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NAME-
I ASSIGNED
(Date)

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I PRINCIPLES
POWER

POWERPLANTBASICSSERIES

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BASICPOWERPLANTOPERATION
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I Completion Date

I Unit 1 The Functionof the PowerPlant

I unit 2 Boilers
Unit 3 TurbineFundamentals
- Unit 4 PlantOPeration

I Book SatisfactorilyComPletedOn (Date)

I Approved (Date)
(sign"G;f-suPervisor)

I NUSFnniNiNqG{PoRArioN
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I (3ol)258-2s00
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Copyright 19g1 by NUS Training
Corporation Ir
All rights reserved. This book
mu$ not be reproduced in
or any part thereof
any form without the
written permission of NUS Training
CorJ."tion.
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Printed in the United States
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January 30, 1gg1

tl
 TABLE OF CONTENTS

Page

THE FUNCTION OF THE POWER PLANT .................. 1.1.1

The Power System ................................. 1.1.1

Energy Conversion ................................ 1.2.1

The Steam Cycle .................................. 1.3.1

The Boiler ....................................... 1.3.2
The ......................................
Turbine 1.3.4
The ....................................
Condenser 1.3.4

Steam Cycle Flow ................................. 1.4.1

Movement of Steam and Water ...................... 1.4.1
Flow Control ..................................... 1.4.2

Emergency Conditions ............................. 1.5.1

General Emergency Actions ........................ 1.5.1
Specific Emergency Actions .Loss of Flame i n
the Boiler ....................................... 1.5.2

BOILERS .......................................... 2.1.1

Water Flow Path .................................. 2.1.1

Steam Flow Path .................................. 2.2.1

Once-Through Boilers ............................. 2.3.1

Critical Conditions .............................. 2.3.1
Operation of a Once-Through Boiler ............... 2.3.3
Advantages and Disadvantages of Once-Through
Boilers .......................................... 2.3.4
Operator Responsibilities ........................ 2.3.4
 Page

Combustion ....................................... 2.4.1

E l e m e n t s N e c e s s a r y f o r C o m b u s t i o n ................ 2.4.1
Combustion in a Coal-Fired Boiler ................ 2.4.3
Combustion in Oil or Natural Gas Fired Boilers ... 2.4.4
Operator Responsibilities ........................ 2.4.5

Air and Gas Flow Paths ........................... 2.5.1

Using Flue Gas to Increase Boiler Efficiency ..... 2.5.1
Pollution Controls ............................... 2.5.3
Sumnary of Air and Gas Flow Path ................. 2.5.4

Boiler Operation ................................. 2.6.1

Operator Responsibilities ........................ 2.6.1
Vents. Drains. and Blowdowns ..................... 2.6.2
Sootblowing ...................................... 2.6-2
The Control Room ................................. 2.6-3

TURBINE FUNDAMENTALS ............................. 3.1-1

Steam Flow Path .................................. 3.1.1

Turbine Parts .................................... 3.1.1
Turbine Rotation ................................. 3.1.3

Gland Seal and Gland Seal Exhaust System ......... 3.2.1

Operation of the Gland Seal System and the Gland
Seal Exhaust System .............................. 3.2.2
Other Types of Turbine Sealing Systems ........... 3.2.5

Bearing Lubrication .............................. 3.3.1

A Typical Turbine Lube Oil System . Basic
Components ....................................... 3.3.1
A Typical Turbine Lube Oil System .Additional
Components ....................................... 3.3.2
Basic Operator Responsibilities .................. 3.3.3
 Page

Turbine Control .................................. 3.4.1

Turbine Speed Control ............................ 3.4.1
Turbine Tripping ................................. 3.4.6

Turbine Operation ................................ 3.5.1

Startup Operation ................................ 3.5.1
Normal Operation ................................. 3.5.3
Shutdown Operation ............................... 3.5.3

PLANT OPERATION .................................. 4.1.1

Load Change ...................................... 4.1.i

Bearings ana Lubrication. Part 1 ................. 4.2.1

Sliding Surface Bearings ......................... 4.2.3
Rolling Contact Bearings ......................... 4.2.5
Lubrication ...................................... 4.2.7
Bearing Temperatures ............................. 4.2-8

Bearings and Lubrication. Part 2 ................. 4.3.1

Grease ........................................... 4.3.1
Oil Lubrication .................................. 4.3.3

Pollution ........................................ 4.4.1

Air Pollution .................................... 4.4.1
Thermal Pollution ................................ 4.4.2
Water Pollution .................................. 4.4.3
Noise Pollution .................................. 4.4.3

Plant Safety ..................................... 4.5.1

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LIST OF ILLUSTRATIONS
I
F ig u r e Title

1 .1 - 1 PowerDemand
for a Typical Twenty_FourHour
Page
T
1.2.1
Period

T y p i c a ' lH y d r o e l e c t r i c p l a n t
1 .1 - 3
t
1.2-2 SimplifiedFossil Fuel plant
1..2-L
1.2-2 t
1.3-i
1.3-2
1.3-3
Typical Drum-TypeBoiler
Typicai SteamTurbine
TypicaI Condenser
r.3-2
1.3-4
I
1.3-5

1.4-1 R e l a t i o n s h i p B e t w e e nS t e a mF l o w and
Power
I
0utput

2.L-I T y p i c a l N a t u r a l C i r c u ' l a t i o nU r u m - T y p e
Boiler .....
1.4-2

2 . t- 2
I
2.r-2 T y p i c a l B o iI e r Drum

2.2-L
2.7-5
fr
T y p i c a l T u r b i n e Secti ons
2.2-3

2.3-I Typical 0nce-ThroughBo.iler

2.3-3
I
2.4-1.
2.,4-2
Typical Burner
Typical Fuel Systemf o r a C o a l - F i r e dg o i l e r
2.4-2
I
...... 2.4-3
2.4-3 Typical 0 i I B u r n e r
2.4-4 Typica1 N a t u r a lG a sB u r n e r
2.4-4 li
2.4-5

2.5-I
2.5-2
T y p i c a l R e g e n e r a t i v eA i r p r e h e a t e r
T y p i c a l T u b u l a rA i r p r e h e a t e r
2.5-2 I
2.5-2
2.5-3 T y p i c a l A i r a n d G a sF l o w p a t h
2.5-4 fr
2.6-I Typical Sootblower
2.6-3
I
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I F ig u r e Title
Page

I 3.1-1
3.r-2
S i m p l i f i e d C r o s s - S e c t i o no f a T y p i c a l T u r b i n e " "
Typica'l Cross-Compound Turbine " '
3.r-2
3 .1 - 4

I 3.2-L
3.?-2
Typ'ica1G l a n d S e a l .
Typica1 G l a n d S e a l S y s t e ma n d T y p i c a l G l a n d S e a l
3.2-2

3.2-3
I 3.2-3
E x h a u sSystem
t
Typ'ica1C a r b o nS e a l S Y s t e m. .
3.?-5
3.2-6
3.2-4 Typ'ica1l , l a t e rS e a l S Y s t e m. . . . . .

I 3.3-1 T y p i c a l T u r b i n e L u b e0 j 1 S Y s t e m
3.3-1

I 3 . 4 -1 Typica'l HYdrauli c Actuator

T y p ' i c a 1T u r b i n e C o n t r o l 0 i l Systemw'ith a
3.4-2

3.4-2 3.4-3
I 3.4-3
F'lyweight Governor
C o n t r o lC i r c u i t a n dT r i P C i r c u i t
3.4-6

I 4.2-l
4.2-2
Axial and Rad'ial Movement"
Typ'ica'l Rad'ial (Sl'id'ing Surface) Bearing
4.2-2
4.2-3
4.2-4
T y p ' i c a 1A x i a l ( S l i d i n g S u r f a c e ) B e a r i n g
I 4.2-3
4.2-4 T y p i c a l R o ' l 1 i n gC o n t a c t R a d i a l B e a r i n g
T a p e r e dR o l l e r B e a r i n g
4.2-5
4.2-6
4.2-5

I 4.2-6
4.2-7
R o l l i n g C o n t a c t T h r u s t Beari ng
Us'ing a PYrometer
4.2-7
4.2-9

I 4.3-1
4.3-2
U s ' i n ga G r e a s eG u n . .
G r e a s eC u P. .
4.3-2
4.3-3
4.3-5
I 4 .3 - 3
4.3-4
0i 1 R'ingLubricati on SYstem
A C o n s t a nLt e v e l 0 i l e r . '
4.3-6
4.3-7
4 .3 - 5 F o r c e dL u b r i c a t i o n S Y s t e m" '
;l 4 .3 - 6 D r i p F e e dL u b r i c a t i o n . . .
4.3-B

IT
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 1. THEFUNCTION PLANT
0F THEPOt^lER

and operating them is a de-

Modernpower stat.ions are extreme'lycomplex,
w o u l d b e a w o r l d l a c k ' i n gt h e
m a n d i n gj o b . A w o r l d w i t h o u t p o w e rs t a t i o n s
mostflex.ible,economica.|,andusefulenergywehave-electricity.Pro-
process' which uses
d u c . i n ga n d s u p p l y i n g e l e c t r i c i t y i s a c o m p f i c a t e d
e q u i p m e n ti s t o d o i t s i o b '
s o p h i s t ' i c a t e de q u i p m e n t . H o w e v e r ,i f t h i s
of this first un'it in the Power
t r a i n e d o p e r a t o r sm u s t r u n ' i t . T h e p u r p o s e
PrinciplesprogramistogiVeyouabroadoverviewofhowpowerisproduced
t h ' i s u n ' i t , y o u w i l l k n o ww h a t a
a n d d i s t r i b u t e d . w h e ny o u h a v e c o m p ' l e t e d
into electrical
power system is, how mechan'icalenergy is converted
energy'whatthesteamcycleis,whatprocessesandcomponentsareinvolved
.inthesteamcycle,andwhatgeneralstepsshouldbetakenifemergency

c o n d i t i o n sa r i s e .

THEBASICCOMPONENTSTHATMAKE UPA
The f.irst segmentof this unit EXPLAINS
IS TYPICALLY hlHYTHERE
DISTRiBUTED, AREVARIATIoNS
P0t,lERSYSTEM,HOh|P0hlER
IN DEMAND, ANDI^JHYSUPPLY EQUALDEMAND'spec'ific terms that
ALI'IAYS
lviUST
youshouldunderstandbytheendofthissegmentareUNIT,t,lATT'MEGAI,IATT'
POhlER
L0ADDISPATCHER, and DEMAND.
SYSTE}4,
STATI0N,St,IITcHYARD,
Pot,lER

VIEI^ISEGMENT 1 OFTHEVIDEOTAPE BEFORE

1 .T1 I N T H I ST E X T .
R E A D I NSGE G M E N

1.1 The PowerSystem

power' A powerp'lant
The purposeof powerp'lants'is to generateelectric
makeselectricitybyusingoneofseveralpossibleenergysources:Foss.il
fuelplantsusecoal,oi'l,ornaturalgas;nuclearplantsuseuranium;and
dams' A powerplant uses
hydroelectric plants use water stored behind
energyfromoneofthesesourcestodriveelectricgenerators.Generators

1.1- 1
 BASICPOhlER PLANT OPERATION
1. T h eF u n c t i o no f t h e p o w e p
r lant (continued)

a r e m a c h i n etsh a t c o n v e r tm e c h a n i c aern e r g y
into erectricarenergy. Each
g e n e r a t o ri n a p o w e rp l a n t i s u s u a i l y
referred to as a unit; a typical
p o w e rp l a n t m a yh a v et w o o r m o r eu n i t s p r o d u c i n g
electricity at the same
time.

T h e a m o u n ot f e l e c t r i c i t y , o r p o w e r , t h a t
a g e n e r a t o rp r o d u c e si s m e a s u r e d
i n w a t t s . A s i n g l e u n i t m a yb e c a p a b l e p r o d u c i
of n g m iI I i o n s o f w a t t s . A
million watts is called a megawatt.

P o w e rp l a n t s h a v e t o d o m o r et h a n j u s t p r o d u c e
e l e c t r i c i t y . 0 n c ep r o d u c e o ,
e l e c t r i c i t y m u s tb e d i s t r i b u t e d . T y p i c a i l y ,
t h i s i s d o n ea s f o i l o w s : E a c h
g e n e r a t o r i n a p o w e rp l a n t i s c o n n e c t e d
to a transformer,which increases
the voltage of the electricity for more
efficient transmission. After the
o u t p u t f r o m a i l g e n e r a t o r si n a p l a n t p a s s e s
t h r o u g h t h e t r a n s f o r m e r s ,i t
goes into a switchyard.

I n t h e s w i t c h y a r d , a l l t h e g e n e r a t o r sa r e
c o n n e c t e dt o g e t h e r , a n d t h e i r
c o m b i n e do u t p u t i s t r a n s m i t t e d o n h i g h - v o l t a g e
t r a n s m i s s i o nl i n e s t o d i f -
f e r e n t a r e a s s e r v e db y t h e p r a n t . T r a n s m i s s i o n
r i n e s c o n n e c tp o w e rp r a n t s
w i t h s u b s t a t i o n s ' s u b s t a t i o n sc o m b i n ee l e c t r i c
p o w e rf r o m s e v e r a l s o u r c e s
together in one location. Transformers
i n t h e s u b s t a t i o n o e c r e a s et h e h i g h
voltage so that the electricity can be used
locally.

F r o mt h e s e t r a n s f o r m e r s , e r e c t r i c i t y . i s
distributed to nearbyneighbor-
h o o d so n l o c a ' r d i s t r i b u t i o n r i n e s . T h e s e
distribution rines are usualry
attached to utir'ity pores or buried underground.
w h e nt h e e r e c t r i c i t y
r e a c h e si t s d e s t i n a t i o n , a t r a n s f o r m e rd e c r e a s e s
t h e v o r t a g eo n c e a g a i n s o
t h a t i t i s c o m p a t i b l ew i t h h o u s e h o l oa p p i i a n c e s .

Eachline entering a buirding is connected

to an erectric meter, which
m e a s u r e st h e a m o u n to f e l e c t r i c i t y t h a t
is taken from the local distri-
bution lines. T h e m e t e r i s c o n n e c t e dt o a c i r c u i t
or fuse box. From
there' the erectricity is distributed throughout
he bu.irding.

whatyou've just read is a highry simplified

e x p l a n a t i o no f h o wp o w e ri s
d i s t r i b u t e d . I n r e a r i t y , p o w e rc o m p a n i e s
usuarly ownseverarprants that
are connectedtogether. Ail the prants ownecr

1 , . r -2
by one companymakeup what
I
/
 PLANTOPERATION
l BASICPOI^IER
L. T h e F u n c t t o n ' b i ' ' i r ' l - ' P o * t tP l a n t
(continued)

.iscalledapowersystem.Themajoradvantageofconnectinganumberof
I oowerplantstogether.isthatitprovidesalarge,reljablesourceof
electric Power'

I Inmanyinstances,differentpowercompaniesarealsoconnectedtogether

I byt.ie-lines.hliththistypeofarrangement,eachindiv.idualcompanycan
b u y p o w e r f r o m o r s u p p l y p o w e r t o t n e o t t r e r c o m p a n i e s w h e n n e c ecsusr a
is an important aspect o f p o w e r p r o d u c t i o n ' since alternating r er n
y t. 'T h . i s

,l w h i c h . i s t h e t y p e o f e l e c t r i c j t y u s e d i n h o m e s a n d b u s . i ns e
stored in batteries f o r f u t u r e u s e - it has to be upplied when'it's
sses,cannotbe

needed.
il y ust be capable
A p o w e rc o m p a n m
of supplying alternat'ing
current to jts

I c u s t o m e r s o n d e m a n d . T h e a c t u a l d e m a n d o n a p o w e r s y s t e mqu'ite
the needsof the customers' Meeting this
appl'iances' and machines
demandcan become
i s d e tcompli-

constantly being
erminedby

cated, since lights' -11e

I sw.itchedonandoff.Thecemandforpowermayrema.inrelat.ivelyconstant
f o r s h o r t p e r i o d s o f t i m e ' b u t o v e r a t w e n t y - f o u r h o u r p e r it o
imd e' i tfcohr aan gt yepsiac a l
1 ' 1 - 1 i s a g r a p h o f d e m a n dv e r s u s
tl great d e a 1 . F
twentY-four hour Period'
i g u r e

rl
il
il
il
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T 1.1- 3

T
 BASICPOI^/ER PLANTOPERATION
1. T h e F u n c t i o no ; l h ; - ; o w e r p l a n t

G e n e r a l l y ' t h e d e m a n df o r p o w e r
(continued)
I
is rowest at night, when
crosedand most people are
asreep. It begins to pick
w n e np e o p r eg e t u p a n d b u s . i n e s s e s
p e a k d e m a n d- u s u a i l y
b u s i n e s s e sa r e
up in the morning
o p e n . T h e h i g h e s t d e m a n od f
the day_ the
t
occurs during the early evening
c o m eh o m ef r o m w o r k a n d u s e
their lights ano appliances.
h o u r s w h e np e o p l e
T
The key to efficient power
d e m a n d .K e e p i n gs u p p r ya n d
distribution is maintain.ing
d e m a ne dq u a ri s t h e j o b o f
supply equal to
t h e r o a dd i s p a t c h e r .
li
The road dispatcher predicts
condition of the power system,
plants so that supply
t h e d e m a n df o r e r e c t r i c i t y ,
and cooroinatesthe output
a l w a y se q u a . l sd e m a n d .
monitors the
of the power
tr
T h ej o b o f t h e d i s p a t c h e ri s
a c o m p r i c a t e do n e , b e c a u s e
t h e d i s p a t c h e rm u s t
l'
m a k ec e r t a i n t h a t p o w e r i s
being suppried.in the
possibre. This means
most efficient manner
o p e r a t i n gt h e m o s te f f i c i e n t p r a n t s
a t o r n e a r o p t i m u ml o a d w h i l e
i n a p o w e rs y s t e m
k e e p i n gt h e l e s s e f f i c i e n t p l a n t s
I
to handreincreases in demand. in reserve
reduction in road on power p'rants
The dispatcher must arso
whenthe demandfor power
coordinatethe
tapers off.
li
Reriabirity is as important
for supply to equal demand,generators
a s e f f i c i e n c y i n p o w e rd i s t r i b u t i o n .
must work properly. However,
In order lr
ators' like all pieces of machinery, gener-
v i c i n g . w h e nt h i s h a p p e n s t, h e
t o m e e t c u s t o m e r s 'n e e d s .
o c c a s i o n a l l y b r e a k d o w no r
d i s p a t c h e rm u s t d e c i d e
n e e ds e r _
h o wt o b e s t c o n t i n u e
lr
Usually, the dispatcherhas

(1) I n c r e a s et h e o u t p u t o f o t h e r
units in the system.
three choices:
t
(Z)
(3)
B u y p o w e rf r o m n e i g h b o r i n gc o m p a n i e s .
C u t o f f s o m ec u s t o m e r st o p r e v e n t
an overload. T
D i s p a t c h e r sm u s tm a k es u c hd e c i s i o n s
power systemis always
t o a s s u r et h a t t h e p o w e rs u p p l i e d
e q u a l t o t h e s y s t e m , sd e m a n d .
Failure to do so
by a T
could resurt in a major'ross
power system.
of e'rectricargenerating
capacity ror tnl
I
T
11A
r. l- .l
I
I
 PLANT
BASICPOhIER OPERATION
I 1. The Functr Plant (coniinued)
on"o?''iht-'po*tt

I I.2 E n e r g yC o n v e r s i o n

i n S e g m e n t l . . l , y o u l e a r n e d t h a t a g e n e r a t ot hr i' issasm
eagmc hei nnyte'ot h
uwa t' icl lo lnevaer rnt s

I m e c h a n i c aeln e r g yi n t o e l e c t r i c a l
energy' In

I ^ I H E R E T H E M E C H A N I C A L E N E R G Y c O M E sthe
someof
T n oADVANTAGES
I , T T n B O TAND H HDIS- YDROELECTRicPLAN
You w'ill a'lso learn
F0SSILFUELPLANTS'
I ADVANTAGEsASS0CIATEDr,lITHHYDRoELECTRIcPLANTSANDF0SSILFUELPLA

I VIEl,I SEGMENT 2 OF THEVIDEOTAPE BEFORE

I 1 .T2 I N T H I ST E X T '
R E A D I NSGE G M E N

t Inahydroelectricplant,themechanicalenergyusedtoturnagenerator

I comesfromthereleaseofwaterfrombehindadam.Adamstoreswaterand
r e g u l a t e s t h e a m o u n t t h a t i s a l l o w e d t o l e a v e t h et lhaek w
u p p r e s s u r e . tJhen
e oart reirvies r .r T
e lheeaws a
edt e' tr h e
d a m b u . i l d s
s t o r e d b e h i n dt h e
I pressureforcesitthroughopen.ingsinthedamandthenthroughthepol|{er
plant.Asthewaterflowsthroughtheplant,.itturnswaterturbines.

I Figure1.2-lshowsthearrangementofthecomponentsthatmakeupatypica.|
hydroelectric Plant'

I
I
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L.2- t

I
 BASICPOI,JER PLANT OPERATION

t
r. t n e F u n c t i o no f i h e p o w e rp l a n t
(continued)

Theturbine has brades, or

b u c k e t s , m o u n t e do n a s h a f t .
w a t e r f r o w i n g f r o m t h e d a mp u s h e s
rotate'
against the brades,causing
T h i s m o v e m e not f m e c h a n i c a rp a r t s
( M e c h a n i c aer n e r g y i s
Theforce of the
the shaft to
c r e a t e s m e c h a n i c a re n e r g y .
t
c r e a t e d w h e n e v em

B e c a u s et h e t u r b i n e s h a f t i s
r e c h a n i c ap r arts move.)

c o n n e c t e dd i r e c i l y t o a g e n e r a t o r ,
I
and the generator turn together.
electricity - by converting
when the generator f,urns,
m e c n a n i c aer n e r g yi n t o e r e c t r i c a r
the turbine
it produces
energy.
t
T h e e n e r g y c o n v e r s i o np r o c e s s
in fossir fuer p.rants is
p r o c e s si n h y d r o e l e c t r i cp . l a n r s , simirar to the
b u t i t i s m o r ec o m p l i c a t e d .
t
In a fossil
fuel plant, energy conversions
ponents:
take place in the folrowing
three com_ T
(i)
(2)
T h eb o i t e r
T h e s t e a mt u r b i n e
T
T
(3) Thegenerator

F i g u r e 1 , . 2 - Zi s a s i m p l i f i e d
d i a g r a mo f t h e m a i n c o m p o n e n t s
t'.tolln_, in a fossil
t
I
I
I
t
I
t
7.2- 2
 BASICPOI^IER PLANTOPERATION
rl 1. T h e F u n c t ' i o n - b i ' [ f ' t - ' P o w tPt l a n t
(continued)

I Inatypicalfossjlfuelplantboiler,'uubesthatconta.inwaterformthe
furnace walls. The fue'l that enters
the furnace is ignited and burned'

T h e b u r n . i n g f u e l r e l e a s e s t h e r m a . | e n e r g y ' w h . i c h i s a b s o r b e d b y t h e w to
aterin
I the tubes. As the temperature of the

boil,andsteamisproduced'Thesteam'issentfromtheboilertothe
waterincreases' the water beg'ins

I turb'ine.

Insidethesteamturbinear-eb.ladesthataresjmilarinfunct.iontothe

I steamturb'ines have both stationary

blades of the water turbine. However,
b.|adesandrotatingblades.Astheh.igh-pressuresteampassesthroughthe

I turb.ineblades,itcausestherotatjngb.|adestomove,thusturn.ingthe
turb.ine.Thestationarybladesdirectthesteamtothenextsetof
rotat.ingblades.intherotatingblades'thepressureandthermalenergy

I .inthesteamareconvertedintomechanica]energy.Likethewaterturbine'

thesteamturb.ineturnsagenerator,whichconvertsthemechan.icalenergy
into electrical energY'
I Afterthesteampassesthroughtheturb.ine,jtflowsintothecondenser.

I Inthecondenser,thesteamiscooledandcondensedbackintowater.The
wateristhenpumpedbacktotheboiler,andthecyclebeginsaga.in.

I Thecomp.leteloopfromtheboiler,throughtheturbine,intothecondenser'
and back to the boiler is called
and
the sigStn:JEg' All the components

I systemsinvolved.inthesteamcyclearegenerallyreferredtoasone
g e n e r a t i n gu n i t o r , s i m p l y , o n e u n ' i t '

I to both hydroelectric plants ano

T h e r e a r e d i s a d v a n t a g e sa n d a d v a n t a g e s
fossilfuelplants.Themajordisadvantageofhydroelectricplantsisthat

I theyaresglglydependen^tonrainfa]lforpowerproduct.ion.Ifthereisa
drought,ahydroelectrjcplantcan.toperate.Inadd.it.ion,themax.imum
p o w e r o u t p u t o f a h y d r o e . | e c t r . i c p l a n t i s l i m i t e d b y t h e h e i g h t o f t h e w a tare
er

I behind the dam. One advantage

r e l a t i v e l y s i m p l e , b e c a u s et h e y
of hydroelectric
don't need boilers or steam
plants is that they
systems'

I Hydroelectricplantsa.|sohaveaneconomicadvantage.Thewaterthat
drivesahydroe.|ectr.icp.|antdoesn.tcostanyth.ing-as.|ongasthereis
ra'infal1, the fuel is free'

ll 1 , . 2 -3

T
 BASICPOWER

t
PLANTOPERATION
1. T h e F u n c t i o n o f t h e p o w e rp l a n t ( c o n t i n u e d )

T h e m a j o r d i s a d v a n t a g eo f f o s s i l f u e l p l a n t s
t o r u n t h e m . A s e c o n dd i s a d v a n t a g ei s t h a t
c o m p l i c a t e dt h a n h y d r o e l e c t r i c p l a n t s .
is the cost of the fuel needed
fossir fuer plants are more t
0n the other hand, fossir fuer prants have
t h e a d v a n t a g eo f n o t b e i n g
I
d e p e n d e not n r a i n f a l l f o r f u e l . T h e r e i s g r e a t e r
locations for fossil fuel plants, and fossir fuel p.lants
w h a t e v e rp o w e ro u t p u t i s n e c e s s a r y . F o r t h e s e
flexib.ility in choosing
can be sized for
r e a s o n s ,f o s s i r f u e r p r a n t s
I
are the major source of electric power today.
I
A n s w etrh e f o l ' l o w . i n qg u e s t i o n s .

r'2'r. A h y d r o e r e c t r i cp r a n t u s e sm e c h a n i c aern e r g yf r o m
I
L.2-2.
to turn a generator.

L i s t t h e t h r e e c o m p o n e not fs a f o s s i r f u e r p r a n t w h e r e
t
c o n v e r s i o ntsa k e p l a c e .
a.
energy
I
b.
c. t
L.2-3. T r u eo r F a l s e . I n a f o s s i l f u e l p 1 a n t , p r e s s u r e
energyin steamare convertedto m e c h a n i c aeln e r g y
a n dt h e r m a l
in a tur-
I
1..2-4.
bine.

L i s t t w o d i s a d v a n t a g eosf f o s s i l f u e l p l a n t s .
I
a.
b.
I
I.2-5. W h ya r e f o s s i l f u e l p l a n t s t h e m a j o r s o u r c e o f e l e c t r i c p o w e r
today?
I
I
CHECKYOURANSWERS
WITHTHOSEGIVENAT
I
THEENDOF THISUNIT.

1 . . 2 -4
 PLANTOPERATION
rl BASICPOhIER
1. The Funct'ion"f?''ii't-'Po*tt Plant
(continued)

I 1.3 T h e S t e a mC y c l e

Inthissegmenl'youw.ill]eaTnH0t,ITHEMAJoRCOMPONENTS0FTHESTEAMcYcLE

I T,JORKBYLoOKINGATTYPICALEXAMPLES0FABoILER,ATURBINE'andAcoN.
D E N S E R . Y o u w i l l a l s o l e a r n H 0 t , l S U P P o R T S Y S T E M S H E L by
P T the
H E Send
E Mof
AJ0RcOM.
JgBs. Specific terms that you should know
''NENTSD0 THEIR
rl thissegmentjncludeSUPPoRTSYSTEM,FUELSYSTEM,C0MBUSTI0NAIRSYSTEM'
MAINSTEAMSYSTEM,CONDENSERCIRCULATINGT^IATERSYSTEM,andMKEUP|.IATE

I SYSTEM.

I 3 OFTHEVIDEOTAPE
SEGMENT
VIEI^J
BEFORT
READING 1.3 IN THISTEXT'
SEGMENT
I
I A systemis a combinationof
and pipes that are connected
equ'ipment
togeth-

ertoperformaspec.ificfunction.Inadd.itiontothemajorsystemsthat
tl makeupthesteamcycle,therearesystemsoutsidethesteamcyclethatare
neededtomakethesteamcyc.|ework.Theseothersystemsarecalled

I support systems.

Thethreemajorcomponentsthatmakeupthesteamcyc.|earethebo,iler,the
I turbine,andthecondenser'Inthissect'ion'we''lllookatatypica'l
exampleofeachofthesecomponentsandseehowtheywork.t,le'.|.|also]ook

I atsomeofthesupportsystemsthatareconnectedtothesecomponents.

I
I
I
I 1.3- 1

T
 BASICPOWER PLANT OPERATION
1.

1.3.1
T h eF u n c t i o no f t h e p o w e rp l a n t ( c o n t i n u e c l )
I
T h eB o i l e r

T h eb o i l e r i n a p o w e rp r a r i to o e st w o
t h i n g s : ( i ) i t b u r n sf u e r t o p r o d u c e
t
h e a t , a n d( 2 ) i t u s e st h e h e a t t o t u r n
s i m p l i fi e d i i l u s t r a t i o n o f a t y p i c a r
gets its namefrom the large steam
w a t e ri n t o s t e a m . F i g u r e1 . 3 _ 1i s
d r u m - t y pbeo i . r e r . T h i s t y p e o f b o i
a
rer
I
drumlocatedon top.
li
t
li
T
I
l,
t
I
T h e d r u mc o l l e c t s t h e s t e a mm a d eb y
t
metal tubes that rine the inside of the
drum. Thesetubes are referred to
t h e b o i ' l e r . T h ew a l l s o f v e r t i c a l
boirer are connected
as waterwails,becausethey are fiiled
to the steam t
w i t h w a t e r . T h es t e a mt h a t ' s u s e dt o d r i v e
waterwa I I s.
the turbine is produced in the
I
The waterwarlssurroundan open area
in the boirer cailed the furnace,
w h i c hi s w h e r et h e f u e r i s b u r n e d . F u e r
burnersthat are usuaily 'rocatedin the
i s s u p p r i e dt o t h e f u r n a c et h r o u g h I
cornersor in one or moresides of
the furnace. Thedesignof the burners
the furnaceburns.
varies with the type of fuer that
I
1 . 3 _2

I
I BASICPOWER
1.
PLANT OPERATION
T h e F u n c t i o n o f t h e P o w e rP ' l a n t ( c o n t i n u e d )

I I n o r d e r f o r p r o p e r c o m b u s t i o nt o t a k e p 1 a c e , a b o i l e r m u s t h a v e a c o n t i n -
uous supply of fue'l and air. F u e l a n d a i r a r e s u p p fi e d b y t w o s u p p o r t
systems: the fuel system and the combustionair system. We can better
I understandhow these systemsperform their iobs if we start at the begin-
n i n g - w i t h h o wf u e l g e t s t o t h e p l a n t - t h a t ' s t h e f i r s t p a r t o f t h e f u e l

I s y s t e m . I n t h j s e x a m p l e ,t h e f u e l i s c o a l , w h i c h i s d e l i v e r e d t o a p l a n t
by barges, trucks, or railroad cars andstored in p'iles in a coal yard. A
conveyor systemusually carries the coal from the coal yard to the plant'

I w h e r e l a r g e p u ' l v e r i z e r sg r i n d t h e c o a l
'into a f ine powder.

I A t t h i s p o i n t , t h e c o m b u s t i o na i r s y s t e mi o i n s t h e f u e l s y s t e m . I n s o m e
d e s i g n s , a i r f r o m t h e p r i m a r y a i r s y s t e mb l o w s t h e c o a l o u t o f t h e p u l v e r -
I n o t h e r s , a n e x h a u s t e rd r a w s
izers and into the burners in the boiler.

I t h e c o a l o u t o f t h e p u l v e r i z e r s a n d i n t o t h e b u r n e r so f t h e b o i l e r . I n t h e
b o i l e r , t h e c o a l i s m i x e d u l i t h m o r e c o m b u s t ' i oani r t h a t b l o w s i n t h r o u g h
ducts around the burners. This air comesfrom the secondaryair syst€m'
I w h j c h i n s u r e s t h a t t h e r e ' i s t h e p r o p e r a m o u n to f a i r i n t h e f u r n a c e t o
support combustion.

t 0ncethe fuel js in the furnace,'it is'ignited. The flamesraise the

t e m p e r a t u r eo f t h e f u r n a c e t o l a p p r o x i m a t e l y2 0 0 0 o F . T h e b u r n i n g p r o c e s s
I p r o d u c e sa n e x h a u s tg a s , c a l l e d f l u e g a s , w h i c h m u s t b e p u s h e do r d r a w no u t
o f t h e f u r n a c e a n d d i s c h a r g e df r o m t h e p l a n t t h r o u g h a s t a c k . 0 n s o m e

I b o i l e r s , f o r c e d d r a f t f a n s p r o v i d e e n o u g hp r e s s u r et o p u s h t h e e x h a u s tg a s
o u t o f t h e f u r n a c e . H o w e v e r o, t h e r b o j l e r s h a v e i n d u c e dd r a f t f a n s , w h ' i c h
d r a w t h e e x h a u s tg a s o u t o f t h e f u r n a c e .
I The heat in the furnace raises the temperatureof the water in the water-

I w a l l s . W h e nt h e t e m p e r a t u r er e a c h e st h e b o i l i n g p o i n t , s t e a mb u b b l e sa r e
produced. The steam bubbles and hot water rise up into the steam drum,
where the water and the steam are separated. The water is recirculated

I b a c k t o t h e w a t e r w a l l st h r o u g h ' l a r g e p i p e s , c a l l e d d o w n c o m e r s .

T h e s t e a mt h a t i s c o l l e c t e d i n t h e s t e a md r u mf l o w s ' i n t o t h e m a i ns t e a m
I s y s t e m ,w h i c h s e n d s ' i t i n t o t h e t u r b i n e t h r o u g hs t e a ml i n e s . T h e t e r m
" m a i ns t e a m "d i s t i n g u i s h e st h i s s y s t e mf r o m o t h e r a u x i l i a r y s t e a ms y s t e m s
I in the plant.

1.3- 3
I
 BASICPOhlER
1.
PLANT OPERATION
T h e F u n c t i o no f t h e P o w e rP l a n t ( c o n t i n u e o ) t
1.3.2 T h eT u r b i n e
I
F i g u r e i . 3 - 2 i s a d i a g r a mo f a s i m p l i f i e d s t e a r nt u r b i n e . T h e t u r b i n e i s
connectedto the b o i l e r b y s t e a ml i n e s a n d to the generator by a shaft.
I
I
I
I
I
I
I
A l o n gt h e t u r b i n e s h a f t i s a s e r i e s o f b l a d e s . E a c h r o w o f r o t a t i n gb l a d e si s
I
c o r m o n l yc a l l e d a w h e e l . S t e a me n t e r s t h e t u r b i n e t h r o u g hn o z z l e sa n d p a s s e s
b e t w e e nt h e f i r s t s e t o f r o t a t i n g b l a d e s . A s t h e s t e a mp a s s e sb e t w e e nt h e I
r o t a t i n g b ' l a d e s ,i t g i v e s u p t h e r m a l e n e r g y ( h e a t ) a n d p r e s s u r e , c a u s i n g
the turbine to spin, and thus turning the generator. Stationary blades
h e l p t o d i r e c t t h e s t e a mt o t h e n e x t s e t o f r o t a t i n g b l a d e s . T h e s t e a m
T
c o n t i n u e su n t i l i t h a s p a s s e ct ih r o u g r ia l l t h e b l a d e s i n t h e t u r b i n e .
I
1.3.3 The Condenser

A f t e r t h e s t e a mg i v e s u p m o s t o f i t s e n e r g y t o t h e t u r b i n e , i t f l o w s i n t o
I
t h e c o n d e n s e r . A c o n d e n s e ri s a i a r g e h e a t e x c h a n g e rt h a t t r a n s f e r s h e a t
from one flu'id to another. The condenserremovesheat from steam, and thus
c o n v e r t s i t b a c k t o w a t e r . F i g u e 1 . 3 - 3 i s a d i a g r a mo f a t y p i c a l c o n -
t
0enser.
I
i.3- 4
I
 BASICPOI^IER PLANTOPERATION
I 1. T h e F u n c t i o n o f t h e P o w e rP l
ant (cont'inued)

I
I
I
I
I
I
I
i

;._,', I

I ..-"*J
I

I Insidethecondenserareanumberofsma].ltubeswithco]dwaterrunning

I t h r o u g h t h e m . A s t h e s t e a m f r o m t h e t u r b i n e p a s s e s o v ewr ht hi ceht udbr iepss' i ttoi s t h e

c o o l e d a n d c o n d e n s e di n t o
water (called condensate),

bottomofthecondenserandisco]lectedinthehotwe]l.Asupportsystem

I ofpipesandpumps'calledthecondensate-feedwatersystem,completesthe
s t e a m c y c l e b y s e n d i n g t h e c o n d e n s a t e b a c k t o t h e b o ,water
i ] e r , wover
h e r e and
i t b e over
comes
again' Because the steam cycle uses

I steam all over

again, it is often called
a closed system'

I Thecondensate.feedwatersystem.isactuallytwosystems:thecondensate.
systemandthefeedwatersystem.Thecondensatesystemremovestheconden-

I s a t e f r o m t h e h o t w e l ] , a n d t h e f e e d w a t e r s y s t e m f e e d s . i t bf ea ec d
boiler. I ' l a t e
neededto replace the water
rt h a t ' i s p u m p e d ' i n t ot h e b o i l e r i s c a l i e d
that leaves the bo'iler as
steam'
t eer- i t ' s
k twoat h

I I.J- f,

I
 BASICPOt^lER PLANTOPERATION
1. T h e F u n c t i o no i f t . - i l o , u . r p i a n t ( c o n t i n u e o )

A s t h e w a t e r i s p u m p e fdr o m t h e h o t w e i l
I
backto the boirer, it is heated
h e a t e x c h a n g e r sc a l l e d f e e d w a t e r
the efficiency of the cycle
h e a t e r s . H e a t i n gt h e f e e d w a t e r
and removesgas and air from
increases
the water ro
by
I
minimize corrosion in the steam
heaters use steam extracted from
turbine as their heat source. This
lines and the boiler.
betweendifferent rows of brades
The feedwater
in tne
I
s t e a mi s c a i l e d e x t r a c t . i o ns t e a m .

A n o t h e r s t e a mc y c r e s u p p o r t s y s t e m
is the circurating water system.
This
T
s y s t e ms u p p l i e s c o o l i n g w a t e r t o t h e
t u b e s i n t h e c o n d e n s e trh a t
c o n d e n s e tro c o n v e r t s t e a mi n t o c o n d e n s a t e .
systemmaybe either an open system
e n a b l et h e
A c o n d e n s e cr i r c u r a t i n g w a t e r li
or a closed system. In an open
w a t e r t y p i c a l l y c o m e sf r o m a r a k e ,
through the condenserand then returned
river, or ocean. Thewater
to the source. A crosed system
system,
is pumped t
u s e s t h e s a m ew a t e r o v e r a n d o v e r
tower through the condensertubes,
The heated water is then pumped
again. water is pumped
where it picks up heat from the
back to the cooring tower, where
from a coo.ring
steam.
I
it is
mixed with a'ir unti'r it's coor.
t h r o u g h t h e c o n d e n s e tr u b e s a s
The coored water is then pumped
t h e c y c . l ei s r e p e a t e d .
back I
Another important support system
used in the steamcycle circurates
is the makeupwater system. As the
through various valves, pipes,
water I
and
p u m p s 's o m ew a t e r i s a l w a y s
must be replaced; that's the job
lost due to leakage. rhe water

w a t e r s y s t e mp u r i f i e s t h e m a k e u p
that,s losr,
o f t h e m a k e u pw a t e r s y s t e m . T h e
makeup
I
water so that scare and foreign materiar
will not buird up in the boirer.
tanks until it is needed. whenwater
Thepurified water.is then stored
needsto be addedto the steamcycre,
in I
it is usually fed into the condenser.
Il
A n s w e rt h e f o l l o w i n g q u e s t i o n s .

1 . 3 - 1. A c o m b i n a t i o no f p i p e s a n d e q u i p m e n t
connected together ro
I
L.3-2.
p e r f o r ma f u n c t i o n i s c a l l e d a

List two things that the boiler in

T
a p . l a n td o e s .
a.
D.
I
1.3- 6
I
I
I BASICPOI^JER
i.
PLANT OPERATION
r l a n t ( c o n t in u e d )
T h eF u n c t i o no f t h e P o w e P

b o i l e r n e e d sa c o n -
F o r P r o P e rc o m b u s t ' i ot on t a k e p l a c e , t h e
I 1.3-3.
t i n u o u s s u P P l Yo f ( a )
and

(b)

I 1.3-4. I n a t y P i c a l c o a l b u r n i n g P l a n t ' coal

is transPortedto the
fed i nto a
p1ant bY a conveyor sYstem and then
I , w h e r e i t is grolnd
'into a f ine Pow-

der.

I 1.3-5. Circle the correct answer'

A 1arge heat exchangerthat i s
p a r t o f t h e s t e a mc Y c l e i s t h e
I a.
b.
Turb'ine
C o n d e n s et r

I c.
d.
B o il e r
Noneof the above

tl 1.3-6.
system do?
l,Jhatdoes the condensate-feedwater

il
ir 1.3-7.
circulat'ingwater systemthat
Trueor False. A condenser
'is an

opensystemuseswater over and over again'

jl
water and
1. 3 - 8 . The makeuPwater sYstem

ll stores it in tanks until it

'is needed'

It
lr
1l
1r L.3- 7

T
I BASICPOt{|ER
1.
PLANTOPERATION
T h e F u n c t i o n o f t h e P o w e rP l a n t ( c o n t i n u e d )

I 1,.4 S t e a mC y c l e F l o w

In this segment,you'1'l learn HOWWATERANDSTEM M0VETHR0UGH

THESTEM

I CYCLE and HOt.lTHIS MoVEMENTIS M0NIT0RED Specific terms

ANDCoNTRoLLED.
t h a t y o u s h o u l d b e f a m i l i a r w i t h b y t h e e n d o f t h i s s e g m e nitn c l u d e V A C U U M ,

I STEAM VALVE,and FEEDWATER

C0NTR0L VALVE.
C0NTROL

I BEFORE
4 OFTHEVIDEOTAPE
VIEl^lSEGMENT
1 .T4 I N T H I ST E X T .
R E A D I NSGE G M E N

I
I A major part of your job in the plant will be monitoring and controlfing
t h e f l o w t h r o u g h t h e s t e a mc y c 1 e . I n o r d e r t o d o t h i s p r o p e r l y , y o u n e e d

I to understandhow water and steammovethrough the cycle.

I 1.4.1 M o v e m e notf S t e a ma n d W a t e r

Steam flows from the boiler to the turb'ine because of differences in

I p r e s s u r e . S t e a m ,l i k e o t h e r f l u i d s , m o v e sf r o m a r e a s o f h ' i g h p r e s s u r et o
a r e a s o f 1 o w p r e s s u r e . T h e s t e a m i n t h e b o i l e r i s p r o d u c e da t h i g h
p r e s s u r e . T h e h i g h p r e s s u r e p u s h e ss t e a mf r o m t h e b o i ' l e r , t h r o u g h t h e
I turbine, and into the condenser.

I A s s t e a m g ' i v e s u p i t s e n e r g y i n t h e t u r b i n e , a n d a s i t j s c o n v e r t e dt o
water in the condenser,the pressure drops dramat'ical1y. Whensteamfirst
e n t e r s t h e c o n d e n s e r ,i t t a k e s u p a g r e a t d e a l o f s p a c e , b u t a s s o o n a s i t
I i s c o n d e n s e dt,h e s p a c et h a t i t t a k e s u p b e c o m ecso n s i d e r a b ' l ys m a 1 l e r . A s
a r e s u l t , m u c ho f t h e c o n d e n s e r i s l e f t u n f i l l e d a n d a v a c u u mi s c r e a t e d .

I A vacuumis a negative pressure. This vacuumtends to draw more steam

t h r o u g h t h e t u r b i n e a n d i n t o t h e c o n d e n s e r t, h u s i n c r e a s i n g t h e e f f i c i e n c y
of the steam cycle.

I
1.4- i
BASICPOhlER
1.
PLANT OPERATION
T h e F u n c t i o n o f t h e P o w e rP l a n t ( c o n t i n u e d ) t
S t e a mt h a t i s c o n c , i e n s e
i nd t h e c o n d e n s e ri s c o l l e c t e d i n t h e h o t w e l l .
order to keep the steam cycle operating, the condensatehas to be moved
In
I
from the low pressure area of the condenserback to the high pressure area
of the boiler.
densate-feedwatersystem.
T h i s i s a c c o m p l i s h e db y a s e r i e s o f p u m p si n t h e c o n - I
Water is removedfrom the hotwel'l by the condensate,or hotwell, pumpand I
pushedinto the boiler by the feedwater pump. In somesystems, there's a
thirdpump, called a condensatebooster pump, located betweenthe con-
densatepumpand the feedwater pump. Eachpumpadds pressure to the water.
I
B y t h e t i m e t h e w a t e r l e a v e s t h e f e e d w a t e r p u m p ,t h e p r e s s u r e ' i s h i g h
enoughto overcomethe steam pressure and force the water back into the I
boi'ler.

r.4.2 F l o wC o n t r o l
I
In order to regu'latethe amountof electric powergeneratedby a unit, it
is necessaryto control the flow of steamand water through the steam
I
c y c l e . F i g u r e 1 . 4 - l i s a g r a p ho f a t y p i c a l r e l a t i o n s h i pb e t w e e n steam
f l o w t h r o u o ha t u r b l l . u l o . 1 . . ] - . : . : . t - . o : T t o u t p u tf r o m i t s s e n e r a t o r .
I
I
I
I
I
t
I
I.4- 2
I BASICPOI^IER PLANTOPERATION
I . - - - i r , . - F u n c t i o n - o i i n . P o w e rP ' l a n t
(continued)

turbine determines the amountof

I The amountof steam f,|owing through the
e l e c t r i c p o w e rp r o d u c e db y t h e g e n e r a t o r .
I f t h e s t e a mf l o w i s h i g h ' t h e
and morepower.is generated'
t u r b . i n ew o r k s h a r d e r t o t u r n t h e g e n e r a t o r ,
rl If steamflow js low, the turb'ine doesn't
t o r , a n d l e s s P o w e ri s P r o d u c e d '
work as hard to turn the genera-

rl The amountof steamflowjng to the turbine

and the amountof water pumped
they aren't, then either the boi'ler
backto the boiler must be equal. If

I or the turbine may be damaged' For example'

turbine and the condenseLis greater than
if the flow of steamto the
the amountof water pumpedback

rl intothebo.iler,watermayfillthecondenserandbackupintotheturbine.
to the turbine blades and other parts of
This would cause severe damage
the

turbi ne.

I Another danger that occurs when steamf'low'is

greater than feedwater flow
.isthatnotenoughwateriSpumpedbackintothebo.iler.t,|henthis

I happens,thewaterleve]inthedrumdrops,andflowthroughthewaterwalls
.is reduced. As a result, the tubes are not adequatelycooled, and they may

I o v e r h e a ta n d f a i l .

I Problemscanalsooccur,ifthefeedwaterflow.isgreaterthansteamflow.
In this case, the level of condensate
in the hotwell drops and the boiler

f i l l s w j t h w a t e r . s o o n , t h e e x c e s sw a t e r
wi1'l get carried along with the
drop'lets can cause a great deal of
I steam into the turb'ine, where the water
damage.

I Topreventtheseproblemsfromoccurring,steamflowandfeedwaterf]oware
regulated by two different types of contro]
va.|ves: turbine steam contro.|

rl v a l v e s a n d f e e d w a t e rc o n t r o l v a l v e s '

Turbinesteamcontro]valvesareactual.|ypartoftheturbine;theyare

I usedtoregulatetheflowofsteam.0peningtheseva]vesa]]owsmoresteam
toflowthroughtheturb.ine,andclosingthevalvesreducesthesteamflow.

I
I
1.4- 3
I
 BASICPOWER PLANT OPERATION
1. T h eF u n c t i o no i t n e - F o w epr l a n t ( c o n t i n u e d )
t
w h e nt h e s t e a mf r o w i s v a r i e d , t h e f r o w o f f e e d w a t e r
varied equally. Feedwaterflow is controlled
t o t h e b o i r e r m u s tb e
by the feedwatercontrol
v a l v e t h a t ' s r o c a t e di n t h e f e e d w a t e rr i n e g o . i n g
to the boirer. The
I
feedwatercontrol valve is opened or closedto matchincreasesor decreases
i n s t e a mf ' l o w . I n s o m ep r a n t s , t h i s c o n t r o ri s
a c c o m p r i s h be yd v a r y i n gt h e
I
speedof the feedwaterpump. Manyprants use a combination
to control feedwaterflow.
of both methods
t
I n a d d i t i o n t o c o n t r o i l i n g w h a t h a p p e n si n t h e
necessary to control whathappens
s t e a mc y c r e , i t i s a r s o
in the fuel system. To producea certain
s t e a mf l o w , a s p e c i f i c a m o u not f f u e l m u s tb e b u r n e d .
I
T h ea m o u not f f u e r
b u r n e dc a n b e r e g u l a t e di n o i l a n dn a t u r a l g a sp l a n t s
plants by coal feeders. coa'l feeders use
the movement
b y v a r v e so r i n c o a . l
of paddles,con_
T
v e y o r s 'o r s i m i r a r d e v i c e st o c o n t r o l t h e a m o u n t
t h e p u l v e r i z e r sa n de v e n t u a l l yb u r n e d .
of coar that is fed into
t
whenever the frow of fuer is increasedor decreased,the
b u s t i o na i r m u s ta l s o ' i n c r e a s oe r d e c r e a s a
amountof com_
e c c o r d i n g l y . c o m b u s t i oani r i s
I
r e g u l a t e di n a v a r i e t y o f w a y s : b y m e a n so f
d i s c h a r g eo a m p e rosn t h e f o r c e d - d r a f tf a n s t h a t
or by varying the speedof the forced-draft fans.
a d j u s t a b r ei n r e t v a n e so r
s u p p l ya i r t o t h e b o i l e r . I
A n s w etrh e f o l l o w i n g q u e s t i o n s . I
1 . 4 - 1. steamflows from the boirer to the turbine because
e n c e si n
of differ- I
L.4-2. T r u e o r F a l s e . W h e ns t e a mf i r s t e n t e r s a c o n d e n s e r ,
it takes
I
u p a l o t o f s p a c e , b u t , a s . i t c o n d e n s e sthe
,
i s d r a m a t i c a l t yr e d u c e d .
space it takes up
I
1.4-3. Circle the comect answer.
A vacuumi s I
a. Positive pressure
b.
c.
N e g a t i v ep r e s s u r e
Zero pressure
I
d. Condensate

1,.4-4
I
I
I PLANT
BASICPOI.IER OPERATION
f.'-- rn. Function-oitte PowerP'lant (cont'inued)

I Answerthe following questions'

that convert mechan-

1.1.-1. True or False. Generatorsare machines

t ical energy
'into electrical energy'

Circ'le the correct answer'

I L.l-z.
Thee.|ectr.icitythatapowerp.|antproducesismeasuredin
a. Ohms

I b.
c.
AnPs
Volts
d. blatts
I 1.1-3. t'lhatdoesa substationdo?

I
I
is often connectedto anotherpower
I 1 .1 - 4 . 0nepowercompany
by.

I I .l -5. b{ha doesa load disPatcherdo?

I
I 1.1-6. The ( a ) of powermust alwaYsequal the
(b) power.
I
t
t
t 1.1- 5

I
t BASiCPOhIER
1.
PLANTOPERATION
T h e F u n c t i o n o f t h e P o w e rP l a n t ( c o n t i n u e c i )

I I.4-4. True or False. To regu'late the amountof power producedby a

g e n e r a t o r , i t i s n e c e s s a r yt o c o n t r o l t h e s t e a mf l o w t h r o u g h
the turbine that drives it.
I 1.4-5. I n t h e s t e a mc y c 1 e , t h e f l o w r a t e s o f s t e a ma n d f e e d w a t e rm u s t

t be

1..4-6. Circle the correct answer.

I A n j m b a l a n c ei n t h e s t e a ma n d f e e d w a t e rf l o w r a t e s m a yr e s u l t
in

I a. W a t e rf i l l i n g
b'ine
t h e c o n d e n s ear n d b a c k i n gu p i n t o t h e t u r -

b. A drop 'in the water level in the boiler drum

I c.
d.
T h e b o i l e r t u b e sm e l t i n g
The boiler f i l ling with water and water being camied

I e.
over into the turbine
All of the above

t L.4-7. If the steam flow and feedwater flow are increased, the
(a) f l o w a n d c o m b u s t i o n( b )
flow must be adjusteoaccordingly.
I
t hjITH THOSEGIVENAT
CHECKYOURANSWERS
T H EE N DO F T H I SU N I T .

I
I
I
I
I
I 1.4- 5
I BASICPOWER
1.
PLANT OPERATION
T h e F u n c t i o n o f t h e P o w e rP l a n t ( c o n t i n u e d )

I 1.5 E m e r g e n cCy o n c i i t i o n s

THATMUSTBE TAKEN
I n t h i s s e g m e n ty,o u ' l ' l l e a r n THREEGENERAL ACTIONS

I WHENEVER AN EMERGENCY
THESEPROCEDURES
SITUATION
APPLYTO THE SPECIFICEII4ERGENCY
N T H EP L A N T . Y o u ' l l a l s o s e e H O W
0 C C U RIS
CONDITION OF A LOSSOF

t F L A MIEN T H EB O I L E R .

t VIEI,JSEGMENT 5 OF THEVIDEOTAPE BEFORT

1 .T5 I N T H I ST E X T .
R E A D I NSGE G M E N

I
I For the most part, the dut'ies of plant operators are part of an estab-
l j s h e d , r e g u l a r r o u t ' i n e . P e r i o d i c c h e c k sa r e m a d eo n e q u i p m e nat n d s y s t e m s
' i n t h e p o w e rp l a n t a n d r e a d i n g s a r e t a k e n f r o m i n d i c a t o r s a n d r e c o r d e r s .
I However,occasiona'lly, an unexpectedevent occurs that may threaten the
s a f e t y o f t h e p l a n t a n d t h e p e r s o n n e la n d e q u i p m e nitn i t . I f a n e m e r g e n c y

t c o n d i t i o n a r i s e s , i m m e d i a t ea c t i o n m u s t b e t a k e n t o p r e v e n t i n i u r i e s a n d
from occurring.
damage

I M a n yp l a n t s h a v e d e v e l o p e dw r i t t e n , s t e p - b y - s t e p p r o c e d u r e sf o r d e a l i n g
w i t h e m e r g e n c cy o n d i t i o n s . I t ' s i m p o r t a n t f o r y o u t o k n o wy o u r p l a n t ' s

I proceduresand understandwhat steps to take

'if an emergencyoccurs. How-

e v e r , s i n c e a p o w e r p l a n t c o n t a ' i n sm a n yc o m p l i c a t e ds y s t e m s , ' i t ' S i m p o S -

s i b l e t o e s t a b l i s h s p e c i f i c p r o c e d u r e sf o r e v e r y e m e r g e n csy' i t u a t i o n . S o ,
I i n a d d i t i o n t o k n o w i n gy o u r p l a n t ' s e m e r g e n cpyr o c e d u r e s 'y o u a l s o h a v e t o
know the systemsand equipmentin the plant so wel'l that if an emergency

I o c c u r s , y o u w ' i l l k n o wi m m e d i a t e l yw h a t a c t i o n s t o t a k e .

1 . 5 .i Act'ions
General Emergency
I Thereare three general act'ionsthat must be taken during any emergency.

I Theyare:

(1) D e t e r m i nwe h a ti s g o i n go n .

I (2)
(3)
P u t t h e p l a n t i n a ' s a f ec o n d i t i o n .
Performany fo1'low-upaction necessaryto return the plant to
normal .
1.5- 1
BASICPOWER
1.
PLANT OPERATION
r lant (cont'inued)
T h eF u n c t i o no f t h e P o w e P I
S i n c e m a n yi m p o r t a n tp l a n t c o n o i t i o n sa r e m o n i t o r e db y i n s t r u m e n t a t i o n
s y s t e m sy, o u r f i r s t i n d i c a t i o n t h a t s o m e t h i n igs w r o n gi s f r e q u e n t l yt h e
I
soundino g f a n a n n u n c i a t oarl a r m . T h ea l a r ms y s t e mc o m p a r easc t u a l 1 e v e 1 s ,
p r e s s u r e sa , n df l o w s i n p l a n t s y s t e m w s ith expected
s i g n i f i c a n t d i f f e r e n c e sb e t w e etnh e e x p e c t e d
values. If there are
v a l u e sa n dt h e a c t u a l v a l u e s ,
I
a n a l a r mr i n g s a n da n a n n u n c i a t owr i n d o wl i g h t s u p i n t h e c o n t r o l r o o m . N o t
all alarmssignify emergency condit'ions,but manydo. As an operator,you I
m u s tb e a b l e t o r e c o g n i z et h e d i f f e r e n c e .

J u s t k n o w i n gt h a t s o m e t h i nigs w r o n gi s n o t e n o u g h .W h e a
n n a l a r ms o u n d s ,
I
you mustknowhowto checkother indicators to find out the status of the
systeminvolvedandthe status of any associatedsupportsystems. As soon I
a s y o u k n o ww h a ti s h a p p e n i n gt h , e nextstep is to put the plant in a safe
c o n d i t i o n . I m m e d i a taec t i o n m u s tb e t a k e nt o p r o t e c t p e r s o n n eal n de q u i p -
ment.
I
Then comesthe third step - r e t u r n ' i n gt h e p l a n t t o n o r m a lb y t a k i n g t h e
T h i s u s u a l l y i n v o l v e sm a k i n ga c a r e f u l a n a -
n e c e s s a r yf o l l o w - u p a c t i o n .
I
l y s i s o f t h e p l a n t t o b e s u r e t h a t i t i s i n a s t a b l e c o n d i t i o na n ds e e i n gi f
the cause of the trouble can be corrected.
t
r.5,2 S p e c ' i f i c E m e r g e n cAyc t i o n s - L o s s o f F l a m ei n t h e B o i l e r I
The three general emergencyactions can be illustrated by an example. Many
b o i l e r s h a v e e l e c t r o n i c d e v i c e s c a l l e d f l a m e s c a n n e r s ,w h i c h m o n i t o r t h e
I
f l a m e ' i n t h e b o i l e r a n d s o u n da n a l a r m i f t h e f l a n e g o e so u t . I f t h e b o i l e r
flame goes out, the steam pressure drops, becausethe heat input to the
b o i l e r h a s d r o p p e d . I f t h e b o i l e r f l a m e w e n t o u t , t h e f l a m e s c a n n e ra l a r m
I
a n d t h e d r o p p i n gs t e a mp r e s s u r ew o u l d h e l p y o u a n a l y z ew h a t w a s h a p p e n i n g .
A s s o o na s y o u k n o ww h a t ' s h a p p e n ' i n gt ,h e n e x t s t e p i s t o p u t t h e p l a n t i n a I
safe condition.

T h e r e a l d a n g e rf r o m a l o s s o f f l a m e i n t h e b o i l e r i s t h a t r a w , u n b u r n e d
t
f u e l b e g i n s t o b u i l d u p t h r o u g h o u tt h e b o i l e r a n d t h e s t a c k , b e c a u s ef u e l
a n d c o m b u s t i o na i r a r e s t i l l b e i n g f e d i n t o t h e f u r n a c e . I f y o u t a k e t h e I
w r o n ga c t i o n a n d s ' i m p ' l rye l i g h t t h e b u r n e r s , t h e n t h e b o i l e r c o u l d e x p l o d e .
S o , t o p u t t h e p l a n t i n a s a f e c o n d i t i o n , y o u h a v et o f i r s t s t o p t h e f l o w o f
I
I.5- 2
I BAsrcPowER PLANT oPERATIoN
I 1. r lant (continued)
T h eF u n c t i o no f t h e P o w e P

f u e ' l i n t o t h e b o i l e r a n d g e t r i d o f t h e u n b u r n efdu e l . T h i s p r o c e s si s
I
r c a l l e d p u r g ' i n gt h e b o i l e r , a n d i t ' s d o n eb y u s i n g t h e c o m b u s t i oani r f l o w
- t h r o u g ht h e f u r n a c et o b l o wt h e f u e l o u t o f t h e s t a c k .
I
After the boiler has beenpurged,the plant can be returned to normalby
I r e ' l i g h t i n gt h e b u r n e r sa n d i n c r e a s i n gb o i l e r s t e a mp r e s s u r eb a c kt o n o r -
t m a l . I f , f o r s o m er e a s o n ,t h e b u r n e r sc a n n o tb e r e l i t , t h e u n i t m u s tb e
shut down.

t
A n s w etrh e f o l ' l o w i n gq u e s t i o n s .
I

I 1.5-1. Circle the correct answer.

In order to deal with emergencyconditions' an operator must

I a.
b.
K n o wt h e p l a n t ' s e m e r g e n cpy r o c e d u r e s
Knowthe systemsand equipmentwel'l enoughto take what-
ever corrective measuresare necessary
I c.
d.
B e a b l e t o a n a l y z ew h a t i s h a p p e n ' i n g
Al I of the above
I
' a n e m e r g e n c cy o n -
L.5-2. L'ist the three general steps to follow if
dition occurs in your p'lant.
I a.
b.

T c.

I CHECKYOURANSWERSI.JITHTHOSEGIVENAT
THE ENDOF THIS UNIT. THENDO THE
I UNIT 1 PROBLEIVI
SET.

I
t
t
1.5- 3
I
lBAsIcP0I'IERPLAIIT0PERATIoN(continued)
I
Unit 1 - ProblemSet
-
I\
1. t'lhatdoesa substationdo?

II
/) connected through
I 2. Two ciifferent power systems are
r
lines.

I
t 3. C'ircle the correct answer'
The highest demand for poweris generatly around
a' Noon
t b' Lateevening
c. I'ilorningand evening
I Late afternoon
I d'
e' All of the above
-
I
r,4.Listthethreemajorcomponentsfoundinthesteamcycle.
a.
I b.
c.
I
electrical energy into mechanical
! 5. True or False. A turbine changes
energy.

6.Acombinationofequipmentandpipesconnectedtogethertoperforma
specific functionis called a

7' C'ircle the correct answer'

by burning
Heat in a boi'ler can be provided
I
a. Coa'l
I b' oll
r
T c. Natural gas
d. All of the above

I e. 0nlY a and c

I
I
 PAllc-P0h,ER
PLANTOPERATToN
Unit I - Problem
Set (continued)

8. Trueor Farse. pressurein the condenser

is usuaty a vacuum.

9. l{hat cools the stearnin the condenser?

l0' steanrflows fromthe boiler to the turbinebecause

of a dlfferencein

ll. Clrcle the correct ansrer.

To regulate the anount of porer generated
by a unit
!. The turblne speednu,rstbe varled
b. AddrHonar water must be addedto the makeup
water system
c. Steammust be recycled through douncomers
d' The frow of feednater and stean rnust be
controiled
€. The poulerproducednr,lst be equal to supply

t2. List.two comnon

waysof controlllng feednater flow.
a.
b.

13. True or Farse. If feedwaterfrow rs greater

than steamfrow, the
boller drumwlll boll dry.

14. Clrcle the correct ansrer.

If an emergencyoccurs, an operator must
d. Performany necessaryfollow-up action
b. Put the plant in a safe condition
c. Determine what,s going on
d. All of the above
e. iloneof the above

15. The
tells you howmuchload
your unit shouldbe generating.
I BASICP0l'lER 0PERATI0N
PLANT
Set (continued)
uiiii-t - Fioblem

systemdoes'
I 16. Expla'inwhat the condensate-feedwater

t
I
L7. Circle the correct answer'

I Pressurein the steamcYcle is

a.
'in 'in
Highest the turbine, lowest the condenser
'in
Highest the boiler, lowest in the turbine
t b.
c.
d.
H'ighestin the feedwatersystem' lowest
Highestin the condenser'lowest
in the condenser
'in the turbine

T e.H.ighestjnthefeedwatersystem,]owestinthecondensatesys*
tem

I ls.TrueorFalse.Feedwaterheatersareheatedbyextractionsteam.

I lg.Asystemwhereafluidisusedoverandoveragainiscalleda
sYstem'

I Inwhatspecificpartoftheboilerissteamactua.|lyproduced?

t
I
I
I
I
I
I
I
I 2. BOILERS

I In the f
.irst unit of th.is top.ic, you
'learneo
how powe|is generated and

t distributed.inatyp.icalpowersystem.Youalsolearnedthattheboi.|er'
theturb.ine,andthecondenserarethethreemajorcomponentsthatmakeup
thesteamcycle.Thisun.itconcentratesonthef.irstofthesecomponents'

I thebo'iler.Whenyoucompleteth'isunit'youw'illknowhowthemostcommon
typesofboilerswork;howcombustiontakesplaceinaboi]erfurnace;how

t water,steam'gas,andairflowthroughabo'iler;andsomebas'icprinciples
of boi'ler oPeration'

I Thisf.irstsegmentFOLLOI^ISTHEI^IATERFL0I^IPATHTHROUGHATYPICALDRUM
B0ILERANDEXPLAINSH0I,INATURALcIRCULATIoNMAKESTHISFL0I,IP0SSIBLE.
Specif.icterrnsthatyoushouldbefamiliarw.ithbythecomp.|etionofthis
I segment
'include DRUM CIRCULATI0N'
B0ILERand NATURAL

I 1 UF THEVIUEOTAPE
SEGMENT
VIEI^I
BEFORT
2.1 OF THIS TEXT'
I READINGSEGMENT

I 2.7 I'Jater F l o w P a t h

p r o v i d e sa
for tworeasons: F'irst,'it
c i r c u l a t j o n i n a b o . i l e ri s n e c e s s a r y
I constantsupplyofwatertobeturned.intosteam;andsecond,itcarries
theintenseheatoftheboilerfurnaceawayfromthewaterwalls.Ifthe

I flow were reducedor cut off'

the tubes could overheat and
rupture'

I Figure2.L-L.|saschematicdrawingofatypica.|naturalcircu]ationdrum.
typeboiler.someofthecomponentsshowninthisf.igurearediscussedin
thissegment.Therema.iningcomponenf,sarediscussedinSegment2.2.One

I o f t h e d i s t i n g u . i s h i n g c h a r a c t e r . i s t . i c s o f t h j s t y p e o f b o i l e r i s t h e d r u m and
Two major tasks that the drum performs are (1.) receiving feedwater
.

produced'
( 2 ) c o l l e c t i n g t h e s t e a mt h a t ' s
I 2.L.T

T
 BASICPOWER PLANT OPERATION
L. 6 0 .t e r s ( c o n t i n u e d )
I
I
I
T
l,
I
I
I
H e a t e dw a t e r . i s p u m p eidn t o
t h e d r u ma t t h e f e e d w a t e ri n l e t .
I
T h ew a t e r
inside the drumcontinuaty circurates
headers. Typicalry, there
throughthe downcomers
are two or more downcomers
h e a d e r s ;h o w e v e rf,o r s i m p l i c i t y ,
to the .rower
and two or more
I
o u r s c h e m a t i cs h o w so n l y o n e
The lower headerssupply water
to the waterwalltubes.
of each.
f'
I n t h e t u b e s , t h e h e a t s u p p r i e db y
someof the water into steam.
drum,whereit is separatedinto
c o m b u s t i oinn t h e b o i r e r f u r n a c e
The water/steam mixture enters the boirer
turns
I
waterandsteamby moistureseparators
d r y e r s . T h e s t e a mc o i l e c t s a t
directed to the bottomof the drum.
t h e t o p o f t h e d r u m ,w h i r e t h e
and
water is I
Theprocessby whichthe water in
the rowerheadergets up to the
o n eo f t h e d i s t i n g u i s h ' i n cgh a r a c t e r i s t i c s drumis
I
o f n a t u r a rc i r c u r a t i o n d r u m _ t y p e
boilers. The key to understand.ing
circulation," andthe key to naturar
t h i s p r o c e s si s t h e t e r m , , n a t u r a l
circulation is the fact that
cord
I'
water weighsmorethan hot water
or steam.

2.1- 2
I
I
t PLANTOPERATION
BASICPOhIER
; ' . "' - b ;i i e rs (co n ti n u e d )

t },|heneverwaterisheated,.itbecomeslessdense,wh.ichmeansthatforthe
samevolume,heatedwaterweighslessthancoldw
'less
than e'ither of them'
a t e r ' and
In the boi'ler' the water
a n d ssteam
t e a m in
w e 'the
ighs

I waterwa]]sarehotterthanthewaterjnthedowncomer,becausethewater.
wa.llsareheatedbytheburn.ingfuel.S.incethiswater/steammixture.is

I h o t t e r t h a n t h e w a t e r i n t h e d o w n c o m e r s , i t i s a l s o . | i g h t e rthe
that the water/steam mixture gets pushed along through
behindit'
. T h etubes
r e s u lDy
t . i sthe

h e a v ' i e rc o l d w a t e r t h a t ' s

I Asthecolderwaterfromthedowncomersgetsheated,italsobecomesless

I densethanthewaterthat,sflow.ingbehindit,soaself.sustain.ingflowis
created.Th.isflowwillcontinueaslongasthereiswaterinthedrumano
h e a t i s b e ' i n gp r o d u c e d
in the furnace'

I Natural circulat'ion in a
boiler is affected by
three factors:

I (1)
(2)
The amountof heat produced
Theheight of the boiler
in the furnace

boiler operates
T h e p r e s s u r ea t w h i c h t h e
I (3)

positive effect on natural

circulat'ion'
The first two factors have a

l Ra,isingthetemperatureinthefurnaceincreasesnaturalc.ircu.lation,be-
cause.itresultsinagreatertemperatured.ifferencebetweenthewater.

I wa.llsandthedowncomers.Increasingtheheightofaboi.lerincreases
naturalcirculat.ion,becauseitresultsinanincreasedweightd.ifference
betweenthewater/steammixture.inthetubesandthewaterjnthedown-

I comers.

I Thethirdfactor,pressure'hasanegativeeffectonnaturalcircu]ation.
Aspressureincreases,natura.|circulat.iondecreases'becauseincreas.ing
thepressuredecreasesthedensitydifferencebetweenwaterandsteam.

I
I
I ?.L- 3

:
 BASICPOt'.iER PLANT0PERATI0N
L.
I
6 0 tt e r s ( c o n t i n u e d )

T h e s et h r e e f a c t o r s a r e
a ' t c o n s i d e r e di n t h e d e s i g n
a r e d e s i g n e dt o b e a c e r t a i n
a n d p r e s s u r e ss o a s t o m a k e
h e i g h t a n d t o o p e r a t ea t
of a boirer. Boirers
certain temperatures
o p t i m u mu s e o f n a t u r a r c i r c u r a t i o n .
T
can't direcily contror 'perators

HT:lrrtlt.,lation
naturar circuration, but
b v m a i n t a i n i n st h e b o i r e r
they can insure proper
a t i t s d e s i s nt e m p e r a t u r e
t
s o m eb o i r e r d e s i g n e r isn c r e a s e
c i r c u r a t i o nb y a d d i n gb o i r e r
w a t e rc i r c u r a -
ll
tion pumpsto the downcomers.
Boirers that have these pumps
controted circurationboirers.
a n d p r e s s u r e st h a n n a t u r a r
T h e yc a n o p e r a t ea t h i g h e r
are cared
temperatures
fi
circurationboilers of the
s a m es i z e . A s a
I;:]t'
c o n t r o , e d c i r c u r a t i o nb o i r e r s
c a n p r o d u c em o r es t e a mf o r
a given I
T h ew a t e r f l o w p a t h t h a t
both natural circulation
h a s o e e nd e s c r i b e di n t h i s
a n d c o n t r o ll e d c i r c u l a t i o n
s e g m e nits t h e s a m ef o r T
d r u mb o i l e r s . W a t e r

I
flows from the drum, through
the downcomers,into the
back into the drum. lower headers, and

Figure Z.I-Z is a cutaway

typicaily kept about harf
view of a typical boiler
fut of water. Feedwater
c l r u m . A b o i l e r d r u mi s
is fed into the drum
I
t h r o u g ht h e d i s t r i b u t i o n p ' i p e .
drum from the waterwalls
directs the mixture into
T h ew a t e r / s t e a mm i x t u r e
is directed against the
that returns to the
drum shroud. The shroud
I
moisture separators, which
from the steam. The water
fats into the rower part
s t e a mc o t e c t s i n t h e u p p e r p a r t .
separate the water
of the drum, whire the
s i n c e t h e s t e a ms t i , h a s s o m ew a t e r
I
mixed in with it, it is next
possibre. Finally, the
s t e a mo u t l e t p i p e s .
sent through dryers to remove
s t e a mi s d i s c h a r g e df r o m
as muchwater as
t h e d r u mt h r o u g h s e v e r a l
I
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2.1- 4
I
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 PLANTOPERATION
I BASICPOI^IER
;."'- b;ilers (continued)

I
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I
I questions'
Answert h e f o l l o w i n g
I 2.1-t. True or False. Two of
the maior jobs that a
bo'il
for t h e b o i l e r a n dc o l l e c t i n g
er drum

performs are receiv'ing feedwater

t steamfrom the boiler
before
'it goes t o t h e t u r b i n e '

' i s n e c e s s a riyn a b o i l e r '

I 2.L-2. L j s t t w o r e a s o n sw h y c i r c u l a t i o n
a.
b.
I
I
I
I 2.1- 5

I
 BASICPOh/ER PLANTOPERATION
2. B o i l e r s( c o n t i n u e d )

2.I-3. Circle the correct answer.

I
which of the fo'owing factors
c u l a t i o n i n a d r u mt y p e b o i l e r ?
does not affect natural cir_ t
a.
I
The amountof heat procjuced
in rhe furnace
b. T h eh e i g h t o f t h e b o i l e r
c. T h e p r e s s u r ea t w h i c h t h e b o i l e r
operates
d. The size of the orum
T
2.1-4. D r u mb o i r e r s t h a t h a v ep u m p s
t o h e r p c i r c u r a t e w a t e rt h r o u g h
the downcomers
are cal led
b o il e r s . t1
2.1.-5. True or False. Natural circulation
h'igher temperaturesand pressures
boilers can operate at
than c o n t r o ll e d c i r c u l a t i o n
I
b o i l e r s o f t h e s a m es i z e .

2.7-6. B e f o r e s t e a m . i s s e n r t h r o u g ht h e
out.let pipes of a drum, it
I
is
usually sent through
t o r e m o v ea d d i t i o n a l w a t e r
t h a t i s n o t r e m o v e db y t h e m o i s t u r e
separators.
I
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2.1- 6
t
r;
 BASICPOI^IER PLANTOPERATION
l Z.--- g o i l e r s (cont'inued)

I 2.2 SteamFlow Path

InSegmentlofth.isunit,youlearnedhowwaterisfed.intoadrum.type

I bojlerandconvertedintosteam.ThissegmentF0LL0I,JSTt|ESTEA}4FLot,tPATH
ANDEXPLAINsHol.lSTEAMISSUPPLIEDT0THETURBINE.Specifictermsthatyou

I s h o u . | d b e f a m i ] . i a r w i t h b y t h e c o m p l e t . i o n o f t h . i s s e g mREHEATER'
SATURATI0N
SPRAY
TEMPERATURE,
ATTEMPERATOR.
SUPERHEATED sTEA|v|, SUPERHEATER,
e n t . i n c l uand
deB0ILING'

I
I VIEI,ISEGMENT
READING
BEFORE
2 OFTHEVIDEOTAPE
2.2 OFTHISTEXT'
SEGMENT

I
Betweenthet.imesteamleavesthebo.i]erdrumandthetimejtentersthe

I condenserr.itisactedonbytwo'importantcomponen
reheaters. Refer back to Figure 2'I-L
ts:superheatersand
to see where superheatersand

reheatersarelocated.Tounderstandhowthesecomponentswork,youfirst
I the following concepts:
haveto understand

I (1)
(2)
Boiling
SaturationtemPerature
(3) SuPerheat
I Bo.i.|.ingistheprocessofconvertingwater.intosteam.Foranygiven

I pressure'thereisacorrespond.ingtemperatureatwhichwaterwillboil:
the higher the pressure,the higher
the required temperature'

is knownas the
I The to
needed
temperature boil water at a given pressure
saturationtemperature.Atatmosphericpressure,whichjs]'4.7poundsper

I s q u a r e . i n c h ( 1 . 4 . 7 p s i ) t h e s a t u r a t i o n t e m p e r a t u r e f o r w afor
Fahrenheit (2L2oF). At 1000 ps'i, the saturat'iontemperature
water and steamare present
together' the temperature
t e rwater
i s 2 L 2isd e g r e e s
of
545oF. Whenever
t boththewaterandthesteamwi]lalwaysbethesaturationtemperature.
Thismeansthatnomatterhowmuchheat.isaddedtotheboiler,the

I temperatureofthesteamandwaterinthewaterwal.|scanneverriseabove
saturation temperatureas long
as wateris present'
2.2' L

I
 BASICPOI.JER

ri
PLANT OPERATION
2. B o i l e r s( c o n t i n u e A ) - '

Thesteamtemperature can be raised abovethe saturation

temperature
if there is no waterwith the
desirable, because higher temperature steamcan do morework, andmore
only
s t e a m . R a i s i n gt h e s t e a mt e m p e r a t u r e

work
is I
meanas m o r ee f f i c i e n t g e n e r a t i n g

steamthat has been heated above

unit.

the saturation temperatureis

t
cailed
superheated steam. In a drum-type
separatorsand dryers to remove
boirer, steamis passedthrough
most of the water and thus prepare
moisture
the
T
steamfor superheating. The steam
b o i l e r t u b e sc a l l e d s u p e r h e a t e r s ,
stean and the steamis superheated.
is then sent to separatesections
w h e r ea n yr e m a i n i n g
of
w a t e r . i st u r n e di n t o t
superheatersare generaily in the path
furnace' superheater
of hot combustion gasesfrom tne
I
tubesabsorbheat, andthen transfer
s t e a mp a s s i n gt h r o u g ht h e m . B e c a u s e
o f t h e s t a c k , s u p e r h e a t e rasc t u a t y
that heat to the
t h i s h e a t w o u r do t h e r w i s eb e r o s t
i n c r e a s et h e e f f i c i e n c y o f t h e
out I
boirer.
There are several ways of c.lassifying
cormon wayis to refer to themas either radiant
superheaters. For examp.le,one
I
superheaters
s u p e r h e a t e r sR
. a d i a n st u p e r h e a t e r s
in a direct "rine of sight' with
or convection
e c e i v eh e a t b y r a d i a t . i o n ,s o t h e y
t h e f r a m e si n t h e f u r n a n c e .
are I
superheatersreceive heat by convection- c o n v e c tion
combustion gases. convectionsuperheaters
t h e f u r n a c et h a n r a d i a n t s u p e r h e a t e r s ,
that is, from the heat in the
are rocatedfarther awayfrom I
because t h e y d o n , t n e e dt o b e d i _
rectly in line with the flames.
I
S u p e r h e a t e rasr e a r s o u s u a l l y r e f e r r e d
T h ep r i m a r ys u p e r h e a t ei sr t h e o n e
usuallya convection
t o a s e i t h e r p r i m a r yo r s e c o n d a r y .
t h a t s t e a mp a s s e st h r o u g hf i r s t .
s u p e r h e a t e ra,n d i s a l m o s ta l w a y sl o c a t e d
It is
I
in a cooler
part of the gas path than the
heater heats steamthat has alreadypassed
secondary superheater. Thesecondary
througha primarysuperheater.
super_ T
I
I
2.2- 2
t
t
I
 PLANT(]PERATION
I BASICPOI^IER
;."'" b;iiers (continued)

I B e t w e e n t h e p r i m a r y s u p e r h e a t e r a n c j t h e s e c o n desuperheater'
be a dev.ice called a spray attemperator, or a
o a r y s u p e r h e a t eThe
r , t h eat-
remay

temperatorkeepsthef.inaltemperatureofthesteamfrombecom.ingtoohot

I andoverheatingthesuperheatertubes'Ifthesteamgetstoohot'the
a t t e m p e r a t o r s p r a y s w a t e r i n t o t h e e n t r a n c e o f t h e sso'
e c oitn dtakes
a r y s usome
p e r h heat
eater.
turns to steam and' by doing

I The waterimmediately
fromthesteamthat.sa.|readythere.Theresultisanoveralldecreasein
steam temPerature'

I Attemperatorsareon.lyonewayofcontro]lingthefinalsteamtemperature.

I othermethodsincludet.iltingtheburnersinthefurnaceandred.irecting
thegasflowpathwithdampers.0ften,severalmethodfareusedtogether
to control steam temPerature'

I Fromthe superheater,steam
goes to the t u r b i n e . A s
Figure
(HP)section' an
2'2-1" indi'

t u r b i n e sc a n h a v ethree sections: a high Pressure

cates,
I intermed'iate p r e s s u r e( I P ) s e c t ' i o n a n d a 1 o wP r e s s u r e( L P )
'
section'

I
I
I
I
I S t e a m e n t e r i n g t h e t u r b . i n e f l o w s f i r s t t h r o u g h t h eup
gives up some of its energy' As the steam gives
HP s e c t , i oitn , w
energy' h e r edown
cools it
ts
the IP sect'ion'the steam
I andits p r e s s
often sent back to the
u r e o r o p s ' B e f o r e i t m o v e so n t o
bo'iler for reheating'

I Reheatersaddenergytosteamby.increasingitstemperature.Theyarevery
similartosuperheaters.Theyareusuallyclassifiedthesameway(primary

I orsecondaryanoradiantorconvection),andtheyalsohaveattemperators.

2.2- 3

I
 BASICPOI,JER PLANTOPERATION
.. b o tt e r s l c o n t i n u e d )

After reheating, the steam

t
is sent to the Ip section
the IP section' the steam
as it drives the turbine brades.
o n c e a g a i n g i v e s u p s o r n eo f
of the turb'ne. In
its heat andpressure
A f t e r p a s s i n gt h r o u g ht h e
Ip section,the
t
t
s t e a n m o v e so n i n t o t h e
Lp section. Finaily, the
s t e a mi s e x h a u s t e df r o m
the Lp section into the
c o n d e n s e r ,w h e r e i t i s c o n d e n s e d
back into water.
T h e s t e a mf r o w p a t h t h a t
boilers'
w e , v eb e e nf o ' t o w i n g i s t y p i c a r
H o w e v e r ,n o t a l l d r u m - t y p e
boilers have superheaters
f o r m o s td r u m _ t y p e
and re-
I
h e a t e r s . T h eb o i r e r s i n m a n y
used to produce steam for
i n d u s t r i a i p r a n t s a n db o i r e r s
heating may not have superheaters.
b o i l e r s p r o d u c eo n l y s a t u r a t e d
s t e a m . ) A l s o , s o m eb o i l e r s
t h a t are just
(These
I
heaters do not have reheaters.

A n s w e rt h e f o l l o w i n g q u e s t i o n s :
t h a t h a v es u p e r _
t
2.2-1,. W h a ti s b o i i i n g ?
I
I
2.2-2. True or False' The temperature
given pressureis called
at whichwater wilr boil
the saturation temperature.
at a t
2.2-3. Circle the correct answer.
wheneverwater and steamare present
T
of both the water and the
a. nzoF
together, the temperature
steam wi I I always be t
b.
c'
d.
The superheatertemperature
T h es a t u r a t i o nt e m p e r a t u rfeo r
T h eb o i l i n g p o i n t o f w a t e ra t
the existing pressure
T
1 4 . 7p s i

?'2-4' True or Farse. superheaters

i n c r e a s et h e e f f i c i e n c y
T
of
boirers by using heat that
stack.
w o u r do t h e r w i s eb e r o s t u p
the
t
2.2-5. A s u p e r h e a t ei sr l o c a t e di n a d i r e c t , , l i n e
of s i g h t " w i t h t h e f u r n a c e f l a m e s . I

2.2- 4
I
I
 PLANTOPERATION
I BASICPOI,IER
il-'- s"iiers (cont'inued)

l^lhatdo attemPeratorsdo?
I 2.2-6.

I
I 2.2-7. Circle the correct answer'
BeforesteamflowsfromtheHPsect.i,onoftheturbinetothe'IP

I sect'ion, it is often
a. Reheatedin the attemPerator
the condenser
Convertedto water in
rl b'
c.
d'
R e t u r n e dt o t h e b o i l e r
for reheating

C o n v e r t e dt o f l u e g a s a n d
u s e d i n c o n v e c t i o nf u r n a c e s

l
I
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I 2.2- 5

rl
 PLANT OPERATION
I BASICPOI,JER
Z'.'---g o i fers ( c o n tinued)

I 2.3 0 n c e - T h r o u gBho i l e r s

Sofar.inthisunitwe.vebeenconcentratingoncirum - t y ppelbaon .t i' l eTr sh,i b

secause
u s e d ' ' i nt o d a y ' s p o w e r
I that,s the most c o r n r n toy p
n e
s e g m e ncto v e r sa n o t h e tr y p e
o f b o i l e r
-
of boiler design the once-through'
or univer-

I salpressure'boiler.You,l]IeaTnH0I,IA0NCE.THR0UGHBoILEROPERATES'
u J H A T I T S B A S I C C 0 M P o N E N T S A R E , A N D h i H A Tby
'ITH IT. The terms you shou'ldunderstand
A Dthe
VAN T Aof
end G Eth'is
SANDDISADVANTAG
ASS0CIATED

t segmentinclude:CRITICALC0NDITIONS,SUPERCRITICAL,andSUBCRITICAL.

I 3 OF THEVIDEOTAPE
VIEI,.ISEGMENT
BEFORE

READING SEGMENT2.3 OF THIS TEXT'

il
I 2.3.L C r i t ' i c a lC o n d i toi n s

f u e l t h a t h e a t sw a t e r
b o i l e r , l i k e a d r u m - t y p eb o ' i 1 e r ,b u r n s

I A once_through
to produce steam' but the operation of the two types of

nif.icantlydifferent.Beforeyoucanunderstandhowonce.throughboi]ers
boilers is sig-

I operate,youfirsthavetounderstandtheconceptof,'cr.iticalcondi.
t ' i o n s ."

rl I n t h e l a s t s e g m e n t , y o u l e a r n e d a b o u t s a t u r a t . i o n t e mat
'is a comespondingtemperature
p e which
r a t u r ewater
: a t a n will
y
given pressure, there

I b o . i l . H o w e v e r , y o u d i d n , t ] e a r n t h a t t h . i s r e ] a t . i o n s h i ptihs eo nployitnr u
a p o i n t . T h a t p o ' i n t i s the critical point' and
it'is t eaut pwt o
hich

t h e r e . i s n o d i s t i n g u i s h a b , | e c l i f f e r e n c e b e t w e e n w aand
t e r athis
n d s tpressure
e a m . T h eare
cr.it-
I .ical point is 7050i and 3206 psi. Th'is temperature
. . c r i t i c a l c o n d . i t . i o n s . . . A t t h i . s p o i n t , t h e d e n s i t y o f w a t e r a n d t h e d e nhave
sity
0nce the boiler's temperature and pressure

I of steam are the same'

g o n e b e y o n dc r i t i c a l c o n d i t i o n s ' a l l
of the steam'
h e a t p r o d u c e di n t h e
boiler goes

toward rais'ing the temperature

I
I 2.3- L

t
 BASICPOh/ER PLANT UPERATION
..
t
b o rt e r s l c o n t i n u e d )

B o i r e r st h a t o p e r a t eb e r o wc r i t i c a r
t e m p e r a t u r easn dp r e s s u r e s( r i k e
type boirers) arwayshave
s t e a m . T h a t e n e r g yc a n , t b e
to use someheat energyto
convert water into
r e c o v e r e ds, o a l l b o j l e r s t h a t
drum-

o p e r a t eb e l o w
I
t h e c r i t i c a l p o i n t h a v ea b u i . l t - i n

I n c o n t r a s tt o d r u m - t y p b
inefficiency.

e o i l e r s , m o s to n c e _ t h r o u g n
T
b o i r e r s o p e r a t ea b o v e
criticar conditions. These
e n e r g yt o c o n v e r tw a t e r i n t o
b o i r e r s d o n , t n e e dt o u s e
a d d i t i o n a rh e a t
s t e a m ;a b o v et h e c r i t i c a l p o i n t ,
there is no
T
difference betweenwater and
steam.

B o i r e r s t h a t o p e r a t ea b o v e
the criticar point are cared
T
supercriticar
b o i ' l e r s , w h ir e b o ir e r s t h a t
o p e r a t eb e r o wt h e c r i t i c a r p o i n t
s u b c r i t i c a rb o i r e r s . A r l s u p e r c r i t i c a r
b u t n o t a l l o n c e - t h r o u gbho i l e r s
are cared
b o i r e r s a r e o n c e - t h r o u gbho i r e r s ,
T
are supercritical. Some
b o it e r s o p e r a t ea t s u b c r i t i c a r once_through
c o n d i t i o n s . O n c e - t h r o u;n; ;n; ; " : ; . ' H ; ,
c a l l e d u n i v e r s a lb o i l e r s , b e c a u s e
t h e y c a n o p e r a t ee i t h e r a b o v e
T
critical concritions. since or berow

;i]:J::]J:nditions,
m o s t o n c e - t h r o u gbho i r e r s
supercriticatboilers are used
o p e r a t ea t s u p e r _
i n o u r e x a m p t eas n d
I
' n c e - t h r o u g hs u p e r c r i t i c a rb o ' i r e r s
a n dd r u m - t y p b
eo i r e r sd i f f e r i n
several
t
i m p o r t a n tw a y s . F o r e x a m p l e ,
f l o w p a t h ' A s s h o w ni n F i g u r e
o n c e . A n o t h e rc o n t r a s t i s t h a t
o n c e - t h r o u gbho i l e r s h a v en o
r
2 - 3 - L ,w a t e r g o e st h r o u g ht h e
e c i r c ulation
boirer on.ry
T
there,sno naturalcircuration
t h r o u g hb o i r e r . w a t e r i s p u s h e d
b o i l e r f e e dp u m p ( s ) .
in a once_
t h r o u g ha o n c e - t h r o u gbho i r e r
by the T
I
T
t
t
2.3- 2
I
I
 PLANT
BASICPOI^IER OPERATION
2. Boilers (continued)

2.3.2 0 p e r a t ' i o no f a 0 n c e - T h r o u g B
ho'iler

Inatypicalonce.throughbo.i.|er,waterfromthefeedwatersystemdis.
the furnace' (You can see this in
charges to a header at the bottom of
Figure2.3-1'.)Thewaterflowsfromtheheaderupthroughthewaterwalls
that l'ine all four walls of the furnance'
'increases. The
its temperature
As the water travels through the tubes,
waterjnthetubesisunderveryhighpressure-typica11yaround3500psi
.we]labovethecriticalpoint.t,,lhenthetemperatureofthewateralso
passesthecritjcalpoint,thewaterandthesteambecomethesame.The
sect.ionoftubeswhereth.ishappensisca]ledthetransitionzone.At
passes
pressure' all of the water that
supercritical temperatureand
indistinguishablefrom steam' There-
throughthe transition zonebecomes
fore,thereisnoneedforadrumorformoistureseparatorsordryersto
no need for a recirculation system
separate water from steam' There is
e i t h e r , s ' i n c et h e r e i s n o w a t e r t o r e c i r c u l a t e '
2-3- 3
 BASICPO|^lER PLANT OPERATION
2. B o ' i l e r s( c o n t i n u e d )

A f t e r t h e w a t e r i s e s s e n t i a l l y c o n v e r t e dt o s t e a m i n t h e t r a n s i t i o n
zone,
the steam leaves the tubes and goes to the superheaters.
The superheaters
in a once-througb h o i l e r a r e b a s i c a l l y t h e s a m ea s t h o s e i n a d r u m
boiler.
T h e ya r e t y p i c a ] l y d i v i d e d i n t o a p r i m a r y s e c t i o n a n d a s e c o n d a r y
section,
a n d t h e r e i s u s u a l l y a n a t t e m p e r a t o rb e t w e e nt h e t w o s e c t i o n s
t o m a k es u r e
t h a t t h e s t e a mt e m p e r a t u r ed o e s n , t g e t t o o h i g h .

T h e s t e a mf l o w p a t h i n a o n c e - t h r o u g hb o i l e r i s v e r y s i m i l a r
to the steam
f l o w p a t h i n a d r u m - t y p eb o i l e r . I n b o t h t y p e s o f b o i l e r s ,
stean that has
p a s s e d t h r o u g h b o t h t h e s u p e r h e a t e r sf l o w s i n t o
the Hp section of the
t u r b i n e . F r o mt h e H p s e c t i o n , t h e s t e a m i s g e n e r a l l y
reheatedand then
sent on to the IP section; it then enters the LP section
of the turbine.
F i n a l l y , t h e s t e a mf l o w s f r o m t h e L p s e c t i o n o f t h e t u r b i n e
to the con-
denser.

2.3.3

T h e m a i n a d v a n t a g eo f o n c e - t h r o u g hb o i l e r s i s t h e i n c r e a s e
in efficiency.
S i n c e o p e r a t i o n a b o v ec r i t i c a l c o n d i t i o n s r e q u i r e s n o a d d i t i o n a l
heat to
c h a n g ew a t e r i n t o s t e a m ,o n c e - t h r o u g hb o i l e r s a r e m o r e
efficient than drum
b o i ' l e r s , a n d t h e y c o s t l e s s t o o p e r a t e . H o w e v e r e, v e n t h o u g h
once-through
b o i l e r s a r e m o r ee f f i c i e n t t o r u n , t h e y a r e m o r e e x p e n s i v e
to build. The
s p e c i a ' l m e t a l s n e e d e dt o w i t h s t a n d s u p e r c r i t . i c a r t e m p e r a t u r e s
and pres-
s u r e s a d d c o n s i d e r a b l yt o c o n s t r u c t i o n c o s t s .

2.3.4 0 p e r a t o r R e s p o n s i bI i t i e s

A s a n o p e r a t o r , y o u w i l l b e r e s p o n s i b l ef o r m a i n t a i n i n g t h e
correct steam
pressurein your bo'iler. To do this, you
n e e d t o u n d e r s t a n ds o m eo f t h e
f a c t o r s t h a t a f f e c t s t e a mp r e s s u r e . I n a d r u m - t y p eb o i l e r ,
s t e a mp r e s s u r e
d e p e n d sp r i m a r i ] y o n t h e f i r i n g r a t e . T o m a i n t a i n a c o n s t a n t p r e s s u r e ,
you
h a v e t o m a k es u r e t h a t t h e h e a t p u t i n t o t h e b o i l e r e q u a l s
the heat that's
t a k e n o u t o f t h e b o i l e r a s s t e a m . I f y o u r e d u c et h e
amouno t f heat in a
d r u m - t y p eb o i l e r f u r n a c e , t h e b o i l e r w i l l p r o d u c el e s s
steam. If you keep
t h e t u r b i n e ] o a d c o n s t a n t , p r e s s u r ew i l l d r o p . I f y o u
a d dm o r eh e a t t o t h e
b o i l e r , a n d l o a d i s h e l d c o n s t a n t , m o r es t e a mw i l l b e p r o d u c e d
andpressure
will 'increase.

2.3- 4
I PLANTOPERATION
BASICPOhIER
2. Boilers (continued)

I I n a o n c e - t h r o u g hb o i l e r , t h e h e a t p r o d u c e di n t h e f u r n a c e h a s v e r y l i t t l e
e f f e c t o n p r e s s u r e , b e c a u s et h e p r e s s u r e ' i n a o n c e - t h r o u g hb o i l e r i s p r i -
marily controlled by the bo'iler feed pump. If load is constant and you
I r e d u c e t h e f l o w t h r o u g h t h e b o i l e r f e e d P u m P ,t h e s t e a m p r e s s u r e w i l l
d e c r e a s e . I f y o u i n c r e a s e t h e f l o w t h r o u g h t h e p u m p ,t h e s t e a mp r e s s u r e

I w ' i l l ' i n c r e a s e . L o w e r j n gt h e f i r i n g r a t e o f a o n c e - t h r o u g hb o i l e r o n ' l y

c a u s e st h e t e m p e r a t u r et o d r o p ; p r e s s u r e i s n o t s i g n i f i c a n t l y a f f e c t e d .

t A n s w e rt h e f o l l o w i n g q u e s t i o n s .

I 2.3-r. T h ep o i n t a t w h i c ht h e r e i s n o d i s t i n g u i s h a b l ed ' i f f e r e n c e
tweenwater and stean is c a l l e d t h e

t 2.3-2. T r u e o r F a l s e . B o i l e r sthat operate at subcritical tempera-

t u r e s a n dp r e s s u r e sh a v ea b u i l t - i n i n e f f i c i e n c y .

I 2.3-3. C'ircle the correct answer.

I n a o n c e - t h r o u g hb o i l e r ,

I a.
b.
W a t e rg o e st h r o u g h o n l Y o n c e
T h e r ei s n o r e c i r c u l a t i o n f l o w p a t h
c. T h e t e m p e r a t u r e sa n d p r e s s u r e sa r e o f t e n s u p e r c r i t i c a l
I d. All of the above

I 2.3-4. W h a ti s t h e t r a n s i t i o n z o n e i n a o n c e - t h r o u g b
hoiler?

I
t CHECKYOURANShlERS l/'IITHTHOSEGIVENAT
T H EE N DO F T H I SU N I T .

I
I
I
I 2.3- 5
I BASICPOI^IER
2.
PLANT OPERATION
B o i l e r s( c o n t ' i n u e d )

I 2.4 st'ion
Combu

Asyouhavelearned,theprocessofconvertingwatertosteaminaboiler
I usesenergythat,ssuppliedbythecombustionoffuel.Inthissegment'
NECESSARY
you w.ill learn the ELEIvIENTS
I'IHAT
FoRCoMBUSTIoN, T0
IS REQUIRED

I STARTC0MBUSTI0N,andWHATISREQUIREDT0KEEPC0MBUSTI0NGoING.

I BEFORI
4 OFTHEVIDEOTAPE
ViEI^ISEGMENT
?.4 OFTHISTEXT.
READING SEGMENT

I
ElementsNecessaryfor Combustion
I 2.4.1

the following four elementsmust be

In order for combustionto take p1ace,

I present:oxygen'fuel,heat,andchem'icalreact'ion'Ifanyofthese
e l e m e n t s i s m ' i s s i n 9 , c o m b u s t i o nw i l l
stop' In addition to these four

I e.|ements,aboilerrequirestwomoreelementstocontrolcombustionsothat
it,s efficient and clean burning.
These two add'itional elements are
(].)turbulence-tomixfuelandairthoroughly;and(2)t.ime-toal]ow

I the combust'ionto be comPlete'

I Eachofthesixelementsnamedabovep.|aysan.importantro]einbojler
operat.ion.0xygencomesfromthea.ir'andfuelcomesfromanyofanumber
ofsources,includingnaturalgas,oi'l'andcoa'l'Inorderforthesefuels

I toburn,theymustbeinaformthatm.ixesthoroughlywithair.w.ith
naturalgas,that,seasy,becausenaturalgasm.ixesread.ilywithajr.0il'
( b r o k e nd o w n ' i n t os m a l ' ld r o p l e t s ) b e f o r e i t
, u s tf i r s t b e a t o m ' i z e d
h o w e v e rm
I w.illburnefficiently.l,ihencoalisused,therock.l.ikechunksofcoa.|
m u s t b e g r o u n di n t o v e r y f i n e g r a n u l e s
before the coal w'i1l mix easily w'ith

I air.

I
I
2 . 4 -r
I
 BASICPOWER PLANTOPERATION
2. Boilers (continued)
I
Fuel, in a form that will mix with air, is sent to burners
f u r n a c e . A t y p i c a l b u r n e r , l i k e t h e o n e s h o w ni n F i g u r e
in the boiler
2.4-r, has three
m a i n p a r t s : a n o z z l e , a n i g n i t o r , a n d o n e o r m o r ea i r r e g i s t e r s .
I
Fueris
injected into the furnace through the nozzle. The ignitor provides
h e a t t h a t ' s n e e d e df o r c o m b u s t i o n ,a n d t h e a i r r e g i s t e r s p r o v i d e s
the
a means
I
f o r c u t t i n g o f f t h e a i r t o a b u r n e r t h a t ' s n o t b e . i n gu s e d . T h e
e n c l o s e db y a w i n d b o x ,w h i c h d i r e c t s a i r a r o u n dt h e b u r n e r .
burner is
t
I
t
t
I
t
I
2.4.2
-C o m b u s t i o n
in a Co'il-FiredBoiler I
F i g u r e 2 . 4 - 2 s h o w st h e p a r t s o f a t y p i c a l c o a l - f i r e d b o i l e r ' s f u e l
system.
I n t h i s s y s t e m ,c o a l e n t e r s a t t h e t o p o f t h e p u l v e r i z e r a n d h e a t e dp r . i m a r y
I
air enters from the side. primary air, which is supplied by the primary
a ' i r f a n , p i c k s u p t h e f i n e l y g r o u n dc o a l , d r i e s i t o u t , a n d c a r r i e s
burners. Secondaryair, which is drawnfrom the atmosphereby the forced
it to the I
d r a f t f a n , i s s e n t t o t h e b u r n e r st h r o u g ht h e w i n d b o x .
I
I
I
2.4- 2
I
 PLANTOPERATION
I BASICPOI^IER
z'.'-- g.i iers (cont'inued)

I
I
I
I
I
I
I
I
I T h e s e c o n o a r y a i r , w h . i c h s u p p l i e s t h e a d d i t i o n a l o x y g e n t h a t , sandej ucsetsasbal er y
f o r c o m b u s t i o n ,i s d . i r e c t e da r o u n d
e a c hb u r n e r t h r o u g ha s e t o f
being used' the
r u l e ' w h e n e v e ra b u r n e r i s
I air registers. As a general
reg'isters for that burner are
ful'ly open'

rl Coa]andprimaryairenterthroughthenozzleandm.ixwiththesecondary
a.irasthemjxture]eavestheburner.Thismixingoffuelandair.isaided

t bytheairregisters:theyswirltheairaround,thuscreat.ingthetur.
bulencethat,snecessaryforeff.icientcombustiontotakep.|ace.

I Theheatthat,sneededtostartcombustionisprovidedbytheign.itors.
I g n i t o r s c o m e j n m a n y d i f f e r e n t s h a p e s a n d s i z e s . O n e c o m m o nttoy pae sc p
oan rski s t s
ignited by a devicesimilar
of a miniatureoll burnerthat's
I plug. During startup, the spark-p1ug-like
device provides an electric

sparkthatignitestheoi'l,which'inturn'ignitesthecoal'Thisprocess

I startsachemicalreactionbetweentheoxygenandthefuelthatresults.in
combusot in .
2.4- 3

I
 BASICPO[^/ER PLANT OPERATION
2. B o i l e r s( c o n t i n u e d )

' n c e c o m b u s t i oins s t a r t e d , t h e
T
b u r n i n gf u e l u s u a r y s u p p r i e s
t o i g n i t e n e wf u e r t h a t e n t e r s t h e enough eat
f u r n a c e ,s o t h e i g n i t o r s c a n b e
o f f ' I n s o m ec a s e s ,h o w e v e re, s p e c i a ' [ y turned
a t l o w 1 o a d s ,i t m a yb e n e c e s s a r y
t
t o k e e pt h e i g n i t o r s o p e r a t i n g .

T h ef i n a r c o n s i d e r a t i o ni s t i m e .
I
T h ef r o w o f f u e r t h r o u g ht h e b o i r e r
b e s l o w e n o u g ht o a l l o w e n o u g ht i m e
c o m b u s t i b rme a t e r i a l sm a yb u i r d u p
i n t h e b o i r e r o r i n t n e s t a c ka n d
must
f o r c o m p l e t ec o m b u s t i o n .0 t h e r w i s e ,
create
I
a n e x p l o s i o nh a z a r d . s u c hh a z a r d s
a r e u s u a l l yp r e v e n t e d
d e s i g n ' T h e f u r n a c em u s t b e r a r g e
that the fuel can burn completely
b y p r o p e rf u r n a c e
e n o u g ht o s r o wd o w nt h e a i r f l o w ,
so
li
before it leavesthe furnace.

2.4.3
B o il e r s
T
T h em a j o rd i f f e r e n c eb e t w e ecno a l ,
t h a t t h e n o z z r e sa r e d e s i g n e d .
o i l , a n dn a t u r a rg a s b u r n e r si s
the way
F i g u r e2 . 4 - 3 r e p r e s e n r sa t y p i c a r
I'
oir
burner. In this burner, the fuel
s p r a y e do u t t h r o u g ht h e f u e r n o z z r e ,
'
is pumpedinto the burner and
w h i c hi s d e s i g n e tdo a t o m i z et h e
then
oir.
I,
i-'
t
l,
li
li
I
I
I
2.4- 4
I
T
 I BASICPOt,'lER
2.
PLANTOPERATION
Boilers (continued)

I In a natural gasburner, like the oneillustrated in Figure2.4-4, the gas

i s f e d u n d e r p r e s s u r ef r o m t h e g a s s u p p l y t o a b u r n e r m a n i f o l d . F r o mt h e
m a n i f o l d ,t h e g a s f l o w s ' i n t o t h e g a s s p u d s . H o l e si n t h e t i p s o f t h e s p u d s
I direct the gas into the furnace.

I
t
I

F
A b o i l e r o f t e n h a s b u r n e r s o f m o r e t h a n o n e t y p e - f o r e x a m p l e ,b o t h

ll n a t u r a l g a s b u r n e r sa n d o i l o r c o a l b u r n e r s . s u c hb o i l e r s h a v e t h e f l e x i -
b i l i t y o f b e i n g a b l e t o u s e m o r et h a n o n e k i n d o f f u e l .

The number,arrangement,and placementof burners varies greatly from one

lt b o i l e r t o a n o t h e r . I n a d d i t i o n , s o m eb u r n e r s c a n b e t i l t e d t o a l l o w f o r
r a i s i n g o r l o w e r i n g t h e f l a m e t o i n c r e a s e o r d e c r e a s et h e t e m p e r a t u r eo f
t h e s u p e r h e a t e ds t e a m .

ll 2.4.4 0 p e r a t o r R e s p o n s i bI i t i e s

It As an operator,you will be responsib'le f o r c o n t r o l ' l i n gt h e r e l a t i v e

a m o u n tosf f u e l a n da i r i n t h e b o i l e r f u r n a c e . y o u ' l l p r o b a b l yh e a rt h e s e

It r e l a t i v e a m o u n trse f e r r e d t o a s t h e f u e l / a i r r a t i o .

lr
t 2.4- 5
 PLANTOPERATION
BASICPOt^lER
2. Bojlers (continued)

In ojl and
I n c o a l b u r n e r s ,t h e f u e l f l o w ' i s r e g u l a t e db y t h e c o a l f e e d e r .
gas burners,it's controlled by regulatingva]ves. In all three burners'
draft fans or by
air flow is controlled by vanes or damperson the forced
varying the sPeedof the fans.

ratio'
C h a n g i n ge i t h e r t h e f u e l f ' l o w o r t h e a i r f l o w c h a n g e st h e f u e l / a i r
oxygen going
The correct ratio js determ'inedby monitoring the amount of
perfectly, you could adiust
out the stack. If fuel and air could be mixed
be supp'lied;
the mixture so that exactly the right amountof oxygenwould
t h e n a l l t h e o x y g e nw o u l d r e a c t c h e m i c a l l yw i t h t h e f u e l ' U n f o r t u n a t e l y ,
air than is
m a i n t a i n i n ga p e r f e c t m j x t u r e i s i m p o s s ' i b 1 e .I n p r a c t ' i c e ' m o r e
- to insure that all the fuel is
n e c e s s a r yf o r c o m b u s t i o ni s s u p p l i e d
possibility of explosion
b u r n e d . B y b u r n i n ga 1 l t h e f u e l , y o u r e d u c et h e
of the
f r o m u n b u r n e dc o m b u s t i b l em a t e r i a l b u i l d i n g u p i n t h e l a t e r s t a g e s
boiler or in the stack.

a l w a y sb e
s i n c e m o r e a . i r t h a n f u e l i s s u p p l ' i e dt o t h e b u r n e r , t h e r e s h o u l d
instrument that
excess oxygengoing out the stack. Most boilers have an
Part of your
measuresthe excess oxygenat the boi'ler outlet to the stack.
job is to use this instrument to keep the amountof excess oxygenwithin a
the necessary
s p e c i f i c r a n g e . I f y o u c h e c kt h e m e t e r p e r i o d i c a l l y a n d m a k e
gxygen
a d j u s t m e n t st o t h e a i r f 1 o w , y o u ' l l b e a b l e t o k e e p t h e e x c e s s
w i t h i n y o u r p l a n t ' s e s t a b l ' i s h e dl i m i t s '

o x y g e n "a n d
I n m a n yp l a n t s , t h e r e i s a d i s t i n c t i O n b e t w e e nt h e t e r m " e x c e s s
t h e t e r m " e x c e s sa i r . " E x c e S S o x y g e n ' a s j u s t d e s c r i b e d , i s t h e a m o u n ot f
to extra
o x y g e ni n t h e g a s e s g o ' i n gt o t h e s t a c k , w h i l e e x c e s s a i r r e f e r s
a ' i r s u p p l i e d t o t h e w i n d b o xb y t h e f o r c e d d r a f t f a n '

2.4- 6
I
 I BASICPOWER
2.
PLANTOPERATION
B o i l e r s( c o n t i n u e d )

I Answerthe f o l l o w i n gq u e s t i o n s .

I 2.4-I. L i s t t h e s i x e l e m e n t sn e c e s s a r yf o r c o n t r o l l e d
take p 1 a c e .
a.
c o m b u s t i o nt o

I b.
c.
d.
I e.
f.

I 2.4-2. Trueor False. In order for oil to mix with air,

i t m u s tf i r s t
be atomized.
ll
2.4-3. Circle the correct answer.

t w h i c ho f t h e f o r l o w i n g i s n o t a m a i n p a r t o f a t y p i c a r
burner?
coal

a. A nozzle
I b.
c.
An atomizer
Air registers

I 2.4-4.
d. An ignitor

T r u e o r F a l s e . 0 n c e c o m b u s t i osnt a r t s , i t i s u s u a l . l y
main_
I t a i n e d b y t h e b u r n i n gf u e l , a n d t h e i g n i t o r s a r d t u r n e d
off.

2.4-5.
I I f t h e r e i s n o t e n o u g ht i m e f o r c o m p l e t eb u r n i n g
combustibrm
of
e a t e r i a r s c o u r d b u iI d u p i n t h e r a t e r
of fuel,
stages
the boiler or in the stack and cause an
I
2.4-6.
I I n a t y p i c a l n a t u r a l g a s b u r n e r , g a s i s f e d u n d e rp r e s s u r e
burner
to a

t
I
t 2.4- 7
 PLANT
BASICPOI,IER
2.
OPERATION
Boilers (continued)
I
2.4-7. C'ircle the correct answer'
In coal burners, the fuel f1ow is regulated
by
I
a.
b.
An atom'izer
A sootblower
I
c. The coal feeder
d. All of the above I
'is imposs'ib1 t oe
2.4-8. T r u eo r F a l s e . A p e r f e c tf u e l a n da i r m i x t u r e
m an' it a i n ' s o a l i t t l e e x t r a a ' i r i s s u p p l i e d
t o m a k es u r e t h a t I
all the fuel is burned.

2.4-9.
of air going to the
The term "excess a'ir" refers to the amount
T
lr
I
I
I
I
I
I
I
I
I
2.4- 8
I
 PLANTOPERATION
BASICPObIER
i : "- b ;i i e rs (co n ti n u e d )
)
A i r a n dG a sF l o wP a t h s
I 2.5

Inthissegment'you,llseeHOI,JTHEHEATENERGY I Nthe
H o TPoLLUTI0N
GAscAl.|BEUSEDT0
you,11 learn about someof
I IMpRovE
.'NTR'L
BoILER rritctrncy'
EQUI'*ENTIN THE GAS FLgt{pATH'andyou'll follow
the FLoW PATtls0F

I AIRANDHoTGAsTHRoUGHABoILER.Someofthetermsthatyoushou]dbe
fam.il.iarwithbytheendofthissegmentareAIRPREHEATER,EC0NOMIZER'
FURNACE BOILER ANdBALANCED BOILER.
DRAFT
PRESSURIZED

I
I VIEI,ISEGMENT
READING
BEFORE
5 OFTHEVIDEOTAPE
2.5 OFTHISTEXT'
SEGMENT

t
I 2.s.1
p r o d u c e d .S o m oe f
i n a f u r n a c e ,h o t g a s , calledflue gas, is
A sf u e l b u r n s
rl theheatjnthefluegas.isgivenuptothesteam.inthesuperheaterandthe
reheater,butthere.ssti.|lagreatdealofheatenergyleftinthegas.

I Toincreaseboilerefficiency,muchofthisheatenergyisrecoveredbefore
thegasisexhaustedoutthestack.Thetwocomponentsthataccompl.ish
economizers'
this are air preheatersand
tl
A i r p r e h e a t e r s t r a n s f e r h e a t f r o m f l u e g a s t o i n c o m . i n g c o and
m b utubular'
st.ionair.
of a.ir preheaters: regenerative
rl There are two common types
i n a r e g e n e r a t i v e a i r p r e h e a t e r l i k e t h e o n e . i n Fmetal
i g u r edrum'
z . S - LThe
, t h edrum
h e ais
t
transfer is accomp.lished by the use of a rotating

I composedofanumberofheattransfersegments,eachmadeupofanumberof
m e t a l p l a t e s . T h e d r u m i s d . i v i d e d i n h a l f b y a s t a t .one
i o n s'ide
a r y sof
e a the
l p l adrum'
te.The
air, wh.ich passesthrough
I seal keepsthe combust.ion
andthefluegas,whichpassesthroughtheotherside'separate'Asthe
d r u m r o t a t e s , t h e m e t a l p l a t e s a r e r o t a t e d f r o m t h e hthe
o t sdrum
tream
tooalter-
ffluegas
,l to the cooler stream of combust'ion air' This causes

natelyheatupandcooldownasheatistransferredfromthef]uegasto
a'ir'
I the combustion

2 . 5 -r
I
 BASICPOWER PLANTOPERATION
..

I
6 0 1t e r s ( c o n t i n u e d )

I
I
I
I
F i g u r e2 . 5 - Z . i l l u s t r a t e sa t y p i c a l
p r e h e a t e r f, l u e g a s u s u a l l y p a s s e s
t u b u l a ra i r p r e h e a t e r .i n a t u b u l a r
air
t
t h r o u g ht h e i n s i d e so f t u b e s ,
b u s t i o na i r f r o w s a r o u n dt h e o u t s i d e
the heatedtubes, heat is transferred
of the tubes. As the air passes
throughthe tubes from the frue gas
a n dc o m _
over I
to the combustion air. Some
g a s t o h e a t t h e c o m b u s t i oani r .
e v e r , t h e h e a t i n gm e d i u m
systemsuse stean in the tubes instead
of frue
R e g a r d r e sosf t h e s y s t e m , sd e s i g n ,
how-
t
a n dt h e a i r n e v e rc o m ei n c o n t a c t
w i t h e a c ho t h e r .
fr
t
li
I,
T
I
I
2.5- 2
T
I
I PLANTOPERATION
BASICPObIER
2. Boilers (cont'inued)

preheaters. The primary dif-

I E c o n o m i z e rws o r k v e r y m u c hl i k e t u b u l a r a i r
ference betweenthem is that economizerstransfer heat
to feedwater in-
tubes, and flue gas
stead of combustiona'ir. Feedwaterpassesthrough the
I flows around the outside of the tubes'

and the economizer'

After the flue gas gives up heat to the air preheater
I j t i s s e n t o u t t h r o u g h t h e s t a c k . I n s o m eb o i ' l e r s , c a l l e d p r e s s u r i z e d
air from the forced draft fan
f u r n a c e b o i l e r s , t h e p r e s s u r eo f t h e ' i n c o m ' i n g

I i s e n o u g ht o p u s h t h e g a s o u t t h e s t a c k . I n o t h e r
o f g a s i s h e l p e d a l o n g b y a n a d o ' i t i o n a lf a n , c a l l e d
boilers, the d'ischarge
a n i n d u c e dd r a f t ( I D )
induced draft fans are
fan. Bo'ilers that use both forced draft fans and
I c a l l e d b a l a n c e dd r a f t b o i l e r s .

t 2.5.2 Polution Contro'ls

potent'ially harmful to
Flue gas contains certain by-productsthat are
I plant equipment and to the environment' For example'by-products
sulfuric acid vaporcan be very corros'ive;andthey can
damage
such as
boj1er parts

I iftheyareallowedtocondense.Topreventacidvaporsfromcondensing,
flue gas temperatureis alwayskept abovethe dew
po'int - that point at
v a p o r sd o n ' t c o n -
w h i c ht h e v a p o r s ' i n a g a s w i l l c o n d e n s e .I f t h e a c i d
I d e n s e ,t h e r i s k o f c o r r o s i o ni s g r e a t l y r e d u c e d '

c o n t r i b u t et o a i r
F l u e g a s a l s O c o n t a i n sp a r t i c ' l e s a n d g a s e st h a t c a n
part'iculatesand
pollution. The dev'icesthat are used to removethese
genera'l]y
gasesare cal led prec'ipitators and scrubbers. Prec'ipitators
I r e m o v ep a r t i c u l a t e s ( s u c ha s a s h p a r t ' i c l e s ) , w h i l e s c r u b b e r s
p a r t i c u l a t e sa n dg a s e s .
r e m o v eb o t h

t
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2.5- 3
I
 /

BASICPOt,'lER
2.
PLANT OPERATION
B o i l e r s( c o n t i n u e d )
l1
2.5.3

F i g u r e2 . 5 - 3 i l l u s t r a t e s t h e t y p i c a l f l o w p a t h f o r a . i r a n d
I
hot gasthrough
a boiler. Thenumbers usedare typical, but they maynot be the sameas the
onesin your plant. Theair flow starts at the forced draft fan,
whereit
t
e n t e r s t h e b o i l e r a t a b o u t9 0 o F . A i r p a s s e st h r o u g ht h e
air preheater,
w h e r ei t s t e m p e r a t u r e ' i s ' i n c r e a st eo d5 0 0 o F . 0 n c et h e a i r t e m p e r a t u r e
b e e ni n c r e a s e dt,h e a i r e n t e r s t h e b u r n e r sa n d i s m i x e dw i t h f u e l .
has I
Thefuel/air mixture is ignited in the burnersand burns at a temperature
I
of about 30000F. The burning fuel producesflue gas at temperatures
around20000F.someof the heat energyin the flue gas is given up to
in the boiler superheaters andreheaters. Theheat energyin the flue gas
of
steam I
i s a l s o u s e di n t h e a i r p r e h e a t e r a s n de c o n o m i z e ar ss a m e a nos f i n c r e a s i n g
b o i l e r e f f i c i e n c y . F i n a r ' r y ,w h e nt h e f r u e g a st e m p e r a t u rhea sd e c r e a s e d
to
t
a b o u t3 0 0 o F ,i t i s e x h a u s t eudp t h e s t a c k .
I
I
I

I
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2.5- 4
I
I PLANTOPERATION
BASICPOt,lER
2. Boilers (cont'inued)

I Answert h e f o l l o w i n g q u e s t i o n s :

types of a'ir preheaters'

2.5-L. Nametwo common
tl d.

b.

rl 2.5-2. Trueor False. Econom'izers are heat transfer devicesthat use

h o t f l u e g a s t o h e a t c o m b u s t ' i oani r '

tl 2.5-3.
of incoming
A p r e s s u r i z e fdu r n a c eb o i l e r u s e st h e p r e s s u r e
air
the stack; in a
from the forced draft fan to pushflue gas out
il balanced draft boiler, an additional fan,
a c c o m Pi sf h e s t h i s .
called an

lr 2.5-4. circle the correct answer.

Flue gas contains particles and gases
that can harm plant

l equipmentand the environment' l^lhichof

the follow'ing methods
prevent these by-products from harmingeither
plant equipment

tl or the env'ironment?
a. Scrubbers
b. PreciPitators

ll c.
d.
Keepingthe temperatureof flue gas above
All of the above
the dew point

rl
I
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I
2.5- 5

I
I PLANTOPERATION
BASICPOt,'lER
,. Boilers (continued)

I 2.6 B o il e r 0 p e r a t i o n

given you a lot of information

T h e f . i r s t f i v e s e g m e n t so f t h i s u n i t h a v e

I y o u ' ' l l g e t a n o V E R V I E0I F

a b o u t t h e w o r k i n g so f b o . i ' l e r s . I n t h ' i s s e g m e n t ,
B0ILERoPERATI0NANDAFEt,,l0FTHEBAsIcRESP0NSIBILITIESTHATAN0PERAT0R
||

I HASINCONNECTIONhJITHBoILERS.Inlatertapes,youwilllearnmoreabout
t h e m a n yo t h e r r e s p o n s i b i ' l i t ' i e st h a t y o u h a v e . T w o
specific termsthat you
and s00T-
are BL0WD0!'JN
should understandby the completion of this segment

I BLOWER.

I 6 OFTHEVIDEOTAPE
SEGMENT
VIEI^J BEFORT
2.6 OF THIS TEXT.
I READINGSEGMENT

I 2.6.1 0 p e r a t o rR e s p o n s i b i l i t i e s

I p l a n t o p e r a t o r s h a v e m a n y r e s p o n s ' i bI ii t i e s i n c o n n e c t i o n w i t h b o i
o p e r a t i o n . O n eo f t h e m o s t ' i m p o r t a n to f t h e s e i s
ler
m a i n t a i n i n gp r o p e r l e v e l

I a n d f l o w i n t h e b o i l e r . E v e nt h o u g h l e v e l s a n d
tained automatically, you, as an operator, will have
flows are normallymain-
to carefully monitor
makesure that they are
the operation of the automatic contro] systemsto
I f u n c t i o n . i n gp r o p e r l y . I f a n a u t o m a t i cS y s t e mf a i 1 s ,
to analyze the s'ituation and take the proper manual
y o u , . | 1h a v et o b e a b l e
actjons necessaryto
the automatic systemthat
I mainta.inproper level and flow. For example,if
controls the water level
' i n a d r u mb o ' i l e r m a l f u n c t i o n s ' y o u s h o u l d b e a b l e

toreadthevariousgauges,meters,andflowchartsthatrecordwater
I leve], steamflow, and feedwater flow information
of the problem. If the water level'in the drum
and determinethe extent
h a s d r o p p e dw h e ni t s h o u l d
to transfer the feedwater
I have increased, for instance, you should be able
pumpcontroller or the feedwater valve controller from automatic
the problem in the system
to manual

and control the drum water level manuatty uhtil

T can be corrected.

I
2.6- I
I
 BASIC POWER
2.
PLANTOPERATION
Boilers (continued)
t
2.6.2 V e n t s Drai ns a n d B l o w d o w n s

various parts of the boiler havevents, drains, and blowdowns.

T
vents are
u s u a l l y l o c a t e d o n t h e t o p s o f c o m p o n e n t st;h e y a r e u s u a l l y
during startup, whenthere may be a great deal of air in the
o p e n e do n l y
system, ano
I
c l o s e d a s s o o n a s s t e a ms t a r t s t o c o m eo u t . D r a i n s , o n t h e o t h e r
u s u a l l y l o c a t e d o n t h e b o t t o m so f c o m p o n e n tasn d a r e u s u a l l y
w h e nt h e c o m p o n e ni st s h u t d o w n . C a u t i o n : 0 p e n i n gw a t e r w a l l
h a n d ,a r e
o p e n e do n l y
drains during
I
operation could upset natural circulation flow and cause overheating
the waterwall tubes.
of
I
T h e r ea r e s o m ed r a i n s , h o w e v e r ,t h a t m u s t b e o p e n e dd u r i n g s t a r t u p .
o n s u p e r h e a t e r s ,f o r e x a m p l e ,a r e u s u a l l y o p e n e dd u r i n g s t a r t u p
Drains
to main_
I
t a i n e n o u g hf l o w t o k e e p t h e s u p e r h e a t e rt u b e s c o o l . O p e n i n g
drains also helps get rid of any water that may have condensed
systemduring shutdown.
superheater
in the
t
Blowdowna s r e d r a i n s t h a t m a y b e o p e n e dd u r i n g b o i l e r o p e r a t i o n .
One
I
conmonblowdownon a boiler is a surface blowdown,wh.ichis
t h e n o r m a lw a t e r l e v e l p o i n t i n t h e b o . i l e r d r u m . I t i s
t o r e m o v ec o n t a m i n a t i o nt h a t b u i l d s u p i n t h e d r u m .
located near
o p e n e dp e r i o d i c a l l y
I
2.6.3 SootbI owing
I
During the operation of most boilers, particularly coa.l-fired
soot builds up on the tubes throughout the boiler as
boilers, I
a by-product of
c o m b u s t i o n . T h i s s o o t b u i ' l d u pb l o c k s e f f e c t i v e h e a t t r a n s f e r ; . i t
r e m o v e di f e f f i c i e n t b o i l e r o p e r a t i o n i s t o b e m a i n t a i n e d .
must be
Sootblowers
t
removesoot by blowing it off the tubes with compressed

A typical sootblower (Figure 2.6-i,) is madeup of a lance tube

air or steam.
I
with
n o z z l e s , a f e e d t u b e , a n d a v a l v e . w h e nt h e v a l v e i s o p e n , a
of either compressedair or steam is sent through the feed tube
b l o w i n gm e d i u m
and
I
d i s c h a r g e do u t t h e n o z z l e s i n t h e l a n c e t u b e .

T
T
2.6- 2
I
t BASIC POWER
2.
PLANTOPERATION
Boilers (continued)

I
I
I
T
I
t S o o t b l o w e r sa r e d i v i d e d
' i n t o t w o g e n e r a ' lt y p e s : r e t r a c t a b l e a n d f i x e d '

Retractable sootblowers are motorized so that the lance tube can be in-
s e r t e d ' i n t o t h e b o i l e r w h i l e s o o t b l o w i n gi s i n p r o g r e s s a n d t h e n r e m o v e o
I w h e n ' i t i s n o t n e e d e d . F i x e d s o o t b l o w e r sa r e p e r m a n e n t l ym o u n t e do n
the

boiler so that the lancetube projects into the bojler. Fixed sootblowers

I a r e g e n e r a l l y u s e d w h e r e t e m p e r a t u r e sa r e r e l a t i v e ' l y 1 o w , s ' i n c e
tubes that are constantly exposedto very high temperatureswould
lance
be dam-
'intense heat.

I aged by

S o o t b l o w i n go p e r a t i o n s a r e t y p i c a ] l y ' i n i t i a t e d
jn the contro'l room, and

I sootblowersare typically progranmedto operate in a spec'ified order.

the most part, sootb]owing'is controlled automatically, but there
maybe
For

or
o c c a s i o n sw h e ny o u m i g h t h a v e t o m a n u a l l y b y p a s sa c e r t a i n s o o t b l o w e r
I m a n u a l l yr e t r a c t a s o o t b l o w e rt h a t w i l l n o t r e s p o n dt o a u t o m a t i cc o n t r o l '
0n these occas'ions, the more you know about how sootblowers
work, the

T b e t t e r p r e p a r e dy o u w i l l b e t o c a m y o u t y o u r r e s p o n s i b i l i t i e s '

2.6.4 TheControl Room

I The control room is the heart of the plant. In it are important
meters'
It's your responsib'ifity as an operator to
I charts, alarmsand the like.
c a r e f u l l y m o n i t o r a l l t h e i n f o r m a t i o n t h a t i s d i s p ] a y e da n d
r e m a i na l e r t t o
potential problems. If an alarm soundS, Or a chart or meter shows an

I abnormalreading, you need to know the proper response.

a n d p l a n t e q u i p r n e nct o u l d b e s e r i o u s l y h a r m e di f
Plant personnel
y o u d o n ' t r e s p o n dq u i c k l y

and corectly.

rl 2.6- 3
BASICPOhJER
2.
PLANTOPERATION
Boilers (continued) I
A n s w e tr h e f o l l o w i n g q u e s t i o n s .
I
2.6-I. The level and flow in a boiler are usualy c o n t r o ll e d

( a u t o m a t i c ally , m a n u a1l y )
I
2.6-2. List three steps that an operator must take if
b o i l e r c o n t r o l s y s t e mf a i l s .
an automatic
I
a.
b.
c.
t
2.6-3. A t y p e o f d r a i n t h a t i s u s u a l l y located near the normal water
l e v e l p o i n t o n a d r u mb o i l e r a n d is used to removecontamina-
t
t i o n f r o m t h e d r u mi s c a l l e d a
I
2.6-4. What does a sootblower do?
I
I
2.6-5. L i s t t w o r e s p o n s i b i l i t i e so f a n o p e r a t o ri n t h e c o n t r o l r o o m .
a.
b.
T
t
CHECKYOURANSWERSl.lITH THOSEGIVENAT
THE ENDOF THIS UNIT. THENDO THE
I
UNIT 2 PROBLEIVI
SET. I
I

t
I
t
2.6- 4
I
I BASIC
P0!|ERPLANT0PERATIoN
I 2. Boi'lers(cont'lnued)

-
I Unit 2 - ProblemSet
I
- 1. List the two most cormontypes of boi'lers.
I a. , ,,.,,
b.

I 2. circle the correctanswer.

The drumof a drum-typeboiler

I a.
b.
Co'llectssteam
Receivesfeedwater
Heatsthe incomingfeedwater
I c.
d.
e.
Both a and b
Both b and c

3. T ru eo r F a l se . B o i ler cir culatingwaterpum ps.allow

a contr olled
circulation boiler to be smaller in size, yet generatethe same
amountof steamas a natural circulation boiler.

I 4. For every pressure,there is a corresponding

I
w h i c hw a t e rw i l l b o i l .

I 5. Nametwo factors, which, whenincreased,will causenat,uralcir-

culationto increase.

I a.
b.

I 6. circle the correctanswer.

Devicesthat removewater from steamin the boiler are

I I ffi;::':1p*^u,.,^,
I I b
ilfi': and
€. Both b and c

t
I
I
BASICPOWER PLANT
Unit 2 - Prob'lem
OPERATION
Set (continued) I
'its
7. True or False. Reheatersadd energy to steam by increasing
temperatureand pressure. I
8. I n a tl4ical steamturblne, steamreturningfrom the reheatersusu-
al ly returns to the sectionof the turbine.
I
9. in a boiler?
Ihy is circulationnecessary I
t
10. Circle the correct answer.
T
llhich of the folloring elementsare necessaryfor combustion?
a. 0xygen,heat, chemicalreacti.on, time, turbulence' fuel
I
b.
c.
d.
0xygen,clrculatlon, saturatlon temperature,tlme' fuel
Carbonmonoxide,fuel, turbulence, heat, oxygen,time
Both a and b
t
. e. Both b and c
I
11. Trueor False. At crltical temperatureandpressure'all heat pro-
ducedin the boller goesto Increasethe tenperatureof steam. I
t2. work like tubular air preheaters' except
instead of transferring heat to air, they transfer heat to feed- I
water.

13. Whyare drains openedduring startup?

I
I
I
I
I
T
I BAsrcPowER
PLANT
opERATroN
I Unit 2 - Problem
Set (continued)

I
f L4. Circle the comect answer.
I
Fixed sootb'lowers are usually located in areasof the boiler with
I a. High temperatures
I b. Lowtemperatures
c. Superheaters
I
d. Both a and c
I
e. All of the above

I 15. True or False. In a pressurizedfurnaceboi'ler, induceddraft fans

are usedto pushflue gas out the stack.
I
r 16. Periodic are performed
on the boiler drum
to removecontaminants.
t L7. W h yi s n ' t f l u e g a s a l l o w e dt o d r o p b e l o wt h e d e wp o i n t ?

t
t
18. Circle the correct answer.
I
t Attemperatorsreduce steamtemperatureby
, a. Usingcooling water flowing throughtubes
b. Injecting water into the steamflow path
I
c. Mixing coo'l air with the steam
I d. Venting someof the steamto the condenser
t e. Recircu'latingsteamf low

I 19. True or False. Someburnerscan be tilted to allow for raising and

I
lowering the flame to increaseor decreasesteamtemperature.

I 20. Durinsstartup, are used to light the

fuel as it comesout of the burner,

I
I
I
t
t 3. TURBINE
FUNDAMENTALS

t I n t h i s u n i t , y o u ' l l l e a r n h o wturbines are constructedand howthe open-

ings aroundturbine shafts are s e a l e dt o p r e v e n tl e a k a g e . Y o u ' l l a ' l s o

I learn howturbine bearingsare lubricated and howturbine control systems

o p e r a t e . F ' i n a ' l l y ,y o u ' ' l l g e t a general overviewof what an operator's
r e s p o n s i b i l i t ' i e sa r e j n r e g a r dt o t u r b i n e o p e r a t i o n .

I Thefirst segrnent in this unit exp'lainsHOIJ

TURBINES AREC0NSTRUCTED AND
I HOliA TURBINE SHAFT R0TATES. Specific termsthat you shou'ldunderstand
by
I the end of this segment are: R0T0R,DIAPHRAGM, BLADE, WHEEL, IMPULSEand
REACTION.

t
I VIEWSEGMENT
R E A D I NSG
1 OFTHEVIDEOTAPE BEFORE
E G M E3N. 1T O FT H I ST E X T .

T
I 3.1 SteamFlow Path

3.1.1 T u r b i n eP a r t s
I Turb'ines convertenergystored in steaminto mechan'ical energythat's used

I to turn a g e n e r a t o r . F ' i g u r e3 . 1 , - 1i s a s i m p l i f i e dc r o s s - s e c t i o n avl i e wo f

a t y p i c a l t u r b i n e u n i t . T h em o v i n gp a r t s a r e t h e s h a f t , w h i c hr u n s t h e
entire lengthof the turbine andis connected to the generator;the wheels,
I which are mountedon the shaft; and the b'lades,or buckets, which are
attachedto the whee'ls. Co'l1ective1y, the mov'ing parts of the turbine are
I
I
c a l ' l e dt h e r o t o r .

I
I

t
3.1- 1
BASICPOl^lER
3.
PLANTOPERATION
T u r b i n e F u n d a m e n t a l(sc o n t i n u e d ) T
t
I
I
I
T
I
$*$$ I
The turbine rotor is supportedat eachend by bearings,andit's housedin
I
that are
the turbine casing,or cyljnder. Theturbine casinganddiaphragms
mounted within it are the major stationary parts of the turbine. I
The diaphragrnsand the whee'lsare similar in that they are both round and
they both contain blades (or, in somecases, nozzles). The distinction
I
betweenthemis'in the way that they function during turbine operation.
Since diaphragrsare stationary, their blades or nozz'lesare fixed in
position. The basic function of diaphragrns is to direct steamflow from
T
one set of rotating blades to the next. Sincewheelsare movingparts,
their bladesrotate as steampassesthroughthem;this rotation turns the
I
turbine shaft.

Sealsare installed wherethe turbine shaft passesthroughthe d'iaphragms.

t
Sea'lingthese openingsm'inimizessteambypassingthe diaphragms. The
pairing of one diaphragmand one or, occasionally,two wheelsis called a I
stage. Typically, a turbine has from I to 25 stages.
I
3.1-2
 BASICPOhIER PLANT OPERATION
il i."-- rttuine F u n d a m e n t a( lcso n t i n u e d )

there js usua.llya specia.|type of

,l Beforethe first row of rotating b.|ades,
diaphragmcallecta nozz]ebox, or nozz.|eb]ock.
Thenozzle b.|ockhousesa

seriesofnozzles,wh.ichdirectsteamfromthesteamin]ettothemoving
I b'ladesof the first whee'|. The steam
then moveson throughthe remain'ing
stagesoftheturbineuntilitisexhaustedjntothecondenser.

I Beforesteamenters the turbine through

the steaminlet, it passesthrough
contro] valves' stop valves
(a'lso
two types of valves: stop valves and
I c a l l e d t h r o t g e v a ] v e s )r e m a i nf u 1 1 yo p e n
d u r i n gn o r m a t' lu r b i n e r o p e r a t j o n '

T h e i r m a i n f u n c t i o n i s t o s h u t o f f s t e a m t h a t . s s u p p . | . i e d t o t h e u n .gov-
itduring
emergency cond'itions. contro'l valves (also called
or under
il shutdown
ernorvalves)regulatetheamountofsteamthatflowstotheturb.ine.
undernorma.lconditions,theyremainpartia'l'lyopenduringturbineopera-
ll ti on.

t Depend.ingontheturbinedesign,steamf]owsfromthestopva]vestothe
contro.l va.lvese.ither through a system
of pipes or through a steamchest'
whichisalargehous.ingbetweenthestopva.|vesandthecontro]valves.

I 3.L.2 Rotation
Turb'ine

t Asyouknow,aturbineconvertstheenergystoredinsteamtomechanical
energy.Thisconversionisaccomp.|ishedby.impulse,reactjon,oracombi.

I nationofboth.impu.|seandreaction.l.lhi.|etheendresu]tjsthesame,the
is different'
way it is Produced

I InanimPu.|seturb.ine,theforceofhjgh.pressuresteamcausesthemov.ing
b]adestoturn,muchthewaythatwindcausesachild.spinwheeltoturn.

t Theconfigurationoftheturbinebladesissuchthatwhensteamtrave.|ing
blades'
strikes the mov'ing
throughthe nozz'lesor b'ladesof the diaphragms
itcausesthemtoturn.Sincethemovingb.|adesareconnectedtothe
I turbine shaft, the shaft also turns'

I
I
3.1- 3
ll
 BASICPOWER PLANT OPERATION
3. T u r b i n eF u n d a m e n t a( lcso n t i n u e d )
Ti
I n a r e a c t i o nt u r b i n e ' e x p a n s i oonf s t e a mc a u s e s
t h e m o v i n gb l a d e st o t u r n .
steampassing from the bradesof the diaphragms
throughthe na*ow throat formedby the moving
expandsas it passes
brades. As the steamreaves
I
themoving bladese , x p a n s i ocnr e a t e sa , ' k i c k , , t h a tc a u s e s
a n d t h e a t t a c h e dt u r b i n e s h a f t t o t u r n . T h i s
princ'ipreas that whichpushesa rocket forward
themoving
is essentiailythe same
b.rades
t
whenhot gasesf.rowout the
b a c ko f i t .
T
M o s tm o d e r tnu r b i n e su s e a c o m b i n a t i oonf b o t h
t h e m o s te f f i c i e n t u s eo f t h e e n e r g yi n t h e
f i r s t s t a g e i s a r m o s tp u r e i m p u ' r s e
i m p u t s ea n dr e a c t i o nt o m a k e
s t e a m . I n t h e s et u r b i n e s , t h e
a n d t h e r a s t s t a g e i s a r m o s tp u r e
t
reaction. The stagesin betweenare most
often a combination of the two. T
L a r g et u r b i n e s a r e u s u a l l y d i v i d e d i n t o s e c t i o n s ,
nected to a common shaft.
w i t h e a c hs e c t i o n c o n _
In other turbine designs, as shown
F i g u r e 3 ' r - 2 , t h e s e c t i o n sm a yb e m o u n t e d
in
lr
on different shafts. This ar-
rangemen i st c a l l e d c r o s s - c o m p o u n d ianngd,a t u r b i n eo f
a c r o s s - c o m p o utnudr b i n e . T h e t u r b i n e
this type is calleo
s h o w ni n F i g u r e3 . L _ 2 h a s t h r e e
T
s e c t i o n s : a h i g h p r e s s u r e( H p ) s e c t i o n ,
s e c t i o n , d r d a r o w p r e s s u r e( L p ) s e c t i o n .
a n i n t e r m e d i a t ep r e s s u r e( I p )
T h e t h r e e s e c t i o n sm a y b e
r e f e * e d t o a s s e p a r a t et u r b i n e s , b u t , o p e r a t i o n a i l y ,
t h e y a l r m a k eu p o n e
T
t u r b in e .
t
T
I
I
I
I
3.1- 4
I
]
T BASICPOI.IER
3.
PLANTOPERATION
T u r b i n eF u n d a m e n t a(l cs o n t i n u e d )

t W h i l e e a c h s e c t i o n o f a l a r g e t u r b i n e w o r k s e s s e n t i a l l y t h e s a m ew a y , t h e y
are not identical. T h e w h e e l s , d i a p h r a g m s ,a n d b l a d e s o f e a c h t u r b i n e
section get larger as you go from the HP section to the LP section. The
I the expansionof steam as
differences in size are necessaryto accommodate
it travels throughthe turbine.

I A s s t e a mt r a v e l s t h r o u g ha t u r b i n e , i t s v o l u m em a y i n c r e a s eu p t o 1 5 0
t i m e s . T h e i n c r e a s ei n t h e s i z e o f t h e w h e e ' l s d , i a p h r a g m sa,n d b l a d e s
t h e ' l p st o t a k e c a r e o f a p o r t i o n o f t h i s e x p a n s i o n . I n a d d i t i o n , s o m eo f
the steamis removed from the turbine by the extraction steamsystemand

I usedto heat feedwater.

S t e a mi n t h e t u r b i n e a l s o g i v e s u p h e a t a s i t t r a v e l s f r o m o n e s t a g e t o t h e

I next. For this reason, it 'is often nec o return the steamto the
b o iI e r f or reheating before it moves-orl'tothe next section. (This usual'ly

I o c c u r sbetweent
return
s e c t i o n so f t h e t u r b i n e . ) R e h e a t esdt e a mi s
t u r b i n e t h r o u g ha n o t h e rs y s t e mo f v a l v e s : t h e r e h e a ts t o p
val ves and the i n t e r c e p t v a l v e s . T h e s ev a l v e s p r o v i d e a d d i t i o n a l p r o -

I t e c t i o n t o t h e turb'ine uni t .

t A s y o u h a v e l e a r n e d , t h e l o a d a n d s p e e do f a t u r b i n e a r e r e g u l a t e d b y t h e
t u r b i n e c o n t r o l v a l v e s . W h e nt h e g e n e r a t o r i s c o n n e c t e dt o t h e p o w e r
s y s t e m , s p e e dr e m a i n se s s e n t ' i a l 1 yc o n s t a n t , a n d l o a d i s v a r i e d . W h e nt h e

I generator js not connectedto the powersystem, the speedof the turb'ine is

c o n t r o l l e d . U n d e rc e r t a i n u n u s u a l c o n d i t i o n s , t h e t u r b i n e m a y b e g i n t o
o v e r s p e e d( r o t a t e a t a s p e e dg r e a t e r t h a n i t i s d e s ' i g n efdo r ) . 0 v e r s p e e d i n igs
I d a n g e r o u s ,b e c a u s et h e t u r b i n e s p e e d c o u l d i n c r e a s e t o t h e p o i n t w h e r e
c e n t r i f u g a l f o r c e w o u l d b r e a k t h e t u r b i n e a p a r t . I f t h e s p e e di n c r e a s e s

I a b o v ed e s i g n , t h e c o n t r o l v a l v e s c o m p e n s a tfeo r t h e i n c r e a s e b y c l o s i n g ,
a n d r e d u c i n g s t e a mf l o w t o t h e t u r b i n e .

I
T
I
I 3.1- 5
BASICPOWER
3.
PLANT OPERATION
T u r b i n eF u n d a m e n t a( lcso n t ' i n u e d ) I
l,lhenthe contro'lvalves c'losein responseto an jncreasejn turbine speed,
t h e r e ' s s t i l l a g r e a t d e a l o f s t e a mi n t h e r e h e a t e rs e c t i o no f t h e b o i l e r .
t
This steamcan continueto f'low throughthe turbine and causejt to con-
t i n u e t o s p e e du p . T o p r e v e n to v e r s p e e d i n gt h, e i n t e r c e p t v a l v e sc ] o s e ,
c u t t i n g o f f s t e a mf r o m t h e r e h e a t e r . I f t h e t u r b ' i n es p e e ds t i 1 1 i n c r e a s e s ,
t
the turbine wil'l trip. T h i s m e a n st h a t t h e s t o p v a l v e s , t h e c o n t r o l
v a l v e s , t h e r e h e a t s t o p v a l v e s , a n d t h e i n t e r c e p t v a l v e s q u i c k ' l yc 1 o s e ,
I
cutting off al'l steamto the unit. A trip protects the turbine from
inmediatedangerby shutt'ingit down. t
A n s w etrh e f o ' l l o w i n gq u e s t i o n s .
I
3.1-1. The turbine shaft, wheels, and bladesare collectively called
the T]
3.I-2. T r u e o r F a l s e . T h et u r b i n e c y l i n d e r a n d t h e d i a p h r a g mas r e t h e
major stationary parts of a turbine. I
3.1-3. Circle the correct answer.
T h ep a i r i n g o f o n e d ' i a p h r a gamn do n e o r t w o w h e e l s ' i sc a l l e d
t
a.
b.
A rotor
A b'lade I
c. A disc
d.
e.
A stage
A wheel
I
3 .1 - 4 . True or False. Turb'inesmay be 'impulseor reaction, but not
comb'inationof both.
I
3 .1 - 5. The valve before the steam inlet to the turbine that rema'ins
I
fu1'ly open during normal turbine operation is
v a lv e .
called a
t
I
t
3.1- 6
I
t BASICPOt^lER
3.
PLANT OPERATION
T u r b i n eF u n d a m e n t a(l cs o n t i n u e d )

t 3.1-6. Circle the correct answer.

A l a r g e h o u s i n g l o c a t e d b e t w e e nt h e s t o p v a l v e s a n d t h e c o n -
trol valves is called a

I a.
b.
S t e a mc h e s t
S t e a mt r u n k

I c.
d.
e.
Turbine cy'li nder
Rotor
Noneof the above

I 3.1-7. Steam fl ows from the reheater to the turbi ne through

(a) v a l v e sa n d( b ) v a lv e s .

3.1-8. W h a ti s a t u r b i n e t r i p ?

I
I
I I^JITHTHOSEGIVENAT
CHECKYOURANSI,JERS

T T H EE N DO F T H I SU N I T .

I
I
I
I
I
I
3.r- 7
t
I BASICPOWER
3.
PLANT OPERATION
T u r b i n eF u n d a m e n t a( 'cl so n t i n u e d )

I 3.2 GlandSea'land GlandSeal ExhaustSystems

The gland sea1systemand the gland seal exhaustsystemseal the po'ints

I w h e r et h e t u r b i n e s h a f t p a s s e st h r o u g ht h e c a s i n g . I n t h i s s e g m e n yt ,o u ' l l
IEATNHO|'lTHESE T}IOSYSTEMS PREVENT LEAKAGE ANDHOt,lTHEYHELPA TURBINE RUN

I EFFICIENTLY ANDSAFELY.Termsthat you shouldbe familiar with by the end

of this segmentinclude GLAND, GLAND SEAL,GLAND STEAM C0NDENSER' GLAND
CARB0N
EXHAUSTER,
STEAM SEAL.
SEAL,and WATER
I
I VIEWSEGMENT
READING
BEFORE
2 OFTHEVIDEOTAPE
3.2 OFTHISTEXT.
SEGMENT

' i s , ' i t v a r i e sw i t h t h e
T h ep r e s s u r ei n s i d e a t u r b i n e v a r j e sw i t h l o a d ; t h a t
a m o u not f s t e a mt h a t ' s f l o w ' i n gt h r o u g ht h e u n j t . A t l o w 1 o a d sm , a n y o ft h e
later stagesmaybe undera vacuum;at higher 1oads,the majority of the
stagesare undera posit'ivepressure,with only the very last stagesunder
a vacuum.

I n a t u r b ' i n et h a t ' s u n d e ra p o s i t ' i v ep r e s s u r e s' t e a mt r i e s t o e s c a p ea t t h e

p o i n t sw h e r et h e s h a f t p e n e t r a t e tsh e t u r b i n e c a s i n g . T h i s i s u n d e s i r a b ' l e ,
because l e a k i n gs t e a mc a n b u r np e o p l en e a r b y ,a n di t w i l l d e c r e a s teu r b i n e
e f f . i c i e n c y . I n a t u r b i n e t h a t ' s u n d e ra v a c u u mo,u t s i d ea i r t r i e s t o ' l e a k
.in. Ai1inleakage also decreases turbine efficiency, and the temperature
difference between the cold outside air andthe hot turbine parts can lead
to cracks. The gland seal and gland seal exhaust systemskeep these
prob'lems
from occurring.

3.2- L
BASICPOWER
3.
PLANTOPERATION
T u r b i n eF u n d a m e n t a(l cs o n t i n u e d )
T
3.2.r 0 p e r a t i o n o f t h e G l a n dS e a l S y s t e ma n d t h e G l a n dS e a l E x h a u s t
System I
A t y p i c a l g l a n d s e a l ( F i g u r e 3 . 2 - 1 ) i s m a d eu p o f s e v e r a l l a b y r i n t h s e a l s .
Eachlabyrinth is madeup of a set of grooves and ridges that correspondto
I
a n o t h e r s e t o f g r o o v e sa n d r i d g e s o n t h e t u r b i n e s h a f t . w h e na ' l a b y r i n t h
seal is properly installed, it creates a tortuous path that makesit
difficult f o r a i r t o l e a k i n o r s t e a mt o l e a k o u t . T y p i c a l l y , t h r e e o r
t
m o r es e a l s a r e u s e d a t e a c h s e a ' l i n gp o i n t , a n d t h e y a r e c o l ' l e c t i v e ] y c a l l e d
a 9 1 a n d . L e t ' s a s s u m et h a t t h e f i r s t s e a l i s t h e o n e c l o s e s t t o t h e
I
turbine and the third seal is the one closest to atmosphere. Then, the
g l a n d s e a l s y s t e m i s c o n n e c t e dt o t h e g l a n d a t t h e o p e n i n g b e t w e e nt h e
first and secondseal. The gland seal exhaust system is connectedat the
I
o p e n i n gb e t w e e nt h e s e c o n da n d t h i r d s e a l .

3.2- 2
 BASICPOWER PLANTOPERATION
3. T u r b i n eF u n d a m e n t a (l sc o n t i n u e d )

F i g u r e 3 . 2 - 2 s h o w sa t y p i c a l g l a n d s e a l s y s t e ma n d a t y p i c a ' l g l a n d s e a l
e x h a u s ts y s t e m . T h e t y p i c a l g l a n d s e a l s y s t e m ' i sm a d eu p o f a s t e a ms u p p l y
l i n e , a s t e a ms u p p l y c o n t r o l v a l v e , a s t e a ml e a k o f f l i n e , a n d a s t e a m
l e a k o f f c o n t r o l v a l v e . W h e na t u r b i n e j s o p e r a t i n g a t 1 o w 1 o a d , w i t h a
v a c u u mi n m o s t s t a g e s , o u t s i d e a i r t r i e s t o l e a k j n . T h e s t e a ms u p p l y
c o n t r o l v a l v e o p e n s , a n d 1 o w - p r e s s u r set e a m i s s u p p l i e d t o t h e g l a n d s .
P a r t o f t h e s t e a mf l o w s t o w a r c tj h e o u t s ' i d e ,p a s t t h e s e c o n ds e a l , w h i l e t h e
r e s t o f t h e s t e a mf l o w s i n t o t h e t u r b i n e . T h e f l o w o f s t e a m t o w a r d t h e
o u t s i d e o f t h e g l a n d s ' i s w h a t k e e p st h e o u t s i d e a i r f r o m l e a k i n g ' i n .

I
:
;

1
!
:
;
'

I I

The steam that flows into t h e t u r b i n e f r o m t h e g l a n d s i s n ' t a p r o b l e m .

'it
I B e c a u s ei t ' s a t e s s e n t ' i allY the sametemperature as the inside steam,
s i m p l y m i x e s w i t h t h e s t e a ma l r e a d y
'in the turbi ne.

I
t
3.2- 3
I
BASICPObIER
PLANTOPERATION
3. (continued)
TurbineFundamentals

W h e na t u r b i n e i s o p e r a t i n ga t h ' i g hl o a d , w i t h a p o s i t i v e p r e s s u r ei n m o s t
stages,air in'leakage is only a problemat one or two po'ints. In the other
sea1s,the mainconcernis steamleakingout of the turbine. Steamleaking
from the turbine into the glandscausesan increasein pressure. Thesteam
supply va]ve c'losesandthe steam'leakoffvalve opensto keepthe pressure
fron getting too high. Steamthat passesthrough the leakoff va'lve is
directed to a low pressurearea, such as the main condenser.

Theglandsea1exhaustsystemdrawsoff steamleaking past the secondsea'lof

the turbine glandsbefore it escapesto the atmosphere.Thetyp'ical gland
seal exhaustsystemshownin Figure 3.2-2 consists of a gland steamcon-
denser,a gland steamexhauster,and connectingpipe.

The gland steamexhaustersare vacuumpumps,which draw a vacuumon the

entire system,pulling air and steamfrom the glandsinto the gland steam
condenser. steamis condensed in the gland steamcondenser,and the
condensateis usually drained into the main condenser. Air and other
noncondensiblegasesare dischargedto the atmosphere by the exhausters.

Most of the time, the gland seal systemand the gland sea'l exhaustsystem
work automatically. However,since your safety and the efficient opera-
tion of the turbine dependon them, they shouldbe checkedper.iodically.
The specific areasthat shou'ldbe checkedinclude:

The gland sea'l steamsupp'lypressure

The temperatureof the cooling water in the gland steamcon-

o
denser
Theoperationof the gland seal exhausters
T
a Vacuum in the gland steamcondenser
a Condensate water leve1 in the gland steamcondenser

I
I
T
3.2- 4
I
I BASICPOIdER
3.
PLANTOPERATION
T u r b i n e F u n d a m e n t a '(l cs o n t i n u e d )

I 3.3 B e a r i n qL u b r i c a t i o n

lube
T h e p r e c i s e o p e r a t i o no f a t u r b i n e ' i s m a d ep o s s i b l e b y t h e t u r b ' i n e ' s

I o i ' l s y s t e m . T u r b i n e l u b e o i l s y s t e m sd i f f e r g r e a t l y i n d e s i g n ,
p r i n c i p ' l e s o f o p e r a t ' i o na r e s i m i l a r .
but their
I n t h i s s e g m e n t ,y o u ' 1 ' l l e a r n T H E
LUBEOIL SYSTEM THATPROVIDES
I PRINCIPLES
OIL FORBOTHLUBRICATION
OFOPERATION OFA TYPICAL
ANDTURBINE
TURBINE
CONTROL.BCATiNgIUbT'iCAtiONiS
js covered in the next segment'
covered in this segment;turbine control

t
I VIEhJSEGMENT 3 OF THE VIDEOTAPE BEFORE
3 .T3 O F T H I ST E X T .
R E A D I NSGE G M E N

I
I 3 . 3 .I A Typical TurbineLube0il System- Bas'icComponents

F ' i g u r e3 . 3 - 1 s h o w sa t y p i c a l t u r b j n e l u b e o i ' l s y s t e m . T h eb a s i c c o m p o n e n t s
I o f t h e s y s t e ma r e a r e s e r v o i r , a m a i n ' l u b eo ' i l p u m p a , b o o s t e rp u m p a
, nd
oil coolers.

I
I
I

F
ll
T
3.3- 1
 BASICPOWER
3.
PLANT OPERATION
T u r b i n eF u n d a m e n t a( cl so n t i n u e d ) I
T h er e s e r v o i ri s t h e c e n t r a l c o l l e c t i n gp o i n t f o r a l l t h e o i l u s e di n t h e
s y s t e m .M o s to f t h e s y s t e m ' sp u m pas r e l o c a t e de i t h e r i n s i d e o r o n t h e t o p t
o f t h e r e s e r v o i r , o r e l s e t h e y a r e a t t a c h e dt o t h e t u r b i n e .

I n t h e s y s t e ms h o w ni n t h e f i g u r e , t h e m a i n l u b e o i l p u m pi s a t t a c h e d t o
I
t h e t u r b i n e a n d d r i v e n b y t h e t u r b i n e s h a f t . I t s f u n c t i o n i s t o s u p p l yo i l
to the turbine control system and the booster pump. f

T h e b o o s t e r p u m pi s p o w e r e db y t h e d i s c h a r g eo f t h e m a i n l u b e o i l p u m p .
I t s f u n c t i o n i s t o s u p p l y o i l t o t h e s u c t i o n o f t h e m a i n l u b e o i l p u m pa n d
I
to the turbine bearings.

L u b eo ' i l c o o l e r s( u s u a l l yt w o ) a r e l o c a t e db e t w e etnh e b o o s t e rp u m p
a n dt h e
t
bearings. Theyare heat exchangers
oil.
that use a flow of water to cool the
L u b eo i l c o o l e r sa r e u s u a ' l l ya r r a n g e di n p a i r s : o n e i s u s e df o r
t
c o o l i n gw h i l e t h e o t h e r s t a y s r e a d ya s a b a c k u p .

T h i s l u b e o ' i l s y s t e mi s a c l o s e d s y s t e m , b e c a u s et h e o i l i s u s e d o v e r a n d
I
o v e r a g a i n . T h e o i l t h a t l e a v e s t h e r e s e r v o ' i r p a s s e st h r o u g h t h e p u m p s ,
o ' i l c o o l e r s a n d b e a r i n g s , a n c it h e n r e t u r n s t o t h e r e s e r v o ' i r . S i n c e t h e o i l
I
in a closed system may becomecontaminatedwith dirt, water, and other
impurities, it must be filtered (either continually or periodically) to
m a i n t a i n t h e n e c e s s a r yp u r i t y .
C o r m om n e t h o d so f f i l t e r i n g the oil include
I
t h e u s e o f b a g s , s k i m m e r s ,s c r e e n s , a n d c e n t r i f u g e s .
I
3.3.2 A T y p i c a l T u r b i n e L u b e0 i l S y s t e m- A d d i t i o n a l C o m p o n e n t s

I n a d d i t i o n t o t h e m a i nl u b e o i ' l p u m pa n dt h e b o o s t e rp u m pa, t y p i c a l l u b e
I
o i 1 s y s t e ma l s o i n c l u d e sa n A Ca u x i l i a r y p u m p a, D Ce m e r g e n cpyu m p a , n da n
A c t u r n i n g g e a r p u m p . ( s e e F i g u r e 3 . 3 - 1 . ) T w oo t h e r i m p o r t a n tc o m -
ponentsare the turning gear and a vaporextractor.

T h e A C a u x i l i a r y p u m ps u p p l i e s o i l d u r i n g s t a r t u p a n d s h u t d o w n ,w h e nt h e
t u r b i n e s h a f t i s r o t a t i n g t o o s l o w l y f o r t h e m a i n l u b e o i ' l p u m pt o b e
e f f e c t i v e . T h e A C a u x i l i a r y p u m pc a n a l s o b e u s e d d u r i n g e m e r g e n c l e tso
s u p p l y o i l t o t h e t u r b i n e w h e nt h e n o r m a l o ' i l s u p p l y i s i n t e r r u p t e d . ilrl
3.3- 2

I
t BASICPOWER
3.
PLANT OPERATION
T u r b i n eF u n d a m e n t a( 'cl so n t ' i n u e d )

I T h eD Ce m e r g e n cpyu m p ' i sa b a t t e r y - o p e r a t epdu m pt h a t s u p p f i e so i l w h e nA C

powelis not available to run the ACpumps. The DCemergency pumpisn't
m e a nfto r c i r c u l a t ' i n go i l d u r i n gc o n t i n u o utsu r b i n e o p e r a t i o n ;i t s p u r p o s e
I i s t o s u p p l yo i l t o t h e t u r b ' i n eb e a r i n g sw h i l e t h e t u r b i n e c o a s t s d o w n
f o l l o w i n ga l o s s o f a l l A CP o w e r .

I WheA n Cp o w e ri s a v a ' i l a b l ea f t e r a s h u t d o w no,i l

' i s s u p p l i e dt o t h e t u r b i n e

b e a r i n g sb y t h e t u r n i n g g e a rp u m pa n dt h e t u r b i n e i s p l a c e do n t h e t u r n i n g
I gear. The turning gear is a small motor and gear arrangement
t h e r o t o r t u r n i n g s 1 o w 1 y . I t ' s i m p o r t a n t ,b e c a u s e
that keeps
t h e t u r b ' i n es h a f t m a y
b e c o mbeo w e du n l e s s i t i s r o t a t e d c o n s t a n t ' l ya s t h e t u r b i n e c o o l s d o w n :
I t h e t u r n i n g g e a r p r o v i d e sf o r t h e c o n s t a n tr o t a t i o n '

t The vaporextractor is a small fan (or blower)connected to the top of the

l u b e o i l r e s e r v o i r . I t ' s u s e dt o r e m o v et h e o i 1 v a p o ra n d o t h e r c o m b u s -
t i b l e g a s e st h a t t e n d t o a c c u m u l a t e ' itnh e r e s e r v o i r . I f t h e s eg a s e sa r e
I not removed, an exp'losioncould occur. Thevaporextractor drawsthe gases
out of the reservoir and vents theminto the atmosphere'

I 3.3.3 B a s i c0 p e r a t o rR e s p o n s i b ' i l i t i e s

I $ n e o f a n o p e r a t o r ' s f i r s t r e s p o n s j b i l i t i e s i s t o m a k es u r e t h a t t h e
c o n t r o l l e r s f o r t h e p u m p sl i s t e d j n S e c t i o n3 . 2 . 2 a r e i n t h e s t a n d - b yo r

I a u t o m a t i cp o s i t ' i o n s o t h a t t h e p u m p sw i l l o p e r a t e a u t o m a t i c a l l yw h e n
t h e y ' r e n e e d e d .I f t h e s t a n d - b yp u m pds o n ' t o p e r a t ew h e nt h e y ' r e s u p p o s e d
to, the bear.ings maynot receive lubricat'ion, andmaybe damaged.
I Qperatorsare also responsiblefor checkingbearing o'il temperatureat

I several locatjons aroundthe turbine. Twoof the moreimportantreadings

are taken from the inlet and the outlet of eachoil coo'lerto makesure
p r o p e r l y . T h eo i l t e m p e r a t u rien t h e s u p p l y
t h a t t h e c o o l e ri s f u n c t i o n ' i n g
I a n d r e t u r n l i n e s f o r e a c hb e a r i n gi s a l s o v e r y i m p o r t a n t . N o r m a l l y t, h e
oil temperature i n t h e s u p p l y l i n e f r o m t h e c o o l e r t o t h e b e a r i n g si s
jn the return lines vary'
t f a i r ] y c o n s t a n t ,b u t t h e t e m p e r a t u r eosf t h e o i l
depend'ing on the load, the ambienttemperature,and the specific bearing'
S o m ev a r i a t i o n i n o i l t e m p e r a t u r ies n o r m a l ,b u t a r a p ' i dc h a n g eu s u a l ] y

I i n d i c a t e st r o u b l e .

3.3- 3
T
BASICPOI^JER
3.
PLANT OPERATION
T u r b i n e F u n d a m e n t a l(sc o n t i n u e c i ) I
O p e r a t o r sa r e a l s o c o n c e r n e dw i t h t h e p u r i t y o f t h e o i l . Y o um i g h t h a v et o
t a k e p e r i o d i c o i l s a m p l e sa n d s u b m i t t h e m t o a l a b f o r a n a l y s i s . I f t h e I
t e s t r e s u l t s s h o wt h a t t h e o i l i s n o t b e i n g p r o p e r l y p u r i f i e d , t h e n a p p r o -
p r i a t e a c t i o n s h o u l d b e t a k e n i n a c c o r d a n c ew i t h p l a n t p r o c e d u r e s .
T
A n s w e rt h e f o l l o w i n g q u e s t ' i o n s .

3.3-1. I n r h e t y p i c a l l u b e o i l s y s t e md e s c r i b e di n t h i s s e g m e n t w
, hat,
t
d o e st h e m a i n l u b e o i 1 p u m pdo?
I
I
3.3-2. True or F a l s e . I n a c l o s e d l u b e o ' i l s y s t e m ,t h e o i l i s u s e d
I
3.3-3.
over and o v e r a g a i n .

L u b e o i I coolers are heat exchangers that use a flow of

t
to cool the o'il.
I
3.3-4.
t
Circle the correct answer.
W h i c ho f t h e f o l ' l o w i n g i s n o t a m e t h o do f o i l f i l t r a t ' i o n ?
a. Bags
b.
c.
Skimmers
Vapor extractors I
d. Centrifuges
e. Screens t
3.3-5. W h a ti s a t u r n i n g g e a r ?
t
I
I
I
3.3- 4
I
I BASICPOhIER
3.
PLANTOPERATION
T u r b j n eF u n d a m e n t a(l cs o n t i n u e d )

I 3 .3 - 6 . Circle the correct answer.

T h e D C e m e r g e n c yp u m p i n a t u r b i n e l u b e o i l system is a
battery-operated pump

I a. T h a t s u p p l i e so i l t o t h e t u r b i n e b e a r i n g sw h ' i l et h e t u r -
b i n e c o a s t s d o w nf o l l o w i n g a l o s s o f a l l A C p o w e r

t b.

c.
T h a t k e e p st h e t u r b i n e o p e r a t i n g n o r m a l l y u s i n g b a t t e r y
p0wer
T h a t p r e v e n t s o i l i n t h e l u b e o i 1 s y s t e mf r o m g e t t i n g

I d.
too hot
N o n eo f t h e a b o v e

l 3.3-7. True or False.

n o r m a,l but
S o m ev a r i a t i o n i n l u b e o i l t e m p e r a t u r ei s
r a p i d t e m p e r a t u r e c h a n g e s u s u a l y j n d ic a t e

t t r o u bI e .

I WITHTHOSEGIVENAT
CHECKYOURANSWERS

I T H EE N DO F T H I SU N I T .

I
t
I
I
I
I
I
3.3- 5
I BASICPOWER
3.
PLANTOPERATIOi'I
T u r b ' i n eF u n d a m e n t a l(sc o n t i n u e d )

I 3.4 T u r b in e C o n t r o l

I n t h e l a s t s e g m e n t y, o u ' l e a r n e dh o wt h e m a i n l u b e o i 1 s y s t e ms u p p l i e s o i l
I STOPVALVES,CONTROL VALVES,REHEAT STOPVALVES,
. l I L I S U S E DT 0 O P E R A T E
t o t h e b e a r i n g s . I n t h i s s e g m e n t y, o u ' l l l e a r n H O tO
ANDINTERCEPT VALVES TO

I TURBINE
CONTROL SPEED.

I VIEI,ISEGI{ENT 4 OFTHEVIDEOTAPE BEFORE

t 3 .T4 O F T H I ST E X T .
R E A D I NSGE G M E N

I Stop valves, control valves, reheat stop valves, and intercept valves have
t w o m a i n f u n c t i o n s : ( 1 ) t o c o n t r o l s t e a mf l o w t h r o u g h t h e t u r b i n e d u r i n g

I normal operation and (2) to shut off all steam to the turbine during
s h u t d o w no r e m e r g e n ccyo n d i t ' i o n s . W l r e na t u r b i n e ' s g e n e r a t o r i s c o n n e c t e d

I t o a p o w e rs y s t e m , i t s s p e e di s e s s e n t i a l l y c o n s t a n t a n d c o n t r o l l e d b y t h e
power system. The control valves are then openedor closed to increase or
decrease generator load. However, turbine speed does change during

I startup, and the valves are used to control that speed. If an emergency
o c c u r s , a l 1 t h e v a l v e s l j s t e d a b o v ea r e c ' l o s e d ,e f f e c t i v e l y ' i s o l a t j n g t h e

I turbine from the boiler.

3.4.1 T u r b i n e S p e e dC o n t r o l

I There are severa'l systemsthat can be used to control turbine speed. The
systems are the mechanical-hydraulic control system and
I two most common
the electro-hydraulic control system. The chief differences betweenthese
systemsare the source of oil for operation and the type of governor used

I to mon'itor and control speed. The mschan'ical-hydrauliccontrol system

uses a flywe'ight governor and oil from the main lube oil systemfor turbine
s p e e dc o n t r o l , w h i ' l e t h e e l e c t r o - h y d r a u l i c c o n t r o l s y s t e mu s e s a n i n d e p e n -
t dent oil supply and an electron'ic governor. The basic princ'ip1esof
operation are the samefor both systems. In this segment,a mechanical-

I h y d r a u l j c c o n t r o l s y s t e mi s u s e d t o i ' l l u s t r a t e t h e s e p r i n c i p ' l e s .

3.4- 1
I
BASICPOWER
3.
PLANT OPERATION
T u r b i n e F u n d a m e n t a l(sc o n i i n u e d ) I
I n a t y p i c a l m e c h a n i c a l - h y d r a u l ci co n t r o l s y s t e m ,o i l i s s u p p ' l i e dt o t h e
s y s t e mb y t h e m a i n l u b e o i l p u m po r , d u r i n g s t a r t u p , b y t h e A C a u x i l i a r y
I
o i 1 p u m p . 0 n c e t h r o u g h t h e s y s t e m ,t h e o i l i s r e t u r n e d t o t h e r e s e r v o i r s o
that it can be used again.
turbine control oi1 system.
T h i s c l o s e d s y s t e mi s u s u a l l y c a l l e d t h e t
0il from the turb'ine control oil system is used to operate hydraulic
t
a c t u a t o r s t h a t o p e no r c l o s e t h e s t o p v a l v e s , c o n t r o l v a l v e s , r e h e a t s t o p
valves, and 'intercept valves. Usually, there is an actuator for each
valve. Hydraulicactuatorsdifferin design, but they al1 operate in much
I
t h e s a m ew a y .
A s F i g u r e 3 . 4 - 1 i l l u s t r a t e s , a s t e mt h a t ' s c o n n e c t e dt o t h e
valve enters the actuator and is attachedto a piston, which is located
w i t h i n a h y d r a u l i c c y l i n d e r . A s p r i n g a b o v et h e p i s t o n a p p l i e s d o w n w a r d
I
p r e s s u r eo n t h e p i s t o n , t h u s c l o s i n g t h e v a l v e . T h e a c t ' i o n o f t h e s p r i n g
c a n b e c o u n t e r e db y a l l o w i n g h i g h - p r e s s u r eo i l t o f l o w b e l o w t h e p i s t o n ,
I
p u s h i n gu p . V a r y i n gt h e a m o u not f o i l i n t h e h y d r a u l i c c y l j n d e r a l l o w s t h e
pos'ition of the piston (and thus the position of the valve) to be varied I
a l l t h e w a y f r o m f u l ' l y o p e n e dt o f u l l y c l o s e d .

I
I
I
I
I
I
I
I
3.4- 2
I
I BASICPOhIER
3.
PLANTOPERATION
T u r b ' i n eF u n d a m e n t a l(sc o n t i n u e d )

I T u r b i n e s u s u a l l y o p e r a t e a t a c o n s t a n t s p e e do f e i t h e r L B 0 0o r 3 6 0 0r e v o -
l u t i o n s p e r m i n u t e . I f t h e s p e e d c h a n g e sf r o m i t s d e s i r e d v a l u e , t h e
g o v e r n o rS e n s e st h e c h a n g ea n d s i g n a l s o n e o r m o r eo f t h e h y d r a u f i c a c t u a -

I by adiust'ing the control valves'

tors to compensate

The governor sends a signal to the control systemthat indicates the

I t u r b . i n es p e e da n d i s u s e d t o r e g u ' l a t et h e c o n t r o l v a l v e s . T h e r e ' s u s u a l ' l y
a s e c o n dg o v e r n o r i n s t a l l e d t o o p e r a t e t h e i n t e r c e p t v a l v e s i f t u r b ' i n e

I speed becomesabnorma'l'lyhigh. In effect, the two governors control the

f l o w o f o j l u n d e rt h e h y d r a u l i c a c t u a t o r s f o r e i t h e r t h e c o n t r o l v a l v e s o r

I the intercept valves.

F ' i g u r e3 . 4 - 2 r e p r e s e n t s a t y p i c a l t u r b ' i n e c o n t r o l o i l s y s t e mt h a t u s e s a

T f l y w e i g h t g o v e r n o r . T h i s s y s t e mi s c o m p o s eodf t h e g o v e r n o r ' a h y d r a u ' l i c

actuator, a Servovalve (usedto control the flow of oil into'and out of
t h e h y d r a u l i c a c t u a t o r ) , a c r o s s b e a ma, n d c o n n e c t i n gr o d s . | | | i t h i t , t h e
I s p e e do f t h e t u r b i n e c a n b e a c c u r a t e l y c o n t r o l l e d .

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BASICPOWER
3.
PLANTOPERATION
T u r b in e F u n d a m e n tsa l( c o n t i n u e d ) I
T h e f l y w e i g h t g o v e r n o r c o n s i s t s o f a s h a f t , w h i c h i s c o n n e c t e dt o t h e
t u r b i n e b y g e a r s , a n d t w o " 1 " s h a p e db r a c k e t s , h e l d t o g e t h e r b y a s p r i n g . t
The brackets are attached to the shaft of the governor by pivots. The top
of each bracket 'is wejghted, and the bottomsof the brackets are connecteo
to the crossbeamby a connecting rod.
t
I f t u r b i n e s p e e dd e c r e a s e s ,c e n t r i f u g a l f o r c e o n t h e s p i n n i n g g o v e r n o ri s I
r e d u c e d . T h e s p r i n g p u l l s t h e w e i g h t s i n w a r d , c a u s i n g t h e b o t t o m so f t h e
b r a c k e t s t o p u s h d o w no n t h e r o d a n d t h e c r o s s b e a m . T h i s c o m b i n e dp u s h
c a u s e st h e s e r v o v a l v e t o o p e n , d i r e c t i n g h i g h - p r e s s u r eo i l i n t o t h e h y -
I
d r a u l ' i c a c t u a t o r . T h e o i 1 p r e s s u r eb e n e a t ht h e p i s t o n c a u s e st h e p i s t o n t o
rise, so the control valve openingincreases. l,lith the increase in the I
c o n t r o l v a l v e o p e n i n g ,m o r es t e a m ' i s s u p p l i e dt o t h e t u r b i n e , a n d t u r b i n e
s p e e di n c r e a s e s .
l
T h e p o s i t i o n o f t h e s e r v o v a l v e i s a f f e c t e d ' i n t w o w a y s : I t i s m o v e db y t h e
a c t i o n o f t h e g o v e r n o r , a n d i t i s m o v e db y t h e a c t i o n o f t h e h y d r a u ] i c
actuator. Whenthe actuator moves, it feeds back jnformation to the servo
I
v a l v e b y m o v ' i n gi t . This is called a reset feature; it gives a certain
amountof information to the control systemto allow speed adjustmentsto
I
b e m a d ei n s m a l l i n c r e m e n t s . I f a d j u s t m e n t sw e r e m a d et o o q u i c k l y , t h e
c o n t r o l s y s t e mw o u ' l dc o n t i n u a l l y f l u c t u a t e u p a n d d o w nw h i l e i t t r i e d t o
f i n d t h e p r o p e r s p e e d . T h i s s e a r c hf o r t h e p r o p e r s p e e d' i s c a l l e d h u n t i n g ;
I
i t ' s u n d e s i r a b l e ,b e c a u s ei t c a u s e st u r b i n e s p e e dt o f l u c t u a t e .
I
The combinedaction of the movement of the governor and the reset feature
r e s u l t s i n c l o s i n g o f f t h e o i l t o t h e a c t u a t o r . w j t h t h e m o v e m e notf t h e
o i l s t a b i l ' i z e d , t h e c o n t r o l v a l v e s t a y s a t i t s n e ws e t t i n g .
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 BASICPOWER PLANT OPERATION
3. T u r b i n eF u n d a m e n t a( lcso n t i n u e d )

T h ef l y w e i g h t g o v e r n oar c t i o n i s r e v e r s e df o r a n i n c r e a s ei n t u r b i n e s p e e d .
Whenthe flyweight governor speedsuP, centrifugal force causes the
w e ' i g h t st o m o v eo u t w a r d ,p u ' l 1 i n gu p o n t h e c r o s s b e a m .T h i s c a u s e st h e
servo valve to drain off oil from the actuator. The spring action of the
piston causesthe control valve to close downthe des'ignated amount're-
d u c i n gt h e s t e a mf l o w t o t h e t u r b i n e . A s t u r b i n e s p e e dd e c r e a s e st,h e
g o v e r n o br e g i n st o m o v ei n w a r da n d , i n c o m b i n a t i own i t h t h e r e s e t f e a t u r e '
pu]ls upon the crossbeam c l,o s i n go f f t h e s e r v ov a l v e . T h ec o n t r o 1v a l v e
i s f r o z e n a t a n e ws e t t i n g .

I n t e r c e p tv a l v e su s e a s y s t e ms i m i l a r t o t h e o n ej u s t d e s c r i b e d h ; owever,
the speedpojnt that actuatesthemis considerablyhigher than the control
v a l v e s ' s p e e ds e t t i n g . T h e r e f o r e ,i n t e r c e p t v a l v e sr e m a i nw i d e o p e nw h e n
t h e t u r b i n e i s o p e r a t i n ga t n o r m a ls p e e d ,b u t b e g i nt o c ' l o s ew h e nt u r b i n e
speedincreasesabovenorma'|.

S t o p v a l v e s a n d r e h e a t s t o p v a l v e s a r e p o s i t i o n e de i t h e r f u l l y o p e no r
fully closed, so they are simpler to control than control valves and
i n t e r c e p tv a l v e s . T h eh y d r a u ' l i ca c t u a t o r sf o r t h e s ev a l v e su s ep i s t o n sa n d
s p r i n g sl i k e t h e o n e su s e df o r c o n t r o l a n d i n t e r c e p t v a l v e s . O i l i s f e d
u n d e rt h e p i s t o n t o o p e na v a ' l v e ,a n do i l i s b 1 e do f f t o c l o s e t h e v a l v e .

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BASICPOl^lER PLANTOPERATION
3. T u r b i n eF u n d a m e n t a (l sc o n t i n u e d )

3.4.2 T u r b j n eT r i p p i n g

B e s ' i d e sc o n t r o l l i n g t h e t u r b i n e , t h e c o n t r o l s y s t e ma l s o p r o v i d e s a m e a n s
to shut downthe turbine irmediately in case of an emergency. A sudden
s h u t d o w ni s c a l l e d a t r i p ; i t c a n b e t r j g g e r e d a u t o m a t i c a l l yo r m a n u a 1 1 y .
F i g u r e 3 . 4 - 3 s h o w st h e t r i p c i r c u i t i n c o n i u n c t i o n w i t h t h e c o n t r o l c ' i r -
c u i t . W h e na t r i p o c c u r s , a v a ' l v eo p e n st h a t d u m p sa l l o f t h e o i l f r o m t h e
h y d r a u ' l i ca c t u a t o r s o f a l l o f t h e v a l v e s - c o n t r o l , i n t e r c e p t , s t o p ' a n d
reheat stop - causing the spring action of the pistons to shut off all
s t e a mt o t h e t u r b i n e . T r i p s o c c u r a u t o m a t i c a l l yo n c o n d i t i o n s s u c h a s l o w
l u b e o i ' l p r e s s u r e , t u r b i n e o v e r s p e e d ,a n d e x c e s s i v ev i b r a t ' i o n . I f a u t o -
m a t i c s y s t e m sf a i 1 , t h e o p e r a t o r m u s t t r i p t h e t u r b i n e m a n u a l l y .

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I BAsIcPowER PLANT oPERATIoN
I 3. T u r b i n eF u n d a m e n t a( lcso n t i n u e d )

I A n s w etrh e f o l l o w i n gq u e s t i o n s .
!

3.4-1. T r u e o r F a l s e . W h e na t u r b i n e ' s g e n e r a t o ri s c o n n e c t etdo a

I
I p o w e sr y s t e m i,t s s p e e di s e s s e n t i a l ' l yc o n s t a n a
t n dc o n t r o l l e d
by the governor.

r 3.4-2. usedto control turbine speedare

Twomajor systemscommonly
(a) hydraulic control systems and

I (b) control systems.

I 3.4-3. Circle the correct answer.

To opena control valve in a typical control system'
a. H i g h - p r e s s u r es t e a m m u s t b e f o r c e d i n t o t h e h y d r a u l i c

T b.
actuator
0'il must be forced under the piston in the hydraulic
cylinder to counterthe force of the piston spring
I c.
d.
T h e o p e r a t o r m u s t m a n u a l l yo p e r a t e t h e r e s e t f e a t u r e
All of the above

I 3.4-4. True or False. A servo valve controls the flow of oil into
h y d r a u fi c a c t u a t o r s .
I 3.4-5. Whatdoes the reset feature do in a typical turb'ine control

I system?

I 3.4-6. Circle the correct answer.

c o n t i n u a l f l u c t u a t i o n o f t u r b j n e s p e e dw h ' i l e t h e c o n t r o l s y s -
t e m s e a r c h e sf o r t h e p r o p e r s p e e di s a n u n d e 3 j r a b l ec o n d i t i o n
I calI ed
a. Search'ing

I b.
c.
H u n tn
i g
R e s e tf e a t u r e
d. Hideandseekism

I e. Noneof the above

I 3.4- 7

I
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BASICPOWER
3.
PLANTOPERATION
T u r b i n eF u n d a m e n t a (l sc o n t i n u e d ) I
3.4-7. A s u d d e ns h u t d o w o
nf a turb'ineis called a
I
CHECKYOURANSWERS
t.lITH THOSEGIVENAT
I
T H EE N DO F T H I SU N I T .
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I BASICPOWER
3.
PLANTOPERATION
(continued)
TurbineFundamenta'ls

I 3 . 5 TurbineOperation

The fina1 segmentin this un'it g'ivesyou a GENERAL 0F TURBII{E

0VERVIEI,I
I OPERATIONANDTHEOPERATOR'S
OFOPERATION.
DUTIESANDRESPONSIBILITIES EACHPHASE
DURING

I
T VIEt.|SEGMENT
READING
BEFORE
5 OFTHEVIDEOTAPE
3.5 OFTHISTEXT.
SEGMENT

t
I Thethree phasesof turbine operationare startup operation,norma'loper-
ation, and shutdown operation. As an operator, you'll be responsiblefor
specific duties during eachof these phases. To help you carry out your
I r e s p o n s i b i ' l i t i e s ,m o s t p l a n t s h a v es p e c i f i c w r i t t e n p r o c e d u r efso r t h e j r
operatorsto fo'l1ow.

T 3.5.1 Startup Operation

I Whena turbine is first started up, the temperature of its interna'l parts
increasesfrom aroundroomtemperatureto more than 10000F. During this
phase,heat must be distributed even'lythroughoutthe turbine to prevent
I the turbine parts from expand'ingunevenly. C'losetolerancesmustbe main-
tained within a turbine if it is to operateeffic'iently. Turbinesuper-

t v'isory instruments,locatedeither in the control roomor besidethe tur-

b'ine unit, al'lowthe operator to monitor temperatures,expansion,to]er-

t ances,vibratjon, andother critical areasof operatorconcern. Keep'ing

c'losewatchon these instrumentshelpsyou spot problemsin advance so that
you can take steps to avoid them. A good operator always antic'ipates
a

T troub'le and is preparedto correct it.

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BASICPOWER
3.
PLANTOPERATION
T u r b i n eF u n d a m e n t a (l sc o n t i n u e d ) t
Before a turbine can be run at full
'load,
it has to go through a warmup
p e r i o d . D u r i n g t h i s t i m e , e x p a n s i o ni s c o n t r o l l e d , a n d t u r b i n e p a r t s
I
s h o u l d n o t b e s u b j e c t e d t o d r a s t i c c h a n g e si n t e m p e r a t u r ea n d p r e s s u r e .
D u r i n g t h i s a n d a l l o t h e r p h a s e so f t u r b i n e o p e r a t i o n , y o u ' ' l ' l b e r e s p o n s ' i -
b ' l e f o r t a k i n g r e a d i n g s o f t h e t u r b i n e s u p e r v i s o r y i n s t r u m e n t sa n d r e -
I
cording those readings in a log. If you keep a log of these readings,
y o u ' l l b e a b l e t o c o m p a r ey o u r r e a d i n g s w i t h n o r m a l t r e n d s f o r t h e u n i t . I
t
During startup, it i s e s p e c i a l l y i m p o r t a n t t o w a t c h t h e t e m p e r a t u r ea n d
p r e s s u r e o f t h e l u b e o ' i 1 s y s t e m . C o m p a r i n gc u m e n t r e a d i n g s t o n o r m a l
o p e r a t i n g t r e n d s w i l l a l l o w y o u t o s p o t a n d c o r r e c t m i n o r p r o b l e m sb e f o r e
they can becomemajor ones.
I
S h a f t r o t a t ' i o n a n d s t e a mf l o w a r e g r a d u a l l y i n c r e a s e dd u r i n g s t a r t u p u n t i l
t h e u n i t r e a c h e s ' i t s d e s i r e d o p e r a t ' i n gc o n d i t i o n s . T h e r e a r e s p e c i f i e d
l i m i t s o n t h e r a t e a t w h i c h a t u r b i n e i s h e a t e du p , b r o u g h tu p t o s p e e da n c
I
l o a d e d . T h e s el i m i t s a r e g i v e n i n t h e m a n u f a c t u r e r ' so p e r a t i n g m a n u a lo r
y o u r p l a n t ' s o p e r a t i n g p r o c e d u r e s . F a j l i n g t o o b s e r v et h e s e l i m i t s c a n I
causeunevenexpansionof turb'ine parts and such serious problemsas crack-
i n g o r f r a c t u r i n g o f t h e r o t o r o r t h e s t a t ' i o n a r yp a r t s .
I
One of the most important concerns during startup is preventing water
buildup in the turbine. B e c a u s eo f t h e t r e m e n d o u s p e e da t w h i c h t u r b i n e
blades rotate, one drop of water impacting w'ith a rotating blade can
I
t h e b l a d e . E x c e s s i v ew a t e r b u i l d u p c a n c a u s et h e b l a d e s
s e r i o u s ' l yd a m a g e
to fracture and f'ly apart.
t
T o p r e v e n t t h i s t y p e o f d a m a g et o a t u r b i n e , d r a i n s a t v a r i o u s p o i n t s i n
t h e t u r b i n e a n d i t s a s s o c i a t e dp i p i n g a r e o p e n e dd u r i n g s t a r t u p t o d r a i n
I
out any water producedby steam condensingwhen it comesin contact with
the relatively cold turbine parts. After startup, the drains are closed,
I
s'ince the internal turbine parts have reached the'ir normal operating tem-
peratures. t
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3.5- 2
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I BASICPOI^JER
3.
PLANTOPERATION
T u r b i n e F u n d a m e n t a l(sc o n t i n u e d )

I 3.5.2 N o r m a lO p e r a t i o n

D u r i n g n o r m a lo p e r a t i o n , t u r b i n e s p e e di s s t a b i l i z e d a n d h e l d e s s e n t i a l l y
I constant, becausethe generator is connected to the power system. The
o p e r a t o r i s r e s p o n s i b l e f o r m a k i n gr o u t i n e c h e c k so n t h e t u r b i n e a n d i t s

I systems. As during startup, o'il temperature and flow to and from the
b e a r i n g sa r e c h e c k e dp e r i o d i c a l l y . 0 t h e r r o u t i n e c h e c k si n c l u d em a i n l u b e
o i l p r e s s u r e , t u r b i n e s p e e d , g e n e r a t o r 1 o a d , c o n d e n s e rv a c u u m ,a n d m a i n
t s t e a mp r e s s u r e .

I 3.5.3 Shutdow0
nperation

S h u t d o wp n r o c e d u r e sa r e s i m i l a r t o s t a r t u p p r o c e d u r e s ,b u t i n r e v e r s e ; t h e

I t u r b i n e i s h o t , s o i t m u s t b e c o o l e d d o w ng r a d u a l l y . I n p r e p a r a t i o n f o r
s h u t d o w n ,t h e o p e r a t o r f j r s t c h e c k s t o m a k e s u r e t h e t u r n i n g g e a r i s

I w o r k i n g p r o p e r l y , t h e n t h e c o n t r o l v a l v e s a r e g r a d u a ' l 1 yc ' l o s e dt o r e d u c e
l o a d o n t h e u n i t . A t a p r e s c r i b e d p o i n t i n t h e s h u t d o w np r o c e d u r e ,d r a i n
v a l v e s a r e o p e n e ds o t h a t c o n d e n s a t ef r o m s t e a mw i l l n o t b u i l d u p i n s i d e

I t h e u n ' i t . A t a s e c o n cpi r e s c r i b e d p o i n t , a c c o r d i n gt o t h e m a n u f a c t u r e r ' s

specifications,the turbine is tripped.

I A s i n a 1 ' l p h a s e so f o p e r a t i o n , i t ' s importantfor the operator to monitor

the turbine supervisoryinstruments. Again, specia'l attention should be

T g i v e n t o t h e l u b e o i l s y s t e m . M a k es u r e t h a t t h e p r o p e r a m o u n o
t f oil is
b e i n g s u p p l i e d t o t h e b e a r i n g s . A s s o o n a s t h e t u r b ' i n e c o m e st o a s t o p ,
t h e t u r b i n e s h a f t i s p ' l a c e do n t h e t u r n i n g g e a r . T h e t u r n i n g g e a r k e e p s
I the shaft in constant, slow rotation until
cooled.
the turbine is thoroughly

t T h e r e s p o n s i b i l i t i e s d e s c r i b e dh e r e a r e o n l y s o m eo f t h e r e s p o n s ' i b i l i t i e s
y o u w i l l h a v e d u r i n g s t a r t u p , n o r m a lo p e r a t i o n , a n d s h u t d o w no f y o u r t u r -
I b i n e s . I n l a t e r u n i t s , y o u w i l l l e a r n a b o u tm o r eo f y o u r r e s p o n s i b i l i t i e s .

t
T
I 3.5- 3
BASICPOl/'lER
3.
PLANT OPERATION
T u r b i n eF u n d a m e n t a (l sc o n t i n u e d ) I
Answert h e f o l l o w i n g q u e s t i o n s .
I
L i s t t h e t h r e e p h a s e so f t u r b i n e o p e r a t i o n .
3.5-1.
a.
b.
I
c.
t
3.5-2. Circle the correct answer.
D u r i n g a l 1 p h a s e so f t u r b i n e o p e r a t ' i o n , t h e o p e r a t o r s h o u l d
carefully monitor the
t
a.
b.
Expansiod
nuring startuP
T u r b i n e s u p e r v i s o r yi n s t r u m e n t s
I
c. T u r n i n gg e a r
d.
e.
Noneof the above
All of the above
I
3.5-3. T r u e o r F a l s e . D u r i n gs t a r t u p , d r a i n s m u s tb e o p e n e di n t h e I
p i p i n g t o p r e v e n tw a t e r b u i l d u p .
t u r b i n ea n di t s a s s o c i a t e d

3 .5 - 4 . T r u eo r F a l s e . T h e r e a r e n o s p e c i f i c l i m i t s o n h o wr a p ' i d l y
I
t u r b i n e c a n b e w a r m e du p , b r o u g h t u p t o s p e e d , o r l o a d e d .
I
3 .5 -5 . Circle the correct answer.
D u r i n g a t u r b i n e s h u t d o w n t, h e s h a f t i s p ' l a c e do n t u r n i n g g e a r
a. Whentemperaturereaches a preset point
I
b.
c.
l , l h e nt h e t u r b i n e d r a i n s a r e o p e n e d
W h e nt h e t u r b i n e h a s c o a s t e dt o a s t o p I
d. W h e nt h e t u r b i n e i s t r i p P e d

I
WITHTHOSEGIVENAT
CHECKYOURANSWERS
T H E E N DO F T H I S U N I T . T H E ND O T H E
I
U N I T3 P R O B L ESM
ET.
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I BASICPOWER
3.
PLANTOPERATION
T u r b in e F u n d a m e n tsa l( c o n t i n u e d)

I 3.2.2 0 t h e r T y p e so f T u r b i n e S e a l i n g S y s t e m s

A l t h o u g hs t e a ms e a l s a r e t h e m o s t c o r m o nm e t h o do f t u r b i n e s e a l i n g , t h e r e
I are other methods. The two most common
system and the water seal system.
alternatives are the carbon seal

I C a r b o ns e a l s a r e u s u a l l y f o u n d o n l o w p r e s s u r et u r b i n e s . I n a c a r b o ns e a l
s y s t e ml i k e t h e o n e i l l u s t r a t e d i n F i g u r e 3 . 2 - 3 , o n e o r m o r e c a r b o n r i n g s

t are held in place against the shaft by springs. As the shaft turns, it
r u b s a g a i n s t t h e c a r b o nr i n g s , a n d a n e f f e c t i v e s e a l i s c r e a t e d b e t w e e nt h e

I s h a f t a n d t h e c a s i n g . S i n c ec a r b o n ' i s s o f t e r t h a n m e t a l , t h e r e i s m i n i m a l
w e a ro n t h e t u r b i n e s h a f t . E v e n t u a l l y , t h e c a r b o nr i n g s w e a r o u t , a n d t h e y
must be replaced.

t
I
I
I
t
I
I
I
I
I
3 . 2 -s
I
BASICPOWER
3.
PLANTOPERATION
T u r b i n e F u n d a m e n t a '(l cs o n t i n u e d ) I
The main advantageof water seal systemsover carbon seal systemsis that
t h e p a r t s l a s t f o r a ' l o n g t i m e . F i g u r e 3 . 2 - 4 s h o w sa t y p i c a l w a t e r s e a l
t
througha special gland to min'i-
s y s t e m . I n t h i s s y s t e m ,w a t e r i s p u m p e d
m'ize l eakage. A typi cal water seal system has an impel
'ler
device thatrs
m o u n t e do n t h e t u r b i n e s h a f t a n d c i r c u l a t e s w a t e r t h r o u g h t h e g ' l a n d . T h e
I
c i r c u l a t i n g w a t e r f i l l s t h e o p e n i n gb e t w e e nt h e s h a f t a n d t h e c a s i n g , a n d
thus prevents leakage. Valves in the water supply lines and the water
I
r e t u r n l i n e s m a i n t a i n p r o p e r w a t e r t e m p e r a t u r ea n d p r e s s u r e i n t h e g l a n d .
S ' i n c es o m ew a t e r d o e s l e a k i n t o t h e t u r b i n e , s h r o u d j n gi s u s u a ' l l y p l a c e d
a r o u n dt h e t u r b i n e s h a f t . W a t e rt h a t c o l l e c t s i n t h e s h r o u d i n gi s d r a i n e d
I
off by a drain pipe.
I
I
I
I
I
I
t
I
A n s w e rt h e f o l l o w i n g q u e s t i o n s . I
3.2-L. W h e na t u r b i n e i s
escapeto the atmosphere.
under a pressure,
(ffi;-ffi).
tries to
I
I
3.2- 6
I
I BASICPOWER
3.
PLANTOPERATION
T u r b i n eF u n d a m e n t a (l sc o n t i n u e d )

I 3.2-2. W h e na t u r b i n e i s o p e r a t i n ga t 1 o wl o a d , o u t s i d e a i r t r i e s t o
l e a k i n . H o wd o e s a g l a n d s e a l s y s t e mp r e v e n t t h i s ?

I
r
3.2-3. Circle the correct answer.
W h e na t u r b i n e i s o p e r a t i n g a t h i g h l o a d a n d s t e a mt r i e s t o
I
leak out, what occurs 'in the gland seal system?
a. The steam supply valve closes and the steam leakoff
I valve opens.
b. T h e s t e a m l e a k o f f v a l v e o p e n s a n d w a t e r i s p u m p e di n t o
the gland.
I
c. A c a r b o ns e a l i s u s e d .
d. All of the above
I
3.2-4. l i h a t i s t h e p u r p o s eo f t h e g l a n d s e a l e x h a u s t s y s t e m ?

I 3.2-5. circle the correct answer.

I A typical water seal system
a. U s e sa n i m p e l ' l e rt o d r a wa i r t h r o u g ht h e g l a n d
I b. C i r c u l a t e sw a t e rt h r o u g ha g l a n d
c. U s e ss t e a mf r o m t h e e x h a u s t e r tso s e a l l e a k i n gs t e a m
d. E x h a u s t s t e a mi n t o a c o n d e n s e r
I

I l^JITHTHOSEGIVENAT
CHECKYOURANSWERS
T H EE N DO F T H I SU N I T .
I
I
t 3.2- 7
I BASICPOtlER PLANT OPERATION
I 3. T u r b i n eF u n d a m e n t a( lcso n t i n u e d )

I Unit3-ProblemSet

I 1. The moving parts of a turbine are col'lectively called the

I

I 2. True or Fa'lse. Turbinesconvertenergystored in steamto mechanical

I energy.
I

I 3. Circle the correct answer.

Diaphragms
I a. Are sealedwherethe turbine shaft passesthroughthem
I b. Contain b'ladesor nozzles
- c. Direct steamfrom one set of rotating bladesto the next set
d. Both b and c
f
e. All of the above

I 4. t,thydoes the size of the turbine increasefrom the high pressure

section to the low pressuresection?

I
I s. Hydraulic are usedto openor close turbine valves.

I 6. True or False. The temperatureof the ojl in the return line of a

I on the load, the ambienttemperature,and
bearing varies depending
the specific bearing.
I 7. Circle the correct answer.
_
The reset feature on a turbine control oil system
I a. Allows the turbine to be restarted
- b. Preventshunting
I c. U n l o a d st h e t u r b i n e
I
d. Rearms the turbine trip feature
e. Engages the turning gear
r

T
I
BASICPOWER PLANT
Unit 3 - Prob'lem
OPERATION
Set (continued) t
8. Wherewouldyou find information about howfast you can put load on
the turbine? t
I
9. Tlryically, turbines operate at a constant speed of elther
(a) - or (b) - FFr.
t
10. True or False. Beforea turblne can be run at full load, lt must
I
perlod.
flrst go througha warmup

1 1 . Clrcle the correct answer.

I
The shaft of a turbine can be sealed by all of the following metlods
except:
I
i. Carbonseals
b.
c.
lfater seals
Rotary seals
I
d.
€.
Glandseals
Labryinth seals
T
12. Explainhowpressureinside a turbine varies with load. T
t
1 3 . A suddenshutdownof the turbine is called a t
14. True or False. I'lhentaking readingsin a powerplant, you should
compare your readingswith normaltrends for the plant. I
I
t
t
t
I BASIcPowER PLANT oPERATIoN
t Unjt 3 - ProblemSet (continued)

I 15. Circle the correct answer.

I
Sealinga turbine is necessarybecause
a. Whenthe turbine is underpressure,steamtries to leak out
I b. t'lhenthe turbine is undera vacuum,air tries to leak in
c. whenthe turbine is undera vacuum,steamtries to leak out
d. Both a and b
I e. Both b and c

I 16. Whatdoesthe vaporextractor on the main lube oil reservoir do?

I
L7. A governorcontrolsa valve, which regulates the
I
anountof oil goingto hydrau'lic
actuators.

t 18. the turbineby bleedingall

Trueor False. A trip circuit shutsdown
the oil off the hydraulicactuator.

r
19. Circle the correctanswer.
Duringnorma'loperat'ion,whenthe turbine is undera load' the tur-
I bine speed
a. Changes frequent'lY

I b.
c.
Fluctuatesslowly
Remains relativelY constant
d. Varies with generatedmegawatts
I e. First increases,then decreases

I andone, or occasionallytwo, bladesis

ZO. Thepairing of one diaphragm
I calleda .

I
t
I
T
I
I 4. PLANT
OPERATION

t I n t h e f i r s t t h r e e u n i t s o f t h i s t o p i c , y o u ' v e g o t t e n a g e n e r a lo v e r v i e wo f
t h e m a j o r e q u i p m e ni tn y o u r p l a n t . I n t h i s u n i t , y o u ' l l r e v i e w s o m eo f t h e

t c o n c e p t sy o u ' v e l e a r n e d b y a p p l y i n g t h e m t o t h e r o u t i n e o p e r a t o r a c t i v i t y
of a load change. Then, you'l'l learn about bearings and how they're
l u b r i c a t e d , a n d f i n a 1 l y , y o u ' 1 1 g e t a n o v e r v i e wo f p o l l u t i o n c o n t r o l a n d

I pl ant safety.

I n t h i s f i r s t s e g m e n ty, o u ' 1 1 l e a r n T H EB A S I CR E S P O N S I B I L I0TFI EASN

I OPERATOR DURING A LOAD CHANGE.

I VIEt,J 1 OFTHEVIDEOTAPE
SEGMENT BEFORL

I N.T1 O F T H I ST E X T .
R E A D I NSGE G M E 4

I 4.1 L o a dC h a n g e

I Wheneverthe demandfor power increases or decreases,the power generated

i n y o u r p l a n t ( o r l o a d ) m u s t c h a n g et o m e e t t h a t d e m a n d . T h e c o d e t h a t
power plants must operate by is "power producedmust always equal demand."
I C h a n g i n gt h e s u p p l y o f p o w e rt o e q u a l t h e d e m a n di s c a l l e d a l o a d c h a n g e .

I L o a dc h a n g e si n v o l v e m o r et h a n j u s t a d j u s t i n g t h e f l o w o f s t e a mt h r o u g ht h e
t u r b i n e . D u r i n g l o a d c h a n g e s ,o p e r a t o r sm u s t c a r e f u l l y m o n i t o r i n d i c a t o r s
a n d c h e c k t h e c o n d i t ' i o no f p l a n t e q u i p m e n t . D u r i n g a l o a d c h a n g e ,y o u h a v e

I t o p a y c l o s e a t t e n t i o n t o f o u r i m p o r t a n tf l o w r a t e s :
nir flow.
f1ow, fuel flow, andcombustioa
s t e a mf l o w , f e e d w a t e r

I I n m o s t s y s t e m s ,a l o a d c h a n g ei s i n i t i a t e d w h e nt h e d i s p a t c h e r c a l l s t h e
control room and asks the operator to increase or decreasegeneratedpower
I (or load). T h e o p e r a t o r b e g ' i n st h e l o a d c h a n g eb y o p e r a t i n g t h e t u r b ' i n e
t
g o v e r n o rt o i n c r e a s eo r d e c r e a s et h e c o n t r o l v a l v e o p e n i n g s . A n i m p o r t a n t

t point to keepin mind here'is that there'isn't iust one controller that

4.1- 1
I
BASICPOI^IER
4.
PLANT OPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d ) T
a c c o m p l i s h e se v e r y t h i n g ; t h e r e a r e u s u a l l y s e p a r a t e c o n t r o l s y s t e m sf o r
t h e t u r b i n e , t h e f e e d w a t e r , t h e f u e l , a n d t h e c o m b u s t i o na i r . Control
I
s y s t e m sv a r y f r o m p l a n t t o p 1 a n t , b u t , i n g e n e r a l , t h e o p e r a t o r c h a n g e st h e
l o a d o n t h e t u r b i n e , a n d t h e o t h e r s y s t e m sa u t o m a t i c a l l y f o ' l l o w . I
A l o a d c h a n g em u s t b e a c c o m p l i s h esdl o w l y s o t h a t o p e r a t i n gl i m i t s o n p l a n t
e q u i p m e nat r e n o t e x c e e d e d . I t i s n o t u n u s u a lf o r a l o a d c h a n g er a t e t o b e
I
f o u r o r f i v e m e g a w a t t sp e r m i n u t e . D u r i n g t h e c h a n g e ,t h e o p e r a t o r m u s t
p a y a t t e n t i o n t o s t e a m f l o w i n d i c a t i o n , f e e d w a t e rf l o w i n d i c a t i o n , f u e l
f l o w i n d i c a t i o n , a n d c o m b u s t i o na i r f l o w ' i n d i c a t i o n t o b e s u r e t h a t a l l
I
systemsare making the proper adjustments.

js that steamflow and

I
You've seen in earlier units how important it
f e e d w a t e rf l o w b e k e p t e q u a 1 . T h i s m e a n st h a t i f s t e a mf l o w t h r o u g h a u n i t
i s d o u b l e d , f e e d w a t e r f l o w m u s t a l s o b e d o u b l e d t o k e e p t h e s y s t e m si n
I
b a l a n c ea n dm a i n t a i nt h e c o r r e c t l e v e l s i n t h e b o i l e r d r u ma n d i n t h e m a i n
condenser. t
Y o u ' v e a ' l s o l e a r n e d t h a t a c e r t a i n a m o u not f f u e l r e q u i r e s a c e r t a i n a m o u n t
o f c o m b u s t i o na i r t o b u r n e f f i c i e n t l y . I f t h e f u e l f l o w r a t e i s d o u b l e dt o
I
k e e p u p w i t h t h e i n c r e a s e i n s t e a mf l o w , t h e n t h e a m o u n o
f l o w n e e d e dt o b u r n t h e f u e l a l s o d o u b l e s .
t f c o m b u s t i o na i r
t
I n c r e a s ' i n go r d e c r e a s i n gt h e c o n t r o l v a l v e o p e n i n g sc h a n g e st h e a m o u n to f
s t e a mf l o w i n g t h r o u g h t h e u n i t a n d a l s o c h a n g e st h e s t e a mp r e s s u r e . T h e
I
other control systemssense these changesand adjust their systemsaccord-
' i n g 1 y . T h e f e e d w a t e rf l o w j n c r e a s e so r d e c r e a s e st o m a t c hs t e a mf l o w , a n d
t h e f u e l a n d c o m b u s t i o na i r f ' l o w s y s t e m si n c r e a s e o r d e c r e a s et o r e s t o r e
I
s t e a mp r e s s u r e t o t h e d e s i r e d l e v e l .
I
t J h i l e a l l t h i s i s t a k i n g p 1 a c e ,t h e o p e r a t o rh a s t o m a k ec a r e f u l c h e c k so f
all the flow rates and comparethem to what he has experiencedfrom other
l o a d c h a n g e so r w h a t h a s b e e nr e c o r d e di n t h e l o g f o r s i m i l a r c o n d i t i o n s .
I
If the operator spots a potential prob'lem,he may have to makeadjustments
t o o n e o f t h e a u t o m a t j cc o n t r o l s y s t e m s . I
I
4.1- 2
I
I BASICPOI,JER
4.
PLANT OPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d )

I I n m o s t c a s e s , a s m a l l a d j u s t m e n tw i l l r e s t o r e t h e s y s t e m t o n o r m a l .
H o w e v e r ,i f a n a d j u s t m e n td o e s n o t t a k e c a r e o f t h e p r o b l e m ,t h e o p e r a t o r
m a yh a v e t o t a k e o v e r m a n u a lc o n t r o l o f t h e s y s t e m . T h i s i s n o t a d e c i s i o n

I t h a t c a n b e t a k e n l ' i g h t 1 y . S i n c e i t m e a n st a k i n g m a n u a l c o n t r o l o f a
s y s t e m t h a t i s u s u a l ' l y c o n t r o l l e d a u t o m a t ' i c a 1 i y ,t h e o p e r a t o r m u s t b e

t p r e p a r e dt o p e r f o r m a l l t h e f u n c t i o n s t h a t t h e a u t o m a t i c s y s t e mn o r m a l l y
p e r f o r m s . I n s i t u a t i o n s l i k e t h i s , o p e r a t o r sm u s t a p p l y e v e r y t h i n gt h e y
h a v e l e a r n e d a b o u t t h e s t e a mc y c l e a n d a b o u t t h e i r u n i t s .

t A n s w e tr h e f o l l o w ' i n gq u e s t i o n s .

I 4.1-1. H o wi s a l o a d c h a n g eb e g u n ?

I
I 4.I-2. T r u e o r F a l s e . t , l o s tg e n e r a t i n gu n i t s h a v e s p e c i fi c I i m i t s o n
r a t e o f c h a n q eo f l o a d .

I 4.1-3. In order for a unit to operatesafely and efficiently, the

steam f I ow must equa'l the (a) w h il e t h e
(b) m u s te q u a l t h e c o m b u s t j o a
nir flow.
I 4.1-4. Whattwo steps can an operator take if an automaticsystem

t faj'ls to adjust a flow rate properly?

b.

I
I CHECKYOURANSWERS
t^JiTHTHOSEGIVENAT
T H EE N DO F T H I SU N I T .

I
T
I
t 4.1- 3
I BASICPOI.IER
4.
PLANT OPERATION
(continued)
P l a n tO p e r a t i o n

I 4.2 s n dL u b r i c a t i o n P
B e a r i n ga , art L

In this segment,you'11 learn THETll0 MAJ0R TYPES 0F BEARINGS, HOt,lBEARINGS

I S U P P 0 RLT0 A D S ,R E D U CFER I C T I 0 NA
AN 0IL I^IEDGE
learn HOW LUBRICATES BEARINGS ANDTHESPECIFIC
MOVINP
, N DP O S I T I 0 N
BEARING CHECKS
GA R T S . Y o u ' l l a l s o

t THAT0PERAT0RSPERF0RM.Specific terms that you should be familiar with by

t h e c o m p l e t i o n o f t h i s s e g m e n ti n c l u o e F R I C T I O NA, X I A LM 0 V E M E NRTA, D I A L
M0VEMENT, and VIBR0METER.
PYR0METER,

I
I VIIhI SEGMENT BEFORE
2 OFTHEVIDEOTAPE
N.T2 O F T H I ST E X T .
R E A D I NSGE G M E 4

I
I Most bearingsfit into one of two general categories: s'liding surface
b e a r i n g sa n d r o l l i n g c o n t a c t b e a r i n g s . I n s l i d i n g s u r f a c e b e a r i n g s ' t w o

I s u r f a c e s w i t h a l u b r i c a n t b e t w e e nt h e m s l i d e o v e r e a c h o t h e r . I n r o ' l 1 i n g
c o n t a c t b e a r i n g s , o n e S u r f a c er o l l s o v e r a n o t h e r s u r f a c e - a g a i n , t h e r e ' s
l u b r i c a n t b e t w e e nt h e t w o s u r f a c e s .

I R e g a r d l e s so f t h e b e a r i n g t y p e , a l l b e a r i n g s p e r f o r m t h r e e f u n c t i o n s :
(1) carrying loads, (2) reducing friction, and (3) positioning moving
I parts. The terms "bearing" and "bealing surfaces" can be used ntanydif-
ferent ways. For purposesof this text, the term bearing refers to the

I entire dev'ice that performs the funct'ions

'listeo
above. The term bearing
s u r f a c e i s u s e dt o d e s c r i b et h e s p e c i f i c p a r t s o f a b e a r i n g t h a t a c t u a l l y
c o m ei n c o n t a c t w i t h a m o v i n gp a r t .
I A t y p i c a l e x a m p l eo f b e a r i n g s a r e t h e b e a r i n g s f o u n d ' i n p u m p s . T h e p u m p

I shaft is able to rotate becausethe shaft and the rotor are supported by
b e a r i n g s . T h e s eb e a r i n g s a n d m o s t o t h e r b e a r i n g s c o n t a i n g r e a s e , o i l , o r
s o m eo t h e r l u b r i c a n t t h a t ' s u s e dt o r e d u c et h e f r i c t i o n b e t w e e nt w o o r m o r e
T
I
I 4.2- L
BASICPOWER
4.
PLANT OPERATION
P l a n t O p e r a t i o n( c o n t i n u e d , l t
s u r f a c e s . B e a r i n g sa l s o k e e pm o v i n gp a r t s ( l i k e p u m ps h a f t s a n d r o t o r s ) i n
their proper places and reduce the chancesof undesirable movement. For
I
example, a pumpshaft must be able to rotate freely to perform its job.
However,if the shaft were allowed to moveforward, backward,or to the
the pump.
s i d e , i t c o u l d s e r i o u s ' l yd a m a g e
I
B e a r i n g s p r e v e n t t h i s f r o m h a p p e n i n gb y l i m i t i n g t h e e n c l - t o - e n d( a x i a l ) I
m o v e m e natn d s ' i d e - t o - s i d e ( r a d i a l ) m o v e m e notf m o v i n gp a r t s . Figure 4.2-L
s h o w sb o t h a x i a l a n d r a d i a l m o v e m e n t .E n d - t o - e n dr n o v e m e ni st c a l l e d a x i a l
movement that follows the ax'is of a shaft.
because'it is movement Movement
t
t h a t m o v e sa w a y , o r r a o ' i a t e s , f r o m t h e c e n t e r l i n e o f t h e s h a f t i s c a l l e d
radia1 movement. A bearing may be designed to prevent radial movement, I
a x i a l m o v e m e n to, r b o t h .

I
I
I
t
t
I
T
I
I
I
4.2- 2
I
 I BASIC POl^lER
4.
PLANT OPERATION
P l a n t 0 p e r a t io n ( c o n t ' n
i ued)

I 4.2.L S l i d i n g S u r f a c eB e a r i n g s

Bearings are often namedfor the type of movement that they are designedto

I p r e v e n t . F o r e x a m p l et,h e s l i d i n g s u r f a c eb e a r i n gs h o w ni n F i g u r e 4 . 2 ' 2 i s
c a l l e d a r a d i a l b e a r i n gb e c a u s ei t s d e s i g np r e v e n t sr a d i a l m o v e m e n t .T h e

I bearingconsists of two parts: t h e h o u s j n ga n d t h e b e a r i n g s u r f a c e . W h e n

t h e b e a r i n gi s c o m p l e t e l ya s s e m b l e dt ,h e h o u s i n gh o l d s t h e b e a r i n gs u r f a c e
i n p 1 a c e . T h i s b e a r i n g p r e v e n t s r a d i a l m o v e m e n tb, u t a x i a l m o v e m e ni ts

I sti I 1 possible.

I
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t
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Ii i
,
i

II
I
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t 4.2- 3
BASICPOI^IER
4.
PLANT OPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d ) t
S l i d i n g s u r f a c e t h r u s t b e a r i n g sa r e u s e dt o l i m i t a x i a l m o v e m e n t .T h r u s t
b e a r i n g sa r e a l s o c a l l e d a x i a l b e a r i n g s . A t y p i c a l s l i d i n g s u r f a c e t h r u s t I
b e a r i n g u s e s a c o l l a r s e c u r e dt o t h e s h a f t t o l i m i t a x i a l m o v e m e n t A . s the
d r a w ' i n gi n F i g u r e 4 . 2 - 3 i l l u s t r a t e s , t h e c o l l a r i s p o s i t i o n e d b e t w e e nt w o
bearing surfaces, which are held in place by the housing. The bearing
I
s u r f a c e s s u r r o u n dt h e s h a f t w i t h o u t t o u c h i n g i t , a n d a r e p o s i t i o n e d s o t h a t
they come'in contact with the collar. As in the rad'ial bearing, the I
h o u s ' i n gc o n t a i n s g r e a s e o r o i l f o r l u b r i c a t i o n ; s e a ' l s , l o c a t e d w h e r et h e
s h a f t p e n e t r a t e st h e h o u s i n g , k e e p t h e l u b r i c a n t f r o m l e a k i n g o u t .
I
I
I
I
t
I
I
Wheneverthe shaft tries t o m o v ea x i a l 1 y , t h e c o l l a r p u s h e sa g a i n s tt h e
bearing surfaces to stop the movement. Actual metal-to-metal contact
I
'layer
b e t w e e nt h e c o l l a r a n d t h e b e a r i n gs u r f a c e sis preventedby a thin
I u b r ic a n t .
of
I
I
I
I
4.2- 4
t
I BASICPOWER
4.
PLANT OPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d )

I 4.2.2 R o l l i n g C o n t a c tB e a r i n g s

Rolling contact bearingscan also be used to prevent radial and axial

I m o v e m e n t . I n o r d e r t o u n d e r s t a n dh o w a r o l l i n g c o n t a c t D e a r i n go p e r a t e s '
y o u f i r s t n e e dt o b e c o m ef a m i l i a r w ' i t h t h e c o m p o n e n tosf a t y p i c a l r o l l i n g

I c o n t a c t r a d i a l b e a r i n g l i k e t h e o n e s h o w ni n F i g u r e 4 . 2 - 4 . T h e c o m p o n e n t s
o f t h ' i s b e a r i n ga r e t h e i n n e r r i n g , t h e r o l l i n g e l e m e n t s ,t h e h o u s i n g ,a n d
the outer ring.

t
I
I
t
I
I
I
T h e o u t e r r i n g i s m o u n t e di n t h e h o u s i n g ,w h i c h , ' i n t u r n , i s a t t a c h e dt o a
I stationary structure. The inner ring
' i s u s u a l l y m o u n t e do n a S h a f t . T h e

inner ring and the shaft rotate together, while the outer ring remains

I s t a t ' i o n a r y . T h e r o l l i n g e l e m e n t sb e t w e e nt h e t w o r i n g s m a i n t a i n a n e q u a l
d j s t a n c e b e t w e e nt h e r j n g s , t h u s p r e v e n t ' i n gr a d i a l m o v e m e n t .

I
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4.2- 5
I
BASICPOWER
4.
PLANTOPERATION
l n t 0 p e r a t io n ( c o n t in u e d)
P'a I
F i g u r e 4 . 2 - 5 s h o w sa c r o s s s e c t i o n o f a n o t h e r t y p e o f r o l f i n g c o n t a c t
b e a r i n g . T h i s o n e ' s c a l l e d a t a p e r e dr o l l e r b e a r i n g , a n d i t p r e v e n t sb o t h I
r a d i a l n t o v e m e natn d a x i a l m o v e m e n t .T h er o l ' l i n g e l e m e n t sm a i n t a i n a n e q u a l
d i s t a n c e b e t w e e nt h e t w o r i n g s t o p r e v e n t r a d i a l m o v e m e n tl,i k e t h e f i r s t
r o l l i n g c o n t a c t b e a r i n g y o u s a w . T h e t a p e r o f t h e r o l l i n g e l e m e n t sk e e p s
I
t h e s h a f t f r o m m o v i n ga x i a l l y , b u t o n l y i n o n e d i r e c t ' i o n . I f t h e s h a f t
t r i e s t o m o v ea x i a ' l l y i n t h e d i r e c t i o n s h o w nb y t h e a r r o w ' i n t h e f i g u r e ,
the rollers meet the outer ring and movementis prevented. A second
t
b e a r i n g w o u l d b e n e e d e dt o p r e v e n t a x i a l m o v e m e ni n
Lubricant betweenthe bearing parts prevents them from actually contacting
t the other direction.
I
eachother.
I
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4.2- 6
I
I BASICPO|/'lER
4.
PLANTOPERATION
P l a n t O P e r a t ' i o n( c o n t i n u e d )

vjewin
A r o l l i n g c o n t a c t t h r u s t b e a r i n g , l i k e t h e o n e s h o w ni n a n e x p ' l o d e d
I F i g u r e 4 . ? - 6 , o n ' l y p r e v e n t s a x i a l m o v e m e n t .I n t h i s c a s e ' t h e
shaft has a

r.ing attachedto jt. The shaft and the ring turn together. Therolling

I e l e m e n t sf i t o v e r t h e s h a f t a n d m e e t t h e r o t a t j n g r i n g .
ring also fits over the shaft; it's placedagainstthe rolling
The stat'ionary
elements'
to move, the
a n d j t , s a t t a c h e d t o t h e h o u s i n g . l , J h e nt h e s h a f t t r i e s
I r o t a t i n g r i n g p u s h e sa g a i n s t t h e r o l l i n g e ' l e m e n t s w, h ' i c hp u s h a g a i n s t t h e
to the housing'
stationary ring. Since the stationary ring is attached

t a x i a l m o v e m e ni n t o n e c l i r e c t i o n ( s h o w nb y t h e a r r o w ) i s
cant betweenthe moving parts keep them from touching each
other'
prevented. Lubri-

t
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I
I 4.2.3 Lubricati on
'l T h r o u g h o u t h i s d i s c u s s i o n o f b e a r i n g s , e m p h a s ' i hs a s b e e n
placed on the

factthatthemovingpartsnevercomeindirectcontactwjtheachother.

t Th.is .is becausesomeform of lubricant is a'lwaysbetween

cases, this lubricant is supplied to the bearjngs
them. In many
b y a p r o c e s s k n o w na s
p r o c e s si s d e s c r i b e d
f i l m l u b r i c a t ' i o n . I n t h e f o l l o w ' i n g p a r a g r a p h s ,t h ' i s

1
T as it occurs in a sfiding surface bearing'

I
4.2- 7
T
 BASICPOl,\lER
4.
PLANTOPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d )
t
A s y o u ' v e s e e n , a s l i d i n g s u r f a c e b e a r i n g c o n s i s t s o f a h o u s i n gt h a t
s u f f o u n d sa s h a f t . T h e s p a c eb e t w e e nt h e b e a r i n g a n d t h e s h a f t i s f i l l e d I
with oil. w h e nt h e s h a f t i s a t r e s t , m o s t o f t h e o i l i s s q u e e z e do u t f r o m
betweenthe shaft and the bearing surface by the weight of the shaft, and
meta'l-to-metal contact is made.
I
w h e nt h e s h a f t b e g i n st o r o t a t e , i t s m o t i o nd r a g so i l u n d e r n e a tiht . O i l
st'icks to the shaft as it turns, and that oil is carried betweenthe two
t
s u r f a c e s . T h e s h a f t i s l i f t e d a w a yf r o m t h e s u r f a c eb y t h e f i l m o f o i 1 ,
a n d i t ' s n o v s' ,u p p o r t e d
on the oi'l f ilm.
I
A s t h e r o t a t i o n a l s p e e do f t h e s h a f t i n c r e a s e s ,m o r ea n d m o r eo i l i s d r a w n
under the shaft, forming a wedgeof oi'1. The oi'l wedgekeeps the surfaces
I
of the shaft and the bearing from touching. If the oil wedgewere not
present' the shaft and the bearing would comein direct contact with each I
other, and the operat'ing temperatureof the bearing would increase due to
friction.
wear.
T h i s c o u l d s e r i o u s l y d a n a g et h e b e a r i n g b y g r e a i l y i n c r e a s i n g I
R o l ' l i n gc o n t a c tb e a r i n g sa l s o u s ea n o i l f i ' l m f o r l u b r i c a t i o n . T h ee f f e c t s T
describedabovefor a shaft occur aroundeachelementin a rolling contact
beari ng. I
4.2.4 BearingTemperatures
I
E v e nw h e na b e a r i n g i s p r o p e r l y l u b n i c a t e d , a c e r t a i n a m o u n to f f r i c t i o n
still remains,so heat is produced. As an operator, one of your respon-
s i b i l i t i e s w i l l b e t o c h e c kb e a r i n gt e m p e r a t u r ep e r . i o d i c a l l y . T o o h i g h a
I
t e m p e r a t u r er e a d i n g m a y i n d i c a t e t h a t a b e a r i n g i s n o t f u n c t i o n i n g p r o p -
erly. I
w h e n e v eyr o u ' r e t a l k i n g a b o u t b e a r i n g t e m p e r a t u r e s ,t h e r e ' s a d i s t i n c t i o n
that must be made. There's a difference betweenthe temperature of the
I
b e a r i n g s u r f a c e a n d t h e t e m p e r a t u r eo f t h e b e a r i n g h o u s i n g . y o u n e e d t o
knowwhich is which whenyou're making a temperaturecheck. Temperature
i n d i c a t o r s o n a b e a r i n g f r e q u e n t l y m e a s u r et h e t e m p e r a t u r eo f t h e b e a r i n g
I
surface, which is normallyhotter than the bearing housing.
I
4.2- B
t
 I BAsIcpohJER nLANT opERATroN
I 4. p ' l a n t0 p e r a t i o n( c o n t i n u e d )

I T h e e a s ' i e s tw a y t o c h e c k t h e a c t u a l t e m p e r a t u r eo f a b e a r i n g i s t o t a k e a
r e a d i n g d i r e c t l y f r o m t h e t e m p e r a t u r ei n d i c a t o r o n t h e b e a r i n g . ( R e m e m -
b e r ' t h i s i n d i c a t o r u s u a l l y r e a o s t h e a c t u a l b e a r i n gs u r f a c et e m p e r a t u r e . )
I H o w e v e rm
must be used.
, a n yb e a r i n g s d o n o t h a v e s u c h i n d i c a t o r s , s o a l t e r n a t e m e t h o d s

I A c o m m ow n a y t o d e t e r m i n e ' i f a b e a r i n g i s r u n n ' i n gt o o h o t i s t o f e e l t h e
b e a r i n g h o u s i n gw i t h y o u r h a n d . R e m e m b etrh, e b e a r i n g h o u s i n gi s u s u a l ' l y

I c o o l e r t h a n t h e b e a r i n g s u r f a c e . | , ' J i t hp r a c t i c e a n d e x p e r i e n c e ,t h i s m e t h o d
c a n b e v e r y r e l i a b l e f o r d e t e r m i n i n g i f t h e b e a r i n g t e m p e r a t u r ei s t o o

I high.

I n s t r u m e n t sc a n a l s o b e u s e d t o t a k e t e m p e r a t u r er e a d i n g s . F i g u r e 4 . 2 - 7

T s h o w sa p y r o m e t e rt h a t i s u s e d f o r t h i s p u r p o s e . w h e ny o u , r e u s i n g a
p y r o m e t e r ,y o u p l a c e t h e p r o b e d i r e c t l y o n t h e b e a r i n g h o u s i n g a n d a l l o w

I t'ime for the probe to warmup to the bearing's temperature. Then, you can
read the temperaturedirecily from ihe pyrometer.

t
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I 4.2- 9
BASICPOWER
4.
PLANTOPERATION
P1ant 0Peration (cont'inued) I
O n et h . i n gt o r e m e m b w
or other components
e rh e ny o u ' r e t a k i n g t e m p e r a t u rree a d i n g so f b e a r i n g s
is that the readings won't be accurate until the
I
has had t'imeto reachoperatingtemperature. Thetime required
equ.ipment
is different for every p'ieceof equipnent. If you take temperature
read- I
ings of bearingsbefore they have reachedtheir operatingtemperatures,
y o u ' l l g e t ' i n a c c u r a tree a d i n g s . I
to check
In addition to makingtemperaturechecks, operators also have
b e a r i n g sf o r e x e c e s s i v ev i b r a t i o n a n d u n u s u a 'sl o u n d s '
T h e s ea r e a l s o I
i n d i c a t i o n st h a t a b e a r i n gi s n o t f u n c t ' i o n i n gp r o p e r l y .

A v i b r o m e t e r . i sa n i n s t r u m e ntth a t ' s u s e dt o c h e c kb e a r i n g sf o r
vibration. I
the amountof
The vibrometerprobe is placedon the bearinghousing,and
vibration present is read direct'ly from the vibrometer
meter' If the
r e a d i n g sa r e o u t s i d e t h e n o r m a ll e v e l s f o r t h e e q u i p m e nbt e i n g
tested'
I
there maybe a Problem.
I
m a yD e p e r -
0 n l a r g e e q u i p m e n tS, u c ha s t u r b i n e s , v i b r a t i o n i n s t r u m e n t s
m a n e n t l yi n s t a l l e d . T h e nt h e o p e r a t o rc a n t a k e r e a d i n g sd i r e c t l y
recorderor meter.
fromthe
I
A n s w etrh e f o l l o w ' i n gq u e s t i o n s .
I
4.2-L. True or False. FrictiOn is the resistance to motion
exists betweentwo bodies in contact with each other'
that
I
4.2-2. Most bearings fit into one of two general categories' Namethe I
two c a t e g o r ie s .
a.
b.
I
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4.2-L0
I
I BASICPOhIER
4.
PLANT OPERATION
P l a n t O p e r a t i o n( c o n t i n u e d )

I 4.2-3. Circle the correct answer.

t ^ / h i c ho f t h e f o l l o w ' i n g j s n o t a f u n c t i o n o f a l l b e a r i n g s ?
a. To carrY loads

t b.
c.
T o d i s t r i b u t e l o a d se v e n l Y
T o r e d u c ef r i c t i o n

I d.
e.
T o P o s i t i o n m o v i n gP a r t s
T o P r e v e n ta x i a l m o v e m e n t

I 4.2-4. t m o v e m e nf rt o m e n d t o e n d .
T r u e o r F a l s e . R a d i a l m o v e m e ni S

A t h r u s t b e a r i n gi s g e n e r a ' l ' luys e dt o p r e v e n t

I 4-2.5.
movement.

I 4.2-6. W h a t' i s f i l m l u b r i c a t i o n ?

I
I 4.2-7. A p o r t a b l ei n s t r u m e nut s e dt o m e a s u rbee a r i n gt e m p e r a t u r e s ' i s
c a ll e d a
I 4.2-8. Circle the correct answer.

I Before taking temperatureread'ingsfrom a bearing

a. R e m o v teh e t e m p e r a t u r ec a p o n a l l b e a r i n g h o u s i n g s
b. M a k es u r e t h e b e a r i n g h a s r e a c h e di t s o p e r a t i n g t e m p e r a -

I c.
t ure
Feel the bearingwith Your hand

I d. Usea vibrometer

I CHECKYOURANSWERS WITHTHOSEGIVENAT
T H EE N DO F T H I SU N I T .

I
I
4.z-rL
I
I BASICPOI,IER
4.
PLANT OPERATION
P l a n t0 p e r a t i o n( c o n t i n u e d )

I 4.3 B e a r i n g sa n d L u b r i c a t i o n ,P a r t 2

I n t h e l a s t s e g m e n yt ,o u l e a r n e dt h a t b e a r i n g sn e e dl u b r i c a t i o nt o s u p p o r t
I l o a d sa n dr e d u c ef r i c t i o n . I n t h i s s e g m e n yt ,o u ' 1 1
USING THEPRoPER LUBRICANT FoR EACH PIECE0F EQUIPMENT,
'learn
T H EI M P 0 R T A N
Ti^10 METHoDS
0 FC E
0F

I APPLYING
TAINER,
GREASE
ANDHOt.l
TO BEARINGS,
SEVERAL SYSTEMS
HOt^l OIL IS REMOVED
AREUSED TOSUPPLY
FROM
OIL TO
ITS ORIGINAL
BEARINGS.
CON.

I
BEFORL
3 OFTHEVIDEOTAPE
VIEt.lSEGMENT

I N.T3 O F T H I ST E X T .
R E A D i NSGE G M E 4

I I n o r d e r t o o p e r a t e e f f i c i e n t ] y a n d p r o p e r l y , e q u i p m e n tb e a r i n g s i n y o u r
plant must havea specific type of lubricant. Lubricantsare not all the

I s a m e ,a n d u s i n g t h e w r o n g ' l u b r j c a n t ' i n a p i e c e o f e q u i p m e nm
d a m a g ei t .
t a ys e r i o u s l y
T o h e l p y o u d e t e r m i n ew h i c h l u b r i c a n t g o e s i n w h ' i c he q u i p m e n t '
m o s t p l a n t s h a v e a l u b r i c a n t i d e n t i f i c a t i o n s y s t e m . Y o u s h o u l d k n o wa n d
I u n d e r s t a n dt h e s y s t e mu s e d i n y o u r p 1 a n t . I f y o u r p l a n t d o e s n ' t h a v e a
'lubricant
i d e n t i f i c a t i o n s y s t e m , t h e n t h e m a n u f a c t u r e r ' sm a n u a l f o r a

I p i e c e o f e q u i p m e n st h o u l d b e c o n s u l t e df o r t h e p r o p e r l u b r i c a n t t y p e .

t 4.3.1

The two most common

Grease

types of lubricants used in a power plant are grease

I andoil. T h e r e a r e a v a r i e t y o f m e t h o d so f a p p l y i n g e a c h o f t h e s e l u b r i -
cants. For example,two of the most common methodsof greas'inga bearing
are greasing with a grease gun and greasing w'ith a grease cup.
I G r e a s e ' i s u s u a l ' l y p u m p e di n t o a b e a r i n g b y u s i n g a g r e a s eg u n . T h e g r e a s e

I is injected into the bearing through a grease fitt'ing on the bearing

h o u s i n g . A g r e a s ef i t t i n g i s a s m a l l r o u n d e dp r o i e c t i o n f r o m t h e h o u s i n g
that has a hole jn the center of it. The fitting o n t h e g r e a s eg u n m u s t

t m a t c ht h e f i t t i n g o n t h e h o u s i n g .

I
4.3- 1
I
BASICPOWER
4.
PLANTOPERATION
P ' l a n t0 p e r a t i o n ( c o n t i n u e d )
I
W h e ny o u g r e a s e a b e a r i n g t h a t h a s a f i t t i n g , y o u m a y h a v e t o r e m o v ea
d r a i n p l u g f r o m t h e h o u s i n gb e f o r e y o u a d d t h e g r e a s e . T h e p l u g i s r e m o v e d I
so that old grease or excess grease can drain out. Before you attach the
g r e a s e g u n t o t h e f i t t i n g , w i p e t h e f i t t i n g c l e a n a n d m a k es u r e t h a t t h e
o p e n i n gi s n o t b l o c k e d . T h e n , a t t a c h t h e g u n t o t h e f i t t i n g o n t h e h o u s i n g
I
( F i g u r e 4 . 3 - 1 ) . I f y o u a p p l y g r e a s ew h i l e t h e b e a r i n gi s i n m o t i o n , y o u , 1 1
b e s u r e t h a t t h e g r e a s e i s e v e n l y d i s t r i b u t e d . A d dt h e g r e a s es l o w l y u n t i l
it b e g i n s t o c o m eo u t t h e d r a i n h o l e . Run the equipnentfor several
t
minutes afterwards to makesure that all excess grease has beenforced out;
t h e n r e p ' l a c et h e d r a i n p l u g .
I
I
I
I
t
I
I
T
I
I
I f t h e r e i s n o d r a i n p l u g , y o u ' 1 1h a v et o e s t i m a t et h e a m o u not f g r e a s et o
add. Becareful not to addtoo much,because too muchgreasecan causethe
b e a r i n gt o o v e r h e a t . E x a c t ' l yh o wm u c hg r e a s et o a d dw i ' l ' l d e p e n do n t h e
I
b e a rni g a n dy o u r p l a n t r s p r o c e d u r e s .
I
4.3- 2
t
I BASICPOI^IER
4.
PLANTOPERATION
P l a n t O p e r a t ' i o n( c o n t i n u e d )

I A second method of
(Figure 4.3-2).
greasing a beari ng 'is to use a grease cup
A g r e a s e c u p i s a c o n t a i n e r o f g r e a s e t h a t ' s m o u n t e do n
t h e b e a r i n g h o u s i n g . T h e c u p i s t u r n e d s e v e r a l t i m e s t o f o r c e g r e a s ei n t o
I t h e h o u s i n g . U s u a 1 1 y ,o n e o r t w o t u r n s i s e n o u g ht o p r o p e r l y g r e a s e a
b e a r i n g . Y o u r p l a n t w i l l m o s t 1 i k e 1 yh a v e s p e c i f i c p r o c e d u r e tsh a t i n d i -

I c a t e w h e ng r e a s i n gs h o u l d t a k e p 1 a c e . I f t h e r e i s e v e r a n y d o u b t , a s k y o u r
supervisor.

I
I
I
I
I
I
I 4.3.2 0il Lubrication

T h e s e c o n dc o m m ol nu b r i c a n t u s e d ' i n a p o w e rp l a n t i s o i l . In mostcases'

I oil'is deliveredto the plant'in large baryels or drums. The original

c o n t a i n e r s a r e t o o l a r g e t o e a s i l y c a r r y a r o u n dt h e p 1 a n t , s o t h e o i l i s

I u s u a l l y t r a n s f e r r e d t o s m a l l e r , m o r e c o n v e n ' i e nct o n t a ' i n e r s . ( i t ' s i m p o r -

t a n t t o w r i t e t h e n a m eo f t h e o i l o n t h e s m a l l e r c o n t a i n e r s o t h a t y o u ' 1 1
k n o ww h a t ' s i n i t . ) T h e r e a r e t w o b a s i c m e t h o d sf o r r e m o v i n go i 1 f r o m a

I barrel: a b a r r e l p u m pa n d a s p i g o t .

I
t
4.3- 3
I
BASICPOWER
4.
PLANTOPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d ) I
W h e ny o u ' r e i n s t a l l i n g a b a r r e l p u m p ,t h e f i r s t s t e p i s t o c l e a n t h e t o p o f
t h e b a r r e l a n d t h e p u m p . D o i n gt h i s r e d u c e st h e p o s s i b i l i t y o f c o n t a m i n a n t s
t
getting into the oil and reducingits effect'iveness. 0ncethe top of the
b a r r e l i s c ' l e a n , t h e b a r r e l c a n b e o p e n e da n d t h e p u m pi n s t a l l e d . M o s t
barrel pumpsare threaded into the barrel. In order for the pumpto
I
operate properly, the barrel needsto be vented. This is done by removing
the small vent cap on top of the barrel. I
Barrel pumpsare operated by rotating a handle or operating a 1ever. When
p u m p i n gi s c o m p l e t e , t h e v e n t c a p s h o u ' l db e r e p l a c e d t o a v o ' i dc o n t a m i n a -
I
tion.
empty.
A b a m e l p u m pi s a l m o s t a l w a y sl e f t i n a b a r r e l u n t i l t h e b a r r e l i s
I
A s e c o n dm e t h o do f r e m o v i n go i ' l f r o m a b a r r e l i s t o u s e a s p i g o t . A s p ' i g o t
fits into the sameopen'ingas the barrel pump,so the top of the bamel has
I
t o b e c l e a n e d . T h e n , t h e b a r r e l i s o p e n e d ,a n d t h e s p i g o t i s s c r e w e di n t o
p 1 a c e . A f t e r y o u m a k es u r e t h a t t h e s p i g o t i s f i r m l y i n p 1 a c e , t h e b a r r e l
must be turned on its side.
I
B e c a r e f u l w h e ny o u ' r e t u r n i n g a b a r r e l o n i t s s i d e . A b a r r e l t h a t ' s f u l l
I
of oi'l maywe'ighas muchas 400 pounds. 0nce on its side, the barrel must
b e v e n t e d . 0 p e n i n gt h e s p i g o t w i l l a l l o w y o u t o d r a w o f f a s m u c ho i l a s
necessary. After the right amountof oil has been removed,the spigot is
t
closed, and the vent cap is replaced.
I
A n i m p o r t a n t p r o c e d u r et o f o l l o w w h e ny o u ' r e w o r k i n g w i t h o i l i s n e v e r t o
r e t u r n o i l t o i t s o r i g i n a l c o n t a i n e r a f t e r y o u ' v e r e m o v e di t .
you''11greatly increase the possibi'lity of contam'ination. Contaminated
If you do' I
o j l s h o u l db e c l e a r l y l a b e l e d a n d p r o p e r ' l yd i s c a r d e do r r e c y c l e d . I f i t ' s
u s e d t o l u b r i c a t e b e a r i n g s , c o n t a m i n a t e do i l c a n s e r i o u s l y s c r a t c h o r
I
critical
o t h e r w ' i s ed a m a g e bearing parts.

Thereare a numberof lubricat'ionsystemsthat are usedto supplyoil to a

I
b e a r i n g . O n eo f t h e s e ' i s t h e o i ' l r i n g l u b r i c a t i o ns y s t e mt h a t i s f r e - r
q u e n t l yu s e do n s l i d i n g s u r f a c eb e a r i n g s . t

I
4.3- 4
I
 BASICPOI^JER PLANT OPERATION
il 4. P la n t 0 p e r a t i o n( c o n t ' i n u e d )

I A s y o u k n o w ,a s l i d ' i n g s u r f a c eb e a r i n gc o n s i s t so f a b e a r i n gh o u s i n gt h a t
s u r r o u n da s s h a f t . I n a n o i l r i n g l u b r i c a t i o n s y s t e m( F ' i g u r e4 . 3 - 3 ) '
the lower half of the housing contains an oiI reservoir, and
I t h e r e ' s a n o ' i 1 r i n g a r o u n dt h e s h a f t .

I
I
I
I
I @' j

I *@j
@
I
I T h e l u b r i c a t i o n s y s t e mw o r k s q u ' i t e s i m p l y . H a l f o f t h e r i n g i s a l w a y s
s u s p e n d e idn t h e o i l r e s e r v o i r . A s t h e r i n g a n d t h e s h a f t t u r n , o i l s t i c k s
I to the oil ring and is deposited on the shaft. The oil then spreads
t h r o u g h o u tt h e b e a r i n g , a n d p r o p e r l u b r i c a t i o n i s a c h i e v e d .

I In an oil ring system, the oil r e s e r v o i r m u s t b e c h e c k e dp e r i o d ' i c a 1 ' l y '

T h i s i s u s u a ' l 1 yd o n e b y r e a d i n g t h e o i l l e v e l o n a s i g h t g l a s s . U n d e r

I n o r m a l c o n d i t ' i o n s ,t h e r e w i l l b e o j l h a l f w a y u p t h e i n s i d e o f t h e g l a s s '
I f t h e r e i s n o s i g h t 9 1 a s s , t h e b e a r i n gm a y h a v e a d i p s t ' i c k t o i n d i c a t e t h e
l e v e l o f o i l i n t h e r e s e r v o ' i r . I f t h e r e s e r v o i r n e e d sf i l l i n g , o i l c a n b e
I p o u r e dd i r e c t l y i n t o i t u n t i l t h e s ' i g h t 9 l a s s o r d i p s t i c k i n d i c a t e s t h a t
the o'il is at the Properlevel.

I
4.3- 5
I
BASICPOWER
4.
PLANTOPERATION
P la n t 0 p e r a t i o n ( c o n t ' i n u e d ) I
S o m eb e a r i n g s d o n ' t h a v e e i t h e r a s i g h t g l a s s o r a d i p s t i c k . T h e r em a yb e
a s p i l l h o l e l o c a t e d o n t h e h o u s i n gw h e r et h e n o r m a lo i l l e v e l s h o u l d b e . I
T h e o p e r a t o r c a n r e m o v et h e s p i l l h o l e p l u g a n d l o o k i n s i d e t o c h e c k t h e
o i l l e v e l . I f o i l n e e d st o b e a d d e d , ' i t ' s p u t i n t h r o u g ha f i l l h o l e o n t h e
t o p o f t h e h o u s i n g . T h e o ' i l i s p o u r e di n u n t i l i t i s v i s i b l e i n t h e s p i l l
I
hole.
I
A n o t h e r m e a n so f m a i n t a i n i n g p r o p e r o i l level in a bearing housing is
the constant level
level oiler
oi'ler. As shown in Figure 4.3-4, a constant
c o n s i s t s o f a c u p c o n n e c t e dt o t h e b e a r i n g h o u s i n g b y a
I
'level
t u b e . T h eo i l i n t h e c u p i s t h e s a m ea s t h e o i ' l l e v e l i n t h e h o u s i n g ,
because of the tube that connects them. There's a reservoir, with an
o p e n i n gi n i t s b o t t o m , p l a c e d i n t h e c u p . A s l o n g a s t h e r e i s o i l i n t h e
I
r e s e r v o ' i r , t h e s y s t e mw i l l m a i n t a i n t h e p r o p e r l e v e l o f l u b r i c a n t i n t h e
bearing housing.
t
I
I
I
I
I
I
The constant level oiler workswith the aid of gravity. As the level of
o i l i n t h e h o u s i n gd r o p s , o ' i 1 b e g ' i n st o f l o w f r o m t h e c u p t o t h e h o u s i n g .
I
O i l c o n t i n u e st o f l o w u n t i l t h e l e v e l s i n t h e c u p a n d h o u s i n ga r e t h e s a m e .
l,lhenthe level of oil in the cup falls below the opening in the bottcrn of I
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4.3- 6
I
I BASICPOhIER
4.
PLANTOPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d )

I the reservoir, o'il flows from the reservoir into the cup. Thjs flow
continues until the level in the oi1 cup is up to the bottom of the
reservoi r .

I The reservoirin a constant level oiler is transparent, so jts level is

I easily checked. To fill the reservoir, you iust lift it off the tube, turn
it upside down,and fill it. T h e o i l l e v e l ' i n t h e h o u s i n gs h o u l d b e
c h e c k e dp e r i o d ' i c a l l y . I f t h e c o n n e c t i n gt u b e b e c o m e sc l o g g e d ' t h e r e s -

I e r v o i r a n d t h e o i l c u p w i l l r e m a i nf u l l , b u t t h e h o u s i n gc o u l d b e e m p t y .
I f t h i s w e r e t o h a p p e n ,n o o i l w o u l d b e s u p p l i e d t o t h e b e a r i n g , a n d i t

I could be damaged.

S o m ep o w e r p l a n t s u s e f o r c e d o i l lubrication systems. As shownin

t F i g u r e 4 . 3 - 5 , a f o r c e d l u b r i c a t i o n s y s t e mu s e s a p u m pt o c o n t i n u a l l y c i r -
c u l a t e o i l t h r o u g ht h e b e a r i n g s . 0 ' i l t h a t h a s b e e nc j r c u l a t e d i s c o l l e c t e d
i n a r e s e r v o i r a n du s e da g a i n . 0 i l f i l t e r s a n d c o o l e r s a r e o f t e n p r o v ' i d e d
I t o k e e pt h e o j l c l e a n a n d c o o l .

I
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4.3- 7
I
BASICPOI^IER
4.
PLANTOPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d ) I
The final type of'lubrication
ri cator.
s y s t e mc o v e r e d h e r e i s t h e d r i p f e e d 1 u b -
Drip f eed I ubri cators al I ow oi I to dri p sl ow'ly 'into a beari ng.
I
F i g u r e 4 . 3 - 6 s h o w sa d i a g r a mo f t h i s t y p e o f s y s t e m .
I
I
I
I
I
I
t
I
I
I
I n t h i s s y s t e m , t h e r e i s a t r a n s p a r e n t r e s e r v o i r a b o v et h e b e a r i n g . A
s m a l l h o l e i n t h e b o t t c r no f t h e r e s e r v o i r a l l o w s o i l t o d r i p s l o w l y i n t o I
the bearing to keep it constantly lubricated. A knobon the top of the
reservoir allows the drip rate to be controlled. The proper rate can be
d e t e r m i n e db y c o n s u l t i n g t h e m a n f a c t u r e r ' sr e c o r m e n d a t i o nosr t h e p l a n t ' s
I
o p e r a t i n g p r o c e d u r e s . A l e v e r i s u s e d t o s t o p t h e f l o w o f o i l w h e nt h e
r e s e r v o i r n e e d sf i l l i n g o r w h e nm a i n t e n a n c ies r e q u i r e d . 0 i l i s u s u a l l y I
a d d e db y p o u r i n g i t d i r e c t l y i n t o t h e t o p o f t h e r e s e r v o i r .

I
4.3- B
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I BASICPOWER
4.
PLANTOPERATiON
Plant 0peration (continueci)

I A n s w e tr h e f o l l o w i n g q u e s t i o n s .

4.3-1. C ' i r c l e t h e s t a t e m e n tt h a t d o e s n o t a p p l y w h e ng r e a s i n ga b e a r -

I i n g w i t h a g r e a s eg u n .
a. Be sure to use the rignt type of grease'

I b.
c.
P u m Pt h e g r e a s e i n s l o w l Y .
C h e c kt h e l e v e l i n t h e s i g h t g l a s s '
D o n ' t a P P I Yt o o m u c hg r e a s e .
d.

I e. Run the machineryfor a wh'ile afterwards to removeany

e x c e s sg r e a s e .

I 4.3-2. Thefirst s t e p i n i n s t a l l i n g a s p i g o t o r a b a r r e l p u m pi s t o

I 4.3-3. T r u e o r F a l s e . U n u s e do i l s h o u l db e r e t u r n e dt o i t s o r i g i n a l
container to prevent contamination.
I 4.3-4. N a m et h e f o u r c o m m ooni l l u b r i c a t i o n s y s t e m sd i s c u s s e di n t h ' i s

t unit.
a.
b.

I d.

I 4.3-5. If a sight glass or dipst'ick is not present on a bearing

h o u s i n g , t h e o i l l e v e l i s o f t e n c h e c k e db y u s i n g a - '

I 4.3-6. C'ircle the corect answer.

t t ^ l h e cn h e c k i n ga c o n s t a n t l e v e ' l o i ' l e r ,
a.The]evelofo.ilisvisib]ethroughatransparentres.
e r v o ir

I b.Besurethatthetubetothebearingisnotblocked
c. The reservoir should be filled with the proper type of
o ' i1 , w h e nn e c e s s a r y
I d. All of the above

I
4.3- 9
I
BASICPO|^IER
4.
PLANT OPERATION
t p e r a t i o n( c o n t i n u e d )
P'lan0 I
4.3-7. A l u b r i c a t o r s u p p il e s a s t e a d y
s u p p l yo f f r e s h o i l t o a b e a r i n g . I
l,
CHECKYOURANSI.IERS
l.lITH THOSEGIVENAT
T H EE N DO F T H I SU N I T . I
I
I
I
I
I
T
I
I
I
I
I
I
4.3-10
I
I PLANTOPERATION
BASICPOI.IER
4. Plant 0peration (continued)

I 4.4 P o Il u t i o n

This segmentpresents A GENERAL

OVERVIEW0F THEF0URMOST COMMON TYPES 0F

I POLLUTION
T0 C0MBAT
ASSOCIATED PLANTSANDTHE ANTI-POLLUTIONDEVICESUSED
hIITH POWER
THEM. Specific terms you should understandby the end of this

I s e g m e n itn c l u d e P A R T I C U L A T P
ERS ,E C I P I T A T O S
RCSR
, UBBERS.

T VIEt,lSEGMENT 4 OFTHEVIDEOTAPE BEFORE

N.T4 O F T H I ST E X T .
R E A D I NSGE G M E 4

I
jndustries in the
W h i l e t h e p o w e ri n d u s t r y j s o n e o f t h e l e a s t p o ' l l u t i n g
I n a t ' i o n , i t d o e s h a v et h e p o t e n t i a l f o r r e l e a s ' i n gp o l 1 u t ' i n ga g e n t s i n t o t h e
e n v i r o n m e n t . M a n yo f t h e p r o c e s s e su s e d b y p o w e r p l a n t s t o ' l ' i m i t t h e

I a m o u n ot f h a r m f u l s u b s t a n c e sr e l e a s e d i n t o t h e e n v i r o n m e nrte q u i r e s p e c ' i a l
equjpment. As an operator, you needto understandwhat this equipmentdoes

I and how it works.

Powerplants can cause four major types of po'lluti on: a'ir po'lI uti on'

I t h e r m a lp o ll u t ' i o n , w a t e r p o ll u t ' i o n , a n d n o i s e p o l l u t i o n . T h e P o w e ri n -
d u s t r y u s e ss p e c ' iifc a n t i - p o l l u t i o n equipment or proceduresto deal with

t eachtype of po'lI uti on.

4.4.L Air Pollution

I B o i l e r s a r e t h e l a r g e s t p o t e n t i a l s o u r c eo f a j r p o l l u t i o n . S m a l lp a r -
t i c l e s , c a l l e d p a r t ' i c u ' l a t e sa, r e r e l e a s e di n t o t h e a i r t h r o u g ht h e s t a c k s '
I P a r t i c u l a t e sc a nt r a v e l g r e a t d i s t a n c e sb e f o r es e t t l i n g t o t h e g r o u n d ,a n d
the messthey causecan be a real nuisance. However, of greater concern
'is

t t h e r e s p i r a t o r yp r o b l e m sw, h i c hc a n b e c a u s e db y b r e a t h i n gi n p a r t i c u l a t e
matter.

I
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4.4- 1
t
BASICPOI^/ER
4.
PLANTOPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d ) t
C o a ' lp l a n t s u s u a l l y h a v e t h e b ' i g g e s tp r o b l e mw i t h p a r t i c u l a t e s . F o r t h i s
r e a s o n , m o s t c o a l p l a n t s u s e d e v i c e s c a l l e d p r e c i p i t a t o r s t o s e p a r a t ep a r - I
t i c u l a t e s f r o m t h e f l u e g a s b e f o r e i t g o e s t o t h e s t a c k s . W h e np r e c i p i -
tators are workingproper'ly, very few particulates are released into the
a ir .
I
B o ' i l e r s a l s o p r o d u c eg a s e o u sp o l ' l u t a n t s i n t h e f o r m o f s u l f u r a n d n i t r o g e n I
o x i d e s w h e nf u e l i s b u r n e d . T h e s ep o l l u t i n g a g e n t s a r e d i f f i c u ' l t t o d e t e c t
w i t h o u t t h e a i d o f m o n i t o r i n g d e v i c e s t h a t a n a l y z ea i r q u a l i t y . | , J h i l et h e
h a r mt h a t t h e s e o x i d e s d o ' i s n o t f u l l y u n d e r s t o o d ,s c i e n t i s t s h a v e d e t e r -
I
m i n e d t h a t l o n g - t e r me x p o s u r et o s u l f u r a n d n i t r o g e n o x i d e s c a n h a r mp l a n t
a n da n i m a ll i f e . F o r t h i s r e a s o n ,t h e a m o u no
t f o x i d e s a n do t h e r p o l l u t i n g I
s u b s t a n c e sr e l e a s e d i n t o t h e e n v i r o n m e n ti s l i m i t e d b y l a w , a n d m u s t b e
controI I ed.
I
O n eo f t h e m o s t c o r m o nm e t h o d so f c o n t r o l l i n g s u l f u r o x i d e s i s b y m e a n so f
scrubbers. Scrubbers, which are located in the path of flue gas between
b o i l e r s a n d t h e i r s t a c k s , u s e c h e m i c a lp r o c e s s e st o r e d u c e t h e a m o u n o
I
tf
s u l f u r o x i d e s i n t h e f l u e g a s e s . B u r n i n g1 o w - s u l f u r c o a l i s a n o t h e rm e t h o d
of limiting sulfur oxides.
I
Nitrogen oxides present a d'ifferent problem, becausescrubbers and other
e x t e r n a ' le q u i p n e n td o v e r y l i t t l eto limit the release of nitrogen oxides.
I
I n s t e a d , t h e f o r m a t i o n o f n i t r o g e n o x i d e s i s r e d u c e db y l i m i t ' i n g f u r n a c e
t e m p e r a t u r e . A d j u s t i n g t h e f u e l / a i r r a t i o i s o n e m e t h o do f l i m i t i n g f u r - I
n a c e t e m p e r a t u r e ,a n d r e c i r c u l a t i n g f l u e g a s b a c k t h r o u g h t h e f u r n a c e i s
a n o t h e r . Y o u s h o u l d l e a r n w h a t e v e rs y s t e my o u r p l a n t u s e s . I
4.4.2 ThermalPolI ut'ion
I
T h e m a j o r s o u r c e o f t h e r m a l p o l l u t i o n i n p o w e rp l a n t s a r e t h e m a i n c o n -
d e n s e r s . Y o u r e m e m b etrh a t t h e c o n d e n s e r s ' j o b i s t o r e m o v eh e a t f r o m
steam by using water. Depend'ing on the type of water cooling systemsused,
t
h e a t ' i s r e l e a s e df r o m t h e c o n d e n s e r d
s irectly into bodiesof water or into
t h e a i r t h r o u g h c o o l i n g t o w e r s . R a i s i n g t h e t e m p e r a t u r eo f a l a k e , r i v e r , I
o r s t r e a mc a n s e r i o u s l y a f f e c t p l a n t a n d a n i m a l l i f e . Heat and moisture
r e l e a s e d i n t o t h e a t m o s p h e r et h r o u g h c o o l i n g t o w e r s c a n c a u s e f o g , l o w
visibil ity, oricing conditions,dependino gn the weather.
I
4.4- 2
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I BASIC POWER
4.
PLANTOPERATION
P'lant 0 p e r a t i o n ( c o n t i n u e d )

I I n m a n yc a s e s , t h e a m o u n to f h e a t r e l e a s e d i n t o t h e a t m o s p h e r e ' i sI i m i t e d
b y 1 a w . A s a n o p e r a t o r , y o u r j o b w i l l i n c l u d e m o n i t o r i n g c o n d e n s eo
r utlet
t e m p e r a t u r e sa n d m a i n t a i n i n g t h e m w i t h i n t h e r e q u i r e d l i m i t s . At times,

,l the load on your generators may need to be reduced to accomplishthis.

I 4.4.3 W a t e rP o l l u t i o n

In addition to releasing heat into a bodyof water, your plant also re-

I leases waste water. This waste water comesfrom a variety of sources,

e s p e c i a l l y f r o m t h e b o i ' l e r i n t h e f o r m o f b l o w d o w n .I n a n e a r l j e r u n i t , w e

I sa'id that blowdownis necessaryto removes'ilt and otherimpurities from

the boiler. B u t , a l o n gw i t h s i l t , d a m a g i ncgh e m i c a l sc a n a l s o b e r e l e a s e d .
Y o u ' l l b e r e s p o n s i b l ef o r m o n i t o r i n g t h e w a s t e w a t e r r e l e a s e d f r o m y o u r

I p l a n t a n d f o r m a k i n gs u r e t h a t i t
di scharged.
has beenproperly treated before it's

I 4.4.4 N o i s e P o ll u t i o n

I N o i s e p o 1 ' l u t i o n i s d ' i f f i c u l t t o e l i m i n a t e . P o w e rp l a n t s u s e a l o t o f
m a c h i n e r yt o p r o d u c ee l e c t r i c i t y , a n d m a c h i n e r ym a k e sn o i s e . E x c e s s i v e l y
n o i s y a r e a s a r e u s u a 1 l y m a r k e dw i t h w a r n i n g s i g n s , a n d m o s t p l a n t p r o -
t cedures conta'in specifications on proper hearing protection to be used by
a n y o n ew o r k i n g ' i n t h e s e a r e a s . A p p r o v e dh e a r i n g p r o t e c t i o n i s t h e o n l y

I s a f e g u a r d a g a ' i n s t p r e m a t u r eh e a r i n g l o s s o r p a r t i a l h e a r i n g i m p a i r m e n t
c a u s e db y n o i s e p o l ' l u t i o n .

I Answerthe fol'lowi ng questions.

I 4.4-t. True or False. The amountof sulfur oxides that can be re-
l e a s e db y a p l a n t i s c o n t r o l l e db y 1 a w .

I 4.4-2.
gas.
are usedto removeparticulatesfromflue

t
I
4.4- 3
I
BASICPOWER
4.
PLANT OPERATION
P l a n t 0 p e r a t i o n( c o n t i n u e d ) I
4.4-3. Circle the correct answer.
t f nitrogen oxides releasedby a plant can be con-
The amouno
t
trolled by
a.
b.
B u r n i n gl o w - s u l f u r c o a l
Recirculating flue gas throughthe furnace
I
c.
d.
A d j u s t i n gt h e f u e l / a i r r a t i o
Both a and c I
e. Both b and c
f. a, b, andc t
4.4-4. l o l l u t i o n i s n o t a p o t e n t i a l p r o b ' l e mi f
T r u e o r F a l s e . T h e r m ap
cooljng towers are used. I
4.4-5. T r u eo r F a l s e . N o i s ep o l l u t i o n c a n b e e l ' i m i n a t e db, u t i t i s
m o r ec o n v e n i e ntto u s e h e a r i n gp r o t e c t i o ne q u i p m e n t .
I
I
t.llTH THOSEGIVENAT
CHECKYOURANSWERS
T H EE N DO F T H I SU N I T . I
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4.4- 4
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I BASICPOhlER
4.
PLANT OPERATION
P l a n t O p e r a t i o n( c o n t i n u e d )

I 4.5 Plant Safety

presentsa BROAD
This segment ANDCOMMON
0F HOhJPLANTPROCEDURES
0VERVIEt,J
I SENSE WORKERS
AREUSEDTO PROTECT ONTHEJ O B .

I VIEt,'l SEGMENT 5 OF THE VIDEOTAPE

I B E F O RREE A D I NSGE G M E4N. 5T O F T H I S

TEXT.

I 0 n t h e a v e r a g e , f o u r t e e n h u n d r e dw o r k e r s a r e i n j u r e d i n p l a n t s a n d f a c -

t t o r i e s e a c h y e a r . W h i l e t h e p o w e ri n d u s t r y e n j o y s a r e m a r k a b l er e c o r d f o r
s a f e t y o n t h e j o b , t h e p o t e n t i a l f o r a c c i d e n t s i s a ' l w a y sp r e s e n t . F o r t h j s
r e a s o n , p l a n t s h a v e s p e c i f i c s a f e t y p r o c e d u r e st h a t a l 1 p e r s o n n e lm u s t

I f o l l o w . H o w e v e rr,e g a r d l e s so f t h e n u m b e or f p r o c e d u r e st h a t a p l a n t m i g h t
h a v e , a c c i d e n t s s t j 1 1 h a p p e n . M o s t o f t e n , a c c i d e n t sa r e a d i r e c t r e s u l t o f

I sense.
workers not using common

Even a superfic'ial look at power p'lants illustrates the potent'ial for

I a c c i d e n t s . M o v i n gm a c h i n e r y ,h o t p i p e s , f l a m m a b l em a t e r i a l , a n d c a u s t i c
c h e m i c a l sa 1 ' l p l a y a p a r t i n t h e p r o d u c t i o n o f p o w e r . C o m m osne n s et e l l s
you that protective equipnent is necessary when work'ing around hazards
T l i k e t h e s e . S p e c i a l c a r e s h o u l d b e t a k e n t o p r o t e c t y o u r h e a d ,e y e s , e a r s '
a r m s , l e g s n a n d f e e t w h e ny o u ' r e w o r k i n g ' i n a p 1 a n t . Y o u r p l a n t ' s s a f e t y

I p r o c e d u r e sw ' i 1 1p r o v i d e s p e c i f i c i n f o r m a t i o n o n e q u i p m e n t o b e u s e d w h e n
p e r f o r m i n gd i f f e r e n t j o b s .

I S i g n s t h r o u g h o u tt h e p l a n t w j l l r e m i n dy o u w h e nh a r d h a t s , e a r p r o t e c t i o n ,
face and eye protection and the l'ike are needed. However,commonsense

I s h o u l d d j c t a t e t h i s t o y o u w e l l i n a d v a n c e . C o m m osne n s ea n d p l a n t p r o -
c e d u r e sw i l l a l s o s p e c i f y t h e t y p e o f p r o t e c t i v e e q u i p m e n t h a t i s n e c e s -
s a r y . F o r e x a m p l e ,m e t a l i s a c o n d u c t o ro f e l e c t l i c i t y , s o i t d o e s n ' t m a k e
t much sense to wear a metal hard hat or metal iewelry when working in a
power p'lant.

I
4.5- 1
I
BASICPOI^/ER
4.
PLANTOPERATION
P ' l a n t O p e r a t ' i o n( c o n t i n u e c i ) I
I t i s a l s o i m p o r t a n t t o m a t c ht h e t y p e o f p r o t e c t i v e e q u i p m e nut s e d t o t h e
s p e c i f i c j o b t h a t n e e d st o b e d o n e . I n a s h o p w h e r ec u t t i n g a n d g r i n d i n g
I
t a k e p ' l a c e , s a f e t y g o g g l e sa r e g o o di n s u r a n c ea g a i n s t e y e i n j u r y . H o w e v e r ,
a f a c e s h i e l d g i v e s y o u a d d e dp r o t e c t i o n w h e ny o u ' r e w o r k ' i n ga r o u n dc h e m ' i -
c a 1 s , a n d a r e s p i r a t o r s h o u l d b e a d d e dt o t h e g o g g l e sw h e ny o u ' r e w o r k i n g
I
in dusty areas.
t
0 t h e r p r e c a u t i o n s t h a t m a k eg o o d s e n s e a r e t h e w e a r i n g o f l o n g - s l e e v e d
s h i r t s , g ' l o v e s a n d p r o t e c t i v e f o o t w e a r w h e ny o u ' r e w o r k ' i n ga r o u n d p i p e s
a n d m a c h i n e r y . S u p e r h e a t esdt e a mi s ' i n v i s i b l e ; y o u u s u a l l y d o n ' t s e e i t o r
I
f e e l i t u n t i l i t h a s c a u s e da s e r i o u s b u r n . I n m o s t c a s e s , t h e m o v ' i n g
p a r t s o f p ' l a n t m a c h i n e r ya r e c o v e r e dw i t h p r o t e c t i v e s h i e l d s o r s c r e e n s , I
but hair, shirttai'ls, and any other loose or torn clothing can still get
c a u g h t i n t h e m a c h i n e s . T h e s a m ei s t r u e o f b r a c e l e t s , n e c k c h a ' i n sa, n d
other items of jewelry. In most cases, you won't realize you're caught
I
until it's too late.
I
T h e b e s t p r o t e c t i o n a g a i n s t a c c i d e n t s i s t o k e e py o u r w o r k a r e a c l e a n . I t
i s i m p o s s i b l et o a v o i d a l l s p i l l s a n d l e a k s i n a p o u , e p r lant. But, it is
p o s s i b l e t o k e e p t h e m f r o m b e c o m i n gp r o b l e m s . 0 i l , u , a t e r , a n d o t h e r
I
s u b s t a n c e so n a p l a n t f l o o r a r e d a n g e r o u s ;t h e y s h o u l d b e c l e a n e d u p
promptly so that no one gets hurt. I
A l a r g e p a r t o f a n o p e r a t o r ' s j o b i s e n s u r i n gt h e s a f e t y o f o t h e r s . A s a n
operator, you may never have to clean a boiler or replace a valve;, however,
t
y o u w i l l b e r e s p o n s i b l e f o r p u t t i n g t h e s y s t e mb e i n g w o r k e do n i n a s a f e
c o n d i t i o n s o t h a t o t h e r s c a n d o t h e w o r k . T h i s i s u s u a l l y d o n eb y t a g g i n g
o u t v a r i o u s s y s t e m sa n d c o m p o n e n t s . E v e r y p ' l a n t h a s s p e c i f i c t a g g i n g
I
proceduresthat must be followed to ensure the safety of maintenancecrews.
I
B a s i c a l l y , w h e n a s y s t e m i s t a g g e d o u t , a c o l o r - c o d e dt a g i s p l a c e d o n
every component that could be a safety hazard if it were operated whi'le the
c r e w ' i s a t w o r k . T h i s m e a n st h a t o p e r a t o r sm u s t b e c a p a b l eo f
maintenance
I
tracing through each system and determin'ingwhich componentsshou'ld be
t a g g e do u t . A t a g g e dp i e c e o f e q u i p m e nst h o u l d n e v e r b e o p e r a t e du n t i l t h e I
tag has been removedaccording to the proper plant procedure.

I
4.5- 2
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I BASICPOWER
4.
PLANTOPERATION
P l a n t O p e r a t ' i o n( c o n t i n u e d )

I A n s w e rt h e f o l l o w i n g q u e s t i o n s .

4.5-1. T r u e o r F a l s e . I t i s i m p o r t a n t t o m a t c ht h e s a f e t y e q u i p m e n t

I that you use to the iob that needs to be done.

I 4.5-2. C'ircle the correct answer.

H a r d h a t s a n d o t h e r p r o t e c t i v e e q u i p m e n st h o u l d b e m a d eo f
a. Steel

t b.
c.
Aluminum
materia'l
Strong, non-conducting
d. Noneof the above
l 4.5-3. A p r o c e d u r ef o r p u t t i n g s y s t e m sa n d c o m p o n e n tisn a s a f e c o n d -

t i ti on so maintenance crews can work on them i s cal I ed

I
CHECK YOUR ANSWERS I^JITH THOSE GIVENAT
I T H EE N DO F T H I SU N I T . T H E ND OT H E
U N I T4 P R O B LS
EEMT .

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4.5- 3
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I BAsIcPowER PLANToPERATIoH
|| 4. Plant 0peration (continued)

Unit 4 - Prob'lem
Set
I
1. True or False. LoadchanEes are usually accomplishedby using the
I
I turbine governorto increasethe stop valve openings.

ll 2, Circle the correct answer.

t are useoEo
In adclitionto reducrngfrrctron, Dear'tngs
, a. Carry loads
b. Control turbine speed
I
c. Position movingparts
d. Both a and c
I e. Both b and c

3. Exptainwhat is meantby an oil wedgeformedduring lubrication of a

I
bearing.

I
I
4. usedto checkvibrationis cal'leda
Aninstrument
I 'lubricants
5. True or False. To prevent contamination, that are re-

I movedfrom their original containersshouldbe carefully labeled so

that any excesscan be returnedto the original container.

I 6. Beforeflue gas is sent to the stack separatepar-

ticulates fron the gas.

r 7. Circle the correct answer.

Sliding surface bearings and rolling contact bearingscan be de-
I signedto
a. Limit axia'l movement

I b.
c.
Limit radial movement
P o s i t i o nm o v i n gp a r t s
d. A'l'l of the above

I e. Both a and b

I
BASICPOWER PLANT
Unit 4 - Prob'lem
OPERATIOI{
Set (continued) I
8. List the steps that an operatorshouldfollow in order to install and
use a barrel pump.
I
a.
b.
C.
I
d.
Q.
I
9. Trueor False. A constantlevel oiler usesoil rings to distribute
lubricatlon to a shaft.
I
10. Gircle the correct answer. I
A drip feed lubrlcator
a.
b.
Usesa small oll punpto supplyoll to the reservoir
Usesgravlty to clrculateoil into an oil cup
I
c.

d.
Hasa smallhole in the bottm of its reservolrto allm oll to
drip slowly onto a bearing
Botha andc
I
e. iloneof the above
I
11. The maln lube oil system ls a good exampleof a
lubricatlon system. I
L2. True or False.
flue gas.
Scrubberscan removemost nltrogen oxides from the
I
13. Circle the correct answer.
lloise pollution
I
i.
b.
Is primarily a probleminside the plant
Is difflcult to elimlnate completely I
c. Cancauseprematurehearing loss
d.
e.
Canbe control1edby wearingapprovedhearingprotection
All of the above
I
I
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I
I BASIC POWERPLANT
Unit 4 - Problem
OPERATION
Set (continued)

I 14. hlhatcanan operatordo lf an automatic

rate properly?
falls to adJusta flow
system

I
I
1.5. Trueor False. Taggingout systems andcomponents ig onet,laythat an
I operatorprotectsthe safety of plant personnel.

I 16.The-hasthep0tentialforbe.ingarnajorsourceofthermal
pollutlon,

I L7, Circle the correct answer.

Twocgnmonmethodsof applying grease are

I a.
b.
c,
Thegreaseseal and the greasefitting
The greasegun and the forced lubrication system
The greasecup and the drip feed lubricator

I d.
e.
The greasegun and the greasecup
llone of the above

I 18. True or Fa'lse. In order to preventboth axlal andradial movement

a shaft, two tapered rolllng contact bearingscan be used.
of

I 19. I'lhenis the best time to take temperaturereadings of a bearing?

I
I
20. In addition to the plant's operating procedune,the best $afety
I practice is usinE

t
I
I
I
I BASICPOI.IER
PLANTOPERATION
GLossARy
I
I This glossarycontainsterms pertinent to the study of powerp'lant opera-
I tion and g'ivesthe meanings
of the terms in that context.

I
t
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t
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t
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G-1
I
BASICPOI,IERPLANTOPERATION
G'lossary(contj nued) I
Air preheater A componentthat transfers heat from
the flue gas leaving a boiler to the I
combustionair f'low'inginto the boil-
er.
I
Axial movement End-to-endmovement.
I
Balanceddraft boiler A boiler that uses both forced draft
fans and induceddraft fans to provide
the necessaryair and flue gas flow
I
through it.

A componentthat carries loads, re-

I
Bearing
ducesfriction, and positions moving
parts.
E
Bl ade A rotating or fixed part of a turbine.
Rotating blades convert energy in
I
steam into mechanicalenergy, which
causesrotation of the turbine shaft;
I
fixed bladesdirect the steaminto the
rotati ng b,lades. I
Blowdown A type of drain that maY be oPened
during boiler operation for specific I
purposes,such as to rfliove contami-
nation that has built up in the drum. I
BoiI er The component in a PowerPlant that
burns fue'l to produceheat and uses I
that heat to convert water into steam.

Boiling The processof convertingwater into

I
steam.
I
I
G-2
I
I BASICPObIER PLANT OPERATION
G l o s s a r y( c o n t i n u e d )

'in which
I carbonseal - A methodof turbine seafing
springs hold carbonrings against the
shaft.

I Circuit - A completepath for current f1ow.

t air system
Combustion - The support systemthat supplies the
air necessaryfor the proper combus-

I tion of fuel in a boiler.

t Condensate The water that is collected in a con-

denser as steam is condensed.

I system -
Condensate-feedwater The support systemthat removescon-
densatefrom the condenserand sends
i t b a c kt o t h e b o i l e r .
t Condenser - A large heat exchangerthat removes

t heat from steamand thus converts the

steaminto water.

I circu'lating water
Condenser
system
- The support system that supplies
tubes.
cool'ingwater to the condenser

t c'irculation
Contro'l'led - A processthat usesboiler water cir-
culation pumpsto movesteamand water

I t h r o u g hb o j l e r t u b e s .

- T h e p o i n t a t w h i c h t h e d e n s ' i t yo f
I Critical conditions
water andthe density of steamare the
;ame;7050Fand 3206psj.

t Current - Themovement, or flow, of e'lectricity

t h r o u g ha c i r c u i t .
I
I
ti- J
BASICPOI,IER PLANTOPERATION
Glossary ( cont'inued)
I
Demand The amountof powerneededby a power
system'scustcrners. I
Diaphragrn A stationary part of a turbine; a dia-
phragn contains blades or nozzles
t
that direct Steamfrom one set of ro-
tating bladesto the next. I
Downcomers The large pipes in drum-typeboilers
that recirculate water frcrn the steam
I
drumbackto the waterwalls.

Drum-type
boiler A type of boiler that has a large
I
steamdrumlocated on top to collect
the steamproducedby the boiler. t
Economizer A componentthat transfers heat from
flue gas leavinga boiler to feedwater
I
flowing into the boiler.

Electro-hydraulic control A turbine control systemthat uses an

system
electronic aovernor and oi'l f rcrn an
independent o'il supplyto monitor and
I
control turbine speed.

Extraction steam Steanthat is extracted from the tur-

bine and used by the feedwater heaters
to heat the feedwater that is being
T
sent to the bo'iler.

Feedwater The water that is pumpedinto the

I
boiler to replace the water that
leavesthe boiler as steam. I
Feedwater
control va]ve A valve usedto control the amountof
water pumpedto the boiler.
I
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I BASICPO[,,ER PLANTOPERATION
G l o s s a r y( c o n t i n u e d )

I Film lubrication A processthat maintains a wedgeof

oil betweena bearingand a shaft.

I Flue gas The exhaust gas producedwhen fuel

burnsin a boiler furnace;flue gas

T must be pushedor drawn out of the

furnaceand dischargedfrom the plant
throughthe stacks.

I Foss'ilf ue'l p'lant A power plant that uses energy from

coal, o'i1, or natural gas to produce
I electric power.

I Friction The res'istanceto motion that exists

betweentwo bodies in contact with
eachother.
I Fue'lsystem The supportsystemthat de]ivers fuel

I to a boiler furnace.

Furnace The openarea in a boiler wherefuel

I is burned.

I Generator A machinethat converts mechanical

energyinto electnical energy.

t Gland The collective term for the gland

seals used at a particular sea'ling

I po'int.

1y composed of several
G'landseal A seal, usua'l

I labyrinth seals, designedto prevent

leakageof air or steamarounda tur-

I bine shaft.

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BASICPOWER PLANTOPERATION
G ] o s s a r y( c o n t in u e d
) t
Glandseal exhaustsystem A system that prevents steam from
leakingout alongthe turbine shaft by
drawingoff the steamand condensing
t
it for reuse.
I
Gland sea'l system A systemthat supplies low-pressure
stean to keepoutside air frcrn leaking T
into the turbine.

Glandsteamcondenser A part of the gt and seal exhaustsys-

tem in which steamleaking past the
turbine shaft is collected and con-
densed;the condensate maybe drained
I
to the maincondenser.
I
Glandsteamexhauster A vacuum pumpthat drawsair andsteam
frcrn the turbine glands to the gland
steamcondenser.
I
Hydroelectricplant A power p'lant that uses energy from I
water stored behind damsto produce
electric power. I
Impu'lseturbi ne A turbine in whichthe force of high-
pressure steam causes the rotating I
bladesto turn.

Labyrinthseal A seal madeup of a set of groovesand

I
ridges that correspond to anotherset
of groovesandridges on, for exanple,
a turbine shaft.
I
Load change The processof changingthe amountof
I
power producedby a power plant to
meeta changein demand. I
I
G-6
I
t BASIC POWER PLANTOPERATION
G'lossary( conti nued)

I Load dispatcher The individual whopredicts the de-

mandfor power, monitors the condi-
tion of a powersystem,and coordi-
I natesthe outputsof the plants 'in the
systemso that supply always equals

I demand.

Main steam system The systemthat transports steamfrom

I a boiI er to i ts turb'ine.

I Makeup
water system The support systemthat replenishes
water lost from the stean cycle as a
result of leakage.

I M e c h a n i c a l - h y d r aiucf control A turbine control systemthat uses a

system mechanicalgovernorand oil frorn the
I turbine lube oil systemto monitorand
control turbine speed.

I Megawatt O n em i l l i o n w a t t s .

I N a t u r a lc i r c u la t i o n The process by which water and steam

movethrough somedrun-type boi'lers;

I basedon the fact that cold water is

heavier than hot water or steam, so
colder water in downcomerspusheshot
I water and stean upwardthroughboiler
tubes.

I Nuc'learpl ant A power plant that uses energy from

uraniumto produceelectric power.
I 0nce-throughboiler A boiler in which water goesthrough

I only once; water is pushedthrough

this type of boiler by boiler feed
pumps.

I
I G-7
BASICPOWER PLANTOPERATION
G ' l o s s a r(yc o n t i n u e d ) I
Particulates $nall unburnedsolid particles that
are left in flue gasafter cmbustion. I
Powerstation A facility that produceselectricity.
I
Powersystem The system that connects al I the
plants ownedby a powercornpany. I
Preci pitator A device used to separate Particu-
lates frcrn flue gas leaving a boiler.

Pressurizedfurnaceboiler A boiler in whichthe pressureof the

incomingair from a forced draft fan
I
pushes flue gas out through the
stacks.
I
Pyrometer An instrument used to take tempera-
ture readings and bearings and other
I
components.
I
Radial movement Side-to-side movement.

Reactionturbine A turbine in which the expansionof

I
stean causes the rotating blades to
turn. I
Reheater A boiler component that adds heat to
steam after it has movedthrough a
I
portion of the turbine. Thereheated
steamthen flows throughthe remain-
der of the turbine.
I
Rolling contact bearing A bearing in which one surface rolls
I
over another surface; there is lubri-
cant betweenthe two surfaces to re-
d u c ef r i c t i o n .
I
Rotor Themovingparts of a turbine.
T
G-B
I
t BASICPOt,lERPLANTOPERATION
G'lossary(continued)

t Saturat'ion temperature The temperatureat which water will

b o i l a t a g i v e np r e s s u r e .

I Scrubber A devicethat useschemicalprocesses

to reduce the amountof pollutants

I such as sulfur oxides in flue gas

l e a v i n ga b o i l e r .

I S'li di ng surf ace beari ng A bearing'in whichtwo surfaces,with

lubricant betweenthem, slide over

I Sootb'lower
eachother.

A devicethat usessteamor compressed

I air to blow off soot that co]lects on

boiler tubes.

I Sprayattemperator A device that sprays water into the

steamflowing through a superheater

I or reheater to prevent the final

outlet steamtemperaturefrom exceed-
i n g e s t a b ' l i s h el di m i t s .
I Steamcontro'l valve A valve usedto control the amountof

I steamflowing throughthe turbine.

Steamcycle I n a p o w e rp ' l a n t , t h e c o m p l e t e ' l o o p

t f r o m t h e b o i l e r , t h r o u g ht h e t u r b i n e ,
throughthe condenser, andbackto the

I S u b c r i t ' i c a cl o n d i t i o n s
b o iI e r .

S t e a mc o n d i t i o n s b e l o w t h e c r i t i c a l

I conditionsof 7050Fand 3206psi.

I Substation A facif ity in which electric power

from severa] sourcesis combinedin
o n e l o c a t i o nf o r l o c a l d i s t r i b u t i o n .

I
G-9
I
,l

BASICPOWER PLANT OPERATION

G l o s s a r y( c o n t i n u e d ) Td
Supercritical conditions Steamconditions above the c r i t i c a l
conditionsof 705oFand 3206p s i . fr
Superheated
steam Steamthat has been heated abovethe
saturation temperature.
Ii
Superheater A component that heats steamabovethe
saturati on temperature.
I
Support system - A systen that supports the operation
l
of another system. For exanple,
several systems outside the steam
cycle are neededto make the steam
I
cycle work.
I
A facility that combinesthe output
Switchyard
frq[ a numberof generatorsand trans-
mits the combinedoutput to different
T
service areas.
I
Transformer A device that increases or decreases
ACvoltage. I
Turbine The componentin a powerplant that
convertsthe energystored in steamor I
falling water into the mechanical
energyneededto turn a generator. t
T u r b i n el u b e o i l system - The turbine systemthat provides oil
for lubrication and, in somecases,
for turbine control.
t
Turbinetrip A suddenshutdownof the turbine in
I
responseto an emergenay
situation.
I
G-10
 TI -9

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