Submitted By:

Praveen Kumar Pandey

Staff No: 2987287
Dy. Manager
6X30 MW OPaL Project Dahej
Subcritical / Supercritical Cycle
Supercritical Cycle
a-b-c-d-e-f-g-h-i-a

Critical Point
221 bar-a,
371 deg-C 6 f h
6 8
Temp
e g
d 4
5
7
b 3 c
2
i 9
a 1
Subcritical Cycle
1-2-3-4-5-6-7-8-9-1

Entropy
STEAM AND WATER CIRUIT OF THE
SUPER CRITICAL BOILERS
 5710C To HP
Turbine To IP
Turbine 5690C
Mixer Header
5340C
4230C 5260C
4620C

Separator FRH

FSH 4730C

Platen
Heater
From CRH Line LTSH
3260C
4430C
LTRH
3240C

NRV
From FRS Line 2830C

2800C Economizer Economizer

Phase 1 Phase 2

Boiler Bottom Ring

Recirculation Pump Header
 DESCRIPTION OF COMPONENTS BOILER SPEC.
Thermal Power Plant
M
ULTRA MEGA POWER PLANT
UNDRA Units 7 & 8 (500MW x 2)
1 FEED WATER PIPE

2 ECONOMIZER INLET HEADER

3 ECONOMIZER ASSEMBLIES

4 ECONOMIZER HANGER TUBES

32 REHEATER REAR FINAL ASSEMBLIES

33 REHEATER OUTLET HEADER

34 REHEATER OUTLET PIPES (HRH)

35 FLASH TANK VENT PIPE

BOILER TYPE

CAPACITY

PRESS.
CONDITION
MAIN STEAM

REHEATER

MAIN STEAM

REHEATER
Supercritical Once-Thru Boiler

1,672

1,325

255

53.6
Ton/Hr

Ton/Hr

Kg/cm2g

Kg/cm2g

SUPERCRITICAL
Su pe r cr itical CCOAL FIRED
oal Fir e d STEAM GENERATOR
Ste am Ge nerato r
5 ECONOMIZER HANGER TUBE OUTLET HEADER 36 SILENCERS (PSV, ERV, START UP VENT)
TEMP. MAIN STEAM 569 ºc
6 FURNACE LOWER RING HEADERS 37 F.D. FAN SUCTION W/SILENCERS CONDITION REHEATER 596 ºC

7 FURNACE SPIRAL W/W TUBES 38 FORCED DRAFT FANS FUEL Hi-Vol. “c” , Bit. Coal

8 FURNACE VERTICAL W/W TUBES 39 SECONDARY AIR DUCT TO GAS AIR PREHEATERS FIRING SYSTEM Low Nox Tangential Burners

DRAFT STSTEM Balanced

9 FURNACE UPP. FRONT HEADER 40 STEAM COIL AIR HEATERS
FURNACE TYPE Spiral Wound / Vertical Wall
10 FURNACE UPP. REAR HEADER 41 GAS AIR PREHEATERS

11 WATER SEPARATORS 42 HOT SECONDARY AIR DUCT TO WINDBOX

12 SEPARATOR STORAGE TANK 43 WINDBOX & TILTING TANGETIAL BURNER

13 FLASH TANK 44 SCANNER & COOLING AIR FANS LEGEND & ABBREVIATIONS
To HP Turbine 14 CONDENSATE RECEIVING TANK 45 PRIMARY AIR FANS
ACCESS DOOR

TO LP Turbine (HRH) 15 CONDENSATE DRAIN TRANSFER PUMPS
16 BOILER WATER RECIRCULATING PUMP
17 BACKPASS LOWER SIDE HEADERS
46 HOT PRIMARY AIR DUCT TO MILLS
ACCESS DOOR IN ROOF EMCLOSURE
47 COLD PRIMARY AIR DUCT TO MILLS
OBSERVATION DOORS
48 MIXED HOT AIR DUCT TO MILLS

From HP Turbine 18 BACKPASS SIDE WALL TUBES 49 COAL TRIPPER CONVEYOR ROOM
WALL BLOWER

(CRH)
RETRACTABLE SOOTBLOWER-DOUBLE SIDE
19 BACKPASS UPPER SIDE WALL INLET HEADERS 50 COAL SILOS

20 BACKPASS LOWER REAR HEADER 51 COAL FEEDERS HALF TRACT SOOTBLOWER-DOUBLE SIDE

21 L.T.S.H. HORIZONTAL ASSEMBLIES 52 COAL MILLS (PULVERIZER) FURNACE TEMPERATURE PROBE

22 L.T.S.H. PENDANT ASSEMBLIES 53 COAL PIPNG FURNACE MONITORING CAMERA (CCTV)

23 L.T.S.H. OUTLET HEADER 54 FURNACE BOTTOM ASH HOPPER

24 SUPERHEATER DIV. PANELETTES 55 ECONOMIZER OUTLET FLUE GAS DUCT

25 SUPERHEATER FINAL INLET HEADER 56 ELECTROSTATIC PRECIPITATOR

26 SUPERHEATER FINAL ASSEMBLIES 57 INDUCED DRAFT FANS

27 SUPERHEATER FINAL OUTLET HEADERS 58 FLUE GAS DUCT TO STACK

28 SUPERHEATER OUTLET PIPES (MS) 59 STACK

29 REHEATER INLET PIPES (CRH) 60 STEAM COIL AIR HEATER DRAIN TANK

30 REHEATER INLET HEADER 61 MILL SEAL AIR FANS

31 REHEATER FRONT PLATTEN ASSEMBLIES 62 PENT HOUSE VENTILATION FANS

TURBINE BUILDING
 Furnace Wall Designs

Spiral Wall Configuration Vertical Wall Configuration

Vertical Wall Sliding Pressure
Supercritical Design
 Feed water control
 In Drum type Boiler Feed water flow control by
Three element controller
 1.Drum level
 2.Ms flow
 3.Feed water flow.

 Drum less Boiler Feed water control by

 1.Water/Fuel ratio
 2.OHD(Over heat degree)
COMPARISION OF SUPER CRITICAL & SUB CRITICAL
DESCRIPTION SUPERCRITICAL SUB-CRITICAL
(660~800MW) (500~600MW)
Circulation Ratio 1 Once-thru=1
Assisted Circulation=3-4
Natural circulation= 7-8

Feed Water Flow Control -Water to Fuel Ratio Three Element Control
-OHD(22-35 OC) -Feed Water Flow
-MS Flow
-Drum Level

Latent Heat Addition Nil Heat addition more

Sp. Enthalpy Less More

Sp. Coal consumption Low(~0.6 kg/kwh) High(~0.68kg/kwh)

Air flow, Dry flu gas loss Low High

Continue…
DESCRIPTION SUPERCRITICAL SUB-CRITICAL
(660~800MW) (500~600MW)
Coal & Ash handling Low High
Capacity
Pollution Low High
Aux. Power Low High
Consumption
Overall Efficiency High Low
(40-42%) (36-37%)
Total heating Low High
surface area Reqd (~128 m2/MW) (~143 m2/MW )
Tube diameter (ID) Low High
Continue…

DESCRIPTION SUPERCRITICAL SUB-CRITICAL

(660~800MW) (500~600MW)
Blow down loss Nil More

Water Consumption Less More

Type(drum) Drum Less Drum Type

Advanced Supercritical Tube Materials
(300 bar/6000c/6200c)
 Material Comparison

Description 660 MW 500 MW

Water wall SA213 T-12/22 Carbon Steel
T23, T91,
TP347H/ T11, T22,
SH Coil TP347HFG T91,347H
T91/TP347H/
TP347HFG/ T22, T91,
RH Coil T12/T23 T11,347H
LTSH T12/T23 T11
Economizer SA210-C Carbon Steel
Welding Joints (Pressure Parts) 50,204 Nos 24,000 Nos

17
Steam Water Cycle
Chemistry Controls
S. Parameter Sub Critical Super Critical
No.
Type of Boiler  LP and HP dosing. Or  No HP dosing
1 water  All Volatile Treatment  Combined water treatment (CWT).
treatment (Hydrazine + Ammonia)

Silica < 20 ppb in feed water and steam, Standard value <15 ppb in the cycle
2
< 250 ppb in boiler drum Expected value <10 ppb in the cycle
pH 9.0 - 9.5 for feed, steam & 9.0 – 9.6 for AVT(All volatile treatment)
3 condensate, 8.0 – 9.0 for CWT(Combine water
9.0 – 10.0 for Boiler drum treatment)
Dissolved < 7 ppb for feed. < 7 ppb for feed in case of AVT
4
Oxygen (DO) 30 – 150 ppb for feed in case of CWT
Cation (H+) <0.20 µS/cm in the feed & steam Standard value <0.15 µS /cm in the cycle
5 Conductivity cycle Expected value- <0.10 µS /cm in the cycle

6 (CPU) CPU is optional CPU is essential for 100% flow.

Silica and TDS By maintaining feed water quality Blow down possible till separators are
7 control and functioning (upto 30% load).
By operating CBD
 Advantages of SC Technology
I ) Higher cycle efficiency means
Primarily
– less fuel consumption
– Per MW infrastructure investments is less
– less emission
– less auxiliary power consumption
– less water consumption
II ) Operational flexibility
– Better temp. control and load change flexibility
– More suitable for widely variable pressure operation
 Sub. vs. Supercritical Cycle
Impact on Emissions
Subcritical Supercritical
Plant Efficiency, %* 34 - 37 37 - 41

Plant Efficiency, % 34% 37% 41%

Fuel Consumption/Total Emissions Base Base-8% Base-17%

including CO2

* HHV Basis
ULTRA SUPER CRITICAL TECHNOLOGY
&
ADVANCED ULTRA SUPER CRITICAL
TECHNOLOGY
 The Basic Heat Cycle
Sub-critical units: Main steam pressure < 221. 1 bar
Super-critical units: Main steam pressure > 221. 1 bar

Ultra-supercritical units:
Higher steam pressure and temperature than supercritical
units
Japan: Main steam pressure >242 Bar, or Steam
temperature >593 ℃
Demark: Main steam pressure >275 Bar
China: Main steam pressure >270 Bar
USA (EPRI) : Main steam temperature>593 ℃
 STEAM PARAMETERS

• Plant with steam pressure exceeding 225 kg/cm2 is said

“Supercritical”

• Supercritical plant with main steam temperature 

600C is said “Ultra Super-Critical”

• Supercritical plant with main steam temperature 

700C is “Advanced Ultra Super-Critical
SNAPS OF SUPER CRITICAL BOILERS ERECTION
SPIRAL WW
PANELS
SPIRAL WW
PANELS
SEPRATORS
Spiral Wall Windbox
Thank you