Power Generation
Power Generation

Image Image Simgrosys engineering solutions to world's leading power generation equipments manufacturers across the product life cycle chain. Our team of engineers has years of engineering experience in solar, tidal and wind energy segments and thus provide best-in-class engineering solutions right from energy generation to transmission and distribution.

We have helped our customers in improving performance efficiency to keep the product cost competitive. We develop eco-friendly technologies to achieve clean & sustainable energy generation goals. Our energy-experts have strong knowledge of various standards and regulations and provide localized engineering solutions to clients worldwide. Besides this, our team also provides project management, procurement assistance, vendor evaluation and liaison services with industry specific regulatory and certifying authorities. Simgrosys provides engineering support in turbines development, design up gradation and retrofit projects for industrial and utility turbines.

Simgrosys provides support in,

  • Gas and steam turbines (gas, compressor and combustion technology)
  • Auxiliary systems (Skid engineering: Inlet, exhaust enclosure, HVAC, dual fuel, lube oil, hydraulic)
  • Renewable energy (wind)
  • Diesel engine, turbine and generation controls, electrical engineering
Turbine and Compressor Design Engineering Services (Component, assembly and sub systems)
  • Design engineering for turbine and turbine components
  • Computer-aided engineering (CAE) simulations, detailing and BoM
  • Skid engineering design and manufacturing support (Mechanical, fluid, electrical, control and instrumentation)
  • Auxiliary systems design engineering and manufacturing support (Inlet, exhaust, coolings, generator and controls, transformers)
  • Dimensional management/stack-up analysis, value engineering, reliability engineering
  • Engineering Change Management
  • Manufacturing and Supply Chain Management Engineering services
  • Supplier qualification, Techno commercial review
  • Design change/supplier deviations
  • Supplier document review
  • Repair and Maintenance Solution
  • Scheduling and repair logistics (EAM)
  • Part catalogues (PLM and ERP),O&M manuals (Tech Pub)
  • Machining solutions (digital manufacturing)
  • Asset management, remote monitoring and diagnostics


Steam by-pass valve

Simgrosys supports in the process of HP turbine bypasses valve fatigue analysis in a lifetime cycle. Our services cover all valve operating conditions - cold start, warm start, hot start, and turbine trip and involve design and optimization, FEM modeling, CFD modeling to predict the thermal loads acting on the valve components and its effects on the structural and thermal deformation.

We perform CFD simulation of the steam and cooling water flow through the valve to calculate surface temperatures and pressures acting on the wetted surfaces of the pressure boundary component. A number of steady state calculations at regular time intervals during the valve operation until it approaches steady state conditions will be performed. The output from these calculations will be the temperature and pressure of the steam next to the pressure boundary wall throughout the valve.

FE simulation of the pressure boundary component

We perform transient non-linear calculation of stresses in the pressure boundary due to applied loads allowing for material non-linearity. Temperatures in pressure boundary component will be calculated using temperatures on wetted surfaces calculated in CFD simulations inside the pressure boundary and an appropriate assumption on the outer surface of the insulation. Time varying pressures acting on wetted surfaces taken from CFD calculations.

The results of each transient simulation of the four operating conditions will be post processed to assess the fatigue life of the pressure boundary component.

Heat Exchangers

AIR COOLED CONDENSERS

Simgrosys design teams design air cooled condenser for thermal power stations. Air Cooled Condensers directly condense exhaust steam from the steam turbine and return condensate to the boiler without water loss. They are frequently used in electrical power plants and waste to energy plants of all sizes. An Air Cooled Condenser (ACC) is a direct dry cooling system where the steam is condensed inside air-cooled finned tubes. Its overall performances is verified by Simgrosys design support centre in Coimbatore, India

Simgrosys validates the long-term mechanical and thermal integrity, corrosion rate and freeze resistance, fan power consumption, reliable operation by simulating the operation using FEA and CFD simulations. An Air Cooled Condenser (ACC) is made of modules arranged in parallel rows. Each module contains a number of fin tube bundles. An axial flow, forced-draft fan located in each module forces the cooling air across the heat exchange area of the fin tubes. CFD Flow and heat transfer analysis is performed by Simgrosys engineers to check the effectiveness of these fins.

The most popular style of Air Cooled Condenser is the modularized A-Frame design, used on power plants of all sizes is designed based on FEA based simulations.

Cooling Towers

A cooling tower is a specialized heat exchanger in which air and water are brought into direct contact with each other in order to reduce the water's temperature. As this occurs, a small volume of water is evaporated, reducing the temperature of the water being circulated through the tower. Water, which has been heated by an industrial process or in an air-conditioning condenser, is pumped to the cooling tower through pipes.

The water flows through nozzles, spraying water into the material called "fill," which slows the flow of water through the cooling tower, and exposes as much water surface as possible for maximum air-water contact. As the water falls down through the cooling tower, it is exposed to air, which is being pulled through the tower by the electric motor-driven fan. When the water and air meet, a small amount of water is evaporated, creating a cooling action. The cooled water is then pumped back to the condenser or process equipment where it becomes reheated. It will then be pumped back to the cooling tower to be cooled once again. Simgrosys design and develops all kind of cooling towers that include cross flow, counter flow, natural and forced draft cooling tower.

Our optimally designed system helps to design and engineer to work together as an integrated system for efficient performance and long life. Simgrosys designs gearboxes in a variety of designs and reduction ratios to accommodate the different fan speeds and horsepower of cooling towers. Perhaps, Simgrosys supports to design Drift eliminators to remove water droplets from the discharged air, drift eliminators cause the air and droplets to make sudden changes in direction. This causes the drops of water to be separated from the air and deposited back into the tower. The performance of spray nozzles also is reviewed by Simgrosys simulation team

Simgrosys engineers design and optimize the performance of cooling tower fans to get large volumes of air efficiently, and with minimum vibration. They analyze materials of manufacture to withstand the corrosive effects of the environment in which the fans are required to operate.