Download - Power Plant Engg Processes
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COMPLETE BUSINESS PROCESS INVOLVES FOLLOWING MAIN ACTIVITIES -
STUDY OF TENDER DOC. , SITE VISIT, COLLECTION AND STUDY OF SITE DATA .
PROCESS OPTIMISATION & SELECTION OF POWER PLANT EQUIPMENTS.
SUBMISSION OF OFFER BY THE MARKETTING GROUP ( RECEIPT OF ORDER )
DESIGN , MANUFACTURE & SUPPLY OF MAIN EQUIPMENTS FROM VARIOUS BHEL
MANUFACTURING UNITS TO SITE.
BASIC DESIGN / SIZING , PROCUREMENT & SUPPLY TO SITE OF THE BALANCE OF
PLANT ( BOP ) EQUIPMENTS FROM VENDORS’ WORKS .
ERECTION & COMMISSIONING BY THE ERECTION AGENCY OF THE PLANT BUILDINGS,
EQUIPMENTS AND FACILITIES AT SITE.
CONDUCTING PERFORMANCE GUARANTEE OF PLANT / EQUIPMENTS.
COMMERCIAL CLOSURE & HANDING OVER OF THE PLANT TO CUSTOMER .
ALL ACTIVITIES REQUIRE COMPLETION AS PER AGREED SCHEDULE.
BHEL CONSTR. GROUPTEMP. SITE OFFICE OF
PLANT AREA - BY CUSTOMER
BHEL MANUF. UNITS
VENDORS’ WORKS
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SELECTION OF MAIN POWER GENERATING EQUIPMENTS WITH ITS INTEGRAL SYSTEMS
STEAM TURBINE , GENERATOR & BOILER
- ( FUELS AVAILABLITY - COAL / OIL / PET- COKE FOR BOILER )
GAS TURBINE , GENERATOR & HRSG
- ( FUELS AVAILABLITY – GAS / LIQUID FOR GAS TURBINE )
HYDRO TURBINE GENERATOR
- ( AVAILABLITY - WATER HEADS / DAMS )
NUCLEAR STEAM TURBINE , GENERATOR
- ( AVAILABLITY - NUCLEAR FUEL REACTOR & STEAM GENERATOR )
PRIMARY INVOLVEMENT OF ENGG. GROUP – PRODUCT ENGINEERING.
PROCESS OPTIMISATION , SYSTEM INTEGRATION , SELECTION OF BOP EQUIPMENTS FOR MECH., ELECTR. & C&I SYSTEMS
EQUIPMENTS SELECTION & ENGG. ACTIVITIES TO SUIT THE OPTIMISED
PROCESS NEEDS OF THE POWER PLANT. SYSTEM INTEGRATION ACTIVITIES.
PRIMARY INVOLVEMENT OF ENGG. GROUP – PROJECT ENGG. DIV.
( PLANT SYSTEMS INTEGRATORS )
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TRNSM. GRID 132 kV
GR -11 kV
TR
BD
100 MW
STEAM TURBINE GENERATOR UNIT BUS DUCT FROM GENERATOR BUS DUCT-TRANSFORMER - SW. YARD.
STEAM TURBINE BASED POWER PLANT
STEAM GENERATOR ( BOILER )
ST
300 tph / 100 bar, @535 Deg-C
0.095 bar@ 45 Deg-C
PARAMETERS INDICATED
ARE TYPICAL
CW@ 42°C
PUMP
CW@ 33°C
CONDENSER
D/A
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FUEL TO GT(100 %)
GAS TURBINE
POWER (25.3 %) EXHAUST HEAT LOSS THRU’ STACK ( 71. 2% )
ENERGY DIAGRAM
GAS TURBINE BASED POWER PLANT- Simple Cycle
Typical – 26 MW - AT 38 °C, 60% RH, 50 m above MSL
BLOCK DIAGRAM
Gass
575 ° C
1100 ° C
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ENERGY DIAGRAM
FUELTO GT(92.8 %)
GAS TURBINE
POWER (24.3%)
MISCL. LOSSES (3.1%)
EXHAUSTHEAT
(65.4%)
HEAT RECOVERY STEAM GENERATOR
FUEL 7.2%)
STACKLOSSES(29.9%) STEAM OUTPUT
TO PROCESS (40.6 %)
MISC. & RADIATION
LOSSES IN HRSG ( 2 .1% )
GAS TURBINE BASED POWER PLANT- Co-Generation Cycle
Gas
BLOCK DIAGRAM
HEAT RECOVERY STEAM GENERATOR ( HRSG )
135 ° C575 ° C
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GAS TURBINE BASED POWER PLANT- Combined Cycle
FUEL Q =100 %
LOSSES IN STEAMTURBINE = 0.3 %
GAS TURBINE
STEAM TURBINE
POWER = 20.1 % POWER = 37.6 %
LOSSES IN GT = 0..5 %
LOSSES IN STEAM GENERATOR = 0.2 % THRU’ STACK OF STEAM
GENERATOR = 11.4 %
CONDENSER OF STEAM TURBINE= 29.9 %
ENERGY DIAGRAM Plant Perf. optimisation –
GT- PRO
Gas
BLOCK DIAGRAM
135 ° C575 ° C
HEAT RECOVERY STEAM GENERATOR ( HRSG )
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GT AIR FILTER
FR 6 FA GAS TURBINE UNIT
GAS TURBINE GENERATOR
BY-PASS STACKHRSG UNIT
PIPING
STG BUILDING
STG UNIT
SWITCH YARD AREAFR 6 FA GT Based
100 MW Combined Cycle Power Plant
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FUEL SYSTEMS ( BOP ) FOR GAS TURBINE
GAS TURBINE ( SHOWN WITHOUT ENCLOSURE )
GAS FUEL DISTRIBUTION POINT
GAS CONDITIONING SKID
GAS BOOSTER COMPRESSOR
SYSTEM
17 – 30 barg
LIQUID FUEL STORAGE TANKS
LIQUID FUEL FORWARDING SKID
2.8 – 3.8 barg
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MECHANICAL BOP
& PIPING SYSTEMS
BOILER FEED PUMPS
DM PLANT
MECHANICAL EQUIPMENTS, INTER CONNECTING PIPING
& PIPE RACKS
COOLING TOWER
PIPING DESIGN – STRESS ANALYSIS & ISOMETRIC DRGS.
PDMS – CEASER / CAEPIPE
PIPING ON PIPE RACK
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ELECTRICAL BOP SYSTEMS
ELECTRICAL LOADS
PUMPS / Other EL. DRIVES
MOV s
PLANT DIGITAL CONTROL SYSTEM
( DCS )
ELECTRICAL CONTROL SYSTEM
INTERCONNECTING CABLING HT & LT PMCC ROOM
BUS DUCTS & TRANSFORMERS
SWITCH YARD
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CONTROL & INSTRUMENTATIONS
BOP SYSTEMS
LARGE VIDEO SCREEN
PLANT DIGITAL CONTROL SYSTEM ( DCS )
DIGITAL CONTROL SYSTEM PANELS
FIELD INSTRUMENTATION
D - I / O
A - I / O
M /Box
DCS CONSOLES –IN CENTRAL CONTROL ROOM
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CIVIL ENGG. SOIL INVESTIGATION AT SITE
STARTING OF 140 MW POWER PLANT IN DESERT SITE AT QARN ALAM ( OMAN )
COMPLETED 140 MW POWER PLANT
AT QARN ALAM ( OMAN )
100 m MULTI-FLUE RCC STACK
CONSTRUCTION OF POWER PLANT BLDG. ( SITE SUPPORT )
PIPE RACK STRUCTURES
STRUCTURAL ANALYSIS
STAAD.Pro
STRUC. CONSTRUCTION AT SITE
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PG-TEST UNDER PROGRESS AT 100 MW COMBINED CYCLE POWER PLANT AT
KOVILKALAPPAL ( TAMILNADU )
GAS TURBINES UNDER COMMISSIONING FROM 600 kms AWAY REMOTE CONTROL
STATION AT YIBAL( OMAN )
PERFORMANCE GUARANTEE TEST BY DESIGNERS AT SITES
REF.
S - CYCLE C- CYCLE
O / P
(MW)
H R
(Kcal/kWh)
Aux-Power
(kw)
O / P
(MW)
H R
(Kcal/kWh)
Aux-Power
(kw)
Guarntee 70.250 2565.0 2967.0 107.8800 1670.00 5102.00
PG-Test Result
74.778 2265.6 2265.6 110.5173 1630.49 4384.89
TYPICAL PG TEST DATA
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WHAT A DESIGNER SHALL ENDEAVOR :
CONTINUOUS UPGARADATION OF ENGG. EXPERTISE & AWARENESS OF LATEST
ENGG. ADVANCEMENTS.
CONVERSANT WITH DESIGN CODES REQUIRED FOR COMPLIANCES-
( ASME, API , BS, DIN, ISO , IEC , IEEE , NEMA, NFPA, HTRI, HIS, IS ( BIS ), TAC, OISD, IBR,
Indian Electricity Rules, HSE Regulations etc. )
FAMILIARITY WITH THE TECHNICAL REQUIREMENTS SPECIFIED BY CUSTOMER
IN THE PROJECT TENDER SPECIFICATION DOCUMENTS.
APTITUDE FOR CALCULATIONS, DOCUMENTATION WORK & EYE FOR DETAILS.
CONTINUOUS ENHANCEMENT OF DOC. DRAFTING METHODS, COMMUNICATION SKILLS.
DISCIPLINED ATTITUDE IN –
ENGG. DOCUMENTATION PREPARATION
DRGS. & DOC. RELEASE FOR MANUFACTURING ( To Shop / To Vendor )
DRGS. & DOC. RELEASE FOR CONSTRUCTIONS AT SITE.
DOCUMENTATION CONTROL METHODS.
APTITUDE FOR LEARNING FROM EXPERIENCES. KM, TO SHARE LEARNING.
INNOVATE & OVERCOME THE ENGG. CHALLENGES FOR TOMORROW – FOR
PROJECTS IN INDIA & ABROAD.
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THANK YOU