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WELCOME TO

CGPL MUNDRA ,UMPP


Presentation
On
5 X 800 MW
SUPERCRITICAL BOILER

Introduction

BOILER MEANS ANY CLOSED VESSEL EXCEEDING 22.75 litres IN


CAPACITY WHICH IS USED FOR GENERATING STEAM UNDER
PRESSURE.

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
562 0C

SubCritical Boiler

Temperature (0 C )

TEMP

70

7
3
2

Entropy KJ / Kg K

ENTROPY

Supercritical

2
m
c
g/
K
1

Sub critical

Super Critical

This consist drums for


separation of steam & water

No Drum. Separators are here


for separation of steam & water.

Vertical Water Wall.

Spiral Water wall.

Natural circulation or forced


circulation

Assisted circulation. Once


through.

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

unit

S/H STEAM FLOW

T/HR

2525

SH STEAM PR

KG/CM2

256

569

T/HR

1742

593

295

SH STEAM TEMP
RH STEAM FLOW

RH STEAM TEMP OUTLET

FEED WATER TEMP

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.

Boiler 3-D Diagram and Boiler Nomenclature

il
Bo

nt
o
r
er F

Boiler L
eft

Boiler R
ight

ile
o
B

ar
e
rR

BOILER WATER FLOW BLOCK DIAGRAM


SUPERHEATER
DESUPERHEATER
SPRAY(STAGE 2)

DIVISIONAL
I./L HEADER

MAIN STEAM O/L

FINAL
SUPERHEATER
O/L HEADER
(MAIN STEAM)

FINAL
SUPERHEATER
I/L HEADER
SUPERHEATER
DESUPERHEATER
SPRAY(STAGE 1)

LTSH O/L
HEADER

ECONOMISER
O/L HEADER

DIVISIONAL
O/L HEADER
ROOF I/L
HEADER

ROOF O/L
HEADER
WATER WALL
O/L HEADER

S
E
P
E
R
A
T
O
R

EXTENDED
WATERWALL
BACKPASS LOWER
RIGHT SIDE HEADER

INTERMEDIATE
HEADER

EXTENDED
WATER WALL
O/L HEADER

BACKPASS
LOWER
FRONT HEADER
BACKPASS UPPER
LEFT
SIDE HEADER

BOTTOM RING
HEADER
I/L HEADER

FROM BFP DISCHARGE


AFTER HPH

BACKPASS LOWER
REAR HEADER
(LTSH I/L HEADER)

ECONOMIZER I/L HEADER

Click Name to see Photograph of that particular Item

Position of all headers in boiler

Waterwall
O/L
RH I/L
Header

Roof O/L Header


FSH O/L
FSH I/L
RH O/L
LTSH O/L Header
Economiser O/L Header

Roof I/L
Header

H Header

Middle Pass
Back Pass

Front Pass

Backpass
Lower Front
Header

C Header

LTSH I/L Header


(Backpass Lower Rear
Header)
Economiser Inter Mediate Header
Intermediate
Header
54.42mtr

Backpass
Lower Side
Header

Economiser Coils
Economiser
I/L Header
49.62 mtr

First Pass Lower Header


(Bottom Ring Header)
8.7 mtr

Divisional SH I/L and O/L hedaer are not shown here

Boiler
Flow
Diagram

MAIN STEAM

Sepera
tor

Waterwall
O/L
Header

DSH #1
Division
al SH I/L
Division
al SH
DSH #2
O/L

Roof O/L Header


FSH O/L

FSH I/L

83.34 mtr

Roof
I/L
Head
er
80.19
5mtr

First and Middle


Pass Roof
Reheater

Extende
d water
wall

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

Spiral Tubes
(232 2)
=464

FLASH TANK
ZR
16mtr

First Pass Lower Header


8.7 mtr

LTSH I/L Header


(Backpass Lower Rear
Header)

Backpass
Lower Front
Header
Intermedi
ate
Header
54.42mtr

Boiler Feed
Pump
Discharge
Header
WR
16mtr

Backpass Roof

Backpass Left
& Right
SideWall

(Nos:4)
Sepera
tor
Storag
e Tank
(Nos:1)

From
BFP
Discha
rge Boiler
Recirculat
ion Pump

LTSH O/L Header


Economiser O/L Header

Economiser Coils

Economi
ser I/L
Header
49.62
mtr

VENT HEADER
1
B

2
B

B C

3
C

D A

5
A

A A

10

11

D
17

15
13

14
12

MAIN STEAM

DSH #1

16
Division
al SH I/L
DSH #2

1. FURNACE WALL RISER PIPE VENT LINE SEPERATOR B


2. FURNACE WALL RISER PIPE VENT LINE SEPERATOR C
3. FURNACE WALL RISER PIPE VENT LINE SEPERATOR D
4. FURNACE WALL RISER PIPE VENT LINE SEPERATOR A
5. CONNECTON PIPE VENT LINE FROM SEPERATOR A,B
6. REHEATER OUTLET HEADER VENT
7. SUPERHEATER DESUPERHEATER OUTLET LINK VENT
8. REHEATER INTERMEDIATE HEADER VENT LINE
9. SUPERHEATER FINISH INLET LINK VENT LNE
10. ECONOMISER OUTLET HEADER VENT LINE
11. FURNACE ROOF OUTLET LINK VENT LINE
12. MAIN STEAM VENT LINE Nos : 2
13. ELECTROMOTIVE RELIEF LINE VENT Nos : 2(RIGHT&
14. MAIN STEAM SAFETY VALVE Nos : 2(RIGHT & LEFT)
15. MAIN STEAM SAFETY VALVE Nos : 2(RIGHT & LEFT)
16. SEPERATOR CONNECTION LINK SAFETY VALVE Nos
17. FLASH TANK STEAM VENT LINE

MAIN STEAM

DRAIN HEADER

DSH #1
Division
al SH I/L

1.ECONOMISER INLET HEADER DRAIN


2.FURNACE FIRST PASS LOWER REAR AND FRONT HEADER DRAIN

DSH #2

3.INTERMEDIATE HEADER DRAIN


4.FURNACE ROOF INLET HEADER DRAIN
5.BACK PASS LOWER SIDE HEADER DRAIN
6.BACKPASS LOWER REAR HEADER DRAIN
7.SUPERHEATER FINISH INLET HEADER DRAIN

FLASH TANK

Reheater

THANK YOU

NRV

TAPPING FOR
MIXING PIECE
IN BRP SUCTION

TAPPING FOR
S/H SPRAY

BOILER FILL PUMP


DISCHARGE TO ECO I/L
FOR BOILER FILLING

BRP DISCHARGE

ECO I/L HEADER


DRAIN LINE

BUCK STAY
VERTICAL TUBES

1 SPIRAL TUBE TO
3 VERTICAL TUBE

SPIRAL TUBES

FROM SEPERATOR
O/L

BACKPASS
SIDE WALL(LEFT)

EXTENDED WATER WALL


SIDE WALL(LEFT)

BACKPASS LOWER RIGHT


HEADER DRAIN

BACKPASS LOWER LEFT


HEADER DRAIN

EXTENDED WATER WALL


O/L HEADER TO
BACKPSS
LOWER FRONT HEADER

MAIN STAEM O/L