349 Advance Us CT Boiler Des

A Note on Advanced Ultra Super Critical Technology - Boiler Design
Page 1 of 6
Uploaded: August 2011

(300 BAR 700 C)
Advanced USC - 800 MW
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Boiler design is being developed to suit 300bar, 700/700C cycle.

The boiler will be of Once thru supercritical with spiral WW tubing
Design concepts of Barh-ll 660 MW and Krishnapatnam 800 MW have been used while evolving the design
Comparison of Advanced USC Vs Once thru Supercritical
Description
Advanced USC 800 MW
OTSC 800 MW
Boiler type
Conv. two Pass
Circulation
Once thru Supercritical with low load recirculation Once thru Supercritical with low load recirculation
Conv. two Pass
Layout
Side Mill Layout
Side Mill Layout

Boiler Parameters
Description
Load
HP Heater In
BMCK TMCK 60% TMCR 35% BMCR
Main Steam
Steam flow at SH Outlet t/h
2160.0 1955.5
1123.3
756.0
Pressure at SH Outlet kg/cm2 (g)
308.0
306.4
204.8
131.2
Temperature at SH Outlet C
703.0
703
703.0
703.0
Reheat Steam
Steam flow at RH Outlet t/h
1694.7 1617.1
1009.9
724.1
Pressure at HPT Outlet RH Inlet kg/cm2(g)
73.28
69.74
48.13
26.51
Temperature at HPT Outlet RH Inlet C
455.4
4476
458.4
404.3
Pressure drop allowed GRHU / RH / HRHL kg/cm2
2.75
2.61
1 82
1.02
Pressure at RH Outlet IPT Inlet kg/cm2 (g)
70.53
67.13
46.31
25.49
Temperature at RH Outlet IPT Inlat C
703.0
703.0
703.0
703.0
Feed Water C
3092
305.0
270.0
2400
Salient Design Parameters @ BMCR

Description
Unit
Advanced use 800 MW OTSC 800 MW
Boiler Parameters
Main Steam Flow
tph
2160
2600
Main Steam Pressure
kg/cm2(g)
308
255
MS/RH Steam Temp.
703/703
568/596
Feed water temp
309.2
294.2
SH Duty
MkCal/h
1178
1246
RH Duty
MkCal/h
242
291
Total
MkCal/h
1420
1537
7.6
Base
Heat Duty
% Reduction of Total Heat Duty %

Fuel Analysis Coal
Description (Source / Type)
Unit
Design Coal
Worst Coal
Proximate Analysis
(70% Indian + 30% Imported)
Indian
Fixed carbon
38.0
30.0
Volatile Matter
26.0
20.0
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10/10/2014
Moisture
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8.0
12.0
38.0
Ash
28.0
Total
100
100
HHV
Kcal/kg
4700
4100
LHV
Kcal/kg
Ash
kg/ 10 Kcal
Ultimate Analysis
Carbon
51.2
41.38
Hydrogen
3.00
2.85
Sulphur
0.40
0.50
Nitrogen
1.50
0.75
Oxygen (difference)
7.90
4.52
Moisture
8.00
12.0
Ash
28.00
38.0
Hard Grov Index
50
50
IT-Initial deformation temp
Deg C
1150
1150
ST - Softening temp H = W
Deg C
1200
HT Hemispherical temp H = W / 2
Deg C
Over 1400
1300
FT = fusion temp
Deg C
Over 1400
1400
A - S2O2
56.66
61.85
A - Al2 O3
27.46
27.36
B - Fez O3
7.60
5.18
B - CoO
1.81
1.47
B - MgO
0.96
1.00
B - Na2 O
1.20
0.71
1.94
1.84
Ash Characteristics
Ash Constituents
B - K2 O
A - Ti O2
P2 O5
1.10
0.54
SO3
0.27
0.05
Base/ Acid Ratio
0.16
Fe2 O3 / CaO Ratio
3.54
Chloride
Site Conditions
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Ambient temperature : 27 Deg. C

Relative Humidity : 60%
Plant elevation above MSL : 351 m
Salient Features of the Boiler Proposed

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Once Through sliding pressure supercritical boiler

Spiral wall evaporator
Conventional Two-pass
Radiant reheat
Balanced draft
Low load start-up system
Tilting Tangential firing system
Side mill layout, cold PA system
Two axial reaction FD fans
Two axial reaction PA fans
Two axial reaction ID fans
Two regenerative Tri-sector air heaters
Eight vertical spindle high performance bowl mills
ESP to suit outlet dust emission requirement
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Pressure Part Arrangement
SH / RH / ECO Arrangement
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No. of SH Stages : 3 (Div. Panel + SH Platen + Finish SH)

No. of RH Stages :2 (LTRH + Finishing RH)
No. of ECO stages : 1 (Economiser)
Design Criteria
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Control Range : 60% TMCR -100% BMCR

Flue Gas Velocity (SH / RH / ECO Sections) : 10 m/s
Excess Air : 20% @ 100% BMCR
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Furnace Heat Loadings

Description
Unit
Adv. USC 800 MW Typical 800 MW (SC)
NHI
MkCal/h
1746
1894
PA Loading
MkCal/h-m2
4.16
4.52
EPRS Loading
10s kCal/h-m2
Volumetric Loading kCal/h-m3
1.49
1.62
64577
70478
SCHEDULE OF ACTIVITIES FOR ADVANCED USC BOILER DESIGN

BOILER PARAMETERS
11/05/2011
FUEL ANALYSIS
11/05/2011
SITE CONDITIONS
11/05/2011
FURNACE SIZING
01/06/2011
THERMAL DESIGN OF SH, RH & ECONOMISER
10/06/2011
FINILISATION OF PRESSURE PART ARRANGEMENT
30/06/2011
DESIGN OF SH, RH, ECONOMISER HEADERS, INTER CONNECT PIPING
JULY 2011 TO FEB 2012
DESIGN OF SH, RH, ECONOMISER TUBING

CIRCULATION CALCULATION
SIZING OF WATERWALL HEADERS AND TUBING
SELECTION OF STARTUP SYSTEM COMPONENTS & RECIRCULATION PUMP
DESIGN VETTING BY ALSTOM OR EXTERNAL CONSULTANT TO BE SENT ON MARCH 2012
Project Status of Advanced Ultra Super Critical Boiler (300 bar and 700 C)
The following performance engineering calculations (Conceptual design) has been carried out
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Furnace Sizing
{ Spiral wall height
{ Vertical Wall height
Number of stages of Superheater and Reheater
Location of Superheaters and Reheaters
Heating surface area of Superheater, Reheater in Radiation zone and in Convection zone
Preliminary heating surface arrangement data of Superheater and Reheater (Tube OD, Transverse Pitch, Longitudinal Pitch, Number of loops, Number of
element per assembly, Number of assemblies)
Soot blower location. Furnace opening requirements
Economiser area requirement.
Back pass height requirement
The final pressure part arrangement will be finalised after analysing the feasibility of using T91 materials for Water wall tubes and fins
Advanced Ultra Super Critical Technology
Test Loop for testing fire side corrosion properties of advanced materials
10/10/2014
Page 5 of 6
Test Loop Tubing

Tube OD, mm Thickness, mm
ASME Spec,
52.0
11.50
N06617
52.0
9.50
SA 213 S304H
54.0
5.60
SA 213 T91
44.5
moo
SA 213 T91
Test Loop Headers and Pipes

Description
OD, mm Thickness, mm ASME Spec.
SH INLET UNK
159.0
30.0
SA 335 P22
SHIN LET HEADER
219.1
25.0
SA 335 P91
SH OUTLET HEADER
219.1
40.0
N06617
SH OUTLET LINK
127.0
20.0
N06617
LINK AFTER PRV
168.3
20.0
N06617
UNK FROM LTSH
127.0
20.0
SA 335 P22
UNK AFTER PRV-LTSH
127.0
8.0
SA 213 Gr B
MIXING Piece
219.1
40.0
N06617
UNK TO HRH
219.1
32.0
SA 335 P22
Schedule of Valves and Fitting

DESCRIPTION
VALVE TYPE SIZE NB/INCH OPERATION
MAX. WORKING PARAMETER
QTY No. REMARKS
Press. kg/cm2 (g) Temp Deg.C

Gate
150
164.4
555
Link from LTSH Isolation Gate
127
173.3
434
219.1
49
555
MO
49
5S5
Test Loop inlet Isolation
Link to HRH Isolation
Gate
SH Vent Valve
GLV
Test Loop PRVs
PRV
127
164.4
715
LTSH Outlet PRV
PRV
127
173.3
434
2 ton/hr Capacity
Other Equipments
Equipments
Details
Qty
Remarks
Flow Meter at SH Inlet Link OD 159 x 130 mm x mm
Flow range is 0 to 20 t/h
MTM Thermocouples
Outside Gas path - 700 deg.C
10/10/2014
Acromat Thermocouples
20
PT
TE-TT
Header Thermocouples
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Inside Gas Path -1200 deg.C
2 nos - 540 deg.C 2 nos 700 deg.C
Project Status - Test loop for testing the Fire-side Corrosion property of Advanced Materials (Super 304 H & Inconel 617)
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Meeting was held among IGCAR, NTPC and BHEL on 26th May 2011 at Trichy. BHEL presented on the Test loop proposed
Dadri 210 MW unit is taken as reference for implementing the Test loop (final confirmation is to be received from NTPC)
It is decided to place the test loop in the open upper furnace of 210 MW which is in Radiation zone
Project Status - Test loop for testing the Rre-side Corrosion property of Advanced Materials (Super 304H & Irtconel 617)
The following work has been carried out
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The tap-off point of steam for test loop

The steam flow requirement.
Heating surface area requirement
The arrangement of test loop (00, length, Number of assemblies, Number of tubes per assembly)
Requirement of steam flow measurement, isolation Valves, Pressure Reducing valves, Mixing piece
Sizes of Critical pipes & headers
Cooling requirement of the outlet steam from the test loop
Tentative System Scheme.
The exact tap-off location will be finalised jointly by NTPC and BHEL during Site Visit.
The next course of action will be to review the test loop design, finalization of specification and material forecasting.
10/10/2014

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A Note on Advanced Ultra Super Critical Technology - Boiler Design

Uploaded: August 2011

A Note on Advanced Ultra Super Critical Technology - Boiler Design

Boiler design is being developed to suit 300bar, 700/700C cycle.

Advanced USC 800 MW

Conv. two Pass

Conv. two Pass

Side Mill Layout

Side Mill Layout

Pressure at SH Outlet kg/cm2 (g)

Pressure at HPT Outlet RH Inlet kg/cm2(g)

Temperature at HPT Outlet RH Inlet C

Pressure drop allowed GRHU / RH / HRHL kg/cm2

Pressure at RH Outlet IPT Inlet kg/cm2 (g)

Temperature at RH Outlet IPT Inlat C

Salient Design Parameters @ BMCR

Advanced use 800 MW OTSC 800 MW

Main Steam Pressure

MS/RH Steam Temp.

Feed water temp

% Reduction of Total Heat Duty %

(70% Indian + 30% Imported)

A Note on Advanced Ultra Super Critical Technology - Boiler Design

Hard Grov Index

IT-Initial deformation temp

Base/ Acid Ratio

Fe2 O3 / CaO Ratio

Ambient temperature : 27 Deg. C

Salient Features of the Boiler Proposed

Once Through sliding pressure supercritical boiler

A Note on Advanced Ultra Super Critical Technology - Boiler Design

Pressure Part Arrangement

No. of SH Stages : 3 (Div. Panel + SH Platen + Finish SH)

Control Range : 60% TMCR -100% BMCR

A Note on Advanced Ultra Super Critical Technology - Boiler Design

Furnace Heat Loadings

Adv. USC 800 MW Typical 800 MW (SC)

Volumetric Loading kCal/h-m3

SCHEDULE OF ACTIVITIES FOR ADVANCED USC BOILER DESIGN

THERMAL DESIGN OF SH, RH & ECONOMISER

FINILISATION OF PRESSURE PART ARRANGEMENT

DESIGN OF SH, RH, ECONOMISER HEADERS, INTER CONNECT PIPING

JULY 2011 TO FEB 2012

DESIGN OF SH, RH, ECONOMISER TUBING

A Note on Advanced Ultra Super Critical Technology - Boiler Design

Test Loop Tubing

Test Loop Headers and Pipes

OD, mm Thickness, mm ASME Spec.

SHIN LET HEADER

LINK AFTER PRV

UNK FROM LTSH

UNK AFTER PRV-LTSH

Schedule of Valves and Fitting

VALVE TYPE SIZE NB/INCH OPERATION

MAX. WORKING PARAMETER

QTY No. REMARKS

Press. kg/cm2 (g) Temp Deg.C

Link from LTSH Isolation Gate