SUPERCRITICAL POWER PLANT

PLTU ADIPALA 1 X 660 MW

BOILER ARRANGEMENT
The boiler adopts typical arrangement of B&W SWUP (Spiral Wound Universal
Pressure) supercritical once through boiler.
Vertical separator and water collecting tanks are located in front of boiler; the furnace is
2 composed of lower spiral membrane water wall and upper vertical membrane water wall.
The platen superheater is located at the furnace outlet; SSH inlet and SSH outlet banks
are arranged above the furnace arch. Reheater outlet banks are located in pendent
convection pass. The down pass is separated to two vertical sections by the division wall.
The reheater inlet and economizer are arranged in the front pass, primary superheater
1 and economizer are arranged in the rear pass. The gas biasing dampers are used to
control the reheater steam outlet temperature. There are two Ljungstrom trisector
regenerative air pre-heaters locating at left and right side each.

Feedwater enters the economizer inlet headers .The water passes upward through the
economizer and stringer tubes, and discharges through the outlet headers into water wall
inlet headers. Then water flows upward through spiral furnace, water wall intermediate
header, vertical furnace and water wall outlet headers into furnace outlet mix header, the
mixture flows into vertical separator.

When the boiler is operated below 30% load, the working fluid that enters vertical
separator is steam-water-mixture. The water separated by separator pass through water
collecting tank and circulating pump, and then return to economizer inlet headers. The
steam separated by separator pass through boiler roof, the convection pass enclosure
walls, primary superheater, platen superheater, SSH inlet and SSH outlet. Two stages of
spray attemperators are used to provide tight temperature control in all high temperature
sections.

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CHARACTERISTIC OF SPIRAL WATER WALL
water wall intermediate
header / transition
1
header

23°35’ spiral angle

1. The water wall attain higher velocity mass flow under the
same circumference of the furnace to prevent the heat
transfer deterioration or the unstable hydrodynamic.
2. Each tube has almost same geometry through heat
Furnace: width×depth×height = 23693.7×16318.7×68000（mm）
absorption zone of furnace, and make it to get heat quantity Lower Spiral Furnace: Quantity of Tubes ：638
closely, so it achieves smaller heat deviation at outlet of tube Size of Tube : Φ35x6.5 (smooth tube / ribbed tube)
3. Insensitive for the thermal load change of furnace Material of Tube:SA-213T12
Space between tubes:50mm
4. Slide pressure operation is allowed because no problem in
inhomogeneous distribution of the mixture of steam and Upper Vertical Furnace: Quantity of Tubes: 1596
water. Size of Tube: Φ32×8 (smooth tube)
Material：15CrMoG
5. Complicated construction of tube panel Space between tubes: 50 mm
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SPIRAL WALL VS VERTICAL WALL
F E
A B
C D
Adipala Boiler Arrangement
VERTICAL WALL (PAITON #3)
q Less ash deposition on wall
q Less mass flow
q More number of tubes
q More boiler height for same capacity
q No uniform heating of tubes and heat
transfer in all tubes of WW
q Rifled Tube
Strictly Confidential
SPIRAL WALL (ADIPALA)
q More ash deposition
q More fluid mass flow
q Less number of tubes
q Less boiler height
q Uniform heat transfer and uniform heating
of WW tubes
q Smooth Tube
For smooth tube, sufficient mass velocity
is required
4
VERTICAL SEPARATORS

Steam separators

2
Steam separators
Separators are located between the water wall outlet header and roof inlet header and is used for affective vapour-water
separation during boiler start-up and shutdown or operation at low load conditions. Two vertical steam separators,
consisted of cylindrical body and spherical heads and are made of SA335P91 material, there are 3.4m in length with a
outside diameter of 947mm and an thickness of 96.5mm.

Water collecting tank

The tank is located below the separators and is used to collect drain water from separators. The tank consists of a
cylindrical body and spherical heads. The material is make of SA335P91, is 16.4m in length with an outside diameter of
1016mm and an thickness of 120mm.

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SUPERHEATER TUBE

Specification and material of SH tubes (1)

Item Tube
1. PSH Vertical section Tube1 Tube2
Tube(OD×Thickne mm Φ51x7.5 Φ51x7.5 Φ51x7.5
ss)
Materail 12Cr1MoVG 12Cr1MoVG 15CrMoG

Applicable temp. ℃ 580 560

limit
2. Platen SH Descending tubes Ascending tubes floor tubes

Tube mm Φ51x6.5 Φ51x6.5 Φ51x6.5

(OD×Thickness)
Oxide scale
Exfoliation Material SA-213T91 SA-213T91 SA-
(TP347H) 213TP347H

Applicable temp. ℃ 635 635 655

limit

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SUPERHEATER TUBE

Specification and material of SH tubes (2)

Item Tube

3. SSH inlet section Descending Outer three floor and Other tubes
tube ascending tubes
Tube(OD×Thickness) mm Φ51x6.5 Φ51x6.5/7.5 Φ51x6.5/7/8

material SA-213T91 SA-213TP347H SA-213T91

Applicable temp. limit ℃ 635 655 635

4. SSH outlet section Descendin Other floor Outer three floor tubes Ascending
g tubes tubes and ascending tubes tubes

Tube(OD×Thickness) mm Φ51x9.0 Φ51x9.5 Φ51x8.0 Φ51x9.5

Oxide scale material SA- SA-213T91 SA-213TP347H SA-

Exfoliation 213T91 213TP347H
(TP347H) Tube(OD×Thickness) ℃ 635 655

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REHEATER TUBE

项目 单位 管组
Item Unit Tube
1.低温再热器 过渡管组 水平管组1 水平管组2~3
RH inlet section Intermediate section Horizontal bank1 Horizontal bank 2~3
管子规格(外径×壁厚) mm Φ60x4.5 Φ60x4.5 Φ60x4.5
Tube(OD×Thickness)
节距（横向/纵向） mm 225/80 112.5/80 112.5/80
RH outlet banks
Tube
spacing(side/back)
RH intermediate banks 材质 material 12Cr1MoVG 15CrMoG 20G

材质适用温度界限 ℃ 580 560 450

Applicable temp. limit
2. 高温再热器 高再炉内管
Oxide scale RH outlet section Tubes in furnace
Exfoliation 管子规格(外径×壁厚) mm Φ51x4.0/4.5
(TP347H) Tube(OD×Thickness)
节距（横向/纵向） mm 225/70
RH inlet banks Tube
spacing(side/back)
材质material SA-213T91、SA-213TP347H

材质适用温度界限 ℃ 635 / 655

Applicable temp. limit
8

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WATER TREATMENT
Supercritical
Sub Critical

Water treatment
PLTU Adipala saat
ini masih
menggunakan
AVT (o), belum
berpindah ke OT

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EXFOLIATION OXIDE SCALE

Operating
Supercritical boiler

Besarnya selisih coefficient thermal expansion

antara austenitic steel TP347 dan oxide scale

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EXFOLIATION OXIDE SCALE

Pengaruh siklus pembebanan Pengaruh oxide scale thickness

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EXFOLIATION OXIDE SCALE

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COMBUSTION SYSTEM

q Six MPS mills (ZGM123G-Ⅱ) supply pulverized coal to the burners, with one mill out-of-service, five mills can meet the full
boiler load capability. One mill will feed pulverized coal flow to six burners on one row. 36 sets of DRB-XCL coal-fired burner
are supplied to one boiler in total, which are arranged in a three row by six column arrangement on both front and rear
furnace walls on the big windbox of front wall and rear wall.

q In order to improve the efficiency of combustion and reduce the NOx emission, the big annular windbox is adopted for this
boiler. Dimension of this windbox is 27.3m×17.2m×2.7m(height × width × depth). The air flow amount can be adjusted by
the windbox inlet damper. To get accurate flow amount, aerofoil type of air flow measuring device is mounted at the
upstream of each damper.
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COMBUSTION SYSTEM

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MAIN DESIGN PARAMETERS

COAL ANALYSIS

Range
Item Description Symbol Unit Typical
Min Max

1 Technical analysis (As-

received basis %)

Total moisture Mt % 25 35 30

Inherent moisture Mar % 13.8 25 18

Ash Aar % 3.3 6 5

Volatile matter Vdaf % 27.9 40 35

Fixed carbon FCar 23 41 30

Higher heating value Qnet,ar kCal/kg 3900 4700 4200

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MAIN DESIGN PARAMETERS
COAL ANALYSIS
Scope
Item Description Symbol Unit Typical
Min Max
2 Elemental analysis
Carbon Cdaf % 65 80 68.57
Hydrogen Hdaf % 3 5.9 5.16
Nitrogen Ndaf % 0.54 1.2 1.18
Oxygen Odaf % 12 30 24.76
Sulfur Sdaf % 0.13 0.35 0.33
3 Hardgrove Grindability Index HGI / 50 65 60

4 Ash fusion point Reductive R.a. R.a.

atmosphere
Deformation temp. DT ℃ 1150
Softening temp. ST ℃ 1200
Hemispherical temp. HT ℃ 1250
Fusion temp. FT ℃ 1300

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MAIN DESIGN PARAMETERS
WATER-STEAM PARAMETER
项 目 单 位
BMCR TMCR
Item Unit
过热蒸汽流量
t/h 2069 1943
MS flow
过热蒸汽压力
MPa,g* 25.4 25.25
MS pressure
过热蒸汽温度
℃ 571 571
MS temp.
给水温度
℃ 283 279
FW temp.
再热蒸汽流量
t/h 1731 1632
RH steam flow

再热蒸汽进口压力
MPa,g 4.713 4.428
RH steam pressure (inlet)

再热蒸汽出口压力
MPa,g 4.513 4.24
RH steam pressure (outlet)

再热蒸汽进口温度
℃ 326 319
RH steam temp. (inlet)
再热蒸汽出口温度
℃ 569 569
RH steam temp. (outlet)

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MAIN DESIGN PARAMETERS

THERMAL PROPERTY
名称及符号 单位
BMCR TMCR
Name and symbol Unit
空气预热器出口热一次风温度
℃ 385 376
AH outlet PA temp.
空气预热器出口热二次风温度
℃ 370 362
AH outlet SA temp.
炉膛出口过剩空气系数
/ 1.16 1.16
Excess air ration at furnace outlet
空气预热器入口空气过剩系数
/ 1.17 1.17
Excess air ration at AH inlet
空气预热器入口烟气温度
℃ 396 387
Gas temp. at AH inlet
炉膛出口烟气温度
℃ 960 944
Gas temp. at furnace outlet
空气预热器出口烟气温度(考虑漏风)
℃ 148 144
Gas temp. at AH outlet (considering air leakage)
空气预热器入口空气温度（一次风/二次风）
℃ 41/33 41/33
Air temp. at AH inlet (PA / SA)

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CURVE OF START UP

1 2 3 Initial Load – 30% Load (180 MW)

1
q BASE MODE (Boiler MAN; Turbin MAN)
q Constant Pressure (< 8,7 Mpa)
q Mode Operasi: WET Condition (WC)
q BCP running

Press 22,1 MPa (supercritical) 2

30% Load (180 MW) – 80% Load (528 MW)
q Bisa menggunakan BOILER FOLLOW
(Boiler AUTO; Turbin MAN) / Coordinate
Control (Boiler AUTO; Turbin AUTO)
q Sliding Press ( 8,7 Mpa – 25,2 MPa)
q Mode Operasi: DRY Condition (WC)
q BCP stop

75% Load (495 MW)

> 80% Load (528 MW)
3
q Coordinate Control (Boiler AUTO; Turbin
AUTO)
q Constant Press (25,2 MPa)
q Mode Operasi: DRY Condition (WC)
q BCP stop

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BOILER START UP SYSTEM

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UNIT MASTER

BASE MODE
q Boiler MAN; Turbin MAN
q Actual press dan temp Main Steam tergantung
pengaturan jumlah bahan bakar dan opening valve
turbin
q Kondisi stabil selama tidak ada gangguan pada
Boiler
BOILER FOLLOW
q Boiler AUTO; Turbin MAN
q Boiler Master akan menjaga press MS stabil sesuai
setting point press
q Perubahan beban didapat dengan melakukan
perubahan Manual pada Turbin Master
q Stabilitas beban dipengaruhi oleh kecepatan respon
Boiler

TURBINE FOLLOW
q Boiler MAN; Turbin AUTO
q Turbine Master akan menjaga press MS stabil sesuai
setting point press
q Perubahan beban didapat dengan melakukan
perubahan Manual pada Boiler Master/Fuel Master
q Stabilitas beban dipengaruhi oleh kecepatan respon
Turbin

COORDINATE CONTROL
q Boiler AUTO; Turbin AUTO
q Turbine Master dan Boiler Master akan menjaga
press MS stabil sesuai setting point press
q Perubahan beban didapat dengan melakukan
BOILER MASTER TURBINE MASTER perubahan Manual pada Load Command
q FAN-FAN AUTO/MAN q BFP AUTO REMOTE/MAN q Beban lebih stabil (fluktuasi beban rendah)
q FUEL MASTER AUTO/MAN

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PERBANDINGAN DRY CONDITION PADA BEBERAPA PEMBEBANAN

BEBAN 211 MW (32% TMCR) BEBAN 330 MW (50% TMCR) BEBAN 660 MW (100% TMCR)
q Press Separators: 11,6 MPa q Press Separators: 17,3 MPa q Press Separators: 26,3 MPa
q Temp Separators: 346-353 oC q Temp Separators: 363-373 oC q Temp Separators: 400-402 oC
q Temp saturasi: 322 oC q Temp saturasi: 353 oC q Temp saturasi: 373 oC

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OPERATION MODE
Mode Operasi
Boiler Follow
(Boiler AUTO– Turbine MAN)
Turbine Follow
(Boiler MAN– Turbine AUTO)
Coordinate Control
(Boiler AUTO– Turbine AUTO)
Sliding Pressure
Boiler Follow
Aplicable /No. Kelebihan Kekurangan
Aplicable
Applicable q Boiler Master akan menjaga press MS stabil q Stabilitas beban dipengaruhi oleh kecepatan
sesuai setting point press respon Boiler
q Bisa digunakan saat terjadi masalah pada q Terjadi swing pembebanan (tidak stabil)
Turbine valve
Applicable q Turbine Master akan menjaga press MS stabil q Stabilitas beban dipengaruhi oleh kecepatan
sesuai setting point press respon Turbin
q Load lebih stabil q Respon agak terlambat diawal perubahan
q Bisa digunakan saat terjadi masalah pada Boiler pembebanan
(fan-fan atau fueal master)
Applicable q Turbine Master dan Boiler Master akan menjaga
press MS stabil sesuai setting point press
q Load paling stabil
Applicable
Turbine Follow Coordinate Control
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