INSTITUTE OF SPACE TECHNOLOGY ISLAMABAD

ME 242Thermodynamics-II
Group # 01
Submitted By:
Name

Reg No.

Aamir Rafiq
(130501037)
Muhammad Ali Zia
(130501038)
M. Umair Saleem

(130501040)

Mansoob Bukhari
(120501039)
BE-MECH-02
Submitted to:
Sir, Shaban
Date: February 09, 2015

DEPARTMENT OF
MECHANICAL ENGINEERING

Thermodynamics -II Project

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Table of Contents
Back Ground............................................................................................................... 3
Objective.................................................................................................................... 3
Turbines...................................................................................................................... 3
Boilers........................................................................................................................ 4
Condenser.................................................................................................................. 4
Generators................................................................................................................. 5
220KV Switch Gear..................................................................................................... 5
Transmission line........................................................................................................ 5
Water treatment plant................................................................................................ 6
Hydrogen generating plant......................................................................................... 6
Fuel Storage............................................................................................................... 6
Town Water storage.................................................................................................... 7
Statistical Data of the Plant........................................................................................ 7
Real Problems Occurring in the Plant (at BQTPS)......................................................11

Thermodynamics -II Project

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Back Ground
At the beginning of the 1985s, maximum load demand for power in Karachi
and surrounding areas, which are served by Karachi Electric Supply
Corporation Ltd. (KESC), was increasing year on year, and in fiscal 1989/1990
(1989/7~1990/6) and fiscal 1990/1991 (1990/7~1991/6) installed generation
capacity fell short of peak demand. The increase rate for maximum load
demand was predicted to exceed 9% in and after fiscal 1991/1992 as the
result of sweeping increases in the demand for power for household and
industrial uses. Electrification of agricultural villages and the dissemination of
domestic electrical appliances were projected to yield sizable increases in
household demand for power. Whilst the easing of regulations relating to
trading policies, the abolition of foreign exchange controls and policies to
promote foreign investment, in combination with the activation of private
investment, was forecast to have a similar effect on power demand for
industrial uses.
In contrast, from a supply perspective, despite the fact that a third
generating unit was scheduled to become operational at Bin Qasim Thermal
Power Station (BQTPS) in fiscal 1992/1993, projected suspension of
operations at the seriously deteriorated West Wharf thermal power plant and
the Karachi nuclear power plant, which supplies KESC catchment areas, and
the leveling off of installed generation capacity, was expected to result in the
reemergence of supply shortages in and after fiscal 1993/1994. In order to
handle these additional load requirements and the shortfalls in supply, the
construction of a thermal power station powered by imported heavy oil was
urgently necessary.

Objective
In order to resolve the projected shortfalls in supply within KESC jurisdictional
areas in and after fiscal 1993/1994, this project was to add a sixth
generating unit (210MW) to the facilities at BQTPS, located approximately
50km to the east of Karachi, by way of plant expansion. The project also
involved the provision of high voltage transmission lines (220KV 2, 35km)
as part of the planned transmission circuit system in order to strengthen the
supply system within the catchment area.

Thermodynamics -II Project

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Turbines

Capacity : 210 MW

Tandem compound double flow

Stages

Unit 1,2,5 & 6:HP-8, IP-6, LP-2X5

Unit 3 & 4: HP-9,IP-7,LP-2x6

Steam condition : 140 bar,525C

Back pressure :0.07bar

Manufacturer

Unit # 1,2,5 & 6 ; Hitachi Japan

Unit # 3 & 4; ANSALDO Italy

Boilers

ELAPSO type single drum;

Natural circulation

Single reheat

Steam: 680T/H,145 bar 530 0C

Naturel gas /HFO fired

Manufacturer

Unit # 1,2,5 & 6 ; Hitachi +Babcock japan

Unit # 3 & 4; deutche + Babcock Germany

Boiler Efficiency Formula.

Thermodynamics -II Project

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Condenser

Once through seawater cooled

2 condensers per unit having 18,000 CM/Hr. seawater flow through

each part.

Cu-Nickel Alloy Tubes having 1-1.2 mm thickness & 9 meter length.

Designed seawater temp. 28-30C

Designed Vacuum ; 0.07bar

Water velocity inside tubes: 2.1 M/s

Filtration of seawater through coarse, fine, travelling band screens and

debris filters.

Generators

248MVA

PF; 0.85

Terminal Voltage:

Stator:

21 KV: Unit # 1&2

18KV : Unit #3, 4, 5 & 6

Water cooled :Unit # 1&2

Hydrogen Cooled : Unit # 3,4,5&6

Manufacturer

Unit # 1,2,5 & 6 ; Hitachi Japan

Unit # 3 & 4; Ercole + Marelli Italy

220KV Switch Gear

SFG gas insulated & Air Operated

Double bus Bar

6 Generator Breakers

4 feeders to pipri west grid station

Thermodynamics -II Project
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2 feeders to korangi East Grid station

3 breakers for feedback to 220/6.6 KV start up transformers

1 bus Coupler breaker

Transmission line

The power is transmitted through 6 no overhead 220KV transmission

lines

Line # 1,2 & 3 are directly connected to pepri west grid station

Line # 4 is connected to pepri west grid station through ICI loop inloop out grid station

Line # 5 & 6 are connected to korangi west grid station

Water treatment plant

6 streams of de-mineralizers of 40 t/h production each

3300CM de-mineralized water storage capacity

2 condensate polishers

Waste water neutralization system

Regeneration & Neutralization chemicals

Caustic soda & sulfuric acid

Condensate & cooling water conditioning chemicals

Ammonia, hydrazine hydrate & tri sodium phosphate

Hydrogen generating plant

2 Electro hydrolyser of 6.05 & 6.23 CM/Hr. capacity

Compression and filling station to fill cylinder at 140 bar

Emergency diesel generators

5 diesel generators sets having 1.75 MW capacity each at 6.6 KV

terminal voltage connected at 6.6 KV common auxiliary bus bar

To facilitate safe shutdown operation in case of black out conditions

Thermodynamics -II Project
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Fuel Storage

Hfo capacity : 120,000 CM

-2 x 10,000 CM

3 x 25,000

1 x 25,000 CM (bonded to custom for receipt of oil from PSO )

LDO: 2 x 500 CM

Town Water storage

4 x 3000 CM underground basins for town water storage

Supply from KWSB through 12 inches line

Supply from steel mills through 8 inch line

Statistical Data of the Plant

Thermodynamics -II Project

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Figure 1 Operating conditions for all generating units at BQTPS

Figure 2 Simplified T-s diagram of steam/water

Thermodynamics -II Project

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Figure 3 Detailed T-s diagram of the boiler steam/water heating process

Process Flow Diagram

Thermodynamics -II Project

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T_S diagram for Brayton Cycle & Rankine Cycle.

Thermodynamics -II Project
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Figure 4 T-S Diagram

Figure 5 T-S Diagram

The gas turbine efficiency is 32.3% and over all Efficency after rankine is 45%

Real Problems Occurring in the Plant (at BQTPS)

The boiler feed pump trip when

o the water level is high and when low,
o pump trip when temperature is high
o when oil level is low
o when lubrication oil temperature is high
o if drain valve is opened mistakenly
o when suction valve is not open
o when level is high or low at derator tank
Efficiency decreases if combustion is not taken proper then much fuel
is required
Efficiency decreases whenever there is leakages in the steam line
Efficiency decreases whenever boiler tubes leaked because water
makeup get filled
Unit trip
o When both BFP trips
Thermodynamics -II Project
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o If vacuum is not controlled

o Vacuum get low or high
o When CWP pump trip then
o When Hp heater 5,6 temperature high then unit trip
o When CP pump trip
o When feed water level high or low
Problems occurs when the open and close system temperature is high

Thermodynamics -II Project

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