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Power Plant

This document summarizes a presentation about the ARL power plant. It discusses the old power plant with three 2.5 MW generators and the new power plant with three 6.8 MW generators. It describes the basic workings of generators, alternators, and diesel engines. It also provides details about the various control systems, software, and panels used to operate and monitor the power plants, including the generator control panel, common control panel, and engine start/stop processes.

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Muhammad Faizan
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© © All Rights Reserved
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460 views42 pages

Power Plant

This document summarizes a presentation about the ARL power plant. It discusses the old power plant with three 2.5 MW generators and the new power plant with three 6.8 MW generators. It describes the basic workings of generators, alternators, and diesel engines. It also provides details about the various control systems, software, and panels used to operate and monitor the power plants, including the generator control panel, common control panel, and engine start/stop processes.

Uploaded by

Muhammad Faizan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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ARL Power Plant

Presentation
By: Arhum Anjum
Trainee Engineer (E&I)
Contents
► ARL power plant.
► New power plant.
► Old/existing power plant.
► Generator.
► Working of alternator.
► Working of diesel engine.
► Single line diagram.
► Software and PLC used.
► Auxiliaries Systems of plant and engine.
► SaCos one.
► Generator control.
► CCP.
► Engine Start/Stop, load control and synchronization.
ARL Power Plant

► Two power plants in ARL


• Old/Existing Power Plant
• New Power Plant
Old Power Plant

► Three generators of 2.5 MW each.


► Total Capacity of 7.5 MW.
► Engines made by SsangYong.
► Alternator made by Leroy Somer.
► 11KV output voltage.
New Power Plant

► Three generators of 6.8 MW each.


► Total Capacity of 20.4 MW.
► Engines made by MAN.
► Alternator made by ABB.
► 11KV output voltage
► BSDG-Black Start Diesel Generator of
320KW(Alternator by Bukuk Corporation & Engine
by Doosan Electric)
► Used during blackout to power up auxiliaries.
Generator
► Electromechanical device that converts mechanical power to
electrical power.
► Prime mover connected to a generator.
► Mechanical power can come from different sources.
► Generator comprises of two main parts:-
Working of Alternator

96V
Working of Diesel Engine

► Internal combustion engine.


► Four stroke diesel engine.(Intake, compression, power/combustion, exhaust)
► Intake stroke: Intake valves open letting in air moving the piston down.
► Compression stroke: Piston moves back & compresses air. Compression of air
increases temperature of air.
► Combustion stroke: As the piston reaches the top, fuel is injected at the
right time, ignited, forces the piston move back.
► Exhaust stroke: Piston moves back to the top, pushing out the exhaust
created from the combustion out of the exhaust value.
Engine Specifications
MAN 14V32/40 Generator
Overview of instruments being used on Engine
WHRB (waste heat recovery boiler)
• Attached at exhaust of engine.
Single line diagram of Power Plant
Software's used in PPE
Software Usage Make

Simatic Step 7 V5.5 Programming for S7-400 i.e New Siemens


plant PLCs

Simatic WinCC V7.2 (CCP) Graphics/HMI Siemens

Power OS (GCP) Graphics/HMI MAN

Rs Logic Programming for PLC 5 i.e old Allen Bradley


plant PLCs

Kepserver For linking old PLCs with new PLCs kepware

SaCoS one Expert MAN engine programming MAN


PLC used in New PPE
Panel Model Make
SIP/SAP CAN Bus(protocol) -
GCP S7-400 Siemens
CCP S7-400H Siemens
Load CCP SYMAP Stucke elektronik
Synchro CCP SYMAP Stucke elektronik
Fuel oil booster Module S7-1200 Siemens
Lube oil module X20CP-0292 B&R
Auxiliary systems

► Auxiliary systems are systems that are vital for


the operation of our engine.
► For e.g. the systems that provide Fuel and lube
oil to our engine are included in auxiliary systems.
► They aren’t considered a main part of our engine.
Auxiliary systems Engine
► Auxiliary systems of engine are systems that are unique to each engine.
1. Lube Oil service system:
► Lube oil module:-
► Lube oil replenish flow rate measurement device:-
► Lube oil separator module:-
► Oil mist eliminator:-
2. HT cooling water system:
► HT cooling-down preheating pump:-
► HT cooling water temperature regulating valve:-
► Expansion tanks for HT LT cooling water:-
3. LT cooling water system:
► LT cooling water temperature control valve:-
4. Circuit radiator cooling system:-
► HT-LT radiator coolers:-
5. Fuel oil system:
► Fuel oil booster module:-
6. Intake air system:
► Intake air filter unit:-
► Charge air blow off system:-
7. Engine exhaust gas system:
► Expansion joint downstream of each turbocharger:-
Auxiliary Systems Plant
► Auxiliary systems of plant are designed to work on the whole plant.
1. Lube oil supply system:
► Lube oil supply pump:-
2. HT cooling water supply system:
3. Fuel injection nozzle cooling system:
► Fuel injection nozzle cooling module:-
4. Fuel system supply and discharge:
► Leakage oil module:-
5. Fuel Treatment and supply unit:
► HFO separator module:-
► HFO supply pump module:-
► DFO supply pump module:-
► Fuel oil filter module:-
► DFO filter module:-
► Pressure limit valve throttle valve HFO:-
► Pressure limit valve throttle valve DFO:-
6. Starting air receiver (30Bar):
► Starting air receiver:-
► Draining equipment(air receiver):-
► Compressor module E-motor driven:-
SaCoSone
► Safety and control system on Engine.
► Include:
• Control Unit
• Safety Module – Generates alarm and engine tripping.
• Alarm Module – Generates alarm only.
• Local Operating Panel
• SIP (SaCoS Interface Panel)
• SAP (SaCoS Auxiliary panel)
• Houses Governor (By Woodward) of engine.
• Governor controls speed of engine by regulating fuel input.
• Governor controls frequency and active power.
SaCoSone
Communication
Generator Control
► GIP – Generator interface panel.
► GIP houses AVR(Automatic voltage regulator)
► AVR by Basler Electric.
► AVR controls voltage and reactive
power.

► GCP - Generator control panel.


► Automatic Synchronization unit – for
Synchronization of generator.
Charge air blow off valve
▪ Used to release excess
air.
Generator communication
► Using optical fiber from SIP to GCP.
► Optical fiber:-
► Immune to noises.
► Long distance so loss of signals in less and communication is faster.
CCP
Location of Panels
Panel Location
Control Unit On engine
SaCoS interfacing panel (SIP) Engine hall near generator
SaCoS auxiliary panel (SAP) Engine hall near generator
Generator interfacing panel (GIP) Engine hall near generator

Generator control panel (GCP) Control room

Common control panel (Main CCP) Power plant MCC


I/O CCP(right side and left side) Power plant MCC
Load control CCP Power plant MCC
Synchro panel for old generators Control room

Remote access cabinet Power plant MCC

SaCoS
Generator Control
Common control
Engine Start
► To start the engine, 30bar of compressed air is used to push the piston that
is at top most position. This starts the engine cycle and engine is started.
Engine Stop
Generator Auto - shutdown list
Alarm Description Setpoint
Engine Over Speed 832rpm
Main Bearing temp high 103°C
 
Lube oil pressure inlet low 1.7bar,(n<600rpm)
2.5bar,(n>600rpm)
Lube oil inlet temperature high 73°C
 
Lube oil pressure turbocharger low 0.9bar
Lube oil temperature turbocharger A & B outlet high 140°C
Oil-mist concentration high 2%
Splash – oil temperature mean value deviation +6k
HTCW pressure engine inlet high 1.0bar,(n<600rpm)
1.5bar,(n>600rpm)
 
HTCW temperature engine outlet high 98°C
Emergency stop air pressure low 10bar
Loss of signals of any of the sensors
Load- Synchronization
Load Synchronization
With WAPDA
Load Sharing for Balancing load
Load sharing in HMI
Load Priority Table

Feeder Load
Bungalow 2500KW

Increasing Priority
LPG/Boiler 1000KW
HBU-I,HBU-II & Preflash 1360KW
HCU/WPH 800KW
Reformer 1000KW
SS-1 2600KW
SS-2 2600KW
Thank you

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