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CGPL MUNDRA ,UMPP

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5 X 800 MW , SUPERCRITICAL BOILER

BOILERBOILER MEANS ANY CLOSED VESSEL EXCEEDING 22.75 Litres IN CAPACITYWHICH IS USED FOR GENERATING STEAM UNDER PRESSURE. - IBR

Types of Boiler Industrial Boiler Utility boilers

Utility Boilers may further Classified into two category

Sub critical

Super critical :- Above 221.2 bar & 374.150C

Difference between sub critical & supercriticalSubCritical Boiler3412657Temperature ( 0 C )Entropy KJ / Kg K

562 0C593CTEMPSupercritical8

Sub critical

This consist drums for separation of steam & water

Vertical Water Wall.

Natural circulation or forced circulation

Fixed pressure mode

Super Critical

No Drum. Separators are here for separation of steam & water.Spiral Water wall.

Assisted circulation. Once through.

Sliding pressure operation

SUPERCRITICALTHERMAL CYCLE ADVANTAGES Improvements in plant efficiency .

Decrease in Coal Consumption

Reduction in Green House gases.

Overall reduction in Auxiliary Power consumption.

4000 MW UMPP MUNDRA Boiler:- It is single reheat, tangential fired, balance draft, once through coal fired Boiler having a generation capacity of 701 Kg/Sec.

BOILER SPECIFICATION

Descriptionunit S/H STEAM FLOWT/HR2525 SH STEAM PRKG/CM2256 SH STEAM TEMP0C569RH STEAM FLOWT/HR1742 RH STEAM TEMP OUTLET0C593 FEED WATER TEMP0C295

Boiler General Arrangement

1.pdf

Boiler :-Activities for erectionSteel Structure :- Bolted structure using HSFG Bolts, thus fast in erection.

Pressure parts ( this incude all headers, Wall bundle, Hangers, backstayseparators, storage tanks, links & desuperheaters. Draft system:- this consist Air preheaters, ducting, FD fan, PA fan, ID fan, expansion joints & duct hanger supports.

Fuel burning System:- This consist Coal silo, pulverizer, Coal air piping, burners, LDO tank & HFO tank with interconnecting piping.

Boiler Accessories:- boiler recirculation pumps, soot blowers, safety valve silencers & control valves & other instruments.

Quantum of work

Sr No.DescriptionQty.1Steel Structure7452 MT2Pressure parts 9029 MTITotal no. of tube joints (Carbon steel)7390 Nos.IITotal no. of tube joints (Alloy steel) 29408Nos.T -304 (ss) tube Joints172 Nos.T12 tube joints20631 Nos.T23 tube joints3108 Nos.T91 tube joints4148 Nos.T92 tube joints1349 Nos.3Draft system4099 MT REGENERATIVE AIR PREHEATERS1765 MT STEAM COIL AIR HEATERS6.9 MTFan & Drivers344 MTDucts1982 MT

Sr No.DescriptionQty.4Fuel burning system2213 MTSilo510.9 MTPulverizer937 MTCoal Feeder & Acc.52.5 MTCoal Air Piping498 MTWindbox206 MTOil Burner7.77 MT5Piping10594 Inch dia6Boiler accessories257 MTTotal Weight of a boiler 23050

Layout of boiler

Left

RightFirst PassSecond Pass

MUNDRA UMPP(800MW5) Boiler CEILING GIRDER

Details of Crane used Unit 10- First, Second & third tier erected with 50MT, 70 MT, 150 MT & 250 tons crane.

Tier IV erected by using 150 MT Crane & 250 tons crane.

Tier 5 will be erected with 250 MT Crane.

Tier 6 & ceiling Girder with 1250 MT crane.

Boiler Pressure parts erectionPressure parts can be divided in two parts:-

First pass or furnace pass

Second pass or back pass

Draft SystemTri-sector Air-PreheaterHotSec. APHPri. APHFlue gas ductPrimary ductingCold Air Mixing to avoid coal burningHot Air From PAPH to coal millESPExpansion Joint of Chimney

Fuel Burning System

Cone PreassemblyCone ErectionShell ErectionCoal SiloCoal FeederPULVERISERCoal & Air Piping

Boiler Accessories Primary Air Fan (2 X 50% ) :- supplies primary air to Pulverizer

Forced Draft Fan (2 X 50% ):- supplies air for combustion

Induced Draft Fan (2 X 50% ):- Extract flue gas from the system.

Seal Air Fan ( 2 x 100%) :- provide sealing to coal mill. Scanner & cooling air Fan (2 x 100% ) :- for cooling of pep holes

Burners (6 for coal, 1 for LDO/HFO common & 2 for HFO) at 6 elevations

Boiler recirculation Pump ( for startup purpose)

Flash tank :- one for collection of drains

Soot blowers ( 32 +10 for eco & 52 for furnace)-

Silencers:- to damper noise pollutions

Safety valves:- to protect overpressurising of system.

MUNDRAThermal Power PlantUnits 7 & 8 (500MW x 2) Supercritical Coal Fired Steam GeneratorMUNDRAULTRA MEGA POWER PLANTUNIT 1 ~ 5 ( 800MW X 5 )SUPERCRITICAL COAL FIRED STEAM GENERATORDESCRIPTION OF COMPONENTSBOILER SPEC.LEGEND & ABBREVIATIONS

CLIENT :ENGINEER :CONTRACTOR :

TURBINE BUILDING

1FEED WATER PIPE32REHEATER REAR FINAL ASSEMBLIES2ECONOMIZER INLET HEADER33REHEATER OUTLET HEADER3ECONOMIZER ASSEMBLIES34REHEATER OUTLET PIPES (HRH)4ECONOMIZER HANGER TUBES35FLASH TANK VENT PIPE5ECONOMIZER HANGER TUBE OUTLET HEADER36SILENCERS (PSV, ERV, START UP VENT)6FURNACE LOWER RING HEADERS37F.D. FAN SUCTION W/SILENCERS7FURNACE SPIRAL W/W TUBES38FORCED DRAFT FANS8FURNACE VERTICAL W/W TUBES39SECONDARY AIR DUCT TO GAS AIR PREHEATERS9FURNACE UPP. FRONT HEADER40STEAM COIL AIR HEATERS10FURNACE UPP. REAR HEADER41GAS AIR PREHEATERS11WATER SEPARATORS42HOT SECONDARY AIR DUCT TO WINDBOX12SEPARATOR STORAGE TANK43WINDBOX & TILTING TANGETIAL BURNER13FLASH TANK44SCANNER & COOLING AIR FANS14CONDENSATE RECEIVING TANK45PRIMARY AIR FANS15CONDENSATE DRAIN TRANSFER PUMPS46HOT PRIMARY AIR DUCT TO MILLS16BOILER WATER RECIRCULATING PUMP47COLD PRIMARY AIR DUCT TO MILLS17BACKPASS LOWER SIDE HEADERS48MIXED HOT AIR DUCT TO MILLS18BACKPASS SIDE WALL TUBES49COAL TRIPPER CONVEYOR ROOM19BACKPASS UPPER SIDE WALL INLET HEADERS50COAL SILOS20BACKPASS LOWER REAR HEADER51COAL FEEDERS21L.T.S.H. HORIZONTAL ASSEMBLIES52COAL MILLS (PULVERIZER)22L.T.S.H. PENDANT ASSEMBLIES53COAL PIPNG23L.T.S.H. OUTLET HEADER54FURNACE BOTTOM ASH HOPPER24SUPERHEATER DIV. PANELETTES55ECONOMIZER OUTLET FLUE GAS DUCT25SUPERHEATER FINAL INLET HEADER56ELECTROSTATIC PRECIPITATOR26SUPERHEATER FINAL ASSEMBLIES57INDUCED DRAFT FANS27SUPERHEATER FINAL OUTLET HEADERS58FLUE GAS DUCT TO STACK28SUPERHEATER OUTLET PIPES (MS)59STACK29REHEATER INLET PIPES (CRH)60STEAM COIL AIR HEATER DRAIN TANK30REHEATER INLET HEADER61MILL SEAL AIR FANS31REHEATER FRONT PLATTEN ASSEMBLIES62PENT HOUSE VENTILATION FANS

BOILER TYPE Supercritical Once-Thru BoilerCAPACITYMAIN STEAM 1,672 Ton/HrREHEATER 1,325 Ton/HrPRESS.CONDITIONMAIN STEAM 255 Kg/cm2gREHEATER 53.6 Kg/cm2gTEMP.CONDITIONMAIN STEAM 569 cREHEATER 596 CFUEL Hi-Vol. c , Bit. CoalFIRING SYSTEM Low Nox Tangential BurnersDRAFT STSTEM BalancedFURNACE TYPE Spiral Wound / Vertical Wall

ACCESS 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)

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