DETAILS OF CALCULATIONS:

POWER OUTPUT = 660 MW

TOTAL ENERGY DELIVERED @ 660 MW FOR A PERIOD OF ONE HOUR =
660MWH
Taking Efficiency = 37.96 % and 90 % PLF

Input = 660* 103 x 0.9 x 860 kcal / 0.3796 = 1345732.35 Kcal

(1 KWH = 860kcal)

Design calorific value of coal = 3300 Kcal/ kg

Coal requirement per hour = 1345732.35 / 3300 = 408 T

At efficiency 38.96 % coal requirement per hour = 397 T

Yearly saving of coal by increasing

efficiency of 1 % = 11 x 24 x 365 days = 96,360 MT

Total value of the coal saved @ Rs 650 / MT = Rs 626 lakhs

If the efficiency increases by 2.5 % = Rs 626 x 2.5 = 1565 Lakhs

Considering the life time as 30 Years, the savings in Fuel cost

will be Rs 46950 Lakhs ~ 470 Crores
 For three units = 470 x 3 = 1410 Crores

INDIRECT SAVINGS

Assuming Auxiliary Power consumption as 8 %

Estimated reduction in auxiliary power consumption = 0.3 %

For 660 MW units savings of auxiliary power

= 8 % x 660 x 0.003 = 0.158MW

Yearly savings in MW = 0.158 x 365 x 24 x 0.9 = 1248 .825

= 1248825 units

Taking the unit cost as Rs 2.50 per unit

Savings = 32.00 Lakhs
Total for three units = 32 x 3 = 96.00 Lakhs
~ 1.0 Crores

For life time = 30. Crores

TOTAL = 1410 + 30 = 1440 CRORES
ASSUMING THE LIFE AS 30 YEARS, THE APPROXIMATE SAVINGS WILL BE
RS 48 CRORES PER YEAR FOR ALL THREE UNITS TOGETHER.
 INCREASE IN PLANT EFFICIENCY by SUPER
CRITICAL PARAMETERS
Efficiency Increase
1.5
6
5 0.9
0.6
4
3.2
3 .

167 bar 250 bar

250 bar 250bar 250 bar
538/538’c 538/538
540/560’c 566/566 ‘c 580/600’c
 Comparison of BHEL V/s Doosan Units

Doosan Units BHEL Units

• Total Weight- 27960 • Total Weight- 28585
MT MT
– Structure – 6924 MT – Structure – 10801 MT
– Pr. Parts – 7080 MT – Pr. Parts – 5800 MT
– P C Piping – 3032 MT – P C Piping – 1445 MT
– P F System – 3823 MT – P F System – 2342 MT
– Draft System – 5004 – Draft System – 5680 MT
MT – Refractory/Insulation
– Refractory/Insulation C&I/Misc – 2517 MT
C&I/Misc – 2097 MT
 COMPARISION OF 660 MW Vs 500 MW BOILER

Description unit 660 500

S/H STEAM FLOW T/HR 2225 1625

SH STEAM PR KG/CM2 256 179
SH STEAM TEMP 0C 540 540
RH STEAM FLOW T/HR 1742 1397.4
RH STEAM TEMP INLET 0C 303.7 338.5
RH STEAM TEMP OUTLET 0C 568 540
RH STEAM PRESS INLET KG/CM2 51.17 46.1
FEED WATER TEMP 0C 291.4 255.2
 Tonnage Comparison

Description 660 MW 500 MW

Structural Steel Erection 7383 9200
Boiler Proper & Accessories (Pre. Parts) 7080 5300
Refractory, Insulation & Cladding 1410 2000
Power Cycle Piping 3032 2200
Soot Blowing System 54 76
Coal Firing System 3573 2000
Draft System 5275 5200
Fuel oil system 62 200
Miscellaneous System 130 280
Electrical & Instrumentation 282 380
TOTAL 28281 26836
 Material Comparison

Description 660 MW 500 MW

Structural Steel Alloy Steel Carbon Steel

Water wall T22 Carbon Steel
SH Coil T23, T91 T11, T22
RH Coil T91,Super 304 H T22, T91,T11
LTSH T12 T11
Economizer SA106-C Carbon Steel
Welding Joints (Pressure Parts) 42,000 Nos 24,000 Nos
 Structural Comparison
Slno 660 MW 500 MW Remarks
1 STRUCTURALS

a
Entire structural is bolting type-
entire structure is bolted. Holes
are drilled on the columns and
gusset plates, and supplied with
matching plates.
b.
No Welding work involved in
assembly/ Erection , except
Walkway rail post welding
c
Material supply is tier wise
including staircases, railing,
gratings etc.
Advantages (660MW) of
Bolting structure:
oFast in erection.
Structural is
oClean environment
assembled at site
oNo Welding network required
with welding
oSafety at site
oPainting finish is good
o( No Weld surface)
Assembly is carried Can be dismantled if required
out with Welding ( For Maintenance purpose)
Material is supplied Erection completion tier wise,
as per the erection including gratings, platforms ,
sequence. staircases etc.
 COST COMPARISON

1 Cost of SG Package 1970.73 Cr 1020.54 Cr with ESP

2 Cost of ESP 183.54Cr

3 Total cost of Boiler + ESP 2154.27 Cr 1020.54 Cr

4 Cost of Boiler per MW with ESP 1.09 Cr 1.02 Cr

5 Cost of TG for entire stage 1204.72 Cr 634.31 Cr

6 TG cost per MW 0.6Cr 0.63 Cr

 BOILER SPECIFICATION

Description unit

S/H STEAM FLOW T/HR 2225

SH STEAM PR KG/CM2 256
SH STEAM TEMP 0C 540
RH STEAM FLOW T/HR 1742
RH STEAM TEMP INLET 0C 303.7
RH STEAM TEMP OUTLET 0C 568
RH STEAM PRESS INLET KG/CM2 51.17
FEED WATER TEMP 0C 291.4
 = Boiler Efficiency Quoted Turbine Heat Rate
100% TMCR 86.27% 100% Load 1904 Kcal / KWH
80% TMCR 86.60% 80% Load 1924 Kcal / KWH
60% TMCR 86.68% 60% Load 1973 Kcal / KWH
50% TMCR 86.91% 50% Load 2065 Kcal / KWH

Net Plant Heat Rate = NTRH

= 2207 KCal / KWHR ( at 100% TMCR)

80% TMCR = 2222 Kcal / KWHR
60% TMCR = 2276 Kcal / KWHR
50% TMCR = 2376 Kcal / KWHR

Plant Efficiency at 100% TMCR = 38.96%

80% TMCR = 38.7 %
60% TMCR = 37.78%
50% TMCR = 36.19%
 SUPERCRITICALTHERMAL CYCLE
ADVANTAGES (1)

• Improvements in plant efficiency .

• Decrease in Coal Consumption
• Reduction in Green House gases.
• Overall reduction in Auxiliary Power
consumption.
• Reduction in requirement of Ash dyke
Land & Consumptive water.
 SUPERCRITICAL – ADVANTAGES (2)

• Sliding pressure operation because of Once

through system .
• Even distribution of heat due to spiral wall
arrangement leading to less Boiler tube
failure, thereby improving system continuity
and availability of the station.
• Low thermal stress in Turbine .
• The startup time is less for boiler.
 SUPERCRITICAL – DISADVANTAGES

• Higher power consumption of BFP

• Higher feed water quality required.
• More complex supporting and framing in Boiler due to
Spiral Wall tubes.
• Slight higher capital cost.
• Increased dependency For Spares and services.
 IMPORTANCE OF EFFICIENCY
• The cost of operating the Plant of 3 x 660 MW, one
percentage point below the design point, will incur
additional fuel cost of Rs. 16 Crores in a year.

• The indirect costs for Maintenance, APC, Ash Dyke land

etc. will give additional burden of Rs. 1Crores in a year.

• The environment will benefit on account of reduction in

GHGs like Co2, NOX & SOX.

• The life time savings of Rs.550- 600 Crores can be

achieved by increasing efficiency by one percentage .

• At Sipat, we gain an efficiency of 2.5 percentage by

adopting super critical technology in 1980 MW station,
thus saving Rs. 1440 Crores in its life time.
 REDUCTION IN CO2 EMMISSION

• CONSIDERING AVG COAL CONSUMPTION OF AT

FULL LOAD OPERATION : 400T/HR
• IMPROVEMENT IN EFFICIENCY
FOR SUPER CRITICAL TECHM
COMPARED TO 500 MW BOILER : 1.5%
• REDUCTION IN COAL FLOW : 6 T/HR
• REDUCTION IN CO2 EMMISSION
(FIXED CARBON CONTENT IN COAL 30%) : 6 T/HR
• REDUCTION IN CO2 EMMISSION
PER YEAR : 52560 TONS