power plant related topics
Post on 14-Sep-2015
5 Views
Preview:
DESCRIPTION
TRANSCRIPT
-
Milestones of GrowthConstruction started 1962
Inauguration of Boiler Plant 1965
Commercial production commenced 1966
First 60 MW boiler order 1966
First 210 MW boiler order 1973
First 500 MW boiler order 1984
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 $)
5554 Cr turnover 2007-08 (1322 Million US $)
7413 Cr turnover 2008-09 (1765 Million US $)
10009 Cr turnover 2009-10 (2383 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
Technology Development Over The Years
-
2000s
Technology tied up for Super critical steam generators
with Alstom.
IT based Soot Blowing Optimisation System
developed.
Designs for firing Washed Coals developed.
Technology Development Over The Years
-
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
-
http://www.bhel.com/ September 5, 2012
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
-
http://www.bhel.com/ September 5, 2012
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
-
http://www.bhel.com/ September 5, 2012
Tripoli (W) TPS 2 x 120 MW
Customer Electricity Corporation, Tripoli, Libya
Parameters at SHO/RHO
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
Parameters at SHO/RHO
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
Tilting Tangential Firing
-
CONTROLLED CIRCULATIONSTEAM GENERATORS
-
http://www.bhel.com/ September 5, 2012
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
-
http://www.bhel.com/ September 5, 2012
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
Tilting Tangential Firing
Trombay TPS Unit 6 - 500 MWTrombay TPS Unit 6 - 500 MW
-
http://www.bhel.com/ September 5, 2012
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
Tilting Tangential Firing
-
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
top related