VUNG ANG 1 THERMAL POWER PLANT PROJECT

TRAINING MATERIAL

Engineering department
BABCOCK & WILCOX BEIJING COMPANY LTD.
INTRODUCTION OF BWBC
The Babcock & Wilcox Company (B&W) has provided decades of unparalleled
professional expertise and service to a host of utility and industrial customers and
continues to be a leader in the supply of boiler equipment for the power generation
industry. With world class manufacturing facilities covering four continents, B&W
has 600,000 megawatts of experience in 90 countries, more than half of the Boilers
around the world adopted B&W’s technology.

Founded in 1867, B&W is the oldest continuously operating boiler company in the
United States. With more than 145 years as a recognized leader in the steam
generation industry, the company is well known for its innovations, cost-effective
solutions and product excellence in the areas of steam generation, fossil fuel
combustion, and environmental controls.
B&W established a Research and Development Division in Alliance, Ohio, in 1947
to maintain its leadership in custom-engineered systems and equipment for the
power generation industry. Today, B&W’s research and development specialists
focus their attention on development in key technology areas including:
combustion processes, emissions control, fuels characterization, numerical
modeling, thermal hydraulics, and structural mechanics. With the help of the
extensive R&D group, B&W achieved several worlds’ firsts listed below:

World’s first water tube boiler in 1867

First boilers for the first public utility in 1882
First Tomlinson recovery boiler in 1929
First welded boiler drum in 1930
Components for world’s first nuclear powered ship in 1953
First commercial supercritical boiler in 1957
Commercial operation of world’s largest boiler（1300MW UP boiler）in 1972
First coal-fired boiler to operate for 607 consecutive days in 1987
Fast Internal recirculating fluid bed boiler
First 600MW Anthracite fired subcritical downshot boiler in 2006（B&WBC）
First Anthracite fired supercritical downshot boiler in 2008（B&WBC）
Babcock & Wilcox Beijing Co. Ltd. (B&WBC) was formed in 1986, the Joint Venture
between Beijing Boiler Works (BBW) and Babcock & Wilcox Company (B&W) with
each partner owning equal share. It is the biggest Joint Venture of B&W with the
strongest capability global-wide. With the support and guidance of B&W, B&WBC
adopts B&W's updated advanced technology and uses B&W's updated procedures
for Material Purchasing, Manufacture and Quality Assurance. With B&W’s technical
support, B&WBC successfully designed, manufactured and put into commercial
operation the world’s first Anthracite fired 600MW downshot boiler.
According to the uncompleted statistics, B&W has designed and manufactured over
400 of 300 MW-875MW Sub-critical units with natural circulation technology and over
160 of 125MW-1300MW supercritical units and ultra-supercritical units. As a Joint
Venture of B&W, B&WBC has designed and manufactured over 100 of 200 MW～
600 MW boilers with B&W's advanced technology. B&WBC has extensive
experience for designing and manufacturing large capacity boilers (for Downshot
boilers B&WBC has got a large market share in both Chinese and international
market as following list shows)
Plant Capacity Coal Pulverizer Burner type
2×350MW Anthracite
Shangan unit 1-2 Direct MPS PAX
Subcritical-Pressure lean coal

2×300MW
Yangquan unit 3-4 Anthracite Bin system EI-XCL
Subcritical-Pressure

2×300MW Double charge and

Qianbei unit 1-2 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill

2×300MW Double charge and

Leiyang unit 3-4 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill

2×300MW Double charge and

Yaxi unit 1-2 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill
 2×300MW Double charge and
Beihai unit 1-2 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill
4×300MW Double charge and
Qianxi unit 3-6 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill
8×600MW Double charge and
Diandong unit 1-8 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill
2×600MW Double charge and
Liyujiang Unit 1-2 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill
2×600MW Double charge and
Xingyi unit 1-2 Anthracite Concentrated HALF-PAX
Supercritical -Pressure discharge mill
2x600MW Double charge and
JinZhuShan unit 1-2 Anthracite Concentrated HALF-PAX
Supercritical-Pressure discharge mill
2×300MW Double charge and
Jincheng unit 1-2 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill
2x600MW Double charge and
Xingyang unit 1-2 Anthracite Concentrated HALF-PAX
Supercritical-Pressure discharge mill
1×330MW
Uong Bi 2 Anthracite Bin system Concentrated HALF-PAX
Subcritical-Pressure
2×600MW Double charge and
Vung Ang 1 Unit 1-2 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill

2×600MW Double charge and

Thai Binh 2 Unit 1-2 Anthracite Concentrated HALF-PAX
Subcritical-Pressure discharge mill
TECHNICAL BACKGROUD
2.1 General technical basis
a. Synchronous technology shares with B&W US.
b. Depending on the results of B&W experience and research in boiler over 140
years
c. Depending on the BWBC experiences in design, manufacture and operation
taken from approximately 90 units, from 200MW to 1000MW
d. Rich experiences in firing anthracite coal.
e. Experience in 600MW ”W” boiler design and operating, such as Diandong
Liyujiang Xingyi Jinzhushan ect.
f. Acquired ASME “S”, “PP”, “U” stamps, “A” class license on manufacturing boiler
from Chinese Ministry of Labor and ISO9001 Certification from the Hartford
Steam Boiler Inspection and Insurance Company.
2.2 VUNGANG Project general technical introduction

The boiler manufactured by BWBC for Vung Ang No.1 Thermal Power Plant
2X600MW Project Vietnam is according to B&W technology. The boiler is drum
type sub-critical with natural circulation, single furnace, balanced draft and single
reheat. The designed coal is Vietnamese hon gai anthracite coal. Adopt the direct
injection system with double inlet and double outlet ball mills and the “W” -shaped
flame downshot combustion. Use the concentrated low Nox HALF-PAX burners
which are designed to burn low volatile coal. The boiler is semi-outdoor
arrangement with solid-tap, fully steel structures.

The whole boiler design, construction, and workmanship conform to ASME Rules
Section I of ASME Boiler and Pressure Vessel Code edition 2007 addenda 2008
and the boiler is ASME “S” stamped.
2.3 BOILER OPERATION MODE ARRANGEMENT
The boiler can be operated with constant or variable pressure mode, which will all
meet the turbine’s requirements. The boiler will be operated with variable
pressure mode. The associated Electric Power Generators and Steam Turbines
are manufactured by TOSHIBA Corporation.
According to the technical specification requirements and B&W design standards,
the designed service life of this boiler is 30 years with the startup limits as follows:
Cold start-up：6-8 hours；>200times
Warm start-up: 3-4 hours；>1000times
Hot start-up：1.5-2 hours；>3000times

2.4 MAIN DESIGN PARAMETER

The boiler design is based on the boiler maximum continuous rate (BMCR). The
steam capacity at boiler rated load (BRL) is the same load with RO load of turbine
，the boiler guarantee efficiency will be tested at BMCR load.
Parameters BMCR 100%RO
SH steam flow (t/h) 2028 1853
SH steam pressure at outlet (Mpa.g) 17.43 17.29
SH steam temperature at outlet (℃) 541 541
RH steam flow (t/h) 1658 1529
RH steam pressure at inlet (Mpa.g) 4.031 3.733
RH steam pressure at outlet (Mpa.g) 3.837 3.560
RH temperature at inlet (℃) 335 325
RH temperature at outlet(℃) 541 541
Feeder water temperature (℃) 291 285
Spray water temperature (℃) 185 181
Boiler design pressure (Mpa.g) 19.65 19.65
Economizer design pressure (Mpa.g) 20.06 20.06
Reheater design pressure (Mpa.g) 5.00 5.00
Turbine pressure at inlet (Mpa.a) 16.7 16.7
Boiler calculating efficiency (HHV basic) 88.54% 88.67%
Guarantee boiler efficiency (HHV basic) 88.2%
2.5 DESIGN BASIS
Coal：Vietnamese anthracite coal from Hon gai and Cam pha coal mine
Unit Design coal Worst coal ASH ANALYSIS
SiO2 % 60.15
Qnet,ar KJ/Kg 21792 21520
Al2O3 % 24.20

Qgr,ar KJ/Kg Fe2O3 % 6.70

CaO % 0.73
ANALYSIS(Weight Percent)
TiO2 % 0.90
Mt % 8.20 12.30
K2O % 4.30
Mad % 1.1 2.23
Vdaf % Na2O % 0.3
7.5 6.0
% MgO % 1.20
28.74 29.9
Car % 57.34 53.70 SO3 % 0.60
Har % OTHERS % 0.92
1.95 2.30
Oar % 2.45 0.40 DT ℃ 1220
Nar % 0.74 0.40 ST ℃ 1300
St,ar % 0.58 1.00 HT ℃ 1300
HGI 42 38 FT ℃ 1410
BWBC consigned TPRI to do the coal analysis and burning test for real coal samples
from Hon gai and Cam pha coal mine.
Hon gai Cam pha
Brief Coal analysis with original design coal and key Characteristics
Hon gai Cam pha Design coal
Higher Heating Value Qgr,ar MJ/kg 22.35 22.43 21.79
Lower Heating Value Qnet,v,a MJ/kg 21.69 21.85 /
r
Total Moisture Mt % 7.00 7.50 8.20
Air Dried Moisture Mad % 1.20 1.60 1.10
Volatile Matter Vdaf % 11.58 9.07 7.50
Ash Aar % 28.97 27.19 28.74
Carbon Car % 58.48 60.51 57.34
Hydrogen Har % 2.44 1.99 1.95
Oxygen Oar % 2.02 1.59 2.45
Nitrogen Nar % 0.85 0.85 0.74
Sulfur St,ar % 0.24 0.37 0.58
Grindability HGI / 74 60 42
Coal reaction index RI ℃ 384 416 370
Coal burning-out index Cb / 14.18 17.14 /

Item Hon gai Cam pha Reaction Index Coal Burn-out

GRADE
(Celsius) Index
Ignition characteristic difficult difficult Extraordinarily
>420 >16.5
difficult
Extraordinarily
Burning-out characteristic difficult Difficult 420-316 16.5-9.6
difficult
Slagging characteristic middle middle Medium 316-272 9.6-6.0
Easy 272-235 6.0-2.2
Impingement abrasion characteristic strong very strong
Very Easy <235 <2.2
Characteristics of coal and boiler design:
1. Ignition stability
Selection for combustion style, burner type, burner parameters, feeding the wind.
2. Burnout characteristics
Selection for combustion style, burner and furnace dimension.
3. Slagging characteristics
Burner layout, furnace thermal index and the heating surface arrangement.
4. Abrasion characteristics
Selection for material, control for gas velocity.

According to the adaptability of the coal,B&WBC s a series of measures for

enhanced combustion and stable combustion. Are as follows:
1. Adopt the “W” flame downshot boiler
2. Use the concentrated low Nox combustion PC EI-XCL burners which are especially
designed to burn low volatile coal.
3. Introduced stage air to furnace, arranged proper refractory covered surface
in lower furnace.
4. Select logical furnace section and furnace volume
5. Adopt the B&W experienced typical arrangement for RBC boilers
6. Provide convenient and flexible measures of control and adjustment, in
order to improve boiler adaptability on the fuel changes.
2.6 HFO Oil: Vietnamese No.2B heavy oil
Viscosity（50℃） 180cst
Sulphur - maximum 3.5% （by weight）
Water content - maximum 1.0％（by volume）
Heating value min. 9800 kcal/kg
The viscosity of the heavy oil before the operations platform will be 3 °E
Standard TCVN 6239-2002 as follows：
Oil
Description Test standard
No. 2B
Density （15oC） ≤ 0.991 TCVN6594:2000 / ASTM D1298
TCVN6701:2000/ASTM D2622/ASTM
(w%) ≤ 3.5
D129/ASTM D4294
Ash (%) ≤ 0.15 TCVN6901:1995/ASTM D482
Water content （%） ≤ 1.0 TCVN2690:1995 / ASTM D95
Impurity （w%） ≤ 0.15 ASTM D473
Conradson（w%） ≤ 16 TCVN6324:2000 / ASTM D189&D4530
Viscosity (CSt 50oC) ≤ 180 ASTM D445
Pour point （oC） ≤ 24 TCVN3753:1995 / ASTM D97
Flash point (oC) ≤ 66 TCVN66084:2000/ASTM D3828/ASTM D93

Gross calorific value (kcal/kg) ≥ 9,800 ASTM D240/ASRM D4809

2.7 Feedwater quality
Normal operation
Item Unit Limit
Hardness µmol/L ≈0
8.8～9.3 (system with copper alloys)
PH at
9.2～9.6 (system w/o copper alloys)
Dissolved oxygen µg/L ≤7
Iron (Fe) µg/L ≤15
Copper (Cu) µg/L ≤3
Silica (SiO2) µg/L <20
Hydrazine residual (2H4) µg/L ≤30 (VAT)
Electric conductivity () µS/cm <0.20
TOC µg/L ≤200

Excursions

Item Unit Limit Hours/incident Hours/year

Silica (SiO2) µg/L <40 100 500
Electric conductivity () µS/cm <0.5 100 500
<1.0 24 100

Start up (target value before turbine rolling)

Item Unit Limit

Hardness µmol/L ≤5.0
Dissolved oxygen µg/L ≤30
Iron (Fe) µg/L ≤75
Silica (SiO2) µg/L ≤80
Electric conductivity () µS/cm ≤1.0
2.8 Steam quality
Normal operation

Item Unit Limit

Silica (SiO2) µg/kg <20
Sodium (a) µg/kg <3
Electric conductivity () µS/cm <0.2

Excursions

Hours/inciden Hours/year
Item Unit Limit
t
Silica (SiO2) µg/kg <40 100 500
Sodium (a) µg/kg <10 100 500
<20 24 100
Electric conductivity () µS/cm <0.5 100 500
<1.0 24 100

2.9 Field operation conditions

（1）Ambient pressure
Design pressure： 0.101325MPa
（2）Ambient temperature
Average ambient temperature (design value): 25℃
Maximum ambient temperature: 40.4℃
Minimum ambient temperature: 7.5℃
（3）Relative humidity
Average relative humidity (design value) 85％
Lowest relative humidity 29％
Highest relative humidity 100％
（4）Rainfall
Yearly mean rainfall 2526.2mm
Highest monthly rainfall 652.2mm
Lowest monthly rainfall 50.7mm
Highest one day rainfall 484.2mm
（5）Wind velocity
Yearly mean wind velocity 2.9m/s
Maximum wind velocity 54m/s
（6） Height above sea level: ~8m
（7）Seismic level

Boiler structure steel seismic design condition (UBC97)

DESCRIPTION VALUE

SEISMIC ZONE FACTOR Z 0.15

SOIL PROFILE TYPE SD

SEISMIC IMPORTANCE FACTOR I 1.25
2.10 Performance datas
Boiler maximum continuous rate (BMCR) 2028t/h
Boiler efficiency (HHV) at RO 88.2%
The total air pre-heater leakage does not exceed 7% in the firsrt year, not exceed 8% after 1st year(RO).
Without oil support, the lowest stable load of a “W” flame boiler will be 45%RO.
The maximum reheater pressure drop should not exceed 0.22MPa.
The MS/RH steam temperature variation under steady load is ±5℃
The Nox emission does not exceed 650mg/Nm3 .（after SCR).

The other expected performance data please view the following transmittals:
VA1-BWBC-00100-M-M1A-CAL-0004 Boiler thermal performance summary
VA1-BWBC-00100-M-M1A-CAL-0003 Steam and water pressure drops calculation
VA1-BWBC-00100-M-M1A-CAL-0002 Aerodynamic calculation summary
GENERAL ARRANGEMENT
OF THE BOILER
Boiler GA drawing
The boiler adopts typical arrangement of B&W RBC natural circulating boiler, which
is drum type sub-critical with natural circulation, single reheat, single furnace, “W” -
shaped flame downshot combustion, balanced draft, dry bottom, semi-outdoor
arrangement with solid-tap and fully steel structures. The furnace is composed of
membrane water wall, the platen superheater is arranged at the upper part of the
furnace, the secondary superheater is on the top of furnace arch nose. The vertical
Reheater is located at the horizontal flue duct. The down pass is separated to two
vertical sections by the division wall. The horizontal reheater is arranged in the front
pass, the primary superheater and economizer are arranged in the rear pass. The
gas damper is designed and arranged at the bottom of end to maintain the reheat
steam outlet temperature at the controlled load range. The gas flow will be induced
to the regenerative air heater after passing the control damper. There are two air
heaters locating at left and right side each.

In order to get the expected movement at three different directions during the boiler
operation, the fixed expansion center is setup, which is symmetrically laid out from
left to right, and 2062.5 mm away from the water wall central line. Physically, this is
the crossing of the axial line of expansion and top lagging, which elevation is
67.65m. To get the expansion point fixed, the hanger-buckstay system is developed,
which is also the basis of each pressure part expansion, piping stress and flexibility
analysis calculation. Additionally, such expansion system will also benefit to the
boiler sealing performance, especially at the roof area.
Fuel and flue gas flow:

Raw coal from coal feeder to pulverizer is grinded by mill, mixed and evaporated by
hot primary air. The mixed pulverized coal flow will be transported by the pressure
head of hot primary air to the burners through PC pipe. Each pulverizer is coincided
with four burners.

Air from the forced draft fan is heated in the secondary section of the airheater and
be distributed to the burner windbox as secondary air.

Hot gas from the furnace passes successively across the platen superheater,the
secondary inlet superheater, the secondary outlet superheater and the pendant
reheater,than turns to the horizental convection pass. The gas is divided to two way
by the baffle wall,one way flows across the pendant primary superheater, horizental
primary superheater and economizer, the other way flows the reheater, than are
converged to airheater.
Fuel and flue gas flow:
Water and steam flow:
In the boiler, feedwater enters the bottom header of the economizer. The water
passes upward through the economizer and stringer tubes, and discharges through
the outlet headers into piping which conducts the heated feedwater to the steam
drum. The heated (but still subcooled) feedwater mixes with saturated water already
in the drum. This subcooled mixture flows down through the downcomer pipes and
is distributed to the various furnace lower headers by supply pipes. From the
furnace wall headers, the fluid rises by means of natural circulation, through the
furnace wall tubes to the upper enclosure headers. The water/steam mixture
leaving the furnace then passes through riser tubes into the steam drum. The
saturated steam/water mixture enters the drum beneath the manifold baffle plates.
This mixture flows between the baffle plates and the drum shell into the cyclone
separators. The essentially steam free saturated water exits the cyclone through
the bottom and mixes with subcooled feedwater. This mixture flows through the
vortex eliminators into the downcomers. The steam leaving the cyclones passes
through the roof suppliers to the CP inlet header.

The saturated steam leaving the drum is routed to the roof inlet header. The steam
in the roof and the steam leaving the pendant convection pass sidewalls flow to the
roof and the steam leaving the pendant convection pass sidewalls flow to the roof
junction header. From this header some of the steam flows down the horizontal
convection pass frontwall, through connecting tubes to the baffle wall lower header,
and up to the lower baffle wall to the primary superheater inlet header.
Some of the steam from the roof junction header flows across the horizontal convection pass
roof and down the upper portion of the horizontal convection pass rearwall to the primary
superheater inlet header. Some of the steam from the roof junction header is routed to the
reheat sidewall upper headers and flows down to the lower enclosure header. From here it is
connected by jumper tubes to the horizontal convection pass rearwall and up to the primary
superheater inlet header. The remaining steam from the roof junction header is delivered to
the back pass horizontal convection pass sidewall lower header, then it flows across the back
pass horizontal convection pass sidewall to the upper header, through connecting tubes to the
baffle wall upper header. It flows down through the baffle wall to the primary inlet header.

Steam flow rises through the primary superheater and discharges through both end outlet
header and through connecting piping along each side through first stage spray
attemperators. From both ends, the steam enters the platen inlet header. After flowing
through the platen sections, it discharges from both ends of the platen outlet header. After
passing through the second stage attemperators located in the platen to secondary
superheater connecting pipes, the steam enters the secondary superheater inlet header and
flows through the secondary superheater sections to the outlet header and to discharge pipes
which terminate ( then flow to the turbine).
Boiler water circulation Boiler Conv. Pass Circuitry
Boiler SH & RH steam circulation
Thank you!

北京巴布科克·威尔科克斯有限公司
Babcock & Wilcox Beijing Co., Ltd.