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by BLACK & VEATCH Lawrence F. Drbal Managing Editor Patricia G. Boston Associate Editor Kayla L. Westra Associate Editor R. Bruce Erickson Art Editor

~. 11_ KLUWER ACADEMIC PUBLISHERS .lIIIIIf BOSTONIDORDRECHTILONDON Distributors for North, Central and South America: Kluwer Academic Publishers 101 Philip Drive Assinippi Park Norwell, Massachusetts 02061 USA Telephone (781) 871-6600 Fax (781) 871-6528 E-Mail <[email protected]>

Distributors for all other countries: Kluwer Academic Publishers Group Distribution Centre Post Office Box 322 3300 AH Dordrecht, THE NETHERLANDS Telephone 31786576000 Fax 31786576474 E-Mail.... [email protected]> " Electronic Services

Library of Congress Cataloging-in-PubUcation

Power plant engineeringlby Black & Veatch;: Lawrence F. Drbal, managing editor, Patricia G. Boston, associate editor, Kayla L. Westra, associate editor. p. em. Includes bibliographical references and index. ISBN-13:978-1-4613-8047-4 e-ISBN-13:978-1-4613-0427-2 DOl: 10.1007/978-1-4613-0427-2

1. Electric power-plants--Design and construction. I. Drbal, Lawrence F. II. Boston, Patricia G. III. Westra, Kayla L. IV. Black & Veatch. TKI191.P64839 1996 96-34590 621.31 '21--dc20 CIP

Copyright «:l 1996 by Chapman & Hall Softcover reprint of the hardcover 1st edition 1996

Sixth Printing 2003 by Kluwer Academic Publishers Cover photo courtesy ofBlack & Veatch; Mike McPheeters (photographer). Intermountain Power Plant. Cover design: Curtis Tow Graphics

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, mechanical, photo-copying, recording, or otherwise, without the prior written permission of the publisher, Kluwer Academic Publishers, 101 Philip Drive, Assinippi Park, Norwell, Massachusetts 02061

Printed on acid-free paper. This printing is a digital duplication ofthe original edition. CONTENTS

Foreword vii

Preface ix

Authors xi

Contributors xiii

Chapter 1 INTRODUCTION 1 Lawrence F. Drbal

Chapter 2 ENGINEERING ECONOMICS 5 John M. Wynne

Chapter 3 THERMODYNAMICS AND POWER PLANT CYCLE ANALYSIS 39 Mark F. McClernon

Chapter 4 FOSSIL FUELS 71 Kenneth E. Carlson

Chapter 5 COAL AND LIMESTONE HANDLING 124 Richard H. McCartney

Chapter 6 COMBUSTION PROCESSES 165 G. Scott Stallard and Todd S. Jonas

Chapter 7 STEAM GENERATORS 185 Benjamin W Jackson

Chapter 8 STEAM TURBINE GENERATORS 218 Stanley A. Armbruster

Chapter 9 STEAM CYCLE HEAT EXCHANGERS 250 Jay F. Nagori and Samuel Tarson

Chapter 10 FANS 286 Kris A. Gamble

Chapter 11 PuMPs 310 Lawrence J. Seibolt

v vi Power Plant Engineering

Chapter 12 CIRCULATING WATER SYSTEMS 353 David J. Brill

Chapter 13 CYCLE PERFORMANCE IMPACTS 385 Michael J. Eddington

Chapter 14 POWER PLANT ATMOSPHERIC EMISSIONS CONTROL 418 Lloyd L. Lavely and Alan W Ferguson

Chapter 15 WATER TREATMENT 464 Richard G. Chapman

Chapter 16 LIQUID AND SOLID WASTE TREATMENT AND DISPOSAL 521 Kenneth R. Weiss

Chapter 17 ELECTRICAL SYSTEMS 551 Lloyd Wade Sherrill

Chapter 18 PLANT CONTROL SYSTEMS 599 Augustine H. Chen

Chapter 19 SITE/PLANT ARRANGEMENTS 642 Roger M. Prewitt

Chapter 20 GAS TuRBINES 659 Jeffrey M. Smith

Chapter 21 FLUIDIZED BED COMBUSTION 689 Kenneth E. Habiger

Chapter 22 RESOURCE RECOVERY 710 Mitchell N. Bjeldanes and Gordon V. Z. Beard

Chapter 23 NUCLEAR POWER 733 Lawrence F. Drbal

Chapter 24 EMERGING TECHNOLOGIES 781 Larry E. Stoddard

Chapter 25 POWER PLANT PLANNING AND DESIGN 809 Stephen M. Garrett

Chapter 26 PERMmING AND ENVIRONMENTAL REVIEW REQUIREMENTS 829 Anne F. Harris, Amy L. Carlson, Douglas C. Timpe, and Lesley A. Wallingford

APPENDIX CONVERSION TABLE 856 FOREWORD

The electric power generation and distribution industry has its structure the complete cast of players necessary to mount evolved during almost exactly one century into its present such a production. Equally important to its success, Black & form. This development has been driven by economics, tech• Veatch management had the vision to encourage the project. nological advancements, and government regulations. These The high level oftalent and the effort expended on the task of diverse forces have produced generation and distribution producing the book are evident in the quality ofthe resulting systems that are reliable, safe, and environmentally accept• product. able, suitable for service throughout the world. The technol• The book wisely concentrates on state-of-the-art technol• ogies which make up the systems have brought a highly ogy. It emphasizes the why and the what ofcurrent practice. convenient and economic form of energy to both densely However, it does not neglect some of the underutilized en• populated cities and remote geographic areas. Electrical en• ergy sources and systems or the more promising of the ergy has become a fundamental requirement for the exis• developing technologies. The reader will gain a firm founda• tence of modern society. Likewise, it is essential for eco• tion in the technology and a good understanding of com• nomic progress in lesser developed regions. monly encountered system configurations. Additionally, the Because the need for electricity is pervasive in our soci• ground work is adequately laid for the reader to be prepared ety, there is a continuing interest in the technology ofelectric for developments in the future. power production and distribution. Unfortunately for those I feel the book should be suitable and of strong appeal to with such interests, a comprehensive source of information university students (and faculty), to equipment manufac• has not been available until now. Existing texts have tended turers, to utility operators and owners, to system design to be single topic treatments that address power plant design engineers, and to representatives of the variety oflocal, state, and plant components (primarily pre-1950) or electrical dis• and federal government agencies involved in planning and tribution system design. Power Plant Engineering, however, regulation. The book will find use as a university textbook, offers a unified treatment ofpower system economics, plan• as a technical reference, and as a comprehensive handbook ning, design, and operation that includes consideration of all and guide to the numerous technologies that are necessary of the forces which have shaped the industry. components of the electric power industry. The problem in producing a reliable book that treats all As a university professor and consultant who has taught aspects of the industry has been in recruiting authors of the and worked in this area for several decades, I am well aware talent level required and in providing time and support for of the lack of suitable texts and references available for use successful completion ofthe project. Producing such a book by students and by those employed in the power industry. I requires developing the concept and organizing the effort believe this book represents a vital service to that community required, as well as managing and encouraging individuals and that it will be considered the standard work in the area. who can effectively communicate their precise technical knowledge and experience in many diverse fields. The Black Robert L. Gorton, PE, Ph.D. & Veatch organization is fortunate to have available within Atanhauan, Jransas

vii PREFACE

Blaise Pascal, scientist, mathematician, and physicist, once Arlene Siegismund, Marsha Johnson, Lori Lange, Pat An• noted that the last thing we discover in writing a book is to derson, and Becky Nanninga. The many excellent figures know what to put at the beginning. I do not have that problem which illustrate the concepts discussed on these pages were with this book, for I believe it is a book of such quality that constructed under the direction of Bruce Erickson, assisted the beginning must be an acknowledgment of the tremen• by Nicole Genever-Watling, Mark Hayden, and Mark Rump. dous effort expended by many, many talented people. The entire effort over the years was overseen by Virgil Snell, In a manner of speaking, it has taken Black & Veatch Manager of Engineering for the Power Division. nearly 80 years to prepare this book. It has required that As the project drew to a close, the person assigned to length of time, not because of the magnitude of the task, but coordinate the efforts was Roy Mcintosh. Also during this rather because we have drawn on the knowledge and experi• last year, the expert charged with technical review of the ence acquired over the full history of the firm to accumulate, entire manuscript was Robert L. Gorton, professor emeritus test, and apply the information compiled here. In one sense, from Kansas State University Engineering Department, a the book has been authored by literally thousands of engi• true gentleman whose comments were consistent, timely, neers, architects, technicians, scientists, and others who have and made with great affection for the profession from which contributed to the success of Black & Veatch. From that he retired during the preparation of the book. resource we recruited 32 authors, each an expert in a specific Black & Veatch wanted to prepare this book for a number field, who could best state the firm's approach to his or her ofreasons. First, though many authoritative texts address the specialty. It is these people who have made this book pos• various aspects of power generation, no text exists which can sible. be used as the definitive source book as well as a teaching As with any book of this magnitude, its preparation re• tool. Second, the various technologies and processes de• quired the efforts and support of countless others who had scribed in this textbook are continuously changing, driven by nothing to do with the writing of chapters. Initially, the the dynamic economic, regulatory, political, and social influ• task of coordinating the contents of 26 disparate chapters ences that shape the power industry. In the new global cli• necessitated a filing system for keeping track of the thou• mate ofworld banks, turnkey contracting, information super• sands of references, figures, tables, permissions, and pages highways, partnering, and other concepts for which "change" ofdraft text produced for the book. And as the development seems to be the watchword, this book reflects a stable, of the book extended into years, people changed positions, proven approach to power plant design which, at the time of retired, had babies, and went on international assignments• publication, reflects current technology. And finally, we be• constantly changing the book's staff roster. The system for lieve Black & Veatch's approach to power plant design is the tracking was begun by Lorraine Gehring, editor turned mar• most effective approach and by sharing our experiences, we keter, and ended by Laura Patton, teacher turned editor are providing a valuable service to everyone connected with turned new mother. In between, editors Dana Campbell and the power industry. Elaine Rhodes cajoled engineers into using simpler, yet proper English, and Marcia Cones corrected and photo• copied the revisions of revisions. The literally countless Dr. Patrick G. Davidson pages of drafts were typed and typed and retyped by the Managing Partner and Head ofthe Power Division world's cheeriest word processing group-Cindy McDonald, Black & Veatch

ix AUTHORS

Stanley A. Armbruster, PoE. Michael J. Eddington, P.E. B.S., Kansas State University, Nuclear Engineering. B.S., University of Missouri-Columbia, Mechanical (Steam Turbine Generators) Engineering. (Cycle Performance Impacts)

Gordon V.l. Beard, P.E., C.P.A. Alan W. Ferguson, P.E. B.S., University of Tennessee-Knoxville, Mechanical B.S., Clarkson University, Mechanical Engineering. Engineering; B.S., University of Tennessee-Knoxville, (Power Plant Atmospheric Emissions Control) Business Administration-Accounting; M.S., Virginia Polytechnic Institute and State University, Mechanical Kris A. Gamble, P.E. Engineering; M.B.A., Virginia Polytechnic Institute B.S., Iowa State University, Mechanical Engineering. and State University. (Resource Recovery) (Fans) Mitchell N. Bjeldanes, P.E. B.S., University of Minnesota, Mechanical Engineer• Stephen M. Garrett, P.E. ing. (Resource Recovery) B.S., Colorado State University, Mechanical Engineer• ing. (Power Plant Planning and Design) David J. Brill, P.E. B.S., University of Dayton, Mechanical Engineering. Kenneth E. Habiger, P.E. (Circulating Water Systems) B.S., Kansas State University, Nuclear Engineering; M.S., Kansas State University, Nuclear Engineering. Amy L. Carlson (Fluidized Bed Combustion) B.A., University of Northern Iowa, Geology; M.S., Iowa State University, Earth Sciences/Meteorology. Anne F. Harris, J.D. (Permitting and Environmental Review Requirements) B.A., Florida State University, Biology; M.A.T., Emory University, Biology; M.S., University of North Caro• Kenneth E. Carlson, P.E. lina, Botany; J.D., University ofKansas, Law. (Permit• B.S., University of Illinois, Mechanical Engineering; ting and Environmental Review Requirements) M.S., University of Illinois, Mechanical Engineering. (Fossil Fuels) Benjamin W. Jackson, P.E. B.S., University of Missouri-Columbia, Mechanical Richard G. Chapman, P.E. Engineering. (Steam Generators) B.S., University of Missouri-Rolla, Chemical Engi• neering; M.S., University of Missouri-Columbia, Civil Todd S. Jonas, P.E. Engineering. (Water Treatment) B.S., North Dakota State University, Mechanical Engi• neering. (Combustion Processes) Augustine H. Chen, P.E. B.S., National Taiwan University, Mechanical Engi• neering; M.S., Oklahoma State University, Mechanical Lloyd l. Lavely Engineering. (Plant Control Systems) B.S., University of Kansas, Chemical Engineering. (Power Plant Atmospheric Emissions Control) Lawrence F. Drbal, Ph.D., P.E. B.S., University of Nebraska, Chemical Engineering; Richard H. McCartney, P.E. M.S., Kansas State University, Nuclear Engineering; B.S., Clarkson University, Mechanical Engineering; Ph.D., Kansas State University, Nuclear Engineering. M.S., Clarkson University, Mechanical Engineering. (Introduction, Nuclear Power) (Coal and Limestone Handling)

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Mark F. McClemon, Ph.D. Larry E. Stoddard, Ph.D., P.E. B.S., Rockhurst College, Engineering Science; M.S., B.S., South Dakota State University, Electrical Engi• University ofNotre Dame, Engineering Science; Ph.D., neering; M.S., University of Missouri-Rolla, Electrical University ofNotre Dame, Engineering Science. (Ther• Engineering; Ph.D., University of Missouri-Rolla, Elec• modynamics and Power Plant Cycle Analysis) trical Engineering. (Emerging Technologies)

Jay F. Nagori, P.E. Samuel larson, P.E. B.E., Osmania University, Hyderabad, India, Mechani• B.S., University of Missouri-Rolla, Mechanical Engi• cal Engineering; M.S., University of Kansas, Mechani• neering; M.S., Purdue University, Mechanical Engi• cal Engineering. (Steam Cycle Heat Exchangers) neering. (Steam Cycle Heat Exchangers) Roger M. Prewitt, P.E. B.S., University of Missouri-Rolla, Mechanical Engi• Douglas C. Timpe neering. (Site/Plant Arrangements) B.S., North Dakota State University, Zoology; M.S., Western Kentucky University, Biology. (Permitting Lawrence J. Seibolt, P.E. and Environmental Review Requirements) B.S., University of Missouri-Columbia, Mechanical Engineering. (Pumps) Kenneth R. Weiss, P.E. B.S., University of Missouri-Rolla, Chemical Engi• Uoyd Wade Sherrill, P.E. neering. (Liquid and Solid Waste Treatment and Dis• A.S., Arkansas Polytechnic College, Engineering; B.S., posal) University of Arkansas, Electrical Engineering; M.S., University of Missouri-Columbia, Electrical Engineer• ing. (Electrical Systems) Lesley A. Wallingford Certificate of Paralegal Studies, Johnson County (Kan• Jeffrey M. Smith, P.E. sas) Community College; Associate of Applied Sci• B.S., University of illinois, Mechanical Engineering. ence, Johnson County (Kansas) Community College. (Gas Turbines) (Permitting and Environmental Review Requirements)

G. Scott Stallard, P.E. John M. Wynne B.S., University of Kansas, Mechanical Engineering; B.S., Northwest Missouri State University, Economics/ B.S., University of Kansas, Business Administration. Management! Marketing; M.S., Bowling Green State (Combustion Processes) University, Economics. (Engineering Economics) CONTRIBUTORS

The authors are grateful to many people and organizations Chapter 11-Pumps who assisted in the development of their chapters. Contribu• Contributors: John W. Kruse tors are those who helped mold the content of the chapters Acknowledgments: Robert E. Cornman, Ingersoll• and, in some cases, wrote specific sections. Acknowledg• Dresser Pump Company; Jeffrey B. Galush, Ingersoll• ments are given to those individuals and businesses who Dresser Pump Company; Michael T. Radio, Ingersoll• helped the authors by sharing technical expertise or critiqu• Dresser Pump Company; Tun L. Wotring, Ingersoll• ing sections ofa chapter. Unless otherwise noted, individuals Dresser Pump Company listed are employees of Black & Veatch. Chapter 12-Circulating Water Systems Chapter 2-Engineering Economics Contributors: Michael H. Ostdiek; Mark D. Shaw; Jeffrey A. Wootton Acknowledgments: Gordon V.Z. Beard; Myron R. Acknowledgments: Marley Cooling Tower Com• Rollins pany; Kermit E. Trout, Jr. Chapter 3-Thermodynamics and Power Plant Cycle Analysis Chapter 13-Cycle Perfonnance Impacts Acknowledgments: Jeffrey R. Dykstra Contributors: Jon C. Erickson; Mitch L. Rackers; Jason A. Zoller Chapter 4-Fossil Fuels Acknowledgments: Carl G. Granberg Acknowledgments: Kristian B. Fosse; Robert L. Ir• vine; Richard B. Rinehart; Phil Rogers, Utilicorp United Chapter 14-Power Plant Atmospheric Emissions Control Inc.; Michael D. Sharp; Richard K. Van Meter; Steven Contributors: John R. Cochran; Diane M. Fischer; R. Witthar Mike G. Gregory; David K. Harris; Benjamin W. Jack• son; Ricki L. Lausman; Kendall R. Shannon; James E. Chapter 5-Coal and Limestone Handling Stresewski, Jr. Acknowledgments: Andrew 1. Schwartz; United States Acknowledgments: Larry R. Alfred; Morgen E. Fagan Environmental Protection Agency Chapter 15-Water Treatment Chapter 6-Combustion Processes Contributors: Russell R. Helling; Bruce A. Larkin; Acknowledgments: John Pavlish James E. O'Connor; Thomas J. Shrader Acknowledgments: Charles H. Fritz; Lester C. Chapter 7-Steam Generators Webb, Jr. Acknowledgments: Lawrence F. Drbal; Charles J. Schutty, II Chapter 16-Liquid and Solid Waste Treatment and Disposal Chapter 8-Steam Turbine Generators Contributors: Lawrence J. Almaleh; James A. Hengel; Contributors: Jon C. Erickson David L. Holt Acknowledgments: Carl G. Granberg, Jr.; General Acknowledgments: David M. Lefebvre; Gary Van Electric Power Systems, Schenectady, NY; Westing• Reissen; Lester C. Webb, Jr. house Power Generation Business Unit, Orlando, FL Chapter 17-Electrical Systems Chapter 9-Steam Cycle Heat Exchangers Acknowledgments: Mike W. Kelly Acknowledgments: David J. Brill; Mark D. Shaw Chapter 18-Plant Control Systems Chapter 10-Fans Acknowledgments: Roger L. Aye~; Daniel G. Cou• Acknowledgments: Anthony L. Compaan ture; Harry B. McCarl; Parke H. Woodard, Jr.

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Chapter 19-5ite/Plant Arrangements Electric Corporation; John C. Kirkland; Joe Miller, Scien• Contributors: Lynn E. Brown tech, Inc.; Dr. M. John Robinson; Dr. Craig Sawyer, Acknowledgments: W. Keith Krambeck; Larry S. GE-Nuclear Energy; DR Shitlett, ABCL Technolo• Newland gies; Don Warembourg, Public Service Company of Colorado; Jan Wistrom, General Atomics Chapter 20-Gas Turbines Contributors: Michael R. Chandler, Steven M. Clark; Chapter 24-Emerging Technologies Linus A. Drouhard; Morgen E. Fagan; John R. Hughes; Contributors: Lawrence F. Drbal; Tracy M. Fiedler, Peter P. Majerle; Michael D. Morris George P. Gruber Acknowledgments: David L. Frieze; Barry J. Scrivner Acknowledgments: John E. Harder; Kevin A. Ker• schen; Paul G. LaHaye, Hague International; Arthur S. Chapter 21-Auidized Bed Combustion Seki, Hawaiian Electric Contributors: Kevin A. Kerschen; Ronald J. Ott Acknowledgments: Lawrence F. Drbal; Benjamin W. Jackson Chapter 25-Power Plant Planning and Design Acknowledgments: Ronald D. Hubbell; Helen Z. Ken• Chapter 22-Resource Recovery non; Richard K. Van Meter Contributors: Stephen M. Garrett Acknowledgments: Hunter F. Taylor Chapter 26-Permitting and Environmental Review Requirements Chapter 23-Nuclear Power Acknowledgments: Larry R. Alfred; Marsha A. Bru• Acknowledgments: Rebecca Jung, Westinghouse stad; Helen Z. Kennon; Stanley L. Rasmussen ---POW ER

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