BHEL Standard 500 MW Boilers

Bharat Heavy Electricals Limited, Tiruchy
BHEL Standard 500 MW Boilers
CEA Workshop, May - 2005
Boiler Parameters
Main Steam
BMCR
500 MW
CL 250 MW
Steam flow at SHO
t/hr
1625
1495.2
772.7
Pressure at SHO
Kg/cm2(g)
178
176.7
171.1
Temp at SHO
540
540
540
Steam flow at RHO
t/hr
1392.4
1334.9
670.2
Pressure at RHI
Kg/cm2(g)
45.03
43.21
21.39
Pressure at RHO
Kg/cm2(g)
42.39
40.69
20.13
Temperature at RHI
337
336.7
311.4
Temp at RHO
540
540
540
Feed Water Temp
254.6
253.4
219.3
Reheat Steam
Proximate Analysis of Unwashed Coal

Group I
Group II
Group III
Design
Coal
Range
Design
Coal
Range
Design
Coal
Range
Fixed Carbon %
34.5
32 37
28
24 32
22
20 24
Volatile Matter %
23
22 24
23
22 24
20.5
19 22
Total Moisture %
10
9 11
12.5
11 14
13.5
12 15
Ash %
32.5
32 33
36.5
33 40
44
42 46
Total %
100
100
HHV K.cal/kg
4250
4000 4500
3700
3400 4000
3100
2800 3400
50
45 - 55
50
45 - 55
50
45 - 55
HGI
100
Proximate Analysis of Unwashed Coal

Group I
Group II
Group III
Best
Coal
Design
Coal
Worst
Coal
Best
Coal
Design
Coal
Worst
Coal
Best
Coal
Fixed
Carbon %
37
34.5
32
32
28
24
24
22
20
Volatile
Matter %
22
23
24
24
23
22
22
20.5
19
Total
Moisture %
10
11
11
12.5
14
12
13.5
15
Ash %
32
32.5
33
33
36.5
40
42
44
46
Total %
100
100
100
100
100
100
100
100
100
HHV
K.cal/kg
4500
4250
4000
4000
3700
3400
3400
3100
2800
55
50
45
55
50
45
55
50
45
HGI
Design Worst
Coal
Coal
Expected Proximate Analysis (Range) of Washed Coal

Group I
Washed
Group II
Unwashed Washed
Group III
Unwashed
Washed
Unwashed
Fixed Carbon
35 - 40
32 - 37
33 38
24 - 32
30 35
20 - 24
Volatile Matter
25 - 28
22 - 24
23 26
22 - 24
21 23
19 - 22
Total Moisture
11 - 13
9 - 11
13 16
11 - 14
14 17
12 - 15
Ash
23 - 25
32 - 33
25 28
33 - 40
28 30
42 - 46
Total
100
100
100
100
100
100
HHV K.cal/kg
4500 4800
4000 4500
4000
4500
3400 - 4000
3500
4000
2800 - 3400
HGI
55 - 65
45 - 55
55 - 65
45 - 55
55 - 65
45 - 55
Salient Features
Two-pass design
Controlled circulation
Pressure part materials selection as per code.
Radiant reheat
Balanced draft
Side mill layout
cold PA system
Salient Features contd.

Axial reaction FD fans
Axial reaction PA fans
Radial ID fans with VFD
Regenerative Tri-sector air preheaters
Vertical spindle bowl mills
Gravimetric feeders
ESP to suit outlet dust emission
Micro-processor based BMS, SADC and SB
controls.
BOILER ARRANGEMENT
Design Details Unwashed Coal

Group I
Group II
Group III
Furnace Depth - mm
~ 1.05 D
1.14 D
Furnace With - mm
Furnace height - mm
~ 1.04 H
~ 1.08 H
Furnace Plan Area - m2
PA
~ 1.05 PA
~ 1.14 PA
Furnace Volume - m3
1.09 V
1.24 V
4.28
4.15
3.86
1.77
1.74
1.68
82.2
75.9
67.4
Furnace Heat Loadings- BMCR DC

Plan Area
EPRS
M K.cal/h-m2
105 K.cal/h-m2
Volumetric 103 K.cal/h-m3
Design Details Unwashed Coal

Heat Input per burner M K.cal / hr
Group I
Group II
Group III
74.8
60.3
50.7
Max Gas Velocity in horz pass /

second pass m/s
12 / 10
Cold air / hot air duct velocity m/s
12.7 / 16
Gas duct velocity m/s
16
Excess Air at Eco. out let %
20
Boiler Exit Gas Temp oC
125 at TMCR with Design coal (DC)
Boiler Efficiency at TMCR DC %
Base
- 0.7
- 1.4
Coal Fired BMCR DC - T/hr
285
330
400
Coal Fired BMCR WC - T/hr
305
365
450
Major Boiler Auxiliaries Unwashed Coal

Bowl Mills
Group I
Group II
Group III
6 Nos
BHEL 280
(XRP 1063)
7 Nos
BHEL 280
(XRP 1063)
8 Nos
BHEL 280
(XRP 1103)
No. of Spare mills
1 mill spare with Worst coal at BMCR
Regenerative AH
2 Nos Tri Sector - 31.5 VI 80 (T)
FD Fans - 2 Nos Axial

PA Fans - 2 Nos Axial
ID Fans
ESP Out let Dust
concentration
AP1-26/16
AP2-20/12
AP2-21/12
2 Nos Radial with VFD - NDZV 47

100 mg/Nm3 with n -1 fields in service
FD Fan Performance (per fan)

Group I
Group II
Group III
BMCR
DC
Fan
DP
BMCR
DC
Fan
DP
BMCR
DC
Fan
DP
Volume
m3/s
155.3
215
145.9
210
126.8
200
Head
mmwc
255
385
238
395
208
360
KW
505
943
453
945
364
823
Fan Efficiency
78.7
86
77.2
86
73.5
85.9
Motor Rating
KW
Fan Shaft Power
1050 KW
at 980 rpm
1050 KW
at 980 rpm
PA Fan Performance (per fan)

Group I
Group II
Group III
BMCR
DC
Fan
DP
BMCR
DC
Fan
DP
BMCR
DC
Fan
DP
Volume
m3/s
90
164
92.7
196
112.5
225
Head
mmwc
822
1230
927
1270
940
1375
KW
872
2339
979
3032
1206
3631
82
81.5
84.4
77.4
84.1
80
Fan Shaft Power

Fan Efficiency
Motor Rating
KW
2575 KW
1480 rpm
3350 KW
1480 rpm
4000 KW
1480 rpm
ID Fan Performance (per fan)

Group I
Group II
Group III
BMCR
DC
Fan
DP
BMCR
DC
Fan
DP
BMCR
DC
Fan
DP
Volume
m3/s
376
500
386.2
515
387
535
Head
mmwc
312
440
331
470
335
470
KW
1419
2682
1544
2949
1565
3044
81
79.6
81
79.5
81
80
Fan Shaft Power

Fan Efficiency
Motor Rating
KW
3000 KW
at 580 rpm
3250 KW
at 580 rpm
3350 KW
at 580 rpm

BHEL Standard 500 MW Boilers

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Bharat Heavy Electricals Limited, Tiruchy