Documente Academic
Documente Profesional
Documente Cultură
SUBMITTED BY
Dev Anand
B.TECH. Mechanical Engineering
SESSION: 2015-2019
Shiv Nadar University
ACKNOWLEDGEMENT
Dev Anand
Summer Training
CONTENTS
1. Introduction
2. MPL Department
2.1 Stress Analysis
2.2 ME Bellows
2.3 Thermal Insulation
3. MAUX Department
3.1 Compressors
3.2 Treatment of Compressed Air
3.3 Dryer
4. MSE Department
4.1 Power Cycle
4.2 Water Cycle
BHEL
BHEL is the largest engineering and manufacturing enterprise in India in the energy
related/infrastructure sector, today. BHEL manufactures over 180 products under 30 major
product groups and caters to core sectors of the Indian Economy viz., Power Generation and
transmission, Industry, Transportation, Telecommunication, Renewable Energy, etc.
BHELs growth has been synchronous with achieving self-sufficiency in indigenous
manufacturing of heavy electrical equipment. Out of the available 35,000 MW per annum
capacity for power plant equipment manufacturing in the country, BHEL constitutes a
mammoth 20,000MW per annum capacity.
BHEL is one of the few companies in the world having the capability to manufacture the
entire range of power plant equipment and has proven turnkey abilities for executing power
projects from concept-to-commissioning. The power generation sector comprises Thermal,
Gas, Hydro and Nuclear power plants.
Bharat Heavy Electricals Limited (BHEL) is Indias largest engineering and manufacturing
enterprise in the energy related infrastructure sector. BHEL caters to the core sectors of
Indian economy, such as Power Generation and Transmission, Industry, Transportation,
Renewable Energy, Defence, etc. For the power generation segment, BHEL manufactures
and supplies major capital equipment and systems for thermal, gas, hydro and nuclear power
plant business like steam generators and auxiliaries, steam turbines, generators and
auxiliaries, gas turbines, transformers, switchgear, heat exchangers, pumps, motors,
electrostatic precipitators, control and instrumentation systems, etc.
Project Engineering Management (PEM) Division is BHELs power plant System Integrator,
a nodal agency providing total engineering solutions for conventional thermal and gas based
power projects and conventional island of nuclear power plant, enabling BHEL to offer
complete Engineering, Procurement and Construction (EPC) services for power projects.
PEM was born in 1974 as Consultancy Services Division (CSD) to address the market
demand for turnkey services in power and related areas. Rechristened in 1976 as Projects
Engineering Division (PED), the division has been known as Project Engineering
Management (PEM) since 1984 onwards.
MECHANICAL & IPDS
a) Mechanical Piping and Layout (MPL)
It is an extensive department which carries out the function of structuring the power plant.
Preparation of plot plan is the first engineering activity which is carried out on receipt of LOI,
followed by preparation of MEP, equipment layout, floor wise composite drawings, isometrics,
stress analysis of piping supports and hangers, preparation of insulation, cost estimation of ME
Bellows and procurement of valves from vendors.
b) Mechanical Systems Engineering (MSE)
MSE Department is an engineering department responsible for proposal & contracts
engineering, preparation of feasibility reports, site assistance including customers complaint &
other development works. It does power cycle system engineering which includes preparation of
Heat Balance Diagrams, guarantee schedules, thermal calculations and performance guarantee
(PG) test procedures & computation methods. It also carries out water system engineering,
preparation of pipe schedule and valve schedule.
c) Mechanical Auxiliaries (MAUX)
Various water quantities requirement such as Chlorination, side stream filtration, dosing etc. are
furnished by MAX and these quantities are inputs required for designing the system on our end.
Water losses in DM plant/clarifiers are also given by the MAX dept.
d) IPDS
IPDS stands for Integrated Plant Design System. Basic functions are as follows:
PDMS/ 3D Modelling support and System Administration
Knowledge Based Engineering [KBE] & Plant Life Cycle Management [PLM]
related work and coordination.
MECHANICAL PIPING AND LAYOUT (MPL)
Bypass system and Feed water system), Power Cycle & LP piping
(including Yard
Piping)
Development of Piping Isometrics
Static (stress and flexibility) analysis of piping
Dynamic analysis of critical piping systems carrying very high
temperature & pressure fluids
Designing of hanger & supports of various pipings
Designing & engineering procurement assistance for:
i. Thermal Insulation
ii. Metallic Bellows & Rubber Expansion joints
iii. Power cycle (Non-Trichy supply) & low pressure valves
iv. GRP piping
Stress Analysis
Thermal Expansion
Weight and Pressure
Valve
TYPE OF ME BELLOWS
Using these kinds of movements enables us to produce different
kinds of expansion joints.
a) UNTIED BELLOWS:
b) TIED BELLOWS:
These expansion joints are generally designed to accommodate
lateral movement only. The addition of tie rods to a Single Bellows
Assembly adds design flexibility to a piping system. The tie rods are
attached to the pipe or flange with lugs that carry the pressure thrust
of the system, eliminating the need for main anchors. With the
assembly tied, the ability to absorb axial growth is lost. Only lateral
and angular movement can be absorbed with the tied expansion joint.
In universal tied bellows, two bellows are separated by a pipe spool
and tie rods designed to contain the pressure thrust force.
These expansion joints contain hinges or pivots which cause the unit
to bend in a single plane. When a Hinged Expansion Joint is used,
movement is limited to angulation in one plane. Single bellows with
overall length restrained by hinge hardware designed to
accommodate pressure thrust. The basic element of hinged expansion
joint is a flexible thin corrugated stainless steel bellow element.
Contrary to axial expansion joints, the bellows of hinged expansion
joint does not work in the direction of pipe axis i.e. by elongation or
compression but in angular rotation in one plane. A pair of pins
through the hinge plate attached to the expansion joint end will
absorb the reaction force as well as limit the angular rotation.
According to the desired deflection, the expansion joint will be
longer or shorter. Hinged expansion joints are provided with the weld
ends for direct weld connection with the piping.
Thermal Insulation
1. INTRODUCTION
In a thermal power station or process plant, thermal insulation or heat lagging
of piping and equipment carrying hot fluids is essential for heat economy and
protection of operating personnel. Any pipe which is at a temperature higher
than its surroundings will lose heat and the amount of heat lost will depend
upon the temperature of the fluid and the thermal conductivity of the piping
material / covering.
4. EFFECT OF EMISSIVITY
Heat coming on top of insulation is emitted out.
Polished surface will emit maximum heat (Aluminum)
Aluminum calls for higher thickness, GI, & Color Coated GI Sheet
lower
thickness
Old aluminum will emit lower heat as compared to new sheet.
MECHANICAL AUXILARIES (MAUX)
Compressor
A gas compressor is a mechanical device that increases the pressure of a gas by
reducing its volume. An air compressor is a specific type of gas compressor.
Compressors are similar to pumps: both increase the pressure on a fluid and
both can transport the fluid through a pipe. As gases are compressible, the
compressor also reduces the volume of a gas.
Types of Compressors
Dynamic compressors
In a dynamic compressor, the pressure increase takes place while the gas flows.
The flowing gas accelerates to a high velocity by means of the rotating blades
on an impeller. The velocity of the gas is subsequently transformed into static
pressure when it is forced to decelerate under expansion in a diffuser.
Depending on the main direction of the gas flow used, these compressors are
called radial or axial compressors.
Centrifugal compressors
Displacement compressors
A displacement compressor encloses a volume of gas or air and then increases
the pressure by reducing the enclosed volume through the displacement of one
or more moving members.
The twin screw elements main parts are the male and female rotors, which
rotate in opposite directions while the volume between them and the housing
decreases. Each screw element has a fixed, build-in pressure ratio that is
dependent on its length, the pitch of the screw and the form of the discharge
port. To attain maximum efficiency, the build-in pressure ratio must be adapted
to the required working pressure. The screw compressor is generally not
equipped with valves and has no mechanical forces that cause unbalance. This
means it can work at a high shaft speed and can combine a large flow rate with
small exterior dimensions. An axial acting force, dependent on the pressure
difference between the inlet and outlet, must be overcome by the bearings.
Instrument air is clean and dry, having been filtered for both particulate and
moisture, Instrument air needs to be clean and dry, for pneumatic
instrumentation. This is important for say, a control valve positioner where the
feedback baffle/nozzle can be plugged off by dirt. Moisture free air is called
service air
All atmospheric air contains water vapour: more at high temperatures and less
at lower temperatures. When the air is compressed the water concentration
increases.
The term pressure dew point (PDP) is used to describe the water content in
the compressed air. It is the temperature at which water vapor condenses into
water at the current working pressure. Low PDP values indicate small amounts
of water vapour in the compressed air.
A special type of HOC dryer is the rotary drum adsorption dryer. This type of
dryer has a rotating drum filled with desiccant of which one sector (a quarter)
is regenerated by means of a partial flow of hot compressed air (at 130200C)
from the compressor. Regenerated air is subsequently cooled, the condensation
is drained and the air is returned via an ejector device into the main compressed
air flow. The rest of the drum surface (three-quarters) is used to dry the
compressed air coming from the compressor after-cooler. A HOC dryer avoids
compressed air loss, and the power requirement is limited to that required for
rotating the drum. For example, a dryer with a capacity of 1000 l/s only
consumes 120 W of electrical power. In addition, no compressed air is lost and
neither oil filters nor particle filters are required.
Refrigerant dryer
Refrigerant drying means that the compressed air is cooled, which allows a
large amount of the water to condense and be separated. After cooling and
condensing, the compressed air is reheated to around room temperature so that
condensation does not form on the outside of the pipe system. This heat
exchange between ingoing and outgoing compressed air also reduces the
temperature of the incoming compressed air, and as such reduces the required
cooling capacity of the refrigerant circuit. Cooling the compressed air takes
place via a closed refrigerant system. Refrigerant dryers are used for dew
points between +2C to +10C and have a lower limit, which is the freezing
point of the condensed water. Modern refrigerant dryers use refrigerant gases
with a low Global Warming Potential (GWP), which means refrigerant gases
that -when accidentally released into the atmosphere- contribute less to global
warming. Future refrigerants will have an even lower GWP value, as dictated
by environmental legislation.
In my project we use the refrigerant R404A.
160/8.
5
Air
Refrigerant
Cooler 45/8.2
Cooler
Compressor
Generally one of the following two types of condenser cooling water system is being
used in a power plant
1. Open Cycle Cooling Water System
2. Closed Cycle Cooling Water System
3. Combined Cooling Water System
Open Cycle Cooling Water System is generally used where cooling water is available
in abundance. The likely sites are:
a) Power station located on sea coast
b) Power station located:
Near large reservoir.
Near a river or canal with perennial water supply.
Closed Cycle Cooling Water System is adopted in situation where open cycle is not
feasible. Due to limited water supply resources, closed cooling system is more often
used. External water supply requirement in this case, is for make-up, to CW system
and it may amount to sum of
a) Evaporation loss from cooling tower
b) Drift loss
c) Blow down from cooling tower to maintain water quality, it being generally
used for ash disposal system requirements.
Combined Cooling Water System is used in such plant locations where in adequate
water supply is assured for only a part of the year. In this system the open cycle is
used when adequate water supply is available and closed cycle is used when water
supply is limited.
Power Plant condenser is essentially a shell and tube exchanger. The function of
condenser is to condense exhaust steam for the steam turbine.
Rejecting the heat of vaporization to the circulating water condenses steam from the
turbine. The condenser is a steam to water, tube and shell heat exchanger with the
cooling water passing through the tubes and steam in the shell. Most of the
condensers are generally two pass type. In two pass type condensers, the cooling
water enters the inlet water box at one end of the shell and passes through the tube
bundle consisting of half the total number of tubes. If then exists the tubes into the
return water box, from that the water passes through the other half of the tubes
existing from the outlet water box at the same end of the shell as inlet water inbox.
Cooling water pumps supply cooling water at the required flow rate and head to the
power plant condenser and the plant auxiliary cooling water heat exchangers. These
pumps are high capacity low head pumps. Cooling water pumps are generally of
vertical wet pit type. Vertical wet pit pumps are typically of the mixed flow, single
stage & single suction type for cooling water service. Vertical wet pit pumps use a
vertical, internally lubricated shaft to drive the impeller. The pump is partially
submersed in a wet pit with the motor mounted directly over the pump above the
water level. Vertical wet pit pumps may be of pull-out or non-pull-out design. Pull-
out design allows the rotating elements and critical non-rotating components such as
impeller shroud and pump bowl/diffuser/volute to be quickly removed without
removing the column or disconnecting the pump discharge. However in non-pull-out
type the disassembly is more difficult and requires a longer pump outage. The
discharge of these pumps could be above floor or above ground discharge indicating
the discharge is above base plate, whereas a below floor discharge refers to the
opposition.
Debris Filters:
The debris filter is provided at the inlet of each CW inlet pipe to the condenser. The
debris filter is provided to remove debris of size 10 mm, debris in the Cooling Water
is collected at the inner surface of screen housed inside the filter. On line automatic
back washing arrangement back washing arrangement is also provided with flushing
pumps to avoid clogging.