Professional Documents
Culture Documents
Introduction
Product profile
Bubbling Fluidized bed combustion (BFBC) boilers Circulating fluidized bed combustion (CFBC) boilers Heat recovery Steam Generator (HRSG)
BFBCs for low grade coal as fuels CFBCs from 75 MW to 250 MW HRSGs for Frame 5 GT to Frame 9FA GT Product turnover 5 fold increase to Rs 1000 Cr. in a span of 4 years
Bharat Heavy Electricals Limited Tiruchirappalli
arrangement engineering
165 95 540
BFBC Boiler at PT-IBR Indonesia 3 x 75 TPH SH Flow SH Pressure SH Temperature t/h Kg/cm2 Deg C 75 65 485
Fuels Tested
Kiln Char
Sunflag Industries,Bandara
Washery Rejects
Tisco, Jamadobha
Fuels Tested
Mill Rejects
Parli TPS Bharat Heavy Electricals Limited Tiruchirappalli
Rice Husk
Rice Mill, Tiruchi
Rice Straw
Tiruchi
Wood Chips
Tiruchi
Palm Shells
Kerala Electricity Board,
Bharat Heavy Electricals Limited Tiruchirappalli
6 6 4 4 1 1 2 2 1 1 3 3 3 3 6 6 6 6
7 7 7 7
9 9
12 12
26 26
Combined Cycle Cogeneration Unfired Supplementary Fired Total 62
9 - 66 - 137
Facility created for larger size HRSG Module Fabrication vertical position welding
Duct
LP Drum
Modules
HP
IP
LP
Internal Liner Inlet duct Bottom brazing beam Inlet duct Beam
Learnings from 158 SARs from SLPP I and BILT Graphics incorporated
Discussions with manufacturing and OP & C groups for using of standard tooling and materials
Discussions with Erection Group Pre engineering and before commencement of erection
For 125 MW category For 250 MW category
FlueGas
CFD Study made and sacrificial Half-shields introduced. Performance found to be good
Bharat Heavy Electricals Limited Tiruchirappalli
No. of WW panels reduced from 187 to 148 In-conel attachments in coils replaced by SS Attachments for easy welding Combination of T12, T22 & T91 avoided in a single coil to have single HT cycle (wherever feasible) Close pitch drilling of headers eliminated ID controlled sleeves for coils attachments for easy insertion Short Radius bends eliminated (Wherever feasible)
Similar Improvements made in SH2A, SH2B, RH1, SH3, SH1, Eco, Seal Pot header connections Bharat Heavy Electricals Limited Tiruchirappalli
Major issues
Trial assembly of cyclones & match marking at works Pullout bends of FBHE front panels to be supplied in loose
Erection weld of FBHE coils at about 250 to 300 mm from water wall panel
Seal boxes, cyclone, inlet & outlet ducting of cyclone to be fully welded from inside for better accessibility
Lignite Rotary Air-lock Feeder trips: Frequent feeder trips due to clutch slipping and resetting of the torque value was analysed and improvements incorporated in the clutch assembly and operating satisfactorily
Bharat Heavy Electricals Limited Tiruchirappalli
Ash handling system Capacity: The fly-ash evacuation system is yet to be fully
established as accumulation of ash in the hoppers is observed even at part loads. The evacuation from intermediate bed ash bin is also not effective and affecting the removal of bed ash from the Combustor as required. These issues have to be resolved for taking up full load operation of the plant
Lignite bunker capacity: The total capacity of the lignite bunkers is only for 4 hrs of
operation at full load. The fuel handling plant has to be operated on a near continuous basis for continuous operation of the boiler at full load
Flue gas analysers : Measurement of CO2 and O2 in order to ensure safe and complete
combustion and SO2 measurement to ensure adequate limestone feeding is yet to be established. So far it has been managed with our portable instrument. Presently the instrument has been calibrated by Vendor and will be observed during operation.
foreign materials. The damaged chain assemblies were stiff. Vendor specialist from UK came to site, analysed and informed that presence of stagnant wet lignite is the cause. Advised that lignite is to be drained in case of unit shut down and also lubrication of the chains periodically to avoid such occurrences. Replaced with new conveyor chain assembly. Failure of Pins noticed during recent operation, Taken up with Supplier for resolution. Meantime, existing chain assembly is being replaced with new material supplied for Unit II
Supply Pipes (64 nos) 40nos168.3 x 14.27 8 nos 141.6 x 16.0 16 nos 88.9 x 11.13
Future
10871.6 x 6807.2
Section Assy# FSH 55 FRH 56 LTSH 110 Eco IV 110 Eco III 110 Eco II 110 Eco I 110 Hanger 3x55
SL 65/102 65/96 76 90 90 90 90
No of Joints 13252 (including FBHE) Section FSH FRH LTSH Eco IV Eco III Eco II Eco I Hanger Assy# 53 106 106 106 106 106 106 3x53 SL 96 96 96 96 96 96 96 ST 203.2 101.6 101.6 101.6 101.6 101.6 101.6 203.2
Manufacture & Erection Friendly 125 MW CFB Design Erection joint reduction
Description No.of WW headers No.of WW Panel DUs Multi cell CLH Convective pass panel bend No.of joints in Integral design 251 297 36 1992 Non integral design 37 114 Nil Nil Variation 86 62 100 100
FBHE WW panel
Combustor HT coils Others
4496
2384 13252 1027
Nil
2384 10112 1027
100
No Change 24 No Change
Total
21159
13523
36
3000 3000
3000 3300 4800 3600 6000 5500 2500 2205
2880 2880
2880 2700 3000 3360 5760 5400 3360 2028
1440 1440
1440 2560 2400 1680 2880 3600 2520 2028
50 50
50 5 20 50 50 33 25 No Change
Total
49205
41838
28904
31
Thank you
Bharat Heavy Electricals Limited Tiruchirappalli