Basic Mechanical Engineering - Power Plant Engineering - Internal Combustion Engine - Nuclear Reactor

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Basic Mechanical Engineering -

Power Plant Engineering
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A Textbook of Power Plant Power Plant
Power System… Engineering - 2… Basics
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Power Plant Engineering

1.1 Introduction
Power plant engineering deals with the study of energ

and utilization of energy for power generation. The power is
prime movers (example Hydraulic turbines, steam turbines, d
Large amount of power is generated using prime movers in a
called power plants, where all the equipments and machinerie
power generation is located.

Energy: Energy may be defined as the capacity to do
exists in various forms, such as Mechanical Energy, th
electrical energy, solar energy etc. Electricity is the only fo
which is easy to produce, easy to transport, easy to use and e
Electricity consumption per capita is the index of the living st
of a place or country i.e. the utilization of energy is an ind
growth of the nation.
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1.2 Power and Power Plant:
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Power is primarily associated with mechanical
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energy. Therefore, power can be defined as the rate of flow
ca n state tha t a power pl a nt is a unit b uilt for pro d uction an
flo w of mechan ical or ele ct rical energ y . In a com m on usage,
assemblage of equipment that produc e s and deliver s a flow of
e lectrical ener gy is a power plant. Hence an intern a l combusti
p ower plant; a water w heel is a p ower plant, e tc. Howe
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produce electrical energy for deliver from the power plant.
1.3 Sources of energy
The basic sources of energy for power generation are co

fuels and gas. These sources are known as “conventional sourc
These sources of energy will one day be used up and are exha
The most reassuring and promising energy, which i

supply and is inexhaustible is “Non – conventional sources of
as solar, wind, tidal, geothermal etc.
Energy resources can be broadly classified as follows
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Energy Re sources
Conventional s ources of e ne rgy Non con ventional

en ergy (Or) or
Power System… NoEn
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Examples: - Examples:-
Fuels like coal, oil, Sun, wind,
energy
Natural gas, nuclear fuels etc. From earth
electric
Power etc.
1.3.1 Non – renewable sources:
Most of the energy we use are from source like coal, o

and nuclear fuels. These primary energy sources are called N o
sources because once they have been used up, they cannot be
1.3.2 Renewable sources:
Sources of energy that can be used over and over ag

renewable sources. These sources can be used to produce el e
of the renewable sources are:
• Energy from the sun (Heat and light energy)

• Energy from the wind (Kinetic energy)
• Energy from the waves and tides (Kinetic energy)
• Energy from earth’s core (Geothermal energy)
1.4 Classification of power plants

A power plant makes use of any one of the energy sourc
power. Depending on the type of energy source the po w
classified as
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• Thermal power plant (It makes use of coal)
• Internal combustion engine plants (makesSign
Search useIn of petrol
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• Gas turbine power plant (makes use of a permanent gas)
•
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• Hydro electric power plant (makes use of the poten

water)
• Wind power (makes use of energy available in wind)
• Geothermal power plant (makes use of heat energy a
the ground)
1.5 Working principle of Steam power plants
1.5.1 Introduction
Steam power plant is also known as Thermal power plant.

A steam power plant converts the chemical energy of the fos
oil, gas) into mechanical / electrical energy. This is achieved
steam in the boilers, expanding it through the turbines and
turbines to the generators which convert mechanical energy
energy as shown in fig. 1.1.
The following two purposes can be served by a steam power pl
1. To produce electric power

2. To produce steam for industrial purposes besides pro
Related titles power. The steam may be used for varying purposes in
such as textiles, food manufacture, paper mills, su
refineries.
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Fig. 1.1. Production of Electric energy by steam power

1.5.2 Classification of steam power plants
The steam power plants may be classified as follows:
1. Central stations
2. Industrial power stations or captive power statio
1. Central stations. The electrical energy available from

is meant for general sale to the customers who wish t
Generally, these stations are condensing type wher e
steam is discharged into a condenser instead of into th
In the condenser the pressure is maintained below th
pressure and the exhaust steam is condensed.
Related titles 2. Industrial power stations or captive power station
power station is run by a manufacturing company for it
its output is not available for general sale.Sign

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Normally
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th
non-condensing because a large quantity of steam (lo
required for different manufacturing operations.
In the condensing steam pow er plants t he followin

accrue:
(i) The amoun t of energy ex tracted pe r kg of stea

(a given size of the engi ne or turbined evelops m
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condenser, can be recirculated to the boilers w
pumps.
In a non – condensing steam power plants a continuous

feed water is required which becomes a problem at places wh
shortage of pure water.
1.5.3 Layout of modern steam power plant
A steam power plant must have the following equipments:
• A furnace to burn the fuel.

• Steam generator or boiler containing water. Heat ge
furnace is utilized to convert water into steam.
• Main power unit such as an engine or turbine to use th
•
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The general layout of the thermal power plant consis

circuits as shown in fig. 1.2. The four main circuits are:
1. Coal and ash circuit

2. Air and gas circuit
3. Feed water and steam flow circuit
4. Cooling water circuit
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Coal and as h circuit: - This circuit consists of c oal storage

c o al handling and ash ha n dling syste ms. The ha nd ling syst
bel t conveyo rs, screw conv eyors etc. Coal arrives at the sto
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boiler and is removed to the ash storage yard through
equipment. The Indian coal contains 30 to 40% of ash and a
100MW produces normally 20 to 25 tones of hot ash per hour.
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Fig.1.2 Layout of Steam Power plant
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Air and gas circuit: - This circuit consists of air filter, air p
collector and chimney. Air is taken in from the atmosph e
preheater thr o ugh the ac tio n of a forc e d or induce d draught f
b ot h. The du st from the air is remov ed by means of using a
su pplying to t h e combusti on chamber. T he exhaus t gases carr
quantity of he at and ash are passed through air preheater whe
h e at of the g a ses is give n to the air and then i t i s passed
Power System… Engineering - 2… Basics Plants 5 Mechanical… Mechanical…
collectors where most of the dust is removed before exhaustin

the atmosphere through chimney.
Feed water and steam flow circuit: - This circuit consists

pump, boiler, turbine and feed heaters. The steam generated
fed to the steam prime mover to develop the power. The stea
of prime mover is condensed in the condenser and then fed to
the help of pump. The condensate is heated in the feed hea
steam tapped from different points of the turbine. The feed h
of mixed type or indirect heating type.
Some of the steam and water is lost passing thr

components of the system, therefore, feed water is supplied
source to compensate this loss. The feed water supplied
source is passed through the purifying plant to reduce the dis
an acceptable level. The purification is necessary to avoid the
boiler tubes.
Cooling water circuit: - This circuit consists of circulating

cooling water pumps and cooling tower. The quantity of
required to condense the steam is considerably large and it
lake, sea or river. The cooling water is taken from the upper si
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it is passed through the condenser and heated water is disc
lower side of the river. Such system of cooling water supply

adequate cooling water is available through theSign
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as open system. When the adequate water is not available, t
coming out f ro m the con de nser is co ol ed either i n cooling p
t ower. The cooling is e ffected by p artly evap o rating th
evaporative loss (this includes evaporation and car ryover) is n
o the cooling ater circul ted in the system. To compensate t
los s, the wat er from the river is cont i uously sup plied. Wh
w ater comin g out of the condenser is cooled a ga in and s
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system provided adequate water is available throughout the ye
The different components, which are used in thermal po

listed below:
Boiler, steam turbine, generator, condenser, cooling tow
water pump, boiler feed pump, induced/forced draug
precipitators etc.
1.5.4 Working of the thermal power plant
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Steam is generated in the boiler of the thermal Join p
heat of the fuel burned in the combustion chamber. The stea

passed throu gh steam turbine where p art of its thermal energ
into mechani cal energy, w hich is furth er used for g e neratinge
T he steam co ming out of t he steam t urbine is co nd ensed in
and the cond e nsate is su p plied back to the boiler with the h
pump and thec ycle is repeated.
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pressure. The function of the steam turbine is to convert part
of steam into mechanical energy. The function of the pump
pressure of the condensate from the condenser pressure (
boiler pressure (200 bar). The other components like
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used in the primary circuit to increase the overall efficiency
power plant.
1.5 . 5 Characteristics of steam power plant:
• Higher efficiency
• Lower cost
• Ability to burn coal especially high ash content, inferior c
• Reduced environmental impact in terms of air pollution
• Reduced water requirement
• Higher reliability and availability
1.5.6 Advantages (merits) of thermal power plant
1. The initial cost of construction of the plant is low comp

electric plant
2. The power plant may be located near the load centre, s
of transmission and the losses due to transmission ar
reduced.
3. The quantity of water in hydroelectric plant depends o
as rain and rivers. This is not so in the case of thermal po
4. The construction and commissioning of thermal pow
lesser period when compared to hydro electric power pla
Related titles1.5.7. Disadvantages (demerits) of thermal power plant

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1. T
exhaustedhe fuel (csinceoal oitr o
isila) non
usedrenewable in thermasourcel poweofr p energylant wtil
2. It cannot be used as peak load plant, as its part l

decreases very rapidly with decreasing load.
3. The transportation of fuel is a major problem for power
away from coal fields.
4. The cost of power generation is considerably high comp
electric power plant.
5. The smoke produced by the burning fuel when exha
atmosphere causes air pollution.
6. The life of thermal power plant according to the Electricit
25 years and that of hydroelectric plant is 35 years.
decreases to less than 10% after its life period. Hydro
plant can have a life of even 100 to 125 years.
7. The turbines in thermal power plants run at a speed of
rpm and they require special material and rigid c
compared to hydro electric plant which has a low runnin
to 400 rpm.
1.6 Gas Turbine Power plant
A gas turbine power plant may be defined as one

principal prime mover is of the turbine type and the workin
permanent gas” .
A simple gas turbine plant consists of the following:
1. compressor
Related titles 2. Intercooler
3. Regenerator
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5. Gas turbine
6. Reheatin g unit
1. Compressor:
In gas tu rbine plan t, the axial an d centrifu ga l flow co

used. In most of the gas turbine power plant, two co mpressors
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through the filter. The major part of the power developed
(about 66%) is used to run the compressor. This low pressure
high pressure compressor through the intercooler. Then the hig
goes into the regenerator.
2. Intercooler:
The intercooler is used to reduce the work of the compressor a

in between the high pressure and low pressure compressor. In
generally used when the pressure ratio is very high. The ener
compress the air is proportional to the air temperature at inle
of compressed air in intercooler is generally done by water.
3. Regenerator:
Regenerators are used to preheat the air which is ente

combustion chamber to reduce the fuel consumption and t
efficiency. His is done by the heat of the hot exhaust gases co
turbine.
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4. Combustion
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Hot air from regenerator flows to the combustion chambers a n

c o al, natural g as or kero sene are in jected into th e combus
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Fig.1.3 Layout of Gas turbine power plant
5. Gas turbine
Two types of gas turbines are used in gas turbine plant.

1. High pressure turbine
2. Low pressure turbine
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1. High Pressure turbine
In the beg inning, the s tarting motor runs the com pressor sha f
burn t gases (p roduct of co mb ustion) expa nd through t he high pr
tu rbine. It is important to not ethat when the turbine shaf t rotates it
dr ives the comp re ssor shaft wh ich is couples to it. Now, t he high pr
turbine runs the compressor a nd the starting motor is stop ped. About
th e power developed by the t urbine is used t o run the co mpressor an
34% of the power developed is used to generate electric power.
2. Low pressure turbine
The purpose of the low pressure turbine is to produce electric p

The shaft of the LPT is coupled with the generator. The burnt fuel (
after leaving the HPT is again sent to a combustion chamber where it f
undergoes combustion.
Even if there is any left out unburnt fuel from the previous tur
gets fully burnt in the combustion chamber. The burnt gases run th
pressure turbine (LPT). The shaft of the turbine is directly coupled wi
generator for producing electricity.
The exhaust hot gases after leaving the LPT passes throu
regenerator before exhausted through the chimney into the atmospher
heat from the hot gases is used to preheat the air leaving the HPC be
enters the combustion chamber. This preheating of the air improv
efficiency of the combustion chamber.
6. Reheating unit
In this unit, the additional fuel is added to the exhaust gases c

out from the high pressure turbine, and the reheated combustion pr
goes into the low pressure turbine.
1.6.1 Working of Gas Turbine Power plant

The working of gas turbine plant is shown in fig.1.3. The atmo
air is drawn into the low pressure compressor through the air filter an
compressed.
The compressed low pressure air goes into the high p

compressor through the intercooler. Here, the heat of the compresse
removed. Then the high pressure compressed air goes into the comb
chamber through the regenerator. In the combustion chamber, the
added to the compressed air and the combustion of the fuel takes plac
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10
The product of the combustion goes into the high pressure turbin
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After the expansion in the low pressure turbine, the exhaust is u
heat the high pressure air coming to the combustion chamber throu
regenerator. After that, the exhaust goes to the atmosphere.
1.6.2..Advantages of Gas turbine power plant
1. For a gas turbine plant, Natural gas is a very suitable fuel. It wo

ideal to install gas turbine plants near the site where natural
readily available.
2. Gas turbine plants can work economically for short running hours
3. Storage of fuel requires less area and handling is easy.
4. Gas turbine plant is small and compact in size as compared to
power plants.
5. It can be started quickly and can be put on load in a very short ti
6. The cost of maintenance is less.
7. It is simple in construction. There is no need for boiler, condens
other accessories as in the case of steam power plants.
8. T arets can operate at high speed since there a

rehceiprgoacsatitnugrbpin
9. Cheaper fuel such as kerosene, paraffin, benzene and powder e
(cheaper than petrol and diesel) can be used.
10. Gas turbine plants can be used in water scarcity areas
11. Less pollution and less water is required.
1.6.3 Disadvantages of gas turbine power plant

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1 66% of the power developed is used to drive the compressor; t
turbine unit has a low thermal efficiency

2.
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running speed of the gas turbine is in the range Join
of (40, 00
00,000 rpm) and the operating temperature is as high as 2000
this reaso n special met al s and alloys have to be u se d for the v
parts of the turbine.
3. Special cooling methodsa re required for cooling the t urbine blad
4. It is difficultto start a gas turbine as co mpared to a diesel engi
diesel power plant
The life o f a gas turb ine plant is u pto 10 yea rs, after wh
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• To drive generators and supply loads in steam, diesel or hydro pl

• To work as combination plants with conventional steam boilers
• Thermal process industries
11
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