power plant related topics

Milestones of GrowthConstruction started 1962

Inauguration of Boiler Plant 1965

Commercial production commenced 1966

First 60 MW boiler order 1966



Crossing 1000 Cr turnover 1995-96

1500 Cr turnover 1997-98

2201 Cr turnover 2003-04

3536 Cr turnover 2005-06 (786Million US $)

4575 Cr turnover 2006-07 (1116 Million US $)




12399 Cr turnover 2010-11 (2755Million US $)

Over 1,15,000 MW added by BHEL in domestic and international segmentsOver 1,15,000 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

BHELS Contribution to Indian Power Sector

Steam Generators Exported

Customer Unit Size NoEEA-Egypt Al-Arish TPS 12 T/h 1ECT-Libya Tripoli West TPS 45 T/h 2PT IBR-Indonesia Bharat Rayon 75 / 80 T/h 3 / 3PT IBR Jawa bharat Indonesia 120 T/h 1PT. ADARO Indoesia 126 T/h 2KONIAMBO-Nickel SAS Koniambo Nickel SAS

New Caledonia 405 T/h 2

NEB-Malaysia Sultan Ismail TPS 30 MW 1EEA-Egypt Al-Arish TPS 30 MW 2NEB-Malaysia Tuanku Jaafar TPS 60 MW 2NEB-Malaysia Tuanku Jaafar TPS 120 MW 3NEB-Malaysia Prai TPS 120 MW 3NEB-Malaysia Pasirgudang TPS 120 MW 2ECT-Libya Tripoli West TPS 120 MW 2NEC-Sudan Kosti TPS 125 MW 4MAYLAN Intra Ltd Senegal / Africa 125 MW 1PEEGT Tishreen,Syria 200 MW 2

Total 36

Trend in unit sizes & 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 MW179

179

540/540

540/568

1979

1985

600 MW 179540/540

540/5682008

660 MW 256 568/596 2008

700 MW 256 568/596 2010

800 MW 256 568/596 2008

Technology Development Over The Years

1960s Boiler design as per Czechoslovakian technology, 30 MW, 60 MW

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;

Unitcapacity 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

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.


BASIC DATA FOR DESIGN

BOILER PARAMTERS

FUEL DATA

SITE DATA

79

6

.

4

8

6

-

HPH

2

4

6

.

0

2

5

5

.

0

FP

HPH

D

717.87

BOILER39.56

816.4150.0

796.486

HPT

537.0

IPT

35.62736.6345.1 717.87

844.4537.0

LPH LPH LPH LPH CP

C

LPT

(0.9227)573.1

552.286

0.1033

deg. c (x)kCal/kg

t/h

ata

Heat balance diagram (270 MW)

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.

1

23

3

4T

S

T1

T2

p1

p2

3-3 BFP raises pressure from p2 to p1

3-4 Heating In feed heaters & economizer

4 -1 Heating In boiler

1-2 Work done in Turbine from p1 to p22-3 Heat reduction in condenser

FUEL ANALYSIS COAL

Fuels HandledCoal / Oil / Natural Gas in any combination

Lignite

Blast Furnace Gas / Coke Oven Gas / Corex Gas

Carbon Monoxide / Tail gas

Asphalt

Black Liquor

Bagasse

Rice Husk

Washery Rejects

Wheat / Rice straw

COAL PROPERTIES AFFECTING BOILER DESIGN

TYPE OF COAL ( ANTHRACITE, BITUMINOUS, LIGNITE)

HIGHER HEATING VALUE

VOLATILE MATTER

MOISTURE CONTENT

ASH CONTENT

ASH CHARACTERISTICS

HARD GROVE INDEX ( HGI )

CHARACTERISTICS OF TYPICAL INDIAN COAL

HIGH ASH (35 50%)

HIGHLY ABRASIVE (55 65%)

MEDIUM MOISTURE (10 15%)

MEDIUM VOLATILE MATTER (18 24%)

LOW HEATING VALUE (HHV kcal / kg) (3000 3500)

LOW SULPHUR (0.2 0.5%)

EPRS LOADING

PLAN AREA LOADING

VOLUMETRIC LOADING

BURNER ZONE HEAT RELEASE RATE

FURNACE HEAT LOADINGS

http://www.bhel.com/ September 5, 2012

Salient Details of Select Steam Generators


Vijayawada Thermal Power Station 2x210 MW

November 1979

Two Pass, Natural Circulation, Balanced Draft , Tilting Tangential Firing

Salient features

Date of commissioning

CoalFuel

t/h 700/580

Kg/Sq.cm(g) 137/24.5

Deg.C 540/540

Parameters at SHO/RHO

Steam flow

Pressure

Temperature

Andhra pradesh Electric Company, India

Customer


Pasirgudang TPS 2 x 120 MWCustomer National Electricity Board,

MalaysiaParameters at SHO/RHOSteam flowPressureTemperature

t/h 389.9/329.4Kg/Sq.cm(g) 130.9/31.55Deg.C 540/540

Fuel Oil / gasDate of commg. January 1982

Salient features Box TypeNatural CirculationBalanced DraftTilting Tangential Firing


Tripoli (W) TPS 2 x 120 MW

Customer Electricity Corporation, Tripoli, Libya


Steam flow

Pressure

Temperature

t/h 375 / 325

Kg/Sq.cm(g) 132 / 25

Deg.C 540/ 540

Fuel Oil / Gas

Date of Commissioning

March 1980

Salient features Box Type

Natural Circulation

Pressurised Furnace

Tilting Tangential Firing

Kosti Power Project, Sudan - 4 x 125 MW

Customer National Electricity Corporation, Sudan


Steam flow

Pressure

Temperature

t/h

Kg/Sq.cm(g)

Deg.C

415 / 329

131 / 31

540 / 540

Fuel Crude Oil

Date of Commissioning

Under Engineering

Salient features Box Type

Natural Circulation

Pressurised Furnace


CONTROLLED CIRCULATIONSTEAM GENERATORS


Trombay TPS Unit 5 - 500 MW

Customer Tata Electric Company, India

Parameters at SHO/RHOSteam flowPressureTemp.

t/h 1672/1423Kg/sq.Cm(g) 178 / 38.5Deg.C 541 / 541

Fuel Coal / Oil / GasDate of commg.

January 1984

Salient features

Two Pass Controlled CirculationBalanced DraftTilting Tangential Firing


CUSTOMER Tata Electric Company, India

PARAMETERS AT

SHO/RHO

Steam flow

Pressure

Temperature

t/h 1614 / 1490

Kg/sq.Cm(g) 178 / 41.7

Deg.C 541 / 568

FUEL Oil / Gas Coal (Future)

DATE OF

COMMISSIONING

March 1990

SALIENT

FEATURES

Two Pass

Controlled Circulation With

Rifle Water Wall Tubes

Balanced Draft


Trombay TPS Unit 6 - 500 MWTrombay TPS Unit 6 - 500 MW


500 MW Oil & Gas fired Boiler - Typical Arrangement

Parameters at

SHO / RHO

Steam flow

Pressure

Temperature

t/h 1700 / 1455

Kg/Cm2(g) 178 / 37.4

C 540 / 540

Fuel Oil / Gas

Salient Features Close coupled

Controlled Circulation With

Rifle Water Wall Tubes

Pressurised Furnace


Once -thru Boiler-Furnace Wall

500 MW TALCHER NTPC

(Sub critical once-through)

IMPLICATIONS OF HIGHER STEAM PAREMTERS ON

BOILER DESIGN

BOILER TYPE

MATERIALS

RELIABILITY AND AVAILABILITY

PROPER SELECTION ENSURE SAFE - METAL TEMPERATURE

UNDER ALL - OPERATING CONDITIONS

PROPER SELECTION HELPS IN REDUCING THE INSTALLATION

COST.

NEED FOR PROPER MATERIAL SELECTION

AIRHEATERS

FANS

MILLS

ELECTROSTATIC PRECIPITATOR

SELECTION OF AUXILIARIES

AIRHEATER PERFORMANCE VARIATIONS

Fuel moisture

Airheater leakage

Airheater seals

Gas temperature leaving the airheater

MILL PERFORMANCE VARIATIONS

MILL OUTLET / INLET TEMPERTURE

FUEL QUALITY LIKE MOISTURE / HGI / HHV

FAN PERFORMANCE

LOADING OF FANS

POWER CONSUMPTION

ESP PERFORMANCE VARIATIONS

DUE TO AIR HEATER LEAKAGE

DUE TO HIGHER GAS TEMPERATURE LEAVING AIR HEATERS

MAJOR VARIABLES AFFECTING THE BOILER

PERFORMANCE

EFFECT OF BOILER PARAMETERS

FUEL ANALYSIS VARIATIONS

VARIATIONS IN AUXILIARY

EQUIPMENT PERFORMANCE VIZ .,

MILLS, AH,FANS

OPERATING VARIABLES AFFECTING SLAGGING

EXCESS AIR

DISTRIBUTION OF AIR

DISTRIBUTION OF COAL

FINENESS OF COAL

NUMBER OF OPERATING BURNER ELEVATIONS

FREQUENCY OF WALL BLOWER OPERATION

LOADING OF BLOWER

OPERATING CONDITIONS AFFECTING THE

PERFORMANCE

LOW PRESSURE OPERATION

HIGHER EXCESS AIR

HP HEATER NOT IN SERVICE

GRID FLUCTUATIONS

FUEL QUALITY AFFECTING THE PERFORMANCE

SLAGGING

FOT VARIATION

SH / RH SPRAY VARIATION

FLUE GAS TEMPERATURE LEAVING BOILER

MILL LOADING

AUX .POWER CONSUMPTION

BOILER EFFICIENCY

E2

E1

E3 E3

E4 E4

E5 E5

E6

E7 E7

R1

D

E

S

H

R2

R3

R4

S2

S1

S3S4

S5 S5

S6S17 S17S6

S8

S18

S7

S9 S11 S11 S9

S7

S18

S19

S12S20 S20

S14 S14S15 S15

S10

S16

S21

S22

S23

LOW TEMP SH

S24

S26

S27

S28 PLATEN SH

S29

S30

FINAL SHS32

S33

DRUM

S13

S31

S

2

5

RH SYSTEM

ECO SYSTEMSH SYSTEM

TYPICAL STEAM & WATER

CIRCUIT

TYPICAL SCHEME OF AIR & GAS DUCTS / CIRCUITS

COLD PA SYSTEM

Once Through Supercritical Steam Generators

NTPC/ BARH II STPP 2 x 660 MW

CoalFuel

568 / 596 oC Temperature

255/54.65 kg/cm2222 (g)Pressure

2120/1708.2 t/h.Steam Flow

31.03.2008Zero Date

U6/1700 & U6/1701Contract No.

Not in SG PackageDust Collector

2 Nos. SAF 42.5/26.6-1, Axial Reaction-TLTID Fan

2 Nos. PAF 19/10.6 2, Axial Reaction-TLTPA Fan

2 Nos. FAF 25/11.2 1, Axial Reaction-TLTFD Fan

PAH - 2 Nos. 28.5 VI 58 (70)MR,2NOS 31.5 VI 70 (82)MR ALSTOM SupplyAirheater

9 Nos. BowlMill, HP 1103Mill

Major Auxiliaries

Parameters at SHO / RHO

BARH II 2 x 660 MWProject

National Thermal Power CorporationCustomer

Heat Rate Improvement

Parameters at Turbine Inlet (bar/oC / oC) % Improvement In Station Heat Rate

170 / 538 / 538 Base

170 / 538 / 565 0.5%

170 / 565 / 565 1.3%

246 / 538 / 538 1.6%

246 / 538 / 565 2.1%

246 / 565 / 565 3.0%

246 / 565 / 598 3.6%

306 / 598 / 598 5.0%

Reduction in Coal consumption and CO2 emissions

Unit 500 MW

(Typical)

660 MW

(Typical)

800 MW

(Typical)

Cycle parameters bar/ 0C/ 0C 170/538/538 246/538/565 246/565/598

Approximate Heat rate

improvement% Base 2.1 3.6

Approximate Savings in

annual coal

consumption

tons Base 56000 96000

Approximate Reduction

in annual CO2emissions

tonsBase 61600 105600

Growth of unit sizes in India

Rating Year of Introduction

60/70MW 1965

110/120MW 1966

200/210MW 1972

250MW 1991

500MW 1979

660MW 2004

800 MW 2006

Steam generation process

Types of Circulation

2Critical Point

221 bar

S

T

1

2

3

4

SC Steam generatorBoiler Steam Pressure above the critical point

Simple Supercritical cycle

Pressure range

Sub critical : Below 221 bar

Super critical : 221 and above

3

CRITICAL CONDITION

Definition

CRITICAL is a thermodynamic expression describing the

state of a substance beyond which there is no clear

distinction between the liquid and gaseous phase.

The critical pressure & temperature for water are

Pressure = 225.5 kg / cm2 (g)

Temperature = 374.2 C

T S DIAGRAM

Entropy KJ / Kg K

T

e

m

p

e

r

a

t

u

r

e

(

0

C

)

-2730

240c

A

B C

D

E

Basic Rankine Cycle

F

OUTPUT INCREASE

0100

200

300

400

500

600

SUPER CRITICAL

BOILER CYCLE WITH

SH, RH & Regeneration

540C568C

ENTROPY

TEMP

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

VESSELE

V

A

P

O

R

A

T

O

R

E

V

A

P

O

R

A

T

O

R

ECO.

ECO.

(LOW LOAD &

CIRCULATION PUMP

START-UP)

F

E

E

D

F

E

E

D

CIRCULATION TYPE

ASSISTED

Circulation Systems

Drum Type Once-through

LOW LOAD SYSTEM WITH CIRC. PUMP

Thank YouThank YouThank YouThank You

power plant related topics

Documents

mw boiler order

cr turnover

usa unit capacities110

nebmalaysia pasirgudang

nebmalaysia prai tps

nebmalaysia tuanku jaafar

nebmalaysia sultan ismail

rankine cycle