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This document provides details on Bharat Heavy Electricals Limited (BHEL) standard 500 MW boilers, including:
1) Boiler parameters such as steam flow and pressure for main steam and reheat steam at different load conditions.
2) Proximate analysis of unwashed and washed coal specifications for three coal groups.
3) Design details for different coal groups such as furnace dimensions and heat loadings.
This document provides details on Bharat Heavy Electricals Limited (BHEL) standard 500 MW boilers, including:
1) Boiler parameters such as steam flow and pressure for main steam and reheat steam at different load conditions.
2) Proximate analysis of unwashed and washed coal specifications for three coal groups.
3) Design details for different coal groups such as furnace dimensions and heat loadings.
This document provides details on Bharat Heavy Electricals Limited (BHEL) standard 500 MW boilers, including:
1) Boiler parameters such as steam flow and pressure for main steam and reheat steam at different load conditions.
2) Proximate analysis of unwashed and washed coal specifications for three coal groups.
3) Design details for different coal groups such as furnace dimensions and heat loadings.
BHEL 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/cm 2 (g) 178 176.7 171.1 Temp at SHO o C 540 540 540 Reheat Steam Steam flow at RHO t/hr 1392.4 1334.9 670.2 Pressure at RHI Kg/cm 2 (g) 45.03 43.21 21.39 Pressure at RHO Kg/cm 2 (g) 42.39 40.69 20.13 Temperature at RHI o C 337 336.7 311.4 Temp at RHO o C 540 540 540 Feed Water Temp o C 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
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 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 - m 2 PA ~ 1.05 PA ~ 1.14 PA Furnace Volume - m 3 V 1.09 V 1.24 V Furnace Heat Loadings- BMCR DC Plan Area M K.cal/h-m 2 4.28 4.15 3.86 EPRS 10 5 K.cal/h-m 2 1.77 1.74 1.68 Volumetric 10 3 K.cal/h-m 3 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 o C
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/Nm 3 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 m 3 /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 KW 1050 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 m 3 /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 KW 2575 KW 1480 rpm
ID Fan Performance (per fan) Group I Group II Group III BMCR DC Fan DP BMCR DC Fan DP BMCR DC Fan DP Volume m 3 /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 KW 3000 KW at 580 rpm 3250 KW at 580 rpm