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111
INTRODUCTION
SUPERCRITICAL TECHNOLOGY
Fig. 1
112
Table 1
660 MW
Under
Commissione
Installatio
d
n
17 Units
53 Units
NTPC : 4
NTPC : 13
units
units
Sipat-3
Barh-1
Others: 13
units
Adani
Mundra-5
Tiroda-3
Sasan-2
CLP
Jhajjar-2
Kawai 1
Fig. 3
Others: 40
units
800 MW
Commissione
d
5 Units
Others: 5
Tata
Mundra - 5
Under Installation
12 Units
NTPC : 7 units
Lara (Chh)2
Kudgi
(Kar)-3
Gadarvara
(MP)-2
Others : 5 units
APGENC
O -2
Yeramarus
-2
Edlapur -1
ADVENT OF
SUPERCRITICAL TECHNOLOGY
INDIA
IN
Table 2
S
No.
1
2
3.
Name of Plant
537 C
566 C
565 C
Re-heat steam
temperature
565 C
566 C
593 C
4.
5.
6.
7.
8.
9.
IV.
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 oncethrough 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.
113
566 C
565 C
566 C
565 C
565 C
565 C
V.
566 C
593 C
593 - 600 C
593 C
593 C
593 C
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
Casings
(shells,
valves,
steam chests,
nozzles)
565 C
CrMoV
(cast)
10CrMoVM
b
621 C
910% Cr (W)
12CrW (Co)
CrMoWVNb
N
Bolting
422
912%
CrMoV
Nimonic
80A
In 718
912%
CrMoV
12
CrMoWVNb
N
704 C
CF8CPlus
CCA61
7
Inconel
625
In 718
Nimoni
c 263
Nimoni
c 105
Nimoni
c 115
In 718
Waspal
oy
Allvac
718Plus
Rotors/Discs
1CrMoV
12CrMoVN
bN
26NiCrMoV
11 5
Nozzles/Bla
des
422
10CrMoVN
bN
Piping
P22
VI.
912 %
CrWCo
12CrMoWVN
bN
912%
CrWCo
10CrMoVCb
N
P92
CCA61
7
Inconel
625
Inconel
740
Hynes
230
Wrough
t
Nibased
CCA61
7
114
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
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