ONCE THROUGH STEAM GENERATORS

Benson boiler growth

1926 Siemens maufactures 30125t/h boilers 1949 First OT boiler with high steam conditions(175 bar/610 DegC Leverkusen) 1963 First spiral tube waterwall in membrane design(Rhodiaceta) 1987- Largest hard coal fired boiler (Heyden 900 MW More than 980 boilers with > 700000 t/h

CONTROLLED CIRCULATION (Vs) ONCE THRU

CC

OT

Once Through Principle

Comparison Natural Circulation / Once-Through-System

Source: Siemens

Cumulative Steam Capacity of Ordered BENSON Boilers

BBPs share about 44 %

Total Steam Output about 200.000 kg/s

Source: Siemens

Once Through Boiler-Concept

Once through system

ONCE - THROUGH OPERATING RANGE

Increase of Cycle Efficiency due to Steam Parameters

Increase of efficiency [%] 10 9 8 7 6 5 4 3 2 1 0 300
Pressure [bar]

6,77 5,74 4,81 4,26 3,37 2,64 2,42 1,78 0

241 175 538 / 538

5,79 3,74 2,76

3,44 1,47

600 / 620

0,75
538 / 566

580 / 600 566 / 566

H P / RH outlet temperature [deg. C ]

Comparison of Plant part load efficiency

46

Plant net efficiency

42,4 % 40,1 %

43,2 %

43,6 %

40

40,5 % 39,3 % 36,7 %

41,1 % Supercritical unit acc. Alternative 2 255 bar 538C / 538C Subcritical unit acc. Alternative 1 166 bar 538C / 538C

30

30

40

50

60

70

80

Load %

90

100

Examples of Boiler Concepts

Tower Boiler Two-Pass Boiler without platen superheater Two-Pass Boiler with platen superheater

66,0 m

PS Staudinger 5 - 550 MW el

PS Heyden 4 - 920 MW el

PS Kogan Creek - 700 MW el

Comparison of Lignite, Coal and Oil Fired Units

PS Offleben (C), 325 MWel

mHD = 1000 t/h; B = 16,4 m

PS Farge, 320 MWel

mHD = 1020 t/h; B = 16,5 m

PS Doha West, 300 MWel

mHD = 1100 t/h; B = 14 m

Heat input / furnace area [kW/m] SH heating surfaces [m] RH heating surfaces [m] Bundel surfaces [m]

215 17.781 15.290 33.071

330 6.791 12.072 18.863

680 10.953 5.202 16.155

Benson Boiler
Main Configuration - Single-pass / Two-pass

Source: Siemens

DRUM vs ONCE THROUGH

ECO
DRUM

SH

STEAM TO TURBINE

SH

STEAM TO TURBINE

DOWN COMER CIRC. PUMP

HEAT Water Wall ORIFICE ECO

HEAT Water Wall

Pressure Steam Separation Types Burner Panel Load Change Cold Start Hot Start

Sub critical Drum Natural / Assisted Straight tube Base 4-5 Hours 1-2 Hours

Sub & super Critical Separator (Low loads) (Sulzer) / (Benson) Spiral Tube / Straight (MHI) Faster 2 Hours 0.5 Hours

Drum type boiler

Steam generation takes place furnace water walls Fixed evaporation end point - the drum Steam -water separation takes place in the drum Separated water mixed with incoming feed water

Once Through Boiler

Once -through flow through all sections of boiler (economiser, water walls & superheater) Feed pump provides the driving head Suitable for sub critical & super critical pressures

Once -thru Boiler

Advantages:
Quick response to load changes Shorter start up time Better suited for sliding pressure operation Steam temperature can be maintained over wider load range under sliding pressure Higher tolerance to varying coal quality Suitable for sub critical & super critical pressures

ADVANTAGES OF ONCE THROUGH BOILERS

Once thru boiler enables : Peak power generation with better efficiency levels Quicker response to TG load changes Better heat rate of lower loads

Characteristics :

Once -through Boiler

Provides Quicker response to TG load changes Supports achievement of better heat rate at lower loads Higher furnace wall pressure drop and consequent higher feed pump auxiliary power consumption Needs ultra pure quality feed water - Cannot operate under conditions of condenser leak

Tower Vs Two pass

For Indian Pit-head power station BBP preference is tower type ( to overcome flyash erosion) For power stations firing beneficiated Indian coals Two pass boiler For coastal power stations firing imported coals Two pass boiler

Flow Scheme of Membrane Walls for Two-Pass Boilers

3.) 1.) 5.) 2.) 4.)

Detail: Ties for Spiral Tubing

Temperature difference between the wall systems

(Example Studstrup Power Plant)

Boiler Load Location 100% 35% 1.) 2K 1K 2.) 7K 1K 3.) 13 K 1K 4.) 2K 3K 5.) 7K 17 K

Flow Scheme of Membrane Walls for Tower Boilers

Transition from Spiral Tubing to Vertical Tubing

Start-Up Times [min] of Power Plants

Plants with Drum Boiler 167 bar / 538C / 538C From ignition to: After shut down hours <1 8 48 >48 first steam to Turbine 20 - 30 40 - 60 150 - 210 150 - 210 full load 60 - 80 80 - 100 300 - 350 450 - 600 Plants with BENSON Boiler 250 bar / 540C / 560C From ignition to: first steam to Turbine 20 - 30 30 - 40 60 - 80 60 - 80 full load 30 - 40 50 - 60 150 - 200 400 - 600

Modern Coal-Fired Power Plant

EV 2 / ; NTPC Presentation.ppt

KWU 99 152d
Page 23

BOILERS - DISCUSSED AT BBP MAJUBA 660 MW TOWER 192 bar 555 C SCHKOPAU 450 MW TOWER 262 bar 545 C VOERDE 700 MW TWO PASS 206 bar 530 C BOXBERG 900 MW TOWER 266 bar 545 C ELKRAFT 300 MW TWO PASS 250 bar 545 C 19286x19286 17846x17846 23668x15773 24086X24086 12720X14280

MAJUBA,SCHKOPAU,VOERDE : WITH VERTICAL TUBE HOPPER BOXBERG: WITH SPIRAL TUBE HOPPER ELKRAFT: WITH SPIRAL HOPPER & SPIRAL IN FRONT/REAR , HORIZONTAL IN SIDES

Once -thru Boiler - Furnace Wall

Furnace Arrangement

SPIRAL TYPE

VERTICAL TYPE

FURNACE WALL ARRANGEMENT

BOILER PRESSURE PARTS WEIGHT

BOILER TYPE PIPES TUBES

210 MW 250 MW 500 MW 660 MW**

315 MT 410 MT 695 MT 1070 MT

1100 MT 1440 MT 2870 MT 5080 MT

** Worked out based on the Alstom BOM supplied for SIPAT boiler.

Technology Acquisition Thru Collaboration Status

BHEL entered into a TCA with M/S Babcock Borsig Power(BBP), Grmany in 1999. First phase of training provided by BPP in 2001. BBP has become insolvent in July 2002 & further training planned during the execution of the first contract and technology transfer was not possible. Subsequently a new Engg company , Babcock Borsig Power Systems (BBPS), owned by Babcock Hitachi, Japan was formed. BBPS was found acceptable for Technical collaboration after due deligence exercises. But the collaboration route with BBPS could not be utilised for Sipat tender as NTPC spec required the collaborator to provide financial guarantees.

SIPAT 3x660MW Joint Bidding with Alstom

In the original bid submitted in Oct 2003, BHEL-Alstom joint bid was placed at L3, with Dossan/Korea as L1 and TPE/Russia as L2. In Dec 2003, NTPC invited snap bids to be submitted by all the three bidders by 9 Jan 2003 The new requirements (with increased steam flow & for vacating certain deviations) called for a total redesign by Alstom with estimated three months time. Accordingly BHEL sought extension till 05 March 2004 for submitting the revised bid. However since the request for extension was not granted by NTPC, the snap bid could not be submitted by BHEL

Immediate OTB projects

NTPC BARH 3x660MW Tender due in May 2004. QR same as Sipat project. APGENCO, Vijayawada 1X660MW Four companies (Alstom, Siemens/Doosan,Sumitomo/Babcock Hitachi & TPE/Russia) have been pre-qualified for EPC