INTRODUCTION TO 1000 MW POWER PLANT

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POWER PROJECT AT A GLANCE

Reliance Power is currently developing Fifteen large and medium sized power projects with a combined planned installed capacity of 35,460 MW. All these projects are in different stages of development and have made significant progress.

S.No PROJECTS CAPACITY in MW UNITS FUEL LOCATION

1 Rosa 1200 4 x 300 Coal based Uttar Pradesh

2 Butibori 300 300 Coal based Maharashtra

3 Sasan 3960 6X660 Coal based Madhya Pradesh

4 Krishnapatnam 4000   Coal based Andra pradesh

5 Chitrangi 5940   Coal based Madhya Pradesh

6 Tilaiya 3,960   coal based Jharkhand

7 Shahpur 4000   Gas based Maharashtra

8 Dadri 7,480   Gas based Uttar Pradesh

9 Urthing Sobla 400   Hydro Uttarakhand.

10 Siyom 1000   Hydro Arunachal Pradesh

11 Tato II 700   Hydro Siyom River

12 Kalai II 1200   Hydro Arunachal Pradesh

13 Amulin 420   Hydro Arunachal Pradesh

14 Emini 500   Hydro Arunachal Pradesh

15 Mihundon 400   Hydro Arunachal Pradesh

Total= 35460

3Data Source: CEA

4Data Source: CEA

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ACTUAL POWER SUPPLY POSITION IN INDIA

Data Source: CEA

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WHAT IS SUPER CRITICAL?

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Decrease of the fuel cost due to the increasing efficiency;

Decrease of CO2 emission per unit of electricity to more than 15% in comparison with the existing coal fired power plant.

Decrease of pollutants including SOx, NOx and PM.

MAJOR ADVANTAGES OF USC

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Cooling tower

Steam lines

Steam generator

Coal

Flue gasinjection

FGDFlue gasdesulphurisation

Draughtfan

Cooling water

PAfan

CoalmillsAsh

removal

Turbine Generator

Feed watertank

Feedpump

Electrostaticprecipitator

LP preheater

HP preheater

Condenser

GypsumFly ash

Airpreheater

FDfan

DeNOx

PROCESS OF POWER PLANT

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DESIGN PARAMETERS

• Power Output 1000MW • Fuel Bituminous coal / Lignite• Primary fuel HFO• Boiler Capacity 2890 t/hr• Live steam / RH steam temp. 600°C / 620°C• Live steam pressure 260 bar• Condenser pressure 35 mbar • Turbine speed 3000 rpm• Plant net efficiency (heat rate) 46,2 % (7792 kJ/kWh)• Generator rated power 958 MVA • Power factor (cos φ) 0,825

Data Source: HITACHI

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11

TYPE OF BOILERS

• Single pass Boiler• Two pass Boiler

Spiral Type Vertical Type

Furnace Classification of Boilers

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BOILER

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Fluid Temperature profile comparison for Water Wall Type

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15TWO PASS BOILERSINGLE PASS BOILER

CONSTRUCTIONAL DIFFERENCE

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TWO PASS BOILER WATER STEAM CYCLE PROCESS

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HPT

IPTLPTCONDENSER

FEED WATER

FRS

STORAGE TANK

SEPARATOR

BWRP

Spiral water w

alls

MS LINE

HRH LINE

VERTICAL WW

ECO I/L

ECO JUNCTION HDR

ECO HGR O/L HDR

FUR LOWER HDR

FUR ROOF I/L HDR

DIV PANELS SH PLATEN SH

FINAL RH

FINAL SH

LTRH

ECONOMISER

GLPT

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SINGLE PASS BOILER WATER STEAM CYCLE PROCESS

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HPT

IPTLPTCONDENSER

GLPT

VERTICAL WW

HRH LINE

SEPARATOR

Spiral w

ater walls

MS LINE

ECONOMISER

STORAGE TANK

RH

SH

CRH LINE

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BOILER EFFICIENCY - 1000 MW

Data Source: MHI

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STEAM TURBINE

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Type : Tandem-compound machine/

Cross Compound

Capacity: 1000 MW and 50 / 60 Hz

Speed :3000/3600 rpm

Steam Inlet Pressure: 246 Bar

Steam Inlet Temp : 600oC

Steam RH Inlet Temp :620oC

STEAM TURBINE

23Data Source: HITACHI

Bird’s-Eye View of Tandem-Compound 1,000-MW Steam Turbine and Generator.

The steam turbine consists of four turbine casings: a high pressure casing, an intermediate -pressure casing, and two low pressure casings. A Ti-alloy 40-inch blade and a 12Cr-alloy 43-inch blade are applied to the last stage blade for 60-Hz use and 50-Hz use, respectively. A large diameter rotor made of improved ductility high-strength shaft material is adopted to shorten the longer rotor length of thegenerator.

24Data Source: HITACHI

LP TURBINE BLADE DESIGN-1000MW

25Courtesy : Siemens

TANDOM COMPOUND TYPE

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CROSS COMPOUND TYPE

Data Source: HITACHI

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GENERATOR

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Sl. Parameter Unit 660MW 1000MW

No Super Critical USC

1 Steam Temperature at HP inlet Deg.C 566 600

2 Steam Pressure at HP inlet Mpa 24.2 26

3 Flow at TMCR/BMCR TPH 1976/2134 2890/3080

4 Cold Reheat Temperature Deg.C 322 365

5 Cold Reheat pressure Mpa 4.65 5.97

6 Hot Reheat Temperature Deg.C 566 602

7 Hot Reheat Pressure Mpa 4.2 5.45

8 Reheater Flow (TMCR) TPH 1658 2373

9 Feed Water Temperature Deg.C 280 294

10 Boiler Efficiency % 84.58 89.21

11 Heat Rate at TMCR Kcal/KWhr 1899 1810

12 Min Load without Oil support % 40% 40%

13 Operation Frequency Range Hz 47.5-51.5 47.5-51.5

14 Type of Boiler   2 Pass Tower Type/Two pass

15 Furnace Size M2 17.64x19.824 24x24

COMPARISON OF 660MW Vs 1000 MW PARAMETERS

Continued….

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Sl. Parameter Unit 660MW 1000MW

No Super Critical USC

16 Start up Pump No 1-30% Load 1-30% Load

17 Type Of Fans   Axial Axial

18 Number of Mills Nos 7(6W+1SB -worst coal) 8(7W+1SB – worst coal)

19 Type of Mills   HP MPS/HP

20 Air Pre Heaters Nos 2 (Trisector) 2(Bisector)

21 Margin On Fans % FD: 20%-Cap+30% - Head FD:20%-Cap+30%-Head

ID: 20%-Cap+44%-Head ID: 20%-Cap+30%-Head

22 Bottom Ash System   Water Impounded Scrapper Conveyor

23 Turbine Type   Tandem compound 3 cylinder Tandem compound 4/5 cylinder/Cross Compound

24 Turbine Module   Combined HP/IP+2 LP HP+IP+2/3 LP

25 BFP Configuration   2x65% TDBFP+1x 35% MDBFP 2x50% TDBFP+1x 30% MDBFP

26 Condenser Type     Dual Pressure

27 Condenser Back Pressure Kpa 10.03 8.7

28 HP/LP Bypass capacity (BMCR) % 60 60

29 Aux Power consumption % 3.64 3.4

30 Excitation System   Static Static

31 Power Factor   0.85 0.825

COMPARISON OF 660MW Vs 1000 MW PARAMETERS

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GE

ALSTOM

SIEMENS

HITACHI

MHI

TOSHIBA

SEC

AVAILABLE VENDERS IN MARKET

Thank YouJ.MURUGADASANSr.Manager.Dept. of Mechanical Construction