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    Mr. Hassan Alam: Heat Recovery Boiler of SNPC Power Plant

    Uploaded by

    Yashal Syed, Ahmed
    The document reports on the heat recovery boiler of the Sindh Nooriabad Power Company power plant. It discusses that the plant uses water tube heat recovery boilers with three stages (economizer, evaporator, superheater) to capture waste heat from the plant's internal combustion engines and produce steam. The steam is then used to power steam turbines and generate additional electricity. The benefits of the heat recovery boilers include increased overall plant efficiency, reduced fuel costs, lower environmental impact, and good return on investment.

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    Mr. Hassan Alam: Heat Recovery Boiler of SNPC Power Plant

    Uploaded by

    Yashal Syed, Ahmed
    48 views11 pages
    The document reports on the heat recovery boiler of the Sindh Nooriabad Power Company power plant. It discusses that the plant uses water tube heat recovery boilers with three stages (economizer, evaporator, superheater) to capture waste heat from the plant's internal combustion engines and produce steam. The steam is then used to power steam turbines and generate additional electricity. The benefits of the heat recovery boilers include increased overall plant efficiency, reduced fuel costs, lower environmental impact, and good return on investment.

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    Report on power plant

    Original Title

    SNPC PPE REPORT

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    The document reports on the heat recovery boiler of the Sindh Nooriabad Power Company power plant. It discusses that the plant uses water tube heat recovery boilers with three stages (economizer, evaporator, superheater) to capture waste heat from the plant's internal combustion engines and produce steam. The steam is then used to power steam turbines and generate additional electricity. The benefits of the heat recovery boilers include increased overall plant efficiency, reduced fuel costs, lower environmental impact, and good return on investment.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    48 views11 pages

    Mr. Hassan Alam: Heat Recovery Boiler of SNPC Power Plant

    Uploaded by

    Yashal Syed, Ahmed
    The document reports on the heat recovery boiler of the Sindh Nooriabad Power Company power plant. It discusses that the plant uses water tube heat recovery boilers with three stages (economizer, evaporator, superheater) to capture waste heat from the plant's internal combustion engines and produce steam. The steam is then used to power steam turbines and generate additional electricity. The benefits of the heat recovery boilers include increased overall plant efficiency, reduced fuel costs, lower environmental impact, and good return on investment.

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    © All Rights Reserved
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    Report on

    Heat Recovery Boiler of SNPC Power Plant

    Submitted to

    Mr. Hassan Alam


    POWER PLANT ENGINEERING COURSE TEACHER

    BY

    Syed Yashal Ahmed (ME-19187)


    Omar Hameed (ME-19193)
    Nasr Haider Qari (ME-19184)
    Muhammad Hassan Nafees (ME-19218)

    DATE: 27 December 2021


    CONTENTS
     About the company
     Power Plant
     Engines
     Steam Turbines
     HEAT RECOVERY BOILER
     Heat recovery boiler at SNPC
     Why water tube boiler are chosen over fire tube boiler
     Components of water tube boiler
     Main stages of water tube boiler
    1) Economiser
    2) Evaporator
    3) Superheater
     Safety Feature
     Benefits of using waste heat recovery boilers
    Sindh- Nooriabad Power Company
    Limited

    About the Company


    SNPCL, or Sindh Nooriabad Power Company is a two phase, 50MW
    Independent Power Plant(IPP) situated in Nooriabad- the outskirts of Karachi. It
    is a Specific Purpose Vehicle(SPV) which is set up under the Public Private
    Partnership mode with the Government of Sindh partnering with a private,
    multinational company called Wartsila.

    Wartsila is a company from Finland which initially started with producing marine
    parts and machinery but later on also entered the Energy or Power Generation
    Industry. At SNPCL, all the machinery and parts are manufactured by Wartsila,
    the plant was commissioned by it and the plant is also overseen by Wartsila.
    Power Plant:
    The plan runs on a Combined Cycle with engines powered by Gas which is
    supplied by Sui Northern Gas Pipelines Limited(SNGPL). It consists of two
    identical phases, with five gas-powered Internal Combustion Engines, one Heat
    Recovery Boiler, one steam turbine, a condenser and a pump. These two phases
    collectively produce a Power Output of 100 MW at an efficiency of 43-44%. The
    water for the Heat Recovery Boilers is sourced from Keenjhar Lake and
    processed further on the plant.

    Engines:
    Many power plants running on the combined cycle use gas turbines but here,
    gas-powered Internal Combustion engines are used. Within the two phases in
    the powerplant, each phase contains five Internal Combustion Engines. These
    engines are powered by natural gas being supplied at a pressure of 4.74 bar.
    They consist of 20 cylinders in a V configuration and are spark ignition engines.
    They have a load of 9719 kW and produce 9.7 MW each and directly power
    generators providing electricity to the grid.
    Steam Turbines:
    Steam turbine is the component of a Rankine cycle that converts the pressure of
    steam into work, leading to the generation of electricity. At this powerplant, each
    phase has only one steam turbine producing 1.8 MW. The steam flow rate going
    through it is 21 tons/hr, and it runs at 7700 rpm. The shaft coming from the
    generator is connected to a reduction gearbox with a gear ratio of 5:1 which
    leads to another shaft running the generator, therefore leading to the grid.
    Heat Recovery Boiler
    A Heat Recovery Boiler is the subtype that uses wasted heat in the form of
    exhaust gases from gas turbines or internal combustion engines to convert water
    to steam in order to power steam turbines and resultingly produced power.

    Heat Recovery Boilers at SNPCL:


    There are a total of two Heat-waste Recovery Boilers at this plant; one for each
    phase. They are 3.9 ton, water tube boilers with natural circulation and three
    stages: Economiser, Evaporator and Superheater. These boilers use the exhaust
    gases from the gas engines to heat up the water flowing through the tubes and
    henceforth, produce steam. These boilers operate at an internal pressure of the
    steam drum situated on top of the boiler of 14 bar and have a capacity of 17 bar.
    There are T-type valves used for venting the steam drum in case the pressure
    starts to increase further than 14 bar. The steam produced from this boiler
    reaches the steam turbine at a temperature of 350°C.
    Why Water Tube Boilers Are Chosen Over Fire Tube Boilers
    Water tube boilers are chosen instead of Fire Tube Boilers due to many reasons.
    Firstly, the amount of waste heat available is not significant enough to operate a
    fire tube boiler, as it requires more heat in order to convert water to steam.
    Secondly, it is due to a few advantages that water tube boilers have over fire
    tube boilers; water tube boilers can produce higher temperature steam, they can
    operate on higher pressures, they are safer and more reliable, they can generate
    superheated steam, and have faster heat recovery.

    Components of the Water Tube Boiler:


    i. Boiler Shell: This shell is the external, cylindrical part of the boiler.
    ii. Mud drum: This is a cylindrical shaped space at the base of the water
    space. Its purpose is to gather impurities like sediments, mud, silica etc.
    iii. Strainer: This part is used to filter out solid particles
    iv. Sight glass: A glass tube is utilized on steam type boilers for giving
    observable signs of the water level in boilers.
    v. Steam stop valve: It controls the steam flow supply outside.
    vi. Feed check valve: The high-force water flows via this valve, which
    releases to the boiler simply and supplies the water to the water type
    boiler.
    vii. Economizer: Accessory used to recover the heat of flue gas that leaving
    the boiler by heating feed water.
    viii. Evaporator: Here the phase change occurs by absorbing the latent heat of
    vaporization pressure.
    ix. Superheater: It finds use to increase the temperature of the steam
    x. Steam drum: It is a collection vessel for steam and water.
    xi. Safety valve: It finds a use for stopping the unnecessary force from the
    construction of a boiler.

    Three Main Stages of the Boiler


    These water tube boilers consist of three stages- economiser, evaporator and
    superheater. In the economiser, the water is heated up after which it is boiled
    and converted to steam, leading itself to the superheater, where steam is
    superheated to high temperatures and led into the steam drum.
    1.) Economiser:
    The steam flow from a heat recovery boiler can be increased by the
    addition of an economiser which plays the role of preheating the feedwater
    before it enters the evaporator. Economizers are designed to recover heat
    which would otherwise be wasted.

    2.) Evaporator:
    This part of the powerplant works on the phenomenon of evaporation.
    Here, the water is converted to steam. It is able to change completely or
    part of a solvent from a solution in the form of liquid to steam. Which
    results in a denser or thick solution. In the industrial sector, the benefits of
    the evaporator are usually for the initial thickening of the liquid before
    further processing, reduction of fluid volume and to reduce water activity.

    3.) Superheater:
    In Waste-heat Recovery Boilers, the superheater re-heats the steam
    generated by the boiler, increasing its thermal energy and decreasing the
    likelihood that it will condense inside the engine. This increases the
    thermal efficiency of the cycle and prevents the steam from condensing
    during the process. It also contributes to the additional increase of
    pressure and temperature. This in turn increases the amount of work done
    by the turbine and increases overall efficiency of the cycle. The steam is
    then stored in the steam drum situated above the boiler.
    Safety Features
    The safety features for the boiler are the blow-off valves attached to the steam
    drum used for venting off steam if pressure exceeds the normal operating
    capacity. There are three most commonly used safety or pressure relief valves
    which include Spring-loaded, Pilot Operated and Deadweight valves. The valves
    used at the plant are Pilot Operated Pressure Relief Valves. The pressure is
    supplied from the upstream side (the system being protected) to the dome often
    by a small pilot tube. The downstream side is the pipe or open air where the
    PORV directs its exhaust. The outlet pipe is typically larger than the inlet. The
    upstream pressure tries to push the piston open but it is opposed by that same
    pressure because the pressure is routed around to the dome above the piston.
    The area of the piston on which fluid force is acting is larger in the dome than it is
    on the upstream side; the result is a larger force on the dome side than the
    upstream side. This produces a net sealing force. The pressure from the pilot
    tube to the dome is routed through the actual control pilot valve. There are many
    designs but the control pilot is essentially a conventional PRV with the special job
    of controlling pressure to the main valve dome. The pressure at which the control
    pilot relieves at is the functional set pressure of the PORV. When the pilot valve
    reaches set pressure it opens and releases the pressure from the dome. The
    piston is then free to open and the main valve exhausts the system fluid. The
    control pilot opens either to the main valve exhaust pipe or to atmosphere.
    Benefits of using Waste Heat Recovery Boilers
    There are quite a lot of benefits due to which Heat-Waste Recovery Boiler is
    used.

     First and foremost, it increases overall efficiency of the plant because it


    utilises the wasted thermal energy from the engines.
     In the case of SNPCL, it increases the total power output of both phases
    by around 3.6%.
     Other than increased efficiency, the costs for fuel decrease which in turn
    increases the total profit over time, it saves resources and cuts costs on
    other operations relating to the supply of more fuel.
     It has a good return on investment and most importantly, it also contributes
    to reducing the negative environmental impact and carbon footprint by
    reducing the temperature of exhaust gases.

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