INTRODUCTION TO 1000 MW POWER PLANT

POWER PROJECT AT A GLANCE

Reliance Power is currently developing Fifteen large and medium sized power projects with a combined planned installed capacity of 35,460 MW. All these projects are in different stages of development and have made significant progress.
S.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2 PROJECTS Rosa Butibori Sasan Krishnapatnam Chitrangi Tilaiya Shahpur Dadri Urthing Sobla Siyom Tato II Kalai II Amulin Emini Mihundon CAPACITY in MW 1200 300 3960 4000 5940 3,960 4000 7,480 400 1000 700 1200 420 500 400 UNITS 4 x 300 300 6X660 FUEL Coal based Coal based Coal based Coal based Coal based coal based Gas based Gas based Hydro Hydro Hydro Hydro Hydro Hydro Hydro LOCATION Uttar Pradesh Maharashtra Madhya Pradesh Andra pradesh Madhya Pradesh Jharkhand Maharashtra Uttar Pradesh Uttarakhand. Arunachal Pradesh Siyom River Arunachal Pradesh Arunachal Pradesh Arunachal Pradesh Arunachal Pradesh

Total=

35460

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Data Source: CEA

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Data Source: CEA

ACTUAL POWER SUPPLY POSITION IN INDIA

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Data Source: CEA

WHAT IS SUPER CRITICAL?

MAJOR ADVANTAGES OF USC

Decrease of the fuel cost due to the increasing efficiency; Decrease of CO2 emission per unit of electricity to more than 15% in comparison with the existing coal fired power plant. Decrease of pollutants including SOx, NOx and PM.

PROCESS OF POWER PLANT

Cooling tower

DeNOx

Steam generator

FGD Flue gas desulphurisation Flue gas injection

Steam lines Coal Feed water tank Turbine Air preheater

HP preheater LP preheater

Generator

Condenser

Gypsum

Draught fan

Electrostatic precipitator

Fly ash

FD fan

PA Ash fan removal

Coal mills

Feed pump

Cooling water

DESIGN PARAMETERS

Power Output Fuel Primary fuel Boiler Capacity 2890 t/hr Live steam / RH steam temp. Live steam pressure Condenser pressure Turbine speed Plant net efficiency (heat rate) Generator rated power Power factor (cos )

1000MW Bituminous coal / Lignite HFO 600C / 620C 260 bar 35 mbar 3000 rpm 46,2 % (7792 kJ/kWh) 958 MVA 0,825

Data Source: HITACHI

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TYPE OF BOILERS
Single pass Boiler Two pass Boiler
Furnace Classification of Boilers

Spiral Type Vertical Type

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BOILER

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Fluid Temperature profile comparison for Water Wall Type

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CONSTRUCTIONAL DIFFERENCE

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SINGLE PASS BOILER

TWO PASS BOILER

TWO PASS BOILER WATER STEAM CYCLE PROCESS

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FUR ROOF I/L HDR

HRH LINE MS LINE

ECO HGR O/L HDR

SEPARATOR
S T O R A G E T A N K HPT
ECONOMISER

FINAL SH FINAL RH DIV PANELS SH PLATEN SH LTRH

VERTICAL WW
ECO JUNCTION HDR

G
LPT
C O N D E N S E R

LPT

IPT

ECO I/L

BWRP

FEED WATER

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FUR LOWER HDR

FRS

SINGLE PASS BOILER WATER STEAM CYCLE PROCESS

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SEPARATOR

ECONOMISER RH

HRH LINE

MS LINE

SH

VERTICAL WW S T O R A G E T A N K CRH LINE

G
LPT
C O N D E N S E R

LPT

IPT HPT

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BOILER EFFICIENCY - 1000 MW

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Data Source: MHI

STEAM TURBINE

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STEAM TURBINE
Type : Tandem-compound machine/ Cross Compound Capacity: 1000 MW and 50 / 60 Hz Speed :3000/3600 rpm : 600oC

Steam Inlet Pressure: 246 Bar Steam Inlet Temp Steam RH Inlet Temp :620oC

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Birds-Eye View of Tandem-Compound 1,000-MW Steam Turbine and Generator.

The steam turbine consists of four turbine casings: a high pressure casing, an intermediate -pressure casing, and two low pressure casings. A Ti-alloy 40-inch blade and a 12Cr-alloy 43-inch blade are applied to the last stage blade for 60-Hz use and 50-Hz use, respectively. A large diameter rotor made of improved ductility high-strength shaft material is adopted to shorten the longer rotor length of the generator.

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Data Source: HITACHI

LP TURBINE BLADE DESIGN-1000MW

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Data Source: HITACHI

TANDOM COMPOUND TYPE

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Courtesy : Siemens

CROSS COMPOUND TYPE

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Data Source: HITACHI

GENERATOR

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COMPARISON OF 660MW Vs 1000 MW PARAMETERS

Sl. No
1 2 3 4 5 6 Steam Temperature at HP inlet Steam Pressure at HP inlet Flow at TMCR/BMCR Cold Reheat Temperature Cold Reheat pressure Hot Reheat Temperature Deg.C Mpa TPH Deg.C Mpa Deg.C

Parameter

Unit

660MW Super Critical

566 24.2 1976/2134 322 4.65 566

1000MW USC
600 26 2890/3080 365 5.97 602

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8 9 10

Hot Reheat Pressure

Reheater Flow (TMCR) Feed Water Temperature Boiler Efficiency

Mpa
TPH Deg.C %

4.2
1658 280 84.58

5.45
2373 294 89.21

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12 13 14 15

Heat Rate at TMCR

Min Load without Oil support Operation Frequency Range Type of Boiler Furnace Size 28

Kcal/KWhr
% Hz

1899
40% 47.5-51.5 2 Pass

1810
40% 47.5-51.5 Tower Type/Two pass 24x24 Continued.

M2

17.64x19.824

COMPARISON OF 660MW Vs 1000 MW PARAMETERS

Sl. No
16 17 18 19 20 21 Start up Pump Type Of Fans Number of Mills Type of Mills Air Pre Heaters Margin On Fans Nos % Nos No

Parameter

Unit

660MW Super Critical

1-30% Load Axial 7(6W+1SB -worst coal) HP 2 (Trisector) FD: 20%-Cap+30% - Head

1000MW USC
1-30% Load Axial 8(7W+1SB worst coal) MPS/HP 2(Bisector) FD:20%-Cap+30%-Head

ID: 20%-Cap+44%-Head
22 23 24 25 26 27 28 29 30 31 Bottom Ash System Turbine Type Turbine Module BFP Configuration Condenser Type Condenser Back Pressure HP/LP Bypass capacity (BMCR) Aux Power consumption Excitation System Power Factor 29 Kpa % % 10.03 60 3.64 Static 0.85 Water Impounded Tandem compound 3 cylinder Combined HP/IP+2 LP 2x65% TDBFP+1x 35% MDBFP

ID: 20%-Cap+30%-Head
Scrapper Conveyor Tandem compound 4/5 cylinder/Cross Compound HP+IP+2/3 LP 2x50% TDBFP+1x 30% MDBFP Dual Pressure 8.7 60 3.4 Static 0.825

AVAILABLE VENDERS IN MARKET

GE
ALSTOM SIEMENS HITACHI MHI TOSHIBA SEC
30

Thank You
J.MURUGADASAN
Sr.Manager.

Dept. of Mechanical Construction