Super critcal_sub critical_higher capacity sets - Copy.pdf

EV 2 / Oktober, 99; NTPC Presentation. ppt
Page 1 of 222
Supercritical Coal Fired Power Plants
Bharat Heavy Electricals Ltd.
Babcock Borsig Power GmbH
Siemens AG KWU
Techno - Economic Seminar
for
National Thermal Power Corporation Ltd.
Central Electricity Authority
New Delhi, India
October 21, 1999

Page 2 of 222
Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG KWU
Techno - Economic Seminar
(Delhi, 21 October 1999)
Author No. Topic
Inauguration
BHEL 1.1 An overview of technical collaboration with BBP/Siemens
BBP 1.2 Babcock Borsig Power - An introduction
Technical Session I
Siemens 2.0 Once Through Technology:
- Principle of once-through technology
- Operation of BENSON boilers
BBP 3.0 Comparison of subcritical and supercritical units in view of:
- efficiency (coal savings, reduction of emission etc.)
- availability
- feedwater treatment
- investment costs
- Trends and tendency of the international market towards once through technology
Technical Session II
BHEL 3.1 Technical aspects of the collaboration and BHEL´s preparedness for once-through Boilers
BHEL 3.2 Design and manufacturing of steam turbines for supercritical Parameters (see folder BHEL)
BBP 4.0 Once-through boiler design & operation experiences, reference plants
BBP 5.0 Firing system
Technical Session III
BBP 6.0 Supercritical boiler concept of BBP
BBP 7.0 Operation & maintenance of once-through boilers based on experiences gained in South Africa
Table of Contents
Table of Contents

Page 3 of 222
1.1
1.1 An
An Overview
Overview of technical collaboration with
of technical collaboration with
BBP /
BBP / Siemens
Siemens
BHEL
BHEL

Page 4 of 222
1.2 Babcock Borsig Power - An introduction
1.2 Babcock Borsig Power - An introduction
The merger units four of the most renowned companies in the energy and environmental technologies to
a new world leading group Babcock Borsig Power.
The new group has an order backlog of approx. seven billion DM, a sales of nearly four billion DM and
worldwide approx. 11,000 employees.
More than a century`s worth of exerience an know-how in the engineering of boilers and environmental
systems has been brought together to provide customers with a wide range of products and services.
Our business partners, who have learned to know an value the quality and service offered by individual
companies within the group, can assure that the new Babcock Borsig Power will more than satisfy their
current expectation. We will however, guarantee continuity but can also now offer our customers the
increased benefits which will result from bringing together of the competence and know-how provided by
each individual company.
Worldwide the new company will consist of a wide spectrum of subsidiaries and affiliated companies which
will provide networked sales, engineering, project management, manufacturing and servicing skills. We will
be wherever our customers need us.
Inuaguration
Inuaguration

Page 5 of 222
Inauguration
Inauguration
Babcock Borsig
Babcock Borsig Power - An
Power - An Introduction
Introduction
• In Babcock Borsig Power (BBP) four of the most renowned companies in the energy and
environmental technologies are united.
• Group order backlog of seven billion DM (15,400 CrRs), sales of 4 billion DM (8,800 CrRs),
approx. 11,000 employees
• More than 100 years of experience and know-how in boiler & environmental technology
• Wide range of products and services with outstanding quality by bringing together
competence and know-how provided by each individual company
• Wide spectrum of subsidiaries and affiliated companies which will provide networked
sales, engineering, project management, manufacturing and service

Page 6 of 222

Page 7 of 222
Group
Group Structure
Structure
Babcock Borsig AG
Other related companies: Borsig, Oberflächentechnik, Balcke-Dürr Thermal Engineering,
Balcke-Dürr Prozeßtechnik, Industrierohrleitungsbau, Precismeca
Power transmission
engineering
A. Friedrich Flender
Flender-
Graffenstaden
Flender-Himmelwerk
Flender ESAT
Flender Guß
Loher
Mechanical
engineering
Moenus
Babcock Textilmaschinen
Sucker-Müller-Hacoba
Krantz Textiltechnik
Babcock-BSH
Schumag
Vits
Turbo-Lufttechnik
Neumag
Power plant
engineering
Babcock Borsig Power
Babcock Steinmüller
Oberhausen
Babcock Steinmüller
Gummersbach
Babcock Borsig Service
AE Energietechnik
DB Power Systems
DB Tangshan Boiler
Company
DB Riley
Thomassen International
IDEA
Power systems
Babcock Prozeß-
automation
Nordex
Tuma Turbomach
Babcock-Omnical
Building
technologies
Krantz-TKT
Lufthansa Gebäude-
management Holding
Babcock Dienstleistungen
Krantz-TKT
Cleanroom Technology

Page 8 of 222
BABCOCK BORSIG POWER GMBH
wSteam generators
wUtility steam generators
wIndustrial boilers
wWaste heat boilers (HRSG)
wSpecial boilers
wFluidized bed technologies
wFiring systems
wCoal mills and pulverizing equipment
wAsh handling systems
wFluidized bed coal drying plants
wDampers for air and flue gas systems
wRehabilitation / repowering
wSteam turbines
wTurnkey plants
wCombined cycle power plants
wIndustrial power plants
wCogeneration plants
wProcess steam generating plants
wBiomass fired power plants
wTotal plant service
wPiping
wManufacturing
wErection and commissioning
wOperation and maintenance
wSpare parts
wPersonnel, tools and equipment
wOpencast mining equipment service
wDemolition, cleaning and disposal
Companies included: Babcock Kraftwerkstechnik, L. & C. Steinmüller, Dt. Babcock Anlagen, NEM and AE Energietechnik
wWaste technology and residue
treatment
wMunicipal waste
wHazardous waste
wSewage sludge
wIndustrial waste
wFlue gas cleaning
wPower plants
wWaste-to-energy plants
wIndustry
wProcess plant technology
wWaste heat systems
wCoal gasification
wWater treatment plants
wDrinking water
wProcess water
wIndustrial waste water
wWaste tip seepage
wMunicipal sewage plants
wBiological waste treatment

Page 9 of 222
Company Structure of the Group
Company Structure of the Group
BABCOCK BORSIG POWER
GMBH
Babcock
Steinmüller
Oberhausen
Babcock
Steinmüller
Oberhausen
Babcock Borsig Service
Meeraner
Dampfkesselbau
DB Riley Energy
DB Tangshan
Boiler Company
L. & C. Steinmüller
(Africa)
DB Power Systems
Babcock
Steinmüller
Gummersbach
Babcock
Steinmüller
Gummersbach
DBEMA Energía y
Medio Ambiente
DB Riley Environment
Steinmüller Rompf
Wassertechnik
AE
Energietechnik
AE
Energietechnik
AE Industrieservice
Duro Dakovic
CT Environnement
Mitteldeutsche
Feuerungs-Union
CT Umwelttechnik
NEM
NEM
Vogt NEM
NEM Power Systems
Other related companies: IDEA, Thomassen International

Page 10 of 222
Power Generation Equipment and Plants
Power Generation Equipment and Plants
Main Business Activities:
u Utility steam generators
u Fluidized bed steam generators
u Rehabilitations
u Combined cycle power plants
u Conventional power plants
u Power plants with FBC
u Industrial boilers and plants
u Fluidized bed coal drying plants
u Firing systems
u Ash handling systems
u Waste heat boilers (HRSG)
u Steam turbines

Page 11 of 222
Personnel Structure of the Group
Personnel Structure of the Group
BABCOCK BORSIG POWER
GMBH
Babcock
Steinmüller
Oberhausen
GmbH, Germany
Board of Directors :
Ludger Kramer
(Chairman)
Klaus Dieter Rennert
Dr. Michael Fübi
Other related companies: IDEA, Thomassen International
Board of Directors: Prof. Dr.-Ing. Klaus G. Lederer (Chairman)
Siegfried Kostrzewa (Dep. Chairman),
Hans Kathage, Heino Martin
Babcock
Steinmüller
Gummersbach
GmbH, Germany
Heino Martin
(Chairman)
Arnfred Kulenkampff
AE
Energietechnik
GmbH, Austria
Claus Brinkmann
(Chairman)
Dr. Heinz Frühauf
Wolfgang Schwarzgruber
NEM b.v.,
Netherland
Ulrich Premel
Gert Spruijtenburg

Page 12 of 222
1999 Foundation of BABCOCK BORSIG POWER GMBH
1994 lignite fired Benson Boiler for 2 x 930 MW Units - Lippendorf P.P.
1993 „The Power Plant Award“for most advanced Heat and Power Plant
1992 first supercritical lignite fired Benson Boiler for 2 x 496 MW Units - Schkopau P.P.
1990 bituminous coal fired supercritical Benson Boiler for 1 x 550 MW Unit - Staudinger P.P.
1987 bituminous coal fired supercritical Benson Boiler with for 910 MW Units - Heyden P.P
1979 lignite fired Benson Boiler for 600 MW Unit - Yuan Bao Shan P.P. China
1972 lignite fired Benson Boiler for 2 x 630 MW Unit G + H - Weisweiler P.P.
1969 bituminous coal fired Benson Boiler for 6 x 500 MW Power Plant - Kriel/ South Africa
1965 first German gas tight welded „membran wall“- Benson Boiler
1963 first 1000 t/h Benson Boiler - 300 MW Unit in Germany
1938 first Benson Boiler in Germany
1928 first „
slag tap“-fired boiler world wide
1898 foundation of Deutsche Babcock & Wilcox Dampfkesselwerke AG
1874 foundation of L. & C. Steinmüller Röhren-Dampfkessel-Fabrik

Page 13 of 222
Worldwide Presence
Worldwide Presence

Page 14 of 222
Outcome of the Merger
Outcome of the Merger
Ü Presence across the whole of Europe
Ü Expansion of our international presence
Ü Using synergetic effects to raise competitiveness
Ü Strengthening of our turn-key plant competence
Ü Strengthening our position in environmental engineering and in
BOX models (build and own models)
Ü Improvement of our global market position in steam generators
Ü Market leader for waste-to-energy (WTE) plants in western Europe
Ü Top supplier of flue gas desulphurization plants

Page 15 of 222
2.0 Once-Through Technology
Technical Session I
Technical Session I
Introduction
When Mark Benson registered the patent for "production of steam at any pressure" in 1922, he had no way
of knowing that one day one of the most frequently constructed once-through boilers in the world would be based on his idea.
Today's BENSON boiler, as the result of numerous innovations and many years' experience,
has become a high-reliability power plant component.
As licensor for BENSON boilers (once-through steam generators), Siemens has a wealth of experience in this field.
The Siemens know-how is supplemented by a continuous exchange of experience with licensees and owner/operators
around the world. To date more than 1000 units incorporating this type of steam generator have been built.
Principles of once-through technology
Evaporator Systems
Evaporator systems can essentially be divided into in systems with constant and systems with variable evaporation endpoints:
•
Systems with constant evaporation endpoint.
A typical example of this system is the drum-type steam generator. Natural circulation is produced by heating
of the risers. The water/steam mixture leaving the risers is separated into water and steam in the drum.
The steam flows into the superheater, and the water is returned to the evaporator inlet through downcomers.
If the system is operated only with natural circulation, the application range is limited to a maximum drum pressure of appr.
190 bar. If a circulating pump is used (so called forced circulation), this range can be extended somewhat.
Fixing the endpoint of evaporation in the drum also sets the size of the heating surfaces in the evaporator and superheater.

Page 16 of 222
•
Systems with variable evaporation endpoint.
Evaporation takes place in a single pass. This principle is used in the BENSON boiler, the world's most frequently
constructed steam generator type. Flow through the evaporator is induced by the feed pump. The system can therefore
be operated at any desired pressure, i. e. at either subcritical or supercritical pressure. The evaporation endpoint
can shiftwithin one or more heating surfaces. The evaporator and superheater areas thus automatically adjust
to operational requirements.
A reliable coaching of the water walls in once-through boilers is reached by sufficiently high flow velocities
of the water/steam mixture. This can be achieved by reducing the number of parallel tubes either using a
multi-pass design or a spiral wound tubing of the furnace, however.
Problems with mixing and demixing of the total flow are disadvantageous in the multi-pass design.
Feedwater Control System
Common to both the drum-type steam generator and the BENSON boiler is that the feedwater control system
setpoint is generated for the location in the pressure section where evaporation is complete. In the drum-type
steam generator, this point is the drum itself. The drum level is used as the setpoint. Control quality can also be
improved by allowing for parameters such as unit output.
The endpoint of evaporation in the once-through steam generator is variable and can move within one or more heating
surfaces as a function of operational requirements. The setpoint is therefore also variable. The setpoint is the steam
temperature downstream of the evaporator at a point where the steam already has a certain degree of superheat.
This setpoint is specified as a function of load such that the main steam temperature remains constant.
Main steam temperature is thus independent of load, fouling of heating surfaces or excess air. Unit output,
steam pressure and other parameters can also be allowed for here to improve control quality.

Page 17 of 222
Operators can track adequate feedwater supply similarly for both steam generator.
While the drum level setpoint is constant, the setpoint for steam temperature downstream
of the evaporator can move in a "window" in front of the temperature scale (see figure).
Startup System
Steam power plants have a steam generator startup system and a unit startup system. The steam generator
startup system for a BENSON boiler and a drum-type steam generator are similar. A separating vessel is located
downstream of the evaporator (separator or drum), via which water is removed from the steam generator on startup.
The separated steam cools the superheater. In BENSON boilers for base-load plants, the water separated out in the
separator is led to a flash tank. Units with frequent startup and shutdown usually have a circulating pump.
The steam is then led through the HP bypass station, the reheater and the LP bypass station to the condenser.
This unit startup system is essentially the same for BENSON boilers and drum-type steam generators. The only
difference may be the flow rate through the bypass station, if a 100 % HP bypass station with safety function is used.
The startup sequence is described by three steps. The evaporator is first filled with water (step 1). Then the burners
are ignited, and the steam produced flows through the turbine bypass into the condenser (step 2). As soon as the steam
at the superheater outlet has a sufficient degree of superheat, the turbines are run up and the generator is synchronized
The mass flow through the bypass stations decreases correspondingly (step 3). The startup sequence is essentially the
same for cold, warm and hot starts.
Reliable forced cooling of the water walls and the thin wall thicknesses of the separators at the end of the evaporator
make the startup time of the BENSON boiler considerably shorter than that for the drum-type boiler up to the admission
of steam to the turbine. Cold startup (shut down > 48 hours) governed by the turbine.

Page 18 of 222
Reheater Temperature Control
An operating advantage of the BENSON steam generator is that the main steam temperature can be held constant,
independent of load, fouling of heating surfaces, changing coal characteristics and excess air, simply by adjusting the ratio
of coal flow rate to feedwater flow rate. The spray attemperators are only used for fine control, particularly in the case of
dynamic processes. On the other hand, additional measures are required to maintain constant reheater temperature,
analogous to those for HP and reheater temperatures on a drum-type steam generator.
In Europe the implementation of spray attemporation is widely used, outside Europe damper control and flue gas
recirculation are dominating.
Tendency of Design Parameters
For a long time - from 1970 to 1990 - the power Plant development regarding the steam parameters stagnated world-wide
e. g. in Germany with about 190 bar, 530 °C and in USA with 167 bar, 538 °C. The power plant net efficiency with these
steam conditions was in the range between 37 % and 39 %, bases on lower heating value. In some countries, especially
in Europe and USA, a few supercritical power plants were developed in addition to the conventional design.
The development to higher steam temperatures started in the beginning of the 90's, when new material (P91) not as
expensive as austenitic steel was available. This development was pushed in Japan and in Europe, particularly
in Germany and Denmark.
Today steam temperatures of 580 °C/600 °C are the design parameters for future German power plants.
In Japan these high steam parameters are also state of the art and the development to higher pressure and temperatures will go on.
A comparison of sub- and supercritical power plants in Germany shows, that there is no difference in the availability
of both types of plants. There is no specific or additional risk for power plants with supercritical pressure. Other experiences
by transition to supercritical pressure in the 60's in USA are rather caused by simultaneously increasing the size of power plants
from 300 MW to 1000 MW and more and other conceptional changes like firing design from under- to overpressure and last not
least by the Boiler design itself. UP/Multi Pass.

1924 Siemens buys the „
BENSON Patent“from Mark Benson
1926 to 1929 Siemens manufactures three BENSON boilers
from 30 t/h to 125 t/h
1933 Siemens awards BENSON licences to several
boiler manufacturers
1933 Siemens proposes variable-pressure operation
1949 The world‘
s first once-through boiler with high steam
conditions (175 bar/610°C, BENSON boiler at Leverkusen)
1963 The world‘
s first spiral-tubed water walls in membrane
design (BENSON boiler at Rhodiaceta)
1987 The world‘
s largest hard-coal-fired boiler with spiral-tubed
water walls (900 MW BENSON boiler at Heyden4)
1993 Siemens proposes vertical tubed water walls in low
mass flux design for BENSON boilers
1997 More than 980 BENSON boilers with > 700.000 t/h in total
BENSON Licence
Milestones in the Field of BENSON Boilers
Milestones in the Field of BENSON Boilers
KWU 99 152d
Page 19 of 222

System of risers and downcomers
(m = 1636kg/m2s)
285
44mm
Tubes
38 x 5.6mm
Evaporator Design
Spiral tubing
(m = 2108kg/m2s)
4 x 44 = 176mm
Tubes 33.7 x 5mm
17°
285
Changeover from Vertical Tubing to Spiral-Wound Tubing,
Changeover from Vertical Tubing to Spiral-Wound Tubing,
Illustrated for a 1000 t/h Steam Generator
Illustrated for a 1000 t/h Steam Generator
KWU 99 152d
Page 20 of 222

BENSON Licence
BENSON License Contracts Cover R&D and Technical Assistance
BENSON License Contracts Cover R&D and Technical Assistance
KWU 99 152d
Technical Assistances
R&D
Boiler concepts
Heat transfer
Pressure drop
Water chemistry
Erosion corrosion
Stress analysis
Fluid dynamics
Two phase separation/
distribution
Computer codes
Results transferred to licensees
in yearly BENSON meeting
Activities in case of orders in
common teams or under Siemens
guidelines
Thermodynamic design
Thermohydraulic design
Evaporator design
Start-up system
Control concepts
Operational concepts
Mechanical design
(evaporator)
Feedwater treatment
Page 21 of 222

Load
Water level i n t he drum
Load
T
em perature behind evaporat or
BE NSON Boiler
Drum Boiler
Drum Boiler
Drum Boiler vs
vs. BENSON Boiler - Feedwater Control
. BENSON Boiler - Feedwater Control
KWU 99 152d
Page 22 of 222

Drum level
High level
Low level
Actual
value
Set point
mm
+250
+50
-50
-150
-250
Drum Boiler
0
+150
A ctual
value
Set point
Temperature at evaporator outlet
°C
440
430
410
400
390
380
BENSON Boiler
420
Low
temperat ure
High
temperat ure
Drum Boiler
Drum Boiler vs
vs. BENSON Boiler
. BENSON Boiler
Indicators for Feedwater Supply
Indicators for Feedwater Supply
KWU 99 152d
Page 23 of 222

250
200
150
100
50
0
S liding press
ure
orconstant
pressure
0 20 40 60 80 % 100
Load
bar
Sliding pressure
Pressure
Constant pressure
Sliding pressure
G
~
Operation Mode of Power Plant
Operation Mode of Power Plant
KWU 99 152d
Page 24 of 222

Comparison of Different Operating Modes of Steam Turbines
Comparison of Different Operating Modes of Steam Turbines
40
%
∆ HR
0
Constant pressure with control stage
Constant pressure with throttling control
Main steam pressure = 250 bar
Heat rate HR =
With turbine driven FWP
Main steam pressure = 250 bar
Heat rate HR =
With turbine driven FWP
P Heat Input
P Terminal output
50 60 70 80 90 100
1
2
3
4
Terminal output P
%
Modified sliding pressure
Sliding pressure
Modern Coal-Fired Power Plant
KWU 99 152d
Page 25 of 222

Load [%]
20 50 100
Turbine
(downstream first stage)
Separator
(BENSON)
Drum
Turbine
Maximum Load Change Rates
Boiler
(Drum)
(Drum)
(BENSON)
(BENSON)
Plant
10
%
min
3
7
3
7
Load [%]
o
C
o
C
20 50 100
300
300
400
400
500
500
Turbine
(downstream first stage)
Separator
(BENSON)
Drum
Turbine
Maximum Load Change Rates
Boiler
(Drum)
(Drum)
(BENSON)
(BENSON)
Plant
1-3
%
min
7
7
1-3
}
Variable Pressure Constant Pressure
Comparison of Different Operating Modes
Comparison of Different Operating Modes
KWU 99 152d
Page 26 of 222

100
80
60
40
20
0
Time [ m in]
Load [ %]
0 10 20 30 40
Turbi ne 1
0% /m in
BENSON boi ler
appr. 5% / mi n
Drum boiler
appr. 2% / mi n
Load Ramps in Sliding Pressure Operation Mode
Load Ramps in Sliding Pressure Operation Mode
KWU 99 152d
Page 27 of 222

KWU 99 152d
Comparison of different Control Structure
Comparison of different Control Structure
Page 28 of 222
Drum Boiler versus BENSON Boiler
BENSON Boiler
Drum Boiler

I P/
LP
HP
Ci rculation
pump
Flash t ank /
Feedwater tank
Atmospheric
flashtank
E v a p o r a t o r
S u p er h ea t er
E c o n o m i z e r
Re h e at er
S e p a ra t o r
Start-Up Systems for BENSON Boiler
Start-Up Systems for BENSON Boiler
Modern Coal-Fired Power Plants
KWU 99 152d
Page 29 of 222

Start-Up Times [min] of Power Plants
Start-Up Times [min] of Power Plants
Plants with BENSON Boiler
250 bar / 540°C / 560°C
Plants with Drum Boiler
167 bar / 538°C / 538°C
first steam
to Turbine
full load
From ignition to:
first steam
to Turbine
full load
From ignition to:
20 - 30
40 - 60
150 - 210
150 - 210
60 - 80
80 - 100
300 - 350
450 - 600
20 - 30
30 - 40
60 - 80
60 - 80
30 - 40
50 - 60
150 - 200
400 - 600
After shut
down hours
<1
8
48
>48
KWU 99 152d
Page 30 of 222

Temperature [ C]
o
50 75 100 125 150
Time [min]
175 200 210
0
-15 25
100
400
200
500
300
600
0
Ignition
1000
n [min ]
Turbine
-1
2000
3000
0
Pressure
[bar]
25
100
50
125
75
150
175
200
250
225
0
Load
Flow
[%]
10
40
20
50
30
60
70
80
100
90
0
RH-Temperature
MS-Temperature
MS-Pressure
Fuel Flow
Load
Oil Flow
Speed
MS-Flow
Start-up Performance after 48hrs shut down
Start-up Performance after 48hrs shut down
700 MW Bituminous Coal - Reference Power Plant With BENSON Boiler
KWU 99 152d
Page 31 of 222

RH2
RH1
Spray attemperator
RH1
Fluegas recirculation
Damper control
RH2
Methods of Temperature Control-Overview
Methods of Temperature Control-Overview
Modern Coal Fired Boiler
KWU 99 152d
Page 32 of 222

Methods of RH Temperature Control - Net Efficiencies
Methods of RH Temperature Control - Net Efficiencies
Load 100% 70% 40%
Basis
(without control measures) 43.72% -0.16% -0.11%
Spray attemperator -0.13% 43.35% 41.10%
Damper control -0.02% -0.06% 41.10%
Flue gas recirculation -0.01% -0.22% -0.31%
Modern Coal-Fired Power Plants KWU 99 152d
Page 33 of 222

Molecular Structure of Water
Molecular Structure of Water
as Function of Pressure and Temperature
as Function of Pressure and Temperature
KWU 99 152d
Page 34 of 222

100
150
200
250
300
350
400
450
500
550
600
650
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400
p [bar]
h
[kJ/kg]
T [°C]
700
750
370
380
390
100% MCR
Economizer
Evaporator
RH1
Superheater 1
Superheater 2
Superheater 3
50% MCR
30% MCR
RH2
100%
MCR
50%
MCR
30%
MCR
Supercritical BENSON Boiler in the h/p-Diagram
Supercritical BENSON Boiler in the h/p-Diagram
KWU 99 152d
Page 35 of 222

Power Plan t Capa city Year of Live ste am
MW comm iss. pressure
ba r
Wilhe lmshave n 820 1976 196
Weiher III 707 1976 187
Me hrum 3 712 1979 196
Ge rste inwe rk K 765 1979 202
Voe rd e A 707 1982 187
Voe rd e B 707 1985 187
Ib be nb üre n 770 1985 200
He yd en IV 911 1987 210
Ba d enwe rk 7 536 1985 220
He rn e IV 500 1989 260
Stauding er 5 550 1983 260
Rostock 550 1995 260
Lip p en dorf A 930 1999 268
Lip p en dorf B 930 1999 268
Boxb erg Q 915 2000 268
Evaporator inlet p ressure
(b ar)
220 240 260 280 300
Coal-Fired Supercritical 500/900 MW
Coal-Fired Supercritical 500/900 MW
BENSON Boiler in Germany
BENSON Boiler in Germany
KWU 99 152d
Page 36 of 222

Temperature
Commissioning year
1994 1996 1998 2000
600
580
560
540
Pressure range:
USA: 251 bar
Japan: 242 bar
Germany: 250 to 285 bar
°
C
HP (Germany)
HP and IP (USA)
HP (Japan)
IP (Japan)
IP (Germany)
Development of Turbine Inlet Temperatures
Development of Turbine Inlet Temperatures
Modern Coal-Fired Power Plants
KWU 99 152d
Page 37 of 222

Trend of boiler steam condition in Japan
Trend of boiler steam condition in Japan
1988 90 92 94 96 98 2000 02 04
Year in commission
41
42
43
44
Plant
efficiency
(%)
Coal fired power plants
246atg/538/566°C
246atg/566/566°C
246atg/566/593°C
246atg/593/593°C
250atg/600/600°C
Higher Efficiency in
Thermal Power Plants
High Strength Steels for Higher
Steam Temperature and Pressure
300atg/625°C
KWU 99 152d
Page 38 of 222

Page 39 of 222
Tendency of
Tendency of Design Parameters
Design Parameters for
for
Once Trough
Once Trough Boilers in
Boilers in Pit Head
Pit Head Power
Power Plants
Plants
Project Capacity Design Parameter Fuel Award Date
Germany Weisweiler PP 2 x 600 MW 530/530° C - 172 bar lignite 1971
Schkopau PP 2 x 480 MW 545/560° C - 263 bar lignite 1992
Schwarze Pumpe PP 2 x 850 MW 545/562° C - 266 bar lignite 1992
Boxberg PP 1 x 900 MW 545/580° C - 266 bar lignite 1992
Lippendorf PP 2 x 930 MW 554/583° C - 267 bar lignite 1994
Niederaußem PP 1 x 950 MW 580/600° C - 260 bar lignite 1997
Design Study Neurath F PP 1 x 950 MW 600/620° C - 260 bar lignite (2004)
South Africa Tutuka PP 6 x 600 MW 540/540° C - 171 bar bitumin. coal 1982
Duvha PP 6 x 600 NW 540/540° C - 174 bar bitumin. coal 1977
Majuba PP 3 x 660 MW 538/538° C - 174 bar bitumin. coal. 1984
3 x 700 MW 538/538° C - 174 bar bitumin. coal. 1984
Australia Calide PP 2 x 420 MW 540/560° C - 250 bar bitumin. coal 1998
Millmeran PP 2 x 350 MW 568/596° C - 250 bar bitumin. coal 1999
Kogan Creek PP 1 x 700 MW 545/563° C - 264 bar bitumin. coal 1999

Page 40 of 222
Technical Session I
Technical Session I
Bharat Heavy Electricals Ltd. - Babcock Borsig Power GmbH - Siemens AG
3.0 Comparison of Subcritical and supercritical Units in View of
Efficiency, Availability,Feedwater Treatment and Investment Costs
The most important effect of supercritical and ultra supercritical plant design is the increase of plant
efficiency. It is obvious that units running with higher efficiency, i.e. burning less quantity of coal to produce
same amount of electric energy, are giving a significant benefit regarding saving of natural coal reserves and
saving of the environment by reducing dust-, CO2, SOx and NOx-emission. Considering only the increase of
efficiency by increasing the steam parameters from 175 bar, 538/538°C to 241 bar, 538/566 °C will give a coal
saving of 210,00 tons per year for a typical Indian super thermal power station of 4x500 MW electric output.
Annual saving of CO2 can be estimated to approx. 262,000 tons per year, SO2, saving can be calculated to
1,600 tons and total ash saving to about 90,900 tons for this power station.
Availability data for subcritical and supercritical power plants based on recent US EPRI and German VGB
publications or from Japan give clear evidence that over the last decades plant availability data for supercritical
units are in the same range as the relevant data for subcritical units. In addition enclosed availability figures
from several once-through boilers supplied by BBP to different utilities illustrate the reliability of the units.
Regarding water chemistry a comparison of the relevant international standards illustrates that no additional
installation for supercritical power plants compared to the requested standards for high pressure subcritical
plants are required. A combination of a condensate polishing plant with oxygenated treatment can be
recommended as a well proven procedure. Further, once-through boilers do not have a boiler blow down. This
has a positive effect on the water balance of the plant with less condensate needed to be fed into the
water-steam cycle and less waste water to be disposed.

Page 41 of 222
In the recent past several studies have been worked out by various companies and institutions comparing
investment costs and electricity generation costs of subcritical and supercritical coal fired thermal power
stations. For example Shell & SEPRIL (a consulant,jointly owned by Electric Power Research Institute and
Sargent & Lundy) have assessed the cost effectiveness and environmental performance of a State of the Art
Power Plant (SOAPP), PF-coal fired, 3500 psig (240 bar, 41% plant efficiency), supercritical, 2x600 MWel, in an
Asian location in a detailed study for the International Energy. The plant investment costs on turn key base have
been found out to be 1% higher in comparison to a comparable subcritical unit (38 % plant efficiency).
Regarding electricity generations costs the effect of the fuel price is very significant but even in case of low fuel
cost (15 US $/to) and lower capital cost the supercritical unit causes lower electricity costs.
Our own investigations based on a 525 MWel world coal fired unit for Israel and 2x660 MWel high ash coal
fired boilers for China confirm the results of the Shell report. The total plant investment costs for the supercritical
unit based on design data (255 bar, 540/560°C) and turn key scope will increase 1.85% in comparison to the
subcritical unit. Further, specific investment costs can be lowered by increasing unit size.
The costs for the boiler itself will increase in the order of 4.5 to 5% by using supercritical steam parameters.
Noted that these studies are mainly based on world coal fired units. Considering high ash Indian coal
investment cost of the units (subcritical or supercritical) in general will increase in comparison to low ash coal
firing units due to the special layout requirements of the boiler, electrostatic precipitator and ash handling
system. However it can be predicted that the price relation of subcritical to supercritical units both firing high ash
Indian coal will not be influenced, i.e. will remain in the range of about 2% higher investment cost for the
supercritical unit.

Page 42 of 222
Technical
Session II
Comparison of Sub
Comparison of Sub-/
-/Supercritical Units
Supercritical Units in
in View of
View of Efficiency,
Efficiency, Availability
Availability,
,
Feedwater
Feedwater Treatment, Investment
Treatment, Investment Costs
Costs
•Increasing steam parameters from subcritical to supercritical like 241bar, 538/566°C
will result in preservation of resources and will consider the greenhouse effect.
For a 4x500MWe power station in India a coal saving of 210,000 tons/a, CO2-saving
of 262,000 tons/a and a SO2-saving of 1,600 tons/a will be reached.
•Availability of supercritical units are comparable to subcritical units.
•International standards for water chemistry do not ask for additional installations for
supercritical units compared to high pressure subcritical units.
•Turn key plant investment costs on international basis for 240bar, 540/560°C
supercritical units are in the range of 1 to 2% higher in comparison to high pressure
subcritical units. Cost increase for the boiler will be about 4.5 to 5%.
•It can be assumed that this price relation will remain the same for power plant
designed for Indian coal.

Page 43 of 222
Development thermal net efficiency of bituminous coal
Development thermal net efficiency of bituminous coal
and lignite power plant in Germany
and lignite power plant in Germany
1980 1990 2000 2010
35
40
45
50
Year
η
th % *
Rostock 550 MW
Staudinger 550 MW
bituminous coal
lignite
Lippendorf
2 x 930 MW
Schkopau 2 x 400 MW
subcritical supercritical
high temperature
steam processes
Hemweg 8
680 MW
Westfalen D
350 MW
Bexbach 1
750 MW
availability of new materials
* η th = including desulpherisation
and denitrification
(based on: LHV
Bexbach 2
750 MW
Niederaußem
980 MW
BoA*-plus
1000 MW

Page 44 of 222
Potential for Efficiency Improvement for Lignite Fired
Potential for Efficiency Improvement for Lignite Fired
Steam Generators
Steam Generators
Source: Energietechnische Tagesfragen 1997-Heft 9
Prof. Dr. Ing. W. Hlubek - Vorstand RWE
up to now: BoA* with integrated drying process
intergrated
drying
hot flue gas
with 1000 °C
row coal
dry coal
+ flue gas
+ vapour
flue gas
plus vapour
separate
drying (WTA)
electric
energy
Steam
vapour
flue gas
Heat Pump
energetic disadvantage:
- predrying on very high
temperatur level
- no use of vapor energy
energetic improvement:
- predrying on low energy
level
- use of vaporenergy
appr. 5% efficiently improvement
η = 43 % η = 48 %
BoA* plus predrying
drying
unit
row coal
condensat
dry coal
Boiler
Boiler

Page 45 of 222
Measures to increase Efficiency
Bexbach
Bexbach I PP versus
I PP versus Bexbach
Bexbach II PP
II PP
Source: VGB-Kraftwerkstechnik 75 (1995) Heft 1
INCREASE SH AND RH STEAM
TEMPERATURE TO 575/595 °C /
Ê = 1,3 %
INCREASE SH-STEAM
PRESSURE TO 250 BAR / Ê = 0,65 %
ADDITIONAL UTILISATION OF FLUE GAS HEAT /
Ê = 0,6 %
COMMISSION OF REHEATING / Ê = 0,15 %
INCREASE OF FEEDWATER TEMPERATURE / Ê = 0,7 %
REDUCTION OF EXHAUST
STEAM PRESSURE / Ê = 1,1 %
REDUCTION OF EXCESS AIR / Ê = 0,4 %
OPTIMISATION OF COMPONENTS
(IN PARTICULAR THE T/G) / Ê = 2,4 %
39,00 % = BASIS VALUE FOR BEXBACH I POWER STATION
39,00
41,40
41,80
42,90
43,60
43,75
44,35
45,00
46,30
NET
EFFICIENCY
%
46,30 % = BASIS VALUE FOR BEXBACH II POWER STATION

Page 46 of 222
Reference Letter
Reference Letter Heyden
Heyden
Thus in our power plant KW Heyden
(900 MWel., commissioning year 1987,
concept without overfire air)
an ratio of 1.12 - 1.16 was achieved.

Page 47 of 222
Ruthenberg
Ruthenberg PP versus
PP versus Rostock
Rostock PP
PP
INCREASED TURBINE EFFICIENCY
/ Ê = 0,4 %
41,6
42,0
43,2
43,6
41,1
INCREASED SH PRESSURE TO 262 BAR
AND INCREASED FEEDWATER TEMPERATURE
TO 272 °C / Ê = 1,2 %
INCREASED REHEATER OUTLET TEMPERATURE TO 560 °C
/ Ê = 0,4 %
INCREASED BOILER EFFICIENCY
/ Ê = 0,5 %
41,1 % = BASIS VALUE FOR RUTHENBERG POWER STATION
43,6 % = BASIS VALUE FOR ROSTOCK POWER STATION
NET
EFFICIENCY
%

Page 48 of 222
Comparison of Plant part load efficiency
Comparison of Plant part load efficiency
30
40
46
30 40 50 60 70 80 90 100
Load %
41,1 %
36,7 %
39,3 %
40,5 %
43,2 %
42,4 %
40,1 %
Plant
net
efficiency
Supercritical unit
acc. Alternative 2
255 bar 538°C / 538°C
Subcritical unit
acc. Alternative 1
166 bar 538°C / 538°C
43,6 %

Page 49 of 222
Relative Plant - h improvement of supercritical steam
Relative Plant - h improvement of supercritical steam
process compare to
process compare to subcritical
subcritical unit
unit
4
5
6
7
8
9
30 40 50 60 70 80 90 100
Load %
Relative
η
-
improvement
∆η/η
in
%

Page 50 of 222
Increase of Cycle
Increase of Cycle Efficiency
Efficiency due
due to
to Steam
Steam Parameters
Parameters
300
241
175 538 / 538
538 / 566
566 / 566
580 / 600
600 / 620
6,77
5,79
3,74
5,74
4,81
2,76
4,26
3,44
1,47
3,37
2,64
0,75
2,42
1,78
0
0
1
2
3
4
5
6
7
8
9
10
HP / RH outlet temperature [deg. C]
Pressure [bar]
Increase of efficiency [%]

Page 51 of 222
Saving of Coal Reserves and Mitigation of Environmental Impact by
Saving of Coal Reserves and Mitigation of Environmental Impact by
Using Supercritical Technology
Using Supercritical Technology
Essential Measures to Increase Plant Efficiency
1. Cycle Efficiency
- Increased steam parameters: 175bar, 538/538°C ð 241 bar, 538/566 °C
- Double reheat: not considered
- Reduced pressure in condenser: not considered
2. Boiler Efficiency
- Reducing flue gas temperature: not considered
3. Turbine efficiency
- Advanced turbine design: not considered

Page 52 of 222
Effect of Increased Cycle
Effect of Increased Cycle Efficiency
Efficiency on Coal Consumption
on Coal Consumption
0,00
10,00
20,00
30,00
40,00
50,00
(Lakh tons/a)
(Cr. Rs/a)
Savings of Coal Reserves / Coal Costs per Year
Coal Saving (Lakh tons/a) 2,15 11,28
Coal Cost-Saving (Cr. Rs/a) 9,67 50,74
Sipat (4x500 MWe) All India (21x500 MWe)
Base of calculation
Efficiency subcritical
cycle: 38.5%
Increase of efficiency:
+ 2.64%rel., (+1%abs.)
LHV 12,937 kJ/kg
Fuel Consumption of
Subcritical Unit: 339 t/h
Operation: 6000 h/a
Fuel Price: 450 Rs/to

Page 53 of 222
Effect of Increased Cycle
Effect of Increased Cycle Efficiency
Efficiency on
on Emission
Emission
0
200
400
600
800
1000
1200
1400
(1000 to/a)
Saving of Emission per Year
CO2 Saving (1000 to/a) 262,3 1376,8
SO2 Saving (1000 to/a) 1,6 8,3
Total Ash Saving (1000 to/a) 90,9 477,2
Sipat (4x500 MWe) All India (21x500 MWe)
Efficiency subcritical cycle: 38.5%
Increase of efficiency:
+ 2.64% rel., (1%abs.)
LHV 12,937 kJ/kg
Ash Content 42.3%
Sulphur Content 0.37%
Fuel Consumption of
Subcritical Unit: 339 t/h
Operation: 6000 h/a

Page 54 of 222
Reduction of Ash due
Reduction of Ash due to
to Increased Cycle
Increased Cycle Efficiency
Efficiency
Sipat ash saving after 5 years of operation
equivalent to a cone of approx. 454,500 m3
appro
x.
76
m
approx. 57 m

Page 55 of 222
Saving of Coal due
Saving of Coal due to
to Increased Cycle
Increased Cycle Efficiency
Efficiency
appro
x.
76
m
approx. 57 m
Sipat coal saving after 2 years of operation
equivalent to a cone of approx. 537,500 m3

Page 56 of 222
Generation
Generation Availability
Availability (VGB)
(VGB) Subcritical
Subcritical,
, Supercritical
Supercritical
Power
Power Plants
Plants
0
10
20
30
40
50
60
70
80
90
100
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
88-97
Subcritical Supercritical
%
Year
0
20
40
60
80
100
85 86 87 88 89 90 91 92 93 94 95 96 97 88-
97
Time Availability
Time Utilization
Energy Availability
Energy Utilization
%
Year
Subcritical
Subcritical
Year 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 88-97
Availability 84,6 83,7 82,4 82,6 81,5 83,2 85,4 82,8 80,2 82,5 81,9 86,1 87,4 83,3
Supercritical
Supercritical
0
20
40
60
80
100
85 86 87 88 89 90 91 92 93 94 95 96 97 88-
97
Time Availability
Time Utilization
Energy Availability
Energy Utilization
%
Year
Year 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 88-97
Availability 83,1 87,2 81,4 78,3 73,2 83 82,9 86,2 90,9 80,5 83,1 79,2 89,2 82,9

Energy
Energy Unavailability
Unavailability not
not Postponable
Postponable (EU)
(EU)
of German Power Plants
of German Power Plants
0
1989 1991 1993 1995 1997
2
4
6
8
10
Year
Subcritical
Supercritical
EU(%) = FOE/MPG*100%
FOE = Forced outage energy
MPG = Maximum possible energy
EU(%) = FOE/MPG*100%
FOE = Forced outage energy
MPG = Maximum possible energy
%
EU
Supercritical versus Subcritical KWU 99 152d
Page 57 of 222

Energy Availability of German Power Plants
Energy Availability of German Power Plants
KWU 99 152d
1989 1991 1993 1995 1997
100
Year
%
EA
90
80
70
60
50
EA(%) = AV/AN*100%
AV = Available Energy
AN = Nominal Energy
EA(%) = AV/AN*100%
AV = Available Energy
AN = Nominal Energy
Subcritical
Supercritical
Supercritical versus Subcritical
Page 58 of 222

Page 59 of 222
Reference Letter
Reference Letter Staudinger
Staudinger
Please find attached the „
Certificate of Experience Record“completed
by PreussenElektra Kraftwerk Staudinger. We would like to confirm that
the steam generators supplied by Deutsche Babcock have fulfilled all
requirements of PreussenElektra Kraftwerk Staudinger as owner and
operator to our full satisfaction during all years of operation.

Page 60 of 222
Experience Record
Experience Record Staudinger
Staudinger
•Commercial Operation date: 1992/06/15 1996/07/16 49
•Capacity Factor:: 91%
•Availability factor: 99%

Page 61 of 222
Reference Letter
Reference Letter Rostock
Rostock

Page 62 of 222
Experience Record
Experience Record Rostock
Rostock
•Continous Operation Period: 94/8/1 until now 57
•Capacity Factor: 98,00%
•Availability factor: 99,2%

Page 63 of 222
*)downstream Condenser
< 200
"... The DOCcontentof completely
demineralized make-upwater should
not exceed 0.2 mg/l..."
ppb
Organicsubstances
(asDOC/TOC)
-
< 100
ppb
Oil /grease / fat
-
≤ 10
ppb
N2H4
≤ 20
≤10 *)
≤10 *)
< 20
< 20
ppb
Silica (SiO2
)
≤2
≤ 5
≤ 2
≤2
< 3
< 3
ppb
Copper(Cu)
≤ 10
≤20
≤ 10
≤ 10
< 10
< 20
< 20
ppb
Iron (Fe)
≤3 *)
≤3 *)
≤ 5 *)
< 10
< 10
ppb
Sodium + Potassium
(Na + K)
≤ 20 - 200
≤ 7
≤ 7
≤ 5
≤5
≤250
< 100
30 to150
< 100
< 100
ppb
Oxygen(O2
)
6.5 - 9.0
9.0 - 9.6
8.5 - 9.6
9.0 - 9.6
9.0 - 9.6
7 .... 10
> 9.2
8 to 9
9 to 10
9 to 10
-
pHvalue at25 °C
≤ 50
ppb
Total Solid
≤0.2
≤ 0.25
≤0.5
≤0.2
≤ 0.2
< 0.2
< 0,2
µS/cm
Acid conductivity
at 25 °C
not specified
-
not specified
µS/cm
Conductivityat 25 °C
clear,
free fromsuspendedsolids
clear and colourless
-
Appearance
> 20
15 - 20
with Reheat
> 6
total range
total range
MPa
Operating pressure
Oxigenated
Treatment
All Volatile
Treatment
Coordinated
Phosphate
Treatment
AllVolatile
Treatment
AllVolatile
Treatment
Phosphate
Treatment
All Volatile
Treatment
./.
Combined
Operation
Alkaline
Operation
Combined
Operation
All Volatile
Treatment
Alkaline
Operation
Operation
Once-through
Drum Type
Once-through
Drum Type
Once-through
Drum Type
Once-through
Drum Type
Boiler
Type
JIS B8223
1989
EPRI CS-4629
1986
EN 12952 Part 12
Draft 1998
VGB-R 450 L
1988
Japan
U.S.A.
Europa
Germany
Supercritical Power Plants/ Evaluation of Design Parameters
Requirements for Feedwater Quality

Page 64 of 222
< 5
ppb
Chloride (Cl)
5
< 20
5
< 20
< 10
< 20
< 10
< 10
ppb
Silica (SiO2)
1
< 3
1
< 3
< 1
< 3
< 1
< 2
ppb
Copper (Cu)
5
< 20
5
< 20
< 5
< 20
< 5
< 20
ppb
Iron (Fe)
2
< 10
2
< 10
< 5
< 10
< 10
< 5
< 3
ppb
Sodium +Potassium
(Na + K)
0,1
< 0.2
0,1
< 0,2
< 0,1
< 0,2
< 0,1
< 0,3
< 0,2
µS/cm
Acid conductivity
at 25 °C
Normal
operating
value
Standard
value
Normal
operating
value
Standard
value
Unit
Parameter
VGB-R 450 L
1988
Siemens / KWU
1998
MAN
ABB
Allis
Chalmers
Westinghouse
General
Electric
Requirements on Steam for Condensing Turbines

Page 65 of 222
High Pressure Drum Boiler: Steam Quality (Silica) and Blow Down Rate
Drum Boiler
Drum pressure: 18 MPa
Silica distribution ratio (C Steam / C Water): 0.08
* Condensate Polishing Plant required
Balance
0
50
625
50 *
Balance
0
30
375
30 *
!!
13.0 *
20
250
50 *
!!
4.3 *
20
250
30 *
2 *
20
250
24.6 *
1
20
250
22.3
Balance
0
20
250
20
!!
8.7 *
10
125
20
Balance
0
10
125
10
%
Feedwater
SiO2
(ppb)
SiO2
(ppb)
SiO2
(ppb)
Blow
down rate
Steam
Boiler
water
Feedwater
Once-through Boiler: Feedwater Quality = Steam Quality
Blow Down Rate = 0
Condensate Polishing Plant required
Boiler water
SiO2 = 250 ppb
Feedwater
SiO2 = 20 ppb
Steam
SiO2 = 20 ppb
Blow down
0 %
Balance at 180 MPa:

Page 66 of 222
1. Study of Shell Coal International & SEPRIL Services
2. BBP evaluation based on 525 MWel power plant project in Israel
3. BBP evaluation based on 660 MWel boiler project in China
Evaluation Subcritical
Evaluation Subcritical/
/Supercritical
Supercritical Power
Power Plants
Plants

Page 67 of 222
Comparison of
Comparison of Plant Investment
Plant Investment
Study
„Increasing the Efficiency of Coal-fired Power Generation“
from Shell Coal International & SEPRIL Services
for publication by the International Energy Agency

Page 68 of 222
Comparison of
Comparison of Plant Investment:
Plant Investment: Subcritical
Subcritical/
/Supercritical
Supercritical
Case-Study
2x600 MWel, pulverized bituminous coal fired power plant in an Asian location
Case (1) 2400 psig (165 bar) subcritical plant,
38 % nominal design efficiency based on LHV
Case (2) 3500 psig (240 bar) supercritical
41% nominal design efficiency based on LHV
Source: Study of Shell Coal International & SEPRIL Service
Calculation Basis
- turn key plant equipment incl. low Nox-burners, structures, switchyard, coal unloading facilities,
sea water cooling
- 60 month construction schedule
- 30 years plant operation period
- 85% availability, 80% capacity factor
- 13% fixed charge rate
- 9.8% interest during construction
- 13$/kW-year O&M (fixed), 2% O&M escalation
- 5$/to waste disposal costs

Page 69 of 222
Comparison of
Subcritical/
/Supercritical
Supercritical
Components Subcritical Plant
Capital Costs ($/kW)
Supercritical Plant
Capital Costs
($/kW, % compared to subcritical)
Boiler (incl. steel structures
and components)
142.94 153.09 (107.1)
Boiler plant piping 27.81 31.03 (111.6)
Feedwater system 28.06 28.62 (102.0)
Turbine-Generator 79.2 82.37 (104.0)
Turbine plant piping 16.25 15.44 (95.0)
Subtotal 294.26 310.38 (105.5)
Remainder of Plant 509.17 500.69 (98.3)
Total Plant Cost 803.43 (100%) 811.07 (101.0)
Source: Study of Shell Coal International & SEPRIL Service
Capital Costs

Page 70 of 222
Comparison of
Subcritical/
/Supercritical
Supercritical
Generating Cost of Electricity (cents/kWh)
0
1
2
3
4
5
6
7
8
Subcritical Supercritical Subcritical Supercritical
Fuel Costs
Variable O&M
Fixed O&M
Capital Charges
Diff. = 0.08 cents/kWh
Diff. = 0.23 cents/kWh
Fuel Cost: 15$/to Fuel Cost: 40$/to

Page 71 of 222
Subcritical/Supercritical Bituminous Coal Fired Units
525 MWel,net
(Rutenberg, Israel)

Page 72 of 222
Single Unit Capacity Single Unit Cost Total Plant Cost
(2000 MW)
Specific Plant Cost
(2000 MW)
500 MW subcritical 100.00 % 359.5 % 100.00 %
500 MW supercritical 101.85 % 366.1 % 101.85 %
660 MW supercritical 125.58 % 342.8 % 95.35 %
660 MW subcritical 123.26 % 336.5 % 93.60 %
Power Plant India: A.) 4 x 500 MW (4 x 100% capacity)
B.) 3 x 660 MW (3 x 132% capacity)
Power Plant Israel: A.) 4 x 525 MW (4 x 100% capacity)
B.) 3 x 693 MW (3 x 132% capacity)
Comparison of Plant Investment based on Experiences in the International Market
Comparison of Plant Investment based on Experiences in the International Market

Page 73 of 222
Comparison of Plant Investment: Subcritical/Supercritical
Alt. 1
(subcritical)
Alt. 2
(supercritical)
Alt. 3
(supercritical)
Alt. 4
(supercritical)
Live steam pressure at turbine (bar) 166 255 255 255
Live steam temp. at turbine (°C) 538 540 540 540
Hot reheat temp. at turbine (°C) 538 560 560 560
Feed water temp. (°C) 250 272 272 272
Condenser pressure (mbar) 50 50 50 50
Power (MWel,net) 525 525 669 693
LHV, world coal (kJ/kg) 25.748 25.748 25.748 25.748
Alternatives investigated

Page 74 of 222
1. Boiler & Auxiliary Plant
Boiler, fuel storage / supply & ash handling, ESP, wet FGD, air heaters / sootblowers / firing
equipment, combustion air & flue gas system,insulation, painting, cleaning, engineering
2. Turbine Set
Turbine, generator & excitation, condenser & auxiliaries, feedheaters, deaerator, engineering
3. BOP
Pumps, pipes, valves, water treatment / dosing unit, cooling main equipment, cranes& hoists,
elevators, engineering, others (e.g. tanks, compressors etc.)
4. Electrical Equipment
Generator rel. Equipment, transformers, motors, med/low voltage switchgears, cable, bus ducts,
cable trays & accessories, communication, lighting, grounding, engineering
Scope of supply breakdown

Page 75 of 222
5. Main and Field I&C
Main I & C, Field I & C, control valves, engineering
6. Civil / HVAC / Fire Fighting
Concrete & architectural works, steel structures, HVAC, fire fighting, engineering
7. Plant Engineering
8. Special Project Cost
M-Turbine set, PM power plant, PM supporting, project travelling
9. Erection/Commissioning
Site management & facilities, erection & commissioning: turbine generator, BOP-equipment, boiler,
training / operation
Scope of supply breakdown

Page 76 of 222
Scope/Component Alternative 1 Alternative 2
525 MWel,net = 100% 525 MW = 100%
165 bar, 538/538°C 255 bar, 540/560°C
% (total) % (relative) % (total) % (relative)
1. Boiler & Auxiliary Plant 29,5 100 30,3 104,6
2. Turbine Set 8,6 100 8,7 102.86
3. BOP 16,1 ) 16 )
4. Electrical Equipment 7,3 ) 7,2 )
5. Main and Field I&C 5,3 ) 5,2 )
6. Civil/HVAC/Fire Fighting 14,2 ) 100 14 ) 100,4
7. Plant Engineering 4,4 ) 4,3 )
8. Special Project Costs 3,3 ) 3,2 )
9. Erection & Commissioning 11,3 ) 11,1 )
Sum (1 Unit) 100 100 100 101,85
Detailed Cost Breakdown in %

Page 77 of 222
525 MWel,net = 100% 669 MW = 127,43%
165 bar, 538/538°C 255 bar, 540/560°C
2. Turbine Set 8,6 100 8,6 120
3. BOP 16,1 ) 16,2 )
6. Civil/HVAC/Fire Fighting 14,2 ) 100 13,9 ) 118,2
7. Plant Engineering 4,4 ) 4,1 )
8. Special Project Costs 3,3 ) 2,9 )
9. Erection & Commissioning 11,3 ) 11,1 )
Sum (1 Unit) 100 100 100 121,38

Page 78 of 222
525 MWel,net = 100% 693 MW = 132%
165 bar, 538/538°C 255 bar, 540/560°C
2. Turbine Set 8,6 100 8,6 124,3
3. BOP 16,1 ) 16,1 )
6. Civil/HVAC/Fire Fighting 14,2 ) 100 13,9 ) 121,8
7. Plant Engineering 4,4 ) 4 )
8. Special Project Costs 3,3 ) 3 )
9. Erection & Commissioning 11,3 ) 11 )
Sum (1 Unit) 100 100 100 125,58

Page 79 of 222
Plant Cost versus Unit Capacity
100
105
110
115
120
125
130
135
100 105 110 115 120 125 130 135
Unit Capacity (%)
Plant
Cost
(%)
525 MWe
supercritical
669 MWe
supercritical
693 MWe
supercritical
Calculation based on
constant price factor
($ / MWe)
Basis
Rutenberg, Israel, Supercritical
Bituminous Coal Fired Power Plant
Effect of Unit Size on Investment Costs
Effect of Unit Size on Investment Costs

Page 80 of 222
Comparison of Subcritical
Comparison of Subcritical/
/Supercritical
Supercritical Boilers
Boilers
Subcritical Boiler
2x660 MW Shalingzi Phase II Power Plant
2x2,150 t/hr ; 175 bar ; 541/540 °C
Supercritical Boiler
2x660 MW Douhe Phase II Power Plant
2x1,981 t/hr ; 260 bar ; 545/562 °C

Page 81 of 222
S H A L I N G Z I Power Plant Phase II
S H A L I N G Z I Power Plant Phase II
(China)
Unit Capacity 2 x 660 MW
Natural Circulation Boiler
with
damper-controlled parallel pass for reheat temperature control
Coal Firing System for NOx = 300/200 ppm
Furnace Exit Temperature < 1,050 °C
Subcritical Steam Condition 175 bar ; 541/540 °C
Modified Sliding Pressure Operation
Base Load Operation 7,500 operating hours per year

Page 82 of 222
2 x 660 MW
2150 t/hr; 175 bar; 541/540 °C
SHALINGZI PHASE II POWER PLANT
SHALINGZI PHASE II POWER PLANT

Page 83 of 222
D O U H E Power Plant Phase II
D O U H E Power Plant Phase II
(China)
Unit Capacity 2 x 660 MW
Benson Type Boiler
with
flue gas recirculation for reheat temperature control
Coal Firing System with low NOx combustion
Furnace Exit Temperature
design coal < 1300°C
check coal < 1050°C
Supercritical Steam Condition 260 bar ; 545/562 °C
Modified Sliding Pressure Operation
Base Load Operation 7,600 operating hours per year

Page 84 of 222
DOUHE PHASE II POWER PLANT
DOUHE PHASE II POWER PLANT
2 X 660 MW
1981 t/hr; 260 bar; 545/562 °C

Page 85 of 222
0
10.000
20.000
30.000
40.000
50.000
60.000
1 2
Total
Weight
(Tons)
Boiler
Electric + I&C
Cleaning/Hoist/etc.
Pipework
Insulation
Ash Removal
E S P
Draft System
Firing System
Sootblower
Air Preheater
Steel Structure
Spare Parts
Bunker Feeding
Shalingzi 2x660 MW
subcritical
Douhe II 2x660 MW
supercritical
Diff. = 3,425 to (30%)
Total Diff. = 4,878 to (10%)
Weight Comparison Shalingzi
Weight Comparison Shalingzi/
/Douhe
Douhe II
II

Page 86 of 222
1x660MW
Shalingzi
subcritical
DIN design
(weightinto)
1x660MW
Douhe II
supercritical
DIN design
(weightinto)
MembranWalls 1,127 991
Heating
Surfaces
1,630 1,420
Headers 332 455
Pipework 612 509
BoilerDrum/
Separator
267 65
Sum
Pressure Parts
3,967(100%) 3,440(87%)
Material Mixture Pressure Part in Weight %
Douhe II (supercritical)
15 Mo3
13CrMo44
15NiCuMoNb5 (WB36)
X10CrMoVNb91 (P91)
X20CrMoV121
Others
Headers
37%
11%
23%
18%
11%
Weight Comparison
(Typical design according to German standard DIN, equivalent material available in India)
Heating
Surfaces
53%
13%
34%
Membran
Walls
53%
46%
1%
Comparison of the Boiler Pressure Part
Comparison of the Boiler Pressure Part

Page 87 of 222
FOB - Boiler
FOB - Boiler Price Comparison
Price Comparison
FOB
-
Price
(currency
unit)
Boiler
PM & Engineering
Electric + I&C
Cleaning/Hoist/etc.
Pipework
Insulation
Ash Removal
E S P
Draft System
Firing System
Sootblower
Air Preheater
Steel Structure
Spare Parts
Bunker Feeding
Shalingzi, subcritical, 2x660 MW
(local pressure part manufacturing)
100 %
104,75 %
Douhe, supercritical, 2x660 MW
(pressure parts partly imported)

Page 88 of 222
3.1 Technical aspects of the collaboration and BHEL´s
preparedness for once-through Boilers
BHEL
BHEL

Page 89 of 222

ONCE - THROUGH BOILER
SALIENT FEATURES
OF
TECHNICAL COLLABORATION
AGREEMENT (TCA)
Page 90 of 222

BACKGROUND & HISTORY
BACKGROUND & HISTORY
TO MEET FUTURE MARKET TREND, BHEL WAS
LOOKING FOR A COMPREHENSIVE TCA TO
COVER ALL AREAS - FROM CONCEPT TO
COMMISSIONING INCLUDING R&D UPDATES
Page 91 of 222

BHEL HAS ENTERED INTO A LONG TERM
LICENSING AGREEMENT WITH
BABCOCK BORSIG POWER GmbH
(A - DEUTSCHE BABCOCK - STEINMULLER COMBINE)
GERMANY
FOR TECHNICAL COLLABORATION
FOR ONCE THROUGH BOILERS
Page 92 of 222

SALIENT FEATURES OF TCA
DURATION OF AGREEMENT
DURATION OF AGREEMENT
Y 1O YEARS FROM EFFECTIVE DATE (27.07.99)
OR
Y 7 YEARS FROM DATE OF COMMENCEMENT OF
COMMERCIAL PRODUCTION
Page 93 of 222

ONCE-THROUGH BOILERS - EXPERIENCE OF BBP GmbH
ONCE-THROUGH BOILERS - EXPERIENCE OF BBP GmbH
SUB-CRITICAL SUPER-CRITICAL
< 300 MW 111 11
> 300 MW
< 500 MW 67 27
> 500 MW 47 19
SUB-TOTAL 225 57
GRAND TOTAL 282
Page 94 of 222

ONCE-THROUGH BOILERS - EXPERIENCE
ONCE-THROUGH BOILERS - EXPERIENCE
OF BBP GmbH
OF BBP GmbH
COAL COAL + OTHER
ALONE OTHER FUELS SUB-TOTAL
FUELS
SUB-CRITICAL
< 300 MW 48 10 54
>300 <500 MW 36 3 17
> 500 MW 38 2 7
---- ---------------------------------
TOTAL 122 15 88 225
----------------------------------------------------------------------------------------------
SUPER-CRITICAL
< 300 MW 5 1 5
>300 <500 MW 17 3 7
> 500 MW 13 1 5
------------------------------------------
TOTAL 35 5 17 57
-----------------------------------------------------------------------------------------------
GRAND TOTAL 282
Page 95 of 222

HIGHEST CAPACITY STEAM GENERATOR
HIGHEST CAPACITY STEAM GENERATOR
(TG RATING IN MW)
(TG RATING IN MW)
SUB-CRITICAL SUPER-CRITICAL
FUEL
COAL 745 750
COAL + OIL 900 707
LIGNITE 600 980
OTHERS 745 700
Page 96 of 222

COAL FIRED SUPERCRITICAL BOILERS WITH
SHO AND / OR RHO TEMPERATURE AROUND 540 DEG. C
PARTIAL LISTING - SELECTED FROM BBP REFERENCE LIST
Page 97 of 222

PLANT NAME CAPACITY SHO PRESS. SHO TEMP. RH TEMP.
(MW) (bar) (DEG. C) (DEG. C)
LEININGERWERK V 460.4 282 540 540
PS HERNE -IV 500 255 535 541
FWK BUER 150 245 540 540
MANNHEIM, 15 217 257 530 540
Page 98 of 222

SHO AND / OR RHO TEMPERATURE ABOVE 540 DEG. C
Page 99 of 222

PLANT NAME CAPACITY SHO PRESS SHO TEMP. RH TEMP
(MW) (bar) (DEG. C) (DEG. C)
STAUDINGER V 500 267 545 562
SCHKOPAU 492 260 545 560
BOXBERG IV 900 266 545 563
ROSTOCK 500 267 545 562
ALTBACH 332 260 545 568
Page 100 of 222

COMPREHENSIVE TCA ENVELOPING
1. SYSTEM ENGINEERING
2. DETAILED ENGINEERING
3. MANUFACTURE
4. QUALITY
5. ERECTION
6. COMMISSIONING
7. TROUBLE-SHOOTING
8. FEED BACK ANALYSIS
9. R&D UPDATES
Page 101 of 222

SALIENT FEATURES OF TCA - TECHNICAL SCOPE
TYPE OF BOILER
ü TOWER & TWO-PASS TYPE
ü SINGLE REHEAT & DOUBLE REHEAT
ü SUB-CRITICAL & SUPER CRITICAL BOILERS
FUELS
SUB-BITUMINOUS & BITUMINOUS COAL
© OIL
© GAS
© LIGNITE
© EITHER INDIVIDUALLY OR IN COMBINATION
FIRING SYSTEM ALSO COVERS LOW NOx AND
LOW EXCESS AIR TECHNOLOGY
UNIT RATINGS
© ALL UNIT RATINGS
Page 102 of 222

SALIENT FEATURES OF TCA-TECHNICAL SCOPE
(
(Contd
Contd...)
...)
^ COMPLETE PRESSURE PARTS FROM ECO. INLET TO SHO
HEADER M. S STOP VALVE
^ COMPLETE COAL FIRING SYSTEM FROM BUNKER OUTLET TO
BURNERS (EXCLUDING FEEDERS AND MILLS)
^ COMPLETE FUEL OIL SYSTEM FROM DAY TANK TO BURNERS
^ COMPLETE FUEL GAS SYSTEM TO BURNERS
^ COMPLETE FLUE GAS SYSTEM UPTO CHIMNEY (EXCLUDING
FANS, AIRHEATERS & ESP)
Page 103 of 222

(
(Contd
Contd...)
...)
¬ COMPLETE AIR SYSTEM (EXCLUDING FANS AND AIRHEATERS)
¬ BOILER SUPPORTING STRUCTURAL STEEL WORK, BUCKSTAYS,
PLATFORMS
¬ LINING AND INSULATION
¬ CONTROLS & INSTRUMENTATION
¬ ENGG., MANUFACTURING, QUALITY, ERECTION, COMMISSIONING
¬ FIELD DATA COLLECTION AND ANALYSIS
¬ TYPICAL PURCHASE SPECIFICATION FOR AUXILIARIES
Page 104 of 222

(
(Contd
Contd..)
..)
Y TRAINING AT COLLABORATOR’
S OFFICES / WORKS / SITE -
ERECTION AND COMMISSIONING INCLUDED
Y ASSISTANCE FROM COLLABORATOR FOR PROPOSAL AND
CONTRACT ENGINEERING
Y DETAILS OF NEW DESIGN DEVELOPED WILL BE GIVEN TO
BHEL
Page 105 of 222

SCOPE OF TECH.INFORMATION
SCOPE OF TECH.INFORMATION
[ DESIGN MANUALS
[ COMPUTER PROGRAMS
[ TYPICAL CONTRACT DRAWINGS
[ QUALITY MANUALS
[ ERECTION METHODS
[ COMMISIONING PROCEDURES
[ TROUBLE SHOOTING PROCEDURES
Page 106 of 222

TECHNICAL SUPPORT
TECHNICAL SUPPORT
q ASSISTANCEFOR PROPOSAL AND CONTRACT PERFOMANCE. ENGINEERING
q SPECIAL ENGG FOR SELECTED AREA / ITEMS INDENTIFIED.
q ASSISTANCE FOR ERECTION, COMMISIONING, OPERATION, REPAIR & SERVICING AND
RETROFITTING & UPGRADING.
Page 107 of 222

BACK-UP GUARANTEE
BACK-UP GUARANTEE
r COLLABORATOR WILL GIVE BACK- UP GUARANTEE FOR MEETING
TENDER REQUIREMENT.
Page 108 of 222

BHEL’
S CAPABILITIES FOR
BHEL’
S CAPABILITIES FOR
ONCE THROUGH BOILER MANUFACTURING
ONCE THROUGH BOILER MANUFACTURING
ü MORE THAN 30 YEARS OF EXPERIENCE IN BOILER MANUFACTURING OF VARYING CAPACITIES/
DIFFERENT CODES/ MATERIALS ETC.
ü MANUFACTURED OT BOILER COMPONENTS FOR TALCHER OT BOILERS
ü BUILT UP ADEQUATE MANUFACTURING CAPACITY AND HAS MODERNISED ITS FACILITIES
CONTINUOUSLY.
ü PLANNING TO TAKE UP A MAJOR INVESTMENT PROGRAMME FOR IMPLEMENTATION DURING NEXT
TWO YEARS FOR COMPLETE MODERNISATION OF ITS MANUFACTURING AND MATERIAL HANDLING
FACILITIES.
Page 109 of 222

MANUFACTURING OF COMPONENTS SPECIFIC TO
ONCE THRO’TECHNOLOGY
ONCE THRO’TECHNOLOGY
_ SPIRAL WATER WALL PANELS
FACILITY AVAILABLE TO MAKE STRAIGHT PANELS.
PLANNING FOR ACQUIRING SUITABLE MACHINERY FOR
SPIRAL WALL PANEL
_ BURNER PANELS
TECHNOLOGY EXISTS TO MAKE BURNER PANEL WITH
BURNERS MOUNTED ON WALLS.
_ VERTICAL SEPERATOR
A SEPERATOR WITH TANGENTIAL ENTRY. LESS
COMPLICATED THAN THE CONVENTIONAL LARGE DRUM.
CAPABILITY EXISTS TO MANUFACTURE SUCH VESSELS.
Page 110 of 222

ONCE THRO’TECHNOLOGY (CONTD.)
_ START-UP HEAT EXCHANGER OR START-UP RECIRCULATING PUMP
SYSTEM
- START-UP HEAT EXCHANGER CAN BE MANUFACTURED
AT BHEL(T) WITH THE EXISTING FACILITIES.
- CIRCULATING PUMP SYSTEM IS ALREADY AN
ESTABLISHED SYSTEM WITH THE PUMP BEING BOUGHT
OUT AS A VENDOR ITEM.
Page 111 of 222

VALVES ( 255 ata / 540 º C / 568 º C CYCLE )
{ MAIN STEAM STOP VALVES WC 9 TO C 12
{ MAIN STEAM VENT & DRAIN VALVES F 22 TO F 91
{ HP BYPASS VALVES F 22 TO F 91
{ MAIN STEAM SAEFTY VALVES
{ MAIN STEAM ELECTROMATIC RELIEF VALVES
{ HOT REHEAT LINE VENT AND DRAIN VALVES
{ HOT REHEAT LINE SAFETY VALVES
{ HOT REHEAT LINE ELECTROMATIC RELIEF VALVES
{ RH ISOLATION DEVICE
ONLY
MATERIAL
SWITCH
NEEDED
ALREADY IN
PRODUCTION
RANGE
TO BE
DEVELOPED /
PROCURED
Page 112 of 222

WITH THE ONCE THROUGH
BOILER TCA
BHEL IS FULLY GEARED UP
TO MEET
EMERGING
MARKET REQUIREMENTS
Page 113 of 222

Page 115 of 222
3.
3.2
2 Design and manufacturing of steam turbines for
Design and manufacturing of steam turbines for
supercritical Parameters
supercritical Parameters
BHEL
BHEL

STEAM TURBINE
FOR
SUPER CRITICAL PARAMETERS
BHEL, HARDWAR, INDIA
Page 116 of 222

WORLD WIDE TRENDS WITH ADVANCED STEAM PARAMETERS
DESIGNER/
SUPPLIER
POWER STATION/
UNIT
RATING
(MW)
PARAMETERS STATUS SOURCE OF
INFORMATION
TOSHIBA,
JAPAN
HEKINAN UNIT3 700 310 BAR / 537ºC/593ºC COMM. POWER, MAY1992
KAWAAGOE UNITS
1&2
700 325 BAR /
571ºC/569ºC/569ºC
COMM. IN
1989 &90
VGB KRAFTWERK
TECHNIK,7/94
JAPAN
MATSUURA UNIT 2 1000 256 BAR/
593ºC/593ºC /593ºC
COMM IN 1997 --DO--
-- 1000 256 BAR/
593ºC/593ºC
COMM. HITACHI REVIEW
VOL.42,1993
HITACHI
JAPAN
-- 1000 310 BAR/
593ºC/593ºC/593ºC
UNDER DEVEL. -DO-
ABB HERNWEG UNIT 8 650 250 BAR /
535ºC/563ºC
COMM. ABB REVIEW JAN
1991
Page 117 of 222

WORLD WIDE TRENDS WITH
ADVANCED STEAM PARAMETERS
DESIGNER /
SUPPLIER
POWER STATION /
UNIT
RATING
(MW)
PARAMETERS STATUS SOURCE OF
INFORMATION
MAN ENERGE /
GEC ALSTHOM
ELSAM CONVOY
UNITS 1& 2
386 290 BAR /
582ºC / 580ºC / 580ºC
COMM.
IN1997, 98
VGB KRAFTWERK
TECHNIK,7/94
ESBJERQVAERKE
UNIT 3
400 250 BAR /
562ºC / 560ºC
COMM. IN
1992
--DO--
LUEBECK UNIT 1 400 275 BAR /
580ºC /600ºC
COMM. IN
1995
--DO--
EUROPE
HESSLER POWER
PLANT
732 275 BAR /
580 ºC / 600ºC
-- VGB KRAFTWERK
TECHNIK , 1/94
EPRI -- 700 325 BAR /
593ºC /593ºC /593ºC
DESIGN
COMPL.
POWER MAY 1992
SIEMENS &
BHEL
TROMBAY UNIT 6 500 170 BAR /
538ºC / 565ºC
COMM. IN
1990
--
Page 118 of 222

WORLD WIDE TRENDS WITH
ADVANCED STEAM PARAMETERS
DESIGNER /
SUPPLIER
POWER STATION / UNIT RATING
(MW)
PARAMETERS STATUS SOURCES OF
INFORMATION
30 TURBINES 7 TO 125 UPTO 293 BAR & TEMP.
RANGE 550 - 640ºC
(USING AUSTENITIC
STEEL)
COMM. SIEMENS PAPER
PRESENTED AT EPRI
CONFERENCE NOV.89
ALTBACH 395 263 BAR /
540ºC / 565ºC
COMM. IN
1997
SIEMENS GREY BOOK
SCHWARZEPUMPE 874 264 BAR /
542ºC / 560 ºC
COMM. IN
1997
SIEMENS GREY BOOK
BOXBERG 910 260 BAR /
540ºC / 580ºC
COMM. IN
1999
SIEMENS GREY BOOK
BEXBACH 750 250 BAR /
575ºC / 600ºC
COMM. IN
1999
SIEMENS GREY BOOK
SIEMENS
GERMANY
FRIMMERSDORF 1000 250 BAR /
580ºC / 600ºC
COMM. IN
1999
SIEMENS GREY BOOK
Page 119 of 222

DESCRIPTION VARIANT-I VARIANT-II
STEAM PARAMETERS
MAIN STEAM PRESSURE (ATA) 250 250
MAIN STEAM TEMP. (oC) 537 565
REHEAT TEMP. (oC) 565 565
BACK PRESSURE (ATA) 0.1 0.1
CYCLE CONFIGURATION
HP HEATERS: (NO.) 2 / 3 2 / 3
DEARATOR: (NO.) 1 1
LP HEATERS (NO.) 3 3
BOILER FEED PUMP 3x50 % 3x50 %
(2 Turbine Driven) (2 Turbine Driven)
(1 stand by motor driven) (1 stand by motor driven)
CONDENSATE EXTRACTION PUMP 2x100 % / 3x50% 2x100 % / 3x50 %
500 MW STEAM TURBINE WITH SUPER CRITICAL PARAMETERS
Page 120 of 222

VARIANT -I VARIANT-II
HP-MODULE H30-100 H30-100
IP-MODULE M30-63 M30-63
(DOUBLE FLOW) (DOUBLE FLOW)
LP-MODULE N30-2x10 N30-2x10
(DOUBLE FLOW) (DOUBLE FLOW)
M.S.VALVES 2xFV250 2xFV250
REHEAT VALVE 2xAV560 2xAV560
TURBINE MODULES
Page 121 of 222

HPT IPT LPT
CROSS SECTIONAL VIEW OF 3 CYLINDER CONVENTIONAL STEAM TURBINE
HMN SERIES
Page 122 of 222

CROSS SECTIONAL ARRANGEMENT OF TURBINE
Page 123 of 222

OUTER CASING BARREL TYPE CASING
INNER CASING SPLIT IN TWO HALVES
ROTOR MONO BLOCK-DRUM TYPE
BLADING:
IST STAGE IMPULSE BLADING
REMAINING STAGES REACTION BLADING
ROTOR COOLING HEAT SHIELD FOR VARIANT II
WITH VORTEX COOLING
COUPLING RIGID
VALVES CASING MOUNTED VALVES
CONSTRUCTIONAL FEATURES OF HP TURBINE
Page 124 of 222

SPECIAL FEATURES :
NEW MATERIALS
HEAT SHIELD AT ROTOR INLET
IMPULSE BLADING FOR FIRST STAGE
INCREASED WALL THICKNESS
HP TURBINE
Page 125 of 222

OUTER CASING HORIZONTALLY SPLIT
INNER CASING HORIZONTALLY SPLIT
ROTOR MONO BLOCK-DRUM TYPE
BLADING:
IST STAGE IMPULSE BLADING
REMAINING STAGES REACTION BLADING
ROTOR COOLING HEAT SHIELD FOR BOTH VARIANTS
COUPLING RIGID
CONSTRUCTIONAL FEATURES OF IP TURBINE
Page 126 of 222

SPECIAL FEATURES :
• NEW MATERIALS
• HEAT SHIELD AT ROTOR INLET
• IMPULSE BLADING FOR FIRST STAGE
IP TURBINE
Page 127 of 222

HEAT SHIELD WITH VORTEX BORES
Page 128 of 222

ROTOR MONO BLOCK
OUTER CASING FABRICATED
INNER CASING CASTING
BLADING:
ALL STAGES REACTION BLADING
LAST STAGE ADVANCE LP LAST STAGE BLADE
GUIDE BLADE - HOLLOW & BANANA TYPE
COUPLING RIGID
CONSTRUCTIONAL FEATURES OF LP TURBINE
Page 129 of 222

LP TURBINE
Page 130 of 222

•THROTTLE CONTROL GOVERNING
•HIGH PRESSURE GOVERNING WITH EHA
(ELECTRO HYDRAULIC ACTUATOR) - FOR VARIANT II
GOVERNING
Page 131 of 222

VARIANT I VARIANT II
HP OUTER CASING GS-17CrMoV511 GS-X12CrMoWVNbN 1011
HP INNER CASING GS-17CrMoV511 GS-X12CrMoWVNbN 1011
HP VALVES GS-17CrMoV511 GS-X12CrMoWVNbN 1011
HP ROTOR 28CrMoNiV59 X12CrMoWVNbN 1011
IP OUTER CASING GGG-40.3 GGG-40.3
IP INNER CASING G-X12CrMoVNbN 1011 G-X12CrMoVNbN 1011
IP VALVES G-X12CrMoWVNbN 1011 G-X12CrMoWVNbN 1011
IP ROTOR X12CrMoWVNbN 1011 X12CrMoWVNbN 1011
LP OUTER CASING ST 37-2 ST-37-2
LP INNER CASING GGG-40.3 GGG-40.3
LP ROTOR 26NiCrMoV 145 26NiCrMoV 145
MATERIALS FOR MAJOR COMPONENTS
Page 132 of 222

BHEL HAS ALREADY SUPPLIED ONE SET OF 500 MW TO
TROMBAY -VI PROJECT WITH STEAM PARAMETERS AS
170 ATA/537/565 oC . IN VIEW OF THIS BHEL WILL BE ABLE
TO SUPPLY STEAM TURBINE WITH STEAM PARAMETERS
OF 250 ATA /537/565oC WITH SUITABLE MODIFICATIONS
IN HP TURBINE AND ASSISTANCE FROM M/S SIEMENS-KWU
IN GOVERNING AREA. LP TURBINE WILL BE WITH
ADVANCE BLADING.
FOR STEAM PARAMETERS 250 ATA/565/565oC BHEL HAS
TIED UP WITH M/S SIEMENS FOR JOINT DEVELOPMENT
IN CASE OF A LIVE PROJECT.
STATUS OF TECHNOLOGY
FOR SUPER CRITICAL PARAMETERS
Page 133 of 222

Page 134 of 222
Technical Session
II
4.0 Once-Through Boiler Design & Operation Experiences, Reference Plants
Due to the merger of all power plants technology activities of Babcock Borsig AG in the company Babcock
Borsig Power (BBP) all experiences about power plant boiler technology are now focused in BBP.
References of steam generators of all kind of design concepts like 2-pass boilers with pendent platen
superheaters or 2-pass design with completely drainable heating surfaces as well as tower-type boilers up to a
hight of more than 160m with subcritical, supercritical or ultra supercritical steam parameters are available. For
the complete range of fossil fuels optimized firing concepts are available with own mills and burner systems. As a
result of the broad experiences gained with engeneering, manufacturing, erection and commissioning of plants
in Germany and abroad a highly sofisticated contract management system has been developted which satisfies
most demanding customers requirements.
The extensive know-how transfer within the frame of the „Technical Collaboration Agreement“ between BHEL
and BBP will enable our Indian partner BHEL by means of extensive training and collaboration activities to
design, manufacture, erect and commission power plants in India with supercritical steam parameters of
comparable technology and quality standards.

Page 135 of 222
Technical
Session II
Once
Once-
-Through
Through Boiler Design & Operation
Boiler Design & Operation Experiences
Experiences,
,
Reference Plants
Reference Plants
•Babcock Borsig Power units all experiences of Babcock Borsig AG regarding
power plant and steam generator technology
•Broad experience in all kind of steam generator design conceps
•
- 2-pass boilers with pendent platen superheaters
•
- 2-pass design with completely drainable heating surfaces
•
- tower-type design up to a hight of more than 160m
•Optimized firing concepts for all kind of fossil fuels with own mills & burner systems
•Strong and experienced contract management system
•Extensive know-how transfer to BHEL within the Technical Collaboration Agreement
will enable BHEL to design, manufacture, erect and commission state of the art
supercritical power plants

Page 136 of 222
Examples of Boiler Concepts
Examples of Boiler Concepts
Two-Pass Boiler
without platen superheater
Two-Pass Boiler
with platen superheater
Tower Boiler
PS Heyden 4 - 920 MW el PS Kogan Creek - 700 MW el
PS Staudinger 5 - 550 MW el
66,0 m

Page 137 of 222
Firing systems
Firing systems
Front Opposed Corner Down Shot
T - Wall Slag Tap Tangential All Wall
Bituminous Coal Lignite Coal
available for all types of fossil fuels.

Page 138 of 222
Firing System/
Power Plant
Unit
Capacity
MW
Boiler Type
Flow System
Fuel Comm.
Year
Front firing
- Doha West 300 Drum Oil/Gas 1982
- Jorge Lacerda 3 125 Drum Bitum. coal 1979
- Farge 320 BENSON Bitum. coal 1969
- Jorge Lacerda 4 350 BENSON Bitum. coal 1986
- CSN 1-3 150 Drum Blast Furnace Gas 2000
Opposed firing
- Avedøreværket 260 BENSON Bitum. coal 1989
- Studstrupvaerket 350 BENSON Bitum. coal 1983
- Voerde 707 BENSON Bitum. coal 1982
- Wilhelmshaven 770 BENSON Bitum. coal 1976
- Heyden 900 BENSON Bitum. coal 1987
- Dezhou 660 Drum Semi-Anthr. 2003
- Majuba 711 Benson Bitum. Coal 1999
T- Wall
- Altbach 320 BENSON Bitum. coal 1995
Tangential firing
- Megalopolis *) 300 Drum Lignite 1975
- Neurath 300 BENSON Lignite 1973
- Schkopau 450 BENSON Lignite 1996
- Weisweiler G + H 630 BENSON Lignite 1976
- Boxberg 800 BENSON Lignite 1996
- Lippendorf 930 BENSON Lignite 1999
- Niederaußem 980 Benson Lignite 2002
Corner firing
- Walsum 400 BENSON Bitum. coal 1991
- Fyensvaerket 7 410 BENSON Bitum. coal 1991
Four-wall firing
- Buschhaus 350 BENSON Lignite
saliferous
1984
Slag tap furnace
- Elverlingsen 330 BENSON Bitum. coal 1982
- Yang Liu Qing 350 BENSON Bitum. coal 1996
- Ibbenbüren 770 BENSON Bitum. coal 1985
Dry vertical firing
- Narcea / La Robla 350 BENSON Anthracite 1981/82
*) Net heating value: 900 ... 1400 kcal/kg
**) Cooperation with other boiler manufacturer
Steam Generators in Operation (Examples)
Steam Generators in Operation (Examples)
Experiences with Different Firing- and Flow Systems
Experiences with Different Firing- and Flow Systems

Page 139 of 222
BBP's
BBP's - Utility Boiler Contracts of the recent Years
- Utility Boiler Contracts of the recent Years
Project Client Qty. Description Award Date Comments
Yang Liu Qing CNTIC Corp. 2 1025 t/hr boiler, bituminous coal-fired Feb 94 Once- Through, Slag Tap Type
Lippendorf VEAG 2 2360 t/hr boiler, lignite-fired Aug 94 Once- Through, Tower Type
Lünen STEAG 1 533 t/hr boiler, bituminous coal-fired Dec. 94 Once- Through, Tower Type
Bexbach Saarbergwerke 1 2048 t/hr boiler, bituminous coal-fired Dec. 94 Once- Through, Tower Type
Niederaußem RWE-Energie AG 1 2514 t/hr boiler, lignite-fired May 95 Once-Through, Tower Type
Boxberg VEAG 1 2423 t/hr boiler, lignite-fired May 95 Once-Through, Tower Type
Yang Shu Pu
Shanghai Municipal
Electric Power Bureau
2 526 t/hr boiler, bituminous coal-fired July 95 Natural Circulation, Two Pass
PCK-Schwedt
PCK-Raffinerie
Schwedt
1 620 t/hr boiler, HSC-Residues Sep 95 Once-Through, Tower Type
Shi Dong Kou SMEPC-Shanghai 1
1050 t/hr boiler,
bituminous / subbituminous coal
Dec. 96 Once- Through, Two Pass
Companhia
Siderugica National
Siemens for CSN 3
337 t/hr boilers, natural gas,
blast furnace gas, steel plant gas,
tar, heavy fuel oil
Sep 97 Natural Circulation
Dezhou HUANENG 2 2009 t/hr boiler, anthracite-fired July 98 Natural Circulation
Elbistan B TEAS 4 1068 t/hr boiler, lignite-fired Aug 98 Once- Through, Tower Type
Westfalen VEW 1 928 t/hr boiler, bituminous coal March 99 Once- Through, Tower Type
HKW Hamborn RWE-Energie AG 1
642 t/hr boiler, blast furnace gas,
coke oven gas, natural gas
Aug. 99 (LOI) Once- Through, Tower Type
TPP- Iskenderun Bay Siemens for Steag 2 1884 t/hr boiler, bituminous coal Jan. 2000 (LOI) Once- Through, Tower Type
Kogan Creek
Siemens for Austa/
Southern Energy
1 2218 t/hr boiler, biuminous coal Dec. 99 (LOI) Once- Through, Tower Type

Page 140 of 222
BBP’
s
BBP’
s STEAM GENERATOR INSTALLATIONS
STEAM GENERATOR INSTALLATIONS
1970 onwards
1970 onwards
Fuel Installed MW
Bituminous Coal 122 000
Lignite 43 000
Oil / Gas 108 000
WTE 4 000
HRSG 33 000
Total 310 000
Fuel Installed MW
Bituminous Coal 122 000
Lignite 43 000
Oil / Gas 108 000
WTE 4 000
HRSG 33 000
Total 310 000

Page 141 of 222
Benson Boiler with Opposed Firing
Voerde
Voerde (707 MW)
(707 MW)
High pressure part
Steam rating 2160 t/h
Allowable working
pressure (gauge) 206 bar
SH-Outlet temperature 530 °C
Reheater
Steam rating (inlet) 1940 t/h
Allowable working
pressure (gauge) 49bar
RH-Outlet temperature 530 °C

Page 142 of 222
Heyden
Heyden (900 MW)
(900 MW)
Reheater
Allowable working
High pressure part
Allowable working

Page 143 of 222
PS
PS Kogan
Kogan Creek, Australia
Creek, Australia
Boiler with supercritical steam parameters
•1 x 700 MWel / 1 x 2218 t/hr
•Once-through steam generator, Benson®
•Bituminous Coal 19,1 MJ/kg
•Steam parameters:
545 °C / 563 °C / 264 bar
•Net efficiency of 39.5 %
(dry cooling system)
•Commissioning: 2002

Page 144 of 222
Studstrup
Studstrup (350 MW)
(350 MW)
Reheater
Allowable working
High pressure part
Allowable working

Page 145 of 222
Rostock
Rostock (550 MW)
(550 MW)
Reheater
Allowable working
High pressure part
Allowable working

Page 146 of 222
Benson Boiler with Tangential Firing
Benson Boiler with Tangential Firing
KW Schkopau
KW Schkopau ( 450 MW )
( 450 MW )
High pressure part
Allowable working
Reheater
Steam rating (inlet) 1206 t/h
Allowable working

Page 147 of 222
Lippendorf Power Plant
Lippendorf Power Plant
2 x 930 MW
2 x 930 MW
Reheater
Allowable working
RH-Outlet
temperature 583 °C
High Pressure Part
Allowable working
SH-Outlet
temperature 554 °C

Page 148 of 222
PS Westfalen D,
PS Westfalen D, Germany
Germany
Boiler with ultra-supercritical steam
parameters
•1 x 350 MWel / 1 x 926 t/hr
•Once-through steam generator, Benson®
•Bituminous Coal 27.5 MJ/kg
•Ultra-supercritical steam parameters:
600 °C / 620 °C / 290 bar
•Net efficiency of 47%

Page 149 of 222
Material Selection for Superheater and Reheater Tubing
Material Selection for Superheater and Reheater Tubing
X20CrMoV12-1 < 565 °C
X3CrNiMoN17-13
Material Live Steam Temperature
ASME Code 2115
Compound Tubes
Coextruded Tubes
HR3C ( 25 Cr 20 Ni Nb N )
600 °C - 620 °C
AC 66 ( 27 Cr 30 Ni Nb Ce )
Esshete 1250
DIN 17 175
DIN 17 459
VdTÜV 497 6.90
565 °C - 580 °C
620 °C - 720 °C
Corrosion Protection 50 % Cr - 50 % Ni Coating?
Alloy 617 ( NiCr23 Co12 Mo ) 700°C,100.000 h, 95 N/mm
2
( < 545 °C for SH )
TP 347H FG ASME Code 2159
BS 3059 Part 2
Incoclad 671 / Incoloy 800 HT Producer INCO
VdTÜV 485 6.90
MITI Code Ka-SUS304J1HTB
580 °C - 600 °C
650°C,100.000 h, 104 N/mm
650°C,100.000 h, 92 N/mm
2
2
650°C,100.000 h, 123 N/mm
2
650°C,100.000 h, 85,5 N/mm
2
VdTÜV 520 12.97
MITI Code Ka-SUS310J2TB
Super 304H FG

Page 150 of 222
Creep Rupture Mean Values
100.000 h
100.000 h
600 620 640 660 680 700
Temperature in °C
50
100
150
200
N/mm
2
Esshete 1250
X 3 CrNiMoN 17 13
1.4910

Page 151 of 222
Chemical Composition of High Alloyed Superheater Tubing
Chemical Composition of High Alloyed Superheater Tubing
Material
Material
C Si Mn P S Fe Cu
Mo
Ni
Cr Ti
Nb
Alloy 617
20,0-
23,0
res.
0,20-
0,60
8,0-
10,0
16,0-
18,0
2,00-
2,80
max.
1,00
-------
-------
0,60-
1,00
Others
X3CrNiMoN
17 13
X7NiCrCeNb
32 27
26,0-
28,0
31,0-
33,0
5,50-
7,00
0,75-
1,25
0,80-
1,20
Esshete 1250
14,0-
16,0
9,0-
11,0
max.
0.75
max.
2,00
max.
0,030
max.
0,030
res. 0,20-
0,60
------
------
Nf 709
0,04-
0,10
24,0-
26,0
17,0-
23,0
N 0,15 - 0,35
1,00-
2,00
19,0-
22,0
------
------
HR3C ------
------
0,04-
0,10
max.
0.75
max.
1,50
max.
0,030
max.
0,010
res. 23,0-
27,0
------
------
0,10-
0,40
0,02-
0,20
N 0,10 - 0,20
B 0,002 - 0,008
0,06-
0,15
0,20-
1,00
max.
0,040
max.
0,030
res. ------
------
------
------
V 0,15 - 0,40
B 0,003 - 0,009
1.4877(AC66)
0,04-
0,08
max.
0.30
max.
0,015
max.
0,010
res.
------
------
------
------
Ce 0,05 - 0,10
Al max. 0,025
1.4910
max.
0,04
max.
0,75
max.
2,00
max.
0,035
max.
0,015 res.
12,0-
14,0
------
------
------
------
------
------ B 0,0015 - 0,0050
NiCr23Co12
Mo, 2.4663
0,05-
0,10
------
------
------
------
------
------
------
------
max.
2,00
------
------
------
------
Co 10,00 - 13,00
Al 0,60 -1,50
N 0,10 - 0,18
TP 347H FG
17,0-
20,0
0,04-
0,10
max.
0.75
max.
2,00
max.
0,040
max.
0,030
res. 9,0-
13,0
------
------
8 x C
Super 304H
17,0-
19,0
0,07-
0,13
max.
0.30
max.
1,00
max.
0,040
max.
0,010
res. 7,5-
10,5
2,50-
3,50
0,30-
0,60
N 0,05 - 0,12
Incoloy 800 HT 19,0-
23,0
0,06-
0,10
max.
0,015
max.
0,010
res. 30,0-
35,0
------
------
------
------
------
------
------
------
------
------
Al 0,25 - 0,60
max.
0.70
max.
1,50
max.
0,50
------
------
0,25-
0,60 Al + Ti 0,85 - 1,20
Incoclad 671 0,05 51,5 48,0

Page 152 of 222
Chemical Composition of Header and Piping Materials
Chemical Composition of Header and Piping Materials
E 911
0,09-
0,13
0,10-
0,50
0,30-
0,60
max.
0,020
max.
0,010
max.
0,040
8,50-
9,50
0,10-
0,40
-------
-------
0,90-
1,10
0,001-
0,006
0,18-
0,25
0,06-
0,10
0,90-
1,10
-------
-------
0,050-
0,090
P 92
0,07-
0,13
max.
0,50
0,30-
0,60
max.
0,020
max.
0,010
max.
0,040
8,50-
9,50
max.
0,40
-------
-------
1,50-
2,00
0,030-
0,070
0,001
0,006
0,15-
0,25
0,04-
0,09
0,30-
0,60
-------
-------
P 122
max.
0,15
max.
0,70
max.
0,70
max.
0,030
max.
0,020
-------
-------
10,00-
12,60
max.
0,70
-------
-------
1,50-
2,50
0,020-
0,100
max.
0,005
0,15-
0,30
0,02-
0,10
0,20-
0,60
max.
1,70
0,08-
0,12
0,20-
0,50
0,30-
0,60
max.
0,020
max.
0,010
max.
0,040
8,00-
9,50
max.
0,40
-------
-------
-------
-------
0,030-
0,070
-------
-------
0,18-
0,25
0,06-
0,10
0,85-
1,05
-------
-------
P 91
C Si Mn P S Al V
Mo
Ni
Cr N B
W
Ti
Nb Cu
0,17-
0,23
max.
0,50
max.
1,00
max.
0,030
max.
0,030
max.
0,040
10,00-
12,50
0,30-
0,80
-------
-------
-------
-------
-------
-------
0,25-
0,35
0,80-
1,20
-------
-------
X20CrMoV
12-1
-------
-------
-------
-------

Page 153 of 222
100.000 h
100.000 h
480 500 520 540 560 580 600 620 640 660 680 700
Temperature in °C
0
50
100
150
200
250
300
X20CrMoV12-1
P 92
E 911
X3CrNiMoN17-13
N/mm
2

Page 154 of 222
Tungsten Containing New Martensitic Steels in Power
Tungsten Containing New Martensitic Steels in Power
Stations
Stations
PS Vestkraft
NF 616
PS Nordjyllands -
vaerket HCM 12A
GK Kiel
Block 3
NF 616 ID 160 x 45
PS Schkopau
Block B
E 911
PS Staudinger
Block 1
PS Skaerbaek
E 911
E 911
Block 3
P 92
ID 230 x 60
ID 240 x 39
( 56 )
406,4 x 77
PS Nippon Steel
Kobe Japan
NF 616
ID 480 x 28
ID 201 x 22
ID 550 x 24
PS Westfalen
E 911
P 92
ID 159 x 27 650 °C Steam, 180 bar May 1998
PS Tachibanawan
Block 1 + 2
1050 MW
P 92
P 122
800 x 120
500 x 80
Header
Piping 600 °C Steam, 250 bar
June 2000
July 2001
Power Station Material Dimension Component Temperature Installation
Live Steam Piping
1950 mm long
4000 mm long
Live Steam Piping
HP-Header
Induction Bend
Reheater Piping
Induction Bend
Live Steam Piping
Induction Bend
Live Steam Piping
Reheater
Header
Connecting Pipes
582 °C Steam, 290 bar
540 °C Steam, 213bar
1996
1996
1996
1996
May 1997
1995
1992

Page 155 of 222
Modern
Modern Steam
Steam Generators
Generators
Niederaußem Power Station Unit K
950 MWe
Fuel Lignite
Maximum cont. rating 698 kg/s
Main steam pressure 260 bar
Main steam temperature 580 deg.C
Reheater steam temperature 600 deg.C
Burner arrangement Tangential
No. and burner capacity 8 x 271 MW
Mill type Beater wheel mill
No. and mill capacity 8 x 143 t/h
Boiler dimensions (WxDxH) 23 x 23 x 149 m
Boiler house (WxDxH) 90 x 88 x 168 m

Page 156 of 222
PS
PS Dezhou
Dezhou,
, Shandong Province
Shandong Province, China
, China
•2 x 660 MWel / 2 x 2209 t/hr
•Natural circulation steam generator
•Semi-Anthracite (ash content 33.05 %
volatile matters daf 11.35 %)
•Steam parameters:
- 541 °C / 174 bar
- 541 °C / 40.3 bar

Page 157 of 222
5.0 Firing System
Babcock Borsig Power (BBP) has decades of experience in the design of firing systems for the whole
range of coal qualities.
To enable the use of a wide range of bituminous coals and low-grade hard coals, an advanced firing system
has to fulfill quite a number of criteria:
- Design of the burner zone and the furnance with due regard to the combustion behaviour and slagging
tendency of the coal
- Flexible mill system with variable grinding force and grinding fitness to adjust mill operation to the coal quality
- Pulverized coal burners with stable ignition over wide working range and varying coals as well as low Nox
emission
- Design of the main components with due regard to the ash content and wearing bahaviour of the mineral
components of the coal
BBP has in-house competence for both combustion chamber design and all firing components
Important features of the BBP firing concept for large hard coal fired steam generators are:
- Opposed firing system
- MPS mill
- DS burner.
For this system a great number of references plants with differing units capacities and steam generator
types are available. The coal qualities used cover the whole range of anthracites available in special locations
through very wide ranges of imported coals used at coastal stations world wide located up to high-ash coals
with high abrasivness which are comparable to the fuels fired in pit head stations in India.

Page 158 of 222
Firing Systems
for Low Grade Hard Coals
and Wide Coal Ranges
in India
Firing Systems
Firing Systems
in India
in India

Page 159 of 222
Outline
Outline
Outline
• Coal Characterization
• Major Design Requirements
• Firing System
Main Features and Design Criteria
• Main Components
• NOx Emission
• Part Load Operation
• Changed Heat Absorption of the Furnace
• References for
– high-ash coals
– wide coal ranges
• Conclusions

Page 160 of 222
Pit Head Stations
Type of coal
Low grade, unwashed
Indian hard coal
Main features
High ash (> 40 %)
Moisture partly higher (up to 16 %)
Ash abrasiv,
Wear factor high (YGP up to 80)
Volatile matter (daf) high
Sulphur low
Slagging tendency low
Coal
Coal Characterization
Characterization
Coastal Stations
Type of coal
Washed Indian hard coal
Imported bit. coal (wide range)
Main features
Ash content and
abrasiveness lower to normal
Coals from various countries
and mines,
with varying grinding,
combustion and slagging/fouling
behaviour

Page 161 of 222
Range of Coal Qualities
Range of Coal Qualities
0 10 20 30
0
20
40
60
80
Net calorific value, 10³ kJ/kg
Volatile
matter
(
daf
),
%
Indian
low grade
hard coal

Page 162 of 222
Coal Data India
Coal Data India
10
30
40
80
0
40
0
20
0
40
GCV
MJ/kg
Ash, ar
%
Moisture ar
%
Vol.M ar
%
Grind.
°H
Indian Indian Imported
unwashed coal washed coal coal
(Talcher Design coal) (Tuticorin) (Tuticorin Perf. Coal)

Page 163 of 222
Wear Factor
Wear Factor Indian Coals
Indian Coals
0
200
400
600
800
1000
0 2 4 6 8 10
Characteristic Ash Factor
Wear
Factor
[(% SiO2 - 2x % Al2 O3) x Ash dry/100]

Page 164 of 222
Range of Imported Coal - 720 MW Unit, Coastal Station
Range of Imported Coal - 720 MW Unit, Coastal Station
Calorific
value raw
MJ/kg
Ash raw
%
Moisture
%
Volatiles raw
%
Grindability
°H
Ash melting
behaviour
°C
oxid. atm.
30
25
20
Design Poland South- Australia USA India Canada Spits- China
and Africa bergen
guarantee value
20
10
0
20
10
0
40
30
20
10
80
60
40
1600
1400
1200
1000 ST HT

Page 165 of 222
Major Firing System Design Requirements
for wide coal ranges and low grade hard coals
• Design of burner zone and furnace with due regard to combustion
behaviour and slagging tendency of the coals
• Flexible mill system, i.e. variable grinding force and grinding fineness,
in order to adjust mill operation to coal quality
• Pulverized coal burner with
– stable ignition over a wide operational range and varying coals
– low NOx emission
• Operation with low excess air
• Design of the main components with due regard to the ash content and
the abrasiveness of the mineral matters of the coal

Page 166 of 222
Firing System, Furnace Design
Firing System,
Firing System, Furnace
Furnace Design
Design
• Direct firing system
• Opposed burner arrangement preferred for large bituminous boilers
(swirl type burners)
Advantages
– stable ignition at each burner
– more flexibility in number of mills and burners
– more homogenious flue gas temperature profile at furnace exit
• P.C. and air supply and control per burner row
• Furnace design tools (available for product development at BBP)
– One dimensional combustion simulation by FANAL
(Temp. profile, burnout, NOx prediction)
– Three dimensional furnace simulation by CFD (FLUENT)
(Temp. profile, flow pattern)

Super critcal_sub critical_higher capacity sets - Copy.pdf

Super critcal_sub critical_higher capacity sets - Copy.pdf

Recommended

Recommended

More Related Content

Similar to Super critcal_sub critical_higher capacity sets - Copy.pdf

Similar to Super critcal_sub critical_higher capacity sets - Copy.pdf (20)

More from vishal laddha

More from vishal laddha (20)

Recently uploaded

Recently uploaded (20)

Super critcal_sub critical_higher capacity sets - Copy.pdf