BHEL Super Critical Thermal Power Plant

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Bharat Heavy Electricals 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 MW
Thermal 2720 MW
Meets nearly 50% of States 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 Singareni
coalfields in Telangana, Western Coalfields in Maharashtra and Talcher
Coalfields 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 Technology
Erection of two Units is in progress
Super 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 10
th
, 11
th
, 12
th
&13
th
5 Year Plans
Sub Critical
(MW)
660
MW
(No.)
800
MW
(No.)
Super Critical
(MW)
TOTAL
MW
10
th
Plan 9620 0 0 0 9620
11
th
Plan 45470 7 1 5420 50890
12th Plan 18270 25 33 42,900 61,170
13
th
Plan 4000 36 36 52,560 56,560
Comparison between SubCritical & SuperCritical (MW)
9620
45470
18270
4000
0
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) Certified
Corporate Office
Manufacturing Unit
Service Centers
VI ZAG
CONTROL & INSTRUMENTATION
TRANSMISSION
TRANSPORTATION
SOLAR CELLS & PHOTOVOLTAICS
CONTROL & INSTRUMENTATION
TRANSMISSION
TRANSPORTATION
SOLAR CELLS & PHOTOVOLTAICS
Electronics Division-Business Areas
BHEL has facilities and expertise for:
Systemengineering with maxDNA / Metso DNA
Manufacturing of maxDNA / Metso DNA modules
SystemTesting
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 under
collaboration 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 ROOM
Operation, Maintenance, Reporting
Firewall
Remote
Connections
OFFICE
Reporting, Enterprise Integration
Metso DNA offers
architecture for
scalability, high
availability and
lifetime
expandability and
upgradeability.
AUTOMATION ROOM
Controls, 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 Projects
PROJECTS 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 C
RESULTS IN SIGNIFICANT IMPROVEMENT IN EFFICIENCY
0
5
10
15
20
25
30
35
40
45
500 MW 660 MW
Sub critical
170 ata / 537 C / 537 C
Super Critical
247 ata / 565 C / 593 C
I
m
p
r
o
v
e
m
e
n
t
4.3 %
Entropy
T
e
m
p
e
r
a
t
u
r
e
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 Drives
10 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 unit
6 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-60870-5-103
PROTOCOL
maxLinks
Status,
Event
and
Alarm
display
(online)
#
1
#
2
A
H
P
C
H
P
W
T
R
W
T
R
S
A
Enlarging the wireless connectivity application
WIRELESS CONNECTIVITY ON maxNet
CCR: Central Control Room
: Latitude - 1511'37.58"N
: Longitude - 7643'8.40"E
: Elevation 1575ft
FOPH: Fuel Oil Pump House
: Latitude -1511'46.48"N
: Longitude - 7643'14.88"E
: Elevation 1576ft
CWPH: Cooling Water Pump House
: Latitude -1511'45.30"N
: Longitude - 7643'4.01"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)
EWS
OWS-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
maxLINK
for 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 Ropar
TPS - 210 MW- SG,TG & BOP C&I including re-cabling
Commissioning of R&M job done in record 33 days for IB
Thermal 210MW- SG,TG & BOP C&I
Other R&Mjobs: 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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BHEL Super Critical Thermal Power Plant

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Brightening Lives .. Powering Progress..

Touching Every Indian Home

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