Calculation of raw water requirement and Reservoir size for a power plant




In order to calculate the raw water requirement for a power plant, first of all we should know the losses in power plant.
As per new law raw water consumption should be 2.5 liters/kwh, presently it is around 4.5 liters/kwh.

Different losses in power plants :

A-Boiler


  • Boiler blow down : 2% of steam generation
  • Deaerator vent loss : 0.1% of Deaeration
  • Soot blower steam : 0.8 to 1% of Boiler steam generation per day


B-Turbine & Process steam 


  • Process steam lines losses due to drain & traps : 1% of steam generation
  • Cooling water evaporation loss : 2% of cooling water circulation
  • Losses in process return condensate : 10% of steam given to process

C-Water treatment plant (WTP)


  • Clarifier : 2% of total raw water input or 5% of DM water generation
  • MGF back wash water loss : 40% of MGF inlet water (Back wash frequency : once in every 8 hours of operation)
  • Reverse Osmosis (RO) plant reject water : 25% of total input water to RO plant or 35% of RO capacity
  • Water losses in DM plant regeneration process : 30% of DM plant capacity for every regeneration process
D-Other miscellaneous losses & cunsumption

  • Losses due to leakages : 10 MT/day
  • Water used for drinking & service : 10 MT/day
  • Fire fighting system : 40 MT/day...Considered Jockey pump is running for 4 hours in a day at 10 M3/hr flow
Let us discuss the above lossed by considering an example of 20 MW Cogeneration based power plant.This plant has Boiler of capacity 130 TPH,Steam given to process application is 65 TPH. Calculate the RO plant , DM plant capacity & Raw water consumption per day.

Calculation of total water requirement by considering various losses

Step-I

Calculate DM water requirement per hour
  • Blow down loss = 130 X 2% = 2.6 TPH
  • Deaerator vent loss = 130 X 0.1% = 0.13 TPH
  • Soot blower steam loss = 130 X 1% / 24 = 0.054 TPH
  • Process steam loss = 130 X 1% = 1.3 TPH
  • Losses in process steam condensate = 65 X 10% = 6.5 TPH
  •  SO total DM plant capacity = 2.6 + 0.13 + 0.054 + 1.3 + 6.5 =10.58 TPH
  • DM plant is being stopped for 4 hours in a day for regeneration purpose,
Therefore, DM plant capacity = 10.58 X 24/20 = 12.696 TPH

Step-II
Calculate the cooling water make up.
  • From the above example, quantity of steam going to the condenser is 130-65 = 65 TPH
  • Cooling water circulation flow is = 65 X 60 = 3900 TPH
  • Note: Considered 60 TPH of CW is required to condensate the 65 TPH of steam
  • So total cooling tower loss = 3900 X 2% = 78 TPH 

Step-III

Calculate WTP losses

  • Clarifier blow down losses = 12.96 X 5% = 0.65 TPH
  • RO plant reject water = 12.96 X 35% = 4.53 TPH
  • DM water regeneration losses (SAC+SBA+MB) = (3 X (12.96 X 30% ))/24 = 0.486 TPH

Step-IV
Other miscellaneous
  • Leakage losses = 10 TPD =10/24 =0.24 TPH
  • Drinking & Service water = 10 TPD =10/24 = 0.24 TPH
  • Fire fighting water = 10 TPD =10/24 =0.24 TPH
So total raw water requirement =12.696 + 78 + 0.65 + 4.53 + 0.486 +0.24 + 0.24 +0.24 = 97.08 =97 TPH

Total raw water required in a day = 97 X 24 =2328 TPD

Take 10% Extra Margin = 2328 X 110% = 2561 TPD

Size of raw water reservoir by considering water requirement for 7 days

Total storage capacity = 7 X 2561 =17927 Tonnes or M3.....As density of water is 1000 kg/m3

Take reservoir  depth of 6 meter
Then tank size 
17927 M3 = Length X Breadth X 6

L X B =2987.3 M2

Take length of the reservoir = 60 meters
then breadth of the reservoir will be = 2987.3/60 = 49.8 =50 M3

So size of the reservoir will be = 60 X 50 X 6 meters
'

Calculation of coal handling plant and bunker capacity





Coal handling plant (CHP) consists of ;


  • Coal unloader from vehicles
  • Coal storage yards
  • Coal vibrofeeders
  • Coal vibroscreen
  • Magnetic seprators
  • Coal crusher
  • Coal weigher
  • Series of Conveyors
  • Water sprinkling system
  • Coal shuttle conveyor
  • Coal storage bunkers

Inorder to calculate the coal handling and coal storage bunkercapacity, first we need to know the coal requireent per day for a plant, coal handling maintenance stratergy

We shall calculate the coal handling & bunker capacity by taking an example of 25 MW thermal power plant consuming coal of GCV 4900 kcal/kg & having heat rate 3200 kcal/kwh running at 100% PLF.

Plant running load = 50 MW X 100/100 = 25 MW

We know that coal consumed = Heat rate X Power generation / (Coal GCV)

Coal consumed =3200 X 25 / 4900 = 16.32 MT/hour

Coal consumed in a day = 16.32 X 24 =391.68 MT take round figure 392 MT/day

A-Coal handling capacity calculation

Consderations:


  • Coal handling plat is operated 14 hours in a day
          Note: Some designer consider operating hour of the plant is 10-12hours
  • 10 hours used for cleaning and preventive maintenance
CHP capacity =392/14 =28 Tonnes / hour

Take 50% extra margin on capacity

CHP capacity = 28 X 150% = 42 Tonnes/hour


B-Coal yard design

For 25 MW power plants coal can be supplied through truckes & lories .It is sufficient to keeping the stock of 7-8 days coal in coalshed.

Coal shed capacity = Lenght 50 meter X Width 30 meter X Avg Height of coalheap 4 meters X coal density 800 kg/m3 = 4800 MT

Which han hold the coal for 12 days of full load operation days

If the plant is of bigger size, then the coal is supplied through railway & Wagons & stored at yard..

Yard capacity =Length X Width X avg.Height of 6 meter X Coal densitykg/3

Coal from Shed & yard is then shifted & dozed to vibrofeeder hopper through chain & tractor dozers

C-Selection of bunker capacity


Buker capacity is generally designed for 12-14 hours of full load operation

Let us calculate with 12 hours of operation hours

Coal consumption in 12 hours = 392 X 12 /24 =196 MT

Volume of bunker = 196 X 1000/800 = 245 M3

Take 10% of extra margin on bunker as some of coal stucked on bunker wall surface cannot be used for Boiler. Which is unaccountable

So total water volume of Bunker = 245 X 110% = 269.5 take round figure =270 M3


Basics terms used in Thermodynamics & related calculations


                                Thermodynamics:

It is an axiomatic science which deals with the relations among heat, work and properties of equilibrium system.It is a science, which deals with interaction between energy and material system.

Terms used in Thermodynamic science:

System:It is a finite quantity of matter or a prescribed region of space.

Boundary:It is the actual or hypothetical envelope enclosing the system.


Closed system: If the boundary of the system is impervious to the flow of matter is called  closed system.


Open system: there is  flow of matter into and out of the system


Isolated system:An isolated system doesnot exchange energy  & matter with any of the other system


Homogeneous system: A system which contains single phase is called homogeneous system


Hetergeneous system : Here system consists of more than two phases


Pure substance: A substance which is homogeneous in compossition &  chemical aggregation


State: It is the condition of the system at an instant of time as described or measured by its properties


Cycle:Any process or series of processes whose end states are identical is termed as a cycle


Process: It occurs when the system undergoes a change in state or n energy transfer at a steady state.


Reversible process: A process is one which can be stopped at any stage and reversed so that the system & surroundings are exactly restored to their initial states.


Example:Exapnsion & compression of springs, Electrolysis


Irrreversible process: In thisprocess heat is transferred through a finite temperature.


Example:Combustion, free expansion, heat transfer


Temperature: It is state of a body  which distinguishes a hot body from a cold body.It is measured in Fahrenheit, Degree centi gare, Kelvin etc


Pressure: It is a force per unit area.Pressure is exerted by gases, vapours & liquids.It is measured in Kg/cm2,Bar, Pascal, N/m2, N/mm2, mm of water column.



Thermal Equilibrium: Temperature of the system does not change with time and has same value at all the points of the system.

Mechanical Equilibrium: It is the condition where there are no unbalanced forces within the system, pressure in the system is same at all the points.

Chemical Equilibrium: Composition of chemicals does not change with time and no chemical reaction takes place in the system.

Enthalpy:It is the total heat content of the steam. Expressed in h…kcal/kg.

Entropy: is a function of a quantity of heat, which shows the possibility of conversion that heat into work. That is, if Entropy is more then there is minimum availability for conversion of heat into work and for minimum entropy there is maximum availability for conversion of heat into work. It is measured in kcal/kg.

Boyle’s law:At constant temperature, pressure of a perfect gas is inversely proportional to its volume.

P = 1/V or PV = Constant

Charles law:At constant pressure, volume of a given mass of a gas is directly varies as its temperature.

V = T
(V1/T1) = (V2/T2) = …… Constant

Gay-Lussac law:The pressure of a given mass of a perfect gas varies directly as its temperature, when the volume remains constant.
P = T
(P1/T1) = (P2/T2) = Constant

Relation among pressure, temperature, enthalpy and specific volume of steam

  • At constant temperature enthalpy decreases with increase in pressure
  • At constant pressure enthalpy increases with increase in temperature.
  • Specific volume increases with decrease in pressure and increase in temperature
  • Enthalpy of evaporation decreases with increase in pressure and temperatures.
Specific heat: Amount of heat required to raise the temperature of unit mass of substance by 1 degree centigrade.It is measured in constant pressure Cp & Constant volume Cv.Mesured in kcal/kg

Specific volume: It is the volume occupied by the unit mass of the system.It is measured in m3/kg.



Intensive property:It is the property of steam, whose value for the entire system is not equal to the sum of their values for the individual parts of the system.

Example: Temperature, pressure and density.


Extensive property:It is the property of steam, whose value for the entire system is equal to the sum of their values for the individual parts of the system.



Example: Volume and mass.


Zeroth law of thermodynamics:The law states that, when two bodies are in thermal equilibrium with a third body, they are also in thermal equilibrium with each other.

First law of thermodynamics: Law states that when a system undergoes a thermodynamic cycle then the net heat supplied to the system from surroundings is equal to net work done by the system on its surroundings.

Second law of thermodynamics:It states that, it is impossible to construct an engine working on a cyclic process, to transfer heat from a body at a lower temperature to a body at a higher temperature without the aid of an external energy.

Different types of heat given to water to convert it into steam


Sensible heat : Amount of heat given to water to bring water from its normal temperature to Boiling temperature or saturation temperature. It is denoted by hf & measured in kcal/kg.


Latent heat: Amount of heat iven to saturated water to convert into saturated steam.It is denoted by hf g& measured in kcal/kg.


Total heat : It is the quantity of heat required to convert 1 kg of water into wet steam at constant pressure.It is the sum of total heat of water and the latent heat.It is also called as enthalpy.Denoted as h for wet steam and hg for dry steam


h = hf + x hfg


x is the dryness fraction of steam.


Dryness fraction of steam (x) : It is the ratio of the mass of actual dry steam to the mass of the steam containing it.


x = Ms/(Ms + Mw)



Superheated steam: when steam is heated after it has become dry and saturated.It is called superheated steam.


hsup = hf + hfg + Cps (Tsup-Ts)


Whwre, Cps = Specific heat of super heated steam = 0.5 kcl/kg

Tsup = Temperature of superheated steam
Ts = Saturated temperature at saturated pressure
(Tsup-Ts) is called as Degree of superheat.

Basic calculations:

1-Convert the pressure 80 cm of Hg to Kpa

Pressure at 760 mm of Hg = Density X g X h

                                           = 13.596 X 1000 X 9.81 X 760/1000
                                           = 101325 Pa =101.325 Kpa

2-Convert 2mm of water column pressure to Pascal

Pressure due to 2 mm of water column =1000 X 9.81 X 2 =19620 Pa

3-On a piston of 15 cm diameter of a force of 2000 N is applied uniformely caluclate the pressure on piston

Pressure = Force applied/Area of the piston

P = 2000 / ((3.142 X 0.152/4).....Area of piston =Pi X D2/4

P = 113636.363 N/M2

3-Atube contains an oil of specific gravity 0.88 to a depth of 1500 mm, find the gauge pressure at this depth

SG of oil =0.88
Depth of the oilin tube =1500 mm
We know that,
P = Density X g X h

P = 0.88 X1000 X  9.81 X 1.5...As SG =Density of oil / Density of water, Density of water is 1000 kg/m3

P = 12,949.2 N=/m2

1 N/M2 =1 X 10-5 kg/cm2

P =0.13 kg/cm2

4-Determine the dryness fraction of steam which has 2 kg of water in suspension with 60 kg of steam

Mass of dry steam Ms = 60 kg

Mass ofwater in suspension = 2 kg

Dryness fraction of steam x = 60/(60+2) =0.967

5-Determine the amount of heat given to 3 kg of water at 25 deg c to convert it into steam at 7 kg/cm2G and 0.9 dry.

Mass of water =Mw = 3 kg

Temperature of water = tw = 25 deg c

Pressure of steam = 7 kg/cm2

Fom the steam table at 7 kg/cm2 pressure (take absolute pressure i.e at 8 kg/cm2),

hf =172.73 kcal/kg

hfg = 488.22 kcal/kg

We have the formula for enthalpy of 1 kg of steam at 0 deg c is

h = hf + xhfg =172.73 + 0.9 X 488.22 =612.12 kcal/kg

Sensible heat of 1 kg of water at 25 deg c is = Mw X Cpw X (tw-t0)

=3 X 1 X (25-0) =75 kcal/kg

Net quantity of heat supplied per kg of water =612.12-75 =537.12 kcal/kg

Therefore total amount of heat to be supplied =3 X 537.12 =1611.38 kcal

6-Determine the mass of 0.2 m3 of wet steam at a pressure of 5 kg/cm2G and dryness fraction of 0.85. Also calculate heat of 1 m3 of steam.

Steam pressure P = 5 kg/cm2

Dryness fraction x =0.85

Fro steam table at 5 kg/cm2G

hf = 160.64 kcal/kg

hfg =497.47 kcal/kg
 Vg = 0.312 m3/kg

Density = 1/(x X Vg) =1/(0.85 X 0.312) =3.77 kg/m3

Mass of 0.2 m3 of steam = 0.2 X 3.77 =0.754 kg

Total heat of 1m3 of steam which has 3.77 kg of mass
=3.77h
=3.77 X (hf + xhfg) = 3.77 X (160.64 + 0.85 X 497.47) = 2199.7 kcal

7-What amount of heat would be required to produce 100 MT of steam at pressure of 67 barA and temperature 490 deg c from 150 deg c? Consider Cp of super heated steam =0.5 kcal/kg

Mass of steam = 100 MT =100 X 1000 =100000 kg

Steam pressure P=67 kg/cm2 absolute

Temperature of steam tsup =490 deg C

Temperature of water t =150 deg C

Refer steam table at 67 kg/cm2A & 490 deg c 

hf =300 kcal/kg

hfg =362.91 kcal/kg

ts = 283.75 kcal/kg

hsup = hf + hfg + Cps X (tsup-ts) =300 + 362.91 + 0.5 X (490-283.75) =766.035 kcal

Amount of heat already associated with 1 kg of water = 1 X 1 X (150-25) =125 kcal..Specifc heat of water is 1 kcal/kg

So net heat required = 766.035-125 =641.035 kcal

Total amount of heat required =641.035 X 100000 =64,103,500‬ kcal







Calculation of power generation cost of Thermal power plants & Co-generation plants


Power generation cost: It is the amount of rupees spent on generation of 1 unit of power


Power export cost: It is the amount of rupees spent on export of 1 unit of power

Generally power generation actual cost is the sum of Fuel cost, man power cost, operation & maintenance costs administration cost, river water cost, plant gardening & vehicles cost  etc

Power generation & Export cost in Thermal power plants:

Part A:Fixed data
  • Total power generation in KWH = A1
  • Total power export KWH = A2
  • Total fuel consumed = A3
  • Rate of per ton of fuel in = A4
  • Raw water consumption per day in MT or M3 = A5
  • Rate of per ton or   of river water in  = A6
  • Rate of per unit power for lifting water from source to Reservoir Rs= A7

Part B:
Operation cost head wise
  • Cost of fuel in Rs B1= A3 X A4
  • Cost of raw water in Rs B2 = A5 X A6
  • Cost of chemicals consumed for water treatment = B3
  • Cost of fuel feeding in =B4
  • Cost of raw water lifting charges from river to reservoir= B5
Total operation cost C = B1 + B2 +B3 + B4 + B5


Part C:
Maintenance cost head wise
  • Cost of spares,consumables consumed  = C1
  • Cost of Lubricants = C2
  • Cost of store inventory= C3
  • Tools tackles testing cost = C4
  • Measuring instruments calibration cost = C5
Total maintenance cost C = C1 +C2 + C3 + C4 + C5

Part D :
Administration cost head wise
  • Cost of  O &M man power salary = D1

  • Cost of site expenditures =  D2

  • Cost of gardening labours salary =D3

  • Cost of Security guards salary = D4

  • Cost of transportation vehicles =D5
Total administration cost = D = D1 + D2 + D3 + D4 + D5
  • Total Cost of production, E = B + C + D
  •  
  • Power generation cost per unit =A1/E....Rupees/KWh or Dollars/Kwh

  • Power export cost per unit = A2/E.....Rupees/KWh or Dollars/Kwh

Note:

1-In calculation power generation cost, power consumed for plant auxiliary running should not be considered

2-In co-generation plants:
  • Cost of power given to process plants should be considered
  • Cost of process steam given should be considered for power generation cost calculation
Read

Power plant: Water sources & impurities present in it.




Water is basically the combination of 2 parts of Hydrogen & 1 part of Oxygen. It is very impossible to get pure water in the nature . Pure water does not exist in nature due to its characteristic as solvent. Number of matters like gases, minerals and organic materials dissolve in the water easily.

Water mixes with  fine particles wherever it flows such as silt, sand, iron,mud & organics etc. Biological growths like algae & bacteria take place in the water. Thus, water is usually contaminated with dissolved & un-dissolved solids along with living matters!



Raw Water sources in nature:

  • Rain water:
  • Surface water:Rivers, Streams, Ponds, Lakes, and Reservoirs
  • Ground water :Springs, Shallow Wells and Deep Wells

For Boilers, heat exchangers ,domestic & other industrial purpose, we cannot use these above water directly from their sources.Before using it, need to carryout some treatment to get required quality for particular application. water being universal solvent has lot of impurities int it.

Rain water is said to be very purest form of water, but after falling on ground it mixes with river, lake,seal water & soil, which makes it impure & unsuitable for direct use.

Effects of impure or raw water :

  • Scales in Boilers and Heat exchangers.
  • Poor quality boiler steam.
  • Corrosion of boilers, heaters and piping.
  • Stains, discoloration, spots.
Impurities present in water:

  • Dissolved impurities also called as Ionic impurities
  • Undissolved impurities also called Non-ionic impurities
  • And Gaseous impurities


1-Dissolved or Ionic impurities:

These are again divided into Cationic & Anionic

Cat ionic dissolved impurities

  • Magnesium
  • Calcium
  • Sodium
  • Potassium
  • Iron
  • Mangnese

Calcium and magnesium are the most common dissolved impurities found in water. When calcium and magnesium salts are present in considerable amount it imparts hardness to water i.e. it does not allow lather to form with soap. 

The salts of calcium and magnesium causes temporary (Carbonate) & permanent hardness (Non carbonate).

Sodium & Potassium are always present in any kind of water, but they will not harm much if the percentage of concentration of these salts are less.

Iron present in the water can cause corrosion & clogging. Iron can be in dissolved & precipitated form.

An ionic dissolved impurities

  • Chlorides
  • Sulphates
  • Nitrates
  • Phosphates
  • Silica.
  • Bi carbonates
  • Carbonates
  • Hydroxide
  • Fluorides

Chlorides: can be found  in all kind of water. The chloride  may be in combination with one or more cations, calcium, magnesium, iron and sodium. Chlorides of these salts are present in water because of their high solubility in water. 

Excessive chloride in water causes corrosion. It also impart taste to water. Chlorides are prominent in crevice corrosion and pitting.

Sulphates: Most raw water contains sulphates due to leaching and erosion of sulphate minerals and oxidation of sulphides. They can also be due to industrial waste discharge and farm drainage.

 Sulphate also occur due to aerobic oxidation of organic matter. Sulphate in water causes corrosion and scaling in boiler. Sulphate are normally found as calcium, magnesium and sodium salt. Sulphate are also aggressive to concretes.

Silica:Most natural water contain silica up to 100  ppm. Silica is an oxide of silicon which is a major constituents of igneous and meta morphic rocks, of clay minerals.Silica can exist in various form as simple silicates or as a complex polymeric material. Colloidal silica is rarely present in Bore well water but is commonly present in surface water. 

Silica can cause deposits on boiler, cooling tower, turbines ,pipe lines etc

2-Undissolved non ionic impurities:

These include
  • Colour
  • Taste and odour
  • Turbidity or suspended solids.
  • Oil.
  • Organic matter
  • Colloidal silica

Colour: is normally expressed in Hazen units and is caused by the presence of colloidal suspension and aquatic growth. It is also caused by dissolved organic substance due to decomposition of vegetation. Some water may have colour due to presence of iron.

Turbidity is caused by the presence of suspended solids in water. It is a measure of total weight of dry solids present whereas turbidity is an optical effect. The suspended impurities include clay, sand, algae and precipitated iron.

Taste and odor: Organics and some inorganic chemicals present in the water contribute taste and odour. These chemicals can originate from municipal or industrial waste or from natural resources such as decomposition of vegetable matter.

Organic impurities: Organic impurities can be due to vegetable decomposition. It is also due to organic matter which comes from animal and human fecal matter or it’s degradation products, industrial waste and agriculture pesticides and herbicides.

3-Gaseous impurities:
 Gaseous impurities mainly include
  • Carbon di-oxide,
  •  Oxygen,
  • Hydrogen sulphide,
  • Ammonia
  • Chlorine.
Carbon di-oxide: Surface water contains small amount of free CO2 but well water may contain more than 100 ppm as Carbon-di-oxide is found in waters coming in contact with decaying organic matter or carbonaceous material.

Depending on the pH of water carbon di- oxide may be present either as free carbonic acid (dissolved CO2 gas) or in a semi carbide form (as bicarbonates) or in a combined form (as carbonates), free CO2 depresses the pH and thus accelerates corrosion.

Oxygen: is practically absent in natural water, but is usually present in surface waters rather in high concentration. Oxygen is corrosive to metals but its  absence in natural waters could produce other obnoxious gases such as methane H2S etc.Dissolved oxygen is highly corrosive and should be removed either chemically or mechanically especially in Boiler feed water.

Hydrogen sulphide: is found in some well waters in areas where the soil contains certain types of organic matter, decomposing under anaerobic conditions .H2S creates unpleasant odour to water, promoters metal corrosion and  causes  clogging of pipes. 

Ammonia: is  due to industrial and agricultural pollution. It is corrosive to copper and brass at pH 9.0. Ammonia can be removed by various methods-Deaeration, chlorination or by hydrogen cation exchange if in ionic form.

In order to safeguard the Boiler, heat exchangers & pipe lines, it is utmost important to carryout the water treatment process to get required quality of water as feed water,cooling water etc.

Water treatment is divided into
Internal treatment: This treatment is done in Boiler drums, cooling water etc

External water treatment : It is carried out out side the unit (Boiler, Cooling water)

External water treatment process includes following sequential  sub processes & systems

  • Sedimentation: Normally happens in water reservoirs
  • Clarification: Removes turbidity , kills microorganisms
  • Filtration: Involves multi grade filters to remove turbidity
  • Ultra-filtration: Process of bringing down the water turbidity to <0.2 NTU
  • Reverse osmosis process: Removes reactive silica & conductivity
  • De-mineralisation: Removes Cation & Anion impurities present in water

15-Emergencies in power plant operation

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