Super Critical Technology OPERATION & MAINTENANCE

(PMI Programme)

Knowledge Management System O&M- Boiler

Date & Venue : January 17-19, 2007 at NTPC, PMI, Noida Key Words

Load Variations, Operational Limitations, High Pressure turbine, Load Demand System

Programme Coordinator : Shri A.K.Shukla, Sr.Faculty, NTPC, PMI, Noida, 9868391589, ashukla@pmintpc.co.in

09/03/2007

ABSTRACTS :
1.1 "Supercritical" is a thermodynamic expression describing the state of a substance where there is no clear distinction between the liquid and the gaseous phase (i.e. they are a homogenous fluid).; The greater the output of electrical energy for a given amount of energy input, the higher the efficiency; The degree of difficulty or ease with which a particular material can be fabricated or welded; Possible degradation of properties caused by long-time service exposure; Dissimilar metal welds to be avoided to the extent possible; In the pursuit of increasing the efficiency, supercritical parameters are used in increasing manner.

1.2 1.3 1.4 1.5 1.6

********************

NTPC LIMITED
SUPERCRTICAL TECHNOLOGY SELECTION OF BOILER AND ITS AUXILIARIES

PRESENTATION BY PROJECT ENGINEERING

PANKAJ 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

PART-I

SUPERCRITICAL TECHNOLOGY

Evolution Of The Coal Fired Plant

60 AGMCFC IGMCF USPCF IGCC

50

T e a E ie c (% h rm l ffic n y )

40

Supercritical boiler Rankine Barrier SUPC

IGHAT

PFBC

30

20

Pulverised Coal

10 First Station 18 80 10 90 12 90 14 90 16 90 17 90 18 90 19 90 20 00 22 00 0

SUPCF: Sub Critical Pulverised Coal Fired PFBC: Pressurised Fluidised Bed Combustion IGCC: Integrated Gasification Combined Cycle IGHAT: Integrated Gasification Humid Air Turbine USPCF: Ultra Super Critical Pulverised Coal Fired IGMCFC: Integrated Gasification Molten Carbonate Fuel Cell AGMCFC: Advanced Gasification Molten Carbonate Fuel Cell

Rankine Cycle Efficiency

net work n = -------------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 input Heat Rate =-----------------Electrical generation (KW) 860 = ------------------- Kcal/Kwh n

EFFECT OF SUPERCRITICAL PARAMETERS

538

Temperature (C)

240 kg/cm2

Expansion Line
170 kg/cm2

Critical Point 225 kg/cm2

Condensation

Enthalpy

THERMAL EFFICIENCY IMPROVEMENT

%
0.41 Efficiency Increase 0.32 5660C/5930C 0.33 0.35 0.27 0.69 5660C/5660C 5380C/5660C 5380C/5380C 6000C/6000C

5660C/5660C

Base Efficiency 38.6%

169

246

310

STEAM PRESSURE (kg/cm2)

SUPERCRITICAL PLANTS-WORLDWIDE TRENDS

90000 80000

CAPACITY (MW)

70000 60000 50000 40000 30000 20000 10000

Total Steam Capacity

Supercritical plants

1968

1971

1974

1977

1980

1983

1986

1989

1992

1995

1998

2001

2004

2007

2010

CALENDER YEAR

2013

Source ABB

TECHNOLOGY ADOPTION STATUS

FINLAND CUBA THAILAND TAIWAN NETHERLANDS SPAIN ITALY IRAN DENMARK CHINA KOREA GERMANY JAPAN USA CIS

Estimated World Total 600 Units

50 1950s

Number of Units
1960s 1970s 1980s

100

150

200 1990s

250

AVAILABILITY : SUPERCRITICAL VS SUBCRITICAL EPRI

EAF 1982-84

Size Range Sub-critical

300-399 400-499 500-599 600-799 800+ 76.5 77.4 76.3 78.5 77.2 74.6 73.8 74.2 75.6

Low availability in 1960s: Rapid unit size escalation Low fuel quality tolerance Inflexibility for cyclic loading
1994 83.8 83.0 1995 83.7 84.7 1996 86.6 79.5 1997 88.5 90.3 1998 84.4 84.0

Super critical 64.4

VGB
Year Subcritical Supercritical 1988 84.2 80.2 1989 82.5 74.9 1990 84.1 84.2 1991 84.9 85.2 1992 84.5 87.1 1993 82.0 89.8

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

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

SUPPLIERS 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 TECHNOLOGY STATUS

Type Benson/ Siemens Construction Spiral wound Smooth tubing Manufacturer Stien/EVT Stienmuller Deustche Babcock Remarks Suitable for variable pressure operation Technology licenced by Siemens Suitable for sliding pressure operation Vertical tube design developed jointly by Sulzer/CE/MHI Used primary in USA and CIS countries European Design

Sulzer

Vertical Ribbed Under Indroduction tubing CE, IHI, MHI Spiral wound Smooth tubing Vertical Ribbed ABB-CE MHI tubing B&W, Foster Wheeler IHI, Hitachi Babcock Taganrog & Podolsk

Universal Vertical Pressure bare tubing type

American Design

MAJOR DIFFERENCES IN SUPERCRITICAL PLANT

Boiler Type Furnace Water walls Tube material Tubing dia Circulation Pressure Parts -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 steel and P-91 material in SH/RH -Drain to condenser -Recirculation thru pump -Drain with regenerative heating Higher Supercritical Once through, Single/ Two pass

Startup system

Start up rate

Load following capability Better Tolerance to coal quality Higher

MAJOR DIFFERENCES IN SUPERCRITICAL PLANT

Critical Piping Main Steam piping Size Thickness Material HRH piping Size Thickness Material Feed piping No change in dia No change in thickness due to P41 material Change in material from P-22, X-20 to P-91 Increase in thickness Supercritical Reduction in diameter due to lower specific volume Increase in thickness Change in material P-22/X-20 to P-91

MAJOR DIFFERENCES IN SUPERCRITICAL PLANT

Steam Turbine Casings Thickness Material Supercritical Marginal increase in thickness Change in material 2 Cr 1 Mo to 12 Cr Change in material for part of the rotor (specific to Mfg) Change in material for first few rows to austinitic steel Marginal change in thickness and change in material 2 Cr Mo to 9 Cr steel.

Rotor

Blade

Stop/control valves and Interconnecting piping

MAJOR DIFFERENCES IN SUPERCRITICAL PLANT

Turbine Feed Cycle Boiler Feed Pump

Supercritical Increase in motor power Increase in thickness of casing Increase in discharge pressure of pump

HP Feed Water Heaters

Increase in thickness of tube sheet, tubes and waterbox.

MAJOR DIFFERENCES IN SUPERCRITICAL PLANT

Balance of plant

Supercritical

Coal Handling Plant

Capacity Reduction by 40t/hr

Ash handling Plant Capacity reduction by 10t/hr CW System Capacity reduction by 1%

MATERIAL APPLICATION FOR HIGH STEAM TEMPERATURES COMPONENT BOILER SH HDR MS PIPE SH TUBE (HOT PARTS) RH HDR RH PIPE RH TUBE (HOT PARTS) TURBINE HP/IP ROTOR HP/IP CASING MAIN VALVE 538 C
2 1/4 Cr Mo 18 Cr steel 2 1/4 Cr Mo steel 9 Cr steel 2 1/4Cr M V steel 2 1/4 Cr Mo steel 2 1/4 Cr Mo steel 18 Cr steel 12 Cr steel 12 Cr steel 9 Cr steel

566 C
9 Cr steel

593 C
12 Cr steel 20-25 Cr steel 9 Cr steel

ENVIRONMENTAL 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 ADVANTAGES
Enhancements
Plant efficiency Fuel tolerance 0.69% to 1.64% More tolerant to coal quality changes

Reductions
Coal Consumption Ash production CO2 SO2 Nox Startup time Sliding Pressure Operation Load following capability

1.79% to 4.24%

Improvements

STEAM CONDITION DEVELOPMENT TREND

(EUROPE)

SUBCRITICAL

SUPERCRITICAL

ULTRA SUPERCRITICAL
382-700/720

Parameters

285-630/650 285-600-620

245-580/600 Super critical 245/540/540 245/546/565 Subcritical 170 K/540oC/540o

Mature Technology 1960s

Mature Technology

R&DCurrent USC Market Introduction

R&DAdvanced USC

1970s

1980s

1990s

2000s

2010s

Year

SELECTION OF RATED PARAMETER

246-538/538

246-538/566

246-566/566

300-580/580

80 70 60 50 40 30 20 10 0

NO OF UNITS (%)

SELECTED PARAMETERS
Ultra supercritical

MSP MST RST

246 kg/cm2 5380C 5660C

PART-II
TECHNOECONOMIC STUDY
CASE STUDY FOR PIT HEAD AND LONG LEAD STATIONS

Base Price Estimates

Equipment Boiler Turbine Coal Handling Ash Handling BOP Total Difference Unit Case-1 per MW Rs mill Rs mill Rs mill Rs mill Rs mill Rs mill % 8.32 4.96 2.36 1.74 13.10 30.48 Base Case-2
246-538/538

Case-3
246-538/566

Case-4
246-566/566

Case-5
246-566/593

169-538/538

8.63 5.12 2.36 1.74 13.10 30.95 1.54

8.69 5.16 2.36 1.74 13.10 31.05 1.87

8.86 5.29 2.36 1.74 13.10 31.35 2.85

9.04 5.41 2.36 1.74 13.10 31.65 3.84

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%.

Note- Cost given are in Rs.Millions/MW

EFFICIENCY GAIN
(Indian ROM coal)
Unit Boiler Efficiency Turbine Heat Rate Gross Heat Rate Gross Efficiency Differential % Kcal/ Kwhr Kcal/ Kwhr % Case-1 87.5 1947 2225.7 38.64 Base Case-2 87.5 1913 2186.6 39.33 0.69 Case-3 87.5 1900 2171.7 39.60 0.96 Case-4 87.5 1883 2152.7 39.95 1.31 Case-5 87.5 1868 2135.05 40.28 1.64

SELECTION OF PARAMETERS FOR STUDY

CASE 1 2 3 4 5 MSP (Ksc) 169 246 246 246 246 MST (deg C) 538 538 538 566 566 RST (deg C) 538 538 566 566 593
Current Market Introduction Matured technologies

Recommended Option

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

S.No. Economic Factors 1. Plant 2. 3. 4. 5. Type of coal
Alt-I

Pithead Stations Sipat ROM

Alt-II

Long Lead Stations Cheyyur WASHED Washed

Alt-VI

Alt-III Alt-IV

Alt-V

Coal cost (Rs.) Coal cost Escalation (%) PLF(%)

441 7 68.5

441 10 68.5

441 10 85

700 10 68.5

700 10 85

1912 7 68.5

Total six alternatives are discussed.

TECHNO ECONOMIC FACTORS CONSIDERED SIPAT STAGE-I ROM COAL ECONOMIC FACTORS
Debt Equity Ratio Return on Equity Interest on loan Depreciation O&M charges Inflation Rate Interest on working capital Heat Rate Auxiliary Power Consumption Fuel Oil Consumption Oil Cost Coal calorific value 70:30 16% 11.19 7.53% 2.5% 7% 16.25% 2225 Kcal/kwh (Base) 8% (Base) 3.5 ml/kwh (Base) 7275 Rs/kL 3200 kcal/kg

OTHER MAJOR FACTORS

TECHNO ECONOMIC EVALUATIONASSUMPTIONS 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 SIPAT- ROM COAL

@68.5% PLF, COAL COST Rs. 441 PER TON AND 7% COAL COST ESCALATION
Sl 1. COAL Parameter Option Bar oC/oC Sub critical Case-1 Indian ROM Coal Super critical Case-3 Case-4

Case-2

Case-5

CAPITAL COST PER 500MW

Total Cost (Rs.crs) Additional Capital (Rs.crs) Cost Yearly Servicing Cost

169-538/538 246-538/538 246-538/566 246-566/566 246-566/593 1891.17 1918.12 1924.50 1943.85 1962.86 Base Base 2225.7 2.0538 441 157.22 Base 199.92 26.95 5.17 2186.6 2.0171 441 154.42 2.81 200.60 1905.92 14.75 801.0 33.33 6.37 2171.7 2.0032 441 153.35 3.88 200.61 1911.44 20.27 717.0 52.68 10.08 2152.7 1.9853 441 151.99 5.24 201.39 1918.88 27.27 838.0 71.69 13.74 2135.05 1.9688 441 150.71 6.51 202.21 1925.56 34.39 917.0

2.

COAL CONSUMPTION PER 500 MW

Heat rate (Kcal/kWh) Coal consump. (mt/year) Coal cost Rs./ton Yearly Levelized value coal bill (Rs.Crs) Reduction

3. 4.

Levelised COG Paisa/kWh Imputed costs Per 500 MW Capital Costs (Rs crs.) Coal Cost (Rs/T) Total cost Additional cost

1891.17 Base 441.0

1. Sub critical Plant is most economical 2. At coal cost of Rs. 717/- the supercritical plant becomes economical 3.Imputed capital cost for supercritical plant is 1911 crores.

ANALYSIS OF CHEYUR - WASHED COAL @68.5% , COAL COST Rs.1912 PER TON AND 7% COAL COST ESCALATION
Sl No 1. COAL Parameter Option Bar C/ C
o o

Indian Washed Coal Sub critical Case-1 169-538/538 Case-2 246-538/538 1870.08 28.90 5.31 Super critical Case-3 246-538/566 1875.97 34.78 6.35 Case-4 246-566/566 1895.21 54.03 9.94 Case-5 246-566/593 1913.65 72.47 13.39

PER 500MW

CAPITAL COST

Total Cost (Rs.crs) Addition Cost al Capital Yearly (Rs.crs) Servicing Cost Heat rate (Kcal/Kwh)

1841.18 Base Base

COAL CONSUMPTION

2.

2209.0 1.7163 1912 569.65 Base 349.72

2170.00 1.6855 1912 559.43 10.22 347.68 1895.33 54.15

2155.00 1.6737 1912 555.50 14.15 346.52 1916.11 74.93

2136.00 1.6587 1912 550.52 19.13 345.91 1942.51 101.33

2119.00 1.6453 1912 546.07 23.58 345.47 1966.13 124.95

PER 500 MW

Coal consump. (mt/year) Landed Coal cost Rs./ton Yearly coal bill (Rs.Crs) Levelized value Reduction

3. 4.

COG Paisa/Kwhr Imputedcosts per500 MW Capital cost (Rs/crs) Total cost Additional cost

1841.18 Base

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 TECHNOLOGY- ECONOMIC EVALUATION

CASE-3 : 246 kg/cm2-5380C/5660C

74.9

14.1

Addn.Cap. Cost (Rs crs)

5 68.
Breakeven

F, PL %

on lati a Esc %

Cushion for Technology Cost

(+)
6.3

33.3

6.3 Shortfall
( )

20.3

3.8 Subcritical 441 717

Addn capital of Rs. 33.3 crs

Supercritical 1912

Coal cost (Rs/ton)

Yr. Saving in Coal Bill (Rs. Crs)

Addn.Cap. Service Cost (Rs crs)

MAIN 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 SUBCRITICAL
MAJOR 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.

PART-III

SELECTION OF BOILER & ITS 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 systemType 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 pressure Constant pressure

Selection of steam parameter

SH pressure, temperature RH pressure, temperature

Rating of boiler (BMCR)

SH flow RH flow
Means of SH/RH Temperature Control

Spray Gas biasing damper Burner tilt

Start up system

COMPARISON OF BENSON AND UP BOILER

S.n o. 1. Description Operability Start up time (Hot Start) Daily Start & Stop (DSS) Operation Benson Boiler (Variable Pressure) 120-130 min (with 30% Turbine bypass) UP Boiler (Constant pressure) 250-300 min [without Turbine bypass] (Complicated operation is required) Not suitable (Because of slightly complicated shift operation.)

2.

Suitable (Smooth shift between start up bypass system and circulation system) 3~4%/min

3.

4. 5.

Load Change Rate (50-100% MCR) Part load efficiency Start up bypass system

3~4%/min.

better Simplified start-up bypass system Shift operation of start up valves is not necessary Operation of drain valves and vent valves is necessary

base Main valve is installed in the main steam line Shift operation of start up valves is necessary Operation of drain valves and vent valves is necessary

S.n o. 6.

Description Heat loss during start up

7.

Mixing Bottles

8.

Sliding pressure operation (Range)

Benson Boiler (Variable Pressure) Warming of start up bypass system Heat recovery of circulated water by BCP Mixing bottled are not necessary due to small fluid temperature unbalance. Acceptable( Sub- Critical Super Critical region)

UP Boiler (Constant pressure) Warming of start up bypass system

Mixing bottled are necessary to cancel large fluid temperature unbalance. 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.

Advatages
lower 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

280 260 240 Pressure(bar) 220 200 Constant pressure mode 180 160 140 30 50 70 Boiler Load (%) 90 110 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
300 250 200 PRESSURE 150 100 50 0 0 20 40 60 LOAD 80 100 120

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.
3500

Enthalpy Vs Boler Load

SH outlet WW outlet h

3000

2500 E n th a lp y (K j/K g )

2000

1500

WW Inlet ECO inlet

1000

500 20 40 60 Boiler Load (% ) 80 100

WATER WALL SYSTEM

Spiral wall arrangement
Many 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. Adv 1. 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 advantage 1. Complicated manufacture, construction Rifled vertical tube

Start-up System Comparison

Increasing Capital Cost Increasing Capital Cost

Three types of start-up Three types of start-up systems offered to suit systems offered to suit operation profile. operation profile.

Heat Exchanger System

Recirculation Pump System

Simplified Drain Discharge

Increasing Heat Recovered Increasing Heat Recovered

Start-up System with Recirculation

Separator

Separator High Level Ctl.

Minimum Economizer Flow Control Valve (MEFCV) Pump

Block Valve

Feedwater Control

Mixing Tee

START UP SYSTEM

PART-IV

SIPAT-I 660 MW DATA

Salient Features of the Steam Generator

Type Rating
At SH Outlet At RH Outlet Supercritical, suitable for variable pressure rifled/plain water wall tubing Tower type or two pass type Flow (T/Hr) 2225 1740 operation with spiral or Temperature Deg C 540 568 Pressure Kg/Cm2(a) 256 52.0

Flue gas temperature at air-heater outlet- 125 Deg C

Fuel Start up system

GCV range 3000 to 4000 Kcal/kg with 10-16% moisture and 32 to 48% ash Start up system with one no. circulating pump is with alternate drain flow to condenser through flash tank .

Major Furnace Sizing Criteria

Net Heat Input/Plan Area Heat liberation rate Burner zone heat release rate Heat input per burner Furnace cooling factor Furnace residence time 4.75X106 Kcal/hr/m2 (Max) 106920 Kcal/hr/m3(max 1.36x106 kcal/hr/m2 (Max) 600X 105 kcal/hr (Max) 1.8X105 kcal/hr/m2(Max) 2.0 Sec(Min)

Boiler Pressure Parts Material

Up to 400 Deg C Above 400 but below 550 deg C Above 550 Deg C Carbon steel to ASME SA210C, SA106 Gr C, SA302C Alloy steel to ASME SA213 T-11/T-22/T91, SA335 P11/P-22,SA-213T23, SA335 P23 Austenitic Stainless steel,T91/P-91 material up to 590 Deg C, Super 304 H, SA-213T92, SA335 P92 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 304H SA-213 T23 SA-335 P23 SA-213 T92 SA-213 P92 SA 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

26144

18256

PENDANT SH (SH I) 21,253

PLATEN SH (SH II) FINAL RH (RH II)

FINAL SH (SH III)

PENDANT RH (RH I-I)

15860

15 o 30 o 8000 50 o

HORIZONTAL REHEATER(RH I) HORIZONTAL REHEATER(RH I) HORIZONTAL REHEATER(RH I)

ECONOMIZER 31186

22,753

ECONOMIZER

ECONOMIZER FW = 18,816 FD = 18,144 ECONOMIZER

CL Top Nozzle

14,612

CL Bottom Nozzle 4,877

SIPAT-I 660MW BOILER

50 o

1,219

Boiler auxiliaries & ESP

S.N Descriptio o. n
1.

Type
Variable pitch axial fan, (2X60%)

PA/FD/ID Fans Coal Mills

2.

Vertical spindle Bowl/E-type/MPS or equivalent Redundancy criteria Worst coal, BMCR- N+1 Worst coal, TMCR- N+2 Design coal, BMCR- N+2

3.

Air preheaters

PAPH-2X60% rotary regenerative, Bisector type SAPH-2X60% rotary regenerative, Bisector type

4.

Electrostatic Criteria Precipitator 50mg/NM3, worst coal with one field out of service

S N
1. BOILER

Description

SIPAT 660 MW SUPERCRITICAL

SIPAT 500 MW SUBCRITICAL

2.

BMCR SHO Steam flow (T/hr) SHO Pressure at outlet (kg/cm2) RHO Pressure (kg/cm2) SHO temperature RH outlet temperature

2225 256 49.89 540 568

1625 179 46.1 540 540

FURNACE

W x D (m) Plan area (m2) Furnace Volume (m3) Roof to Ring header distance (m)

18816X18144 341.4 21450 73.58

15.797X19.177 302.9 16900 64.168

Roof elevation (m) Ring header elevation (m) Distance from center line of top burner to nose arch (m) No. of coal burner elevations

83 9 22.75

74.5 10.25 18.52

10 10047

10 7391

EPRS (m2) SUPERHEATER AREA (m2)

LTSH FINAL SH Div panel PLATEN SH

2153 7537 2091 7537 14149+3159 4450 34170

7100+1492 1615 1588 1615 3180 3532 19000

REHEATER FRONT (m2) REHEATER REAR (m2) ECONOMIZER AREA (m2)

COMPARISON OF MATERIAL
Description ECONOMISER WATER WALL DRUM/SEPERATOR LTSH DIVISIONAL SH FINAL SH LTRH FINAL RH SH OUTLET HEADER RH OUTLET HEADER 500MW 660MW SA210Gr A1 SA210Gr C SA299 SA213T11 SA213T11,22,91 SA213 T22,91 and TP347H SA213T11,22 SA213 T22,91 and TP347H SA335P22 SA335P22 SA213T11,23,91, 92 SA210Gr C,SA213T12, 23 SA213T23,91, Super304H SA335P91 SA335P23, P91 SA210Gr C SA213T22 SA302C SA213T11,23,91

THANK YOU