supercritical technology.pdf
TRANSCRIPT
Enhancing Capacity – Empowering Nation
CII EPC POWER MEET 2009 Supercritical Technology
Presentation on Supercritical Technology
Presentation By
R.Kumar
General Manager
BPP & PM (FB)
BHEL, Tiruchirappalli, India
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CII EPC POWER MEET 2009 Supercritical Technology
India’s installed capacity 1,44,922 MW
BHEL-built sets account for 91,481 MW
(64 % of India’s installed capacity)
PLF
National average 77.0 %
BHEL Thermal Sets 80.1 %
BHEL’s 200/210/250/500 MW Set 82.2 %
BHEL’s CONTRIBUTION TO POWER SECTOR (As on 31.03.2010)
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GENERATION ~ 662,000 MUs
2009-10
OTHERS
26.0%
BHEL
74.0%
INSTALLED CAPACITY - Utility
~ 1,44,922 MW (31.03.10)
OTHERS
36%
BHEL
64%
Over 1,00,000 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
BHEL’s Contribution to Indian Power Sector
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Source: CEA
Capacity Addition : XI Plan (2007 – 12)
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Category Capacity in MW
Thermal (incl. Gas) 70,000
Nuclear 5,000 - 6,000
Hydro 20,000
Total 95,000 - 96,000
XII Plan (2012-17) : Total (Tentative) Capacity Addition
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CAPACITY ADDITION PROGRAMME IN
Xth, XIth, XIIth & XIIIth FIVE YEAR NATIONAL PLAN
TYPE
THERMAL
10 th PLAN
(2002-2007)
(Actual
11 th PLAN
(2007-2012)
(Planned)
12 th PLAN
(2012-2017)
(Tentative)***
13 th PLAN
(2017-2022)
(Tentative)***
MW MW MW MW
SUB-CRITICAL (Upto 600
MW)
12114 48230 20650 NIL
SUPER CRITICAL
(660 & 800 MW)
---- 5940 42280 64100
THERE IS A CLEAR SHIFT IN THE PLANNED UNITS FROM SUB-CRITICAL TOSUPER-CRITICAL UNITS.
AS PER CEA, 13th PLAN ONWARDS ALL THERMAL SETS SHALL BESUPERCRITICAL SETS ONLY
*** Based on Sites/Rating identified by Central Electricity Authority, Govt Of India. This may undergo changes keeping in view the commissioning schedule/coal linkages etc.
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CII EPC POWER MEET 2009 Supercritical Technology
Use Of Super Critical Technology
• Supercritical Technology is widely established and accepted with more than 500units in operation.
• Widely prevalent cycle parameters (At turbine end):
– Pressure: 246 -250 kg/cm2
– Temperature: 537/566 deg C (In 660MW Sipat & Barh TPS)
565/593 deg C (In 660 MW Barh-II and
2 X 800MW Krishnapattnam)
593/593 or 600/600 deg C
(Ultra Supercritical parameters-Yet to be adopted in ourcountry)
• Parameters adopted for 800MW are 247kg/cm2 /565/593 deg C.
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CII EPC POWER MEET 2009 Supercritical Technology
Supercritical Technology – Indian scenario
• Supercritical technology being adopted to enhance efficiency, reduce coal
consumption and GHG emission
• 660/ 800 MW units planned in big way.
• Parameters adopted 247kg/ cm2/ 565/ 593 deg C
• 5 units of 660 MW under execution at Sipat and Barh II
• Ultra Mega Projects, 4000 MW each, envisaged with supercritical units.
• 4 projects already awarded to IPPs through tariff based competitive
bidding.
• Many more supercritical units in pipeline.
• Introduction of supercritical units would improve the efficiency in power
generation.
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CII EPC POWER MEET 2009 Supercritical Technology
SUPERCRITICAL BUSINESS IN INDIA
STORY SO FAR
SL.
No
PROJECT NAME ORDER FOR BTG
PACKAGE
PLACED ON
REMARKS
1 3X660 MW SIPAT-NTPC SG: Doosan ESP Package by BHEL
2 3X660 MW BARH STAGE I
NTPC
SG :
Technoprom
ESP Package by BHEL
3 3X660 MW MUNDRA
(TIRORA) ADANI
EPC Contract
awarded to SEPCO
4 Sasan,Mundra,Krishnapatn
am,Tilaya 4000MW each
Mundra-Tatas
Others-Reliance
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Order for 2X660 MW Barh Stage –II (SG Package) received from NTPC in 2008
against ICB (single bidder)
Order for 2X800 MW Krishnapatnam STPS (SG Package) received from
APPDCL in July 08
Order for 3X660 MW Bara (SG+TG Package) received from Jaypee Group in
2009
Order for 2X800 MW Yeramarus received from KPCL in April 2010
MAJOR SUCCESS FOR BHEL IN THE AREAS OF
SUPERCRITICAL SETS
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Emerging market requirements for Utility Units
• Highest economically achievable plant Efficiency and Lowest
Heat Rate
• High Reliability & Availability
• Suitable for differing modes of operation
• Suitable for different quality of fuel(Especially High Ash,Low grade
Indian Coals)
• Ability to operate under adverse grid conditions / fluctuations
• Minimum emission of Pollutants
• Lowest life cycle cost
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Benefits of supercritical technology
• Reduced fuel costs due to improved overall plant efficiency.
• Reduced CO2 emission rate.
• Reduced sulphur oxides and particulates.
• Better suited for sliding pressure operation. Better load change
rates are possible due to less temperature variation at turbine
inlet and absence of thick walled drum.
• Better suited for varying coal quality as there is no fixed
evaporation end point.
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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.
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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
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Evolution of Steam Power Stations Efficiency Worldwide
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Trend in unit sizes in India & 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 MW179179
540/540 540/568
19791985
600 MW179179
540/540 540/568
2008
660 MW 256 568/596 2008
800 MW 256 568/596 2008
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Parameters at Turbine Inlet(kg/cm2 / o C/ o C)
Increase in efficiency (% points)
170 / 537 / 537 Base (500MW)
247 / 537 / 537 0.69%
247 / 537 / 565 0.96%
247 / 565 / 565 1.31%
247 / 565 / 593 1.64%
247 / 600 / 600 1.96%
Improvement in cycle efficiency with higher steam parameters
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Savings in coal consumed: 0.63 x 106 Tons/Year Reduction of CO2 emissions: 0.93 x 106 Tons/YearAt 80% PLF & HHV of 4000 kcal/kg
Station
Capacity (MW)
Units(No.x MW)
MS
Pressure (kg/cm2)
MS/RH
Temp 0C
Efficiency
(%)
Coal
Consumption (MMT/Yr)
CO2
Emissions (MMT/Yr)
4000 8x500 170 537/537 38.6 15.61 22.90
4000 5x800 247 565/593 40.24 14.98 21.97
Environmental Benefits
Source : CEA
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Principal equipment in Thermal Power Plant
TURBINE
B
O
I
L
E
R CONDENSER
CE PUMP
DEAERATOR
BFP
ONCE THROUGH BOILER
boils the water to steam
upto 565 Deg C
Temperature
TURBINE
produce
power
GENERATOR
produce electricity
CONDENSER
Condenses the
steam to water
CEP
Increases the
pressure of
water
LP HEATERS
Heat the waterHP HEATERS
Heat the water
BFP
Increases the
pressure of
water
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Types of boilers
Drum type
Once-through type
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500 MW Boiler – Typical Arrangement
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Separators
Collecting
vessel
High Efficiency Supercritical Technology
for Clean power
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Increased mass flow
through spiral waterwall
tubing, or improved heat
transfer through rifled
vertical wall tubing.
No fixed evaporator end
point
No thick wall components
Features
Once Through Boiler Flow Diagram
Evaporator
Water separator
Feedwater
Economizer
FW-
Pump
Live steam
Superheater
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Supercritical Boilers
Supercritical pressure boiler has no drum and heat absorbing
surface being, in effect, one continuous tube, in which the water &
steam generated in the furnace water walls passes through only
once 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.
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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
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STEAM TO TURBINESTEAM TO TURBINE
SHSH
DRUM
SEPERATING
VESSEL
EVAPO
RATO
R
EVAPO
RATO
R
ECO.
ECO.
(LOW LOAD &
CIRCULATION PUMP
START-UP)
FEED
FEED
CIRCULATION TYPE
ASSISTED
Circulation Systems
Drum Type Once-through
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Features of Once Through Steam Generator
To ensure adequate mass flow rates through water wall, spirally
wound water wall tubes are used.
Start-up and low load system up to 30-40% BMCR required.
Feed water quality requirements are very stringent.
Can be designed for both sub-critical and super-critical
pressures.
Ideally suited for sliding pressure operation due to the absence
of thick walled components.
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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
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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.
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CII EPC POWER MEET 2009 Supercritical Technology
Design Features of 660 / 800 MW
Supercritical Turbines & Boilers for
Indian Coal Fired Power Stations
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CII EPC POWER MEET 2009 Supercritical Technology
Technology tie-ups for SuperCritical:
A) SuperCritical Boilers
Technical Collaboration Agreement (TCA) valid for 15 years,
for complete range of Once – Through, Super-Critical Boilers
established with ALSTOM in Oct. 2005.
- TCA Covers 2-pass & Single pass tower type design
- Boiler TCA includes higher capacity mills (HP 1103 – HP 1303)
B) Collaboration for other Auxiliaries tied up
C)Turbines- Existing Technical Collaboration Agreement with Siemens
recently extended further
BHEL: Solution for Power Equipment
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Comparison of Parameters
PARAMETER UNIT 500 MW 800 MW
Main Steam Pressure ATA 170 247
Main Steam Temp OC 537 565
Main Steam Flow T/Hr 1,515 2,340
Reheat Pressure ATA 41 56.6
Reheat Temperature OC 537 593
Reheat Flow T/Hr 1,335 1,940
Cold Reheat Pressure ATA 45 61.5
Cold Reheat Temp OC 336 348
Final FW Temp OC 253 290
BMCR T/Hr 1,625 2,600
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Power Cycle Equipment
EQUIPMENT 500 MW SUB CRITICAL 800 MW SUPER CRITICAL
BOILER Drum Type Once Through Type
TURBINE 1HP + 1IP + 1LP 1HP + 1IP+ 2LP
CONDENSER One Two
GENERATOR 588 MVA 950 MVA
LP HEATERS 3 Nos 4 Nos
HP HEATERS TWO ( 2X50% EACH) THREE ( 2X50% EACH)
DEAERATOR ONE ONE
CONDENSATE EXTN. PUMPS 3 x 50% 3 x 50%
BOILER FEED PUMPS 2 x 50%(TD) / 1 x 50% (MD) 2 x 50 % (TD) / 1 x 35 %MD
VACUUM PUMPS 2x100%2 x 100%
(For Each Condenser)
CONDENSATE POLISHING
UNIT2 x 50% 3 x 50%
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Boiler Parameters
BMCRBMCRBMCR-Boiler Parameters
162521002585t/hSH steam flow
oC
oC
kg/cm2(a)
Unit
254291294Feed water temp.
540/540568/596568/596SHO/RHO temp.
179256256SHO pressure
500 MW660 MW800 MWDescription
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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
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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 reqd. outlet concentration
Features of Boiler (Contd.)
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A. Evaporators
• T12
• T23 and T24 : For 600oC (SHO) /620oC (RHO)
B. Superheaters and Reheaters
• T91 : for 550oC (SHO)/570oC (RHO).
• P91 : Upto 270 bar and 580oC (SHO)
• P92 : Upto 290 bar and 600oC (SHO)
• Austenitic steels Super 304H/TP347HFG: For temperature
600oC (SHO)/620oC (RHO)
New materials for high temperature
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Capacity Building
Capability Building
Handling New materials
Development of more Vendors
Balance of Plant
Logistics
KEY CHALLENGES
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Experienced Erection and Construction Personnel
Experienced Commissioning Personnel
Project Management Capability
Availability of Skilled Man power (High Pressure Welder)
Coal Linkages
Land Availability
KEY CHALLENGES – Contd..
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Unique experience of having designed and installed more than 300 coal
fired utility Steam Generators ranging from 60 MW to 500 MW including
35sets of 500MW and 175 sets of 210-250 MW (as on March 2009)
firing Low Calorific value/High Ash/Erosive nature Indian coals.
Boiler design is continuously updated by BHEL incorporating the state
of art improvements and feedbacks gained from operating units and its
R&D initiatives.
660/800MW designs of BHEL/ALSTOM offered to utilities is based on the
above rich experience and the Collaborator Alstom support
BHEL Operating Experience with Indian Coals
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SUMMARY
660/800 MW units offer better cycle efficiency
Proven technologies leading to lower GHG emissions and
lesser fuel burnt
BHEL has the technology for offering 660/800 MW
supercritical units
BHEL is executing NTPC BARH 2x660MW Stage-II , APPDCL
Krishnapatnam 2x800MW ,BARA 3x660MW from jaypee
group and recently contracted Yermarus 2x800MW from
KPCL
BHEL has geared up to meet the huge capacity addition in
the country and offer better economics to Indian Power
Utilities
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