SCHEMATIC DIAGRAM

Selection of Power plant site

Availability of fuel.
ASH Disposal facilities.
Space requirement.
Nature of Land.
Availability of water transport facilities.
Availability of Labour.
Public problems.
Size of the Plant.
BOILER

5
TYPE OF Boilers
TYPE OF Boilers
TYPE OF Boilers
TYPE OF Boilers
 TYPE OF MEDIA INSIDE TUBE
Tube

Fluid
Fluid
Gas

Gas

Water Tube Fire Tube

Combination of water and fire tube boilers do exists

 VARIOUS PRESSURES TERMS

Super heater 2 Super heater Main Steam

Safety V/v Stop V/v
Super heater S.V Set Pressure
Attemperator Operating Pressure/ 0.93

Drum Operating Pressure

Operating Pr+ Pressure drop from drum to MSSV
Super heater 1
Drum Safety Valve Set Pressure
SH Safety v/v Set pressure + Pr. Drop from drum to MSSV

Feed Pump discharge Pressure

Drum Pressure+ P( Eco+Control Valve+ HPH+ FE+ PPG )+Static Head

Economiser
FW Control Valve Feed Pump
TURBINE

12
13
 The ways by which efficiency of the
Rankine cycle can be increased are :

(a) Lowering the condenser pressure.

(b) Superheating the steam to high
temperatures.
(c) Increasing the boiler pressure.
d) Reheating
e) Regenerative Feedwater heating
TYPES OF STEAM TURBINE
STEAM FLOW INSIDE TURBINE
Turbine Photos

PRESENTATION BY POWER GROUP TRICHY 17

Turbine Photos

PRESENTATION BY POWER GROUP TRICHY 18

BALANCE OF POWER PLANT
• Balance of plant refers to
supporting and auxiliary
components based on the power
source or site-specific
requirements and integrated into
a comprehensive power system
package.

In other words, all the systems in a power plant other than Boiler
and Turbine Generator.
BOP comprises…
 Plant Water System

 Cooling Water System

 Fuel Handling System

 Ash handling system

 Mechanical auxiliaries

 Plant Electricals

 Instrumentation & Control system

AIR COOLED CONDENSER

21
 AIR COOLED CONDENSER

 Air Cooled Condensers are universally preferred over the conventional

water cooled condensers where the water sources are found scarce to meet
out the Cooling water requirements of the Steam Turbine.

 Air cooled condenser normally employs a series of Finned tubes

supported on “A” Frame structure generally referred to as modules
and large sized fans for air handling.

 The Effective heat transfer area is determined by the Steam Exhaust

Flow, Enthalpy difference with reference to the Design Ambient
temperature.

22
Air Cooled Steam Condenser
Air Cooled Steam Condenser
GENERAL ARRANGEMENT DRAWING

25
COOLING TOWER

26
Factors contributing the selection

27
 Cooling tower parameter’s
Hot
Water flow
Hea Air out: Warm and Saturated
te xcha
Hot Water nge
by E
VAP
ORA
TIO
Air in : Cold and Dry N
Range

Cold Water c h
oa Air Wet Bulb
pr
Ap 28
 The atmospheric air will be allowed to flow through the
fills because of it’s hyperbolic shape. The warm air
rises up through the shell by the 'chimney effect',
Types of Cooling Tower
creating the natural draught to provide airflow and
operate the tower. These towers therefore do not
require fans and have low operating costs.
Based on air circulation
The atmospheric air will be sucked to flow
 Natural Draught Cooling
through the fillsTowers
so as to remove the heat of
circulating water.
 Mechanical Draught Cooling TheTowers
atmospheric air will be forced to
flow through the fills so as to remove
 Induced Draught Cooling Towers
the heat of circulating water.
 Forced Draught Cooling Towers
The air & Water gets contact at
right angle where the air travels
Based on air-water vertically
flow up through the fill.
direction
 Cross flow cooling towers
The air & Water gets contact at
180° angle where the air travels
 Counter flow cooling towers
horizontally through the fill.
 Typical Cooling Tower - Arrangement

Counter flow cooling towers Cross flow cooling towers

NATURAL DRAUGHT COOLING TOWERS
FUEL HANDLING SYSTEM

32
 Fuel Handling System

To Prepare and handle the Fuel up to bunker

Factors contributing the selection of FHS

Fuel GCV Capacity
Hours of operation Capacity
Raw Fuel Size Stages of Crushing &
Screening
Sieve analysis To Determine the
introduction of pre screen

33
 Capacity Selection
Fuel handling capacity = Fuel Qty x 24 x 1.1
Hours of operation
Example:
Fuel quantity = 13846 Kg/hr
Hours of operation = 12 hrs
Fuel handling capacity = 13846 x 24 x 1.1

12
= 31 TPH
Fuel handling capacity = 13846 x 24 x 1.1
8
= 46 TPH

34
Scheme

35
 1. Roads – Truck tipplers
FUEL HANDLING SYSTEM
2. Rails - Wagon tippler
3. Ship - Barge unloader
Screens:
STAGES : For PC Boilers – Roller screens to separate (-) 20 / 25 mm.
For CFBC Boilers – Vibrating screens to separate (-) 6 / 10 /
12 mm.
 Unloading Crushers:
For PC Boilers – Ring granulator crushers
 Fuel preparation
For CFBC – Unidirectional impactor crusher.
 Stacking
 Reclaiming Stacker is used for stacking the prepared fuel in the
storage yard

Reclaiming the fuel from storage yard is done by Reclaimer.

Emergency reclaiming is done by using mobile equipments
such as Dozers, Front end loaders etc.
ASH HANDLING SYSTEM

37
ASH HANDLING AND DISPOSAL SYSTEM

 The generation of ash is obvious, during burning of solid

fuels.
 Ash content depends on the quality & quantity of the fuel
used.
 Generation of ash in the boiler to be disposed or removed
through dedicated system.
VARIOUS FACTORS WHICH DETERMINE THE
METHOD OF HANDLING AND STORAGE.
ASH COLLECTION POINTS IN BOILER
 TYPES OF ASH HANDLING SYSTEM

ASH HANDLING SYSTEM

DRY SYSTEM WET SYSTEM

PNEUMATIC STEEL PLATE CONVEYORS

SLURRY SYSTEM

DENSE PHASE VACUUM

LCSD SYSTEM HCSD SYSTEM

PLANT WATER SYSTEM
It deals the entire water management system for the
power plant like boiler, cooling system, fire fighting, ash
& coal handling etc.,

It includes...
 Water for Steam generation
 Water for Potable/Service
 Water for cooling application
 Water for auxiliary packages
Water Treatment System
Raw Water
Clarification Filtration UF / RO DM Plant
Reservoir

Sludge DM water
Sludge pit
treatment storage tanks

BOILER FEED WATER QUALITY Boiler feed water

pH Value - 8 – 8.5

Total Hardness as CaCO3 (ppm) - Nil

Conductivity (µs/cm) - < 0.5

Total Silica as SiO2 (ppm) - < 0.02

Water Treatment Plants
Water Treatment Plant

45
AIR COMPRESSORS AND
AIR DRIER

46
 Description

 Air Compressors are used to supply the Compressed

air at required Pressure for Instruments and
Conveying air requirement for Dense Phase Ash
Handling system.

 Instrument air Compressors (Dry & Oil free) supplies

the Air required for Power Plant Instruments like
Pneumatic Actuation of valves, Open / Close of
Dampers, I/P Converters, Purge instruments, Bag
Filters, etc.,

 Ash conveying Air Compressor is dedicatedly

provided for Ash Conveying system for Conveying the
ash to Ash Silo and general plant utility requirements.
47
 Types of Compressors

 Reciprocating Compressors
Lubricated
Non Lubricated

 Screw Compressors
Lubricated
Non Lubricated

 Centrifugal Compressors

48
 Factors Contributing the Selection

 Site atmospheric condition such as

Relative Humidity, Altitude above MSL

 Compressor type either with Lubricated / Non
Lubricated
 Operating pressure

49
ELECTRICAL

50
 SINGLE LINE DIAGRAM

52
 POWER PLANT ELECTRICAL COMPONENTS

53
 ALTERNATOR
• An alternator is
coupled to the
turbine, which
converts mechanical
energy into electrical
energy.
• The whole point of
the power plant is to
turn the generators to
produce electrical
energy.
54
55
 Generation, Transmission and Distribution of
voltage levels in India

Sl. No. Particulars Values

1. Generation 11KV,6.6KV, 3.3KV
2. Transmission System 440KV, 220KV, 132KV, 110KV and 66KV
3. Sub-Transmission System 33KV
Distribution System
• Primary Side 22KV, 11KV, 6.6KV
• Secondary Side 415Volts & 230Volts
 Generation

Main Transmission

Sub Transmission

Primary Distribution Secondary Distribution

 POWER UTILISATION

Generated Power shall be utilized as follows:

• In-house Auxiliaries.
• Power Distribution to Existing plant.
• Power Evacuation to EB Grid.

60
 OPERATIONAL PHILOSOPHY
• The generated power shall be delivered to MV switch
board.
• Surplus power after catering power requirement of
proposed power plant and existing plant load requirement
(if any), shall be exported to the grid through grid
transformer.
• The Power plant load distribution shall be catered through
the MV switch board. The incoming power supply of Turbo
generator shall be fed to the MV Switch board through
cable (or) bus duct.
• The required numbers of feeders shall be provided at
MV board for the power distribution to the power plant
auxiliaries and existing plant auxiliaries.

For Plant Start-up with DG set

• The generation plant shall be started with DG Set.
• The DG set supply shall be extended to PCC through LT
cable (or) Bus duct.
• The LV power at PCC shall be stepped up to MV power
through back charging of Distribution Transformer.
• By closing of Distribution Transformer MV Breaker, MV
bus gets charged.
• Once all start up auxiliaries are started and the boiler
and turbine is ready, the TG shall be excited to rated
voltage after ensuring the rated speed of turbine.
• The Generator Circuit Breaker shall be momentarily
synchronized with DG supply, which is already available
at MV bus. After momentary paralleling, the DG set
shall be stopped immediately.
 For Parallel with Grid
• EHV supply from EB grid shall be extended to
evacuation feeder at MV switchboard through grid
transformer by closing switchyard SF6 circuit
breaker.
• The TG set shall be synchronized with EB supply
through MV evacuation feeder Circuit Breaker at MV
Switch Board.
 For Plant Start-up with Grid
• EHV supply from EB grid shall be extended to MV
switchboard through grid transformer by closing
switchyard SF6 circuit breaker & power evacuation circuit
breaker in MV switchboard.
• Grid supply shall be extended to power plant loads through
distribution transformer by closing MV circuit breaker of
distribution transformer and then by closing incomer circuit
breaker of PCC.
• Once all auxiliaries are started and the boiler and turbine is
ready, the TG shall be excited to rated voltage after
ensuring the rated speed of turbine.
 The generator circuit breaker shall be synchronized
with grid supply, which is already available at MV bus.

For Reparallel with Grid

• In case of grid disturbance, the evacuation MV Circuit
Breaker shall be tripped by the grid disturbance relay
which is provided in Switchyard Relay panel.
• Once the grid is ready, the plant shall be re paralleled
through MV evacuation Circuit Breaker.
 SWITCHYARD
It is a switching station which has the following
credits :
• Main link between Generating plant and
Transmission system, which has a large
influence on the security of the supply.
• Step-up and/or Step-down the voltage levels
depending upon the Network Node.
• Switching ON/OFF Reactive Power Control
devices, which has effect on Quality of power.

67
 Transmission...

For Long distances: High Voltage/Low Current ~ High Pressure/low flow

Suitable for Transmission, but not for Consumption

For Short distances

and consumption: Lower Voltage/High Current ~ Low Pressure/high flow

Suitable for Consumption and short distances

 OUTDOOR SWITCHYARD

69
 SWITCHYARD COMPONENTS
• Circuit Breaker • PLCC
• Current Transformer • Wave Trap
• Potential Transformer
• SCADA
• Isolator
• Transmission Line
• Lighting Arrester
• Earth Switch
• Towers
• Post Insulator • Control & Relay
Panel

70
 INDOOR SWITCHYARD

71
INDOOR SWITCHYARD
1. Bus bar with combined
disconnector and earth
switch
2. Circuit breaker
3. Current transformer
4. Voltage transformer
5. Line disconnector with
earthing switch
6. Make-safe earthing
switch
7. Cable sealing end
8. Control cubicle
72
 MV SWITCHGEAR

Medium voltage switchgear is the

combinations of electrical disconnector,
circuit breakers and earth switch used to
control, protect and isolate electrical
equipment / system. Switchgear is used both
to de-energize equipment to allow work to be
done and to clear faults downstream.

73
 MV SWITCHGEAR

74
 MV SWITCHGEAR COMPONENTS
(Each Feeder)

• Circuit Breaker (VCB / SF6)

• Current transformer
• Potential transformer
• Meters (Ammeter, Voltmeter, Energey
Meters, MFM / TVM, etc)
• Relays (Numerical / Electro static / Electro
mechanical relays)
75
 TRANSFORMER
• A transformer is a static machine used for
transforming power from one circuit to
another without changing frequency.
• Transformers are used to increase or decrease
the voltages of alternating current in electric
power applications
• To change the voltage
– Increase = “step-up”
– Decrease = “step-down”
76
 TRANSFORMER

77
 Why do we need a Transformer

•
Generating electricity at High Voltage is not
practicable (generator output is 11kV)
•
Transmitting electricity at the same voltage as
generated is expensive
(too low, high losses due to high current)
•
Using electricity at the same voltage as
generated is dangerous and expensive
(6kV at home?!, all appliances too expensive )
 Why do we need a Transformer...
•
To convert electrical energy from one
Voltage level to another

Note: Transformer does not change the Relative size of Conductor

frequency! for same power rating:

Example: 1 phase
10kVA transformer
Crosssectio
Primary 11000V, 0.91A: n
11000V*0.91A=10000VA=10kVA 40times
bigger
Secondary 250V, 40A:
250V*40A=10000VA=10kVA 11000V 250V
 Where do we need a transformer...

•
Generation of Electric Power
(Power Transformer (up))
•
Transmission of the power
Power Transformer
(up/down)
–
Distance and transmission
voltages
–
Losses on transmission
•
Distribution System for
Utilities (Distribution
Transformer- down)
 TRANSFORMER ACCESSORIES
• Winding • Radiator
• Core • Explosion vent
• Tank • Cooling fans
• Wheels
• Oil
• Oil level indicator
• Conservator
• Tap changer
• Buchholz Relay
• Control and Relay Panel
• Bushings
• Breather
81
 TYPES OF TRANSFORMER

Major Type • Converter Transformer

• Oil Immersed • Unit Auxiliary
• Dry Type Transformer
Based on Place • Station Transformer
• Generator Transformer • Isolation Transformer
• Grid Transformer (Unit ratio)
• Power Transformer
• Auxiliary Distribution
Transformer

82
 BUS DUCTS
An enclosed metal unit containing bus
bars for distribution of large amounts of 
power between components of the
distribution system.

Types of Bus duct:

• Segregated Phase bus duct (SPBD)
• Non Segregated Phase bus duct (NSPBD)

83
 BUS DUCT

SPBD NSPBD

84
 LV SWITCHGEAR

• LV Switchgear is the combinations of

electrical disconnect switches, fuses, or circuit
breakers used to control, protect and isolate
electrical equipment. Switchgear is used both
to de-energize equipment to allow work to be
done and to clear faults downstream. 

85
 LV SWITCHGEAR

86
 FEATURES AND TYPE OF LV SWITCHGEAR

• Non Draw out / Draw out

• Conventional Panel / Intelligent panel
• Fused / Fuse less
• Aluminium bus bar / Copper bus bar
• Single Incomer / Double incomer
• Compartmentalised / Non Compartmentalised

87
 CABLES
Wires having a protective casing and used for
transmitting electricity

FEATURES AND TYPE

• Outer Sheath : PVC / FRLS PVC
• Conductor : Aluminium / Copper

88
 MOTORS

A machine that
converts electrical
energy into mechanical
energy, as an induction
motor.

89
 DIESEL GENERATOR
A diesel generator is
the combination of a
diesel engine with an
electric generator
(often an alternator)
to generate
electrical energy.

90
 DIESEL GENERATOR
Black start DG set:
A black start DG Set is used to start the power
plant Auxiliaries as well as the process of restoring
an electric power station.

Emergency DG set:
To provide an alternate source of power if the
normal source of power, most often the serving
utility fails.
91
 VARIABLE FREQUENCY DRIVE
A Variable Frequency FEATURES AND
Drive (VFD) is a type of TYPE
motor controller that
• 6 Pulse / 12 Pulse
drives an electric motor by
varying the frequency and • LV VFD / MV VFD
voltage supplied to the
electric motor. Other
names for a VFD are
variable speed drive.
92
 VARIABLE FREQUENCY DRIVE

93
 DC SYSTEM

The DC system supplies direct current as a

source of operating power for control,
signalling, relays, tripping and closing of
switchgears, Emergency motors of most
important auxiliary systems.

94
 DC SYSTEM

95
 CONTROL & RELAY PANEL
Control panel is a
cabinet which contains
electrical components
to control the motors
and equipments.

96
 SYNCHRONIZATION PANEL
Synchronization is the process of matching the
voltage and frequency of a generator or other
source to a running network. 

97
 APFC PANEL
Automatic power factor
correction systems are
designed to automatically
turn power factor
correction capacitors on or
off to maintain a desired
target power factor under
varying load conditions on
the distribution systems of
power plant.
98
 INSTRUMENTATION &
CONTROL SYSTEM
 INSTRUMENTATION  CONTROL SYSTEM
WHAT IS “DCS” ?
TURBINE

AUXILLIARIES
ELECTRICAL

POWER

BOILER BOP

OUTSIDE
WORLD

DISTRIBUTED CONTROL SYSTEM

100
 DCS SYSTEM CONFIGURATION
ES/OS OS-1 OS-2 OS-3

19”
DMP
19”
CGP
19” 19” LEVEL-1

Vibration monitoring
&
Governor control MODBUS
Gateway interface
LEVEL-2

System Bus (Red)

Boiler, TG, Redundant

FHS, Controller
&
others
I/Os
LEVEL-3

P R O C E S S

101
LEVELS

SUPERVISORY LVL

COMMUNICATION LVL

FIELD CONTROL LVL

102
 BUS COMMUNICATION

ETHERNET
PROPRIETARY
(Supplier std)
FIBRE OPTIC
103
REDUNDANCY
PROCESSOR

POWER SUPPLY

COMMUNICATION

104
THIRD PARTY INTERFACE
OPC

MODBUS

PROFIBUS

105
 DCS
CONTROLLER / PROCESSOR
RAM SIZE

8 MB

16 MB

32 MB

64 MB
!
!
!
1 GB
106
 I/O MODULES
COMMUNICATION ANALOG ANALOG DIGITAL DIGITAL T/C RTD
I/P O/P I/P O/P I/P I/P
CARD

COMMUNICATION HART HART HART HART HART HART

ANALOG ANALOG DIGITAL DIGITAL T/C RTD
CARD I/P O/P I/P O/P I/P I/P

CHANNEL DENSITY 4 - 8 - 16 - 32 - 64

107
 ENGINEERING STATION
TO DO ENGINEERING ACTIVIES AS FEW LISTED

PROGRAMMING
CLOSED LOOP

LOGGING OPEN LOOP

TRENDS
ENGINEERING
REPORTS etc…. STATION
GRAPHICS GENERATION
DIAGNOSTICS

108
DIAGNOSTICS
BUS STATUS

I/O MODULE LEVEL

WIRE BREAK

109
SIGNAL COMMUNICATION STAGE
FIELD
FIELD

MARSHALLING
MARSHALLING
TB
TB

I/O
I/OMODULES
MODULES

COMMN.
COMMN.
CARD
CARD

CONTROLLER
CONTROLLER

ETHERNET
ETHERNET
SWITCH
SWITCH

ES OS
110
PRESENTATION BY POWER GROUP TRICHY 111