supercritical technology.pdf

Enhancing Capacity – Empowering Nation

CII EPC POWER MEET 2009 Supercritical Technology

Presentation on Supercritical Technology

Presentation By

R.Kumar

General Manager

BPP & PM (FB)

BHEL, Tiruchirappalli, India



India’s installed capacity 1,44,922 MW

BHEL-built sets account for 91,481 MW

(64 % of India’s installed capacity)

PLF

National average 77.0 %

BHEL Thermal Sets 80.1 %

BHEL’s 200/210/250/500 MW Set 82.2 %

BHEL’s CONTRIBUTION TO POWER SECTOR (As on 31.03.2010)



GENERATION ~ 662,000 MUs

2009-10

OTHERS

26.0%

BHEL

74.0%

INSTALLED CAPACITY - Utility

~ 1,44,922 MW (31.03.10)

OTHERS

36%

BHEL

64%

Over 1,00,000 MW added by BHEL in domestic and international segments

Practically every 3 houses out of 4 in India

are supplied power, generated from BHEL sets

BHEL’s Contribution to Indian Power Sector



Source: CEA

Capacity Addition : XI Plan (2007 – 12)



Category Capacity in MW

Thermal (incl. Gas) 70,000

Nuclear 5,000 - 6,000

Hydro 20,000

Total 95,000 - 96,000

XII Plan (2012-17) : Total (Tentative) Capacity Addition



CAPACITY ADDITION PROGRAMME IN

Xth, XIth, XIIth & XIIIth FIVE YEAR NATIONAL PLAN

TYPE

THERMAL

10 th PLAN

(2002-2007)

(Actual

11 th PLAN

(2007-2012)

(Planned)

12 th PLAN

(2012-2017)

(Tentative)***

13 th PLAN

(2017-2022)

(Tentative)***

MW MW MW MW

SUB-CRITICAL (Upto 600

MW)

12114 48230 20650 NIL

SUPER CRITICAL

(660 & 800 MW)

---- 5940 42280 64100

THERE IS A CLEAR SHIFT IN THE PLANNED UNITS FROM SUB-CRITICAL TOSUPER-CRITICAL UNITS.

AS PER CEA, 13th PLAN ONWARDS ALL THERMAL SETS SHALL BESUPERCRITICAL SETS ONLY

*** Based on Sites/Rating identified by Central Electricity Authority, Govt Of India. This may undergo changes keeping in view the commissioning schedule/coal linkages etc.



Use Of Super Critical Technology

• Supercritical Technology is widely established and accepted with more than 500units in operation.

• Widely prevalent cycle parameters (At turbine end):

– Pressure: 246 -250 kg/cm2

– Temperature: 537/566 deg C (In 660MW Sipat & Barh TPS)

565/593 deg C (In 660 MW Barh-II and

2 X 800MW Krishnapattnam)

593/593 or 600/600 deg C

(Ultra Supercritical parameters-Yet to be adopted in ourcountry)

• Parameters adopted for 800MW are 247kg/cm2 /565/593 deg C.



Supercritical Technology – Indian scenario

• Supercritical technology being adopted to enhance efficiency, reduce coal

consumption and GHG emission

• 660/ 800 MW units planned in big way.

• Parameters adopted 247kg/ cm2/ 565/ 593 deg C

• 5 units of 660 MW under execution at Sipat and Barh II

• Ultra Mega Projects, 4000 MW each, envisaged with supercritical units.

• 4 projects already awarded to IPPs through tariff based competitive

bidding.

• Many more supercritical units in pipeline.

• Introduction of supercritical units would improve the efficiency in power

generation.



SUPERCRITICAL BUSINESS IN INDIA

STORY SO FAR

SL.

No

PROJECT NAME ORDER FOR BTG

PACKAGE

PLACED ON

REMARKS

1 3X660 MW SIPAT-NTPC SG: Doosan ESP Package by BHEL

2 3X660 MW BARH STAGE I

NTPC

SG :

Technoprom

ESP Package by BHEL

3 3X660 MW MUNDRA

(TIRORA) ADANI

EPC Contract

awarded to SEPCO

4 Sasan,Mundra,Krishnapatn

am,Tilaya 4000MW each

Mundra-Tatas

Others-Reliance



Order for 2X660 MW Barh Stage –II (SG Package) received from NTPC in 2008

against ICB (single bidder)

Order for 2X800 MW Krishnapatnam STPS (SG Package) received from

APPDCL in July 08

Order for 3X660 MW Bara (SG+TG Package) received from Jaypee Group in

2009

Order for 2X800 MW Yeramarus received from KPCL in April 2010

MAJOR SUCCESS FOR BHEL IN THE AREAS OF

SUPERCRITICAL SETS



Emerging market requirements for Utility Units

• Highest economically achievable plant Efficiency and Lowest

Heat Rate

• High Reliability & Availability

• Suitable for differing modes of operation

• Suitable for different quality of fuel(Especially High Ash,Low grade

Indian Coals)

• Ability to operate under adverse grid conditions / fluctuations

• Minimum emission of Pollutants

• Lowest life cycle cost



Benefits of supercritical technology

• Reduced fuel costs due to improved overall plant efficiency.

• Reduced CO2 emission rate.

• Reduced sulphur oxides and particulates.

• Better suited for sliding pressure operation. Better load change

rates are possible due to less temperature variation at turbine

inlet and absence of thick walled drum.

• Better suited for varying coal quality as there is no fixed

evaporation end point.



Parameters for increasing Cycle Efficiency in PC-fired Units

Increasing main steam pressure

Increasing superheat and reheat temperatures

Adopting double reheat

Increasing the vacuum of condenser

Increasing final feed water temperature.



Current Trends in Steam Parameters

1980s : Pressure increased from 175-180 bar to 225

bar; temp mostly around 540 Deg.C

1990s : Pressures raised to 285 bar; Temp raised to

565 Deg.C

300 bar & 620 Deg.C not unusual today

255 bar 568/596 Deg C commonly used presently



Evolution of Steam Power Stations Efficiency Worldwide



Trend in unit sizes in India & Cycle parameters

Unit SizeSHO Pressure (kg/cm2(a))

SHO/RHO Temperature

(Deg.C)

Year of Introduction

60 / 70 MW 96 540 1965

110 / 120 MW 139 540/540 1966

200 / 210 MW 137 / 156 540/540 1972

250 MW 156 540/540 1991

500 MW179179

540/540 540/568

19791985

600 MW179179

540/540 540/568

2008

660 MW 256 568/596 2008

800 MW 256 568/596 2008



Parameters at Turbine Inlet(kg/cm2 / o C/ o C)

Increase in efficiency (% points)

170 / 537 / 537 Base (500MW)

247 / 537 / 537 0.69%

247 / 537 / 565 0.96%

247 / 565 / 565 1.31%

247 / 565 / 593 1.64%

247 / 600 / 600 1.96%

Improvement in cycle efficiency with higher steam parameters



Savings in coal consumed: 0.63 x 106 Tons/Year Reduction of CO2 emissions: 0.93 x 106 Tons/YearAt 80% PLF & HHV of 4000 kcal/kg

Station

Capacity (MW)

Units(No.x MW)

MS

Pressure (kg/cm2)

MS/RH

Temp 0C

Efficiency

(%)

Coal

Consumption (MMT/Yr)

CO2

Emissions (MMT/Yr)

4000 8x500 170 537/537 38.6 15.61 22.90

4000 5x800 247 565/593 40.24 14.98 21.97

Environmental Benefits

Source : CEA



Principal equipment in Thermal Power Plant

TURBINE

B

O

I

L

E

R CONDENSER

CE PUMP

DEAERATOR

BFP

ONCE THROUGH BOILER

boils the water to steam

upto 565 Deg C

Temperature

TURBINE

produce

power

GENERATOR

produce electricity

CONDENSER

Condenses the

steam to water

CEP

Increases the

pressure of

water

LP HEATERS

Heat the waterHP HEATERS

Heat the water

BFP

Increases the

pressure of

water



Types of boilers

Drum type

Once-through type



500 MW Boiler – Typical Arrangement



Separators

Collecting

vessel

High Efficiency Supercritical Technology

for Clean power



Increased mass flow

through spiral waterwall

tubing, or improved heat

transfer through rifled

vertical wall tubing.

No fixed evaporator end

point

No thick wall components

Features

Once Through Boiler Flow Diagram

Evaporator

Water separator

Feedwater

Economizer

FW-

Pump

Live steam

Superheater



Supercritical Boilers

Supercritical pressure boiler has no drum and heat absorbing

surface being, in effect, one continuous tube, in which the water &

steam generated in the furnace water walls passes through only

once hence called ‘Once through Supercritical pressure boilers’

The water in boiler is pressurized by Boiler Feed Pump, sensible

heat is added in feed heaters, economizer and furnace tubes, until

water attains saturation temperature and flashes instantaneously

to dry saturated steam and super heating commences.



The Concept

The mass flow rate thru’ all heat transfer circuits

from Eco. inlet to SH outlet is kept same except at

low loads wherein recirculation is resorted to

protect the water wall system



STEAM TO TURBINESTEAM TO TURBINE

SHSH

DRUM

SEPERATING

VESSEL

EVAPO

RATO

R

EVAPO

RATO

R

ECO.

ECO.

(LOW LOAD &

CIRCULATION PUMP

START-UP)

FEED

FEED

CIRCULATION TYPE

ASSISTED

Circulation Systems

Drum Type Once-through



Features of Once Through Steam Generator

To ensure adequate mass flow rates through water wall, spirally

wound water wall tubes are used.

Start-up and low load system up to 30-40% BMCR required.

Feed water quality requirements are very stringent.

Can be designed for both sub-critical and super-critical

pressures.

Ideally suited for sliding pressure operation due to the absence

of thick walled components.



Once -thru Boiler

Evaporator system :

Formed by a number of parallel tubes

Tubes spirally wound around the furnace to reduce number of

tubes and to increase the mass flow rate thru’ the tubes

Small tube diameter

Arrangement ensures high mass velocity thru the tubes



Vertical Furnace Wall Design

Vertical tube furnace walls will provide all the

operational benefits of the currently popular spiral

design while significantly reducing the cost and

construction time for the furnace and providing some

reduction in pressure drop.



Design Features of 660 / 800 MW

Supercritical Turbines & Boilers for

Indian Coal Fired Power Stations



Technology tie-ups for SuperCritical:

A) SuperCritical Boilers

Technical Collaboration Agreement (TCA) valid for 15 years,

for complete range of Once – Through, Super-Critical Boilers

established with ALSTOM in Oct. 2005.

- TCA Covers 2-pass & Single pass tower type design

- Boiler TCA includes higher capacity mills (HP 1103 – HP 1303)

B) Collaboration for other Auxiliaries tied up

C)Turbines- Existing Technical Collaboration Agreement with Siemens

recently extended further

BHEL: Solution for Power Equipment



Comparison of Parameters

PARAMETER UNIT 500 MW 800 MW

Main Steam Pressure ATA 170 247

Main Steam Temp OC 537 565

Main Steam Flow T/Hr 1,515 2,340

Reheat Pressure ATA 41 56.6

Reheat Temperature OC 537 593

Reheat Flow T/Hr 1,335 1,940

Cold Reheat Pressure ATA 45 61.5

Cold Reheat Temp OC 336 348

Final FW Temp OC 253 290

BMCR T/Hr 1,625 2,600



Power Cycle Equipment

EQUIPMENT 500 MW SUB CRITICAL 800 MW SUPER CRITICAL

BOILER Drum Type Once Through Type

TURBINE 1HP + 1IP + 1LP 1HP + 1IP+ 2LP

CONDENSER One Two

GENERATOR 588 MVA 950 MVA

LP HEATERS 3 Nos 4 Nos

HP HEATERS TWO ( 2X50% EACH) THREE ( 2X50% EACH)

DEAERATOR ONE ONE

CONDENSATE EXTN. PUMPS 3 x 50% 3 x 50%

BOILER FEED PUMPS 2 x 50%(TD) / 1 x 50% (MD) 2 x 50 % (TD) / 1 x 35 %MD

VACUUM PUMPS 2x100%2 x 100%

(For Each Condenser)

CONDENSATE POLISHING

UNIT2 x 50% 3 x 50%



Boiler Parameters

BMCRBMCRBMCR-Boiler Parameters

162521002585t/hSH steam flow

oC

oC

kg/cm2(a)

Unit

254291294Feed water temp.

540/540568/596568/596SHO/RHO temp.

179256256SHO pressure

500 MW660 MW800 MWDescription



Features of Boiler

Pulverised coal fired

Once through, evaporator suitable for

variable pressure operation

Single reheat

Tilting Tangential firing System

Dry Bottom

Balanced draft furnace

Side mill layout



Dry Bottom

Balanced draft furnace

High performance Bowl Mills

Two Nos. of Axial FD Fans

Two Nos. of Axial PA Fans

Two Nos. of Axial ID Fans

ESP to meet reqd. outlet concentration

Features of Boiler (Contd.)



A. Evaporators

• T12

• T23 and T24 : For 600oC (SHO) /620oC (RHO)

B. Superheaters and Reheaters

• T91 : for 550oC (SHO)/570oC (RHO).

• P91 : Upto 270 bar and 580oC (SHO)

• P92 : Upto 290 bar and 600oC (SHO)

• Austenitic steels Super 304H/TP347HFG: For temperature

600oC (SHO)/620oC (RHO)

New materials for high temperature



Capacity Building

Capability Building

Handling New materials

Development of more Vendors

Balance of Plant

Logistics

KEY CHALLENGES



Experienced Erection and Construction Personnel

Experienced Commissioning Personnel

Project Management Capability

Availability of Skilled Man power (High Pressure Welder)

Coal Linkages

Land Availability

KEY CHALLENGES – Contd..



Unique experience of having designed and installed more than 300 coal

fired utility Steam Generators ranging from 60 MW to 500 MW including

35sets of 500MW and 175 sets of 210-250 MW (as on March 2009)

firing Low Calorific value/High Ash/Erosive nature Indian coals.

Boiler design is continuously updated by BHEL incorporating the state

of art improvements and feedbacks gained from operating units and its

R&D initiatives.

660/800MW designs of BHEL/ALSTOM offered to utilities is based on the

above rich experience and the Collaborator Alstom support

BHEL Operating Experience with Indian Coals



SUMMARY

660/800 MW units offer better cycle efficiency

Proven technologies leading to lower GHG emissions and

lesser fuel burnt

BHEL has the technology for offering 660/800 MW

supercritical units

BHEL is executing NTPC BARH 2x660MW Stage-II , APPDCL

Krishnapatnam 2x800MW ,BARA 3x660MW from jaypee

group and recently contracted Yermarus 2x800MW from

KPCL

BHEL has geared up to meet the huge capacity addition in

the country and offer better economics to Indian Power

Utilities

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