Presentation Title Mundra UMPP

Presentation Subtitle CGPL, Tata Power Company Limited

23 May, 2010

Tata Power Welcomes Dignitaries from Boiler Inspectorate, Maharashtra.

Mr. B. N. Waghchaure
Mr. G. T. Choughule Mr. S. T. Badhe Mr. S. M. Sarode Mr. D. K. Londe

Director
Joint Director Joint Director Deputy Director Deputy Director

Tata Power Company Limited

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

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Flue gas desulphurisation plant using sea water

First 150 MW thermal unit

First 500 MW thermal unit

First Gas insulated Switchgear 220kV and 110 kV

Touch Screen based distributed digital control and energy management systems

Computerized grid control and energy management systems

220 kV Transmissi on line in Four Circuit Towers

220 kV Cable Transmissio n Network

First pumped storage First To unit of 150 introduce SCADA and MW Fibre optic capacity ground wire communicati on

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

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Ultra Mega Power Projects

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.

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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.

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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/kWh World Average: 0.919 kg CO2/kWh UMPP: 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).

Super Critical Boiler

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.

Super Critical Boiler

Subcritical vs. Super Critical

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

Subcritical Boiler Super Critical Boiler

(Trombay 500 MW) Circulation Mode Drum Type Pr. At SH Outlet 168 bar Temp at SH Outlet 541C MS Steam Flow 1670 tph Generator Ouput 500 MW Efficiency 37.60% Pressure at RH Outlet 38 bar Temperature at RH Outlet 541C Waterwall Vertical Control System Automation Desired
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(Mundra 830 MW) Once Through 255 bar 568.5C 2425 tph 830 MW 42% 57.1 bar 595C Spiral & Vertical 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.
Adanis 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.

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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

Sr. 1 Equipment Steam Generator & Auxiliaries Supplier Doosan Heavy Industries and Construction Company Limited, South Korea Toshiba Corporation, Japan. Larsen & Toubro

2 3

Steam Turbine Generator & Auxiliaries Feed Water Heaters, Deaerator & Surface Condenser

4 5
6 7 8 9

Concrete Volute CW Pumps Boiler Feed Pump

Condensate Extraction Pump 400 kV Switchyard Internal Coal handling System External Coal handling System

Kirloskar Brother Limited KSB, Germany

KSB, India Siemens, India ThyssenKrupp Industries India Pvt Ltd F L Smidth Minerals Pvt. Ltd., India

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Major Equipment & Vendors- 2

Sr. Equipment Supplier

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Desalination (RO) Plant

Critical Piping

Aquatech, India
Shaw Group, USA Wymen Gordon Forgings, USA Tectubi Raccordi, Spain Seonghwa, South Korea Indure, India Gammon, India Gammon, India

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Ash Handling System Multi Flue Chimney CW intake & Outfall Channel

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Station DCS

Invensys Process Systems, India

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

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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

Condition
Criteria
Light Off

Cold Start-up Warm Start-up Hot Start-up

>72 hr > 48 hr
0 min 5 bar 200C 0%

Hot Restart
< 2 hr
0 min 85 bar 400C 0% HFO-AB 50 min 85 bar 460C 1 Mill & 3 HFO Tiers 65 min 85 bar 495C 1 Mill & 3 HFO Tiers

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< 8 hr
0 min 85 bar 340C 0% HFO-CD 60 min 85 bar 435C 1 Mill & 2 HFO Tiers

Time 0 min P 0 bar T 30C S. Flow 0% Remark s Time 170 min P 85 bar T 360C S. Flow Remark s HFO Tiers 2 Time 215 min P 85 bar T 395C S. Flow Remark s HFO Tiers 2

Turbine Rolling

110 min 85 bar 420C

Gen. Synch

145 min 85 bar 420C

75 min 85 bar 465C 1 Mill & 2 HFO Tiers

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Boiler Start-up Sequence

Condition
Ist Mill

Cold Start-up Warm Start-up Hot Start-up

165 min 85 bar 415C 2 HFO Tiers 265 min 85 bar 540C 30 min 85 bar 365C 2 HFO Tiers 110 min 85 bar 540C 2 Mills & 2 HFO Tiers 305 min 221 bar 565C 82% 5 Mills 315 min 242.2 bar 565C 100% 5 Mills
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Hot Restart
30 min 85 bar 420C 2 HFO Tiers 100 min 85 bar 545C 2 Mills & 2 HFO Tiers 120 min 221 bar 540C 5 Mills 127 min 242.2 bar 565C 100% 5 Mills

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Time 240 min P 85 bar T 395C S. Flow Remark s HFO Tiers 2 Time 425 min P 90 bar T 510C S. Flow 42% Remark s Mills & 2 HFO Tiers 3 Time 490 min P 221 bar T 520C S. Flow 82% Remark s Mills 5 Time 505 min P 242.2 bar T 565C S. Flow 100% Remark s Mills 5

Dry Mode Operation

130 min 221 bar 540C 82% 5 Mills 140 min 242.2 bar 565C 100% 5 Mills

Full Load

Supercritical Parameters

Boiler Datasheet
The Specification of Mundra Boilers are: Once-Through Supercritical, Two Pass, Radiant Reheat, Balanced Draft, Outdoor Fuel Hi Volatile Bituminous; GCV = 5700 kCal/kg Furnace Type Spriral Wound/ vertical Wall Furnace Volume 22,757 m 3 Furnace Width 19,488 mm Furnace Depth 19,488 mm Ash Fusion Temperature 1180 C Designation

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Boiler Datasheet- 2
The equipments provided as part of Boiler Island is as follows: -

Equipments
ID Fans FD Fans PA Fans Pulverisers

Details

2 X 50% Single Stage, Constant Speed, Variable Blade Pitch, Axial Fans 2 X 50% Single Stage, Constant Speed, Variable Blade Pitch, Axial Fans 2 X 50% Two Stage, Constant Speed, Variable Blade Pitch, Axial Fans 6 nos Vertical Bowl Mills-XHPS 1103 Coal- Low Nox Tangential Firing System 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 Smart Sootblowing System comprising of Wall Blowers, Long Sootblowers RetractableSoot Blowers and Short RetractableSoot Blowers Fuel Oil System LDO and HFO Handling and Firing System
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Predicted Performance Data

Section
Superheater

Parameter
Flow Pressure Temperature

EU
tph bar C

BMCR
2525.76 251 568.5 2016 60.8 349.9 59.1 595.6 294 295 2128 623 15% 306 128.8 89.24%

TMCR
2422 250.1 568.5 1959.5 58.8 348.6 57.1 595.6 290 293.2 2039 615 15% 295.2 128.6 89.23%

Flow tph Pressure-Inlet bar Reheater Temperature-Inlet C Pressure-Outlet bar Temperature-Outlet C Pressure bar Feedwater Temperature C Secondary Air Flow tph Primary Air Flow tph Excess Air at Econ. % Fuel Flow tph FG Exit Temperature C Boiler Efficiency %
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M UNDRA MUNDRA

ULTRA MEGA POWER PLANT

T h er mal Power Pl an t

DESCRIPTION OF COMPONENTS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 FEED WATER PIPE ECONOMIZER INLET HEADER ECONOMIZER ASSEMBLIES ECONOMIZER HANGER TUBES ECONOMIZER HANGER TUBE OUTLET HEADER FURNACE LOWER RING HEADERS FURNACE SPIRAL W/W TUBES FURNACE VERTICAL W/W TUBES FURNACE UPP. FRONT HEADER FURNACE UPP. REAR HEADER WATER SEPARATORS SEPARATOR STORAGE TANK FLASH TANK CONDENSATE RECEIVING TANK CONDENSATE DRAIN TRANSFER PUMPS 32 REHEATER REAR FINAL ASSEMBLIES 33 REHEATER OUTLET HEADER 34 REHEATER OUTLET PIPES (HRH) 35 FLASH TANK VENT PIPE 36 SILENCERS (PSV, ERV, START UP VENT) 37 F.D. FAN SUCTION W/SILENCERS 38 FORCED DRAFT FANS 39 SECONDARY AIR DUCT TO GAS AIR PREHEATERS

LEGEND & ABBREVIATIONS

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)

Units 5 ( 800MW X 5 ) UNIT 1 ~ 7 & 8 (500MW x 2)

SUPERCRITICAL COAL FIRED STEAM GENERATOR

40 STEAM COIL AIR HEATERS 41 GAS AIR PREHEATERS 42 HOT SECONDARY AIR DUCT TO WINDBOX 43 WINDBOX & TILTING TANGETIAL BURNER 44 SCANNER & COOLING AIR FANS 45 PRIMARY AIR FANS 46 HOT PRIMARY AIR DUCT TO MILLS

BOILER WATER RECIRCULATING PUMP 47 COLD PRIMARY AIR DUCT TO MILLS BACKPASS LOWER SIDE HEADERS BACKPASS SIDE WALL TUBES BACKPASS UPPER SIDE WALL INLET HEADERS BACKPASS LOWER REAR HEADER L.T.S.H. HORIZONTAL ASSEMBLIES L.T.S.H. PENDANT ASSEMBLIES L.T.S.H. OUTLET HEADER SUPERHEATER DIV. PANELETTES SUPERHEATER FINAL INLET HEADER SUPERHEATER FINAL ASSEMBLIES SUPERHEATER FINAL OUTLET HEADERS SUPERHEATER OUTLET PIPES (MS) REHEATER INLET PIPES (CRH) REHEATER INLET HEADER REHEATER FRONT PLATTEN ASSEMBLIES 48 MIXED HOT AIR DUCT TO MILLS 49 COAL TRIPPER CONVEYOR ROOM 50 COAL SILOS 51 COAL FEEDERS 52 COAL MILLS (PULVERIZER) 53 COAL PIPNG 54 FURNACE BOTTOM ASH HOPPER 55 ECONOMIZER OUTLET FLUE GAS DUCT 56 ELECTROSTATIC PRECIPITATOR 57 INDUCED DRAFT FANS 58 FLUE GAS DUCT TO STACK 59 STACK 60 STEAM COIL AIR HEATER DRAIN TANK 61 MILL SEAL AIR FANS 62 PENT HOUSE VENTILATION FANS

TURBINE BUILDING

CLIENT :

ENGINEER :

CONTRACTOR :

Boiler Flow Diagram

Seperator (Nos:4) Seperator Storage Tank (Nos:1)

MAIN STEAM Waterwall O/L Header Divisional SH I/L Divisional SH O/L

DSH #1

Roof O/L Header DSH #2 FSH O/L FSH I/L LTSH O/L Header Economiser O/L Header

83.34 mtr

Roof I/L Header 80.195 mtr

First and Middle Pass Roof Reheater

Extended water wall

Backpass Roof

Backpass Left & Right SideWall

From BFP Discharge Boiler Recirculation Pump

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

Backpass Lower Front Header Intermediate Header 54.42mtr

LTSH I/L Header (Backpass Lower Rear Header)

Economiser Coils

Spiral Tubes (232 2) =464

Boiler Feed Pump Discharge Header Economiser I/L Header 49.62 mtr

FLASH TANK WR 16mtr

ZR 16mtr

First Pass Lower Header 8.7 mtr

Quantum of Work
Sr.
1 2 Steel Structure Pressure Parts

Description

Quantity
7452 Metric Tonne 9029 Metric Tonne

Sr.
1 2 2(a) 2(b) 2(c) 2(d) 2(e)

Desrciption
Carbon Steel Alloy Steel T- 304 (Stainless Steel) T- 12 T- 23 T- 91 T- 92

No. of Joints
7390 29408 172 20631 3108 4148 1349

T-92 Welding is being carried out for the first time in India.
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Safety Valves
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Location No. Set Pressure Relieving Capacity

(kg/cm 2) 4 2 2 2 2 2 2 2 304.9 268.9 277 68.3 69 70.4 65.6 66.3 (tph) 427 222 229 2608 215 217 222 211 213 2156

Seperator MS SV-1 MS SV-2 TOTAL- MS CRH SV-1 CRH SV-2 CRH SV-3 HRH SV-1 HRH SV-2 TOTAL- RH

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Material Data Sheet

Sr. Pressure Part Material OD / Thk
(mm) 54.0 / 6.6 44.5 / 6.6 63.2 / 12.5 38 / 5.8 38 / 5.8 34 / 5.6 38 / 6.6 63.5 / 8.3 57.0 / 7.4 76.2 / 9.9 57.0 / 7.4 50.8 / 8.1 50.8 / 6.1 50.8 / 6.1

Heating Surface Area

(m 2 ) 14066 9053 655 25.3 5247 557.5 414.9 734.1 11311 1411

1 2 3 4 5 6 7 8 9

Economiser Bank- 1 Economiser Bank- 2 Economiser Hanger Tubes Furnace Hopper Spiral Water Wall Vertical Water Wall

SA 210 C SA 213 T-12 SA 213 T-12 SA 213 T-12 SA 213 T-12

Furnace Roof Backpass Side Wall SA 213 T-12 Backpass Front Roof & Rear Wall SA 213 T-12 10 Horizontal LTSH SA 213 T-12 SA 213 T-23 11 Pendant LTSH SA 213 T-23

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Material Data Sheet- 2

Sr. Pressure Part Material OD / Thk Heating Surface Area
(m 2 ) 1855

12 Divisional Superheater

13 Final Superheater 14 Front Reheater

15 Rear Reheater

(mm) SA 213 T-23 50.8 / 7.3 SA 213 T-91 50.8 / 7.5 SA 214 T-92 50.8 / 7.5 SUPER 304 H (Fine Grain) 50 .8 / 6.8 SA 213 T-23 42.2 / 6.4 SA 213 TP-347 H 42.2 / 7.3 SA 213 T-12 63.5 / 6.4 SA 213 T-91 63.5 / 6.1 SUPER 304 H (Fine Grain) 63.5 / 5.7 63.5 / 6.1 SA 213 T-91 70.0 / 6.1 SA 213 TP-304 H 63.5 / 6.1 63.5 / 5.7 SUPER 304 H (Fine Grain) 70.0 / 5.7

6159 3804

4335

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