Pankaj Ekbote

pankajekbote@ntpc.co.in
Supercritical pressure boiler has no drum and heat absorbing surface
being, in effect, one continuous tube, in which the water & steam
generated in the furnace water walls passes through only once hence
called Once through Supercritical pressure boilers
The water in boiler is pressurized by Boiler Feed Pump, sensible heat is
added in feed heaters, economizer and furnace tubes, until water attains
saturation temperature and flashes instantaneously to dry saturated
steam and super heating commences.
The mass flow rate thru all heat transfer circuits
from Eco. inlet to SH outlet is kept same except at
low loads wherein recirculation is resorted to protect
the water wall system
Major differences from Drum type boiler :
Circulation system
Evaporator system
Separator
Item Subcritical boiler Supercritical boiler Remark
Circulation Recirculation at all load














Water Saturated Steam
Circulation ratio : 2 - 4
Recirculation below minimum
load












Water Vapor
Circulation ratio : 1

Circulation ratio :
Flow in evaporator

Steam required

Eco
BFP
Condenser
Evapor
ator
6
Supercritical Boiler Technology
Item Subcritical boiler Supercritical boiler Remark
Evaporator Vertical wall

Non uniform in heat
absorption at each tube
Suitable for Base load

Spiral wall










Uniform in heat
absorption at each tube
Suitable for Variable load















Temp. distribution at
evaporator outlet

Heat distribution at
evaporator


Difference between Sub and Super- critical boiler
7
Supercritical Boiler Technology
The inclination of tube can reduce the
number of evaporator wall tubes and
ensures a minimum waterwall flow to
protect waterwall tube from overheati
ng regardless of the unit size
Spiral wall ensures an even distributio
n of heat, and avoid higher thermal str
esses in waterwalls by reducing the fl
uid temperature differences in adjace
nt tubes
Spiral Wall Evaporator
Reduced number of
tubes with pitch.
Increased mass flow.
Mass flow rate can
be selected by
number of tubes.
Features
Spiral Tube Arrangement
10
Spiral wall outlet temp at BMCR (front wall)
Spiral Wall Evaporator
Configuration of Evaporator panel
Spiral wall : Vertical wall = 3 : 1
Supercritical Boiler Technology
Spiral Wall Tubes
Spiral Tube Forgings
Vertical Wall Tubes
Vertical Tube
Forgings
35 mm Vertical Tube
Forgings
SPIRAL WALL SUPPORT
Support
Fingers
Spiral to Vertical Transition Area - Load Transfer
Sliding Pressure Supercritical Design
Furnace walls are not self supporting because
the tubes are inclined.
External support strap system is needed
Fabrication and installation are more difficult.
Above aspects tend to increase the cost.
16
Difference between Sub and Super- critical boiler
Item Subcritical boiler Supercritical boiler Remark
Thermodynanics




- Limited thermodynamics by
fixed evaporating end point
- Suitable for narrow range of
coal

- Flexible thermodynamics by
variable evaporating end
point
- Suitable for wide range of
coal


Supercritical Boiler Technology
17
The proposed startup system gives :
1. Startup in sliding pressure mode with dry superheater
2. Ensures sufficient cooling of economizer evaporator, and superheater
3. Maintains the mass flow required for the stability of the evaporator
4. Minimum heat and water losses during the startup phase
Water separator
Startup flow diagram
with circulating pump
Recirculation System for Start-up and Low load operation
Supercritical Boiler Technology
PARAMETERS UNIT 100% BMCR 100% TMCR
SH SYSTEM
STEAM FLOW AT SHO T/Hr 2225 2023.75
STEAM PRESSURE AT SHO Ksc 256 254.45
STEAM TEMP AT SHO Degree C 540 540
RH SYSTEM
STEAM FLOW T/Hr 1741.82 1678.37
STEAM PRESSURE AT RHI Ksc 48.3 46.7
STEAM TEMP AT RHO Degree C 568 568
STEAM TEMP AT RHI Degree C 299 296
Pr Drop Across RH Ksc 1.69 1.62
19
IPT LPT
C
O
N
D
E
N
S
E
R
FEED WATER
FRS
S
T
O
R
A
G
E
T
A
N
K
SEPARATOR
BWRP
S
p
i
r
a
l

w
a
t
e
r

w
a
l
l
s
MS LINE
HRH LINE
VERTICAL WW
ECO I/L
ECO
JUNCTION
HDR
ECO HGR
O/L HDR
FUR LOWER HDR
FUR ROOF
I/L HDR
DIV PANELS SH PLATEN
SH
FINAL
RH
FINAL SH
LTRH
ECONOMISER
290C, 302 KSC
411C,
277Ksc
411C,
275 Ksc
492C, 260 Ksc
540C, 255 Ksc
3
0
5

C
,

4
9

K
s
c
457C, 49 Ksc
568C, 47
Ksc
G
LPT
HPT
DESH
*Spiral + Vertical water walls.
*Counter Flow Final Super heater.
*Two Stage Re-heater.
*Fans Hydraulic Actuator.
*Axial ID fan.
*HRSB in Eco Zone.
*Hydraulic Safety valves.
*BCP suction valve for isolation.
21

SIPAT Boiler Design
Start up & Low Load Recirculation System
Application
1. Minimum once-thru load : 30%
2. Heat recuperation : Circulating Pump
3. No of separator : Two
storage tank : One
1. Assure a minimum flow (normally 30%) thru
economizer and evaporator by mixing of circul
ation flow (20%) and flow from BFP (10%) at lo
w load, eg, 10%.
2. No water losses from circulation system by circ
ulation pump
FEED WATER
FLASH
TANK

BRP
MIXING
PIECE
SEPERATOR
TO ECO ECO I/L
UG
V/V
ECO NRV
WR ZR
DRY MODE CONDITIONS
Difference between feed water temperature
and eco flow temperature<2 degree
Separator level <5000 mm
Separator outlet steam superheated by 20
degree
Steam flow >30%
ARRANGEMENT OF SEPARATOR AND
COLLECTING VESSEL
Typical Separator sizes
Number of separators 2 4
Inside diameter approx mm 850 600
Thickness mm 95 70