Thermal Power Plant – Design and Engineering

WATPL04
(Instrumentation & Controls)

Outstanding Features

The Course will help participants to gain detailed knowledge on major design and engineering aspects of thermal power generation technologies. This includes in depth discussions on design approach of equipment and system sizing, defining required margins, establishing performance and guarantee requirements, mitigating of design operational issues, and planning for safe start up, operation, transient and shutdown operation of each of the combined cycle (CC) and rankine cycle (RC) technologies. At the end of the session, the trainees will have a solid understanding of the design issues to apply to the actual projects with confidence.

Course Overview

This course is a natural progression from the overview course on thermal power plants offered by the Academy. The course will begin with a broad recap of the major topics covered in the overview. Participants will then be divided into their discipline groups, Mechanical, Electrical, Instrumentation & Controls (I&C), Civil & Structural. Each discipline will look at design criteria for each technology, system configurations and shut down operations.

Target Audience

Engineers and Designers at all levels, Project Engineers and Project Managers

You Will Learn How to

To gain detailed knowledge to support thermal power plant
engineering and design for each discipline, participants will learn how to:establish the equipment and system requirements

specify equipment and systems for procurementavoid
pitfalls in the design and engineeringoptimize power plant performance and designidentify critical issues for plant start up,
shutdown, steady state operation and develop mitigating measuresestablish inventory requirements for various
utilities

Topics

Recap Power Plant Design Overview: A summary level recap of what was covered in
Session 1 and how the equipment and system related issues will be addressed in
the breakout individual discipline sessions will be presented.Mechanical: This breakout sessions will cover the following major topics for each of the CC and RC technology as applicable:- Codes and Standards: An overview of applicable codes and standards for mechanical equipment and system designs will be presented.- Major Equipment : Overview and Design Criteria. This will include Gas Turbine, HRSG, Boiler, Steam Turbine, Condenser, Cooling Tower/Air Cooled Condenser, Feed Water Heaters, large power cycle and balance of system pumps, fuel handling equipment, ash handling, compressors (gas and air), tanks, cranes/hoists, water treatment, emission controls. This will also include sample calculations for pumps/fans and select equipment sizing- Power Cycle Systems:Design Criteria and system descriptions for the power cycle system will be presented supported by the respective P&IDs and heat balance diagrams: The systems will include main steam, cold and hot reheat, extraction steam, LP /auxiliary steam, steam bypass, condensate, boiler feed water, heater drains, boiler/HRSG blowdown, steam drains and vents, condenser air removal chemical feed, sampling, air and flue gas systems.- BOP Systems: Design Criteria and system descriptions of the balance of plant (BOP)
systems will be presented supported by the respective P&IDs, water balance
diagrams: This will include fuel storage and handling, circulating water,
closed/auxiliary cooling water, plant make up water/ demin water, potable and
service water, lube oil, compressed air, inert gases, emission control
(ammonia, lime/sorbent, FGD), HVAC and fire protection system
– Layout: Typical Plot Plan and General arrangement drawing will be presented for
each type plants that would construction laydown, operation and maintenance
clearance requirements. A goby table will be provided showing the overall space
requirements for each type of plant
– Equipment Specifications: This session will include high level discussions on contents,
performance guarantees and bid evaluation criteria. Sample documents will be
presented addressing the above
– Value Engineering: -The presentation will include value engineering
topics, option evaluation methodology and a sample example showing the value
engineering selection process.
Electrical-
Codes and Standards: An overview of applicable codes and standards
for electrical equipment and system designs will be presented. – Major Equipment: Overview and Design Criteria. This would include Generators, Transformers, Switchgears / MCCS, Breakers, Motors, Bus ducts, UPS, Battery, Emergency / Black Start Generators- Electrical Systems: Design Criteria, system configurations and calculations for the electrical systems will be presented supported by the one lines. The systems will include High/ Medium/Low voltage supply and distribution, electrical protection, UPS and battery, bus ducts, cabling, lighting, fire alarm, lightning protection, grounding, communication and security systems. Sample calculations will also be presented to include statistics and balance for MV/LV, DC Load statistics, UPS load, Plant aux loads, grounding, lightning, short circuit and protection systems.- Equipment Specifications: This session will include high level discussions on contents, performance guarantees and bid evaluation criteria. Sample documents will be presented addressing the above.Instrumentation & Controls (I&C) – Codes and Standards: An overview of applicable codes and standards for I&C equipment and system designs will be presented.- Major Equipment : Overview and Design Criteria. This would include DCS, PLCs, CEMS, metering equipment, steam turbine bypass valves, control valves, pressure/temperature/flow /level measurement, transmission and alarm equipment – I&C Systems: Design Criteria, system configurations and calculations for the I&C systems will be presented supported by the control system diagrams. This would include overall plant control philosophy and protection systems, and major equipment control and protection systems included in Mechanical and Electrical sections. In addition, the plant start-up, transient, load following, and shutdown methodologies will be presented –
Equipment Specifications: This session will include high level discussions on contents,
performance guarantees and bid evaluation criteria. Sample documents will be
presented addressing the above
Civil & Structural- Codes and Standards: An overview of applicable codes and standards for Civil & Structural system designs will be presented.- Major Systems : Design Criteria and calculations for the Civil and Structural systems will be presented. This would include Geotech, plant grading, clearing and grubbing, surfacing, plant drainage, storm water runoff, erosion control, foundation design for major equipment covered under mechanical and electrical systems, power house and auxiliary facility buildings per layout, major structures for various buildings and pipe racks, containment of runoff from coal pile and ash pond, liquid fuel storage, transformers, fencing, roads and parking.- Specifications:
This session will include high level discussions on contents of civil
and structural systems. Sample documents will be presented addressing the above

Course Details

Morning session: 4-hour duration with 15 to 20 minutes breaks between for questions and answers. Lunch Break is for 1 hours. Afternoon Session: 3 to 4 hours with breaks in between. This will be common for all disciplines. The days below represent regular business working days

Day 1: Common Session to include all disciplines

Morning Session: – Recap Power Plant Design Overview from previous overview training course
Afternoon Session: – Plant Layout
Day 2: Common session in the morning and Individual discipline breakout sessions in the afternoon

Morning Session: – General discussions on plant design philosophy, codes and standards, environmental requirements, operation and maintenance
Afternoon Session:- Mechanical: Gas Turbine and HRSGs- Electrical: Generators, and Transformers- I&C:DCS, PLCs- Civil & Structural: Geotech
Day 3: Individual discipline breakout
session

Morning Session:- Mechanical: Boilers & Steam Turbines- Electrical: Switchgears / MCCS- I&C: CEMs, metering equipment,- Civil & Structural: Plant Grading, clearing, grubbing, surfacing
Afternoon Session:-
Mechanical: Condenser,
Cooling Tower, Air-cooled Condenser

Electrical: Motors,
Breakers, Bus ducts

I&C: DCS, Steam Turbine Bypass Valves, Control
Valves
– Civil & Structural:
plant drainage, storm water runoff, erosion control

Day 4: Individual discipline breakout
session

Morning Session:-
Mechanical: Feed Water Heaters, Large Power
Cycle Pumps

Electrical: UPS, Battery System and
Emergency/Black Start Generator

I&C: Various measuring instruments (flow,
pressure, temperature, level and such),

Civil & Structural: Foundation design
criteria of rotating equipment (Gas Turbine, Steam Turbine, Pumps)
Afternoon Session:-
Mechanical: Coal and Ash Handling Systems

Electrical: Electrical One Lines, Design
Criteria and System Descriptions for electrical distribution system (HV/MV/LV)

I&C: Control system architecture and plant
control philosophy

Civil/Structural: Foundation design static
equipment (Boilers/HRSGs/Condenser /ACC)

Day 5: Individual discipline breakout
session

Morning Session:-
Mechanical: Air and Gas Compressors, Tanks,
Cranes & Hoists

Electrical: Design Criteria and System
descriptions for electrical protection systems

I&C: Design Criteria and System Descriptions
for major equipment controls and Protection (Gas Turbines, STG, HRSG, Boilers)

Civil & Structural: Foundation design
criteria of BOP systems and equipment (Cooling Tower, Water Treatment,
Transformers and other major items)
Afternoon Session:- Mechanical: Water Treatment & Emission Controls- Electrical: Design Criteria and System descriptions for UPS and Battery Systems- I&C: Design Criteria and System Descriptions for BOP Systems (Water Treatment, Coal/Ash Handling)-Civil/Structural: Design Criteria – Buildings (Power House and Auxiliary Facilities)
Day 6: Individual discipline breakout session

Morning Session: – Mechanical: Design Criteria and System descriptions for main steam, cold and hot reheat systems. – Electrical: Design Criteria and System descriptions for bus ducts and cabling system (HV/MV/LV)- I&C: Design Criteria and System Descriptions for various electrical system control and protection- Civil & Structural: Design Criteria – Misc. Structures (Pipe Rack, Boilers, ACC, coal transfer towers and other major items)
Afternoon Session:- Mechanical: Design Criteria and System descriptions for Extraction steam, LP/Auxiliary Steam and Steam Bypass systems- I&C: Plant operation, start up, shut down, transient operation- Civil/Structural: Design Criteria – Containment off run from coal pile and ash pond, liquid fuel storage, transformers- Electrical: Design Criteria and System descriptions for lighting and fire alarm system
Day 7: Individual discipline breakout session

Morning Session: -Mechanical: Design Criteria and System descriptions for boiler feed water and condensate systems. – Electrical: Design Criteria and System descriptions for bus ducts and cabling system (HV/MV/LV)- I&C: Design Specifications and Sample Calculations- Civil & Structural: Design Criteria – Fencing, Roads, Parking
Afternoon Session:-Mechanical: Design Criteria and System descriptions for drains and vent systems (heater drains, boiler/HRSG blowdown, steam drains and vents)- Electrical: Design Criteria and System descriptions for plant communications and security systems- I&C: Recap of previous presentations and discussions on Tests- Civil/Structural: Design Criteria – Recap of previous presentations and discussions on Tests
Day 8: Individual discipline breakout session

Morning Session: -Mechanical: Design Criteria and System descriptions for chemical feed and sampling systems both for power cycle and BOP systems. – Electrical: Sample Calculation – Electrical systems (HV/MV/LV, DC)- I&C: Test Quizzes- Civil & Structural: Design Criteria – Test Quizzes
Afternoon Session:- Mechanical: Design Criteria and System descriptions for air and flue gas systems – Electrical: Sample Calculation – Electrical systems (UPS, Electrical Load Lists)- I&C: NA (Depart)- Civil/Structural: NA (Depart)
Day 9: Individual discipline breakout session

Morning Session:- Mechanical: Design Criteria and System descriptions for fuel storage and handling system (coal, oil)- Electrical: Sample Calculation – Electrical systems (grounding and lighting systems)
Afternoon Session:- Mechanical: Water Balance Diagram and Design Criteria and System descriptions for plant water systems (circulating water, demin water, potable & service water systems) – Electrical: Sample Calculation – Electrical systems (short circuit and protection)
Day 10: Individual discipline breakout session

Morning Session:- Mechanical: Design Criteria and System descriptions for lube oil, compressed air and inert gases (CO2 and Nitrogen)- Electrical: Sample Calculation – Electrical systems (grounding and lighting systems)
Afternoon Session:- Mechanical: Design Criteria and System descriptions for emission controls (ammonia, lime/sorbent, FGD) – Electrical: Sample Calculation – Electrical systems (short circuit and protection)
Day 11: Individual discipline breakout session

Morning Session:- Mechanical: Design Criteria and System descriptions for HVAC and Fire Protection systems- Electrical: Specifications (generator, transformer, bus duct and other major items,
Afternoon Session:- Mechanical: Equipment Specifications (Gas Turbines, Steam Turbines, Boilers, HRSG) – Electrical: Sample Calculation – Recap of previous presentations and discussions on tests
Day 12: Individual discipline breakout session

Morning Session:- Mechanical: Equipment Specifications (Condenser, Cooling Tower, ACC. Pumps)- Electrical: Test Quizzes
Afternoon Session:- Mechanical: Equipment Specifications (Coal and Ash Handling system) – Electrical: NA (Depart)
Day 13: Mechanical Only

Morning Session: Equipment Specifications (Emission Controls, Pumps and miscellaneous equipment
Afternoon Session: Sample Calculations
Day 14: Mechanical Only

Morning Session: Value Engineering
Afternoon Session: Recap of previous presentations and discussions on tests
Day 15: Mechanical Only

Morning Sessions: Test Quizzes
Afternoon Session: Depart

Course Length

15 Days

Pre-requisite: It is recommended that this course immediately follow the overview course to maintain continuity and achieve better learning experience. Individual Discipline Courses will be offered in parallel to maximize efficiency.

Certifications

Upon completion, you will receive a Worley Academy Certificate of Completion

Course Schedule

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