Installation of APL Indias First 660 MW Supercritical Unit at Mundra

Sundara Kavidass Vice President , Engineering Services Adani Power Ltd, Ahmadabad July 20, 2011

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

Introduction
Indias 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

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

1011 > 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

Effect of Increasing Steam Temperature and Pressure on Cycle Efficiency

HRH MS

Water And Steam Path Subcritical

DRUM

`
Roof Tube I/L Header

DOWN COMER

PLATEN SH

FSH

FRH

LP-BP
LTRH
HP-BP

LTSH

ECO

G
LPT IPT HPT

LTRH I/L Header

CRH

ECO I/L Header

CONDENSER

Water Wall
CEP A B C

Deareator
GSC A B BFBP

LP Heater #1

B BFP

WW LOWER Header

LP Heater #2 LP Heater #3 No. 1 HP Heater No. 2 HP Heater No. 3 HP Heater

HP BFWP

Natural Circulation Vs. Once Through System

10

660 MW SC Unit Design Coal Data

MUNDRA Parameters Moisture % Ash % FC% VM% GCV Kcal/kg Value 33.00 4.02 32.50 30.48 4500 TIRODA Parameters Moisture % Ash % FC% VM% GCV Kcal/kg Value 10.0 37.0 25.4 27.6 3927

660 MW Unit Design Aspects

Boiler
Description
Furnace Size : Height : WW lower header elevation Roof elevation

Unit
mxm m m m

Mundra Data
20.4023x20.072 68 7 75

Tiroda Data
19.824x17.64 69 9 78

Transition header elevation

Furnace plan heat release Furnace volume heat release Water Wall area/ No of tubes Superheater area Reheater area Economizer area

m
Kcal/m2 Kcal/m3 m2 m2 m2 m2

50.47
3.419 x 10^6 58.05 x 10^3 4667/ 1468 12034 24395 12542

53.34
4.486 x 10^6 68.07 x 10^3 5952 / 1338 14954 23615 12606
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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 Steam Path SC Unit

SEPARATOR
ROOF TUBE I/L Header

SEPARATOR DRAIN TANK SH DIV Panel FSH

FRH

LP-BP

LTRH
HP-BP

LTSH

ECO
VERTICAL WATER WALL

G
LTRH I/L Header ECO I/L Header

LPT

LPT

IPT

HPT

CRP CONDENSER BRCP

CEP

DEAERATOR
GSC
No.7AB&8AB LP Heater

BFBP

A TD-BFP

B MD-BFP

No.6 LP Heater

No.5 LP Heater

14
No. 3 HP Heater No. 2 HP Heater No. 1 HP Heater
WW LOWER Header

HP BFWP

15

16

% Heat Absorption

50
40

45%
29.5%

Heat Absorption in 660 MW Supercritical Boiler

18.5%

30
20 10 0

7%

Water wall SH

RH

Economizer

Tiroda 660 MW
% Heat Absorption
50

Mundra 660 MW

48%

40
30 20 10 0

24 % 19 % 9%

Water wall SH

RH

Economizer
17

PF FIRING OPTIONS - COMPARISON

BURNER

FIRE BALL

BURNER

660 MW Tiroda SC Unit Tangential Firing

660 MW Mundra SC Unit Off-Set Firing

18

F (F ELEVATION COAL NOZZLE)

FF (AIR DAMPER) Coal Burners Arrangement (Mundra) EF (AIR DAMPER) OD (HFO OIL NOZZLE)

E (E ELEVATION COAL NOZZLE) D (D ELEVATION COAL NOZZLE)

1687 mm

DE (AIR DAMPER)
OC (HFO OIL NOZZLE) DD (AIR DAMPER)

CC (AIR DAMPER) C (C ELEVATION COAL NOZZLE) B (B ELEVATION COAL NOZZLE)

BC (AIR DAMPER)
OB (HFO OIL NOZZLE) AB (AIR DAMPER)

A (A ELEVATION COAL NOZZLE)

OA (LDO OIL NOZZLE)

AA (AIR DAMPER)
19

Coal Burners Arrangement (Tiroda)

Engineering Design Aspects

Steam Turbine & Heat Cycle
Type (N660.24.2/566/566) Dongfang Steam Turbine
TMCR Output BMCR Output HP turbine IP turbine LP turbine HP heaters LP heaters No of Extractions

Impulse type, tandem compound three cylinders, four flow exhaust, single reheat, condensing turbine
660 MW 694 MW 8 Stages, 2 Stop valves, 4 control valves 6 Stages, 2 Stop valves, 2 control valves Double flow 2x7 Stages 3 4 8

No of Journal bearings

21

From Reheater Boiler

FCS

HPT
3 1

IPT
8

LPT A
7 5 6 7 8 8

LPT B
7 5 6 7 8

HPH - 1

LPH -7A LPH -8A

LPH -7B LPH -8B

2
HPH - 2 EXT From CRH

Condenser Deaerator

Condenser

HPH -3

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

CEP
3x55%

GSC
CPP

1482 TPH
LPH -6 LPH -5

22

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 FD Fan PA Fan ID Fan APH ESP BFP CEP CWP HP1203 - 6 Axial 2 x 50% Axial Fan 2 x 50% Axial Fan 2 x 50% Regenerative rotary type, Tri-sector - 2 4 passes, 2 sections, 5 fields MD BFP-1x35%, TD BFP-2x50% 3 x 50% 3 x 50%

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660 MW Supercritical Unit Design & Operating Parameters

Item
1 2 3 4 5

Description
SH steam flow rate Superheated steam temp SH steam pressure RH steam flow rate RH steam outlet temp

Unit
TPH Deg C MPa TPH Deg C

TMCR
1994 571 25.26 1624 569

Operating Data
2131 567 23.57 1650 567

6
7 8 9 10 11 12 13 14 15

RH outlet pressure
FW temperature FW Pressure Separator temp Separator pressure APH flue gas outlet temp Total Air Flow ( To Wind box) Back Pressure Fuel Flow Rate Turbine Heat Rate

MPa
Deg C MPa Deg C MPa Deg C TPH KPa TPH Kcal/kWh

4.36
288.7 28.4 421 27.02 147 2251 10.2 323 1894

4.21
288 26.93 430 26.37 150 2093 10.3 293.3 1900

16

MW Output

MW

660

663

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Material Used for 660 MW Unit (Mundra & Tiroda)

Equipment Material Specification Design Temperature 0 C Allowable Stress in MPa

Water Wall
Low Temperature SH Final SH Final SH Low Temperature RH High temperature RH High temperature RH

SA213T12
SA213T22 SA213T91 SA213 TP 347H SA213T22 SA213T91 SA213 TP 347H

440
490 590 590 355 605 605

103
80 65 89 114 65 89

Final SH header
Final RH header Turbine rotor HP Turbine 1st stage Blades

SA335P91
SA335P91 New 12Cr forging 2Cr11Mo1VNbN

590
605 590 590

65
65 65 65

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Recommended Water Chemistry for SC Units

All Volatile Treatment (Start Up) Oxygenated Treatment (Operation) Feed Water Quality 8.0 - 9.0 Condensate 8.0 - 9.0 Main Steam 8.0 - 9.0

Description pH Dissolved Oxygen

Unit

Feed Water Quality 9.0 - 9.6

Condensate 9.0 - 9.6

Main steam 9.0 - 9.5

g/l g/l S /cm g/l g/l g/l g/l

<5

< 10

30 - 150

< 10

Hydrazine
Cation Conductivity Silica Iron Sodium Chloride

< 50
< 0.2 < 20 < 10 <5 <5 < 0.15 < 20 <5 <3 <3 < 0.2 < 20 < 10 <5 < 0.15 < 15 < 10 <5 <5 < 0.12 < 10 <5 <3 <3 < 0.15 < 15 < 10 <5

Copper

g/l

<3

<2

<3

<3

<2

<3

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EFFECT OF CYCLE CHEMISTRY KEY PARAMETERS

Parameter Low pH
1. 2. 3. 4.

Potential Cause
Condenser tube leak Upset in water Treatment Improper chemical cleaning Improper CPU operation

Long -Term Impact

1. Hydrogen damage 2. Excessive deposits lead to BTF by overheating. 3. Potential for FAC, 4. Stress corrosion cracking. 1. Caustic gouging, 2. High conc. deposit leads to turbine damage 1. Hydrogen damage 2. Pitting on economizer & turbine blades 3. Stress corrosion cracking in LP turbine 1. Caustic gouging 2. Deposits on turbine blade lead to rpm reduction.

High pH

1. Excess dosing of NaOH during startup 2. Upset in water treatment. 3. Improper CPU operation. 1. Condenser tube leak 2. Upset in water treatment.

Chlorides

Sodium

1. Condenser tube leak 2. Upset in water treatment plant 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

-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

APLs 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. 38 authorities

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 Indias 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

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SEPERATORS

55

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