Balance of Plant Systems

1

Presentation to cover:

• Plant water balance

• Cooling water System

• Water treatment plant

• Condensate polishing unit

• Effluent treatment plant

• HVAC

• Fire protection system

2

Plant Water Balance• Plant water balance drg

• Drg shows:

� Source of water supply

� Water qualities

� Consumers for different qualities

� Flow rates

� Storages

� Effluents

• Use of PWB� Plan for raw water supply

� Sizing of piping, pumps, storages

� Plan for effluents treatment / disposal

� Water consumption optimisation

� Storage sizes for use in plot plan

� Development of Plot Plan

3

Cooling Water System• Condenser cooling water system

– To remove heat of condensation from the condenser• Closed Cycle System

• Open Cycle system

– Major equipments / buildings:• CW PH

• CW Pumps

• Condenser

• Cooling towers

• Make up system

• Blow down system

• Tube cleaning system

• Debris filter system

• Chlorination system

– Flow rate 30000, 58000, 70000 m3/h for 250, 500 and 660 MW units

– Temperature rise 8.5 to 10 C

– Flow velocity in pipe 2 – 2.6 m/s

• Auxiliary cooling water system

• Closed cycle cooling water system

4

Water treatment

• Water analysis

• Pre-treatment

– Clarifier (To remove turbidity to a level of 15 parts per million -ppm)

• Chemicals used:

– Alum

– Lime

– PE

• Aeration

• Coagulation

• Flocculation

– Filteration (To remove turbidity to a level of 2 to 5 ppm)

• No chemical dosing

• Multi-grade gravity or pressure filter

5

Water treatment• Dissolved solids in water:

– Cations• Na, Ca, Mg, K, Fe etc

– Anions• HCO3, CO3, OH, Cl, SO4, NO3 etc

• Demineralisation – To remove color, smell (ACF)

– To remove Cations (SAC, WAC)

– To remove Anions (SBA, WBA)

– Treated water (DM) analysis• pH 6.8 to 7.2• Conductivity 0.1 microS / cm• Silica 0.01 to 0.02 mg/L as SiO2

• Chemicals used:– Acid

– Alkali

– Technologies:• Cation, Anion, Mix-bed exchangers• Reverse-Osmosis and Mix-Bed technology

6

Water treatment

• Chlorination (to dose active chlorine solution)

– To control

• Bio growth

• Biological Oxygen Demand

– Chlorination is done in:

• Raw water intake

• Pre-treatment plant

• CW system

• Potable water

– Technologies:

• Gas chlorination

• Electro-chlorination

- Chlorination dosing rates

7

Condensate Polishing Unit• Power Cycle System flow Scheme

– Typical Water quality in power cycle system

CPU Inlet CPU-Outlet (maximum)

• Conductivity 0.1 microS / cm

• pH 8.8 to 9.3 -• Total dissolved solids 95 25 ppb

• Ammonia 100 -

• Chlorides 10 2 ppb

• SiO2 20 5 ppb

• Crud (start up) 500 70 ppb• Cu 5 3 ppb

• Fe 50 5 ppb

• Na (CW leakage) 2000 20 ppb

– Source of impurities:• DM make up

• Corrosion products

• CW system leak

• Potable water

– Technologies:• Cation-Anion Mix-bed (Resin Ion Exchange)

8

Effluent Treatment Plant• Central Pollution Control Board (CPCB), State Pollution Control Boards (SPCBs)

• ETP Diagram

• Sources of liquid effluents– Condenser CW system blow down

– Boiler blow-down– DM Plant / CPU regeneration waste

– Clarifier sludge

– Filter back wash

– Oily effluent

– Service / potable water / STP waste

• Process– Collection of effluents

– API / TPI for oily Effluents– Lamella for removing turbidity

– Collection in Central Monitoring Basin

– Reuse without further treatment

– Treatment for reuse

• Permissible limits for disposal of liquid effluents:– PH 6.5 to 8.5

– Suspended solids < 100 ppm– Oil and grease < 5 – 10 ppm

– Residual Chlorine < 0. 5 ppm

– Temperature 5 - 7 C

9

Heating Ventilation and Air-Conditioning• Air Conditioning

– For comfort

– Requisite environment for instruments and equipment

– Diagram

• Ambient conditions for Summer, Winter and Rainy-season are site specific data

• Conditioned environment:– Dry bulb-temperature 22 to 24 C

– Humidity 50 + - 5%

• A/C is provided for:– Main control-room

– ESP control room

– CHP, AHP control rooms

– Control room having Electronic equipments

– Laboratory– Office accommodation – customer specific

• Major equipments:– Chiller

– CT system

– Air Handling Unit

– Ducting

– Heating system

10

Heating Ventilation and Air-Conditioning• Ventilation

– For comfort

– Air quality (Air changes)

– Diagram

• Ambient conditions for Summer are site specific data

• Evaporative Cooling System for Turbine hall– Fan

– Ducting

– Air Washer

– Water system

• Air changes:– Laboratory 10

– Toilets, Pantries 15

– Chemical house 15

– Pump-houses 15

– TG hall 6

– Canteen 20

11

Fire Detection and Protection System• Codes

– Tariff Advisory Committee - TAC (India)

– National Fire Protection Association - USA (NFPA) for contracts outside India

• Category of Hazard (TAC)

– Coal fired Power Plants Ordinary hazard

– Open Cycle Gas Turbine Projects Ordinary hazard

– Combined cycle power project Ordinary hazard

– Sub-stations Light hazard

– Hydro-projects Light hazard

• Systems – Hydrant System (Drawing)

– Spray system (Drg)

– Foam System (Drg)

– Portable / mobile (Fire Extinguishers, Fire –tender)

• Major buildings / Equipments:– Fire water PH

– Hydrant Pumps

– Jockey pumps

– Spray water pumps

– Ring mains

– Hydrant / water monitors

– Risers and hose rolls

– Detection system

– Control and monitoring system

124.183.73mg/lIron as Fe24

BDLBDLmg/lCopper as Cu23

BDLBDLmg/lBOD (3 days)22

6.66.9mg/lDissolved oxygen21

24005300umohs/cmConductivity @ 25 degC20

12080NTUTurbidity19

14903408mg/lTotal Dissolved Solids18

286179mg/lSuspended Solids17

119.7mg/lDissolved Silica16

400716716mg/lTotal Hardness as CaCo314

NILNILmg/lPhenolp Alkalinity as CaCo313

169165165mg/lMethyl Orange alkalinity as CaCo312

2.433.790123.07mg/lNitrate as CaCo311

5472.115475mg/lSulphate as CaCo310

10241835.462588mg/lChloride as CaCo39

NILNILmg/lCarbonates as CaCo38

169201.22165mg/lBicarbonates as CaCo37

21.823.203129.7mg/lPotassium as CaCo35

817957.3392087mg/lSodium as CaCo34

240102.041500mg/lMagnesium as CaCo33

16086.4216mg/lCalcium as CaCo32

8.18.........pH1

21/02/07UnitParameterS. No

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34