JUNE

2011

TS TIDINGS

Published by Technical Services / PSSR

For internal circulation

KUDANKULAM NPP

JUNE
: 2011
VOLUME : 15.01

HIGHLIGHTS
KOTHAGUDEM 500 MW UNIT 1 :

UNIT REACHED FULL LOAD FOR THE FIRST TIME.

NALCO DAMANJODI UNIT 5 :

COAL FIRING WAS CARRIED OUT FOR THE FIRST TIME.

NEYVELI TS II EXP, CFBC UNIT 1:

LIGNITE FIRING WAS ESTABLISHED FOR THE FIRST TIME.

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2011

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INSIDE

1. STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

2009 - 2012.
2. SERVICE RENDERED TO OTHER REGIONS/SAS/PROJECTS AFTER
CONTRACT CLOSING/ CUSTOMER TRAINING.
3. APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED.
4. FEED BACK ON EQUIPMENTS FROM SITES.
5. LET US KNOW.

100% PETCOKE FIRED CFBC BOILER UNIQUE DESIGN

CHALLENGES

Feed backs and suggestions from all departments of BHEL for improvement of TS
TIDINGS are welcome and may please be addressed to ADDL. GENERAL MANAGER
(TSX)/BHEL-PSSR/CHENNAI
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2011

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STATUS OF PROJECTS COMMISSIONED / TO BE COMMISSIONED DURING

2009 2012:
KAKATIYA 500 MW UNIT 1 :

Unit is running around 400 MW, load limited due to poor quality of
due to coal feeding problem.

coal and

BELLARY 500 MW UNIT 2:

PA fan B oil flushing

was completed.

PA fan A stage 1 and stage II lube oil flushing

APH A: Guide bearing

oil flushing
was completed and support bearing oil
flushing is in progress. Main motor 04 hrs trial run was completed.

Drum internal inspection was carried out and modification work was completed.

MDBFP breaker testing was completed.

RODM plant MCC : CTs

GRP panel checking

SAT 2 Transformer
completed.

SP bus duct HIPOT

CW pump house MCC - CTs

Ash handling plant MCC testing is in progress.

M/s PROCON vendor rep. is at site for commissioning alarms.

AC plant MCC was charged and drives commissioning is in progress.

Bluestar vendor is available at site.

completed.

testing was completed.

was completed.
:

OCC

&

SCC testing, protection checking

was

test was completed.

& PTs testing

was completed.

M/s

KOTHAGUDAM 500 MW, UNIT 1:

Unit was under shut down from 28.05.11 due to rubbing in the Bearing-3
oil catcher area. BHEL/Haridwar team reached site and machining of the rotor
was done at site by grinding with machine on barring gear.

TDBFP B turbovisory system commissioning was completed.

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JUNE

water fill

test

was

2011

carried out

TS TIDINGS

Condenser
attended.

and

identified leaks were

Wall blowers and LRSBs electrical commissioning is in progress.

Unit was synchronized on 11.06.11. Unit was hand tripped on 17.06.11due to

tube leakage in the divisional panel.

Load shedding relay was

UNIT REACHED
FULL LOAD FOR THE FIRST TIME ON 26.06.11 AND
MAXIMUM LOAD REACHED WAS 515 MW.

Unit

commissioned.

is presently running around 305 MW.

KUTTIYADI 2 x 50 MW UNIT 1:

Unit is in service as per the requirement of customer.

LGB oil leakage through oil vapour seal assembly was attended.

KUTTIYADI 2 x 50 MW UNIT 2:

Nozzle 2 modification work was completed and unit was synchronized on

18.06.2011.

Unit is in service as per the requirement of customer.

NALCO -120 MW UNIT 9:

Unit was running at 90-115 MW as per requirement of customer.

NALCO 120 MW UNIT 10:

Unit was
work.

under shut

down

since

27.05.11 for

carrying

out

maintenance

TG PG Test flow nozzle in HPH drip line and condensate line erection was
completed.
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TG PG test pressure points and temperature

points erection is in progress.

Condenser on load tube cleaning system (COLTCS) erection work (piping) is in

progress.

NALCO DAMANJODI UNIT 5:

Boiler was lighted up on 03.06.11 and stopped due to water wall leakages.

Water wall tube leakage works were completed and subsequently hydro test was
carried out.

Boiler Drum Safety valves 2 nos floating was completed.

COAL FIRING

Unit was stopped due to

bunker choking ( customer scope ) and HFO pump
mechanical seal
damage, which
was
attended, pump was run and
the
performance was found to be alright.

BFP B trial run was carried out.

Boiler was boxed up on 20.06.2011 for attending the coal leakages.

WAS CARRIED OUT FOR THE FIRST TIME ON 08.06.11.

NEYVELI TS II EXP CFBC, 2 X 250 MW, UNIT 1:

Unit is under shut down

firing is in progress.

since

18.05.11.

Preparatory

works

for

lignite

Emergency BFP: suction and discharge piping flushing was

completed, oil
flushing was completed and lines were normalised. 2 hrs trial run of emergency
BFP was completed.

All the six nos. of spies valve operation was checked.

ESP

Ash cooler - rear bed ash feeder motor trial

Transport feeders B,C& D trial run was completed.

Self Cleaning air-lock feeders B& C trial run was completed.

GD test was completed .

run was completed.

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B1 & C1 Extraction feeders alignment and coupling were completed. Extraction

Feeder B1 trial run was completed.

DMCW 1A: suction valve door seal was replaced, pump NDE mech seal was
replaced and pump was taken into service.

Ash cooler 1B - 8 hours

PA fan -1A trial run was carried out after impeller design modification.

CFBC boiler was lighted up

17.06.11 and tripped due to the failure of
V belts of purge and seal oil blowers, which were replaced. CFBC boiler was
lighted up again on 18.06.11.

Lignite firing was established for the first time on 18/06/2011.

CFBC was boxed up

due to NMEJ (Non Metallic Expansion
which was replaced by vendor and lighted up on 25.06.11.

MS safety floating was completed and drum safety valve 1/3 floating was done
and is to be adjusted.

Unit was synchronized and load was raised upto 77 MW. LP

taken into service for the first time.

Unit was boxed up on 1.07.2011 due to transport conveyors B& C chain got cut.

trial run was completed.

Joint) failure,

heaters

were

RAICHUR 1 x 250 MW UNIT 8:

Unit
was
under shut down
from 07.05.11 due to internal
Generator Transformer ( customer scope ).

fault of

Unit was rolled to 3000 rpm on 14.06.11 and Generator

were carried out. During voltage builtup flash over of
circuit breaker occurred.

Boiler was lighted up on 23.06.1 and unit was synchronized on 25.06.11, after
attending to 400 KV CB.

Presently unit is running at 210 MW.

OCC & SCC tests

Y phase generator

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RAYALASEEMA 1 x 210 MW - UNIT 5:

Unit is running around 200 MW.

SIMHADRI STAGE II, 2 X 500 MW, UNIT 3:

Unit is under shut down after full load operation on 31/03/2011 for attending
to pending jobs and balance system commissioning.

SH safety valve 02nos, ERV 04nos floating was completed.

ECO hoppers flue gas duct air tightness test was carried out.

TDBFP B: Emergency governor problem was attended.

TDBFP A : Governing system checking, control valve calibration and hydro test
of lines was completed. Feed water line flushing was completed.

Drum safety valves

assembly was completed after
BHEL/Trichy representative.

Turbine ATT: Checking

ESP C pass: Dummy load test of BAPCON panels

was carried out. SCC
and OCC test of HVRs was completed . All 20 nos of fields were charged.
EERMs 20 nos trial run was completed.

CC pump C trial run was done after replacement with unit 4 CC Pump.

FD Fan 3A blades were replaced with anodised blades.

Boiler hydro test

Furnace ATT

HPH, LPH and TDBFP A&B MOVs commissioning is in progress.

Wall blowers remote commissioning is in progress. 78/88 was completed.

rectification

by

of control valves was completed.

was carried out and identified leaks were attended.

was carried out and identified leaks were attended

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JUNE

2011

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SERVICES RENDERED TO CUSTOMER /SAS/MUs:

Shri S. Elangovan, AE-I/TSX, PSSR, Chennai
was deputed to Bellary TPS
Unit 1 on 04.06.11 for attending to Generator hydrogen pressure dropping
problem. The hydrogen leakage was observed from liquid detector rack valve
and same was replaced by new one.
The Generator air tightness test was
conducted
from 07.06.11 to 08.06.11 and found that the drop rate was
within limits. Generator was released for hydrogen filling on 08.06.11.

CUSTOMER TRAINING & TECHNICAL PAPER PRESENTED:

--- NIL --APPRECIATION FROM CUSTOMER FOR SERVICES RENDERED :
--- NIL ---

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2011

TS TIDINGS

FEED BACK NO.1

Project:
Problem:

NTPC Simhadri, stage II, unit 3, 500 MW

Repeated Failure of pin in tripping device while conducting oil injection
test and overspeed test of Drive Turbine of TDBFP-B

Problem detail and analysis:

TDBFP-B drive turbine was rolled to 5400 rpm (Rated operating speed) on
27/03/2011.Oil injection test was attempted to check the freeness of over speed
tripping device before going for actual over speed test. But oil injection test was not
successful. The following are the observations during the test:
1. At test position of tester, the hand tripping knob of over speed trip device is
coming out instead of going inside.
2. Hand tripping was also attempted but could not be achieved as the trip lever was
extremely tight.
3. During releasing of the lever of over speed tester, turbine is getting tripped and
the trip device was not coming to reset position.
4. The Trip device assembly was dismantled in presence of technicians from BHEL,
Hyderabad and it was observed that the Pin (shown in the attached figure:1 ) has
sheared off.
5. This pin was replaced and the Drive turbine was put on Barring gear. After
replacement of the pin resetting and hand tripping of the turbine was normal. Due
to lack of time (March end), the actual over speed testing was not attempted and
pump was taken in service.

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TDBFP-B drive turbine was re-rolled to 5400 rpm on 29.05.2011. Oil injection test
was attempted and could not be achieved at 4KSC test oil pressure. Hand tripping was
also attempted but without any success. Suspecting jamming, the trip device was
opened and serviced; the pin was again found to be sheared. The pin was replaced and
the Drive turbine was cleared for rolling. After rolling the same phenomena were
observed again for the third time and the turbine was stopped and kept on Barring
Gear for analysis:
1. Hand trip knob was pressed in test position and it did not operate. It was
observed that holding/reset oil line is getting heated up during testing process.
2. Doubting generation of reset oil pressure during testing a dummy was provided to
block reset oil.
3. The turbine was reset. Lever of over speed tester is pressed down and hand wheel
is tightened to test position. Trip device knob was pressed and found to be
behaving normally (with the dummy in reset oil line).
4. It was suspected that the overspeed tester pilot position is not correct, which may
be causing the build up of reset oil pressure in the tester.
5. Over speed governor tester is dismantled. It was observed that in test condition
pilot piston is moving 12 mm (instead of 5 mm) downwards and oil above piston is
getting connected to holding oil port due to over travel of piston which is leading to
build up of reset oil. Shown in figures: 2 & 3.
6. The hand wheel position of tester in TDBFP A was checked and compared with
TDBFP B for establishing the overtravel.It was found that the TDBFP-B tester
hand wheel position was up by 6mm (approx) when compared to TDBFP A. The
tester was kept at intermediate position by partially closing the hand wheel and
Trip device knob was pressed and found to be behaving normally. Shown in
figure:4.
7. The downward movement of the pilot is stopped by the hand wheel after required
travel of 5 mm as per drawing. This over travel confirmed the improper fixing of
Hand wheel at works.

It was also observed that locking pin of over speed tester

hand wheel has partially come out, as a result

holding oil path is not getting

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closed at hand wheel fully closed condition. Hand wheel was fixed in correct
position and the locking pin was tightened properly.
Conclusion
After the above correction, Turbine resetting was done. Trip device operation was
checked, repeatedly, by pressing the hand lever in test condition. The behaviour of
the trip device was found to be normal. Oil injection test and actual over speed test
was carried out, the performance was found normal. Over speed pin acted at 4 ksc of
test oil pressure and tripped at 5881 RPM during actual over speed test.
The feedback of this defect in assembly was given to BHEL, Hyderabad. Limiting the
travel of over speed tester pilot to the required length by other than hand wheel is
to be reviewed to avoid such problem.

Courtesy:1. Shri. Sanjiba Nanda Naik,Manager, Simhadri site

2. Shri. Bikash Mishra, Manager, Simhadri site
3. Shri. LN Prasad Sarakadam, Asst Engineer, Simhadri site

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Figure: 1

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Figure:2

JUNE 2011

13

Figure:3

Figure:4

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2011

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FEED BACK NO. 2

Project:
Problem:

KTPS, Stage VI, Kothagudam, unit 11, 500 MW

Fouling of IP rotor with the Oil guard ring (Turbine side) of IP Rear
pedestal (pedestal no-3)

Problem detail:
Kothagudam unit 11 was synchronized for the first time with grid on 30/03/2011.
Subsequently unit was restarted on 27/05/2011 at 13:55 hrs. Unit was loaded upto
120 MW with four mills taken into service. The main steam temperature of almost
rated parameter was reached. At 16:00 hours sparks were observed at IP rear oil
guard area for few seconds and disappeared. Again at 21:00 hrs similar observation
was made. Close monitoring of all parameters were made and there were vibration
changes during this period. Unit tripped at 01:30 hrs due to tripping of 80mva
transformer causing tripping of auxiliaries. After trip out, during machine on barring
gear oil leakages and smoke were observed in IP rear area. It was planned for
inspection of IP rear pedestal.
Analysis and rectification:
The expansion achieved in IP rotor was 15mm during these above observations. Axial
rubbing marks of IP Rotor collar with the oil guard ring (Turbine side) at bearing
pedestal number 3 were observed. On further inspection & dimensional measurement it
was observed that the maximum axial clearance available for expansion of IP rotor
towards +VE side (Gen side) in front of pedestal no-3, in present condition, is only
15mm instead of the required gap of 25mm approx as per design/drawing. Damage
was noticed on oil guard ring (Turbine side) of pedestal 3 after axial expansion of IP
rotor (refer photo I and II). This is due to the IP rotor dimension which is physically
maintained as 80 mm in manufacturing instead of 70 mm as shown in the section EE of
drg no 0-10201-41000 IP ROTOR (refer sketch I and II). All other dimensions
are found to be as per drawing and shown in the SKETCH I. Damage to oil guard ring
(Turbine side) of pedestal no 3 and its outermost sealing strip due to axial rubbing is
beyond repair and the oil guard needed replacement (refer attached photos).
BHEL/Hardwar was referred to analyze the failure. Team from BHEL,Hardwar was
deputed and the dimensions of the rotor was verified and it was decided to carry out
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in situ machining of the rotor. The rotor was machined by grinding by BHEL hardwar
technicians with machine in barring gear. As the gap available for machining was small,
it could be done with pedestal top half removed condition only. For putting the
machine on barring gear with pedestal No.3 top half open condition, the oil flow to
the bearing was reduced to minimum by adjusting the lub oil inlet throttle. The speed
of barring gear was maintained around 35 RPM during machining by throttling of
barring gear inlet valve. The final diameter of the rotor to the tolerance limit of
0.02 mm was achieved by polishing with emery paper during machine on barring gear.
The damaged oil guard was replaced with new one.
Conclusion:
After machining of the rotor, unit was restarted and full load of the unit was
achieved and rubbing problem was resolved. The axial dimensional check of machines in
other projects were also carried out as per advice of BHEL,Hardwar for such
deviations and it was found in few of the units machining was required to avoid axial
rubbing. This dimension was not in Quality checklist for production and it was
suggested to BHEL, Hardwar to introduce the same to avoid such occurrence in
future.

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Photo 1
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Photo 2

Courtesy : 1. Shri B. Murmu, SDGM, BHEL PSSR, Chennai

2. Shri. Sandip Mondal, Engineer, Kothagudam Site.

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100% PETCOKE FIRED CFBC BOILER UNIQUE DESIGN CHALLENGES

Abstract
The role of power in driving growth of country and any industry is now established
beyond doubt. In developing countries, fuel security and environmental issues are
taking centre stage of public concern.
In this present environment, the design of power equipments for utilizing newer fuels
offers unique challenges for design. Petcoke is a by product of the oil refining
process. Ongoing advances in refining technologies enchanced conversion of bottom of
crude and increased global demand for oil has increased the quantum of coke
production. Petcoke in addition, to being used for needle or anode grade coke
production, is used as primary fuel or for co-firing with other fuels. Petcoke fuel
with low volatile and high sulphur content poses a significant design challenge for
ensuring good combustion and minimal impact on environment.
The paper outlines the unique issues arising out of designing Circulating Fluidised Bed
Combustion boiler for exclusive Petcoke firing along with process involved in CFB
combustor, The design for ensuring good carbon burnout and high sulphur capture is
key in utilization of Petcoke as fuel. CFB process by nature is best suited for
combustion of petcoke as it offers sulphur capture option at the combustion stage
itself.
BHELs experience in CFB technology is also brought out with reference to two major
boiler installations at BILT Graphics, Pune and SLPP, Mangrol. The experience gained
in designing, erecting, commissioning, and running these boilers have given immense
understanding of CFB technology. This along with continuous trials being undertaken at
CFBC test facility at BHEL, Trichy are key to developing technology to utilize newer
challenging fuels like Petcoke.

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Design issues arising out of adapting for low volatile fuel are discussed and path
forward is elucidated.
Key Words :
Bharat Heavy Electricals Limited (BHEL); Circulating Fluidised Bed (CFB); Circulating
Fluidised Bed Combustion (CFBC); Petcoke; Cofiring; FBHE (Fluidised Bed Heat
Exchangers); Oxides of sulphur Sox; Oxides of Nitrogen NOx; Selective Catalytic
Reduction (SCR); Flue Gas Desulphurisation (FGD).
Introduction to CFB Technology:
The fluid bed combustion process facilitates power production firing a wide range of
fuels while meeting stringent required emissions limits. CFB technology has
demonstrated an unparalleled ability to achieve low NOx production without the need
for post- combustion temperatures (850-900* C) and the staging of air by application
of secondary air admission zones. Furthermore, CFB technology has exhibited fuel
flexibility with an ability to burn waste materials and fuels previously deemed
uneconomical and/or impossible to handle by conventional boiler firing system
technologies.
A large mass of solid particles, once heated, help in maintaining combustion
temperature and stabilize combustion over wide ranges of heating values of fuels thus
allowing a range of poor quality and waste fuels, as well as usual fuels, to be
combusted.
In a fluidizing bed, gas is passed upward through a bed of solid particles. At low
flow, solid particles remain in contact with one another and the bed solid particles are
stagnant. As the gas flow increases, a point is reached at which the forces are
sufficient to separate the solid particles, and the beds acts much like a fluid.
Large portions of the fuel and limestone are suspended in the gas stream and the
gas-solid phase extends throughout the furnace. Even though the velocity in the
combustor is sufficient to entrain most of the particles, the dynamics of solids in the
combustor is such that suspended particles tend to form clusters. The size of these
clusters increases to sizes for which velocity of the gas is below entrainment velocity
causing the material to fall down the furnace. On their way down, these clusters
collide with rising material, breakup, and the smaller particles travel up again. This
action promotes mixing and gas to solid contact in the bed. Some of the material in
the bed is too large to be entrained until it is reduced in size by combustion and
attrition. Fresh feed of coal and limestone maintains the bed condition. In a typical

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combustor, bed velocity is maintained at approx. 4-6 m/s. At this velocity. Erosion
rates are low and heat transfer rates are reasonable. The circulating inventory would
normally consist of particles of size ranges of 0.03 to 2 mm, depending on the fuel.
In general, fuels with low volatile content. Low volatile matter fuels would require
finer sizes and high recycle rates, in the range of 10:1 to 100:1 to ensure good
carbon burn out. The size of the particles is critical, if the feed is too fine,
excessive material will remain in the gas leaving the cyclones resulting in an
insufficient material in circulation.
A combustor temperature between 8500 C and 9000 C is usually selected in CFBC.
Combustion stability is provided by the high thermal inertia of the large mass of fuel
and inert material in the bed. Acceptable burnout of fuel results from the long
residence time of fuel in the bed and by recycles of material captured. A wide range
of fuels may be fired in fluidized bed boilers because the design is for combustion
temperatures that are lower than the ash softening temperatures of most of the
fuels. The use of a scrubber may not be required for S0X control. The potential for
high temperature corrosion due to high vanadium content in the fuel and low
temperature corrosion due to high sulphur in the fuel is reduced by bed absorption. In
the combustor, limestone continuously reacts and, therefore, it is necessary to
continuously feed limestone with the fuel. The Sulphation reaction requires that there
is always an excess amount of limestone present. The amount of excess limestone that
is required is dependent on a number of factors such as the amount of sulphur in the
fuel, the temperature of the bed, and the physical and chemical characteristics of
the limestone. Sulphur capture by mixing higher percentage of limestone.
Fuel characteristics & Impact on Emission.
The uncontrolled SOX emission from the combussion of a coal with 1.0% - (weight%)
sulphur with a heating value of 3800kcal/kg under normal combustion conditions is
about 2000 mg/nm3 In number of countries with 3% (wt) sulphur removal would be
required for environmental compliance. Sulphur dioxide emissions can be reasonably
predicted given the sulphur content in the fuel, however NO X emissions are not so
easy to predict, because the amount of NOX produced in a combustor depends not only
on the type of fuel being burned but also on the process conditions observed in a
particular combustion device.

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Uncontrolled NO X emissions from coal combustion in CFBC ranges from 200-400

mg/nm3. In conventional pulverized Combustion Boilers, it could be even upto 200 mg/
nm3
In power plants particulate emissions arise mostly from combustion of solid fuels e.g.
fly ash and bottom ash, Current technology options like ESPs, bag filters provide
effective means of controlling emissions of particulate from combustion sources.
Petcoke is unique fuel because of low volatile component and high sulphur content
which makes it difficult to burn in conventional pulverized boilers.
Low volatile content makes it difficult to sustain the combussion. High sulphur content
makes it economically unviable for employment of downstream FGD equipments to
control SOX emission. Lower grindability index makes the fuel difficult for the
processing in pulveriser.

Constituents
Average
Range
Carbon
79.74
75.0-85.0
Hydrogen
3.31
3.0-3.6
Nitrogen
1.61
1.3-1.9
Sulphur
4.47
3.4-5.3
Ash
0.27
0.0-0.6
Oxygen
0.00
0.0-0.1
Moisture
10.60
5.5-15.0
HHV kcal/kg
7475
7000-8050
HGI
55
35-55
Ash Properties, ppm
Vanadium
<2000
500-2000
Nickel
336
250-450
Iron
84
50-250
Table 1
A typical representative of Petcoke is presented in table 1. The above fuel
characteristics have forced many utilities to opt for only co-firing or blending with
coal to improve flame stability and avoid preclude ignition problems. The low volatile
matter in the coke makes it the fuel harder to burn unless the temperatures are

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raised higher and longer residence time are provided. Both the requirements increases
the NOX generation potential.
Petcoke is produced from virgin crude residues by precipitation reactions of high
molecular weight compounds, asphaltenes, and resins or from highly aromatic tar or
decanted oil stokes by condensation and polymerization of aromatic compounds.
Delayed Petcoke is produced by a semi continuous process, which can be carried
through in one of the following ways: ultimate, once-through, or intermediate coking.
The sulphur content of the Petcoke strongly depends on the nature of the cokinf
feedstock (crude oil) and its sulphur content. The sulphur content of the feed stocks
increase with increasing the concentration of asphaltenes and conradson carbon
content. For instance, higher sulphur contents were found in sponge coke (produced
from high-resin asphaltene feed stocks) than in honeycomb coke (produced from
low-resin asphaltene feed stocks) or needle coke (produced from highly-aromatic
feed stocks).
The sulphur content in petcoke varies widely mainly depending on the sulphur content
of feedstock, Typically sponge coke contains between 1% and 6% Sulphur sponge coke
containing 4% Sulphur is used for fuel whereas that of less than 4% sulphur content is
used in anode manufacturing. Needle cokes used for electode manufacturing, are
required to have less than 1% sulphur content.
Coking temperature also affects the sulphur content of petcoke, though in less
degree, mainly due to the vaporization and removal of the low sulphur containing
volatile matter, which result in a reduction of the total sulphur content in the coke.
Most of the sulphur in Petcoke exists as organic sulphur bound to the carbon matrix
of the coke. Some sulphur could also exist as sulphates and as pyretic sulphur, but
these do not in general make up more than 0.02% of the total sulphur in coke.
Hence, it is more critical to ensure a fair degree of desulphurization to capture the
SOX emanating from combustion of petcoke.
Advantages of CFB process for Petcoke Firing:
The following list of process advantages in combination with unique design innovations
have enabled the 100% firing of Petcoke Large amount of ignition energy in the bed
makes up for the delayed combustion characteristics of the fuel. Pulverisers are not
employed as the process support combussion of
larger particles of millimeter
diameter.
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The process employs part of combussion air to fluidise or hold up the particle thus
ensuring oxygen concentration all around the particle.
This improves carbon utilization also. High carbon content with low volatiles would be
precursor for high carbon loss and it is overcome by process capability of employment
of primary loop of cyclone, which provides good residence time for the finer particles
to burn out the carbon content.
Lower combustion temperatures aids in in-situ sulphur capture. It also avoids fouling
and slagging problems.
The bed with its larger inventory provides better restart capability.
As the bed provides a near homogenous temperature to high turbulence mixing of bed,
the local hot or cold spots are avoided.
Description of Process Design of CFB boiler for Petcoke Firing.
The major components of the CFB boiler system are the furnace cyclone separator,
the non-mechanical loop seal/seal pot and the convection superheater surface. In the
furnace the bed material, with the fuel, is fluidized with primary air, which
turbulently transports the solids up the full height of the furnace. Combustion of the
fuel takes place as it rises and heat is transferred to the membrane water-wall
tubing that form the walls of the furnace. The hot combustion gases with the
entrained solids exit at the top of the furnace into the cyclone separator. The
cyclone separates the solids from the combustion gases and returns the solids,
including any unburned solid fuel, through the non-mechanical loop seal or seal pot to
the furnace where they mix with incoming fresh fuel. The long solids residence time
due to recirculation of the solids ensure high combustion efficiencies for a wide range
of fuels.
Heat for steam generation is removed from the system in three main areas:
A primary loop: where heat is removed from the solids circulating in the CFB system.
Here the heat removal is achieved by transfer through the water walls of the upper
part of the combustor.
External fluid bed heat exchanger (FBHE): FBHE consisting of fluidized chambers,
where part of the solids circulating in the system are directed and fluidized in order
to maintain flow and optimum heat transfer conditions and after heat transfer to
superheat/evaporator surfaces, are returned to the combustor at reduced
temperature, The system operates like a conventional fluidized bed.
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In back pass, heat is removed from the flue gas through superheater and economizer
surfaces and an air preheater.
The entire combustor as well as the grate is enclosed by water walls and the lower
water wall section is refractory lined to prevent corrosion and attack of the metal
surfaces.
The upper water wall section is not refractory lined and provides the majority of the
evaporative duty of the boiler.
Flue gas resulting from the combustion of the fuel along with the entrained solids exit
the combustor via gas outlet located in the upper portion of the water wall and is
ducted to the recycling cyclone designed to remove more than 99% of the solids
entrained by the gas from the combustion chamber. The flue gas exiting the cyclone
follows a path some what similar to a conventional boiler system namely:
A)
B)
C)
D)
E)
F)
G)

Steam Cooled Enclosure

Superheat surfaces
Economizer Surfaces
Air Pre-Heater for Primary, Secondary and FBHE air
Electrostatic precipitator for removing finely entrained dust
Induced draft fan
Stack

Unique Advatage of Using FBHE Surfaces

The solids separated by the recycling cyclone is collected and returned directly into
the combustor via seal pots fed with a small amount of fluidizing air, This is
necessary because the pressure at the base of the cyclone is less than in the
cmbustor. The solids returning via this route to the combustor are at essentially the
combustor exit temperature.
Part of the solids from the seal pot are directed at a controlled rate to the FBHE
for heat removal and subsequently returned to the combustor at lower temperature.
The fluid bed exchanger replaces the need for additional heat transfer surface in the
combustor. The heat exchanger facilitates turndown because part of the steam
production is de-coupled from the combustion process. In the absence of the FBHE,
turndown has to be achieved by simultaneously balancing combustion and heat transfer
requirements in the combustor. This would require adjustment of excess air,
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temperature, and solids concentration to arrive at a compromise between combustion

and heat transfer requirements. The FBHE, on the other hand, provides an additional
degree of freedom allowing combustion and heat transfer to be controlled
independently. Being in low velocity regime, the heat transfer surfaces are not
affected by erosion (as opposed to heat transfer surfaces in Combustor where high
velocity fluidization regime is employed). As the FBHE is supported with separate
fluidization air from high-pressure blowers through efficient distribution nozzles, the
process also avoids potential agglomeration problems. As a result, the use of the
FBHE simplifies plant operation and provides better efficiency at turndown conditions.
Start Up System
An oil system consisting of a set of over bed burners for start-up for initial heat-up
of the combustion system and oil lances for support fuel firing to bring the CFB
combustion system up to fuel ignition temperature during start-up and to maintain
proper combustion temperatures during shortage or loss of solid fuel. The optimum
temperature for ensuring petcoke combustion sustenance was determined during trials
undertaken at CFBC test facility. Start Up System design was developed to meet this
criteria.
Operating Experience Gained at Bilt Graphics & SLPP
The unit at BILT Graphics was started in 1998. The boiler has been burning a
mixture of Indian and Indonesian coal though it was designed for firing high ash
Indian coal. The boiler has been in operation, meeting the full load requirements of
the turbine and paper plant. The load response has been good considering the highly
fluctuating demand of the paper plant.
Initially the boiler was operating at low loads till the turbine became ready, and the
low laod capability of the uint has been excellent. The plant had operated at a load
of25% MCR (45 t/h) without oil support.
The combustor temperatures were uniform and the combustibles in the bottom and fly
ash have been consistently low, indicating good fluidization and circulation of solids,
resulting in high efficiency of the unit
The unit has been in continuous operation throughout last year till the annual overall
of the unit was taken.
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The units at SLPP were started up in November 1999 and after resolving teething
problems, commercial operation of the units began in February 2000, The units
underwent a reliability trial for a month (May 2000), and this included a full load trial
for 10 days during which they were operated continuously at rated load.
Although the units were designed for lignite of HHV of 4240 kcal/kg the units are
now being fired with lignite having heat value of close to 3000 kcal/kg. The units
performance matches design predictions quite well. The operational and erection
feedbacks has been captured and incorporated in subsequent CFBC designs.
Unique Design Challenges Involved for 100% Petcoke Firing
Petcoke is a difficuilt fuel for combustion and offered for the first time for 100%
firing in CFBC boiler in India. This fuel contains very low volatiles (in range of 10%
viz a viz >25% for lignite), higher sulphur (in range of 6% viz a viz 1% for lignite) as
compared with other coals like lignite.
Other coals such as Lignite has more volatiles and the ash is more friable than that
from Petcoke. Petcoke is devoid of its volatile content as it has already been exposed
to high temperatures in the refinery process and is of high Carbon content (>70%),
The absence of volatiles makes the combustion of carbon in Petcoke difficult. The
combustion characteristic of Petcoke is such that the heat release is delayed by a
couple of minutes after entering the combustor.
Sulphur capture reaction is a complex gas-solid reaction, which is highly dependent on
surface property and size of the solid under reaction (limestone). The sulphur-dioxide formed from combustion of fuel sulphur has to penetrate the pores in the
calcium sulphate. This capture is further critical in Petcoke, which has higher sulphur
content in comparison to other coal like lignite.
The design development of CFBC boiler firing 100% Petcoke involved extensive trials
at CFBC test facility to evaluate fuel characteristics in CFBC environment. Fixing two
levels of secondary air elevation to ensure better control over NOX and combustion
process are other unique features employed in the design. The trials were also used
to arrive at optimum level of Ca/S ratio to reduce SOX to desired levels

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A) Low Ash Content

Utilising a low ash content exclusively in CFBC boiler poses a significant challenge as
the process is highly dependent on the bed material for heat transfer to walls,
maintenance of lower dense bed etc.
In absence of continuous generation of adequate ash quantity from fuel (which
generally is the major source of bed material) additional features such continuous bed
material addition are envisaged in the design to ensure adequate combustor inventory
with optimizing the ash contribution from limestone and better uitlisation of the
bottom ash generated.
B) Effective NOx Control
Fuel characteristics of delayed heat release and higher carbon content would entail
maintenance of higher combustor temperature, which has the tendency to increase
NOx generation potential. This feature of fuel has also been accommodated by
increasing the quantum of refactory lined zone to provide ample time for the fuel to
maintain bed temperatures conducive for better carbon utilization.
The innovative location of secondary nozzles aids in effective NOx control strategy of
staging the oxygen available while promoting good turbulence and mixing of the bed.
C) FBHE Sizing
One of critical
challenges in sizing the combustor considering the conflicting
requirement arising out of inherent fuel characteristics of delayed heat release due to
low volatiles and higher carbon content . The former demanded that maintenance of
sufficient temperature and inventory (Quality & Quantity of Ignition Energy) where as
the latter demanded a very good residence time which lead to taller furnace. The
requirement of
latter leads to larger area leading to depression of operating
temperatures at part loads thereby affecting the combustion characteristics.
Envisaging higher refractory zone and reduction of evaporative duty to provide optimum
combustor loading at part loads formed part of the design problem. The current design
envisages three evaporative FBHE circuit to optimize the boiler performance at part
loads while providing sufficient residence time.

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Additionally, one more FBHE surface is envisaged to provide superheat duty to

maintain superheat temperature at part loads also thus meeting the specified process
parameters.
Conclusion
The Petcoke generated in Refineries are difficult to burn in conventional boilers due to
low volatiles and very high sulphur content.
The CFBC boiler has been designed to fire Petcoke exclusively taking care of specific
fuel characteristics.
References
1.

Challengers and Economics of Using

Petroleum Coke for Power Generation
Narula, Ram G. Bechtel Power
Corporation, USA

2.

Gasification in Petroleum Refinery of 21st

Century E. Fuminsky

3.

Review of fluid bed coking technologies

DG Hammond Exxonmobil Research and
Engineering Company.

Courtesy : 1. Shri. M. Lakshminarasimhan, BHEL, Trichy

2. Shri. B. Ravikumar, BHEL, Trichy
3. Shri. S. Sundararajan, BHEL, Trichy

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UNITS WHICH HAVE ACHIEVED 100% OA

THERMAL
500 MW
RAMAGUNDAM UNITS
SIMHADRI UNIT
SIPAT UNIT
VTPS UNIT -

4, 5, 6 & 7
1 & 2
5
7

250 MW
KOTHAGUDEM UNIT - 10
210 MW
VIJAYAWADA UNIT 1 & 6
MUDDANUR UNITS - 2 & 4
RAICHUR UNIT - 6
METTUR UNIT 3 & 4
NORTH CHENNAI UNIT - 2
NEYVELI UNIT 4 & 6

UNITS WHICH HAVE ACHIEVED PLF MORE THAN 100%

500 MW
RAMAGUNDAM UNITS - 4, 5, 6 & 7
SIMHADRI UNIT 1 & 2
SIPAT UNIT 4 & 5

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UNITS WHICH HAVE ACHIEVED PLF BETWEEN 90 & 100%

THERMAL
500 MW

TALCHER UNITS 4, 5 & 6

VTPS UNIT 7
250 MW
KOTHAGUDAM UNIT 10
210 MW
VIJAYAWADA UNITS 1, 2, 4, 5 & 6
MUDDANUR UNITS 1, 2 & 4
RAICHUR UNIT 6
METTUR UNITS 1, 2, 3 & 4
TUTICORIN UNITS - 1, 4 & 5
NORTH CHENNAI UNITS 2 & 3
NEYVELI UNITS - 4, 5, 6 & 7
AMARKANTAK UNIT - 5

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PERFORMANCE OF BHEL THERMAL SETS IN SR (210 MW AND ABOVE)

FOR THE PERIOD FROM 01/04/2011 TO 30/06/2011 COMPARED WITH THE
CORRESPONDING PERIOD IN THE PREVIOUS YEAR.
( PLF IN PERCENTAGE )

STATION

2010-11

2011-12

North Chennai
Neyveli
Raichur
Tuticorin
Ramagundam
Muddanur
Kothagudam
Vijayawada
VTPS - 7
Mettur
Talcher
Simhadri
Sipat
Amarkantak

69.95
89.12
57.45
89.60
101.03
92.77
81.75
78.53
62.37
90.08
93.69
100.35
96.55
--

90.91
95.10
81.58
87.94
89.52
89.53
89.30
93.44
98.46
98.07
91.44
101.62
91.18
95.10

120.00
2010 - 11

2011 - 12

100.00

80.00

60.00

40.00

Am
arkantak

Sipat

Sim
hadri

Talcher

M
ettur

VTPS- 7

Vijayaw
ada

Kothagudam

M
uddanur

R
am
agundam

Tuticorin

R
aichur

N
orthC
hennai

0.00

N
eyveli

20.00

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