Boiler Presentation.pdf

4000MW

Boiler & Auxiliaries Erection Presentation

DateDepartment

4000MW ULTRA MEGA POWER PROJECT

Power Boiler Design TeamThermal Power Plant Business Group

800 MW Large Capacity 800 MW Large Capacity Coal Fired Steam GeneratorCoal Fired Steam Generator

M U N D RA

Thermal Power Plant

Units 7 & 8 (500MW x 2 )

Supercritical Coal Fired Steam Generator

MUNDRA ULTRA MEGA POWER PLANTUNIT 1 ~ 5 ( 800MW X 5 )SUPERCRITICAL COAL FIRED STEAM GENERATOR

REHEATER INLET

STEAM COIL AIR HEATER DRAIN TANK60

REHEATER INLET PIPES (CRH)29

ECONOMIZER OUTLET FLUE GAS DUCT55

SUPERHEATER DIV. PANELETTES24

FURNACE BOTTOM ASH HOPPER54L.T.S.H. OUTLET HEADER23

COAL PIPNG53L.T.S.H. PENDANT ASSEMBLIES22

COAL MILLS (PULVERIZER)52

L.T.S.H. HORIZONTAL ASSEMBLIES21

COAL FEEDERS51BACKPASS LOWER REAR HEADER20

FLUE GAS DUCT TO STACK58

SUPERHEATER FINAL OUTLET HEADERS27

INDUCED DRAFT FANS57SUPERHEATER FINAL ASSEMBLIES26

ELECTROSTATIC PRECIPITATOR56

SUPERHEATER FINAL INLET HEADER25

STACK59SUPERHEATER OUTLET PIPES (MS)28

COAL SILOS50BACKPASS UPPER SIDE WALL INLET HEADERS19

COAL TRIPPER CONVEYOR ROOM49

BACKPASS SIDE WALL TUBES18

MIXED HOT AIR DUCT TO MILLS48

BACKPASS LOWER SIDE HEADERS17

COLD PRIMARY AIR DUCT TO MILLS47

BOILER WATER RECIRCULATING PUMP16

HOT PRIMARY AIR DUCT TO MILLS46

CONDENSATE DRAIN TRANSFER PUMPS15

PRIMARY AIR FANS45CONDENSATE RECEIVING TANK14

SCANNER & COOLING AIR FANS44FLASH TANK13

WINDBOX & TILTING TANGETIAL BURNER43

SEPARATOR STORAGE TANK12

HOT SECONDARY AIR DUCT TO WINDBOX42WATER SEPARATORS11

GAS AIR PREHEATERS41FURNACE UPP. REAR HEADER10

STEAM COIL AIR HEATERS40

FURNACE UPP. FRONT HEADER9

SECONDARY AIR DUCT TO GAS AIR PREHEATERS

39FURNACE VERTICAL W/W TUBES8

FORCED DRAFT FANS38FURNACE SPIRAL W/W TUBES7

F.D. FAN SUCTION W/SILENCERS37

FURNACE LOWER RING HEADERS6

SILENCERS (PSV, ERV, START UP VENT)36

ECONOMIZER HANGER TUBE OUTLET HEADER5

FLASH TANK VENT PIPE35ECONOMIZER HANGER TUBES4

REHEATER OUTLET PIPES (HRH)34

ECONOMIZER ASSEMBLIES3

REHEATER OUTLET HEADER33

ECONOMIZER INLET HEADER2

REHEATER REAR FINAL ASSEMBLIES32FEED WATER PIPE1

Spiral Wound / Vertical Wall

FURNACE TYPE

BalancedDRAFT STSTEM

Low Nox Tangential Burners

FIRING SYSTEM

Hi-Vol. c , Bit. CoalFUEL

596 C

REHEATER

569 cMAIN STEAMTEMP.CONDITION

53.6 Kg/cm2g

REHEATER

255 Kg/cm2g

MAIN STEAM

PRESS.CONDITION

1,325 Ton/Hr

REHEATER

1,672 Ton/Hr

MAIN STEAMCAPA

CITY

Supercritical Once-Thru BoilerBOILER TYPE

DESCRIPTION OF COMPONENTS BOILER SPEC.

LEGEND & ABBREVIATIONSACCESS DOOR

ACCESS DOOR IN ROOF EMCLOSURE

OBSERVATION DOORS

WALL BLOWER

RETRACTABLE SOOTBLOWER-DOUBLE SIDE

HALF TRACT SOOTBLOWER-DOUBLE SIDE

FURNACE TEMPERATURE PROBE

FURNACE MONITORING CAMERA (CCTV)

CLIENT : ENGINEER : CONTRACTOR :

TUR

BIN

E B

UILD

ING

Table of Contents

1. General

2. Organization

3. Schedule

4. Steel Structure Erection

5. Temporary Works ( Boiler )

6. Construction Plans

7. Erection Procedure

1. General

1) Summary of Construction

Project Title

Type/Capacity

Owner

Location

Scope

Ordering Mode

Duration

Major Quantity

4000MW Mundra Ultra Mega Power Project

Supercritical One-Thru Boiler / 800 MW x 5 Units

TATA Power

Mundra, Gujarat state

Boiler Island + EP System + Fuel Tank

Exclusive Bidding with TATA Power

40mths/1Unit, 56mths/5Unit, Except LD Moratorium 2mths

Total : 146,923ton BLR Steel : 40,500ton Boiler : 68,798ton

EP :28,575ton Con'c : 74,738 Re-bar : 4,783ton

Steel : 1,602ton Pile : 2,716(dia 600 L 25m)

Cable : 1,500,000M TRAY : 70,000M CONDUIT : 50,000M

1. General

2) Steam Condition

1. General

3) Major Progress of Works

2. Organization

1) Present

/

/ () 1 K 1 K 2 K 1 K 1 K

() 1 K 1 K 1 K 1 K

/ ` 1 K 1 K

P.R.O* () MGR 1 L Engin 2 L Engin 3 L Engin 1 L Engin 2 L Engin 3 L

Staff 2 L Engin 2 L Engin 3 L Engin 1 L Engin 1 L Engin 2 L

// / Office 3 L Engin 2 L Engin 2 L Engin 1 L

*PRO : Public Relation Officer

1

1

FDN / Building

1 1

Piling

FDN

Building

Quality

Safety

1

()

Piling

Contractor Adv.

1

1 1 12 14 3 10 13 10 4 14 3 / 5 8 17 1 31 49

2. Organization

2) Peak

3. Schedule

1) Man Power

3. Schedule

2) Equipment

3. Schedule

3) Milestone

3. Schedule

4) Detail

4. Steel Structure Erection

5. Temporary Works

1) Plan

5. Temporary Works

2) Shop DWG

5. Temporary Works (Power)

3) Temporary Power

5. Temporary Works (Power)

2.1 Panel erection

3.4 PWHT Machine2.3 Welding machine

2.2 Panel erection

5. Temporary Works (Lift Car)

4) Lift Car

Man Lift Car

5. Temporary Works (Lift Car)

5.3 Lift Car Bell

5.1 lift car FDN 5.2 Lift Car

5.4 Test

5. Temporary Works (Winch)

5) Winch


3.1 Winch temp. sup,t

3.4 Winch lifting3.3 Winch lifting

3.2 Winch temp. supt


3.5 Winch erection 3.6 Warning

3.7 Winch wire temp. jig 3.8 Winch lifting device

5. Temporary Works (Gas & Air Distribution)

6) Gas & Air Distribution

4.4 Gas manifold

4.1 Gas Station 4.2 Gas manifold

4.3 Gas test


4.7 Gas Piping

4.5 Gas manifold 4.6 Compressor room

4.8 Gas Piping


5. Temporary Works (Ground assemble bed)

7) Ground assemble bed


7) Tube Panel assembly


7) Spiral wall panel


7) Ground assemble bed


6.3 panel lifting divice6.2 Ground Assy temp die

6.4 wall panel ground assy


1) Scope of Works


1) Scope of Works

- Pressure part

- Non pressure part

- Permit

- IBR Welder

- Paint

- Heat Treatment requirements

- Equipment Supply

- NDE

BoilerBoiler

Steel StructureSteel Structure - Structure tructure

- Handrail & Grating

- Enclosure

- Deck Concrete


2) Flow of Erection


3) Construction Quantity


4) Welding Points


5) Ground Assembly

Items


Furnace Rear Arch Panel Lifting of component Lifting after ground assembly Arch Panel and Buckstay1

ITEM Preceding unit Improved method No.

5-1) Rear Arch Panel

Furn Rear Wall Screen & Hanger Tube

1 2 3 4 5 6 7

5Ton 4.9Ton 4.9Ton 5.4Ton 5.1Ton 5.3Ton 5Ton

A

BUCKSTAY

19,486 mm

10

,433

mm

Furnace Rear Arch panel


LEL.99,700

EL.92,700

K

9.2m 9.1m

1

.WINCH(5TON 2 ).:PNL

.WINCH(10TON 2 ). : PNL

2

.WINCH WIRE ROPE18mm92


J

A

A

L

EL.99,700

EL.92,700

K

9.2m 9.1m

J

A

A

.TEMPORARY

. WINCH

EL.70,000()



.TEMPORARY &PERMANENT BEAM

Arch Panel Lifting


Backpass Outlet Header & Backpass Front Screen Tube

Lifting of component Lifting after assembly HDR and Wall Screen Tube2


5-2) BP Front Screen Tube


500L

9670

850

1,000

H-200200812(TYP.6)

850

9670

19.2

64

290

H-200200812(TYP.4)

HD-S05 :BP ROOF OUTLET HDR(5.1 Ton)

BP FRONT SCREEN TUBE (7SET): 18.6 Ton

1

L-75756 (TYP.8)

3

EV-200

EV-201

EV-202

EV-203

EV-204

EV-205

EV-206

2

N

Ground Assembly BP Roof Outlet Header & BP Front Screen Tube


.WINCH(5TON 2 ). :

.18mm 6

.Wire rope 25 2 2 (:23.5Ton)

.SNATCH BLOCK(14"4)

5.5 8.7

.

EV-200 EV-201 EV-202 EV-203 EV-204 EV-205 EV-206

EL.43,700

.WINCH(5TON 2 ). :

.18mm 6

.Wire rope 25 2 2 (:23.5Ton)

.SNATCH BLOCK(14"4)

5.5 8.7

.

EV-200 EV-201 EV-202 EV-203 EV-204 EV-205 EV-206

EL.43,700

ERECTION

Screen Tube Lifting


Backpass extended Floor Panel Lifting of component

Lifting ground Assembly HDR Floor Panel and Buckstay

3


5-3) BP. Extended floor panel


W-19

W-19

EV-109 EV-110 EV-111

EV-106 EV-107 EV-108

W-20

UNIT

BP EXT. FLOOR PANEL

S-16 (BP EXT.SIDE INLET HDR): 5.2 Ton

PANEL TOTAL WEIGHT: 13.1Ton

BUCKSTAY(TYP.7)B/S Total : 8.8 Ton

Ground Assemble BP EXT. Floor Panel


Furnace Upper Rear Header & Screen Tube Lifting of component

Lifting after ground assyHeader and Screen Tube4


5-4) Furnace upper rear screen tube


H-200200812(TYP.6)

1,00

015

,834

19.5

00

290

H-200200812(TYP.4)

FD-F19 FURN UPPER REAR HDR(7.98 Ton)

FURN REAR WALL SCREEN TUBE(58SET) : 66.5 Ton

1

L-75756 (TYP.58)

2

3

15,8

34

1,0

00

Furnace Upper Rear HDR & Screen Tube


.WINCH(10TON 2 ). :

.22mm 9

.Wire rope 25 4 2 (:78Ton)

.SNATCH BLOCK(14"4)

5.5 8.7

.

.WINCH(10TON 2 ). :

.22mm 9

.Wire rope 25 4 2 (:78Ton)

.SNATCH BLOCK(14"4)

5.5 8.7

.

Lifting Furnace Upper Rear HDR & Screen Tube


Hopper Panel Lifting of component Lifting after ground assyHopper Panel and Buckstay5


5-5) Hopper Panel


UnitA

BUCKSTAY

A

Hopper Rear & Front Pan


LEL.99,700

EL.92,700

K

9.2m 9.1m

1



2

.WINCH WIRE ROPE18mm92.WINCH WIRE ROPE

22mm122

J

A A



EL.40,000

. WINCH

3

4

DETAL "A"

H-250*250

H-200*200

1500

H-300*300

350

400

PL-400*350*30T

DETAL "A"

PL-20T

Hopper Panel


Transition Panel Lifting of component Lifting ground assyHeader, Tran. Panel and Spiral Panel6


5-6) Transition panel


Spiral Wall Panel


LEL.99,700

EL.92,700

1


.WINCH WIRE ROPE 18mm82

J

A

A

.WINCH(5TON 2 ).:

2


EL+57,670 ( )


HEADER

BUCK - STAY BUCK STAY


B

B

SECTION "B-B"

Temp.Beam (3EA)Temp.HDR Band

(5EA)

Temp.Beam (5EA)

PanelHead e r

Temp.Beam (3EA)

Buckstay

Transition Panel Lifting


Furnace Panel Lifting of component Lifting ground ass,yFurn.PNL UPP.HDR,Buckstay7


5-7) Furnace panel


7. Erection Procedure

END OF DOCUMENT

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Boiler Presentation.pdf