BASIC AND DETAILED ENGINEERING
Methodology for Project Engineering of a Typical Power Plant
At the onset of a project a multi-disciplinary team of Engineers comprising Architectural, Civil, Structural, Mechanical, Electrical, Control & Instrumentation and Environmental will appraise the project and converge their efforts to deliver engineered documentation and drawings.
- Project Logistics
- Determination of power evacuation for electricity generated to State/Interstate grid. System studies to ensure adequacy of grid would be undertaken.
- Consumptive water system: Source of intake from River / Reservoir / Lake etc. Cross-country pipeline and other infrastructure.
- Fuel source and its analysis, transportation from source to site, handling and storage at site.
- Road & Rail connectivity.
- ENVIRONMENTAL CONSIDERATIONS
- Stack flue gas dispersion studies
- Ash Pond Water recovery system
- Plant Effluent and Sewage treatment and recycling.
- Acoustics
- Disaster Management studies
- SITE SPECIFIC STUDIES
- Geo Technical investigations to determine soil characteristics to conceptualize
- Type of foundations and
- Safeguard viz. sulphates, chlorides etc.
- System studies for
- Fault level and
- Power flow.
- Hydrological studies
- Hydraulic studies for Circulating Water Pump House
- Wind Tunnel studies for tall structures like Chimney and Natural Draft Cooling Towers.
- PLANT CONCEPTUALIZATION
- Preparation of a Plot Plan depicting the disposition of each key equipment / system / facility required for the installation.
- To dovetail the switchyard with the transmission line corridor.
- Connectivity with road and rail network in the near vicinity.
- Develop an in-plant railway marshalling yard to receive / park coal rakes.
- To route the consumptive water make up line from the offsite make-up water pump house to the in plant reservoir.
- To prepare a composite water scheme for optimum utilization of various categories of water viz. raw, clarifier, service, D.M., effluent etc.
- To prepare a master single line diagram for electrical distribution for all voltage levels.
- To prepare a Station, Control & Instrumentation architecture.
- MAJOR ENGINEERING DELIVERABLES
MECHANICAL
- Design Basis Report for each system General Arrangement Drawings:
- General Arrangement Drawings:
- Turbine Building all floors including the Central Control Room with disposition of equipment / facilities.
- General Arrangement of Boiler Area Plan with disposition of Boiler, I D & FD Fans, Chimney, Draft duct etc.
- General Arrangement of Transformer yard with disposition of Generator, Station & Unit Auxiliary Transformers, their respective bus ducts, Fire Fighting pipes, Cable trenches between Switchyard and Power House etc.
- General Arrangement of Switchyard layout with Control Room, metering equipment, interconnecting transformers, as required and outgoing feeders.
- General Arrangement of all Auxiliary Buildings viz. C.W. Pump house, Pretreatment Plant, D.M. Plant, Air Compressors, Coal Handling Plant, Ash Handling Plant, Sewage & Effluent Treatment Plant/s, Hydrogen Generation Plant, work shop building, store sheds, D.G. Sets etc.
- Flow Schemes for all systems / sub-systems.
- Technical Specifications with sizing criteria for procurement of equipment.
- Techno-Commercial appraisal of bid/s received for equipment.
- Participate in negotiation with equipment supplier/s and to further assist the client in finalization of purchase order/s.
- Vendor drawing and document review to ensure conformity to specification and performance parameter/s of the respective Purchase Order / Contract/s.
- Update G.A. drawings to incorporate equipment, piping, cable trenches / trays etc for preparation of construction drawings.
CIVIL, STRUCTURAL AND ARCHITECTURAL
- Basic Engineering Deliverables
- Technical Specification for Site Survey and Contour Plan along with Site Plan Drawing and BOQ.
- Technical Specification for Geotechnical Specification including BOQ and drawing.
- Wind Load assessment as per Wind Load Code.
- Seismic Load assessment as per Earthquake Load Code.
- Site Rainfall and Temperature data.
- Design Basis Report.
- Tender Engineering Deliverables
- Finalization of Packaging philosophy.
- Technical Specification and BOQ for various packages along with Tender drawings.
- Bid clarification, Bid analysis and final recommendation.
- Technical specification for BOP packages viz Coal Handling, Ash Handling Plant, Water Treatment Plant, Cooling Tower etc.
- Detailed Engineering
- Preparation of Design and Construction drawings for Power House Building including, GTG Foundation/TG foundation, BFP foundation, CEP foundation, Crane Girder etc.
- Design and drawings of Single / Multi Flue RCC Chimney.
- Transformer yard.
- Boiler, ESP, Fans, Duct support and Mill foundations, including Bunkers, Mill & Bunker Building.
- Balance of Plant drawings for Cooling Water System, F.O. system, ACW system etc.
- Roads, Drainage, Boundary Wall, Security Wall, Gate & Security complex, Admin & Canteen Building, Workshop, Sewerage, ETP etc.
- Review and approval of BOP package design and drawings.
- Preparation of Architectural Drawings including Colour Scheme.
- Preparation of As-built drawings.
ELECTRICAL
- Conceptual Engineering:
- Preliminary Load List
- Preliminary One Line Diagram
- Load Flow / Short Circuit Study Report
- Main Equipment Sizing
- Preliminary Electrical Equipment / Switchgears Layouts
- Block Logic Diagrams
- Design Basis Reports
- Procurement Engineering:
- Procurement Specifications & BOQ of Electrical Equipments / Systems
- Pre-bid & Post-bid clarifications / discussions
- Bid analysis and recommendations
- Contract Specifications
- Vendor document review
- Inspection at Manufacturer’s Works, inspection/test reports
- Detailed Engineering:
- Electrical Equipment / switchgear /switchyard/transformer yard layouts & sections
- Earthing system design & layouts
- Detailed load list & feeder lists for switchgears, MCCs, DBs
- HV / LV Power cable sizing & layout
- Cable carrier system design and detailed cabling layouts
- Design of illumination system and areawise illumination layouts & details
- Lightning protection layouts
- Plant inter communication system layouts
- Equipment hookup / interconnection drawings
- Power & Control Cable Listing & Cable Schedules
- Relay Settings Schedules & Protection Co-ordination Charts
- Site Erection & Commissioning Instructions
- Operation & Maintenance Manuals
- As-built drawings
CONTROLS & INSTRUMENTATION
- Basic design deliverables
- Design Basis Report
- Control Valve Sizing
- Flow Element Sizing
- Tender Purpose deliverables
- Purchase Specifications & BOQ
- Field Instrumentation Items
- Measuring Instruments
- Final Control Elements
- Analytical Measurements
- Instrumentation Cables
- Erection Hardware
- DCS, PLC and Relay Based Control System Specifications
- System Configuration Diagrams
- UPS Specification & Single Line Diagrams
- Steam and Water Analytical System (SWAS) Specification and P&ID
- Continuous Emission Monitoring System Specification
- Lab Instruments & Testing Instruments Specification
- Ambient Air Quality Monitoring System (AAQMS) Specifications
- Plant Security Surveillance System Specification & System Configuration Diagram
- Vibration Monitoring System & Online Computer Aided Microprocessor Based Machinery Maintenance System (OCAMMMS).
- Station LAN and Management Information System.
- Computerized Maintenance and Inventory Management System (CMIMS)
- Master Clock System
- Simulator
- 24V DC System
- Detailed Engineering Documents
- DCS / PLC System Configuration
- DCS / PLC Input / Output List
- Instrument List
- Logic Diagrams
- Closed Loop Control Schemes
- Cable Instrumentation Diagrams
- Cable Schedules
- Instrument Hook-Up Diagrams
- Instrument Loop Diagrams
- Control Room Layout
- Control Console Layout
- JB Schedules
- JB Location Plan
- Quality Plans
- As-Built Drawings