BOILER AND AUXILIARIES

KORBA SIMULATOR

19

KORBA SIMULATOR

20

BOILER AND AUXILIARIES SALIENT FEATURES OF 500 MW BOILER. With increase in demand of power in India, new power projects are being constructed with higher capacity and advanced technology for the better economy and reliability of operation. Compared to other lower capacity Boilers supplied by BHEL, these 500 MW capacity boiler have incorporated certain special technical features which are detailed here under: CONTROLLED CIRCULATION SYSTEM This is achieved by three numbers of glandless pump and wet motor installed in the downcomer line after the suction manifold. These pump motor assemblies have single suction and double discharge introduction of these pumps in the boiler system have led to the designing of a furnace with lesser diameter tubes and high parameters operating characteristics. The advantages of the controlled circulation boiler over natural circulation boiler are given below: Uniform drum cooling and heating. In controlled circulation boilers this is possible because of arrangement of relief tubes inlets to the drum and the internal baffles of the drum from both sides. The internal base plates are arranged in such a way that it guides the steam water mixture from the relief tubes along the whole circumference of the drum. The drum is therefore uniformly heated and cooled.

Whereas in Natural Circulation Boiler, the arrangement of relief tubes and baffle plates is only on one side of the drum and this imposes a constraint on uniform heating of drum. Similar arrangement of relief as in controlled circulation boiler does not exist in natural circulation (NC) boiler because in that case the relief required to be taken over the drum and fed from both sides. This shall increase the pressure losses in the riser tubes and also the hot static head requirement for start up. Since the available head in NC Boiler is very less; efforts are always made to reduce the pressure loss and improve the circulation. Second reason is to commence flow in the riser tubes immediately after light up hot static head is kept as minimum as possible. Rapid heating & cooling (start up & shut down): As mentioned in Para 1, the controlled circulation boiler does not impose any thermal constraints on the drum and hence rapid cooling and heating of the boiler is possible. In NC boiler, rise in saturation temperatures is limited to maximum of 110OC/hr. Hence, the controlled circulation boiler can be started at a rate two to three times faster than NC boilers.

KORBA SIMULATOR

21

Better cleaning of boiler: For effective acid washing, the acid has to be kept at certain temperature uniformly through the system. This is possible with the assistance of controlled circulation. Uniform expansion of pressure part and lower metal temperature: This means lesser thermal stresses on the tubes. Because of controlled circulation, lower diameter tubes are used, which result in high mass flow rate thereby preventing departure from nucleate boiling (DNB) maintains a lower metal temperature.

USE OF RIFLE TUBES FOR FURNACE CONSTRUCTION This is one of the extraordinary features of 500 MW capacity boilers. Because of the excessive heat release in the burner zone of the furnace, the metal tubes constituting the furnace at that zone are exposed to the maximum temperature. This being a water-cooled furnace, the steam water mixture inside the tubes should effectively carry the heat from the burner zone of the furnace. In this zone, the tubes have an internally cut spiral like a rifle bore so that when water flows through the tubes, due to hot static heat, it takes a screwed path and attains a certain degree of spin by which the watness of the tube is always maintained. This prevents the tubes form departure from Nucleate boiling under all operating condition of the boiler and increases the circulation ratio. OVER FIRE AIR SYSTEM FOR NOX (OXIDES OF NITROGEN) CONTROL Industrial growth in the recent years has necessitated the need to have a cleaner and pollution free atmosphere, by controlling the production of industrial wastes with the application of improved technology. Power plants are the major sources of the industrial pollution by virture of the stanch emission in the atmosphere. These emissions contain mostly gases and dust particles, which have ill effect on the ecological system. In the 500 MW capacity boiler design, this aspect has been given due importance and certain technical improvements have been incorporated. These are tilting tangential firing and over fire air system. Tangential firing helps in keeping the temperature of the furnace low so that NOX emission is reduced considerably. In addition to the above the over fire air is provided which is used as combustion process adjustment technically for keeping the furnace temperature low and thereby low Nox formation. Each corner of the burner windbox is provided with two numbers of separate over fire air compartments, kept one above the other and the over fire air is admitted tangentially into the furnace.

KORBA SIMULATOR

22

The over fire air nozzles has got tilting arrangement and compartment flow control dampers for working in unison with the tilting tangential type burner system for effective control of Nox formation. AIR PRE-HEATER SYSTEM As compared to trisector air pre-heater in 200 MW units, 500 MW units have been incorporated with bisector air pre-heaters. This has been done for optimum utilisation of space and also improved system layout. This has resulted in the flexibility and efficient operation and maintenance of the air pre-heaters and the boiler as a whole. PRIMARY AIR SYSTEM The primary air system delivers air to the mills for coal drying and transportation of coal powder to furnace. The 500 MW units have two stage axial flow primary fans as compared to radial fans in 200 MW units. By introducing axial flow fans, the system efficiency has gone up as the axial flow fans consistently high efficiency at all operating loads. MILLING SYSTEM In the 500 MW units at SSTPS, Raymonds Pressurised bowl mills have been installed. These are similar to the 200 MW mills except that 500 MW mills have vane wheel surrounding the bowl and external lubrication unit. Introduction of vane wheel has led to uniform distribution of primary air within the mill and less rejects. These mills are also supplied with weld overlay technology, which has increased the minimum wear life of grinding parts to 6000 hrs. I. D. FANS Unlike 200 MW units, the 500 MW units have been supplied with radial type I.D. fans. These fans have a lower speed and are less susceptible to wear and tear due to the abrasive flue gases. The control of the I.D. fans is achieved through a variable speed hydraulic coupling and motorised inlet damper. By introducing variable speed control through a hydraulic coupling the losses in the fan at various load has been minimised and efficiency of the fan has remained high at all operating conditions. ELECTROSTATIC PRECIPITATORS: Electro static precipitators are installed in the 500 MW units for minimising the particulate emission from the stack flue gases. There are four ESP passes for one unit of 500 MW and each is independently operated. The emitting electrodes are changed at high-ve voltage DC and the gas while crossing this charged path gets jonised. The ionised ash particles of the gas are attracted towards the collecting electrode, which is maintained at high +ve voltage. The ash collects at the collecting electrode and is periodically tapped to dislodge the accumulated ash. The ash falls into the hopper, which is evacuated by the ash handling system and taken out as slurry.

KORBA SIMULATOR

23

TECHNICAL SPECIFICATION OF 500 MW BOILER

Circulation plus. : Tilting Tangential Minimum load at which the steam generator : 2 Mills at 50%

Minimum load at which the steam generator can be operated continuosly with complete flame.
Stability with oil support (% MCR) Maximum load for which individual

: 20%

mill : 50%

beyond which no oil support is required FURNACE SPECIFICATION Wall Bottom Tube arrangement Explosion/Implosion withstand capacity (MWG) at 67% yields point. Residence time for fuel particles in the furnace. Effective volume used to calculate the : 14770 residence time (M3) Height from furnace bottom ash hopper to furnace roof (M) Depth (M) Width (M) Furnace projected area (M2) : : : 15.289 18.049 7610 : 63.65 : 3 second : : : : Water Steam cooled Dry Membrane + 660

KORBA SIMULATOR

24

Furnace volume (M3) WATER WALLS FRONT WALLS Number OD (MM) Design thickness (MM) Pitch (MM) Actual thickness used (MM) Material Total projected surface (M2) Method of joining long tube Total wt. of tubes (kgs) Design pr. of tubes Kg/cm2 (ABS) Max. pressure of tubes Kg/cm2 (ABS) Design metal temp OC SIDEWALLS, REAR WALLS Side walls & ROOF Number OD (MM) Design thickness (MM) Pitch (MM) Actual thickness used Total projected surface area of tubes (M2) Method of joining long tubes. BUTT WELD Total wt. of tubes (Kgs) Design Pr. of tubes Kgs/cm2 (ABS) Max pr. of tubes Kgs/cm2 (ABS) Design metal Temp o C 417 193.3 277000 207.3 444 51 5.19 63.5 5.6 1430

14770

: : : : : : : : : : : :

283 51.00 5.19 63.5 5.6 SA 210C 1160 Butt weld 181000 207.3 197.3 416 Roof 142 57 5.54 127 5.7 220

Rear walls 283 51 5.19 63.5 5.6 930

BUTT WELD 186000 207.3

BUTT WELD 45000 204.9

197.3

192.3

417

416

KORBA SIMULATOR

25

WATER WALL HEADERS No. of headers Outside Dia (Dia (MM) Design thickness (MM) Actual thickness (MM) Total wt. of headers (Kgs.) Design pressure of headers kg/cm2 (ABS) HEADERS Max working pressure of headers Kg/cm2 (ABS) Material specification DRUM Material specification Design pressure Kg/cm2 (ABS) Design metal temp OC Max operating pressure Kg/cm2 (ABS) Actual thickness used for dished ends Overall length of Drum (MM) OD of Drum (MM) Internal dia (MM) Corrosion allowance (MM) Number of distribution headers No. of Cyclone separator No. Of Secondary driers Shroud material Max permissible temp differential between any two parts of the drum (oC).

Lower drum 1 914 86 89 166000 207.3 Lower drum 197.3

WW outlet 5 273 38.5 45 37300 204.9 WW outlet 192.4

SA-299 : : : : : : : : : : : : : :

SA-106 Gr-B SA-299 204.9 366 192.4 152.4 22070 2130 1778 0.75 6 96 96 Carbon Steel 50

Water capacity at MCR conditions (in seconds) between : normal and lowest water level permitted (up to LL trip) Drum wt. with internals (tonnes) Drum wt. without internals (tonnes) : :

10

237.00 215.00

KORBA SIMULATOR

26