Utility Plant Description

UTILITIES PLANT DESCRIPTION Presented By:

Zaheer Anwer (UM UTY)

We Provide the Following Utilities 

Demin Water



BFW



Steam



Power



Cooling Water



Instrument Air



Inert Gas



Air Conditioning

 Waste Management  Potable Water

Water Sources • Surface Source –Includes streams, drainage areas, reservoirs and rain water.

• Ground Water –Includes wells and springs water.

F D C

E

Road

L

W

U

Z

WELL AREA N

H

B A

K

J

G

X

I

S T

M

P

V

O

Y

al Can

Q R

< 32 ppm 32-50 ppm > 50 ppm

Canal Intake

Water Reservoir

Physical Properties • Transparent and colorless liquid. • Pure water has no taste. • High surface tension. • Same composition in liquid, solid or gas form

Impurities in Water Ionic and dissolved

Nonionic & undissolved

Gaseo us

Catio nic

Anionic

Calcium Magnesi um Sodium Potassi um Ammoni um Iron Mangan ese

Bicarbona te Carbonate Hydroxide Sulfate Chloride Nitrate Phosphate Silica Organic matter Color

Turbidity, silt, mud, dirt and other suspended matter Organic matter Microorganisms Bacteria Oil Corrosion products

Carbon dioxide Hydroge n sulfide Ammoni a Methane Oxygen Chlorine  

Poly Lime

Alum

CLARIFIED WATER Pre-treatment of water CLARIFIER FILTERED FILTER SLUDGE WATER

Principle of Clarifier • •

Sedimentation – Liquid solid separation process after the water has been coagulated and flocculated. Coagulants – Widely used Alum, Ferrous and ferric salts.

•

Organic Polymers – Called poly electrolytes used as a coagulant aids to improve treatment. – Long chain anionic polymers are normally used.

•

Advantages with coagulation / Flocculation i. settling rate increases ii. Sludge formed denser

Lime Softening • Lime softening is the process used to reduce temporary hardness of water by treatment with lime. • • •

Ca(HCO3)2 + Ca(OH)2  2CaCO3 + 2H2O Mg(HCO3)2 + Ca(OH)2 Mg(OH)2+ 2CaCO3 +2H2O CO2 + Ca(OH)2

 CaCO3 + H2O

Clarifier Top View

Mixing Zone

Settling Zone

Deionization of Water – Cation Exchange Resin Removes cations from water

–Anion Exchange Resin Removes anions from water

Ion Exchange Reactions –Cation Exchange Reaction −− + + SO  Ca 4  − + + Cl Mg  + − − RSO3 H + → RSO  3 − + HCO K  3 Na+  SiO − − 3

 Ca+ +  ++  Mg + + H  +  K  Na+

−− SO  4  − Cl   − HCO  3  SiO3− −

Ion Exchange Reactions – Anion Exchange Reaction

(

)

 R N+ C H  O H− + H + 3 3  

−− −− SO SO  4  4   − − C l  Cl  + −  R N+ C H  → + H O H   3 − −   3   H C O H C O   3 3   SiO3− − SiO3− −

(

)

Pre-heating De-aerator

Hydrazine

BFW and STEAM V-201

distribution system B-605 KS header HS header LS header

B-601/602

Power Generation • Two Gas Turbines

18 MW Each

• Two Emergency diesel Generators

1.5 MW Each

• Fermont Generators ( for Emergency)

200 KW each

Power Generation GAS TURBINE

Gas Turbine Atmospheric Air

Fuel

Ignition Source

Exhaust

Combustion Chamber Torque Output to

Compressor

Torque Output Turbine to driven Load

Accessories

Rotor

Gas Turbine Cycle 1 – 2 : Reversible Adiabatic Compression

(Ideal)

1 – 2’ : Ir-reversible Adiabatic Compression

(Actual)

2’– 3 : Constant Pressure Heat Supply in combustion chamber 3 – 4 : Reversible Adiabatic Expansion

(Ideal)

3 – 4’ : Ir-reversible Adiabatic Expansion

( Actual)

3

T 2 2’ 4’ 4

1

S

FFC GAS TURBINES No. of Gas turbines Gas Turbine make

: 02 : General Electric Co. USA DATA SUMMARY

Gas Turbine model series (Specific model: PG-5341) Gas Turbine application Base out put Operation cycle Shaft speed Air inlet temp. Exhaust temp. (On Gas fuel) Atmospheric Pressure

: MS-5001 : Single Shaft Unit : Generator Drive : 18 MW : Simple : 5089 rpm : 43 Ċ : 482 Ċ : 0.99 bar22

FFC GAS TURBINES Compressor Section Compressor type No. of compressor stages Inlet Guide Vanes Turbine Section No. of Turbine Stages

: Axial Flow Horizontal Split Casing : 17 : Variable : Two

Combustion Section Combustors : 10 ( multiple combustors, reverse flow design) Chamber Arrangement : Concentrically (located around the compressor)

FFC GAS TURBINES

• • •

: Pressure atomizing 1 – Fuel nozzle : 02, Electrical type, spring – Spark plugs retracting – Flame detectors: 02, ultra-violet type Starting system – Starting device : Diesel Engine Reduction Gear : 5089/3000 rpm – Shaft speed ratio Generator – Type : Air cooled open ventilated – Rating : 31375 kva – Rpm : 3000 – Volts : 6300 volts : 50 Hz. – Frequency

per chamber injected, self

COOLING WATER BASIN

COOLING TOWER

UTILITIES

PROCESS

Air Conditioning Absorption Chillers •

Plant site

•

Township 02 Units (245 Tons Each) & 01 Unit (450 Tons)

02 Units (210 Tons Each)

Absorption Chillers Use Water as Refrigerant & LiBr as absorbent Working Principle: 1) Water Boils and Flash-Cools Itself at Low Temperatures When Maintained at a High Vacuum. (e.g. At 6.35 mm Hg B.P. of water is 4.4 °C) 2) Some Salt Solutions have ability to absorb water vapors.

Main components • Evaporator: Returning chilled water is cooled indirectly by water sprayed over tubes. Due to vacuum, water flashes and cools the remaining water.

• Absorber: Strong salt solution absorbs water vapor flashed in the evaporator. Total heat load is transferred to cooling water.

• Heat Exchanger: Used to improve cycle efficiency by heat between weak solution leaving the Absorber & strong hot solution returning from the Generator.

Main components (Cont’d.) Generator: A steam heated section used to restore solution concentration by boiling off the water vapor absorbed .

Condenser: The water vapor boiled off in the Generator is condensed in this section and returned to the Evaporator

Air Conditioning

The Climatisation System Air Duct

window

room Coil C

Fan

C Pump Control valve chilled water chiller

Wall

Waste Management • Liquid Wastes Cooling Tower Blow Down Oily water Storm/ washing water Chemically Contaminated Water • Solid Wastes Chromate Sludge Lime Sludge

Chromate Removal Plant • Why to remove Chromate? • Electro chemical Cells. 6H2O + 6e-

3H2 + 6OH-

3Fe 3Fe+2 + 6e3Fe+2 + 4OH- + CrO4 + 4H2O 3Fe(OH)3 + Cr(OH)3 Zn+2 + 2OH- Zn(OH)2

• Sludge Contact Clarifier. • Anthracite Filters • Disposal options

Chromate Removal Plant Clarifier & Filters

Electrochemical Cell

Chemical and Oily Water treatment • Separation of oil from water • Neutralization of Chemical water • Disposal Options Evaporation Ponds SCARP Drain line • Lime and Chromate Sludge Disposal

Instrument and Plant Air • • • • •

Requirement Quality Moisture Removal Filtration Difference between Instrument and plant Air

IN S T R U M E N T A IR P L A N T

T o P la n t A ir Header

A ir D r y e r s

In s tr u m e n t A ir S to r a g e T a n k

F r o m M a in C o m p re s s o r

c a p a c ity 1 3 0 0 N M C

F ilte r s

A fte r C o o le r

A fte r C o o le r

2 n d S ta g e

2 n d S ta g e

A ir

In te r S ta g e C o o le r

A ir

In te r S ta g e C o o le r 1 s t S ta g e

T o In s tr u m e n t A ir C o m p r e s s o r A ir H e a d e r

1 s t S ta g e

A ir C o m p re s s o r

Inert Gas Plant • Inert Gas Uses – Purging of vessels, tanks, pipelines, heat exchangers – To maintain inert atmosphere in oil consoles – Consumption during Shutdown/Turnaround – Blanketing of catalysts • Generation Processes – Natural Gas Combustion (Process Employed at Base Unit) – Air Liquefaction Process (Process Employed at Expansions Unit)

Inert gas Generation • Natural Gas Combustion

CH4 + 2O2 2CH4+ 3O2

CO2 + 2H2O 2CO + 4H2O

• Main Equipments – – – – –

Combustion Chamber Main Compressors Carbon Dioxide absorbers Booster Compressors Storage tank

Inert Gas Generation CO2 and Moisture Removal CO2 Adsorbers Ultrasorbers Condensate traps