Professional Documents
Culture Documents
1- A professor of Thermodynamics?
2- An Engineer in Thermodynamics?
3- A process Engineer?
4- A design office?
It is why; to explain you, what is a power plant, I'll have to expose you those different
points-of-view that are complementary, and useful for people who will work on site:
- Working on site, you need to know where turbines, pumps, valves, instruments are
located, how they look like… when you need to do local checks and actions. (for this
you have document like the layout arrangements)
- Because you are controlling the operation of each component, you need to know
how the process works. For you, it will be the core of your knowledge of the power
plant.
- But, such an understanding of the power plant, becomes a real understanding,
when all the rules of operating and maintenance of a power plant are linked
together by an overview. Thanks to general operation description, heat balances
and notions of thermodynamics, you acquire such an overview that is required for
anticipation and taking fast a good decision. There are always particular cases that
not have been foreseen and described. Then, your knowledge will be a coherent
whole… giving sense to what else, could have been described as a catalogue of
rules to follow.
Content
4- General layout
1- AN OVERVIEW OF THERMODYNAMICS (view from a professor of
Thermodynamics)
Heat exchanged
ΔU = W + Q with external
environment
Work exchanged
Internal with external
Energy environment
variation
1.1.2- Toward the second principle
Temperature (°K)
(toward absolute zero)
S
A new abstract
value, called
"ENTROPY"
Experience
HEAT always move from a hot body toward a cold body, never
backwards.
Note:
Entropy is often compared with disorder at the atomic level.
A disorder that can only increase
M
V
oltage
e
e
e
e
e
e
V2 e
M
V
1.2- Thermodynamics cycles
T
Thot Gain of thermal energy
S
T
Thot Conversion into mechanical energy
S
T
Thot Loss of thermal energy
S
T
Thot Gain due to external work
S Surplus of
T energy
Converted Cycle efficiency (%)
Thot into (Theoretical maximum):
mechanical
Heat
Thot − Tcold
Received work
η=
Tcold Thot
Heat Loss
Note: temperatures are
in degree KELVIN (°K)
S
1.2.2- Generalisation
S
1.2.3- Application to the steam/water cycle
T
Cycle of Carnot:
It is very difficult to realise this ideal cycle in
practice, because we have always a mixing
of liquid and steam
S
T
Simplest possible cycle:
… But a very low efficiency
T Gain of
efficiency with a superheater:
… a better efficiency
S
RETURN
In case of high pressure : steam has to be sent to the steam-turbine, before to have
reached the temperature it would have reached, if materials could have supported very
high temperatures. But it is not the case, …materials have limits (elasticity, fatigue,
smelting…)
But if steam it reheated, we can add to the thermodynamic cycle an additional part that
has a better mean efficiency than the cycle without re-heating.
It is why, for high pressure thermodynamic cycle, a cycle with reheat has a better
efficiency than a cycle without.
TEMPERATURE MAXIMUM
allowed by the materials
Additional part
with a better
mean efficiency
S
1 .2 .4 - S te a m /W a te r c y c le o f M A R IT Z A T
G I
H e re a fte r y o u c a n s e e th e w a te r/s te a m c y c le o f M A R IT Z A te m p e ra tu re
w ith its th e r m o d y n a m ic a l c y c le .
Y o u c a n a lo s s e e th e r e la tio n b e tw e e n th e th e r m o d y n a m ic E
tr a n s fo r m a tio n a n d th e e q u ip m e n t o n a p r o c e s s d ia g r a m F
H
( e .g . : C D is th e fe e d w a te r p u m p ) .
G
I D
B C
A J
S
B O IL E R
e n tro p y
S U P E R H E A T E R
R E H E A T E R
F H P
T U R B IN E
IP T U R B IN E L P T U R B IN E
G
E V A P O R A T O R
E 6 4 3
J
H
2
1
E C O N O M IZ E R
7 5
T U R B IN E C O N D E N S E R
4 3 2 1 A
7 6 C O N D E N S A T E
L P 4 L P 3 L P 2 L P 1 E X T R A C T IO N
H P 7 H P 6 P U M P S
2 x 1 0 0 %
5 D E A E R A T O R
G L A N D S T E A M
C O N D E N S E R
F E E D W A T E R T A N K
B O IL E R F E E D
P U M P S
3 x 5 0 %
H O L D IN G E J E C T O R S
2 x 1 0 0 %
D
1. OBJECTIVE
The objective
2- MARITZA of thebalances
‘s heat present calculation sheet is to provide
: fundamental valuesthe(pressure,
Heat and Mass balance diagrams
specified for Review and Information by the Owner as per list of Appendix A WDB Vol1 Part3C
temperature or flow…) - (view from a thermodynamician Engineer)
chap 3C.4.2.
100 % TMCR - Year average GMD2 023 209 - Sheet 1/10 Heat Rate Guarantee
(T amb.=12.5°C, RH=73%)
90 % TMCR - Year average GMD2 023 209 - Sheet 2/10
(T amb.=12.5°C, RH=73%)
75 % TMCR - Year average GMD2 023 209 - Sheet 3/10
(T amb.=12.5°C, RH=73%)
50 % TMCR - Year average GMD2 023 209 - Sheet 4/10
(T amb.=12.5°C, RH=73%)
42.5 % TMCR - Year average GMD2 023 209 - Sheet 6/10 Boiler minimum load – 120 MW
(T amb.=12.5°C, RH=73%) net max with guaranted lignite.
3. REFERENCE DOCUMENTS
Not Applicable.
5. NOT APPLICALBLE
6. ATTACHMENTS
Heat and Mass balance diagrams as per above list.
Legal Owner / Официален собственик Project Doc. No. № на проектния документ Rev. / Date / Дата Lang. Sheet
Език Страница
ALSTOM Power Turbo-Systems MTZ/12/M/----------/CA/111 0 05.05.2006
en 3/10
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third
parties without express authority is strictly forbidden. Правата върху този документ и информацията в него са запазени.
Размножаването, използването или разпространяването на трети страни без специални пълномощия е строго
забранено
2.2- Principle of the reheaters (from the condensate water to the feedwater)
HYPOTHESIS
To observe only, the power output of the generator,
the consumption of the turbine…
Water Steam
boiling cooling
100°
Steam
condensing steam
liquide
liquide
hielo
Ice Water &
heating steam
50° &
y
liquide
liquido
Water
cooling
Ice
Ice
Ice melting
warming
0°
Water
Ice freezing
cooling
Specific
heat kj/kg
37 335 419 2256 97
LOW PRESSURE
IP s t a g e s
LP stages H P s tages
5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1
500
400
Temperature (°C)
HP cylinder
300 IP cylinder
LP cylinder
200
100
0
0 20 40 60 80 100 120 140 160 180
P r e ssure (bar abs)
Temperature (°C)
200,0
179 °C
108 °C
100,0
Con
den
sate
wat 50,0
er
31 °C
Condenser
0,0
0 50 100 150 200 250
Pressure (bar abs)
398 °C Saturation temperature
400,0
and
Gland steam condenser
254 °C feedwater
L.P. heater 2
250,0
tank 252 °C
Temperature (°C)
1
197 °C 200,0
L.P. heater
145 °C 150,0
Con 90 °C 100,0
den
sate
wat
er 50,0
31 °C
Condenser
0,0
0 50 100 150 200 250
Pressure (bar abs)
417 °C
Saturation temperature
400
334 °C
Feedwater
312 °C
pumps
H.P. heater
L.P. heater 3
Deaerator
250
L.P. heater 2
254 °C
Temperature (°C)
L.P. heater 1
164 °C
150
123 °C
100
Con
den 78.2 °C
sate
wat 50
er
31 °C
Condenser
0
0 50 100 150 200 250
Pressure (bar abs)
463 °C
Saturation temperature
400
H.P. heater 1
H.P. heater 2
334 °C
Feedwater
Deaerator
pumps
300
L.P. heater 3
254 °C 255 °C
250
Temperature (°C)
L.P. heater 2
219 °C
200
L.P. heater 1
179 °C
150
145 °C
141 °C
108 °C
100
Con
den
sate 71 °C
wat 50
er
31 °C
Condensador
0
0 50 100 150 200 250
Presssure (bar abs)
A2_5 GB
540
177 HP 1 Flow 540 292
3390
IP 1 Flow LP 2 Flows
40.5 6.5
278.9 3535 3045
336 259 221.6 X=0.91
Boiler 45 0.045
3046 2347
18.5 187.2
251 230 221 202 194 190 158 134 126 102 94 71 63 39.9 31.8 31.2
+++ +++ +++ +++ 216 +++ +++ +++ +++ +++ +++ +++ +++ +++ +++ +++
1093 989 957 863 836 807 667 565 531 430 397 297 265 167 135 132
279 18.5 279 +++ 279 279 235 +++ 235 +++ 235 +++ 235 +++ 235 235
Temperature ° C Enthalpy kJ / kg T° saturated ° C
Pressure Bar A Flow kg / s ∆Τ difference ° K
feedwater tank
452 °C
HP heater 2
Dearator and
HP heater 1
Saturation temperature
400,0
300,0
LP heater 4
274 °C
263 °C
257.7 °C
LP heater 3
255 °C
Gland steam condenser
250,0
HP heater 1 bis
Temperature (°C)
214 °C
LP heater 2
200,0
LP heater 1
180 °C
151 °C
150,0
108 °C
90 °C 100,0
Con
den 65 °C
sate
wat
er 31 °C
50,0
Condenser
0,0
0 50 100 150 200 250
Pressure (bar abs)
A2_6 GB
540
177 HP 1 Flow 540 260
3390
IP 1 Flow LP 2 Flows
40.5 5.2
278.9 3535 2980
338 251.6 212 X=0.90
Boiler 45 0.045
3052 2325
26 185.3
253.6 219 211 193 185 181 151 113 105 95.3 87 62.1 65.1 32 31.2
+++ +++ +++ +++ 216 +++ +++ +++ +++ +++ +++ +++ +++ +++ +++
1104 939 909 822 796 768 637 477 444 400 367 261 272 136 132
279 26 279 +++ 279 279 230 +++ 230 +++ 230 197 +++ 197 197
Temperature ° C Enthalpy kJ / kg T° saturated ° C
Pressure Bar A Flow kg / s ∆Τ difference ° K
case Power Efficiency
(MW) (%)
gland steam + 1 LP + feed. tank + 1 HP 1 342,03 45,14%
gland steam + 2 LP + feed. tank + 1 HP 2 346,08 45,42%
WITHOUT drain pump gland steam + 3 LP + feed. tank + 1 HP 3 347,87 45,56%
gland steam + 3 LP + feed. tank + 2 HP 4 350,56 45,77%
gland steam + 4 LP + feed. tank + 2 HP 5 352,50 45,94%
gland steam + 4 LP + feed. tank + 3 HP (WITH crossing) 6 351,10 46,56%
WITH drain pump
gland steam + 4 LP + feed. tank + 2 HP (WITHOUT crossing) 7 352,67 46,46%
46,80%
6
46,60% 7
46,40%
Efficiency (%)
46,20%
46,00% 5
4
45,80%
3
45,60%
2
45,40%
45,20% 1
45,00%
340,00 342,00 344,00 346,00 348,00 350,00 352,00 354,00
Power (MW)
3- MAIN PROCESS AND EQUIPEMENT CHARACTERISTICS OF THE POWER PLANT OF MARITZA
MARITZA East 1 Power Station, which is located in Bulgaria, is composed of two identical lignite-fired
units, each composed of a controlled tangential firing, reheat steam generator, a turbine generator
group and a condensing and feedwater heating plant. The power station is designed with steam turbine
bypasses.
The power supplied by the plant is in the form of three-phase 50-Hertz AC current, at a nominal voltage
of 400 kV.
The basic operation mode of the plant is to supply electrical power to the grid. The facility operates with
lignite.
The superheated steam conditions at the turbine inlet (at TMCR, T° amb = 12,5°C) are :
Live steam: P = 166.7 bar abs, T = 540 °C, m = 941 t/h,
Hot reheat steam: P = 35.9 bar abs, T = 540 °C, m = 891 t/h, condenser vacuum 64 mbar abs (at the
design Main Cooling Water temperature of 22°C)
3.2.1- Boiler
The drum type, natural circulation steam generator in proven single pass is equipped with two
economisers, three superheaters & two reheaters.
Fuel oil burners (Alstom Power jet burner type) are used during boiler start-up. There are 4 fuel oil
burners all of which are of the pressure-atomised type. Oil burners are ignited by using gas fuel.
Lignite is pulverised by six mills (N440.41V type) and burnt by 6 puverized coal burners each with a
upper/ lower and vapour burner segments.
. 2 forced draught fans (2x50%) are supplying coal burners, overfire air levels, and mills.
. 2 induced draught fans (2x50%) that draw the flue gases to the cooling tower.
. 1 regenerative air preheater (RAPH), Ljungström type regenerative air heaters that receives
combustion air from the two forced draught fans.
. 2 steam-coil-air preheater (SCAPH, located upstream the FD fans) are used for supporting the hot
air recirculation (according air ambient temperature).
. a flue gas system: two electrostatic precipitators upstream each ID fan; one flue gas desulphurisation
unit (with absorber tower), is installed upstream the cooling tower.
The 3000-rpm steam turbine is composed of one HP cylinder, one IP cylinder and 1 double flow LP
cylinder. The HP cylinder is equipped with 2 admission chest, each comprises a main stop valve and 2
control valves. IP cylinder has 2 main stop valves and 2 control valves located also in 2 symetrical
chests. There are 7 steam extractions to feed the feedwater LP and HP heaters and the deaerator.
The LP turbine exhaust steam is condensed in a single shell, 2-pass condenser designed for lateral
turbine steam flow exhaust.
The generator is driven by the steam turbine and is equipped with static excitation. The cooling of the
generator is assured by hydrogen, which is cooled, by water from the closed cooling water system.
The generated electric power is transferred to the generator step-up transformer before being delivered
to the grid.
There are three 50 % motor-driven variable speed feedwater pumps, normally two in service and one on
auto standby which deliver feedwater to the boiler drum. Drum level at start-up is controlled by a 1x30%
start up control valve; at higher load (>30%), drum level is controlled by a 1x100% full load control
valve. The feedwater pumps speed controls the differential pressure around the start up and full load
control valves.
One of two 100 % duty condensate extraction pumps deliver the condensate water from the condenser
via the LP heaters to the deaerator. The condensate is heated in a first stage through four LP heaters
(No 1 to No 4) supplied by steam from the LP turbine cylinder extractions (1 to 3) and IP cylinder
exhaust (N° 4). LP heater 1 is mounted inside the condenser neck.
Two High-Pressure heaters (No 6 to No 7) then heat feedwater in a second stage to its terminal
temperature at delivery to the boiler. The HP extraction steam is from the IP cylinder for HP6 and from
the cold reheat line for HP7.
The deaerator is normally fed by extraction No. 5 at IP cylinder. In case of by-pass operation, the
pressure in the deaerator is supported by cold reheat.
An auxiliary boiler (common for both units) is provided to ease unit start-up.
The steam turbine generator is connected to the LV side (20 kV) of its associated generator transformer
via a generator circuit breaker and isolated phase busbars. Connections from the HV side (400 kV) of
the generator transformers to the 400 kV switchgear are via overhead interconnect lines.
AC distribution system
This supplies, from auxiliary transformers, the various unit and common auxiliary systems and
equipment :
Medium voltage
- 10 kV switchgear : its function is to control and distribute power supplies from the auxiliary transformer
to 10 kV station, the unit switch boards, the 10 kV / 400 V, 10 kV / 690 V transformers and to motors
generally having ratings of 450 kW and above,
Low voltage
- 400 V - 690 V switchboards : they are provided to control and supply power to motors generally with
ratings lower than 450 kW for lignite and ash handling, boiler, ST, ESP, FGD, water treatment, general
servive, lighting and small power, battery chargers and various other 400 V loads; the voltage levels of
motors within the coal and limestone handling plant are 690 V for motors with ratings lower or equal to
450 kW and 400 V for auxiliary purposes but not for motor drives.
- one emergency diesel generator (common for both units), supplies emergency 400 V AC power to the
essential consumers in the event of a loss of the normal supplies.
DC distribution system
The DC systems provide a secure power supply for the control and protection systems, switchgear
operation and emergency motors :
The purpose of the lignite handling plant is the transportation from delivery point, storage and
reclaiming, crushing and forwarding to boilers milling system.
Bunkers serve as intermediate storage from which the lignite is fed to the mills. Each bunker has a net
volume of approximately 560 m³. This allows an operation of approximately 4 hours at full load
(guarantee fuel).
Lignite is extracted from the bunker by means of a drag-link conveyors and transported to the mill inlet
duct by means of belt conveyors
A dust and pressure tight housing for each conveyors is provided.
The process involves the continuous extraction of furnace bottom ash and fly ash from the boiler with
onward transport to the downstream storage and disposal systems.
Furnace bottom ash is temporarily held in a storage silo, one for both units, until disposal.
The bottom ash is removed from the furnace by means of longitudinally positioned pusher-type grates
and a downstream submerged scraper conveyor. Downstream the submerged scraper conveyor, a
drag-link conveyor transfers the ash to the pipe conveyor (common for both boilers).
This pipe conveyor transfers the ash to the bottom ash silo.
The ash accumulated in the open gas pass upstream of the air heater is discharged by screw conveyors
and downcomers and led to the submerged scraper conveyor.
3.2.8- Flue gas treatment devices
Two 50% duty precipitators are provided for each boiler. They are located between air preheaters and
ID Fans. They consist of parallel gas path between vertical steel plates connected to high voltage
electrodes. The fly ash particles receive an electrical charge which forces them to stick and accumulate
on collector plates.
The accumulated ash deposits are removed from the collecting plated by mechanical impacts. This
causes the ash to be shaken and fall into collecting hoppers below.
Fly ash is pneumatically conveyed to the fly ash silo for interim storage.
Desulphurisation plant
The flue gas desulphurisation is of the wet limestone / gypsum type which uses limestone slurry as the
reagent and produces a gypsum slurry as the reaction product. Its goal is to reduce the SO2 stack
emissions.
The plant includes a dedicated absorber tower per boiler (downstream ID fan) and common limestone
preparation and gypsum dewatering equipment.
One 100 % main cooling water pump per unit provides cooling water to the units through a common
discharge header. The two pumps must be in operation to cool the condensers of both units at full load.
The main cooling water is taken from the cooling tower basin and mechanically cleaned by coarse
screen. Downstream of the condensers, the heated main cooling water is led back to the common
natural draft Cooling Tower where is rejects the heat to the atmosphere.