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Super critical thermal power plants
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Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
KARNATAKA POWER CORPORATION LIMITED
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
– 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
KARNATAKA POWER CORPORATION LIMITED
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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.
KARNATAKA POWER CORPORATION LIMITED
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
CONTROL & INSTRUMENTATION
TRANSMISSION
TRANSPORTATION
SOLAR CELLS & PHOTOVOLTAICS
CONTROL & INSTRUMENTATION
TRANSMISSION
TRANSPORTATION
SOLAR CELLS & PHOTOVOLTAICS
Electronics Division-Business Areas
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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.
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
Leader in Power plant DCS
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
Super critical Power Plant Controls Configuration
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
Super critical Power Plant Graphics
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
OFF SITES IN DCS PLATFORM
Flue Gas Desulphurization Water Treatment Plant
HPCL import facility
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited
• 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
Brightening Lives .. Powering Progress..Touching Every Indian Home…Bharat Heavy Electricals LimitedKarnataka Power Corporation Limited