Installation of APL India’s First

660 MW Supercritical Unit at

Mundra

Sundara Kavidass
Vice President , Engineering Services
Adani Power Ltd, Ahmadabad

July 20, 2011

1
 Presentation Overview

• Introduction
• Supercritical technology
• Design aspects of 660 MW unit
• First 660 MW Project implementation
• Operating Experience
• Conclusion

2
 Introduction
• India’s current installed capacity is 156,784
MW
• Projected additional power demand is 95,750
MW up to 2012
• Plan to add 1,58,124 MW of power generation
capacity in year 2007-17 (ten years)
• Adani Power Limited is contributing to add
power generation capacity

3
 What is Supercritical Technology?
• The supercritical technology is the thermodynamic state where
there is no clear distinction between the Water and Steam phase
in the Rankine Cycle

• Water reaches to steam state at a critical pressure above 22.1 MPa

at 374 oC.

Rankine Cycle
• The “efficiency “of the thermodynamic process is the heat energy
fed into the Rankine cycle is converted into electrical energy.
• Heat energy input to the Rankine cycle is kept constant, the output
can be increased by selecting high pressures and high temperatures.
• The key components are supercritical once through boiler and high
pressure & high temperature steam turbine.

4
Rankine Cycle Subcritical Unit
1 - 2 > CEP work
2 - 3 > LP Heating
3 - 4 > BFP work
4 - 5 > HP Heating
5 – 6 > Eco, WW
6 – 7 > Superheating
7 – 8 > HPT Work
8 – 9 > Reheating
9 – 10 > IPT Work
10–11 > LPT Work
11 – 1 > Condensing
 Rankine Cycle Supercritical Unit

1-2 > CEP work

2 – 2s > Regeneration
2s - 3 > Boiler Superheating
3 – 4 > HPT expansion
4 – 5 > Reheating
5 – 6 > IPT & LPT Expansion
6 – 1 > Condenser Heat rejection
Various Regimes of Pressures

7
Effect of Increasing Steam Temperature and
Pressure on Cycle Efficiency

8
 HRH
MS

Water And DRUM

`
Steam Path
Subcritical Roof
DOWN Tube FRH
PLATEN FSH
COMER I/L SH
Header

LP-BP LTSH
LTRH
HP-BP
ECO

G
LTRH I/L
LPT IPT HPT ECO I/L
Header
Header
CRH

CONDENSER

Water Wall
A B C
CEP

Deareator
GSC
A B
BFBP
LP Heater
#1 A B
BFP WW LOWER
Header
LP Heater #2

HP
LP Heater #3 No. 1 No. 2 No. 3
BFWP
HP Heater HP Heater HP Heater
Natural Circulation Vs. Once Through System

10
660 MW SC Unit Design Coal Data

MUNDRA TIRODA
Parameters Value Parameters Value
Moisture % 33.00 Moisture % 10.0
Ash % 4.02 Ash % 37.0
FC% 32.50 FC% 25.4
VM% 30.48 VM% 27.6
GCV Kcal/kg 4500 GCV Kcal/kg 3927
 660 MW Unit Design Aspects
Boiler
Description Unit Mundra Data Tiroda Data
Furnace Size : mxm 20.4023x20.072 19.824x17.64
Height : m 68 69

WW lower header elevation m 7 9

Roof elevation m 75 78

Transition header elevation m 50.47 53.34

Furnace plan heat release Kcal/m2 3.419 x 10^6 4.486 x 10^6

Furnace volume heat release Kcal/m3 58.05 x 10^3 68.07 x 10^3

Water Wall area/ No of tubes m2 4667/ 1468 5952 / 1338

Superheater area m2 12034 14954

Reheater area m2 24395 23615

Economizer area m2 12542 12606

12
 Supercritical Boiler Features
Bottom spiral & top vertical tube furnace arrangement

• Once through design feature is used for boiler water wall design
• The supercritical water wall is exposed to the higher heat flux
• Utilize intensive radiant heat transfer in the furnace firing zone
• Spiral tube wall design (wrapped around the unit) with high
mass flow & velocity of steam/water mixture through each spiral
tube (2630 kg/m2/s & mass flow velocity for vertical tubes ~
1259 kg/m2/s)
• Higher mass flow improves heat transfer between the WW tube
and the fluid at high heat flux.
• Improved materials are utilized for superheater and reheater
tubes

13
 HRP
MSP

Water And SEPARATOR

Steam Path ROOF TUBE

I/L Header

SC Unit SEPARATOR
FRH
DRAIN TANK SH DIV FSH
Panel

LP-BP
LTSH
LTRH

HP-BP
ECO
VERTICAL WATER WALL

G LTRH I/L Header

ECO I/L Header
LPT LPT IPT HPT

CRP

CONDENSER
BRCP

A B C
CEP
DEAERATOR
GSC
A B
BFBP
No.7AB&8AB
LP Heater A B
MD-BFP
TD-BFP
No.6 LP Heater

No.5 LP Heater 14
No. 3 No. 2 No. 1
WW LOWER Header HP BFWP
HP Heater HP Heater HP Heater
15
16
 Heat Absorption in 660 MW
50 45% Supercritical Boiler
% Heat Absorption

40
29.5%
30
18.5%
20
7%
10
0
Water wall SH RH Economizer Tiroda 660 MW

Mundra 660 MW 48%

50

% Heat Absorption
40
30 24 %
19 %
20
9%
10
0
Water wall SH RH Economizer
17
 PF FIRING OPTIONS - COMPARISON

BURNER

FIRE
BALL

BURNER

660 MW Tiroda SC Unit 660 MW Mundra SC Unit

Tangential Firing Off-Set Firing

18
 FF (AIR
Coal Burners Arrangement DAMPER)
(Mundra)
F (F ELEVATION COAL
NOZZLE)
EF (AIR DAMPER)

E (E ELEVATION COAL OD (HFO OIL NOZZLE)

NOZZLE)
DE (AIR DAMPER)

D (D ELEVATION COAL OC (HFO OIL NOZZLE)

NOZZLE)
DD (AIR DAMPER)

1687 mm

CC (AIR DAMPER)
C (C ELEVATION COAL
NOZZLE)
BC (AIR DAMPER)
OB (HFO OIL NOZZLE)
B (B ELEVATION COAL
NOZZLE) AB (AIR DAMPER)

OA (LDO OIL NOZZLE)

A (A ELEVATION COAL
NOZZLE) 19
AA (AIR DAMPER)
Coal Burners Arrangement (Tiroda)
 Engineering Design Aspects
Steam Turbine & Heat Cycle

Type Impulse type, tandem compound three

(N660.24.2/566/566) cylinders, four flow exhaust, single reheat,
Dongfang Steam Turbine condensing turbine

TMCR Output 660 MW

BMCR Output 694 MW
HP turbine 8 Stages, 2 Stop valves, 4 control valves
IP turbine 6 Stages, 2 Stop valves, 2 control valves
LP turbine Double flow 2x7 Stages
HP heaters 3
LP heaters 4
No of Extractions 8
No of Journal bearings 6

21
 From Reheater

Boiler
FCS

HPT IPT LPT A LPT B

5 6 5 6
7 7 7 7
3 8 8 8 8
1 4 LPH -7A
LPH -7B
HPH - 1

LPH -8A
LPH -8B

Condenser
2
Condenser
Deaerator
HPH - 2

EXT From
CRH
HPH -3

TD BFP 2x50%
(MD BFP 1x35%) CEP
1994 TPH 3x55%

GSC

CPP
1482 TPH
22
LPH -6 LPH -5
660 MW Turbine Cross Section Overview

23
660 MW Mundra Steam Turbine

24
 Features of 660 MW Mundra Steam Turbine

 Combined HP & IP Section

 Shorter Turbine Length – More Efficient

 Reduced No. of Bearings

 Reduced No. of Packing segments

 Opposite flow in HP & IP Turbines makes thrust force

balanced

 Casings upper & lower halves are nearly symmetrical

25
 Key Plant Equipment

• Coal Mills HP1203 - 6

• FD Fan Axial 2 x 50%
• PA Fan Axial Fan 2 x 50%
• ID Fan Axial Fan 2 x 50%
• APH Regenerative rotary type,
Tri-sector - 2
• ESP 4 passes, 2 sections, 5 fields
• BFP MD BFP-1x35%, TD BFP-2x50%
• CEP 3 x 50%
• CWP 3 x 50%

26
 660 MW Supercritical Unit Design &
Operating Parameters
Item Description Unit TMCR Operating
Data
1 SH steam flow rate TPH 1994 2131
2 Superheated steam temp Deg C 571 567
3 SH steam pressure MPa 25.26 23.57
4 RH steam flow rate TPH 1624 1650
5 RH steam outlet temp Deg C 569 567
6 RH outlet pressure MPa 4.36 4.21
7 FW temperature Deg C 288.7 288
8 FW Pressure MPa 28.4 26.93
9 Separator temp Deg C 421 430
10 Separator pressure MPa 27.02 26.37
11 APH flue gas outlet temp Deg C 147 150
12 Total Air Flow ( To Wind box) TPH 2251 2093
13 Back Pressure KPa 10.2 10.3
14 Fuel Flow Rate TPH 323 293.3
15 Turbine Heat Rate Kcal/kWh 1894 1900
16 MW Output MW 660 663
27
 Material Used for 660 MW Unit
(Mundra & Tiroda)
Material Design Allowable
Equipment
Specification Temperature 0 C Stress in MPa
Water Wall SA213T12 440 103
Low Temperature SH SA213T22 490 80
Final SH SA213T91 590 65
Final SH SA213 TP 347H 590 89
Low Temperature RH SA213T22 355 114
High temperature RH SA213T91 605 65
High temperature RH SA213 TP 347H 605 89
Final SH header SA335P91 590 65
Final RH header SA335P91 605 65
Turbine rotor New 12Cr forging 590 65
HP Turbine 1st stage
2Cr11Mo1VNbN 590 65
Blades

28
 Recommended Water Chemistry for SC Units
All Volatile Treatment Oxygenated Treatment
(Start Up) (Operation)
Feed Feed
Main Main
Description Unit Water Condensate
steam
Water Condensate
Steam
Quality Quality
pH 9.0 - 9.6 9.0 - 9.6 9.0 - 9.5 8.0 - 9.0 8.0 - 9.0 8.0 - 9.0
Dissolved
Oxygen µg/l <5 < 10 30 - 150 < 10
Hydrazine µg/l < 50
Cation µS
Conductivity /cm < 0.2 < 0.15 < 0.2 < 0.15 < 0.12 < 0.15
Silica µg/l < 20 < 20 < 20 < 15 < 10 < 15
Iron µg/l < 10 <5 < 10 < 10 <5 < 10
Sodium µg/l <5 <3 <5 <5 <3 <5
Chloride µg/l <5 <3 <5 <3
Copper µg/l <3 <2 <3 <3 <2 <3

29
 EFFECT OF CYCLE CHEMISTRY – KEY PARAMETERS
Parameter Potential Cause Long -Term Impact
Low pH 1. Condenser tube leak 1. Hydrogen damage
2. Upset in water Treatment 2. Excessive deposits lead to BTF by
3. Improper chemical cleaning overheating.
4. Improper CPU operation 3. Potential for FAC,
4. Stress corrosion cracking.
High pH 1. Excess dosing of NaOH 1. Caustic gouging,
during startup 2. High conc. deposit leads to turbine
2. Upset in water treatment. damage
3. Improper CPU operation.
Chlorides 1. Condenser tube leak 1. Hydrogen damage
2. Upset in water treatment. 2. Pitting on economizer & turbine
blades
3. Stress corrosion cracking in LP
turbine
Sodium 1. Condenser tube leak 1. Caustic gouging
2. Upset in water treatment 2. Deposits on turbine blade lead to rpm
plant reduction.
3. Excess dosing of NaOH
during startup
 BOILER WATER TREATMENT FOR SC UNIT
All VolatileTreatment (AVT)
 Ammonia & Hydrazine added at feed water & condensate
 Boiler water pH to be maintained 9.0 – 9.5
 Dissolved oxygen in feed water is <7ppb.
 Magnetite layer formation for corrosion protection.
 Used during start up to minimize contamination in the system.

Oxygenated Treatment (OT)

 Ammonia & oxygen added to feed water & condensate
 Boiler water pH to be maintained 8.5 – 9.0.
 Dissolved oxygen in feed water is 50 – 150 ppb.
 Hematite layer formation for corrosion protection.

Benefits of OT
 Minimize FAC in feed water piping & economizer inlet header.
 Corrosion product transportation is minimized. Helps to reduce
thermal fatigue , overheating & turbine fouling.
 Formed Hematite layer is stronger than Magnetite layer for corrosion
protection.
 Operation & Maintenance Challenges

• Availability of expertise in the industry

• Operator training including simulators & External
Agency
• Maintaining cycle chemistry
• Limited equipment standby (or) redundancy
• Maintaining adequate spares
• Proper cycling and control load operation
• Coal quality
• Plant Equipment Margin
• Lack of SC operating experience

32
Cold Start up Curve for 660 SC Unit

33
SC Unit Load Ramp up Rate
 Supercritical unit cyclic operation
120

Not Recommended Practice

100

80
% Load

60

40

20
Recommended Practice

0
-60 -10 40 90 140 190 240 290 340 390
Time
 Operating Experience of 660 MW Unit

• Unit has operated beyond 660 MW

• Unit is operating at sliding pressure mode

• Required cycle chemistry - OK

• Power evacuation system - Grid Restriction

• Coal /Ash handling system - OK

• Boiler efficiency (85%) & heat rate – 2200 KCal/kWh

• No significant slagging / fouling for Indonesian coal

• Combustion efficiency - 98 - 99%

• No major maintenance issues on SC boiler & Steam Turbine

• Meeting environmental requirements (pm < 50 mg/Nm^3)

36
 Benefits of Supercritical Unit
• Higher unit cycle efficiency (40 - 42%)

• Superior environmental performance (< 8 % CO2 reduction)

• Lower heat rate and electricity generation cost is lower

• Lower water losses because no continuous blow down

• Reduced auxiliary power consumption

Environmental Benefits

• Reduce carbon dioxide (CO2) emissions with carbon credit

within the Rankine cycle

37
 Highlights of E&C of 660 MW SC Unit
• Erection and Commissioning were successfully
completed in less than 36 months
• Green field power project and all the environmental
clearances were received in time
• No site pilings are required
• Contractor brought major handling equipment from China
• APL’s QA/QC team are placed in china to ensure the
quality.
• Ensured sequential delivery of the equipment to meet the
schedule and Mundra Seaport is very close to the plant
• Project commissioning was done through DCS
• Good team work between Chinese and Indian project
teams
• Received good cooperation from state and central govt.
authorities 38
 Conclusion
• Unit #5 E&C was completed in 36 months

• Unit operating performance as per design

• SC Coal fired power plant cycle efficiency increased by 3% and

contributes reduce CO2 emissions by 5 to 8%

• APL is installing several 660 MW SC units across the country

• APL goal is to install 20,000 MW by end of year 2020

• India’s power demand can be met utilizing larger size SC /USC

Technology

• SC technology can be operated economically as well as

environmentally acceptable manner

39
Power Business Goal - 20,000 MW
Adani Power Limited

21-Jul-11
Complete excavation for main
plant foundations

41
Concrete roads all over plant
area - Main plant front road

42
APH & duct erection start before ceiling
girder

43
 Erection of Coal Bunkers
simultaneously with Main Structure

44
ESP electrodes erection with
exclusive tower crane

45
Furnace hopper assembly with all buckstay
arrangements and erection in two parts only

46
Furnace hopper erection in two
parts

47
Generator stator 276 MT lifting by
2x80T EOT crane

48
Rear arch assembly at site & erection
from boiler top with tower crane

49
Water wall assembly at site & Erection
from Boiler top by tower crane

50
 FINAL SUPER
HEATER

BURNER PANEL DIVISIONAL SUPER HEATER

PANEL
ARCH PANEL

SPIRAL WATER WALL

51
 LTSH COILS

ECONOMISER COILS
ECONOMISER
O/L HEADER

ECONOMISER I/L HEADER 52

53
54
SEPERATORS

55
56