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S Sy ys st t e em m D De es sc cr ri i p pt t i i o on n
M Ma an nu ua al l N No o. . S SD D- -0 06 6
R Re ev vi i s si i o on n 0 00 03 3

P.T. CENTRAL J AVA POWER
TANJ UNG J ATI-B (3&4) EXPANSION PROJ ECT

Note
This System Description manual is intended to provide the Tanjung J ati-B 3&4 Power Project
operation personnel with the basic information to understand the Bottom Ash Handling System.
No part of this document may be reproduced for use by parties other than Mitsubishi Heavy
Industries, Ltd. and P.T. Central J ava Power.

P P. .T T. . C CE EN NT TR RA AL L J JA AV VA A P PO OW WE ER R

3
Be sure to read this manual.
Contents
1
2
Major Equipment
4
5
6
Flow Path
Technical Data
1
2
3
4
5
6
General
Process Control
Instrumentation Control,
Alarm & Trip Setpoints
System
Handling
Bottom Ash


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Page
Number
Description of Revision
Revision
Issue Date
Date Revised
Pages
Inserted
Page xii Abbreviations section revised to
include all
2011/04/29 2010/10/28 1
Page 1
Table of Contents Section 1.2 and 1.3
interchanged.
2011/04/29 2010/11/18 -
Page 2 & 3
Chapter 1 - General Section 1.2 and
1.3 interchanged.
2011/04/29 2010/11/18 -
General P&ID replaced with legible prints 2011/04/29 2010/10/28 -
Page 1-5
Chapter 1 General, Section 1.4.2
Logic Diagrams MHI drawing Nos.
replaced by as applicable
Owners/Toshibas Reference
Document Nos.
2011/10/05 -
Page 2-7
Chapter 2 Flow Path-Section 2.5
DCC Chemical Dosing System- Dilute
sulfuric acid concentration changed to
10% and caustic soda concentration
changed to 48%.
2011/10/05 -
Page 2-8
Chapter 2 Figure 2-1 Bottom Ash
System P & ID replaced with As-built
drawing.
2011/10/07 -
Page 5-1
Chapter 5 Process Control
Reference Document Nos. indicated
at the beginning, as per result of
discussion dated 19
th
September,
2011.
2011/10/05 -
Page 5-2
Chapter 5 Process Control Section
5.3-DCC water storage basin level
control- additional statement added in
para 2 as per commissioning result.
2011/10/05 -
Page 6-1,
6-2 and 6-3
Chapter 6- Instrumentation, Alarm&
Trip Set Points-Section 6.1 &6.2
Normal range and set points changed
as per commissioning result.
2011/10/05 -



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Purpose of the Plant Usage
This plant is designed to generate electric power of 660MW by the steam turbine
generator.
The plant is only used for electric power generation purpose that supports stable
and reliable electric power supply to the power grid and supplying steam for
auxiliary equipment in the power station.
General
1. To satisfy the purpose mentioned above the following points must be strictly
observed,
a) The operation, maintenance and inspection of Equipment must be
performed by the persons who have basic technical knowledge and
have been trained concerning the hazard of the Equipment and the
avoidance of the hazard.
b) The operators and maintainers must read and understand these
manuals before starting the operation, maintenance or inspection.
It is often experienced that serious damages to the equipment or
personnel have occurred by the unexpected action of operators or
maintainers who do not fully understand the equipment.
c) The modification or change of operational specification must be
performed under MHI supervision or as per the written acceptances of
MHI.
The modification or change of specification causes not only a decline in
performance but also a decline in safety for operation of the equipment.
The Customer is requested to contact MHI regarding any modification or
changes before the work commences.
The address for MHI to be contacted is shown in this chapter.
2. The operation and maintenance must be performed according to the
applicable laws and regulations at the location of the power station.
3. Disposal from the power station must be treated to satisfy the local
regulations.
4. The copyright of software, drawings and other documents provided by MHI at
all times, is still reserved by MHI.



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5. Use or copying of the whole or part of any information provided by MHI for
any purpose other than operation and maintenance of this plant without
written consent is strictly prohibited.
Important General Notice for Safety
1. The operator and maintainer must have knowledge about the equipment to
maintain good operating condition and to avoid danger when using the
equipment and systems.
2. The protection measures must satisfy all of the operational functions.
3. The safety activity must be planned systematically as a Safety and Health
management system and operate continuously.
Safety and Health management system must include the following points,
a) Instruction for use and the maintenance of the personal protective
equipment available to operators and maintainers
b) The establishment of a work management organization to make clear the
operation directives and work procedures
c) Implementation of training for operator and maintainer
4. The Customer must train the operators and maintainers to act positively and
to prevent the occurrence of an accident by using their knowledge of the
power plant.
5. The Customer must make the operators and maintainers understand that the
most important purpose of safety control is to protect all personnel from
accidents and also to maintain operation of the plant without troubles.
6. To prevent accidents involving personnel and equipment, it is necessary to
observe the notices of this manual and to keep the correct operation
according to the description provided in this manual.
If the notices are not observed, the following dangers could occur to the
operator, and to the maintainer.
a) Risk of a fatal accident
b) Danger to lose his health and fitness
c) Danger of damage to the equipment
7. MHI can not forecast all possible dangers existing in the plant such as danger
due to human error and/or dangers caused by operating environment.
As this manual and the alert label cannot cover all of the dangers, the
operators and maintainers have to pay their full attention to all general safety
notices.


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8. MHI can not be responsible for damages and injury caused by neglecting the
notices in this manual, and other necessary general notices.
Instruction of this Manual
1. This manual is provided for people familiar with the use of English. If some
person not familiar with English is going to operate the plant, the Customer
must then train him specially.
2. The warning labels must be expressed in the English.
3. This manual contains optional matters.
4. Some figures in this manual include internal parts of the equipment which
may not be obvious, when looking at the completed equipment drawing.
5. MHI may change the content of this manual without notice.
6. This manual is intended for the use by the operators and maintainers and it
must be accessible to them at all times.
7. If the Customer needs more detailed information, please contact MHI local
office or MHIs official agent.



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The provisions set forth in this section are in addition to all liability and warranty
disclaimers and limitations set forth in the Contract, whether arising under law
or from course of performance, course of dealing, or usage of trade
Nothing in these provisions shall constitute or be deemed to constitute any
additional liability undertaking or warranty, express or implied, with respect to
the Plant. All capitalized terms used, but not defined in this Warranty
Limitations section shall have the respective meanings ascribed to them in the
Contract.
The Contract Warranties are subject to the construction, installation and
Commissioning works having been performed in full compliance with the
requirements stated in (a) the Contract, (b) all manuals provided by MHI,
including this manual, (c) all applicable rules, regulations and laws prevailing in
the location where the Plant has been installed and will operate, and (d) any
other instructions, if any, provided by MHI (collectively, Rules and
Requirements). The Contract Warranties will NOT cover any accidents, partial
or total failure of the Plant, losses or damages to personnel or property
(including, without limitation, the Plants components, parts, systems and other
equipment), or any other liability (collectively, Accidents and Damages) in the
case of any breach of the stated Rules and Requirements.
For the detailed terms and conditions of the warranty concerning the Works
and Project, refer to the Contract.




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In addition to the foregoing, the Contract Warranties will NOT cover any of the
following Accidents and Damages:
Accidents and Damages caused by any deviation from the Rules and
Requirements;
Accidents and Damages caused by the modification or re-installation of the
Plant after the original installation, or caused by operation of the Plant for a
purpose other than that for which it is designed;
Accidents and Damages caused by natural disasters or accidents during
transfer or related handling;
Accidents and Damages occurring after the term of the warranty has expired;
Accidents and Damages due to faulty operation or operation not in accordance
with the Rules and Requirements;
Accidents and Damages due to inappropriate maintenance or servicing
performed by the Customer, its personnel or any other party.
Accidents and Damages caused by any components, parts, systems or other
equipment other than those delivered by MHI;
Accidents and Damages caused by unidentifiable reasons including loss of the
damaged parts which is necessary to pinpoint a cause of the failure;
Accidents and Damages caused by referring to inadequate, or incorrect
references, data or information provided by the Customer;
Accidents and Damages or rust/corrosion due to inadequate handling and/or
storage by the Customer; or
Accidents and Damages due to handling, storage and/ or use of the Plant
under severe conditions or in an environment that does not meet the design
specification conditions.



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General
Nothing in this Limitation of Liability section or manual shall constitute or be
deemed to constitute any additional liability undertaking or warranty, express
or implied, with respect to the Plant. All capitalized terms used, but not defined
in this Limitation of Liability section shall have the respective meanings
ascribed to them in the Contract.
The contents of this manual are subject to change without prior notice and
without any obligation or liability to MHI.

Use and Disposal
Use of the Plant must be limited to the use specified by MHI, including without
limitation, use of the Plant in accordance with the Contract, this manual, all
Safety Manuals, all applicable laws and regulations, and any other instructions,
if any, provided by MHI. The Plant components, parts, systems and other
equipment (collectively, Equipment) must be appropriately disposed of in
accordance with the Contract, this manual, all Safety Manuals, all applicable
laws and regulations, and any other instructions, if any, provided by MHI.
For Documents and Safety Training
The Customers personnel must read, understand and abide by all documents
provided by MHI, including without limitation, the operation and maintenance
manuals, safety manuals, and instruction manuals (collectively, Safety
Manuals) and must have received all required and/or necessary safety training
prior to the start of their work. Persons who have not received such safety
training are not permitted to work on the installed Plant. This initial training,
however, is merely the minimum requirements prior to allowing any personnel to
work on the installed Plant. The Customer must, on a continual and regular
schedule, give up-to-date training to its personnel on safety requirements,
provide testing or other methods to confirm their understanding of the safety
training, and confirm that they have the physical and mental capability to
perform their respective roles. The Customers obligation for safety training and
personnel supervision is an ongoing obligation and must be continuously
performed and kept current throughout the operation of the Plant. Accidents,
partial or total failure of the Plant, damage to personnel or property, loss,
injuries, and other liability (collectively, Liability) caused by inadequate safety
training or the Customers personnels failure to abide by the documents
provided by MHI are expressly excluded from the coverage of any warranty
provided by MHI and are the sole and exclusive responsibility of the Customer.




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MHI will NOT be liable for any Liability caused by modification or changes made
in Plant-related documents (including any Safety Manual) by anyone other than
MHI.
For Damage to the Plant
Accidents may occur by use of Equipment that is acquired from anyone other
than MHI or anyone not appointed by MHI to modify or repair this Plant. The
Customer shall not be permitted to modify or repair the Plant or change
Equipment of the Plant without MHIs prior written approval, under any
circumstance.
MHI will NOT be liable for any Liability resulting from any abuse, misuse,
misapplication of the Equipment supplied by MHI.
MHI will NOT be liable for any Liability caused by an act by the Customer in
violation of the Contract, this manual, any applicable law or regulation, or any
Safety Manual or any other instruction provided by MHI, including without
limitation, a change of the installation environment or the removal and
installation of any Equipment in a location different to that originally selected by
MHI.
MHI will NOT be liable for any Liability caused by a defect, imperfection, or fault,
in material or Equipment that was used during a repair, even when such a
repair was performed by or under an instruction given by MHI.


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COPYRIGHT 2009, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS
RESERVED. ANY REPRODUCTION IS EXPRESSLY PROHIBITED.

All of the content contained in this manual is protected by J apanese,
International and/or United States copyright laws.
All copyright, trade secrets, and other proprietary and intellectual property
rights in the documents provided by Mitsubishi Heavy Industries, Ltd.(MHI)
(including safety-and-instruction manuals) are at all times owned and reserved
by MHI. Subject to your compliance with the restrictions set forth below, MHI
grants to you a limited, non-exclusive license in the copyright for the sole
purpose of allowing you to use, operate, maintain and inspect the Plant.
Use, copying, other reproduction of the whole or part of the documents
provided by MHI (including safety-and-instruction manuals) for any purpose
other than the purpose described above without MHIs prior written consent is
strictly prohibited.
The act of rewriting, translating, modifying, revising, creating electronic copies,
uploading, selling, sublicensing, or otherwise disclosing the whole or part of the
manuals is strictly prohibited.
Except as specifically set forth above, no right, title or license to the documents
provided by MHI, whether arising from contract, implication, estoppel or
otherwise, is being granted or otherwise transferred.




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This Manual was prepared for all personnel who will participate in the operation and
maintenance of the plant, and other related mechanical plant and equipment
installed.
In this Manual, MHI classifies personnel into the following two classes based on
their ability, experience and their attitude to the safety of personnel, and the plant
installed.
Only the personnel recognized by the Customer as trained personnel are allowed to
perform the operation and maintenance specified in the manuals.
Maintainers and Operators are required to have read and understood the contents
of the safety, operation, and maintenance manuals and sufficiently understand the
work procedures before actually starting their tasks.


Operators following the instructions of their supervisor or the Shift Charge Engineer
are permitted to handle materials to be used in the operation of the plant.
Operators are allowed to turn on the power supply, startup equipment, open up or
remove covers or panels on receipt of an instruction or authorization from their
superior.
Operators are permitted access to the emergency stop devices following
instructions given by their superior when dangerous or hazardous situations are
recognized.


Maintainers are permitted to perform maintenance on the plant. They will also
perform troubleshooting routine and periodical inspections of the installed
equipment. The maintainer will also work under the supervision of MHIs
supervisors during on-the-job training and annual maintenance and overhaul work if
MHIs supervisors are requested to witness periodical inspections, etc.
Maintainers MUST have attended the training programme initially provided by MHI
and subsequently by the Customer, and they must have obtained the necessary
knowledge and maintenance skills to understand the characteristics of their tasks
before actually starting their work.



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Operator
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For any question or any clarification required, please do not hesitate to contact MHI
through the following address(es).
For Support before Operation:
MITSUBISHI HEAVY INDUSTRIES, Ltd.
Nagasaki Shipyard & Machinery Works
1-1, Akunoura Machi, Nagasaki 850-063




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Abb. Expanded Form Abb. Expanded Form
1RY Primary ECR Economical Continuous Rating
2RY Secondary ESP Electrostatic Precipitator
3RY Tertiary FD Forced Draft
AC Alternating Current FDF Forced Draft Fan
AUX Auxiliary FCB Fast Cut back
BCP Boiler Water Circulation Pump FGD Flue Gas Desulphurization
BFP Boiler Feed Pump FO Fuel Oil
BFPT Boiler Feed Pump Turbine Gen. Generator
BOP Balance Of Plant H2 Hydrogen
BMCR Boiler Maximum Continuous Rating HDR Header
BMS Burner Management System HP High Pressure
BP Break point HRH Hot Reheat
BSQ Boiler Sequence I&C Instrument and Control
CAC Common Auxiliary Control System IDF Induced Draft Fan
CES Common Electrical Control System IP Intermediate Pressure
CCR Central Control Room LFO Light Fuel Oil
CCCW Closed Cycle Cooling Water LP Low Pressure
CRH Cold Reheat MAX Maximum
CV Control Valve M-BFP Motor Driven Boiler Feed Pump
CW Cooling Water MFT Master Fuel Trip
DCC Drag Chain Conveyor MIN Minimum
DCS Distributed Control System MS Main Steam
DEHC Digital Electro Hydraulic Control MSDS Material Safety Data Sheet
DESH Desuperheater MT Main Turbine
ECO Economizer MV Motor Valve
ECP Electro Chlorination Plant MW Mega Watt




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Continued from previous page.
Abb. Expanded Form Abb. Expanded Form
MWD Megawatt Demand PVC Polyvinyl Chloride
N2 Nitrogen RAPH Regenerative Air Preheater
NDT Non Destructive Test RH Reheater
NWL Normal Working Level SG Steam Generator
OD Outside Diameter SH Superheater
OJ T On J ob Training SOV Shut Off Valve
OPM Operation Manual SP Secondary Pass
OPS Operator Station ST Steam Turbine
PAF Primary air Fan T-BFP Turbine Driven Boiler Feed Pump
PAS Plant Automation System TCV Temperature Control Valve
PB Push Button TMCR
Turbine Maximum Continuous
Rating
PCV Pressure Control Valve TSQ Turbine Sequence
P&ID Piping and Instrumentation
Diagram
WB Wind Box
PPE Personal Protective Equipment WW Water Wall
PTW Permit to Work UCS Unit Coordination & Boiler
Modulating Control System




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This manual is arranged as follows.

Chapter 1



Chapter 2



Chapter 3



Chapter 4



Chapter 5



Chapter 6




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Contents


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Revision Recordi
Important Informationii
Warranty v
Limitation of Liabilityvii
Copyright ix
Personnel to whom the Manual is Directedx
Contact Addressxi
Abbreviations xii
Arrangement of the System Description Manualxiv
C Ch ha ap pt t e er r
1
1 G Ge en ne er r a al l _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
1.1 Introduction1-1
1.2 Purpose and Scope 1-2
1.3 System Over View1-3
1.4 References1-5
1.4.1 P & ID1-5
1.4.2 Control and Logic Diagrams 1-5
1.4.3 Vendor Information1-5
C Ch ha ap pt t e er r
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2 F Fl l o ow w P Pa at t h h _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
2.1 Ash & Slag from Furnace Bottom through DCC and Clinker
Crusher to Bottom Ash Bunker 2-2
2.2 Settling Basin, Water Storage Basin and Recirculation Water
back to DCC Trough2-3
2.3 Settling Water Recovery2-4
2.4 Service Water as Makeup Water to Upper Trough and Other
User Points 2-5
2.5 DCC Chemical Dosing System2-7



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3 M Ma aj j o or r E Eq qu ui i p pm me en nt t _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
3.1 Drag Chain Conveyor 3-1
3.2 Clinker Crusher3-5
3.3 DCC Cooling Water Recirculation Pump3-8
3.4 DCC Sludge Pump 3-11
3.5 DCC Cooling Water Heat Exchanger3-14
C Ch ha ap pt t e er r
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4 T Te ec ch hn ni i c ca al l D Da at ta a _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
C Ch ha ap pt t e er r
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5 P Pr r o oc ce es ss s C Co on nt t r r o ol l _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
5.1 DCC Water Temperature Control 5-2
5.2 DCC Water Level Control5-2
5.3 DCC Water Storage Basin Level Control 5-2
C Ch ha ap pt t e er r
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6 I In ns st t r r u um me en nt ta at t i i o on ns s, , A Al l a ar r m m & & T Tr r i i p p S Se et t
P Po oi i n nt ts s _ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ _
6.1 Instrumentation Parameters Monitored at CCR6-1
6.2 Instrumentation Parameters Monitored at Local 6-3
Contents


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L Li i s st t O Of f F Fi i g gu ur r e es s
Figure 2-1 Bottom Ash P & ID2-8
Figure 3-1 DCC General Arrangement 1/23-3
Figure 3-2 DCC General Arrangement 2/23-4
Figure 3-3 Clinker Crusher Assembly3-6
Figure 3-4 Clinker Crusher Arrangement3-7
Figure 3-5 DCC Cooling Water Recirculation Pump Outline3-9
Figure 3-6 DCC Cooling Water Recirculation Pump Sectional
Assembly3-10
Figure 3-7 DCC Sludge Pump Sectional Assembly 1/23-12
Figure 3-8 DCC Sludge Pump Sectional Assembly 2/23-13
Figure 3-9 DCC Cooler Unit General Arrangement 3-15
L Li i s st t o of f T Ta ab bl l e es s
Table 4-1 Drag Chain Conveyor4-1
Table 4-2 Clinker Crusher4-2
Table 4-3 DCC Cooling Water Heat Exchanger4-2
Table 4-4 DCC Cooling Water Recirculation Pump4-3
Table 4-5 DCC Sludge Pump4-3
Table 4-6 DCC Chemical Dosing System4-4
Table 6-1 Operation Parameters, Alarm & Trip Set Points - CCR6-1
Table 6-2 Operation Parameters, Alarm & Trip Set Points - Local 6-3
Chapter-1 General


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1.1 Introduction
Tanjung J ati B Units 3 & 4 (TJ B 3&4) are 660MW coal fired power plants. The
two steam generators are of maximum continuous rating (MCR) 2,285t/hr, with
associated auxiliaries. The boilers are sub-critical, forced circulation, balanced
draft type with coal as the main fuel and light fuel oil as the startup fuel.
The System Description of Boiler Island (LOT1 scope of supply) is subdivided
into the following six (6) manuals for easy understanding and avoiding large
amount of data in one manual.
Boiler Pressure Part, Main & Reheat Steam System (SD-01)
Air and Flue Gas System (SD-02)
Fuel Firing System (SD-03)
Soot Blowing System (SD-04)
Chemical Dosing System (SD-05)
Bottom Ash Handling System (DCC) (SD-06).
This manual SD-06 describes the Bottom Ash Handling System of TJ B (3&4).
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1.2 Purpose and Scope
The Bottom Ash Handling System consists of the drag chain conveyor (DCC)
with driving motor and travel rails, bottom ash grinder (Clinker Crusher), heat
exchangers & cooling water recirculation pumps, sludge pumps, chemical
dosing system and all necessary piping and valves.
The purpose and scope of this manual is to provide an overview of all these
equipment and components in the system and details so as to:
Understand the various components of the Bottom Ash Handling System.
Give a comprehensive technical specification of all the major equipments in
the system.
Identify the flow paths of the bottom ash, cooling water recirculation,
makeup water, and settling water recovery to DCC trough etc.
Understand the bottom ash conveying philosophy and makeup water
control and re-circulating water temperature control.
The manual also details the instrumentation provided for monitoring, alarm &
protection of the system.
Chapter-1 General


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1.3 System Over View
The Steam Generator (SG) is fired with coal and is capable to be fired with light
fuel oil (LFO) for start-up, low-load, and shutdown purposes. The steam from
each SG is passed to its associated steam turbine and, each of the two units
can be operated completely independent of each other.
The steam generator is sub-critical, balanced draft, drum-type design, with
single reheat and the design live main steam parameters are 174.3barg and
541C and the reheat steam parameters are 37.5barg and 541C.
The function of Bottom Ash Handling system is to collect, cool and crush the
furnace bottom ash and deliver it to the bottom ash bunker. The bottom ash
handling system uses a submerged drag chain conveyor (DCC).
The bottom ash system includes the following major components for each unit:
1. One (1) drag chain conveyor with driving motor and travel rails
2. One (1) bottom ash grinder (Clinker Crusher)
3. Two (2) DCC Cooling Water Recirculation Pump
4. Two (2) DCC Sludge Pump
5. Two (2) DCC Cooling Water Heat Exchanger
6. All necessary piping and valves.
Bottom ash from the steam generator is guided into the water impounded drag
chain conveyor upper trough. The submerged drag chain conveyor drags the
ash up the inclined section for dewatering before discharging through a
discharge chute to a clinker crusher for further grinding and disposal.
The level of water above the submerged drag chain conveyor is automatically
controlled to maintain a boiler seal and to protect the conveyor from radiant heat
at all times. The capacity of the water trough is sufficient to accommodate at
least 8 hours production of ash at 100% MCR with worst coal.
The bottom and the inclined surface are lined with wear plates (30 mm
thickness) to extend the life against erosion. The chain return path on the lower
dry trough side is lined with abrasion resistant material.
The submerged drag chain conveyor is mounted on rails and equipped with
wheels to facilitate rolling it to one side for conveyor and boiler maintenance.
One (1) bottom ash grinder (Clinker Crusher) is provided to grind the maximum
amount of bottom ash occurring under all operating conditions and dropped
down to the bottom ash bunker. The drive unit of the clinker crusher is an
electric motor with reduction gear. The electric motor is designed to permit
reverse rotation. Materials used for the clinker crusher is capable of
withstanding any abrasion by ash and corrosion by bottom water.
Chapter-1 General


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The makeup water consumption for the Bottom Ash Handling System is
minimized by providing a re-circulating cooling water system. The system
consists of cooling water heat exchangers, cooling water recirculation pumps
and necessary pipelines and valves and utilizes the cooling water from the
CCCW System.
A chemical dosing system consisting of dilute sulfuric and caustic soda is
provided to maintain the recirculation water quality within limits.
From the clinker crusher, the ash is dropped down to the bottom ash bunker,
from where it is disposed to the trucks using wheel loader and carried away
periodically.
Chapter-1 General


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1.4 Reference
1.4.1 P&ID
Bottom Ash P&I Diagram
Project Dwg. No.: A-BAD-0-MH-0001
MHI Dwg. No:97000-2165-2-A
1.4.2 Control and Logic Diagrams
Logic Diagram for Boiler DCC Group (BJ )
Owners Document No.:A-DCS-I-TS-6425
(Toshibas Document No. 3GCH00577)
Logic Diagrams for UCS-A & UCS-B
Owners Document No.:A-DCS-I-TS-6468
(Toshibas Document No.7M6S2273/2274)
1.4.3 Vendor Information
System/Equipment Vendor
General Arrangement of DCC MHI, Nagasaki
DCC Cooling Water Heat Exchanger Dong Hwa Entec
DCC Chemical Dosing System Sakura Seisakusho, Ltd
DCC Cooling Water Recirculation Pump Yokota Manufacturing Co. ,Ltd
DCC Sludge Pumps E.I.M. Electric Co. Ltd

Chapter-2 Flow Path


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The function of Bottom Ash Handling system is to collect, cool and crush the furnace
bottom ash and deliver it to the bottom ash bunker. The bottom ash handling system
uses a submerged drag chain conveyor (DCC).
The bottom ash system includes the following major components for each unit:
1. One (1) drag chain conveyor with driving motor and travel rails
2. One (1) bottom ash grinder (Clinker Crusher)
3. Two (2) DCC Cooling Water Recirculation Pump
4. Two (2) DCC Sludge Pump
5. Two (2) DCC Cooling Water Heat Exchanger
6. All necessary piping and valves.
Bottom ash from the steam generator is guided into the water impounded drag chain
conveyor upper trough. The submerged drag chain conveyor drags the ash up the
inclined section for dewatering before discharging through a discharge chute to a
clinker crusher for further grinding and disposal.
The level of water above the submerged drag chain conveyor is automatically
controlled to maintain a boiler seal and to protect the conveyor from radiant heat at all
times. The capacity of the water trough is sufficient to accommodate at least 8 hours
production of ash at 100% MCR with worst coal.
The bottom and the inclined surface are lined with wear plates (30 mm thickness) to
extend the life against erosion. The chain return path on the lower dry trough side is
lined with abrasion resistant material.
The submerged drag chain conveyor is mounted on rails and equipped with wheels to
facilitate rolling it to one side for conveyor and boiler maintenance.
One (1) bottom ash grinder (Clinker Crusher) is provided to grind the maximum amount
of bottom ash occurring under all operating conditions and dropped down to the bottom
ash bunker. The drive unit of the clinker crusher is an electric motor with reduction gear.
The electric motor is designed to permit reverse rotation. Materials used for the clinker
crusher is capable of withstanding any abrasion by ash and corrosion by bottom water.
The makeup water consumption for the Bottom Ash Handling System is minimized by
providing a re-circulating cooling water system. The system consists of cooling water
heat exchangers, cooling water recirculation pumps and necessary pipelines and
valves and utilizes the cooling water from the CCCW System.
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A chemical dosing system consisting of dilute sulfuric and caustic soda is provided to
maintain the recirculation water quality within limits.
From the clinker crusher, the ash is dropped down to the bottom ash bunker, from
where it is disposed to the trucks using wheel loader and carried away periodically.
The flow paths associated with Bottom Ash Handling System are:
Ash & slag from furnace bottom through DCC and Clinker Crusher to bottom ash
bunker.
Settling basin, water storage basin and recirculation water back to DCC trough.
Settling Water Recovery
Makeup Water to DCC Trough
DCC Chemical Dosing System.
2.1 Ash & Slag from Furnace Bottom through DCC and Clinker
Crusher to Bottom Ash Bunker
Ash and slag from furnace falls to the water impounded drag chain conveyor
upper trough and gets quenched in the water. The submerged drag chain
conveyor (DCC) drags the ash up the inclined section for dewatering before
discharging through a discharge chute to a clinker crusher for further grinding
and disposes to the bottom ash bunker area. The DCC rotating speed is
adjustable by inverter control.
The upper trough receives the makeup water, recirculation water and the
recovered settling water. An overflow is provided in upper trough and flows to
the trench from where it is guided to the settling basin. The upper trough has a
drain connection with isolation valve (3BAD-V520). A temperature indicating
switch (3AW-TGS501) is provided for high/high-high DCC water temperature
annunciation and ON/OFF control of makeup water. The temperature can also
be monitored locally.
A level switch (3AW-LS501) is provided in the DCC upper trough for ON/OFF
control of makeup water and also annunciation of high and low levels. A level
switch (3BAD-LS503) is provided above the clinker crusher spout to alarm the
shoot blockage and also trip DCC. The drag chain is continuously washed down
on its return path. Gutters are provided at the rear and front side of the bottom
trough to direct the water to the trench.
The crusher sealing requirement is provided by service air. The service air
pressure can be monitored at local.
Chapter-2 Flow Path


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2.2 Settling Basin, Water Storage Basin and Recirculation Water
back to DCC Trough
The overflow water from upper trough and the drain water from bottom trough
flows through the trench to the settling basin. Dilute sulfuric acid/caustic soda is
dosed (refer section 2.5) into the settling basin periodically to maintain the water
quality, when the water quality becomes beyond the set values. The settled
water is pumped back to upper trough (refer section 2.3), also periodically by
sludge pumps. The clear water overflows to the adjacent water storage basin.
The water storage basin level is monitored locally at level indicating switch
(3BAD-LGS501), which is also used for alarm and pump protection and interlock
purposes.
The water from storage basin is re-circulated back to the upper trough by the
DCC cooling water recirculation pumps. There are 2 x 100% duty pumps, one in
service and the other standby. Each pump takes it suction from storage basin
through suction strainers and suction valves (3BAD-V501A/B). The pump
discharge is provided with an exhaust valve (3BAD-V516A/B), which vents
air/water mixture automatically and is connected back to basin. The pump
suction and discharge pressures are monitored locally through the pressure
indicators (3BAD-PG501A/B&502A/B).
The pump discharge flows to a common line through discharge check valves
(3BAD-V502A/B) and discharge valve (3BAD-V503A/B). A drain connection is
provided at the inlet of discharge valve. The pH of the recirculation water is
monitored by the analyzer (3BAD-AX501) provided in the common discharge
line.
An emergency blow line with blow shutoff valve (3BAD-PN501) is provided to
dump water to drain pit, when the water storage level is high-high during
operation. The blow off line has an isolation valve (3BAD-V519) at the inlet of
shutoff valve.
The recirculation water is tapped from the common discharge line and
connected to the DCC upper end of slope for washing down the chain of
ash/debris on its return path. This line has a stop valve (3BAD-V513) in common
line and isolation valves (3BAD-V514/515) as the line bifurcates to both sides.
Another provision by way of tapping of recirculation water is provided to agitate
the water storage basin around the suction strainers when necessary.
The recirculation water is cooled in heat exchanger before it is re-circulated to
DCC upper trough. The discharge common line from recirculation pump
bifurcates and connects to the inlet of 2 x 100% duty heat exchangers (both
working normally, and can be isolated for backwashing when necessary). The
heat exchangers are provided with inlet and outlet isolation valves
(3BAD-V504A/B & 505A/B). Air vent and drains with isolation valves are
provided in both heat exchangers. Temperature indicators (3BAD-TG501/502)
are provided to monitor the recirculation water temperature at the inlet and
outlet of heat exchangers.
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The heat exchanger outlets join to form a common line and are connected to the
DCC upper trough. The recirculation water flow is monitored by the flow
transmitter (3BAD-FX501) in DCS. At the DCC upper trough end a stop valve
(3BAD-V511) is provided for isolation.
2.3 Settling Water Recovery
As explained earlier, the overflow water from upper trough and the drain water
from bottom trough flows through the trench to the settling basin. The settled
sludge with water is pumped back periodically to upper trough by the sludge
pumps (3BAD-P521A/B).
The pump discharge has check valves (3BAD-V521A/B) and joins to form a
single line. A tap off is taken from this line and connected to the agitator nozzles
surrounding the sludge pumps through an isolation valve (3BAD-V523). These
nozzles mix the settled mud/debris around the pump suction, so that the water
carries it to the upper trough.
The common discharge line has an isolation valve (3BAD-V524) and a pressure
indicator (3BAD-PG503) is provided to monitor the discharge pressure locally.
The common line is routed to the upper trough. A stop valve (3BAD-V525) is
provided in this line for isolation, when the line is to be drained off to the drain pit
through another isolation valve (3BAD-V526).
Chapter-2 Flow Path


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2.4 Service Water as Makeup Water to Upper Trough and Other
User Points
Makeup water is supplied to DCC upper trough to replenish the loss of water, as
some recirculation water evaporates while quenching the falling hot ash & slag
from furnace and any other system loss like seal leakages, gland leakages,
water carried away by ash to the bottom ash bunker etc. The makeup water
shutoff valve opens/closes to maintain the DCC upper trough level within range.
Service water is used as makeup water and flows to upper trough through a
makeup water shutoff valve (3AW-PN501). Isolating valves (3AW-V501/502)
are provided at the inlet and outlet of makeup water shutoff valve and a bypass
valve (3AW-V503) across the shutoff valve for use during initial fill up/ and or
emergency. A drain valve is also provided at the inlet of shutoff valve.
Service water is also tapped for the following purposes:
Backwashing of the DCC cooling water heat exchangers
Backwashing of the suction strainers of DCC recirculation pump
Initial fill up of water storage basin
Dilution water to DCC caustic soda tank
Washing down DCC around.
Backwashing of the DCC cooling water heat exchangers
Service water is used for backwashing as and when the heat exchangers are
clogged. The service water is connected to the heat exchanger outlet side
through isolation valves (3AW-V531A/B). The backwash water from the inlet
pipe of the heat exchangers flows to the drain pit through isolation valves
(3AW-V533A/B).
Backwashing of the suction strainers of DCC recirculation pump
Service water is used for backwashing the suction strainers and is connected
before the suction valves of the DCC cooling water recirculation pump through
isolation valves (3AW-V541A/B). The washed water flows to the water storage
basin.
Initial fill up of water storage basin
Another tapping of service water from the common line for backwashing suction
strainers is used to fill up the water storage basin initially. An isolation valve
(3AW-V543) is provided for this purpose in this line.
Chapter-2 Flow Path


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Dilution water to DCC caustic soda tank
A tap off connection of service water from the common line is taken and
connected to DCC caustic soda tank through a stop valve (3AW-V525) and
isolation valve (3AW-V524). The isolation valve is normally kept closed and
used while preparing fresh caustic soda solution.
Another connection from the above common line is provided for settling and
storage basin washing. This line also has an isolation valve (3AW-V523).
Washing down DCC around
A separate tapping from the service water line is taken for the supply to DCC
around areas for washing, cleaning etc. Three separate tapings are taken for
this purpose all around DCC through isolation valves (3AW-V520/521/522).
Chapter-2 Flow Path


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2.5 DCC Chemical Dosing System
A chemical dosing system is provided to maintain the recirculation water quality
within limits. Service water is used as makeup water and for initial filling of water
storage basin. However, due to ash/slag falling & quenching process, the water
quality gets affected due the property of ash/slag. The pH of the water varies
and so it is necessary to maintain the pH with in allowable limits of 5-11. Dilute
sulfuric acid is dosed when pH is >9 and dilute caustic soda is dosed when pH is
<7. An acid dosing and caustic dosing facility is provided.
Dilute sulfuric acid (10%) is stored in DCC dilute sulfuric tank (3BAD-T532) of
600L capacity. The tank has a local level indicator (3BAD-LG502) and level
switch (3BAD-LS502) for low alarm annunciation. Acid fill connection is at top of
tank through quick connect coupling and isolation valve (3CD-V568) and tank
has an open vent. The tank has a drain connection with isolation valve. The
dilute acid flows by gravity to the settling basin through a pipeline connected
from tank bottom side through a stop valve (3CD-V561), an isolation valve
(3CD-V562) & shutoff valve (3CD-PN 502).
Caustic soda (48%) solution is prepared and stored in DCC caustic soda tank
(3BAD-T531) of 1000L capacity. The tank has a local level indicator
(3BAD-LG501) and level switch (3BAD-LS501) for low alarm annunciation.
Service water for dilution is connected at top of tank through stop and isolating
valves. An agitator (3BAD-AG531) is provided for thorough mixing to obtain
uniform concentration of caustic soda solution during fresh solution preparation.
The tank has a drain connection with isolation valve. The caustic soda solution
flows by gravity to the settling basin through a pipeline connected from tank
bottom side through a stop valve (3CD-V551), an isolation valve (3CD-V552) &
shutoff valve (3CD-PN 501).
Chapter-2 Flow Path

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FIGURE 2-1 BOTTOM ASH P & ID MTD-3-0266
Chapter-3 Major Equipment


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The major equipment associated with Soot Blowing System are the following:
Drag Chain Conveyor
Clinker Crusher
DCC Cooling Water Recirculation Pump
DCC Sludge Pump
DCC Cooling Water Heat Exchanger.
3.1 Drag Chain Conveyor
The bottom ash handling system uses a submerged drag chain conveyor (DCC).
Bottom ash from the steam generator is guided into the water impounded drag
chain conveyor upper trough. The submerged drag chain conveyor drags the
ash up the inclined section for dewatering before discharging through a
discharge chute to a clinker crusher for further grinding and disposal. DCC
upper trough, lower trough and sloped trough - simplified view is depicted
below.





DCC Upper Trough, Lower Trough and
Sloped Trough Simplified View

The upper trough is always filled with water to a fixed level. Recirculation cooling
water is constantly supplied to provide an overflow to maintain the water
temperature at about 60C or lower and to seal the furnace gas. The lower
trough provides a return channel for the chain conveyor. It is of an open-sided
construction, permitting the drive chain and the scrapers to be visually inspected
and easily serviced.
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Mechanism of Ash Conveyance Through
DCC Sloped Trough

The bottom and the inclined surface are lined with 30 mm basalt liners to extend
the life of the scraper bar against erosion. Also basalt liners are superior against
the acid corrosion. The chain return path on the lower dry trough side is lined
with abrasion resistant material.
The submerged drag chain conveyor is mounted on rails and equipped with
wheels to facilitate rolling it to one side, for conveyor and boiler maintenance.
The submerged drag chain conveyor is designed such that the temperature of
the outer surface shall not exceed 60 C. Carbon steel is used for the fabrication
of parts not subject to corrosion. The drag chain shafts are made of stainless
steel. Figure 3-1 & 3-2 depict the DCC general arrangement.
Refer to maintenance manual for more details of DCC.
Clinker
Clinker Crusher
Water
Sprocket
Clinker
Clinker Crusher
Water
Sprocket
Chapter-3 Major Equipment

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FIGURE 3-1 DCC GENERAL ARRANGEMENT 1/2
MTD-3-0294
Chapter-3 Major Equipment

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FIGURE 3-2 DCC GENERAL ARRANGEMENT 2/2
MTD-3-0295
Chapter-3 Major Equipment


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3.2 Clinker Crusher
One (1) bottom ash clinker crusher is supplied. Bottom ash clinker crusher is
capable of grinding the maximum amount of bottom ash occurring under all
operating conditions to such a particle size as to ensure the smooth flow of
slurry to bottom ash bunker. Materials used for the bottom ash grinder is
capable of withstanding any abrasion by ash and corrosion by bottom ash
water.
The crusher is single roll cutter type. The drive unit of the clinker crusher is an
electric geared motor with fluid coupling. The electric motor is designed to
permit reverse rotation. Refer section 4 Technical data for the specifications of
clinker crusher.
Figures 3-3 & 3-4 depict the clinker crusher assembly and arrangement
respectively.
Chapter-3 Major Equipment

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FIGURE 3-3 CLINKER CRUSHER ASSEMBLY
MTD-3-0295
Chapter-3 Major Equipment

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FIGURE 3-4 CLINKER CRUSHER ARRANGEMENT
MTD-3-0295
Chapter-3 Major Equipment


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3.3 DCC Cooling Water Recirculation Pump
There are 2 x 100% duty DCC cooling water recirculation pumps provided per
DCC, one in service and the other on standby. The pump is a standard
centrifugal type, horizontally mounted. It handles DCC water of varying pH 7- 9.
The impeller is semi-open type and thrust & radial bearings are ball bearings.
The rated capacity of the pump is 40m
3
/h and it develops a differential head of
23m. The drive unit is an electric motor of 5.5kW and coupling used is flexible
type.
Figures 3-5 & 3-6 depict the pump outline and sectional assembly respectively.

Chapter-3 Major Equipment


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FIGURE 3-5 DCC COOLING WATER RECIRCULATION PUMP OUTLINE
MTD-3-0298
Chapter-3 Major Equipment


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FIGURE 3-6 DCC COOLING WATER RECIRCULATION PUMP SECTIONAL ASSEMBLY

MTD-3-0299
Chapter-3 Major Equipment


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3.4 DCC Sludge Pump
There are 2 x 100% duty DCC sludge pumps provided per DCC, one in service
and the other on standby. The pump is a standard submersible type, vertically
mounted. It handles DCC sludge water of varying pH 7-9.
The rated capacity of the pump is 0.5m
3
/min and it develops a total head of 12m.
The drive unit is an electric motor of 3.7kW and motor is designed for
submerged water condition.
Figure 3-7 depicts the sludge pump sectional assembly.
Chapter-3 Major Equipment


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FIGURE 3-7 DCC SLUDGE PUMP SECTIONAL ASSEMBLY 1/2
MTD-3-0300
Chapter-3 Major Equipment


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FIGURE 3-8 DCC SLUDGE PUMP SECTIONAL ASSEMBLY 2/2
Chapter-3 Major Equipment


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3.5 DCC Cooling Water Heat Exchanger
There are 2 x 100% duty DCC cooling water heat exchangers provided per DCC,
both in service normally at 50% duty. However, when any maintenance, or
clogging & backwashing of a heat exchanger is necessary, the DCC continues
in operation with the available heat exchanger on 100% duty.
The heat exchanger is a standard shell & tube type, vertically mounted. It
handles DCC recirculation water on tube side and closed cooling water on shell
side. The design specifications are listed in section 4.0 Technical Data.
Figure 3-9 depicts the general assembly of the DCC cooler unit.
Chapter-3 Major Equipment

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FIGURE 3-9 DCC COOLER UNIT GENERAL ASSEMBLY
MTD-3-0301
Chapter-4 Technical Data


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TABLE 4-1 DRAG CHAIN CONVEYOR
Description Details
Quantity One(1) per boiler
Equipment number 3BAD-CV501
Type Submerged, scrapper conveyor
Discharge Capacity Range 4t/h 11t/h
DCC speed 0.4m/min 1.0m/min
Chain size 25mm x 90mm
DCC width 2,150 mm
Horizontal length Approx. 7770mm
Sloped (Ramp) length Approx. 11,300mm
Upper Trough water volume 130m
3

Ramp angle 40
Motor 11kW / 380V /3 /4P/50 Hz
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Chapter-4 Technical Data


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TABLE 4-2 CLINKER CRUSHER
Description Details
Quantity One (1) per boiler
Equipment number 3BAD-CR541
Type Single Roll Cutter
Ability for crushing Max. 4.4t/h (Dry)/ Nor. 2.2t/h (Dry)
Inlet clinker size
Outlet clinker size
Max. 200mmcubic
Max. 25~75mm
Water content. 30 wt%
Bulk density of clinker 0.6~0.8t/m
3

Motor 5.5kW / 380V / 3/4P/50 Hz
Speed 30rpm


TABLE 4-3 DCC COOLING WATER HEAT EXCHANGER
Description Details
Quantity/ Type Two (2) per boiler/Shell and Tube
Equipment number
3BAD-H511A/B
Surface area 25.39m
2

Tube size O.D 15.88mm x (Min) t1.245m x 3350L
Tube pitch Qty: 152/pitch 19.844mm

Shell side Tube side
Kind of fluid
Cooling water from
CCW system
DCC recirculation
water
Flow
75.6t/h 37.8t/h
Design pressure
11barg 18barg
Operating pressure
6.35barg 1.96barg
Design temperature
60C 80C
Operating (IN/OUT)
38C/43C 60C/50C

Chapter-4 Technical Data


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TABLE 4-4 DCC COOLING WATER RECIRCULATION PUMP
Description Details
Quantity/Type Two (2) per boiler/ Centrifugal
Equipment number
3BAD-P511A/B
Capacity-rated 40m
3
/h
Head 23m
Liquid handled DCC water (pH 5.0-11.0)
Motor 5.5kW / 380V / 3 /4P/50 Hz




TABLE 4-5 DCC SLUDGE PUMP
Description Details
Quantity/Type Two (2) per boiler/ Submersible
Equipment number
3BAD-P521A/B
Rated Flow 0.5m
3
/min
Rated Head 12m
Liquid handled DCC water (pH 5.0-11.0)
Motor 3.7kW / 380V / 3 /4P/50 Hz

Chapter-4 Technical Data


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TABLE 4-6 CHEMICAL DOSING SYSTEM
Description Details
Caustic Soda Tank
Quantity One (1) per DCC
Equipment number 3BAD-T531
Capacity 1000L
Tank dimensions 1000ID x 1500H
Agitator Portable/ Type TGP4-0.4
Agitator Motor 0.4kW / 380V / 3 /4P/50 Hz
Dilute Sulfuric Acid Tank
Quantity One (1) per DCC
Equipment number 3BAD-T532
Capacity 600L
Tank dimensions 1106ID x 1160H
Barrel pump Type-HP-201

Chapter-5 Process Control


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Reference is made to the following documents:
Logic Diagrams for UCS-A & UCS-B Owners Document No.:A-DCS-I-TS-6468
(Toshiba Doc. No.7M6S2273/2274)
(Schematic Diagram of UCS-A & UCS-B:A-DCS-I-TS-5456/5457
(7K6S0 383/384)
DCS is provided for the Tanjung J ati 3&4 Units and basically all operations are carried
out from the Central Control Room. The DCS consists of Unit DCS and Common DCS
and coordinates with other systems like EHV System etc. for the complete operation of
the plant.
Boiler modulating control is implemented by UCS and the functions consist of the
following items.
1 Unit coordinate control
2 Combustion control
3 Furnace draft control
4 Feed water control
5 Steam temperature control
6 Primary air flow/pulverizer outlet temperature control
7 Primary air pressure control
8 Auxiliary steam pressure control
9 AH cold end metal temperature control
10 Wind box damper control
11 Burner atomizing steam/air pressure control
12 Pulverizer inerting steam pressure control
13 Boiler blowdown tank level/temperature control
14 Soot blower pressure control
15 Chemical injection control
16 Turbine bypass control.
All the above controls are described in System Description documents SD-01 to SD-05
as applicable to the system.
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Chapter-5 Process Control


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This section details the Bottom Ash Handling System controls provided to maintain the
DCC water level and DCC water temperature control.
5.1 DCC Water Temperature Control
Shell & tube heat exchangers are provided for the DCC recirculation water
temperature control. The DCC water flows through the tube side and closed
cooling water flows through the shell side. During commissioning, the closed
cooling water flow is set through the heat exchanger. Normally the DCC
recirculation water flow is around 37.8t/h through the heat exchanger tube side.
This operating condition generally maintains a DCC water temperature of 60C
in the upper trough.
However, when the balance is upset and if the DCC upper trough water
temperature increases beyond 65C, the DCC makeup water shutoff valve is
opened to admit fresh service water. Thus the DCC water temperature is
controlled within a 5C on upper side.
5.2 DCC Water Level Control
DCC is provided with an overflow facility and during normal operation the level
is maintained up to the overflow. When level goes down to a preset value
(<NWL-75mm) the DCC makeup water shutoff valve opens. The makeup water
shut-off valve closes when the level reaches a higher preset value (NWL).
5.3 DCC Water Storage Basin Level Control
The water storage basin level is under natural control with the DCC water
draining to settling basin which overflows to water storage basin and is pumped
back to DCC upper trough by the recirculation pump through the heat
exchangers.
The selected DCC cooling water recirculation pump is started automatically
when the water storage basin level is >bottom2530mm and stopped when
level is <bottom1030mm. The standby pump is started, if the level further
increases beyond >bottom3300mm and stopped when level is <bottom
2530mm. After 600 seconds from when water storage basin level is <bottom
2530mm, the makeup water shutoff valve is automatically opened. This is the
normal water storage basin level control. The running DCC cooling water
recirculation is tripped when level falls to <bottom830mm.
However, when the regime is upset due to high DCC water temperature and
makeup water addition, the storage basin level goes higher. When level goes up
to a preset value (>bottom3300mm) the DCC cooling water emergency blow
shutoff valve opens to dump some water to drain pit. The valve closes
automatically when the level remains below bottom3300mm for more than 5
seconds. Thus the ON/OFF control takes care of the high-high water level
situation.
The makeup water shutoff valve, DCC recirculation cooling water pumps and
DCC emergency shutoff valves can be operated manually from DCS after taking
the control to manual mode.
Chapter-6 Instrumentations, Alarm & Trip Set Points


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The instrumentation shown in the TABLE 6-1/6-2 is provided in the Bottom Ash Handling
System.
6.1 Instrumentation Parameters Monitored at CCR
TABLE 6-1 OPERATION PARAMETERS, ALARM & TRIP SET POINTS-CCR
Instrument
Tag No
Description Normal Range at
or near full load
Alarm/Trip Set
Point
Function
3BAD-FX501 DCC recirculation water flow 40t/h - Monitoring
3BAD-AX501 DCC recirculation water pH 7-9 <6.5 Caustic soda
dosing shutoff
valve open
permit
<NWL-75 mm Low alarm
DCC Make up
water shutoff
valve open
NWL DCC Make up
water shutoff
valve close
<NWL-90 mm DCC trip
3AW-LS501 DCC cooling water level NWL
>NWL+100 mm High alarm
>65C DCC Make up
water shutoff
valve open
3AW-TGS501 DCC cooling water temperature <60C
>70C High alarm
3BAD-LS503 DCC shoot level >Top-2660mm <Top-2660mm Clinker level
high alarm &
DCC trip
3BAD-LS502 Dilute sulfuric acid dosing tank level >Bottom +180
mm
<Bottom +180
mm
Low alarm
3BAD-LS501 Dilute caustic soda acid dosing tank
level
>Bottom +700
mm
<Bottom +700
mm
Low alarm
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Chapter-6 Instrumentations, Alarm & Trip Set Points


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Continued from previous page.
TABLE 6-1 OPERATION PARAMETERS, ALARM & TRIP SET POINTS-CCR
Instrument
Tag No
Description Normal Range at
or near full load
Alarm/Trip Set
Point
Function
>Bottom+3300
mm
High High alarm
DCC cooling water
emergency blow
shutoff valve open
DCC recirculation
pump standby
start
<Bottom+2530
mm
Stand by pump
stop
>Bottom+2530
mm
DCC recirculation
pump start
<Bottom+1030
mm
DCC recirculation
pump stop
3BAD-LGS501 DCC water storage basin level Approx.
Bottom+2000 mm
<Bottom+830
mm
DCC recirculation
pump trip
Low alarm
3BAD-ZS501 DCC tension upper limit <600 mm >600 mm Alarm

Chapter-6 Instrumentations, Alarm & Trip Set Points


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6.2 Instrumentation Parameters Monitored at Local
TABLE 6-2 OPERATION PARAMETERS, ALARM & TRIP SET POINTS-LOCAL
Instrument Tag No Description Normal Range at or
near full load
Alarm/Trip
Set Point
Function
3BAD-PG501A/B DCC CW recirculating pump
A/B suction pressure
- 0.5barg - Local
Monitoring
3BAD-PG502A/B
DCC CW recirculating pump
A/B discharge pressure
1.8barg - Local
Monitoring
3BAD-TG501
DCC CW temperature at
heat exchanger inlet
40C - Local
Monitoring
3BAD-TG502
DCC CW temperature at
heat exchanger outlet
37C - Local
Monitoring
3BAD-PG503
DCC sludge pump
discharge pressure
- - Local
Monitoring
3BAD-LG502
Dilute sulfuric acid dosing
tank level
>Bottom +180 mm - Local
Monitoring
3BAD-LG501
Caustic soda dosing tank
level
>Bottom +700 mm - Local
Monitoring