PAITON PRIVATE POWER - PHASE I

UNIT 7 & 8

BOILER SYSTEM DESCRIPTION

INCLUDING ENGINEERING SYSTEM: BOTTOM ASH (BA), BOILER FUEL (BF) AND
BOILER GAS (BG)

REVISION LOG

1. 5.

2. 6.

3. 7.

4. 8.

PT PAITON ENERGY COMPANY

PAITON PRIVATE POWER PROJECT PHASE-I
PAITON, EAST JAVA, INDONESIA
MITSUI & CO., LTD.

L TOYO ENGINEERING CORP.

PROJECT
DOC. NO. : P101-11-1723.06, 07 & 95–0001 REV. 0
ITEM NO. : -

REQ. NO. : -

PURCHASE ORDER NO. : -----------------------------------

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0

 DUKE/FLUOR DANIEL
2300 Yorkmont Road
P.O. Box 1011
Charlotte, N.C 28201-1011

VERIFICATION OF PROCEDURE FORMAT AND CONTENT

OWNER: P.T. Paiton Energy Company

PROJECT: Paiton Private Power Phase I: Unit 7 & 8

TITLE OF PROCEDURE: Boiler System Description

PROCEDURE NUMBER: P101-11-1723.06, 07 & 95-0001

REVISION: 0

In accordance with established procedures, the quality has been assured, and the above system
description has been prepared, checked and approved as noted below.

ORIGINATED BY: ________________________________________ DATE:

CHECKED BY: ________________________________________ DATE:

APPROVED BY: ________________________________________ DATE:

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0

 TABLE OF CONTENTS

1.0 SYSTEM PURPOSE....................................................................................................... 1

2.0 SYSTEM DESCRIPTION AND FUNCTIONS.............................................................. 1
2.1 General..................................................................................................................... 1
2.2 BOILER PRESSURE SIDE..................................................................................... 2
2.2.1 GENERAL................................................................................................... 2
2.2.2 ECONOMIZER............................................................................................ 2
2.2.3 STEAM DRUM........................................................................................... 3
2.2.4 BOILER CIRCULATING PUMPS..............................................................4
2.2.5 WATER COOLED FURNACE...................................................................5
2.2.6 SUPERHEATER.......................................................................................... 5
2.2.7 REHEATER................................................................................................. 7
2.3 BOILER AIR AND GAS SIDE................................................................................ 7
2.4 BOILER FUEL SYSTEM........................................................................................ 9
2.4.1 GENERAL................................................................................................... 9
2.4.2 PULVERIZED COAL SYSTEM.................................................................9
2.4.3 FEEDERS.................................................................................................. 10
2.4.4 COAL PIPE SLIDE GATE VALVES........................................................10
2.5 BOTTOM ASH SYSTEM...................................................................................... 11
3.0 SYSTEM OPERATION................................................................................................ 11
3.1 SYSTEM LIMITS AND PRECAUTIONS.............................................................11
3.2 STARTUP.............................................................................................................. 12
3.3 NORMAL OPERATION........................................................................................ 12
3.4 ABNORMAL CONDITIONS................................................................................. 12
4.0 SYSTEM CONTROLS................................................................................................. 12
4.1 BOILER PRESSURE SIDE...................................................................................12
4.1.1 BOILER VENTS (BS-MOV-104A, 104B, 146A, 146B, 200B, 201B, 205,
210, 230A, 230B, 240, 250A, 250B, 290A, 290B, 300 )............................12
4.1.2 SUPERHEATER / SECONDARY SUPERHEATER................................13
4.1.2.1 BACKPASS HEADER DRAIN VALVES (BS-MOV-220, 221, 222,
223, & 224)..................................................................................... 13
4.1.2.2 POWER-ACTUATED RELIEF VALVES (BS-ERV-106 A & B).13
4.1.3 SOOTBLOWERS......................................................................................13
4.1.3.1 SOOT BLOWER HEADER ISOLATION VALVES (BS-MOV-400,
520, &700)...................................................................................... 13
4.1.3.1 SOOTBLOWER STEAM SUPPLY CONTROL VALVES (BS-PV-
400, 520, & 700).............................................................................13

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 TABLE OF CONTENTS

4.1.3.2 SOOT BLOWER HEADER THERMAL DRAINS (BS-DRV-460,

510, 565, 600, 640, 680, &720).......................................................13
4.1.3.3 SERVICE AIR SUPPLY ISOLATION VALVE (BS-MOV-715)...13
4.1.4 PULVERIZER INERTING STEAM SYSTEM.........................................13
4.1.5 PIPING DRAIN POTS............................................................................... 13
4.1.5.1 AUTOMATIC DRAIN VALVES...................................................13
4.1.5.2 REMOTE MANUAL DRAIN VALVES.........................................13
4.1.6 FINAL FEEDWATER...............................................................................14
4.1.6.1 STEAM DRUM LEVEL CONTROL..............................................14
4.1.6.2 BOILER CIRCULATING PUMPS (FW-P-300A, 300B, & 300C). 14
4.1.6.3 BOILER DESUPERHEATER SPRAY BLOCK VALVES (FW-FV-
324, 337A, & 337B)........................................................................14
4.1.6.4 BOILER SUPERHEATER SPRAY CONTROL VALVES (FW-TV-
325A, 325B, 338A, 338B, 338C, & 338D)......................................14
4.1.6.5 ECONOMIZER RECIRCULATION VALVE (FW-MOV-114).....14
4.2 BOILER AIR AND GAS SIDE..............................................................................14
4.2.1 FORCED DRAFT (FD) FANS...................................................................14
4.2.2 FORCED DRAFT FAN OUTLET DAMPERS..........................................14
4.2.3 INDUCED DRAFT (ID) FANS.................................................................14
4.2.4 INDUCED DRAFT FAN INLET DAMPER..............................................14
4.2.5 ID FAN SEAL AIR FANS.........................................................................15
4.2.6 SECONDARY AIR HEATERS.................................................................15
4.2.7 SECONDARY AIR HEATER LEAKAGE CONTROL SECTOR DRIVES
................................................................................................................... 15
4.2.8 ELECTROSTATIC PERCIPITATORS (ESP)...........................................15
4.3 BOILER FUEL SYSTEM...................................................................................... 15
4.3.1 PRIMARY AIR (PA) FANS......................................................................15
4.3.2 PRIMARY AIR FAN OUTLET DAMPER................................................15
4.3.3 PULVERIZERS......................................................................................... 15
4.3.4 COAL FEEDERS....................................................................................... 15
4.3.5 PULVERIZER SEAL AIR BOOSTER FANS...........................................15
4.3.6 WARMUP BURNERS AND IGNITERS...................................................16
4.3.7 PRIMARY AIR HEATER.........................................................................16
4.3.8 PRIMARY AIR HEATER LEAKAGE CONTROL SECTOR DRIVES....16
4.4 BOTTOM ASH SYSTEM...................................................................................... 16
4.4.1 SUBMERGED CHAIN CONVEYOR HYDRAULIC PUMP....................16

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 TABLE OF CONTENTS

4.4.2 ASH CRUSHER HYDRAULIC PUMP.....................................................16

4.4.3 SUBMERGED CHAIN CONVEYOR HYDRAULIC DRIVE...................16
4.4.4 ASH CRUSHER HYDRAULIC DRIVE....................................................16
4.4.5 SCREW FEED CONVEYOR....................................................................16
4.4.6 CONVEYORS........................................................................................... 17
4.4.7 ASH LOADOUT SILO CONVEYOR.......................................................17
4.4.8 PYRITES SYSTEM................................................................................... 17
5.0 SYSTEM COMPONENT DESIGN PARAMETERS.................................................... 18
5.1 ECONOMIZER...................................................................................................... 18
5.2 STEAM DRUM...................................................................................................... 18
5.3 BOILER CIRCULATING PUMPS........................................................................18
5.4 SUPERHEATER.................................................................................................... 19
5.5 REHEATER........................................................................................................... 19
5.6 FORCED DRAFT (FD) FANS............................................................................... 20
5.7 PRIMARY AIR FANS........................................................................................... 20
5.8 SECONDARY AIR PREHEATERS......................................................................21
5.9 PRIMARY AIR PREHEATER............................................................................... 21
5.10ELECTROSTATIC PERCIPITATORS..................................................................22
5.11INDUCED DRAFT (ID) FANS.............................................................................. 22
5.12ID FAN SEAL AIR FANS..................................................................................... 23
5.13PULVERIZERS..................................................................................................... 23
5.14PULVERIZER SEAL AIR BOOSTER FANS........................................................23
5.15WARMUP BURNERS AND IGNITERS...............................................................24
5.16BOTTOM ASH SYSTEM...................................................................................... 24
5.16.1 BOTTOM ASH PYRITES HOPPER / JET PUMP....................................24
5.16.2 SUBMERGED CHAIN CONVEYOR.......................................................25
5.16.3 ASH CRUSHER........................................................................................ 26
5.16.4 SCREW FEED CONVEYOR....................................................................26
5.16.5 CONVEYOR A.......................................................................................... 27
5.16.6 CONVEYOR B.......................................................................................... 27
5.16.7 CONVEYOR 7C........................................................................................ 28
5.16.8 ASH LOADOUT SILO..............................................................................28
5.16.9 ASH LOADOUT SILO CONVEYOR.......................................................28
6.0 FLOW DIAGRAMS....................................................................................................... 29
7.0 REFERENCES.............................................................................................................. 38

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0

 TABLE OF CONTENTS

7.1 P&IDS.................................................................................................................... 38
7.2 EQUIPMENT INSTRUCTION MANUALS..........................................................38

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0

 NOMENCLATURE

BA Bottom Ash

BF: Boiler Fuel

BG: Boiler Gas

BMS: Burner Management System

DCS: Distributed Control System

FD: Forced Draft

ID: Induced Draft

MCR: Maximum Continuous Rating

NOx: Nitrous oxides

PA: Primary Air

P&ID: Process and Instrumentation Diagram

PLC: Programmable Logic Controller

SCC Submerged Chain Conveyor

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0

1.0 SYSTEM PURPOSE
The Steam Generator converts the stored chemical energy in coal to heat by combustion in
the steam generator furnace. The heat then vaporizes water in the boiler tubes fed from the
Feedwater (FW) System, and superheats steam in superheater and reheater sections. This
superheated steam is then supplied to the turbine generator.

This system description is for unit 7, unit 8 is identical.

2.0 SYSTEM DESCRIPTION AND FUNCTIONS

2.1 General
The steam generator is a Controlled Circulation Radiant Reheat unit. The firing equipment
consists of three elevations (four per elevation) retractable air atomizing light oil warm-up
guns (the lower elevation normally being utilized for warm-up service), six elevations (four
per elevation) of pulverized coal nozzles and three elevations of High Energy Arc (HEA)
igniters adjacent to the oil gun elevations. The six elevations of pulverized coal nozzles are
supplied with coal from six pulverizers.

The steam generator consists of the furnace area (front), and backpass area (rear) through
which the flue gases pass before entering the air heaters. After leaving the air heaters, the
flue gases continue through the precipitators, Induced Draft (ID) fans, flue gas scrubbers and
then to the stack. Located around the steam generator are the various auxiliary systems
required to meet air, fuel, water and ash removal requirements

The steam generator is of the open bottom, top supported design. The unit is supported from
a structural steel framework which allows all vertical expansion in the downward direction.
The expanding furnace moves downward into a water filled Submerged Chain Conveyor
(SCC). The water filled SCC serves to seals the pressure of the furnace and remove bottom
ash.

The steam generator consists of drums, headers and tube assemblies located throughout the
steam generator structure to provide for the flow of water and processing steam. These
components are part of the pressure part of the structure.

The furnace is the area of the steam generator where combustion of the fuel takes place and
is formed by four waterwalls of welded tube panels. The furnace wall tubes are supplied
from the lower furnace waterwall drums. Water and saturated steam generated in the furnace
wall tubes collects in the upper waterwall headers and is discharged into the steam drum.

Main steam and reheat steam is superheated by flue gas through superheaters and reheaters
located in upper region and backpass of the furnace. Incoming feedwater, prior to entering
the steam drum, is heated in the backpass section of the furnace through economizer tubes .

The furnace has been designed for oil and pulverized coal firing. The firing equipment for
combustion consists of three elevations (four per elevation) of retractable air atomizing light
oil warmup guns (lower elevation normally utilized for warmup service), six elevations (four
per elevation) of pulverized coal nozzles and three elevations of High Energy (HEA) igniters
adjacent to the oil gun elevations. The six elevations of pulverized coal nozzles are supplied
with coal from six pulverizers.
File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 1
Combustion air for fuel firing is supplied by the forced daft (FD) fans through associated
ductwork and air heating equipment. Flue gases carrying the products of combustion are
removed and delivered to the stack by the induced draft (ID) fans. Bottom ash produced in
the combustion process is removed by the furnace bottom ash system. Most of the fly ash
remaining in the flue gas is removed by the Electrostatic Precipitator (ESP) located upstream
of the ID fans. Most of the Sulfur Dioxide (SO2) generated in combustion process is
removed by flue gas scrubbers located downstream of the ID fans.

2.2 BOILER PRESSURE SIDE

2.2.1 GENERAL
Heat is transferred from fuel in combustion in the furnace on outside of tubes to steam and
feedwater on inside of tubes. Steam and feedwater inside the tubes is the pressure side of the
steam generator. Flow path of the feedwater and consists of the following basic components:

Economizer

Steam Drum

Circulating System

Water Cooled Furnace

Superheater

Reheater

2.2.2 ECONOMIZER
The function of the economizer is to preheat the steam generator feedwater before it is
introduced into the steam drum by recovering some of the heat of the flue gases leaving the
steam generator.

The economizer is located below the rear horizontal superheater assemblies in the lower
section of the boiler backpass. It is composed of two banks of 189 parallel tube elements,
arranged in horizontal rows in such a manner that each row is in line in relation the row
above and below. All tube circuits originate from the economizer inlet header, and discharge
into three economizer junction headers.

Feedwater is supplied to the economizer inlet header through feed stop and check valves.
The feedwater flow is upward through the economizer counter flow to the hot flue gases.
Counter flow flue gas and feedwater provides the most efficient heat transfer, while
possibility of steam generation within the economizer is minimized by the upward water
flow. From the outlet header, the feedwater is led to the steam drum through the three
economizer links.

The economizer recirculating line, which connects the economizer inlet header with the
furnace lower rear drum, provides a means of ensuring water flow through the economizer
during start-ups. This helps prevent steaming. The valve in this line must open during unit
start-up until continuous feedwater flow is established.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 2

2.2.3 STEAM DRUM
The function of the steam drum is to separate the water from the steam generated in the
furnace walls. This must be done as efficiently as possible to prevent carryover of dissolved
impurities into the super-heater sections of the boiler where they would be permanently
deposited.

Separation occurs in three stages; the first two are incorporated into the turbo-separators and
the third in the corrugated plate dryers just before the steam leaves the drum via the
connecting tubes.

The steam-water mixture enters the top of the drum via risers from the waterwall outlet
headers and sweeps down along both sides of the drum through the narrow annulus formed
by baffles. These baffles extend the length of the drum, concentric with the drum shell. This
arrangement insures uniform heat transfer and maintains the entire drum shell at a constant
temperature.

At the lower end of the concentric baffles the steam is forced upward through the two rows
of turbo-separators. Each turbo-separator consists of a primary stage and a secondary stage.

The primary stage is formed by two concentric cans. Spinner blades in the inner can impart
centrifugal motion to the steam-water. The water, being denser, is forced to the outside
periphery of the can and is directed by a skim-off lip above the blades to the annulus between
the inner and outer can and thence to the bottom of the drum. The steam proceeds upward
into the secondary separator stage.

The secondary stage consists of two opposed banks of closely spaced thin corrugated plates
which direct the steam on a tortuous path. As the velocity is relatively low, this water is not
picked up again but drips off the lips of the plates.

From the secondary separators the steam flows upward to the final separators. This stage
consists of four rows of corrugated plate dryers extending the length of the drum with a drain
through between them. As in the secondary separator, the low velocity passage of the steam
along the tortuous path presented by the corrugations separate the water from the steam. The
water runs down into the trough and down through drains to the drum bottom. The drain
lines are necessary to prevent rewetting the steam from the secondary separators.

In addition to its functions of steam separation the drum serves as water reservoir for steam
generations sections of the boiler. The boiler feed water is admitted into the bottom of the
drum from the economizer via three economizer outlet links. Suction for the circulating
pumps is by six downcomers to the circulating pump suction manifold. Maintenance of
proper water level is imperative to prevent carryover from a high level and tube failure due
to overheating with subsequent loss of circulation in the waterwall tubes.

The concentration of dissolved impurities in the boiler is limited by means of a continuous

blowdown from the drum. The frequency and rate of blowdown depends upon operating
conditions, such as character of water and nature of feedwater treatment.

2.2.4 BOILER CIRCULATING PUMPS

Three boiler circulating pumps provide controlled circulation of the boiler water through the
waterwall system. The pumps are suspended from a common suction manifold , from which

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 3

they take their suction. The suction manifold is supplied from six downcomers from steam
drum. Each pump has two discharge lines, which discharge into lower front water wall
drum.

The boiler is designed to permit full load operation with only two of the three boiler
circulating pumps in service. The boiler may be operated with three pumps in service for
increased operating flexibility.

With only one boiler circulating pump in service, boiler load must be immediately reduced to
60% design capacity. Continuous operation at 60% design capacity is permitted with one
boiler circulating pump in service.

Operation with all boiler circulating pumps out of service is not permitted and is prevented
by a fuel trip interlock with the boiler circulating pump differential pressure measuring
instruments.

For start-up, it is recommended that at least two boiler circulating pumps be in service. Two
pumps in service reduces the probability of boiler trip due to loss of a pump during start-up.
Two pumps also provide the design circulation in the economizer recirculation system.

Two boiler circulating pumps must be in operation at all loads to avoid the possibility of a
load run back in the event of the loss of one of the two pumps. The third pump may be place
in service after unit synchronization; however, it should not be started during a rapid boiler
temperature change.

Each boiler circulating pumps consists of a single stage pump and a submerged, or wet, stator
induction motor mounted in a common pressure vessel. The vessel is made up of three main
parts: the pump casing, the motor housing and the motor cover.

The pump consists of a single suction, dual discharge casing. A key driven, fully shrouded,
mixed flow type impeller, mounted on the end of the extended motor shaft, rotates within the
pump casing cavity.

The motor is suspended below the pump casing and is filled with boiler water to full system
pressure. No seal exists between the pump and motor, but provision is made to thermally
isolate the pump from the motor by:

1. Thermal Conduction

Because the pump temperature is so high, usually above 340 C (650 F), and the
motor temperature is limited to about 54 C (130 C), a simple restriction in the form
of a "neck" is provided to minimize heat conduction.

2. Hot Water Diffusion

To minimize diffusion of boiler water, a narrow annulus surrounds the rotor shaft
between the hot and cold regions. A baffle wear ring restricts solids entering the
annulus.

3. Motor Cooling

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 4

 The cavity is maintained at a low temperature by the pump cooler, which is a heat
exchanger in a closed loop water circulation system, thus extracting the heat
conducted from the pump.

In addition, the water circulates through the stator and bearings extracting the heat
generated in the windings and also provides bearing lubrication. An internal filter is
incorporated in the circulating system.

In emergency conditions, if low pressure coolant to the pump cooler fails or is

inadequate to cope with heat flow from the pump case, a cold purge can be applied to
the bottom of the motor to limit temperature rise.

2.2.5 WATER COOLED FURNACE

The Boiler Circulating Pumps discharge into the furnace front drum. Furnace lower right
and left side drums assure proper distribution of the water to the furnace lower drum. In the
furnace lower front, side and rear drums, the boiler water passes through strainers and then
through orifices that feed the furnace wall tubes and the economizer recirculating line. The
strainers consist of a number of panels with 4.76 mm (3/16 in.) perforations. These
perforated panels, made in sections to facilitate removal and replacement, are secured in the
inlet drums with mounting studs. Each orifice is installed on an orifice mount adapter which
is tack welded to the drum interior wall.

From the furnace lower front, rear and side drums, the water rises through furnace waterwall
tubes where it absorbs heat. The front wall tubes, rear wall tubes, rear wall hanger tubes,
rear arch tubes, furnace screen tubes, furnace extended side wall tubes, and furnace side wall
tubes form parallel flow paths.

The resulting mixture of water and steam collects in the waterwall outlet headers and is
discharged into the steam drum through riser tubes.

2.2.6 SUPERHEATER
The superheater is intended to elevate the temperature of the dry saturated steam from the
drum to 540 C (1005 F). The steam is superheated to increase turbine cycle efficiency.

The superheater is composed of five basic stages or sections; namely the superheater (SH)
vertical platen, or finishing section, the SH division panel section, the low temperature
superheater (LTSH) pendant section, the LTSH horizontal section, and the back pass wall
and roof section.

The SH vertical platen section is located directly above the furnace in front of the furnace
arch. It is composed of 29 (53.975 mm O.D. tube) assemblies across the width of the
furnace.

The SH division panel section is located directly above the furnace between the front wall
and the SH vertical platen section. It consists of six front and six rear division panel (50.8
mm O.D. tube) assemblies across the furnace width.

The LTSH pendant section is located in the furnace rear back pass directly behind the back
pass front wall screen tubes and above the LTSH horizontal section. It is composed of 76
(57.15 mm O.D. tube) assemblies across the back pass width.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 5

The LTSH horizontal section is located above the economizer in the furnace back pass. It
consists of 151 (50.8 mm O.D. tube) LTSH horizontal lower assemblies and 151 (50.8 mm
O.D. tube) LTSH horizontal upper assemblies across the back pass width.

The back pass wall and roof section forms the back pass side wall tubes at front, back pass
side wall tubes at rear, back pass front wall tubes, back pass front wall screen tubes, back
pass roof tubes, back pass rear wall tubes and the back pass lower rear wall tubes of the
vertical gas pass. The back pass at furnace front roof and rear tubes form the roof above the
furnace and arch.

From the steam drum, the main steam flow is through the superheater connecting tubes to the
backpass at roof inlet header. From the backpass roof inlet header, the steam flows through
the various backpass roof and backpass wall tubes to the LTSH horizontal inlet header.
From the LTSH horizontal inlet header, the steam flows through the LTSH lower, upper and
pendant assemblies to the LTSH outlet header. From the LTSH outlet header, the steam
flows to No. 1 SH desuperheaters, then to the SH division inlet headers. These headers
supply steam through the SH division panels to the SH division panel outlet headers. From
the SH division outlet headers, the steam is carried through the No. 2 SH desuperheaters to
the SH vertical platen inlet header. This header supplies steam through the SH vertical
platen assemblies to the SH vertical platen outlet headers and the SH outlet leads.

Superheated steam from the SH vertical platen outlet header goes to the high pressure stages
of the turbine via the main steam lines.

After passing through the high pressure stages of the turbine, steam is returned to the reheater
via the cold reheat lines.

The two spray-type SH desuperheaters (No. 1) are installed in the connecting links between
the LTSH outlet header and the SH division inlet headers, and two additional spray type
desuperheaters (No. 2) are installed in the connecting links between the SH division outlet
headers and the SH vertical platen inlet header to permit reduction of steam temperature,
when necessary, and to maintain the temperatures at design values, within the limits of the
nozzle capacity. Temperature reduction is accomplished by spraying water into the path of
the steam through a nozzle at the inlet end of the desuperheater.

The locations of the desuperheaters, between the LTSH pendant sections and the SH division
panel section and between the SH division panel section and the SH pendant platen section,
help to ensure that water carry-over to the turbine does not occur. It also eliminates the
necessity for high temperature resisting material in the desuperheater construction.

A control valve linked to an automatic control drive regulates the flow of spray water
supplied to each SH desuperheater. A manually operated isolation valve is located
downstream of each control valve to permit isolation when required. The isolating valve
should only be used in an emergency, or when the automatic control valves may require
maintenance. Blowoff valve downstream of the control valve are used to relieve system
pressure and drain the control valve piping for maintenance.

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2.2.7 REHEATER
The reheater is designed, for purpose of thermal efficiency, to accept the exhaust steam from
the high pressure stages of the turbine and reheat it to 540 C (1005 F) for admission to the
intermediate pressure stages.

The reheater is composed of four stages, or sections; namely, the reheater (RH) vertical
platen (finishing) front section, the RH vertical rear section, the RH radiant wall front section
and the RH radiant wall side section.

After passing through the high pressure stages of the turbine, steam is returned to the reheater
via the cold reheat lines. The reheater desuperheaters are located in the cold reheat lines.

Steam enters the reheater through the RH radiant wall inlet headers. The steam then flows
through RH radiant wall tubes to the RH radiant wall outlet headers. From the RH radiant
wall outlet headers , the steam is carried by the RH vertical rear inlet links to the RH vertical
rear assemblies, the RH vertical platen front assemblies to the RH vertical front outlet
headers and RH outlet leads.

The reheated steam, now at 540 C, is returned to the intermediate pressure section of the
turbine via the hot reheat lines.

2.3 BOILER AIR AND GAS SIDE

Air flow through the unit is handled by the two forced draft (FD) fans, two induced draft
(ID) fans, and two primary air (PA) fans. Four booster fans (Two Scanner Air Fans and Two
Seal Air Booster Air Fans) assure that air pressures are adequate to overcome resistance in
their respective systems. The air is utilized for:

1. Combustion - Secondary Air and Overfire Air.

2. Cooling - Flame Scanners (Two Booster Fans)

3. Conveying and Drying of Pulverized Coal - Primary Air.

4. Sealing - Pulverizers (Two Booster Fans)

5. Sealing - Feeders and Coal Pipes

Major components for the boiler air side and flue gas systems are:

Forced Draft (FD) Fan

Primary Air (PA) Fans
Lungstrom Air Preheaters
Induced Air (ID) Fans
Electrostatic Precipitator (ESP)
The secondary air for combustion is preheated by means of two Lungstrom bisector air
heaters, one for each set of FD and ID fans. The air heater air inlet and outlet ducts are
interconnected to provide a balanced airflow to the furnace and to make it possible to operate
the unit at reduced rating with only one set of fans and one secondary air heater in service.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 7

 Fuel air, which is a part of secondary air, is admitted to the furnace through air annulus
around the fuel nozzles. Auxiliary air which is the balance of the secondary air, is injected
into the furnace through the air nozzles located in separate compartments above, below, and
between fuel elevations.

Overfire air can be admitted to the furnace through the two upper levels of furnace main
windboxes can be admitted to the furnace through the two upper levels of furnace main
windbox nozzles and through four levels of Separated Overfire Air (SOFA) register nozzles
to assist in reducing the amount of NOx formed in the furnace.

Control of unit air flow is obtained by positioning the FD and ID fan blade pitch, while the
distribution of secondary air the windbox compartments is controlled by secondary air
dampers. These are positioned by a subloop control system associated with the furnace
safeguard supervisory system.

Flame scanner cooling air is supplied from the cold secondary air crossover duct. Either of
two booster fans serving the flame scanner air manifold can be used to boost the air pressure
automatically if cooling air pressure fails below a minimum set point. A filter upstream of
the fans helps to assure clean air for cooling. An alarm system will indicate when a filter
requires service.

A scanner fan should be in service whenever a fire is in the furnace and should be kept in
service until the unit is shut down and the flame scanners are cooled to their acceptable high
temperature limit.

The air used to convey and dry the pulverized coal is referred to as primary air. Two
primary air (PA) fans supply the air to the pulverizer primary air system. To assure proper
drying in the pulverizers, both hot and cold air must be available; therefore, a portion of the
air from the PA fans passes through the primary bisector air preheater. The PA fan inlet
vanes are controlled to maintain a predetermined pressure in the pulverizer primary air ducts.

The flow of air from the hot and cold air ducts is controlled by the hot and cold air control
dampers at each pulverizer to deliver the necessary total primary air flow requirement for the
pulverizer and also to maintain a predetermined outlet temperature.

If a PA fan is not available for service and the other fan is operating, it must be isolated from
the system by closing its outlet shutoff dampers (furnished with the fans). The number of
pulverizers in service is then limited.

Seal air for the pulverizer bowl hub, journal bearings, and journal spring assemblies is taken
from the cold air duct to the pulverizers. Either of the two seal air booster fans in the supply
duct can be used to ensure a flow of air into the pulverizer openings under all normal
operating conditions. Shutoff valves in the seal air duct at each pulverizer can be closed
when the pulverizer is out of service for maintenance.

The heat from the flue gas is transferred to the primary and secondary air going to the boilers
in the air preheaters. After the preheaters, the flue gas goes to the electrostatic precipitators
where the flyash is removed. It then goes to the ID fans, the seawater scrubber and to the
stack.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 8

2.4 BOILER FUEL SYSTEM
2.4.1 GENERAL
The boiler fuel systems provide the hardware to condition, deliver, ignite, monitor and
control the fuel flow to the furnace. The actual functions of this equipment are controlled by
the burner controls and combustion control systems. The systems principle equipment is the
mill pulverizers and the tangential firing system that admits the pulverized coal, the oil
together with the air for combustion in the furnace.

The furnace is fired tangentially from all four corners by six elevations of coal nozzles and
three elevations of retractable air atomizing light oil guns. Ignition energy for these burners
is provided by automatic High Energy Arc (HEA) light oil igniters.

Combustion air is admitted to the furnace as primary air through the coal mills with the
pulverized coal, or as secondary air. The air and fuel streams into the furnace are vertically
adjustable by means of the movable nozzle tips in each windbox compartment. The auxiliary
air and oil gun compartment nozzle tips can be tilted upward or downward through a total
angle of sixty degrees (thirty degrees up, thirty degrees down). The coal nozzle tips in the
coal compartments can be tilted upward or downward through a total angle of forty degrees
(twenty degrees up, twenty degrees down). The movement of the nozzle tips is proportional.
At the horizontal position, all nozzles are at zero degrees. The drive units for the nozzles may
be positioned manually, but normally responds automatically to signals from the steam
temperature control system. The burner tilt drives at each corner operate in unison so the
nozzle tips at the same windbox levels have identical tilt positions.

Each elevation of coal nozzles is supplied by a mill pulverizer. These mills accept coal from
a coal feeder situated directly above it and using hot air from the Primary Air fans, dry the
coal, pulverize it to a fine dust and then propel it via the coal piping to the burner nozzles.

Gravimetric feeders deliver a controlled quantity flow of coal from the coal hoppers above
them via an endless belt to the pulverizers below.

The air atomized, retractable oil guns use light oil (No. 2), to provide sufficient energy to
heat up the boiler at a reasonable rate, light off the coal nozzles, for steam generation up to
approximately thirty percent of rated boiler load, and for limited overfiring of the boiler.

2.4.2 PULVERIZED COAL SYSTEM

A system for the direct firing of pulverized coal is provided on these units, utilizing six bowl
mills to pulverize the coal and tilting tangential burners located at the corners of the furnace
to admit coal and air required for combustion into the furnace.

As coal is fed to each mill, at a rate varied to suit the steam load, hot air is blown through the
mill by the Primary Air Fans. The hot air dries the coal as it is being pulverized and
transports it from the grinding bowl, through the classifiers, and coal piping system to the
burner.

The fuel and air discharged from the burners is directed to the center of the furnace at a
tangent to an imaginary circle. The primary air that conveys the coal has been partially
preheated to a temperature of around 76oC. The total primary air requirement may vary from
fifteen to twenty-five percent of the total air.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 9

The bowl mill consists essentially of a grinding chamber with a classifier mounted above it.
The mill takes it's name from the rotating bowl by means of which centrifugal force is
utilized to move the coal, delivered by the feeder, outward against the grinding ring. Here
rollers revolving on journals attached to the mill housing, pulverize the coal sufficiently to
enable the air stream to pick it up. Heavy springs, acting on the journals, provide the
necessary pressure between the grinding surfaces. A bottom strip is provided to prevent the
rollers from contacting the bull ring even if the mill is empty. Tramp iron and other non-
grindable materials fall down through the air inlets to the grinding area and is swept into the
tramp iron spout by pivoting sweeps.

For satisfactory mill performance, the temperature of the primary air-coal mixture leaving
the mill classifier should be kept at approximately 76oC. Temperatures too high may lead to
mill fires and temperatures too low may not dry the coal sufficiently. The amount of heat
necessary to maintain this temperature will depend largely upon the amount of drying to be
done. In any case, the mill outlet-temperature should not exceed 93oC. These temperatures
are controlled by varying the relative amounts of hot air from the preheaters and ambient air
by means of dampers.

A hot air blast gate is provided to shut off the hot air to each pulverizer and is interlocked
with the mill motor such that it cannot be opened until the mill is running.

The classifier accepts the coal-air mixture from the pulverizer bowl and delivers it to the
burners.

Orifice plates are installed in the coal piping leaving the classifier to compensate for unequal
resistance due to unequal lengths of piping to the burners.

Each mill supplies a single elevation of burners. By distributing the fuel in this fashion, a
balanced fire is maintained regardless of which mills are in or out of service.

2.4.3 FEEDERS
Six gravimetric coal feeders are provided to continuously deliver coal to the pulverizers
according to the demand controlled by the combustion controls. The feeders are located
directly above the associated coal mills on the feeder floor (platform 22800).

Solid state load cells continuously weigh a span of the feeder belt. The speed of the belt is
also monitored. These two inputs to the feeder controller are used to determine the mass
flow rate into the pulverizer. The feeder controller compares the calculated mass flow rate
with inputted demand from DCS and adjusts the speed of the feeder drive.

2.4.4 COAL PIPE SLIDE GATE VALVES

Coal pipe slide gates valves are provided in the coal pipe to the windbox coal nozzles to
prevent furnace gasses from traveling back into the pulverizer when it is open for inspection
or maintenance with the boiler is in operation.

The slide gates are usually located near the wind boxes, between the inlet elbows and the coal
nozzles. However, if this is not possible, they should be located as close to the windboxes as
possible.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 10

The coal pipe slide gate valves are provided with air cylinders to move the gates. They
require manual operation and are normally left open. The valves are to be closed only for the
time the associated pulverizer(s) is open for inspection or maintenance. The valves have limit
switches for position indication and should be either fully open or fully closed.

There is a slide type manually operated coal gate above the feeder to isolate it from the coal
hopper above.

2.5 BOTTOM ASH SYSTEM

The Bottom Ash (BA) System serves to seal the open boiler bottom, remove bottom ash,
remove pulverizer pyrites, and convey bottom ash and pyrites to ash loadout silo. From
bottom ash silo, the bottom ash is transported to the ash landfill by Ash Disposal (AD)
System.

The BA system major components are as follows:

Submerged Chain Conveyor (SCC)

Bottom Ash Transfer Conveyors

Ash Loadout Silo

Pyrites Hoppers / Jet Pumps

The submerged conveyor is a water filled drag chain conveyor. Water serves to seal the
bottom of the boiler and cool the bottom ash. The ash is transported out of the water filled
conveyor trough by the drag chain up an incline. The incline serves to dewater the ash
before it is dumped into a screw conveyor. The larger pieces of bottom ash are directed
through a crusher before entering the screw conveyor. The bottom ash is then transferred by
a series of belt conveyors to the ash loadout silo.

The pyrites hoppers serve to collect pulverizer rejects. A jet pump is located at the bottom of
each pyrites hopper. Service Water is used as the jet pump motive fluid to transport pyrites
to the submerged chain conveyor. The pyrites are then transported to the ash loadout silo
along with the bottom ash.

3.0 SYSTEM OPERATION

3.1 SYSTEM LIMITS AND PRECAUTIONS
When motor-operated valves are closed to isolate equipment for maintenance, the valve
breakers should be opened and tagged to prevent inadvertent operation from the DCS.
Although all motor-operated valves can be stopped in mid travel, this feature should not be
used to throttle gate valves as damage may result.
The temperature of the primary air/coal mixture leaving the pulverizer should be maintained
within the pulverizer supplier's recommended limits. Temperatures too high may lead to
pulverizer fires and temperatures too low may not dry the coal sufficiently.
The ID fans should be started before the FD fans to avoid pressurizing the wind boxes and
furnace and to assure a free flow of air through the system.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 11

3.2 STARTUP
The various boiler systems are an integral part of the entire steam generator and must be
started accordance with ABB CE vendor requirements.

3.3 NORMAL OPERATION

During normal operation and unit at design load following equipment is in operation

1. Three boiler circulating water pump

2. Two forced draft fans

3. Two induced draft fans

4. Two secondary air heaters

5. One primary air heater

6. One seal air fan

7. One scanner air fan

8. Five pulverizers (when burning design coal)

9. Five coal feeders

10. Two electrostatic precipitators

11. Two scrubber vessels

12. Bottom Ash System

Unit load changes may alter pulverizer loading rate and the number of pulverizers in service.
A wide range of load control can be achieved with the pulverizers on automatic. Also,
pulverizers are placed into and removed from service as unit load varies.

3.4 ABNORMAL CONDITIONS

Refer to vendor manual for operation limits and precautions for operation under abnormal
conditions.

4.0 SYSTEM CONTROLS

4.1 BOILER PRESSURE SIDE
4.1.1 BOILER VENTS (BS-MOV-104A, 104B, 146A, 146B, 200B, 201B, 205, 210,
230A, 230B, 240, 250A, 250B, 290A, 290B, 300 )
Each boiler vent valve can be jogged opened or closed from the DCS operator's station. The
motor operated vent valves are normally opened as the boiler is first fired to vent non-
condensable gasses.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 12

4.1.2 SUPERHEATER / SECONDARY SUPERHEATER
4.1.2.1 BACKPASS HEADER DRAIN VALVES (BS-MOV-220, 221, 222, 223, & 224)
Each backpass drain can each be opened and closed from the DCS operator station. The
backpass drains are opened before lighting off the unit and must be closed immediately after
synchronization to prevent possible overheating of the superheater elements. These motor
operated valves should be either fully opened or fully closed.

4.1.2.2 POWER-ACTUATED RELIEF VALVES (BS-ERV-106 A & B)

Each PARV can be either operated automatically or manually positioned fully opened or
closed from the DCS operator station. When in automatic mode, a PARV will open on high
pressure and close on reset. The PARVs fail closed.

4.1.3 SOOTBLOWERS
4.1.3.1 SOOT BLOWER HEADER ISOLATION VALVES (BS-MOV-400, 520, &700)
Each of the three soot blower headers is equipped with a motor operated block valve that can
be opened or closed from the DCS operator's station.

4.1.3.1 SOOTBLOWER STEAM SUPPLY CONTROL VALVES (BS-PV- 400, 520, &
700)
Each sootblower steam supply valve is automatically controlled by the DCS to maintain soot
blower header pressure. Each valve can also be manually positioned from the DCS operator's
station.

4.1.3.2 SOOT BLOWER HEADER THERMAL DRAINS (BS-DRV-460, 510, 565, 600,
640, 680, &720)
The soot blower header thermal (i.e. low point) drains are automatically opened during
header warmup or in the event of high drainpot liquid level. Each thermal drain can also be
manually opened or closed from the DCS operator's station.

4.1.3.3 SERVICE AIR SUPPLY ISOLATION VALVE (BS-MOV-715)

The service air supply isolation valve is controlled from the DCS. This valve is opened on
plant startup until Auxiliary Steam is available for Air Heater Soot Blowing.

4.1.4 PULVERIZER INERTING STEAM SYSTEM

The pulverizer inerting valves are automatically positioned by the Boiler Burner
Management System (BMS) to maintain proper flowrate to the pulverizers for clearing and
inerting.

4.1.5 PIPING DRAIN POTS

4.1.5.1 AUTOMATIC DRAIN VALVES
The drain valves can be automatically or manually opened/closed from the DCS operator's
station.

4.1.5.2 REMOTE MANUAL DRAIN VALVES

Remote manual drain valves are manually opened or closed from the DCS operator's station.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 13

4.1.6 FINAL FEEDWATER
4.1.6.1 STEAM DRUM LEVEL CONTROL
Steam drum level is maintained through BFP speed control (turbine steam flow for turbine-
driven feed pumps - fluid coupling for the motor-driven feed pump). The control signal is
based upon feedwater flow, main steam flow, and boiler drum level.

4.1.6.2 BOILER CIRCULATING PUMPS (FW-P-300A, 300B, & 300C)

Each BCP is manually started and stopped from the DCS operator's station

4.1.6.3 BOILER DESUPERHEATER SPRAY BLOCK VALVES (FW-FV-324, 337A, &

337B)
Each boiler superheater or reheater spray block valves is automatically operated by the DCS
to automatically open just after its associated spray water control valve. Similarly, each spray
block valve will automatically close just before the closure of its associated spray valve. The
spray block valves can also be manually opened and closed from the DCS operator's station.

4.1.6.4 BOILER SUPERHEATER SPRAY CONTROL VALVES (FW-TV-325A, 325B,

338A, 338B, 338C, & 338D)
The spray water control valves automatically adjust flow rate to maintain proper superheater
and reheater outlet temperature. The spray water control valves can also be manually
positioned from the DCS operator's station.

4.1.6.5 ECONOMIZER RECIRCULATION VALVE (FW-MOV-114)

Economizer recirculation valve is manually opened or closed from the DCS. Position
switches provide indication in DCS of valve position.

4.2 BOILER AIR AND GAS SIDE

4.2.1 FORCED DRAFT (FD) FANS
Each FD fan is manually started and stopped from the DCS operator’s station. Air flow is
controlled from DCS by varying the pitch of the axial FD fan blades. Blade positioning and
blade sticking detector signals are sent to the DCS.

4.2.2 FORCED DRAFT FAN OUTLET DAMPERS

An OPEN/CLOSE station at the DCS for each FD Fan Outlet damper that allows the
operator to open or close the dampers to isolate the fans as needed. Position switches indicate
at the DCS if the dampers are opened or closed.

4.2.3 INDUCED DRAFT (ID) FANS

Each ID fan is manually started and stopped from the DCS operator’s station. Air flow is
controlled from DCS by varying the pitch of the axial FD fan blades. Blade positioning and
blade sticking detector signals are sent to the DCS.

4.2.4 INDUCED DRAFT FAN INLET DAMPER

An OPEN/CLOSE station at the DCS for each ID Fan Inlet damper that allows the operator
to open or close the dampers to isolate the fans as needed. Position switches indicate at the
DCS if the dampers are opened or closed.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 14

4.2.5 ID FAN SEAL AIR FANS
The two constant speed Seal Air Fans for each ID Fan are started and stopped from the DCS.

4.2.6 SECONDARY AIR HEATERS

Each Secondary Air Heater motor drive is manually started and stopped from the DCS
operator’s station. An air motor drive automatically starts and engages the air heater upon
failure of motor drive.

4.2.7 SECONDARY AIR HEATER LEAKAGE CONTROL SECTOR DRIVES

The secondary air heaters are equipped with automatically actuated hot end sector plates to
reduce hot end leakage. Each of the two sector plates for each air heater is automatically
positioned by a micro-processor controllers. A local control panel is also provided for each
sector plate to manually extend and retract the sector plate.

4.2.8 ELECTROSTATIC PERCIPITATORS (ESP)

The ESP is started and stopped automatically via inputs from the DCS, the Burner
Management System PLC, and the dust content signal from the opacity monitor at the ESP
outlet. It can also be operated locally by operating switches on the ESP Total Control Panel
in the Precipitator Control Building. Level switches on the ESP hoppers provide signals to
the fly ash system.

4.3 BOILER FUEL SYSTEM

4.3.1 PRIMARY AIR (PA) FANS
Each PA fan is manually started and stopped from the DCS operator’s station. Inlet guide
vanes controlled from DCS control air flow.

4.3.2 PRIMARY AIR FAN OUTLET DAMPER

There is an OPEN/CLOSE station at the DCS for each Primary Air Fan Outlet damper that
allows the operator to open or close the dampers to isolate the fans as needed. Position
switches indicate at the DCS if the dampers are opened or closed.

4.3.3 PULVERIZERS
The six pulverizers can be started and stopped manually or automatically through the Burner
Management Systems PLC as needed by the operator.

4.3.4 COAL FEEDERS

Each pulverizer has a Coal Feeder that measures and controls the amount of coal delivered to
the pulverizer. The coal feeder PLC receives inputs of conveyor speed, weight of the coal on
the conveyor and from the DCS, the unit demand. It produces an output to an eddy current
clutch that connects a constant speed motor to the conveyor. This allows the speed of the
conveyor and amount of coal delivered to the pulverizer to vary as needed.

4.3.5 PULVERIZER SEAL AIR BOOSTER FANS

The two constant speed Seal Air Fans are started and stopped from the DCS.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 15

4.3.6 WARMUP BURNERS AND IGNITERS
The warmup burners and igniters are controlled from the Burner Management System’s
PLC.

4.3.7 PRIMARY AIR HEATER

The Primary Air Heater motor drive is manually started and stopped from the DCS
operator’s station. An air motor drive automatically starts and engages the air heater upon
failure of motor drive.

4.3.8 PRIMARY AIR HEATER LEAKAGE CONTROL SECTOR DRIVES

Primary air heater is equipped with automatically actuated hot end sector plates to reduce hot
end leakage. Each of the two sector plates is automatically positioned by a micro-processor
controller. A local control panel is also provided for each sector plate to manually extend
and retract the sector plate.

4.4 BOTTOM ASH SYSTEM

4.4.1 SUBMERGED CHAIN CONVEYOR HYDRAULIC PUMP
The submerged chain conveyor hydraulic pump is controlled from the bottom ash system
PLC. The operator can select remote manual, remote automatic or local manual at the
bottom ash PLC cabinet. In local manual, the hydraulic pump can be controlled from a local
control panel. In remote manual, operator can manually control the pump from PLC cabinet.
In remote automatic, the bottom ash PLC controls operation of the pump.

4.4.2 ASH CRUSHER HYDRAULIC PUMP

The ash crusher hydraulic pump is controlled from the bottom ash system PLC. The operator
can select remote manual, remote automatic or local manual at the bottom ash PLC cabinet.
In local manual, the hydraulic pump can be controlled from a local control panel. In remote
manual, operator can manually control the pump from PLC cabinet. In remote automatic, the
bottom ash PLC controls operation of the pump.

4.4.3 SUBMERGED CHAIN CONVEYOR HYDRAULIC DRIVE

The submerged chain conveyor hydraulic drive is controlled from the bottom ash system
PLC. The operator can select remote manual, remote automatic or local manual at the
bottom ash PLC cabinet. In local manual, the hydraulic drive can be controlled from a local
control panel. In remote manual, operator can manually control the hydraulic drive from
PLC cabinet. In remote automatic, the bottom ash PLC controls operation of the hydraulic
drive.

4.4.4 ASH CRUSHER HYDRAULIC DRIVE

The ash crusher hydraulic drive is controlled from the bottom ash system PLC. The operator
can select remote manual, remote automatic or local manual at the bottom ash PLC cabinet.
In local manual, the hydraulic drive can be controlled from a local control panel. In remote
manual, operator can manually control the hydraulic drive from PLC cabinet. In remote
automatic, the bottom ash PLC controls operation of the hydraulic drive.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 16

4.4.5 SCREW FEED CONVEYOR
The screw feed conveyor is controlled from the bottom ash system PLC. The operator can
select remote manual, remote automatic or local manual at the bottom ash PLC cabinet. In
local manual, the screw feed conveyor can be controlled from a local control panel. In
remote manual, operator can manually control the screw feed conveyor from PLC cabinet.
In remote automatic, the bottom ash PLC controls operation of the screw feed conveyor.

4.4.6 CONVEYORS
Each conveyor is controlled from the bottom ash system PLC. The operator can select
remote manual, remote automatic or local manual at the bottom ash PLC cabinet. In local
manual, a conveyor can be controlled from a local control panel. In remote manual, operator
can manually control a conveyor from PLC cabinet. In remote automatic, the bottom ash
PLC controls operation of each conveyor.

4.4.7 ASH LOADOUT SILO CONVEYOR

The ash loadout silo conveyor is controlled from the bottom ash system PLC. The operator
can select remote manual, remote automatic or local manual at the bottom ash PLC cabinet.
In local manual, the ash loadout silo conveyor can be controlled from a local control panel.
In remote manual, operator can manually control the ash loadout silo conveyor from PLC
cabinet. In remote automatic, the bottom ash PLC controls operation of the ash loadout silo
conveyor.

4.4.8 PYRITES SYSTEM

The bottom ash system PLC controls operation of pyrites hopper inlet valve, pyrites hopper
outlet valve, jet pump inlet valve and hopper flushing valve in sequence to remove pyrites
from the pyrites hopper. The operator can select remote manual, remote automatic or local
manual at the bottom ash PLC cabinet. In local manual, the pyrites removal system can be
controlled from a local control panel. In remote manual, operator can manually control the
pyrites removal system from PLC cabinet. In remote automatic, the bottom ash PLC controls
operation of the pyrites removal system.

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 17

5.0 SYSTEM COMPONENT DESIGN PARAMETERS
5.1 ECONOMIZER
GENERAL:
Equipment No.: FW-ECON-100
P&ID No. P101-51-700-FW-0004
TCD No.: P101-15-1701.00-0101
Efficient Heat Transfer Surface: 17,833 M2 (191,953 ft2 )

PERFORMANCE DATA
Gas Inlet Temp: 611° C (1132° F)
Gas Outlet Temp: 344° C (652° F)
Water Outlet Temp: 369° C (696° F)

5.2 STEAM DRUM

GENERAL:
Equipment No.: BS-DRUM-200
P&ID No. P101-51-700-BS-0001
TCD No.: P101-15-1701.00-0101
Design Pressure: 20,615 kPa (2990 psig)
Size: 1.78M ID X 30 M Long
Steam Purifier Type: Centrifugal Separators with Plate Dryers
Steam Purifier Quantity: 126

5.3 BOILER CIRCULATING PUMPS

GENERAL:
Equipment No.: FW-P-300A/B/C
P&ID No. P101-51-700-FW-0004
TCD No.: P101-15-1701.00-0101
Manufacturer: Hayward-Tyler
Type: Single Stage Centrifugal

PERFORMANCE DATA
Capacity (MCR): 620 kg/s (20,564 US gpm)
Shaft Power: 255 kW

File No. P101-11-1723.06, 07 & 95-0001 Rev. 0 Page 18

5.4 SUPERHEATER
GENERAL:
Equipment No.: BS-SH-220, -240, -260
P&ID No. P101-51-700-BS-0001
TCD No.: P101-15-1701.00-0101
Type: Vertical Radiant Panel and Platen with
Convective Horizontal
Design Pressure: 20,615 kPa ( 2990 psig)
Note: Tube material and diameter varies
depending on location. See ABB-CE
drawings 00494-1D1253 and 00494-1E1229
in Design and Operation Manual, Volume 2,
Part 2 (P101-25-1701.00-001700).

PERFORMANCE DATA
Primary SH Temp (MCR): 546° C (1015° F)
Intermediate SH Temp (MCR): 482° C (900° F)
Secondary SH Temp (MCR): 442° C (827° F)

5.5 REHEATER
GENERAL:
Equipment No.: BS-RHTR-300, -310
P&ID No. P101-51-700-BS-0002
TCD No.: P101-15-1701.00-0101
Type: Vertical Radiant and Convection
Design Pressure: 4861 kPa (705 psig)
Note: Tube material and diameter varies
depending on location. See ABB-CE
drawing 00494-1E1230 in Design and
Operation Manual, Volume 2, Part 2 (P101-
25-1701.00-001700).

File No. P101-11-1723.00-0001 Rev. 0 Page 19

5.6 FORCED DRAFT (FD) FANS
GENERAL:
Equipment No.: BG-FAN-510A/B
P&ID No.: P101-51-700-BG-0001
TCD No.: P101-15-1701.00-0101
Manufacturer: Howden Fan Co.
Type: Axial
P&ID No: P101-51-700-BG SERIES

PERFORMANCE DATA:
Fan Speed: 990 RPM
Test Block Power at Shaft: 1341 kW
Test Block Volume Flow: 312.48 m3/sec
Test Block Inlet Temperature 37° C
Test Block Inlet Density: 1.16 kg/m3
Test Block Outlet Static Pressure: 307.8 mm Wg
Test Block Mass Flow: 1,269,328 kg/hr

MOTOR:
Manufacturer: Westinghouse
Speed: 1000 rpm
Rated Power: 1343 kW
Voltage: 6600 Volt

5.7 PRIMARY AIR FANS

GENERAL:
Equipment No.: 7BF-FAN-600A/B
P&ID No.: P101-51-700-BF-0002
TCD No.: P101-15-1701.00-0101
Manufacturer: Howden Fan Co.
Type: Centrifugal
P&ID No: P101-51-700-BF SERIES

PERFORMANCE DATA:
Fan Speed: 1482
Test Block Power at Shaft: 1659 Kw
Test Block Volume Flow: 133.34 m3/sec
Test Block Inlet Temperature: 37° C
Test Block Inlet Density: 1.12 kg/m3
Test Block Outlet Static Pressure: 1076.6 mm Wg
Test Block Mass Flow: 541,651 kg/hr

MOTOR
Manufacturer: Westinghouse
Speed: 1500 rpm
Rated Power: 1660 kW
Voltage: 6600 Volt

File No. P101-11-1723.00-0001 Rev. 0 20

5.8 SECONDARY AIR PREHEATERS
GENERAL:
Equipment No.: BG-HTR-510A/B
P&ID No.: P101-51-700-BG-0001
TCD No.: P101-15-1701.00-0101
Manufacturer: ABB Air Preheater (Lungstrom)

EQUIPMENT DATA:
Type: Regenerative
Rotating Speed: .92 rpm

ELECTRIC MOTOR
Manufacturer: Reliance
Speed: 1500 rpm
Rated Power: 22.4 kW
Voltage: 380

5.9 PRIMARY AIR PREHEATER

GENERAL:
Equipment No.: BF-HTR-600
P&ID No.: P101-51-700-BF-0002
TCD No.: P101-15-1701.00-0101
Manufacturer: ABB Air Preheater (Lungstrom)
Quantity: One

EQUIPMENT DATA:
Type: Regenerative
Rotating Speed: 1.04

ELECTRIC MOTOR
Manufacturer: Reliance
Speed: 1500 rpm
Rated Power: 14.9 kW
Voltage: 380

File No. P101-11-1723.00-0001 Rev. 0 21

5.10 ELECTROSTATIC PERCIPITATORS
GENERAL:
Equipment No.: BG-PCP-800A/B
P&ID No.: P101-51-700-BG-0003
TCD No.: P101-15-1709.01-113
Manufacturer: MHI
Type: Mitsubishi Horizontal Dry ESP
P&ID No: P101-51-700-BG SERIES

EQUIPMENT DATA:
Design Pressure: + 889 mm Wg
Design Temperature – Normal: 152o C
Design Temperature – Emergency: 357o C with 30 min
Number of chambers: 2 / ESP
Number of Gas Packages: 74 /ESP
Total Effective Collecting Area: 34667 m2 / ESP
Specific Collecting Area Actual: 65.3m2 / m3 / sec
ESP Internal Gas Velocity: 1.2 m/s
Total Treatment Time: 12.7 sec
Hopper Storage Capacity: 90 hrs
Electric Power: 6900VAC, 3 phase, 50 Hz
125 VDC (Control source for incoming
switchgear)

5.11 INDUCED DRAFT (ID) FANS

GENERAL:
Equipment No.: BG-FAN-500A/B
P&ID No: P101-51-700-BG-0004
TCD No.: P101-15-1707.00-110
Manufacturer: MHI
Model No.: ML-H2-R200/364
Type: Axial

PERFORMANCE DATA:
Fan Speed: 740 RPMS
Test Block Volume Flow 717.6 m3/sec
Test Block Inlet Density 0.779 kg/m3
Fan Test Block Total Pressure 9.07 kPa

FAN MOTOR DATA:

Fan Motor Manufacturer: Toshiba
Speed: 740 RPM
Rated Power: 7458 kW
Voltage 13800 Volts

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5.12 ID FAN SEAL AIR FANS
GENERAL:
Equipment No.: BG-FAN-907A/B, -908A/B
P&ID No: P101-51-700-BG-0008
TCD No.: P101-15-1707.00-110
Manufacturer : MHI
Type: Centrifugal w/ Pneumatic control drives
Model: CTB-E-MDC/ #9H

PERFORMANCE DATA
Capacity: 1.17m3/sec
Total Static Pressure: 0.006 Mpa

5.13 PULVERIZERS
GENERAL:
Equipment No.: BF-PVR-500A/B/C/D/E/F
P&ID No.: P101-51-700-BF-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : ABB CE
Type: HP 1103
PERFORMANCE DATA
Capacity: 79,365 kg/hr (175,000 lb/hr)
Fineness @ Design Capacity: 70% by weight through 200 mesh screen

MOTOR
Motor Manufacturer: Westinghouse
Speed: 1500 rpm
Rated Power: 746 kW
Voltage 6600 Volt

5.14 PULVERIZER SEAL AIR BOOSTER FANS

GENERAL:
Equipment No.: BF-FAN-620A/B
P&ID No.: P101-51-700-BF-0003
TCD No.: P101-15-1701.00-0101
Manufacturer : Buffalo Forge
Type: HDL 805 L-25 Arrangement 8

PERFORMANCE DATA
Volumetric Flow Rate: 11.3 m3/sec
Inlet Pressure: 1327 Pa
Outlet Pressure: 8703 Pa
Speed: 1480 RPM @ 63.2 kW

File No. P101-11-1723.00-0001 Rev. 0 Page 23

5.15 WARMUP BURNERS AND IGNITERS
GENERAL:
Equipment No.: FO-IGN-800 Series, FO-IGN-900 Series
Quantity: 12
Manufacturer : ABB CE
P&ID No.: P101-51-700-FO-0001
TCD No.: P101-15-1701.00-0101
Type: Air Atomized Oil Burners, 12 HEA igniters
30% of MCR on Oil

PERFORMANCE DATA
Capacity (each burner) : #2 Oil, 680 kg/hr (1500 lb/hr)

5.16 BOTTOM ASH SYSTEM

5.16.1 BOTTOM ASH PYRITES HOPPER / JET PUMP
GENERAL:
Equipment No.: BA-TK-300A/ B/ C/ D/ E/ F
BA-P-300A/ B/ C/ D/ E/ F
P&ID No.: P101-51-700-BA-0002
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson

PHYSICAL DATA
Pyrites Hopper Material: Carbon Steel
Pyrites Hopper Storage Volume: 0.552 m3
Jet Pump Casing Material: Stainless Steel
Jet Pump Nozzle Material: Hardened Stainless Steel and Ni Hard
combining tube

PERFORMANCE DATA
Water Supply Connection: 4”
Required Water Pressure: 900 kPa(g)
Required Water Flow: 108 m3/hr

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5.16.2 SUBMERGED CHAIN CONVEYOR
GENERAL:
Equipment No.: BA-CNVR-100
P&ID No.: P101-51-700-BA-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson

PHYSICAL DATA
Trough Material: 10 mm Carbon Steel Plate
Upper Trough Bottom Material: Replaceable liners made 25 mm abrasion-
resistant steel plate (minimum hardness of
400 BHN).
Lower Trough and Dewatering Trough 30 & 40 mm Basalt Tiles
Bottom Material:
Dewatering Ramp Slope: 35°
SCC Drive: Hydraulic Motor
Chain Type: Double-stranded, round link, case hardened
steel chain

PERFORMANCE DATA
Conveying Rate – Normal: 6.5 tonnes per hour
Conveying Rate – Maximum 21.5 tonnes per hour
Submerged Chain Conveyor Storage 40 tonnes
Capacity:
Required Water Pressure: 900 kPa(g)
Required Water Flow: 108 m3/hr

HYDRAULIC PUMP MOTOR

Manufacturer: Toshiba
Speed: 1450 rpm
Rated Power: 30 kW
Voltage: 380 Volt

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5.16.3 ASH CRUSHER
GENERAL:
Equipment No.: BA-CRSH-100
P&ID No.: P101-51-700-BA-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson

PHYSICAL DATA
Type: 340 mm Dual Roll
Roll Material: Manganese Steel Grade H1A
Crusher Liner Material: Bisalloy 320 and 360 replaceable wear
plates
Lower Trough and Dewatering Trough 30 & 40 mm Basalt Tiles
Bottom Material:
Drive: Hydraulic

PERFORMANCE DATA
Capacity: 40 tonnes / hr
Size Reduction: 30 mm
Drive Capacity: 1250 Nm
Speed 60 rpm

HYDRAULIC PUMP MOTOR

Manufacturer: Toshiba
Speed: 1450 rpm
Rated Power: 11 kW
Voltage: 380 Volt

5.16.4 SCREW FEED CONVEYOR

GENERAL:
Equipment No.: BA-CNVR-300
P&ID No.: P101-51-700-BA-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson
Type: Screw
Capacity: 40 tonnes / hr

MOTOR
Manufacturer: Toshiba
Speed: 1450 rpm
Rated Power: 15 kW
Voltage: 380 Volt

File No. P101-11-1723.00-0001 Rev. 0 Page 26

5.16.5 CONVEYOR A
GENERAL:
Equipment No.: BA-CNVR-200
P&ID No.: P101-51-700-BA-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson
Type: Belt
Capacity: 40 tonnes / hr
Belt Speed 1.2 m/sec

MOTOR
Manufacturer: Toshiba
Speed: 1450 rpm
Rated Power: 4 kW
Voltage: 380 Volt

5.16.6 CONVEYOR B
GENERAL:
Equipment No.: BA-CNVR-400
P&ID No.: P101-51-700-BA-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson
Type: Belt
Capacity: 40 tonnes / hr
Belt Speed 1.2 m/sec

MOTOR
Manufacturer: Toshiba
Speed: 1450 rpm
Rated Power: 5.5 kW
Voltage: 380 Volt

File No. P101-11-1723.00-0001 Rev. 0 Page 27

5.16.7 CONVEYOR 7C
GENERAL:
Equipment No.: BA-CNVR-500
P&ID No.: P101-51-700-BA-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson
Type: Belt
Capacity: 40 tonnes / hr
Belt Speed 1.2 m/sec

MOTOR
Manufacturer: Toshiba
Speed: 1450 rpm
Rated Power: 5.5 kW
Voltage: 380 Volt

5.16.8 ASH LOADOUT SILO

GENERAL:
Equipment No.: BA-TK-100
P&ID No.: P101-51-700-BA-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson
Capacity: 208 m3
Material Carbon Steel

5.16.9 ASH LOADOUT SILO CONVEYOR

GENERAL:
Equipment No.: BA-CNVR-600
P&ID No.: P101-51-700-BA-0001
TCD No.: P101-15-1701.00-0101
Manufacturer : John Thompson
Type: Screw
Capacity: 40 tonnes / hr

MOTOR
Manufacturer: Toshiba
Speed: 1450 rpm
Rated Power: 15 Kw
Voltage: 380 Volt

File No. P101-11-1723.00-0001 Rev. 0 Page 28

6.0 FLOW DIAGRAMS
(Following pages)

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7.0 REFERENCES
7.1 P&IDS
P101-51-700-BA-0001 P101-51-700-BA-0002

P101-51-700-BF-0001 P101-51-700-BF-0002 P101-51-700-BF-0003

P101-51-700-BF-0004 P101-51-700-BF-0005

P101-51-700-BG-0001 P101-51-700-BG-0002 P101-51-700-BG-0003

P101-51-700-BG-0004 P101-51-700-BG-0005 P101-51-700-BG-0006

P101-51-700-BG-0007 P101-51-700-BG-0008

P101-51-700-BS-0001 P101-51-700-BS-0002 P101-51-700-BS-0005

P101-51-700-BS-0006 P101-51-700-BS-0007

P101-51-700-FO-0001

P101-51-700-FW-0004 P101-51-700-FW-0005 P101-51-700-FW-0006

P101-51-700-FW-0007

7.2 EQUIPMENT INSTRUCTION MANUALS

Steam Generator Instruction Manuals P101-25-1701.00

Electrostatic Precipitator Instruction Manual P101-25-1709.01

Scrubber Instruction Manual P101-25-1709.03

File No. P101-11-1723.00-0001 Rev. 0 Page 38