Super Critical Boiler_100523

Presentation Title

Presentation Subtitle

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Mundra UMPP

CGPL,Tata Power Company Limited

23 May, 2010

Tata Power Welcomes Dignitaries from Boiler Inspectorate, Maharashtra.

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Mr. B. N. Waghchaure Director

Mr. G. T. Choughule Joint Director

Mr. S. T. Badhe Joint Director

Mr. S. M. Sarode Deputy Director

Mr. D. K. Londe Deputy Director

Tata Power Company Limited

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Lighting Up Lives

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First 150 MW thermal unit

First To introduce SCADA and Fibre optic ground wire communication

Flue gas de-sulphurisation plant using sea water

220 kV Transmission line in Four Circuit Towers

Touch Screen based distributed digital control and energy management systemsFirst

500 MW thermal unit

Computerized grid control and energy management systems

220 kV Cable Transmission Network

First pumped storage unit of 150 MW capacity

Apart from being pioneers in power production in the private sector, Tata Power has many firsts to its credit

First Gas insulated Switchgear 220kV and 110 kV

And Now…..1st 800 MW Supercritical Unit in India.

Ultra Mega Power Projects

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UMPP….Salient Features

Salient Features of UMPPs: -

• Large single location (4000 MW capacity each) Supercritical Technology based coal fired thermal power stations located at pit-head (captive mines) or in coastal regions (imported coal based) to leverage economy of scale.

• Project to be awarded through Tariff Based Competitive Bidding (as per Guidelines of Central Government) for development on Build, Own and Operate basis.

• Location, Technology and Fuel is specified.

• Power to be procured by multiple procurers.

• Scope of expansion in future.4

UMPP….Salient Features- 2

Salient Features of UMPPs: -

• Power to be sold at bus-bar (Central Transmission Utility to evacuate and transmit power to procurers)

• Regulatory role minimised.

• Flexibility in Unit size (supercritical parameters to be met & size not less than 500 MW).

• Central Excise Duty exempted fully on goods procured under supercritical technology.

• The project is transferred to the successful bidder in the form of a Shell Company.

• Time bound project development.5

UMPP….Salient Features- 3

Salient Features of UMPPs: -

• UMPPs will utilise coal more efficiently, hence producing considerably less green house gas.

India Average: 1.259 kg CO2/kWhWorld Average: 0.919 kg CO2/kWhUMPP: 0.750 kg CO2/kWh

The concept of UMPPs was proposed by Tata Group Chairman Mr. Ratan Tata in the capacity of Task Force Member of Infrastructure Special Subject Group (Council Of Trade & Industry set up by GOI).

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Super Critical Boiler

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Super Critical Boiler

•Super Critical Boilers work above Supercritical Pressure (221.2 bar) to leverage high cycle efficiency.

•The Super Critical boilers work on Modified Sliding Pressure Operation. Graph

•Super Critical Boilers employ Spiral Wall Design to minimise Differential temperature between adjacent tubes. The tubes are inclined at an angle of 17.3°. This is required as the heat flux in the furnace zone is very high.

•A Start-up System is provided to start the boiler in ‘Wet’ Condition and raise the parameters to achieve ‘Dry’ Mode Operation.

•A minimum Water Flow (~35%) is maintained through the boiler to prevent overheating of waterwall tubes.

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Super Critical Boiler

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Subcritical vs. Super Critical

The comparison between Sub-Critical and Super Critical Boilers is as shown below: -

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Subcritical Boiler Super Critical Boiler(Trombay 500 MW) (Mundra 830 MW)

Circulation Mode Drum Type Once ThroughPr. At SH Outlet 168 bar 255 barTemp at SH Outlet 541°C 568.5°CMS Steam Flow 1670 tph 2425 tphGenerator Ouput 500 MW 830 MWEffi ciency 37.60% 42%Pressure at RH Outlet 38 bar 57.1 barTemperature at RH Outlet 541°C 595°CWaterwall Vertical Spiral & Vertical

Control System Automation Desired Full Automation Required

Mundra…..An Overview

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Mundra UMPP

Mundra Ultra Mega Power Plant is situated in the State of Gujarat in Kutch district.

Mundra UMPP Shell Company was registered as ‘Coastal Gujarat Power Limited’ by Power Finance Company.

It is a coastal project using imported coal as primary fuel and sea water for plant use.

The Special Purpose Vehicle (CGPL) was handed over to Tata Power in April, 2007.

Project is situated in Seismic zone 5 (highest).

Other key competitors in the fray were Reliance (next lowest), NTPC, Lanco, L&T, Adani, Ansaldo, Torrent, Essar, Sterlite etc.

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Mundra UMPP- 2

The project will require 12 Million ton of imported Sub-bituminous coal.

Adani’s West Port in Mundra will have a dedicated coal berth where the coal will be unloaded and transported through High Speed Conveyor.

Mundra Power Purchase Agreement was signed on 21st April, 2007. The validity of the PPA is for 25 contract years from the COD of the 5th unit.

PFC acted as facilitator.

Mundra UMPP has been adjudged Power Deal of the Year-2008 in Asia-Pacific Region by Power Finance International.

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Mundra- Salient Features

• First 800 MW Supercritical Units in India.

• Most Efficient Thermal Units in India.

• Largest 400 kV Switchyard in India.

• 2 X 50% Motor Driven Boiler Feed Pumps for which Special Approval from Central Inspectorate of Boilers was secured.

• 2 X 50% Concrete Volute Condenser Cooling Water Pumps. Station sea water requirement is 6,30,000 tph.

• Largest Reverse Osmosis Based Desalination Plant in India.

• 500 m long Turbo-Generator Building.14

Mundra- Salient Features- 2

• First Green Field Project to have five large size supercritical units coming in single phase.

• Electro-Static Precipitators having more than 99 % collection efficiency.

• Hi-Fidelity Training Simulator of 830 MW for Operator Training.

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Major Equipment & Vendors

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Sr.

Equipment Supplier

1 Steam Generator & Auxiliaries

Doosan Heavy Industries and Construction Company Limited, South Korea

2 Steam Turbine Generator & Auxiliaries

Toshiba Corporation, Japan.

3 Feed Water Heaters, Deaerator & Surface Condenser

Larsen & Toubro

4 Concrete Volute CW Pumps Kirloskar Brother Limited

5 Boiler Feed Pump KSB, Germany

6 Condensate Extraction Pump KSB, India

7 400 kV Switchyard Siemens, India

8 Internal Coal handling System ThyssenKrupp Industries India Pvt Ltd

9 External Coal handling System

F L Smidth Minerals Pvt. Ltd., India

Major Equipment & Vendors- 2

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Sr.

Equipment Supplier

10 Desalination (RO) Plant Aquatech, India

11 Critical Piping Shaw Group, USAWymen Gordon Forgings, USATectubi Raccordi, SpainSeonghwa, South Korea

12 Ash Handling System Indure, India

13 Multi Flue Chimney Gammon, India

14 CW intake & Outfall Channel Gammon, India

15 Station DCS Invensys Process Systems, India

Tata Consulting Engineers are the Project Consultant.Korea Power Engineering Company (KOPEC) are acting as Consulting Advisors.

Supercritical Boiler

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SC Boiler Protection

Supercritical Boilers have certain additional/different protections from the Subcritical Boilers. These are: -

•Economiser Inlet Flow Low Trip

•All Feedwater Pumps Off

•Spiral Wall Tubes Metal Temperature High Trip

•Separator Tank Level High Trip

In addition to the above, several other Automation loops are provided for Supercritical Boilers. In general, level of Automation in Super Critical Boilers is high as compared to Sub-Critical counterparts.

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Boiler Start-up Sequence

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Condition Cold Start-up Warm Start-up Hot Start-up Hot Restart>72 hr > 48 hr < 8 hr < 2 hr

Time 0 min 0 min 0 min 0 min

P 0 bar 5 bar 85 bar 85 bar

T 30°C 200°C 340°C 400°C

S. Flow 0% 0% 0% 0%

Remarks HFO-CD HFO-AB

Time 170 min 110 min 60 min 50 min

P 85 bar 85 bar 85 bar 85 bar

T 360°C 420°C 435°C 460°C

S. Flow

Remarks2 HFO Tiers 1 Mill & 2 HFO Tiers 1 Mill & 3 HFO Tiers

Time 215 min 145 min 75 min 65 min

P 85 bar 85 bar 85 bar 85 bar

T 395°C 420°C 465°C 495°C

S. Flow

Remarks2 HFO Tiers 1 Mill & 2 HFO Tiers 1 Mill & 3 HFO Tiers

Criteria

Lig

ht O

ffTurb

ine

Rollin

gG

en. Syn

ch

Boiler Start-up Sequence

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Condition Cold Start-up Warm Start-up Hot Start-up Hot RestartTime 240 min 165 min 30 min 30 min

P 85 bar 85 bar 85 bar 85 bar

T 395°C 415°C 365°C 420°C

S. Flow

Remarks2 HFO Tiers 2 HFO Tiers 2 HFO Tiers 2 HFO Tiers

Time 425 min 265 min 110 min 100 min

P 90 bar 85 bar 85 bar 85 bar

T 510°C 540°C 540°C 545°C

S. Flow 42%

Remarks3 Mills & 2 HFO Tiers 2 Mills & 2 HFO Tiers 2 Mills & 2 HFO Tiers

Time 490 min 305 min 130 min 120 min

P 221 bar 221 bar 221 bar 221 bar

T 520°C 565°C 540°C 540°C

S. Flow 82% 82% 82%

Remarks5 Mills 5 Mills 5 Mills 5 Mills

Time 505 min 315 min 140 min 127 min

P 242.2 bar 242.2 bar 242.2 bar 242.2 bar

T 565°C 565°C 565°C 565°C

S. Flow 100% 100% 100% 100%

Remarks5 Mills 5 Mills 5 Mills 5 Mills

Full L

oad

Ist M

ill

Dry

Mode

Oper

atio

nSuper

critic

al

Par

amet

ers

Boiler Datasheet

The Specification of Mundra Boilers are: -

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DesignationOnce-Through Supercritical, Two Pass, Radiant Reheat, Balanced Draft, Outdoor

Fuel Hi Volatile Bituminous; GCV = 5700 kCal/kgFurnace Type Spriral Wound/ vertical WallFurnace Volume 22,757 m3

Furnace Width 19,488 mmFurnace Depth 19,488 mmAsh Fusion Temperature 1180 °C

Boiler Datasheet- 2

The equipments provided as part of Boiler Island is as follows: -

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Equipments DetailsID Fans 2 X 50% Single Stage, Constant Speed, Variable Blade Pitch, Axial Fans

FD Fans 2 X 50% Single Stage, Constant Speed, Variable Blade Pitch, Axial Fans

PA Fans 2 X 50% Two Stage, Constant Speed, Variable Blade Pitch, Axial Fans

Pulverisers 6 nos Vertical Bowl Mills-XHPS 1103

Coal- Low Nox Tangential Firing System

LDO- 1 Tier; HFO- 3 Tiers

BRP 1 No. Glandless Pump with Motor Drive (wet)

Air Preheater 2 X 50% Regenerative, Trisector

ESP 2 X 50% Electro Static Precipitator

SootblowersSmart Sootblowing System comprising of Wall Blowers, Long RetractableSoot Blowers and Short RetractableSoot Blowers

Fuel Oil System LDO and HFO Handling and Firing System

Firing System

Predicted Performance Data

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Section Parameter EU BMCR TMCRFlow tph 2525.76 2422Pressure bar 251 250.1

Temperature °C 568.5 568.5

Flow tph 2016 1959.5Pressure-Inlet bar 60.8 58.8Temperature-Inlet °C 349.9 348.6Pressure-Outlet bar 59.1 57.1Temperature-Outlet°C 595.6 595.6Pressure bar 294 290Temperature °C 295 293.2

tph 2128 2039tph 623 615% 15% 15%tph 306 295.2°C 128.8 128.6% 89.24% 89.23%

Superheater

Reheater

Feedwater

Boiler Efficiency

Excess Air at Econ.

FG Exit Temperature

Secondary Air FlowPrimary Air Flow

Fuel Flow

MUNDRA

Thermal Power Plant

Units 7 & 8 (500MW x 2) MUNDRA ULTRA MEGA POWER PLANT

UNIT 1 ~ 5 ( 800MW X 5 )

SUPERCRITICAL COAL FIRED STEAM GENERATOR

1 FEED WATER PIPE 32 REHEATER REAR FINAL ASSEMBLIES

2 ECONOMIZER INLET HEADER 33 REHEATER OUTLET HEADER

3 ECONOMIZER ASSEMBLIES 34 REHEATER OUTLET PIPES (HRH)

4 ECONOMIZER HANGER TUBES 35 FLASH TANK VENT PIPE

5ECONOMIZER 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 39SECONDARY AIR DUCT TO GAS AIR PREHEATERS

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

12 SEPARATOR STORAGE TANK 43 WINDBOX & TILTING TANGETIAL BURNER

13 FLASH TANK 44 SCANNER & COOLING AIR FANS

14 CONDENSATE RECEIVING TANK 45 PRIMARY AIR FANS

15CONDENSATE 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

19BACKPASS 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

27SUPERHEATER 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

31REHEATER FRONT PLATTEN ASSEMBLIES

62 PENT HOUSE VENTILATION FANS

DESCRIPTION OF COMPONENTS 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 :

TU

RB

INE

BU

ILD

ING

MAIN STEAM

From BFP Discharge

Boiler Recirculation Pump

Boiler Feed Pump Discharge Header Economiser

I/L Header49.62 mtr

Economiser Coils

LTSH I/L Header

Backpass Lower Front Header

Intermediate Header54.42mtr

(Backpass Lower Rear Header)

Economiser O/L Header

First Pass Lower Header 8.7 mtr

Divisional SH I/L

Divisional SH O/L

FSH I/LFSH O/L

Roof I/L Header80.195mtr

Waterwall O/L Header

Seperator (Nos:4)

Seperator Storage Tank(Nos:1)

DSH #1

DSH #2

Spiral Tubes (232 ×2) =464

Vertical tubes(464 × 3)=(348 × 4) =1392

LTSH O/L Header

Roof O/L Header

Backpass Roof

Backpass Left & Right SideWall

Extended water wall

First and Middle Pass Roof

Reheater

Boiler Flow Diagram

FLASH TANKWR16mtr

ZR16mtr

83.34 mtr

Quantum of Work

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T-92 Welding is being carried out for the first time in India.

Sr. Description Quantity1 Steel Structure 7452 Metric Tonne2 Pressure Parts 9029 Metric Tonne

Sr. Desrciption No. of J oints1 Carbon Steel 73902 Alloy Steel 294082(a) T- 304 (Stainless Steel)  1722(b) T- 12 206312(c) T- 23  31082(d) T- 91  41482(e) T- 92  1349

Safety Valves

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Location No. Set Pressure Relieving Capacity(kg/cm2) (tph)

Seperator 4 304.9 427MS SV-1 2 268.9 222MS SV-2 2 277 229

2608CRH SV-1 2 68.3 215CRH SV-2 2 69 217CRH SV-3 2 70.4 222HRH SV-1 2 65.6 211HRH SV-2 2 66.3 213

2156

TOTAL- MS

TOTAL- RH

Material Data Sheet

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Sr. Pressure Part Material OD / Thk Heating Surface Area

(mm) (m2)1 Economiser Bank- 1 54.0 / 6.6 140662 Economiser Bank- 2 44.5 / 6.6 90533 Economiser Hanger Tubes 63.2 / 12.5 6554 Furnace Hopper SA 213 T-12 38 / 5.8 25.35 Spiral Water Wall SA 213 T-12 38 / 5.8

SA 213 T-12 34 / 5.6SA 213 T-12 38 / 6.6

7 Furnace Roof 63.5 / 8.3 557.58 Backpass Side Wall 57.0 / 7.4 414.99 Backpass Front Roof & Rear Wall 76.2 / 9.9 734.1

SA 213 T-12 57.0 / 7.4SA 213 T-12 50.8 / 8.1SA 213 T-23 50.8 / 6.1

11 Pendant LTSH SA 213 T-23 50.8 / 6.1 1411

5247

11311

SA 210 C

Vertical Water Wall

Horizontal LTSH

SA 213 T-12

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6

Material Data Sheet- 2

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Sr. Pressure Part Material OD / Thk Heating Surface Area

(mm) (m2)SA 213 T-23 50.8 / 7.3SA 213 T-91 50.8 / 7.5SA 214 T-92 50.8 / 7.5SUPER 304 H (Fine Grain) 50 .8 / 6.8SA 213 T-23 42.2 / 6.4SA 213 TP-347 H 42.2 / 7.3SA 213 T-12 63.5 / 6.4SA 213 T-91 63.5 / 6.1SUPER 304 H (Fine Grain) 63.5 / 5.7

63.5 / 6.170.0 / 6.1

SA 213 TP-304 H 63.5 / 6.163.5 / 5.770.0 / 5.7

3804

4335

Divisional Superheater

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14

13

12

SUPER 304 H (Fine Grain)

Front Reheater

SA 213 T-91

Rear Reheater

Final Superheater

1855

6159