WELCOME

Advance Power Plant Technologies

&
Steam Cycles for Supercritical
Application
Sanjoy Bhattacharya
BHEL, Hardwar
1
 Bharat Heavy Electricals Ltd.
Powering Progress ….

•1897:Power Generation in India starts with Clean Technologies- advent of

Hydro turbine -Sidrapong Hydel Power Station, with two 65 kW Crompton-Brunton
alternators & two Gunther's Turbines.
•Followed by 3 MW Sivasamudram Hydro plant by the erstwhile Maharajah of Mysore
•Abundant availability of Coal, Large numbers of small thermal sets by British.

1958: Setting up fo HEIL,

1958: HEIL, Bhopal Indigenous manufacture of Thermal &
Hydro sets
1973:: Commissioning of 1st Thermal set of LMZ design by Hardwar
1973

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 Clean Technologies….
Technologies
•WIND: Wind Electric Generators upto 2 MW
Rating
•Contribution of almost 15000 MW to the grid,
5th largest in the world.
•Problem of continued availability &
dependability

•SOLAR:
•Linear Fresnel Reflector – BHEL has tied
up with Abengoa Spain
•Parabolic Trough Technology
•Solar Tower Technology

•TIDAL ENERGY: potential in India is huge,

•A large coastline of almost 5000 Km.
•Potential in India is of the order of 8000-
9000 MW in the Gulf of Cambay & in the
Gulf of Kutch.

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 Clean Technologies….
Technologies

•NUCLEAR POWER:
•1969- India’s First Nuclear Power
station - Tarapur
•BHEL equips many Power stations with 235
MW TG sets based on CANDU Reactors.
•BHEL commissions India’s first 540 Mwe
Nuclear PS based on PHWR Reactors.
•BHEL building first 500 MW PFBR Turbine

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 Features of Clean technologies
•Characterized by low to Zero emissions & pollutions & therefore
environment friendly
•Ongoing debate both in favour of & against these Clean technologies.
•Characterized by higher capital investment & longer pay back periods.
Also, these are site specific & always cannot be set up near consumption
centers.
•Limited to those countries which have a good Financial position or
wherein the demand for Clean technologies has surpassed the negative
aspects of these technologies.
•Common factor emerges from the above technologies is the Steam
Turbine,
•World focus has again shifted to further development of Steam
Turbine based Power plants as these are not very capital expensive, are
relatively efficient & have a long & reliable service life.
•The adoption of “ Supercritical cycles” for thermal
plants on a wide scale has the ability to improve
overall system efficiency , as well as provide benefits
of lower emissions both on land & in air.
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 Introduction of Steam Turbines with
supercritical parameters

As the fluid pressure increases, Latent

Heat (Enthalpy of Steam –Enthalpy of
Water) reduces.
At Critical point it becomes zero.
In physical terms at this pressure
water transforms to steam
spontaneously. 4.3 %

SUPER CRITICAL STEAM PARAMETERS:

Improvement
45
40

PARAMETERS MORE THAN CRITICAL STATE 35

30

• STEAM PRESSURE > 221.2 BAR 25

20
15
• STEAM TEMPERATURE > 374.15 Deg C 10
5
ULTRA SUPERCRITICAL PRESSURE(≥
≥ 300 BAR) 0
500 MW Critical 800 MW
Super
Subcritical
170 ata / 537 °C / 537 °C 247 ata / 565 °C / 593 °C

INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg C
RESULTS IN SIGNIFICANT IMPROVEMENT IN HEAT RATE
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 Supercritical Cycles

Steam Power plant efficiency increases with increase in

steam pressure and temperature.

Power plant Cycles operating above critical pressure

(221.2 bar) are classified as Supercritical cycles

With higher cycle efficiency, the supercritical cycle

offers the advantage of ‘burn less fuel for the same
output’ and lower emission.

Lesser Pollutants – SOX , NOX & CO2

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 IMPROVEMENT IN EFFICIENCY WITH
INCREASING INLET PARAMETERS FOR STEAM
TURBINES

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 Supercritical Technology :
600~1000 MW units installed worldwide

Mature technology; Units have given reliable commercial service over half-a-
century

Main steam pressure range of 240-250 Kg/cm2

Units built in 1970s typically have MS/RH temp. of 540/540 or 540/565 ºC

Units built in late 1990s have MS/RH temp. of 566/592 or 592/592 ºC

º pressure over 300 Kg/cm2 and
Ultra-supercritical parameters for
temperature over 600 ºC also in operation in Europe & Japan.

Populationº of 600~1000 MW supercritical units installed worldwide

USA Japan Russia Germany South Korea China Ukraine Uzbekistan

35 21 19 5 3 3 2 1
Total Units = ~89 Coal Fired = ~54
 Environmental Benefits
Station Units MS MS/ RH Efficiency Coal CO2
Cap (No.x Pressure Temp °C (%) Consumption Emissions
(MW) MW) (kg/cm2) (MMT/Yr)
(MMT/Yr)*

4000 8x500 169 538/538 38.6 15.61 22.90

4000 5x800 246 565/592 40.24 14.98 21.97

Savings in coal consumed: 0.63 MMT/Yr (about 4% Saving)

Savings is CO2 emissions: 0.93 MMT/Yr

* at 80%PLF, 4000 HHV and 40% carbon

Source : CEA
 MAJOR POWER CYCLE EQUIPMENT

SUBCRITICAL SUPERCRITICAL
EQUIPMENT
500/600 MW 660 MW
BOILER DRUM TYPE ONCE THROUGH TYPE
TURBINE 1HP + 1IP + 1LP 1HP+1IP+1LP
LP HEATERS THREE NOS FOUR NOS
HP HEATERS TWO THREE
DEAERATOR ONE ONE
CONDENSATE EXTN. 3x50% 3x50%
PUMPS
BOILER FEED PUMPS 2x50% (TD) / 2x50% (TD) /
1x50% (MD) 1x50% (MD)
VACUUM PUMPS 2x100% 2X100%
HP BYPASS VALVES 2 Nos 2 Nos
LP BYPASS VALVES 2 Nos 2 Nos
500/ 600 MW SUB CRITICAL CYCLE

WITH 2 HP HEATERS, 3 LP HEATERS

660 MW Supercritical TG Cycle

WITH 3 HP HEATERS, 4 LP HEATERS

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 Steam Cycle Parameters :
Subcritical v/s Supercritical

SUBCRITICAL SUPERCRITICAL
PARAMETERS UNIT 660
500 / 600 MW 800 MW
MW
MS PRESSURE ata 170 247 247
MS TEMPERATURE oC 537 565 565
MAIN STEAM FLOW Tph 1500 1919 2380
REHEAT
ata 40.5 50 56.7
PRESSURE
RH TEMPERATURE oC 537 / 565 593 593
FINAL FEED WATER oC 253 290 290
TEMP.
 Recent Orders on BHEL

2 x 660 MW NTPC Barh- II TPP

3 x 660 MW Jaypee Bara TPP

2 x 800 MW RPCL Yeramarus

1 x 700 MW KPCL Bellary TPP

3 x 660 MW Bajaj Lalitpur TPP

2 x 660 MW DB Power Singrauli TPP
Other expected orders :

NTPC Bulk tender 4 x 660 MW

NTPC Bulk tender 2 x 800 MW

RRVUNL Chhabra & Suratgarh (2x660 MW
each)

JITPL Derang, Jhabua Power & Visa Raigarh
( 1 x 660 MW each) 15
16
 660MW Steam turbine: With Supercritical
parameters

Salient Features:
• Impulse tilted blade in HP & IP turbines
• Heat Shield at the inlet section
• Increase in wall/pipe thickness
• Material with improved properties for higher steam temperature
• Optimum flow path

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Diagonal Impulse Blading

HPT FIRST STAGE

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IP Turbine : HEAT SHIELD WITH VORTEX BORES

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VIEW OF INLET GUIDE RING IN IP TURBINE
FOR 660 / 800 MW

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 LP TURBINE
DIFFERENCES IN CONSTRUCTIONAL FEATURES
500 MW V/S 660 MW

600 MW 660 MW

INNER CASING RESTS ON INNER CASING IS INDEPENDENT

OUTER CASING OF OUTER CASING

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 PUSH ROD
ARRANGEMENT

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LP TURBINE INNER CASING SUPPORT
DETAILS FOR 660 / 800 MW

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 HP & IP BLADING
NO. OF HP STAGES (Tentative) : 15
NO. OF IP STAGES (Tentative) : 10
TYPE OF BLADING : ADVANCED CLASS (3DS , TX & F
BLADES)

3 DS BLADES TWISTED BLADE(F)

CYLINDRICAL BLADE
(TX)
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 LP BLADING
NO. STAGES : 2 x 7(800 MW) ; 2 X 6(660 MW)
TYPE OF BLADING : ADVANCED CLASS

* INITIAL STAGES - TX PROFILE

* MIDDLE STAGES - TWISTED PROFILE
* LAST 3 STAGES - ADVANCED CLASS
WITH
BANANA TYPE GUIDE
BLADE IN LAST STAGE

LAST STAGE BLADE

HEIGHT=908.8 MM GUIDE BLADE CARRIER
TIP DIA.=3458.8 MM-
WITH BANANA BLADING
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Thank you for a
Patient
hearing………… 26