Karnataka Power Corporation Limited
Bharat Heavy Electricals Limited
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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 MW
Thermal 2720 MW
Meets nearly 50% of States energy demand
Karnataka Power Corporation Limited
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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 Singareni
coalfields in Telangana, Western Coalfields in Maharashtra and Talcher
Coalfields in Orissa
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KARNATAKA 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
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KARNATAKA 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 Technology
Erection of two Units is in progress
Super 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.
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Present power Scenario
Installed capacity as on 31.03.2014
Renewable Energy Sources,
29462.55MW, 12.12%
NUCLEAR,
4780 MW, 1.97%
HYDRO,
40531.41 MW, 16.68%
THERMAL,
168254.99 MW, 69.23%
Total Installed capacity: 243028.95 MW
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Power Projections
Details of Super-Critical Units in 10th , 11th , 12th &13th
Sub Critical
(MW)
660
MW
(No.)
800
MW
(No.)
Super Critical
(MW)
5 Year Plans
TOTAL
MW
10th Plan
9620
9620
11th Plan
45470
5420
50890
12th Plan
18270
25
33
42,900
61,170
13th Plan
4000
36
36
52,560
56,560
Comparison between SubCritical & SuperCritical (MW)
60000
52,560
50000
45470
42,900
40000
30000
18270
20000
10000
9620
5420
4000
0
10th Plan
11th Plan
Total Subcritical (MW)
Karnataka Power Corporation Limited
12th Plan
13th Plan
Total Super critical (MW)
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Bharat Heavy Electricals Limited (BHEL)
ISO 9001
VIZAG
Corporate Office
Manufacturing Unit
Service Centers
Karnataka Power Corporation Limited
- 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) Certified
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Electronics Division-Business Areas
CONTROL & INSTRUMENTATION
TRANSMISSION
TRANSPORTATION
SOLAR CELLS & PHOTOVOLTAICS
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Brief Overview
BHEL-Electronics Division ties up with Metso Automation for DCS under
collaboration agreement for both maxDNA and Metso DNA.
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]
Karnataka Power Corporation Limited
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Leader in Power plant DCS
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Unified solution for C&I from BHEL
(Advantage to Customer)
THERMAL PLANTS (15 - 800MW)
HYDRO PLANTS (3 - 200MW)
Boiler Controls
Turbine Controls
Station C&I
HMI
Power Plant SCADA
PADO (Performance Analysis
Diagnostics & Optimisation)
Offsite Balance Of Plant Controls
Other Systems
Interlocking in Excitation Systems
Interlocking in FSC / CSR / SVC /
STATCOM
Interlocking in VFD system
Karnataka Power Corporation Limited
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
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DCS solutions from BHEL
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
Karnataka Power Corporation Limited
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Metso DNA Architecture
Remote
Connections
CONTROL ROOM
Operation, Maintenance, Reporting
Star or ring topology
redundant Ethernet network
Firewall
OFFICE
Reporting, Enterprise Integration
Name based communication
AUTOMATION ROOM
Controls, Optimization, Connectivity
Distributed
Metso DNA offers
architecture for
scalability, high
availability and
lifetime
expandability and
upgradeability.
Engineering and Maintenance,
Asset Management, DNA Historian
Centralized
Safety
instrumented
system
FIELD
Wireless solutions
for operation and
maintenance
FIELD
One platform for all control applications
Integrates major field buses and field
asset management
Karnataka Power Corporation Limited
FIELD
FIELD
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No longer a concept.A reality
Metso DNA on Virtual
Engineering Servers
Supercritical Projects
PROJECTS 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
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PARAMETERS ABOVE CRITICAL STATE
STEAM PRESSURE
> 221.2 BAR
STEAM TEMPERATURE > 374.15 Deg C
ULTRA SUPERCRITICAL PRESSURE( 300 BAR)
Improvement
4.3 %
Temperature
Super critical Cycles
45
40
35
30
25
20
15
Entropy
10
5
0
500 MW
Sub critical
170 ata / 537 C / 537 C
660 MW
Super Critical
247 ata / 565 C / 593 C
INCREASE IN PRESSURE AND MAIN & REHEAT TEMP. > 537 Deg C
RESULTS IN SIGNIFICANT IMPROVEMENT IN EFFICIENCY
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Super critical Cycles
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
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Super critical Power Plant Controls Configuration
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Super critical Power Plant Graphics
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Large Thermal Projects
Sagardhighi 2x500 MW
Lalitpur 3x660 MW
Totally Metso DNA based,
Totally Metso DNA based,
including CW/FOPH systems
including Off-site systems
Integrated system handles
>19,000 physical I/Os and >300
operator displays
Integrated system handles
>25,000 physical I/Os and >300
operator displays per unit
43 Pairs of ACN-CS Controllers
60 Pairs of ACN-CS Controllers
>1200 Drives
10 OPS + 10 OPS - LVS + EAS +
EAC + INFO + 2 LIS
>1800 Drives per unit
6 OPS + 6 OPS - LVS + EAS +2 EAC
+ INFO + 2 LIS
Karnataka Power Corporation Limited
Bharat Heavy Electricals Limited
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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
#
1
A
H
P
C
H
P
W
T
R
W
T
R
S
A
#
2
maxLinks
RS 485
Karnataka Power Corporation Limited
Bharat Heavy Electricals Limited
Status,
Event
and
Alarm
display
IEC-60870-5-103
(online)
PROTOCOL
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Enlarging the wireless connectivity application
WIRELESS CONNECTIVITY ON maxNet
CCR: Central Control Room
: Latitude - 1511'37.58"N
: Longitude - 7643'8.40"E
: Elevation 1575ft
54Mbps RF
Link1
25Mbps
Throughput
FOPH: Fuel Oil Pump House
54Mbps RF
Link2
: Latitude -1511'46.48"N
: Longitude - 7643'14.88"E
: Elevation 1576ft
25Mbps
Throughput
CWPH: Cooling Water Pump House
: Latitude -1511'45.30"N
: Longitude - 7643'4.01"E
: Elevation 1566ft
8 Kms Wireless link is under execution at NTPC Korba
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OFF SITES IN DCS PLATFORM
Flue Gas Desulphurization
Water Treatment Plant
HPCL import facility
Karnataka Power Corporation Limited
Bharat Heavy Electricals Limited
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Special Projects with maxDNA
GIU(Graphical Interface Units)
OPERATOR
ENGINEER
maxSTORIAN
maxLINK
RS485
CONVERTER
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
GIUs at Remote
Locations
RPU PANEL
Karnataka Power Corporation Limited
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ECS Experience
GT Control Room
EWS
ECS Room
Existing Control Room
OWS-1 OWS-2
Disturbance
( Portable)
EWS CIJP
DMP B/W LP
Analyser Node
(A4/A3 LP (A4)
HISTORIAN
(A4/A3
)
To Existing Control
)
OWS-3
Room (Approx. 1000 FOC
meters)
IRIG-B
output from
the existing
Master
clock
Redundant
maxNET (data
highway)
Control Panels
(ECS RTU)
FOC
maxLINK
Transducer panels
FOC
for interfacing
numerical relays on
relay & metering
LAN
Relay panels
GT System SWITCHBOARD
To DHDT S/s Control
Room (Approx. 500
meters)
To SRU S/s Control
Room (Approx. 2000
meters)
Reference list of projects
IOCL-Mathura 2005
IOCL-Bongaigaon 2009
IOCL-Paradip 2011
GSPC-Kakinada 2011
OPaL-Dahej (under
commissioning)
Rack Room
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Special Projects with maxDNA
R&M Projects with maxDNA
Commissioning of R&M job done in record 32 days for Ropar
TPS - 210 MW - SG,TG & BOP C&I including re-cabling
Commissioning of R&M job done in record 33 days for IB
Thermal 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 ..
Karnataka Power Corporation Limited
Bharat Heavy Electricals Limited
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Karnataka Power Corporation Limited
Bharat Heavy Electricals Limited
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