ONCE THROUGH

STEAM GENERATORS
Benson boiler growth

• 1926 –Siemens maufactures 30–125t/h boilers

• 1949 –First OT boiler with high steam conditions(175 bar/610 DegC
– Leverkusen)
• 1963 – First spiral tube waterwall in membrane design(Rhodiaceta)
• 1987- Largest hard coal fired boiler
(Heyden 900 MW
More than 980 boilers with > 700000 t/h
CONTROLLED CIRCULATION (Vs)
ONCE THRU’

CC OT
 Once Through Principle
Comparison Natural Circulation /
Once-Through-System

Source: Siemens
Cumulative Steam Capacity of
Ordered BENSON Boilers
BBP´s share about 44 %

Total Steam Output about 200.000 kg/s  Source: Siemens

Once Through Boiler-Concept

Once through system

ONCE - THROUGH OPERATING RANGE
Increase of Cycle Efficiency due
to Steam Parameters
Increase of efficiency [%]

10
6,77
9
5,79
8 5,74
7 4,81
3,74
6 4,26
5 3,44 2,76
3,37
4
2,64
3
2,42 1,47
2 600 / 620
1,78 0,75
1 580 / 600

0 566 / 566
0 538 / 566
300
241 HP / RH outlet temperature [deg. C]
Pressure [bar] 175 538 / 538
 Comparison of Plant part load
efficiency
46

43,2 % 43,6 %
42,4 %
Plant net efficiency

40,1 %
40 41,1 %
40,5 %
39,3 % Supercritical unit
acc. Alternative 2
36,7 % 255 bar 538°C / 538°C
Subcritical unit
acc. Alternative 1
166 bar 538°C / 538°C
30

30 40 50 60 70 80 90 100
Load %
 Examples of Boiler Concepts
Tower Boiler Two-Pass Boiler Two-Pass Boiler
without platen superheater with platen superheater

66,0 m

PS Staudinger 5 - 550 MW el PS Heyden 4 - 920 MW el PS Kogan Creek - 700 MW el

 Comparison of Lignite, Coal and Oil
Fired Units

PS Offleben (C), 325 MWel PS Farge, 320 MWel PS Doha West, 300 MWel
mHD = 1000 t/h; B = 16,4 m mHD = 1020 t/h; B = 16,5 m mHD = 1100 t/h; B = 14 m

Heat input / furnace area [kW/m²] 215 330 680

 SH heating surfaces [m²] 17.781 6.791 10.953
 RH heating surfaces [m²] 15.290 12.072 5.202
 Bundel surfaces [m²] 33.071 18.863 16.155
 Benson Boiler
Main Configuration - Single-pass /
Two-pass

Source: Siemens
 DRUM vs ONCE THROUGH
STEAM TO STEAM TO
TURBINE SH TURBINE
SH
ECO
DRUM

HEAT HEAT
DOWN Water Wall
COMER Water Wall
ECO
ORIFICE
CIRC. PUMP

Pressure Sub critical Sub & super Critical

Steam Separation Drum Separator (Low loads)
Types Natural / Assisted (Sulzer) / (Benson)
Burner Panel Straight tube Spiral Tube / Straight (MHI)
Load Change Base Faster
Cold Start 4-5 Hours 2 Hours
Hot Start 1-2 Hours 0.5 Hours
 Drum type boiler
• Steam generation takes place furnace water
walls
• Fixed evaporation end point - the drum
• Steam -water separation takes place in the
drum
• Separated water mixed with incoming feed
water
 Once Through Boiler
• Once -through flow through all sections of
boiler (economiser, water walls &
superheater)
• Feed pump provides the driving head
• Suitable for sub critical & super critical
pressures
 Once -thru Boiler
Advantages:
• Quick response to load changes
• Shorter start up time
• Better suited for sliding pressure operation
• Steam temperature can be maintained over wider
load range under sliding pressure
• Higher tolerance to varying coal quality
• Suitable for sub critical & super critical pressures
 ADVANTAGES OF ONCE THROUGH
BOILERS
Once thru boiler enables :
• Peak power generation with better
efficiency levels
• Quicker response to TG load changes
• Better heat rate of lower loads
 Once -through Boiler
Characteristics :
• Provides Quicker response to TG load changes
• Supports achievement of better heat rate at lower
loads
• Higher furnace wall pressure drop and consequent
higher feed pump auxiliary power consumption
• Needs ultra pure quality feed water - Cannot
operate under conditions of condenser leak
Tower Vs Two pass

• For Indian Pit-head power station BBP preference is tower type

( to overcome flyash erosion)
• For power stations firing beneficiated Indian coals – Two pass
boiler
• For coastal power stations firing imported coals – Two pass boiler
 Flow Scheme of Membrane
Walls for Two-Pass Boilers
3.) 1.) 5.) 4.)
Detail: Temperature difference
2.) Ties for Spiral Tubing between the wall systems
(Example Studstrup Power Plant)

Boiler Load
Location 100% 35%
1.) 2K 1K
2.) 7K 1K
3.) 13 K 1K
4.) 2K 3K
5.) 7K 17 K
Flow Scheme of Membrane Walls
for Tower Boilers

Transition from Spiral Tubing to

Vertical Tubing
 Start-Up Times [min] of Power
Plants
Plants with Drum Boiler Plants with BENSON Boiler
167 bar / 538°C / 538°C 250 bar / 540°C / 560°C
From ignition to: From ignition to:
After shut first steam full load first steam full load
down hours to Turbine to Turbine

<1 20 - 30 60 - 80 20 - 30 30 - 40

8 40 - 60 80 - 100 30 - 40 50 - 60

48 150 - 210 300 - 350 60 - 80 150 - 200

>48 150 - 210 450 - 600 60 - 80 400 - 600

KWU 99 152d
Modern Coal-Fired Power Plant Page 23
EV 2 / ; NTPC Presentation.ppt
 BOILERS - DISCUSSED AT BBP

MAJUBA 660 MW TOWER 192 bar 555 C 19286x19286

SCHKOPAU 450 MW TOWER 262 bar 545 C 17846x17846
VOERDE 700 MW TWO PASS 206 bar 530 C 23668x15773

BOXBERG 900 MW TOWER 266 bar 545 C 24086X24086

ELKRAFT 300 MW TWO PASS 250 bar 545 C 12720X14280

MAJUBA,SCHKOPAU,VOERDE :
WITH VERTICAL TUBE HOPPER
BOXBERG:
WITH SPIRAL TUBE HOPPER
ELKRAFT:
WITH SPIRAL HOPPER &
SPIRAL IN FRONT/REAR , HORIZONTAL IN SIDES
Once -thru Boiler - Furnace Wall
Furnace Arrangement

SPIRAL TYPE

VERTICAL TYPE
FURNACE WALL ARRANGEMENT
 BOILER PRESSURE PARTS
WEIGHT
BOILER TYPE PIPES TUBES

210 MW 315 MT 1100 MT

250 MW 410 MT 1440 MT
500 MW 695 MT 2870 MT
660 MW** 1070 MT 5080 MT
** Worked out based on the Alstom BOM supplied
for SIPAT boiler.
 Technology Acquisition Thru
Collaboration – Status
•BHEL entered into a TCA with M/S Babcock Borsig
Power(BBP), Grmany in 1999.
•First phase of training provided by BPP in 2001.
•BBP has become insolvent in July 2002 & further training
planned during the execution of the first contract and
technology transfer was not possible.
•Subsequently a new Engg company , Babcock Borsig
Power Systems (BBPS), owned by Babcock Hitachi, Japan
was formed.
•BBPS was found acceptable for Technical collaboration
after “due deligence” exercises. But the collaboration route
with BBPS could not be utilised for Sipat tender as NTPC
spec required the collaborator to provide financial
guarantees.
 SIPAT 3x660MW – Joint Bidding with Alstom

•In the original bid submitted in Oct 2003, BHEL-Alstom joint bid
was placed at L3, with Dossan/Korea as L1 and TPE/Russia as L2.
•In Dec 2003, NTPC invited snap bids to be submitted by all the
three bidders by 9 Jan 2003
•The new requirements (with increased steam flow & for vacating
certain deviations) called for a total redesign by Alstom with
estimated three months time. Accordingly BHEL sought extension
till 05 March 2004 for submitting the revised bid.
•However since the request for extension was not granted by NTPC,
the snap bid could not be submitted by BHEL
 Immediate OTB projects

•NTPC – BARH 3x660MW

Tender due in May 2004. QR same as Sipat project.
•APGENCO, Vijayawada 1X660MW
Four companies (Alstom, Siemens/Doosan,Sumitomo/Babcock
Hitachi & TPE/Russia) have been pre-qualified for EPC