Professional Documents
Culture Documents
Electricity
Indian Scenario
Per Capita Electric Power Consumption
Country Per Capita Electric Power Consumption kWh
1995 2005 2011
India 367 461 684
Mexico 1364 1853 2092
Turkey 1227 2019 2709
China 770 1784 3298
Malaysia 1982 2857 4246
Italy 4598 5669 5393
United Kingdom 5576 6272 5472
Spain 3951 6111 5530
Russia 5110 5785 6486
Germany 6328 7113 7081
France 6619 7665 7289
Japan 7365 8213 7848
Switzerland 7283 8305 7928
South Korea 3881 7804 10162
USA 12660 13705 13246
Sweden 15475 15431 14030
Canada 16503 17319 16473
Norway 24528 25083 23174
International Energy Agency (IEA Statistics OECD/IEA, http://www.iea.org/stats/index.asp),
Energy Statistics and Balances of Non-OECD Countries and Energy Statistics of OECD Countries.
Catalog Sources World Development Indicators
BHEL - Boiler
1970s
Technology from Combustion Engineering, USA;
Unit capacities 110 MW, 210 MW Low Pressure Steam cycle
1980s
Pressure ratings increased to achieve higher plant efficiency; Unit capacity
increased to 500 MW; Controlled circulation introduced for very high pressures
Firing system design for Low NOx emission
Deteriorating coal properties led to increased tube erosion and performance
deviations; units redesigned for inferior coals.
Tower type boilers introduced for highly erosive coals
Technology Development over the Years
1990s
250 MW units developed
130 MW unit firing Steel plant by- product gas (Corex gas)
Boiler efficiency improvement by designing for low exit gas temperatures
2000s
Technology tied up for Super critical steam generators with Alstom.
IT based Soot Blowing Optimisation System developed.
Designs for firing Washed Coals developed.
Technology through Collaborations
Products (HPBP) Collaborators
Steam Generators Skoda, Czech; Combustion Engg., USA(now GE)
Gravimetric Feeders Stock Equipment Co., USA (now part of SPX Corporation)
Safety, Safety Relief, Y Type Valves Dresser Industries Inc. USA (now part of Halliburton Group)
HPLP Bypass System Sulzer Brothers Ltd (now part of CCI, USA)
Christmas Trees & Wellhead Assemblies, Kvaerner Oilfield Products, Singapore (now AKER KVAERNER,
Subsea Well Head, Casing support & Mudline Norway)
Suspension Systems & Block Valves
Circulating Fluidised Bed Combustion (CFBC) LLA, Germany (earlier LLB, Germany)
Boilers
Technology
10
6,77
9
5,79
8 5,74
7 4,81
3,74
6 4,26
5 3,44 2,76
3,37
4
2,64
3
2,42 1,47
2 600 / 620
1,78
1
0,75 580 / 600
0 566 / 566
0 538 / 566
300
241 HP / RH outlet temperature [deg. C]
Pressure [bar] 175 538 / 538
Heat Rate Improvement vs Steam Conditions
(Single Reheat)
Unit Size Growth
Size Flow Pressure Temperature
(T/H) (Kg/Cm2) (Deg.C)
30MW 150 63 490
60/70MW 260 96 540
110/120MW 375 139 540/540
200/210MW 690 137/156 540/540
250MW 805 156 540/540
500MW 1670 179 540/540
600MW 1950 179 540/540
660 MW 2120 255 568/596
700 MW 2310 255 568/596
800MW 2590 255 568/596
800 MW 2485 280 603/603
Utility Boiler Technology Growth
30 SUBCRITICAL SUPERCRITICAL
250 ata,
568C/598C
500 MW 20.5
210/250 MW 500 MW 170 ata,
20 540C/568C
150 ata, 170 ata,
540C/540C 540C/540C 17.2
110/200 MW
130 ata, 15.7
14.6
15 540C/540C
12.5
60/100 MW
96 ata,
10 540C
0
1960 1970 1980 1990 2000 2010 2020
Year
Rankine Cycle
The Carnot Cycle is theoretically most efficient, but it is having
practical difficulties.
For steam power plant, practical thermal cycle was suggested by
Rankine, called Ideal cycle or Rankine cycle.
3-3 : BFP raises pressure from p2 to p1
T
4 1 3-4 : Heating In feed heaters & economizer
T1 P1
4 -1 : Heating In boiler
3
1-2 : Work done in Turbine from p1 to p2
T2 3 2
P2 2-3 : Heat reduction in condenser
S
Rankine Cycle Subcritical & Supercritical
Critical Point : 221
bar, 374C
Supercritical condition
Pressure range
3
What is Supercritical Parameters
Improvement
In physical terms at this Pressure Water transforms
25
to Steam spontaneously. 20
15
Super critical Steam Parameters :
10
Application
Utility
(Power Generation)
Industrial
(Process Steam
Requirements)
Types of Boilers
Steam
Application
Parameters
Subcritical
Utility
(Power Generation)
Supercritical
Industrial
(Process Steam Subcritical
Requirements)
Types of Boilers
Steam
Application
Parameters
Subcritical
Utility
(Power Generation)
Supercritical
Industrial
(Process Steam Subcritical
Requirements)
Types of Boilers
Steam
Application Circulation
Parameters
Natural Circulation
Industrial
(Process Steam Subcritical Natural Circulation
Requirements)
Basic Data for Design
Boiler Parameters
Fuel Data
Site Data
Boiler Parameters
Boiler Parameters
NHI / PA
NHI/ EPRS
Q Fired / Volume
Burner Zone Heat Release Rate
Furnace Residence Time
Distance between Furnace Bottom-hopper & Lower Most
Fuel Nozzle
Distance between Upper Most Fuel - Nozzle & Bottom of SH
Furnace Outlet Temperature
Aspect Ratio
Furnace Design
EPRS Loading
Plan Area Loading
Volumetric Loading
Burner Zone Heat Release Rate
Definition in Furnace Design
Design criteria
Adequate heating surface to get rated SHO / RHO temperature
over control load for the range of coals.
Low gas velocity to minimise pressure part erosion
Proper tube spacing to prevent plugging and fouling of heat
transfer surfaces
Proper pressure part support and alignments
Pressure Part Arrangement 500 MW
SH Platen RH Front RH Rear LTSH Term
Assy = 27 Assy = 80 Assy = 80 Assy = 134
Ele = 513 Ele = 960 Ele = 960 Ele = 804
ST = 762 ST = 254 ST = 254 ST = 304.8
SL = 60.3 SL = 73 SL = 100 SL = 101
OD = 51.0 OD = 63.5 OD = 54.0 OD = 51.0
75731
SH Panellete LTSH
Assy = 48 Assy = 134
12211
Ele = 432 Ele = 804
ST = 3048 ST = 152.4
SL = 60.5 SL = 101
OD = 51.0 OD = 51.0
30
55
22276
Future Provision
Economiser
Assy = 228
Ele = 684
ST = 90
FD 18146.7 x FW 20701 6451.6
SL = 76.2
OD = 38.1
13258.8
Pressure Part Arrangement 210 MW
RH Front RH Rear SH Final LTSH
Assy = 65 Assy = 65 Assy = 131 Assy = 132
Ele = 6 Ele = 6 Ele = 3 Ele = 114.3
ST = 228.6 ST = 228.6 ST = 114.3 ST = 4
SL = 100 SL = 100 SL = 114.3 SL = 101/102
OD = 54 OD = 54 OD = 47.63 OD = 47.63
458.1 650
55863 55920
658.8 1100 1100 1254 763
LTSH Terminal
SH Platen
SH Finish
Platen SH
Assy = 32
RH Front
9750
RH Rear
Ele
12325
= 7+1
ST = 457.2
SL = 57
20
OD = 47.63
30
770
1518
LTSH
1923
LTSH
50
Economiser
1650
7593 1653 1829 Assy = 177
2080
Ele = 1 Economiser
770
ST = 85
SL = 130
2080
Economiser
885
OD = 44.5
34494
Main Steam
Some amount of Superheating
in WW itself
Higher SH Temperature after
SCW
Gas Temperature at the 2nd
Pass not adequate to heat the
SH Steam
Platen SH and Final SH are
provided
Reheat Steam
Hence RH is arranged in the 2nd
Pass as LTRH
Final RH is above the arch
Challenges in Boiler Design
Fuel Flexibility
Blending of Coals
Pollution Control
Boiler Design
.
India Coal vs Foreign Coals
INDIA GERMANY USA CANADA AUSTRLIA
Proximate Analysis
Ultimate Analysis
Calorific Value
Ash Constituents
Ash Fusion Temperatures
Hard Grove Index
YGP Index
Coal Analysis (Proximate) - Typical Indian Coals
Provides indicators to
Erosion potential
Corrosion potential
Design Considerations for Indian Coals
Boilers
Conservative Furnace Heat Loadings
Lower Flue Gas Velocity Over Tube Banks
Plain Tube InLine Arrangement of Heat Transfer Surface
Optimum End Gaps to avoid Preferential Gas Flow
Erosion Shields / Cassette Baffles
Erosion Allowance for Leading Tubes
Cast Steel PF Bends & Ceramic Lined PF Bends
Design Considerations for Indian Coals
Auxiliaries
Improved Sealing Arrangement in Airheaters
Extended Tube - Tubular APH
Low Speed Radial ID Fans
Lined Impellers of Radial Fans
Boiler Water Circulating Systems
Circulation through WW by Thermo-Siphon Effect The Density difference between Water & Steam
provides the driving Force for the Circulating Fluid
Natural Circulation
CR = 4 to 8
Higher Pressures units warrant Pumps to ensure Circulation through WW by Thermo-Siphon Effect
Circulation (Natural Circulation not adequate) supplemented by Pumps
Controlled Circulation
CR = 2 to 4
Circulation Boiler
Natural Circulation Controlled Circulation
Presentation title - P 80
Advantages of
Controlled Circulation vs Natural Circulation
Presentation title - P 81
Advantages of Controlled
Circulation
Presentation title - P 82
Advantages of Controlled
Circulation
Presentation title - P 83
Start-Up and Shut Down
Presentation title - P 84
Circulation Boiler Drum Type
Mass Flow Rate thru all Heat Transfer Circuits from Eco Inlet
Super Critical Once Through
to SH Outlet is kept same (no circulation in Water Walls),
and
except at Low Loads wherein Recirculation is resorted to
Sub Critical Once Through
protect the Water Wall system
Once Through Boiler Separator Type
or
Evaporator
Feedwater
Once through Boiler - Supercritical
Advantages:
Better suited for sliding pressure operation
Steam temperature can be maintained over wider load range
under sliding pressure
226
(3208)
Economiz
er
201 Eco omizer Waterwalls
(2865) Wa Superheater
A TER Controlleterwalls
d Circulati Superheat e
SAT U
on r
T ED W
STEAM &
RATE
WATER WATER
STEAM & STEAM
D STE AM
SATURA
WATER
MIXTURE
127 MIXTURE
Waterwalls
(1800)
Economiz Examples of Steam by Weight
er
Thermal C
25%
irculati on Superheater
100%
0%
Increasing Enthalpy ( h )
Enthalpy Kj/Kg (BTU/lb)
Presentation title - P 96
Sliding Pressure Supercritical Design
Enthalpy Variations vs Pressure and Boiler Load
SUPERCRITICAL FLUID
Full Load
Operation
Economiz
er SUPERCRITICAL FLUID
Waterwalls
Superheater
CRITICALPRESSURE
CRITICAL PRESSURE
PRESSURE K g /cm 2 (ps ia )
226
(3208)
Economiz
er
201 Eco omizer Waterwalls
(2865) Waterwalls Superheater
A TER
Middle Lo Superheat e
SAT U
ad r
Operation
T ED W
STEAM &
RATE
WATER WATER
STEAM & STEAM
D STE AM
SATURA
WATER
MIXTURE
127 MIXTURE
(1800) Waterwalls
Economiz Examples of Steam by Weight
er
Low Load
25% Operatio n
Superheater
100%
0%
Increasing Enthalpy ( h )
Separator
Evaporator system
A A STEAM
OUT
TANGENTIAL OUTLETS
(In Lieu of Axial Outlets)
View A - A
IMMERSION TUBE
BAFFLE
B B
MIXTURE
IN
TANGENTIAL INLETS
View B - B
C ROOF TUBES
5 - 70 TYP.
WATER
OUT
D
VORTEX
BREAKERS View C - C
2 OR 4
UPPER LEVEL TAP
Water
Level
Range
C C
LOWER LEVEL TAP
ALTERNATE:
TANGENTIAL WATER
AXIAL WATER OUTLET OUTLET
Arrangement of Separator & Collecting Vessel
Evaporator (Water Wall) System
Evaporator (Water Wall) system
Spiral Water Wall Vertical Water Wall
Plain Tubes used as Mass Flow per tube is High Rifled Tube used as the Mass Flow per tube is
less
Requires intermediate furnace wall transition
from spiral to vertical. (spiral wall cannot be Elimination of intermediate furnace wall
continued into the arch zone and horizontal transition header
pass)
Water Wall Pressure Drop due to plain tubes Water Wall Pressure Drop due to Orifices and
which are longer due to the Spiralling. Rifled Tubes
Welding required in the Four Corners also. Less welding in the Lower Furnace Wall
Not easy to identify the Tube Leaks Easier to identify and repair tubes leaks
or
Recirculation Pump
Separator
C
Flash
Tank
W
W
HWL
ECO
To Condenser
Deaerator
C
HPH
WL
BFP
Start Up System with Heat Exchanger
Low Load StartUp system with Circulating Pump
Separator
WW
C
Flash
Tank
ECO
HWL
To Condenser
C
Deaerator
HPH
C
BFP
Start Up Drain System
Warm up System
Separator
Storage Tank
To Desuperheater
#1
Warm up Control Valve
Economizer Outlet
Flow
Feedwater Flow
Dp
Once through Supercritical Boilers
Major Components
Once through Supercritical Spiral Wall Boiler
Vertical Separator
Spiral to Vertical Transition Intermediate Header
Vertical Wall Tubes
Support
Fingers
Side Wall
Rifled Tubing
Rear Wall
Rifled Tubing
Front Wall
Rifled Tubing
Smooth Tubing
from this Elevation
All Walls
Vertical Wall Furnace Windbox
Straight Tubes
SubCritical Vs SuperCrtical
Particulars Sub critical Super critical
Type Drum type Once through Once through
Operating pressure Below 221.1 bar Below 221.1 bar Above 221.1 bar
No boiling process.
Steam generation Boiling (Two phase Boiling (Two phase
Phase change is
process heat transfer) heat transfer)
gradual.
Thick walled Thick walled drum is
Smaller vertical separators provided
component provided
Start up and load
Base Better start up and load change rates
change rates
Water wall Generally spiral wall.
Vertical
construction Vertical wall for higher capacity
Higher loads: Once through
Circulation Circulation at all loads
Lower loads : Circulation
Water quality Base More stringent requirements
Comparison of Parameters
Parameter Unit 500 MW 800 MW
Main Steam Pressure ATA 170.0 247.0
O
Main Steam Temp C 537.0 565.0
Main Steam Flow T/Hr 1515.0 2340.0
Reheat Pressure ATA 40.5 56.6
O
Reheat Temperature C 537.0 593.0
Reheat Flow T/Hr 1335.0 1940.0
Cold Reheat Pressure ATA 45.0 61.5
O
Cold Reheat Temp C 336.0 348.0
O
Final FW Temp C 253.0 290.0
BMCR T/Hr 1625.0 2600.0
Thank You