BHEL Supercritical

Bharat Heavy Electricals Limited, Tiruchirapalli
Supercritical Boiler and

Once through
Steam Generators
Design Aspects
HRDC 1st June 2009
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
Emerging market requirements
HRDC 1st June 2009
Fuels for Steam Power Plants

Coal & Lignite:
Abundant availability
Lower cost
Will continue as the main fuels in many countries
HRDC 1st June 2009
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
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
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
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
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
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

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
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
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
Subcritical
Vs
Supercritical Boilers
HRDC 1st June 2009
Steam generation process
HRDC 1st June 2009
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
Rankine cycle with Superheater
HRDC 1st June 2009
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

(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
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
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
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
Types of Circulation
HRDC 1st June 2009
Natural Circulation
Controlled Circulation
HRDC 1st June 2009
Types of boilers
Drum type
Once-through type
HRDC 1st June 2009
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
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
210 MW Boiler Typical Arrangement
HRDC 1st June 2009
500 MW Boiler Typical Arrangement
HRDC 1st June 2009
500 MW Arrangement Of Circulating System
HRDC 1st June 2009
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
Multiple-lead Rifled Tube
HRDC 1st June 2009
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
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
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
Pressure range
Sub critical
: Below 221 bar
Super critical
: 221 and above
HRDC
1st
June 2009
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
Once Through Boiler-Concept
HRDC 1st June 2009
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
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
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
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
Operating Pressure Range
HRDC 1st June 2009
Once-thru Boiler
Major differences from Drum type boiler :
Evaporator system
Low load circulation system
Separator
HRDC 1st June 2009
Evaporator system
HRDC 1st June 2009
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
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
Once -thru Boiler - Furnace Wall
HRDC 1st June 2009
Furnace Wall Designs
Spiral Wall Configuration
Vertical Wall Configuration

HRDC 1st June 2009
Spiral Furnace
Windbox Panel
HRDC 1st June 2009
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
Vertical Wall Windbox
Only a Few Bends at the

Top and Bottom
Straight Tubes
HRDC 1st June 2009
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
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
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
Start-up and Low load system
HRDC 1st June 2009
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
ONCE - THROUGH OPERATING RANGE
HRDC 1st June 2009
LOW LOAD SYSTEM WITH CIRC. PUMP
HRDC 1st June 2009
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
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
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
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
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
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
Typical General Arrangement of Once Through

Steam Generator
Separators
Collecting
vessel
LTRH
HRDC 1st June 2009
Indian Coal fired 800 MW

Steam Generator
HRDC 1st June 2009
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
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
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
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
Side View of Boiler Arrangement
HRDC 1st June 2009
Plan View of Boiler Arrangement
HRDC 1st June 2009
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
Spiral Water wall Tubing
Lateral Heat Flux Profile
HRDC 1st June 2009
Transition Area
Vertical Wall Tubes
Vertical Tube
Forgings
Spiral Wall Tubes

Spiral Tube Forgings
35 mm Vertical Tube Forgings
HRDC 1st June 2009
Sliding Pressure Supercritical Design

Spiral to Vertical Transition Area - Load Transfer
Support
Fingers
SPIRAL WALL SUPPORT

HRDC 1st June 2009
Sliding Pressure Supercritical Design
Spiral Wall
Windbox
HRDC 1st June 2009
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
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
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
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
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
Materials in typical 800MW
HRDC 1st June 2009
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
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
HRDC 1st June 2009

BHEL Supercritical

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BHEL Supercritical

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Droits d'auteur :

Formats disponibles

Bharat Heavy Electricals Limited, Tiruchirapalli

Supercritical Boiler and

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Emerging market requirements

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Fuels for Steam Power Plants

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Emerging market requirements for Utility

High Reliability & Availability

Suitable for differing modes of operation

Suitable for different quality of fuel

Lowest life cycle cost

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Thermal Power Generation

Conservation of fuel resources

Better economy in power generation where fuel costs are

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Measures to improve Plant Efficiency

Minimum SH spray (if tapped off before feed heaters)

Minimum excess air at AH outlet

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Parameters for increasing Cycle Efficiency in

Increasing superheat and reheat temperatures

Increasing final feed water temperature.

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Current Trends in Steam Parameters

300 bar & 620 Deg.C not unusual today

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Heat Rate Improvement

% Improvement In Station Heat Rate

170 / 538 / 538

170 / 538 / 565

170 / 565 / 565

246 / 538 / 538

246 / 538 / 565

246 / 565 / 565

246 / 565 / 598

306 / 598 / 598

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Growth of unit sizes in India

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Increase in unit sizes to match increase in Cycle

Bharat Heavy Electricals Limited, Tiruchirapalli

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

Steam generation process

HRDC 1st June 2009

Bharat Heavy Electricals Limited, Tiruchirapalli

The Carnot Cycle is theoretically most efficient, but it is having practical

3-3 BFP raises pressure from p2 to p1