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

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Emerging market requirements

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Fuels for Steam Power Plants

Coal & Lignite:

Abundant availability

Lower cost

Will continue as the main fuels in many countries

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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

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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

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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

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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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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%

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Reduction in Coal consumption and CO2 emissions

Unit 500 MW 660 MW 800 MW

Cycle parameters Bar/0C/0C 170/538/538 246/538/565 246/565/598

Heat rate
% Base 2.1 3.6
improvement

Savings in annual
tons Base 56000 96000
coal consumption

Reduction in annual tons

Base 61600 105600
CO2 emissions

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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

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Increase in unit sizes to match increase in Cycle

parameters

Unit Steam SHO SHO/RHO

Size Flow Pressure Temperature
(t/h.) (Kg/cm2) (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

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Subcritical
Vs
Supercritical Boilers

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Steam generation process

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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
T1 4 1 3-3 BFP raises pressure from p2 to p1
p1
3-4 Heating In feed heaters & economizer
3 4 -1 Heating In boiler
1-2 Work done in Turbine from p1 to p2
T2 2 2-3 Heat reduction in condenser
3 p2

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Rankine cycle with Superheater

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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.

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(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.

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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

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Boiler Parameters
Raichur Bellary Ramagundam
210MW 500MW 500 MW

Steam flow at SHO t/h 680 1625 1675

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 Deg.C 247.5 254.6 253.7

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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)

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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

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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

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210 MW Boiler Typical Arrangement

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500 MW Boiler Typical Arrangement

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500 MW Arrangement Of Circulating System

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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)
Air heaters 2 Trisector 2 Trisector (or)
4 Bisector
Mill arrangement Front or Rear Both sides or
Rear

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Multiple-lead Rifled Tube

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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 3
T
Critical Point
221 bar

Temperature 1-2 Pumping Process

2-3 Heat addition Rad.
Heating in the Boiler
2
3-4 Expansion process in
Turbine
1 4 4-1 Heat reduction in
Condenser
S
Entropy

Simple Supercritical cycle

2
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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.

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Pressure range

Sub critical : Below 221 bar

Super critical : 221 and above

3
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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

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Once Through Boiler-Concept

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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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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.

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Circulation Systems
STEAM TO TURBINE
STEAM TO TURBINE

SH
SH

DRUM

SEPERATING
VESSEL
EVAPORATOR

EVAPORATOR
ECO.

ECO.

CIRCULATION PUMP
FEED

(LOW LOAD &

ASSISTED FEED
START-UP)
CIRCULATION TYPE

Drum Type Once-through

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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

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Operating Pressure Range

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Once-thru Boiler

Major differences from Drum type boiler :

Evaporator system
Low load circulation system
Separator

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Evaporator system

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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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Spiral Tube Arrangement

Features

Reduced number of
tubes with pitch.

Increased mass flow.

Mass flow rate can be

selected by number of
tubes.

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Once -thru Boiler - Furnace Wall

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Furnace Wall Designs

Spiral Wall Configuration Vertical Wall Configuration

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Spiral Furnace
Windbox Panel

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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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Vertical Wall Windbox

Only a Few Bends at the

Top and Bottom

Straight Tubes

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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.

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Spiral vs. Vertical Wall Comparison

Spiral Furnace System Applicable for Vertical Furnace Wall System Limited
all size units to larger capacity units (>600 MW
depending on fuel)
Benefits from averaging of lateral heat
absorption variation (each tube forms a Less complicated windbox openings
part of each furnace wall) Traditional furnace water wall support
Simplified inlet header arrangement system
Large number of operating units Elimination of intermediate furnace wall
Use of smooth bore tubing transition header
throughout entire furnace wall Less welding in the lower furnace wall
system system
One material utilized throughout entire Easier to identify and repair tubes leaks
waterwall system Lower water wall system pressure
No individual tube orifices Less drop thereby reducing required feed
maintenance & pluggage potential pump power

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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

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Start-up and Low load system

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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

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ONCE - THROUGH OPERATING RANGE

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LOW LOAD SYSTEM WITH CIRC. PUMP

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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

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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

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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

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Sliding Pressure Supercritical Operation

Pressure operation mode at boiler outlet
4350

1
3625
psig)

2900
2
2175

1450
3 1. Constant Pressure Operation

725
2. Modified Sliding Pressure Operation
3. Pure Sliding Pressure Operation
0

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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

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Super Critical (Once thru) boiler enables :

Peak power generation with better TG efficiency levels

Quicker response to TG load changes
Better heat rate of lower loads

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Typical General Arrangement of Once Through

Steam Generator

Separators

Collecting
vessel LTRH

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Indian Coal fired 800 MW

Steam Generator

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800 MW Boiler Parameters

Pressure,
Flow, t/h Temp. 0C
kg/cm2(g)

Main Steam 2585 255 568

Reheat steam 2061 59.53 596

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Fuel Analysis
Proximate Analysis

Design Coal

Total Moisture % 12

Ash % 32 (Max.38)

Volatile Matter % 24

Fixed Carbon % 32

HHV kcal/kg 4100

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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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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

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Side View of Boiler Arrangement

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Plan View of Boiler Arrangement

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Spiral Tube Arrangement

Features

Reduced number of
tubes with pitch.

Increased mass
flow.

Mass flow rate can

be selected by
number of tubes.

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Spiral Water wall Tubing

Lateral Heat Flux Profile

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Transition Area Vertical Wall Tubes

Vertical Tube
Forgings

Spiral Wall Tubes

Spiral Tube Forgings

35 mm Vertical Tube Forgings

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Sliding Pressure Supercritical Design

Spiral to Vertical Transition Area - Load Transfer

Support
Fingers

SPIRAL WALL SUPPORT

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Sliding Pressure Supercritical Design

Spiral Wall
Windbox
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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)

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Vertical Wall Sliding

FRONT WALL
RIFLED TUBING
SIDE WALL
Pressure Supercritical Design
RIFLED TUBING 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

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Boiler Pressure Part Materials

Tubing Oxidation Temperature Limits
MATERIAL ASME ALLOY OXIDATION LIMIT
Carbon Steel SA-178C/ D 454C (850F)
SA-210 A-1/ C
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)

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Materials used in various pressure parts of

conventional boilers
Area of application Material ASME specification

Tubes Pipes

Drum Carbon steel / Low - SA 299

alloy steel

Water walls, Carbon Steel SA192 SA106 Gr.B

Economizer SA210 Gr.A1 SA106 Gr.C
SA210 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 -

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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)

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Materials in typical 800MW

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Boiler Equipment Upgrades

500 MW DRUM TYPE 800 MW Once Thru Supercritical

INCORPORATE ONCE-THRU
CIRCULATION SYSTEM, INCLUDING
VERTICAL SEPARATOR
ELIMINATE REVERSE SLOPE
DIVISION PANELS OF CONVECTIVE
PASS FLOOR
FLAT-BOTTOM SMOOTH WATERWALL TUBE IN
PENDANT SPIRAL CONFIGURATION OR
SECTIONS RIFLED WATERWALL TUBE IN
SINGLE FIREBALL VERTICAL CONFIGURATION
FOR LARGE WINDBOX TILT DRIVE
CAPACITY UNITS SYSTEM UPGRADE

SQUARE-UP
FURNACE TWO (2) REGENERATIVE
TRI-SECTOR AIR-
50 HOPPER HEATERS IN LIEU OF
SLOPE FOUR (4) BISECTOR
AIR-HEATERS
REPLACE RP MILLS
WITH HP MILLS

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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

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HRDC 1st June 2009