WELCOME

TO
PRESENTATION ON

SUPERCRITICAL
TECHNOLOGY
1
Stage-1 Capacity: 3X660 MW Super Critical tech.
gives Higher Efficiency
(Super Critical technology) (η%) means
SG Supplied by •Less fuel input.
M/s Doosan, Korea.
•Low capacity fuel
handling system.
TG Supplied by
M/s Power Machine Ltd. Russia •Low capacity ash
handling system.
Stage-II Capacity: 2x500 MW
(Sub-critical Technology) • Less Emissions
(1% improvement in the
efficiency of a conventional
SG & TG supplied by pulverized coal combustion
plant results in a 2-3%
M/s BHEL, India reduction in CO2 emissions.)
Basic Rankine cycle
Reheat Rankine Cycle
Regenerative Rankine Cycle
 Introduction to Supercritical
Technology
What is Supercritical Pressure ?

Critical point in water vapour cycle is a

thermodynamic state where there is no clear
distinction between liquid and gaseous state
of water.
Water reaches to this state at a critical
pressure above 22.1 MPa and 374 oC.

6
 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

7
 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

8
 T - S DIAGRAM

OUTPUT INCREASE D

Temperature ( 0 C )

Dr
y
r
e

Sa
at

tu
W

ra
B C
ng

te
i li

d
Bo

St
ea
E

m
24’0c
A F

-273
0
Entropy KJ / Kg K

9
No Religious Attitude
BOILER COMPONENTS
 BOILER STEAM SEPARATOR,
 DOWNCOMERS,
 CC PUMP,
 FURNACE,(WATER WALL AND STEAM COOLED
WALL)
 FUEL FIRING SYSTEM,(oil gun,ignitor,burner,burner tilt
mechanism,scanner)
 SADC,(secondary air damper control)
 WATER WALL TUBE OR RISER
 ECONOMISER ,(THREE STAGE)
 SUPER HEATER,(LTSH,DIVISIONAL PANEL,PLATEN
S/H)
• REHEATER,
• SOOT BLOWER SYSTEM(WATER WALL,LRSB AND
APH)
• BOTTOM ASH
HOPPER(CRUSHER,REFACTORY,THROUGH SEAL)
• BOILER AUXILARIES
• FANS(PA FANS,FD FANS, ID FANS)
• MILLING SYSTEM(MILL,RAW COAL FEERDER,SEAL
AIR FAN)
• AIR PREHEATER(SAPH,PAPH)
• ESP
• ASH DISPOSAL SYSTEM.(DRY ASH SYSTEM,WET ASH
SYSTEM
 540°C, 255 Ksc

568°C, 47
Ksc 492°C, 260 Ksc

457°C, 49 Ksc
FUR ROOF I/
L HDR ECO HGR O/L
HRH LINE
HDR
BOILER
MS LINE

411°C, 411°C, STAGE I 660 MW

277Ksc 275 Ksc

SEPARATOR 1. NO DRUM
S
T FINAL SH 2. TWO STAGES OF
O FINAL
R RH LTRH
REHEATER
A
DIV PANELS SH PLATEN
G SH
E
3. FINAL SUPER HEATER
T
A
VERTICAL WW
(COUNTER FLOW)
N
K
ECO

305°C, 49 Ksc
G
JUNCTION
HDR 4. SPIRAL WALL
LPT LPT IPT
C
O HPT
N
D
E
ECONOMISER
5. VERTICAL BUCK STAYS
N
S
E
R
6. AXIAL ID FANS
ECO I/L
s
all
e rw
at 7. BOILER FILLING ONLY
lw
ira
Sp THROUGH ECO FEED LINE

8. OXYGENATED WATER
BWRP FEED WATER TREATMENT
290°C, 302 KSC

FUR LOWER HDR

FRS
ABOUT BOILER :

• Spiral + Vertical water walls.

• Counter Flow Final Super heater.
• Two Stage Re-heater.
• Fans Hydraulic Actuator.
• Axial ID fan.
• HRSB in Eco Zone.
• Hydraulic Safety valves.
• BCP suction valve for isolation.
 Natural Circulation Vs. Once Through
System

17
 Water Wall Design

19
 WATER WALL ARRANGEMENT
 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

 Spiral tube wall design (wrapped around the unit) with high mass flow
& velocity of steam/water mixture through each spiral

 Higher mass flow improves heat transfer between the WW tube and
the fluid at high heat flux.

20
 SPIRAL VS VERTICAL WALL
VERTICAL WALL
 Less ash deposition on wall
 Less mass flow
 More number of tubes
 More boiler height for same
capacity
 No uniform heating of tubes and
heat transfer in all tubes of WW
21
SPIRAL WALL
 More ash deposition
 More fluid mass flow
 Less number of tubes
 Less boiler height
 Uniform heat transfer and
uniform heating of WW tubes
 Furnace Arrangement

SPIRAL TYPE

VERTICAL TYPE

22
 Supercritical Sliding Pressure Boiler
Water Wall Design
Comparison of Vertical Wall and Spiral
Wall

23
 Ash accumulation on walls
Vertical water walls Spiral water walls

24
 Sipat super critical boiler

Boiler type : Super Critical Once Through Boiler

Draft System : Balanced Draft

Firing System : Tilting tangential corner burner firing

Evaporator : Spiral / vertical wall Pressure  SH: 256 ksc

RH:50.17 ksc
Pulverizer : 10 Bowl mills.

Fuel : Indian Bituminous Coal. Temperature  SH: 540 oC

RH: 568 oC
Operating Mode : Sliding Pressure Operation

Steam Flow  SH: 2225 T/hr

RH: 1743 T/hr

FW Temp.  291 oC

25
 BOILER OPERATING PARAMETER
FD FAN 2 No’S ( AXIAL ) 11 kv / 1950 KW 228 mmwc

1732 T / Hr
PA FAN 2 No’s ( AXIAL) 11 KV / 3920 KW 884 mmwc

947 T / Hr
ID FAN 2 No’s ( AXIAL) 11 KV / 5820 KW 3020 T / Hr
TOTAL AIR 2535 T / Hr
SH OUT LET PRESSURE / TEMPERATURE / 256 Ksc / 540 C
FLOW 2225 T / Hr
RH OUTLET PRESSURE/ TEMPERATURE / 46 Ksc / 568 C
FLOW 1742 T / Hr
SEPARATOR OUT LET PRESSURE/ 277 Ksc / 412 C
TEMPERATURE
ECONOMISER INLET 304 Ksc / 270 C
MILL OPERATION 7 / 10

COAL REQUIREMENT 471 T / Hr

SH / RH SPRAY 89 / 0.0 T / Hr
BOILER EFFICIENCY 87 %
 AIR AND FLUE GAS SYSTEM

AIR PATH : Similar as 500 MW Unit

FLUE GAS PATH :

No Of ESP Passes : 6 Pass

No Of Fields / Pass : 18 1-7 fields  70 KV.

8&9 field  90 KV

No Of Hopper / Pass : 36

Flue Gas Flow / Pass : 1058 T/ Hr

 Main Steam

HPT IPT LPT GEN

Cold Reheat
Drum
Hot Reheat Condenser
Steam
Generator Deareator
BCW Pp
Eco Secondary Air

Primary Air
APH CEP
LPH-1,2,3
PA Fan

Chimney
BFP
FD Fan
ID Fan Cooling
Tower
ESP
CW Pump
HPH-6 HPH-5
Open Channel
 Steam

Tie Rod

Drum
Flu Gas

- 10 mm WC
ID Fan

FD Fan

300 mm
PA Fan

Bottom Ash Hopper Mills

 SH CRH HRH
DRUM

SECONDARY AIR
TO BLR
BCW
PUMP PRIMARY AIR
TO MILLS
FEED
WTR

PAPH-A SAPH-A SAPH-B PAPH-B

BOTTOM RING
HEADER
PA FAN-B

ID FAN-B
ESP HOPPER
FD FAN-B

FD FAN-A

ID FAN-A PA FAN-A
 M M M
M TO PULVERISER SYSTEM

HOT PRIMARY AIR DUCT

PAPH # A
M M
PA FAN # A
M AIR MOTOR

M
M M M
M M AIR MOTOR

M
SAPH # A
M M
FD FAN # A
M

M M
M SAPH # B

M AIR MOTOR
M M M
FD FAN # B

M
M AIR MOTOR

M M
M PAPH # B HOT PRIMARY AIR DUCT

TO PULVERISER SYSTEM
M M
M
PA FAN # B

LHS WIND BOX

FURNACE
FINAL SUPERHEATER
DIVISIONAL PANEL

FINAL REHEATER

BACK PASS
ECONOMISER
PLATEN COILS

LTRH

RHS WIND BOX

 FLUE GAS PATH

M M
ESP
M PASS # M
A

M M M
M M
ESP
M PASS # M
B
6 passes.
M M
ESP 9 Fields in each pass.
M PASS # M
C 1-7 fields  70 KV.

8&9 field  90 KV.

M M
ESP
M PASS # M
D

M M M
M M
ESP
M PASS # M
E
ID fan
Axial Flow, Blade Pitch control.
M M
ESP
M PASS # M
32
F
 Difference of Subcritical(500MW)
and Supercritical(660MW)

33
 DIFFRENCE BETWEEN 660 MW & 500 MW UNITS

DESCRIPTION SUPERCRITICAL SUB-CRITICAL

(660) (500MW)
Circulation Ratio 1 Assisted Circulation=3-4

Feed Water Flow -TEMP DIFF BW (ECO Three Element Control

I/L & HPH O/L FW -Feed Water Flow
Control TEMP ) IN DRY MODE.
-SEPERATOR LVL IN -MS Flow
WET MODE. -Drum Level

Latent Heat Addition Nil Heat addition more

Sp. Enthalpy Less More
Sp. Coal consumption Low(~0.6 kg/kwh) High(~0.68kg/kwh)
Air flow, Dry flu gas loss Low High
 DIFFRENCE BETWEEN 660 MW & 500 MW
UNITS
DESCRIPTION SUPERCRITICAL SUB-CRITICAL
(660MW) (500MW)
Coal & Ash handling Low High
Capacity
Pollution Low High
Aux. Power Low High
Consumption
Overall Efficiency High Low
(40-42%) (36-37%)
Total heating Low High
surface area Reqd (~128 m2/MW) (~143 m2/MW )
Tube diameter (ID) Low High
 DIFFRENCE BETWEEN 660 MW & 500 MW UNITS

DESCRIPTION SUPERCRITICAL SUB-

(660MW) CRITICAL
(500MW)
Blow down loss Nil More

Water Consumption Less More

Type(drum) Drum Less Drum Type

 DIFFRENCE BETWEEN 660 MW & 500 MW UNITS
PARAMETERS 500 MW 660 MW
FLOW PARAMETERS (TON/HR)
SH OUTLET 1457 1918
RH OUTLET 1302 1612
FEED WATER OUTLET 1432 1841
TOTAL COMBUSTION AIR 1855 2303
TEMPERATURE PARAMETERS
FINAL SH OUTLET 540 568
FINISH RH OUTLET 568 596
ECO INLET 253 290
ECO OUTLET 315 342
APH AIR OUTLET(PAPH) 305 311
APH AIR OUTLET(SAPH) 305 311
APH GAS INLET 332 314
APH GAS OUTLET 125 120
 DIFFRENCE BETWEEN 660 MW & 500 MW UNITS
PARAMETERS 500 MW 660 MW
FLUE GAS CONTENT(%)
O2 AT ECO OUTLET 3.58 3.6
CO2 AT ECO OUTLET 15 14.75
EXCESS AIR AT ECO OUTLET 20 20
PRESSURE PARAMETERS(KG/CM2)
ECO INLET 196 279
SH OUTLET 176.6 253.4
FINISH RH OUTLET 40.7 51
FUEL AND EFFICIENCY
COAL CONSUMPTION(T/Hr) 347 428

TOTAL HEAT LOSS SG(%) 15.90 14.60

EFFICIENCY OF SG, 84.1 85.5
100%TMCR
COAL/MW RATIO(T/MW) 0.69 0.64
 Super Critical Boiler
Materials

39
 Advanced Supercritical Tube Materials
(300 bar/6000c/6200c)

40
 Material Comparison

Description 660 MW 500 MW

Structural Steel Alloy Steel Carbon Steel
Water wall T22 Carbon Steel
SH Coil T23, T91 T11, T22
T91,Super 304
RH Coil H T22, T91,T11
LTSH T12 T11
Economizer SA106-C Carbon Steel
Welding Joints (Pressure Parts) 42,000 Nos 24,000 Nos

41
 Advantages of SC Technology
I ) Higher cycle efficiency means
Primarily
– less fuel consumption
– less per MW infrastructure investments
– less emission
– less auxiliary power consumption
– less water consumption
II ) Operational flexibility
– Better temp. control and load change flexibility
– Shorter start-up time
– More suitable for widely variable pressure operation

42
 ECONOMY
Higher Efficiency (η%)
•Less fuel input.
•Low capacity fuel handling system.
•Low capacity ash handling system.
•Less Emissions.

Approximate improvement in Cycle

Efficiency
Pressure increase : 0.005 % per bar
Temp increase : 0.011 % per deg K

43
 Increase of Cycle Efficiency due to Steam
Parameters
Increase of efficiency [%]

10
6,77
9
5,79
8 5,74
7 4,81
3,74
6 4,26
5 3,44 2,76
3,37
4
2,64
3
2,42 1,47
2 600 / 620
1,78
1
0,75 580 / 600

0 566 / 566
0 538 / 566
300
241 HP / RH outlet temperature [deg. C]
Pressure [bar] 175 538 / 538
44
 Sub. vs. Supercritical Cycle
Impact on Emissions
Subcritical Supercritical
Plant Efficiency, %* 34 - 37 37 - 41
Plant Efficiency, Btu / kw-hr 10,000 - 9,200 9,200 - 8,300

Plant Efficiency, % 34% 37% 41%

Base Base-8% Base-17%

Fuel Consumption/Total Emissions
including CO2

45 * HHV Basis
 Challenges of supercritical technology

 Water chemistry is more stringent in super critical once through

boiler.
 Metallurgical Challenges
 More complex in erection due to spiral water wall.
 More feed pump power is required due to more friction losses in
spiral water wall.
 Maintenance of tube leakage is difficult due to complex design of
water wall.
 Ash sticking tendency is more in spiral water wall in comparison
of vertical wall.

46
MAIN FEATURES
Turbine: HPT, IPT, LPT1 and LPT2
 Turbine length :36.32 Mtr.(without generator)
 Two condensers(single pass) for Main Turbine
 Turbine Stop Valves: 04 (HPSV-1&2, IPSV-1&2)
 Turbine Control Valves: 08 (4 HPCV & 4 IPCV)
 IP Turbine has throttle governing – all four control valves open
simultaneously
 HP Turbine has nozzle governing – all four control valves open in
preset sequence
 2 MDBFP (2 X 30%)
 2 TDBFP (2 X 60%)
 Drip pump.
 Separate condensers and vacuum pumps for TDBFPs
 Clockwise direction of rotation (from front pedestal)
 HP Turbine IP Turbine LP Turbine # 1 LP Turbine # 2
540ºC 247 KSc 298ºC 47.9 KSc 565ºC 43.1 KSc
MS CRH HRH
Governing
Box

349ºC 68.8 KSc

LPH#1
LPH#1a LPH#1
LPH#1b
CRH

HPH#8A
Deareator
HPH#7A LPH#4
HPH#8B

HPH#7B
LPH#3

Steam cooler

LPH#2

HPH#6A HPH#6B
OPERATING PARAMETERS
OPERATIONAL FEATURES
 Turbine rolling by IPT

 HPC & IPC flange heating system

 IP Turbine rotor and first stage blade cooling system

 Turbine motorized barring gear

 HPT heating by CRHNRV bypass line.

 No shaft driven MOP

 Separate governing box in front pedestal

 High pressure governing system

 Pressurized damper tanks with no separate air / h2 seal oil pumps

OPERATIONAL FEATURES
 Total of 12 bearings having first two of segmental journal type and
rest are normal journal type.
 Rotor jacking oil provided in brg. No.1-10.
 Bearing jacking oil provided in brg. No.4-9.
 Thrust bearing integrated with bearing no 3.
 TG motorised barring (speed 1.05 rpm) located at brg.No. 5.
 Individual emergency oil tank provided on the top of each bearing.
 Mechanical PRV for maintaining lub oil hdr pressure.
 Quick 3 way valve bypass mechanism for HP heaters.
 No disengaging mechanism between pump and turbine (TDBFP)
 Warm up line for all BFP.
 No JOP for TDBFP.
 Turbine Layout

53
 Stages in cylinders

HPC..........(1 control stage + {8+8 reactive})................17

IPC..............................................................................11x2

LPC.............................................................................(5x2)x2

TOTAL..........................................................................59

TOTAL Bearings ----12

HPBP : 65% capacity LPBP : 65% capacity

54
HP TURBINE
 Single reverse flow turbine (1 – 9 stages: left flow, 10 -17 stages: right
flow)
 17 stages (1 control stage + 16 reaction stages.
 Type of Casing: Horizontally split inner & outer casing
 Four main steam inlet and two cold reheat outlet
 Stationary blades are fixed in casing. No diaphragms in HPT
 HP Cylinder

1+8+8 stages

HPC
Rear HP
56 Fr
IP TURBINE
 Double flow turbine (2 X 11 impulse type)

 Type of Casing: Horizontally split inner & outer casing

 All four HRH steam inlet from bottom side

 IP Turbine rotor and stationary blades (1st & 2nd stages) cooling system

from CRH & HRH source.

 Flange heating system from HRH source.

 Stationary blades are fixed in diaphragms

 IP Cylinder

2X 11 stages

58
LP TURBINE # 1 & 2
No of LP Turbine: 2

Type of turbine cylinders: Double flow

Type of Casing: Horizontally split inner & outer casing

No of Stages: 2 X 5 (impulse)

Last Stage Blade height: 1000 mm

Extraction Steam at 2nd stage & 4th Stage

Last stage – locking shrouded blades with lacing wire

 LP Cylinder

2X 5 stages
LPC1,LPC2

60 Why two LPCs?

FLANGE HEATING SYSTEM
From HRH

From HRH

To condenser

1.To decrease differential

 Turbine Extractions

Ext. Ext. location Consumer Qty. of Steam parameter in Ext.

No After the stage Ext. steam Chamber
(t/hr) Abs. Pr. Temperature. oC/
(ksc) Relative humidity %

1 13th stage of HPT HPH-8 146.8 72.42 352.5

2 CRH HPH-7 177.1 48.0 298.5
3 3rd stage of IPT HPH-6 * 78.9 22.84 470.3
3 3rd stage of IPT TDBFP 39.4 22.84 470.3
4 6th stage of IPT DEA 52.2 12.32 381.9
5 8th stage of IPT LPH-4 75.2 6.58 299.9
6 11th stage of IPT LPH-3 113.9 3.13 214.5
7 2nd stage of LPT LPH-2 47.3 0.657 0.95%
8 4th stage of LPT LPH-1 34.6 0.277 4.48%
* After passing through De-super heater of HPH-6
62
 Turning gear

☼The turbine has a shaft turning gear installed in the middle

part of housing cover of bearings No. 4 and No. 5.

☼The drive of shaft turning gear is an induction electrical motor

of 30 KW capacity and 12.25 s-1 (735 rpm) rate speed.

☼Shaft turning gear rotates the shaft line with 0.0175s-1 (1.05 rpm)
speed for uniform warming up/ uniform cooling of rotors.

☼For manual rotation a wrench with arresting device

is set onto shaft end of reducing gear first stage.

63
 Generator

Manufacturer's Name ELECTROSILA

Type designation H2 /H2O
Model No TBB-660-2T
Rated/economic maximum continuous output at
rated H2 Pr & PW temp. 660MW/776.5MVA

Maximum continuous output 687.1MW/808.4MVA

Rated Terminal Voltage 24 KV
Rated Stator Current 18680 Amps
Rated freq 50 Hz.
Rated PF 0.85
Field current 5823 Amps
Field voltage 390 V
Number of phases 3
Number of parallel paths/phase 2
Line terminals brought out 3
Neutral terminals brought out 6
Type of Excitation system Brushless
64
 660MW UNIT
GENERATOR
NTPC NTPC SpSTPS

BUNK
ER

BOILER

PA
FAN FU CEP

PULVERSER

RN DEARATO
R
ID
FAN
ESP FD
FAN AC COOLING
BFP
E
TOWER

TO ASH
DYKE
CW PUMP
THANK YOU
 H.
R.
M.S C.R.H H

BOILER
500 MW

FROM F.R.S
BOTTOM RNG HDR & Z-PANEL 1ST PASS W.W
1ST PASS W.W O/L HDRS ROOF I/L HEADER
2ND PASS UPPER C-HDR 2nd PASS LOWER C-HDRS
LTSH I/L HEADER LTSH O/L HEADER
D.P.I/L HEADER D.P.O/L HEADER
S.H. HEADER R.H.HEADER
November 21, PMI Revision 00 2ND PASS ROOF O/L HDR(REAR 67
ECONOMISER

2020
Reheater steam temperature control by burner tilting

68