C2E

Coal Electricity
Bharat Bhushan Chugh DGM (PMI)
In this Presentation

Types of Electricity Generation Plants Our Coal reserves Power Scenario in India Basic of Power Generation Combustion Process Power Plant Cycle Boilers and Turbines Transmission of Power and Switching
Bharat Bhushan Chugh DGM (PMI) 2
TYPES OF POWER STATIONS

Thermal Hydro Nuclear Solar Wind Tidal Geo Thermal

Thermal Power Stations
Coal Gas Oil
Power Scenario (Apr08-May08)

Demand Supply Surplus/ Deficit -10.8 %
Energy
126145 MU 106922 MW
112482 MU 91481 MW
Peak Demand
-14.4 %
Installed Capacity
Sector State Sector Central Sector Private Sector Total MW
(As on 31/05/2008)
%age
75,097.93 48,470.99 20,996.05 1,44,564.97
52.5 34.0 13.5
Source Wise Capacity Mix

Fuel Thermal Coal Gas Oil Hydro Nuclear R enew able Total M W 9 ,9 .9 99 99 9,9.9 99 99 9,9.9 99 99 99 99 , 9. 9 9,9.9 99 99 99 99 , 9. 9 9,9.9 99 99 11 , 1 . 1 , 11 11
% age 9 . 99 9. 99 9. 99 99 . 9. 99 99 . 99 .
Source Wise Capacity Mix

3% 8%
Coal Gas
25%
Oil
53%
Hydro Nuclear
1% 10%
Renewable
10
Energy & Coal
(Status & Outlook)
Coal Reserves in India in plenty but quality low 10 % of the Worlds coal Third only to USA and China 11th largest Energy producer (2.4%) 6th largest Energy consumer (3.7%)
11
Thermal Power Station
Thermal power stations produce electricity by burning fuel in a boiler to heat water to produce steam. The steam, at tremendous pressure, flows into a turbine, which spins a generator to produce electricity. The steam is cooled, condensed back into water, and Bharat Bhushan Chugh 12 returned to the boiler to start the process over.
DGM (PMI)
Why Coal?
Advantages of Coal Fuel Abundantly available in India Low cost Technology for Power Generation well developed. Easy to handle, transport, store and use Shortcomings of Coal Low Calorific Value Large quantity to be Handled Produces pollutants, ash Disposal of ash is Problematic Reserves depleting fast
Indias Coal Reserves are estimated to be 260 billion tonnes. Present consumption is about 450 million tonnes. Cost of coal for producing 1 unit of electricity (Cost of coal Rs 1000/MT)is Rs 0.75.
Coal Electricity
Pollutants
(Transformation Basics)
Coal
Heat Loss
Super Heated Steam

Heat Loss In Condense r
Turbine Torque
Mech. Energy Loss
Alternating current in Stator

Elect. Energy Loss
ASH
Chemical Energy
Thermal Energy
Kinetic Energy
Electrical Energy
14
Steam Power Plant-Parameters

Boiler 1500 T/Hr Turbine Generator 500 MW
300 T/Hr 1500Bharat Bhushan Chugh T/Hr (PMI) DGM
Condenser 60000 T/Hr

15
Simplified Diagram
16
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
17
Coal for combustion

Anthracite Semi-anthracite Bituminous Semi-Bituminous Lignite Peat
High CV, low VM High CV, low VM Medium CV, medium VM Medium CV, medium VM Low CV, high VM, high TM Very low CV, high VM & TM
18
Transporting Coal

Rail Wagon Ship Truck Belt Conveyor Bucket Conveyor
19
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
20
Wagon Tippler
21
Bottom Discharge Wagon
22
Coal Stacking / Feeding

Unloaded from Wagon Conveyor Belt to Crusher House Crusher to Stack Yard or Bunkers Reclaimed from Stack Yard and conveyed to Bunkers
23
Coal Crushers
24
Stacker / Reclaimer
25
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
26
Processing of Coal

Bunkers Raw Coal Feeders Pulverizers (Coal Mills) Primary Air Fan Seal Air Fan Coal Fineness
27
28
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
29
Combustion Fundamentals
Adequacy of Oxygen Oxygen and Fuel to be thoroughly mixed Fuel / Air mixture to be maintained Temperature to be above Ignition Temperature Furnace Volume large enough to give adequate time for Combustion
Fuel Oil
Three liquid fuels used in power plants

1. Heavy Fuel Oil (HFO) 2. LSHS (Low Sulfur Heavy stock) 3. High speed Diesel (HSD)
Oil firing is preceded by Lowering viscosity and increasing flowability on heating for better combustion in given turn down ratio.(125oC) Droplet formation on atomization (by steam/ compressed air/ mechanical pressurization) Combustion initiation by High energy spark ignition
Coal Burner Assembly
32
Fire Ball inside Furnace
33
Steam Generator Components

Furnace Drum Boiler Circulating Pump Convective Pass

Super heaters Reheaters Economizers
Air pre heaters Soot Blowers Coal Bunkers and feeders Pulverizes Coal Piping Burners Ignitors & warm-up Burners Duct work Insulation and Legging
35
Steam generator
Once through (Drumless)
Converts water to steam in one pass through the system rather than recirculating through the drum. Natural circulation
Two pass (With drum)
Uses density differential between water in the downcomer and steam in waterwall tubes for circulation Controlled circulation Uses boiler water circulation pumps to Bharat Bhushan Chugh 36 circulate water through steam water circuit.
DGM (PMI)
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
37
Flue Gases and Ash Extraction
After Steam Generator Flue gases pass through Electrostatic Precipitator Ash gets extracted from Flue gas and discharged away Flue gases are then extracted out by means of Induced Draft Fan and Stack (Chimney)
38
FURNACE
CHIMNEY FD FAN A ID FAN A Atmospheric air ESP ID FAN B
SECONDARY AIR HEATER
MILLS
FD FAN B
PRIMARY AIR HEATER
PA FAN A
PA FAN B
Atmospheric air
ID Fan at Location
40
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
41
Ash Disposal
Ash extracted from Furnace through Scrapper Conveyor and mixed with water (slurry) Ash extracted from ESP slurry / dry Slurry collected in Ash Tank Slurry extracted from Ash tank through Ash pumps Discharge into Ash Pond / Dyke
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
43
Boiler/ steam generator
Steam generating device for a specific purpose. Capable to meet variation in load demand Capable of generating steam in a range of operating pressure and temperature For utility purpose, it should generate steam uninterruptedly at operating pressure and temperature for running steam turbines
Types of Boilers
Fire-Tube Boilers Fire-tube boilers rely on hot gases
circulating through the boiler inside tubes that are submerged in water. These gases usually make several passes through the tubes, thereby transferring their heat through the tube walls and causing the water to boil on the other side. Fire-tube boilers are generally available in the range of 20 through 800 boiler horsepower (bhp) and in pressures up to 150 psi.
Types of Boilers
Electric Boilers Electric
boilers are very efficient sources of hot water or steam, which are available in ratings from 5 to over 50,000 kW. They can provide sufficient heat for any HVAC requirement in applications ranging from humidification to primary heat sources.
46
Types of Boilers
Water Tube Boiler:
Here the heat source is outside the tubes and the water to be heated is inside. Most high-pressure and large boilers are of this type. In the watertube boiler, gases flow over water-filled tubes. These water-filled tubes are in turn connected to large containers called drums.
Water Cycle
Water from River / Canal / Reservoir is clarified Some portion of the clarified water treated further in WTP to produce DM Water DM Water pumped into the boiler water circuit for once and thereafter for make up DM Water remains in closed cycle
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
49
Water / Steam Cycle
Water from Boiler Drum reaches water wall through Downcomers and Bottom Ring Headers Heated Boiling water rises to Boiler Drum, Steam is seperated Water re-circulates whereas Steam passes through Super Heaters
50
51
Boiler Drum
52
Water / Steam Cycle

Superheated steam at high pressure enters HP turbine and rotates it Steam from exit of the turbine sent back to Boiler for Re-heating Re-heated steam enters IP turbine Steam exiting from IP turbine enters LP turbine (2 pass) Steam exiting LP turbine is condensed in condenser Raw water from source used for cooling in condenser
Steam Turbine
Steam Turbine Stages:

Impulse Reaction Control and Stop Valve HP/IP Turbine LP Turbine Rotor Bearings (Journal and Thrust) Turning Gear Front Pedestal Bharat Bhushan Chugh DGM (PMI) Condenser
Steam Turbine Components

54
Impulse and reaction Turbine
55
Turbine are multistage

The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency from the use of multiple stages in the expansion of the steam
56
57
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
58
Water / Steam Cycle
Condensed steam is extracted from Hot well by means of Condensate Extraction Pumps Condensate passes through LP Heaters and enters Deaerator Dissolved Oxygen is removed in Deaerator and collected in Storage tank below
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
60
Water / Steam Cycle
Water is then pumped by means of Boiler Feed Pump at a high pressure to the Boiler Drum to make a closed water / steam cycle Enroute to Boiler drum, water passes through HP heaters and Economiser coils
61
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
62
Generation of Electricity

Steam rotates turbine at a speed of 3000 rpm All the turbines are coupled together An Alternator / Generator is also coupled to the same shaft Excitation is provided in the rotor winding of the generator which produces Magnetic Field With the rotation and cutting of field flux, Electricity is generated in Generator Stator Core
Turbo - Generator
64
65
Stator Core
Cooler Insert Cover Rotor fan
End Shield Wdg Overhang Oil Catcher Rotor
Bearing Shaft Seal
Stator
Terminal Bushing
Main Parts of Turbogenerator
COAL TO ELECTRICITY
SMOKE
9 8
10
ATMOSPHERIC AIR
11
12
23
15
13
20
1 6
22
1 7
24 14
1 8
19 21 RIVER
ELECTRICITY 25
67
Generation / Transmission of Electricity
Voltage level of Electricity generated (3 phase) in Generator is stepped up to 220 or 400 kV by means of Generator Transformer This electricity is transmitted to the Switch Yard Various feeders then transmit the electricity to the Grid
Electricity Grid
LOAD
LOAD LOAD
Generator Transformer
70
SF6 CB
71
SF-6 Breaker
SWGR : CIRCUIT BREAKERS Bhushan Chugh Bharat

DGM (PMI)
72
73
Power Generation, Transmission and Distribution
74
75
Typical Parameters Of a 500 MW Unit

Generation Per Day 12 Million Units
Coal Consumption Per Day -
7200 Tonnes
Water Per Day Ash Discharge Per Day
30000 Tonnes 2200 Tonnes

76
Auxiliaries Supply

Unit Auxiliary Transformers (UATs) Connected to output of the Generator Step Down Voltage to desired level (3.3 kV / 6.6 kV / 11 kV) Auxiliary Buses charged HT Buses More Transformers for further stepping down for LT motors / supplies
Unit Supply Line Diagram

STN Supply
400KV Bus Bar GT STN Supply
20.5 KV 6.6 KV Unit Bus-2
6.6KV Unit Bus
6.6KV 6.6 KV 415 V 6.6 KV 440V Motor Feeders 440 V
Motors
78
DC Chargers
Indoor CBs
79
Transfer Bus 400 KV Main Bus II Main Bus I
Bus Isolator CB CB Transfer Bus Bay
CB Earth Switch opened GT 20.5/400KV Voltage 21 KV Generator RPM 3000
Switchyard line Diagram

Bharat Bhushan Chugh DGM (PMI) Feeder Bay 80
81

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Coal Electricity

Bharat Bhushan Chugh DGM (PMI)

TYPES OF POWER STATIONS

Thermal Hydro Nuclear Solar Wind Tidal Geo Thermal

Thermal Power Stations

Coal Gas Oil

Bharat Bhushan Chugh DGM (PMI)

Power Scenario (Apr08-May08)

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

75,097.93 48,470.99 20,996.05 1,44,564.97

52.5 34.0 13.5

Bharat Bhushan Chugh DGM (PMI)

Source Wise Capacity Mix

Source Wise Capacity Mix

Bharat Bhushan Chugh DGM (PMI)

Energy & Coal

(Status & Outlook)

Bharat Bhushan Chugh DGM (PMI)

Thermal Power Station

Super Heated Steam

Alternating current in Stator

Bharat Bhushan Chugh DGM (PMI)

Steam Power Plant-Parameters

300 T/Hr 1500Bharat Bhushan Chugh T/Hr (PMI) DGM

Condenser 60000 T/Hr

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Coal for combustion

Anthracite Semi-anthracite Bituminous Semi-Bituminous Lignite Peat

Bharat Bhushan Chugh DGM (PMI)

Rail Wagon Ship Truck Belt Conveyor Bucket Conveyor

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Bottom Discharge Wagon

Bharat Bhushan Chugh DGM (PMI)

Coal Stacking / Feeding

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Bharat Bhushan Chugh DGM (PMI)

Three liquid fuels used in power plants

Coal Burner Assembly

Bharat Bhushan Chugh DGM (PMI)

Fire Ball inside Furnace

Bharat Bhushan Chugh DGM (PMI)

Steam Generator Components

Furnace Drum Boiler Circulating Pump Convective Pass

Super heaters Reheaters Economizers

Bharat Bhushan Chugh DGM (PMI)

Once through (Drumless)

Two pass (With drum)

Bharat Bhushan Chugh DGM (PMI)

Flue Gases and Ash Extraction

Bharat Bhushan Chugh DGM (PMI)

CHIMNEY FD FAN A ID FAN A Atmospheric air ESP ID FAN B

SECONDARY AIR HEATER

PRIMARY AIR HEATER

Bharat Bhushan Chugh DGM (PMI)