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Sinhgad Technical Education Society’s

Sinhgad College of Engineering,


Pune-41
Department of Mechanical Engineering
Power Plant Engineering

Practical File

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Sinhgad College of Engineering, Pune – 41

Department of Mechanical Engineering


Subject: PPE

Practical Plan

Practical
Topic Planned Dates Actual Dates
No.

01 Study of FBC system.

02 Study of High Pressure boilers.

03 Trial on steam power plant.

04 Trial on Diesel Power Plant.

05 Study of power plant instruments.

06 Study of Nuclear Power Plants.

07 Study of Environmental Impact of Power Plants.

Visit to thermal Power plant /Co-generation Power


08 plant or explain working of power plant by using
Suitable software.

Signature of Faculty Subject H.O.D. Principal


Co-ordinator Mechanical Engg. Dept. SCOE, pune

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List of Experiments

Term Work: Any Eight experiments of the following-


1) Visit to thermal Power plant /Co-generation Power plant or explain working of
power plant by using suitable software.
2) Visit to HEPP/GTPP/Non-Conventional Power Plants.
3) Study of FBC system.
4) Study of High Pressure boilers.
5) Trial on steam power plant.
6) Trial on Diesel Power Plant.
7) Study of power plant instruments.
8) Study of Nuclear Power Plants.
9) Study of Environmental Impact of Power Plants.
Reference Books
1. E.I.Wakil, ―Power Plant Engineering‖, McGraw Hill Publica ons New Delhi
2. P.K.Nag, ―Power Plant Engineering‖, McGraw Hill Publica ons New Delhi.
3. K K Ramalingam ,‖ Power Plant Engineering, SCITECH Publications Pvt Ltd.
4. Domkundwar & Arora, ―Power Plant Engineering‖, Dhanpat Rai & Sons, New
Delhi.
5. R.K.Rajput, ―Power Plant Engineering‖, Laxmi Publica ons New Delhi.
6. R.Yadav , ―Steam and Gas Turbines‖ ,Central Publishing House, Allahabad.
7. D.K.Chavan & G.K.Phatak, ―Power Plant Engineering‖, Standard Book House, New
Delhi.
8. G.D.Rai, ― Non-Conventional Energy Sources‖ Khanna Publishers,Delhi
9. S.P.Sukhatme, ―Solar Energy‖ Tata McGraw-Hill Publications, New Delhi

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Sinhgad College Of Engineering, Pune - 41
Department of Mechanical Engineering

Power Plant Engineering Laboratory

Term Work No: - 01

Study of “Fluidized Bed Combustion


Boilers”

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AIM:- Study of Fluidized Bed Combustion Boilers
THEORY:-
3.1 Introduction
When air is passed through a fixed or packed bed of particles, air simply percolates
through the interstitial gaps between the particles. As the air flow rate through the
bed is steadily increased, A point is eventually reached reached at which the
pressure drop across the bed becomes equal to weight of the particles per unit
cross-sectional area of the bed. This critical velocity is called the minimum
fluidization velocity, Umf, at which the bed is said to be incipiently fluidized. As the air
velocity is increased further, the particles are buoyed up and imparted a violently
turbulent fluid like motion, with the drag forces exerted by the fluid on the particles
exceeding their weight. There is high degree of particle mixing and equilibrium
between gas and particles is rapidly established. This is called a fluidized bed.
In Fig.1 air supplied by a centrifugal blower is passed through a perforated or porous
plate, called the distributor, and then a bed of particles of wide size distribution. The
air flow rate is regulated by a bypass valve along with a control valve, and it is
measured by a rotameter. Dividing the mass flow rate, so measured, by the product
of the bed cross sectional area and density of air, the superficial velocity of air, U, is
estimated. For each mass flow rate or superficial velocity, which is gradually
increased, the pressure drop across the bed is measured.

Fig. 1: Measurement of Umf and Ut of Fluidized Bed

Fig. 2 demonstrates the variation of bed pressure drop with superficial velocity. The
pressure drop ∆p varies with the superficial velocity linearly along AB till it
approaches W/At, where W is the weight of particles in the bed and At is the bed
crosses sectional area. This is the fixed bed regime. With further increase in air flow,
the particles are buoyed up by the drag force only to fall back into the bed yielding
high turbulence, with ∆p=W/At remaining constant. This continues till there is

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considerable pressure fluctuation and finally the superficial velocity reaches the
state C when particles start getting entrained in the air system, The superficial
velocity of air at which particle entrainment starts is called terminal velocity, Ut, of
the particles, The state of the bed in the range of superficial velocity from B to C, i.e.
between Umf and Ut is the fluidized bed regime. With further increase in velocity, the
entrained particles carried away, the weight of particles in the bed and so ∆p
decrease till it reaches the state D when all the particles are carried away, by the air
stream, bed becomes empty and ∆p zero.

Fig. 2: Variation of bed pressure drop with superficial velocity

i. Packed bed
A packed or fixed bed consists of a bed of stationary particles on perforated
grid through which a gas is flowing. The pressure drop per unit height of packed
bed of uniformly sized particles, ∆ /L, is given by Ergun’s equation.

ii. Bubbling fluidized bed


When the superficial velocity of gas flowing through a fixed bed reaches the
minimum fluidization velocity, Umf the fixed bed transfer into an incipiently fluidized

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bed and bed starts behaving as a liquid. Since the pressure across the bed is equal to
the weight of the bed.

iii. Slugging
If the bed is small in cross section and deep, the bubble may increase to a size
comparable to the diameter or width of the bed. The bubble then passes through
the bed as a slug. This is known as slugging and there is large fluctuation of pressure
drop across the bed which is unstable.

iv. Turbulent bed


As the velocity of gas through a bubbling fluidized bed is increased, the bed
expands, and a point is eventually reached when the emulsion walls become very
thin, the bubbles constantly collapse and re-form resulting in an active bed. The bed
surface is highly diffused and particles are thrown into the freeboard above. Such a
bed is called a turbulent bed. The pressure drop across the bed fluctuates rapidly.

v. Fast Fluidized bed


It is regime lying between the turbulent fluidized bed and pneumatic
transport. Following Basu and Fraser (1991), a fast fluidized bed may be defined as a
high-velocity gas-solid suspension where particles, elutriated by fluidizing gas above
the terminal velocity of single particles, are recovered and returned to the base of
the furnace at a rate sufficiently high as to cause a degree of solid refluxing that will

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ensure a minimum level of temperature uniformity in the furnace. The term “fast
bed” has become synonymous with the circulating fluidized bed.

.2 Fluidized Bed Boilers


Fluidized bed boilers produce steam from fossil and waste fuels by using a technique
called fluidized bed combustion which has been discussed above.
These can be of two types:
I. Bubbling fluidized bed (BFB) boilers
II. Circulating fluidized bed (CFB) boilers

In BFB crushed coal (6-20 mm) is injected into the fluidized bed of limestone just
above an air-distribution grid at the bottom of the bed (Fig. 3). The air flows upwards
through the grid from the air plenum into the bed, where the combustion of coal
occurs. The products of combustion leaving the bed contain large proportion of un-
burnt carbon particles which are collected in cyclone separator and fed back to the
bed. The boiler water tubes are in the furnace.

Fig. 3: Schematic of Bubbling Fluidized Bed Boiler

Since most of the sulphur in coal is retrained in the bed by the bed material used
(limestone), the gases can be cooled to a lower temperature before leaving the stack
with less formation of acid (H2SO4). As a result of low combustion temperatures
(800-900 ℃), inferior grades of coal can be used without slagging problems and
there is less formation of NO, Cheaper alloy materials can also be used, resulting in
economy of construction. Further economics are achieved since no pulverizer is
required. The volumetric heat release rates are 10 to 15 times higher and the surface
heat transfer rates are 2 to 3 higher than the conventional boiler. This makes the
boiler more compact.

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Fig. 4 shows a bubbling fluid bed boiler system operating at atmospheric pressure,
similar to the one of 160 MWe Tennessee Valley Authority (TVA) project at Shawnee,
USA, recently installed (1993).

Fig. 4: An atmospheric bubbling fluid bed boiler system

The CFB boiler is said to be second generation fluidized bed boiler (Fig 5). It is divided
into two sections. The first section consists of (a) furnace or fast fluidized bed, (b)
gas-solid separator (cyclone), (c) solid recycle device (loop seal or L-valve), and (d)
external heat exchanger (optional). These components from a solid circulation loop
in which fuel is burned. The furnace enclosure of CFB boiler is generally made of
water tubes as in pulverized coal fired (PC) boilers. A fraction of the generated heat
is absorbed by these heat transferring tubes. The second section is the back-pass,
where the remaining heat from the flue gas is absorbed by the reheater,
superheater, economizer, and air preheater surfaces (as in conventional PC boiler).
Coal is generally injected into the lower section of the furnace. Sometimes fed into
the loop-seal, from which it enters the furnace along returned hot solids, Limestone
is fed into the bed in a similar manner. Coal when mixed hot bed solids.
The primary combustion air enters furnace through an air distributor grate at the
furnace floor. The secondary air is injected at some height above grate to complete
the combustion. Bed solids are well mixed throughout the height of the furnace.
Thus, the bed temperature is nearly uniform in the 800-900℃, through heat is
extracted along its height. Relatively coarse par of sorbent (limestone) and unburned
char, larger than the cyclone cut-off are captured in the cyclone and are recycled

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back near the base of the furnace. Finer solid residues (ash and spent sorbents)
generated during combustion desulphurization leave the furnace, escaping through
the cyclones, but collected by a bag-house or electrostatic precipitator located
further downstream.

Fig. 5: An schematic of a Circulating Fluidized Bed Boiler


Advantages of CFB Boilers:
Circulating fluidized bed boilers have a number of unique: that makes them more
attractive than other solid fuel fired boilers as given below.
i. Fuel Flexibility: This one of the most attractive features of CFB boilers. Fuel particles
constitute less than 1-3% by weight of all solids in the furnace of typical CFB boilers.
The rest of the solids are non-combustible: sorbents (limestone or dolomite) and
fuel-ash. The special hydrodynamic condition in the CFB furnace allows an excellent
gas-solid and solid-solid mixing. Thus fuel particles fed to the furnace are quickly
dispersed into the large mass of bed solids , which rapidly heat the fuel particles
above their ignition temperature without any drop in the temperature of bed solids.
This feature of a CFB furnace allows it to burn any fuel without the support of an
auxiliary fuel.
ii. High combustion efficiency :
Superior mixing in the CFB , large reaction space (combustion zone extending up to
the top of the furnace , about 40m and above large utility boilers, and further
beyond into the hot cyclone) and consequently long residence time of combustion

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afford high combustion efficiencies which can be 99% for a wide variety of fuels
under different operating conditions.
iii. Efficient Sulphur removal :
When coal burns, sulphur is oxidized to sulphur dioxideS+O2=SO2+9260kJ/kg.Some
part of SO2 converted toSO3.This SO2 and SO3 if thrown out to atmosphere undergo
chemical reaction with moisture, catalyzed by sunlight to form acids.
Limestone and dolomite (CaCO3, MgCO3) are two principle sorbents used for the
absorption of S02 in fluidized bed combustors. For limestone directly fed into the CFB
furnace as bed material, there is calcination when the limestone is decomposed into
CaO and CO2 through an endothermic reaction. Good contact between the gas and
solid and long residence time in the CFB combustor afford better sulphur capture at
Ca/S ratio of 1.5 to 2.0.
iv. Low NOx emission :
Owing to low combustion temperature and the staged combustion process, NOx
emission in a CFB can be kept low, in the range of 50-150 ppm.
v. Small furnace cross section :
A high heat release rate per unit furnace cross-section (about 5MW/m2) is a major
advantage of CFB boiler. It results in less floor area. A high superficial velocity (4-7
m/s) along with, intense gas solid mixing promotes high heat release and heat
dispersion in the bed.

.3 Pressurized Fluidized Bed Boiler


The combustion process takes place in a pressurized environment resulting in a
compact furnace and improved combustion efficiency. There is situ sulphur capture
and low NOx generation with bed operating at about 850℃ like atmospheric
fluidized bed combustion. (AFBe) furnace. The process allows the use of a gas
turbine, driven by pressurized hot combustion gases. Thus, in addition to having the
ability to burn high sulphur and low grade coal in an environmentally acceptable
manner and the compactness of the steam generator.

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Fig6. Pressurized Fluidized Bed Boiler

The advantages of PBFBC are as follows:


i. There is increase in its specific power output and hence a potential reduction
in capital cost. At a typical fluidizing velocity of 2 m/s the bed area of AFBC at
1 bar is 2 m2/MW, while it is 0.2 m2/MW at 10 bars.
ii. By combining a gas turbine with a steam turbine, the overall efficiency of
power generation system can be increased from 33% for conventional power
plants to more than 40% in PBFBC plants.
iii. The emission of nitrogen oxides can be substantially reduced.
iv. The PBFBC has higher combustion efficiency than an AFBC.

v. The gas residence time in an AFBC is about 0.5 s, in a PBFBC (due to fluidizing
velocity of about 1 m/s for a higher gas density), Therefore, the sulphur
capture is more.

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Sinhgad College Of Engineering, Pune - 41
Department of Mechanical Engineering

Power Plant Engineering Laboratory

Term Work No: - 02

Study of “High Pressure Boilers”

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AIM: - Study of high pressure Boilers
THEORY:-
In all modern power plants, high pressure boilers (> 100 bar) are universally used as
they offer the following advantages. In order to obtain efficient operation and high
capacity, forced circulation of water through boiler tubes is found helpful. Some
special types of boilers operating at super critical pressures and using forced
circulations are described in this experiment.
1. The efficiency and the capacity of the plant can be increased as reduced quantity
of steam is required for the same power generation if high pressure steam is used.
2. The forced circulation of water through boiler tubes provides freedom in the
arrangement of furnace and water walls, in addition to the reduction in the heat
exchange area.
3. The tendency of scale formation is reduced due to high velocity of water.
4. The danger of overheating is reduced as all the parts are uniformly heated.
5. The differential expansion is reduced due to uniform temperature and this
reduces the possibility of gas and air leakages.
6. Some special types of high pressure supercritical boilers are described in this
experiment.

1. LA MONT BOILER
A forced circulation boiler was first introduced in 1925 by La Mont. The arrangement
of water circulation and different components are shown in Fig. 1 The feed water
from hot well is supplied to a storage and separating drum (boiler) through the
economizer. Most of the sensible heat is supplied to the feed water passing through
the economizer. A pump circulates the water at a rate 8 to 10 times the mass of
steam evaporated. This water is circulated through the evaporator tubes and the
part of the vapour is separated in the separator drum. The large quantity of water
circulated (10 times that of evaporation) prevents the tubes from being overheated.

The centrifugal pump delivers the water to the headers at a pressure of 2.5 bar
above the drum pressure. The distribution headers distribute the water through the
nozzle into the evaporator. The steam separated in the boiler is further passed
through the super-heater. Secure a uniform flow of feed water through each of the
parallel boiler circuits a choke is fitted entrance to each circuit. These boilers have
been built to generate 45 to 50 tonnes of superheated steam at a pressure of 120
bar and temperature of 500°C. Recently forced circulation has been introduced in
large capacity power.

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Fig.1 LA MONT BOILER

2. BENSON BOILER
The main difficulty experienced in the La Mont boiler is the formation and
attachment of bubbles on the inner surfaces of the heating tubes. The attached
bubbles reduce the heat flow and steam generation as it offers higher thermal
resistance compared to water film
1. Benson in 1922 argued that if the boiler pressure was raised to critical
pressure (225 atm.), the steam and water would have the same density and
therefore the danger of bubble formation can be completely
2. Natural circulation boilers require expansion joints but these are not required
for Benson as the pipes are welded. The erection of Benson boiler is easier and
quicker as all the parts are welded at site and workshop job of tube expansion is
altogether avoided.
3. The transport of Benson boiler parts is easy as no drums are required and
majority of the parts are carried to the site without pre-assembly.
4. The Benson boiler can be erected in a comparatively smaller floor area. The
space problem does not control the size of Benson boiler used.
5. The furnace walls of the boiler can be more efficiently protected by using
small diameter and close pitched tubes.
6. The superheater in the Benson boiler is an integral part of forced circulation
system, therefore no special starting arrangement for superheater is required.
7. The Benson boiler can be started very quickly because of welded joints.
8. The Benson boiler can be operated most economically by varying the
temperature and pressure at partial loads and overloads. The desired
temperature can also be maintained constant at any pressure.
9. Sudden fall of demand creates circulation problems due to bubble formation
in the natural circulation boiler which never occurs in Benson boiler. This feature

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of insensitiveness to load fluctuations makes it more suitable for grid power
station as it has better adaptive capacity to meet sudden load fluctuations.
10. The blow-down losses of Benson boiler are hardly 4% of natural circulation
boilers of same capacity.
11. Explosion hazards are not at all severe as it consists of only tubes of small
diameter and has very little storage capacity compared to drum type boiler.
During starting, the water is passed through the economiser, evaporator,
superheater and back to the feed line via starting valve A. During starting the valve B
is closed. As the steam generation starts and it becomes superheated, the valve A is
closed and the valve B is opened. During starting, first circulating pumps are started
and then the burners are started to avoid the overheating of evaporator and
superheater tubes.

3. LOEFFLER BOILER

The major difficulty experienced in Benson boiler is the deposition of salt and
sediment on the inner surfaces of the water tubes. The deposition reduced the heat
transfer and ultimately the generating capacity. This further increased the danger of
overheating the tubes due to salt deposition as it has high thermal resistance.
The difficulty was solved in Loeffler boiler by preventing the flow of water into the
boiler tubes. Most of the steam is generated outside from the feedwater using part
of the superheated steam coming out from the boiler. The pressure feed pump
draws the water through the economiser and delivers it into the evaporator drum as
shown in the figure. About 65% of the steam coming out of superheater is passed

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through the evaporator drum in order to evaporate the feed water coming from
economiser. The steam circulating pump draws the saturated steam from the
evaporator drum and is passed through the radiant superheater and then connective
superheater. About 35% of the steam coming out from the superheater is supplied
to the H.P. steam turbine. The steam coming out from H.P. turbine is passed through
reheater before supplying to L.P. turbine as shown in the figure.
The amount of steam generated in the evaporator drum is equal to the steam
tapped (65%) from the superheater. The nozzles which distribute the superheated
steam through the water into the evaporator drum are of special design to avoid
priming and noise.
This boiler can carry higher salt concentration than any other type and is more
compact than indirectly heated boilers having natural circulation. These qualities fit
it for land or sea transport power generation. Loeffler boilers with generating
capacity of 94.5 tonnes/hr and operating at 140 bar have already been
commissioned.

Fig. 3 Loeffler Boiler

4. Ones through boiler

Boilers can be designed to operate at pressures above the critical pressure (221.2
bar). No drum is necessary in such boilers since no separation of the water and
steam occurs, the two being at the same density.

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2- Steam Separator

3- Boiler Feed Pump

5- Economiser

6-Evaporator

7- Superheater

Fig. 4 Ones through boiler


Thus, there is no circulation. The water enters the bottom of the tubes and is
completely transformed to steam by the time it reaches the top, passing through the
tubes only ones. For this reason it is known as a ones-through boiler, often referred
to as drumless boiler.

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Sinhgad College Of Engineering, Pune - 41
Department of Mechanical Engineering

Power Plant Engineering Laboratory

Term Work No: - 03

Trial on “Steam Power Plant”

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TITLE: Trial on steam power plant
AIM: To conduct a trial on steam power plant and determine the Optimum Point
Load

THEORY:

5.1 Introduction:

Steam power plants are the most common source of electrical energy in the world
today. They also find use as captive power plants in various industries and co-
generation power plants. Steam power plants work on the Rankine cycle with
modified superheating and regenerative feed heating. Operating pressure ranges
from 30 bar to 180 bar and can occasionally peak at 240 bar. Temperature ranges
from 450°C to 585°C. Thermal power plants use a condensing turbine while those
meant for captive power plants use a non-condensing turbine as well. Plant capacity
ranges from 5 MW to 500 MW. Steam power plants can use a wide range of fuels
such as coal (crushed or pulverized), oil, natural gas, waste gas at high temperature,
industrial waste fuels of furnace oils and LSHS. These days, waste heat recovery
plants are becoming very popular because of their reduced fuel consumption and
are finding use in steel, cement, soda-ash industries, etc. Steam plants are also used
as bottoming plants in combined cycle power plants with gas turbine plants as
topping power plants.

5.2 Description of the Laboratory Steam Plant:

The boiler consists of two helical coils through which water, under pressure, flows.
The feed water pump pumps water from the exit of the economizer to the lower end
of the water tubes. When flowing through the tubes, feed water is directly flashed
into steam and is collected in the common header, which is placed at the top of the
boiler. Steam is generally wet and hence moisture needs to be separated at the exit.
Moisture separator and steam traps are provided in the steam line to supply dry
steam to the turbine. The boiler works on high speed diesel (HSD) oil, which is stored
in an overhead tank. It is supplied to the burner by a gear pump under a constant
pressure for proper atomization.

High temperature gas generated in the furnace flows from the top of the boiler to
the bottom through the inner core of the tube. They are then deflected upward from
the outer side of the tube and enter the economiser where it preheats feed water
and then leaves the boiler through the chimney.

In the steam line, steam flow meter and separating and throttling calorimeters are
provided to find the steam flow and dryness fraction of the steam. A separate
pressure gauge near the turbine gives the steam pressure.

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Steam turbine is a re-entry type impulse turbine with single disc i.e. it is a two-stage
velocity compounded steam turbine with hemispherical buckets. To keep the turbine
speed constant, pressure of the incoming steam is governed by a centrifugal
governor. The output of the turbine is used to drive a single phase alternator, which
supplies constant load to the lamp bank and variable water load.

1 Stack 8 To separating and Throttling calorimeter


2 Water Tank 9 Load Bank
3 Economizer 10 Generator Set
4 Feed Water Pump 11 Steam Turbine
(reciprocating)
5 Main body of Boiler 12 Economizer
6 Fuel Injector with Burner 13 Fuel Pump (gear pump)
7 FCV 14 Flexible Coupling

Fig. 1 Schematic of Diesel power plant

Steam passes through the condenser where it is condensed by cooling water. The
turbine can be operated in condensing and non-condensing modes. The condensate
is sent to the supply water tank of the boiler.

5.3 Plant Specification:


 Boiler
1. Manufacturer : 3M Boilers Pvt. Ltd., Pune
2. Working Pressure : 15 bar
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3. Evaporation Rate : 800 kg/hr (wet steam)
4. Fuel Used : High Speed Diesel (HSD) Oil, LDO, FO
5. Type : Non-IBR, Water Tube, Package Type
 Turbine Generator Set
1. Output : 6 KVA
2. Voltage : 230 V, Single Phase, 50 Hz
3. Speed : 3000 rpm
5.4 Procedure:

1. Open the cocks on the fuel tank and water tank and switch on the supply
through the panel mounted on the boiler.
2. Put the main switch in ‘CIRL’ position, so that the feed pump starts pumping
water through the boiler tubes and pumps out air trapped in the tubes
through the air valve on the top of the boiler.
3. Put the switch on the ‘AUTO’ mode, which will start the blower and fuel
pump. The burner will be immediately fired by a spark plug.
4. Observe the steam coming out of the vent in about one minute.
5. Slowly close the valve on the vent pipe, when temperature reaches 192°C.
Allow the turbine to increase speed. This will cause the lamps in the control
panel to glow. The lamp-bank remains on the turbine through out to the
control panel, since there is no emergency trip on the turbine.
6. Adjust the depth of immersion of the electrode in the water loading system
to give the required load current, such as 5 A, and record all the readings,
once the system reaches steady state.
7. After the test is over, slowly remove the load and simultaneously close the
steam stop valve, so that the turbine slows down.
8. Open the valve on the vent pipe and allow the boiler steam to discharge to
the atmosphere.
9. Put the selector control switch to ‘CIRL’ and let water circulate through the
boiler tube. Observe this for about five minutes, by which time, the boiler will
cool down. Switch off the main supply and close all cocks and valves except
for the vent pipes.
10. Clean the unit.

5.5 Observations:
1. Barometric Reading (Pa) = 1 bar
2. Room temperature (Ta) = °C
3. Diameter of the Orifice = 24 mm
4. Rate of Fuel Firing = 60 lph

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5. Density of Fuel (ρ) = 0.83 kg/l
6. Calorific Value of Fuel = 42,500 kJ/kg
7. Feed-water Temperature (ti) = °C

5.5.1 Observation Table:


Sr
Description 1 2 3 4
No
1. Steam pressure at boiler valve (P1) (kg/cm2)
Temperature of steam at boiler steam stop
2.
valve (t1) (°C)
3. Pressure difference at orifice (ΔP) (kg/cm2)
Time for collecting 100 cc water in separating
4.
calorimeter (T2) (s)
Temperature of water in separating
5.
calorimeter (t2) (°C)
Time for collecting 1000 cc water in throttling
6.
calorimeter (T3) (s)
Temperature of water in throttling
7.
calorimeter (t3) (°C)
Pressure of steam before throttling (P3)
8.
(kg/cm2)
9. Temperature of steam after throttling (t4) (°C)

10. Pressure of steam near turbine (P4) (kg/cm2)

11. Turbine speed (N) (rpm)

12. Generator voltage (V) (volts)

13. Load Current (I) (Amps)


Time for boiler operation out of 5 minutes (T1)
14.
(s)
15. Load (W)

5.6 Sample Calculations:

1. Steam pressure at boiler (P1):


P1(abs) = P1(gauge) + Pa
=
P1(abs) =

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2. Absolute Pressure before throttling (P3):
P3(abs) = P3(gauge) + Pa
=
P3(abs) =

3. Pressure at turbine inlet (P4):


P4(abs) = P4(gauge) + Pa
=
P4(abs) =

4. Pressure of steam at orifice-meter (P2):


P1(abs) + P4(abs)
P2(abs) = 2
=
P2(abs) =

5. Fuel fired in boiler for 5 min load duration (mf):


( )× ×ρ
=
=
=

6. Thermal energy supplied to boiler during 5 min load duration (QS):


QS = mf x C.V.
=
QS =

7. Rate of heat supplied (I):


QS × 3600
I = 5 × 60
=
I =

8. Plant output (electrical) (Le):


Le = Le(const) + Le(variable)
V.I
= + 1000
=
Le =

9. Plant efficiency (ηp):

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×
ηp = × 100
=
ηp =

10. Heat Rate ( HR):


I
HR = Le
=
HR =

Incremental heat rate (IHR) = dI/dL


IHR is found from graph of I vs L by measuring the slope of the
tangent at the given load.

5.7 Result Table:


Sr
Plant Performance Parameter 1 2 3 4
No
1. Plant Load (kW)
2. Plant Input (kJ/hr)
3. Plant efficiency (%)
4. Heat Rate (kJ/kW-hr) (×103)
5. IHR (kJ/kW-hr) (×103)

5.8 Conclusions:

The graph of IHR and HR vs Load indicates that the optimum loading point
occurs at KW.

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Graphical Analysis

Load kW

26
Sinhgad College Of Engineering, Pune - 41
Department of Mechanical Engineering

Power Plant Engineering Laboratory

Term Work No: - 04

Study of “Trial on Diesel Power


Plant”

TITLE: Trial on Diesel Power Plant

27
AIM: To conduct a trial on diesel power plant and to determine the operating
parameters and economical load of the plant.
THEORY:
4.1 Introduction:
Diesel power plants have the advantages over other types of power plants that they
don’t need any warming time and don’t need to be run for a very long time before
loading. There are no standby losses, like those in steam power plants. Diesel power
plants are used in applications where fuel costs are low, water supply is limited and
plant capacity is less (5 to 10 MW).
4.1.1 Advantages of Diesel Power Plants over Thermal Power Plants:
1. Diesel power plants are more efficient than thermal power plants for
lower capacity plants.
2. Diesel power plants can run on a wide range of fuels such as HSD, LSD,
FO, HFO and LHSH and can also use natural gas.
3. Low initial cost.
4. Quick starting.
5. Easy to maintain.
6. Compact.
7. Can be installed.
8. No ash handling system required.
9. Simple lubrication system required.
10. High efficiency.
4.1.2 Disadvantages
1. These plants have lower capacity than thermal power plants.
2. Higher repair costs.
3. Diesel power plant has shorter life.
4. They produce excessive noise.
5. High lubricating oil consumption.
6. These plants are not suitable for long control operations.
4.1.3 Applications
1. Central Power plant
Power generation capacity of diesel power plants is limited to 50 to 100 MW. This
capacity depends upon the economics of cost of the plant and load conditions.
2. Standby Plant
Diesel power plants are used as standby plant to supply a part of the load in
power station when required. e.g. if hydroelectric power plant is a main source of
electricity and water supply falls, a diesel power plant is used temporarily in
parallel with hydroelectric power plant.

28
3. Peak Load Plant
Diesel power plants are used for meeting peak load requirement, while base load
is supplied by a thermal of hydroelectric power plant. Diesel power plants are
ideally suited to this application because they can be started to meet the required
load.
4. Emergency Plant
Diesel power plants are also used as emergency plants to meet the power
requirement when main power plant fails.
5. Nursery station
Whenever smaller power plants are to be setup, diesel power plants are the
most suitable since generation period is smaller. These small capacity plants are
called nursery stations.
6. Setup Plants
Diesel power plants are used as auxiliary power plants for starting large plants.
7. Mobile Plants
Mobile diesel power plants, usually trailer mounted, can be used for a wide range
of applications, supplying power to construction sites etc.
4.2 Experimental Setup
The setup consists of 5HP diesel engine which is mounted on a foundation. Water is
circulated through a water jacket for cooling the plant. Water is also provided to the
exhaust gas calorimeter. The engine is connected to a single phase ac generator by
means of a coupling. Electricity thus generated is supplied to load bank.
4.2.1 Specifications:
Engine:
1. Make : Kirloskar Oil Engines
2. Type : Single cylinder, vertically mounted
3. Speed : 1500 rpm
4. Bore*Stroke : 90 mm * 110 mm
5. Power : 5 HP (3.75 kW)
Generator:
1. Type: Electric generator
2. Capacity: 5kVA, 50Hz, 230 at 1500 rpm.
4.2.2 Test Setup:
An electric load bank consists six 500W bulbs and five 100W bulbs with digital
voltmeter, ammeter, shell and tube exhaust calorimeter, air box with an orifice and
digital gas calorimeter at various points with thermocouple.

29
4.2.3 Procedure:
1. Ensure that there is sufficient fuel in the tank.
2. Starts the water tap to supply water to the engine and the exhaust gas
calorimeter.
3. Switch on the AC supply.
4. Note all reading.
5. Gradually load the engine by turning on the bulbs one by one.
6. Repeat the above procedure for different values of load.
7. To stop the engine, first unload the engine and then pull the stop lever.
4.2.4 Observations:
1. Density of fuel(ρ) : 0.83kg/ltr
2. Calorific value of fuel : 42500kJ/kg

Speed Voltage Current Load Time for 10 ml Exhaust gas


(rpm) V (volts) I (Amp) (kW) of Fuel ‘t’ (sec) temp. (℃)

4.2.5 Calculations
1. Power output from engine (Load) (L) = V×I =
2. Fuel Consumption(mf) = × ρ × 10 =
( )
3. Plant efficiency (η) = =
× .
4. Brake Specific Fuel Consumption (B.S.F.C) = mf × =
. ( )

30
5. Plant input (I) = mf × C. V. =
6. Heat rate (HR) = =

7. Incremental heat rate ( )=∆ =

4.2.6 Result Table

Fuel flow Plant Plant I/P H.R. I. H. R.


Load L B.S.F.C
rate (mf × efficiency (I) kJ/hr kJ/kW-hr (kJ/kw-
(W) (kg/kw-hr)
103) (kg/s) ɳ (%) 103 ×103 hr) × 103

4.3 Conclusions
1. From the graph of mass flow rate Vs load, it is observed that as load
increases engine has to produce more work.
2. The graph of BSFC Vs load shows a dropping nature. BSFC decreases with
load because higher fuel is consumed more efficiently.
3. Brake thermal efficiency increases with load. Graph of IHR & HR Vs load
indicated optimum loading point occurs at __________.

31
Graphical Analysis

Load kW

32
Sinhgad College Of Engineering, Pune - 41
Department of Mechanical Engineering

Power Plant Engineering Laboratory

Term Work No: - 05

Study of “Power Plant Instruments”

33
TITLE: Study of power plant instruments

THEORY:

In the power plants instruments are used for a number of reasons as to operate the
power plant as efficiently as possible. Instruments provide accurate information for
guidance to safe, continuous and proper plant operation.

6.1 Classification of instruments

The two general classifications of instruments are:


1. Those employing purely mechanical methods
2. Those employing electromechanical methods

With the increase in automation electronics is being used more widely in the field of
instruments. Remote control has become an established practice in power plant
engineering and especially in nuclear power station where the complete instrument
is watched and controlled from a distance. Hence the importance of instrumentation
in power plant engineering has increased.

The instruments can also be classified as follows:


1. Indicating instruments
2. Recording instruments
3. Indicating and recording instruments
4. Indicating and integrating instruments
5. Indicating, recording and integrating instruments

Commonly used instruments in a power plant:


1. Pressure gauges
2. Thermometers
3. Liquid level gauges
4. Flow meters(steam and gas)
5. PH measuring instruments
6. Gas analyzers
7. Humidity measuring instruments
8. Impurity measuring instruments
9. Stem calorimeters and fuel calorimeters
10. Speed measuring instruments
11. Gong alarms
12. Electrical instruments
(i) Ammeters (ii) Voltmeters
(iii) Watt meters (iv) Power factor meters
(v) Reactive volt ampere meters (vi) Ground detectors
6.2 Control board equipment

34
The control room or the operating room is the nerve center of power station. The
various controls located in it are: circuit breakers, load and voltage adjustments,
transformer tap changing, emergency tripping of turbines, instruments for indicating
the load, voltage, frequency, power factor, winding temperatures and water levels in
the case of hydro stations, synchronizing equipments, voltage regulators, relays,
integrating meter and other appliances, as well as mimic diagram and suitable
indicating equipment to show the open or closed positions of circuit breakers,
isolators etc . In the era of digital, each information appears on the computer screen.

The location of the room in relation to the other sections of the station is of
importance and suitable position should be obtained. It should be located away from
the sources of noise and it should be near the switch house to shorten the lengths of
the multi-core cables. The control room should not be affected in the case of any fire
in switch house. There should be access from the control room to the turbine house.
The various locations of the control room relative to the other sections of the plant
are shown in Fig I. The control room should be clean, comfortable, well ventilated,
well lighted and free from draughts.

6.3 Mechanical instruments

1. Temperature measurement:

a) Glass tube mercury thermometers: These are used for installation in the
thermometer well in the flow lines, measuring temperature of condensate,
circulating water, feed water, bearing oil etc. They are necessarily local
reading but are often installed as a check on remote reading bulb and tube
thermometers.
b) Gas filled bulb and tube thermometer: These are used to measure the
temperature of gases or liquid up to 540°C and indicate or record same at
point as far distant as 100 m from the location of the bulb.
c) Vapor pressure thermometer: These are used to measure temperature up to
260°C. It contains of a bulb partially filled with a liquid connected to the
length of tubing. It has less power plant applications than gas filled type.
d) Electrical resistance thermometer: These are used for accurate
measurement of feed water and condensate temperatures and for
measurement of temperature of winding of electric machines.
e) Thermocouple, thermometer or pyrometer: The thermocouple is used to
measure high-range temperatures such as furnace, flue gases, preheated air
or superheated air or superheated steam temperatures.

2. Pressure measurement:

35
a) Standard, Bourdon tube type, steam pressure gauge: These are extensively
used for measuring the pressure of moderate and high pressure steam.
Remote indicating or recording type may be placed on panel boards but
primary information is always taken from standard short lead gauge mounted
on boiler itself.
b) Helical tube or diaphragm type low steam pressure gauge: Such gauges are
used to measure bleeder steam pressures etc.
c) Vacuum gauges and manometers: These are used to measure condenser
vacuum and heater pressures.
d) Draft gauges (inclined glass tube, diaphragm and liquid-sealed bell types):
The draft gauge is employed to obtain and maintain the best furnace
conditions, to check the condition of boiler setting the flues. These also
measure the performance of draft fans and chimneys.
e) Miscellaneous pressure gauges on oil, air and water lines.

3. Flow measurement:

a) Steam flow meters: The steam flow meter is used to measure individual
boiler output, group boiler output, turbine supply, auxiliary steam and
industrial steam.
b) Water flow meters: Measure condensate, feed water, pump discharge etc.
c) Air flow meters: They are generally used in the form of a differential draft
gauge. Air flow is metered only occasionally outside of the ‘gas loop’.

4. Fuel measurement:

a) Coal: Coal is usually weighed in batches although belt conveyer weighers and
some pulverized coal weighers are continuous. Chain grate strokes may be
equipped with continuous coal volume measuring meters.
b) Gas meters: These are either the positive displacement or differential head
type.
c) Oil meters: Positive displacement type.

5. Gas analysis:

Orsat apparatus and CO2 or O2 instruments: The types of CO2 meters in present
use employ one of the following principles:

a) Chemical: modification of the Orsat apparatus.


b) Electrical: Based on the measurement of conductivity of flue gases.
c) Mechanical: Flue gas density balanced against air.

36
CO2 meters are instruments for measuring smoke density.
6. Speed measurement:

a) Vibrating reed tachometer


b) Electrical tachometer
c) Clock type tachometer
d) Centrifugal tachometer
e) Stroboscope
f) Revolution counter

Tachometers are used to gauge the turbine speed, also the speed of some larger
plant auxiliaries.

7. Level recorders:
Liquid level in the boilers, tank, canals, coal level in pulverized coal bin.

8. Gong alarms:
Gong alarms with or without annunciators are used to give warning of high
generator or transformer coil temperatures, generator cooling air temperature,
lubricating oil temperature of high water in the hot well or of low water in the
boiler feed tank. The annunciator system is usually mounted on main switch or panel
board.

9. Calorimeters, steam and fuel:


These are not ordinary used for operating supervision or guidance but are put in
service during the course of special test. However their use necessitates inclusion of
proper fitting to which they may be connected when in use.

10. Atmospheric measurements:


Barometer, hygrometer, thermometer.

11. Electrical instruments

a) Ammeters: Ammeters are used in generator leads, feeder circuits, auxiliary


power circuits and field circuits
b) Voltmeters: They are used to maintain proper voltage, check automatic
voltage regulators, synchronized and with proper connection, detect
grounds.
c) Wattmeters: Show power in generator or feeder circuit.
d) Synchroscope: Used to parallel alternators.
e) Reactive volt ampere meters
f) Ground detectors

37
Sinhgad College Of Engineering, Pune - 41
Department of Mechanical Engineering

Power Plant Engineering Laboratory

Term Work No: - 06

Study of “Study of Nuclear Power


Plants”

38
Introduction:
There is strategic as well as economic necessity for nuclear power in the United States
and indeed most of the world. The strategic importance lies primarily in the fact that
one large nuclear power plant saves more than 50,000 barrels of oil per day. At $30 to
$40 per barrel (1982), such a power plant would pay for its capital cost in a few short
years. For those countries that now rely on but do not have oil, or must reduce the
importation of foreign oil, these strategic and economic advantages are obvious.
For those countries that are oil exporters, nuclear power represents an insurance
against the day when oil is depleted. A modest start now will assure that they would
not be left behind when the time comes to have to use nuclear technology.
The unit costs per kilowatt-hour for nuclear energy are now comparable to or lower
than the unit costs for coal in most parts of the world. Other advantages are the lack of
environmental problems that are associated with coal or oil-fired power plants and the
near absence of issues of mine safety, labor problems, and transportation bottle-necks.
Natural gas is a good, relatively clean-burning fuel, but it has some availability
problems in many countries and should, in any case, be conserved for small-scale
industrial and domestic uses. Thus nuclear power is bound to become the social
choice relative to other societal risks and overall health and safety risks.

GENERAL HISTORY AND TRENDS


 MAJOR EVENTS
1945 : “Nuclear energy emerged from scientific obscurity and military secrecy.”
1945-55 : “An enthusiastic vision developed of a future in which nuclear power
would provide a virtually unlimited solution for the world’s energy needs.”
1955-73 : The pros and cons of nuclear energy were debated; however, the optimists
prevailed and nuclear energy grew to become an important source of electricity.
Pros : Abundant, clean, and cheap energy. (We now know nuclear energy is not
cheap.)
Cons : Large amounts of radioactivity are produced in the nuclear reactor, mishaps
cannot be totally ruled out, and nuclear energy cannot be divorced from nuclear
weapons. (Also, the long-term
storage of nuclear wastes is now a very important issue.)
1955-65 : Many reactors designed, built, and put into operation.
1965-73 : Most of the US reactors were ordered during this period.
39
1973-85 : Many US reactors cancelled during this period.
1970-90 : Most US reactors licensed to operate during this period.
1990-present : The number of nuclear reactors operating in the US and in the world
levelled off, reaching a plateau. Few new reactors ordered and built.

10.4 SUMMARY OF NUCLEAR ENERGY CONCEPTS AND TERMS


 SUMMARY OF FEATURES
1. Heat energy source is fission of radioactive material, (U-235)
2. Two typical plant designs:
Pressurized water reactor (PWR) (U.S.)
Boiling water reactor (BWR) (Russian)
3. Fuel pellets are in a large number of tubes (fuel rods)
4. Water circulates through core
5. Water converted to steam drives turbine
6. Turbine turns generator → electricity

NUCLEAR REACTOR
 PARTS OF A NUCLEAR REACTOR
A nuclear reactor is an apparatus in which heat is produced due to nuclear fission
chain reaction.
Fig. 10.6 shows the various parts of reactor, which are as follows :
1. Nuclear Fuel
2. Moderator
3. Control Rods
4. Reflector
5. Reactors Vessel
6. Biological Shielding
7. Coolant.
Fig. 10.6 shows a schematic diagram of nuclear reactor

40
NUCLEAR FUEL
Fuel of a nuclear reactor should be fissionable material which can be defined as an
element or isotope whose nuclei can be caused to undergo nuclear fission by nuclear
bombardment and to produce a fission chain reaction. It can be one or all of the
following U233, U235 and Pu239.
Natural uranium found in earth crust contains three isotopes namely U234, U235 and
U238 and their average percentage is as follows :
U238 — 99.3%
U235 — 0.7%
U234 — Trace
Out of these U235 is most unstable and is capable of sustaining chain reaction and has
been given the name as primary fuel. U233 arid Pu239 are artificially produced from
Th232 and U238 respectively and are called secondary fuel. Pu239 and U233 so
produced can be fissioned by thermal neutrons. Nuclear fuel should not be expensive
to fabricate. It should be able to operate at high temperatures and should be resistant
to radiation damage.

MODERATOR
In the chain reaction the neutrons produced are fast moving neutrons. These fast
moving neutrons are far less effective in causing the fission of U235 and try to escape
from the reactor. To improve the utilization of these neutrons their speed is reduced. It
is done by colliding them with the nuclei of other material which is lighter, does not
capture the neutrons but scatters them. Each such collision causes loss of energy, and

41
the speed of the fast moving neutrons is reduced. Such material is called Moderator.
The slow neutrons (Thermal Neutrons) so produced are easily captured by the nuclear
fuel and the chain reaction proceeds smoothly. Graphite, heavy water and beryllium
are generally used as moderator.
Reactors using enriched uranium do not require moderator. But enriched uranium is
costly due to processing needed.
A moderator should process the following properties :
1. It should have high thermal conductivity.
2. It should be available in large quantities in pure form.
3. It should have high melting point in case of solid moderators and low melting point
in case of liquid moderators. Solid moderators should also possess good strength and
machinability.
4. It should provide good resistance to corrosion.
5. It should be stable under heat and radiation.
6. It should be able to slow down neutrons.

Control Rods. The Control and operation of a nuclear reactor is quite different frorn
a fossil and fuelled (coal or oil fired) furnace. The furnace is fed continuously and the
heat energy in the furnace is controlled by regulating the fuel feed, and the
combustion air whereas a nuclear reactor contains as much fuel as is sufficient to
operate a large power plant for some months. The consumption of this fuel and the
power level of the reactor depends upon its neutron flux in the reactor core. The
energy produced in the reactor due to fission of nuclear fuel during chain reaction is
so much that if it is not controlled properly the entire core and surrounding structure
may melt and radioactive fission products may come out of the reactor thus making it
uninhabitable. This implies that we should have some means to control the power of
reactor. This is done by means of control rods.
Control rods in the cylindrical or sheet form are made of boron or cadmium. These
rods can be moved in and out of the holes in the reactor core assembly. Their insertion
absorbs more neutrons and damps down the reaction and their withdrawal absorbs less
neutrons. Thus power of reaction is controlled by shifting control rods which may be
done manually or automatically.
Control rods should possess the following properties :
1. They should have adequate heat transfer properties.

42
2. They should be stable under heat and radiation.
3. They should be corrosion resistant.
4. They should be sufficient strong and should be able to shut down the reactor almost
instantly under all conditions.They should have sufficient cross-sectional area for the
absorption.
REFLECTOR

The neutrons produced during the fission process will be partly absorbed by the fuel
rods,

 moderator, coolant or structural material etc. Neutrons left unabsorbed will try to
leave the reactor core
 never to return to it and will be lost. Such losses should be minimized. It is done
by surrounding the
 reactor core by a material called reflector which will send the neutrons back into
the core. The returned
 neutrons can then cause more fission and improve the neutrons economy of' the
reactor. Generally the
 reflector is made up of graphite and beryllium.

REACTOR VESSEL
It is a. strong walled container housing the cure of the power reactor. It contains
moderator, reflector, thermal shielding and control rods.

ADVANTAGES OF NUCLEAR POWER PLANT


The various advantages of a nuclear power plant are as follows:
1. Space requirement of a nuclear power plant is less as compared to other
conventional power plants are of equal size.
2. A nuclear power plant consumes very small quantity of fuel. Thus fuel
transportation cost is less and large fuel storage facilities are not needed Further the
nuclear power plants will conserve the fossil fuels (coal, oil, gas etc.) for other energy
need.
3. There is increased reliability of operation.
4. Nuclear power plants are not effected by adverse weather conditions.

43
5. Nuclear power plants are well suited to meet large power demands. They give
better performance at higher load factors (80 to 90%).
6. Materials expenditure on metal structures, piping, storage mechanisms are much
lower for a nuclear power plant than a coal burning power plant.

DISADVANTAGES
1. Initial cost of nuclear power plant is higher as compared to hydro or steam power
plant.
2. Nuclear power plants are not well suited for varying load conditions.
3. Radioactive wastes if not disposed carefully may have bad effect on the health of
workers and other population. In a nuclear power plant the major problem faced is the
disposal of highly radioactive waste in form of liquid, solid and gas without any
injury to the atmosphere. The preservation of waste for a long time creates lot of
difficulties and requires huge capital.
4. Maintenance cost of the plant is high.
5. It requires trained personnel to handle nuclear power plants.

***

44
Sinhgad College Of Engineering, Pune - 41
Department of Mechanical Engineering

Power Plant Engineering Laboratory

Term Work No: - 07

Study of “Environmental Impact of


Power Plant”

45
AIM: - Study of Environmental Impact of Power Plant
THEORY:-
7.1 Pollutants from Power Plants:
Various types of pollutants released by various power plants are summarised
in below Table:
Table: Production of pollutants and effects of various pollutants
Pollutant Cause Effect
Incomplete combustion Headache, nausea, breathlessness,
CO
of fuel reduced O2 carrying capacity to lungs
Unburnt HC in lean and
HC Irritation in respiratory system
rich mixtures
Combustion at
Irritation to eyes nose and throat,
NOx temperature more
damage to lungs, smog formation
than 1000oC
Soot Unburnt solid C Lung cancer
Suffocation, irritation of throat and eyes,
SO2 and lung cancer, destruction of crops,
Burning of S in fuel
H2S reduced vegetation, corrosion of metal
parts
Suspended
Particulate Respiratory system, soiling and corrosion
Burning of fossil fuels
matter of metal parts
(SPMs)
CO2 Combustion of fuel Global warming, flooding of coastal areas
The various pollutants emitted by respective power plant is given below:

7.1.1. From fossil fuel power plants:


a) Sulphur dioxide (SO2) and H2S
b) Oxides of Nitrogen like Nitric Oxide (NO), Nitrous Oxide (N2O), Nitrogen
Dioxide (NO2), Nitrogen Trioxide (NO3) etc. All these oxides of nitrogen are
commonly referred as NOx emission, pronounced as NOX.
c) Particulate matter
d) Thermal pollution
e) Carbon dioxide (CO2)
7.1.2. Diesel Power Plants:
a) Carbon monoxide (CO)
46
b) Unburned hydrocarbons (HC)
c) NOx
d) Aldehyde and other emissions like H2S and SO2
e) Smoke and particulate
f) CO2

7.1.3. Gas Turbine Power Plants:


a) SO2
b) Unburned hydrocarbons (HC)
c) NOx
d) CO2
7.1.4. Nuclear Power Plants:
a) Radioactivity release
b) Radioactive waste
c) Thermal pollution
7.1.5. Hydroelectric and Solar Power Plants:
These are basically non-polluting type power plants.

7.2 Acid Rains:

47
They are formed during rainy seasons due to combining of SO2 and NOx in presence
of water to form H2SO4 and HNO3. It affects marine life, fertility of soil and damages
monuments and buildings.

7.3 Thermal Pollution:


This is caused by discharge of cooling water in thermal power plants. Increased
temperatures affect the plant and animal life in water.

7.4 Impact of cooling towers:


The cooling towers using natural air draught for cooling of water can produce drift
deposits and affect the environment of the region at the place they are erected. The
impacts of cooling towers are:
7.4.1. Drift Deposits: The cooling air carries along with it some water droplets
leaving the cooling tower called drift. These droplets carry with them salts
and chemicals. When these are deposited on the earth’s surface cause soil
and metal corrosion thus it damages vegetation.
7.4.2. Fog Plumes: The condensation of water droplets in atmosphere air
may cause formation of fog at ground level and reduce local visibility in that
area.

7.5 Noise Pollution in Thermal Power Plants and Control


Noise pollution is defined as the creation of noise by increasing the sound level of
atmosphere. The normal level of sound under which the persons can work is limited
to 60 dB of atmosphere. However, in power plants the main source of noise
pollution is due to turbo alternators, fans and power transfers. These equipments
increase the noise level in power plants that a noise level of 100 dB can have an
adverse effect on hearing ability in a very short period on the persons working in
such environment. Due to this, as per regulations, the noise pollution in thermal
power plants is limited to a maximum of 85-90 dB for a worker working to maximum
8 hrs of working.
The various methods of noise control to reduce noise level up to 85 dB are as
follows:
1. Sound proofing by providing adequate insulation of piping.
2. Provision of dashpot on air inlet to the fans.
3. Complete casing for turbo alternators.
4. Complete sound proofing of power transformers and switch gears.
5. Provision of sound proof cabins for other workers except working directly
on machines.
6. Use of ear plugs by the workers to reduce the effect of noise pollution on
hearing as preventive measure.
48
7.6 Effect of CO2 on environment and global warming:
Generally speaking the air pollution is related to presence of various contaminants
like dust, fumes, gas, mist, and smoke, odour in atmosphere which is injurious to the
health of human, vegetation and marine life. Through CO2 produced by power plants
has no ill effects on human life biologically, but increased concentration of CO2 n
atmosphere is causing the climatic changes due to its heat trapping quality.

The increased CO2 is causing global warming and mean temperature of earth’s
atmosphere is on the threshold of 2 OC increase. Thus, it is essential to control
release of CO2 into atmosphere by making strict laws for pollution control. All over
the world, the work is being done in this direction. Apart from using better
technologies, we need to arrest the cutting of trees and planting more and more
trees since these trees absorb CO2 and convert into O2 by photosynthesis.

Various methods adopted for nuclear waste disposal are:


a) Gaseous wastes are passed through filters and discharged at a high level
through stacks.
b) Moderate liquid wastes are discharged after filtration, preliminary
treatment (pH value is adjusted) by diluting with cooling water discharge
into deep pits or dry wells.
c) Highly radioactive liquid wastes are kept in concrete tanks and buried into
ground till their decay of radioactivity.
d) Solid wastes (control rods, fuel cans etc.) are stored in shielded concrete
vaults.
e) Combustible wastes are burnt in incinators and flue gases formed are
filtered and disposed off through stacks.
f) Active solid wastes are stored in water for more than 100 days to allow
radioactivity to decay. Then these are disposed off to deep salt mines or
ocean floor in deep well in stable geological strata.

Energy and environment:


The usage of energy resources in industry leads to environmental damages by
polluting the atmosphere. Few of the examples of air pollution are sulphur dioxide
(SO2), nitrous oxide (NOx) and carbon dioxide (CO) emissions from boilers and
furnaces, Chloro-Fluro Carbons (CFC) emissions from refrigerants use etc. In chemical
and fertilizer industries toxic gases are released. Cement plants and power plants
spew out particulate matter.

49
Air pollution
A variety of air pollutants have known or suspected harmful effects on human
health and the environment. These air pollutants are basically the products of
combustion from fossil fuel use. Air pollutants are basically the products of
combustion from fossil fuel use. Air pollutants from these sources may not only
create problems near to these sources but also can cause problems far away. Air
pollutants can travel long distances, chemically react in the atmosphere to
produce secondary pollutants such as acid rain or ozone.

Evolutionary trends in pollution problems


In both developed and rapidly industrialising countries, the major historic air
pollution problem has typically been high levels of smoke and SO2 arising from the
combustion of sulphur containing fossil fuels such as coal for domestic and
industrial purposes.

Smog’s resulting from the combined effects of black smoke, sulphate / acid aerosol
and fog have been in European cities until few decades ago and still occur in many
cities in developing world. In developed countries, this problem has significantly
reduced over recent decades as a result of changing fuel-use patterns; the
increasing use of cleaner fuels such as natural gas and the implantation of
effective smoke and emission control policies.

In both developed and developing countries, the major threat to clean air is now
posed by traffic emissions. Petrol and diesel-engine motor vehicles emit a wide
variety of pollutants principally carbon monoxide (CO), oxides of nitrogen (NOx),
volatile organic compounds (VOCs) and particulates which have an increasing
impact on urban air quality.

50
Sinhgad College Of Engineering, Pune - 41
Department of Mechanical Engineering

Power Plant Engineering Laboratory

Term Work No: - 08

Industrial Visit

51
AIM: - To visit one Thermal Power Plant

THEORY: -

The students are expected to visit one Thermal Power Plant and write
a report on it. The report should summarize the following points:

(a) Name of Thermal Power Plant


(b) Place of visit.
(c) Day / Date
(d) Introduction of power plant
(e) Unique features of power plant
(f) Specifications
(g) Summarization
(h) Photographs

52

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