ET Class 1

Gadarwara
(2 x 800 MW)
 Gadarwara Super Thermal Power Station

Riser tubes, Superheater & reheater
Presented by:-
1. Ankush Rajput, Sr. Manager (BMD-PP)
SUPERHEATER AND
REHEATER:
Material

selection
The SH and RH materials provided will be of various
grades. The material selection is done after finding out
the mid wall metal temp as well as outer surface temp
at a number of points. These temp are calculated
considering all the possible heat contributions like:
 Direct radiation from furnace
 Convection and non luminous radiation
 Front and rear cavity radiation
SH/RH General materials
SN ASTM GRADE DESCRIPTION MAX TEMP
( OXIDATION
LIMIT)
1 SA 210 A1 Carbon steel 425
2 SA 209 T1 ½% Mo Steel 480
3 SA 213 T11 1% cr ½% Mo Steel 550
4 SA 213 T22 2.25% cr 1% Mo Steel 580
5 SA 213 T91 8.5%cr 2.25 % MO steel 605

6 SA 213 TP 304 H 18% cr 8% Ni Steel 690
(Stainless steel)
7 SA 213 TP 347H 18% cr 10% Ni Steel 690
SH, RH and Desuperheaters
 Superheaters are meant to raise the steam temp above
saturation temp by absorbing heat from flue gas.
 Reheater is used to raise the temp of steam from which
part of the energy has been extracted in high pressure
turbine. This is another method of increasing cycle
efficiency which increases with no of stages of
reheating. No of stages depends on economy and
incremental efficiency obtained.
Types Of Superheater
 These surfaces depending heat transfer mode such as

convection or radiant type.
 Even though the surfaces get heat by both radiation
and convection the ratio b/w them varies according to
location and temp of the flue gases at that location.
 The RH/SH placed above furnace which can view the
flame are called radiant type.
 the other surfaces are called convection type
Platen SH
 As the radiant surfaces are located in high temp region,

they are widely pitched to reduce the velocity of flue
gas and bridging the surfaces by the ash and they are
arranged with least longitudinal pitch.
 They can be arranged either horizontally or allowed to
hang vertically.
 The vertical arrangement is simpler in supporting and
allowing for expansion and is called pendent type.
Arrangement
 Heating surfaces are arranged staggered type.

 The surfaces are arranged normally for counterflow
arrangement as counterflow has adv of min surface but
higher metal temp at leaving portion.
 No of SH stages depends cost vs adv principle.
 There are three sections, LTSH, Platen and final Sh.
 Between LTSH and Platen SH desuperheaters are
provided.
Platen Superheater
 Platen Superheater : Flat
panels of tubes located in the
upper part of the furnace,
where the gas temperature is
high.
 The tubes of the platen SH
receive very high radiation as
well as a heavy dust burden.
 Mechanism of HT : High
Radiation & Low convection
 Thermal Structure:
 No. of platens
 No. of tubes in a platen
 Dia of a tube
 Length of a tube
8
Convective Superheater (Pendant)
 Convective super heaters are vertical

type (Pendant ) or horizontal types.
 The Pendant SH is always arranged in the
horizontal crossover duct.
 Pendant SH tubes are widely spaced due
to high temperature and ash is soft.
 Transverse pitch : S1/d > 4.5
 Longitudinal pitch : S2/d > 3.5.
 The outside tube diameter : 32 – 51mm
 Tube thickness : 3 – 7mm
S1
S2
9
Convective Superheater (Horizontal)
 The horizontal SH are located in the back pass.
 The tubes are arranged in the in-line configuration.
 The outer diameter of the tube is 32 – 51 mm.
 The tube thickness of the tube is 3 – 7 mm.
 The transverse pitch : S1/d = 2 – 3.
 The longitudinal pitch :S2/d = 1.6 – 2.5.
 The tubes are arranged in multiple parallel sets.
 The desired velocity depends on the type of SH and operating
steam pressures.
 The outside tube diameter : 32 – 51mm
 Tube thickness : 3 – 7mm
S1
S2
10
Reheater
 Purpose:
RE-HEAT THE STEAM FROM HP
TURBINE TO 540 DEG
 COMPOSED OF THREE SECTIONS
 RADIANT WALL REHEATER ARRANGED IN FRONT &
SIDE WATER WALLS
 REAR PENDANT SECTION ARRANGED ABOVE GOOSE
NECK
 FRONT SECTION ARRANGED BETWEEN UPER
HEATER PLATEN & REAR WATER WALL HANGER
TUBES
11
November 22, 2023 PMI Revision 00 12
Procedure to Determine
Optimum Reheat Pressure
 Calculate the efficiency of Rankine cycle,
Rankine.
 Calculate mean effective temperature of
heat addition, Tm,in using
Tc
 Rankine   Eq.Carnot  1
Tm ,in
 Find out pressure corresponding to T m,in
and entropy at HP turbine inlet.
 Add reheating at this pressure and
calculate efficiency of the Reheat Cycle.
 Repeat above steps for few iterations.

Arrangement and Construction
 The arrangement and construction of a re-heater is similar to

that of a super-heater. In large modern boiler plant, the reheat
sections are mixed equally with super-heater sections.

• The pressure drop inside re-heater tubes has an
important adverse effect on the efficiency of
turbine.
• Pressure drop through the re-heater should be kept
as low as possible.
• The tube diameter : 42 – 76mm.
• The design is similar to convective super-heaters.
• Overall Heat Transfer Coefficient : 90 – 110 W/m2
K.
Evolution Of The Coal Fired Plant
60
AGMCFC
Thermal Efficiency (%)
IGMCF
50
USPCF
Supercritical boiler IGCC IGHAT

40
Rankine Barrier PFBC
SUPC
30
20 Pulverised Coal
10
First Station
0
1880
1900
1920
1940
1960
1970
1980
1990
2000
2020
SUPCF: Sub Critical Pulverised Coal Fired
PFBC: Pressurised Fluidised Bed Combustion
IGCC: Integrated Gasification Combined Cycle
IGHAT: Integrated Gasification Humid Air Turbine
USPCF: Ultra Super Critical Pulverised Coal Fired
IGMCFC: Integrated Gasification Molten Carbonate Fuel Cell
AGMCFC: Advanced Gasification Molten Carbonate Fuel Cell
Rankine Cycle Efficiency
net work
n = --------------
Qin
Cycle thermal efficiency is improved by increasing the

mean temperature of heat addition process. This
temperature is increased because the boiler inlet pressure
sets the saturation temperature in Rankine cycle.
Total fuel input
Heat Rate =------------------
Electrical generation (KW)
860
= ------------------- Kcal/Kwh
n
EFFECT OF SUPERCRITICAL PARAMETERS
538
Temperature (C)
240 kg/cm2
Expansion Line
170 kg/cm2
Critical Point 225 kg/cm2
Condensation
Enthalpy
SUPPLIERS OF SUPERCRITICAL PLANT
BOILER TURBINE
 B&W, USA  GE,USA
 ABB-CE  LMZ, RUSSIA
 MHI, JAPAN  WESTING HOUSE, USA
 PODOLSK, RUSSIA  TOSHIBA, JAPAN
 FOSTER WHEELER, USA  ABB, GERMANY
 IHI, JAPAN  HITACHI, JAPAN
 ANSALDO, ITALY  MHI, JAPAN
 TAGANROG, RUSSIA  ANSALDO, ITALY
 BABCOCK HITACHI, JAPAN  SIEMENS AG
 STEIN MULLER, GERMANY
 STEIN INDUSRIE, FRANCE
 EVT, GERMANY
 DEUTCHE BABCOCK, GERMANY
 MBEL, U.K.
ENVIRONMENTAL ASPECTS
 Reduction in CO2, SO2 and NOx between

1.79% to 4.24%
 Reduction for 500 MW at 68.5% PLF per

year is
- CO2 78300 tons
- SO2 365 tons
- Nox 71 tons
SUPERCRITICAL ADVANTAGES
Enhancements
 Plant efficiency 0.69% to 1.64%
 Fuel tolerance More tolerant to coal
quality changes
Reductions
 Coal Consumption
 Ash production
 CO2
 SO2
 Nox
1.79% to 4.24%
Improvements
 Startup time
 Sliding Pressure Operation
 Load following capability
Natural Circulation Controlled Circulation
WATER WALLS
 HEATING AND EVAPORATING THE FEED WATER

SUPPLIED TO THE BOILER FROM THE ECONOMISERS.
 THESE ARE VERTICAL TUBES CONNECTED AT THE TOP

AND BOTTOM TO THE HEADERS.
 THESE TUBES RECEIVE WATER FROM THE BOILER

DRUM BY MEANS OF DOWNCOMERS CONNECTED
BETWEEN DRUM AND WATER WALLS LOWER HEADER.
 APPROXIMATELY 50% OF THE HEAT RELEASED BY THE

COMBUSTION OF THE FUEL IN THE FURNACE IS
ABSORBED BY THE WATER WALLS.
WATER WALL SYSTEM
Spiral wall arrangement
Many variable pressure units are running and basic idea
behind it to reduce the number of tubes required to
envelope the furnace wall without increasing the spacing
between the tubes.
Adv
1. By spiraling around the furnace, every tube is part of all four
walls which means that not only the difference in the length
of the parallel tube is minimized but also the heat pick up of
individual tubes is particularly equalised.
2. At low load also sufficient cooling of the tubes can be
assured.
Dis advantage
1. Complicated manufacture, construction
Rifled vertical tube
Construction of Water Walls
 Tangent tube The
construction consists
of water wall placed
side by side nearly
touching each other.
An envelope of thin
sheet of steel called
"SKIN CASING" is
placed in contact
with the tubes, which
provides a seal
against furnace
leakage.
Construction of Water Walls
Membrance Wall A number of tubes

are joined by a process of fusion
welding or by means of steel strips
called 'fins pressurised furnace is
possible with the related Advantages
•Increase in efficiency
•Better load response simpler
combustion control.
•Quicker starting and stopping
•Increased availability of boiler.
•Heat transfer is better
•Weight is saved in refractory and
structure
•Erection is made easy and quick
Supercritical Boiler Flow Chart
28
Cycle of Supercritical Power Plant
29
30
31
THANK YOU

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Gadarwara

 Gadarwara Super Thermal Power Station

5 SA 213 T91 8.5%cr 2.25 % MO steel 605

 These surfaces depending heat transfer mode such as

 As the radiant surfaces are located in high temp region,

 Heating surfaces are arranged staggered type.

 Convective super heaters are vertical

November 22, 2023 PMI Revision 00 13

 The arrangement and construction of a re-heater is similar to

November 22, 2023 PMI Revision 00 14

Supercritical boiler IGCC IGHAT

Cycle thermal efficiency is improved by increasing the

Critical Point 225 kg/cm2

 Reduction in CO2, SO2 and NOx between

 Reduction for 500 MW at 68.5% PLF per

 HEATING AND EVAPORATING THE FEED WATER

 THESE ARE VERTICAL TUBES CONNECTED AT THE TOP

 THESE TUBES RECEIVE WATER FROM THE BOILER

 APPROXIMATELY 50% OF THE HEAT RELEASED BY THE

Membrance Wall A number of tubes

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