NTPC Presentation

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


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


1.1 1.1 An An Overview Overview of technical collaboration withof technical collaboration withBBP / BBP / SiemensSiemens

BHELBHEL


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.


InuagurationInuaguration


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



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


Company Structure of the GroupCompany Structure of the Group

BABCOCK BORSIG POWERBABCOCK BORSIG POWER GMBH GMBH



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


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


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


Heino Martin(Chairman)

Arnfred Kulenkampff

AEEnergietechnikGmbH, Austria


Claus Brinkmann(Chairman)

Dr. Heinz Frühauf

Wolfgang Schwarzgruber

NEM b.v.,Netherland


Ulrich Premel

Gert Spruijtenburg


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


Worldwide PresenceWorldwide Presence


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


2.0 Once-Through Technology


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.


• 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.


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.


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

EV 2 / Oktober, 99; NTPC Presentation. ppt

Page 19 of 222

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

KWU 99 152dPage 20 of 222


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

Page 21 of 222EV 2 / Oktober, 99; NTPC Presentation. ppt

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



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



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



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

Modern Coal-Fired Power Plant KWU 99 152dPage 25 of 222


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



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



KWU 99 152d

Comparison of different Control StructureComparison of different Control Structure

Page 28 of 222EV 2 / Oktober, 99; NTPC Presentation. ppt

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

Modern Coal-Fired Power Plants KWU 99 152dPage 29 of 222


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



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

700 MW Bituminous Coal - Reference Power Plant With BENSON Boiler KWU 99 152dPage 31 of 222


RH2

RH1

Spray attemperator

RH1

Flue gas reci rculation

Damper control

RH2

Methods of Temperature Control-OverviewMethods of Temperature Control-Overview

Modern Coal Fired Boiler KWU 99 152dPage 32 of 222


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%



Molecular Structure of WaterMolecular Structure of Wateras Function of Pressure and Temperatureas Function of Pressure and Temperature



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



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



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



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




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


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.


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


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.


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


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


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


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.


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 %


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 %


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

%


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 [%]


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


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


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


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


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


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


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.


Experience RecordExperience Record Staudinger Staudinger

• Commercial Operation date: 1992/06/15 1996/07/16 49

• Capacity Factor: : 91%• Availability factor: 99%


Reference LetterReference Letter Rostock Rostock


Experience RecordExperience Record Rostock Rostock

• Continous Operation Period: 94/8/1 until now 57

• Capacity Factor: 98,00%

• Availability factor: 99,2%


*) 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



PhosphateTreatment


. / .CombinedOperation

AlkalineOperation

CombinedOperation


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


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


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:


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


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


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



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



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


Subcritical/Supercritical Bituminous Coal Fired Units525 MWel,net

(Rutenberg, Israel)

Comparison of Plant InvestmentComparison of Plant Investment


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


Comparison of Plant Investment: Subcritical/SupercriticalComparison of Plant Investment: Subcritical/Supercritical

Alt. 1(subcritical)

Alt. 2(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



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



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



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 %



525 MWel,net = 100% 669 MW = 127,43%

165 bar, 538/538°C 255 bar, 540/560°C



2. Turbine Set 8,6 100 8,6 120

3. BOP 16,1 ) 16,2 )



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






525 MWel,net = 100% 693 MW = 132%

165 bar, 538/538°C 255 bar, 540/560°C



2. Turbine Set 8,6 100 8,6 124,3

3. BOP 16,1 ) 16,1 )



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



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



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


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


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


2 x 660 MW2150 t/hr; 175 bar; 541/540 °C

SHALINGZI PHASE II POWER PLANTSHALINGZI PHASE II POWER PLANT


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


DOUHE PHASE II POWER PLANTDOUHE PHASE II POWER PLANT

2 X 660 MW1981 t/hr; 260 bar; 545/562 °C


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


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


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)


Technical Session IITechnical Session II

3.1 Technical aspects of the collaboration and BHEL´spreparedness for once-through Boilers

BHELBHEL


ONCE - THROUGH BOILER

SALIENT FEATURESOF

TECHNICAL COLLABORATIONAGREEMENT (TCA)


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


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


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


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


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


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



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



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


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


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


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)


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


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


SCOPE OF TECH.INFORMATIONSCOPE OF TECH.INFORMATION

☯ DESIGN MANUALS

☯ COMPUTER PROGRAMS

☯ TYPICAL CONTRACT DRAWINGS

☯ QUALITY MANUALS

☯ ERECTION METHODS

☯ COMMISIONING PROCEDURES

☯ TROUBLE SHOOTING PROCEDURES


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.


BACK-UP GUARANTEEBACK-UP GUARANTEE

r COLLABORATOR WILL GIVE BACK- UP GUARANTEE FOR MEETINGTENDER REQUIREMENT.


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.


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.


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.


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


WITH THE ONCE THROUGHBOILER TCA

BHEL IS FULLY GEARED UP

TO MEET

EMERGING

MARKET REQUIREMENTS




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


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

--


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


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


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


HPT IPT LPT

CROSS SECTIONAL VIEW OF 3 CYLINDER CONVENTIONAL STEAM TURBINEHMN SERIES


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


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


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


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


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


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


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




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.


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


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


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.


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


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


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


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


Benson Boiler with Opposed FiringBenson Boiler with Opposed FiringHeydenHeyden (900 MW) (900 MW)

Reheater


Allowable working



High pressure part


Allowable working




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


Benson Boiler with Opposed FiringBenson Boiler with Opposed FiringStudstrupStudstrup (350 MW) (350 MW)

Reheater


Allowable working



High pressure part


Allowable working




Benson Boiler with Opposed FiringBenson Boiler with Opposed FiringRostockRostock (550 MW) (550 MW)

Reheater


Allowable working



High pressure part


Allowable working




Benson Boiler with Tangential FiringBenson Boiler with Tangential FiringKW SchkopauKW Schkopau ( 450 MW ) ( 450 MW )

High pressure part


Allowable working



Reheater

Steam rating (inlet) 1206 t/h

Allowable working




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


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


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


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


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


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

--------------

--------------


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


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







1996

1996

1996

1996

May 1997

1995

1992


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


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



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.


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


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


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


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


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)


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]


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


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


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)


Tower TypeTower TypeBensonBenson Boiler Boiler

withwithOpposed FiringOpposed Firing

SystemSystem


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


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


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


CFDCFD Furnace Furnace Simulation Simulation

TemperatureDistribution

Velocity VectorsGeometry

z4

z3

z2

z1

y2

y1


In-In-HouseHouseCompetenceCompetence

ofof

All All Firing ComponentsFiring Components


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


TheThe DevelopmentDevelopment of of thethe MPS MPS MillMill


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


MPS MPS MillMill


MPS MPS MillMill

SLS Louvre-type, Rotary Air Classifier SLK Vane Air Classifier


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


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


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:


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:


DS-BurnerDS-Burner


Tertiary air

IR-FlameMonitor

Secondary air

Core air

Oil lance

UV-Flame-Monitor

DS-BurnerDS-BurnerSwirler

Pulverized coal

Flame-stabilizer


Design of DS BurnersDesign of DS Design of DS BurnersBurners

30 MW Test Facility

Operating Results

CFD FLUENTCalculation of the Flame


DS-BurnerDS-Burner

Temperature Mass Temperature Mass FractionFraction of O of O22


Staudinger P.S., Unit 5 - DS Burner FlameStaudinger P.S., Unit 5 - DS Burner Flame


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


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


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


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


Part Load OperationPartPart Load Load Operation Operation

• Min. boiler load w/o supporting fuel

– Low grade coal: 40 - 30 %– Imported bit. coal: - 20 %


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!)


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


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


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


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


Staudinger P.S., Unit 5550-MW

Staudinger P.S., Unit 5Staudinger P.S., Unit 5550-MW550-MW


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


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


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

, %


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


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


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


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


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)


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



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


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


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


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


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


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


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.


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


Operation & Maintenance of Once - Through Boilers

Statistics from ESCOM, Republic of South Africa

- Availability Figures / Tube Failure Rate

- Maintenance Costs


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


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


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)


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


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


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


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

NTPC Presentation

Documents