I.

INTRODUCTION
ANY regions of the world are experiencing fast
growing electricity demand. Permitted emissions from
power plants have been reduced so as to meet air
quality standards. Power plants are a source of CO2, one of
the greenhouse gasses that the Kyoto Protocol intends to limit.
Electricity generated from coal currently accounts for about 40
% of worldwide generation & more than 60 % in India. Coal is
an abundant fuel resource in many of the worlds developing
regions and the forecasts indicate that coal is likely to remain a
dominant fuel for electricity generation in many countries for
years to come.
It is against this backdrop that power plant suppliers have
invested heavily in generation technologies that produce
power more efficiently. Worldwide, more than 400
supercritical plants are in operation. Super Critical plants
reduce CO
2
emissions and other pollutants significantly by
using less fuel per unit of electricity generated.
II. SUPERCRITICAL TECHNOLOGY
While the definition of supercritical conditions is
straightforward, the meaning of ultra supercritical is subject to
interpretation. Depending on upper limit of pressure and
temperature parameters, supercritical cycles are generally
categorized as supercritical (SC), ultra-supercritical (USC) and
advanced ultra-supercritical (advanced USC) as indicated
below:
SC is a thermal cycle with main steam temperature of
less than 600 C operating at pressures between
221.18 and 275 bar.
USC is a thermal cycle with maximum steam
temperature greater than 600 C operating at pressures
higher than 275 bar.
Advanced USC is a thermal cycle with steam
temperature of 705 C or greater.

Fig. 1
R.S. Yadav, Sr. Vice President Engineering, Reliance Infrastructure
Ltd.A-2, Sec-24, Noida. E-mail: radheyShyam.Yadav@relianceada.com
Vaibhav Chauhan, Sr. Manager, Engineering Dept, Reliance
Infrastructure Ltd.A-2, Sec-24, Noida. E-mail:
vaibhav.Chauhan@relianceada.com
Ef f i ci ency Improvement wi t h Supercri t i cal
Technol ogy
Improvement in efficiency can be achieved by using
supercritical steam conditions. The supercritical design not
only improves efficiency by increasing the working fluid
pressure but it allows superheating of the steam to higher
temperatures which provides significant further efficiency
improvement. For many years the most popular boiler design
has been the sub critical drum boiler. This technology is low
cost and well proven but does not have the potential for
efficiency improvement inherent in supercritical cycles.

Fig. 2: Typical Improvement in Cycle Efficiency with Increase
of Steam Temperature & Pressure
Note also that the efficiency of a supercritical boiler does
not fall off significantly at part load, as it does for most
subcritical boilers, especially in units that can operate in
sliding-pressure mode. Typically, unit efficiency at 50% of
maximum continuous rating for a supercritical unit is 95% of
that at full load.
The initial step in the development process is
thermodynamic cycle optimization, followed by an effort to
increase steam turbine overall efficiency by improving the
efficiency of high pressure (HP) and intermediate pressure
(IP) modules.
Besides steam turbine technology dictating the selection of
the temperatures and pressures, cycle optimization is
sometimes governed by coal properties and the effect of
aggressive/corrosive coals on the materials selected for the
boiler tubes, headers, and other internal components. If the
coal contains deleterious components, the thermal cycle
optimization should focus on pressure increases rather than
more-effective temperature increases.
Equipment manufacturers also continue to aggressively
pursue upgrading the low pressure (LP) turbine, which, in
many cases, accounts for 40 percent of the power generated by
the turbine. One of the development objectives is to increase
the size of the last-stage blade (LSB), which could reduce the
number of LP modules and boost the power output at lower
condenser pressures.


Supercritical Technology in Indian Power Sector
R.S. Yadav and Vaibhav Chauhan


M
National Seminar on Thermal Power Plant Performance Management - NSTPPPM 111
ISBN 978-93-83459-12-4 2014 Bonfring
Environmental Benefits of Supercritical Technology
Current supercritical coal fired power plants have
efficiencies above 42%. Higher efficiency leads to lower coal
consumption and aux power reduction. It also leads to lower
specific water consumption & small BOP systems. One
percent (1%) increase in efficiency leads to reduction of
specific emissions such as CO2, NOx, SOx and particulates by
two percent (2%).

Fig. 3

Fig. 4: Effect of Plant Efficiency on Carbon Dioxide
Emissions
I I I . ADVENT OF SUPERCRI TI CAL TECHNOL OGY I N
I NDI A
After Electricity Act 2003 came into effect, rapid buildup
of generation capacity was stressed in India. To cater the
rising demand of electricity, the power sector was opened up
to private players. Maximum numbers of thermal units
installed initially were with subcritical technology of 250/500
MW class. But for Ultra Mega Power Projects of 4000 MW &
above capacity, the Government made it compulsory to use
supercritical steam parameters.
In order to improve coal-fired power plant efficiency
leading to a proportional reduction in coal consumption and
carbon dioxide emissions, it is widely accepted that the
domestic power industry must move from sub critical to
supercritical steam cycles. Medium to large capacity thermal
power plants in India are now increasingly adopting the more
efficient & bigger 660/800 MW supercritical units. Current
status of supercritical units of 660/800 MW size presently
under operation & construction in India is tabulated below:

Table 1
660 MW 800 MW
Commissione
d
Under
Installatio
n
Commissione
d
Under Installation
17 Units 53 Units 5 Units 12 Units
NTPC : 4
units
Sipat-3
Barh-1

NTPC : 13
units

NTPC : 7 units
Lara (Chh)-
2
Kudgi
(Kar)-3
Gadarvara
(MP)-2
Others: 13
units
Adani
Mundra-5
Tiroda-3
Sasan-2
CLP
J hajjar-2
Kawai -
1
Others: 40
units
Others: 5
Tata
Mundra - 5
Others : 5 units
APGENC
O -2
Yeramarus
-2
Edlapur -1
St eam Paramet ers Adopt ed i n Indi a
The first generations of SC parameters used in India for
3x660MW Sipat are with lower steam temperature (MS - 537
C with re-heater 565 C). To take enhanced benefits of SC
technology, CEA vide its regulation dated August 2010 has
specified maximum permissible turbine heat rate for
supercritical units as 1850 kcal/kwh with TD BFPs and 1810
kcal/kwh with MD BFPs with cooling water inlet temperature
of 33 deg C and 0% cycle make-up.
Further, CEA in their Standard Technical Features of BTG
System for Supercritical 660/800 MW Thermal Units
published in J uly 2013 have also recommended (not
mandatory) to use minimum reheat steam temperature as 593
deg C.
As per present trend in India and in keeping with the
recommendations of CEA, main steam and re-heat
temperature are preferred as 566 C and 593 C respectively.
The metallurgy for this temperature range is techno
commercially proven all over the globe and there are many
thermal power plants presently under satisfactory operation.
Main steam and reheat steam temperatures adopted by
various utilities in India are tabulated hereunder:
Table 2
S
No.
Name of Plant Main steam temperature Re-heat steam
temperature
1 Sipat NTPC (660 MW) 537 C 565 C
2 Sasan Ultra Mega Reliance (660 MW) 566 C 566 C
3. Mundra TATA (660 MW) 565 C 593 C
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4. Adani Tiroda (660 MW) 566 C 566 C
5. NTPC Barh-2 (660 MW) 565 C 593 C
6. Tilaiya UMPP Reliance (proposed) 566 C 593 - 600 C
7. NTPC Gadarwara (800 MW) 565 C 593 C
8. RPCL Yeramarus (800 MW) 565 C 593 C
9. NTPC Bulk tender (660 MW) 565 C 593 C
IV. CHALLENGES/ISSUES WITH SC TECHNOLOGY IN INDIA
While the steam turbine extracts maximum
thermodynamic benefit of supercritical technology, it is the
boiler that has to undergo maximum changes in construction
(w.r.t. sub-critical) to produce steam with supercritical
parameters. The construction features of steam turbines for
supercritical parameters essentially remain the same as for
subcritical turbines; only the metallurgy of the components
changes to take care of higher pressure and temperature
conditions.
Construction-wise, all supercritical boilers are of a once-
through arrangement, meaning that water and steam flow
through the boiler circuitry only once. In sub-critical drum
type boilers, the water and steam recirculate through the
furnace enclosure number of times.
Most of the supercritical boilers being manufactured today
have spiral tubing in the lower furnace. Spiral furnace
configuration, in combination with a boiler recirculation
pump, was developed to minimize thermal shock during
transients. However, the spiral tubing along with transition
header make the furnace support arrangement quite
complicated. Welding of spiral tube panels and corner tubes
pose construction challenges. Supercritical technology has
proved itself most economical w.r.t. operating cost &
environment considerations and is widely used in Europe,
USA & China for low ash, high GCV coals. However, SC
boiler performance with high ash Indian coals is yet to be
established. Limited availability of skilled manpower for
construction, operation & maintenance for large capacity
supercritical units is also other major issue of concern in India.
Welding of spiral panels, high temperature alloy steel (P91,
92) is new for Indian erection agencies. Weld joints in these
areas with proper heat treatment is necessary for trouble free
operation of the units.
660 MW supercritical units at Sipat, Tiroda, Sasan & Barh
are presently under operation with domestic coal. The
performances of these plants are presently under observation.
The design of 800 MW furnace for high ash Indian coals is the
biggest challenge. An 800 MW supercritical unit using high
ash domestic coal is yet to be commissioned in India. Learning
from the problem/issues faced during operation &
maintenance of these units will go a long way to decide the
future of SC technology in India.





V. ALLOY STEELS FOR SUPERCRITICAL TECHNOLOGY

Fig. 5
The high thermal efficiency of the SC and USC steam
power plants cannot be achieved without the use of new alloys
with higher creep strength and improved oxidation resistance.
Operation above 537C was possible due to the continuous
development effort to improve the 912 percent ferritic steels
(T91/P91, T92/P92, T112/P122 ref fig. above), as well as
some advanced austenitic alloys (TP347, TP347HFG, Super
304). While the most severe requirements to withstand SC and
USC operating conditions apply to boilers, significant
constraints are also relevant to steam turbines and
interconnecting hardware such as main steam pipes, valves,
and so on. A major problem associated with the use of
P91/P92 materials is the need for quality control at the
manufacturing facilities. In project execution, the quality of
the welding and post-welding treatments, particularly in the
field, continues to be a concern, requiring the heat treatments
to be monitored very closely.
The status of material development for Steam Turbine
parts used in various high pressure and high temperature
applications is given in Table below.
Table 3: High Pressure and High Temperature Materials for
Turbines
Component 565 C 621 C 704 C
Casings
(shells,
valves,
steam chests,
nozzles)
CrMoV
(cast)
10CrMoVM
b
910% Cr (W)
12CrW (Co)
CrMoWVNb
N
CF8C-
Plus
CCA61
7
Inconel
625
In 718
Nimoni
c 263
Bolting 422
912%
CrMoV
Nimonic
80A
In 718
912%
CrMoV
12
CrMoWVNb
N
Nimoni
c 105
Nimoni
c 115
In 718
Waspal
oy
Allvac
718Plus
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Rotors/Discs 1CrMoV
12CrMoVN
bN
26NiCrMoV
11 5
912 %
CrWCo
12CrMoWVN
bN
CCA61
7
Inconel
625
Inconel
740
Hynes
230
Nozzles/Bla
des
422
10CrMoVN
bN
912%
CrWCo
10CrMoVCb
N
Wrough
t
Ni-
based
Piping P22 P92 CCA61
7
VI. USE OF OVER LOAD VALVES (FUTURE TREND)
At rated condition (TMCR), there are always throttling
losses in the turbine control valves. The reserve in the control
valve results in continuous loss of useful energy which can be
preserved to improve overall turbine efficiency. To improve
turbine efficiency at rated condition (TMCR), the use overload
control valves enables injection of additional steam for a fast
load increase while high efficiency at the design point is
ensured. With overload valve arrangement, there is
improvement in heat rate of about 5 to 6 Kcal/kwh compared
to rated operating condition w.r.t. conventional throttle reserve
control valves. Whenever there is demand over and above
rated power output of steam turbine, the overload valve opens
to inject high pressure temperature steam in the 4
th
or 5
th
Stage
of the turbine to increase the load up to VWO, which is
typically 105% of TMCR condition.

Fig. 6
The overload valve (item 3) allows running the turbine in
sliding pressure operation with main steam valves (items 1 &
2) wide open over the whole load range. It means that steam
admission to the turbine occurs with a minimum of throttling
losses which results in a low turbine heat rate. The overload
valve is used for both frequency response and for load
increase >100 %.
In the sliding pressure range up to 100 % load, the steam
turbine control valves are 100 % open and the overload valve
is closed. To achieve 105 % load, the boiler increases the
steam generation and the overload valve opens partly and
controls the pressure at 100% in fixed pressure mode whereas
the steam flow through the turbine increases. In the load range
below 100 %, where the steam turbine is in sliding pressure
operation, an instantaneous load increase can be achieved by
rapidly opening the overload valve.
Use of overload valve is presently not practiced in
subcritical units in India. But in view of stiff competition for
better and better turbine heat rates, the turbine manufacturers
are going for over load valves to minimize the turbine heat
rate. To win the project even small advantage in heat rate at
rated condition is being taken seriously to avoid financial
loading during contract finalization stage.
VII. CONCLUSION
Supercritical technology is already mature and is being
widely used in Europe, America, J apan & China but with high
GCV coals. In India also, with increasing prices of coal and
gradually decreasing prices of SC technology, the balance has
already tilted in favor of SC units. However, performance of
supercritical units, particularly higher size 800 MW units, is
yet to be established with respect to lower GCV, high ash
Indian coals. The performance of the few supercritical units
which are operating with domestic coals is presently under
observation. Critical observation and objective resolution of
the initial teething problems will help stabilize the use of SC
technology in India.
REFERENCE
[1] Steamturbine design considerations for supercritical cycles by J ustin by
Zachary, Paul Kochis, RamNarula Presented at Coal Gen 2007
[2] Supercritical Boiler Technology Matures by Mark Richardson,
Yoshihiro Kidera, Yoshio Shimogori
[3] Supercritical Coal Fired Power Plants, Techno - Economic Seminar for
National Thermal Power Corporation Ltd. & Central Electricity
Authority by BHEL & Babcock Borsig
ABOUT THE AUTHOR
Mr. Radhey Shyam Yadav Presently working in the
position of Sr. Vice President (HOD Mechanical) at
EPC engineering division of Reliance Infra Ltd. Earlier
worked in NTPC at Sr. level positions. 33 yrs of
working experience in Engineering and O&M of BTG
& BOP systems.


Mr. Vaibhav Chauhan Presently working as Sr.
Manager at EPC engineering division of Reliance Infra
Ltd. 7.5 Yrs of working experience in engineering of
BTG & its Auxiliaries

National Seminar on Thermal Power Plant Performance Management - NSTPPPM 114
ISBN 978-93-83459-12-4 2014 Bonfring