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