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1

INTRODUCTION

Lawrence

F.

Drbal

o n e only has to experience a power outage o be reminded

of

how much we rake electricity

for

granted.

our

lighting.

heating, and cooling systems no longer operate. Computers.

televisions. videos, and other communication systems be-

come unusable. Trafiic con aol lights become Useless: e h a -

commercial buildings

become virmally inoperable.

tors

no

longermove

people;

and indusmes.schools. and

We

are

clearly dependent

on

elecmcity for most of

UT

every day activities. This dependence also demonstrates why

electricity is regarded as one of the most significant ociolog

ical inventions

of

the 20th century. Although he Un ited.

States andour industrialized neighborsenjoy the full benefits

of electricity, the world’s developing nations do not. Su pply -

ing electricity to these areas under various economic, envi-

ronmental, social, andpolitical con suain ts will be One of the

major challenges

in

the 21st century.

nomic conditions

in

the conceptual and planning phases of

Power producers

must consider the

l o c l

soc ia l a nd e c e

all projects. Their engineering decisions must reflect an

awareness and knowledge oft he best equipment and y stems

available. The final product. the electrical generation and

distribution system , must reflect m p n s i b l e application of

economic and engineering principles and of thoughtful rec-

ognition of social and environm ental concerns. T he ap-

proach Black Veatch has used to meet these chal leng es is

described in this book.

tures prepared

by Black Veatch ins mc tor s for

use n

Power lum

Engineering

originated from a sene$

of lec-

teaching steam power lant design hrough the University

of

Ihsas Th e material was later expanded by the fum for use

i n teaching its ow n en,$neen and technical specialists. As a

book was

developed

from the

system design engineer’s

per-

definitive

text on the design

of

coal-fueled power plants,

this

Spective. nothe r words. the

book

describes the approach the

engineer uses to desig n and integrate the plant system s and

o

SPeClfyperformance and design requiremenrs. but it does not

address the detailed design of the equipment. which is usu

ally done by the manufacturer.

application of the major areas of power plant related

Power Plant Engineering

include s both theory and practi-

ranging

from

permining and engineering economics

Io coal and imestone handling. from design processes to

plant thermal heat balmces. Although the focus of the text is

On coal. the book reviews .dl m ajor pow er-senerating tech-

nologies. giving particular emp hasi s to curren t approaches.

It funher defines and analyzes the features

of

various plant

systems andmajorcomponents, and discusses promising

emerging technologies.

pulverized coal-fueled pow er plant from theo ry through th e

The text presents a

full

development of the design of

a

details of application.

Figure 1-1depicts a mo dem pulverized coal-fueled elec-

trical generation facility that uses the mo st com mo nly en-

countered Rankine-based thermodynamic cycle. This facil-

itygenerateselectricitybyproducingsteam in

a

s t e a m

generator and expanding the steam through turbi ne genera-

tor. The steam

is

then condensed n a cond ense r, and the

condensed liquid

is

used again in the steam generator.

ship

between engineering

design and economic

costs

and

Chapter 2

Engineering

Economics,

presents the relation-

provides the designer with economic analysis conc epts to

iden ufy the least-cost o ptions mo ng alternatives. Chapter

3

Therm odynam ics and Pow er Plant Cycle Analysis, presents

based cycle and procedures for

a

simplified heat balance

a method for nalysis and evaluation of the modem Rankine-

analysis.

Chapter

4.

Fossil Fuels. provides information

on

reserves.

prod uctio n, consumption, specific properties, and econ om ics

coal,which supplies ove r 50 of the fue l for lectrical gene-

for oil. natural gas, and othe r major fossil fuels, including

ration in the United States.

thou gh barges and trucks are

also

used. T he c oal handling

Coa l is usually delivered to the facility by unit nai ns

al-

system unloads the coal, then stacks. reclaims, crushes. and

conveys it to storage silos near the steam generator. Coal and

limestone handling system designs

are

discussed in Chapter

5.

Coa l is fed

from

the storage silos,pulverized

to

a powder.

and blown

into

the steamgenerator. Within thesteam genera-

combustion energy is used to produce s t e m . The charac-

tor, pulverized coal is mixed with

i r

and combusted. and the

quantities, and s t e m generator efficiencies are discussed in

teristics of the combustion process. air requirements. flue gas

Chapter

6.

steam

as i t

proceeds through the cycle. Chapter 7 discusses

The steamgeneratorproduces,superheats.andreheats

s t e m generator system and component design. steam tem-

perature control. and pulverizer design.

T h e

steam turbine generator. addressed

in

Chapter

8

I

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COAL HANDLING

SYSTEM

TURBINES

CIRCUL ATINQ WATER

SYSTEM

POSTCOMBUSTION CLEANUP SYSTEM

STEAM GENERAllON SYSTEM

SO

REMOVAL

SYSTEM

-

AIR

HEATER

A

STACK

FORCED DR FTFAN

RAFT FAN(S)

FLY SH TO L NDFILL

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converts the thermal energy of the superheated and reheated

steamfrom the steamgen erato r to electrical energy. The

sream turbine converts the s t e m thermal energy to rotating

me chan icd energ y, and the generator, which is coupled to

the stezm turbine. converts the mechanical enerxy to elecm-

cal snergy.

Steamexh auste d rom the low-pressure section of the

steam Nrbine is condensed to liquid in the condenser. The

condensed liquid is mo ved from the condenser by conden-

satepumps hrough ow -pressureregenerative feedwater

heaters to a deaerator. Boiler feed umps move the deaerated

liquid throughhigh-pressure regenerative he aters o he

steam generator. Extraction steam from the steam nub ine is

supplied to the low- and high-pressure feedw ater heaters for

the liquid rege nera tive heating, which improves cycle effi-

ciency. These steam cycle heat exchangers, w h c h include

the condenser,deaerator,and feedwater heaters. aredis-

cussed in Chapter 9. Design, performance, and arrangement

requirements are addressed,

as

well

as

design parameters for

steam turbine water protection.

Forced draft fanssupply combustion ir to thesteam

generator, and the primary

i r

fans transport pulverized coal

into the steam generator. h d u ce d draft fans remove the flue

gases from the steam gene rator nd exhaust them to the plant

stack. Chapter IO discusses the specific fan design require-

ments for the combus tion

i r

and Rue gas exhaust, including

performance. siz ing requirements. operating characteristics.

and fan selection.

Just

as

fans move air, pumps move liquids through the

plant. Chapter 11 focuses on pumps (primarily centrifugal

pumps) used in po we r plant applications, addressing circu-

lating water, condensate.

and

boiler feed pumps. Pump

per-

formance.sizingrequireme nts, operating characteristics,

and specific cons idera tions for selection are addressed.

Cooling water for the condenser

s

supplied by the circu-

condense r and rejects it

to

cooling towers or another heat

lating water system, which lakes the heat removed

from

the

Sink such

as

a cooling lake. Chapter 12, Circulating Water

Systems. ad dress es the circulating water system design, sys-

tem and com pon ent design requirements, arrangem ents.per-

fOrmance requ irem ents, material considerations. and perfor-

m a c e optimization of cooling towers with the condenser.

cycle

performance

is

affected

by numerous design and

Chapter

13, Cycle Performance

Impacts. describes how

OP rating parameters such as main steam and reheat s t e m

Pressure and temperature,steam turbine back pressure, num-

ber of feed wat er heaters. fee dw ater heater design parame-

a d superheatand reheat emperaturespray flows.

steam cycle mass and energy balances. Th e use of a steam

cycle performance impacts x e eflected in changes in

genera tor thermal kit

is

dso

demonstrated.

treatment for removal

of

fly ash particulates. sul-

Comb ustion gase s exiting the steam generator equire

fur

dioxide. m d nitrogen oxides by the plant pollution con-

systems before the gases are released through the plant

exhaust st3Ck.

Environmcntal regulations included in the

i n r roducnon

3

Clean Air Act of 1970 and subsequent 1977 and

1990

iunend-

ments have established emissions limits fo r particulate mat-

ter. wlf ur dioxide, and niuogen oxides. Chapter 14, Power

Plant Atmospheric Emissions Con trol, summarizes current

air emission regulations. emissionreduction echnologies,

and emission m onitorins systems.

Chapter 15. Water Treatment, addresses the proper treat-

ment and conditioning of water fo r the multirude of uses

in power plant processes. Th is chapter provides basic in-

formation on water technology, principal rypes of treaunent

considerations and techniquesapplicable to steampower

and conditioning equipment. and the more important design

tion, treatment. anddisposal of liquid andsolid wastes.

Coal-fueled po wer plants also require yste ms for co llec-

Liq uid wastes may include cooling tow er blowdown. ash

transport water. demineralizer regeneration chemicals, sulfur

diox ide removal system wastewater, an d coal pile runoff.

Solid wastes include s t e m generator

bottom

and Ry ash and

combustion gas desulfurization solid wastes. Ch apter 16 dis-

cuss es the current federal nd state regulations for liquid and

solid wastes,

s

well as treatment and disposal systems.

Power plants not onlyproduceenergy: hey also

use

electrical energy toc o n m l and power he various systems in

the plant. Chapter 17.Electrical Systems, addresses some of

the important design considerations fo r the auxiliary electri-

cal systems that power the coal handling, feedwater, conden-

sate, circulating water, combustionair, sulfu r dioxide re-

moval, and padculate removalsystems. Chapter

17

also

describes the uansmission syste ms used to transmit electri-

cal energy to the end user.

plant operation for the reliable and

efficient production of

The plant control system enables

the operators

to

direct

electrical energy. Chapter 18, Plant Control Systems. pre

sents an overview of the plant control system, i ts functions,

and the

type

of control equipment used in a mo dem coal-

fuele d electrical generating facility

mentsfor

site and plant arrangements.

Site arrangements

Chapter

19. Sire/Plant

Arrangement,

discusses require-

show the locations of ma jor power plant facilities, utilities

and facilities entering and exiting the site. the interconnec-

tions of major areas

on

the site. and traffic pa ne ms . Plant

arrangements define the physical arrangement of the build-

ings on the site and thesignificantequipment within the

buildings: locations and spacings of suppo rt columns: and

locations of wdls. Roors, doors. etc.

Although coal

is

the source

of

Fuel for over 50% of the

electricalgenera tion in the United States.natural 93s is

incre ssin& used with combustion turbines, in eithersimple

or combined cycle applications.

N3Iural gas.

used in

a

mod-

ified Brayton thermodynamiccycle (Chapter

3).

supplies

about

l0 o

of the electrical genera tion in the United States.

Chapter 10 Combustion Turbines. discusses combustion tur-

bine and combinedcycle echnology. its advantages.and

current s y s k m design requirements.

Fluidized bed combustion has emerged :1s a iensible alter-

pIanrS.

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  ower

P lan r ~~ in rmn ,q

native to pulverized coal steam generators A solid

bed of

fuel (such s coal) is fluidized by an upward flo w of air at a

velocity sufftcient to expand hebed. Com bustion takes

place w it h i the bed under

either

atmospheric or pres surized

conditions. Chapter

21.

Fluidized Bed Combustion. dis-

cusses this technology , its advantages and &sad vantages in

comparison to pulverized coal designs, and the current flu-

idizing bed approaches (bubbling bed and circulating bed).

Important system design requirements. supponing equip-

ment, steam temperature control. and fuel requirements are

also addressed.

Chapter

22,

Resource Recovery, describes the use of

energy production. Technologies that convertwaste to elec-

municipal and a g r i c u l d solid waste as fuel for electrical

trical energy en able resource recovery of m unicipal wastes,

landfill volume reduction, material recycling, and energy

recovery by burning waste in steam generators to produce

electricity.

The

chapter discusses these technologies. basic

designs, c omm ercial availability, fuels, and cost and perfor-

mance data.

Nuclear power, discussed in Chapter 23 supplies about

20 of the

electricity generated in the Unitedtates and

19

of the electricity generated worldwide. Current b o i i g water

and pressurized water designs are discussed, including the

supporting fuel cycle and radioactive waste management.

Future design s fo r large revolutionary reactors and sm aller

passive reactor designs are presented as well.

plete withou t a discussion

of

futureor

emerging technolog ies

No textbook on power

plant engineering would be com-

forelectricalenergy production. Chapter

24,

Emerging

Techno logies, presents

this

evaluation. Technologies

are

pre-

sented for fossil fuelgasification combined cyc le, magneto-

mass, ocean, and geothermal); energy storage (battery and

hydrody namics, an d fuel cell); renewables (solar,wind, bio-

compressed air); and nuclear (including fusion).

gether. Chapter 25, Power Plant Planning and Design, pre-

The remaining two chapters tie he design process to-

sents the planning and design process, which v ai es with

specific financial, engineering, environmental, and other

plant requirements.

T h ~ s

rocess may involve

special

studies.

such

as uel supply, system planning, siting evaluations,

transmission planning. and other analy ses. early

in

the proj-

ect development.Design engineering includes concep tual

design. which suppons permitting and licensing activities,

and detailed design, which etermines the technical require-

equipment procurement and con smc tion specifications.

Es-

ments for

all plant systems

and components and supports

sential project control activities include critical path sched ul-

ing of engineering and plant consmction, cost control. de-

sign control, and construction control.

Chapter

26

discusses essential permits and approvals and

the requirements for satisfying the environmental review

processes applicable to construction and operation

of

an

electrical generation facility, a critical first step. Chapter

26 gives generic desc riptions of

the

permits and approvals

typically required for fossil-fueled uni ts in the United States.

Power

Planr ngineering is the result of over80 years of

successful utility engineering by Black Veatch and more

than SO years of power plant engineering. design, and con-

struction wo rldwide.

This book may be

the most complete

reference source available. offering inform ation that is prac-

tical andproven n he field. This

source

is intended to

become the standard in the professional engineer's library as

the primary source of information on steam power plant

generation systems.

EDITOR S NOTE ON THE STYLE OF MIS BOOK

As

stated previously,

this

text

was

authored and supported by

many experienced Black Veatch engineers and specialists.

In a l l cases, thestyles of the ndividual authors were etained

as

much

as

possible, and

no

attempt was made to reconcile

the diversity of approach es. Every effort has been made to

use engineering codes and standards that are current as

of

publication. Readers should consult these publications di-

rectlyhensing information for design purposes.