20-Apr-05

COMPARATIVE FEATURES OF 500 MW UNITS

U5
1 Make MCR Rating Cooling Gen self excitation Generaton voltage
KWU / BHEL 500 MW 588 MVA H2 & primary water 319V, 4030 A 21 KV

U6
SIEMENS / BHEL 500 MW 588 MVA H2 & primary water 340V, 4040 A 21 KV

Turbo-generator

2
HP Turbine IP Turbine LP Turbine

Turbine
Barrel type outer casing, 20 stages Double flow split casing, 14 stages Double flow split casing, 6 stages Barrel type outer casing, 18 stages Double flow split casing, 11 stages Double flow split casing, 6 stages

3
Type & nos

MS stop / Control valves

Valve assembly & turbine casing interconnected by piping, 4 nos Valve assembly integral with turbine casing, 4 nos

4
4 nos

RH stop / Control valves

2 nos

5
Rigid RCC

TG foundation
Spring mounted

6
Make Rating 7 Make Furnace heat release Rated MS flow (VWO) MS pr/temp RH pr / temp Fuels No. of burners Water wall tubes SGWCPs Flue gas condotioning MS piping Furnace Soot Blowers FD fans PA fans ID fans GR fans Coal mills APH 8
60% HP bypass 100% LP Bypass

Generator transformer
Telk 3 X 1phase, 200 MVA each, 21 / 220 KV, Gen current = 16000amp Telk 3 X 1phase, 200 MVA each, 21 / 220 KV, 16000amp Gen current =

Steam generator
BHEL / CE 80,000 Kcal/M3/hr 1672.2 T/H 178 bar / 541 deg 40 bar / 541 deg oil / gas / coal ( Any combination) 16 each for oil / gas ( 4 elevations) 32 for coal (8 elevations) Plain tube (carbon steel) Side-1038, each 50.8 mmOD Roof-139, each 57.0 mmOD 4 (485 KW each), wet motor type ESP & FGD Low alloy ferric steel P22 17.653 X 15.289 X 72 M height 30 LRSB 9M each, 4 dual purpose, 100 furnace wall blowers, 2 nos axial single stage variable pitch 6.6KV/990rpm/2700KW 2 nos axial 2 stage variable pitch, 6.6KV/1480rpm/2750KW 4 nos radial 740 rpm, 6.6KV / 740 rpm / 2050 KW 2 nos radial,6.6KV/ 740rpm/1050KW 8 bowl mills, 6.6KV/600rpm/500KW BHEL 100,000 Kcal/M3/hr 1614 T/H 178 bar / 541 deg 41 bar / 568 deg oil / gas ( Any combination) 20 each for oil / gas ( 5 elevations)

Rifled Tubes (seamless carbon steel) 3 (380 KW each), Wet motor type Clean fuel X-20 MoCrV 120 17.653 X 15.289 X 68 M height 26 LRSBs, 4 dual purpose 2 nos axial single stage variable pitch 6.6KV/990rpm/2750KW No PA 4 radial LCI drive 2 nos radial,6.6KV 740rpm/1050KW No coal provision

2 ljusgstrom regenerative 3-tier trisector, 415V / 25HP 2 ljusgstrom regenerative 3-tier bisector, 415V / 25HP

HP-LP Bypass
60% HP bypass 100% LP Bypass

9 Make Rated Vacuum Heat Load CW flow No. of Tubes Cooling Surface Back Pr Suppport Plates 10 Material Height Base Dia Top Dia 11 CW Pumps Make Type Capacity Material of Bowl Housing Etc Cleaning of Condenser tubes Methods of chlorine dosing 12 Make Motor of MBFP Turbine of STBFP 13 Pump Motor 14 Make Number Material 15 Make Type 16 Make 17 Make 18 Suppplier
Weir RCC 152 M 14.27 M 7.32 M Inside Refractory Lining BHEL 0.1187 Bar 644.76 x 106 Kcal/Kwh 3 60,000 M /Hr 24,690 26,272 M2 0.12 Bar 88

Condenser
L&T 0.1187 Bar 586.25 x 106 Kcal/Kwh 3 60,000 M /Hr 24,690 26,272 M2 0.12 Bar

Chimney
RCC 275 M 19.82 M 7.60 M

Cooling Water System

Inside Refractory Lining 425 rpm, 1 stage Kubota Fixed bowl Semi Pull out 16,000 M3/Hr each pump SS-316 Debris filter & ball cleaning system Electrochlorination i.e. dosing of hypochloride solution Worthington Anasaid, Variable speed with hydraulic coupling BHEL Worthimgton

425 rpm, 1 stage Kubota Pull out type bowl impeller 16,000 M3/Hr each pump Ni-Resist Back-wash 4 way valve Liquified chlorine gas injection KSB Siemens, Constant speed BHEL

Boiler Feed Pumps

CEP

Feed water heaters

Yuba 5 nos + 1 dearator HPH vertical + 3 LPH Horizontal) HP monel & LP Admiraldy (2 BHEL 6 nos + 1 dearator HPH + 3 LPH All horizontal) SS 304 for both L&T Mixing type of heat exchanger consisting of spray nozzles Gaco system ltd, 2 streams, 45 M /Hr each.
3

(3

Deaerator

IAEC Mixing type of heat exchanger consisting of no. of trays

DM plant
Ion exchanger ltd, 3 streams, 45 M /Hr each
3

Condensate Polishing unit Instrumentation & control

Ion exchange Ltd, 2 stream 50% each I.e. 733 M3/Hr each.

Siemens, Germany. Honeywell, USA. Teleperm / Iskamatic b modular hardwired system with System Honeywell USA TDC 3000 distributed digital system. Simatic S-5 PLCs. Sequence of events recording Part of DAS. Stand alone Redundant system.

Annunciation system Analog control system Binary control system Logs,reports, Journals etc. Measurement Ease of on line 19

Hardwired. Hardwired, Implimentation of control loops. Hardwired, Implimentation of control loops. Part og DAS 3000 parameters, 120 field instrument enclosures, Analog 30 closed loops, Binary controls 50 ON-OFF controls, Audio Visual alarms 716 displays. Modification fairly flexible. 2100.8 Kcal/Kwhr

Micro processor based ,Alarms are printed & historised. software, Implimentation of control loops. software, Implimentation of control loops. Partly on TDC 3000 In addition , process information computer system (PICS) is provided for performance calculation , start up , shut down guidence etc.

Turbine cycle heat rate

Highly flexible. 2057.5 Kcal/Kwhr

Improvement in turbine cycle heat rate in U6= 43.3 Kcal/Kwhr, % improvement = 2.06 %

20
o

Break up of improvement in turbine cycle heat rate

RH temp 568 C instead of 540oC New HP turbine module New IP turbine module New blade profile 10% RH pressure drop 7 feed water heaters instaead of 6 Total
11.5 Kcal/Kwhr 14 Kcal/Kwhr 2 Kcal/Kwhr 3 Kcal/Kwhr 7.2 Kcal/Kwhr 5.6 Kcal/Kwhr

21 Rating Cooling Taps 22

Station transformer
4 X 1phase, 40/3 MVA 220 / 6.9 / 6.9 KV ON OLTC 10% in steps of 1.25%

43.3 Kcal/Kwhr

Bus duct

21KV isolated phase aluminium generator bus ducts, 7.2 KV segregated phase coppor bus ducts.

23

Coppor conducted cables

Fire resistant , Instrumentation cables 350 KM , PVC aux cables 270 Km, XLPE 6.6 KV cables 30Km, PVC control cables 430Km, Heat resistant cable 90 Km

24 Type Tonnage Electrode material Flue gas flow Collection efficiency 25 Bottom Ash Collection capacity Operation Fly Ash Collection capacity Operation

ESP
5 streams each with 4 fields rigid frame 4200 T Corton steel 943 M3/Sec 99.5 % plus

Ash handeling System

20% 205 T/Hr Intermittent, Jet pump sluice ash to disposal area. 80% 160 T/Hr Continuous