Transcript
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 1 of 222
Supercritical Coal Fired Power PlantsSupercritical Coal Fired Power Plants
Bharat Heavy Electricals Ltd.Babcock Borsig Power GmbHSiemens AG KWU
Techno - Economic Seminarfor
National Thermal Power Corporation Ltd. Central Electricity Authority
New Delhi, IndiaOctober 21, 1999
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Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG KWU
Supercritical Coal Fired Power PlantsSupercritical Coal Fired Power PlantsTechno - Economic Seminar
(Delhi, 21 October 1999)
Author No. Topic InaugurationBHEL 1.1 An overview of technical collaboration with BBP/SiemensBBP 1.2 Babcock Borsig Power - An introduction
Technical Session ISiemens 2.0 Once Through Technology: - Principle of once-through technology - Operation of BENSON boilers
BBP 3.0 Comparison of subcritical and supercritical units in view of: - efficiency (coal savings, reduction of emission etc.) - availability - feedwater treatment - investment costs - Trends and tendency of the international market towards once through technology
Technical Session IIBHEL 3.1 Technical aspects of the collaboration and BHEL´s preparedness for once-through BoilersBHEL 3.2 Design and manufacturing of steam turbines for supercritical Parameters (see folder BHEL)BBP 4.0 Once-through boiler design & operation experiences, reference plantsBBP 5.0 Firing system
Technical Session IIIBBP 6.0 Supercritical boiler concept of BBPBBP 7.0 Operation & maintenance of once-through boilers based on experiences gained in South Africa
Table of ContentsTable of Contents
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1.1 1.1 An An Overview Overview of technical collaboration withof technical collaboration withBBP / BBP / SiemensSiemens
BHELBHEL
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1.2 Babcock Borsig Power - An introduction1.2 Babcock Borsig Power - An introductionThe merger units four of the most renowned companies in the energy and environmental technologies toa new world leading group Babcock Borsig Power.
The new group has an order backlog of approx. seven billion DM, a sales of nearly four billion DM and worldwide approx. 11,000 employees.
More than a century`s worth of exerience an know-how in the engineering of boilers and environmentalsystems has been brought together to provide customers with a wide range of products and services.
Our business partners, who have learned to know an value the quality and service offered by individualcompanies within the group, can assure that the new Babcock Borsig Power will more than satisfy their current expectation. We will however, guarantee continuity but can also now offer our customers the increased benefits which will result from bringing together of the competence and know-how provided byeach individual company.
Worldwide the new company will consist of a wide spectrum of subsidiaries and affiliated companies whichwill provide networked sales, engineering, project management, manufacturing and servicing skills. We willbe wherever our customers need us.
Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG KWU
InuagurationInuaguration
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InaugurationInaugurationBabcock BorsigBabcock Borsig Power - An Power - An Introduction Introduction
• In Babcock Borsig Power (BBP) four of the most renowned companies in the energy andenvironmental technologies are united.
• Group order backlog of seven billion DM (15,400 CrRs), sales of 4 billion DM (8,800 CrRs),approx. 11,000 employees
• More than 100 years of experience and know-how in boiler & environmental technology
• Wide range of products and services with outstanding quality by bringing togethercompetence and know-how provided by each individual company
• Wide spectrum of subsidiaries and affiliated companies which will provide networked sales, engineering, project management, manufacturing and service
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GroupGroup Structure Structure
Babcock Borsig AG
Other related companies: Borsig, Oberflächentechnik, Balcke-Dürr Thermal Engineering,Balcke-Dürr Prozeßtechnik, Industrierohrleitungsbau, Precismeca
Power transmission engineering
A. Friedrich Flender
Flender-Graffenstaden
Flender-Himmelwerk
Flender ESAT
Flender Guß
Loher
Mechanical engineering
Moenus
Babcock Textilmaschinen
Sucker-Müller-Hacoba
Krantz Textiltechnik
Babcock-BSH
Schumag
Vits
Turbo-Lufttechnik
Neumag
Power plant engineering
Babcock Borsig Power
Babcock SteinmüllerOberhausen
Babcock SteinmüllerGummersbach
Babcock Borsig Service
AE Energietechnik
DB Power Systems
DB Tangshan BoilerCompany
DB Riley
Thomassen International
IDEA
Power systems
Babcock Prozeß-automation
Nordex
Tuma Turbomach
Babcock-Omnical
Building technologies
Krantz-TKT
Lufthansa Gebäude-management Holding
Babcock Dienstleistungen
Krantz-TKTCleanroom Technology
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 8 of 222BABCOCK BORSIG POWER GMBH
wSteam generatorswUtility steam generatorswIndustrial boilerswWaste heat boilers (HRSG)wSpecial boilers
wFluidized bed technologieswFiring systemswCoal mills and pulverizing equipmentwAsh handling systemswFluidized bed coal drying plantswDampers for air and flue gas systemswRehabilitation / repoweringwSteam turbineswTurnkey plants
wCombined cycle power plantswIndustrial power plantswCogeneration plantswProcess steam generating plantswBiomass fired power plants
wTotal plant servicewPipingwManufacturingwErection and commissioningwOperation and maintenancewSpare partswPersonnel, tools and equipmentwOpencast mining equipment servicewDemolition, cleaning and disposal
Companies included: Babcock Kraftwerkstechnik, L. & C. Steinmüller, Dt. Babcock Anlagen, NEM and AE Energietechnik
wWaste technology and residuetreatmentwMunicipal wastewHazardous wastewSewage sludgewIndustrial waste
wFlue gas cleaningwPower plantswWaste-to-energy plantswIndustry
wProcess plant technologywWaste heat systemswCoal gasification
wWater treatment plantswDrinking waterwProcess waterwIndustrial waste waterwWaste tip seepage
wMunicipal sewage plantswBiological waste treatment
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Company Structure of the GroupCompany Structure of the Group
BABCOCK BORSIG POWERBABCOCK BORSIG POWER GMBH GMBH
Babcock SteinmüllerOberhausen
Babcock SteinmüllerOberhausen
Babcock Borsig Service
Meeraner Dampfkesselbau
DB Riley Energy
DB Tangshan Boiler Company
L. & C. Steinmüller(Africa)
DB Power Systems
Babcock Steinmüller
Gummersbach
Babcock Steinmüller
Gummersbach
DBEMA Energía yMedio Ambiente
DB Riley Environment
Steinmüller RompfWassertechnik
AEEnergietechnik
AEEnergietechnik
AE Industrieservice
Duro Dakovic
CT Environnement
MitteldeutscheFeuerungs-Union
CT Umwelttechnik
NEMNEM
Vogt NEM
NEM Power Systems
Other related companies: IDEA, Thomassen International
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Power Generation Equipment and PlantsPower Generation Equipment and Plants
Main Business Activities:
u Utility steam generators
u Fluidized bed steam generators
u Rehabilitations
u Combined cycle power plants
u Conventional power plants
u Power plants with FBC
u Industrial boilers and plants
u Fluidized bed coal drying plants
u Firing systems
u Ash handling systems
u Waste heat boilers (HRSG)
u Steam turbines
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Personnel Structure of the GroupPersonnel Structure of the Group
BABCOCK BORSIG POWERBABCOCK BORSIG POWER GMBH GMBH
BabcockSteinmüllerOberhausen
GmbH, Germany
Board of Directors :
Ludger Kramer(Chairman)
Klaus Dieter Rennert
Dr. Michael Fübi
Other related companies: IDEA, Thomassen International
Board of Directors: Prof. Dr.-Ing. Klaus G. Lederer (Chairman)Siegfried Kostrzewa (Dep. Chairman),Hans Kathage, Heino Martin
BabcockSteinmüller
GummersbachGmbH, Germany
Board of Directors :
Heino Martin(Chairman)
Arnfred Kulenkampff
AEEnergietechnikGmbH, Austria
Board of Directors :
Claus Brinkmann(Chairman)
Dr. Heinz Frühauf
Wolfgang Schwarzgruber
NEM b.v.,Netherland
Board of Directors :
Ulrich Premel
Gert Spruijtenburg
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1999 Foundation of BABCOCK BORSIG POWER GMBH
1994 lignite fired Benson Boiler for 2 x 930 MW Units - Lippendorf P.P.
1993 „The Power Plant Award“ for most advanced Heat and Power Plant
1992 first supercritical lignite fired Benson Boiler for 2 x 496 MW Units - Schkopau P.P.
1990 bituminous coal fired supercritical Benson Boiler for 1 x 550 MW Unit - Staudinger P.P.
1987 bituminous coal fired supercritical Benson Boiler with for 910 MW Units - Heyden P.P
1979 lignite fired Benson Boiler for 600 MW Unit - Yuan Bao Shan P.P. China
1972 lignite fired Benson Boiler for 2 x 630 MW Unit G + H - Weisweiler P.P.
1969 bituminous coal fired Benson Boiler for 6 x 500 MW Power Plant - Kriel/ South Africa
1965 first German gas tight welded „ membran wall“ - Benson Boiler
1963 first 1000 t/h Benson Boiler - 300 MW Unit in Germany
1938 first Benson Boiler in Germany
1928 first „slag tap“ - fired boiler world wide
1898 foundation of Deutsche Babcock & Wilcox Dampfkesselwerke AG
1874 foundation of L. & C. Steinmüller Röhren-Dampfkessel-Fabrik
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Worldwide PresenceWorldwide Presence
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Outcome of the MergerOutcome of the Merger
Ü Presence across the whole of Europe
Ü Expansion of our international presence
Ü Using synergetic effects to raise competitiveness
Ü Strengthening of our turn-key plant competence
Ü Strengthening our position in environmental engineering and inBOX models (build and own models)
Ü Improvement of our global market position in steam generators
Ü Market leader for waste-to-energy (WTE) plants in western Europe
Ü Top supplier of flue gas desulphurization plants
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2.0 Once-Through Technology
Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG KWU
Technical Session ITechnical Session I
Introduction
When Mark Benson registered the patent for "production of steam at any pressure" in 1922, he had no wayof knowing that one day one of the most frequently constructed once-through boilers in the world would be based on his idea.Today's BENSON boiler, as the result of numerous innovations and many years' experience,has become a high-reliability power plant component.
As licensor for BENSON boilers (once-through steam generators), Siemens has a wealth of experience in this field.The Siemens know-how is supplemented by a continuous exchange of experience with licensees and owner/operatorsaround the world. To date more than 1000 units incorporating this type of steam generator have been built.
Principles of once-through technologyEvaporator Systems
Evaporator systems can essentially be divided into in systems with constant and systems with variable evaporation endpoints:
• Systems with constant evaporation endpoint.
A typical example of this system is the drum-type steam generator. Natural circulation is produced by heatingof the risers. The water/steam mixture leaving the risers is separated into water and steam in the drum.The steam flows into the superheater, and the water is returned to the evaporator inlet through downcomers.If the system is operated only with natural circulation, the application range is limited to a maximum drum pressure of appr.190 bar. If a circulating pump is used (so called forced circulation), this range can be extended somewhat.Fixing the endpoint of evaporation in the drum also sets the size of the heating surfaces in the evaporator and superheater.
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• Systems with variable evaporation endpoint.
Evaporation takes place in a single pass. This principle is used in the BENSON boiler, the world's most frequentlyconstructed steam generator type. Flow through the evaporator is induced by the feed pump. The system can thereforebe operated at any desired pressure, i. e. at either subcritical or supercritical pressure. The evaporation endpointcan shiftwithin one or more heating surfaces. The evaporator and superheater areas thus automatically adjustto operational requirements.
A reliable coaching of the water walls in once-through boilers is reached by sufficiently high flow velocitiesof the water/steam mixture. This can be achieved by reducing the number of parallel tubes either using amulti-pass design or a spiral wound tubing of the furnace, however.
Problems with mixing and demixing of the total flow are disadvantageous in the multi-pass design.
Feedwater Control System
Common to both the drum-type steam generator and the BENSON boiler is that the feedwater control systemsetpoint is generated for the location in the pressure section where evaporation is complete. In the drum-typesteam generator, this point is the drum itself. The drum level is used as the setpoint. Control quality can also beimproved by allowing for parameters such as unit output.
The endpoint of evaporation in the once-through steam generator is variable and can move within one or more heatingsurfaces as a function of operational requirements. The setpoint is therefore also variable. The setpoint is the steamtemperature downstream of the evaporator at a point where the steam already has a certain degree of superheat.This setpoint is specified as a function of load such that the main steam temperature remains constant.Main steam temperature is thus independent of load, fouling of heating surfaces or excess air. Unit output,steam pressure and other parameters can also be allowed for here to improve control quality.
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Operators can track adequate feedwater supply similarly for both steam generator.While the drum level setpoint is constant, the setpoint for steam temperature downstreamof the evaporator can move in a "window" in front of the temperature scale (see figure).
Startup System
Steam power plants have a steam generator startup system and a unit startup system. The steam generatorstartup system for a BENSON boiler and a drum-type steam generator are similar. A separating vessel is locateddownstream of the evaporator (separator or drum), via which water is removed from the steam generator on startup.The separated steam cools the superheater. In BENSON boilers for base-load plants, the water separated out in theseparator is led to a flash tank. Units with frequent startup and shutdown usually have a circulating pump.
The steam is then led through the HP bypass station, the reheater and the LP bypass station to the condenser.This unit startup system is essentially the same for BENSON boilers and drum-type steam generators. The onlydifference may be the flow rate through the bypass station, if a 100 % HP bypass station with safety function is used.
The startup sequence is described by three steps. The evaporator is first filled with water (step 1). Then the burnersare ignited, and the steam produced flows through the turbine bypass into the condenser (step 2). As soon as the steamat the superheater outlet has a sufficient degree of superheat, the turbines are run up and the generator is synchronized The mass flow through the bypass stations decreases correspondingly (step 3). The startup sequence is essentially thesame for cold, warm and hot starts.
Reliable forced cooling of the water walls and the thin wall thicknesses of the separators at the end of the evaporatormake the startup time of the BENSON boiler considerably shorter than that for the drum-type boiler up to the admissionof steam to the turbine. Cold startup (shut down > 48 hours) governed by the turbine.
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Reheater Temperature Control
An operating advantage of the BENSON steam generator is that the main steam temperature can be held constant,independent of load, fouling of heating surfaces, changing coal characteristics and excess air, simply by adjusting the ratioof coal flow rate to feedwater flow rate. The spray attemperators are only used for fine control, particularly in the case ofdynamic processes. On the other hand, additional measures are required to maintain constant reheater temperature,analogous to those for HP and reheater temperatures on a drum-type steam generator.
In Europe the implementation of spray attemporation is widely used, outside Europe damper control and flue gasrecirculation are dominating.
Tendency of Design Parameters
For a long time - from 1970 to 1990 - the power Plant development regarding the steam parameters stagnated world-wide e. g. in Germany with about 190 bar, 530 °C and in USA with 167 bar, 538 °C. The power plant net efficiency with thesesteam conditions was in the range between 37 % and 39 %, bases on lower heating value. In some countries, especiallyin Europe and USA, a few supercritical power plants were developed in addition to the conventional design.
The development to higher steam temperatures started in the beginning of the 90's, when new material (P91) not asexpensive as austenitic steel was available. This development was pushed in Japan and in Europe, particularlyin Germany and Denmark.
Today steam temperatures of 580 °C/600 °C are the design parameters for future German power plants.
In Japan these high steam parameters are also state of the art and the development to higher pressure and temperatures will go on.
A comparison of sub- and supercritical power plants in Germany shows, that there is no difference in the availabilityof both types of plants. There is no specific or additional risk for power plants with supercritical pressure. Other experiencesby transition to supercritical pressure in the 60's in USA are rather caused by simultaneously increasing the size of power plantsfrom 300 MW to 1000 MW and more and other conceptional changes like firing design from under- to overpressure and last notleast by the Boiler design itself. UP/Multi Pass.
1924 Siemens buys the „BENSON Patent“ from Mark Benson
1926 to 1929 Siemens manufactures three BENSON boilersfrom 30 t/h to 125 t/h
1933 Siemens awards BENSON licences to severalboiler manufacturers
1933 Siemens proposes variable-pressure operation
1949 The world‘s first once-through boiler with high steamconditions (175 bar/610°C, BENSON boiler at Leverkusen)
1963 The world‘s first spiral-tubed water walls in membranedesign (BENSON boiler at Rhodiaceta)
1987 The world‘s largest hard-coal-fired boiler with spiral-tubedwater walls (900 MW BENSON boiler at Heyden4)
1993 Siemens proposes vertical tubed water walls in lowmass flux design for BENSON boilers
1997 More than 980 BENSON boilers with > 700.000 t/h in total
BENSON Licence
Milestones in the Field of BENSON BoilersMilestones in the Field of BENSON Boilers
KWU 99 152d
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System of risers and downcomers(m = 1636kg/m2s)
28544mm
Tubes38 x 5.6mm
Evaporator Design
Spiral tubing(m = 2108kg/m2s)
4 x 44 = 176mm
Tubes 33.7 x 5mm
17°
285
Changeover from Vertical Tubing to Spiral-Wound Tubing,Changeover from Vertical Tubing to Spiral-Wound Tubing,Illustrated for a 1000 t/h Steam GeneratorIllustrated for a 1000 t/h Steam Generator
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BENSON Licence
BENSON License Contracts Cover R&D and Technical AssistanceBENSON License Contracts Cover R&D and Technical Assistance
KWU 99 152d
Technical AssistancesR&D
Boiler conceptsHeat transferPressure dropWater chemistryErosion corrosionStress analysisFluid dynamicsTwo phase separation/distributionComputer codes
Results transferred to licenseesin yearly BENSON meeting
Activities in case of orders incommon teams or under Siemensguidelines
Thermodynamic designThermohydraulic designEvaporator designStart-up systemControl conceptsOperational conceptsMechanical design(evaporator)Feedwater treatment
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Load
Wat er level i n t he drum
Load
Tem perat ure behi nd evaporat or
BE NSON Boiler
Drum Boiler
Drum Boiler Drum Boiler vsvs. BENSON Boiler - Feedwater Control. BENSON Boiler - Feedwater Control
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Drum level
High l evel
Low l evel
A ct ualvalue
Set point
mm
+250
+50
-50
-150
-250
Drum Boiler
0
+150
A ct ualvalu eSet poi nt
Temperature at evaporator outlet
°C
440
430
410
40 0
390
380
BENSON Boiler
420
Lowt em perat ure
Hight em perat ure
Drum Boiler Drum Boiler vsvs. BENSON Boiler. BENSON BoilerIndicators for Feedwater SupplyIndicators for Feedwater Supply
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250
200
150
100
50
0
S lidi ng pressu reo r const antpressure
0 20 40 60 80 % 100Load
bar
S li ding pressure
Pressure
Constant pressure
Sl iding pressure
G~
Operation Mode of Power PlantOperation Mode of Power Plant
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Comparison of Different Operating Modes of Steam TurbinesComparison of Different Operating Modes of Steam Turbines
40
%
∆ HR
0
Constant pressure with control stage
Constant pressure with throttling control
Main steam pressure = 250 bar
Heat rate HR =
With turbine driven FWP
Main steam pressure = 250 bar
Heat rate HR =
With turbine driven FWP
P Heat InputP Terminal output
50 60 70 80 90 100
1
2
3
4
Terminal output P%
Modified sliding pressure
Sliding pressure
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Load [%] 20 50 100
Turbine(downstream first stage)
Separator(BENSON)
Drum
Turbine
Maximum Load Change Rates
Boiler (Drum)
(Drum)(BENSON)
(BENSON)Plant
10
%min
3 7 3 7
Load [%]
o CoC
20 50 100
300 300
400 400
500 500 Turbine(downstream first stage)
Separator(BENSON)
Drum
Turbine
Maximum Load Change Rates
Boiler (Drum )
(Drum )(BENSON)
(BENSON)Plant
1-3
%min
7 7
1-3}
Variable Pressure Constant Pressure
Comparison of Different Operating ModesComparison of Different Operating Modes
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100
80
60
40
20
0
Ti m e [ m in]
Load [ %]
0 10 20 30 40
Turbi ne 10% / m in
BE NSON boi lerappr. 5% / m i n
Drum boilerappr. 2% / m i n
Load Ramps in Sliding Pressure Operation ModeLoad Ramps in Sliding Pressure Operation Mode
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KWU 99 152d
Comparison of different Control StructureComparison of different Control Structure
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Drum Boiler versus BENSON Boiler
BENSON BoilerDrum Boiler
I P/LPHP
Ci rculat ionpumpFlash t ank /Feedwater tankA tmosphericflash ta nk
E v a p o r a t o r
S u p er h ea t er
E c o n o m i z e rRe h e at er
S e p a r a t o r
Start-Up Systems for BENSON BoilerStart-Up Systems for BENSON Boiler
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Start-Up Times [min] of Power PlantsStart-Up Times [min] of Power Plants
Plants with BENSON Boiler250 bar / 540°C / 560°C
Plants with Drum Boiler167 bar / 538°C / 538°C
first steamto Turbine
full load
From ignition to:
first steamto Turbine
full load
From ignition to:
20 - 30
40 - 60
150 - 210
150 - 210
60 - 80
80 - 100
300 - 350
450 - 600
20 - 30
30 - 40
60 - 80
60 - 80
30 - 40
50 - 60
150 - 200
400 - 600
After shutdown hours
<1
8
48
>48
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Temperature [ C]o
50 75 100 125 150Time [min]
175 200 2100-15 25
100
400
200
500
300
600
0
Ignition
1000
n [min ]Turbine
-1
2000
3000
0
Pres
sure
[bar
]
25
100
50
125
75
150
175
200
250
225
0
Load
Flow
[%]
10
40
20
50
30
60
70
80
100
90
0
RH-Temperature
MS-Temperature
MS-Pressure
Fuel Flow
Load
Oil Flow
Speed
MS-Flow
Start-up Performance after 48hrs shut downStart-up Performance after 48hrs shut down
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RH2
RH1
Spray attemperator
RH1
Flue gas reci rculation
Damper control
RH2
Methods of Temperature Control-OverviewMethods of Temperature Control-Overview
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Methods of RH Temperature Control - Net EfficienciesMethods of RH Temperature Control - Net Efficiencies
Load 100% 70% 40%
Basis(without control measures) 43.72% -0.16% -0.11%
Spray attemperator -0.13% 43.35% 41.10%
Damper control -0.02% -0.06% 41.10%
Flue gas recirculation -0.01% -0.22% -0.31%
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Molecular Structure of WaterMolecular Structure of Wateras Function of Pressure and Temperatureas Function of Pressure and Temperature
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100
150
200
250
300
350
400
450
500
550
600
650
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400p [bar]
h [k
J/kg
]
T [°C]
700
750
370
380
390
100% MCR
Economizer
Evaporator
RH1
Superheater 1
Superheater 2
Superheater 3
50% MCR30% MCR
RH2
100%MCR
50%MCR
30%MCR
Supercritical BENSON Boiler in the h/p-DiagramSupercritical BENSON Boiler in the h/p-Diagram
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Pow er Plan t Capa city Year of Live s te amMW com m iss . press ure
ba rWilhe lm s have n 820 1976 196Weiher III 707 1976 187Me hrum 3 712 1979 196Ge rs te inw e rk K 765 1979 202Voe rd e A 707 1982 187Voe rd e B 707 1985 187Ib be nb üre n 770 1985 200He yd en IV 911 1987 210Ba d enw e rk 7 536 1985 220He rn e IV 500 1989 260Stauding er 5 550 1983 260Ros tock 550 1995 260Lip p en dorf A 930 1999 268Lip p en dorf B 930 1999 268Boxb erg Q 915 2000 268
Evaporator in let p res sure(b ar)
220 240 260 280 300
Coal-Fired Supercritical 500/900 MWCoal-Fired Supercritical 500/900 MWBENSON Boiler in GermanyBENSON Boiler in Germany
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Temperature
Commissioni ng year
1994 1996 1998 2000
600
580
560
540
Pressure range:
US A: 251 barJapan: 242 barGermany: 250 to 285 bar
°
C
HP (Germany) HP and IP (USA)
HP (Japan)
IP (Japan)
IP (Germany)
Development of Turbine Inlet TemperaturesDevelopment of Turbine Inlet Temperatures
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Trend of boiler steam condition in JapanTrend of boiler steam condition in Japan
1988 90 92 94 96 98 2000 02 04
Year in commission
41
42
43
44
Plan
t eff
icie
ncy
(%)
Coal fired power plants
246atg/538/566°C
246atg/566/566°C
246atg/566/593°C
246atg/593/593°C
250atg/600/600°C
Higher Efficiency inThermal Power Plants
High Strength Steels for HigherSteam Temperature and Pressure
300atg/625°C
KWU 99 152dPage 38 of 222
EV 2 / Oktober, 99; NTPC Presentation. ppt
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 39 of 222
Tendency of Tendency of Design Parameters Design Parameters forforOnce TroughOnce Trough Boilers in Boilers in Pit HeadPit Head Power Power PlantsPlants
Project Capacity Design Parameter Fuel Award DateGermany Weisweiler PP 2 x 600 MW 530/530° C - 172 bar lignite 1971
Schkopau PP 2 x 480 MW 545/560° C - 263 bar lignite 1992Schwarze Pumpe PP 2 x 850 MW 545/562° C - 266 bar lignite 1992Boxberg PP 1 x 900 MW 545/580° C - 266 bar lignite 1992Lippendorf PP 2 x 930 MW 554/583° C - 267 bar lignite 1994Niederaußem PP 1 x 950 MW 580/600° C - 260 bar lignite 1997
Design Study Neurath F PP 1 x 950 MW 600/620° C - 260 bar lignite (2004)
South Africa Tutuka PP 6 x 600 MW 540/540° C - 171 bar bitumin. coal 1982Duvha PP 6 x 600 NW 540/540° C - 174 bar bitumin. coal 1977Majuba PP 3 x 660 MW 538/538° C - 174 bar bitumin. coal. 1984
3 x 700 MW 538/538° C - 174 bar bitumin. coal. 1984Australia Calide PP 2 x 420 MW 540/560° C - 250 bar bitumin. coal 1998
Millmeran PP 2 x 350 MW 568/596° C - 250 bar bitumin. coal 1999Kogan Creek PP 1 x 700 MW 545/563° C - 264 bar bitumin. coal 1999
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 40 of 222
Technical Session ITechnical Session IBharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG
3.0 Comparison of Subcritical and supercritical Units in View of Efficiency, Availability,Feedwater Treatment and Investment Costs
The most important effect of supercritical and ultra supercritical plant design is the increase of plantefficiency. It is obvious that units running with higher efficiency, i.e. burning less quantity of coal to produce same amount of electric energy, are giving a significant benefit regarding saving of natural coal reserves andsaving of the environment by reducing dust-, CO2, SOx and NOx-emission. Considering only the increase of efficiency by increasing the steam parameters from 175 bar, 538/538°C to 241 bar, 538/566 °C will give a coalsaving of 210,00 tons per year for a typical Indian super thermal power station of 4x500 MW electric output.Annual saving of CO2 can be estimated to approx. 262,000 tons per year, SO2, saving can be calculated to 1,600 tons and total ash saving to about 90,900 tons for this power station.
Availability data for subcritical and supercritical power plants based on recent US EPRI and German VGB publications or from Japan give clear evidence that over the last decades plant availability data for supercriticalunits are in the same range as the relevant data for subcritical units. In addition enclosed availability figures from several once-through boilers supplied by BBP to different utilities illustrate the reliability of the units.
Regarding water chemistry a comparison of the relevant international standards illustrates that no additional installation for supercritical power plants compared to the requested standards for high pressure subcritical plants are required. A combination of a condensate polishing plant with oxygenated treatment can be recommended as a well proven procedure. Further, once-through boilers do not have a boiler blow down. This has a positive effect on the water balance of the plant with less condensate needed to be fed into the water-steam cycle and less waste water to be disposed.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 41 of 222
In the recent past several studies have been worked out by various companies and institutions comparing investment costs and electricity generation costs of subcritical and supercritical coal fired thermal power stations. For example Shell & SEPRIL (a consulant,jointly owned by Electric Power Research Institute andSargent & Lundy) have assessed the cost effectiveness and environmental performance of a State of the ArtPower Plant (SOAPP), PF-coal fired, 3500 psig (240 bar, 41% plant efficiency), supercritical, 2x600 MWel, in anAsian location in a detailed study for the International Energy. The plant investment costs on turn key base havebeen found out to be 1% higher in comparison to a comparable subcritical unit (38 % plant efficiency). Regarding electricity generations costs the effect of the fuel price is very significant but even in case of low fuel cost (15 US $/to) and lower capital cost the supercritical unit causes lower electricity costs.Our own investigations based on a 525 MWel world coal fired unit for Israel and 2x660 MWel high ash coal fired boilers for China confirm the results of the Shell report. The total plant investment costs for the supercriticalunit based on design data (255 bar, 540/560°C) and turn key scope will increase 1.85% in comparison to the subcritical unit. Further, specific investment costs can be lowered by increasing unit size.The costs for the boiler itself will increase in the order of 4.5 to 5% by using supercritical steam parameters.Noted that these studies are mainly based on world coal fired units. Considering high ash Indian coal investment cost of the units (subcritical or supercritical) in general will increase in comparison to low ash coalfiring units due to the special layout requirements of the boiler, electrostatic precipitator and ash handling system. However it can be predicted that the price relation of subcritical to supercritical units both firing high ashIndian coal will not be influenced, i.e. will remain in the range of about 2% higher investment cost for the supercritical unit.
Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 42 of 222
TechnicalTechnical Session II Session IIComparison of SubComparison of Sub-/-/Supercritical UnitsSupercritical Units in in View of View of Efficiency, Efficiency, Availability Availability,,
FeedwaterFeedwater Treatment, Investment Treatment, Investment Costs Costs
• Increasing steam parameters from subcritical to supercritical like 241bar, 538/566°C will result in preservation of resources and will consider the greenhouse effect. For a 4x500MWe power station in India a coal saving of 210,000 tons/a, CO2-saving of 262,000 tons/a and a SO2-saving of 1,600 tons/a will be reached.
• Availability of supercritical units are comparable to subcritical units.
• International standards for water chemistry do not ask for additional installations for supercritical units compared to high pressure subcritical units.
• Turn key plant investment costs on international basis for 240bar, 540/560°C supercritical units are in the range of 1 to 2% higher in comparison to high pressure subcritical units. Cost increase for the boiler will be about 4.5 to 5%.
• It can be assumed that this price relation will remain the same for power plant designed for Indian coal.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 43 of 222
Development thermal net efficiency of bituminous coalDevelopment thermal net efficiency of bituminous coaland lignite power plant in Germanyand lignite power plant in Germany
1980 1990 2000 201035
40
45
50
Year
η th % *
Rostock 550 MW
Staudinger 550 MW
bituminous coal
ligniteLippendorf2 x 930 MW
Schkopau 2 x 400 MW
subcritical supercritical
high temperaturesteam processes
Hemweg 8680 MW
Westfalen D350 MW
Bexbach 1750 MW
availability of new materials
* η th = including desulpherisation and denitrification
(based on: LHV
Bexbach 2750 MW
Niederaußem980 MW
BoA*-plus1000 MW
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 44 of 222
Potential for Efficiency Improvement for Lignite FiredPotential for Efficiency Improvement for Lignite FiredSteam GeneratorsSteam Generators
Source: Energietechnische Tagesfragen 1997-Heft 9 Prof. Dr. Ing. W. Hlubek - Vorstand RWE
up to now: BoA* with integrated drying process
intergrateddrying
hot flue gaswith 1000 °C
row coal
dry coal+ flue gas+ vapour
flue gasplus vapour
separatedrying (WTA)
electricenergy
Steamvapour
flue gasHeat Pump
energetic disadvantage:- predrying on very high temperatur level- no use of vapor energy
energetic improvement:- predrying on low energy level- use of vaporenergy
appr. 5% efficiently improvementη = 43 % η = 48 %
BoA* plus predrying
drying unit
row coal
condensat
dry coal
BoilerBoiler
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 45 of 222
Measures to increase EfficiencyMeasures to increase EfficiencyBexbachBexbach I PP versus I PP versus Bexbach Bexbach II PP II PP
Source: VGB-Kraftwerkstechnik 75 (1995) Heft 1
INCREASE SH AND RH STEAMTEMPERATURE TO 575/595 °C /
Ê = 1,3 %
INCREASE SH-STEAM
PRESSURE TO 250 BAR / Ê = 0,65 %
ADDITIONAL UTILISATION OF FLUE GAS HEAT /
Ê = 0,6 %COMMISSION OF REHEATING / Ê = 0,15 %
INCREASE OF FEEDWATER TEMPERATURE / Ê = 0,7 %
REDUCTION OF EXHAUST
STEAM PRESSURE / Ê = 1,1 %
REDUCTION OF EXCESS AIR / Ê = 0,4 %
OPTIMISATION OF COMPONENTS
(IN PARTICULAR THE T/G) / Ê = 2,4 %
39,00 % = BASIS VALUE FOR BEXBACH I POWER STATION39,00
41,40
41,80
42,90
43,6043,75
44,35
45,00
46,30
NE
T E
FFIC
IEN
CY
%
46,30 % = BASIS VALUE FOR BEXBACH II POWER STATION
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 46 of 222
Reference LetterReference Letter Heyden Heyden
Thus in our power plant KW Heyden(900 MWel., commissioning year 1987,concept without overfire air)an ratio of 1.12 - 1.16 was achieved.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 47 of 222
Measures to increase EfficiencyMeasures to increase EfficiencyRuthenbergRuthenberg PP versus PP versus Rostock Rostock PP PP
INCREASED TURBINE EFFICIENCY
/ Ê = 0,4 %
41,6
42,0
43,2
43,6
41,1
INCREASED SH PRESSURE TO 262 BARAND INCREASED FEEDWATER TEMPERATURE
TO 272 °C / Ê = 1,2 %
INCREASED REHEATER OUTLET TEMPERATURE TO 560 °C
/ Ê = 0,4 %
INCREASED BOILER EFFICIENCY
/ Ê = 0,5 %41,1 % = BASIS VALUE FOR RUTHENBERG POWER STATION
43,6 % = BASIS VALUE FOR ROSTOCK POWER STATIONN
ET
EFF
ICIE
NC
Y %
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 48 of 222
Comparison of Plant part load efficiencyComparison of Plant part load efficiency
30
40
46
30 40 50 60 70 80 90 100Load %
41,1 %
36,7 %
39,3 %40,5 %
43,2 %42,4 %
40,1 %
Plan
t net
eff
icie
ncy
Supercritical unitacc. Alternative 2255 bar 538°C / 538°C
Subcritical unitacc. Alternative 1166 bar 538°C / 538°C
43,6 %
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 49 of 222
Relative Plant - h improvement of supercritical steamRelative Plant - h improvement of supercritical steamprocess compare toprocess compare to subcritical subcritical unit unit
4
5
6
7
8
9
30 40 50 60 70 80 90 100
Load %
Rel
ativ
e η
- im
prov
emen
t ∆η/
η in
%
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 50 of 222
Increase of CycleIncrease of Cycle Efficiency Efficiency due due to to Steam Steam Parameters Parameters
300241
175 538 / 538
538 / 566
566 / 566
580 / 600
600 / 620
6,775,79
3,74
5,744,81
2,76
4,263,44
1,47
3,372,64
0,75
2,421,78
00
1
2
3
4
5
6
7
8
9
10
HP / RH outlet temperature [deg. C]Pressure [bar]
Increase of efficiency [%]
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 51 of 222
Saving of Coal Reserves and Mitigation of Environmental Impact bySaving of Coal Reserves and Mitigation of Environmental Impact byUsing Supercritical TechnologyUsing Supercritical Technology
Essential Measures to Increase Plant Efficiency
1. Cycle Efficiency
- Increased steam parameters: 175bar, 538/538°C ð 241 bar, 538/566 °C
- Double reheat: not considered
- Reduced pressure in condenser: not considered
2. Boiler Efficiency
- Reducing flue gas temperature: not considered
3. Turbine efficiency
- Advanced turbine design: not considered
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 52 of 222
Effect of Increased CycleEffect of Increased Cycle Efficiency Efficiency on Coal Consumption on Coal Consumption
0,00
10,00
20,00
30,00
40,00
50,00
(Lakh tons/a) (Cr. Rs/a)
Savings of Coal Reserves / Coal Costs per Year
Coal Saving (Lakh tons/a) 2,15 11,28
Coal Cost-Saving (Cr. Rs/a) 9,67 50,74
Sipat (4x500 MWe) All India (21x500 MWe)
Base of calculationEfficiency subcriticalcycle: 38.5% Increase of efficiency:+ 2.64%rel., (+1%abs.)
LHV 12,937 kJ/kg
Fuel Consumption of Subcritical Unit: 339 t/h
Operation: 6000 h/a
Fuel Price: 450 Rs/to
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 53 of 222
Effect of Increased CycleEffect of Increased Cycle Efficiency Efficiency on on Emission Emission
0
200
400
600
800
1000
1200
1400
(1000 to/a)
Saving of Emission per Year
CO2 Saving (1000 to/a) 262,3 1376,8SO2 Saving (1000 to/a) 1,6 8,3Total Ash Saving (1000 to/a) 90,9 477,2
Sipat (4x500 MWe) All India (21x500 MWe)
Efficiency subcritical cycle: 38.5%Increase of efficiency:+ 2.64% rel., (1%abs.)
LHV 12,937 kJ/kgAsh Content 42.3%Sulphur Content 0.37%
Fuel Consumption of Subcritical Unit: 339 t/h
Operation: 6000 h/a
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 54 of 222
Reduction of Ash dueReduction of Ash due to to Increased Cycle Increased Cycle Efficiency EfficiencySipat ash saving after 5 years of operationequivalent to a cone of approx. 454,500 m3
appr
ox. 7
6 m
approx. 57 m
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 55 of 222
Saving of Coal dueSaving of Coal due to to Increased Cycle Increased Cycle Efficiency Efficiencyap
prox
. 76
m
approx. 57 m
Sipat coal saving after 2 years of operationequivalent to a cone of approx. 537,500 m3
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 56 of 222
GenerationGeneration Availability Availability (VGB) (VGB) Subcritical Subcritical,, Supercritical SupercriticalPowerPower Plants Plants
0
10
20
30
40
50
60
7080
90
100
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
88-9
7
Subcritical Supercritical%
Year
0
20
40
60
80
100
85 86 87 88 89 90 91 92 93 94 95 96 97 88-97
Time Availability
Time Utilization
Energy Availability
Energy Utilization
%
Year
SubcriticalSubcritical
Year 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 88-97Availability 84,6 83,7 82,4 82,6 81,5 83,2 85,4 82,8 80,2 82,5 81,9 86,1 87,4 83,3
SupercriticalSupercritical
0
20
40
60
80
100
85 86 87 88 89 90 91 92 93 94 95 96 97 88-97
Time Availability
Time Utilization
Energy Availability
Energy Utilization
%
Year
Year 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 88-97Availability 83,1 87,2 81,4 78,3 73,2 83 82,9 86,2 90,9 80,5 83,1 79,2 89,2 82,9
EnergyEnergy Unavailability Unavailability not not Postponable Postponable (EU) (EU)of German Power Plantsof German Power Plants
01989 1991 1993 1995 1997
2
4
6
8
10
Year
Subcritical
Supercritical
EU(%) = FOE/MPG*100%FOE = Forced outage energyMPG = Maximum possible energy
EU(%) = FOE/MPG*100%FOE = Forced outage energyMPG = Maximum possible energy
%
EU
Supercritical versus Subcritical KWU 99 152d
EV 2 / Oktober, 99; NTPC Presentation. pptPage 57 of 222
Energy Availability of German Power PlantsEnergy Availability of German Power Plants
KWU 99 152d
1989 1991 1993 1995 1997
100
Year
%
EA
90
80
70
60
50
EA(%) = AV/AN*100%AV = Available EnergyAN = Nominal Energy
EA(%) = AV/AN*100%AV = Available EnergyAN = Nominal Energy
Subcritical
Supercritical
Supercritical versus SubcriticalEV 2 / Oktober, 99; NTPC Presentation. ppt
Page 58 of 222
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 59 of 222
Reference LetterReference Letter Staudinger Staudinger
Please find attached the „Certificate of Experience Record“ completedby PreussenElektra Kraftwerk Staudinger. We would like to confirm thatthe steam generators supplied by Deutsche Babcock have fulfilled allrequirements of PreussenElektra Kraftwerk Staudinger as owner andoperator to our full satisfaction during all years of operation.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 60 of 222
Experience RecordExperience Record Staudinger Staudinger
• Commercial Operation date: 1992/06/15 1996/07/16 49
• Capacity Factor: : 91%• Availability factor: 99%
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 61 of 222
Reference LetterReference Letter Rostock Rostock
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 62 of 222
Experience RecordExperience Record Rostock Rostock
• Continous Operation Period: 94/8/1 until now 57
• Capacity Factor: 98,00%
• Availability factor: 99,2%
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 63 of 222
*) downstream Condenser
< 200"... The DOC content of completelydemineralized make-up water shouldnot exceed 0.2 mg/l..."
ppb Organic substances (as DOC/TOC)
-< 100 ppb Oil /grease / fa t
-≤ 10 ppb N2H4
≤ 20≤ 10 *)≤ 10 *)< 20< 20 ppb Silica (SiO2)
≤ 2≤ 5≤ 2≤ 2< 3< 3 ppb Copper (Cu)
≤ 10≤ 20≤ 10≤ 10 < 10< 20< 20 ppb Iron (Fe)
≤ 3 *)≤ 3 *)≤ 5 *)< 10< 10 ppb Sodium + Potassium (Na + K)
≤ 20 - 200≤ 7≤ 7≤ 5≤ 5 ≤ 250< 10030 to 150< 100< 100 ppb Oxygen (O2)
6.5 - 9.09.0 - 9.68.5 - 9.69.0 - 9.69.0 - 9.6 7 .... 10> 9.28 to 99 to 109 to 10 - pH value at 25 °C
≤ 50 ppb Total Solid
≤ 0.2≤ 0.25≤ 0.5≤ 0.2≤ 0.2< 0.2< 0,2 µS/cm Acid conductivity at 25 °C
not specified-not specified µS/cm Conductivity at 25 °C
clear, free from suspended solids
clear and colourless - Appearance
> 2015 - 20with Reheat> 6 total range total range MPa Operating pressure
OxigenatedTreatment
All VolatileTreatment
CoordinatedPhosphateTreatment
All VolatileTreatment
All VolatileTreatment
PhosphateTreatment
All VolatileTreatment
. / .CombinedOperation
AlkalineOperation
CombinedOperation
All VolatileTreatment
AlkalineOperation
Operation
Once-through Drum TypeOnce-through Drum TypeOnce-through Drum TypeOnce-through Drum TypeBoilerType
JIS B82231989
EPRI CS-46291986
EN 12952 Part 12Draft 1998
VGB-R 450 L1988
JapanU.S.A.EuropaGermany
Supercritical Power Plants/ Evaluation of Design ParametersSupercritical Power Plants/ Evaluation of Design Parameters
Requirements for Feedwater Quality
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 64 of 222
Supercritical Power Plants/ Evaluation of Design ParametersSupercritical Power Plants/ Evaluation of Design Parameters
< 5 ppb Chloride (Cl) 5< 205< 20< 10< 20< 10< 10 ppb Silica (SiO2)1< 31< 3< 1< 3< 1< 2 ppb Copper (Cu) 5< 205< 20< 5< 20< 5< 20 ppb Iron (Fe)
2< 102< 10< 5< 10< 10< 5< 3 ppb Sodium + Potassium (Na + K)
0,1< 0.20,1< 0,2< 0,1< 0,2< 0,1< 0,3< 0,2 µS/cm Acid conductivity at 25 °C
Normaloperating
value
Standardvalue
Normaloperating
value
Standardvalue
Unit Parameter
VGB-R 450 L1988
Siemens / KWU1998
MANABBAllisChalmers
WestinghouseGeneralElectric
Requirements on Steam for Condensing Turbines
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 65 of 222
Supercritical Power Plants/ Evaluation of Design ParametersSupercritical Power Plants/ Evaluation of Design ParametersHigh Pressure Drum Boiler: Steam Quality (Silica) and Blow Down Rate
Drum Boiler
Drum pressure: 18 MPaSilica distribution ratio (C Steam / C Water): 0.08
* Condensate Polishing Plant required
Balance05062550 *Balance03037530 *
!!13.0 *2025050 *
!!4.3 *2025030 *2 *2025024.6 *
12025022.3Balance02025020
!!8.7 *1012520
Balance01012510
%Feedwater
SiO2
(ppb)SiO2
(ppb)SiO2
(ppb)
Blowdown rate
SteamBoilerwater
Feedwater
Once-through Boiler: Feedwater Quality = Steam QualityBlow Down Rate = 0Condensate Polishing Plant required
Boiler water
SiO2 = 250 ppb
Feedwater
SiO2 = 20 ppb
Steam
SiO2 = 20 ppb
Blow down
0 %
Balance at 180 MPa:
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 66 of 222
1. Study of Shell Coal International & SEPRIL Services
2. BBP evaluation based on 525 MWel power plant project in Israel
3. BBP evaluation based on 660 MWel boiler project in China
Evaluation SubcriticalEvaluation Subcritical//SupercriticalSupercritical Power Power Plants Plants
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 67 of 222
Comparison ofComparison of Plant Investment Plant Investment
Study
„Increasing the Efficiency of Coal-fired Power Generation“
from Shell Coal International & SEPRIL Servicesfor publication by the International Energy Agency
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 68 of 222
Comparison ofComparison of Plant Investment: Plant Investment: Subcritical Subcritical//SupercriticalSupercritical
Case-Study2x600 MWel, pulverized bituminous coal fired power plant in an Asian location
Case (1) 2400 psig (165 bar) subcritical plant,38 % nominal design efficiency based on LHV
Case (2) 3500 psig (240 bar) supercritical41% nominal design efficiency based on LHV
Source: Study of Shell Coal International & SEPRIL Service
Calculation Basis- turn key plant equipment incl. low Nox-burners, structures, switchyard, coal unloading facilities, sea water cooling- 60 month construction schedule- 30 years plant operation period- 85% availability, 80% capacity factor- 13% fixed charge rate- 9.8% interest during construction- 13$/kW-year O&M (fixed), 2% O&M escalation - 5$/to waste disposal costs
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 69 of 222
Comparison ofComparison of Plant Investment: Plant Investment: Subcritical Subcritical//SupercriticalSupercritical
Components Subcritical PlantCapital Costs ($/kW)
Supercritical PlantCapital Costs($/kW, % compared to subcritical)
Boiler (incl. steel structuresand components)
142.94 153.09 (107.1)
Boiler plant piping 27.81 31.03 (111.6)
Feedwater system 28.06 28.62 (102.0)
Turbine-Generator 79.2 82.37 (104.0)
Turbine plant piping 16.25 15.44 (95.0)
Subtotal 294.26 310.38 (105.5)
Remainder of Plant 509.17 500.69 (98.3)
Total Plant Cost 803.43 (100%) 811.07 (101.0)
Source: Study of Shell Coal International & SEPRIL Service
Capital Costs
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 70 of 222
Comparison ofComparison of Plant Investment: Plant Investment: Subcritical Subcritical//SupercriticalSupercritical
Generating Cost of Electricity (cents/kWh)
0
1
2
3
4
5
6
7
8
Subcritical Supercritical Subcritical Supercritical
Fuel Costs
V ariable O&M
Fixed O&M
Capital Charges
Diff. = 0.08 cents/kWh
Diff. = 0.23 cents/kWhFuel Cost: 15$/to Fuel Cost: 40$/to
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 71 of 222
Subcritical/Supercritical Bituminous Coal Fired Units525 MWel,net
(Rutenberg, Israel)
Comparison of Plant InvestmentComparison of Plant Investment
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 72 of 222
Single Unit Capacity Single Unit Cost Total Plant Cost(2000 MW)
Specific Plant Cost(2000 MW)
500 MW subcritical 100.00 % 359.5 % 100.00 %
500 MW supercritical 101.85 % 366.1 % 101.85 %
660 MW supercritical 125.58 % 342.8 % 95.35 %
660 MW subcritical 123.26 % 336.5 % 93.60 %
Power Plant India: A.) 4 x 500 MW (4 x 100% capacity)
B.) 3 x 660 MW (3 x 132% capacity)
Power Plant Israel: A.) 4 x 525 MW (4 x 100% capacity)
B.) 3 x 693 MW (3 x 132% capacity)
Comparison of Plant Investment based on Experiences in the International MarketComparison of Plant Investment based on Experiences in the International Market
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 73 of 222
Comparison of Plant Investment: Subcritical/SupercriticalComparison of Plant Investment: Subcritical/Supercritical
Alt. 1(subcritical)
Alt. 2(supercritical)
Alt. 3(supercritical)
Alt. 4(supercritical)
Live steam pressure at turbine (bar) 166 255 255 255
Live steam temp. at turbine (°C) 538 540 540 540
Hot reheat temp. at turbine (°C) 538 560 560 560
Feed water temp. (°C) 250 272 272 272
Condenser pressure (mbar) 50 50 50 50
Power (MWel,net) 525 525 669 693
LHV, world coal (kJ/kg) 25.748 25.748 25.748 25.748
Alternatives investigated
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 74 of 222
Comparison of Plant Investment: Subcritical/SupercriticalComparison of Plant Investment: Subcritical/Supercritical
1. Boiler & Auxiliary Plant Boiler, fuel storage / supply & ash handling, ESP, wet FGD, air heaters / sootblowers / firing equipment, combustion air & flue gas system,insulation, painting, cleaning, engineering
2. Turbine Set Turbine, generator & excitation, condenser & auxiliaries, feedheaters, deaerator, engineering
3. BOP Pumps, pipes, valves, water treatment / dosing unit, cooling main equipment, cranes & hoists, elevators, engineering, others (e.g. tanks, compressors etc.)
4. Electrical Equipment Generator rel. Equipment, transformers, motors, med/low voltage switchgears, cable, bus ducts, cable trays & accessories, communication, lighting, grounding, engineering
Scope of supply breakdown
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 75 of 222
Comparison of Plant Investment: Subcritical/SupercriticalComparison of Plant Investment: Subcritical/Supercritical
5. Main and Field I&C Main I & C, Field I & C, control valves, engineering
6. Civil / HVAC / Fire Fighting Concrete & architectural works, steel structures, HVAC, fire fighting, engineering
7. Plant Engineering
8. Special Project Cost M-Turbine set, PM power plant, PM supporting, project travelling
9. Erection/Commissioning Site management & facilities, erection & commissioning: turbine generator, BOP-equipment, boiler, training / operation
Scope of supply breakdown
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 76 of 222
Comparison of Plant Investment: Subcritical/SupercriticalComparison of Plant Investment: Subcritical/Supercritical
Scope/Component Alternative 1 Alternative 2
525 MWel,net = 100% 525 MW = 100%
165 bar, 538/538°C 255 bar, 540/560°C
% (total) % (relative) % (total) % (relative)
1. Boiler & Auxiliary Plant 29,5 100 30,3 104,6
2. Turbine Set 8,6 100 8,7 102.86
3. BOP 16,1 ) 16 )
4. Electrical Equipment 7,3 ) 7,2 )
5. Main and Field I&C 5,3 ) 5,2 )
6. Civil/HVAC/Fire Fighting 14,2 ) 100 14 ) 100,4
7. Plant Engineering 4,4 ) 4,3 )
8. Special Project Costs 3,3 ) 3,2 )
9. Erection & Commissioning 11,3 ) 11,1 )
Sum (1 Unit) 100 100 100 101,85
Detailed Cost Breakdown in %
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 77 of 222
Scope/Component Alternative 1 Alternative 3
525 MWel,net = 100% 669 MW = 127,43%
165 bar, 538/538°C 255 bar, 540/560°C
% (total) % (relative) % (total) % (relative)
1. Boiler & Auxiliary Plant 29,5 100 31,3 128,5
2. Turbine Set 8,6 100 8,6 120
3. BOP 16,1 ) 16,2 )
4. Electrical Equipment 7,3 ) 7,1 )
5. Main and Field I&C 5,3 ) 4,8 )
6. Civil/HVAC/Fire Fighting 14,2 ) 100 13,9 ) 118,2
7. Plant Engineering 4,4 ) 4,1 )
8. Special Project Costs 3,3 ) 2,9 )
9. Erection & Commissioning 11,3 ) 11,1 )
Sum (1 Unit) 100 100 100 121,38
Detailed Cost Breakdown in %
Comparison of Plant Investment: Subcritical/SupercriticalComparison of Plant Investment: Subcritical/Supercritical
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 78 of 222
Detailed Cost Breakdown in %
Scope/Component Alternative 1 Alternative 4
525 MWel,net = 100% 693 MW = 132%
165 bar, 538/538°C 255 bar, 540/560°C
% (total) % (relative) % (total) % (relative)
1. Boiler & Auxiliary Plant 29,5 100 31,5 133,9
2. Turbine Set 8,6 100 8,6 124,3
3. BOP 16,1 ) 16,1 )
4. Electrical Equipment 7,3 ) 7,1 )
5. Main and Field I&C 5,3 ) 4,8 )
6. Civil/HVAC/Fire Fighting 14,2 ) 100 13,9 ) 121,8
7. Plant Engineering 4,4 ) 4 )
8. Special Project Costs 3,3 ) 3 )
9. Erection & Commissioning 11,3 ) 11 )
Sum (1 Unit) 100 100 100 125,58
Comparison of Plant Investment: Subcritical/SupercriticalComparison of Plant Investment: Subcritical/Supercritical
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 79 of 222
Plant Cost versus Unit Capacity
100
105
110
115
120
125
130
135
100 105 110 115 120 125 130 135
Unit Capacity (%)
Plan
t Cos
t (%
)
525 MWesupercritical
669 MWesupercritical
693 MWesupercritical
Calculation based onconstant price factor($ / MWe)
BasisRutenberg, Israel, Supercritical Bituminous Coal Fired Power Plant
Effect of Unit Size on Investment CostsEffect of Unit Size on Investment Costs
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 80 of 222
Comparison of SubcriticalComparison of Subcritical//SupercriticalSupercritical Boilers Boilers
Subcritical Boiler2x660 MW Shalingzi Phase II Power Plant
2x2,150 t/hr ; 175 bar ; 541/540 °C
Supercritical Boiler2x660 MW Douhe Phase II Power Plant
2x1,981 t/hr ; 260 bar ; 545/562 °C
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 81 of 222
S H A L I N G Z I Power Plant Phase IIS H A L I N G Z I Power Plant Phase II(China)
Unit Capacity 2 x 660 MW
Natural Circulation Boilerwith
damper-controlled parallel pass for reheat temperature control
Coal Firing System for NOx = 300/200 ppm
Furnace Exit Temperature < 1,050 °C
Subcritical Steam Condition 175 bar ; 541/540 °C
Modified Sliding Pressure Operation
Base Load Operation 7,500 operating hours per year
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 82 of 222
2 x 660 MW2150 t/hr; 175 bar; 541/540 °C
SHALINGZI PHASE II POWER PLANTSHALINGZI PHASE II POWER PLANT
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 83 of 222
D O U H E Power Plant Phase IID O U H E Power Plant Phase II(China)
Unit Capacity 2 x 660 MW
Benson Type Boilerwith
flue gas recirculation for reheat temperature control
Coal Firing System with low NOx combustion
Furnace Exit Temperaturedesign coal < 1300°Ccheck coal < 1050°C
Supercritical Steam Condition 260 bar ; 545/562 °C
Modified Sliding Pressure Operation
Base Load Operation 7,600 operating hours per year
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 84 of 222
DOUHE PHASE II POWER PLANTDOUHE PHASE II POWER PLANT
2 X 660 MW1981 t/hr; 260 bar; 545/562 °C
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 85 of 222
0
10.000
20.000
30.000
40.000
50.000
60.000
1 2
Tota
l Wei
ght (
Tons
)
BoilerElectric + I&CCleaning/Hoist/etc.PipeworkInsulationAsh RemovalE S PDraft SystemFiring SystemSootblowerAir PreheaterSteel StructureSpare PartsBunker Feeding
Shalingzi 2x660 MWsubcritical
Douhe II 2x660 MWsupercritical
Diff. = 3,425 to (30%)
Total Diff. = 4,878 to (10%)
Weight Comparison ShalingziWeight Comparison Shalingzi//DouheDouhe II II
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 86 of 222
1 x 660 MWShalingzisubcriticalDIN design
(weight in to)
1 x 660 MWDouhe II
supercriticalDIN design
(weight in to)Membran Walls 1,127 991
HeatingSurfaces
1,630 1,420
Headers 332 455
Pipework 612 509
Boiler Drum /Separator
267 65
SumPressure Parts
3,967 (100%) 3,440 (87%)
Material Mixture Pressure Part in Weight %Douhe II (supercritical)
15 Mo3
13CrMo4415NiCuMoNb5 (WB36)
X10CrMoVNb91 (P91)
X20CrMoV121Others
Headers
37%
11%
23%18%
11%
Weight Comparison
(Typical design according to German standard DIN, equivalent material available in India)
HeatingSurfaces
53%
13%
34%
MembranWalls
53%
46%
1%
Comparison of the Boiler Pressure PartComparison of the Boiler Pressure Part
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 87 of 222
FOB - BoilerFOB - Boiler Price Comparison Price ComparisonFO
B -
Pric
e (c
urre
ncy
unit
)
BoilerPM & EngineeringElectric + I&CCleaning/Hoist/etc.PipeworkInsulationAsh RemovalE S PDraft SystemFiring SystemSootblowerAir PreheaterSteel StructureSpare PartsBunker Feeding
Shalingzi, subcritical, 2x660 MW(local pressure part manufacturing)
100 %104,75 %
Douhe, supercritical, 2x660 MW(pressure parts partly imported)
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 88 of 222
Technical Session IITechnical Session II
3.1 Technical aspects of the collaboration and BHEL´spreparedness for once-through Boilers
BHELBHEL
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 89 of 222
ONCE - THROUGH BOILER
SALIENT FEATURESOF
TECHNICAL COLLABORATIONAGREEMENT (TCA)
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 90 of 222
BACKGROUND & HISTORYBACKGROUND & HISTORY
TO MEET FUTURE MARKET TREND, BHEL WAS
LOOKING FOR A COMPREHENSIVE TCA TO
COVER ALL AREAS - FROM CONCEPT TO
COMMISSIONING INCLUDING R&D UPDATES
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 91 of 222
BHEL HAS ENTERED INTO A LONG TERMLICENSING AGREEMENT WITH
BABCOCK BORSIG POWER GmbH(A - DEUTSCHE BABCOCK - STEINMULLER COMBINE)
GERMANY
FOR TECHNICAL COLLABORATIONFOR ONCE THROUGH BOILERS
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 92 of 222
SALIENT FEATURES OF TCASALIENT FEATURES OF TCA
DURATION OF AGREEMENTDURATION OF AGREEMENT
Y 1O YEARS FROM EFFECTIVE DATE (27.07.99)
OR
Y 7 YEARS FROM DATE OF COMMENCEMENT OF COMMERCIAL PRODUCTION
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 93 of 222
ONCE-THROUGH BOILERS - EXPERIENCE OF BBP GmbHONCE-THROUGH BOILERS - EXPERIENCE OF BBP GmbH
SUB-CRITICAL SUPER-CRITICAL
< 300 MW 111 11
> 300 MW < 500 MW 67 27
> 500 MW 47 19
SUB-TOTAL 225 57
GRAND TOTAL 282EV 2 / Oktober, 99; NTPC Presentation. ppt Page 94 of 222
ONCE-THROUGH BOILERS - EXPERIENCEONCE-THROUGH BOILERS - EXPERIENCEOF BBP GmbHOF BBP GmbH
COAL COAL + OTHERALONE OTHER FUELS SUB-TOTAL FUELSSUB-CRITICAL
< 300 MW 48 10 54>300 <500 MW 36 3 17 > 500 MW 38 2 7 ---- --------------------------------- TOTAL 122 15 88 225 ----------------------------------------------------------------------------------------------SUPER-CRITICAL < 300 MW 5 1 5 >300 <500 MW 17 3 7 > 500 MW 13 1 5 ------------------------------------------
TOTAL 35 5 17 57-----------------------------------------------------------------------------------------------
GRAND TOTAL 282 EV 2 / Oktober, 99; NTPC Presentation. ppt Page 95 of 222
HIGHEST CAPACITY STEAM GENERATORHIGHEST CAPACITY STEAM GENERATOR(TG RATING IN MW)(TG RATING IN MW)
SUB-CRITICAL SUPER-CRITICALFUEL
COAL 745 750
COAL + OIL 900 707
LIGNITE 600 980
OTHERS 745 700
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 96 of 222
COAL FIRED SUPERCRITICAL BOILERS WITHCOAL FIRED SUPERCRITICAL BOILERS WITHSHO AND / OR RHO TEMPERATURE AROUND 540 DEG. CSHO AND / OR RHO TEMPERATURE AROUND 540 DEG. C
PARTIAL LISTING - SELECTED FROM BBP REFERENCE LIST
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 97 of 222
COAL FIRED SUPERCRITICAL BOILERS WITHCOAL FIRED SUPERCRITICAL BOILERS WITHSHO AND / OR RHO TEMPERATURE AROUND 540 DEG. CSHO AND / OR RHO TEMPERATURE AROUND 540 DEG. C
PLANT NAME CAPACITY SHO PRESS. SHO TEMP. RH TEMP. (MW) (bar) (DEG. C) (DEG. C)
LEININGERWERK V 460.4 282 540 540
PS HERNE -IV 500 255 535 541
FWK BUER 150 245 540 540
MANNHEIM, 15 217 257 530 540
PARTIAL LISTING - SELECTED FROM BBP REFERENCE LIST
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 98 of 222
COAL FIRED SUPERCRITICAL BOILERS WITHCOAL FIRED SUPERCRITICAL BOILERS WITHSHO AND / OR RHO TEMPERATURE ABOVE 540 DEG. CSHO AND / OR RHO TEMPERATURE ABOVE 540 DEG. C
PARTIAL LISTING - SELECTED FROM BBP REFERENCE LIST
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 99 of 222
COAL FIRED SUPERCRITICAL BOILERS WITHCOAL FIRED SUPERCRITICAL BOILERS WITHSHO AND / OR RHO TEMPERATURE ABOVE 540 DEG. CSHO AND / OR RHO TEMPERATURE ABOVE 540 DEG. C
PLANT NAME CAPACITY SHO PRESS SHO TEMP. RH TEMP (MW) (bar) (DEG. C) (DEG. C)
STAUDINGER V 500 267 545 562
SCHKOPAU 492 260 545 560
BOXBERG IV 900 266 545 563
ROSTOCK 500 267 545 562
ALTBACH 332 260 545 568PARTIAL LISTING - SELECTED FROM BBP REFERENCE LIST
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 100 of 222
SALIENT FEATURES OF TCASALIENT FEATURES OF TCA
COMPREHENSIVE TCA ENVELOPING
1. SYSTEM ENGINEERING
2. DETAILED ENGINEERING
3. MANUFACTURE
4. QUALITY
5. ERECTION
6. COMMISSIONING
7. TROUBLE-SHOOTING
8. FEED BACK ANALYSIS
9. R&D UPDATES
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 101 of 222
SALIENT FEATURES OF TCA - TECHNICAL SCOPESALIENT FEATURES OF TCA - TECHNICAL SCOPE
TYPE OF BOILER
ü TOWER & TWO-PASS TYPEü SINGLE REHEAT & DOUBLE REHEATü SUB-CRITICAL & SUPER CRITICAL BOILERSFUELS SUB-BITUMINOUS & BITUMINOUS COAL© OIL© GAS© LIGNITE© EITHER INDIVIDUALLY OR IN COMBINATION FIRING SYSTEM ALSO COVERS LOW NOx AND LOW EXCESS AIR TECHNOLOGYUNIT RATINGS© ALL UNIT RATINGS
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 102 of 222
SALIENT FEATURES OF TCA-TECHNICAL SCOPESALIENT FEATURES OF TCA-TECHNICAL SCOPE((ContdContd...)...)
^ COMPLETE PRESSURE PARTS FROM ECO. INLET TO SHOHEADER M. S STOP VALVE
^ COMPLETE COAL FIRING SYSTEM FROM BUNKER OUTLET TOBURNERS (EXCLUDING FEEDERS AND MILLS)
^ COMPLETE FUEL OIL SYSTEM FROM DAY TANK TO BURNERS
^ COMPLETE FUEL GAS SYSTEM TO BURNERS
^ COMPLETE FLUE GAS SYSTEM UPTO CHIMNEY (EXCLUDINGFANS, AIRHEATERS & ESP)
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 103 of 222
SALIENT FEATURES OF TCA-TECHNICAL SCOPESALIENT FEATURES OF TCA-TECHNICAL SCOPE((ContdContd...)...)
¬ COMPLETE AIR SYSTEM (EXCLUDING FANS AND AIRHEATERS)
¬ BOILER SUPPORTING STRUCTURAL STEEL WORK, BUCKSTAYS,PLATFORMS
¬ LINING AND INSULATION
¬ CONTROLS & INSTRUMENTATION
¬ ENGG., MANUFACTURING, QUALITY, ERECTION, COMMISSIONING
¬ FIELD DATA COLLECTION AND ANALYSIS
¬ TYPICAL PURCHASE SPECIFICATION FOR AUXILIARIES
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 104 of 222
SALIENT FEATURES OF TCA - TECHNICAL SCOPESALIENT FEATURES OF TCA - TECHNICAL SCOPE((ContdContd..)..)
Y TRAINING AT COLLABORATOR’S OFFICES / WORKS / SITE -ERECTION AND COMMISSIONING INCLUDED
Y ASSISTANCE FROM COLLABORATOR FOR PROPOSAL ANDCONTRACT ENGINEERING
Y DETAILS OF NEW DESIGN DEVELOPED WILL BE GIVEN TOBHEL
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 105 of 222
SCOPE OF TECH.INFORMATIONSCOPE OF TECH.INFORMATION
☯ DESIGN MANUALS
☯ COMPUTER PROGRAMS
☯ TYPICAL CONTRACT DRAWINGS
☯ QUALITY MANUALS
☯ ERECTION METHODS
☯ COMMISIONING PROCEDURES
☯ TROUBLE SHOOTING PROCEDURES
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 106 of 222
TECHNICAL SUPPORTTECHNICAL SUPPORT
q ASSISTANCEFOR PROPOSAL AND CONTRACT PERFOMANCE. ENGINEERING
q SPECIAL ENGG FOR SELECTED AREA / ITEMS INDENTIFIED.
q ASSISTANCE FOR ERECTION, COMMISIONING, OPERATION, REPAIR & SERVICING AND
RETROFITTING & UPGRADING.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 107 of 222
BACK-UP GUARANTEEBACK-UP GUARANTEE
r COLLABORATOR WILL GIVE BACK- UP GUARANTEE FOR MEETINGTENDER REQUIREMENT.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 108 of 222
BHEL’S CAPABILITIES FORBHEL’S CAPABILITIES FORONCE THROUGH BOILER MANUFACTURINGONCE THROUGH BOILER MANUFACTURING
ü MORE THAN 30 YEARS OF EXPERIENCE IN BOILER MANUFACTURING OF VARYING CAPACITIES/DIFFERENT CODES/ MATERIALS ETC.
ü MANUFACTURED OT BOILER COMPONENTS FOR TALCHER OT BOILERS
ü BUILT UP ADEQUATE MANUFACTURING CAPACITY AND HAS MODERNISED ITS FACILITIESCONTINUOUSLY.
ü PLANNING TO TAKE UP A MAJOR INVESTMENT PROGRAMME FOR IMPLEMENTATION DURING NEXTTWO YEARS FOR COMPLETE MODERNISATION OF ITS MANUFACTURING AND MATERIAL HANDLINGFACILITIES.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 109 of 222
MANUFACTURING OF COMPONENTS SPECIFIC TOMANUFACTURING OF COMPONENTS SPECIFIC TO ONCE THRO’ TECHNOLOGY ONCE THRO’ TECHNOLOGY
_ SPIRAL WATER WALL PANELS FACILITY AVAILABLE TO MAKE STRAIGHT PANELS.PLANNING FOR ACQUIRING SUITABLE MACHINERY FOR
SPIRAL WALL PANEL
_ BURNER PANELSTECHNOLOGY EXISTS TO MAKE BURNER PANEL WITH
BURNERS MOUNTED ON WALLS.
_ VERTICAL SEPERATORA SEPERATOR WITH TANGENTIAL ENTRY. LESS
COMPLICATED THAN THE CONVENTIONAL LARGE DRUM.CAPABILITY EXISTS TO MANUFACTURE SUCH VESSELS.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 110 of 222
MANUFACTURING OF COMPONENTS SPECIFIC TOMANUFACTURING OF COMPONENTS SPECIFIC TO ONCE THRO’ TECHNOLOGY (CONTD.) ONCE THRO’ TECHNOLOGY (CONTD.)
_ START-UP HEAT EXCHANGER OR START-UP RECIRCULATING PUMPSYSTEM
- START-UP HEAT EXCHANGER CAN BE MANUFACTURED AT BHEL(T) WITH THE EXISTING FACILITIES.
- CIRCULATING PUMP SYSTEM IS ALREADY AN ESTABLISHED SYSTEM WITH THE PUMP BEING BOUGHT OUT AS A VENDOR ITEM.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 111 of 222
VALVES ( 255 ata / 540 º C / 568 º C CYCLE )
{ MAIN STEAM STOP VALVES WC 9 TO C 12
{ MAIN STEAM VENT & DRAIN VALVES F 22 TO F 91
{ HP BYPASS VALVES F 22 TO F 91
{ MAIN STEAM SAEFTY VALVES
{ MAIN STEAM ELECTROMATIC RELIEF VALVES
{ HOT REHEAT LINE VENT AND DRAIN VALVES
{ HOT REHEAT LINE SAFETY VALVES
{ HOT REHEAT LINE ELECTROMATIC RELIEF VALVES
{ RH ISOLATION DEVICE
MANUFACTURING OF COMPONENTS SPECIFIC TOMANUFACTURING OF COMPONENTS SPECIFIC TO ONCE THRO’ TECHNOLOGY (CONTD.) ONCE THRO’ TECHNOLOGY (CONTD.)
ONLYMATERIALSWITCHNEEDED
ALREADY INPRODUCTIONRANGE
TO BEDEVELOPED /PROCURED
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 112 of 222
WITH THE ONCE THROUGHBOILER TCA
BHEL IS FULLY GEARED UP
TO MEET
EMERGING
MARKET REQUIREMENTS
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 113 of 222
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 114 of 222
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 115 of 222
3.3.22 Design and manufacturing of steam turbines for Design and manufacturing of steam turbines for supercritical Parameterssupercritical Parameters
BHELBHEL
STEAM TURBINE
FOR
SUPER CRITICAL PARAMETERS
BHEL, HARDWAR, INDIAEV 2 / Oktober, 99; NTPC Presentation. ppt Page 116 of 222
WORLD WIDE TRENDS WITH ADVANCED STEAM PARAMETERSWORLD WIDE TRENDS WITH ADVANCED STEAM PARAMETERS
DESIGNER/SUPPLIER
POWER STATION/UNIT
RATING(MW)
PARAMETERS STATUS SOURCE OFINFORMATION
TOSHIBA,JAPAN
HEKINAN UNIT3 700 310 BAR / 537ºC/593ºC COMM. POWER, MAY1992
KAWAAGOE UNITS1&2
700 325 BAR /571ºC/569ºC/569ºC
COMM. IN1989 &90
VGB KRAFTWERKTECHNIK,7/94
JAPAN
MATSUURA UNIT 2 1000 256 BAR/593ºC/593ºC /593ºC
COMM IN 1997 --DO--
-- 1000 256 BAR/593ºC/593ºC
COMM. HITACHI REVIEWVOL.42,1993
HITACHIJAPAN
-- 1000 310 BAR/593ºC/593ºC/593ºC
UNDER DEVEL. -DO-
ABB HERNWEG UNIT 8 650 250 BAR /535ºC/563ºC
COMM. ABB REVIEW JAN1991
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 117 of 222
WORLD WIDE TRENDS WITHWORLD WIDE TRENDS WITH ADVANCED STEAM PARAMETERSADVANCED STEAM PARAMETERS
DESIGNER /SUPPLIER
POWER STATION /UNIT
RATING(MW)
PARAMETERS STATUS SOURCE OFINFORMATION
MAN ENERGE /GEC ALSTHOM
ELSAM CONVOYUNITS 1& 2
386 290 BAR /582ºC / 580ºC / 580ºC
COMM.IN1997, 98
VGB KRAFTWERKTECHNIK,7/94
ESBJERQVAERKEUNIT 3
400 250 BAR /562ºC / 560ºC
COMM. IN1992
--DO--
LUEBECK UNIT 1 400 275 BAR /580ºC /600ºC
COMM. IN1995
--DO--
EUROPE
HESSLER POWERPLANT
732 275 BAR /580 ºC / 600ºC
-- VGB KRAFTWERKTECHNIK , 1/94
EPRI -- 700 325 BAR /593ºC /593ºC /593ºC
DESIGNCOMPL.
POWER MAY 1992
SIEMENS &BHEL
TROMBAY UNIT 6 500 170 BAR /538ºC / 565ºC
COMM. IN1990
--
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 118 of 222
WORLD WIDE TRENDS WITHWORLD WIDE TRENDS WITH ADVANCED STEAM PARAMETERSADVANCED STEAM PARAMETERS
DESIGNER /SUPPLIER
POWER STATION / UNIT RATING(MW)
PARAMETERS STATUS SOURCES OFINFORMATION
30 TURBINES 7 TO 125 UPTO 293 BAR & TEMP.RANGE 550 - 640ºC(USING AUSTENITICSTEEL)
COMM. SIEMENS PAPERPRESENTED AT EPRICONFERENCE NOV.89
ALTBACH 395 263 BAR /540ºC / 565ºC
COMM. IN1997
SIEMENS GREY BOOK
SCHWARZEPUMPE 874 264 BAR /542ºC / 560 ºC
COMM. IN1997
SIEMENS GREY BOOK
BOXBERG 910 260 BAR /540ºC / 580ºC
COMM. IN1999
SIEMENS GREY BOOK
BEXBACH 750 250 BAR /575ºC / 600ºC
COMM. IN1999
SIEMENS GREY BOOK
SIEMENSGERMANY
FRIMMERSDORF 1000 250 BAR /580ºC / 600ºC
COMM. IN1999
SIEMENS GREY BOOK
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 119 of 222
DESCRIPTION VARIANT-I VARIANT-II
STEAM PARAMETERS
MAIN STEAM PRESSURE (ATA) 250 250
MAIN STEAM TEMP. (oC) 537 565
REHEAT TEMP. (oC) 565 565
BACK PRESSURE (ATA) 0.1 0.1
CYCLE CONFIGURATION
HP HEATERS: (NO.) 2 / 3 2 / 3
DEARATOR: (NO.) 1 1
LP HEATERS (NO.) 3 3
BOILER FEED PUMP 3x50 % 3x50 %(2 Turbine Driven) (2 Turbine Driven)(1 stand by motor driven) (1 stand by motor driven)
CONDENSATE EXTRACTION PUMP 2x100 % / 3x50% 2x100 % / 3x50 %
500 MW STEAM TURBINE WITH SUPER CRITICAL PARAMETERS
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 120 of 222
VARIANT -I VARIANT-II
HP-MODULE H30-100 H30-100
IP-MODULE M30-63 M30-63(DOUBLE FLOW) (DOUBLE FLOW)
LP-MODULE N30-2x10 N30-2x10(DOUBLE FLOW) (DOUBLE FLOW)
M.S.VALVES 2xFV250 2xFV250
REHEAT VALVE 2xAV560 2xAV560
TURBINE MODULES
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 121 of 222
HPT IPT LPT
CROSS SECTIONAL VIEW OF 3 CYLINDER CONVENTIONAL STEAM TURBINEHMN SERIES
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 122 of 222
CROSS SECTIONAL ARRANGEMENT OF TURBINEEV 2 / Oktober, 99; NTPC Presentation. ppt Page 123 of 222
OUTER CASING BARREL TYPE CASINGINNER CASING SPLIT IN TWO HALVESROTOR MONO BLOCK-DRUM TYPE
BLADING:
IST STAGE IMPULSE BLADINGREMAINING STAGES REACTION BLADING
ROTOR COOLING HEAT SHIELD FOR VARIANT II WITH VORTEX COOLING
COUPLING RIGID
VALVES CASING MOUNTED VALVES
CONSTRUCTIONAL FEATURES OF HP TURBINE
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 124 of 222
SPECIAL FEATURES :NEW MATERIALSHEAT SHIELD AT ROTOR INLETIMPULSE BLADING FOR FIRST STAGEINCREASED WALL THICKNESS
HP TURBINEEV 2 / Oktober, 99; NTPC Presentation. ppt Page 125 of 222
OUTER CASING HORIZONTALLY SPLIT
INNER CASING HORIZONTALLY SPLIT
ROTOR MONO BLOCK-DRUM TYPE
BLADING:IST STAGE IMPULSE BLADINGREMAINING STAGES REACTION BLADING
ROTOR COOLING HEAT SHIELD FOR BOTH VARIANTS
COUPLING RIGID
CONSTRUCTIONAL FEATURES OF IP TURBINE
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 126 of 222
SPECIAL FEATURES :
• NEW MATERIALS• HEAT SHIELD AT ROTOR INLET• IMPULSE BLADING FOR FIRST STAGE
IP TURBINEEV 2 / Oktober, 99; NTPC Presentation. ppt Page 127 of 222
HEAT SHIELD WITH VORTEX BORES
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 128 of 222
ROTOR MONO BLOCK
OUTER CASING FABRICATED
INNER CASING CASTING
BLADING:
ALL STAGES REACTION BLADING
LAST STAGE ADVANCE LP LAST STAGE BLADEGUIDE BLADE - HOLLOW & BANANA TYPE
COUPLING RIGID
CONSTRUCTIONAL FEATURES OF LP TURBINE
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 129 of 222
LP TURBINEEV 2 / Oktober, 99; NTPC Presentation. ppt Page 130 of 222
• THROTTLE CONTROL GOVERNING
• HIGH PRESSURE GOVERNING WITH EHA (ELECTRO HYDRAULIC ACTUATOR) - FOR VARIANT II
GOVERNING
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 131 of 222
VARIANT I VARIANT II
HP OUTER CASING GS-17CrMoV511 GS-X12CrMoWVNbN 1011
HP INNER CASING GS-17CrMoV511 GS-X12CrMoWVNbN 1011
HP VALVES GS-17CrMoV511 GS-X12CrMoWVNbN 1011
HP ROTOR 28CrMoNiV59 X12CrMoWVNbN 1011
IP OUTER CASING GGG-40.3 GGG-40.3
IP INNER CASING G-X12CrMoVNbN 1011 G-X12CrMoVNbN 1011
IP VALVES G-X12CrMoWVNbN 1011 G-X12CrMoWVNbN 1011
IP ROTOR X12CrMoWVNbN 1011 X12CrMoWVNbN 1011
LP OUTER CASING ST 37-2 ST-37-2
LP INNER CASING GGG-40.3 GGG-40.3
LP ROTOR 26NiCrMoV 145 26NiCrMoV 145
MATERIALS FOR MAJOR COMPONENTS
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 132 of 222
BHEL HAS ALREADY SUPPLIED ONE SET OF 500 MW TO TROMBAY -VI PROJECT WITH STEAM PARAMETERS AS 170 ATA/537/565 oC . IN VIEW OF THIS BHEL WILL BE ABLETO SUPPLY STEAM TURBINE WITH STEAM PARAMETERS OF 250 ATA /537/565oC WITH SUITABLE MODIFICATIONSIN HP TURBINE AND ASSISTANCE FROM M/S SIEMENS-KWUIN GOVERNING AREA. LP TURBINE WILL BE WITH ADVANCE BLADING.
FOR STEAM PARAMETERS 250 ATA/565/565oC BHEL HAS TIED UP WITH M/S SIEMENS FOR JOINT DEVELOPMENT IN CASE OF A LIVE PROJECT.
STATUS OF TECHNOLOGY FOR SUPER CRITICAL PARAMETERS
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 133 of 222
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 134 of 222
Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG
Technical SessionTechnical Session IIII
4.0 Once-Through Boiler Design & Operation Experiences, Reference Plants
Due to the merger of all power plants technology activities of Babcock Borsig AG in the company BabcockBorsig Power (BBP) all experiences about power plant boiler technology are now focused in BBP.
References of steam generators of all kind of design concepts like 2-pass boilers with pendent platen superheaters or 2-pass design with completely drainable heating surfaces as well as tower-type boilers up to ahight of more than 160m with subcritical, supercritical or ultra supercritical steam parameters are available. Forthe complete range of fossil fuels optimized firing concepts are available with own mills and burner systems. As aresult of the broad experiences gained with engeneering, manufacturing, erection and commissioning of plantsin Germany and abroad a highly sofisticated contract management system has been developted which satisfiesmost demanding customers requirements.
The extensive know-how transfer within the frame of the „Technical Collaboration Agreement“ between BHELand BBP will enable our Indian partner BHEL by means of extensive training and collaboration activities todesign, manufacture, erect and commission power plants in India with supercritical steam parameters of comparable technology and quality standards.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 135 of 222
TechnicalTechnical Session II Session IIOnceOnce--ThroughThrough Boiler Design & Operation Boiler Design & Operation Experiences Experiences,,
Reference PlantsReference Plants
• Babcock Borsig Power units all experiences of Babcock Borsig AG regarding power plant and steam generator technology
• Broad experience in all kind of steam generator design conceps•- 2-pass boilers with pendent platen superheaters•- 2-pass design with completely drainable heating surfaces•- tower-type design up to a hight of more than 160m
• Optimized firing concepts for all kind of fossil fuels with own mills & burner systems
• Strong and experienced contract management system
• Extensive know-how transfer to BHEL within the Technical Collaboration Agreement will enable BHEL to design, manufacture, erect and commission state of the art supercritical power plants
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 136 of 222
Examples of Boiler ConceptsExamples of Boiler Concepts
Two-Pass Boilerwithout platen superheater
Two-Pass Boilerwith platen superheater
Tower Boiler
PS Heyden 4 - 920 MW el PS Kogan Creek - 700 MW elPS Staudinger 5 - 550 MW el
66,0 m
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 137 of 222
Firing systemsFiring systems
Front Opposed Corner Down ShotT - Wall Slag Tap Tangential All Wall
Bituminous Coal Lignite Coal
available for all types of fossil fuels.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 138 of 222
Firing System/Power Plant
UnitCapacity
MW
Boiler TypeFlow System
Fuel Comm.Year
Front firing- Doha West 300 Drum Oil/Gas 1982- Jorge Lacerda 3 125 Drum Bitum. coal 1979- Farge 320 BENSON Bitum. coal 1969- Jorge Lacerda 4 350 BENSON Bitum. coal 1986- CSN 1-3 150 Drum Blast Furnace Gas 2000
Opposed firing- Avedøreværket 260 BENSON Bitum. coal 1989- Studstrupvaerket 350 BENSON Bitum. coal 1983- Voerde 707 BENSON Bitum. coal 1982- Wilhelmshaven 770 BENSON Bitum. coal 1976- Heyden 900 BENSON Bitum. coal 1987- Dezhou 660 Drum Semi-Anthr. 2003- Majuba 711 Benson Bitum. Coal 1999
T- Wall- Altbach 320 BENSON Bitum. coal 1995
Tangential firing- Megalopolis *) 300 Drum Lignite 1975- Neurath 300 BENSON Lignite 1973- Schkopau 450 BENSON Lignite 1996- Weisweiler G + H 630 BENSON Lignite 1976- Boxberg 800 BENSON Lignite 1996- Lippendorf 930 BENSON Lignite 1999- Niederaußem 980 Benson Lignite 2002
Corner firing- Walsum 400 BENSON Bitum. coal 1991- Fyensvaerket 7 410 BENSON Bitum. coal 1991
Four-wall firing- Buschhaus 350 BENSON Lignite
saliferous1984
Slag tap furnace- Elverlingsen 330 BENSON Bitum. coal 1982- Yang Liu Qing 350 BENSON Bitum. coal 1996- Ibbenbüren 770 BENSON Bitum. coal 1985
Dry vertical firing- Narcea / La Robla 350 BENSON Anthracite 1981/82*) Net heating value: 900 ... 1400 kcal/kg
**) Cooperation with other boiler manufacturer
Steam Generators in Operation (Examples)Steam Generators in Operation (Examples)Experiences with Different Firing- and Flow SystemsExperiences with Different Firing- and Flow Systems
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 139 of 222
BBP'sBBP's - Utility Boiler Contracts of the recent Years - Utility Boiler Contracts of the recent YearsProject Client Qty. Description Award Date Comments
Yang Liu Qing CNTIC Corp. 2 1025 t/hr boiler, bituminous coal-fired Feb 94 Once- Through, Slag Tap Type
Lippendorf VEAG 2 2360 t/hr boiler, lignite-fired Aug 94 Once- Through, Tower Type
Lünen STEAG 1 533 t/hr boiler, bituminous coal-fired Dec. 94 Once- Through, Tower Type
Bexbach Saarbergwerke 1 2048 t/hr boiler, bituminous coal-fired Dec. 94 Once- Through, Tower Type
Niederaußem RWE-Energie AG 1 2514 t/hr boiler, lignite-fired May 95 Once-Through, Tower Type
Boxberg VEAG 1 2423 t/hr boiler, lignite-fired May 95 Once-Through, Tower Type
Yang Shu Pu Shanghai MunicipalElectric Power Bureau
2 526 t/hr boiler, bituminous coal-fired July 95 Natural Circulation, Two Pass
PCK-Schwedt PCK-Raffinerie Schwedt
1 620 t/hr boiler, HSC-Residues Sep 95 Once-Through, Tower Type
Shi Dong Kou SMEPC-Shanghai 1 1050 t/hr boiler, bituminous / subbituminous coal
Dec. 96 Once- Through, Two Pass
Companhia Siderugica National Siemens for CSN 3
337 t/hr boilers, natural gas, blast furnace gas, steel plant gas, tar, heavy fuel oil
Sep 97 Natural Circulation
Dezhou HUANENG 2 2009 t/hr boiler, anthracite-fired July 98 Natural Circulation
Elbistan B TEAS 4 1068 t/hr boiler, lignite-fired Aug 98 Once- Through, Tower Type
Westfalen VEW 1 928 t/hr boiler, bituminous coal March 99 Once- Through, Tower Type
HKW Hamborn RWE-Energie AG 1 642 t/hr boiler, blast furnace gas, coke oven gas, natural gas
Aug. 99 (LOI) Once- Through, Tower Type
TPP- Iskenderun Bay Siemens for Steag 2 1884 t/hr boiler, bituminous coal Jan. 2000 (LOI) Once- Through, Tower Type
Kogan Creek Siemens for Austa/Southern Energy
1 2218 t/hr boiler, biuminous coal Dec. 99 (LOI) Once- Through, Tower Type
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 140 of 222
BBP’sBBP’s STEAM GENERATOR INSTALLATIONS STEAM GENERATOR INSTALLATIONS1970 onwards1970 onwards
Fuel Installed MW
Bituminous Coal 122 000Lignite 43 000Oil / Gas 108 000WTE 4 000HRSG 33 000
Total 310 000
Fuel Installed MW
Bituminous Coal 122 000Lignite 43 000Oil / Gas 108 000WTE 4 000HRSG 33 000
Total 310 000
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 141 of 222
Benson Boiler with Opposed FiringBenson Boiler with Opposed FiringVoerdeVoerde (707 MW) (707 MW)
High pressure part
Steam rating 2160 t/h
Allowable working
pressure (gauge) 206 bar
SH-Outlet temperature 530 °C
Reheater
Steam rating (inlet) 1940 t/h
Allowable working
pressure (gauge) 49bar
RH-Outlet temperature 530 °C
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 142 of 222
Benson Boiler with Opposed FiringBenson Boiler with Opposed FiringHeydenHeyden (900 MW) (900 MW)
Reheater
Steam rating 2200 t/h
Allowable working
pressure (gauge) 53 bar
RH-Outlet temperature 535 °C
High pressure part
Steam rating 2405 t/h
Allowable working
pressure (gauge) 215 bar
SH-Outlet temperature 535 °C
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 143 of 222
PSPS Kogan Kogan Creek, Australia Creek, AustraliaBoiler with supercritical steam parameters
• 1 x 700 MWel / 1 x 2218 t/hr• Once-through steam generator, Benson®
• Bituminous Coal 19,1 MJ/kg• Steam parameters: 545 °C / 563 °C / 264 bar• Net efficiency of 39.5 % (dry cooling system)• Commissioning: 2002
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 144 of 222
Benson Boiler with Opposed FiringBenson Boiler with Opposed FiringStudstrupStudstrup (350 MW) (350 MW)
Reheater
Steam rating 978 t/h
Allowable working
pressure (gauge) 60 bar
RH-Outlet temperature 540 °C
High pressure part
Steam rating 1080 t/h
Allowable working
pressure (gauge) 270 bar
SH-Outlet temperature 540 °C
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 145 of 222
Benson Boiler with Opposed FiringBenson Boiler with Opposed FiringRostockRostock (550 MW) (550 MW)
Reheater
Steam rating 1335 t/h
Allowable working
pressure (gauge) 70 bar
RH-Outlet temperature 562 °C
High pressure part
Steam rating 1500 t/h
Allowable working
pressure (gauge) 285 bar
SH-Outlet temperature 545 °C
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 146 of 222
Benson Boiler with Tangential FiringBenson Boiler with Tangential FiringKW SchkopauKW Schkopau ( 450 MW ) ( 450 MW )
High pressure part
Steam rating 1360 t/h
Allowable working
pressure (gauge) 262 bar
SH-Outlet temperature 545 °C
Reheater
Steam rating (inlet) 1206 t/h
Allowable working
pressure (gauge) 54 bar
RH-Outlet temperature 560 °C
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 147 of 222
Lippendorf Power PlantLippendorf Power Plant2 x 930 MW2 x 930 MW
Reheater
Steam rating 2213 t/hAllowable working pressure (gauge) 69 barRH-Outlet temperature 583 °C
High Pressure Part
Steam rating 2420 t/hAllowable working pressure (gauge) 285 barSH-Outlet temperature 554 °C
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 148 of 222
PS Westfalen D,PS Westfalen D, Germany GermanyBoiler with ultra-supercritical steamparameters
• 1 x 350 MWel / 1 x 926 t/hr• Once-through steam generator, Benson®
• Bituminous Coal 27.5 MJ/kg• Ultra-supercritical steam parameters: 600 °C / 620 °C / 290 bar• Net efficiency of 47%• Commissioning: 2003
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 149 of 222
Material Selection for Superheater and Reheater TubingMaterial Selection for Superheater and Reheater Tubing
X20CrMoV12-1 < 565 °C
X3CrNiMoN17-13
Material Live Steam Temperature
ASME Code 2115
Compound Tubes Coextruded Tubes
HR3C ( 25 Cr 20 Ni Nb N ) 600 °C - 620 °C
AC 66 ( 27 Cr 30 Ni Nb Ce )
Esshete 1250
DIN 17 175
DIN 17 459
VdTÜV 497 6.90
565 °C - 580 °C
620 °C - 720 °C
Corrosion Protection 50 % Cr - 50 % Ni Coating?
Alloy 617 ( NiCr23 Co12 Mo ) 700°C,100.000 h, 95 N/mm2
( < 545 °C for SH )
TP 347H FG ASME Code 2159
BS 3059 Part 2
Incoclad 671 / Incoloy 800 HT Producer INCO
VdTÜV 485 6.90
MITI Code Ka-SUS304J1HTB 580 °C - 600 °C
650°C,100.000 h, 104 N/mm
650°C,100.000 h, 92 N/mm
2
2
650°C,100.000 h, 123 N/mm 2
650°C,100.000 h, 85,5 N/mm2
VdTÜV 520 12.97
MITI Code Ka-SUS310J2TB
Super 304H FG
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 150 of 222
Creep Rupture Mean ValuesCreep Rupture Mean Values100.000 h100.000 h
600 620 640 660 680 700
Temperature in °C
50
100
150
200N/mm
2
Esshete 1250
X 3 CrNiMoN 17 131.4910
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 151 of 222
Chemical Composition of High Alloyed Superheater TubingChemical Composition of High Alloyed Superheater TubingMaterialMaterial
C Si Mn P S Fe CuMoNiCr TiNbAlloy 617 20,0-
23,0 res.0,20-0,60
8,0-10,0
16,0-18,0
2,00-2,80
max.1,00
--------------
0,60-1,00
Others
X3CrNiMoN17 13
X7NiCrCeNb32 27 26,0-
28,031,0-33,0
5,50-7,00
0,75-1,25
0,80-1,20Esshete 1250 14,0-
16,0 9,0-11,0
max.0.75
max.2,00
max.0,030
max.0,030 res. 0,20-
0,60------------
Nf 709
0,04-0,10
24,0-26,0
17,0-23,0
N 0,15 - 0,35
1,00-2,00
19,0-22,0
------------HR3C ------
------0,04-0,10
max.0.75
max.1,50
max.0,030
max.0,010
res. 23,0-27,0
------------
0,10-0,40
0,02-0,20
N 0,10 - 0,20B 0,002 - 0,008
0,06-0,15
0,20-1,00
max.0,040
max.0,030
res. ------------
------------
V 0,15 - 0,40B 0,003 - 0,009
1.4877(AC66)
0,04-0,08
max.0.30
max.0,015
max.0,010 res.
------------
------------
Ce 0,05 - 0,10Al max. 0,025
1.4910
max.0,04
max.0,75
max.2,00
max.0,035
max.0,015 res.
12,0-14,0
------------
------------
------------ B 0,0015 - 0,0050
NiCr23Co12Mo, 2.4663
0,05-0,10
------------
------------
------------
------------
max.2,00
------------
------------
Co 10,00 - 13,00Al 0,60 -1,50
N 0,10 - 0,18
TP 347H FG 17,0-20,0
0,04-0,10
max.0.75
max.2,00
max.0,040
max.0,030
res. 9,0-13,0
------------
8 x C
Super 304H 17,0-19,0
0,07-0,13
max.0.30
max.1,00
max.0,040
max.0,010
res. 7,5-10,5
2,50-3,50
0,30-0,60
N 0,05 - 0,12
Incoloy 800 HT 19,0-23,0
0,06-0,10
max.0,015
max.0,010
res. 30,0-35,0
------------
------------
------------
------------
------------
Al 0,25 - 0,60max.0.70
max.1,50
max.0,50
------------
0,25-0,60 Al + Ti 0,85 - 1,20
Incoclad 671 0,05 51,5 48,0
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 152 of 222
Chemical Composition of Header and Piping MaterialsChemical Composition of Header and Piping Materials
E 9110,09-0,13
0,10-0,50
0,30-0,60
max.0,020
max.0,010
max.0,040
8,50-9,50
0,10-0,40
--------------
0,90-1,10
0,001-0,006
0,18-0,25
0,06-0,10
0,90-1,10
--------------
0,050-0,090
P 920,07-0,13
max.0,50
0,30-0,60
max.0,020
max.0,010
max.0,040
8,50-9,50
max.0,40
--------------
1,50-2,00
0,030-0,070
0,0010,006
0,15-0,25
0,04-0,09
0,30-0,60
--------------
P 122 max.0,15
max.0,70
max.0,70
max.0,030
max.0,020
--------------
10,00-12,60
max.0,70
--------------
1,50-2,50
0,020-0,100
max.0,005
0,15-0,30
0,02-0,10
0,20-0,60
max.1,70
0,08-0,12
0,20-0,50
0,30-0,60
max.0,020
max.0,010
max.0,040
8,00-9,50
max.0,40
--------------
--------------
0,030-0,070
--------------
0,18-0,25
0,06-0,10
0,85-1,05
--------------
P 91
C Si Mn P S Al VMoNiCr N BWTiNb Cu
0,17-0,23
max.0,50
max.1,00
max.0,030
max.0,030
max.0,040
10,00-12,50
0,30-0,80
--------------
--------------
--------------
0,25-0,35
0,80-1,20
--------------
X20CrMoV12-1
--------------
--------------
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 153 of 222
Creep Rupture Mean ValuesCreep Rupture Mean Values100.000 h100.000 h
480 500 520 540 560 580 600 620 640 660 680 700Temperature in °C
0
50
100
150
200
250
300
X20CrMoV12-1P 92
E 911X3CrNiMoN17-13
N/mm2
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 154 of 222
Tungsten Containing New Martensitic Steels in PowerTungsten Containing New Martensitic Steels in PowerStationsStations
PS VestkraftNF 616
PS Nordjyllands -vaerket HCM 12A
GK Kiel
Block 3
NF 616 ID 160 x 45
PS SchkopauBlock B E 911
PS StaudingerBlock 1PS Skaerbaek E 911
E 911
Block 3
P 92
ID 230 x 60
ID 240 x 39 ( 56 )
406,4 x 77 PS Nippon SteelKobe Japan NF 616
ID 480 x 28
ID 201 x 22
ID 550 x 24
PS WestfalenE 911P 92 ID 159 x 27 650 °C Steam, 180 bar May 1998
PS TachibanawanBlock 1 + 21050 MW
P 92P 122
800 x 120 500 x 80
HeaderPiping 600 °C Steam, 250 bar
June 2000July 2001
Power Station Material Dimension Component Temperature InstallationLive Steam Piping
1950 mm long
4000 mm long Live Steam Piping
HP-Header
Induction Bend Reheater Piping
Induction BendLive Steam Piping
Induction BendLive Steam Piping
ReheaterHeader
Connecting Pipes
582 °C Steam, 290 bar
582 °C Steam, 290 bar
560 °C Steam, 250 bar
569 °C Steam, 179 bar
560 °C Steam, 70 bar
540 °C Steam, 213 bar
545 °C Steam, 53 bar
1996
1996
1996
1996
May 1997
1995
1992
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 155 of 222
ModernModern Steam Steam Generators GeneratorsNiederaußem Power Station Unit K
950 MWe
Fuel Lignite
Maximum cont. rating 698 kg/sMain steam pressure 260 barMain steam temperature 580 deg.CReheater steam temperature 600 deg.C
Burner arrangement TangentialNo. and burner capacity 8 x 271 MWMill type Beater wheel millNo. and mill capacity 8 x 143 t/h
Boiler dimensions (WxDxH) 23 x 23 x 149 mBoiler house (WxDxH) 90 x 88 x 168 m
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 156 of 222
PSPS Dezhou Dezhou,, Shandong Province Shandong Province, China, China
• 2 x 660 MWel / 2 x 2209 t/hr• Natural circulation steam generator• Semi-Anthracite (ash content 33.05 %
volatile matters daf 11.35 %)• Steam parameters: - 541 °C / 174 bar - 541 °C / 40.3 bar• Commissioning: 2003
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 157 of 222
Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG
Technical Session II5.0 Firing SystemBabcock Borsig Power (BBP) has decades of experience in the design of firing systems for the whole range of coal qualities.
To enable the use of a wide range of bituminous coals and low-grade hard coals, an advanced firing system has to fulfill quite a number of criteria:- Design of the burner zone and the furnance with due regard to the combustion behaviour and slagging tendency of the coal- Flexible mill system with variable grinding force and grinding fitness to adjust mill operation to the coal quality- Pulverized coal burners with stable ignition over wide working range and varying coals as well as low Nox emission- Design of the main components with due regard to the ash content and wearing bahaviour of the mineral components of the coal
BBP has in-house competence for both combustion chamber design and all firing components
Important features of the BBP firing concept for large hard coal fired steam generators are:- Opposed firing system- MPS mill- DS burner.
For this system a great number of references plants with differing units capacities and steam generator types are available. The coal qualities used cover the whole range of anthracites available in special locationsthrough very wide ranges of imported coals used at coastal stations world wide located up to high-ash coalswith high abrasivness which are comparable to the fuels fired in pit head stations in India.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 158 of 222
Firing Systems
for Low Grade Hard Coalsand Wide Coal Ranges
in India
Firing SystemsFiring Systems
for Low Grade Hard Coalsfor Low Grade Hard Coalsand Wide Coal Rangesand Wide Coal Ranges
in Indiain India
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 159 of 222
OutlineOutlineOutline• Coal Characterization• Major Design Requirements• Firing System
Main Features and Design Criteria• Main Components• NOx Emission• Part Load Operation• Changed Heat Absorption of the Furnace• References for
– high-ash coals– wide coal ranges
• Conclusions
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 160 of 222
Pit Head Stations
Type of coalLow grade, unwashedIndian hard coal
Main featuresHigh ash (> 40 %)Moisture partly higher (up to 16 %)Ash abrasiv,Wear factor high (YGP up to 80)Volatile matter (daf) highSulphur lowSlagging tendency low
CoalCoal Characterization Characterization
Coastal Stations
Type of coalWashed Indian hard coalImported b it. coal (wide range)
Main featuresAsh content andabrasiveness lower to normalCoals from various countriesand mines,with varying grinding,combustion and slagging/foulingbehaviour
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 161 of 222
Range of Coal QualitiesRange of Coal Qualities
0 10 20 300
20
40
60
80
Net calorific value, 10³ kJ/kg
Vol
atile
mat
ter
(daf
), %
Indianlow gradehard coal
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 162 of 222
Coal Data IndiaCoal Data India
10
30
40
80
0
40
0
20
0
40
GCVMJ/kg
Ash, ar%
Moisture ar%
Vol.M ar%
Grind. °H
Indian Indian Imported unwashed coal washed coal coal
(Talcher Design coal) (Tuticorin) (Tuticorin Perf. Coal)
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 163 of 222
Wear FactorWear Factor Indian Coals Indian Coals
0
200
400
600
800
1000
0 2 4 6 8 10
Characteristic Ash Factor
Wea
r Fa
ctor
[(% SiO2 - 2x % Al2 O3) x Ash dry/100]
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 164 of 222
Range of Imported Coal - 720 MW Unit, Coastal StationRange of Imported Coal - 720 MW Unit, Coastal StationCalorificvalue rawMJ/kg
Ash raw%
Moisture%
Volatiles raw%
Grindability°H
Ash meltingbehaviour°Coxid. atm.
30
25
20
Design Poland South- Australia USA India Canada Spits- Chinaand Africa bergenguarantee value
2010 02010 040302010
80
60
401600
1400
1200
1000 ST HT
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 165 of 222
Major Firing System Design Requirementsfor wide coal ranges and low grade hard coalsMajor Firing System Design RequirementsMajor Firing System Design Requirementsfor wide coal ranges and low grade hard coalsfor wide coal ranges and low grade hard coals
• Design of burner zone and furnace with due regard to combustionbehaviour and slagging tendency of the coals
• Flexible mill system, i.e. variable grinding force and grinding fineness,in order to adjust mill operation to coal quality
• Pulverized coal burner with– stable ignition over a wide operational range and varying coals– low NOx emission
• Operation with low excess air
• Design of the main components with due regard to the ash content andthe abrasiveness of the mineral matters of the coal
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 166 of 222
Firing System, Furnace DesignFiring System,Firing System, Furnace Furnace Design Design
• Direct firing system• Opposed burner arrangement preferred for large bituminous boilers
(swirl type burners)Advantages
– stable ignition at each burner– more flexibility in number of mills and burners– more homogenious flue gas temperature profile at furnace exit
• P.C. and air supply and control per burner row• Furnace design tools (available for product development at BBP)
– One dimensional combustion simulation by FANAL(Temp. profile, burnout, NOx prediction)
– Three dimensional furnace simulation by CFD (FLUENT)(Temp. profile, flow pattern)
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 167 of 222
Tower TypeTower TypeBensonBenson Boiler Boiler
withwithOpposed FiringOpposed Firing
SystemSystem
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 168 of 222
Firing systems for large bituminous coal fired boilersFiring systems for large bituminous coal fired boilers
• Opposed firing system is preferred regarding to– more flexibility in number of mills– more flexibility in number of burners
Opposed Corner
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 169 of 222
Furnace DesignFurnace Furnace DesignDesign
ÄBurner and Air nozzles Arrangement
Main Combustion Zone
Burnout Zone
NOx Reduction
Burn-Out RateNOx Generation
- Temperatures- Velocities- Concentrations
3D Calculation of the FurnaceHeat Transfer Calculation
Boiler Geometry
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 170 of 222
Furnace Model FANAL for Furnace DimensioningFurnace Furnace Model FANALModel FANAL for Furnace Dimensioning for Furnace Dimensioning
•• BasisBasis–– Physical modelling Physical modelling of of kinetics and heat exchangekinetics and heat exchange–– SemiSemi--empirical calculation empirical calculation of of mixingmixing
•• InputInput Data Data–– GeometryGeometry–– StoechiometryStoechiometry–– WallWall Conditions Conditions–– CoalCoal Data Data–– Grinding FinenessGrinding Fineness–– BurnertypeBurnertype–– OverOver--FireFire Air Air–– HeatHeat Input Input
•• Calculated DataCalculated Data–– Homogeneous and heterogeneous ReactionsHomogeneous and heterogeneous Reactions–– Turbulent Turbulent Mixing and Mixing and DiffusionDiffusion–– BurnoutBurnout–– EmissionsEmissions–– TemperatureTemperature
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 171 of 222
CFDCFD Furnace Furnace Simulation Simulation
TemperatureDistribution
Velocity VectorsGeometry
z4
z3
z2
z1
y2
y1
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 172 of 222
In-In-HouseHouseCompetenceCompetence
ofof
All All Firing ComponentsFiring Components
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 173 of 222
Main Components - MPS MillMain Components - MPS MillMain Components - MPS Mill
• Development of the MPS Milll Considerable development within the last decadel Only few licensees are participating in this development
• Main features of modern MPS Milll Hydropneumatic grinding force adjustmentl Static classifier or rotating classifierl Rotating nozzle ring
– Flexible grinding force for load conditions and differing grindingbehaviour of the coal
– Variable grinding fineness for wide range of coals
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 174 of 222
TheThe DevelopmentDevelopment of of thethe MPS MPS MillMill
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 175 of 222
BBP BBP Licence OverviewLicence OverviewMPS MPS MillsMills
Babcock& Wilcox
USA
BasicLicenser
Gebr.Pfeiffer
AG
BabcockHitachi K.K.
Japan
AnsaldoBredaItalien
BPEGP.R.China
SHMPP.R. China
CMECP.R. China
KawasakiHeavy Ind .
Japan DB RileyUSA
P.H.I.England
Licensintorg
Russian
Finished
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 176 of 222
MPS MPS MillMill
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 177 of 222
MPS MPS MillMill
SLS Louvre-type, Rotary Air Classifier SLK Vane Air Classifier
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 178 of 222
Main Features of BBP-MPS Mills for Indian P.S.Main Features of BBP-MPS Mills for Indian P.S.Main Features of BBP-MPS Mills for Indian P.S.
• Hydropneumatic grinding forcel Optimal adjustment of grinding force to load conditions and coal qualityl Turn down ratio 1:4
l Mill start-up operation unloaded (cheaper drive motor)
– High flexibility during operation
• Mill design and material of wearing partsl Adequate wear life of grinding elements
§ Indian high ash coal: appr. 7 000 hbased on evaluation of experience in India and SA
§ Imported coals: pending on coal quality, up to 25 000 h
l Wearing part replacement from side possible
l Inside hard surfacing possiblel Maintenance simple
– Low operation cost
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 179 of 222
1
1 Vane classifier
2
2 Classifier riser
4
4 Neck bearing
5
5 Mill drum
6
6 Drive spur gear
7
7 Front / end wall
8
8 Spiral screw conveyor
Raw coal
Pulverized Fuel / Gas Mixture
3 Coarse particle return
3
Bypass
Hot air
RKD RKD MillMill
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 180 of 222
Main Components - Burner
DS Burner
Main Components - BurnerMain Components - Burner
DS BurnerDS Burner
• High flame stability• Low burner loads• Good burnout• Low NOx-Emission• Operation independent of coal
• Intensive pyrolysis in fuel rich zone• Early ignition• Defined and delayed air supply and mixing
Features:
Process:
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 181 of 222
DS BurnerDS BurnerDS Burner
• About 800 burners delivered• Wide range of coals
• Expected lifetime of wear partsfor high ash coals:
Burner: appr. 24 000 hrs (hardened steel, Ni-Hard)
P.c. pipe: appr. 24 000 hrs (hardened steel) 32 000 hrs (ceramic lining)
References:
Wear protectiondesign:
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 182 of 222
DS-BurnerDS-Burner
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 183 of 222
Tertiary air
IR-FlameMonitor
Secondary air
Core air
Oil lance
UV-Flame-Monitor
DS-BurnerDS-BurnerSwirler
Pulverized coal
Flame-stabilizer
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 184 of 222
Design of DS BurnersDesign of DS Design of DS BurnersBurners
30 MW Test Facility
Operating Results
CFD FLUENTCalculation of the Flame
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 185 of 222
DS-BurnerDS-Burner
Temperature Mass Temperature Mass FractionFraction of O of O22
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 186 of 222
Staudinger P.S., Unit 5 - DS Burner FlameStaudinger P.S., Unit 5 - DS Burner Flame
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 187 of 222
ReferenceReference listlist DS-Burner - 1999 September DS-Burner - 1999 September
8 9 9
129 175
263
383
643
787 795 819843
0100200300400500600700800900
1000
Qua
ntity
of D
eliv
ered
Bur
ners
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2002 2003 2004
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 188 of 222
Coals burned successfully with Coals burned successfully with p.c.-burnersp.c.-burners
Range
Min. Max.
LCV MJ/kg 17.68 29.98
W (ar) % 1.6 18.5
A (ar) % 4.7 38.3
VM (daf) % 5.9 54.5
S (daf) % 0.4 1.34
O (daf) % 5.6 15.8
N g/MJ 0.39 0.85
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 189 of 222
NOxNOx Emission Emission
w LowLow NOx NOx DS Burner DS Burner
ww Expected Expected value for Indian coal value for Indian coal
< 650 mg/m³ < 650 mg/m³
In In Compliance Compliance with with
World Bank Environmental World Bank Environmental Guidelines Guidelines 1997 1997
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 190 of 222
NOx-EmissionNOx-Emission
0
200
400
600
800
1000
0 10 20 30 40 50
Volatiles (daf) %
NO
x-Em
issi
on m
g/m
³
Shen AORostockMKVFargeAvedoreStaudingerVoerdeFlensburgHKWLünenNanticoke
World Bank Environmental Guidelines 1997
Expected valuesfor Indian coal
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 191 of 222
Part Load OperationPartPart Load Load Operation Operation
• Min. boiler load w/o supporting fuel
– Low grade coal: 40 - 30 %– Imported bit. coal: - 20 %
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 192 of 222
Changed heat release in the furnaceby varying coal qualitiesChanged heat releaseChanged heat release in the in the furnace furnaceby varying coal qualitiesby varying coal qualities
• Varying combustion and fouling behaviour of different coalswithin a wide range of coals cause varying heat release andheat absorption in the furnace
• Benson boiler principle compensates these effects by shiftingof the final evaporation point without diminishing efficiency
(Refer to former explanation!)
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 193 of 222
HeatHeat Absorption of the Heating Absorption of the Heating Surface Sections Surface SectionsStaudinger Power Station, Unit 5Staudinger Power Station, Unit 5
0 50 100 150 200 250 300 350
Pressure p, bar
Ent
halp
y h,
kJ/
kg
3500
3000
2500
2000
1500
1000
500
0
Design point
Shifting of final evaporation point60 % 100 %
LoadE
vapo
rato
r
SH Outlet
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 194 of 222
References for Firing SystemReferences for Firing SystemReferences for Firing System
• References for wide range of imported bituminous coals(examples)
– 720 MW Two pass type boiler, Coastal Station– 550 MW Tower type boiler
• References for high ash hard coals in Germany, SouthAmerica, China and South Africa
• From South Africa experience with coals with abrasivenessfactors similar to Indian coals
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 195 of 222
Steam GeneratorWilhelmshaven P.S.
720-MW Unit
Steam GeneratorSteam GeneratorWilhelmshaven P.S.Wilhelmshaven P.S.
720-MW Unit720-MW Unit
92,1 m
77,7 m
0 m
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 196 of 222
Range of Imported Coal - 720 MW Unit, Coastal StationRange of Imported Coal - 720 MW Unit, Coastal StationCalorificvalue rawMJ/kg
Ash raw%
Moisture%
Volatiles raw%
Grindability°H
Ash meltingbehaviour°Coxid. atm.
30
25
20
Design Poland South- Australia USA India Canada Spits- Chinaand Africa bergenguarantee value
2010 02010 040302010
80
60
401600
1400
1200
1000 ST HT
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 197 of 222
Staudinger P.S., Unit 5550-MW
Staudinger P.S., Unit 5Staudinger P.S., Unit 5550-MW550-MW
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 198 of 222
Staudinger P.S., Unit 5 - Coal DataStaudinger P.S., Unit 5 - Coal Data
202530
NCV ar MJ/kg
05
101520
Moisture ar %
0102030
Ash ar %
1.0001.2001.4001.600Ash Def.Temp. °C
406080
Grind. °H
010203040
Vol.M. ar %
Contractual range Imported coal used of imported coal
Contractual range Imported coal used of imported coal
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 199 of 222
Steam Generator forHigh-ash Hard Coal
330-MW Unit
Pucheng P.S., China
Steam Generator forSteam Generator forHigh-ash Hard CoalHigh-ash Hard Coal
330-MW Unit330-MW Unit
PuchengPucheng P.S., China P.S., China
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 200 of 222
High-ash Coals Used inHigh-ash Coals Used in Benson Benson Boilers Boilers
0 10 20 30 40 500
10
20
30
40
Volatile matter, daf, %
Ash
con
tent
, %
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 201 of 222
Tutuka PS, 6 x 600 MWe (Republic of South Africa)
Design CharacteristicsTower TypeOnce-Through (BENSON)
Design DataMax. Allow. Work. Pressure 195 barMax. Continuos Rating 1825 t/hOutlet Temperature 540/540°C
Firing SystemHigh Ash Bituminous CoalDry Bottom , Opposed FiringNo. and Burner Capacity 24x94 MWNo. And Mill Capacity 6x69 t/h
Start of Commercial ServiceUnit 1 - 6 1985-90
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 202 of 222
Bituminous - High Ash - Coal Fired Steam GeneratorsBituminous - High Ash - Coal Fired Steam Generators
20
25
30
35
40
0 200 400 600 800
Unit Capacity [MWel]
Ash
Con
tent
of C
oal [
%(a
r)]
5 Units
6 Units
6 Units
6 Units
3 Units
3Units
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 203 of 222
Comparison of South African Coals toComparison of South African Coals to Talcher Talcher Coal Coal
Coal Abrasivness andCoal Abrasivness and Grindability Grindability
0
20
40
60
80
100
120
140
Duvha Hendrina Kriel Majuba Tutuka Talcher
Ash-Content %
SiO2-Content in Ash %
YGP-Index (2kg Coal used)
Hardgrove
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 204 of 222
0
20
40
60
80
100
120
140
0 10 20 30 40 50
Ash Content, %
Abr
asiv
enes
s (m
g Fe
/kg
coal
)AbrasivenessAbrasiveness of Coals of Coals
Analyses1984 to 1998
1997 specificationfrom NTPC
Indian coalTalcher
South Africancoals
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 205 of 222
ConclusionsConclusionsConclusions
• Well-proved firing systems are available for the whole range of coal qualities
• Advanced pulverizing and firing equipment allow the use of low grade coal and widefuel ranges with favorable ignition and burnout behaviour and reduced pollutantemission
• BBP has extensive experience with coal qualities similar to Indian low grade coals
• Marks of BBP firing system for Indian high ash coal– Optimum operation of mills over load range and varying coal qualities
(MPS mill with hydropneumatic grinding force system)– Stable ignition of the flames over a wide operational range (DS burner)
– Adequate life time of wear parts (mills 7 000 h, burners and p.c. pipes 24 000 h)
– Operation with low excess air (air ratio 1.15)
– Low NOx emission (in compliance with WB Standards)
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 206 of 222
Conclusions (cont‘d)ConclusionsConclusions ( (contcont‘d)‘d)
• Varying heat release and heat absorption in the furnace firing differingcoals are compensated in a Benson boiler due to its variable finalevaporation point
• Benson boiler with advanced firing system forms the optimumtechnical solution for the use of a wide coal range and low grade coals
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 207 of 222
Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG
6.0 Supercritical boiler concept of BBP
Babcock Borsig Power (BBP) has gained broad experiences with subcritical and supercritical steam generators in tower-type and 2-pass design. Both types of design, tower-type/2-pass, have their own advantages and the decision for the most adequate design depends on an optimization process considering the- fuel type (fouling, slagging, abrasivness of ash etc.)- client requests regarding number of mills, max. burner capacity, general arragement, limitation of building hight etc.- manufacturing and erection limitation- costs and prices
For Indian pit-head power stations firing non beneficiated (unwashed), highly abrasiv coal with extremly high ash content and based on the broad experience of BBP with firing high ash bituminous coal especially gained inSouth Africa (see chapter 6) BBP would prefer tower-type design. In respect of mitigating erosion problems byavoiding flue gas stratification before entering convective heating surfaces tower-type design shows an advantage in comparision to 2-pass design due lower tube failure rate. Power stations using beneficiated (washed) Indian coal with lower ash content or costal power stations firing imported coal 2-pass design may bechosen.
Technical Session IIITechnical Session III
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 208 of 222
Technical Session III
Supercritical Boiler Concept of BBP in India
• BBP has gained broad experiences with sub-/supercritical steam generators in tower-type and 2-pass design
• Optimized design in principle depends on certain criteria like- fuel type (fouling, slagging, abrasiveness of ash etc.)- client request regarding no. of mills, max. burner capacity, general arrangement etc.- manufacturing and erection limitations- local costs for labor and raw materials
• For Indian pit-head power stations firing non benificiated (unwashed) local high ash coal BBP would prefer tower type design to mitigate fly ash erosion
• For power stations firing benificiated (washed) Indian coal or costal power stations firing imported coal 2-pass design may be chosen
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 209 of 222
Flow Scheme of Membrane WallsFlow Scheme of Membrane Wallsfor Tower Boilersfor Tower Boilers
Advantages of Tower Type Design
• No temperature difference between
wall systems
• Even profile of flue gas temperature
and dust concentration
• Lower velocity of dust particles
• Less erosion on pressure parts
• Direct load transition to boiler roof;
through furnace walls and from
bundle system through support
tubes.
• Free expansion of all systems
Transition from Spiral Tubing toVertical Tubing
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 210 of 222
Flow Scheme of Membrane Walls for Two-Pass BoilersFlow Scheme of Membrane Walls for Two-Pass Boilers
3.) 1.)
2.)
4.)5.)Detail:Ties for Spiral Tubing
Temperature differencebetween the wall systems
(Example Studstrup Power Plant)
Boiler LoadLocation 100% 35%
1.) 2 K 1 K2.) 7 K 1 K3.) 13 K 1 K4.) 2 K 3 K5.) 7 K 17 K
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 211 of 222
700 MW Supercritical Unit700 MW Supercritical UnitGeneral Arrangement Plant
41,9 m
0,0 m
15,7 m
49,3 m
66,0 m
C C
B
B
AA
Section A - A Section B - B
Section C - C
9500 1100020000230008500
72000
2750011500 11500
98000
11000
50500
5700
0
21816
31600
170000
55400
17056
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 212 of 222
605 MW Supercritical Unit605 MW Supercritical UnitGeneral Arrangement Plant
+15,0 m
0 , 0 m
+39,7 m
+83,1 m
+87,6 m
+50,0 m
28500
110006000
17100
21200
10800
8500
8500
8500
8500
22700
15480
23053
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 213 of 222
Technical Session IIITechnical Session IIIBharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG
7.0 Operation & maintenance of once-through boilers based on experiences gained in South Africa
Babcock Borsig Power (BBP) has supplied 46 bit. coal steam generators with an overall steaming capacityof about 57,000t/h in the last decades to the Republic of South Africa, thus broad experiences has been gained with firing high ash South Africa coal.
Up-to-date statistics based on data from the last five years (1994 - 1998) from South African utility ESCOM show a trend to slightly lower average values of the forced outage rate of power stations with once-through,tower-type steam generators in comparison to those with drum-type, 2-pass steam generators.
A comparision of the tube failure rate of South Africa 600 MW units (data from 1998) with values available fromIndia show lower failure rate in the South African units. In addition a tendency to lower failure rate in tower-type units can be detected from the South African data which is among other reasons caused in a low tube failure rate caused by fly ash erosion in these tower-type steam generators.
Actual data based on South African 600 MW units give evidence that the maintenance costs of the power stations with once-through, tower-type steam generators are within the same range or even lower than power stations with steam generators of drum-type, 2-pass design.
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 214 of 222
Technical Session III
O. & M. of Once-Through Boilers, Experiences from Republic of South Africa
• BBP has decades of experiences gained in 46 units with total 57,000 t/h steaming capacity with firing South African high ash hard coal
• Statistic data from the last 5 years (1994-98) from ESCOM power stations show a trend to slightly lower forced outage rate of units with once-through, tower-type steam generators in comparison to those with drum-type, 2-pass design
• Lower tube failure rate of tower-type steam generators is among other reasons caused in a low number of tube failures by fly ash erosion due to tower-type design
• Maintenance costs of S.A. power stations with BBP once-through, tower-type steam generators are comparable or even lower than power stations with drum-type, 2-pass steam generators
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 215 of 222
Operation & Maintenance of Once - Through Boilers
Statistics from ESCOM, Republic of South Africa
- Availability Figures / Tube Failure Rate
- Maintenance Costs
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 216 of 222
PowerPlant
No.of
Boilers
SteamingCapacity
(t/h)
Fuel Type Boiler Type SteamSH
(°C/bar)
ConditionsRH
(°C/bar)
Majuba 1-6 6 2,077 Hard Coal Once-Through 538/173 538/36
Sasol III 8 540 Hard Coal Nat. Circulation 435/56 -
Sasol II(extension)
2 540 Hard Coal Nat. Circulation 435/56 -
Sasol II 6 540 Hard Coal Nat. Circulation 435/42 -
Tutuka 6 1,825 Hard Coal Once-Through 540/171 540/38
Duvha 6 1,825 Hard-Coal Once-Through 540/174 540/39
Kriel 6 1,584 Hard-Coal Once-Through 516/174 516/34
Hendrina 5 771 Hard Coal Nat. Circulation 543/134.4 -
Grootvlei 1 830 Hard Coal Nat. Circulation 543/111.3 -
Sum: 46 57,191
Steam Generators delivered by BBP to Republic of South Africa
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 217 of 222
Tutuka PS, 6 x 600 MWe (Republic of South Africa)
Design CharacteristicsTower TypeOnce-Through (BENSON)
Design DataMax. Allow. Work. Pressure 195 barMax. Continuos Rating 1825 t/hOutlet Temperature 540/540°C
Firing SystemHigh Ash Bituminous CoalDry Bottom , Opposed FiringNo. and Burner Capacity 24x94 MWNo. And Mill Capacity 6x69 t/h
Start of Commercial ServiceUnit 1 - 6 1985-90
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 218 of 222
Lethabo PS, 6x618 MWe(Republic of South Africa)
Boiler Manufacturer Brit. Babcock
Design Characteristics2-passNatural Circulation
Design DataFinal Steam Pressure 173 barMax. Continuos Rating 1834 t/hOutlet Temperature 540/540°C
Firing SystemHigh Ash Bituminous CoalDry BottomNo. Of Burners 36No. And Mill Capacity 6x80 t/hMill Type Horizontal Tube
(typical drawing)
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 219 of 222
Forced Outage Rate of ESCOM Power Stations, Rep. of South Africa
Source: ESCOM, Rep. of South Africa
Power Station Unplanned Capability Loss Factor
0
2
4
6
8
10
12
1994 1995 1996 1997 1998 Average(1994-1998)
(%)
Tower-Type, Once-Through2-pass, Drum-Type
Steam Generator Design
Power Stations EvaluatedTower-Type, Once-Through:Majuba, Tutuka, Duvha, Kriel, Matimba
2-Pass, Drum-Type:Kendal, Matla, Lethabo, Arnot
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 220 of 222
Comparison of Tube Failure Rate
Source: ESCOM , Rep. of South Africa, 1998; BHEL Technical Paper at Conference on Boiler Tube Failure, 24th - 26th June 1998, NTPC, Noida, India
SG Tube Failure Rate per Year per Unit
0
1
2
3
4
India India South Africa South Africa
200 - 250 MW Units 500 MW Units
ESCOM, 200 to 700 MW Units
Tower-Type 2-Pass
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 221 of 222
Boiler Tube Failure Caused By Fly Ash Erosion (Rep. of South Africa)
Source: ESCOM Power Plant Engineering Division, Rep. of South Afrika
Power Station Duvha Tutuka
No. of Units / Capacity (MWel) 6 x 600 6 x 600
Commissioning Period 1980-84 1985-90
Evaporator System once-through once-through
Boiler Design tower-type tower-type
Operation Mode base load base load
Fuel bit. coal bit. coal
Fuel Ash Content (%) 27 27
Year Total number of boiler tube failures in 6 units caused by fly ash erosion
1995 1 0
1996 1 2
1997 1 3
EV 2 / Oktober, 99; NTPC Presentation. ppt Page 222 of 222
Comparison of Maintenance Costs(6x600 MW - Units, Rep. of South Africa, 1998)
Source: ESCOM, Rep. of South Afrika
-2
0
2
4
6
8
10
12
14
(%)
Tutuka Duvha Lethabo Matla
Power Station
Relation of total Maintenance Costs for Power Stations
Basis + 0.08% - 1.1% + 7.7%
Steam Generator Design
Once-Through, Tower-Type Drum-Type, 2-pass
top related