Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

BHEL Standard 500 MW BoilersBHEL Standard 500 MW Boilers

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Boiler Parameters

Main Steam BMCR 500 MW CL 250 MW

Steam flow at SHO t/hr 1625 1495.2 772.7

Pressure at SHO Kg/cm2(g) 178 176.7 171.1

Temp at SHO oC 540 540 540

Reheat Steam

Steam flow at RHO t/hr 1392.4 1334.9 670.2

Pressure at RHI Kg/cm2(g) 45.03 43.21 21.39

Pressure at RHO Kg/cm2(g) 42.39 40.69 20.13

Temperature at RHI oC 337 336.7 311.4

Temp at RHO oC 540 540 540

Feed Water Temp oC 254.6 253.4 219.3

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Proximate Analysis of Unwashed Coal

Group I Group II Group III

Design Coal

Range Design Coal

Range Design Coal

Range

Fixed Carbon % 34.5 32 – 37 28 24 – 32 22 20 – 24

Volatile Matter % 23 22 – 24 23 22 – 24 20.5 19 – 22

Total Moisture % 10 9 – 11 12.5 11 – 14 13.5 12 – 15

Ash % 32.5 32 – 33 36.5 33 – 40 44 42 – 46

Total % 100 - 100 100

HHV K.cal/kg 4250 4000 - 4500

3700 3400 - 4000

3100 2800 - 3400

HGI 50 45 - 55 50 45 - 55 50 45 - 55

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Proximate Analysis of Unwashed Coal

Group I Group II Group III

Best Coal

Design Coal

Worst Coal

Best Coal

Design Coal

Worst Coal

Best Coal

Design Coal

Worst Coal

Fixed Carbon %

37 34.5 32 32 28 24 24 22 20

Volatile Matter %

22 23 24 24 23 22 22 20.5 19

Total Moisture %

9 10 11 11 12.5 14 12 13.5 15

Ash % 32 32.5 33 33 36.5 40 42 44 46

Total % 100 100 100 100 100 100 100 100 100

HHV K.cal/kg

4500 4250 4000 4000 3700 3400 3400 3100 2800

HGI 55 50 45 55 50 45 55 50 45

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Expected Proximate Analysis (Range) of Washed Coal

Group I Group II Group III

Washed Unwashed Washed Unwashed Washed Unwashed

Fixed Carbon 35 - 40 32 - 37 33 – 38 24 - 32 30 – 35 20 - 24

Volatile Matter 25 - 28 22 - 24 23 – 26 22 - 24 21 – 23 19 - 22

Total Moisture 11 - 13 9 - 11 13 – 16 11 - 14 14 – 17 12 - 15

Ash 23 - 25 32 - 33 25 – 28 33 - 40 28 – 30 42 - 46

Total 100 100 100 100 100 100

HHV K.cal/kg 4500 - 4800

4000 - 4500

4000 – 4500

3400 - 4000 3500 – 4000

2800 - 3400

HGI 55 - 65 45 - 55 55 - 65 45 - 55 55 - 65 45 - 55

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Salient Features

Two-pass design

Controlled circulation

Pressure part materials selection as per code.

Radiant reheat

Balanced draft

Side mill layout

cold PA system

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Salient Features contd.

Axial reaction FD fans

Axial reaction PA fans

Radial ID fans with VFD

Regenerative Tri-sector air preheaters

Vertical spindle bowl mills

Gravimetric feeders

ESP to suit outlet dust emission

Micro-processor based BMS, SADC and SB controls.

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

BOILER ARRANGEMENTBOILER ARRANGEMENT

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Design Details – Unwashed Coal

Group I Group II Group III

Furnace Depth - mm D ~ 1.05 D 1.14 D

Furnace With - mm W W W

Furnace height - mm H ~ 1.04 H ~ 1.08 H

Furnace Plan Area - m2 PA ~ 1.05 PA ~ 1.14 PA

Furnace Volume - m3 V 1.09 V 1.24 V

Furnace Heat Loadings- BMCR DC

• Plan Area M K.cal/h-m2 4.28 4.15 3.86

• EPRS 105 K.cal/h-m2 1.77 1.74 1.68

• Volumetric 103 K.cal/h-m3 82.2 75.9 67.4

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Design Details – Unwashed Coal

Group I Group II Group III

Heat Input per burner M K.cal / hr 74.8 60.3 50.7

Max Gas Velocity in horz pass / second pass m/s

12 / 10

Cold air / hot air duct velocity m/s 12.7 / 16

Gas duct velocity m/s 16

Excess Air at Eco. out let % 20

Boiler Exit Gas Temp oC 125 at TMCR with Design coal (DC)

Boiler Efficiency at TMCR – DC % Base - 0.7 - 1.4

Coal Fired – BMCR DC - T/hr 285 330 400

Coal Fired – BMCR WC - T/hr 305 365 450

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

Major Boiler Auxiliaries – Unwashed Coal

Group I Group II Group III

Bowl Mills 6 Nos

BHEL 280

(XRP 1063)

7 Nos

BHEL 280

(XRP 1063)

8 Nos

BHEL 280

(XRP 1103)

No. of Spare mills 1 mill spare with Worst coal at BMCR

Regenerative AH 2 Nos Tri Sector - 31.5 VI 80 (T)

FD Fans - 2 Nos Axial AP1-26/16

PA Fans - 2 Nos Axial AP2-20/12 AP2-21/12

ID Fans 2 Nos Radial with VFD - NDZV 47

ESP Out let Dust concentration

100 mg/Nm3 with n -1 fields in service

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

FD Fan Performance (per fan)

Group I Group II Group III

BMCR DC

Fan DP

BMCR DC

Fan DP

BMCR DC

Fan DP

Volume m3/s 155.3 215 145.9 210 126.8 200

Head mmwc 255 385 238 395 208 360

Fan Shaft Power KW 505 943 453 945 364 823

Fan Efficiency % 78.7 86 77.2 86 73.5 85.9

Motor Rating KW1050 KW

at 980 rpm

1050 KW

at 980 rpm

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

PA Fan Performance (per fan)

Group I Group II Group III

BMCR DC

Fan DP

BMCR DC

Fan DP

BMCR DC

Fan DP

Volume m3/s 90 164 92.7 196 112.5 225

Head mmwc 822 1230 927 1270 940 1375

Fan Shaft Power KW 872 2339 979 3032 1206 3631

Fan Efficiency % 82 81.5 84.4 77.4 84.1 80

Motor Rating KW2575 KW

1480 rpm 3350 KW 1480 rpm

4000 KW 1480 rpm

Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

ID Fan Performance (per fan)

Group I Group II Group III

BMCR DC

Fan DP

BMCR DC

Fan DP

BMCR DC

Fan DP

Volume m3/s 376 500 386.2 515 387 535

Head mmwc 312 440 331 470 335 470

Fan Shaft Power KW 1419 2682 1544 2949 1565 3044

Fan Efficiency % 81 79.6 81 79.5 81 80

Motor Rating KW3000 KW

at 580 rpm

3250 KW

at 580 rpm

3350 KW

at 580 rpm