UNIT-IV POWER PLANT ENGINEERING

LECTURE NOTES
ON

POWER PLANT ENGINEERING

Prepared
By

RAM BABU DARA

Senior Assistant Professor
Department of Mechanical Engineering

Aditya Nagar, ADB Road, Surampalem, East Godavari Dist,

Andhra Pradesh-533437

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Syllabus:

UNIT– IV:
COMBINED OPERATIONS OF DIFFERENT POWER PLANTS: Introduction,
advantages of combined working, load division between power stations, storage type hydro-
electric plant in combination with steam plant, run-of-river plant in combination with steam
plant, pump storage plant in combination with steam or nuclear power plant, co-ordination of
hydro-electric and gas turbine stations, co-ordination of hydro-electric and nuclear power
stations, co-ordination of different types of power plants.
POWER PLANT INSTRUMENTATION AND CONTROL: Importance of measurement
and instrumentation in power plant, measurement of water purity, gas analysis, O2 and CO2
measurements, measurement of smoke and dust, measurement of moisture in carbon dioxide
circuit, nuclear measurements.

Combined Operations of Different Power Plants

• If several power plants work together to meet the demand of the consumer then the
system is known as ―Interconnected System‖
Example: Combined steam and gas turbine power plant

Figure 4.1: Combined steam and gas turbine power plant

Advantages of Combined Operation of Plants
1. Greater reliability of supply to the consumers.
2. When one of the stations fails to operate the consumers can be fed from the other
stations, thus avoiding complete shutdown.
3. The overall cost of the energy per unit of an interconnected system is less.
4. There is more effective use of transmission line facilities at higher voltage.

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5. Less capital investment required.

6. Less expenses on supervision, operation and maintenance.
7. Spinning reserve required is reduced.(Spinning reserve is any back-up energy
production capacity which is can be made available to a transmission system within
ten minutes' notice and can operate continuously for at least two hours once it is
brought online.)
Load Division between power stations
• A load duration curve illustrates the variation of a certain load in a downward form
such that the greatest load is plotted in the left and the smallest one in the right. On
the time axis, the time duration for which each certain load continues during the day is
given.

Figure 4.2: Load division curve

• When the load curve has a very high peak value, it is usually supplied for two or more
power stations by interconnection.
• Total load may be divided into two parts:
A. Base Load B. Peak Load
• Base load is supplied by one power station and other power station takes care of the
peak load.
I. Requirements of a plant supplying Base Load:
 Minimum operational cost
 Continuous supply of load
 Capital cost of the plant should be minimum
 Requirement of plant maintenance should be minimum
 Plant should be such that it can be easily located near the load centre
 The number of operators required should be minimum
 The spare parts etc. should be readily available

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Example for base load plant:

Hydraulic power plants:
 Operating cost is minimum
 Maintenance cost is lower
 Initial cost is high
 Can’t be located near to load
Steam power plants:
 Capital cost is more
 Can be located near to load center.
 Maintenance requirement is slightly higher.
Diesel Power Plants:
 Due to limited generating capacity, it is not used as base load plant.
Nuclear Power Plant:
 Initial Cost is High
 Limited availability of fuel, not favoured.
 Whenever they are constructed they are used as base load plants due to constant
supply.
II. Requirements of a plant supplying Peak Load:
 Low operating cost
 Minimum capital cost
 The plant should be capable of being started from cold conditions within minimum
time
 In case of emergency the plant should have the capacity to withstand the peak load for
sometime
 It must have quick response to the change in load

Example for peak load plant:

Hydroelectric Plants: can be considered as peak load plant.
 It can be easily started.
 No fuel required.
Nuclear Power Plants: they are not used as peak load plants.
Diesel Power Plants: can be used for peak load plants
 Easily start from cold conditions.

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 Number of auxiliaries required is limited, so less maintenance.

 They have good overload capacity.
 They have high thermal efficiency therefore less operating cost than steam power
plants.
Combined Cycle Power Plants
1. Hydroelectric Plant in combination with Steam Power Plant.
 Hydro Electric plants can take up the load quickly and follow the peak variations
much better than thermal plants.
 When the run-off is sufficient (in monsoons) Hydro plant is used as base load plant
and thermal plant is used as peak load plant.
 Thermal plant is used as base load plant during the draught period and hydro plant
works as peak load plant.

Figure 4.3: Load division curve of hydraulic and steam power plants
Hydroelectric power plant:
• This system generates electricity using water flow to drive turbines. It's clean,
sustainable, and has low operational costs once the dam and plant are in place.
• However, it relies on water availability and is often subject to seasonal fluctuations.
Steam power plant:
• The steam plant can be powered by fossil fuels, biomass, or even nuclear power,
depending on the setup. By heating water to produce steam, it drives turbines to
generate electricity.
• Steam plants are typically dispatchable, meaning they can be turned on and off based
on grid demand.

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Energy Storage and Grid Management:

• An essential feature of combining these two plants is having some form of energy
storage or load management system.
• Pumped-storage hydropower (where water is pumped back to a reservoir during low
demand periods) can be used to store energy generated by the steam plant or other
excess grid energy.
Advantages of the Combination
• Load Balancing: Hydroelectric plants can quickly adjust output to meet demand,
while the steam plant can provide a consistent, reliable base load. Together, they can
balance peak demands and ensure grid stability.
• Seasonal Flexibility: During dry seasons or droughts when water levels are low, the
steam plant can be used more intensively. During high-water seasons, the
hydroelectric component can reduce reliance on the steam plant, lowering fossil fuel
use or other fuel-based costs.
• Efficiency and Reduced Emissions: Using the steam plant during off-peak times to
pump water back to the reservoir (pumped-storage hydro) increases overall efficiency
and reduces emissions if fossil fuels are used, by allowing for more selective,
optimized fuel usage.
• Cost Management: Initial investment costs are high, but the combination of
renewable hydro and flexible steam generation leads to long-term savings on fuel
costs and increases grid resilience.
Challenges or Disadvantages
• Capital Costs: High initial infrastructure investment for both the hydroelectric and
steam plant components, especially for water storage and management systems, is
necessary.
• Environmental Impact: Both hydroelectric and steam power plants can have
environmental impacts—hydroelectric dams affect aquatic ecosystems, and steam
plants using fossil fuels can contribute to air pollution and CO₂ emissions.
• Water Availability: Both systems rely on water—one to drive turbines and the other
to produce steam— so managing and sustaining water resources is critical.

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2. Diesel Plant in combination with Steam Power Plant

 The Combined Cycle Power Plant or combined cycle gas turbine, a gas turbine generator
generates electricity and waste heat is used to make steam to generate additional
electricity via a steam turbine.
 A Combined Cycle Power Plant produces high power outputs at high efficiencies (up to
55%) and with low emissions. In a Conventional power plant we are getting 33%
electricity only and remaining 67% as waste.
 By using combined cycle power plant we are getting 68% electricity.

Figure 4.3: Combined diesel and steam power plants

Inner Workings of a Combined-Cycle Power Plant
• A combined-cycle power plant uses both a gas and a steam turbine together to
produce up to 50 percent more electricity from the same fuel than a traditional simple-
cycle plant. The waste heat from the gas turbine is routed to the nearby steam turbine,
which generates extra power.
How a Combined-Cycle Power Plant Produces Electricity
Gas turbine burns fuel:
• The fast-spinning turbine drives a generator that converts a portion of the spinning
energy into electricity.
Heat recovery system captures exhaust:
• The HRSG creates steam from the gas turbine exhaust heat and delivers it to the
steam turbine.
Steam turbine delivers additional electricity:

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• The steam turbine sends its energy to the generator drive shaft, where it is converted
into additional electricity.
Advantages
• The efficiency of the combined cycle plant is better or higher than the turbine cycle or
steam cycle plant. The efficiency of combined cycle power plant will be of the order
of about 45 to 50%.
• fewer moving parts and less vibration than a reciprocating engine
• very low toxic emissions
• runs on a wide variety of fuels
• high operating speeds
Disadvantages
• Higher cost
• longer start-up
• less responsive to power demands
• Shrill whining noise.

3. Storage-Type Hydroelectric Plant Combined with Steam Plant

Working Principle:
• A storage-type hydroelectric plant uses a large reservoir behind a dam to store water,
which provides a controlled, steady water flow to the turbines.
• The steam plant, which uses fossil fuels, biomass, or other fuel sources, can operate
alongside the hydroelectric system.
• When energy demand is low, excess energy from the steam plant can pump water back
into the reservoir (pumped-storage).
Key Components:
• Reservoir and Dam: Stores large amounts of water, ensuring a stable water supply year-
round, regardless of seasonal variations.
• Hydroelectric Turbines and Generators: Generate electricity from the controlled
release of water.
• Steam Plant Components: Boiler, turbine, and generator.
• Pumped-Storage System (Optional): Uses steam-generated power to pump water back
to the reservoir when demand is low, creating additional storage.

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Advantages:
• Load Balancing: The hydro plant can quickly adjust output to meet peak demand,
while the steam plant provides a steady base load.
• Seasonal Flexibility: During low-water seasons, the steam plant compensates for
reduced hydroelectric generation.
• Efficiency and Storage: Pumped-storage allows the system to store energy for future
use, improving overall efficiency.
4. Run-of-River Plant Combined with Steam Plant
Working Principle
• Run-of-river hydro plants do not have large reservoirs; they generate power using the
natural flow of a river. This makes them dependent on water availability, which can
vary daily or seasonally.
• A steam plant complements this setup by ensuring a reliable energy supply when
river flow is low. Unlike storage-type plants, run-of-river setups are usually more
environmentally friendly as they don’t disrupt river ecosystems as much.
Key Components
• River Flow and Small Reservoir (or Diversion Canal): Diverts river water to
turbines without a large storage reservoir.
• Hydroelectric Turbines and Generators: Generate power based on real-time river
flow.
• Steam Plant Components: Boiler, turbine, and generator to complement variable
river flow.
Advantages
• Lower Environmental Impact: Minimal reservoir reduces ecological disruption.
• Complementary Output: The steam plant provides energy when river flow is
insufficient, allowing for a steady output.
• Reduced Infrastructure Needs: Requires less land and lower initial costs compared
to storage-type hydroelectric plants.
Comparison and Suitability
Large reservoir provides
Water Management Dependent on natural river flow
steady flow
Energy Storage Can store energy (via pumped- Limited or no energy storage

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storage)
Environmental Higher due to dam and
Lower; minimal river disruption
Impact reservoir
Highly reliable with Reliable with steam backup
Reliability
year-round water storage but river flow-dependent
Higher initial costs due Lower initial costs without
Cost
to dam infrastructure large reservoir
Areas with variable Consistent-flow rivers
Ideal Location
seasonal water flow with minimal seasonal changes
Large reservoir provides
Water Management Dependent on natural river flow
steady flow
Can store energy
Energy Storage Limited or no energy storage
(via pumped-storage)

5. Coordination of Hydroelectric and Nuclear Power Stations

 Hydroelectric and nuclear power plants have quite different operating characteristics.
 Nuclear plants provide a consistent and reliable base load due to their high capacity
factor and relatively inflexible operation.
 Hydroelectric plants, on the other hand, can quickly adjust their output to handle
fluctuations in demand.
 Coordinating these two types allows for an efficient and stable energy supply, where
nuclear power provides steady baseline power and hydroelectric manages peak
demand.
Working Principle
• Base Load from Nuclear Power: Nuclear plants operate continuously at high output,
providing a stable base load to the grid, which minimizes the need for frequent
adjustments and maintains a high efficiency.
• Peak Load Management with Hydroelectric: Hydroelectric plants adjust output as
needed to manage demand spikes. During off-peak periods, excess nuclear-generated
electricity can pump water back to reservoirs for future use (pumped-storage).
• Seasonal and Daily Balancing: Nuclear provides reliability for the grid, while
hydroelectric plants handle daily or seasonal variations, ensuring optimal power
supply across varying demand.

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Key Advantages
• High Efficiency and Low Operational Costs: Nuclear power provides cost-effective
base load, while hydro allows for flexible peak management with low operating costs.
• Reliability and Stability: Nuclear power ensures steady, long-term reliability, while
hydro’s flexibility enhances grid stability during peak times.
• Reduced Emissions: Both systems produce minimal carbon emissions, making this
combination environmentally sustainable.
Suitable Applications
• The coordination of hydroelectric and nuclear power is particularly beneficial for
regions with high and steady base load requirements, such as industrial areas or
regions with high population density. This combination also suits countries aiming to
reduce carbon emissions while maintaining reliable power for grid stability.
6. Coordination of Hydroelectric and Gas Turbine Stations
• Hydroelectric plants are highly flexible and can adjust their output quickly to meet
changing demand, while gas turbines can also ramp up and down rapidly, though they
are generally more expensive to operate due to fuel costs.
• Coordinating these plants allows for efficient peak load management and demand
response.
Working Principle
• Load Balancing: During peak demand, the hydroelectric plant can respond quickly
by increasing its power output, and the gas turbines can be used to provide additional
power if the hydroelectric plant alone is insufficient.
• Reserve Capacity: The gas turbine station can remain on standby, ready to start up
quickly in case of sudden demand spikes or hydroelectric shortfalls (e.g., during low-
water conditions).
• Backup Support: In cases of low water availability or during dry seasons, gas
turbines can supply power, ensuring grid reliability.
Key Advantages
• Quick Response to Demand: Both systems can adjust output rapidly, making the
combination effective for managing peak loads and intermittent demand fluctuations.
• Efficient Fuel Use: By using hydroelectric power when available, fuel consumption
in the gas turbines is minimized, which lowers operational costs.
• Grid Stability: The combination can provide reliable backup power, ensuring stable
grid performance, especially in regions where renewable integration is high.
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• Suitable Applications: This coordination is ideal for regions with variable or

seasonal water flows where gas turbines can offset periods of low hydroelectric
output. It is also beneficial for power grids with high peak demand requirements,
where the rapid response of gas turbines complements hydroelectric flexibility.
Comparison of the Two Coordinations
Hydroelectric + Gas
Aspect Hydroelectric + Nuclear
Turbine
Very flexible, both can Nuclear provides steady base load;
Flexibility
adjust quickly hydro manages peak
Response to Peak Effective for peak load; gas Hydro handles peaks; nuclear
Demand turbines fill gaps provides steady supply
Lower hydro costs; gas Nuclear cost-effective for base load;
Cost Efficiency
turbine fuel costs higher hydro reduces peak cost
Environmental Gas turbines have higher Minimal emissions; nuclear and hydro
Impact emissions are low-carbon
Limited, unless paired with Excellent with pumped-storage for
Energy Storage
pumped-storage peak demand
Regions with variable water Areas with steady demand and a need
Best Application
and peak demands for stable, low-emission power

POWER PLANT INSTRUMENTATION AND CONTROL

• Instrumentation and Control in power plants are critical for ensuring safe, efficient,
pollution control and reliable operations.
• Measurement and control systems provide continuous monitoring, regulate critical
processes, and detect any deviations or issues early on.
Importance of Measurement and Instrumentation in Power Plants
1. Safety and Reliability
• Continuous monitoring of parameters like temperature, pressure, flow rate, and
vibration ensures safe operation of critical equipment (e.g., turbines, boilers,
condensers).
• Alarms and automated controls enable prompt responses to abnormal
conditions, preventing equipment failure and potential hazards.

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2. Efficiency Optimization
• Proper instrumentation helps regulate fuel usage, steam production, and electrical
output to maximize efficiency.
• By tracking key metrics (e.g., fuel-to-air ratio, turbine efficiency), operators can
fine-tune processes for optimal performance and reduced fuel consumption.
3. Environmental Compliance
• Instruments for emissions monitoring ensure the plant adheres to environmental
regulations (e.g., controlling CO₂, SO₂, and NOₓ emissions).
• Water quality measurement instruments prevent discharge of contaminated water,
ensuring compliance with water pollution standards.
4. Cost Reduction
• Preventive monitoring reduces maintenance costs by detecting issues early and
minimizing unplanned downtime.
• Efficient control systems reduce fuel consumption and resource waste, lowering
operational expenses.
5. Automation and Remote Control
• Advanced control systems, like Distributed Control Systems (DCS) and
Supervisory Control and Data Acquisition (SCADA), enable automation and
remote monitoring.
• Automation minimizes human error and allows centralized control of complex
processes, improving response time and overall operational stability.

For a Plant Measurement system needs to be:

• Very accurate
• Reliable
• Delays should be as small as possible
• Should be switched on manually when an overall control system fails.
Quantities to Be Measured:
 Pressure
 Temperature
 Flow
 Level
 Expansion/ Contraction
 Analysis of (1) Water (2) Steam (3) Flue Gases And Others
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Measurement Points & Variables

Variables/ Parameters Measuring Points Types Of Instruments
Pressure (a) Boiler Bourdon Tube
(b) Turbine Diaphragm
(c) Turbine Throttle Bellows Gauges
(d) Furnace Bellows Gauges
Temperature (a) Steam at super heater Thermocouple/RTD
inlet & outlet
(b) Feed Water at economizer inlet Thermocouple/RTD
(c) Water at condenser inlet Thermocouple/RTD
(d) Air Preheater Thermocouple/RTD
(e) Flue Gases
(a) Bearing of turbine & generator, Thermocouple/RTD
feed pump, condensate pump
Flow High Pressure Steam, Feed water Orifice, Venturi, Flow
inlet, Condensate Nozzle,etc.
Level Boiler Drum, condensate tank, Relative Displacement
Water line
Expansion Turbine Shaft, Turbine casing Thermocouple/RTD
Vibration turbine & generator shafts & Mass spring with
bearing shells Potentiometric Capacitive,
eddy current, piezo electric &
optical types are used

Analysis
Variables/ Parameters Measuring Points Types Of Instruments
WATER feed water at economiser inlet, Conductive cell with meter
Boiler inlet, Condenser,
Condensate pump discharge
Steam Saturated steam, Main line Conductive cell with meter
steam, Super heater inlet
Flue Gases O – Economiser to air heater Zirconia cell
2

CO – Air heater inlet & outlet CO analyser

2 2

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CO – stack CO analyser
Nitrogen Oxide- stack N- Oxide Analyser

Measurement of Water Purity in Power Plants

Water purity is critical in power plants, especially in boilers, condensers, and cooling
systems. Impurities in water can lead to scaling, corrosion, and deposits, which compromise
efficiency and can, damage equipment.
Key Parameters for Water Purity Measurement
1. Conductivity
• Measures the amount of dissolved ions (salts, acids, bases) in water, indicating the
overall ionic purity.
• High conductivity means higher impurity levels, which can cause scaling and
corrosion in boilers and turbines.
2. pH Level
• Indicates water’s acidity or alkalinity, which can affect corrosion rates. Ideal pH
levels are carefully maintained to minimize corrosion risks.
• pH sensors continuously monitor and control water chemistry, especially in boiler and
feed water systems.
3. Dissolved Oxygen (DO)
• High oxygen levels increase corrosion, particularly in boilers and turbines.
• DO sensors, usually placed in the deaerator and feed water systems, ensure DO levels
are kept low to prevent oxidative damage.
4. Silica Concentration
• Silica forms hard, insulating deposits on boiler tubes and turbine blades, reducing
thermal conductivity and efficiency.
• Silica analyzers monitor levels, especially in high-pressure systems, and alert
operators to take corrective actions if necessary.
5. Turbidity
• Measures the presence of suspended particles, which can lead to deposits and scaling
in boilers and turbines.
• Turbidity meters ensure that suspended solids are within acceptable limits, especially
in cooling and feedwater systems.
6. Total Dissolved Solids (TDS)

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• Indicates the total concentration of dissolved substances in water, impacting scaling

potential.
Importance of Water Purity Measurement
• Prevents Scaling and Fouling: Impurities like silica, calcium, and magnesium form
scales in boilers and turbines, reducing efficiency and increasing maintenance costs.
• Minimizes Corrosion: Maintaining correct pH and low dissolved oxygen levels
reduces corrosion, prolonging equipment life and minimizing costly repairs.
• Maintains Thermal Efficiency: Clean water with low impurity levels enables
efficient heat transfer, maintaining high thermal efficiency and reducing fuel
consumption.
• Ensures Compliance and Safety: Monitoring water purity ensures compliance with
environmental standards and keeps the plant operating within safe parameters.
• Prolongs Equipment Lifespan: Maintaining pure water reduces wear and tear on
critical components, extending their operational lifespan and lowering long-term
capital expenses.
Instrumentation Techniques for Water Purity Measurement
• Sensors and Analyzers: Conductivity meters, pH sensors, DO analyzers, silica
analyzers, and TDS meters are often installed throughout the water and steam cycle.
• Automated Sampling Systems: Regular water sampling systems use sensors to
automate the testing of water parameters and adjust treatment chemicals as needed.
• Data Logging and Alarm Systems: Instruments connected to control systems log
data and trigger alarms if parameters deviate from safe limits, enabling prompt
corrective action.

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