BHEL’S Contribution to Indian Power Sector

Practically every 3 houses out of 4 in India

are supplied power, generated from BHEL sets

Over 1,15,000 MW added by BHEL in domestic and international segments

 Steam Generators - Contracted
Power Boilers:
30 to 150 MW 159
200/210/250/270 MW 232
Total utility Power > 136073 MW
500/525/600 MW 109
660/800 MW 17
CFBC 28

Process Plant Boilers:

Chemical Recovery 17
Total
Conventional Firing 151
BFBC 72 960
HRSG (Includes Co-gen Plants) 175
 Valves
Boiler
Components USA
Japan
•USA Indonesia
•China Malta
•Egypt Cyprus
•Bangladesh Egypt

Steam Generators
Malaysia 11 Nos 1110 MW R&M and
Libya 2 Nos 240 MW gas conversion
R&M jobs Egypt 2 Nos 60 MW in Malaysia
in Libya Sudan 4 Nos 500 MW
Syria 2 Nos 400 MW
 Steam Generators Exported
Customer Unit Size No
EEA-Egypt Al-Arish TPS 12 T/h 1
ECT-Libya Tripoli West TPS 45 T/h 2
PT IBR-Indonesia Bharat Rayon 75 / 80 T/h 3/3
PT – IBR Jawa bharat Indonesia 120 T/h 1
PT. ADARO Indoesia 126 T/h 2
KONIAMBO-Nickel SAS Koniambo Nickel SAS – 405 T/h 2
New Caledonia
NEB-Malaysia Sultan Ismail TPS 30 MW 1
EEA-Egypt Al-Arish TPS 30 MW 2
NEB-Malaysia Tuanku Jaafar TPS 60 MW 2
NEB-Malaysia Tuanku Jaafar TPS 120 MW 3
NEB-Malaysia Prai TPS 120 MW 3
NEB-Malaysia Pasirgudang TPS 120 MW 2
ECT-Libya Tripoli West TPS 120 MW 2
NEC-Sudan Kosti TPS 125 MW 4
MAYLAN Intra Ltd Senegal / Africa 125 MW 1 Total 36
PEEGT Tishreen,Syria 200 MW 2
 Trend in unit sizes & Cycle parameters
SHO/RHO
SHO Pressure Year of
Unit Size Temperature
(kg/cm2(a) Introduction
(Deg.C)
60 / 70 MW 96 540 1965
110 / 120 MW 139 540/540 1966
200 / 210 MW 137 / 156 540/540 1972
250 MW 156 540/540 1991
179 540/540 1979
500 MW
179 540/568 1985
540/540
600 MW 179 2008
540/568
660 MW 256 568/596 2008
700 MW 256 568/596 2010
800 MW 256 568/596 2008
 BASIC DATA FOR DESIGN

BOILER PARAMTERS
FUEL DATA
SITE DATA
 Heat balance diagram (270 MW)
150.0 816.4
796.486 537.0

HPT LPT LPT

BOILER
39.56 736.6 35.62 844.4
717.87 345.1 717.87 537.0

0.1033 573.1
552.286 (0.9227)

C
246.0
255.0

D
796.486

HPH HPH LPH LPH LPH LPH

CP
-

FP

ata kCal/kg
t/h deg. c (x)
FUEL ANALYSIS COAL
 Fuels Handled
Coal / Oil / Natural Gas in any combination
Lignite
Blast Furnace Gas / Coke Oven Gas / Corex Gas
Carbon Monoxide / Tail gas
Asphalt
Black Liquor
Bagasse
Rice Husk
Washery Rejects
Wheat / Rice straw
 COAL PROPERTIES AFFECTING BOILER DESIGN

TYPE OF COAL ( ANTHRACITE, BITUMINOUS, LIGNITE)

HIGHER HEATING VALUE
VOLATILE MATTER
MOISTURE CONTENT
ASH CONTENT
ASH CHARACTERISTICS
HARD GROVE INDEX ( HGI )
 INDIAN COALS Vs COALS OF OTHER COUNTRIES

INDIA GERMANY USA CANADA AUSTRLIA INDONESIA

Coal A B C RUHR WESTERN ALBERTA NSW

MOISTURE % 15.0 12.0 12.0 8.5 16.0 4.0 8.0 20 16

VOL.
% 20.0 18.0 30.0 20.5 33.0 18.0 29.0 30 45
MATTER

ASH % 40.0 40.0 30.0 8.0 8.0 8.5 15.7 10 10

SULPHUR % 0.5 0.3 0.2 1.5 0.5 0.5 0.69 0.9 0.8

HHV kCal/kg 3200 3500 4500 6700 5730 7600 6200 5800 6500

PER Max. Moisture

COAL ASH mkal 125 114 67 12 14 11 25
kg 42 %
 CHARACTERISTICS OF TYPICAL INDIAN COAL

HIGH ASH (35 – 50%)

HIGHLY ABRASIVE (55 – 65%)

MEDIUM MOISTURE (10 – 15%)

MEDIUM VOLATILE MATTER (18 – 24%)

LOW HEATING VALUE (HHV kcal / kg) (3000 – 3500)

LOW SULPHUR (0.2 – 0.5%)

 PROBLEMS ASSOCIATED WITH INDIAN COALS

INCONSISTENT COAL PROPERTIES

PRESENCE OF EXTRANEOUS MATTERS IN COAL

HIGH QUANTUM OF ASH WITH HIGH PERCENTAGE OF QUARTZ

HIGHLY ABBRASIVE NATURE OF COAL ASH

DUE TO LOW SULPHUR CONTENT- EXTREMLY HIGH ELECTRICAL

RESISTIVITY OF ASH

LOW HEATING VALUE OF THE COAL

 FURNACE SELECTION CRITERIA

 NHI / PA

 NHI / EPRS

 Q FIRED / VOLUME

 BURNER ZONE HEAT RELEASE RATE

 FURNACE RESIDENCE TIME

 DISTANCE BETWEEN FURNACE BOTTOM-HOPPER & LOWER MOST FUEL NOZZLE

 DISTANCE BETWEEN UPPER MOST FUEL - NOZZLE & BOTTOM OF SH

 FURNACE OUTLET TEMPERATURE

 ASPECT RATIO
 FURNACE HEAT LOADINGS

 EPRS LOADING
 PLAN AREA LOADING
 VOLUMETRIC LOADING
 BURNER ZONE HEAT RELEASE RATE
VU40
RENUSAGAR 67.5MW
CESE CALCUTTA 67.5 MW
110 MW SABARMATHI
CONTROLLED CIRCULATION
STEAM GENERATORS
500 MW NTPC SINGRAULI 6
Once -thru Boiler-Furnace Wall
500 MW TALCHER –NTPC

(Sub critical once-through)

 BHEL Industrial Boilers

1 VP Vertical Package Boiler

2 VU 60 Vertical Unit
3 VU 40 Vertical Unit
4 VU 40S Vertical Unit (Stoker)
5 VU 60S Vertical Unit (Stoker)
6 MU Modular Unit
7 V2R Chemical Recovery
 VP Boiler Design Features

 Bi-Drum Bottom supported

 Natural Circulation
 Wall firing - Oil/Gas
 Pressurised/Balanced Draft
 Welded Furnace Wall
 Single/Multi Pass Gas Flow across Boiler bank
 Drainable Superheaters
 Economiser and/or Airpreheater.
 Minimum Refractory & Insulation
 Wide steam temperature control range
 Fast response to load swings
 VU60 Boiler Design Features

 Bi-Drum Bottom supported

 Natural Circulation
 Front wall/Tangential Firing - Oil/Gas
 Pressurised / Balanced Draft
 Welded Furnace Wall
 Multi-Pass Gas flow across Boiler Bank
 Economiser and/or Airpreheater
 Minimum Refractory & Insulation
 Wide steam temperature control range
 Fast response to load swings
 VU40 Boiler Design Features

 Bi-Drum Top supported

 Natural Circulation
 Tangential/Front wall Firing -Coal/Oil/Gas
 Balanced Draft Welded Furnace wall
 Single Pass Gas flow across Boiler Bank
 Economiser and Airpreheater
 Minimum Refractory & Insulation
 Fast response to load swings
 VU40 (Stoker) Boiler Design Features

 Bi-Drum Top supported

 Natural Circulation
 Grate Firing - Coal/Lignite/Cellulose Fuels
 Balanced Draft Welded Furnace wall
 Single Pass Gas flow across Boiler Bank
 Economiser and Airpreheater
 Minimum Refractory & Insulation
 Fast response to load swings
 MU Boiler Design Features

 Single Drum Natural Circulation

 Bottom or top supported
 Fully welded construction
 Drainable Superheater
 Integral Economiser
 Pressurised/Balanced Draft
 Wider control range
 Minimum Refractory & Insulation
 Quick start-up
 Less space requirement
 V2R Recovery Boiler Design Features

 Bi-Drum top supported

 Natural Circulation
 Balanced Draft
 Welded Furnace Wall
 Widely spaced Tangent tube SH
 Single Pass Gas Flow across Boiler bank
 Vertical straight Finned Economiser
 Twin wheel cascade evaporator system or Large Economiser system.
 Suspension firing system with multiple black liquor guns
 Decanting hearth
 Optimised combustion air system
 HEA ignitors for starting burners
 Minimum Refractory & Insulation
 Additional QC checks for WW tubes
IMPLICATIONS OF HIGHER STAEM PAREMTERS ON
BOILER DESIGN

BOILER TYPE
MATERIALS
RELIABILITY AND AVAILABILITY
 NEED FOR PROPER MATERIAL SELECTION

PROPER SELECTION ENSURE SAFE - METAL TEMPERATURE

UNDER ALL - OPERATING CONDITIONS
PROPER SELECTION HELPS IN - - ---REDUCING THE

INSTALLATION COST.
 SELECTION OF AUXILIARIES

AIRHEATERS
FANS
MILLS
ELECTROSTATIC PRECIPITATOR
AIRHEATER PERFORMANCE VARIATIONS

Fuel moisture
Airheater leakage
Airheater seals
Gas temperature leaving the airheater
MILL PERFORMANCE VARIATIONS

MILL OUTLET / INLET TEMPERTURE

FUEL QUALITY LIKE MOISTURE / HGI / HHV
FAN PERFORMANCE

LOADING OF FANS
POWER CONSUMPTION
 ESP PERFORMANCE VARIATIONS

DUE TO AIR HEATER LEAKAGE

DUE TO HIGHER GAS TEMPERATURE LEAVING AIR HEATERS
MAJOR VARIABLES AFFECTING THE BOILER
PERFORMANCE

EFFECT OF BOILER PARAMETERS

FUEL ANALYSIS VARIATIONS
VARIATIONS IN AUXILIARY
EQUIPMENT PERFORMANCE VIZ .,
MILLS, AH,FANS
 OPERATING VARIABLES AFFECTING SLAGGING

EXCESS AIR
DISTRIBUTION OF AIR
DISTRIBUTION OF COAL
FINENESS OF COAL
NUMBER OF OPERATING BURNER ELEVATIONS
FREQUENCY OF WALL BLOWER OPERATION
LOADING OF BLOWER
OPERATING CONDITIONS AFFECTING THE
PERFORMANCE

LOW PRESSURE OPERATION

HIGHER EXCESS AIR
HP HEATER NOT IN SERVICE
GRID FLUCTUATIONS
FUEL QUALITY AFFECTING THE PERFORMANCE

SLAGGING
FOT VARIATION
SH / RH SPRAY VARIATION
FLUE GAS TEMPERATURE LEAVING BOILER
MILL LOADING
AUX .POWER CONSUMPTION
BOILER EFFICIENCY
 USE OF INDIAN COALS DESIGN CONSIDERATIONS
BOILERS:
CONSERVATIVE FURNACE HEAT LOADINGS
LOWER FLUE GAS VELOCITY OVER TUBE BANKS
PLAIN TUBE IN – LINE ARRANGEMENT OF HEAT TRANSFER SURFACE
-OPTIMUM END GAPS TO AVOID PREFERENTIAL GAS FLOW
-EROSION SHIELSA / CASSETTE BAFFLES
-EROSION ALLOWANCE FOR LEADING TUBES
-CAST STEEL PF BENDS & CERAMIC LINEDPF BENDS
*BOILER AUXILIARIES
-IMPROVED SEALING ARRANGEMENT IN AIRHEATERS
-EXTENDED TUBE-TUBULAR APH
-LOW SPEED RADIAL ID FANS
-LINED IMPELLERS OF RADIAL FANS
 STEAM & WATER CIRCUIT
DRUM

S1 R4

S2
S3 R3
S4
S5 S5
S17 S6 S17 R2
S6
S8
S7 S7

DESH
S9 S11 S11 S9 R1
S18 S18
S19

S12 S20
S20
S13 RH SYSTEM
S14 S14
S15 S15
S10
S16
S21
S22 LOW TEMP SH
S23
E7 E7
S24
E6
S25

E5 E5
S26
S27 E4 E4

S28 PLATEN SH
S29

E3 E3
S30
E2
E1
S31
S32 FINAL SH
S33

SH SYSTEM ECO SYSTEM

SCHEME OF AIR & GAS DUCTS / CIRCUITS
COLD PA SYSTEM
 TOWER TYPE BOILERS ADVANTAGES
A TRULY SINGLE – PASS
ELIMINATES CHANGE IN DIRECTION OF GAS FLOW
MINIMISES EROSION OF PRESSURE PARTS.
INHERENTLY LOW GAS VELOCITY
DUE TO SH / RH SPACING
LESSER EROSION OF PRESSURE PARTS.
DRAINABLE SH ,RH SECTIONS
FASTER START-UP AND SHUT-DOWNS.
OCCUPIES LESS GROND SPACE.
ADOPTED THROUGHOUT EUROPE
WELL ESTABLISHED DESIGN
 TWO PASS Vs TOWER TYPE

Gas flow passes 2 1

No. of turns 2 None
Gas velocity Base Lower

Erosion Potential Base Less

Height of Boiler Base + 30 %
Weight of boiler Base + 5 % - 15 %
Erection` Multi Single front
front
Thank You