WELCOME TO

CGPL MUNDRA ,UMPP

Presentation
On
5 X 800 MW ,
SUPERCRITICAL BOILER

BOILER
BOILER MEANS ANY CLOSED VESSEL
EXCEEDING 22.75 Litres IN CAPACITY
WHICH 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 & supercritical

593C

Supercritical

SubCritical Boiler
6

Temperature (0 C )

TEMP
70

562 0C

m2
c
/
g
1K

7
3
2

Entropy KJ / Kg K
ENTROPY

Sub critical

Super Critical

Vertical Water Wall.

No Drum. Separators are

here for separation of steam
& water.
Spiral Water wall.

Natural circulation or forced

circulation

Assisted circulation. Once

through.

This consist drums for

separation of steam & water

Fixed pressure mode

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
Description

S/H STEAM FLOW

SH

STEAM PR

SH STEAM TEMP
RH STEAM FLOW

unit

T/HR

2525

KG/CM2

256

569

T/HR

1742

RH STEAM TEMP OUTLET

593

FEED WATER TEMP

295

Boiler General Arrangement

Boiler :-Activities for erection

Steel 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
ID fan, expansion joints & duct hanger supports.

fan,

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.

Description

Qty.

Steel Structure

7452 MT

Pressure parts

9029 MT

Total no. of tube joints (Carbon steel)

7390 Nos.

II

Total no. of tube joints (Alloy steel)

29408Nos.

T -304 (ss) tube Joints

172 Nos.

T12 tube joints

20631 Nos.

T23 tube joints

3108 Nos.

T91 tube joints

4148 Nos.

T92 tube joints

1349 Nos.

Draft system

4099 MT

REGENERATIVE AIR PREHEATERS

1765 MT

STEAM COIL AIR HEATERS

6.9 MT

Fan & Drivers

344 MT

Ducts

1982 MT

Sr No.

Description

Qty.

Fuel burning system

2213 MT

Silo

510.9 MT

Pulverizer

937 MT

Coal Feeder & Acc.

52.5 MT

Coal Air Piping

498 MT

Windbox

206 MT

Oil Burner

7.77 MT

Piping

10594 Inch dia

Boiler accessories

257 MT

Total Weight of a boiler

23050

Layout of boiler

Right

REAR

First Pass

Second Pass

FRONT

Left

MUNDRA UMPP(800MW5) Boiler CEILING GIRDER

E
13500

5800

4
5
0
0

1
8

F
9500

G
10500

H
11300

9200

9700

E
2

9
4
0
0

1
7

6
4
0
0

8
5
0
0

0
3
0
.
2
T
O
N

2
0/

M
6
H
G
0
10
64
M
6
H
G
0
0
5
M
6/
H
G
6
02
0.
73
M
T
/6O
H
N
G
7
0
0
.0
6
7
T
/
O
N
1
2
7
.
6
T
O
N
1
2
c

1
2
1
1
a

M6HG001 /
20.8TON

3
0
.
2
T
O
N

1
3

1
4

M
6
H
G
0
0
3

M6MB001 /
38.9TON

1
6

M6MB001 /
38.9TON

1
4

1
1

1
5
b

M6HG002 /
20.8TON

1
5
a

9
4
0
0

1
5

1
6
a

1
4
1
0
0

9
4
0
0

1
6

1
6
a

1
2
b

1
2
1
1
a

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 erection

Pressure parts can be divided in two parts:1) First pass or furnace pass
2) Second pass or back pass

Furnace Pass Erection Sequence

Hanger Rods Assly

SH.Links & Desh

Link Pipes

WW Riser Tubes
RH.Links & Desh

Links from Furnce Roof Hdr to Separator

Separator
SH Final Outlet

Upper Headers

SH Final

RH Final Outlet
RH Final

SH Platen Outlet
SH Platen

SH Final Inlet

RH Final Inlet

SH Div. Outlet
SH Divisonal

SH Platen Inlet

SH Div. Inlet

Links
Furnace Roof Inlet Hdr

Links to Seperator
Upper B/stays

Stotage Tank
Furnace O/L Front Hdr

Buckstays

Front Pass

Middle B/stays
Links
Lower B/stays

Furnace O/L RHS Hdr

SH Final Outlet
Crown Plate Assly

SH Final

RH Final Outlet
RH Final

SH Final Inlet

RH Final Inlet

Front WW
Corner Panels Align
LHS WW
Buckstay Alignment
RHS WW

Rear Arch
Screen Tubes

Coil Assly

SH Final Assly

RH Final Assly

Cor.01

Cor.04

Hanger Tubes

SH Platen Assly

Burner Blocks

Spiral Panels

Cor.03

Buner Blocks Align

Hopper Panels

Furnace Lower Inlet Header

HYDRAULIC TEST

To Drain HDR

Rear Arch Panel

SH Div. Panelletes

Inter Headers

Cor.02

Furnace O/L LHS Hdr

SH Platen Inlet

Roof Panels

Water wall Panels

To BRP

SH Platen Outlet
SH Platen

Draft System
Hot
Tri-sector AirPreheater

Sec. APH

Pri. APH

DUCTING

Hot Secondary
duct

Flue gas duct

ESP

Primary ducting

Hot Air From PAPH to coal

mill

Cold Air Mixing to

avoid coal burning

Cold secondary
ducting

Expansion Joint of Chimney

Fuel Burning System

Coal Silo

Cone Preassembly

Shell fabrication

Shell Erection

Cone Erection

Coal Feeder

PULVERISER

Coal & 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.

MUNDRA
M
UNDR
A

Thermal
Power
Plant
ULTRA
MEGA
POWER
PLANT
UNIT
5 (8800MW
X 5x) 2)
Units17~ &
(500MW

SUPERCRITICAL
COALFired
FIRED
STEAM
GENERATOR
Supercritical Coal
Steam
Generator

BOILER SPEC.

DESCRIPTION OF COMPONENTS
1 FEED WATER PIPE

32 REHEATER REAR FINAL ASSEMBLIES

BOILER TYPE

2 ECONOMIZER INLET HEADER

33 REHEATER OUTLET HEADER

CAPACITY

3 ECONOMIZER ASSEMBLIES

34 REHEATER OUTLET PIPES (HRH)

4 ECONOMIZER HANGER TUBES

35 FLASH TANK VENT PIPE

5 ECONOMIZER HANGER TUBE OUTLET HEADER

36 SILENCERS (PSV, ERV, START UP VENT)

6 FURNACE LOWER RING HEADERS

37 F.D. FAN SUCTION W/SILENCERS

7 FURNACE SPIRAL W/W TUBES

38 FORCED DRAFT FANS

8 FURNACE VERTICAL W/W TUBES

39 SECONDARY AIR DUCT TO GAS AIR PREHEATERS

Supercritical Once-Thru Boiler

MAIN STEAM

1,672

Ton/Hr

REHEATER

1,325

Ton/Hr

PRESS.
CONDITION

MAIN STEAM

255

Kg/cm2g

REHEATER

53.6

Kg/cm2g

TEMP.
CONDITION

MAIN STEAM

569

596

REHEATER

FUEL

Hi-Vol. c , Bit. Coal

FIRING SYSTEM

Low Nox Tangential Burners

DRAFT STSTEM

Balanced

FURNACE TYPE

Spiral Wound / Vertical Wall

9 FURNACE UPP. FRONT HEADER

40 STEAM COIL AIR HEATERS

10 FURNACE UPP. REAR HEADER

41 GAS AIR PREHEATERS

11 WATER SEPARATORS

42 HOT SECONDARY AIR DUCT TO WINDBOX

ACCESS DOOR

12 SEPARATOR STORAGE TANK

43 WINDBOX & TILTING TANGETIAL BURNER

ACCESS DOOR IN ROOF EMCLOSURE

13 FLASH TANK

44 SCANNER & COOLING AIR FANS

14 CONDENSATE RECEIVING TANK

45 PRIMARY AIR FANS

15 CONDENSATE DRAIN TRANSFER PUMPS

46 HOT PRIMARY AIR DUCT TO MILLS

16 BOILER WATER RECIRCULATING PUMP

47 COLD PRIMARY AIR DUCT TO MILLS

17 BACKPASS LOWER SIDE HEADERS

48 MIXED HOT AIR DUCT TO MILLS

18 BACKPASS SIDE WALL TUBES

49 COAL TRIPPER CONVEYOR ROOM

19 BACKPASS UPPER SIDE WALL INLET HEADERS

50 COAL SILOS

20 BACKPASS LOWER REAR HEADER

51 COAL FEEDERS

21 L.T.S.H. HORIZONTAL ASSEMBLIES

52 COAL MILLS (PULVERIZER)

22 L.T.S.H. PENDANT ASSEMBLIES

53 COAL PIPNG

23 L.T.S.H. OUTLET HEADER

54 FURNACE BOTTOM ASH HOPPER

24 SUPERHEATER DIV. PANELETTES

55 ECONOMIZER OUTLET FLUE GAS DUCT

25 SUPERHEATER FINAL INLET HEADER

56 ELECTROSTATIC PRECIPITATOR

26 SUPERHEATER FINAL ASSEMBLIES

57 INDUCED DRAFT FANS

27 SUPERHEATER FINAL OUTLET HEADERS

58 FLUE GAS DUCT TO STACK

28 SUPERHEATER OUTLET PIPES (MS)

59 STACK

29 REHEATER INLET PIPES (CRH)

60 STEAM COIL AIR HEATER DRAIN TANK

30 REHEATER INLET HEADER

61 MILL SEAL AIR FANS

31 REHEATER FRONT PLATTEN ASSEMBLIES

62 PENT HOUSE VENTILATION FANS

LEGEND & ABBREVIATIONS

OBSERVATION DOORS
WALL BLOWER
RETRACTABLE SOOTBLOWER-DOUBLE SIDE
HALF TRACT SOOTBLOWER-DOUBLE SIDE
FURNACE TEMPERATURE PROBE

TURBINE BUILDING

FURNACE MONITORING CAMERA (CCTV)

CLIENT :

ENGINEER :

CONTRACTOR :

Thank

You