
lbfuel

lbSO2
mSO2 0.0148
%GSO2 = ∗ 100% = ( lbfuel ) ∗ 100% = 0.1105%
mdg lbdg
13.3943
lbfuel

lbN2
mN2 9.8490
%GN2 = ∗ 100% = ( lbfuel ) ∗ 100% = 73.5313%
mdg lbdg
13.3943
lbfuel

37
 lbO2
mO2 0.4919
%GO2 = ∗ 100% = ( lbfuel ) ∗ 100% = 3.6725%
mdg lbdg
13.3943
lbfuel

For Wet Gas:

lbH2 O lbH2 lbH2

mH2 O = 9 (0.0367 ) = 0.3303
lbH2 lbfuel lbfuel

lbdg lbH2 lbwg

mwg = mdg + mH2 O = 13.3943 + 0.3303 = 13.7246
lbfuel lbfuel lbfuel

lbCO2
mCO2 3.0386
%GCO2 = ∗ 100% = ( lbfuel ) ∗ 100% = 22.1398%
mwg lbwg
13.7246
lbfuel

lbSO2
mSO2 0.0148
%GSO2 = ∗ 100% = ( lbfuel ) ∗ 100% = 0.1078%
mwg lbwg
13.7246
lbfuel

lbN2
mN2 9.8490
%GN2 = ∗ 100% = ( lbfuel ) ∗ 100% = 71.7617%
mwg lbwg
13.7246
lbfuel

lbO2
mO2 0.4919
%GO2 = ∗ 100% = ( lbfuel ) ∗ 100% = 3.5841%
mwg lbwg
13.7246
lbfuel

lbH2 O
mH2 O 0.3303
%GH2 O = ∗ 100% = ( lbfuel ) ∗ 100% = 2.4066%
mwg lbwg
13.7246
lbfuel
mwg
mwg 1
MWwg = = m mSO2 mN2 mO2 mH2 O
nwg CO2
+ + + +
MWCO2 MWSO2 MWN2 MWO2 MWH2 O

mwg 1
MWwg = = mCO2 mSO2 mN2 mO2 mH2 O
nwg + + + +
mwg MWCO2 mwg MWSO2 mwg MWN2 mwg MWO2 mwg MWH2 O

38
 mwg 1
MWwg = =
nwg GCO2 GSO2 GN2 GO2 GH2 O
+ + + +
MWCO2 MWSO2 MWN2 MWO2 MWH2 O

mwg 1
MWwg = =
nwg 0.221398 + 0.001078 + 0.717617 + 0.035841 + 0.024066
44 64 28 32 18

𝐥𝐛
𝐌𝐖𝐰𝐠 = 𝟑𝟎. 𝟏𝟕𝟗𝟕
𝐥𝐛𝐦𝐨𝐥𝐞

MWwg 30.1797
%VCO2 = %GCO2 = 22.1398 ( ) = 15.1857%
MWCO2 44

MWwg 30.1797
%VSO2 = %GSO2 = 0.1078 ( ) = 0.05083%
MWSO2 64

MWwg 30.1797
%VN2 = %GN2 = 71.7617 ( ) = 77.3478%
MWN2 28

MWwg 30.1797
%VO2 = %GO2 = 3.5841 ( ) = 3.3802%
MWO2 32

MWwg 30.1797
%VH2 O = %GH2 O = 2.4066 ( ) = 4.0350%
MWH2 O 18

CALCULATING THE HEATING VALUE OF COAL

O2
HHV = 33,820C + 144,212 (H2 − ) + 9,304S
8

0.0514
HHV = 33,820(0.8287) + 144,212 (0.0367 − ) + 9,304(0.0074)
8

𝐊𝐉
𝐇𝐇𝐕 = 𝐐𝐡 = 𝟑𝟐, 𝟒𝟔𝟏. 𝟓𝟎𝟏𝟗
𝐤𝐠

39
 2.2.1. CALCULATING THE HEATING VALUE OF COAL

O
QH coal = 33820 C + 144212 (H − ) + 9.304S
8

0.0994
QH coal = 33820 (0.4898) + 144212 (0.045 − ) + 9.304(0.0079)
8

𝐤𝐉
𝐐𝐇 𝐜𝐨𝐚𝐥 = 𝟐𝟏𝟐𝟔𝟐. 𝟖𝟏𝟓𝟒
𝐤𝐠

2.3. DESIGN AND CALCULATIONS OF STEAM TURBINES

2.3.1. CALCULATING THE MASS FLOW RATE OF STEAM

Figure 2.5 Schematic diagram of proposed Reheat Rankine Cycle

40
 Figure 2.5 TS Diagram of the Design Power Plant
We design the pump and turbine of the steam power plant assumed an efficiency of
ηpump&𝑡𝑢𝑟𝑏𝑖𝑛𝑒 = 90%
Solving for ℎ1 :
From Steam Table:
@P1 = 14 MPa & T1 = 540°C

kJ
s1 = 6.5289
kgK

𝐤𝐉
𝐡𝟏 = 𝟑𝟒𝟑𝟐. 𝟒
𝐤𝐠
Solving for ℎ2 :
kJ
@P2 = 4.5 MPa & s1 = s2 = 6.5289
kgK

𝑘𝐽 𝑘𝐽
Entropy(s, 𝑘𝑔𝐾) Enthalpy(h, 𝑘𝑔)

6.5131 3080.6
6.5289 ℎ2

41
 6.5537 3106.1
𝐤𝐉
𝐡𝟐 = 𝟑𝟎𝟗𝟎. 𝟓𝟐𝟑𝟔
𝐤𝐠
Solving for ℎ3 :
@P3 = 4.5 MPa & T3 = 540°C

kJ
s3 = 7.1467
kg K

𝐤𝐉
𝐡𝟑 = 𝟑𝟓𝟑𝟏. 𝟗
𝐤𝐠

Solving for ℎ4 :
@P4 = 2.5 MPa

kJ
s3 = s4 = 7.1467
kg K

𝑘𝐽 𝑘𝐽
Entropy(s, 𝑘𝑔𝐾) Enthalpy(h, 𝑘𝑔)

7.1436 3328.6
7.1467 ℎ4
7.1746 3350.8
𝐤𝐉
𝐡𝟒 = 𝟑𝟑𝟑𝟎. 𝟖𝟐
𝐤𝐠
Solving for ℎ5 :
@P5 = 0.03 MPa

kJ
s4 = s5 = 7.1467
kg K

42
 Table 2 : Saturated Pressure

P (Mpa) 𝑇𝑠𝑎𝑡 (°𝐶) 𝐾𝐽 𝐾𝐽 𝐾𝐽 𝐾𝐽

ℎ𝑓 ( ) ℎ𝑓𝑔 ( ) 𝑠𝑓 ( ) 𝑠𝑓𝑔 ( )
𝑘𝑔 𝑘𝑔 𝑘𝑔 − 𝐾 𝑘𝑔
0.03 69.10 289.23 2336.1 0.9439 6.8247
Solving for 𝑋5 :

S5 = sf + X 5 sfg
S5 − sf
X5 =
sfg
7.1467 − 0.9439
X5 =
6.8247
X5 = 0.9089
h5 = hf + X 5 hfg
h5 = 289.23 + (0.9089)2336.1
𝐊𝐉
𝐡𝟓 = 𝟐𝟒𝟏𝟐. 𝟓𝟏𝟏𝟑
𝐤𝐠

Solving for ℎ6 :
m3
vf6 = [email protected] Mpa = 1.0223 x 10−3
kg
𝐊𝐉
𝐡𝟔 = 𝐡𝐟@𝐏=𝟎.𝟎𝟑 𝐌𝐩𝐚 = 𝟐𝟖𝟗. 𝟐𝟑
𝐤𝐠
Solving for ℎ7 :
𝑃7 = 2.5 𝑀𝑝𝑎
𝑃6 = 0.03 𝑀𝑝𝑎
ℎ7 = ℎ6 + 𝑣𝑓6 (𝑃7 − 𝑃6 )
𝐾𝑁
m3 1000 2
ℎ7 = 289.23 + 1.0223 x 10 −3 (2.5 − 0.03) ( 𝑚 )
kg 1 𝑀𝑝𝑎
𝐊𝐉
𝐡𝟕 = 𝟐𝟗𝟏. 𝟕𝟓𝟓𝟏
𝐤𝐠
Solving for ℎ8 :
P8 = P7 = 2.5 Mpa
m3
vf8 = vf@P=2.5 Mpa = 1.1973 x 10−3
kg
𝐊𝐉
𝐡𝟖 = 𝐡𝐟@𝐏=𝟐.𝟓 𝐌𝐩𝐚 = 𝟗𝟔𝟐. 𝟏𝟏
𝐤𝐠
Solving for ℎ9 :
P9 = 14 Mpa
P8 = 2.5 Mpa
h9 = h8 + vf8 (P9 − P8 )

43
 KN
m3 1000 2
h9 = 962.11 + (1.1973 x 10−3 ) (12 − 2.5) ( m )
kg 1 Mpa
𝐊𝐉
𝐡𝟗 = 𝟗𝟕𝟑. 𝟒𝟖𝟒𝟒
𝐤𝐠

h1 − h2 kJ
0.90 = ; h′2 = 3052.5373
h1 − h2 ′ kg
h3 − h4 kJ
0.90 = ; h′4 = 3308.4778
h3 − h4 ′ kg
h3 − h5 kJ
0.90 = ; h′5 = 2288.1348
h3 − h5 ′ kg
h7 ′ − h6 ′ kJ
0.90 = ; h7 = 291.5026
h7 − h6 kg
h9 ′ − h8 ′ kJ
0.90 = ; h9 = 972.347
h9 − h8 kg

Summary of Enthalpy
h1 3432.4 KJ/kg
h2 3090.5236
KJ/kg
h3 3531.9 KJ/kg
h4 3330.82 KJ/kg
h5 2412.5113
KJ/kg
h6 289.23 KJ/kg
h7 291.7551 KJ/kg
h8 962.11 KJ/kg
h9 973.4844 KJ/kg
h2 ′ 3052.5373
KJ/kg
h4 ′ 3308.4778
KJ/kg
h5 ′ 2288.1348
KJ/kg
h7 ′ 291.5026 KJ/kg
h9 ′ 972.347 KJ/kg

44
 EP 40 MW
Based on Design, ηg = 98% = =
BP BP
BP = 40.8163 MW

BP 40.8163 MW
Based on Design, ηm = 0.85 = =
Wt′ Wt′
′
𝐖𝐭 = 𝟒𝟖. 𝟎𝟏𝟗𝟐 𝐌𝐖

MASS AND ENERGY BALANCE AT OPEN FEEDWATER HEATER

m1

h4
OPEN

m FEEDWATER m-m1

h8 HEATER h7

Figure 2.6 Open Feedwater Heater Energy Balance Diagram

In this part we are solving for the m1 ′ which at first we assume that the m to be 100% and
solving it by using energy balance.
m1 (3330.82) + (1 − m1 )(291.7551) = 1(962.11)
𝑚1 = 0.2206 kg
m1 ’(3308.4778) + (1 − m1 ’)(291.5026) = 1(972.347)
m1′ = 0.2257 kg
Wt′ = m′ (h1 − h2 ′) + m′ (h3 − h4 ′ ) + (m′ )(h4 ′ − h5 ′ ) + (m′ )(h6 − h7 ′ )
48,019.2 KW = m′ (3432.4 − 3052.5373) + m′ (3531.9 − 3308.4778 )
+ m′ (3308.4778 − 2288.1348) + m′ (289.23 − 291.5026)
𝐤𝐠
𝐦′ = 𝟐𝟗. 𝟔𝟏𝟔𝟕 𝐬
𝐤𝐠
𝐦𝟏 ′ = 𝟔. 𝟔𝟖𝟒𝟓
𝐬
2.3.2. 2.3.2. CALCULATING FOR THE TURBINE WORK

QA = m′ (h1 − h9 ′ ) + m′ (h3 − h2 ′ ) + (m′ − m1 ′ )(h4 − h5 ′ ) = EC

kg kJ kg kJ
QA = (29.6167 ) (3432.4 − 972.347) + (29.6167 ) (3531.9 − 3052.5373)
s kg s kg

kg kJ
+ (29.6167 − 6.6845) (3330.82 − 2288.1348)
s kg

45
 𝐐𝐀 = 𝟏𝟏𝟎, 𝟗𝟔𝟔. 𝟖𝟓𝟖𝟓 𝐊𝐖

QA = mf (Qh ); mf = mcoal

KJ
110,966.8585 kg lb
kg
mcoal = = 3.4184 = 27,073.728
KJ s hr
32,461.5019
kg

KJ
h1 − h2 (3432.4 − 3090.5236) kg
RCR = = = 0.9
h1 − h2 ′ (3432.4 − 3052.5373) KJ
kg

Wt ′ 48.0192 MW
Wt = = = 𝟓𝟑. 𝟑𝟓𝟒𝟕 𝐌𝐖
RCR 0.9

2.4. DESIGN AND CALCULATIONS OF BOILER

2.4.1. CALCULATING THE ASME EVAPORATION UNITS

ASME Eva. Unit = ms (h1 − h9 )

kg kJ sec
ASME Eva. Unit = 29.6167 (3432.4 − 973.4844) (3600 )
s kg hr

𝐤𝐉
𝐀𝐒𝐌𝐄 𝐄𝐯𝐚. 𝐔𝐧𝐢𝐭 = 𝟐𝟔𝟐, 𝟏𝟔𝟗, 𝟖𝟕𝟔. 𝟑
𝐡𝐫

2.4.2. CALCULATING THE DEVELOPED BOILER HORSEPOWER

ms (h1 − h9 )
Developed Boiler HP =
33522

kg kJ sec
29.6167 s (3432.4 − 973.4844) (3600 )
kg hr
Developed Boiler HP =
33522

𝐃𝐞𝐯𝐞𝐥𝐨𝐩𝐞𝐝 𝐁𝐨𝐢𝐥𝐞𝐫 𝐇𝐏 = 𝟕, 𝟖𝟐𝟎. 𝟖𝟑𝟎𝟒 𝐇𝐏

46
 2.4.3. CALCULATING THE RATED BOILER HORSEPOWER

In our design, the Percent Rating of the Boiler is 200%.

Developed Boiler HP
Percent Rating = × 100%
Rated Boiler HP

Rated Boiler HP = Percent Rating × Developed Boiler HP

Rated Boiler HP = 2(7,820.8304 HP)

𝐑𝐚𝐭𝐞𝐝 𝐁𝐨𝐢𝐥𝐞𝐫 𝐇𝐏 = 𝟏𝟓, 𝟔𝟒𝟏. 𝟔𝟔𝟎𝟖 𝐇𝐏

2.4.4. CALCULATING THE HEATING SURFACE

Based on our design, K = 0.93

HS
Rated Boiler HP =
K

HS = Rated Boiler HP × K

HS = 15,641.6608 HP × 0.93

𝐇𝐒 = 𝟏𝟒, 𝟓𝟒𝟔. 𝟕𝟒𝟒𝟓 𝐦𝟐

2.4.5. CALCULATING THE FACTOR OF EVAPORATION

kJ kJ
From Rankine Cycle, hs = h1 = 3432.4 kg and hf = h9 = 973.4844 kg

hs − hf
FE =
2257

kJ
(3432.4 − 973.4844)
kg
FE =
kJ
2257
kg

𝐅𝐄 = 𝟏. 𝟎𝟖𝟗𝟓

47
 2.4.6. CALCULATING THE EQUIVALENT EVAPORATION

EE = ms (FE)

kg 3600 sec
EE = 29.6167 ( ) (1.0895)
s 1 hr

𝐤𝐠
𝐄𝐄 = 𝟏𝟏𝟔, 𝟏𝟔𝟐. 𝟔𝟐𝟎𝟕
𝐬

2.4.7. CALCULATING THE OVERALL BOILER EFFICIENCY

Developed Boiler HP × 35,322

ηo =
mf (HHV𝑐𝑜𝑎𝑙 )

7,820.8304 HP × 35,322
ηo = × 100% =
kg 3600 sec 𝐾𝐽
6.6845 s ( ) (32,461.5019 )
1 hr 𝑘𝑔

𝛈𝐨 = 𝟑𝟓. 𝟑𝟔𝟑𝟕%

2.5. DESIGN AND CALCULATIONS OF CONDENSER

CALCULATING THE LOG MEAN TEMPERATURE

In our design, the Condenser Pressure Pcond = 0.03 MPa = 4.3511psi with a corresponding

Temperature of T = 156℉. It has a terminal difference of 10℉ and an entering cooling water

temperature of 80.6 ℉.

kg 2.2 lb 3600 s
ms = 29.6167 ( )( )
s 1 kg 1 hr

lb
= 234,564.264
hr
Tout − Tin 146℉ − 80.6℉
θm = =
T −T 156 − 80.6
ln (T s− T in ) ln ( )
s out 156 − 146

𝛉𝐦 = 𝟑𝟐. 𝟑𝟕𝟐𝟕 ℉

48
 2.5.1. CALCULATING THE OVERALL HEAT TRANSFER COEFFICIENT

In the design, the cooling water velocity v = 8 fpm and the tube is a 3/4“18 BWG Admiralty

Metal.

Figure 2.7. Figure 8-9 Condenser

From Figure 8 – 9: FT = 1.05; Fm = 1; c = 270

𝐁𝐓𝐔
̅ = c√v̅ = 270√8 = 𝟕𝟔𝟑. 𝟔𝟕𝟓𝟑
U
𝐟𝐭 𝟐 𝐡𝐫℉

𝐁𝐓𝐔
̅ FT Fc Fm Fp = 763.6753(1.05)(0.85)(1)(1) = 𝟔𝟖𝟏. 𝟓𝟖𝟎𝟐
U= U
𝐟𝐭 𝟐 𝐡℉

2.5.2. CALCULATING THE HEATING SURFACE AREA

QR = UAθm = ms hfg@Pcond

kJ 1 BTU 1 kg
hfg = (2412.5113 − 289.23) ( )( )
kg 1.055 kJ 2.204 lb

49
 BTU
= 913.1529
lb

lb BTU
ms hfg 234,564.264 (913.1529 )
A= = hr lb
Uθm BTU
681.5802 2 (32.3727 ℉)
ft hr℉

𝐀 = 𝟗, 𝟕𝟎𝟕. 𝟓𝟒𝟔𝟏𝟏 𝐟𝐭 𝟐

2.5.3. CALCULATING THE VOLUME OF COOLING WATER

lb BTU
ms hfg 234,564.264 (913.1529 )
mcw = = hr lb
cp (Tout − Tin ) BTU
cw 1 (146 − 80.6)℉
lb − ℉

lb
mcw = 3,275,122.904
hr

𝑙𝑏
mcw 3,275,122.904 1 hr ft 3 7.48 gal
Qcw = =( ℎ𝑟 )( ) = 874.7657 ( )
ρ 𝑙𝑏 60 min min 1ft 3
62.4 3
𝑓𝑡

𝐐𝐜𝐰 = 𝟔, 𝟓𝟒𝟑. 𝟐𝟒𝟕𝟕 𝐠𝐩𝐦

50
2.5.4. CALCULATING THE NUMBER OF TUBES

Figure 2.8 Table 8-1

A ft2
From Table 8-1: factor = 1.042 = 0.1963
L ft

Qcw 6,543.2477 gpm 𝐭𝐮𝐛𝐞𝐬

No. of Tubes = = = 𝟕𝟖𝟒. 𝟗𝟑𝟖𝟓
factor(v) 1.042 x 8fps 𝐩𝐚𝐬𝐬

51
CALCULATING THE ACTUAL LENGTH OF TUBES

Area 9,707.5461 ft 2
𝐿= =
A ft 2
No. of Tubes ( L ) 784.9385 (0.1963)
ft

𝐿 = 𝟔𝟑. 𝟎𝟎𝟏𝟗 𝐟𝐭

Based on table 8-2, condenser with surface area of 6,000 – 10,000 sq. ft. has an approximate tube

length of 16-22 ft. In order to get the maximum length within the range, the number of passes

must be 3.

Figure 2.9.Table 8-2

𝟔𝟑. 𝟎𝟎𝟏𝟗 𝐟𝐭
𝑳𝒂𝒄𝒕𝒖𝒂𝒍 =
𝟑 𝒑𝒂𝒔𝒔𝒆𝒔

𝐋𝐚𝐜𝐭𝐮𝐚𝐥 = 𝟐𝟏. 𝟎𝟎𝟎𝟔 𝒇𝒕

52
2.5.5. CALCULATING THE PUMP-MOTOR POWER

ηpumpmotor = 90%, No. of Pass = 4

hf = no. of pass⌊(Lactual )(factor) + pressure loss⌋

From Figure 8-11: Factor = 0.51 Pressure Loss = 1.72

53
 Figure 2.10.Table 8-11

hL = 3[(21.0006 x 0.51) + 1.72]

hL = 37.2909 ft

g
hL Qcw ρ ( go )
c
BP =
33000η

54
 1
𝜌=
𝑉𝑓@𝑇𝑠

1 𝑙𝑏
𝜌= = 61.35
𝑓𝑡 3 𝑓𝑡 3
0.0163
𝑙𝑏

ft
ft 3 lb 32.2 2
37.2909 ft (874.7657 min) (61.35 3 ) ( s )
ft lbm − ft
32.2
lbf −s2
BP = = 𝟔𝟕. 𝟑𝟖𝟑𝟒𝐡𝐩
ft − lbf
33000 (0.90)
hp − min

2.6. DESIGN AND CALCULATIONS OF CHIMNEY

2.6.1. CALCULATING THE MASS OF AIR

Calculations are for a natural draft chimney.

t DP@Sat = Pa (%VH2 0 ) = 101.325kPa(0.040350)

= 4.0885 kPa = Psat = 0.0040885 MPa

Using Steam Table:

0.0040 − 0.0040885 28.96 − TDP

=
0.0040 − 0.0042 28.96 − 29.81

TDP = 29.3361°C

𝐀 𝐤𝐠 𝐟 𝐤𝐠 𝐚 𝐤𝐠 𝐚
𝐦𝐚 = 𝐦𝐟 ( ) = 𝟑. 𝟒𝟏𝟖𝟒 (𝟏𝟐. 𝟕𝟕𝟔𝟔 ) = 𝟒𝟑. 𝟔𝟕𝟓𝟓
𝐅 𝐬 𝐤𝐠 𝐟 𝐬

55
 2.6.2. CALCULATING THE DENSITY OF AIR

Based on the Pressure and Temperature of Ambient air, Pair = 101.325 kPa and Tair = 27℃.

Pair
ρair =
R air Tair

101.325kPa
ρair =
kJ
0.287 (27 + 273)K
kgK

𝐤𝐠
𝛒𝐚𝐢𝐫 = 𝟏. 𝟏𝟕𝟔𝟖
𝐦𝟑

2.6.3. CALCULATING THE DENSITY OF FLUE GAS

Based on the design Temperature of the Flue Gas, Tgas = 280℃

Pgas
ρgas =
R gas Tgas

101.325kPa
ρgas =
8.314 kJ
(30.1797) (280 + 273)K
kg − K

𝐤𝐠
𝛒𝐠𝐚𝐬 = 𝟎. 𝟔𝟔𝟓𝟏
𝐦𝟑

2.6.4. CALCULATING THE HEIGHT OF CHIMNEY

With a designed Draft Head, Dtw = 3 cm WG

Dtw ρwater
H=
ρair − ρgas

kg
0.03m (1000 )
m3
H=
kg
(1.1768 − 0.6651) 3
m

𝐇 = 𝟓𝟖. 𝟔𝟐𝟖𝟏𝐦

56
 2.6.5. CALCULATING THE FLOW RATE OF FLUE GAS

mRT
Q=
P

kg air kg 8.314 kJ
(12.7766 ) ( 3.4184 s f ) (30.1797 ) (280 + 273)K
kg fuel kg − K
Q=
101.325kPa

𝐦𝟑
𝐐 = 𝟔𝟓. 𝟔𝟔𝟔𝟏
𝐬

2.6.6. CALCULATING THE DIAMETER OF CHIMNEY

𝑚
Based on the design the Velocity was assumed to be, 𝑣 = 7.5 and Velocity Coefficient,
𝑠

𝐶𝑣 = 0.4

Figure 2.10: Plant Engineer's Handbook by R. Keith Mobley

4Q
D=√
Cv πv

m3
4 (65.6661 s )
D=√ m
0.4(π) (7.5 s )

57
 𝐃 = 𝟓. 𝟐𝟕𝟗𝟐 𝐦

2.7. EQUIPMENT SELECTION

2.7.1. 2.7.1 STEAM GENERATOR / BOILER

The boiler chosen for the proposed coal-fired power plant is the Two-Drum Boiler

with Traveling Grate Firing Biomass and Pulverized Coal, manufactured by Babcock &

Wilcox (B&W) Enterprises, since this type of boiler can accommodate a capacity of

steam flow up to more than 1,200,000 lbs/hr. This boiler is custom-engineered depending

on project’s unique specifications for varying inputs and desired outputs.

Specifications:

Top- or mid-supported, one- or two-drum, single gas pass unit

pressurized or balanced draft operation, with membrane wall
Design Features construction, furnace nose arch and economizer and/or air heater
for economical heat recovery. Typical fuels used are Bituminous,
Sub-bituminous, Semi-anthracite, and Lignite.
 Pulverized coal, oil, gas: 80,000 to 1,200,000 lb/h (10.1
to 151.2 kg/s).
Capacity:  Stoker coal: 60,000 to 400,000 lb/h (7.6 to 50.4 kg/s).
 Stoker wood, bagasse, biomass: 80,000 to 900,000 lb/h
(10.1 to 113.4 kg/s).

 To 2200 psig (15.2 MPa) design for one-drum unit.

Steam pressure:
 To 1800 psig (12.4 MPa) design for two-drum unit.

Steam temperature: To 1000F (538C).

Solid, liquid or gaseous fuels such as pulverized and stoker coal,

oil, natural gas, wood, bark, bagasse and other biomass, CO, blast
Fuels:
furnace gas (BFG), coke oven gas (COG), and various other
byproduct solid, liquid and gaseous fuels

58
Design Features:

 Furnace wall water cooling – eliminates refractory and related maintenance

 Gas-tight setting membrane – inhibits dew point sulfur corrosion and outages caused

by gas leaks

 Rugged steel-based frame – supports boiler and allows jacking and skidding

 Outer lagging – galvanized, weather-tight for outdoor installations

 Drum internals – ensure positive circulation, low-moisture, high steam purity

 Water wash troughs and drains

 Grooved tube seats – protect against leaks during transportation and throughout

operation

 Solid membraned division wall – prohibits furnace gases from bypassing generating

tubes

 Larger tube diameter – helps to prevent membrane thermal cracking and contributes

to a faster load response

 Inverted loop, fully drainable superheaters

59
 Figure 2.11 Boiler Schematic Diagram

Figure 2.12 Two-Drum Boiler with Traveling Grate Firing Biomass and Pulverized Coal

60
 2.7.2. 2.7.2 STEAM TURBINE

For the design, the SST-400 Steam Turbine manufactured by SIEMENS was selected.

Figure 2.13 Steam Turbine Specifications

61
 Figure 2.14: SST-400 Design Features

Design Features:

 Turbine Casting – The single-body turbine with horizontal split has nearly symmetrical casing,

which allows short start-up times and quick load changes. The design of all supports for

labyrinths and blade carriers allows steam path flexibility and adjustment to individual steam

parameters. Internal valve arrangements or adaptive stages control the steam flow to the back

62
 end of the turbine and are used to maintain constant process-steam extraction pressures over a

wide flow range. The utilization of selected proven components assures high reliability and easy

maintenance.

 Rotor and Blades – The SST-400 rotor is fitted with resonance-proof blading. The blading design

guarantees high efficiency over the whole operation range, including rapid changes of load for

smooth plant operation. The reliability of the blading is achieved primarily through a low total

stress load on the blades.

 Gearbox – The reduction gears are taken from the existing range of world-class gear

manufacturers and have proven high reliability and performance.

 Base Frame – SST-400 turbines are delivered as packaged units. The components of the turboset

are installed on a common base frame, including the complete oil system. The oil tank is inside

the base frame. All instrumentation is pre-wired to junction boxes located at the front of the

frame. The number of external connections is reduced to the minimum; all connections (piping,

wiring, etc.) are clearly defined. The SST-400 base-frame packaged unit can either be placed on

a simple ground-level concrete block foundation or on an elevated foundation. It can be placed

on an existing foundation or be elevated on simple concrete or steel columns on spring packages

(a concrete foundation upper desk is not required if the base frame is placed on springs).

 Exhaust – The SST-400 range can be equipped with upward, downward or axial exhaust

orientation to fit in with the selected installation arrangement.

63
 Figure 2.15 SST-400 Steam Turbine Schematic Diagram

2.7.3. 2.7.3 CONDENSER

For the design, surface condenser is used since it can handle large volumetric flow rate of

vapour with very low pressure drop. WKG Surface Condenser is the selected condenser for the

design, which is manufactured by Oeltechnik.

Specifications:

64
Design Features:

 Evacuation unit (steam ejector or vacuum pump)

 Inter-condenser

 Hot-well

 Condensate pump

 Safety valve steam side

 Gland Surface Condenser

 System Control Instrumentation

65
 Figure 2.9 WKG Surface Condenser

Figure 2.17 Surface Condenser Schematic Digaram

66
 2.7.4. 2.7.4 GENERATOR

For the design, the SGen-100A-4P generator series, manufactured by Siemens AG, since

its performance ranges 25 to 70 MVA or MW. The SGen-100A-4P is designed using the

building-block system with optimized diameter and length sizing to achieve perfect alignment

with your plant and the grid requirements. Grid studies can be performed. Many more options

are available including variants of the cooling system and the position of the generator leads. All

parts and connections are readily accessible, and the enclosure can be easily removed for

installation of maintenance. This generator can also be custom-engineered depending on

project’s unique specification for varying input and desired output.

Specifications:

Design Features:

Outstanding design features of the Siemens air-cooled SGen-100A-4P series

generators include:

 high efficiency
 low noise emissions
 low installation and commissioning costs
 high serviceability
 long service life
Siemens four-pole three-phase synchronous generators are used as high-voltage

generators with a solid silent pole rotor. Their rotor windings are indirectly cooled by air.

67
These generators use brushless excitation as a standard. The excitation current is supplied

by an exciter with rotating rectifiers. The exciter is a stationary-field machine with the

rotor mounted on the generator shaft. Alternatively, static excitation using slip rings is

also available. Industrial plants with steam and gas turbines that use SGen-100A-4P

series generators are able to keep their operating costs down due to high efficiency levels

of cogeneration. This ensures a considerable degree of independence from public power

supply.

Figure 2.18 Four-pole Three-phase Synchronous Generator Schematic Diagram

68
 Figure 2.19. SGen-100A-4P Generator Series Schematic Diagram

2.7.5. 2.7.5 CONVEYOR

Belt Conveyor is the type of conveyer that is used in the design of the power plant

for transporting coal from the coal yard. The design of general-purpose conveyor belts

enables application in all areas of materials handling. Due to the carcass construction and

quality of cover, these belts are noted for their reliability and long life in all industrial

applications, either for general purposes or handling of sharp-edged and extremely

abrasive materials.

Specifications:

69
70
71
Figure 2.20 Belt Conveyor

72
2.7.6. 2.7.6. EMMISSION CONTROL

SYSTEM

2.7.6.1. 2.7.6.1 PARTICULATE CONTROL

2.7.6.1.1. 2.7.6.1.1 DRY AND WET ELECTROSTATIC

PRECIPITATORS (ESP)

73
2.7.6.1.2. 2.7.6.1.2 FABRIC FILTER

74
2.7.6.2. 2.7.6.1.2 SOx FILTER

2.7.6.2.1. 2.7.6.1.2.1 DRY FLUE GAS DESULPHURIZATION

75
2.7.6.2.2. 2.7.6.1.2.2 WET FLUE GAS DESULPHURIZATION

76
2.7.6.3. 2.7.6.1.3 NOx FILTER

2.7.6.3.1. 2.7.6.1.3.1 SELECTIVE TEST CATALYTIC REDUCTION

77
 2.7.7. 2.7.7 CONTROL SYSTEM COMPONENTS

2.7.8. 2.7.7.1 OPERATOR STATION (OPS) FUNCTIONS

The Operator Station (OPS) provides functions for plant operation and monitoring.

An OPS includes the following functions.

 Display of graphics (system diagrams)

 Control loop plate (controller)
 Alarm Display
 Trend Display
 Logic computation status monitoring

78
 2.7.9. 2.7.7.2 ACCESSORY STATION (ACS)

The Accessory Station (ACS) is a piece of equipment that saves and manages various

equipment data over the long-term, and interfaces with printers and other peripherals. As with

the OPS, the ACS runs on Windows.

The ACS includes a wide range of data management functions to support operation.

 Forms
 Data Logs
 List Display, etc.
Reducing Cumbersome Tasks by Automatically Generating Daily and Monthly Reports

Process data managed by the ACS database is printed out in the form of daily and monthly

reports.

Data can be printed to any Excel form, allowing forms tailored to customer requirements to be

output.

79
80
 2.7.10. 2.7.7.3 ENGINEERING & MAINTENANCE STATION (EMS)

The Engineering & Maintenance Station (EMS) is a device that performs maintenance on

various DIASYS Netmation and DIASYS Netmation4S services.

The EMS includes the following functions.

 Control system configuration

 Creation and modification of control logic for the Multiple Process Station (MPS),
Compact Process Station (CPS) and Dependable Process Station (DPS)
 Creation of graphics for rendering on an Operator Station (OPS)
 Configuration of OPS functions
 Drawing management

81
 2.7.11. 2.7.7.3 DIASYS NETMATION

All elements related to plant control including design, operation, monitoring,

maintenance and backups are controlled using computers and communications technologies.

With DIASYS Netmation, devices can be selected based on system size to develop an optimum

system configuration.

Features of DIASYS Netmation

High reliability

High reliability achieved through thorough design theory and a stringent quality control system

integrates main plant equipment to provide comprehensive support.

Advanced control functions

32-Bit processors, high-speed networks and extensive process I/O modules demonstrate

excellent controllability.

Excellent operability

The ergonomically designed human interface provides a comfortable operating environment for

users.

Easy maintenance

Thanks to the superior user interface of the ORCA-View maintenance software, dramatic

improvements are made to operability during maintenance management.

Flexibility and expandability

From small to large-scale systems, a wide range of applications are supported regardless of size,

and system expansion in the future is also a simple matter.

82
2.7.12. 2.7.7.3 FEEDWATER HEATER

As for the feedwater heater our design choose the FG-24.

83
84
 CHAPTER 3: INSTALLATION AND COMMISSIONING

3.1. INSTALLATION

In a coal-fired powerplant, many processes which uses different equipment should be

considered in order to meet its maximum capacity. Therefore, it is important to take note that

the area location of the powerplant and its system design, the area of a particular system and

the equipment that is to be used in a particular system to be thoroughly studied before

installation. Since the power plant’s performance greatly depends on the system of operations

and equipment, the equipment should be carefully installed with consideration on its space

requirement, environmental condition, safety and other factors along with the associated

operations in it. Thus, it is best to consider the top systematical arrangement of the equipment

in order to ensure the maximum efficiency and conservation of the resources.

3.1.1. LAND REQUIREMENT

Within the power plant cycle, the chemical energy on the coal is transformed into

steam thermal energy by the boiler, then it is transformed into rotational mechanical

energy by the turbine, and finally it is transformed into electric energy by the generator

which is transferred to the power plant’s transformer and switch yard before going to the

transmission system. To function normally, space requirement for operation and

maintenance is needed. It should also be open to the possibility of future expansion along

with the accompanying construction work to be done without interfering with the current

power plant.

As mentioned earlier, systematical arrangement of units is needed. To do so, the

space should be divided to the main plant area, coal storage & handling system, station

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water system and raw water reservoir, switchyard, ash handling system and

miscellaneous facilities.

In accordance to the requirement of the department of energy, the following

requirement must be submitted to them before the plant is built in its location:

1. Feasibility Study of the Project

2. Geological survey and study area (land,soil,rock formations, above

ground,underground, undersea, seafloor,water) where the infrastructure for the

project will be erected.

3. Atmospheric survey and study of the area (weather system, typhoon paths.

4. Zoning/Locational Clearance and/or Certificate of approved Land Use

Conversion if proposed site is not within an industrial or commercial zone

5. Baranggay Business Clearance

6. Mayor's Business Permit

7. Building Permit

8. Mechanical Permit

9. Sanitary/Plumbing Permit

10. Electrical Permit

11. Fire Safety Inspection Certificate from the bureau of Fire Protection (BFP)

12. National Water Regulatory Board Permit , if applicable.

13. System Handover Manual

14. Health, Safety, Security, Environment (HSSE) Plan

15. Emergency Response Procedure/Safety amd Emergency Manual

16. Operation and Maintenace Manual

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 17. Fire and Gas Electrical Checklist Manual

18. Certification of Personnel Training Conducted including results of

competency assessment.

19. Certificate of calibration of All Metered Units

20. Certificate of Final Electrical Inspection

21. Certificate of Occupancy

22. Insurance Coverage of the project (certified true copy). It should comply with

and satisfy the health, safety, security, and environment (HSSE) Plan, the

immediate locality and its people near the facility should be covered and protected

by the insurance.

3.1.1.1. Main Plant

This consist of the area from the chimney to one side of the transformer yard.

turbine-generator area, steam generator area, auxiliary bay area and the electrical

equipment area. Aside from the area for the operation and maintenance, the

arrangement should also consider the pipe lines, electrical cables, machine supports,

installation requirement, ventilation and equipment generated noise and vibration

level. The safety, accessibility for personnel in it and movements of mobile

equipment for maintenance, replacement or repairs. The requirement for land in the

main plant depends on different factors mentioned below:

1. The boiler size and the coal characteristics

2. The size of the electrostatic precipitator that will depend on the ash

content in the coal and the emission levels that will be allowed for the

station.

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 3. Number and arrangement of the coal mills that depend upon calorific

value of coal.

4. Arrangement of the size maintenance bay depending on the number of

units.

5. Distance between units.

3.1.1.2. Coal Storage & Handling System

Area for the coal storage and handling system depends on the plant location,

coal’s quality, storage requirement, coal unloading and other factors. The coal handling

operation and pulveriser must also be in accordance to ASME PTC 4.2-1969(see

appendix I). This factors shouldn’t be taken lightly since it’s the core of a power plant.

The efficiency of power generation is greatly affected by its reliability, flexibility and

efficiency in delivering large amount of coal in a short period of time. Among other

factors, the design should prioritize the maximization of the fuel burn rate of power plant.

It is important to note that the area is not a function of the plant’s capacity but the

operation, equipment and storage accompanying it.

The factors are thoroughly explained below:

1. Location of the power plant

The pit head station, where the mine is located and usually where

the mined coal is kept before being transported to power companies,

requires more area to ensure smooth unloading and return of empty coal

rakes. The system that allows the unloading needs more area. This is

greatly dependent on the capacity of the power plant and number of coal

rakes needed daily.

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2. Type of coal unloading system

Area for the wagon tipplers in thermal station needs a lot of space.

The position of the track hopper is dependent on the bottom discharge

wagons which becomes a problem on arranging with the railways. There

are two types of coal unloading system:

 Merry-Go-Round(MGR)

This kind of system requires wagons with bottom discharge

hoppers fitted with a pneumatically actuated automatic door

operating mechanism. The unloading of coals from the wagons in

an underground track hoppers. From this, the coal is delivered to

the crusher house through a reclaimed conveyors below the track

hopper. Its capacity depends on the track hopper to ensure that it is

emptied before the next batch or coal rake comes. The pit head

power stations uses this system too.

 Wagon Tippler Type System

Unlike the MGR, this system unloads coal form wagons

using a wagon tippler in delivering it to the wagon tippler hopper.

From this, the coal is delivered to the crusher hoes using an apron

feeder or vibratory feeder. An apron feeder is a mechanical feeder

used to extract raw material typically from dump hoppers, bins and

stockpiles while vibratory feeders use both vibration and gravity to

move material to a process or machine. The implementation of

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 such systems is used for power station located away from the coal

mines.

3. Storage requirement

This is greatly dependent on the station capacity in terms of the

needed coal stack piles. For effective operation, power stations keeps a

month of coal requirement for load center stations and 15 days for case pit

head station. In total, this requires a lot of area considering the amount of

ash produced by the coal.

4. Redundancies to be kept for the system

This pertains to the redundancy of the conveyor system, wagon

tippler/track hopper system, stacker reclaimed, crushers and other

processes affecting the reliability of supplying the coal and the

effectiveness of its delivery at a short period of time.

3.1.1.3. Station Water System And Raw Water Reservoir

Water system pertains to the pre-treatment and clarification plant, water

treatment plant, circulating water system accompanying the cooling towers and

effluent treatment system. The land allotment is greatly dependent on the cooling

towers utilized and the raw water’s quality. A condenser cooling system can be added

when space reduction is needed. There are two types of cooling towers: the natural

draught cooling towers that required more space than an induced draught cooling

tower. The space needed is proportional to the plant’s capacity. It is recommended to

use a natural draft cooling tower to lessen the auxiliary consumption.

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 On the other hand, the storage capacity of reservoir depends entirely on the

resource of water, its reliability and the cooling system of the power plant. Usage of

sea water for the condenser would yield to a lesser needed reservoir capacity. Since

using sea water, direct cooling is preferred the water discharged temperature

shouldn’t rise to 7 degree to avoid damage to the aquatic life. The cooling will be

done such that the discharge water passes through a pond or through long discharge

channels, adding to the total area needed.

In cases where supply of water isn’t available on certain times of the year, an

alternate or storage reservoir is needed. The land allotment of it depends on the depth

of the reservoir varying between 4 to 8 meters depending upon the soil strata and the

water table in the area. It should capably supply for a period of time which can go up

to 30 days especially when the water channels is closed for maintenance.

3.1.1.4. Switch yard

The space needed for switchyard depends on the type of scheme, voltage level

and number of bays. The size of the switchyard specifically depends on the number of

bays needed in order to evacuate the power from the generating station. As such, the

width of the switchyard should be restricted to that of the main plant. When there is a

shortage of land, a gas insulated switchgear switchyard(GIS) is advised to reduce the

space allotment for about 30%.

3.1.1.5. ASH HANDLING SYSTEM

This system is responsible for method of collection, conveying, interim storage

and load out of various types of ash residue produced by the plant. The evacuation of the

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fly ash uses dry and wet system while the bottom ash uses air preheater in wet system.

The space for the ash handling system will depend on the capacity of the plant and also

the ash content that is found in the coal used. The difference on the two types of modes

that is used is mentioned below:

 Dry fly ash handling system

This consist of the vacuum collection system, pressure

conveying system, intermediate silo, main silo, compressor house

and etc.

 Wet fly ash handling system

It consist of the vacuum collecting system and subsequent

wetting unit that will convert the ash into the slurry and discharge

it into a common ash slurry pit.

3.1.1.6. Miscellaneous Facilities

This facilities includes the service building, workshop, computer house, fire

station, canteen, security office, lab, auxiliary boiler, roads, and fire pump house and fire

water tank. Although this is comparably smaller than all areas, it still needs consideration

to ensure that the functionality, safety and effectiveness of the power plant.

3.1.2. INSTALLATION OF REQUIREMENT

3.1.2.1. UNIT TRANSFORMER

An electrical transformer should be inspected for any visible damage, lose or

broken parts, dirt or the presence of moisture before installation. The manufactured part

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must be in accordance with the International Electrotechnical Commission edition 1 of

IEC Std C57.15.

i. Ensure the area is well ventilated and free from explosive or

corrosive gas or vapors.

ii. Check the transformer nameplate and verify that it is the correct

kVA, frequency, line and load voltage for the application

iii. Mount the transformer securely

iv. Shut off primary voltage using approved lockout/tag-out

procedures

v. Remove the cover over the wiring compartment.

Note: On ventilated transformers the bottom screws should be

loosened and not removed for easier replacement of the cover

vi. Adjust primary taps if necessary and insulate any unused taps

individually. Before changing taps, the protective coating must be

removed from the top and bottom of each tap. The tap’s surface

must be clean and coated with electrical compound before bolting

the wire.

vii. Route wires into enclosure using the predefined access holes or by

creating holes as needed. On ventilated units the wires should enter

the unit below the terminals and in front of the coil.

viii. Connect the transformer primary according to the wiring diagram

on the nameplate.

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 ix. Ground the enclosure in accordance with NEC and local electrical

codes.

x. Energize the unit and check the secondary voltage to ensure it is

proper for the load.

xi. Shut off the primary voltage using approved lockout/tag-out

procedures

xii. Connect the load to the secondary terminals according to the

wiring diagram on the nameplate

Note: After installation of cables and connectors, a minimum of 1”

clearance should be maintained between the enclosure and any energized

parts 13. Replace the cover over the wiring compartment

xiii. Energize the unit.

3.1.2.2. STEAM TURBINE

In accordance with the ASME PTC 6-2004 steam turbines(see appendix),

the steam turbine used must have the following:

i. The steam turbine should be composed of compound construction,

condensing type with six (6) or seven (7) steam extractions at optimum

points for regenerative feed heating. HP turbine shall be of double

casing design while LP turbine may consist of two separate turbines.

The casing of the HP, IP and LP should be independent of each other

or a HP-IP combined casing while the LP casing is separated. It is

important to note that the casings of HP’s inner, IP and LP should be a

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 horizontally split type. The dumping device of the HP steam should

provide for the steam’s evacuation form the HP turbine to the after

shutdown to avoid windage.

ii. The casing, rotors, bearings, temperature sensor, couplings, steam

gland seal, rotor turning gear must be which is preferably hydraulic

type with a remote operation facility, handing barring gear, emergency

stop and control valves and reheat stop and control valves with their

servomotors, removable type steam strainers for start-up and normal

operation upstream of emergency stop and reheat stop valves,

crossover/ cross around piping and electric motors for all its integral

subsystems should be complete. It is also applicable to add main steam

emergency stop and reheat stop valves to steam strainers.

iii. The quick closing non-return valves (QCNRV) which is

hydraulic/pneumatic power and ordinary non-return valves for each

extraction including steam lines to BFP turbine drives excluding the

heater in condenser neck and for each cold reheat line one hydraulic /

pneumatic power operated QCNRV. The type of actuation, which is

hydraulic/ pneumatic, shall be in accordance as per the standard

proven practice of the manufacturer.

3.1.2.3. PUMPS

3.1.2.3.1. Location

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 Consideration for the pump’s location mst ensure a sufficient positive

suction head while the NPSH is kept at minimum. The selected pump must be

approved by ASME accredited officials and be in accordance with ASME PTC

8.2-1990(see appendix).It is also advisable to make the suction line as short and

direct as possible. It should also be large enough to keep the velocity low and

friction loss to a minimum. Installation of a sluice valve is necessary on the

suction side while elbows should be far away from the pump.

3.1.2.3.2. By-pass

On the discharge side, a by pass line is necessary. It should have the same

connection with the lower pressure in the boiler feed cycle, not directly to the

pump suction. This by pass may be operated manually or automatically and may

include set of orifice to keep the safe and minimum capacity of the pump. It

should also be always open whenever the pump is functioning at the rated or full

capacity. Note that it is especially needed when operating at reduced capacities.

3.1.2.3.3. Orifice installation

As mentioned earlier, the by-pass pipping is in the discharge side. It

should be connected at a point between the pump’s discharge and the cheek valve.

On the other hand, check valves, except globe valves, should be placed o both

sides of the upstream and downstream side of the orifice for cleaning purposes,

when necessary. It should have a minimum of a straight run pipe on either side of

the orifice with a measurement of about 2 feet for the turbulence reduction and

lessen the possible cause of noise.

3.1.2.3.4. The re-circulation line

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 The recirculation line must enter at a point in the feed water heater below

the minimum level and should be far from the pump possible. If the

configurations allows, preventing the bypass flow from directly entering the pump

suction line through the installation of a baffle in the heater. The increase in

temperature in the water flowing is evident on the by-pass flow is evidence of the

absorbed heat however its effects lessens with a large heater capacity.

3.1.2.3.5. Important Instructions for operation of Boiler Feed Pump

i. In operating, The discharge valve can only be closed when the by-

pass line back to the source is wide open. Note that, throttling on

the suction side of the pump increases friction and possibility oof

flashing in the suction side, all of which should be avoided. The

capacity must also be manage by either throttling the discharge

valve or adjustment on the pump speed if possible.

ii. Be caution on the suction and discharge gauges. When serious

fluctuations is observed, turn off the unit and check for trouble.

iii. Never subject the pump to severe temperature changes. When

necessary, gradually increase the temperature before starting and

lessen it slowly when taking the pump off the line.

3.1.2.4. CONDENSER

The following must be done in accordance to the 11th edition of the

standard for steam surface condenser:

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 i. The materials for plates, tubes and nozzles should be tested first to

ensure its mechanical properties and chemical compositions.

ii. The plates should undergo ultrasonic testing(UT).

iii. The dimensions of tube should be determined through eddy current and

hydraulic tests. When the latter can’t be executed, leakage detection of

air under water or helium must be done.

iv. MPE and UT should be done when forging nozzles.

v. Visual examinations of the welds should also be done. In addition,

about 10% of all the butt weld must undergo radiographic examination.

In cases where welds are done in a vacuum, Radiographic test on of at

least 10% of the butt weld should be executed. Damages on the

surfaces should be examined through MPE or equivalent tests method

to at least 10% of the weldments. Note that it must also be applied to

site welds. On the other hand, nozzle should undergo DPT and MPE

testing.

vi. Damages on surface on its edge should be examined. The edges should

be carefully prepared for welds before dispatch.by using a magnetic

particle examination method.

vii. Freedom form internal and surface damages must be ensure by doing

RT, UT and MPE on fabricated flanges.

viii. Try out a few tubes through the main tubes and support plates to verify

the alignment of tube plates and proper fitting and matching of parts

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 and sub-assemblies. This is to guarantee the dimensional control of

condenser, parts/ sub-assemblies shall be trial assembled at shop.

3.1.2.5. Boiler

In accordance to BPCV.1-2010 of the ASME code the following must be

present in super heater, rehearters and economizers:

 Manufacturer's serial number

 certified by (name of Manufacturer)

 maximum allowable working pressure when built

 heating surface (or power input for electric boilers)

 year built

 maximum designed steaming capacity

i. Ensure that the general boiler system requirement is installed in

building free from the risk of dust and dripping water. Other

prevention for adequate ventilation for combustion air supply must

be designed properly while paying utmost attention for the

absences of corrosive elements such as chlorine or halogenated

compounds can be drawn in the combustion air.

ii. The location must be leveled and has enough load-bearing

capacity. The load bearing capacity pertains to the over-all weight

while operating which is its total weight with all fitted

components. Special foundations for boilers aren’t necessary

however it is advised to have foundation to easily clean the

installation room whenever necessary.

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 iii. Professional personnel authorized by the specific boiler’s

manufacturer must provide the boiler installation.

iv. The space requirement for the boiler room should considered a dry

and well ventilated space.

v. Protection against overheating and overpressure. It must comply

according to PG-67.4.3.2.3 of BPVC.I-2017 Rules for

Construction of Power Boilers which states that “A direct-acting

overpressure trip-actuating mechanism, using an independent

pressure sensing device, hat will stop the flow of fuel and feed

water to the boiler, at a pressure higher than the set pressure of PG-

67A.3.2.2, but less than 20% above the maximum allowable

working pressure”

vi. It should be as near as possible to the power source and away from

extreme ambient temperature changes and weather conditions

vii. Its mounting must provide support against adequate vibration.

viii. At least 1 meter of clearance on all side must be considered for

maintenance and service access

ix. The Vibration isolators under the supports must uniformly

distribute the load of the equipment

x. A drum type steam generator integrated with circulation water

tube, direct pulverized coal fired, balanced draft furnace, single

reheat, radiant, dry bottom, suitable semi-outdoor installation and

top support. The gas path arrangement of steam generators shall be

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 two pass type. The design and sizing of various plants, systems,

equipment offered for the steam generators and auxiliaries shall

comply with the general requirements indicated in the specification

xi. The design specification must comply with the minimum design

and sizing requirements of the purchaser and all the accompanying

components, equipment and systems. Contractor's utilization of

various values and criteria indicated by the purchaser shall in no

way relieve the Contractor of his responsibilities to meet all

guarantee requirements or of providing completely safe and

reliable operating equipment/ systems.

xii. The requirements for the latest editions of the ASME BPVC.I-

2017 Rules for Construction of Power Boilers should be complied

by the designed steam generator.

xiii. Aside from that, compliance on other standards with requirements

equivalent or exceeding the IBR requirements is acceptable.

xiv. The contractor is responsible for attaining the approval of

Inspection Authority/ Chief Inspector of Boilers on behalf of the

purchaser for the designing and design calculations, manufacturing

and erection procedure, testing etc.. Papers relating to it must be

submitted to statutory authorities and purchaser for his review.

Additionally, the contractor is responsible in furnishing the

requisite documentation as required by the purchaser for getting

the boiler registered under IBR

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3.1.2.6. SUPERHEATER AND REHEATER

In accordance to BPCV.1-2017 of the ASME code the following must be

present in super heater, rehearters and economizers:

 Manufacturer's serial number

 certified by (name of Manufacturer)

 maximum allowable working pressure when built

 heating surface

i. A suitable design of the super heater(s) and reheater(s) should be

oriented to comply with the requirements of the specified load(s),

coal(s) and whole range of operating conditions.

ii. Compliance on the operation requirements as elaborated at

BPVC.I-2017 throughout the control range, for specified fuel and

under all operating conditions like variable and constant pressure

operations, HP heaters out of service, HP-LP bypass operation, top

mills in service and others must be considered in the design of

super heater(s) and reheater(s).

iii. The design of the steam generator must also achieve the rated RH

outlet temperature for the whole entire range of operation by use of

primary control device only, while firing from the specified range

of coals and following all the operating conditions mentioned

below:

a. Normal operation.

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 b. Operation of a reduced feed water inlet temperature integrated

in a steam generator during the conditions of HP heaters out of

operation and/or HP-LP bypass operation.

c. There must be compliance with the BMCR conditions on

continuous operation of steam generator.

d. Unit start-up.

e. With middle mill combination at 100% TMCR load. The RH

spray water shall be used for temperature control in case of

emergency conditions.

iv. In ensuring that no defect on the reheaters with sudden closure of

turbine interceptor valves, bidder should be used.

v. Minimum number of thermocouple should be provided for

continuous temperature monitoring as per the following guidelines:

a. For super heaters and reheaters elements placed before furnace

exit plane (in the direction of gas flow), chromel-alumel

thermocouples on at least two elements of every fifth assembly

between the two headers shall be provided for tube metal

temperature detection out of gas path (in SG casing).

b. In addition to the above, adequate number of chromel-alumel

thermocouples for measurement of tube metal temperatures

outside the gas path shall also be provided. Total number of

thermocouples including those at (a) above shall, however, not

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 be less than 2 (two) thermocouples per RH/SH assembly

between the two headers.

3.1.2.7. ECONOMIZER

i. The economizer arranged for counter flow of feed water and flue gases

with modular construction shall be bare tube and inline type. It shall be

fabricated from seamless tubes in suitable modules to facilitate block

erection.

ii. Stainless steel erosion shields shall be provided with for the leading

tubes of each tube bank of the economizer. A minimum 5 mm thick

sturdy cassette baffles shall be provided for all front and rear bends of

the economizer banks. The cassette baffles shall cover complete bends

and additional 300 mm straight tube length.

iii. Steam/ water cooled hanger tubes/headers should not cause any

dislocation /damage to the tube banks/setting by supporting the

economizer shall form part of steam/ water circuit.

iv. A proper barrier and clear side spacing (gas lane) of minimum 63.5

mm shall be provided to avoid gas lining

v. Ash hoppers shall be provided for the economizer.

vi. The piping from the economizer outlet to the boiler drum must not

have any valve.

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 vii. The top most row shall be shielded to reduce erosion when the steam

generator has the flue gas down flow section with horizontal tube

banks.

viii. The location of the headers should be in the external gas path and shall

be drainable to the maximum possible extent. Suitable erosion shields

must be provided when locating the headers in gas path becomes

unavoidable.

ix. Drains and suitable opening with forged weld on caps for internal

inspection and chemical cleaning should be integrated with the

economizer header.

3.1.3. UTILITY INSTALLATIONS

3.1.3.1. CONTINUOUS DEWATERING AND RECIRCULATION (CDR)

SYSTEMS

The requirements for the replacement of a bottom ash hopper includes the

included limited outage time and physical space constraint. The existing bottom

ash hoppers and equipment remained in place while the sluice conveying pipes

were intercepted and routed to the remote SFC's in these circumstances. After the

particulate was removed from the sluice conveying water, the clarified water is

returned to the boiler house to complete a zero liquid discharge system, while

again decommissioning the existing bottom ash pond. This particular option is

particularly cost effective when considering installations with two or more

operating units due to the multiple unit synergies, and is also highly favorable by

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 maintaining plant availability as it requires no major changes to existing bottom

ash hoppers and minimal outage time with proper tie-in planning for piping,

power and controls.

3.1.3.2. DEWATERING SYSTEM

Dewatering Bins, Settling Tanks and Surge Tanks is used on Traditional

dewatering system. Retaining the dewatering bins while providing additional

particulate separation and water clarifying in the new tanks for this system. Like the

CDR system, the key decision criteria included limited outage time and reuse of

existing equipment and the clarified water is returned to the boiler house to complete

a zero liquid discharge system, while again decommissioning the existing bottom ash

ponds. This option is favorable on plants with existing equipment that can be reused

and is cost effective when considering installations with two or more operating units

due to the multiple unit synergies. Aside from that, it can also be implemented with

little time with proper tie-in planning.

3.1.3.3. DRY UCC PNEUMATIC ASH EXTRACTOR SYSTEMS (PAX)

In the design, the elimination of wastewater generation and long-term life

cycle cost is greatly considered. In its installation, the bottom ash hoppers

impounding the existing water were entirely replaced by dry, refractory-lined

hoppers, vacuum conveying systems and a common dry bottom ash storage silo. In

doing so, the existing bottom ash pond was decommissioned.

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 3.1.3.4. UCC SUBMERGED FLIGHT CONVEYOR TECHNOLOGY (SFC)

In its installation, the design greatly considered the outage time constraints,

reduced maintenance and operations costs, physical space availability and the

age/condition of the existing bottom ash hopper. To do so, the existing bottom ash

hoppers were in need of major repair or replacement was decommissioned and a new

SFC replaced the existing bottom ash hopper/sluice conveying system.

3.2. COMMISSIONING

Commissioning ensures the all systems and components of the coal-fired power

plant are suitably designed, installed, tested, operated and maintained accordingly with its

operational requirement. The components for this specific plant includes the steam

generator, deaerator, turbine, generator, steam system piping and the like. Since the

power plant’s functionality greatly depends on the system of operations and equipment,

includes the steam generator, deaerator, turbine, generator, steam system piping and the

like. Examining each equipment or system is necessary to ensure its performance,

compatibility and efficiency in working is necessary. That’s why its construction happens

in a long period of time while the machines, equipment and systems are moderately

installed.

Particularly, the power plant commissioning ensure proper installation of its

components. A clear fluid flow on the pipe is designed and tested by manually

pressurizing it. Through this, It will be determined if it can sustain the pressure and flow

rate to perform at its rated load. Additionally, the management and safety system are

evaluated for normal operation. Finally, the power plant’s function accordingly to its

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designed system. However, it is important to take note that problems about some

machines that aren’t assembled properly or some system obtains blocked or obstructed

despite of all the given precautions.

3.2.1. COMMISIONING MANAGEMENT SYSTEM

3.2.1.1. COMMISSIONING OF STEAM TURBINE

3.2.1.1.1. STEAM BLOWING

This test is done to remove any foreign particle remaining in steam inlet

pipeline by blowing the steam lines prior to starting up a new unit. The difference

in co-efficient of thermal expansion as it is heated by steam and cooled would

remove the mill scale/weld slag away from the pipe wall.

i. Disconnect steam inlet pipe from turbine emergency stop valve

ii. Arrange for target plate of mirror finished aluminum of thickness

10 to 12 mm to be fitted at 1 meter away in the temporary blowing

line which is placed in the main steam line by making a fixture.

iii. During the blowing down process open all the drain lines from

boiler to inlet pipe flange.

iv. Steam blows should be carried out by fully opening the isolating

valve.

v. Bring the boiler press. up to 70 to 80% of working press. & temp.,

blow down the steam line until press. drops to 20 to 30% of

working press./temp. recommended by boiler manufacturer and

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 then allow the line to get cooled(~40°C ) and then hammer the

steam pipe line near joints.

vi. Repeat this procedure for three times.

vii. Now place the target plate in the fixture & blow down the steam

line and allow it to cool.

viii. This cycle is repeated till we get acceptance value, In each cycle

continue hammering and Stamp the cycle no. on the receiving face

of the target plate.

3.2.1.1.2. WATER LEAK TESTS

i. The DM water pump is connected by the pipe line to the condenser shell.

ii. Fill the condenser with DM water up to the bottom of exhaust casing until

water leaks from the exhaust well of turbine.

iii. Guarantee that all the pipe lines are filled with water which are connected

in the vacuum system.

iv. Hold the water up to one hour and observe any leakage from the flange

and welded joints.

v. Confirm that there is no leakage in the system

vi. Completely remove the water from the system after the completion of test

3.2.1.1.3. VACUUM DROP TEST

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 i. Provide a ms plate of approximate 10 to 15 mm thickness between

condenser flange and bellow flange provided at the turbine exhaust flange

along with turbine to isolate the it from the condenser.

ii. Fill the condenser hot well up to its normal level.

iii. Start hoggeer ejector and create vacuum to the designed value of 0.1 ATA

then close the hogger ejector.

iv. Check the rate of vacuum drop.

v. Remember that the decrease in vacuum should not exceed 0.01 kg/sq.cm

in 30 minutes.

3.2.1.1.4. COMMISSIONING PROCEDURE FOR SOLO RUN TEST

AND LOAD RUN TEST

i. Open all drains of steam in turbine

ii. SEV drain

iii. Nozzle chest drain

iv. Wheel case drain

v. Casing drain

vi. Throttle valve drain

vii. Inspect oil level in oil tank through oil level gauge and temperature. Its

temperature must be , at its minimum, equal to 35°C

viii. Ensure that cooling water to oil cooler, condenser, GVC is flowing

ix. Start AOP

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 x. Start the motor driven barring gear since an interlock ensures that the

baring gear cannot be started before bearing oil pressure is established

xi. Run barring gear for a period of 12 hours, if turbine is started first time for

an SCG 3 turbine.

xii. survey the vibration level if its within the limit

xiii. Allow sealing steam for lay packing

xiv. Reset all safety trips

xv. Crack open the steam supply isolating valve and warm up the steam pipe

line to turbine SEV. It is important to warm it up to avoid uneven

expansion of pipe line, rotor and casing and water hammering effect.

xvi. Start GVC blower

xvii. Initially lift the HP actuator lever

xviii. Gradually open the SEV, which should be sufficient for warming nozzles

and casing.

xix. After few minutes, when the turbine warmed through and all water has

been expelled, then partially close the turbine drains

3.2.1.2. COMMISSIONING OF BOILER AND AUXILIARIES

It is important for the boiler to function well without being a hindrance to

other system and equipment in the power plant. Cooperation between the boiler and

the plan operation is especially necessary in starting up. Since it’s a critical part of the

plant, it must be synchronized well with plant operation to meet the specific steam

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 demands of the plant. It’s a continuous fine tuning since specific boiler’s

characteristics and data from actual performance can help in its improvement.

The commissioning procedures and instructions for boiler and auxiliaries

includes the hydraulic test and wet preservation, air and gas tightness test, trial run of

equipment, electronic precipitators, fuel oil system, preparation for first light up,

alkali boil – out, acid cleaning and passivation, thermal flow test of economizer,

water walls, and super heater, valves, steam boiling, safety valve setting, and soot

blowers. Each boiler, superheater, waterwall, or steel economizer shall be inspected

during construction and after completion by an Authorized Inspector.

The authorized inspector must be accredited by an ASME authorized agency.

3.2.1.2.1 Gas pressure

For this step, Measure the gas pressure on the inlet of the furnace. For accurate

values, determine the gas pressure at the manifold on both high- and low-fire. The gas

pressure measured at the manifold should be close to 1.7” of water column (WC) on the

rating plate for low-fire and 3.5” WC on the rating plate for high-fire. A high gas pressure

or too low pressure indicates that the combustion process will not burn at engineered

design. Once the gas pressure is set, the temperature rise is will assist in adjusting the fan

speeds. That said, some high-efficiency furnaces with variable speed motors (ECM) are

engineered to ramp up air speed to produce a temperature rise that will protect the heat

exchanger.

3.2.1.2.2 Clocking the Meter

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 This step aims to verify that the furnace’s burning rate of gas is equal to its

rating and show if the wrong size orifices were installed. The value reflects its

performance: too high or too low BTU, it means the furnace is not firing or

performing to engineered design. The value should be within the range of BTU

which is should be within the acceptable measured BTU versus sized BTU with a

variance of five per cent.

3.2.1.2.3Temperature rise

For this step, ensure that sufficient air flows on the heat exchanger: if the

temperature is too low, condensation may occur in the primary heat exchanger;

and if it the temperature is too high based on the furnace testing outside of

manufacturer’s specifications for temperature rise, it will result in poor comfort

levels and potential premature degradation of the heat exchanger if results are too

high. It is preferable to have the fan speed in the middle of the set up range as

possible.

3.2.1.2.4. External static pressure

The external static pressure (ESP) tests must be done on the supply and

return air to indicate the adequacy of both the return air and supply air duct

systems to handle required air flow. It is also useful in determinng the additional

pressure drop imposed by the air filter, furnace cabinet, elbow connection or

overall system effect. Generally, higher air flows accompanies high efficiency

furnaces. Thus the duct system must be considered when changing the furnaces.

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3.2.1.2.5. NORMAL COLD START UP OF THE BOILER

i. Purge the furnace enough by sending sufficient air to evacuate any

combustible gases/material left in the furnace before lighting up the

boiler.

ii. A high air flow must be maintained during the light-up until the boiler

is on the line and reaches a load where additional air is required to

maintain the design of excess air. it is recommended that a high air

flow of at least 30% MCR be used in order to produce an air rich

furnace atmosphere to guarantee maximized safety during cold start-

ups.

iii. The rate of increase in a drum pressure should be maintained when

bringing the unit up to the rated pressure and temperature, the

saturated steam temperature rise, should be limited to 50 C per hour

iv. To avoid overheating tubes in the furnace downstream, the maximum

temperatures of the gases leaving the furnace should be below 500° C

during start-ups. To do so, The firing rate must be controlled.

3.2.1.2.6. PREPARATION

i. Check the following items prior to start-up:

ii. All access doors closed.

iii. Check the starting equipment and interlocks for any defects

iv. Ensure that there’s a large distance from the retractable soot blower

elements to the gas path.

v. Ensure that boiler fittings and valves are in proper order.

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 vi. A closed and a manual control must be present in the feed water

regulating valves.

vii. Close all blowdown and drain valves on boiler, water walls and the

soot blower master steam supply valves.

viii. The main steam line stop valve closed while the dum vent valves are

open.

ix. Water level gauge valves kept open.

x. Main steam line drains should be open.

xi. Check the auxiliary equipment for adequate lubrication and / or

cooling water flow.

xii. Open all instruments control connections and put all automatic control

equipment on manual control and see that all control equipment are

ready for service.

xiii. Ensure that the instrument panel power, compressed air and power for

fan / pump starting is available. These instruments should be adjusted

and checked to master gauges for corrections.

3.2.1.2.7. AIR LEAK TEST

This test is done before hydro teste on the boiler. The aim of air leak test is to

ensure that erection of pressure parts is completed. Air leak test is conducted by

introducing air into the boiler pressure parts at a pressure and the entire boiler pressure

parts are checked manually for any leakage. Vital points of leakage is in the Vital point

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for leakage are in the manhole doors, peephole doors, duct joints, fan flanges

Specifically, the procedure is as follow:

i. Ensure that mechanical erection of boiler and ducting up to the chimney is

completed.

ii. Ensure Trial run of the fan is completed.

iii. Check the completion of sealing system and all weld joints and flange

joints in ducting exposed to test.

iv. Close the discharge damper of ID fan to chimney.

v. Run FD fan and keep open all the dampers in the air and flue gas path.

Keep the air pressure and running time as approved by design.

vi. Detect leakage by soap solution/smoke test.

3.2.1.2.8. BOILER HYDRO TEST

In this test, the equipment should be hydrostatically tested to attain a

minimum of 1½ times the design pressure but no less than 1 1/4 times the

maximum allowable working pressure of any part of the boiler, excluding the

boiler external piping as shown on the data report to be stamped on the boiler.

After a boiler has been completed, it shall be subjected to pressure tests using

water at not less than ambient temperature, but in no case less than 70°F (20°C) in

accordance to PG-99 of BPCV.I-2017. Also, the pressure relief valves does not

need to be included in the hydrostatic test.It should be done every year and is

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considered as annually tests. The test is done by filling water from the bottom

most portion of the boiler. After ensuring full flow of water through the vents the

vents are closed and pressurization is done by an external pump installed near the

drain header. The steam’s color is used as indication of the debris being removed

from the contour. In addition, the aberration on the polished target plates fixed in

the exhaust piping will be used to indicate the effectiveness of blowing. Softer

material like aluminum, brass, copper etc. can also be used for target plates. For

evaluating the cleanliness and termination point of steam blowing, target plates

made of alloy steel are to be used. It is important to note that the complete system,

along with all interconnecting piping, should be hydrostatically tested before

start-up to comply with code requirements and to check for leaks that may have

occurred during shipping and handling.

i. Open the steam drum vent valve and gag the safety valves in

accordance with safety valve manufacturer's recommendations. In lieu

of gagging, the safety valves may be removed and replaced with test

plugs or blind flanges.

ii. Open the vents on the interconnecting piping. Close steam outlet

valve.

iii. Isolate pressure switches, gauge glasses or control components that are

not intended to be subjected to a hydrostatic test.

iv. Fill the system with treated water in accordance with

recommendations from the coal fired powerplant’s water treatment

consultant.

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 v. Apply pressure slowly. The recommended rate of pressure increase is

less than 50 psi per minute. Proper control must be maintained so that

pressure does not exceed the 1.5 times the design pressure.

vi. When the proper test pressure is reached, inspection in accordance

with the test objective can begin. Examine the system for any leaks. If

no leaks are visible, hold the system in a pressurized static condition

for a period long enough to satisfy the code requirement.

vii. Upon completion of the test, release pressure slowly through a small

drain valve. Then fully open vents and drains when the pressure drops

to 20 psig. Particular Care must be given to make sure that parts not

normally containing water during Operations are drained free of water.

The system should be drained fully after hydrostatic testing, to prevent

freezing, if the unit is installed in a cold weather area, and to minimize

corrosion of the metal surfaces.

viii. If temporary handhole or manway gaskets were used for the test, they

should be replaced with regular service gaskets before readying the

unit for operation. Gaskets should never be reused. Replace gage glass

if necessary and make sure that the gage cocks are open.

ix. Additional inspection at this time by the Authorized inspector will

determine whether the installation including piping arrangements,

valve gauges and controls and other equipment on the unit meets Code

and/or other jurisdictional requirements.

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 It must be noted that the HYDROSTATIC TEST must comply with the

following stated on the PG-99 clause of the BPCV.I-2017:

 No part of the boiler shall be subjected to a general

membrane stress 75 greater than 90% of its yield strength

(0.2% offset) at test temperature

 The metal temperature shall not exceed 120°F (50°C)

during the close examination.

 For the second stage test, the hydrostatic test pressure may

be reduced to not less than the maximum allowable

working pressure at the super heater outlet

 An indicating gage, visible to the operator controlling the

pressure applied, shall be connected to the pressure parts

 Dial pressure gages used in testing shall preferably have

dials graduated over their entire range of about double the

intended maximum test pressure, but in no case shall the

range be less than 1.5 times that pressure.

3.2.1.2.9. GAS DISTRIBUTION TEST

This test aim to ensure that the velocity of flue gas is constant through the

entire are of ESP. this test is done on all fans and blower operating at rated

parameters while the flue gas is continuously measured between collecting

electrodes for the entire width of ESP at various heights. The gas flow distribution

is important since it affects the collection efficiency since high velocity would

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result for the particles to be collected particles on the collecting plate would again

enter into the gas stream. The data from it is recorded to see the changes and

improve the flow on the whole cross section.

3.2.1.2.10. CHEMICAL CLEANING OF BOILERS

Boiler must be chemically clean to prevent the failure os tube and

improvement on the unit’s availability. Since small quantity of deposits makes it

hard for boiler to attain high pressiis, these deposits from the the fabrication is a

crucial problem. This is done to remove foreign materials and keeps the pressure

part internals clean. . Whenever carbon low alloy steels are subjected to high

temperatures in the presence of air, oxidation occurs, the oxides produced are

known as mill scale. Thus, it is desirable to subject all pressure parts of a steam

generator may be subjected to heat treatment of some sort during fabrication or

erection – during forming operations, stress relief, welding or bending. The

processes mentioned below is repeated two or three times till the water collected

from the drains are clear.

i. To empty boiler, blend in concentrated alkaline boil out cleaning

solution at an acceptable concentration proportionally with softened

water make up to fill boiler to normal operating level.

ii. Fire boiler and slowly increase pressure to its normal operating

pressure.

iii. Hold pressure for four hours, remove heat and allow to sit for 15

minutes, blow out all boiler connections for 10 15 seconds, re fill

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 boiler with alkaline boil out cleaning solution treated softened water,

apply heat, and raise pressure. Hold pressure for one hour and repeat

blowdown, treated water re fill, heat and pressure sequence.

iv. Maintain boil out conditions (ie blowdown, make up, chemical levels

and pressure) for a period of at least 48 hours. The best guide for

determining when to end the boil out is the condition and appearance

of water blown from the boiler. A leveling off of the oil and grease,

suspended solids, dissolved solids concentrations, and color indicate

that maximum capacity of alkaline boil out cleaning solution is

attained.

v. At end of boil out period, deconcentrate alkaline boil out chemical

cleaning solution concentration in boiler by alternately blowing down

1/2 gauge glass and make up with softened make up water containing

no alkaline boil out chemical cleaning solution.

vi. When boiler water phosphate concentration has been reduced to 10

mg/L as PO4, relieve boiler pressure and drain boiler by opening

bottom drains.

vii. When completely drained, open boiler for inspection. If wetted

surfaces or boiler are free of oil and grease, boil out is complete, but if

a film of oil and grease are present, repeat boiler cleaning procedure.

viii. If operation of steam boiler is not imminent, flood pre boiler and

boiler with sulphite and caustic treated softened water such that final

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 sulphite concentration of at least 200 mg/L as SO3 and final hydroxide

alkalinity concentration of 200 mg/L as CaCO3 are maintained.

ix. If operation of steam boiler system is imminent, fill system with

chemically treated softened water so that concentrations of control

parameters are maintained within control limits.

To remove the deposits,

i. Fill system with domestic water, establish circulation, and heat

system contents to a temperature of 60°C;

ii. Blend in prepared concentrated cleaning solution for removal

of deposits etc., establish circulation, and maintain system

temperature at 60°C until total iron concentration stabilizes;

iii. Dump spent cleaning solution to disposal, fill system with

domestic water, circulate system contents for at least two

hours, and drain spent rinse water from various locations in

system to disposal;

iv. . Fill system with domestic water and repeat step 3 until water

samples collected from system are free of suspended material;

v. Drain system and perform visual inspections of metal surfaces

at three different locations;

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 Note that it is important to complete steps 3, 4, & 5 within a 24 hour

period .If metal surfaces contain scale or iron deposits and are not

passivated, fill system with domestic water and repeat steps 2, 3, 4 & 5.

3.2.1.3. COMMISSIONING OF ELECTROSTATIC PRECIPITATORS

Many industrial, power generation and chemical processes produce unwanted fine

particulate material as a consequence of their operation. Electrostatic precipitation (ESP)

is a highly efficient method of removing entrained particulate contaminants from exhaust

gases and is extensively used in these industries to limit particulate emissions.

The electrostatic precipitators (ESP) are extensively used in the thermal power

plant or steam power plant for removal of fly ash from the electric utility boiler

emissions. The use of electrostatic precipitators is growing rapidly because of the new

strict air code and environmental laws. An electrostatic precipitators can be designed to

operate at any desired efficiency for use as primary collector or a supplementary unit to

cyclone collector. The quality of construction required by an ESP cannot be obtained

merely by inspecting and correcting the completed job. A complete quality assurance

program covering the design, procurement, fabrication, and erection phases will, if

properly carried out, result in a satisfactory installation. It is often considered worthwhile

to retain an existing cyclone collector as primary collector in the case where the fly-ash

collection efficiencies must be upgraded especially where there is a large amount of

unburnt carbon in the fly-ash. In view of this, the erection contractor's QA program

should be closely monitored by the purchaser throughout the erection. The following

must also be considered:

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 3.2.1.3.5. EMITTING ELECTRODES AND COLLECTING PLATES

ALIGNMENT

Uniform spacing is critical on the performance of the emitting and collecting

systems. The closest electrical clearance within that section is affected greatly by the

maximum voltage that can be carried on any bus section. The design or sketch of vital

electrical clearances from the emitting system to the grounded members have various

dimension with tolerances is furnished by most suppliers. If these tolerances are not

carefully observed throughout the entire precipitator, maximum performance will not be

attained. In view of above, insure proper installation of discharge electrodes and

collection plates. Collection electrodes are usually installed first, and the discharge wires

or rigid frames are positioned relative to them. Plumb, level, and properly aligned

electrode is desired. In attaining it, carful inspection of each section of electrodes is

necessary.

3.2.1.3.6. SEAL WELDING

The purpose of a seal weld is not to prevent leakage out of a container, but to

prevent entry of a fluid into a space where some type of harmful behavior, often

corrosion, is expected to occur. Since the precipitator chamber, regardless if it is operated

in positive or negative pressure, should be gas tight, seal welds is used. Under negative

pressure, air in leakage at incomplete seal welds, flanges or collector access points adds

additional airflow to be processed. The leakage of cold air creates cold spots which can

lead to moisture or acid condensation and possible corrosion. If severe, it can cause the

entire process gas temperature to fall below the gas dew point, causing moisture or acid

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to condense on the hopper walls, the discharge electrode, or collection plates. In addition,

air in leakage and moisture condensation can cause caking of fly ash in the hopper,

making normal dust removal by the discharge device very difficult. Under positive

pressure, the out leakage from the same locations will cause process gas and particulate

matter to leak into the thermal insulation and lagging, eventually destroying it. The out

leakage of process gas and particulate matter will also pollute the environment. In finding

the leaks, the areas of which light penetrates from the outside of the walls is identified.

3.2.1.3.7. RAPPERS INSTALLATION

Rapping is the process by which electrodes and particles are broken apart by

vibrations from the rappers. To do so, rappers transmit strong shearing forces to

collecting plates in order to release deposited dust particles. The collection plate rappers

and discharge electrode rappers is installed and aligned according to vendor

specifications.

3.2.1.3.8. THERMAL INSULATION

To keep the temperature of the flue gas high, some type of thermal insulation is

used by most ESPs. The insulating material keeps heat from transferring between the

materials that are in thermal contact. Thus, prevents any moisture or acids present in the

flue gas from condensing on the hoppers, electrodes, or duct surfaces. In addition, it also

protects personnel and equipment adjacent to the precipitator from radiant heat. Because

most ESPs are installed in the field, check that all surfaces and areas of potential heat loss

are adequately covered.

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 The test ports should be acceptable to the inlet and outlet duct to prevent

overlooking it.. When the ports located on the top of the ducts and no access walkways

are provided, the foot traffic generated in just one test can often ruin the insulation on the

top of the ducts. Thus, access walkways and platforms for such test ports should always

be installed.

3.2.1.3.9. THERMAL EXPANSION

Since ESPs on power plants are shaped liked large boxes, numerous points of

supports is also needed. Generally, steel supports are fixed at one location, normally at

the center, and, at operating temperature, they expand as much as several inches in all

directions from the fixed point. temperature, they expand as much as several inches in all

directions from the fixed point. Designers allow for this expansion by including sliding

connections of various types at all support points except the fixed point. Thus, the inlet

and outlet ducts of the system have expansion joints which compress when heated.

The precipitator supports will be temporarily fixed in their "cold" position on the

support steel on its construction,. Upon completion of steel erection, and before applying

thermal insulation, all such temporary tack welds and stops must be removed so that

sliding supports can move in the designed manner. The structural steel can be torn apart

by expansion forces if sliding supports are inadvertently restrained, which make it a

crucial factor on the design.

3.2.1.3.10. LOCATION OF ELECTRICAL EQUIPMENT

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 Recently, transformer rectifier cabinet are placed on top of the precipitator.

Although these cabinets are invariably weather-proof (NEMA-IV construction), they are

frequently mounted within a weather enclosure. Control cabinets are most commonly

located in a room especially built to accommodate them and ancillary electrical gear such

as main breakers, heater and rapper controls, etc. The room is often located close to the

precipitator and the distribution transformer to shorten the lengths of low voltage cable.

The precipitator control rooms must not be on dirty surrounding such as on ash

handling equipment during its servicing. Thus, in keeping the control room clean, filters

are often used on the ventilating air intake. In a very dirty environment, such filters

rapidly become clogged, restricting the flow of ventilating air, and adding ambient

temperature problems to that of dust covering the electronic equipment. In addition to

the items listed above, each ESP erection should have its own checklist reflecting the

unique construction features of that unit.

3.2.1.3.11. ESP COMMISSIONING FOR COAL FIRED BOILERS

Commonly, there number of problems in the start-up of a retrofit ESP is smaller

than those that are encountered in the simultaneous start-up of a new boiler plant and a

new ESP. This is because everything that might affect boiler operation affects the ESP

too. When the boiler has been stabilized, it is usually possible to minimize low load

operation which often results in condensation in the precipitator with resulting ash

handling problems .Thus it also needs to be in accordance of the republic act no. 6969

which specifies the act to control toxic substances and hazardous and nuclear wastes,

providing penalties for violations thereof, and for other purposes Problems in the

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precipitator may come from repeated startups and prolonged low-load operation on new

boilers.

3.2.1.3.12. ESP STARTUP AND SHUTDOWN PROCEDURE FOR

COAL-FIRED BOILER

Generally, the startup of an electrostatic precipitator is considered as a routine

operation which pertains to heating components such as support insulators and hoppers. It

is recommended to turn off the ESP unless the process reaches steady state conditions. A

typical startup procedure for an ESP used on a boiler is given below:

Startup (preoperational checks - at least 2 hours prior to gas load):

1. Complete all maintenance/inspection items.

2. Remove all debris from ESP.

3. Safety interlocks should be operational and all keys accounted for.

4. No personnel should be in ESP.

5. Lock out ESP and insert keys in transfer blocks.

Prestart (at least one hour prior to gas load):

6. Check hoppers.

a. Level-indicating system should be operational.

b. Ash-handling system operating and sequence check leave in operational mode.

c. Hopper heaters should be on.

7. Check top housing seal-air system.

a. Check operation of seal-air fan—leave running.

b. Bushing heaters should be on.

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 8. Check rappers.

a. Energize control, run rapid sequence, ensure that all rappers are operational.

b. Set cycle time and intensity adjustments, using installed instrumentation—

leave rappers operating.

9. Check T-R sets.

a. Check half-wave/full-wave operation(half-wave operation is recommended for

filtering fly ash when lignite is burned and a cold-side ESP is used.

b. Keys should be in all breakers.

c. Test-energize all T-R sets and check local control alarm functions.

d. Set power levels and de-energize all T-R controls.

e. Lamp and function-test all local and remote alarms

Gas load:

10. After gas at temperature of 200°F has entered ESP for 2 hours -

a. Energize T-R sets.

b. Check for normal operation of T-R control.

c. Check all alarm functions in local and remote.

d. Within 2 hours, check proper operation of ash removal system.

3.2.1.4. COMMISSIONING OF FUEL SYSTEM

Fuel injectors are critical part of the fuel system since leakage in it are fire

hazards and must comply with PTC 4.2-1969 Coal Pulverizers. Potential

problems from this can cause sever and costly damage to the boiler. Proper fuel

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injector cleaning techniques can restore your injectors to function like new at a

fraction of the cost of new fuel injectors

3.2.1.4.5. PRE-COMMISSIONING PROCEDURE FOR FUEL SYSTEM

Coal power plant commonly uses conveyor to transfer coal to the plant. Once

inside the plant, the coal is stored in bunkers and is moved to the pulverizer and

spins in a large drum where it is turned into powder. Large fans add warm air and

coal powder to the boiler.

1. Ensure that the system installation is complete and mechanical completion

is approved.

2. There must be no damage between the mechanical completion & pre-

commissioning.

3. Repair all damages to the equipment & piping.

4. Check that the Fuel piping network is complete with proper filling pipe

valves & pressure switches in place as per final approved shop drawing.

5. Ensure that the Fuel network is pneumatically pressure tested and

approved as per method statement & specifications.

6. Ensure that the entire system is cleaned internally & externally.

7. Ensure that the fuel fans are as per approved material submittal.

8. Ensure that the fuel fans are pre-commissioned and commissioned in line

with the approved procedure.

9. The wiring to the DDC & fire alarm panel from the fan panel and power

supply to panel is complete.

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 3.2.1.5. COMMISSIONING OF CONDENSER WATER SYSTEM

In a glass of water, bubbles may form on its sides. The formation of air bubbles

from the sides of a glass of cold water after drawing it from the tap is oxygen that tends

to become dissolved in our tap water both at the source and via the treatment process.

Due to surface tension., the resulting air bubbles will adhere to the side of the glass. In

the same way, the water in the condenser water system will be exposed to a lot of air due

to dissolved air in the makeup water and due to the fact that it is spread out and splashed

through the cooling tower fill while convection and

When the water in the system is warmed up, some of the air will be driven out of

solution, either because the system was filled with relatively cold “city water”, or the

system has been idle and then placed on line, or because of temperature changes in the

system as shown in figure 12. As the temperature increases, the oxygen content

decreases.

Figure 14. Solubility of dissolved oxygen

Additionally, changes in pressure has the similar effect especially in the pump

impellers. At this points, the velocity is high which, in turn, lessens the pressure. In the

131
illustration, the relationship of the pressure and velocity in the eye of the impeller is

shown. Air tends to accumulate at the high points in systems, which, for the system we

are discussing, is the inverted trap at roof level and the cooling tower basin. The top

of the volute on a horizontal split case style pump can also represent an intermediate high

point in most systems, which is why they are often provided with a tapped opening which

can be fitted with a manual vent. The pumps on this project are just so equipped, as

illustrated below.

On the supply side of the system located from the towers to the load, things could

be hardened for the air to be carried out of the system. It needs to be forced all the way

down through the building and back out again. This would allow it to accumulate in

intermediate high points like the tops of pump volutes and also would compound the

problem on the return side. Specifically, at full load, the velocities in the system are high

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enough to carry the air through the trap and into the cooling tower on the return side of

the system. The velocities are extremely low in the large 14″ lines and the commissioning

team was concerned that significant air could accumulate in the inverted traps when the

modular chiller is in operation. Once it did, the low velocities signifies insufficient

available energy to carry it out of the system. As a result, the air pocket would begin to

obstruct flow.

3.2.1.5.5. DESIGN BENEFIT

Utilization of the existing continuous process system which can remove all

crud and dissolved contaminants from the condenser effluent stream the power

station. It should be capable to retain its on line connection during the start-up

phase of the air-cooled condenser. The condensate polishing units also provided a

secondary benefit of heat recovery, and thus saving fuel, as well as minimizing

the requirement for further make up water normally required due to the discharge

of the contaminated condensate. Also, the maintenance outage frequency of the

gas turbines is directly linked to the number of plant shut downs and start-ups.

3.2.1.6. TESTING AND COMMISSIONING OF COOLING TOWER SYSTEMS

Testing and Commissioning of cooling tower is necessary to ensure that the

cooling tower system works functionally. Since a typical cooling tower system consists

of cooling tower, chiller condenser / heat exchanger, water pump, chemical water

treatment equipment, physical water treatment equipment, make-up water tank, bleed-off

and drainage, pipework and fittings and metering devices, careful consideration and

assistance for registered professional engineer (RPE) in building services engineering or

mechanical engineering discipline is recommended.

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 3.2.1.6.5. OCCUPATIONAL SAFETY AND HEALTH

Safety should be taken as a priority. As such, sufficient personal protective

equipment for personnel should be provided in testing and commissioning work of a

cooling tower system. For emergencies, eye wash bottles or washing basin with fresh

water tap shall be provided adjacent to water treatment chemicals. The water contained in

the eye wash bottle should be replaced periodically. As for the water treatment chemical,

the chemical handling facility must be in a proper location having this characteristics:

 Proper mechanical / natural ventilation

 Weather-proof and corrosion resistant type electrical

fittings

Records on its design and commissioning must be kept for the whole life of the

power plant’s cooling tower system. This data can be should be readily available for

inspections upon request by Government appointed officials. The record shall include,

but not limited to the following:

1. Information about the owner of the cooling tower system such as

his/her name, contact phone and address.

2. Information about the cooling tower specialist contractor(s)

(CTSC) such as his/her name, contact phone and address of the

cooling tower specialist contractor(s) (CTSC). That person should

be responsible for the design, installation, testing and

commissioning of the cooling tower system.

3. Detailed design of the cooling tower system;

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 4. Descriptions of the cooling towers and water treatment equipment,

including their locations, technical specifications, models,

capacities and year of manufacture / installation as well as correct

operation procedure;

5. Testing results of all equipment in the cooling tower system; and

6. Water sampling results.

The cooling tower specialist contractor must ensure that the cooling tower’s

operation and maintenance must be well documented and include the following:

1. Details of all equipment in a cooling tower system, including the

technical drawings of the plant, equipment and systems;

2. The specific location of the locations of cooling towers and the

nearby openings in the building and the adjacent buildings shall

have a system schematic and layout plan;

3. Manufacturers’ recommendations on operation and maintenance of

all equipment in the cooling tower system;

4. A program for routine chemical treatment, cleaning, desludging

and disinfection of the cooling tower;

5. Details of water chemicals used for water treatment;

6. Recommended cleaning methods and dismantling instructions; and

7. Code of Practice for Water-cooled Air Conditioning Systems

including its Start-up, operating and shut-down procedures.

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3.2.1.6.6. RISK MANAGEMENT OF A COOLING TOWER SYSTEM

In identifying potential problems before they occur, risk management is

necessary. A risk management plan for the cooling tower system shall be

developed by the owner / designer of the cooling tower system. It must also

comply with the latest Iranian Petroleum Standards standard Also, risk-handling

activities must be planned and invoked as needed across the life of the product or

project to mitigate adverse impacts on achieving objective: Achieve maximum

efficiency on its life.

3.2.1.6.7. RISK MANAGEMENT PLAN

Risk management is recognized as an integral component for the cooling

tower system when designing the cooling tower system. It is about identifying

opportunities as avoiding or mitigating losses. In developing risk management

plan for complicated cooling tower systems, consultation with experienced system

designers, cooling tower suppliers, cooling tower specialist contractors and

occupational hygienists is suggested. The general guidelines for developing a risk

management plan for a cooling tower system are explained below:

a. Prepare the key contact data of the cooling tower system

b. The following risk that are potentially found in a cooling tower

system such as: stagnant water, nutrient growth, poor water

quality, deficiencies in the cooling tower system, location and

access should be recognized.

c. To assess the above risks if they are found in the respective

cooling tower system.

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 d. To recommend the mitigation measures if the above risks are

found in the respective cooling tower system

e. An operational program based on the above risk assessment

results and recommended mitigation measures must be

established. The contents should at least include frequencies of

inspection, service, cleaning and disinfection

f. To provide a communication plan in case the cooling tower

system is required to be attended urgently.

g. Make a detailed step by step instruction for monitoring

3.2.1.6.8. COOLING WATER QUALITY CONTROL

In ensuring the quality of water, the following guidelines should be

followed. First, fresh water and seawater type and, second, the quality of cooling

water discharged from cooling tower systems. The type of cooling tower system

should be properly designed to achieve the relevant water quality targets as in

accordance with the Iranian Petroleum Standards. More precise levels shall be

advised by water treatment services providers. As for the quality of cooling water

discharged from cooling tower system, it must comply with the requirements

stipulated in the EPD’s Technical Memorandum on Standards for Effluent

Discharged into Drainage and Sewerage Systems, Inland and Coastal Waters. It

should be noted that the effluent discharge requirement may vary with the

discharge flowrate.

Generally, Bleed off is preferred to be performed automatically controlled

by conductivity sensor or timer controlled drain valves. It is required to maintain

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 the concentration of total dissolved solids (TDS), insoluble precipitates, other

chemical constituents and pH value of cooling tower at an acceptable level.

Manual bleed-off control is not preferred unless automatic bleed-off is not

practicable. Also, the bleed-off immediately after chemical dosage shall be

avoided to minimize chemicals wastage.

To ensure the bleed off water quality, the bleed-off water from cooling

tower shall satisfy the standard specified in the Technical Memorandum on

Standards for Effluent Discharged into Drainage and Sewerage System, Inland

and Coastal Waters issued under the Water Pollution Control Ordinance. Other

standards that are set for toxic metals shall also be complied with. In addition, the

drainage system shall be designed based on the estimated bleed-off quantity.

Also, the minimum cycle of concentration in designing water treatment program

and bleed off requirement shall not be less than 6 and 2 for fresh water and

seawater cooling tower system respectively.

3.2.1.7. COMMISSIONING OF GENERATOR SYSTEM

3.2.1.7.5. Fuel system

In a coal fire-power plant, power is produced by the chemical energy on the coal

is transformed into steam thermal energy by the boiler, then it is transformed into

rotational mechanical energy by the turbine, and finally it is transformed into electric

energy by the generator which is transferred to the power plant’s transformer and switch

yard before going to the transmission system. Thus, the fuel system is a critical factor on

it and must be in accordance to ASME PTC 4-2013 Fired Steam Generators. The

consumption will be provided in BTU per hour. Information about the consumption

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provided in BTU per hour must be shared with your supplier to ensure the gas flow will

meet the requirements of the generator system. A flexible section of pipe on each gas

generator must be supplied to dampen vibration and keep the gas line from being

damaged. This is usually found inside the enclosure. This flex pipe should be used as the

final connection from the supply source to the generator system. Diesel units should be

filled with fuel prior to starting up being scheduled, or the unit cannot be started and

tested.

The connections between the gas meters to the generator makes a big difference.

Depending on the piping length, the generator system can be affected if not accounted for

by the contractor: the pressure decreases as the length increases.

1. All equipment connections between items supplied by the customer and

the generator manufacturer should be properly installed.

2. Guarantee that the equipment was subjected to load bank tested

3. Assure that equipment is tested with “live” plant load too.

4. Verify that any form of issues allowing the air quality and the

corresponding operations of equipment are clearly understood during the commissioning

process

5. Verify that it is clearly understood how actual plant load will react upon

loss of utility power, start-up of the generator, and return to utility power. Also ensure

that adequate time delays is allotted for building it into equipment operations

6. Ensure that protective relaying for cases such as being under voltage the

protective relays and the generator’s protective functions to activate when the cooling

water is loss or in any circumstances similar to this, are installed and tested.

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 3.2.1.7.6. AIR FLOW

The enclosed area allocated for generators must be sufficient enough for air flow.

Thus, trees, plants or anything that can be damages due to heat. Thus, the minimum

recommended space allowance from the installation manual should be followed.

3.2.1.7.7. WIRING

The Wiring arrangement must be thoroughly designed and its location should be

in accordance with the International Electro technical Commission edition 1 of IEC Std

C57.15 the following guide:

1. Ensure that the generator’s environment is safe and free from any potential

hazards. Thus, it should be far away from other construction work or

equipment that may be happening around the generator.

2. Guarantee that the generator is fully accessible and tech has a clear path to

perform commissioning for technicians at work. Also debris around the

unit must be cleared.

3. City codes have been met for all install items including grounding, tank

venting, etc.

4. The generator must be securely anchored to its concrete pad.

5. The exhaust system full installation must be guaranteed.

6. In order to properly test the system, utility power must be available for

commissioning. Also, confirm if the end user will allow a transfer test

during start up.

7. For the wires:

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 i. Ensure that the output voltage of each generator should match the

facility it will be supplying.

ii. Wiring from the switchgear from utility power, and out of

switchgear to customer load should be properly done Wiring

should also be run between the generator output and proper

location inside switchgear, and ready to be energized.

iii. Block heater and battery chargers should have proper voltage

provided prior to starting up, but not hooked up. The technician

will hook up and test these items.

iv. Proper wiring is provided for accessories (remote annunciators,

other remote monitoring, etc.) including power and

communications wiring.

v. Wiring is provided for alarms required and run to proper

locations. The generator technician will configure the proper

outputs on the generator.

vi. Ensure wiring for start circuit is provided and properly sized.

3.2.1.7.8 COMMISSIONING OF TRANSFORMER SYSTEM

Transformers system are devices used in electrical circuits to change the voltage

of electricity flowing in the circuit. To attain Maximum reliability and availability,

commissioning on power transformer is necessary. To do so, follow the guidelines

explained below properly.

• Installing the transformer according to its manufacturer’s instruction.

• Reinstalling parts that were removed for transportation

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 • Processing the oil and filling the insulating oil

• Accepting the transformer, including reading out the impact recorder

• Testing the transformer.

To do so, transformers of every power class must have the necessary equipment

from renowned metrology device manufacturers available. This measurements for

transformers done during commissioning maintenance and inspections are as follow:

The following measurements are part of standard services:

• Measurement of the winding resistance

• measurement of the insulation resistance or ground measurement

• Transformer ratio test to measure the polarity

• Short-circuit impedance measurement

• Measurement of the dielectric loss factor

3.2.1.7.9 Electrical

Protection from over land and over current should be properly installed for all

motor starter. Also, the connecting elements on the skid should be tested and proved to be

suitable for all modes of operation.

3.2.1.7.10 Field instruments

All valves and accessories related with instruments in the operation should be

calibrated and removed for inspection and maintenance. Remember that calibration is a

must for all field devices.

3.2.1.7.11 Controls

In this part, the equipment should be operated accordingly to its function and

needs. To do so, a control panel should allow its operator to perform some functions in

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the field while other functions can only be performed through the manual and/or on a

process control network.

3.2.1.7.12. Switchgear

It is the combination of electrical disconnect switches, fuses or circuit breakers for

controlling, protecting and isolating electrical equipment. To function accordingly, the

flowing guideline is advised.:

1. Guarantee that proof of the gear being reviewed and approved by the

utility, a confirmed, by all parties, protective relaying functions, inspected source of

power for all protective relaying and monitoring was done.

2. In system operation using more than one source of power, assure that

proper switching can be done between one source and another.

3. All of the connections and cables between the switchgear and various

loads must be carefully checked

3.2.1.8. COMMISSIONING OF PUMP

The feed pump raises the feed water to a pressure high enough for it to enter the

boiler. Thus, a pump used must be in accordance with the ASME PTC 8.2-1990 Pumps,

As taking suction from a condensate system is a high pressure application, steam boiler

feed pumps are generally high head and low flow pumps, making multistage pumps a

common choice. The guideline for this is as follow:

1. When operating the pump, no maintenance staff should be present.

2. Ensure that all root valves for different gauges are opened and all control

instruments and gauges are in proper location

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3. The cooling water for booster pump bearing cooling as well as gland

sealing water supply is sufficient.

4. For pneumatically operated valves, check the availability of compressed

air.

5. Inspection on the Deaerators level must be normal. Also, make examine

and confirm it by draining the gauge glass and recharging it.

6. Check that the oil level in lube oil tank is normal

7. Take the clearance from the electric department of auxiliary Lube oil

pump. Confirm that it start and develop required lube oil pressure. Oil

pressure of oil before journal bearing should be 0.8 to 1 kg/cm2 and 0.5

kg/cm2 before the thrust bearing. Check lube oil flow through drain line is

normal.

8. Check that both lube oil and working oil coolers are charged from water as

well as oil side.

9. Check lube oil level of booster pump is normal

10. Ensure that its power operated recirculation valve is closed while the

manual operated valve at Deaerators is open.

11. Check that manual valve at Deaerators on balancing chamber leak off line

is open.

12. Check BFP discharge valve and it’s bypass valve is closed

13. Check that drain valves are closed

14. Charged the feed line after opening vents provide, up to feed regulating

stations and then close all the vents.

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 15. Charged seal water cooler and stiffing box and LP cover cooling lInes

16. Charge feed pump motor cooler

17. Check scope tube is in minimum position

18. Check that the difference of temperature between pump body metal and

feed water temperature is less than 30 degree C.

3.2.1.8.5. START THE BOILER FEED PUMP

To start the boiler feed pump, follow the guidelines below:

1. Record the initial starting current and time

2. Ensure that the recirculation valves are opens, proper suction flow

in maintained, the electrically operated cooling water valve opens,

cooling water flow is established, warm up valve is closed ,

auxiliary lube

3. The oil pump must stop then proceed by checking the following:

normal feed pump vibration; normal balancing leak off pressure;

normal bearing temperature of main pump, motor and hydraulic

coupling bearings and if the lube oil drain flows again.

4. Open the feed pump discharged valve and take the flow as per

requirement in boiler

5. Check recirculation valve operation after sufficient discharge flow

is maintained

3.2.1.9. COMMISSIONING OF TRANSFORMER SYSTEM

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 Transformers system are devices used in electrical circuits to change the

voltage of electricity flowing in the circuit. To attain Maximum reliability and

availability, commissioning on power transformer is necessary. To do so, follow the

guidelines explained below properly.

 Installing the transformer according to its manufacturer’s instruction.

 Reinstalling parts that were removed for transportation

 Processing the oil and filling the insulating oil

 Accepting the transformer, including reading out the impact recorder

 Testing the transformer.

To do so, transformers of every power class must have the necessary

equipment from renowned metrology device manufacturers available. This

measurements for transformers done during commissioning maintenance and

inspections are as follow:

The following measurements are part of standard services:

 Measurement of the winding resistance

 measurement of the insulation resistance or ground measurement

 Transformer ratio test to measure the polarity

 Short-circuit impedance measurement

 Measurement of the dielectric loss factor

3.2.1.9.1 Electrical

Protection from over land and over current should be properly installed for

all motor starter. Also, the connecting elements on the skid should be

tested and proved to be suitable for all modes of operation.

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3.2.1.9.2 Field instruments

All valves and accessories related with instruments in the operation should

be calibrated and removed for inspection and maintenance. Remember that

calibration is a must for all field devices.

3.2.1.9.3 Controls

In this part, the equipment should be operated accordingly to its

function and needs. To do so, a control panel should allow its operator to

perform some functions in the field while other functions can only be

performed through the manual and/or on a process control network.

3.2.1.9.4. Switchgear

It is the combination of electrical disconnect switches, fuses or

circuit breakers for controlling, protecting and isolating electrical

equipment. To function accordingly, the flowing guideline is advised.:

1. Guarantee that proof of the gear being reviewed and approved by

the utility, a confirmed, by all parties, protective relaying functions,

inspected source of power for all protective relaying and monitoring was

done.

2. In system operation using more than one source of power, assure

that proper switching can be done between one source and another.

3. All of the connections and cables between the switchgear and

various loads must be carefully checked

3.2.1.9.5 Generator

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 Generator, a device responsible for converting mechanical energy

to an electrical one, is critical on the power plant’s capability to produce

power. As such the following guide line is advised to be considered:

1. All equipment connections between items supplied by the

customer and the generator manufacturer should be properly installed.

2. Guarantee that the equipment was subjected to load bank tested

3. Assure that equipment is tested with “live” plant load too.

4. Verify that any form of issues allowing the air quality and the

corresponding operations of equipment are clearly understood during the

commissioning process

5. Verify that it is clearly understood how actual plant load will react

upon loss of utility power, start-up of the generator, and return to utility

power. Also ensure that adequate time delays is allotted for building it

into equipment operations

6. Ensure that protective relaying for cases such as being under

voltage the protective relays and the generator’s protective functions to

activate when the cooling water is loss or in any circumstances similar to

this, are installed and tested.

3.2.1.9.6. FINAL COMMISSIONING CHECK

It is critical to ensure consistent, full and properly integrated power

transformer in the power plant’s substation after the commissioning tests specified

above is done. Additionally, check if all transformer elements along with its

external factors are functional and operational using the guideline below:

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 1. Before commissioning, verification and comparison of the

factory results and the units test result should be done.

2. No leakage of oil in any part of unit.

3. The switchyard with transformer body, gantry, column,

jumpers, fire wall etc on external electrical clearance of

conductor jumpers should be inspected.

4. Guarantee that tertiary winding terminals are insulated,

shouldn’t be used or connected to any system.

5. Ensure earthing of Neutral, main tank body, radiator frame

structure, fans and motor

3.2.1.10. COMMISSIONING OF WASTEWATER TREATMENT PLANT

Water desalination processes separate dissolved salts and other minerals from

water. This commissioning aims to confirm that the desalination plant can

reliably produce high quality water in quantities.

3.2.1.11. COM-MISSIONING OF DESALINATION TREATMENT PLANT

Water desalination processes separate dissolved salts and other minerals from

water.The pplant must be in accordance with the recent latest Iranian Petroleum standard.

This commissioning aims to confirm that the desalination plant can reliably produce high

quality water in quantities.

3.2.1.11.1. PRE-COMMISSIONING

It aims to ensure that each elements on the desalination plant can work

safely. In this stage, it includes cleaning of all pipes by using means like air

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 plowing and flushing. Detailed quality assurance ensures that equipment has been

installed correctly and conform with the specifications. Equipment should

function correctly as part of the plant’s sophisticated operating system through

further test. Also, mechanical cleaning of vessels and tanks and ensuring no

subjected on motors is done.

3.2.1.11.2. WET COMMISSIONING

In this stage, data from the test confirms that the that equipment is capable

of moving water at the required flow and pressure, and that control systems

continue to operate correctly as water is introduces to the system.

3.2.1.11.3. PROCESS COMMISSIONING

In this stage, evidences of effluent wastewater treatment plants meets the

regulation under normal operating conditions

3.2.1.11.4. PERFORMANCE TESTING

A series of performance tests to prove that the plant is capable of reliably

producing while the entire plants is fully operated. In water treatment plants it means

that all units of screen , grits removal , odor control , aeration , secondary

sedimentation , SAS and RAS pumps , scum pumps and filter belt press will work

together as whole unit.

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 CHAPTER 4: OPERATION AND MAINTENANCE

4.1. OPERATION

Coal-fired power plant uses steam to be able to provide energy. And steam is the most common

working fluid when it comes to vapour power cycle. The reason why steam is the most common

working fluid because of its low cost, availability, and enthalpy of vaporization. Other working

fluids used include sodium, potassium, and mercury for high-temperature applications. Steam

power plants are commonly referred to as coal plants, nuclear plants, or natural gas plants,

depending on the type of the fuel used to supply heat to the steam. But the steam goes through

the same basic cycle in all of them. Therefore, all can be analyzed in the same manner. This

section discusses the operations involved in the coal-fired power plant.

4.1.1. General Operation Processes

There are four commonly used cycles involved in a coal-fired powerplant: Carnot Vapor,

Rankine Cycle, Regenerative Cycle and Reheat Cycle.

4.1.1.1. The Carnot Vapor Cycle

The Carnot cycle is the most efficient cycle operating between two specified temperature

levels making use of steam as the working fluid. Thus it is natural to look at the Carnot cycle

first as a prospective ideal cycle for vapor power plants. If we could, we would certainly adopt it

as the ideal cycle. But as explained below, the Carnot cycle is not a suitable model for power

cycles. The assumption is that steam is the working fluid used since it is the working fluid

predominantly used in vapor power cycles

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 Figure 4.1 Carnot Vapor cycle T-S diagram

4.1.1.2. Rankine Cycle: The Ideal for Vapour Power Cycles

The efficiency of the Rankine cycle is limited by the high heat of vaporization by the

fluid. The fluid must be cycled through and reused constantly, therefore, water is the most

practical fluid for this cycle. This is not why many power plants are located near a body of

water—that's for the waste heat. As the water condenses in the condenser, waste heat is given off

in the form of water vapour—which can be seen billowing from a plant's cooling towers. This

waste heat is necessary in any thermodynamic cycle. Due to this condensation step, the pressure

at the turbine outlet is lowered. This means the pump requires less work to compress the water—

resulting in higher overall efficiencies. As have stated from the above, since Carnot Cycle is not

suitable for steam or vapor power cycles due to the reason that to increase temperature of the

working fluid on that cycle, it must be on constant pressure process, which is present on Rankine

Cycles.

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 Figure 4.2 A simple schematic with components for the Rankine Cycle

Water enters the pump at state 1 as saturated liquid and is compressed isentropically to

the operating pressure of the boiler. The water temperature increases somewhat during this

isentropic compression process due to slight decrease in the specific volume of the water. The

vertical distance between states 1 and 2 on T-s diagram is greatly exaggerated for clarity. Water

enters the boiler as a compressed liquid at state 2 and leaves as a superheated vapor at state 3.

The boiler is basically a large heat exchanger consisting of an economizer, an evaporator, and

superheater where heat originating from combustion gases, nuclear reactor or other sources is

transferred to the water essentially at constant pressure. The boiler, together with the section

where the steam is superheated (the superheater), is often called the steam generator. The

superheated vapor at state 3 enters the turbine, where it expands isentropically and produces

work by rotating the shaft connected to an electric generator. The pressure and the temperature of

the steam enters the condenser. At this state, steam is usually a saturated liquid-vapor mixture

with a high quality. Steam is condensed at constant pressure in the condenser, which is basically

a large heat exchanger, by rejecting heat to a cooling medium such as lake or a river or

atmosphere. Steam leaves the condenser as saturated liquid and enters the pump, completing the

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cycle. In areas where water is precious, the power plant operates by air instead of water. This

method of cooling which is also used in car engines is called dry cooling. Several power plants in

the world and a few in the United States use dry cooling to conserve water.

Remembering that the area under the process curve on the T-s diagram represents the

heat transfer for internally reversible processes, it is seen that the area under the process curve 2-

3 represents the heat transferred to the water in the boiler and the area under the process curve

represents the heat rejected in the condenser. The difference between these two is the work

produced during the cycle.

4.1.1.3. Reheat Cycle

There are two reasons for the use of Reheat cycle. Firstly, there are limits to the degree of

superheat due to metallurgical conditions, so that it is not possible to get all super heat in one

stage. And secondly, the inevitable effects of higher pressures are that saturation line is reached

earlier during isentropic expansion and most of the turbine stages operate in the relatively

undesirable saturated steam region. Due to the impact of particles of suspended water on the

turbine blades, there will be blade erosion. The safe maximum limit of moisture in the exhaust

steam should be in order of 12%. Therefore, reheating is necessarily practiced in high pressure

plants. The reheating is accomplished by constructing the turbine so that all the steam may be

extracted at a suitable point, superheated in the reheat boiler and then readmitted to the

154
remaining stages of the turbine for further expansion. Or the superheated steam can be expanded

in the pressure turbine and its exhaust reheated and then expanded in the low pressure turbine.

The advantages of Reheat cycle are

• The moisture in the exhaust steam is greatly reduced and due to this the erosion of the turbine
blade is greatly reduced tremendously.
• The thermal efficiency of the turbine is increased by 4% to 5% if the reheat temperature is
equal
to the initial throttle temperature.
• Condenser size is reduced by 7% to 8%.
• The size of the boiler is reduced because the steam flow is reduced by about 15% to 18%.
• The size of the low-pressure turbine is reduced due to reduction in specific volume by about
7% to 8%.
• Station heat rate is improved due to reduction in the feed pump power by about 15% to 18%.

4.1.1.4. Regenerative Cycle

In this cycle, the feed water is preheated by means of steam taken from some sections of

the turbine, before it enters the boilers from the condenser. This process of draining steam from

the turbine at certain point during its expansion and using this steam for heating the feed water

supplied to the boiler is known as bleeding. The effect of this is to supply the boiler with hotter

water while small amount of work is lost by the turbine. There is a slight increase, in the

efficiency but there is also a decrease in the power developed.

• Smaller condenser and boiler 35""

• The difficulty of passing large volumes of steam through the last stage in the low pressure
turbine is lessened
• Improved turbine drainage, hence less trouble from erosion
• Increased blade heights in the high pressure turbine to accommodate
• The initial increased steam consumption

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 4.1.2. Superheat Steam Temperature Control

High turbine efficiency over a wide load range depends a great deal on having a constant

steam temperature over that load range. Therefore, it is necessary to design a boiler that can

provide this constant steam temperature over the load range, which can be 50 percent of full load

or more. For plants that use a reheat cycle, it is also necessary that the boiler provides reheat

steam temperatures that are also constant over the control range. This section discusses the

superheat steam temperature control involved in the operation of the coal-fired power plant

4.1.3. How do Coal Fired Power Plant Operate

The conversion from coal to electricity takes place in three stages.

Stage 1
The first conversion of energy takes place in the boiler. Coal is burnt in the boiler furnace to
produce heat. Carbon in the coal and Oxygen in the air combine to produce Carbon Dioxide and
heat.
Stage 2
1. The second stage is the thermodynamic process.
2. The heat from combustion of the coal boils water in the boiler to produce steam. In
modern power plant, boilers produce steam at a high pressure and temperature.
3. The steam is then piped to a turbine.
4. The high pressure steam impinges and expands across a number of sets of blades in the
turbine.
5. The impulse and the thrust created rotates the turbine.
6. The steam is then condensed and pumped back into the boiler to repeat the cycle.

Stage 3
In the third stage, rotation of the turbine rotates the generator rotor to produce electricity based of
Faraday’s Principle of electromagnetic induction.

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4.2. MAINTENANCE

The definition of maintenance often states that maintenance is an activity carried out for any
equipment to ensure its reliability to perform its functions.
Maintenance to most people is any activity carried out on an asset in order to ensure that
the asset continues to perform its intended functions, or to restore to its favorable operating
condition. The purpose of maintenance is to extend equipment lifetime, or at least the mean time
to the next failure the repair of which may be costly. Furthermore, it is expected that effective
maintenance policies can reduce the frequency of service interruptions and the many undesirable
consequences of such interruptions. Maintenance clearly impacts on component and reliability; if
too little is done, this may result in an excessive number of costly failures and poor system
performance and therefore, reliability is degraded, done often, reliability may improve but the
cost of maintenance will sharply increase. In a cost-effective scheme, the two expenditures must
be balanced.
Maintenance is just one of the devices for up keeping or if necessary, improving the level
of reliability of components and systems. Over the years, many new strategies have been
implemented as maintenance strategies which are intended to overcome the problems which are
related to equipment breakdown. Some of the common maintenance strategies are as follows.

Figure 4.3 Types of Maintenance Strategy

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 4.2.1. BOILER

4.2.1.1. General Requirements for a Safe and Efficient Boiler Room

The Boiler room contains all the facilities that are auxiliaries and accessories to the boiler

or steam generating unit. This must be taken care of by conforming to the following safety

procedures listed:

1. Keep the boiler room clean and clear of all unnecessary items. The boiler

room should not be considered an all-purpose storage area. The burner

requires proper air circulation in order to prevent incomplete fuel

combustion. Use boiler operating log sheets, maintenance records, and the

production of carbon monoxide. The boiler room is for the boiler.

2. Ensure that the whole personnel operating or maintaining the boiler room

are properly trained on all equipment, controls, safety devices, and up-to-

date operating procedures.

3. Before start-up, ensure that the boiler room is free of all potentially

dangerous situations, like flammable materials, mechanical, or physical

damage to the boiler or related equipment. Clear intakes and exhaust

vents; check for deterioration and possible leaks.

4. Ensure a thorough inspection by a properly qualified inspector.

5. After any extensive repair or new installation of equipment, make sure a

qualified boiler inspector reinspects the entire system.

6. Monitor all new equipment closely until safety and efficiency are

demonstrated.

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 7. Use boiler operating log sheets, maintenance records, and manufacturer’s

recommendations to establish a preventive maintenance schedule based on

operating conditions, past maintenance, repair, and replacement that were

performed on the equipment.

8. Establish a checklist for proper startup and shutdown of boilers and all

related equipment according to manufacturer’s recommendations.

9. Observe equipment extensively before allowing an automating operation

system to be used with minimal supervision.

10. Establish a periodic preventive maintenance and safety program that

follows manufacturer’s recommendations.

11. Maintenance of boiler is carried out on frequent basis depending on the

component part. Maintenance can be done daily, weekly, monthly,

quarterly or annually.

4.2.1.2. BOILER MAINTENANCE CHECKLIST

The checklist containing more literal tasks to follow are:

1. Check the Water Gauges – One of the most fundamental aspects of good

boiler maintenance is ensuring that the boiler has the correct water levels.

2. Clean the Water Gauges – Over time water gauge glass may become

cloudy or stained which could distort readings. Thorough cleaning or even

full replacement of gauges or gauge glass may be performed during

turnarounds or other periods of shutdown.

3. Clean Piping and Float Chamber – Proper water level control is key and

it is the float chamber and surrounding piping that ensures water levels are

159
 correctly maintained. Remove all sludge or sediment from pipes and flush

the float chamber.

4. Test the Fuel Cut-off Feature – The fuel cut off feature automatically

stops fuel from entering the boiler if the water level drops to low. This is

an extremely important safety feature and should be carefully tested by a

qualified technician during boiler inspections.

5. Check Water Treatment System – The water treatment systems remove

impurities that could result in corrosion or sediment build-up if left

unchecked. Thoroughly check and maintain this system to improve the

boiler’s efficiency and reduce the risk of breakdowns.

6. Check Condensate Recovery System – Boilers that employ a condensate

recovery system are able to trap, condense, and reuse steam as feedwater,

dramatically increasing efficiency since the water does not have to be

heated from as low a temperature. Checking and maintaining the

condensate recovery system keeps operating costs down.

7. Inspect for Signs of Corrosion and Leakage – During boiler inspections

it is important to watch for signs of corrosion and leaks, especially around

safety valves and piping. Even small problems can quickly worsen, so

address issues promptly.

8. Check the Stack Temperature Gauge – The stack temperature gauge

monitors the temperature of flue gas leaving the boiler. If gauge readings

are too high, this could indicate a serious efficiency problem since hot

160
 gases might be bypassing the heat transfer surfaces in the boiler and

resulting in thermal loss and higher operating costs.

9. Analyse Air-to-Fuel Ratio – The air-to-fuel ratio of oxygen to fuel being

burnt during combustion is important for optimizing the boiler’s

efficiency. If too much air is used, too much heat may be expended; by

contrast, if too little air is used, an incomplete fuel burning may occur,

resulting in waste. Analyze this delicate ratio and make adjustments as

necessary to optimize efficiency.

10. Clean Heat Transfer Surfaces – Remove soot and other buildup from the

boiler’s heat transfer surface to ensure an efficient transfer between the

combustion gas and steam generation.

11. Check and Maintain the Economizer – the economizer redirects heat

from the stack back to the boiler feedwater for preheating, preventing heat

loss and increasing boiler efficiency. Check that the economizer is in good

working order during boiler inspections to ensure maximum benefit.

12. Update and Review Boiler Logs – Every time the boiler is inspected or

serviced the boiler logs should be updated. Likewise it is important to

review these logs on a regular basis so that gradual trends can be

determined and so that boiler technicians are operating with the most

information available.

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 4.2.1.3. DEPARTMENT OF LABOR AND EMPLOYMENT

REQUIREMENTS

This part talks about mainly the maintenance of the components that

will be used in a coal-fired power plant. This part is very important when running

a power plant, because this is for the purpose of fabrication, as well as inspection,

checking, test, and other consideration prior to the approval / clearance of any of

the fabrication and installation application and the most important of all, safety.

And plans and use of any boiler, the following in accordance with the latest

revision are hereby adapted:

1. ASME Boiler and Pressure Vessel Code;

2. (American Society of Mechanical Engineers, 2010) (American Society of

Mechanical Engineers, 2010) (American Society of Mechanical Engineers, 2010)

(American Society of Mechanical Engineers, 2010) (American Society of

Mechanical Engineers, 2010) (Security Chimneys International, 2012) (Security

Chimneys International, 2012) (Security Chimneys International, 2012) (U.S.

Geological Survey) (Security Chimneys International, 2012) (Security Chimneys

International, 2012) (Security Chimneys International, 2012) (U.S. Geological

Survey) (American Society of Mechanical Engineers, 2010) (American Society of

Mechanical Engineers, 2010) (American Society of Mechanical Engineers, 2010)

(Antique Electric Cooperative, 2018) Code for Pressure Piping;

3. API code for petroleum gases and liquids;

4. ISO code; and

162
 5. The Philippine Society of Mechanical Engineers (PSME) Code.

4.2.1.4. ASHRAE MAINTENANCE TASK FOR BOILERS

The American Society of Heating, Refrigeration and Air-Conditioning Engineers

mandates the following inspection and maintenance for boilers:

4.2.2. STEAM TURBINE

A steam turbine is a mechanical device that extracts thermal energy from

pressurized steam and converts it into rotary motion. There are several classifications for
modern steam turbines. These types include condensing, noncondensing, reheat,
extraction and induction.

163
 • Noncondensing or backpressure turbines are most widely used for process steam
applications. The exhaust pressure is controlled by regulating valve to suit the
needs of the process steam pressure. These are commonly found at refineries,
district heating units, pulp, and paper plants, and desalination facilities where
large amounts of low-pressure process steam are available.
• Condensing turbines are most commonly found in electrical power plants. These
turbines
exhaust steam in a partially condensed state, typically of a quality near 90%, at a
pressure well below atmospheric to a condenser.
• Reheat turbines are also used almost exclusively in electrical power plants. In a
reheat turbine, steam flow exits from a high-pressure section of the turbine and is
returned to the boiler where additional superheat is added. The steam then goes
back to the intermediate pressure section of the turbine and continues its
expansion.
• Extraction type turbines are common in all applications. In an extracting type
turbine, steam is released from various stages of the turbine, and used for
industrial process needs or sent to boiler feed water heaters to improve overall
efficiency. Extraction flows may be controlled with a valve or left uncontrolled.
Induction turbines introduce low pressure steam at an intermediate stage to
produce additional power.

Steam piping should be reviewed, analysed, designed, and properly installed to ensure

there will be no excessive forces transmitted to the turbine flanges. Steam piping may

exert forces from four sources:

1. Pipe dead weight

2. Thermal expansion

3. Thrust

4. Spring rate caused by different types of expansion joints

164
 Thermal expansion also causes movement of the turbine’s flanged connections,

which must be considered during the piping design.

4.2.2.1. BLADING

Steam turbine blading can be subjected to several failure mechanisms in

service. For steam turbines to operate with high reliability and availability, the

ability to regularly inspect and assess the steam blading condition is important as

any of the failure mechanisms can lead to failure such as Corrosion, Creep,

Erosion, Fatigue, Foreign/Domestic, Object Damage (FOD/DOD), Stress

Corrosion Cracking (SCC) and Thermal Fatigue if left undiagnosed or neglected.

4.2.2.2. PIPING

Steam piping should be reviewed, analysed, designed, and properly

installed to ensure there will be no excessive forces transmitted to the turbine

flanges. Steam piping may exert forces from four sources:

1. Pipe dead weight

2. Thermal expansion

3. Thrust

4. Spring rate caused by different types of expansion joints

Thermal expansion also causes movement of the turbine’s flanged connections, which

must be considered during the piping design.

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4.2.2.3. EXHAUST AND SUPPLY LINE SIZING

1. Steam piping must be designed to provide full-line steam pressure at the

turbine inlet at full-load capacity. The supply line size needs to be

calculated not only for the load, but also to include the pressure drops due

to length of pipe and system components, including valves and fittings.

Any pressure loss in the supply line will affect turbine performance.

2. The discharge piping exhaust pressure will dictate the required discharge

line size. As with the inlet piping, all pressure drops must be taken into

consideration. Excessive pressure must be eliminated so turbine

performance is not affected.

3. Typically, the inlet and outlet steam piping size will be equal to or greater

than the actual turbine connections provided for by the manufacturer.

4.2.2.4. INSPECTIONS AND TEST PLANS

 Steam Turbine casings to be identified against foundry test certificates and

thicknesses checked to conform to approved drawings.

 Witnessing hydrostatic test on Steam Turbine casing, Steam chest,

Emergency stop valves and Governor Valves.

 For steam turbine impellers, welding procedure and welder`s

qualifications to be established and impellers to be inspected before

assembly by Vendor and certificates need to be submitted with data-

dossier in final documentation.

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 Ensuring that steam turbine overspeed tests on impellers/rotors have been

carried out as well as dynamic balancing of impellers/rotors. Witness the

dynamic balancing of the complete rotating assembly.

 Witnessing leak test on lube oil tank and carry out internal and external

inspection.

 Inspection of prefabricated lube oil piping.

 Witnessing steam turbine mechanical running tests, check all safety and

alarm devise when contact instrumentation is fitted.

 Fit-it Tests of spare rotors and mechanical running test.

 Strip inspection of steam turbine on completion of running tests. To

include examination of all running surface, checking of critical clearances,

and examination of lube oil filters in the tests as specified.

 Steam turbine gearing, pinion forgings and main wheel forgings or

castings to be inspected at forge shop or foundry.

 Any dynamic balancing of steam turbine gearing rotors to be witnessed by

Vendor and certificates need to be submitted with data-dossier in final

documentation.

 Fabricated gear cases to be inspected at sub supplier’s works.

 Light or full load running tests, as specified to be witnessed on gearing.

 Inspection and final dimensional checking of gearing to be done on

manufacture’s works.

 Inspection of special purpose steam turbines shall be as specified in data

sheets & specifications.

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4.2.2.5. BEST PRACTICES

1. Ensure proper steam quality is delivered to the turbine

2. Proper expansion compensation

3. Supply and exhaust line are sized properly

4. Steam piping needs to be properly supported

4.2.2.6. MONITORING

1. Technical manuals and service bulletins available, complete and current

2. Equipment logbooks (records starts, trips, unscheduled and scheduled

events/maintenance) maintained and current

3. Pre-start checklist for auxiliaries (lubrication, hydraulic, cooling water,

sealing steam, etc.)

4. Pre-start checklist for turbine

5. Starting/warm-up/slow roll procedures

6. Loading procedure

7. Operating procedures (changing loads/responding to changes in turbine

conditions and alarms)

8. Unloading and shutdown procedures

9. Emergency shutdown procedure

10. Steam purity corrective action procedures

11. Overspeed test procedures for steam turbine and steam driven boiler feed

pumps

12. Control valve, main stop, and trip and throttle valve test procedures

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 13. Loss of lubrication test procedures including pressure switches, pump start

logic, etc.

4.2.2.7. ANNUAL STEM TURBINE MAINTENANCE

FREQUENCIES AND TASKS (BASING ON US STANDARDS)

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170
 4.2.3. CONDENSER

In addition to the mandated requirements, managers should ensure operators and technicians
complete a number of regular tasks:
 They should examine the boiler or domestic water heater for code compliance at least
once each year.
 They should identify and correct all installation deficiencies.
 They should inspect and test all safety and interlocks for proper operation.
 They should test the operation of the boiler’s control system over a range of loads.
 They should test all shutoff valves annually to confirm they close and do not leak.
 They should check all interior surfaces during the boiler’s annual inspection to ensure no
localized overheating, erosion, or corrosion formation occurs

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The American Society of Heating, Refrigeration and Air-Conditioning Engineers

mandates the following inspection and maintenance for Cooling Towers and

Evaporative Cooled Devices

172
4.2.4. CONTROL SYSTEMS

The American Society of Heating, Refrigeration and Air-Conditioning Engineers

mandates the following inspection and maintenance for Control Systems

4.2.5. ECONOMIZERS

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4.2.6. Fans

The American Society of Heating, Refrigeration and Air-Conditioning Engineers

mandates the following inspection and maintenance for Free-Standing Fans (Exhaust,

Supply, Transfer, Return)

4.2.7. Furnaces

The American Society of Heating, Refrigeration and Air-Conditioning Engineers

mandates the following inspection and maintenance for Furnaces, Combustion Unit

Heaters

174
4.2.8. Generators

The American Society of Heating, Refrigeration and Air-Conditioning Engineers

mandates the following inspection and maintenance for Generators (Engine,

Microturbines

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 4.2.9. Steam Distribution System

4.2.10. Water treatment/ Water treatment

The primary goal of preventive maintenance is to prevent the failure of pumps and

equipment before it actually occurs. It is designed to preserve and enhance equipment reliability

by replacing worn components before they actually fail.

Preventive maintenance activities include lift stations, air release valves (ARVs),

headworks structures (screening and in some cases grit removal) aeration equipment and return

and waste sludge pumps and digestion aeration equipment. Partial or complete overhauls at

regular specified periods; oil changes; lubrication; and so on. In addition, operators can record

equipment deterioration so they know to replace or repair worn parts before they cause system

failure. This information can be used as part of a systems asset management plan and help

176
prioritize and budget for the repairs. Wastewater lift stations and wastewater plants have to stay

in compliance at all times and can’t be taken offline for the needed maintenance.

Each item of equipment in the wastewater treatment plant and collection system shall be

inspected on a daily, weekly, monthly, or yearly basis as indicated in the attached “Wastewater

Treatment Plant Operational and Preventive Maintenance Check List.”

4.2.11. water desalination treatment plant

4.2.11.1. Daily tasks

 Check water meter readings and record water production.

 Check and record water levels in storage tanks.

 Check chemical solution tanks and record amounts used.

 Inspect chemical feed pumps.

 Check and record residual chlorine at the chlorine contact tank and in the

distribution system.

 Inspect inlet pumps, motors and controls.

 Record inlet pump running times and pump cycle starts.

 Complete a daily security check.

4.2.11.2. Annual tasks

The schedule for these tasks is spread throughout the year with some allocated for

January, some for February, etc. so that workload is managed sensibly. Some of these tasks may

need to be completed three or four times a year.

 Overhaul chemical feed pumps.

 Inspect and clean chemical feed lines and solution tanks.

 Calibrate chemical feed pumps.

177
  Operate all valves inside the treatment plant and pump-house. Maintain

log continuously throughout the year.

 Inspect chemical safety equipment and repair or replace as needed.

 Inspect, clean and repair control panels in pump house and treatment

plant.

 Inspect storage tanks for defects and deficiencies, and clean if necessary.

 Flush the distribution system and exercise/check all fire hydrant valves.

 Perform preventive maintenance on treatment plant and pump house

buildings.

4.2.12. Fly Ash Treatment Plant

The design, manufacture, inspection and testing of all equipment shall comply with all

the currently applicable statutory regulations and safety codes in the locality where the

equipment are to be installed. The equipment shall also conform to the latest applicable

Indian/British/American standards. Other internationally acceptable standards, which ensure

equal or higher performance than those specified, shall also be accepted. Nothing in this

specification shall be construed to relieve the Contractor of the required statutory

responsibility. A list of standards of some is given below for reference:

IS:1239 : Mild steel tubes, tubular and other

(Part I & II) wrought steel fittings

IS:1367 : Technical supply condition for threaded steel

fastener introduction and general information.

IS:3589 : Electrically welded steel pipes for water gas and

sewage (200 to 2000 nomi¬nal dia).

178
IS:4736 : Hot dip zinc coating on steel tubes.

IS::6392 : Steel pipe flanges.

179
 CHAPTER 5: ENVIRONMENTAL STUDIES

This chapter focuses on the different concerns for building and operating a coal power

plant in the environment. Coal has been a noteworthy source for many commodities in the world

especially for power generation, meanwhile there is need in using it efficiently to reduce it

environmental impact to the world. The misuse of coal would lead to a waste of natural resource

and will cause unnecessary pollutant, also to greenhouse gas emissions. Moreover, as the world

moves to develop and deploy carbon dioxide capture and storage technology, high-efficiency

coal-fired power plants will become even more important to compensate for the energy while not

affecting the environmental aspect.

Contents

 Potential impacts
o Air
o Water
o Health
 Articles
 DENR Standards

5.1. POTENTIAL IMPACTS OF THE PROPOSED PROJECT

5.1.1. RISKS ON THE AIR QUALITY

Particulate matter, toxic gases (SO2, NOx, CO) and greenhouse gases

(CO2, CH4) are the main air pollutants produced by coal-related activities. Dust

(including particulate matter) is the most important air problem in and around the coal

mining areas and coal processing facilities among the various pollutants. Coal power

180
plants affect air quality during both plant construction and operation phases. In the

construction phase, transportation and other activities are producing a significant amount

of dusts. Air pollutants are also produced during the combustion of coal in boilers and

during the handling of coal ash during the plant operation phase.

Coal ash is also a major contributor to air pollution, the main solid waste derived

from coal combustion processes in coal power plants. Coal power plants produce large

quantities of coal ash. All operating coal power plants are estimated to release millions of

tons of coal ash every year. Coal ash is affecting air quality by its transportation and

storage. Dust is carried by strong winds causing air pollution that significantly impact

local people. Air pollutants, particularly dust, produced from the operation of coal - fired

power plants (coal transport to the plant, coal combustion, ash transport and storage) have

a significant impact on the health and daily activities of people in the area around the

plant sites.

181
5.1.2. RISKS ON THE WATER QUALITY

Coal includes negative effects from the mining, processing, burning, and waste

storage of coal, including acid mine drainage, thermal pollution from coal plants, acid

rain, and contamination of groundwater, streams, rivers, and seas from heavy metals and

other toxins and pollutants found in coal wastes which causes water pollution. Coal

mining requires large quantities of water to suppress dust and on - site workers ' needs.

Once 148 returned, this water may contaminate for long periods of time both

groundwater and nearby streams. One factor that contributes to water pollution is acid

mine drainage. Acid mine drainage, toxic trace elements, high content of dissolved solids

in mine drainage water, and increased loads of sediments discharged into streams result

in stream deterioration of stream quality. The sulfuric acid moves into and contaminates

the waterways as water drains from the mines. The acid mine drainage continues even

after the mines stop its operations as long as rain and coal remain in the mines.

Another factor that contributes to water pollution is thermal pollution. Thermal

pollution is water quality degradation through any process that changes the temperature

of the ambient water. Coal power plants need a significant amount of water for the

cooling systems. Water is released into the lake, river, or ocean after that. The

environmental average temperature at the point of discharge of cooling water is often

higher than the water temperature of the normal water flow, high speed and waste water

also contains chlorine at a certain amount. The sudden rise in water temperature will

cause the temperature shock of living organisms in the ecosystem, increasing living

activity in water and dissolved oxygen (DO) in water, and dissolving toxic matter in

water, resulting in an imbalanced ecosystem.

182
 Lastly, water pollution includes contamination from heavy metals and other

toxins. Coal mining, processing, transportation and burning can release large quantities of

coal waste such as coal sludge, coal ash and other pollutants. Coal waste contains many

heavy metals that are capable of causing acute or chronic toxicity such as lead, mercury,

nickel, tin, cadmium, antimony and arsenic. Once these toxics enter the river ecosystem,

it can 149 enter the food chain and bio-accumulate, leading to serious harm to wildlife, as

well as threatening people

5.1.3. HEALTH IMPACTS

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5.2. PHILIPPINE ENVIRONMENTAL LAWS RELEVANT TO THE PROPOSED

PROJECT

5.2.1. REPUBLIC ACT 9003 ECOLOGICAL SOLID WASTE MANAGEMENT

ACT OF 2000

In partnership with stakeholders, the law aims to adopt a systematic,

comprehensive and ecological solid waste management program that shall ensure the

protection of public health and environment. The law ensures proper segregation,

collection, storage, treatment and disposal of solid waste through the formulation and

adaptation of best eco-waste products

5.2.2. REPUBLIC ACT 9275 PHILIPPINE CLEAN WATER ACT OF 2004

The law aims to protect the country's water bodies from pollution from land-based

sources (industries and commercial establishments, agriculture and community/household

activities). It provides for comprehensive and integrated strategy to prevent and minimize

pollution through a multi-sectoral and participatory approach involving all the

stakeholders.

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 5.2.3. REPUBLIC ACT 8749 PHILIPPINE CLEAN AIR ACT OF 1999

The law aims to achieve and maintain clean air that meets the National Air

Quality guideline values for criteria pollutants, throughout the Philippines, while

minimizing the possible associated impacts to the economy

5.3. DENR STANDARDS

Stationary sources refer to any building or immobile structure, facility or

installation which emits or may emit any air pollutant, and may be defined generally as

individual points of air emissions (e.g. smokestacks). Under RA 8749, all industries classified as

a stationary source should perform their own emissions monitoring and report the results to the

DENR. Coal plants, like any other corporation, are expected to submit a quarterly submission of

Self-Monitoring Report or SMR. In the SMR, all the activities of the operation which has impact

to the environment are stated and where compliance with existing environmental laws is

monitored. For fossil fuel-fired power plants over 10 MW rating, DENR requires the plant to

install a Continuous Emission Monitoring System(CEMS)

185
186
REFERENCES:

Chattopadhyay, R. (1997). Textile Rope - A Review. Indian Journal of Fibre and Textile

Research, 360-368.

Omeroglu, S. (2006). The Effect of Braiding Parameters on the Mechanical Properties of Braided

Ropes.

Foster, G. P. (2002). Advantages of Fibre Rope Over Wire Rope. Journal of Industrial Textiles.

Glushko, M. F., Sklatasky, V. K., & Zakhryamin, A. D. (1987). Rope-Twisitng Machine for

Making Rope. United States Patent.

Benk, C. (1964). Machine for Making Rope. United States Patent.

Newman, S. B., & Curtis, J. H. (1947). A Statistical Analysis of Some Mechanical Properties of

Manila Rope. Journal of Research of the National Bureau of Standards.

Dakhov, M. I., Nesterov, P. P., Semkin, A. T., & Alexeeva, L. A. (1974). Rope-Twisting

Machine. United States Patent.

Budynas, R. G., & Nisbett, K. J. (2011). Shigley's Mechanical Engineering Design. McGraw-

Hill.

Juvinall, R. C., & Marshek, K. M. (2012). Fundamentals of Machine Component Design. John

Wiley & Sons, Inc. .

Martin, G. H. (1982). Kinematics and Dynamics of Machines. McGraw-Hill.

Khurmi, R. S., & Gupta, J. K. (2017). Machine Design. Eurasia Publication House.

Ahmed, S., & Logarta, J. (2017). Carving Out Coal in the Philippines.

187
Japan Pacific Consultants International. (December, 2004). The Pre-Feasibility Study on the

Project for Winf Power Development in Panay Island, the Philippines. 5-11.

Antique Electric Cooperative. (2018). Anteco. Retrieved from

https://anteco.com.ph/index.php/about

American Society of Mechanical Engineers. (1 July, 2010). ASME Boiler and Pressure Vessel

Code.

Security Chimneys International. (19 October, 2012). SECTION 235100 – BREECHING,

CHIMNEYS AND STACKS .

U.S. Geological Survey. (n.d.). The Republic of the Philippines Coalbed Methane Assessment:

Based on Seventeen High Pressure Methane Adsorption Isotherms.

Heat Exchange Institute. (October, 2012). STANDARDS for STEAM SURFACE CONDENSERS.

PHILIPPINE ENERGY REGULATORY COMMISION. (30 September, 2015). THE -~

APPROVAL OF THE POWER SUPPLY AGREEMENT (PSA) BETWEEN ZAMBOANGA

DEL SUR II ELECTRIC COOPERATIVE, INC. (ZAMSURECO II) AND KING ENERGY

GENERATION, INC. (KEGI),.

Xing, Z. (2016). Emission Standards and Control of PM2.5 from coal fired-power plant

Nawaz, I. (2013). Disposal and Utilization of Fly Ash to Protect the Environment. International

Journal of Innovative Research In Science, Engineering and Technology

188
APPENDIX I

CODES

• Additional requirements for all types of permit (as applicable) from DOE

1. Feasibility Study of the Project

2. Geological survey and study area (land,soil,rock formations, above

ground,underground, undersea, seafloor,water) where the infrastructure

for the project will be erected.

3. Atmospheric survey and study of the area (weather system, typhoon

paths.

4. Zoning/Locational Clearance and/or Certificate of approved Land Use

Conversion if proposed site is not within an industrial or commercial zone

5. Baranggay Business Clearance

6. Mayor's Business Permit

7. Building Permit

8. Mechanical Permit

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 9. Sanitary/Plumbing Permit

10. Electrical Permit

11. Fire Safety Inspection Certificate from the bureau of Fire Protection

(BFP)

12. National Water Regulatory Board Permit , if applicable.

13. System Handover Manual

14. Health, Safety, Security, Environment (HSSE) Plan

15. Emergency Response Procedure/Safety amd Emergency Manual

16. Operation and Maintenace Manual

17. Fire and Gas Electrical Checklist Manual

18. Certification of Personnel Training Conducted including results of

competency assessment.

19. Certificate of calibration of All Metered Units

20. Certificate of Final Electrical Inspection

21. Certificate of Occupancy

22. Insurance Coverage of the project (certified true copy). It should

comply with and satisfy the health, safety , security, and environment

(HSSE ) Plan, the immediate locality and its people near the facility

should be covered and protected by the insurance

 ASMEPTC 4.2 1969 performance test code for coal pulveriser

3.4.1 The capcity immedietely priopto the test shall be as close to thhe porposed

test rate as possible. After insuring that the test coal has reached the pulveriser,

at least 3o mins of stable operation shall be obtainge before the tests is starter.

190
 The level of the coal in the pulveriser feeder hopper as well as in the pulveriser

must be the sa,e before and after the test.

3.4.2. The reading s of all instruments, particularly integrating instrument shall

be recorded at the starting and stopping time

3.2.3. Each test shall be run with all predetermined conditiondd maintaned as

nearly as possible

3.5 duration. Performance test of pulverizer shal eah be of at least two hours

durayion

4.2.01 scales for weighing cola-idndividual automatic scales included in the

pulverizing system may be used for weighing fuel before delivery to the feed

hopper. Automatic scales shall be calibrated for accuracy and reliability and

balanced after each damp.

4.2.02 Calibrated cola feeder- where the degree of accuracy is adequate fo rthe

purpose of the test, calibrates coal feeders may be used to determine the coal

weight

4.2.03 round hole screns- for sizing coal to the pulverisers the screen to be used

shall comply wit the test code for soild fuels

 International Electrotechnical Commission first edition of IEC Std C57.15.

Requirements for transformers having a tapped winding

5.1 General – Notation of tapping range

The following subclauses apply to transformers in which only one

of the findings is a tappedwinding.In a multi-winding transformer, the

statements apply to the combination of the tapped winding with either of

the untapped windings.In auto-connected transformers, tappings are

191
sometimes arranged at the neutral which means that the effective number

of turns is changed simultaneously in both windings. For such

transformers, the tapping particulars are subject to agreement. The

requirements of thisclause should be used as far as applicable.

Unless otherwise specified, the principal tapping is located in the

middle of the tapping range.Other tappings are identified by their tapping

factors. The number of tappings and the range of variation of the

transformer ratio may be expressed in short notation by the deviations of

the tapping factor percentages from the value 100.

5.4 Specification of tappings in enquiry and order

The following data are necessary to define the design of the

transformer.

a) Which winding shall be tapped.

b) The number of steps and the tapping step (or the tapping range
and number of steps).
c) Unless otherwise specified it shall be assumed that the range is
symmetrical around theprincipal tapping and that the tapping
steps in the tapped winding are equal. If for some reason the
design has unequal steps, this shall be indicated in the tender.
d) The category of voltage variation and, if combined variation is
applied, the change-over point
e) Whether maximum current limitation (reduced power tappings)
shall apply, and if so, for which tappings.
6. Connection and phase displacement symbols for three-phase

transformers

The star, delta, or zigzag connection of a set of phase windings of

a three-phase transformer or of windings of the same voltage of single-

phase transformers associated in a three-phase bank shall be indicated by

192
the capital letters Y, D or Z for the high-voltage (HV) winding andsmall

letters y, d or z for the intermediate and low-voltage (LV) windings. If the

neutral point of a star-connected or zigzag-connected winding is brought

out, the indication shall be YN (yn)or ZN (zn) respectively.

Open windings in a three-phase transformer (that are not

connected together in the transformer but have both ends of each phase

winding brought out to terminals) are indicatedas III (HV), or iii

(intermediate or low-voltage windings).

For an auto-connected pair of windings, the symbol of the lower

voltage winding is replaced by 'auto', or 'a', for example, 'YNauto' or

'YNa' or 'YNa0', 'ZNa11'.

Letter symbols for the different windings of a transformer are

noted in descending order of rated voltage. The winding connection letter

for any intermediate and low-voltage winding is immediately followed by

its phase displacement 'clock number'.

The existence of a stabilizing winding (a delta-connected winding

which is not terminated for external three-phase loading) is indicated,

after the symbols of loadable windings, with the symbol '+d'.

If a transformer is specified with its winding connection

changeable (series-parallel or Y-D), both connections will be noted,

coupled with the corresponding rated voltages

7. Rating plates

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 The transformer shall be provided with a rating plate of

weatherproof material, fitted in a visible position, showing the

appropriate items indicated below. The entries on the plate shall be

indelibly marked.

8.1 Dimensioning of neutral connection

The neutral conductor and terminal of transformers intended to

carry a load between phase and neutral (for example, distribution

transformers) shall be dimensioned for the appropriate load current and

earth-fault current. The neutral conductor and terminal of transformers

not intended to carry load between phase and neutral shall be

dimensioned for earth-fault current.

 ASME PTC 6-2004 steam turbines

3.6 Location of turbine valve points

3.6.1 the method sued to establish turbine valve points depend on

valve point definition. A valve point may be established in terms of

high pressure turbine efficiency, certain measure turbines

pressures or valve stem positions. The turbine is the tested

accordingly

3.6.2 for units with a high pressure section operating entirely in

the super heat region a valve point may be located by finding a

point of local maximum pressure section efficiency. To do this, the

flow to the unit is changed in small increments throughout a range

which includes the valve point. At each flow increments pressure

and temperature measurement are taken at both inlet and exhaust

194
 so that high pressure section efficiency can be derived. A local

maximum efficiency will be evident provided suitable instruments

and test procedure have been used. During testing, a parameter

which varies with flow(such as control calve positions or pressure

ratios accord either the first stage or the complete high pressure

section should also be recorded so the valve can be readily steady

during the test series.

3.7.1recommended test, as a minimum duplicate test runs should be

performed at valves wide open and at two part load points duplicate test

runs at the same operating condition reduce the random error component

of uncertainty

3.8.1 constancy of test conditions preparatory to any test run the turbine

and all associated equipment shall be operated for a sufficient time to

attain a steady state condition.

3.9.2 duration of test run. This code recommend a minimum steady state

test run of two hours duration for each load point

 ASME PTC 8.2-1990 CENTRIFUGAL PUMPS

3.8A Five or more readings shall be taken and recorded at equal time intervals

for each test point. The result shall be the average of the readings.

3.8B One reading shall be taken at each test point.

3.12A The NPSH required by the pump shall be determined in accordance with

the procedures describedin Section 4 of this Code.

4.2 In testing, it is generally necessary to measure

(a) pressure (suction, discharge, barometric)

195
 (6) temperature (liquid and ambient)

(c) volume rate of flow (pump capacity)

(d) pump speed

(e) pump input power

4.5 The measurement of pressure for the determination of head is carried out by

pressure-indicating devices (gages, manometers, transducers) connected to the

liquid passage through pressure taps, or through pressure transmitters which are

in turn connected to the liquid passage through pressure taps

4.7 Pressure taps (see Fig. 4.7.1) shall be placed in sections of constant diameter,

concentric with the suction and discharge nozzles. They shall be located a

minimum of two pipe diameters upstream from the pump suction flange, and a

minimum of two pipe diameters downstream from the pump. Discharge flange.

For pumps which includeea pipe elbow or other disturbance upstream from the

pressure tap connection, it is necessary to locate the pressure tap sufficient

distance away from the disturbance to assure a uniform flow profile. Five

diameters of straight pipe upstream of the pressure tap is the minimum distance

for pressure tap location after a single disturbance.

4.1 1 All instrument lines, piping and fittings shall be checked under pressure

prior to taking test readings to assure that there are no leaks. All lines between

pressure taps and measuring instruments shall be prevented prior to the test

 11th edition of the standard for steam surface condenser:

Field Installation

9.7.1 This section provides general information on the field installation of a steam

surface condenser. Due to jobsite space limitations, available erection facilities,

196
and shipping constraints, it is not possible to provide an exact erection sequence.

The Purchaser may consult with the Manufacturer for general guidelines.

9. 7.2 The Purchaser must ensure that all condenser components can be safely

erected at the jobsite.

9.7.3 The Purchaser must follow directions and precautions included in

Manufacturer's installation, operation, and maintenance manuals, drawings, and

other documents furnished by the Manufacturer, and auxiliary equipment

suppliers.

9. 7.4 The condenser should be erected on a clean level surface as close as

possible to the condenser foundation to minimize handling.

9.7.5 The condenser should not be lifted or jacked in any area unless designated

by the Manufacturer.

9.7.6 During the erection of the condenser, all components must be protected

against damage. Particular attention should be given to protection of tubes and

tubesheets from arc strikes, falling objects, flame cutting, debris, etc.

197
 BPCV.1-2010 BOILER AND PRESSURE LEVELS
PG-25.2.1.2.2The technique for liquid penetrant examination shall be in accordance

with Article 6 of Section V. Surface indications determined by liquid penetrant

examination are unacceptable if they exceed the following:

a) all cracks and hot tears

b) any group of more than six linear indications other than those in (a) in any
rectangular area of I ~ in. X 6 in. (38 mm X I SO mm) or less, or any circular
area having a diameter of 3 ~ in. (89 mm) or less, these areas being taken in
the most unfavorable location relative to the indications being evaluated
c) other linear indications more than %; in. (6 mm) long for thicknesses up to %
in. (19 mm) inclusive, more than one-third of the thickness in length for
thicknesses from % in. to 2~ in. (19 mm to 57 mm), and more than % in.(19
mm) long for thicknesses over 2~ in. (57 mm) (Alignedacceptable indications
separated from one another by a distance equal to the length of the longer
indication are acceptable.)
d) all indications of nonlinear imperfection
PG-2S.2.2.2 All parts of castings shall be subjected to complete radiographic

inspection in accordance with Article 2 of Section V, and the radiographs shall

conform to the requirements of ASTM E 280, Standard Reference Radiographs for

Heavy Walled [4~ in. to 12 in. (114 mm to 305 mm)] Steel Castings.

198
PG-2S.2.2.4 All weld repairs of depth exceeding I in. (25 mm) or 20% of the

section thickness, whichever is less, shall be inspected by radiography in

accordance with PG-PG25.2.2.2 and by magnetic particle or dye penetrant

inspection of the finished weld surface. All weld repairs of depth less than 20% of

the section thickness, or 1 in. (25 mm), whichever is less, and all weld repairs of

sections which cannot be effectively radiographed shall be examined by magnetic

particle or dye penetrant inspection of

the first layer, of each ~ in. (6 mm) thickness of deposited weld metal and of the

finished weld surface. Magnetic particle or dye penetrant testing of the finished

weld surface

shall be done after postweld heat treatment.

PG-55.1 Lugs or hangers when used to support a boiler of any type shall be

properly fitted to the surfaces to which they are attached.

PG-58.3.2 When two or more boilers are connected to a common steam header,

or when a single boiler is connected to a header having another steam source

(e.g.,a turbine extraction line), the connection from each boiler having a manhole

opening shall be fitted with two stop valves having an ample free-blow drain

between them. The boiler external piping includes all piping from the boiler

proper up to and including the second stop valve and the free-blow drain valve.

PG-67.1 Each boiler shall have at least one pressure relief valve and if it has

more than 500 ft2 (47 m2 ) of bare tube water-heating surface, or if an electric

boiler has a

199
power input more than 1,100 kW, it shall have two or more pressure relief valves.

For a boiler with combined bare tube and extended water-heating surface

exceeding

500 ft2 (47 m2 ), two or more pressure relief valves are required only if the

design steam generating capacity of the boiler exceeds 4,000 Ib/hr (I 800 kg/hr).

Organic fluid vaporizer generators require special consideration as given in Part

PYG.

PG-67.4.3.2 The boiler shall be provided with automatic devices, responsive to

variations in steam pressure, which include not less than all the following:

PG-67.4.3.2.1 A control capable of maintaining steam pressure at the desired

operating level and of modulating firing rates and feedwater flow in proportion to

a variable steam output.

PG-68.1 every attached superheater shall have one or more pressure relief valves

in the steam flow path between the superheater outlet and the first stop valve. The

location shall be suitable for the service intended and shall provide the

overpressure protection required. The pressure drop upstream of each pressure

relief valve shall be considered in the determination of set pressure and relieving

capacity of that valve. If the superheater outlet header has a full, free steam

passage from end to end and is so constructed that steam is supplied to it at

practically equal intervals throughout its length so that there is a uniform flow of

steam through the superheater tubes and the header, the pressure relief valve, or

valves, may be located anywhere in the length of the header.

200
PG-68.4 Every reheater shall have one or more pressure relief valves, such that

the total relieving capacity is at least equal to the maximum steam flow for which

the heater is designed. The capacity of the reheater pressure relief valves shall

not be included in the required relieving capacity for the boiler and superheater.

One or more pressure relief valves with a combined relieving capacity not less

than 15% of the required total shall be located along the steam flow path between

the reheater outlet and the first stop valve. The pressure drop upstream of the

pressure relief valves on the outlet side of the reheater shall be considered in

determining their set pressure.

PG-Ill.IO Superheaters - on superheater header near the outlet. Other headers

shall carry identifying marks.

PG-lll.l1 Economizers - at a handy location on water inlet header or drums.

Other headers shall carry identifying marks.

PG-106.4.1 Items on Boilers

(a) Manufacturer's serial number

(b) certified by (name of Manufacturer)

(c) maximum allowable working pressure when built

(d) heating surface (or power input for electric boilers)

(e) year built

Cf) maximum designed steaming capacity (or, for high temperature

water boilers, maximum designed output)

PG-I06.4.2 Items on Waterwalls, Superheaters, orSteel Economizers

(a) Manufacturer's serial number

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 (b) certified by (name of Manufacturer)

(c) maximum allowable working pressure when built

(d) heating surface (not required for integral superheaters) (rated

absorption for an isolable economizer)

(e) for isolable or nonintegral separately fired superheaters,heating

surface or the minimum pressure relief valve discharge capacity

calculated from the maximum expected heat absorption (as determined by

the Manufacturer)

 Philippine Electrical code

2.50.6.1 Equipment Fastened in Place or Connected by Permanent Wiring Methods

Exposed non–current-carrying metal parts of fixed equipment likely to become

energized shall be grounded under any of the following conditions:

(1) Where within 2 400 mm vertically or 1 500 mm horizontally of ground or

grounded metal objects and subject to contact by persons
(2) Where located in a wet or damp location and not isolated
(3) Where in electrical contact with metal
(4) Where in a hazardous (classified) location as covered by Articles 5.0 through
5.17
(5) Where supplied by a metal-clad, metal-sheathed, metal- raceway, or other
wiring method that provides an equipment ground, except as permitted by
2.50.4.7, Exception No. 2, for short sections of metal enclosures
(6) Where equipment operates with any terminal at over 150 volts to ground
2.50.6.10 Identification of Equipment Grounding Conductors.

Unless required elsewhere in this Code, equipment grounding conductors

shall be permitted to be bare, covered, or insulated. Individually covered or

insulated equipment grounding conductors shall have a continuous outer

finish that is either green or green with one or more yellow stripes except as

permitted in this section.

202
 Conductors with insulation or individual covering that is green, green

with one or more yellow stripes, or otherwise identified as permitted by this

section shall not be used for ungrounded or grounded circuit conductors.

(a) Conductors Larger Than 14 mm2. Equipment grounding conductors

larger than 14 mm2 shall comply with 2.50.6.10(a)(1) and (a)(2).

(1) An insulated or covered conductor larger than 14 mm2 shall be

permitted, at the time of installation, to be permanently identified as an

equipment grounding conductor at each end and at every point where the

conductor is accessible.

Exception: Conductors larger than 14 mm2 shall not be required to be

marked in conduit bodies that contain no splices or unused hubs.

(2) Identification shall encircle the conductor and shall be accomplished

by one of the following:

a. Stripping the insulation or covering from the entire exposed length

b. Coloring the exposed insulation or covering green

c. Marking the exposed insulation or covering with green tape or green

adhesive labels

(b) Multiconductor Cable. Where the conditions of maintenance and

supervision ensure that only licensed electrical practitioner or non licensed

electrical practitioner under the supervision of a licensed electrical

practitioner service the installation, one or more insulated conductors in a

multiconductor cable, at the time of installation, shall be permitted to be

permanently identified as equipment grounding conductors at each end and at

203
every point where the conductors are accessible by one of the following

means:

(1) Stripping the insulation from the entire exposed length

(2) Coloring the exposed insulation green

(3) Marking the exposed insulation with green tape or green adhesive

labels

(c) Flexible Cord. An uninsulated equipment grounding conductor shall be

permitted, but, if individually covered, the covering shall have a

continuous outer finish that is either green or green with one or more

yellow stripes.

2.50.6.11 Equipment Grounding Conductor Installation.

An equipment grounding conductor shall be installed in accordance with

2.50.6.11(a), (b), and (c).

Aluminum and Copper-Clad Aluminum Conductors. Equipment grounding

conductors of bare or insulated aluminum or copper-clad aluminum shall be

permitted. Bare conductors shall not come in direct contact with masonry or

the earth or where subject to corrosive conditions. Aluminum or copper-clad

aluminum conductors shall not be terminated within 450 mm of the earth.

Equipment Grounding Conductors Smaller Than 14 mm2. Equipment

grounding conductors smaller than 14 mm2 shall be protected from physical

damage by a raceway or cable armor except where run in hollow spaces of

walls or partitions, where not subject to physical damage, or where protected

from physical damage.

204
 2.50.6.13 Size of Equipment Grounding Conductors.

General. Copper, aluminum, or copper-clad aluminum equipment

grounding conductors of the wire type shall not be smaller than shown in

Table 2.50.6.13 but shall not be required to be larger than the circuit

conductors supplying the equipment. Where a raceway or a cable armor or

sheath is used as the equipment grounding conductor, as provided in 2.50.6.9

and 2.50.7.5(a), it shall comply with 2.50.1.4(a)(5) or (b)(4).

 Engineering standard for process design of cooling towers by Iranian petroleum

standards(IPS)
11.2.1 Tower levels

The cooling tower should be located at a suitable site and due

consideration should be given to the

question of drainback from the system resulting in loss of water and flooding.

11.2.2 Air restrictions

On small industrial tower installations, due to aesthetic reasons or sound

attenuation requirements,enclosures or barriers are sometimes built to shield the

towers. These barriers or enclosures shouldbe spaced and designed to achieve the

minimum of air restriction with the maximum maintenanceworking area.The

exclusion of birds and bird droppings may also necessitate the provision of

barriers which should be subject to the same considerations. The total flow area

in the barrier or enclosure should be a minimum of twice the area of the tower

inlet openings on that side.

11.2.3 Recirculation

205
 The extent of recirculation depends mainly upon wind direction and its

velocity, tower length and atmospheric conditions. Further factors that may exert

some influence are spacing, topography or geographical situations with respect

to downdraught, exit air speed, tower height and the density difference between

exit air and ambient temperatures.

11.2.4 Orientation of cooling towers

The orientation of cooling towers should be as follows:

a) Towers with air inlets on one side should be oriented so that the
air inlets face the prevailing wind.
b) Towers with air inlets on opposite faces of the cooling tower
should be oriented so that the air inlets face at 90° to the
prevailing wind.
c) Large mechanical draught towers should preferably be divided
into banks, each of which should have a length-to-width ratio of
about 5 to 1.
d) The wind loading on any tower within a group will be affected by
the grouping and spacing and should be considered in their
structural design.
11.3.1 The spacing of cooling tower banks should be based upon the

recommendations in 11.3.2 to 11.3.5.

11.3.2 When the long axis of one bank is perpendicular to the prevailing wind

direction, the influence on another bank will be minimized when the distance, X,

between the banks is greater than their average length. The long axes of the tower

banks should be in line.

11.3.3 When the long axis of the existing tower is parallel to the wind direction

(see Fig. 3b), the influence of the existing tower on the new will be minimized if

the distance, X, is greater than their average length.

206
 11.3.4 When the long axis of the existing tower is at 45° to the wind direction

influence of the existing tower on the new will be minimized if the distance, X,

between the towers measured normal to the wind direction is greater than their

average length.

11.3.5 Spacing of large natural draught cooling towers is considered to be

adequate if adjacent cooling towers are spaced so that the distance between the

towers is equal to or greater than half the base diameter of the large tower).

Should a tower be sited in close proximity to large buildings such as the turbine

and boiler houses, the nearest point of the tower relative to the buildings should

be at least one tower diameter away.

 Emission standards and control of PM2.5 from coal-fired power plant

Fine particulate matter, PM2.5, can include SO2, NOx, toxic volatile organic

compounds, heavy metals, water and biogenic organic species. PM2.5 can be

emitted directly or form in the atmosphere from the reactions of other pollutants.

Coal-fired power plants are a major source of PM2.5. There are international

and national emission standards to limit PM2.

207
PM2.5, NOx, and SO2 emissions by the Sector Group in Europe in 2013 (European Environment

Agency)

Clean air is considered to be a basic requirement for human health and well-

being. The World Health Organisation (WHO) has produced air quality

guidelines for reducing the health impacts of air pollution worldwide. The WHO

guidelines updated in 2005 include thresholds and limits for PM, NO2 and SO2,

shown in Table 1 (WHO, 2006). Based on known health effects, both 24-hour

(short-term) and annual mean (long term) guidelines are needed as indicators of

PM pollution. For SO2, the recommended guideline values are not linked to those

for PM. The 24-hour guideline might be difficult for some countries to achieve, so

a stepped approach using an interim goal of 50 μg/m3 for controlling vehicle

emissions, industrial emissions and/or emissions from power production is

recommended.

208
Air quality standards are regulatory measures designed to achieve a desired level

of air quality by regulating the amount of pollutants that can be emitted from a

facility. Emission standards have had a major influence on cutting emissions from

coal-fired power plants and other sources. Most commonly, parties establish

emission standards and emission limit values (ELVs) based on the best available

technologies (BAT), and require emission data to be reported as specified in the

standards.

The emission limits given in the policy relevant to coal combustion equipment are

shown in Table 4 but only apply to new installations and facility upgrades.

209
 ISO 3297: 2007 Vol. 2, Issue 10, October2013

Disposal and Utilization of Fly Ash to Protect the Environment

Depletion of natural resources is a particular environmental concern to a

highly technological society which depends on resources for energy,

building materials and recreation. Exhaustion of natural resources viz.,

oil, mineral and timber will lead to deterioration in the quality of life. In

order to maintain the present rate of technological development some

alternative materials viz., fibre glass, reinforced plastics and glass,

reinforced gypsum have a great potential of use as building materials in

place of present conventional materials like timber, steal etc. Fly Ash

utilization scenario in India is shown in Figure.

Fly ash Utilization Scenario In India

210
APPENDIX II

PLANT LAYOUT

Legend:

1. Coal Stockpile 17. Ash Handling Facility

2. Coal Conveyor 18. Ash Storage
3. Coal Hopper 19. Admin Building
4. Pulverised Fuel Mill 20. Parking Lot
5. Boiler
6. High Pressure Turbine
7. Low Pressure Turbine
8. Condenser
9. Generator
10. Unit Transformer
11. Transmission Line
12. Cooling towers
13. Deaerator
14. Feedwater Heater
15. Precipitator
16. Chimney

211