THERMAL POWER PLANTS – Vol. I - Power Plant Technology - R.A.

Chaplin

POWER PLANT TECHNOLOGY

R.A. Chaplin
Department of Chemical Engineering, University of New Brunswick, Canada

Keywords: Power Plants, Technology, Economics, Energy, Thermodynamic Cycles,

Materials, Chemistry

Contents

1. Technological Decisions
1.1 Scope of Topic
1.2 Scientific Knowledge
1.3 Engineering Experience

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2. Fundamental Requirements
2.1 Common Principles

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2.2 Capital Cost
2.3 Fuel Cost
2.4 Efficiency
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2.5 Availability
2.6 Reliability
2.7 Unplanned Maintenance
2.8 Planned Maintenance
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2.9 Maintenance Costs

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3. Environmental Considerations
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3.1 General Scope

3.2 Plant Safety
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3.3 Environmental Safety

3.4 Sustainability
4. Thermodynamic Cycles
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4.1 Basic Concepts

4.2 Now-Flow Gas Cycles
4.2.1 Otto cycle (Spark Ignition)
4.2.2 Diesel Cycle (Compression Ignition)
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4.2.3 Dual Cycle

4.3 Steady-Flow Gas Cycles
4.3.1 Brayton Cycle
4.3.2 Actual and Modified Cycles
4.3.3 Regenerating Cycle
4.3.4 Intercooling Cycle
4.3.5 Reheating Cycle or Afterburning Cycle
4.3.6 Turbojet Cycle
4.4 Steady-Flow Steam Cycles
4.4.1 Saturated Rankine Cycle
4.4.2 Superheated Rankine Cycle
4.4.3 Superheated-Reheated Rankine Cycle
4.4.4 Saturated-Reheated Rankine Cycle

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4.4.5 Regenerative Cycle

4.4.6 Actual and Modified Cycles
4.5 Combined and Hybrid Cycles
4.5.1 Combined Cycles
4.5.2 Steam Injected Gas Turbine
4.5.3 Pressurized Fluidized Beds
4.5.4 Nuclear Gas Turbines
5. Applications of Thermodynamic Cycles
6. Heat and Energy Flows
6.1 Thermal Cycle Efficiency
6.2 Heat Transfer
6.3 Energy and Exergy Flows
6.4 Thermo-economic Analysis
7. Fuels and Efficiency
7.1 Calorific Value

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7.2 Combustion Calculations

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7.3 Efficiency Determination
7.4 Gaseous Effluents
7.5 Nuclear Fuel
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8. Metallurgy and Chemistry
8.1 Material Selection
8.2 Carbon Steel
8.3 Other Metals
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8.4 Material Damage

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8.5 Material Inspection

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8.6 Water Chemistry

8.7 Water Treatment
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8.8 Operation and Monitoring

Acknowledgements
Glossary
Bibliography
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Biographical Sketch

Summary
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In order to generate electricity using a source of heat it is necessary to employ a

thermodynamic cycle with a working fluid. The working fluid receives heat from the heat
source and rejects part of it to a heat sink while producing work. The First Law of
Thermodynamics requires that energy be conserved and that the work and heat rejected
be equal in quantity to the heat supplied. The second Law of Thermodynamics requires
that a certain amount of heat be rejected for the cycle to produce work. For an idealistic
situation the amount rejected depends upon the temperatures of the heat source and heat
sink. Since not all the heat entering the thermodynamic cycle can be converted into work,
any such cycle can only have a certain maximum efficiency defined as work output
divided by heat input.

The working fluid of a thermodynamic cycle circulates around or through the system
while receiving or rejecting heat and doing work. Usually a common fluid such as

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THERMAL POWER PLANTS – Vol. I - Power Plant Technology - R.A. Chaplin

water-steam or air-gas is employed although other fluids are sometimes used for special
applications. Generally the working fluid receives heat at a high pressure, does work
while expanding and rejects heat at a low pressure. In a water-steam cycle there is a
change of phase associated with the absorption and rejection of heat which occurs during
boiling and condensation respectively. Steam at high pressure expands in a turbine to
produce work. In an open air-gas cycle, hot gas at a high pressure expands in a turbine to
produce work while in a closed cycle, it expands in a cylinder to drive a piston. All cycles
require that the working fluid be pumped or compressed to the required pressure before
receiving heat. This requires that some of the work output be directed back into the cycle
to sustain it.

Various modifications to the basic cycles have been adopted to suit certain applications
and to improve thermodynamic efficiency. Combined cycles actually make use of two
thermodynamic cycles with the heat rejected from one cycle being the heat source of the
other. Thus improved efficiency can be obtained which is an important factor when using

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costly fuels.

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While proper selection of the fuel and the thermodynamic cycle ensures good plant
efficiency, proper selection of materials of construction is required to ensure good plant
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reliability. This is important for the overall economy of operation. Generally carbon
steel is used for most structural and system components but special alloys and other
materials are used where resistance to stress, temperature and corrosion is required. With
high temperature working fluids, especially water-steam, corrosion can cause weakening
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and wastage of materials. This can be minimized by appropriate chemical treatment of

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the working fluid to inhibit corrosion. Water chemistry is therefore an important aspect
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in steam power plant operation.

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1. Technological Decisions

1.1 Scope of Topic

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In the planning, construction, operation and maintenance of power plants, certain

technological decisions must be made. As background, some fundamental requirements
and environmental considerations are outlined to indicate the scope of such decisions.
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However a certain depth of knowledge is required in making appropriate decisions.

Generally management decisions are based on cost or, to be more correct, least cost. This
does not necessarily guarantee a good decision because of the technological implications.
On the other hand a good technical decision may have unsatisfactory financial
implications. The technical and financial aspects both have to be taken into account.

In the construction of new plant or installation of new equipment, a specification setting

out the minimum technical requirements is generally drawn up and the contract awarded
to the bidder with the lowest cost. With maintenance there are certain technical
requirements with regard to degree of wear or maximum running hours and the
maintenance is scheduled for a period with the lowest cost penalty for lost production.
However, when considering alternative technologies for similar purposes there may be
unknown technical factors or hidden costs which make the selection of one or the other
difficult. This is especially true for new technological developments for which there is no

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existing operational experience. Because of the high capital cost of power plant
equipment there is generally a high degree of conservatism in the management of power
utilities. Thus technical recommendations must be well founded and supported by
extensive scientific knowledge and engineering experience.

This and related chapters, deals with the scientific basis applicable to power plants while
Production of Steam and Production of Power cover the engineering constraints related
to the design and operation of large commercial power plants.

1.2 Scientific Knowledge

To fully understand the concept of plant thermal efficiency, for example, a basic
knowledge of thermodynamic cycles is required. This indicates that temperatures in the
cycle are a key parameter and that one should strive for the highest peak temperature in
the cycle for optimum efficiency. Furthermore there is a maximum theoretical efficiency

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which is considerably less that 100 % due to the fact that the lowest temperature in the

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cycle cannot be less than that of the environment.

This topic gives an overview of the basic scientific knowledge associated with power
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plants while the individual articles within the topic address certain important aspects,
such as heat transfer and fluid flow, which is important as a basis to the understanding of
the engineering constraints covered in the latter topics. Although nuclear energy is
addressed in a separate theme, an article on nuclear theory is included to complement the
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article on combustion theory as both nuclear and fossil fuels provide the necessary heat to
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drive thermal power plants.

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1.3 Engineering Experience

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Returning to the concept of efficiency it was noted that the highest thermodynamic cycle
temperature will give the best efficiency. There are however certain engineering
constraints to the use of high temperatures. Structural materials weaken and deform at
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temperatures beyond certain maximum values thus imposing a limit on the operating
temperature and hence the plant thermal efficiency. Comparing a small steam turbine and
an industrial gas turbine of similar capacity, for example, it is found that the gas turbine
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can receive gas at a higher temperature than that of the steam entering the steam turbine.
Such temperature constraints which ultimately impact the plant thermal efficiency are
explained, along with many other engineering limitations, in the later topics.

Ultimately a combination of engineering experience and scientific knowledge can

provide a sound basis for technological decisions which have to be weighed against their
financial implications. The purpose of this theme, Thermal Power Plants, is to provide a
suitable background of knowledge and experience for the reader to recognize some of the
complexities of modern thermal power plants. Before embarking on the technicalities
however some fundamental requirements for power plants and certain environmental
considerations should be reviewed.

2. Fundamental Requirements

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THERMAL POWER PLANTS – Vol. I - Power Plant Technology - R.A. Chaplin

2.1 Common Principles

Whether purchasing a motor vehicle, an aircraft or a power plant, the same basic
principles apply. It must meet the intended purpose and provide good service.
Furthermore it must be properly financed and economical to operate. It must also comply
with various regulations regarding human safety and environmental impact. Some of
these common principles related to certain aspects are outlined below. Naturally the
greater the investment the greater the consideration given to the individual aspects.

2.2 Capital Cost

Capital cost is often seen to be the most important aspect. Finance for the purchase must
be obtained and the expenditure justified. Usually there are constraints regarding the
maximum expenditure and a lower cost item is perceived more favorably. Often,
provided similar items meet the required technical specification, a very small difference

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in cost will determine whether to purchase the item from one vendor or another. In the

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case of a power plant, which will take many years to build, a small difference in cost can
escalate considerably before the payment is actually made in full. Capital cost, however,
is not necessarily a measure of the ultimate lifetime cost of operation as there are many
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other costs to be taken into account. Also different models or types have very different
capital costs for same capacity. This is certainly the case in motor vehicles and follows
through to power plants where nuclear, hydro and fossil fueled plants have widely
ranging costs per megawatt of installed capacity.
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2.3 Fuel Cost

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The cost of fuel is a very important consideration as it is the one cost that is directly and
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immediately reflected in the product. Most other costs are not nearly as clearly defined.
Capital costs, although fixed, are repaid over a period of time which is not based on
operating hours. Maintenance costs which are usually based on running hours are not
necessarily fixed. Fuel however is purchased and almost immediately used at a certain
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efficiency to product of a given value. In a fossil fueled power plant the chemical energy
in the fuel is converted to electrical energy at an efficiency determined by the design of
the plant. The cost of the fuel therefore becomes a known fraction of the cost of
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electricity. Power utilities thus preferentially operate those plants which have high
efficiencies and low fuel costs so as to minimize the fraction of fuel cost in the overall
cost of producing electricity. Similarly some airlines operate only very high fuel
efficiency aircraft to minimize the fraction of the total flying cost that is related to fuel.
For motor vehicles the cost of using the vehicle is often related to the cost of fuel even
though this may be only about a quarter of the overall lifetime operating costs.

2.4 Efficiency

Following from fuel costs is efficiency. The two go hand in hand as part of the cost of the
product and the cost of the fuel are linked by the efficiency of the process. There is,
however, also a link between capital cost and efficiency. In many energy conversion
processes, efficiency can be increased by improved technology which invariably results
in increased capital cost. In a thermal power plant, efficiency can be increased by, for

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example, increasing the upper temperature of the thermodynamic cycle. This requires the
use of exotic and expensive heat resistant materials which increase the cost of the plant.
Whether this is a desirable route to follow depends upon the fuel cost. For a plant with a
higher fuel cost there is justification for a higher capital cost to improve the efficiency and
hence to lower the fuel cost fraction of the final product. Naturally the increase in the
capital cost fraction should not be greater than the reduction in the fuel cost fraction.

In this context it should be noted that nuclear fueled plants generally have high capital
costs and low fuel costs and moderate thermal efficiencies. Fossil fueled plants on the
other hand have lower capital costs and higher fuel costs and hence a greater incentive for
higher efficiencies. There are technical reasons for the differences in efficiency but
nuclear plants are able to operate economically at lower thermal efficiencies because of
the generally lower fuel costs. Combined cycle gas turbine plants generally have even
lower capital costs and higher fuel costs but their inherent high cycle efficiency makes
them attractive in certain applications.

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This leads to the question of load scheduling. Generally plants with low fuel costs are
scheduled to operate for long periods as base load plants and those with high fuel costs for
short periods as peak load plants. This tends to balance the repayment of capital costs.
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Plants with high capital costs thus tend to run longer hours than those with low capital
costs so the capital cost fraction appearing in the final product cost is more equitable. The
converse, though, is a more logical way of viewing it. Plants operating for short periods
should not have too high a capital cost as there are insufficient running hours over their
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lifetimes to recover excessive costs.

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2.5 Availability
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From the above it follows that power plants do not have to operate continuously. In fact,
with the daily variation in demand, some plants only have to operate when there is a peak
demand for power. It is important, however, that, when required to operate, the plant can
produce the power required, that is, it is available for service when needed. The same
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applies to aircraft and motor vehicles. Even if required for only short periods there must
be the assurance they will start and run as expected.
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Equipment that stands idle for a period of time has the advantage of being checked and
maintained regularly when in a shutdown condition but is also prone to startup failures
when required for service. Generally equipment that does not suffer thermal transients on
startup is less prone to problems arising from short periods of operation. Hydro turbines,
for example, may be operated through many startup and shutdown cycles without
significant adverse effects.

2.6 Reliability

Reliability is similar to availability but is related to the condition of the equipment when
in operation. Once running, it should continue to operate without failure for a
predetermined period. This is particularly evident in aircraft where a failure in flight can
have disastrous consequences. For a power plant, a failure of a key component may
require an immediate shutdown of the turbine generator. The consequent loss of

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electrical generating capacity requires immediate replacement with alternative more

expensive sources of electrical power. There is thus an economic penalty arising from a
loss in reliability.

2.7 Unplanned Maintenance

Associated with both availability and reliability is maintenance. A loss of either

availability or reliability inevitably results in a maintenance cost in addition to the cost of
providing alternative more expensive power. This maintenance cost ultimately becomes
part of the overall lifetime cost of operation. Furthermore, the loss of electrical
generation for a period ultimately gives a higher overall lifetime cost per unit of
electricity generated.

2.8 Planned Maintenance

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All plants, aircraft and vehicles require regular servicing after a period of operation. This

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invariably requires the equipment to be out of service for an extended period which may
require the use of alternative equipment. Power plants are generally part of a system that
has a variable annual power demand so that they may be taken out of service for several
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weeks at a time for major maintenance. This is an important factor in the case of those
nuclear plants which require off-load refueling on an annual basis. The planning of this
routine maintenance is important and is usually scheduled for periods when the system
power demand is low.
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Not all planned maintenance can be done during the low load periods when there is
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surplus generating capacity due to the availability of human resources and some routine
maintenance has to be done on an ongoing basis throughout the year when a plant can be
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taken out of service for a short period.

2.9 Maintenance Costs

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The overall costs associated with both planned and unplanned maintenance have to be
factored into the overall lifetime cost of the plant. There are thus three major components
associated with this overall lifetime cost namely: capital cost, fuel cost and maintenance
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cost. The last is related to availability and reliability and is not easy to predict prior to the
plant going into operation. Sound experience in plant operations and maintenance,
however, can allow for a critical assessment of a proposed design. Appropriate
modifications can ensure better availability and reliability and easier planned
maintenance. Such modifications invariably increase the capital cost but, if savings in
maintenance costs over the lifetime of the plant are greater than the increase in the capital
cost portion over the same period, the modifications are desirable.

3. Environmental Considerations

3.1 General Scope

When a power plant is built and operated it must comply with certain requirements and
regulations which are externally imposed and generally not related to the above

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considerations of efficiency and economy. They are generally related to the health and
safety of both the plant staff and the general public. From the time of the first power
plants their scope has been progressively extended from the well-being of the plant
operator to that of the most remote citizen. Initially there was only concern for the
physical safety of the plant operators working on systems containing high pressure steam
produced from high temperature gases. More recently concern has been extended to the
general public living far away from the plant but in the same atmosphere as that to which
the plant discharges its effluent.

3.2 Plant Safety

All power plants are built in accordance with a variety of codes and standards. These
ensure a certain quality of material and workmanship and also a certain level of safety.
Although failures of equipment may result in severe damage to the plant, safety to
personnel tends to be the governing factor when instituting safety regulations. This means

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that, with regard to certain aspects of the plant, the level of safety required for personnel

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protection is greater than that required for equipment reliability. There is thus a cost
associated with safety beyond that which is required for optimum economical operation.
To ensure that plants do provide adequate safety for the operating staff, therefore, some
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legislation is generally required to ensure compliance with appropriate safety measures.

In most countries therefore, there are building and manufacturing codes to ensure
integrity of equipment and a safe working environment. Such codes range from pressure
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vessel design to the design and layout of stairs and walkways. Once in operation other
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codes ensure that proper procedures are followed for a range of operations from the
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periodic testing of pressure vessels to the proper isolation of electrical equipment during
maintenance.
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Although most safety procedures are legislated by a government body, most plants have
additional standing instructions for personnel to follow when carrying out certain
operations. These tend to be for the protection of the plant and to ensure good long term
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reliability. Machine startup procedures for example can prevent inappropriate actions
and consequent damage to the equipment. Such procedures are related to safety as any
failure poses some risk to the operating staff.
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Bibliography

Black & Veatch (1996). Power Plant Engineering, Chapman and Hall.[ This gives a good information on
different types of power plants and their main components.]

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THERMAL POWER PLANTS – Vol. I - Power Plant Technology - R.A. Chaplin

British Electricity International (1992). Modern Power Station Practice, Volume E, Chemistry and
Metallurgy, Pergamon Press.[ This provides detailed information on both chemistry and materials as used
in power plants. Very good book with regard to the understanding of the processes and the operation of
power plants.]
Elliott T.C. (1989). Standard Handbook of Power Plant Engineering, McGraw-Hill.[ This gives good
information on the basics of power generation with reference to different plant components.]
El-Wakil M.M. (1984). Powerplant Technology, McGraw-Hill.[ This covers all types of power generation
including alternative and emerging technologies. Good for an initial study and overview of power
production.]
Haywood R.W. (1991). Analysis of Engineering Cycles, Pergamon Press.[ This is a concise review of
basic engineering cycles. Good for an initial understanding of thermodynamic cycles in which work is
produced from heat.]
Khalil E.E. (1989). Power Plant Design, Abacus Press.[ This provides a follow up of basic engineering
cycles with applications to conventional power plants. It includes heat exchange and energy conversion
equipment.]

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Kotas T.J. (1985). The Exergy Method of Thermal Plant Analysis, Butterworths.[ This gives a theoretical
and advanced presentation of exergy analysis as applicable to power generation and other thermodynamic

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processes.]
Stultz S.C. & Kitto J. B. (1992). Steam, Its Generation and Use, Babcock & Wilcox.[ This gives extensive
design information on fossil fuel fired boilers for production of steam. It includes a section on emission
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control and effluent handling as well as nuclear reactor design.]
Woodruff E.B., Lammers H.B. & Lammers T.F. (1998). Steam Plant Operation, McGraw-Hill.[ This is a
basic book on plant equipment. It illustrates various power plant components and describes their use and
operation.]
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Biographical Sketch
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Robin Chaplin obtained a [Link]. and [Link]. in mechanical engineering from University of Cape Town in
1965 and 1968 respectively. Between these two periods of study he spent two years gaining experience in
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the operation and maintenance of coal fired power plants in South Africa. He subsequently spent a further
year gaining experience on research and prototype nuclear reactors in South Africa and the United
Kingdom and obtained [Link]. in nuclear engineering from Imperial College of London University in 1971.
On returning and taking up a position in the head office of Eskom he spent some twelve years initially in
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project management and then as head of steam turbine specialists. During this period he was involved with
the construction of Ruacana Hydro Power Station in Namibia and Koeberg Nuclear Power Station in South
Africa being responsible for the underground mechanical equipment and civil structures and for the
mechanical balance-of-plant equipment at the respective plants. Continuing his interests in power plant
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modeling and simulation he obtained a Ph.D. in mechanical engineering from Queen’s University in
Canada in 1986 and was subsequently appointed as Chair in Power Plant Engineering at the University of
New Brunswick. Here he teaches thermodynamics and fluid mechanics and specialized courses in nuclear
and power plant engineering in the Department of Chemical Engineering. An important function is
involvement in the plant operator and shift supervisor training programs at Point Lepreau Nuclear
Generating Station. This includes the development of material and the teaching of courses in both nuclear
and non-nuclear aspects of the program.

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