DETAILS OF CALCULATIONS:

POWER OUTPUT
= 660 MW
TOTAL ENERGY DELIVERED @ 660 MW FOR A PERIOD OF ONE HOUR =
660MWH
Taking Efficiency = 37.96 % and 90 % PLF
Input = 660* 103 x 0.9 x 860 kcal / 0.3796

= 1345732.35 Kcal
(1 KWH = 860kcal)

Design calorific value of coal = 3300 Kcal/ kg

Coal requirement per hour

= 1345732.35 / 3300 = 408 T

At efficiency 38.96 % coal requirement per hour = 397 T

Yearly saving of coal by increasing
efficiency of 1 % = 11 x 24 x 365 days = 96,360 MT
Total value of the coal saved @ Rs 650 / MT = Rs 626 lakhs
If the efficiency increases by 2.5 % = Rs 626 x 2.5 = 1565 Lakhs
Considering the life time as 30 Years, the savings in Fuel cost
will be Rs 46950 Lakhs ~ 470 Crores

For three units = 470 x 3 = 1410 Crores

INDIRECT SAVINGS
Assuming Auxiliary Power consumption as 8 %
Estimated reduction in auxiliary power consumption = 0.3 %
For 660 MW units savings of auxiliary power
= 8 % x 660 x 0.003 = 0.158MW
Yearly savings in MW

= 0.158 x 365 x 24 x 0.9 = 1248 .825

= 1248825 units

Taking the unit cost as Rs 2.50 per unit

Savings
= 32.00 Lakhs
Total for three units
= 32 x 3 = 96.00 Lakhs
~ 1.0 Crores
For life time = 30. Crores
TOTAL = 1410 + 30 = 1440 CRORES
ASSUMING THE LIFE AS 30 YEARS, THE APPROXIMATE SAVINGS WILL BE
RS 48 CRORES PER YEAR FOR ALL THREE UNITS TOGETHER.

INCREASE IN PLANT EFFICIENCY by SUPER

CRITICAL PARAMETERS
Efficiency Increase

1.5

6
5
4

0.6

0.9

3.2

3 .
2
1
167 bar 250 bar
250 bar
250bar
250 bar
538/538c 538/538
540/560c 566/566 c 580/600c

Comparison of BHEL V/s Doosan Units

Doosan Units

BHEL Units

Total Weight- 27960

MT

Total
MT

Structure 6924 MT
Pr. Parts 7080 MT
P C Piping 3032 MT
P F System 3823 MT
Draft System 5004
MT
Refractory/Insulation
C&I/Misc 2097 MT

Weight-

28585

Structure 10801 MT
Pr. Parts 5800 MT
P C Piping 1445 MT
P F System 2342 MT
Draft System 5680 MT
Refractory/Insulation
C&I/Misc 2517 MT

COMPARISION OF 660 MW Vs 500 MW BOILER

Description

S/H STEAM FLOW

SH

STEAM PR

SH STEAM TEMP

660

T/HR

2225

1625

KG/CM2

256

179

540

540

T/HR

1742

1397.4

303.7

338.5

568

540

KG/CM2

51.17

46.1

291.4

255.2

RH STEAM FLOW
RH STEAM TEMP

unit

INLET

RH STEAM TEMP OUTLET

RH STEAM PRESS INLET
FEED WATER TEMP

0
0

500

Tonnage Comparison
Description

660 MW

500 MW

Structural Steel Erection

7383

9200

Boiler Proper & Accessories (Pre. Parts)

7080

5300

Refractory, Insulation & Cladding

1410

2000

Power Cycle Piping

3032

2200

54

76

Coal Firing System

3573

2000

Draft System

5275

5200

62

200

Miscellaneous System

130

280

Electrical & Instrumentation

282

380

28281

26836

Soot Blowing System

Fuel oil system

TOTAL

Material Comparison
Description

660 MW

500 MW

Structural Steel

Alloy Steel

Carbon Steel

Water wall

T22

Carbon Steel

SH Coil

T23, T91

T11, T22

RH Coil

T91,Super 304 H

T22, T91,T11

LTSH

T12

T11

Economizer

SA106-C

Carbon Steel

Welding Joints (Pressure Parts)

42,000 Nos

24,000 Nos

Structural Comparison
Slno

660 MW

STRUCTURALS

500 MW

b.

Remarks

Entire structural is bolting typeentire structure is bolted. Holes

are drilled on the columns and
gusset plates, and supplied with
matching plates.

Structural is
assembled at site
with welding

Advantages (660MW) of
Bolting structure:
oFast in erection.
oClean environment
oNo Welding network required
oSafety at site
oPainting finish is good
o( No Weld surface)

No Welding work involved in

assembly/ Erection , except
Walkway rail post welding

Assembly is carried
out with Welding

Can be dismantled if required

( For Maintenance purpose)

Material supply is tier wise

including staircases, railing,
gratings etc.

Material is supplied
as per the erection
sequence.

Erection completion tier wise,

including gratings, platforms ,
staircases etc.

COST COMPARISON
1 Cost of SG Package

1970.73 Cr

1020.54 Cr with ESP

2 Cost of ESP

183.54Cr

3 Total cost of Boiler + ESP

2154.27 Cr

1020.54 Cr

4 Cost of Boiler per MW with ESP

1.09 Cr

1.02 Cr

5 Cost of TG for entire stage

1204.72 Cr

634.31 Cr

6 TG cost per MW

0.6Cr

0.63 Cr

BOILER SPECIFICATION
Description

unit

S/H STEAM FLOW

SH

STEAM PR

SH STEAM TEMP

2225

KG/CM2

256

540

T/HR

1742

303.7

568

KG/CM2

51.17

291.4

RH STEAM FLOW
RH STEAM TEMP

T/HR

INLET

RH STEAM TEMP OUTLET

RH STEAM PRESS INLET
FEED WATER TEMP

0
0

= Boiler Efficiency

Quoted Turbine Heat Rate

100% TMCR

86.27%

100% Load 1904 Kcal / KWH

80% TMCR

86.60%

80% Load

1924 Kcal / KWH

60% TMCR

86.68%

60% Load

1973 Kcal / KWH

50% TMCR

86.91%

50% Load

2065 Kcal / KWH

Net Plant Heat Rate = NTRH

= 2207 KCal / KWHR ( at 100% TMCR)

80% TMCR
60% TMCR
50% TMCR

= 2222 Kcal / KWHR

= 2276 Kcal / KWHR
= 2376 Kcal / KWHR
Plant Efficiency at 100% TMCR = 38.96%
80% TMCR = 38.7 %
60% TMCR = 37.78%
50% TMCR = 36.19%

SUPERCRITICALTHERMAL CYCLE
ADVANTAGES

(1)

Improvements in plant efficiency .

Decrease in Coal Consumption
Reduction in Green House gases.
Overall reduction in Auxiliary Power
consumption.
Reduction in requirement of Ash dyke
Land & Consumptive water.

SUPERCRITICAL ADVANTAGES

(2)

Sliding pressure operation because of Once

through system .
Even distribution of heat due to spiral wall
arrangement leading to less Boiler tube
failure, thereby improving system continuity
and availability of the station.
Low thermal stress in Turbine .
The startup time is less for boiler.

SUPERCRITICAL DISADVANTAGES
Higher power consumption of BFP
Higher feed water quality required.
More complex supporting and framing in Boiler due to
Spiral Wall tubes.
Slight higher capital cost.
Increased dependency For Spares and services.

IMPORTANCE OF EFFICIENCY
The cost of operating the Plant of 3 x 660 MW, one percentage
point below the design point, will incur additional fuel cost of
Rs. 16 Crores in a year.
The indirect costs for Maintenance, APC, Ash Dyke land etc. will
give additional burden of Rs. 1Crores in a year.
The environment will benefit on account of reduction in GHGs like
Co2, NOX & SOX.
The life time savings of Rs.550- 600 Crores can be achieved by
increasing efficiency by one percentage .
At Sipat, we gain an efficiency of 2.5 percentage by adopting
super critical technology in 1980 MW station, thus saving Rs. 1440
Crores in its life time.

REDUCTION IN CO2 EMMISSION

CONSIDERING AVG COAL CONSUMPTION OF AT
FULL LOAD OPERATION
:
400T/HR
IMPROVEMENT IN EFFICIENCY
FOR SUPER CRITICAL TECHM
COMPARED TO 500 MW BOILER
:
1.5%
REDUCTION IN COAL FLOW
:
6 T/HR
REDUCTION IN CO2 EMMISSION
(FIXED CARBON CONTENT IN COAL 30%) : 6 T/HR
REDUCTION IN CO2 EMMISSION
PER YEAR
: 52560 TONS