Industrial Engineering Knowledge Center: Industrial Engineering in Electrical Engineering

Friday, April 9, 2021

Industrial Engineering in Electrical Engineering

Ubiquity of Industrial Engineering Principle - Industrial Engineering is applicable to all branches of engineering.

Picture source: https://www.engie.com/en/activities/thermal-energy/thermal-power-stations

https://www.kepco.co.jp/english/energy/fuel/thermal_power/shikumi/index.html

Thermal Electricity Generation - ASME - Gilbreth Process Chart for Productivity Improvement

The process chart records all activities taking place in the process under 5 major operations of the process.

1. Operation - Processing the inputs into the process.

2. Inspection - Inspection activities

3. Transportation and mechanical and manual handling activities in the process.

4. Delays occurring the in the process - Electricity may not be produced. Equipment may remain idles. Delays occur due to problems purchase planning, production quantity planning, manpower planning, maintenance planning etc.

5. All stores and items stored in the process. The incremental cost of stores has to be brought down. Stores procedures may lead to elongation of cycle times and delays.

Related News Relevant for Industrial Engineers in Power Plants

1. Operation - Processing the inputs into the process.

New Paths to Productivity in Power Generation

AUGUST 07, 2017

https://www.bcg.com/en-in/publications/2017/power-utilities-energy-environment-new-paths-productivity-power-generation

Methods of Improving the Efficiency of Thermal Power Plants

Tongjun Zhang 2020 J. Phys.: Conf. Ser. 1449 012001

[1] Harvey, Abby et al. 2017 History of Power: The Evolution of the Electric Generation Industry

Powermag. [Online] Available: https: //www. powermag. com/

history-of-power-the-evolution-of-the-electric-generation-industry [Accessed on Aug. 20,

2019].

[2] BP p.l.c. 2019 BP Statistical Review of World Energy (68th edition). UK: Pureprint Group Limited.

[3] Swapan Basu and Ajay Kumar Debnath 2019 Power Plant Instrumentation and Control Handbook

(2nd Edition). Academic Press p 1152

[4] W He, H Zhu, Y G. Liu, G Z Yi, and S C Pan 2019 Forest for ultra-super critical power generation

technology China Energy and Environmental Protection vol 41 chapter 6 pp 77-81

[5] Augusto Di Gianfrancesco 2016 Materials for Ultra-Supercritical and Advanced

Ultra-Supercritical Power Plants Woodhead Publishing

[6] Q C Fei, C Liang 2012 Analysis on Energy Saving for Water Cooling System in Thermal Power

Plants Electric Power vol 9

[7] L J Chen, L J Mi, C Xu,and Y Lei 2010 Development and Analysis of Direct and Indirect Air

Cooling under New Situation Power System Engineering vol 26 chapter 6

[8] Y Q Kong, W J Wang, X W Huang, L J Yang, X Z Du,and Y P Yang 2017 Direct dry cooling

system through hybrid ventilation for improving cooling efficiency in power plants Applied

thermal engineering: Design, processes, equipment, economics vol 119 5 June pp 254-268

[9] Y Y Jiang, X Z Du, H M Hu, and Z G Li 2018 Thermodynamic characteristics of thermal power

plant with hybrid (dry/wet) cooling system Energy 2018

[10]G Xu, L Zhou,S Zhao, F Liang, C Xu, and Y Yang 2015 Optimum superheat utilization of

extraction steam in double reheat ultra-supercritical power plants Applied Energy vol 160 pp

863–872

[11]Y J Ye and S L Shen 2011 Characteristics of European High-Efficiency Coal Fired Units and

Their Implications for Chinese Power Plant Electric Power Construction vol 32 chapter l pp

54-58

[12]K L Xu, Y H Xiong, H 2015 Pan Reheat Pressure and Feed-water Enthalpy Rise Optimization of

Double Reheat Unit Turbine Technology vol 57 chapter 10 pp 371-373

[13]K Wang, Y Q Chen, B H Huang, X F Chen 2011 Performance Research on Domestic Gas-Steam

Combined Cycle Unit North China Electric Power 4 pp 18-21

2. Inspection - Inspection activities

Thermal Power Plant Performance Testing: Major Equipment Performance Testing, Boilers, Turbines, Condensers, Pumps, Fans, Test Methodology and Code Requirements, Equipment Efficiency, Heat Rate Calculations, Correction Factors

Introduction

This seminar provides detailed description of the all performance testing methods for all thermal power plant equipment including boilers, turbines, condensers, pumps, fans, deaerators, and feedwater heaters. The methodology, and code requirements for the performance tests for all thermal power plant equipment will be covered thoroughly in this seminar. The preparatory work and instrumentation required for each test will be described in detail in this seminar.

The efficiency calculations for all the equipment used in circulating fluidized-bed (CFB) boiler and pulverized coal boiler power plants will be covered in-depth in this seminar. All the processes, operational and maintenance activities, capital projects, technical options, potential initiatives and incentives to implement upgrades/repairs for increasing the power plant equipment efficiency will also be covered in detail. This seminar will also provide a thorough explanation of CFB and pulverized coal boiler technology including hydrodynamics, combustion, emissions, design considerations, gas-solid separators, design of CFB and pulverized coal boiler components, management of solid residues, materials, stoichiometric calculations, and model for sulfur capture. The operation, maintenance, testing, and refurbishment options of all the equipment and systems used in CFB and pulverized coal power plants will be covered in detail including, boilers, superheaters, reheaters, turbines, condensers, feedwater heaters, deaerators, pumps, compressors, fans, electric generators, instrumentation and control systems, and governing systems, etc. All the factors which affect CFB and pulverized coal boiler power plant efficiency and emissions will be explained thoroughly. All the methods used to calculate the heat rate of CFB and pulverized coal power plants will be covered in detail. All the areas in CFB and pulverized coal boiler power plants where efficiency loss can occur will be explained. This seminar will also provide up-dated information in respect to the following methods used to improve CFB boiler and pulverized coal boiler power plant heat rate:

Optimizing the Combustion Process and Sootblowing

Controlling the Steam Temperature

Recovering Moisture from Boiler Flue Gas

Performing Steam Turbine Maintenance

Lowering Condenser Back Pressure

Pre-drying High Moisture Coal and Reducing Stack Temperature

Seminar Outcome

Thermal Plant Performance Testing: Gain a thorough understanding of all the performance testing methods for all thermal power plant equipment including boilers, turbines, condensers, pumps, fans, deaerators, and feedwater heaters.

Performance Test Methodology and Code Requirements: Understand the methodology, and code requirements for the performance tests of all thermal power plant equipment

Performance Test Preparatory Work and Instrumentation: Learn about the preparatory work and instrumentation required for each equipment performance test in a thermal power plant

Equipment Efficiency Calculations: Gain a thorough understanding of the efficiency calculations for all the equipment used in circulating fluidized-bed (CFB) boilers and pulverized coal boilers power plants

Calculating the Heat Rate of CFB and Pulverized Coal Boiler Power Plants: Learn all the methods used to calculate the heat rate of CFB and pulverized coal boiler coal power plants

Benefits of Lowering the Heat Rate of CFB and Pulverized Coal Boiler Power Plants: Understand all the benefits of lowering the heat rate of circulating fluidized-bed boiler coal power plants

Methods Used to Improve CFB and Pulverized Coal Boiler Power Plants Heat Rate: Gain a thorough understanding of all the methods used to improve the heat rate of CFB and pulverized boiler coal power plants

Processes, Operational and Maintenance Activities in CFB and Pulverized Coal Boiler Power Plants: Discover all the processes, operational and maintenance activities used to improve the heat rate of CFB and pulverized coal power plants

Capital Projects Used to Improve the Heat Rate of CFB and Pulverized Coal Boiler Power Plants: Learn about all the capital projects used to improve the heat rate of CFB and pulverized coal power plants

Technical Options for Improving the Heat Rate of CFB and Pulverized Coal Boiler Power Plants: Understand all the technical options used to improve the heat rate of CFB and pulverized coal boiler power plants

Potential Initiatives and Incentives to Implement Upgrades/Repairs for Improving the Heat Rate of CFB and Pulverized Coal Bed Boiler Power Plants: Discover all the potential initiatives and incentives to implement upgrades/repairs for improving the heat rate of CFB and pulverized coal power plants

Factors Affecting CFB and Pulverized Coal Boiler Power Plants Efficiency and Emissions: Learn about all the factors which affect CFB and pulverized coal boiler power plants efficiency and emissions

Areas in CFB and Pulverized Coal Power Plants where Efficiency Loss Can Occur: Discover all the areas in CFB and pulverized coal power plants where efficiency loss can occur

Optimize the Operation of CFB and Pulverized Coal Power Plant Equipment and Systems to Improve the Plant Heat Rate: Understand all the techniques and methods used to optimize the operation of CFB and pulverized coal power plant equipment and systems to improve the plant heat rate

CFB and Pulverized Coal Power Plant Equipment and Systems: Learn about various types of CFB and pulverized coal power plant equipment and systems including: boilers, superheaters, reheaters, steam turbines, governing systems, deaerators, feedwater heaters, coal-handling equipment, transformers, generators and auxiliaries

Special Feature

Each delegate will receive a digital copy of the following materials written by the instructor:

“POWER GENERATION HANDBOOK” second edition published by McGraw-Hill in 2012 (800 pages)

Excerpt of the relevant chapters from the “POWER PLANT EQUIPMENT OPERATION AND MAINTENANCE GUIDE” published by McGraw-Hill in 2012 (800 pages)

THERMAL POWER PLANT PERFORMANCE TESTING MANUAL (includes practical information about all the performance testing methods for all thermal power plant equipment - 300 pages)

Course Materials

Each participant will receive a complete set of course notes and handouts that will serve as informative references.

https://www.tlnt-training.com/14511/Thermal-Power-Plant-Performance-Testing-Major-Equipment-Performance

Toshiba Group Develops Inspection Technology for Plant Facilities and Equipment in High Inaccessible Places

- To provide safe and secure inspection solution by combining Group’s cyber and physical technologies.

October 29 2019

Toshiba Corporation

Toshiba Energy Systems & Solutions Corporation

https://www.toshiba-energy.com/en/info/info2019_1029.htm

3. Transportation and mechanical and manual handling activities in the process.

Materials Handling In Power Plants

MATERIAL HANDLINGTECHNOLOGY

On Nov 30, 2013

https://engmag.in/materials-handling-in-power-plants/

5. All stores and items stored in the process. The incremental cost of stores has to be brought down. Stores procedures may lead to elongation of cycle times and delays.

Related Information

Increasing power plant productivity to cover the ever-rising demand for energy.

The world’s largest producers of power generation equipment build on Oerlikon advanced materials, functional coatings or process technologies to improve performance and cut the environmental impact of energy generation systems.

Recently, our products improved the wear resistance of steam turbine components by a factor of 25. (2021).

Oerlikon materials and coating technologies for hydropower turbine components reduce material erosion by a factor of up to 50 and increase the service life of components three to five times compared to uncoated components. (2021)

https://www.oerlikon.com/en/industries/energy/

Productivity Science of Power Plants

FACTORS AFFECTING PRODUCTIVITY IN THE LARGE THERMAL POWER GENERATION STATIONS IN KENYA

Mungatana Mwaka

2007, MBA Thesis

http://erepository.uonbi.ac.ke/handle/11295/21342

Thermal Power Plant - Technical Note
http://www.slideshare.net/mastersheel007/thermal-power-plant-s

Manual on Best Practices for Thermal Plants in India
ftp://asiapacificpartnership.org/PowerGenTF/Power_Plant___All_pages.pdf
CII - USAid - ICICI Bank Report

Detailed Note on Cost Reduction Opportunities Power Systems
http://nraoiekc.blogspot.com/2013/11/cost-reduction-opportunities-in-power.html

International Comparison

Comparison of Power Plants Efficiency among 73 Countries, by Tser-Yieth Chen, Tsai-Lien Yeh, and Yi-Ting Lee, Journal of Energy
Volume 2013 (2013), Article ID 916413, 8 pages
http://www.hindawi.com/journals/jen/2013/916413/

Productivity in Generation

Productivity of Grid connected plants in Nicaragua
http://mpra.ub.uni-muenchen.de/49356/1/MPRA_paper_49356.pdf

Energy Conservation in 210 MW Thermal Plant
http://www.emt-india.net/Presentations2009/3L_2009Jan29-30_PowerPlant/Day1/2.%20NPC-%203L%20programme_%2029.%2001.%2009.pdf

Productivity in Distribution

Improving Efficiency in Transmission and Distribution System
Mallesh Gadeppanavar and , Vinay Pattanashetti
Electrical and Electronics Engineering department, Angadi institute of technology and management Belgaum-590008, India
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 3, March 2013)

http://www.ijetae.com/files/Volume3Issue3/IJETAE_0313_25.pdf

Productivity of Boilers in Thermal Plants

An Investigation Of Productivity In Boilers Of Thermal Power Plants With Fuzzy Gain Scheduled PI Controller, January 2010
http://ijerad.kku.edu.tr/sayi_3/IJERAD1001_09.pdf

Optimization of Components and Products