Resource Person/ Facilitator:

Mr. Sunil B. Kumbhar,
Deputy General Manager, Sitson India Ltd, Pune.

Summary:

The Department of Mechanical Engineering organized a guest lecture on the topic “Advanced Thermal Power Plant Layout & Piping Design” for Third Year Mechanical Engineering students. The session was conducted by Mr. Sunil B. Kumbhar, an industry expert with over 20 years work with company Adani Power plant, Ambuja Cement, ThyssenKrupp Industries.

Key Highlights of the Session

 🔹 Understanding of Overall Plant Layout

1. Importance of optimal equipment placement for safety, efficiency and maintenance
2. Zoning of boiler area, turbine hall, cooling system, coal and ash handling areas

🔹 Steam–Water Cycle Arrangement

1. Layout of boiler, superheater, economizer, condenser and feedwater systems
2. Flow path optimization for minimum heat and pressure losses

🔹 Piping Design Principles

1. Selection of pipe materials for high temperature and high pressure service
2. Stress analysis, thermal expansion and pipe support design
3. Routing of steam, feedwater, condensate and auxiliary pipelines

🔹 Boiler and Turbine Interconnection

1. Main steam, reheat and feedwater piping layout
2. Minimizing bends and joints to reduce energy losses

🔹 Safety and Maintenance Considerations

1. Provision for isolation valves, drains, vents and safety relief systems
2. Accessibility for inspection, repair and emergency operations

🔹 Thermal Expansion and Flexibility

1. Use of expansion loops, bellows and flexible joints
2. Support and hanger arrangement to prevent pipeline stress

🔹 Modern Design Practices

1. Use of 3D modeling and CAD tools for layout and clash detection
2. Integration of piping with structural and equipment layout

🔹 Environmental and Space Optimization

1. Compact layout for reduced land use
2. Proper routing to avoid heat loss and improve plant efficiency

🔹 Industry Standards and Codes

1. Application of ASME, IS codes and power plant piping standards

🔹 Impact on Plant Efficiency and Reliability

1. Proper layout and piping design improves heat rate, safety and long-term performance

The lecture provided valuable industrial insights to the students, bridging the gap between academics and real-world applications. It motivated the mechanical students to understand the scope, challenges, and future opportunities in Boiler manufacturing industries. The session concluded with an interactive Q & A, where students clarified their queries about industry expectations and career paths.

Objective / Purpose:

1. To provide students with a practical understanding of modern thermal power plant layout and piping systems.
2. To familiarize students with the arrangement of major equipment such as boilers, turbines, condensers, cooling towers, coal handling and ash handling systems.
3. To explain the design principles of high-pressure and high-temperature piping systems used in thermal power plants.
4. To develop the ability to analyze steam, feed water and condensate flow paths for efficient plant operation.
5. To introduce industrial standards, codes and safety practices used in power plant piping design.
6. To make students aware of thermal expansion, stress analysis and pipe support requirements in real plant installations.
7. To bridge the gap between theoretical concepts and actual industrial practice.
8. To enhance students’ employability by exposing them to modern power plant engineering methods.