BHEL Supercritical

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The key takeaways are about emerging requirements for utility units like high reliability, availability and efficiency. Supercritical parameters and once through boilers are also discussed.

The emerging market requirements for utility units discussed are high reliability & availability, highest achievable plant efficiency and heat rate, suitable for differing modes of operation and fuel quality, ability to operate under adverse conditions, minimum emission of pollutants and lowest life cycle cost.

The measures discussed to improve plant efficiency and heat rate are minimizing RH spray, SH spray, flue gas temperature at AH outlet, excess air at AH outlet, unburnt carbon loss and reduced auxiliary power consumption.

Bharat Heavy Electricals Limited, Tiruchirapalli

Supercritical Boiler and


Once through
Steam Generators
Design Aspects

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Contents
Emerging Market Requirements
Sub critical Vs Supercritical Boilers
Once Through Boilers Major systems
Features of 800 MW Once Through Boiler

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Emerging market requirements

HRDC 1st June 2009

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Fuels for Steam Power Plants


Coal & Lignite:

Abundant availability
Lower cost
Will continue as the main fuels in many countries

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Emerging market requirements for Utility


Units

High Reliability & Availability


Highest economically achievable plant efficiency and
heat rate

Suitable for differing modes of operation

Suitable for different quality of fuel


Ability to operate under adverse grid conditions / fluctuations
Minimum emission of Pollutants

Lowest life cycle cost

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Thermal Power Generation


Higher cycle efficiency for :

Conservation of fuel resources


Reduction of Atmospheric Pollutants - SOX & NOX
Reduction in CO2 emission (linked to global warming)

Better economy in power generation where fuel costs are


high and pollution control requirements are stringent

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Measures to improve Plant Efficiency


and / or Heat Rate
Boiler side measures :

Minimum RH spray

Minimum SH spray (if tapped off before feed heaters)


Minimum flue gas temperature at AH outlet

Minimum excess air at AH outlet


Minimum unburnt Carbon loss
Reduced auxiliary power consumption

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Parameters for increasing Cycle Efficiency in


PC-fired Units
Increasing main steam pressure

Increasing superheat and reheat temperatures


Adopting double reheat
Increasing the vacuum of condenser

Increasing final feed water temperature.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Current Trends in Steam Parameters


1980s : Pressure increased from 175-180 bar to 225
bar; temp mostly around 540 Deg.C
1990s : Pressures raised to 285 bar; Temp raised to
565 Deg.C

300 bar & 620 Deg.C not unusual today


255 bar 568/596 Deg C commonly used presently

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

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%

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli


Reduction in Coal consumption and CO2 emissions

Cycle parameters
Heat rate
improvement

Savings in annual
coal consumption
Reduction in annual
CO2 emissions

Unit

500 MW

660 MW

800 MW

Bar/0C/0C

170/538/538

246/538/565

246/565/598

Base

2.1

3.6

tons

Base

56000

96000

Base

61600

105600

tons

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

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

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Increase in unit sizes to match increase in Cycle


parameters
Unit
Size

Steam
Flow
(t/h.)

SHO
Pressure
(Kg/cm2)

SHO/RHO
Temperature
(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

660MW

2120

256

568/596

800MW

2592

256

568/596
HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Subcritical
Vs
Supercritical Boilers

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Steam generation process

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

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.
T
4

T1

p1

3
T2

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 p2
2-3 Heat reduction in condenser

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Rankine cycle with Superheater

HRDC 1st June 2009

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Methods of increasing Rankine Cycle


Efficiency

Raising supply temperature by super heating.


Increasing the inlet temperature will raise the heat
supply to the cycle more than the heat rejection.

Raising inlet pressure of steam :


Increasing the pressure will mean increase in
saturation temperature at which steam evaporates thus
increasing the average temperature (T1) of heat
addition.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli


(Contd..)

Dropping the final pressure (or temperature) at which heat is rejected.

Regenerative Heating : Heating the feed water pumped to Boiler by bleeding

steam from turbine.

Reheat Cycle : Reheating of steam in boiler after it has already expanded in


HP Turbine will avoid moisture formation in LP Turbine. Also, more heat
content of steam before IP Turbine, will improve efficiency.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Trends in Operating Pressures


Increased Operating Pressures are employed to
improve Thermal Power Plant Cycle Efficiency
Unit size increase has traditionally been associated
with pressure increase
Higher Unit Sizes (500 MW and above ) currently
employ pressure cycles around 170 ata and above

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Boiler Parameters
Raichur

Bellary

Ramagundam

210MW

500MW

500 MW

680

1625

1675

Steam flow at SHO

t/h

Steam pressure at SHO

kg/Sq.Cm(g) 155

178

178

Steam temperature at SHO

Deg.C

540

540

540

Reheat steam flow

t/hr.

597.2

1389.76

1387.2

Steam temperature at RHO Deg.C

540

540

540

Feed water temperature

247.5

254.6

253.7

Deg.C

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Boiler Water Circulating Systems


Choice of Circulating system depends on Operating Pressure
The density difference between water and steam provides the
driving force for the Circulating fluid

Higher pressures units warrant pumps to ensure circulation


(Natural circulation not adequate)

HRDC 1st June 2009

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Types of Circulation

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Natural Circulation

Controlled Circulation

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Types of boilers
Drum type

Once-through type

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Drum type boiler

Steam generation takes place in furnace water walls

Fixed evaporation end point - the drum


Steam -water separation takes place in the drum
Separated water mixed with incoming feed water

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Drum type boiler

Natural Circulation Boiler


Circulation thru water walls by
thermo-siphon effect

Controlled Circulation Boiler

At higher operating pressures


just below critical pressure levels,
thermo-siphon effect supplemented

by pumps

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

210 MW Boiler Typical Arrangement

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

500 MW Boiler Typical Arrangement

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Bharat Heavy Electricals Limited, Tiruchirapalli

500 MW Arrangement Of Circulating System

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Comparison Of 210 & 500 MW Boilers


210 MW

500MW

Furnace

Double arch

Single arch

Upper furnace

Open

Panellete

Type of circulation

Natural

Controlled

Water wall tubing

Plain tubes

Rifled

(63.5mm)

tubes(51mm)

2 Trisector

2 Trisector (or)

Air heaters

4 Bisector

Mill arrangement

Front or Rear

Both sides or
Rear
HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Multiple-lead Rifled Tube

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Bharat Heavy Electricals Limited, Tiruchirapalli

QUEST FOR EFFICIENCY IMPROVEMENT

Since the time thermal power stations have been


engineered, there is a quest for efficiency improvement.

And supercritical parameters (Pressure above 225Kg/cm2

and temperature above 374.15 C) is an effort in that


direction.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

SC Steam generator
Boiler Steam Pressure
above the critical point

T
Critical Point
221 bar

Temperature

1-2 Pumping Process


2-3 Heat addition Rad.
Heating in the Boiler

3-4 Expansion process in


Turbine
4

4-1 Heat reduction in


Condenser

S
Entropy

Simple Supercritical cycle


HRDC

1st

June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Why Supercritical Pressure

The purpose of having high inlet steam pressure for turbine has
already been discussed in this presentation.

A Boiler operating at a pressure above critical point is called


SUPERCRITICAL BOILER

A point where boiling water and dry saturated lines meet so that
associated latent heat is zero, this point is called Critical Point.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Pressure range

Sub critical

: Below 221 bar

Super critical

: 221 and above

HRDC

1st

June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

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 = 225.56 Kg / cm2

Temperature = 374.15 C

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once Through Boiler-Concept

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

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

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

SUPERCRITICAL BOILER

Supercritical pressure boiler has no drum and heat absorbing surface being,
in effect, one continuous tube, hence called once through Supercritical

pressure boilers.

The water in boiler is pressurized by Boiler Feed Pump, sensible heat is added
in feed heaters, economizer and furnace tubes, until water attains saturation
temperature and flashes instantaneously to dry saturated steam and super
heating commences.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Circulation Systems
STEAM TO TURBINE

STEAM TO TURBINE

SH

SH

DRUM

EVAPORATOR

ECO.

EVAPORATOR

SEPERATING
VESSEL

ASSISTED
CIRCULATION TYPE

Drum Type

FEED

FEED

ECO.
CIRCULATION PUMP
(LOW LOAD &
START-UP)

Once-through
HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once Through Boiler

Once -through flow through all sections of boiler


(economiser, water walls & superheater)

Feed pump provides the driving head

Suitable for sub critical & super critical pressures

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Operating Pressure Range

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once-thru Boiler
Major differences from Drum type boiler :
Evaporator system
Low load circulation system
Separator

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Bharat Heavy Electricals Limited, Tiruchirapalli

Evaporator system

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once -thru Boiler

Evaporator system :
Formed by a number of parallel tubes
Tubes spirally wound around the furnace to reduce number of
tubes and to increase the mass flow rate thru the tubes
Small tube diameter
Arrangement ensures high mass velocity thru the tubes

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Spiral Tube Arrangement


Features

Reduced number of
tubes with pitch.
Increased mass flow.
Mass flow rate can be
selected by number of
tubes.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once -thru Boiler - Furnace Wall

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Furnace Wall Designs

Spiral Wall Configuration

Vertical Wall Configuration


HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Spiral Furnace
Windbox Panel

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Vertical Furnace Wall Design


Vertical tube furnace walls will provide all the
operational benefits of the currently popular spiral
design while significantly reducing the cost

and

construction time for the furnace and providing some


reduction in pressure drop.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Vertical Wall Windbox

Only a Few Bends at the


Top and Bottom

Straight Tubes

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Spiral Walls
Furnace walls are not self supporting because the tubes are

inclined.
External support strap system is needed

Fabrication and installation are more difficult.


Above aspects tend to increase the cost.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Spiral vs. Vertical Wall Comparison

Spiral Furnace System Applicable for


all size units

Benefits from averaging of lateral heat


absorption variation (each tube forms a
part of each furnace wall)
Simplified inlet header arrangement
Large number of operating units

Use of smooth bore tubing


throughout entire furnace wall
system
One material utilized throughout entire
waterwall system
No individual tube orifices Less
maintenance & pluggage potential

Vertical Furnace Wall System Limited


to larger capacity units (>600 MW
depending on fuel)

Less complicated windbox openings

Traditional furnace water wall support


system

Elimination of intermediate furnace wall


transition header

Less welding in the lower furnace wall


system
Easier to identify and repair tubes leaks

Lower water wall system pressure


drop thereby reducing required feed
pump power

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Vertical Wall Design - Advantages


The tubes are self supporting.

Transition

headers

at

spiral/vertical

interface

are

avoided.
Ash hopper tubing geometry simplified
Corners are easier to form
Reduced pressure drop, auxiliary power

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Start-up and Low load system

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once -thru Boiler

Low load circulation system :

At part loads once -thru flow not adequate to cool the tubes

To maintain required mass velocities boiler operates on circulating


mode at low loads

Excess flow supplied by feed pump or a dedicated circulating pump

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

ONCE - THROUGH OPERATING RANGE

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

LOW LOAD SYSTEM WITH CIRC. PUMP

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Bharat Heavy Electricals Limited, Tiruchirapalli

Once - thru Boiler


Low load circulation system :
The excess flow over the once-thru flow separated in
separator and

Returned to the condenser thru a heat


exchanger
or
Recirculated back to the boiler directly by
the dedicated circulating pump

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once -thru Boiler


Separator :

Separates steam and water during the circulating


mode operation

Runs dry during once-thru flow mode


Smaller in size compared to drum in a drum type
boiler

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once -thru Boiler


Advantages:
Better suited for sliding pressure operation
Steam temperature can be maintained over wider load range
under sliding pressure

Quick response to load changes


Shorter start up time
Higher tolerance to varying coal quality
Suitable for sub critical & super critical pressures

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Sliding Pressure Supercritical Operation


Pressure operation mode at boiler outlet
4350

1
psig)

3625

2900

2
2175

1450

725

1. Constant Pressure Operation


2. Modified Sliding Pressure Operation
3. Pure Sliding Pressure Operation

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Once -thru Boiler


Requirements :

Stringent water quality

Sophisticated control system

Low load circulation system

Special design to support the spiral furnace wall weight

High pressure drop in pressure parts

Higher design pressure for components from feed pump to


separator

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Super Critical (Once thru) boiler enables :

Peak power generation with better TG

Quicker response to TG load changes

Better heat rate of lower loads

efficiency levels

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Typical General Arrangement of Once Through


Steam Generator

Separators
Collecting
vessel

LTRH

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Indian Coal fired 800 MW


Steam Generator

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

800 MW Boiler Parameters


Flow, t/h

Pressure,
kg/cm2(g)

Temp. 0C

Main Steam

2585

255

568

Reheat steam

2061

59.53

596

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Fuel Analysis
Proximate Analysis
Design Coal
Total Moisture

12

Ash

32 (Max.38)

Volatile Matter

24

Fixed Carbon

32

HHV

kcal/kg

4100

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Features of Boiler
Pulverised coal fired
Once through, evaporator suitable for

variable pressure operation


Single reheat

Tilting Tangential firing System


Dry Bottom
Balanced draft furnace
Side mill layout

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Features of 800 MW OT Boiler (Contd.)


Dry Bottom
Balanced draft furnace
High performance Bowl Mills
Two Nos. of Axial FD Fans
Two Nos. of Axial PA Fans
Two Nos. of Axial ID Fans

ESP to meet outlet concentration

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Side View of Boiler Arrangement

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Bharat Heavy Electricals Limited, Tiruchirapalli

Plan View of Boiler Arrangement

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Spiral Tube Arrangement


Features

Reduced number of
tubes with pitch.
Increased mass
flow.
Mass flow rate can
be selected by
number of tubes.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Spiral Water wall Tubing

Lateral Heat Flux Profile

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Transition Area

Vertical Wall Tubes

Vertical Tube
Forgings

Spiral Wall Tubes


Spiral Tube Forgings

35 mm Vertical Tube Forgings

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Sliding Pressure Supercritical Design


Spiral to Vertical Transition Area - Load Transfer

Support
Fingers

SPIRAL WALL SUPPORT


HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Sliding Pressure Supercritical Design

Spiral Wall
Windbox
HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Supercritical Boiler with Vertical wall


Unit Mwe:

750

Max. Continuous Rating: 5,560,000 lb/hr (2522 t/hr)


SH Outlet Press: 3800 psig (262 bar)
SH Outlet Temp: 1054F (568C)
RH Outlet Temp: 1105F (596 C)
Fuel: Sub-bituminous (PRB)

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

FRONT WALL
RIFLED TUBING

SIDE WALL
RIFLED TUBING

Vertical Wall Sliding


Pressure Supercritical Design
SCREEN TUBES
SMOOTH TUBING
HANGER TUBES
SMOOTH TUBING
ARCH
RIFLED TUBING

1 1/4 (31.8 mm)O.D. Tubing

1 1/8 (28.5 mm)O.D. Tubing


SIDE WALL
RIFLED TUBING

REAR WALL
RIFLED TUBING
FRONT WALL
RIFLED TUBING

SMOOTH TUBING
FROM THIS ELEVATION
ALL WALLS

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Boiler Pressure Part Materials


Tubing Oxidation Temperature Limits
MATERIAL

ASME ALLOY

OXIDATION LIMIT

Carbon Steel

SA-178C/ D

454C (850F)

Carbon-1/2 Mo

SA-209 T-1A

482C (900F)

1 Cr-1/2 Mo

SA-213 T-12

552C (1025F)

2-1/4 Cr-1 Mo

SA-213 T-22

593C (1100F)

2-1/4 Cr-1.6W-V-Cb

SA-213 T-23

593C (1100F)

9 Cr-1 Mo-V

SA-213 T91

649C (1200F)

9 Cr-2W

SA-213 T92

649C (1200F)

18 Cr-8 Ni

SA-213 TP304H

760C (1400F)

18 Cr-10 Ni-Cb

SA-213 TP347H

760C (1400F)

18 Cr-9 Ni-3Cu-Cb-N

SA-213 Super304H

760C (1400F)

25 Cr-20 Ni-Cb-N

SA-213 HR3C

760C (1400F)

SA-210 A-1/ C

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Materials used in various pressure parts of


conventional boilers
Area of application

Material

ASME specification
Tubes

Pipes

Drum

Carbon steel / Low


alloy steel

SA 299

Water walls,
Economizer

Carbon Steel

SA192
SA210 Gr.A1
SA210 Gr.C

SA106 Gr.B
SA106 Gr.C

SH and RH

1 Cr Mo

SA213 T11

SA335 P11

2 Cr 1 Mo

SA213 T22

SA335 P22

9 Cr 1 Mo V

SA213 T91

SA335 P91

18 Cr 8 Ni

SA213 TP304 H

18 Cr 10 Ni Cb

SA213 TP347 H

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

New materials for high temperature

A. Evaporators
T12
T23 and T24 : For 600 oC (SHO) /620 oC (RHO)

B. Superheaters and Reheaters


T91 : for 550 oC (SHO)/570 oC (RHO).
P91 : Upto 270 bar and 580 oC (SHO)
P92 : Upto 290 bar and 600 oC (SHO)
Austenitic steels Super 304H/TP347 HFG :

For

temperature 600oC (SHO)/620oC (RHO)


HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Materials in typical 800MW

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Boiler Equipment Upgrades


500 MW DRUM TYPE

ELIMINATE
DIVISION PANELS
FLAT-BOTTOM
PENDANT
SECTIONS
SINGLE FIREBALL
FOR LARGE
CAPACITY UNITS
SQUARE-UP
FURNACE
50 HOPPER
SLOPE

800 MW Once Thru Supercritical


INCORPORATE ONCE-THRU
CIRCULATION SYSTEM, INCLUDING
VERTICAL SEPARATOR
REVERSE SLOPE
OF CONVECTIVE
PASS FLOOR
SMOOTH WATERWALL TUBE IN
SPIRAL CONFIGURATION OR
RIFLED WATERWALL TUBE IN
VERTICAL CONFIGURATION
WINDBOX TILT DRIVE
SYSTEM UPGRADE

TWO (2) REGENERATIVE


TRI-SECTOR AIRHEATERS IN LIEU OF
FOUR (4) BISECTOR
AIR-HEATERS

REPLACE RP MILLS
WITH HP MILLS

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Summary
CE/Sulzer (later ALSTOM) mono tube technology
Sliding pressure in water walls over load range (rifled tubing
affording water wall protection).

Conventional vertical water wall construction


Simplified startup system

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

HRDC 1st June 2009

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