Download - India First 660MW
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Installation of APL India’s First
660 MW Supercritical Unit at
Mundra
Sundara Kavidass
Vice President , Engineering Services
Adani Power Ltd, Ahmadabad
July 20, 2011
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Presentation Overview
• Introduction
• Supercritical technology
• Design aspects of 660 MW unit
• First 660 MW Project implementation
• Operating Experience
• Conclusion
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Introduction
• India’s current installed capacity is 156,784
MW
• Projected additional power demand is 95,750
MW up to 2012
• Plan to add 1,58,124 MW of power generation
capacity in year 2007-17 (ten years)
• Adani Power Limited is contributing to add
power generation capacity
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What is Supercritical Technology?
• The supercritical technology is the thermodynamic state wherethere is no clear distinction between the Water and Steam phase
in the Rankine Cycle
• Water reaches to steam state at a critical pressure above 22.1 MPa
at 374 oC.
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Rankine Cycle
• The “efficiency “of the thermodynamic process is the heat energy
fed into the Rankine cycle is converted into electrical energy.
• Heat energy input to the Rankine cycle is kept constant, the output
can be increased by selecting high pressures and high temperatures.
• The key components are supercritical once through boiler and high
pressure & high temperature steam turbine.
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Rankine Cycle Subcritical Unit
1 - 2 > CEP work
2 - 3 > LP Heating
3 - 4 > BFP work
4 - 5 > HP Heating
5 – 6 > Eco, WW
6 – 7 > Superheating
7 – 8 > HPT Work
8 – 9 > Reheating
9 – 10 > IPT Work
10–11 > LPT Work
11 – 1 > Condensing
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Rankine Cycle Supercritical Unit
1 - 2 > CEP work
2 – 2s > Regeneration
2s - 3 > Boiler Superheating
3 – 4 > HPT expansion
4 – 5 > Reheating
5 – 6 > IPT & LPT Expansion
6 – 1 > Condenser Heat rejection
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Various Regimes of Pressures
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Effect of Increasing Steam Temperature and
Pressure on Cycle Efficiency
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CONDENSER
`
No. 3
HP Heater
BFBP
BFP
CEP
GSC
LP Heater
#1
LP Heater #3
Deareator
LPT IPT HPT
No. 2
HP Heater
No. 1
HP Heater
LTRH I/L
Header
LTRH
ECO I/L
Header
LTSH
ECO
LP Heater #2
HP
BFWP
CRH
DRUM
DOWN
COMER
Roof
Tube
I/L
Header
PLATEN
SHFSH
FRH
Water Wall
MS
HRH
HP-BP
LP-BP
WW LOWER
Header
GG
A B
BA
A B C
Water And
Steam Path
Subcritical
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Natural Circulation Once Through SystemVs.
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660 MW SC Unit Design Coal Data
Parameters Value Parameters Value
Moisture % 33.00 Moisture % 10.0
Ash % 4.02 Ash % 37.0
F C % 32.50 F C % 25.4
V M % 30.48 V M % 27.6
GCV Kcal/kg 4500 GCV Kcal/kg 3927
MUNDRA TIRODA
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660 MW Unit Design Aspects
Boiler
Description Unit Mundra Data Tiroda Data
Furnace Size :
Height :
m x m
m
20.4023x20.072
68
19.824x17.64
69
WW lower header elevation m 7 9
Roof elevation m 75 78
Transition header elevation m 50.47 53.34
Furnace plan heat release Kcal/m2 3.419 x 10^6 4.486 x 10^6
Furnace volume heat release Kcal/m3 58.05 x 10^3 68.07 x 10^3
Water Wall area/ No of tubes m2 4667/ 1468 5952 / 1338
Superheater area m2 12034 14954
Reheater area m2 24395 23615
Economizer area m2 12542 12606
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Supercritical Boiler Features
Bottom spiral & top vertical tube furnace arrangement
• Once through design feature is used for boiler water wall design
• The supercritical water wall is exposed to the higher heat flux
• Utilize intensive radiant heat transfer in the furnace firing zone
• Spiral tube wall design (wrapped around the unit) with high
mass flow & velocity of steam/water mixture through each spiral
tube (2630 kg/m2/s & mass flow velocity for vertical tubes ~
1259 kg/m2/s)
• Higher mass flow improves heat transfer between the WW tube
and the fluid at high heat flux.
• Improved materials are utilized for superheater and reheater
tubes
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No. 1
HP Heater
BFBP
MD-BFP
CEP
GSC
No.7AB&8AB
LP Heater
No.5 LP Heater
DEAERATOR
CONDENSER
LPT LPT IPT HPT
No. 2
HP Heater
No. 3
HP Heater
BRCP
LTRH I/L Header
LTRH
ECO I/L Header
LTSH
ECO
No.6 LP Heater
HP BFWP
CRP
SEPARATOR
SEPARATOR
DRAIN TANK
ROOF TUBE
I/L Header
SH DIV
Panel
FSHFRH
VERTICAL WATER WALL
MSP
HRP
HP-BP
LP-BP
WW LOWER Header
GG
TD-BFP
A B
BA
A B C
Water And
Steam Path
SC Unit
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Heat Absorption in 660 MW
Supercritical Boiler
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% H
ea
t A
bs
orp
tio
n
17
0
10
20
30
40
50
Water wall SH RH Economizer
45%
29.5%
18.5%
7%
Mundra 660 MW
Tiroda 660 MW
0
10
20
30
40
50
Water wall SH RH Economizer
% H
eat
Ab
so
rpti
on
48%
24 %19 %
9%
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660 MW Mundra SC Unit
Off-Set Firing
660 MW Tiroda SC Unit
Tangential Firing
PF FIRING OPTIONS - COMPARISON
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BURNER
BURNER
FIRE
BALL
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Coal Burners Arrangement (Mundra)
AA (AIR DAMPER)
A (A ELEVATION COAL NOZZLE)
OA (LDO OIL NOZZLE)
AB (AIR DAMPER)B (B ELEVATION COAL NOZZLE)
OB (HFO OIL NOZZLE)
BC (AIR DAMPER)
C (C ELEVATION COAL NOZZLE)
CC (AIR DAMPER)
DD (AIR DAMPER)
D (D ELEVATION COAL NOZZLE)
OC (HFO OIL NOZZLE)
DE (AIR DAMPER)
E (E ELEVATION COAL NOZZLE)
OD (HFO OIL NOZZLE)
EF (AIR DAMPER)
F (F ELEVATION COAL NOZZLE)
FF (AIR DAMPER)
1687 m
m
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Coal Burners Arrangement (Tiroda)
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Steam Turbine & Heat Cycle
Engineering Design Aspects
Type
(N660.24.2/566/566)
Dongfang Steam Turbine
Impulse type, tandem compound three
cylinders, four flow exhaust, single reheat,
condensing turbine
TMCR Output 660 MW
BMCR Output 694 MW
HP turbine 8 Stages, 2 Stop valves, 4 control valves
IP turbine 6 Stages, 2 Stop valves, 2 control valves
LP turbine Double flow 2x7 Stages
HP heaters 3
LP heaters 4
No of Extractions 8
No of Journal bearings 6
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HPT IPT LPT A LPT B
CPP
GSC
Condenser
1
HP
H -
1H
PH
-2
HP
H -
3
EXT From CRH
LPH -5LPH -6
LPH -7ALPH -7B
LPH -8ALPH -8B
3
Deaerator
TD BFP
Boiler
CEP3x55%
2x50%
FC
S
5 56 6
From Reheater
1482 TPH
1994 TPH
(MD BFP 1x35%)
78
78 8
778
Condenser
4
2
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660 MW Turbine Cross Section Overview
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660 MW Mundra Steam Turbine
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Features of 660 MW Mundra Steam Turbine
Combined HP & IP Section
Shorter Turbine Length – More Efficient
Reduced No. of Bearings
Reduced No. of Packing segments
Opposite flow in HP & IP Turbines makes thrust force
balanced
Casings upper & lower halves are nearly symmetrical
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• Coal Mills HP1203 - 6
• FD Fan Axial 2 x 50%
• PA Fan Axial Fan 2 x 50%
• ID Fan Axial Fan 2 x 50%
• APH Regenerative rotary type,
Tri-sector - 2
• ESP 4 passes, 2 sections, 5 fields
• BFP MD BFP-1x35%, TD BFP-2x50%
• CEP 3 x 50%
• CWP 3 x 50%
Key Plant Equipment
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660 MW Supercritical Unit Design &
Operating ParametersItem Description Unit TMCR Operating
Data
1 SH steam flow rate TPH 1994 2131
2 Superheated steam temp Deg C 571 567
3 SH steam pressure MPa 25.26 23.57
4 RH steam flow rate TPH 1624 1650
5 RH steam outlet temp Deg C 569 567
6 RH outlet pressure MPa 4.36 4.21
7 FW temperature Deg C 288.7 288
8 FW Pressure MPa 28.4 26.93
9 Separator temp Deg C 421 430
10 Separator pressure MPa 27.02 26.37
11 APH flue gas outlet temp Deg C 147 150
12 Total Air Flow ( To Wind box) TPH 2251 2093
13 Back Pressure KPa 10.2 10.3
14 Fuel Flow Rate TPH 323 293.3
15 Turbine Heat Rate Kcal/kWh 1894 1900
16 MW Output MW 660 66327
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Material Used for 660 MW Unit
(Mundra & Tiroda)
EquipmentMaterial
Specification
Design
Temperature 0 C
Allowable
Stress in MPa
Water Wall SA213T12 440 103
Low Temperature SH SA213T22 490 80
Final SH SA213T91 590 65
Final SH SA213 TP 347H 590 89
Low Temperature RH SA213T22 355 114
High temperature RH SA213T91 605 65
High temperature RH SA213 TP 347H 605 89
Final SH header SA335P91 590 65
Final RH header SA335P91 605 65
Turbine rotor New 12Cr forging 590 65
HP Turbine 1st stage
Blades2Cr11Mo1VNbN 590 65
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Recommended Water Chemistry for SC Units
All Volatile Treatment
(Start Up)
Oxygenated Treatment
(Operation)
Description Unit
Feed
Water
Quality
CondensateMain
steam
Feed
Water
Quality
CondensateMain
Steam
pH 9.0 - 9.6 9.0 - 9.6 9.0 - 9.5 8.0 - 9.0 8.0 - 9.0 8.0 - 9.0
Dissolved
Oxygen µg/l < 5 < 10 30 - 150 < 10
Hydrazine µg/l < 50
Cation
ConductivityµS
/cm < 0.2 < 0.15 < 0.2 < 0.15 < 0.12 < 0.15
Silica µg/l < 20 < 20 < 20 < 15 < 10 < 15
Iron µg/l < 10 < 5 < 10 < 10 < 5 < 10
Sodium µg/l < 5 < 3 < 5 < 5 < 3 < 5
Chloride µg/l < 5 < 3 < 5 < 3
Copper µg/l < 3 < 2 < 3 < 3 < 2 < 3
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EFFECT OF CYCLE CHEMISTRY – KEY PARAMETERS
Parameter Potential Cause Long -Term Impact
Low pH 1. Condenser tube leak
2. Upset in water Treatment
3. Improper chemical cleaning
4. Improper CPU operation
1. Hydrogen damage
2. Excessive deposits lead to BTF by
overheating.
3. Potential for FAC,
4. Stress corrosion cracking.
High pH 1. Excess dosing of NaOH
during startup
2. Upset in water treatment.
3. Improper CPU operation.
1. Caustic gouging,
2. High conc. deposit leads to turbine
damage
Chlorides 1. Condenser tube leak
2. Upset in water treatment.
1. Hydrogen damage
2. Pitting on economizer & turbine
blades
3. Stress corrosion cracking in LP
turbine
Sodium 1. Condenser tube leak
2. Upset in water treatment
plant
3. Excess dosing of NaOH
during startup
1. Caustic gouging
2. Deposits on turbine blade lead to rpm
reduction.
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BOILER WATER TREATMENT FOR SC UNIT
All VolatileTreatment (AVT)
Ammonia & Hydrazine added at feed water & condensate
Boiler water pH to be maintained 9.0 – 9.5
Dissolved oxygen in feed water is <7ppb.
Magnetite layer formation for corrosion protection.
Used during start up to minimize contamination in the system.
Oxygenated Treatment (OT)
Ammonia & oxygen added to feed water & condensate
Boiler water pH to be maintained 8.5 – 9.0.
Dissolved oxygen in feed water is 50 – 150 ppb.
Hematite layer formation for corrosion protection.
Benefits of OT
Minimize FAC in feed water piping & economizer inlet header.
Corrosion product transportation is minimized. Helps to reduce
thermal fatigue , overheating & turbine fouling.
Formed Hematite layer is stronger than Magnetite layer for corrosion
protection.
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Operation & Maintenance Challenges
• Availability of expertise in the industry
• Operator training including simulators & External
Agency
• Maintaining cycle chemistry
• Limited equipment standby (or) redundancy
• Maintaining adequate spares
• Proper cycling and control load operation
• Coal quality
• Plant Equipment Margin
• Lack of SC operating experience
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Cold Start up Curve for 660 SC Unit
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SC Unit Load Ramp up Rate
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0
20
40
60
80
100
120
-60 -10 40 90 140 190 240 290 340 390
% L
oad
Time
Recommended Practice
Not Recommended Practice
Supercritical unit cyclic operation
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Operating Experience of 660 MW Unit
• Unit has operated beyond 660 MW
• Unit is operating at sliding pressure mode
• Required cycle chemistry - OK
• Power evacuation system - Grid Restriction
• Coal /Ash handling system - OK
• Boiler efficiency (85%) & heat rate – 2200 KCal/kWh
• No significant slagging / fouling for Indonesian coal
• Combustion efficiency - 98 - 99%
• No major maintenance issues on SC boiler & Steam Turbine
• Meeting environmental requirements (pm < 50 mg/Nm^3)
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Benefits of Supercritical Unit
• Higher unit cycle efficiency (40 - 42%)
• Superior environmental performance (< 8 % CO2 reduction)
• Lower heat rate and electricity generation cost is lower
• Lower water losses because no continuous blow down
• Reduced auxiliary power consumption
Environmental Benefits
• Reduce carbon dioxide (CO2) emissions with carbon credit
within the Rankine cycle
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Highlights of E&C of 660 MW SC Unit
• Erection and Commissioning were successfully completed in less than 36 months
• Green field power project and all the environmental clearances were received in time
• No site pilings are required
• Contractor brought major handling equipment from China
• APL’s QA/QC team are placed in china to ensure the quality.
• Ensured sequential delivery of the equipment to meet the schedule and Mundra Seaport is very close to the plant
• Project commissioning was done through DCS
• Good team work between Chinese and Indian project teams
• Received good cooperation from state and central govt. authorities 38
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Conclusion
• Unit #5 E&C was completed in 36 months
• Unit operating performance as per design
• SC Coal fired power plant cycle efficiency increased by 3% and
contributes reduce CO2 emissions by 5 to 8%
• APL is installing several 660 MW SC units across the country
• APL goal is to install 20,000 MW by end of year 2020
• India’s power demand can be met utilizing larger size SC /USC
Technology
• SC technology can be operated economically as well as
environmentally acceptable manner
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21-Jul-11
Power Business Goal - 20,000 MWAdani Power Limited
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Complete excavation for main
plant foundations
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Concrete roads all over plant
area - Main plant front road
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APH & duct erection start before ceiling
girder
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Erection of Coal Bunkers
simultaneously with Main Structure
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ESP electrodes erection with
exclusive tower crane
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Furnace hopper assembly with all buckstay
arrangements and erection in two parts only
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Furnace hopper erection in two
parts
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Generator stator 276 MT lifting by
2x80T EOT crane
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Rear arch assembly at site & erection
from boiler top with tower crane
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Water wall assembly at site & Erection
from Boiler top by tower crane
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DIVISIONAL SUPER HEATER
PANEL
SPIRAL WATER WALL
BURNER PANEL
FINAL SUPER
HEATER
ARCH PANEL
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LTSH COILS
ECONOMISER COILS
ECONOMISER I/L HEADER
ECONOMISER
O/L HEADER
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SEPERATORS
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