bhel super critical thermal power plant

Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited


KARNATAKA POWER CORPORATION LIMITED

Karnataka Power Corporation Limited (KPCL)- a premier Govt. of Karnataka organisation in the field of power generation

Present Installed generation capacity Hydro 3652.35 MWThermal 2720 MW

Meets nearly 50% of State’s energy demand



Present Thermal Generation

Operating Stations Raichur Thermal Power Station (RTPS)- 1720 MW ( 7X210+1X250)

First Unit commissioned during 1984 and the last Unit (250 MW) was commissioned during 2010

Boilers of all Units are of BHEL make All Turbine sets except Unit 4 are also from BHEL. Unit 4 turbine is MHI make

Coal for RTPS is through long term linkages allocated from Singarenicoalfields in Telangana, Western Coalfields in Maharashtra and TalcherCoalfields in Orissa


– Bellary Thermal Power Station (BTPS) ( 2X500 MW)

First Unit was commissioned during 2008 and the Second Unit was commissioned during 2012

Boilers and Turbine of all Units are of BHEL make

Third Unit of 700 MW Super critical of BHEL design is under erection and is scheduled for commissioning during early 2015.

Coal for BTPS is from the coal block in Maharashtra allocated to KPCL



In order to meet the ever growing energy demand of the State, KPCL is implementing the following projects in Joint Venture agreement with BHEL

Yermarus TPP ( 2 X 800 MW) - Super critical TechnologyErection of two Units is in progressSuper critical boilers are of ALSTHOM+BHEL Design Turbines are of SIEMENS+BHEL Design First Unit is scheduled for commissioning by early 2015 Second Unit by the end of 2015

Edlapur TPP ( 1 X 800MW)

KPCL has been allocated a coal block to meet the fuel requirement of both the above projects.



Renewable Energy Sources, 29462.55MW, 12.12%

NUCLEAR, 4780 MW, 1.97%

THERMAL,

168254.99 MW, 69.23%

HYDRO, 40531.41 MW, 16.68%

Installed capacity as on 31.03.2014

Total Installed capacity: 243028.95 MW

Present power Scenario


Details of Super-Critical Units in 10th , 11th , 12th &13th 5 Year PlansSub Critical

(MW)660 MW (No.)

800 MW (No.)

Super Critical (MW)

TOTAL MW

10th Plan 9620 0 0 0 962011th Plan 45470 7 1 5420 5089012th Plan 18270 25 33 42,900 61,17013th Plan 4000 36 36 52,560 56,560

Comparison between SubCritical & SuperCritical (MW)

9620

45470

18270

40000

5420

42,900

52,560

0

10000

20000

30000

40000

50000

60000

10th Plan 11th Plan 12th Plan 13th Plan

Total Subcritical (MW) Total Super critical (MW)

Power Projections


Bharat Heavy Electricals Limited (BHEL)

ISO 9001 - Quality Management System Certified

ISO 14001 - Environmental Management System Certified

OHSAS 18001 - Occupational Health & Safety Management System Certified

ISO/IEC 27001 - Information Security Management System (ISMS) CertifiedCorporate Office

Manufacturing Unit Service Centers

VIZAG


CONTROL & INSTRUMENTATION

TRANSMISSION

TRANSPORTATION

SOLAR CELLS & PHOTOVOLTAICS

CONTROL & INSTRUMENTATION

TRANSMISSION

TRANSPORTATION

SOLAR CELLS & PHOTOVOLTAICS

Electronics Division-Business Areas


BHEL has facilities and expertise for:• System engineering with maxDNA / Metso DNA• Manufacturing of maxDNA / Metso DNA modules• System Testing• Erection & Commissioning

• Cumulative Running hours has crossed over 30 Lakh Hours in over 270 units

• Engineering for all rating of sub critical up to 600 MW and supercritical up to 800 MW

• Total MW (maxDNA & Metso DNA) – 1,37,546 MW [118991+18555]

Brief Overview

BHEL-Electronics Division ties up with Metso Automation for DCS undercollaboration agreement for both maxDNA and Metso DNA.


Leader in Power plant DCS


THERMAL PLANTS (15 - 800MW)

• Boiler Controls• Turbine Controls• Station C&I• HMI• Power Plant SCADA• PADO (Performance Analysis

Diagnostics & Optimisation)• Offsite Balance Of Plant Controls

THERMAL PLANTS (15 - 800MW)

• Boiler Controls• Turbine Controls• Station C&I• HMI• Power Plant SCADA• PADO (Performance Analysis

Diagnostics & Optimisation)• Offsite Balance Of Plant Controls

HYDRO PLANTS (3 - 200MW)

• Auto Sequencer• Governor Controls• Remote Operation• HMI• Optimization Packages

HYDRO PLANTS (3 - 200MW)

• Auto Sequencer• Governor Controls• Remote Operation• HMI• Optimization Packages

CCPP PLANTS (21 – 1500MW)

• HRSG Controls• Steam Turbine Controls • Station C&I• HMI• Interface to Gas Turbines• Power Plant SCADA

CCPP PLANTS (21 – 1500MW)

• HRSG Controls• Steam Turbine Controls • Station C&I• HMI• Interface to Gas Turbines• Power Plant SCADA

Other Systems

• Interlocking in Excitation Systems• Interlocking in FSC / CSR / SVC /

STATCOM • Interlocking in VFD system

Other Systems

• Interlocking in Excitation Systems• Interlocking in FSC / CSR / SVC /

STATCOM • Interlocking in VFD system

(Advantage to Customer)(Advantage to Customer)

Unified solution for C&I from BHEL


Off-site Plant DCS

Ash Handing Plant Coal Handling Plant AC & Ventilation System DM PLANT Condensate & Polishing Units COLTCS Self Cleaning Strainer(SCS) WATER SYSTEM Flue Gas Desulphurization Mill Reject Systems Cooling Tower fan controls

Off-site Plant DCS

Ash Handing Plant Coal Handling Plant AC & Ventilation System DM PLANT Condensate & Polishing Units COLTCS Self Cleaning Strainer(SCS) WATER SYSTEM Flue Gas Desulphurization Mill Reject Systems Cooling Tower fan controls

Advantage to customer (Unified Solution)

• Common DCS platform for entire plant instead of separate PLCs• Ease of connectivity & maintenance• Monitoring & Operability – Local & Central • Inventory management • Familiarity for O&M Engineers

Advantage to customer (Unified Solution)

• Common DCS platform for entire plant instead of separate PLCs• Ease of connectivity & maintenance• Monitoring & Operability – Local & Central • Inventory management • Familiarity for O&M Engineers

DCS solutions from BHEL


Metso DNA Architecture

CONTROL ROOMOperation, Maintenance, Reporting

Firewall

Remote Connections

OFFICEReporting, Enterprise Integration

Metso DNA offers architecture for scalability, high availability and lifetime expandability and upgradeability.

AUTOMATION ROOMControls, Optimization, Connectivity

Engineering and Maintenance, Asset Management, DNA Historian

Distributed

FIELD FIELD

FIELD FIELD

Wireless solutions for operation and maintenance

One platform for all control applications • Integrates major field buses and field asset management

Centralized

Safety instrumented system

Star or ring topology redundant Ethernet network

Name based communication

No longer a concept….A reality

Metso DNA on Virtual Engineering Servers


Supercritical ProjectsPROJECTS Executed• Bara 3x660MW• Lalitpur Power Generation

Co.Ltd. (LPGCL) 3x660MW• Yeramaras 2x800 MW• Bellary Phase-3 1x700 MW

PROJECTS Under Execution• North Karanpura 3x660 MW • Suratgarh 2x660 MW• IB Valley 2x660 MW• Gadarwara 2x800 MW


PARAMETERS ABOVE CRITICAL STATE• STEAM PRESSURE > 221.2 BAR• STEAM TEMPERATURE > 374.15 Deg C

ULTRA SUPERCRITICAL PRESSURE(≥ 300 BAR)

INCREASE IN PRESSURE AND MAIN & REHEAT TEMP. > 537 Deg CRESULTS IN SIGNIFICANT IMPROVEMENT IN EFFICIENCY

05

1015202530354045

500 MW 660 MW

Sub critical170 ata / 537 °C / 537 °C

Super Critical247 ata / 565 °C / 593 °C

Impr

ovem

ent

4.3 %

Entropy

Tem

pera

ture

Super critical Cycles


Steam Power plant efficiency increases with increase in steam pressure and temperature.

Power plant Cycles operating above critical pressure (221.2 bar) are classified as Supercritical cycles.

With higher cycle efficiency, the supercritical cycle offers the advantage of ‘burn less fuel for the same output’ and lower emission.

Lesser Pollutants – SOX , NOX & CO2

Super critical Cycles


Super critical Power Plant Controls Configuration


Super critical Power Plant Graphics


Large Thermal Projects

• Sagardhighi 2x500 MW

Totally Metso DNA based, including CW/FOPH systems

Integrated system handles >19,000 physical I/Os and >300

operator displays

43 Pairs of ACN-CS Controllers

>1200 Drives10 OPS + 10 OPS - LVS + EAS +

EAC + INFO + 2 LIS

• Lalitpur 3x660 MW

Totally Metso DNA based, including Off-site systems

Integrated system handles >25,000 physical I/Os and >300

operator displays per unit

60 Pairs of ACN-CS Controllers

>1800 Drives per unit6 OPS + 6 OPS - LVS + EAS +2 EAC

+ INFO + 2 LIS


New Applications

Add on packages:– LVS Alarm Annunciation– Alarm Analysis System– ABT – Wireless Connectivity on maxNet– History replay– RPDM– IEC 60870-5-103 – Numerical Relay

Interface

RS 485

IEC-60870-5-103PROTOCOL

maxLinksStatus, Event and

Alarm display (online)

#

1

#

2

AHP

CHP

WTR

WTR

SA


Enlarging the wireless connectivity application

• WIRELESS CONNECTIVITY ON maxNet

CCR: Central Control Room: Latitude - 15°11'37.58"N

: Longitude - 76°43'8.40"E: Elevation – 1575ft

FOPH: Fuel Oil Pump House: Latitude -15°11'46.48"N: Longitude - 76°43'14.88"E: Elevation – 1576ft

CWPH: Cooling Water Pump House: Latitude -15°11'45.30"N

: Longitude - 76°43'4.01"E: Elevation – 1566ft

54Mbps RF Link2

25Mbps Throughput

54Mbps RF Link1

25Mbps Throughput

8 Kms Wireless link is under execution at NTPC Korba


OFF SITES IN DCS PLATFORM

Flue Gas Desulphurization Water Treatment Plant

HPCL import facility


OPERATOR ENGINEER maxSTORIAN maxLINK

RS485 CONVERTER

GIUs at Remote Locations

RPU PANEL

GIU(Graphical Interface Units) at 35 various field locations for assisting during Local operation –Interfaced through MODBUS

• 10” COLOR TFT SCREEN• IP-65 Case• FUNCTION

& NUMERIC KEYS

GIU(Graphical Interface Units)

Special Projects with maxDNA


Redundant maxNET (data highway)

EWSOWS-2

Control Panels(ECS RTU)

GT Control Room

DMP

Existing Control Room

HISTORIAN CIJP (A4/A3)

Rack Room

OWS-3

IRIG-B output from the existing Master clock

EWS( Portable)

OWS-1

Transducer panels

FOC

GT System SWITCHBOARD

To DHDT S/s Control Room (Approx. 500 meters)

To SRU S/s Control Room (Approx. 2000 meters)

FOC

FOC

maxLINKfor interfacing numerical relays on relay & metering LAN

To Existing Control Room (Approx. 1000 meters)

B/W LP (A4/A3)

LP (A4)

ECS Room Disturbance Analyser Node

Relay panels

• Reference list of projects – IOCL-Mathura 2005– IOCL-Bongaigaon 2009 – IOCL-Paradip 2011– GSPC-Kakinada 2011– OPaL-Dahej (under

commissioning)

ECS Experience


• Commissioning of R&M job done in record 32 days for RoparTPS - 210 MW - SG,TG & BOP C&I including re-cabling

• Commissioning of R&M job done in record 33 days for IBThermal – 210MW - SG,TG & BOP C&I

• Other R&M jobs: Vijayawada 210MW, Trombay 500MW,Tata Jojobera, Reliance Dahanu 250MW, Vizag Steel plant,15 Industrial Turbines ……..

R&M Projects with maxDNA

Special Projects with maxDNA

bhel super critical thermal power plant

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