Bharat Heavy Electricals Limited, Tiruchy

CEA Workshop, May - 2005

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




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 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

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 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

3350 KW
at 580 rpm