I watched the raw video and was fascinated but it was hard to understand the flow of everything. This edit is great so far. Just a friendly suggestion- if you ever do this again consider changing you mouse cursor color to bright pink or yellow and change the cursor size to extra large as it's a bit difficult to see the cursor while watching on a TV. Are you the plant superintendent? Like how do possibly know SO much about the system? Finally, I remember you talked about the main generator circuit breakers on each phase. What would cause those to trip and must they be rebuilt if they trip? Thanks for doing this! Paul from Cincinnati
Thanks for watching and the feedback. I'm surprised that the mouse pointer wasn't big enough since I did almost double the size of it so it would be easier to see on small screens. I can look into changing the color since maybe a regular white color would be easier to see. I forwarded your questions since I just do the video recording and editing, and got a response back about the generator trips. To answer your question about the boiler draft (as best as I understand it), the Induced Draft fans located at the base of the stack are what pulls the negative pressure. The Primary Air fans are what blow air through the pulverisors and carry the coal to the burners. The Forced Draft fans blow air into the windbox and provide the secondary air for combustion. All 3 work together to provide necessary air flow and boiler draft. It should make more sense when we get around to doing a video about the fans in the simulator. "Thank you for your comments The generator breakers (one per phase) are Cogenel air blast breakers with 2 contacts. One is a hard material which closes first and opens last to take the arc. The other contact carries the load current. They are designed for 24,00 volts, 24,000amp and interrupt in 4 cycles (60HZ). They are designed for many cycles of use. The generator breaker trips: () is the relay number as type of relay. (78) Generator out of step. Generator has slipped a pole and is not insync with the grid. (21) 500KV line phase distance relay. Line problem. (50TXN) 500kv line line to line and line to ground. (78GX) phase distance (direction toward generator detector. (Part of the 500kv line protection). Steam turbine trip (this includes oil pressure/temp vacuum over speed etc.). Main transformer trip. (Over pressure, temperatures differential current, etc.) (59N) Generator neutral over voltage, (51N) generator neutral overcurrent. These protect against ground faults as the generator neutral goes through a grounding resister to limit fault current. (87G) Generator differential current. These relays measure the current inflow of the protected equipment with the output current. Current leakage to ground should trip the breaker before a full-blown fault. (32) Reverse power. Prevents motorizing the generator. (16 megawatts minimum). (46) Generator negative phase sequence. Windings. current out of balance. (51) Generator instantaneous over current. (76) Exciter field over excitation. (81 and 59) Generator and transformer over excitation. Prevents over fluxing of transformers which can cause damage. (81) Generator under frequency (57 Hz). Transformer damage cause by excess magnetic flux through the steel core. (81) Generator under frequency (58.5 Hz for 30 seconds). (40) Generator loss of excitation. (60) loss of generator potential transformer fuse. No voltage indication. (50TG) Generator current detector. Breaker or phase closed when generator stopped. Prevents a disaster. (81) Generator at standstill under freq (54hz) prevents breaker closing when generator is stopped or not up to speed. Prevents a disaster."
Here's the more technical explanation of the draft: The air/draft control has quite a lot of logic involved. The boiler will trip at less than 25% total air flow, -8 inches water column (IWC), or +5 IWC. The draft is usually set for -.5 IWC. The induced draft fans (4) variable frequency drive (3500 hp) double suction fan controlled the draft. The secondary air fans (2) (2000 hp) double suction provided the air for part of the combustion. This air flow was controlled with inlet vanes. The oxygen control master and the draft logic adjusted the vanes. The primary air for combustion is the primary air fans (2) (3500 hp) double suction fans controlled with guide vanes. The discharge pressure usually runs at 56 IWC. This air feeds the pulverizers with a coal to air ratio (it varied for load) of for example 100,000 pounds of coal per hour requires 186,000 pounds of air per hour. This air was the motive force to move the coal dust into the burners and boiler. The control scheme went from the boiler master to the fuel and draft master, with the oxygen master adjusting the secondary fan dampers. The air leads the fuel, and the fuel is cut before the air. If the boiler trips and all the fire is removed the furnace can go very negative to the point of imploding the furnace. This was figured into the logic to prevent this. The O2 is controlled at 10% until 20%-megawatt load, by 60% the O2 is at 2.7%. The air flows are temperature and pressure compensated. The furnace draft is measured right above the burners. The draft at the top of the boiler is less and at the bottom it is higher due to a chimney effect.
Here's another response that I had posted to the original video a while ago and thought that I should add it here to centralize these detailed answers. "In response to your questions: at 1:15 of the video this is the Turbine Generator lube oil dehydrator. A vacuum is pulled on the vessel and a slip stream of heated (130 deg F) lube oil is sprayed through filters to remove moisture. If the lube oil temp on the outlet is too cold the oil is recirculated through the dryer as this means a lot of moisture is being removed. This comes from gland seal steam, and air pulled in through the bearings. There is some refractory at the burners, but the furnace is of a welded membrane construction. The water wall tubes have spacers between them and are welded. A -.5 inches water column furnace pressure can be maintained. If the boiler goes positive fire and hot gases escape. Pulverized coal builds up a lot of ash which melts to form a slag. (This really depends on the type of coal being burned) This slag builds up on everything. At the burners a buildup in excess of 8 feet from the water wall can develop. We call this an 'eyebrow'. Water cannons (4 total) use a high-pressure jet of water to remove this slag from the waterwalls in preprogramed zones. The is very little refractory in this boiler. This fire box is 150 feet to the bull nose and 200 feet to the roof. It is suspended from the roof beams so it can expand downward approx. 11 inches. From cold to hot. This slag (rock) is sluiced every shift with the hopper doors opened once a week to remove large ash sheets (boulders). A jackhammer with a long rod is used to break it up and racks are used to help move this to the grinder and sluice system. As far as sootblowing there are 68 sootblowers using various amounts of steam. About 30,000 gallon per hour is required for boiler make up. The soot blowers are approx. 30 feet long and reach halfway across the boiler. The steam used for blowing and the rotating motion keep the lances (soot blower tubes) straight. The critical areas are division walls (platens), finishing super heat, and primary superheater. The finishing superheater are 16 inches apart which slag can bridge and plug up the furnace outlet, A plugging primary super heater forces more flue gas to the reheater section which make temp control impossible (1005 deg F). Although this give you more megawatts it is hard on the turbine casing, rotor and piping. Only 2 sootblowers can run at a time and it can be difficult to keep up with the ash build up so soot blower is a continuous operation."
I worked on a conventional (non-nuke) aircraft carrier steam propulsion plant (make ship go, generate electricity, steam for hotel services and provide steam to launch aircraft. This thing looks about 1000x more complex and it only does one of those things... ugh 😵💫
Can I just say that I have found both the first and this re edited video absolutley facinating. Watched both in full several times and found it very interesting. Sad to read that this plant that you and your collegues have cared for for so many years is now dimolished. Kind regards Charlie, Sussex UK
Good memories. Worked in the maintenance dept at the 2400MW Longannet Power Station in Scotland (picture this station times four) for 15 yrs before they shut it down and demolished it. All in the name of eco friendly energy policy. Now we are paying the highest energy prices in Europe. Absolute criminal.
Another question: Who designed this plant? Also, what is the cost to build this plant? What is the cost to run the plant? Can you tell the story about the explosion that damaged the side of the plant?
I made it unlisted to try go get people to watch this video instead since it's such a big improvement. You should still be able to find the original in my "Power Plant Videos" playlist, or here's the link: ruclips.net/video/q34TvvkrQcQ/видео.html
Sorry another question! Can you explain how the furnace has a lower atmosphere than outside? Arnt you forcing air into the furnace for combustion? Sorry for so many questions I'm just fascinated by all this.
This is by far the most detailed and accurate power plant tour video on the internet, he goes into a ton of detail that a lot of other more... consumer oriented videos would just gloss over for simplicity.
I would give credit to him, just for the effort to bring out this video. The subject is difficult in its nature, I believe you understand that. People related to this job will agree, it is hard to condense all that info in an hour long clip, without losing track. It's a highly specialised subject, not suitable for beginners or general RUclips viewers. Don't get me wrong, not trying to be offensive here...
I watched the raw video and was fascinated but it was hard to understand the flow of everything. This edit is great so far. Just a friendly suggestion- if you ever do this again consider changing you mouse cursor color to bright pink or yellow and change the cursor size to extra large as it's a bit difficult to see the cursor while watching on a TV.
Are you the plant superintendent? Like how do possibly know SO much about the system?
Finally, I remember you talked about the main generator circuit breakers on each phase. What would cause those to trip and must they be rebuilt if they trip?
Thanks for doing this!
Paul from Cincinnati
Thanks for watching and the feedback. I'm surprised that the mouse pointer wasn't big enough since I did almost double the size of it so it would be easier to see on small screens. I can look into changing the color since maybe a regular white color would be easier to see.
I forwarded your questions since I just do the video recording and editing, and got a response back about the generator trips. To answer your question about the boiler draft (as best as I understand it), the Induced Draft fans located at the base of the stack are what pulls the negative pressure. The Primary Air fans are what blow air through the pulverisors and carry the coal to the burners. The Forced Draft fans blow air into the windbox and provide the secondary air for combustion. All 3 work together to provide necessary air flow and boiler draft. It should make more sense when we get around to doing a video about the fans in the simulator.
"Thank you for your comments
The generator breakers (one per phase) are Cogenel air blast breakers with 2 contacts. One is a hard material which closes first and opens last to take the arc. The other contact carries the load current. They are designed for 24,00 volts, 24,000amp and interrupt in 4 cycles (60HZ). They are designed for many cycles of use.
The generator breaker trips: () is the relay number as type of relay.
(78) Generator out of step. Generator has slipped a pole and is not insync with the grid.
(21) 500KV line phase distance relay. Line problem.
(50TXN) 500kv line line to line and line to ground.
(78GX) phase distance (direction toward generator detector. (Part of the 500kv line protection).
Steam turbine trip (this includes oil pressure/temp vacuum over speed etc.).
Main transformer trip. (Over pressure, temperatures differential current, etc.)
(59N) Generator neutral over voltage, (51N) generator neutral overcurrent. These protect against ground faults as the generator neutral goes through a grounding resister to limit fault current.
(87G) Generator differential current. These relays measure the current inflow of the protected equipment with the output current. Current leakage to ground should trip the breaker before a full-blown fault.
(32) Reverse power. Prevents motorizing the generator. (16 megawatts minimum).
(46) Generator negative phase sequence. Windings. current out of balance.
(51) Generator instantaneous over current.
(76) Exciter field over excitation.
(81 and 59) Generator and transformer over excitation. Prevents over fluxing of transformers which can cause damage.
(81) Generator under frequency (57 Hz). Transformer damage cause by excess magnetic flux through the steel core.
(81) Generator under frequency (58.5 Hz for 30 seconds).
(40) Generator loss of excitation.
(60) loss of generator potential transformer fuse. No voltage indication.
(50TG) Generator current detector. Breaker or phase closed when generator stopped. Prevents a disaster.
(81) Generator at standstill under freq (54hz) prevents breaker closing when generator is stopped or not up to speed. Prevents a disaster."
@@briantrue9930 thank you for answering my questions! I am very grateful that multiple people took time to reply!
Here's the more technical explanation of the draft:
The air/draft control has quite a lot of logic involved. The boiler will trip at less than 25% total air flow, -8
inches water column (IWC), or +5 IWC. The draft is usually set for -.5 IWC. The induced draft fans (4)
variable frequency drive (3500 hp) double suction fan controlled the draft. The secondary air fans (2)
(2000 hp) double suction provided the air for part of the combustion. This air flow was controlled with
inlet vanes. The oxygen control master and the draft logic adjusted the vanes. The primary air for
combustion is the primary air fans (2) (3500 hp) double suction fans controlled with guide vanes. The
discharge pressure usually runs at 56 IWC. This air feeds the pulverizers with a coal to air ratio (it varied
for load) of for example 100,000 pounds of coal per hour requires 186,000 pounds of air per hour. This
air was the motive force to move the coal dust into the burners and boiler.
The control scheme went from the boiler master to the fuel and draft master, with the oxygen master
adjusting the secondary fan dampers. The air leads the fuel, and the fuel is cut before the air. If the
boiler trips and all the fire is removed the furnace can go very negative to the point of imploding the
furnace. This was figured into the logic to prevent this. The O2 is controlled at 10% until 20%-megawatt
load, by 60% the O2 is at 2.7%. The air flows are temperature and pressure compensated. The furnace
draft is measured right above the burners. The draft at the top of the boiler is less and at the bottom it is
higher due to a chimney effect.
@@briantrue9930 I am very grateful for the time everyone spent to answer my questions.
Here's another response that I had posted to the original video a while ago and thought that I should add it here to centralize these detailed answers.
"In response to your questions: at 1:15 of the video this is the Turbine Generator lube oil dehydrator. A vacuum is pulled on the vessel and a slip stream of heated (130 deg F) lube oil is sprayed through filters to remove moisture. If the lube oil temp on the outlet is too cold the oil is recirculated through the dryer as this means a lot of moisture is being removed. This comes from gland seal steam, and air pulled in through the bearings.
There is some refractory at the burners, but the furnace is of a welded membrane construction. The water wall tubes have spacers between them and are welded. A -.5 inches water column furnace pressure can be maintained. If the boiler goes positive fire and hot gases escape. Pulverized coal builds up a lot of ash which melts to form a slag. (This really depends on the type of coal being burned) This slag builds up on everything. At the burners a buildup in excess of 8 feet from the water wall can develop. We call this an 'eyebrow'. Water cannons (4 total) use a high-pressure jet of water to remove this slag from the waterwalls in preprogramed zones. The is very little refractory in this boiler. This fire box is 150 feet to the bull nose and 200 feet to the roof. It is suspended from the roof beams so it can expand downward approx. 11 inches. From cold to hot. This slag (rock) is sluiced every shift with the hopper doors opened once a week to remove large ash sheets (boulders). A jackhammer with a long rod is used to break it up and racks are used to help move this to the grinder and sluice system.
As far as sootblowing there are 68 sootblowers using various amounts of steam. About 30,000 gallon per hour is required for boiler make up. The soot blowers are approx. 30 feet long and reach halfway across the boiler. The steam used for blowing and the rotating motion keep the lances (soot blower tubes) straight. The critical areas are division walls (platens), finishing super heat, and primary superheater. The finishing superheater are 16 inches apart which slag can bridge and plug up the furnace outlet, A plugging primary super heater forces more flue gas to the reheater section which make temp control impossible (1005 deg F). Although this give you more megawatts it is hard on the turbine casing, rotor and piping. Only 2 sootblowers can run at a time and it can be difficult to keep up with the ash build up so soot blower is a continuous operation."
You brought back great memories with this video! I started my career on a 300 MW coal power plant, 14 years ago!
Pretty remarkable all that goes into one plant… can’t imagine the crew that helps maintain. Thanks for sharing your passion!
I worked on a conventional (non-nuke) aircraft carrier steam propulsion plant (make ship go, generate electricity, steam for hotel services and provide steam to launch aircraft. This thing looks about 1000x more complex and it only does one of those things... ugh 😵💫
nice vid, nice technical detail and 😀relaxing voice tone
Can I just say that I have found both the first and this re edited video absolutley facinating. Watched both in full several times and found it very interesting. Sad to read that this plant that you and your collegues have cared for for so many years is now dimolished.
Kind regards
Charlie, Sussex UK
very impressed with a 1981 coal power station in such a good condition.
Good memories. Worked in the maintenance dept at the 2400MW Longannet Power Station in Scotland (picture this station times four) for 15 yrs before they shut it down and demolished it. All in the name of eco friendly energy policy. Now we are paying the highest energy prices in Europe. Absolute criminal.
This is so impressive and fascinating, I wanted to work as a mechanical engineer in one plant like that.
Another question:
Who designed this plant?
Also, what is the cost to build this plant?
What is the cost to run the plant?
Can you tell the story about the explosion that damaged the side of the plant?
What happens to the ash? I'm trying to figure out where it goes or if it's available to buy.
38:10 Big Ass Fan!
I can't find the raw video that this was from. I watched it along time ago but now i cant find it.
I made it unlisted to try go get people to watch this video instead since it's such a big improvement. You should still be able to find the original in my "Power Plant Videos" playlist, or here's the link: ruclips.net/video/q34TvvkrQcQ/видео.html
With the two 12V71TT diesel generators are those just for emergency power or is this a black start capable plant?
Those are just for emergency power if the plant goes black. This plant isn't black start capable.
I see why to ditch coal. To much Aux equipment.
Sorry another question!
Can you explain how the furnace has a lower atmosphere than outside? Arnt you forcing air into the furnace for combustion?
Sorry for so many questions I'm just fascinated by all this.
The induced draft fan is higher power and volume than the combustion air feed fan.
Been looking for a video like this.. Well done. Now I get it... LOL...
you just go around and around in circles - none of this makes ANY SENSE at all... what the hell nonsense is this
This is by far the most detailed and accurate power plant tour video on the internet, he goes into a ton of detail that a lot of other more... consumer oriented videos would just gloss over for simplicity.
skill issue
It makes perfect sense, I had no problem following it at all.
I would give credit to him, just for the effort to bring out this video. The subject is difficult in its nature, I believe you understand that. People related to this job will agree, it is hard to condense all that info in an hour long clip, without losing track. It's a highly specialised subject, not suitable for beginners or general RUclips viewers. Don't get me wrong, not trying to be offensive here...