Supercritical PMI

NTPC LIMITED

SUPERCRTICAL TECHNOLOGYSUPERCRTICAL TECHNOLOGY

SELECTION OF BOILERAND

ITS AUXILIARIES

PRESENTATION BY PROJECT ENGINEERINGPANKAJ KR GUPTA

WHY SUPERCRITICAL TECHNOLOGY

WHAT IS THE ADVANTAGE AND DISADVANTAGE OF THIS TECHNOLOGY FROM SUBCRITICAL

TECHNO ECONOMICS

SELECTION OF SUPERCRITICAL PARAMETERS

WHAT IS THE DIFFERENCE BETWEEN SUPERCRITICAL AND SUBCRITICAL IN MAJOR EQUIPMENTS/ COMPONENTS

BOILER EFFICIENCY, TURBINE EFFICIENCY,CYCLE EFFICIENCY

PART-I: SUPER CRITICAL TECHNOLOGY

PART-II: TECHNO ECONOMIC STUDY

PART-III DESIGN OF BOILER & ITS AUX.

PART-IV : SIPAT- I BOILER FEATURES

PARTPART--II

SUPERCRITICAL TECHNOLOGYSUPERCRITICAL TECHNOLOGY

0

10

20

30

40

50

60

1880

1900

1920

1940

1960

1970

1980

1990

2000

2020

Ther

mal

Efficien

cy (%

)

Rankine Barrier

Supercritical boiler IGCC

PFBC

AGMCFC

IGHAT

Pulverised Coal

First Station

USPCFIGMCF

SUPC

SUPCF: Sub Critical Pulverised Coal FiredPFBC: Pressurised Fluidised Bed CombustionIGCC: Integrated Gasification Combined CycleIGHAT: Integrated Gasification Humid Air TurbineUSPCF: Ultra Super Critical Pulverised Coal FiredIGMCFC: Integrated Gasification Molten Carbonate Fuel CellAGMCFC: Advanced Gasification Molten Carbonate Fuel Cell

Evolution Of The Coal Fired Plant

Rankine Cycle Efficiency

net workn = --------------

Qin

Cycle thermal efficiency is improved by increasing the mean temperature of heat addition process. This temperature is increased because the boiler inlet pressure sets the saturation temperature in Rankine cycle.

Total fuel inputHeat Rate =------------------

Electrical generation (KW)

860= ------------------- Kcal/Kwh

n

T em

p er a

ture

( C)

Enthalpy

538

Expansion Line

170 kg/cm2

240 kg/cm2

Critical Point 225 kg/cm2

Condensation

EFFECT OF SUPERCRITICAL PARAMETERSEFFECT OF SUPERCRITICAL PARAMETERS

THERMAL EFFICIENCY IMPROVEMENTTHERMAL EFFICIENCY IMPROVEMENT

169 246 310STEAM PRESSURE (kg/cm2)

Base Efficiency 38.6%

%

0.69

0.27

0.35

0.33

0.32

5380C/5380C

5380C/5660C

5660C/5660C

5660C/5930C

6000C/6000CE

ffic

ienc

y In

crea

se

0.41

5660C/5660C

SUPERCRITICAL PLANTSSUPERCRITICAL PLANTS--WORLDWIDE TRENDSWORLDWIDE TRENDS

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

1968

1971

1974

1977

1980

1983

1986

1989

1992

1995

1998

2001

2004

2007

2010

2013

CALENDER YEAR

CA

PAC

ITY

(MW

)

Total Steam Capacity

Source ABB

Supercriticalplants

TECHNOLOGY ADOPTION STATUSTECHNOLOGY ADOPTION STATUS

0 50 100 150 200 250

CISUSA

JAPAN

GERMANY

KOREA

CHINA

DENMARK

IRAN

ITALY

SPAINNETHERLANDS

TAIWAN

THAILAND

CUBA

FINLAND

1950s 1960s 1970s 1980s 1990s

Number of UnitsNumber of Units

Estimated World Total

600 Units

Size Range 300-399 400-499 500-599 600-799 800+Sub-critical 76.5 77.4 76.3 78.5 77.2

Super critical 64.4 74.6 73.8 74.2 75.6

AVAILABILITY : SUPERCRITICAL VS SUBCRITICALAVAILABILITY : SUPERCRITICAL VS SUBCRITICALEPRI

EAF 1982-84Low availability in 1960s:

• Rapid unit size escalation• Low fuel quality tolerance• Inflexibility for cyclic

loading

Year 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998Subcritical 84.2 82.5 84.1 84.9 84.5 82.0 83.8 83.7 86.6 88.5 84.4

Supercritical 80.2 74.9 84.2 85.2 87.1 89.8 83.0 84.7 79.5 90.3 84.0

VGB

Report Concludes Report Concludes --No difference in availability with No difference in availability with .. present day design.. present day design.

JEPIC/FEPC Data- Supercritical units higher than subcritical unitsEPDC Experience- EPDC own plants do not show any difference.CIS Countries- Russian units have high availability.

SUPPLIERS OF SUPERCRITICAL PLANTSUPPLIERS OF SUPERCRITICAL PLANT

BOILER• B&W, USA• ABB-CE• MHI, JAPAN• PODOLSK, RUSSIA• FOSTER WHEELER, USA• IHI, JAPAN• ANSALDO, ITALY• TAGANROG, RUSSIA• BABCOCK HITACHI, JAPAN• STEIN MULLER, GERMANY• STEIN INDUSRIE, FRANCE• EVT, GERMANY• DEUTCHE BABCOCK,

GERMANY• MBEL, U.K.

TURBINE• GE,USA• LMZ, RUSSIA• WESTING HOUSE, USA• TOSHIBA, JAPAN• ABB, GERMANY• HITACHI, JAPAN• MHI, JAPAN• ANSALDO, ITALY• SIEMENS AG

SUPERCRITICAL PLANT BOILER SUPERCRITICAL PLANT BOILER TECHNOLOGY STATUSTECHNOLOGY STATUS

Type Construction Manufacturer Remarks

Spiral woundSmooth tubing

Stien/EVT Stienmuller Deustche Babcock

Benson/Siemens

Vertical Ribbedtubing

Under Indroduction

Suitable for variablepressure operation

Technology licenced bySiemens

Spiral woundSmooth tubing

CE, IHI, MHISulzer

Vertical Ribbedtubing

ABB-CE MHI

Suitable for slidingpressure operation

Vertical tube designdeveloped jointly bySulzer/CE/MHI

European Design

UniversalPressure type

Verticalbare tubing

B&W, FosterWheeler

IHI, Hitachi Babcock Taganrog & Podolsk

Used primary in USAand CIS countries

Am

ericanD

esign

Boiler SupercriticalType Once through, Single/ Two passFurnace

• Water walls

• Tube material• Tubing dia• Circulation

Pressure Parts

Startup system

Start up rate

Load following capability

Tolerance to coal quality

-Spiral bare tubing-Vertical bare/rifled tubing-Low alloy steel-31-38 mm-Forced once thru

-Increase in thickness of tubing-Increase use of Stainless steeland P-91 material in SH/RH

-Drain to condenser-Recirculation thru pump-Drain with regenerative heating

Higher

Better

Higher

MAJOR DIFFERENCES IN SUPERCRITICAL PLANT MAJOR DIFFERENCES IN SUPERCRITICAL PLANT

Critical Piping SupercriticalMain Steam piping• Size

• Thickness• Material

HRH piping

• Size• Thickness

• Material

Feed piping

Reduction in diameter due tolower specific volumeIncrease in thicknessChange in material P-22/X-20 toP-91

No change in diaNo change in thickness due to P-41 materialChange in material from P-22,X-20 to P-91

Increase in thickness


Steam Turbine SupercriticalCasings• Thickness

• Material

Rotor

Blade

Stop/control valves andInterconnecting piping

• Marginal increase inthickness

• Change in material 2 ¼ Cr 1Mo to 12 Cr

Change in material for part ofthe rotor (specific to Mfg)

Change in material for first fewrows to austinitic steel

Marginal change in thicknessand change in material 2 ¼ CrMo to 9 Cr steel.


Turbine Feed Cycle SupercriticalBoiler Feed Pump

HP Feed Water Heaters

• Increase in motor power• Increase in thickness of

casing• Increase in discharge

pressure of pump

Increase in thickness of tubesheet, tubes and waterbox.


Balance of plant Supercritical

Coal HandlingPlant

Ash handling Plant

CW System

Capacity Reduction by40t/hr

Capacity reduction by10t/hr

Capacity reduction by1%


MATERIAL APPLICATION FOR HIGH STEAM TEMPERATURESMATERIAL APPLICATION FOR HIGH STEAM TEMPERATURES

538 C 566 C 593 CCOMPONENT

2 1/4 Cr MoSH HDR MS PIPE

SH TUBE (HOT PARTS)

RH HDR RH PIPE

RH TUBE (HOT PARTS)

9 Cr steel 12 Cr steel

HP/IP ROTOR

HP/IP CASING

MAIN VALVE

18 Cr steel 20-25 Cr steel

2 1/4 Cr Mo steel 9 Cr steel

9 Cr steel 18 Cr steel

2 1/4Cr M V steel 12 Cr steel



TURBINETURBINE

BOILERBOILER

ENVIRONMENTAL ASPECTSENVIRONMENTAL ASPECTS

• Reduction in CO2, SO2 and NOx between 1.79% to 4.24%

• Reduction for 500 MW at 68.5% PLF per year is - CO2 78300 tons - SO2 365 tons - Nox 71 tons

SUPERCRITICAL ADVANTAGESSUPERCRITICAL ADVANTAGES

Enhancements• Plant efficiency 0.69% to 1.64%• Fuel tolerance More tolerant to coal

quality changes

Reductions• Coal Consumption • Ash production • CO2

• SO2

• Nox

Improvements• Startup time • Sliding Pressure Operation• Load following capability

1.79% to 4.24%

STEAM CONDITION DEVELOPMENT TRENDSTEAM CONDITION DEVELOPMENT TREND

1960s 1970s 1980s 1990s 2000s 2010s

MatureTechnology

MatureTechnology

Current Market Introduc-tion

R&D-USC

R&D-Advanced USC

(EUROPE)(EUROPE)

Subcritical 170 K/540oC/540o

Super critical 245/540/540

245/546/565

245-580/600

285-600-620

285-630/650

382-700/720ULTRA SUPERCRITICAL

Para

met

e rs

Year

SUPERCRITICALSUB-CRITICAL

SELECTION OF RATED PARAMETERSELECTION OF RATED PARAMETER

01020304050607080

246-

538/

538

246-

538/

566

246-

566/

566

300-

580/

580

NO

OF

UN

ITS

(%)

SELECTED PARAMETERS

MSP 246 kg/cm2

MST 5380C

RST 5660CUltr

a su

perc

ritic

al

PARTPART--IIII

TECHNOECONOMIC STUDYTECHNOECONOMIC STUDY

CASE STUDY FOR PIT HEAD CASE STUDY FOR PIT HEAD AND AND

LONG LEAD STATIONSLONG LEAD STATIONS

Base Price EstimatesBase Price EstimatesEquipment Unit

per MWCase-1169-538/538

Case-2246-538/538

Case-3246-538/566

Case-4246-566/566

Case-5246-566/593

Boiler Rs mill 8.32 8.63 8.69 8.86 9.04Turbine Rs mill 4.96 5.12 5.16 5.29 5.41Coal Handling Rs mill 2.36 2.36 2.36 2.36 2.36Ash Handling Rs mill 1.74 1.74 1.74 1.74 1.74BOP Rs mill 13.10 13.10 13.10 13.10 13.10Total Rs mill 30.48 30.95 31.05 31.35 31.65Difference % Base 1.54 1.87 2.85 3.84

Note- Cost given are in Rs.Millions/MW

Difference in boiler cost w.r.t. supercritical plant (case-3) is 4.5%.Difference in turbine cost w.r.t. supercritical plant (case-3) is 4.0%Difference in total cost w.r.t. supercritical plant (case-3) is 1.87%.

EFFICIENCY GAINEFFICIENCY GAIN(Indian ROM coal)

Unit Case-1 Case-2 Case-3 Case-4 Case-5Boiler Efficiency

% 87.5 87.5 87.5 87.5 87.5

Turbine Heat Rate

Kcal/Kwhr

1947 1913 1900 1883 1868

Gross Heat Rate

Kcal/Kwhr

2225.7 2186.6 2171.7 2152.7 2135.05

GrossEfficiency

% 38.64 39.33 39.60 39.95 40.28

Differential Base 0.69 0.96 1.31 1.64

SELECTION OF PARAMETERS FOR STUDYSELECTION OF PARAMETERS FOR STUDY

CASE MSP(Ksc)

MST(deg C)

RST(deg C)

1 169 538 538

2 246 538 538

3 246 538 566

4 246 566 566

5 246 566 593

Matured technologies

Current Market Introduction

Recommended Option

TECHNO ECONOMIC EVALUATION OF ALTERNATIVESTECHNO ECONOMIC EVALUATION OF ALTERNATIVES(246 kg/cm2 , 538 / 566)(246 kg/cm2 , 538 / 566)

Total six alternatives are discussed.

S.No. EconomicFactors

Pithead Stations Long LeadStations

1. Plant Sipat Cheyyur

ROM WASHED Washed2. Type of coalAlt-I Alt-II Alt-III Alt-IV Alt-V Alt-VI

3. Coal cost (Rs.) 441 441 441 700 700 1912

4. Coal costEscalation (%)

7 10 10 10 10 7

5. PLF(%) 68.5 68.5 85 68.5 85 68.5

TECHNO ECONOMIC FACTORS CONSIDEREDTECHNO ECONOMIC FACTORS CONSIDEREDSIPAT STAGESIPAT STAGE--I ROM COALI ROM COAL

ECONOMIC FACTORS• Debt Equity Ratio 70:30• Return on Equity 16%• Interest on loan 11.19• Depreciation 7.53%• O&M charges 2.5%• Inflation Rate 7%• Interest on working capital 16.25%

OTHER MAJOR FACTORS• Heat Rate 2225 Kcal/kwh (Base)• Auxiliary Power Consumption 8% (Base)• Fuel Oil Consumption 3.5 ml/kwh (Base)• Oil Cost 7275 Rs/kL• Coal calorific value 3200 kcal/kg

TECHNO ECONOMIC EVALUATIONTECHNO ECONOMIC EVALUATION--ASSUMPTIONSASSUMPTIONS

• Technology cost in total capital cost is zero• Capital cost of equipment is based on

competitive International prices.• Coal cost is based on administered pricing

mechanism

ANALYSIS OF SIPATANALYSIS OF SIPAT-- ROM COALROM [email protected]% PLF, COAL COST @68.5% PLF, COAL COST RsRs. 441 PER TON AND 7% COAL COST ESCALATION. 441 PER TON AND 7% COAL COST ESCALATION

S lCOAL Indian ROM Coal

Sub critical Super criticalCase-1 Case-2 Case-3 Case-4 Case-5

Parameter OptionBar –oC/oC

169-538/538 246-538/538 246-538/566 246-566/566 246-566/593Total Cost (Rs.crs) 1891.17 1918.12 1924.50 1943.85 1962.86

Cost Base 26.95 33.33 52.68 71.69

1.

CA

PITA

LC

OST

PE

R50

0MW

AdditionalCapital(Rs.crs) Yearly Servicing Cost Base 5.17 6.37 10.08 13.74

Heat rate (Kcal/kWh) 2225.7 2186.6 2171.7 2152.7 2135.05

Coal consump. (mt/year) 2.0538 2.0171 2.0032 1.9853 1.9688

Coal cost Rs./ton 441 441 441 441 441 Levelized value 157.22 154.42 153.35 151.99 150.71

2.

CO

ALC

ON

SUM

PTIO

N P

ER50

0 M

W

Yearlycoal bill(Rs.Crs) Reduction Base 2.81 3.88 5.24 6.51

3.Levelised COG Paisa/kWh 199.92 200.60 200.61 201.39 202.21

Total cost 1891.17 1905.92 1911.44 1918.88 1925.56Capital Costs(Rs crs.) Additional cost Base 14.75 20.27 27.27 34.394.

ImputedcostsPer 500MW

Coal Cost (Rs/T) 441.0 801.0 717.0 838.0 917.0

1. Sub critical Plant is most economical2. At coal cost of Rs. 717/- the supercritical plant becomes economical3.Imputed capital cost for supercritical plant is 1911 crores.

ANALYSIS OF CHEYUR ANALYSIS OF CHEYUR -- WASHED COALWASHED [email protected]% , COAL COST Rs.1912 PER TON AND 7% COAL COST [email protected]% , COAL COST Rs.1912 PER TON AND 7% COAL COST ESCALATION

SlNo

COAL Indian Washed Coal

Sub critical Super critical

Case-1 Case-2 Case-3 Case-4 Case-5

Parameter Option

Bar –oC/oC

169-538/538 246-538/538 246-538/566 246-566/566 246-566/593

Total Cost (Rs.crs) 1841.18 1870.08 1875.97 1895.21 1913.65

Cost Base 28.90 34.78 54.03 72.47

1.

CA

PIT

ALC

OST

PER

500

MW

AdditionalCapital(Rs.crs)

YearlyServicing Cost

Base 5.31 6.35 9.94 13.39

Heat rate (Kcal/Kwh) 2209.0 2170.00 2155.00 2136.00 2119.00

Coal consump. (mt/year) 1.7163 1.6855 1.6737 1.6587 1.6453

Landed Coal costRs./ton

1912 1912 1912 1912 1912

Levelizedvalue

569.65 559.43 555.50 550.52 546.07

2.

CO

AL

CO

NSU

MPT

ION

PER

500

MW

Yearlycoal bill(Rs.Crs)

Reduction Base 10.22 14.15 19.13 23.58

3. COG Paisa/Kwhr 349.72 347.68 346.52 345.91 345.47

Total cost 1841.18 1895.33 1916.11 1942.51 1966.13Capitalcost(Rs/crs) Additional

costBase 54.15 74.93 101.33 124.95

4. Imputedcostsper500 MW

Coat cost (Rs/ton) 1912 1022.0 890.0 1021.0 1111.0

1.Subcritical plant is most economical.2.Imputed capital cost for supercritical plant is 1916 crores.

SUPERCRITICAL TECHNOLOGYSUPERCRITICAL TECHNOLOGY-- ECONOMIC EVALUATIONECONOMIC EVALUATION

441 717 1912

3.8

6.3

Coal cost (Rs/ton)

Add

n.C

ap. S

ervi

ce C

ost

(Rs c

rs)

Yr.

Sav i

ng in

Coa

l Bill

(Rs.

Crs

)

CASECASE--3 : 246 kg/cm3 : 246 kg/cm22--53853800C/566C/56600CC

Shortfall

Cushion for Technology Cost

(-)

(+)

SupercriticalSubcritical

Breakeven

14.1

68.5% PLF , 7% Escalation

Addn capital of Rs. 33.3 crs

6.3

20.3

33.3

74.9

Add

n.C

ap. C

ost

(Rs c

rs)

MAIN CONCLUSIONMAIN CONCLUSION

• Technology - Mature and establish• Availability - Same as sub-critical• Project Implementation- Essentially same as sub-critical• O&M - By & large same as sub-critical• Reduced Environmental Impact • Most preferred parameters- 246 Kg/cm2-538oC/566oC• Materials proven and already in use• Technology cost for Indian OEM is not possible to assess.

SUPERCRITICAL VS SUBCRITICALSUPERCRITICAL VS SUBCRITICALMAJOR DESIGN DIFFERENCE

• Boiler- Once Through instead of drum type and use of superior material in certain pressure parts

• Piping- Reduced diameter. Superior Material.• Turbine- Increase in thickness of various parts to suit higher parameters• Feed Heaters-Increased thickness of tubes, water boxes and tube plate• BFP-Increased motor rating. Higher thickness of certain parts• Boiler Control- Change in philosophy• Water Chemistry- No blow down. 100% flow CPU. Different chemistry

control.• No new superior material is used. Only the quantity of superior material

increases.

PARTPART--IIIIII

SELECTION OF BOILER & ITS SELECTION OF BOILER & ITS COMPONENT COMPONENT

SELECTION OF BOILER

TYPE OF BOILER

Based on steam parameter- Subcritical/ Supercritacal

Based on steam/ water circuit-Once throuh/ drum type

Based on air/ flue gas path- Tower/Two path/ T-type

Type of fuel- Coal fired/ oil fired

Type of draft system-

Type of burner arrangement- Tangential/Front/ opposed

Selection of Firing system- Type of mills

Single reheat/ double reheat

Type of water wall tube- Plain, rifled

Type of tubing arrangement- Spiral/ straight

Mode of Operation

Sliding pressureConstant pressure

Selection of steam parameter

SH pressure, temperatureRH pressure, temperature

Rating of boiler (BMCR)

SH flowRH flow

Means of SH/RH Temperature Control

SprayGas biasing damper

Burner tilt

Start up system

S.no.

Description Benson Boiler (VariablePressure)

UP Boiler (Constantpressure)

1. Operability Start up time (Hot Start)

120-130 min (with 30%Turbine bypass)

250-300 min [withoutTurbine bypass](Complicated operation isrequired)

2. Daily Start &Stop (DSS)Operation

Suitable (Smooth shiftbetween start up bypasssystem and circulationsystem)

Not suitable (Because ofslightly complicated shiftoperation.)

3. Load ChangeRate (50-100%MCR)

3~4%/min 3~4%/min.

4. Part loadefficiency

better base

5. Start up bypasssystem

• Simplified start-up bypasssystem

• Shift operation of start upvalves is not necessary

• Operation of drain valvesand vent valves isnecessary

• Main valve is installed inthe main steam line

• Shift operation of start upvalves is necessary

• Operation of drain valvesand vent valves isnecessary

COMPARISON OF BENSON AND UP BOILER

S.no.

Description Benson Boiler (VariablePressure)

UP Boiler (Constantpressure)

6. Heat loss duringstart up

Warming of start up bypasssystem Heat recovery of circulatedwater by BCP

Warming of start up bypasssystem

7. Mixing Bottles Mixing bottled are notnecessary due to small fluidtemperature unbalance.

Mixing bottled are necessaryto cancel large fluidtemperature unbalance.

8. Sliding pressureoperation(Range)

Acceptable( Sub- Critical –Super Critical region)

Limited (Max=20 kg/cm2)

Sliding pressure V/s Constant pressure

In sliding operation, turbine inlet valves remains fully open during normal operation. As a result the live.

Advatageslower thermal stresses

The control range of the reheater final steam is extended.

Reduce pressure level at low loads prolong the life span of plant components.

Overall reduction in power consumption

Disadvantages

No storage in the drum hence for any load change difficult to meet requirement immediately.

Modified sliding pressure operation with active turbine valves .

Pressure Operation Mode

140

160

180

200

220

240

260

280

30 50 70 90 110

Boiler Load (%)

Pre

ssur

e(ba

r)

Constant pressure mode

Sliding pressure

Modified Sloding pressure

BOILER DESIGN

The design of boiler requires proper selection from a number of major options. The most important of these options which have significant impact on the design are:

•Waterwall system design

•Arrangement of convective surfaces

LOAD VS PRESSURE

0

50

100

150

200

250

300

0 20 40 60 80 100 120

LOAD

PRES

SUR

E

Thermal behaviour of water walls

The proportion of heat needed for evaporation and superheating changes with load. At low load the heat required for evaporation is high and superheat the steam is small. In subcritical the evaporation end point is fixed. In once through boiler, the evaporation end point is also changing within the waterwalls. So there is no division between superheater and evaporator.

Enthalpy Vs Boler Load

500

1000

1500

2000

2500

3000

3500

20 40 60 80 100

Boiler Load (% )

Enth

alpy

(Kj/K

g)

h”

h’

ECO inlet

WW Inlet

WW outlet

SH outlet

WATER WALL SYSTEMSpiral wall arrangementMany variable pressure units are running and basic idea

behind it to reduce the number of tubes required to envelope the furnace wall without increasing the spacing between the tubes.

Adv1. By spiraling around the furnace, every tube is part of all four

walls which means that not only the difference in the length of the parallel tube is minimized but also the heat pick up of individual tubes is particularly equalised.

2. At low load also sufficient cooling of the tubes can be assured.

Dis advantage1. Complicated manufacture, constructionRifled vertical tube

Start-up System Comparison

Increasing Heat RecoveredIncreasing Heat Recovered

Incr

easi

ng C

apita

l Cos

tIn

crea

sing

Cap

ital C

ost

Simplified Drain Discharge

Recirculation Pump System

Heat Exchanger System

Three types of start-up systems offered to suit

operation profile.

Three types of start-up systems offered to suit

operation profile.

Start-up System with Recirculation

Minimum Economizer

Flow Control Valve (MEFCV)

Separator

Feedwater Control

Separator HighLevel Ctl.

Block Valve

Pump

Mixing Tee

START UP SYSTEM

PARTPART--IVIV

SIPATSIPAT--I 660 MW DATAI 660 MW DATA

Start up system with one no. circulating pump is with alternate drain flow to condenser through flash tank .

Start up system

GCV range 3000 to 4000 Kcal/kg with 10-16% moisture and 32 to 48% ashFuelFlue gas temperature at air-heater outlet- 125 Deg C

52.05681740At RH Outlet

2565402225At SH Outlet

Pressure Kg/Cm2(a)

Temperature Deg C

Flow (T/Hr)Rating

Supercritical, suitable for variable pressure operation with spiral or rifled/plain water wall tubingTower type or two pass type

Type

Salient Features of the Steam Generator

Austenitic Stainless steel,T91/P-91 material up to 590 Deg C, Super 304 H, SA-213T92, SA335 P92

Above 550 Deg C

Alloy steel to ASME SA213 T-11/T-22/T91, SA335 P-11/P-22,SA-213T23, SA335 P23

Above 400 but below 550 deg C

Carbon steel to ASME SA210C, SA106 Gr C, SA302CUp to 400 Deg C

Boiler Pressure Parts Material

Major Furnace Sizing Criteria

2.0 Sec(Min)Furnace residence time1.8X105 kcal/hr/m2(Max)Furnace cooling factor600X 105 kcal/hr (Max)Heat input per burner1.36x106 kcal/hr/m2 (Max)Burner zone heat release rate106920 Kcal/hr/m3(maxHeat liberation rate4.75X106 Kcal/hr/m2 (Max)Net Heat Input/Plan Area

1.05 times the maximum operating pressure, for maximum operating pressure up to separator, additional 5% margin due to scaling to be added.

Design pressure of pressure parts

NEW MATERIAL• In addition to conventional material the following new materials are being

adopted on recent-660MW supercritical units and to take care of higher temperature of steam parameters:

Super 304HSA-213 T23 SA-335 P23SA-213 T92SA-213 P92SA 302 C

Design pressure of Pressure Parts:

1.05 times the maximum operating pressure For maximum operating pressure up to separator, additional 5% margin due to scaling to be added.

Typical Tubing for 568 / 595 °C Steam Temperatures

OR AUSTENITIC

SUPER 304

8000

21,253

26144

CL Top Nozzle

CL Bottom Nozzle

FW = 18,816

FD = 18,144

22,753

14,612

4,877

30 o

50 o

50 o

15 o

ECONOMIZER

ECONOMIZER

ECONOMIZER

ECONOMIZER

HORIZONTAL REHEATER(RH I)



15860

31186

PENDANT SH(SH I)

PLATEN SH(SH II)

FINAL RH(RH II)

FINAL SH(SH III)

PENDANT RH(RH I-I)

1,219

18256

SIPAT-I 660MW BOILER

Boiler auxiliaries & ESP

Vertical spindle Bowl/E-type/MPS or equivalent

Coal Mills2.

Redundancy criteria

Worst coal, BMCR- N+1Worst coal, TMCR- N+2Design coal, BMCR- N+2

Criteria50mg/NM3, worst coal with one field out of service

Electrostatic Precipitator

4.

PAPH-2X60% rotary regenerative, Bisector type

SAPH-2X60% rotary regenerative, Bisector type

Air preheaters

3.

Variable pitch axial fan, (2X60%)PA/FD/ID Fans

1.

TypeDescription

S.No.

64.16873.58• Roof to Ring header distance (m)

1690021450• Furnace Volume (m3)

302.9341.4• Plan area (m2)

15.797X19.17718816X18144• W x D (m)

FURNACE2.

540568• RH outlet temperature

540540• SHO temperature

46.149.89• RHO Pressure (kg/cm2)

179256• SHO Pressure at outlet (kg/cm2)

16252225• BMCR SHO Steam flow (T/hr)

BOILER 1.

SIPAT 500 MWSUBCRITICAL

SIPAT 660 MWSUPERCRITICAL

DescriptionSN

1900034170ECONOMIZER AREA (m2)

35324450REHEATER REAR (m2)

318014149+3159REHEATER FRONT (m2)

16157537• PLATEN SH

15882091• Div panel

16157537• FINAL SH

7100+14922153• LTSH

SUPERHEATER AREA (m2)

739110047EPRS (m2)

1010• No. of coal burner elevations

18.5222.75• Distance from center line of top burner to nose arch (m)

10.259• Ring header elevation (m)

74.583• Roof elevation (m)

COMPARISON OF MATERIAL

SA335P23, P91SA335P22RH OUTLET HEADERSA335P91SA335P22SH OUTLET HEADER

SA213T23,91, Super304H

SA213 T22,91 and TP347HFINAL RH

SA210Gr C,SA213T12,23

SA213T11,22LTRH

SA213T11,23,91,92

SA213 T22,91 and TP347HFINAL SH

SA213T11,22,91DIVISIONAL SHSA213T11,23,91

SA213T11LTSH

SA302CSA299DRUM/SEPERATOR

SA213T22SA210Gr CWATER WALL

SA210Gr CSA210Gr A1ECONOMISER

660MW500MWDescription

THANK YOUTHANK YOU

Documents

Supercritical PMI