FUNCIONAL

FUNCTIONAL DESIGN SPECIFICATION
Document No C062930114-R04 FDS.doc

KRK Doc No RT-10-E-MDD-KRK-114
Rio Turbio, Santa Cruz Power Plant

Argentina
Fly Ash and Bed Ash Conveying Systems
ISSUE: 04
DATE: 24/01/11
BY: F Patel
Clyde Bergemann
Lakeside Boulevard
Lakeside
Doncaster, South Yorkshire
DN4 5PL, England
Telephone: +44 (0) 1302 552200

Facsimile: +44 (0) 1302 369055
Email: sales-projects@cbmh.co.uk
C062930114-R04 .doc
Functional Design Specification Sheet: 2 of 120
Date: 24/01/11
C06293 – Rio Turbio, Santa Cruz Power Plant Issue: 04
Introduction By: Fpatel
CONTENTS
1 INTRODUCTION......................................................................................................................... 7
2 CONTROL SYSTEM ................................................................................................................... 9
2.1 OVERVIEW – UNIT 1 & UNIT 2 ......................................................................................... 9
3 UNIT 1- MODEL 3.0/8 ASH VESSELS – AIR PRE-HEATERS .......................................... 10
3.1 OVERVIEW ......................................................................................................................... 10
3.2 SYSTEM AT REST.............................................................................................................. 11
3.3 ASH VESSEL OPERATING SEQUENCE ......................................................................... 12
3.4 TIMER DEFINITIONS AND VALUES .............................................................................. 15
3.5 OPERATOR CONTROLS AND INDICATIONS ............................................................... 16
3.6 SUMMARY OF ALARM CONDITIONS ........................................................................... 18
4 350M3 ASH STORAGE SILO ................................................................................................... 20
4.1 INDICATIONS ..................................................................................................................... 20
5 175M3 FLY ASH STORAGE SILO .......................................................................................... 21
5.1 INDICATIONS ..................................................................................................................... 21
6 UNIT 1- MODEL 8.0/12 ASH VESSELS- DUST COLLECTOR, ROW 1........................... 22
6.1 OVERVIEW ......................................................................................................................... 22
6.2 SYSTEM AT REST.............................................................................................................. 23
7.1 INDICATIONS ..................................................................................................................... 32

Date: 24/01/11
8.1 INDICATIONS ..................................................................................................................... 33
9.1 OVERVIEW ......................................................................................................................... 34
9.2 SYSTEM AT REST.............................................................................................................. 35
10.1 INDICATIONS ..................................................................................................................... 44
11.1 INDICATIONS ..................................................................................................................... 45
12 UNIT 2- MODEL 3.0/8 ASH VESSELS – AIR PRE-HEATERS .......................................... 46
12.1 OVERVIEW ......................................................................................................................... 46
12.2 SYSTEM AT REST.............................................................................................................. 47
13.1 INDICATIONS ..................................................................................................................... 56
14.1 OVERVIEW ......................................................................................................................... 57
14.2 SYSTEM AT REST.............................................................................................................. 58

Date: 24/01/11
15.1 INDICATIONS ..................................................................................................................... 67
16.1 OVERVIEW ......................................................................................................................... 68
16.2 SYSTEM AT REST.............................................................................................................. 69
17.1 INDICATIONS ..................................................................................................................... 78
18 CONVEYING ROUTE CONTROL- UNIT 1, AIR PREHEATER SYSTEM ..................... 79
18.1 OVERVIEW ......................................................................................................................... 79
18.2 DOME SWITCH VALVE .................................................................................................... 80
19.1 INDICATIONS ..................................................................................................................... 84
20.1 INDICATIONS ..................................................................................................................... 85

Date: 24/01/11
21 CONVEYING ROUTE CONTROL- UNIT 1, DUST COLLECTOR ROW 1 & 2 ............. 86
21.1 OVERVIEW ......................................................................................................................... 86
21.2 DOME SWITCH VALVE .................................................................................................... 87
22.1 INDICATIONS ..................................................................................................................... 91
23.1 INDICATIONS ..................................................................................................................... 92
24 BED ASH TRANSFER SYSTEM ............................................................................................. 93
24.1 OVERVIEW ......................................................................................................................... 93
24.2 SYSTEM AT REST.............................................................................................................. 94
25 350M3 ASH STORAGE SILO ................................................................................................. 101
25.1 INDICATIONS ................................................................................................................... 101
26 175M3 BED ASH STORAGE SILO ........................................................................................ 102
26.1 INDICATIONS ................................................................................................................... 102
27 MOTOR STOP/START ........................................................................................................... 103
27.1 OVERVIEW ....................................................................................................................... 103
28 SILO DISCHARGE EQUIPMENT ........................................................................................ 104
28.1 OVERVIEW ....................................................................................................................... 104

Date: 24/01/11
28.2 SYSTEM AT REST............................................................................................................ 105
28.3 CONDITIONED ASH DISCHARGE SEQUENCE .......................................................... 106
28.4 ASH CONDITIONER WASHOUT SEQUENCE ............................................................. 108
28.5 TIMER DEFINITIONS AND VALUES ............................................................................ 109
28.6 OPERATOR CONTROLS AND INDICATIONS ............................................................. 110
28.7 SUMMARY OF ALARM CONDITIONS ......................................................................... 112
29 350M3 ASH STORAGE SILO ................................................................................................. 115
29.1 INDICATIONS ................................................................................................................... 115
30 175M3 FLY ASH STORAGE SILO ........................................................................................ 116
30.1 INDICATIONS ................................................................................................................... 116
31 175M3 BED ASH STORAGE SILO ........................................................................................ 117
31.1 INDICATIONS ................................................................................................................... 117
32 MOTOR STOP/START ........................................................................................................... 118
32.1 OVERVIEW ....................................................................................................................... 118
33 COMPRESSOR SYSTEM ....................................................................................................... 119
33.1 OPERATOR CONTROLS AND INDICATIONS ............................................................. 119
34 RE-ISSUE NOTES.................................................................................................................... 120

Date: 24/01/11
1 INTRODUCTION
This description should be read in conjunction with the following drawings:
Process Flow Diagram C062930100
Unit 1 Air Pre-heaters

C062930105
P&ID 3.0/8 Ash vessels
Unit 1, Row 1
C062930101
Unit 1, Row 2
C062930102
Unit 2 Air Pre-heaters

C062930106
Unit 2, Row 1
C062930103
Unit 2, Row 2
C062930104
Unit 1 Bed Ash

C062930108
P&ID Bed Ash System & Blowers
Unit 2 Bed Ash

C062930109
P&ID Bed Ash System
350m3, 175m3 Fly ash & 175m3 Bed Ash Silo Tops
C062930107
P&ID Silo Top Arrangements
Switch Valves
C062930113
P&ID Dome Switch Valves
Date: 24/01/11
350m3 Silo Discharge
C062930110
P&ID 350m3 Silo Discharge System
175m3 Silo Discharge

C062930111
P&ID 2 x 175m3 Silo Discharge System
Compressors
C062930112
P&ID Compressor System
Date: 24/01/11
Control System By: F Patel
2 CONTROL SYSTEM
2.1 OVERVIEW – UNIT 1 & UNIT 2
The complete control system consists of One (1) Allen Bradley PLC Control Panel complete
with hot standby processors and door mounted HMI.
The PLC control panel will be used for the control and sequencing of the ash conveying
machines complete with their associated pneumatic panels and instrumentation, compressors,
air blowers and ash conditioners. Motor starters for the equipment will be located in a
separate MCC provided by the client. The termination for field wiring from the ash conveying
systems will be facilitated via dedicated terminal strips located in each panel. Operator
Interface will be via a local HMI operator terminal located to the front of the processor panel,
or remotely via the clients SCADA control system. Communications between the processor
panel and the clients SCADA system will be via dual redundant Ethernet.
C062930114-R04 .doc
Date: 24/01/11
Model 3.0/8 Ash Vessels By: F Patel
3 UNIT 1- MODEL 3.0/8 ASH VESSELS – AIR PRE-HEATERS
3.1 OVERVIEW
During normal operation of the system, ash will accumulate in the outlets from the Air
preaters. The ash will be discharged into the line of ash vessels mounted beneath the ESP
hoppers and will then be pneumatically conveyed to the ash silos via a switch valve. The ash
vessel system transfers ash in batches at a frequency set to achieve the system design transfer
rate.
A conveying sequence will be initiated when all of the start interlock conditions become true
and will proceed as follows:-
Level probes located in the 2 feed hoppers will signal the presence of material and will
initiate a conveying cycle for this line of ash vessels. The master vessel inlet Dome Valve will
be opened and ash will gravity discharge into the vessel. After a short time delay, the inlet
Dome Valves on the outlet ash vessel will be opened.
During filling, the outlet Dome Valve will be closed to prevent air from being drawn through
the conveying pipeline by the vacuum in the ESP.
Each inlet Dome Valve will remain open for a pre set time before closing.
When all of the inlet Dome Valves have closed and sealed, and the outlet Dome Valve has
opened, air will be introduced into the master ash vessel. The material will then be discharged
from all of the vessels into the conveying pipeline and will be conveyed to the ash silo.
Conveying air will also be introduced into the conveying pipe after each vessel to ensure
smooth conveying.
When the material has been discharged into the ash storage silo, signalled by a drop in
conveying pressure, the conveying air valves will be closed and the cycle will be complete.
High level switches in the ash silo will signal when the silo is full and the control system will
inhibit further operation of the Ash vessels.
The conveying air from the ash storage silo will be vented to atmosphere via a filter. It is
important that the filter cleaning is operated continuously while the ash vessels are in
operation. The exhaust from the filter must be unobstructed and open to atmosphere at all
times, even when the ash vessels are not in operation. This is to permit any compressed air
leakage into the system, or expansion of the air due to an increase in temperature, to be safely
vented.
Date: 24/01/11
3.2 SYSTEM AT REST
When the system is stopped and at rest the status of the valves will be as follows:
Control air off Control air on Control air on

Electrical power off Electrical power off Electrical power on
PLC mode off PLC mode off PLC mode run
Master vessel inlet Dome Valve Last position Closed Closed
(11ETG21 AA201Q01)
Outlet vessel inlet Dome Valve Last position Closed Closed
(11ETG22 AA201Q01)
Outlet Dome Valve Last position Open Open
(11ETG22 AA202Q02)
Conveying air valve Closed Closed Closed
(11ETG21 AA601P01)
Supplementary air valve Closed Closed Closed
(11ETG21 AA202 Q02)
The Ash vessels should be empty and at zero pressure.
Note: The Dome Valve incorporates an inflating seal. In the event of the loss of control air
pressure the valve will not be sealed.
Date: 24/01/11
3.3 ASH VESSEL OPERATING SEQUENCE
At the start of a conveying cycle the control system will check that the following cycle start
interlock conditions are fulfilled:
The start / stop / purge command is set to “START” or “PURGE”.
The conveying pipe pressure transmitter has not failed (11ETG21 PT01) (see summary
of alarms conditions).
Conveying pressure is < 0.3 Barg (11ETG21 PT01).
All vessel inlet Dome Valves are closed and sealed (11QFB21 PS01).
Low level probe in one or more of the ESP * outlets is covered (11ETG21 LS01) or
(11ETG22 LS01)
OR
Cycle start override command is activated.
Minimum cycle period timer is not running.

OR
The target ash silo high level probes are uncovered (11ETH01 LS01, 11ETH01 LS02)
or (10ETH01 LS01, 10ETH01 LS02)
Target silo differential pressure is not high (11ETH01 PD01, 11ETH01 PD02,
11ETH01 PD03 or 10ETH01 PD02 )
Dome switch valve is healthy - no alarms (see section 18.5)
Providing the start interlock conditions are true a conveying cycle will be initiated and will
proceed as follows:
3.3.1 Step 1
The master ash vessel inlet Dome Valve will be opened by energising solenoid (11QFB21
AA201-Y01). The master vessel inlet Dome Valve open timer (10 seconds), outlet vessel inlet
Dome Valve open delay timer (1 second), cycle watchdog timer (140 seconds), and minimum
cycle period timer (115 seconds - adjustable) will be started. Material will fall under gravity
into the master ash vessel.
Note: If purge is selected at the HMI the inlet Dome valves will not be opened and the cycle
will continue from step 4.
3.3.2 Step 2
When the outlet vessel inlet Dome Valve open delay timer has expired the outlet vessel inlet
Dome Valve will be opened by energising solenoid (11QFB22 AA201-YO1) and the outlet
Date: 24/01/11
vessel inlet Dome Valve open timer (10 seconds) and the outlet Dome Valve close delay
timer (1 second) will be started.
3.3.3 Step 3
When the outlet Dome Valve close delay timer has expired the outlet Dome Valve will be
closed by energising solenoid (11QFB22 AA202-Y02).
Note: As each of the inlet Dome Valve open timers expire, the appropriate inlet Dome Valve
will be closed by de-energising solenoids (11QFB21 AA201-Y01) (11QFB22 AA201-
Y01). When the outlet vessel inlet Dome Valve open timer expires the outlet vessel
inlet Dome Valve will be closed by de-energising solenoid (11QFB22 AA201-Y01)
and the outlet Dome Valve will be opened by de-energising solenoid (11QFB22
AA202-Y02).
3.3.4 Step 4
When all of the inlet Dome Valves have closed and sealed (11QFB21 PS01) (11QFB22
PS01) and the outlet Dome Valve has opened (11ETG22 ZS01), the conveying air valve
(11ETG21 AA203Q03) and supplementary air valve (11ETG21 AA202Q02) will be opened
by energising solenoids (11QFB21 AA202-Y02) and (11QFB21 AA202-Y02) respectively.
Simultaneously, the convey secure timer (20 seconds) will be started. Air will enter the
master ash vessel and the material will be discharged into the conveying pipe.
Note: If it takes longer than 60 seconds to move from step 3 to step 4 (i.e. for the valves to
close and seal) then the cycle shutdown alarm will be raised, the conveying cycle will
be terminated and the ash vessel system will return to the at rest condition. The system
start signals will also be disabled.
Note: If during conveying the vessel pressure rises above 3.0 Barg (11ETG21 PT01) then the
conveying air valve (11ETG21 AA203Q03) will be closed by de-energising the
solenoid (11QFB21 AA202-Y02). When the pressure has fallen below 2.5 Barg the
main conveying air valve (11ETG21 AA203Q03) will be re-opened. If the conveying
pressure rises above 4.0 Barg (11ETG21 PT01) then the supplementary air valve
(11ETG21 AA202Q02) will be closed by de-energising the solenoid (11QFB21
AA203-Y03). When the pressure has fallen below 3.5 Barg the supplementary air
valve (11ETG21 AA202Q02) will be re-opened.
3.3.5 Step 5
When the convey secure timer has expired and the pressure in the conveying pipeline has
fallen to less than 0.3 Barg (11ETG21 PT01), signalling that the transfer is complete, the
conveying air valve (11ETG21 AA203Q03) and supplementary air valve (11ETG21
AA202Q02) will be closed by de-energising solenoids (11QFB21 AA202-Y02) and
(11QFB21 AA203-Y03) respectively. The cycle reset timer (3 seconds) will be started.
3.3.6 Step 6
When the cycle reset timer has expired the conveying cycle is complete and the system is at
rest.
Note: If during the cycle any start interlocks become untrue, then that cycle will be permitted
to continue and end. The system will then stop until all of the start interlock conditions
once again become true. For example, at the start of the cycle the low level probe will
Date: 24/01/11
be covered. If this level probe becomes uncovered during the cycle, this will be ignored
and will not cause the cycle to stop or reset.
Similarly, where an event has to occur to permit the cycle to proceed to the next step,
then the progress of the cycle will be halted until that interlock condition has become
true. The cycle will then proceed to the next step.
Some cycle step interlocks may be used to shut down the conveying cycle if they have
not occurred within a preset time. If this happens then the conveying cycle will be
terminated and put to the at rest condition and the cycle start or purge commands will
be disabled.
Date: 24/01/11
3.4 TIMER DEFINITIONS AND VALUES
Timer name Purpose of timer Timer setting Timer range
Inlet Dome Valve During filling of the ash vessels the inlet 10 seconds 0 – 60 seconds
open timer Dome Valve will be opened for the duration
of the inlet Dome Valve open timer.
Inlet Dome Valve The opening of the inlet Dome Valves are 1 seconds 0 – 60 seconds
open delay timer staggered to allow the vessels to fill
uniformly. The stagger is set by the inlet
Dome Valve open delay timer.
Outlet Dome The outlet Dome Valve is closed after the 1 second 0 – 60 seconds
Valve close delay outlet vessel inlet Dome Valve is opened.
timer This is to allow the displaced air in the ash
vessels to be released and enables the ash
flow to become established before the
pipeline is sealed.
Cycle watchdog The cycle watchdog timer provides a 140 seconds 0 – 300 seconds
timer conveying cycle fault alarm if the conveying
cycle is not completed within the pre-set
time period.
Minimum cycle This regulates the maximum conveying 115 seconds 0 – 300 seconds
period timer cycle frequency. Adjustable
Convey secure The convey secure timer is to allow time for 20 seconds 0 – 120 seconds
timer the conveying pressure to rise before the line
pressure switch (11ETG21 PT01) is
interrogated.
Cycle reset timer The cycle reset timer provides time for the 3 seconds 0 – 20 seconds
pressure in the vessel and conveying
pipework to be completely released before
the start of another conveying cycle.
Dome Valve fault This allows a delay for the Dome Valve to 5 seconds 0 – 20 seconds
timer open / close before initiating a Dome Valve
fault alarm.
Hopper not This timer provides a fault alarm if the low 1800 seconds 0 – 2000
clearing timer level probes (11ETG21 LS01) or (11ETG22 seconds
LS01) are covered for more than a pre-set
time period (while the field is running).
Cycle shut down This timer allows a delay for the interlock 60 seconds 0 – 200 seconds
alarm timer fault to become healthy before a cycle shut
down is initiated.
Date: 24/01/11
3.5 OPERATOR CONTROLS AND INDICATIONS
3.5.1 PNEUMATIC CONTROL PANEL

A pneumatic control panel is provided at the ash vessel which houses the solenoid valves and
pressure switches associated with that vessel.
A pressure gauge mounted on the conveying air manifold adjacent to the ash vessel provides
local indication of the pressure in the conveying pipe.
3.5.2 ELECTRICAL CONTROL PANEL

The Ash vessels will be controlled by a PLC located in the main electrical control panel.
Operator Interface will be via a local HMI operator terminal located to the front of the
processor panel, or remotely via the clients SCADA control system
The following describes the operator controls, indications and alarms which should be made
available at the local and remote (if required) control stations.
Ash vessel main start / stop / purge command. This will permit the operators to start
and stop the line of ash vessels. When the command is set to “START” the ash
vessels will run normally. When the command is set to “PURGE” position the ash
vessels will cycle once without the inlet Dome Valves being opened. This is intended
for use in maintenance, or when clearing residual material from the system.
Note: If the “Cycle shut down alarm” is initiated (see alarm section), the start or
purge command will be disabled.
Cycle start override command. This command allows the ash vessels to be cycled
once in the absence of material or during the minimum cycle period timer by
overriding the low level probe in the feed hopper outlet and the minimum cycle
period timer.
Low level probe covered indication. This will be “on” when the low level probe
(11ETG21 LS01) or (11ETG22 LS01) in the feed hopper outlet is covered.
Inlet Dome Valve open / fault indication. This will be “on” when the inlet Dome
Valve open solenoid (11QFB21 AA201-Y01) or (11QFB22 AA201-Y01) is
energised and the seal pressure is < 5 Barg (11QFB21 PS01) or (11QFB22 PS01).
Indication will flash in the event of the inlet Dome Valve failing to open or failing to
close and seal. See summary of alarm conditions.
Outlet Dome Valve open / fault indication. This will be “on” when the outlet Dome
Valve close solenoid (11QFB22 AA202-Y02) is de-energised and the open limit
switch (11ETG22 ZS01) is made. Indication will flash in the event of the outlet
Dome Valve failing to open or failing to close. See summary of alarm conditions.
Conveying air valve open indication. The indication will be “on” when the
conveying air valve open solenoid (11QFB21 AA202-Y02) is energised.
Supplementary air valve open indication. The indication will be “on” when the
supplementary air valve open solenoid (11QFB21 AA203-Y03) is energised.
Date: 24/01/11
Ash chutes not clearing alarm indication. This will be “on” if one or more of the low
level probes (11ETG21 LS01) or (11ETG22 LS01) in the ESP outlets remain
covered for more than 30 minutes (while the Ash vessel system is running).
Conveying in progress indication. The indication will be “on” when the ash vessel
system is in the material conveying part of the cycle (steps 4 & 5).
Note:- The indication will remain illuminated throughout this part of the cycle even
if all the air valves have closed due to the high conveying pressure limit being
reached.
Sequence step indication. This will indicate the PLC operating sequence step
currently active (steps 1 to 6).
Conveying cycle fault indication. This will be “on” to indicate that there is a
conveying cycle fault. Indication will be given when any of the following occur:
The cycle watchdog timer has expired and a conveying cycle is still in
progress.
Conveying pressure is > 0.3 Barg (11ETG21 PT01) and a conveying cycle is
not in progress.
Conveying pressure indication. This will display a pressure between 0 and 6 Barg,
calibrated against the 4-20 mA signal from the pressure transducer (11ETG21 PT01).
Conveying pressure trace. This is a graphical representation of the conveying

pressure (11ETG21 PT01) over time. A minimum of 3 complete cycles will be
displayed, although the time axis should be easily configurable.
Conveying pressure transmitter failed indication. The indication will be “on” when
the conveying pressure transmitter has failed (see summary of alarms conditions).
Cycle shut down alarm indication. This indication will be “on” when the cycle shut
down alarm is activated (This alarm is latched within the PLC until the “START” or
“PURGE” command is set). (see summary of alarms).
The indications associated with the ash silos are described in section 4 & 5 – 350m3
Ash Storage Silo & 175m3 Fly Ash Storage Silo.
Date: 24/01/11
3.6 SUMMARY OF ALARM CONDITIONS
3.6.1 INLET DOME VALVE NOT OPEN ALARM

Definition:
Inlet Dome Valve open solenoid (11QFB21 AA201-Y01) or (11QFB22 AA201-Y01)
energised and seal pressure > 5.0 Barg (11QFB21 PS01) or (11QFB22 PS01) for more than 5
seconds.
Control Action:
Visual alarm only.
3.6.2 INLET DOME VALVE NOT CLOSED AND SEALED ALARM

Definition:
Inlet Dome Valve open solenoid (11QFB21 AA201-Y01) or (11QFB22 AA201-Y01) de-
energised and seal pressure < 5.0 Barg (11QFB21 PS01) or (11QFB22 PS01) for more than 5
seconds.
Control Action:
Visual alarm and conveying cycle start/progress inhibited.
3.6.3 OUTLET DOME VALVE NOT OPEN ALARM

Definition:
Outlet Valve close solenoid (11QFB22 AA202-Y02) de-energised and open limit switch
(11ETG22 ZS01) not made for more than 5 seconds.
Control Action:
Visual alarm and conveying cycle progress inhibited.
3.6.4 OUTLET DOME VALVE NOT CLOSED ALARM

Definition:
Outlet Valve close solenoid (11QFB22 AA202-Y02) energised and close limit switch
Control Action:
Visual alarm only.
3.6.5 CONVEYING CYCLE FAULT ALARM

Definition:
The cycle watchdog timer has expired and a conveying cycle is still in progress.
OR
Conveying pressure is > 0.3 Barg (11ETG21 PT01) and a conveying cycle is not in progress.
Control Action:
Visual alarm only and conveying cycle start inhibited if (11ETG21 PT01) > 0.3 Barg.
3.6.6 ASH CHUTES NOT CLEARING ALARM

Definition:
The “START” command is active and one or more of the low level probes (11ETG21 LS01)
or (11ETG22 LS01) in the ESP outlets is covered for more than 30 minutes.
Control Action:
Visual alarm only.
Date: 24/01/11
3.6.7 CONVEYING PIPE PRESSURE TRANSMITTER FAILED ALARM

Definition:
Conveying pressure transmitter signal (11ETG21 PT01) has been less than 3.5 mA for more
than 5 seconds or greater than 20.5 mA for more than 5 seconds.
Control Action:
Visual alarm and conveying cycle start inhibited.
3.6.8 CYCLE SHUT DOWN ALARM

Definition:
If a conveying cycle is at step 3 and any inlet Dome Valve has taken more than 60 seconds to
close and seal.
OR
If a conveying cycle is at step 3 and the outlet Dome Valve has taken more than 60 seconds to
open.
Control Action:
Visual alarm, conveying cycle terminated and system start signal disabled.
Date: 24/01/11
4 350m3 ASH STORAGE SILO
4.1 INDICATIONS

The following describes the indications and alarms available at the local and remote control
stations.
High level probe covered indication. This will be “on” when the high level probe
(11ETH01 LS01) or (11ETH01 LS02) in the ash silo is covered.
4.1.2 SILO FILTER DIFFERENTIAL PRESSURE HIGH / POWER FAULT ALARM

Definition:
Silo filter differential pressure greater than a set pressure (11ETH01 PD01, 11ETH01 PD02,
11ETH01 PD03)
OR
There is a power fault.
Control Action:
Date: 24/01/11
5 175m3 FLY ASH STORAGE SILO
5.1 INDICATIONS

stations.

Definition:
Silo filter differential pressure greater than a set pressure (10ETH01 PD01)
OR
Control Action:
Date: 24/01/11
6 UNIT 1- MODEL 8.0/12 ASH VESSELS- DUST COLLECTOR, ROW 1
6.1 OVERVIEW
During normal operation of the system, ash will accumulate in the outlets from the Dust
collectors. The ash will be discharged into the line of ash vessels mounted beneath the ESP
rate.
be opened and ash will gravity discharge into the vessel. Starting with the slave, the inlet
Dome Valves on the other ash vessels will be sequentially opened, with a short time delay
between each valve, until the outlet vessel inlet Dome valve has opened.
During filling, the open Dome switch valve leg will be closed to prevent air from being drawn
through the conveying pipeline by the vacuum in the ESP.
When all of the inlet Dome Valves have closed and sealed, and the relevant Dome switch
valve leg has opened, air will be introduced into the master ash vessel. The material will then
be discharged from all of the vessels into the conveying pipeline and will be conveyed to the
ash silo.
Conveying air will also be introduced into the conveying pipe after each slave vessel to
ensure smooth conveying.
vented.
Date: 24/01/11
6.2 SYSTEM AT REST

(11ETG31 AA201 Q01)
(11ETG32 AA201 Q01)
Slave vessel 1 inlet Dome Valve Last position Closed Closed
(11ETG33 AA201 Q01)
(11ETG34 AA201 Q01)
(11ETG31 AA203Q03)
(11ETG31 AA202Q02)
Date: 24/01/11
All vessel inlet Dome Valves are closed and sealed (11QFB31 PS01), (11QFB32 PS01),
(11QFB33 PS01), & (11QFB34 PS01).
Low level probe in one or more of the ESP * outlets is covered (11ETG31 LS01),
(11ETG32 LS01), (11ETG33 LS01) & (11ETG34 LS01).
OR

OR
or (10ETH01 LS01, 10ETH01 LS02)
proceed as follows:
6.3.1 Step 1
AA201-Y01). The master vessel inlet Dome Valve open timer (10 seconds), slave vessel 1
inlet dome valve open delay timer (1 second), cycle watchdog timer (200 seconds), and
minimum cycle period timer (105 seconds - adjustable) will be started. Material will fall
under gravity into the master ash vessel.
6.3.2 Step 2
When the slave 1 inlet Dome Valve open delay timer has expired the slave 1 vessel inlet
Dome Valve will be opened by energising solenoid (11QFB32 AA201-Y01) and the slave 1
Date: 24/01/11
vessel inlet Dome Valve open timer (10 seconds) and the slave 2 vessel inlet Dome valve
open delay timer (1 second) will be started.
6.3.3 Step 3
When the slave 2 vessel inlet Dome Valve open delay timer has expired the slave 2 vessel
inlet Dome Valve will be opened by energising solenoid (11QFB33 AA201-Y01) and the
slave 2 vessel inlet Dome Valve open timer (10 seconds) and the outlet vessel inlet Dome
Valve open delay timer (1 second) will be started.
6.3.4 Step 4
Dome Valve will be opened by energising solenoid (11QFB34 AA201-Y01) and the outlet
vessel inlet Dome Valve open timer (10 seconds) and the Dome Switch Valve close delay
6.3.5 Step 5
When the Dome Switch Valve close delay timer has expired and the 350m3 silo is the selected
route the Y Dome Switch Valve will be closed by de-energising solenoids (11QFB30 AA202-
Y02A) and energising (11QFB30 AA202-Y02B) - see section 19.
or
When the Dome Switch Valve close delay timer has expired and the 175m3 Fly ash silo is the
selected route the X Dome Switch Valve will be closed by de-energising solenoids (11QFB30
AA201-Y01A) and energising (11QFB30 AA201-Y01B) - see section 19.
will be closed by de-energising solenoids (11QFB31 AA201-Y01), (11QFB32 AA201-
Y01), (11QFB33 AA201-Y01) and (11QFB34 AA201-Y01). When the outlet vessel
inlet Dome Valve open timer expires the outlet vessel inlet Dome Valve will be closed
by de-energising solenoid (11QFB34 AA201-Y01).
Note 2: If the 350m3 silo is the selected route the X Dome Switch Valve will be opened by
energising solenoids (11QFB30 AA201-Y01A) and de-energising (11QFB30 AA201-
Y01B) - see section 19.
or
If the 175m3 Fly ash silo is the selected route the Y Dome Switch Valve will be opened
by energising solenoids (11QFB30 AA202-Y02A) and de-energising (11QFB30
AA202-Y02B) - see section 19.
6.3.6 Step 6
When all of the inlet Dome Valves have closed and sealed (11QFB31 PS01), (11QFB32
PS01), (11QFB33 PS01) and (11QFB34 PS01) and the relevant Dome Switch Valve leg is
open (11ETG30 ZS02 or 11ETG30 ZS01), the conveying air valve (11ETG31 AA203Q03)
and supplementary air valve (11ETG31 AA202Q02) will be opened by energising solenoid
(11QFB31 AA202-Y02) and (11QFB31 AA203-Y03) respectively. Simultaneously, the
convey secure timer (20 seconds) will be started. Air will enter the master ash vessel and the
material will be discharged into the conveying pipe.
Date: 24/01/11
6.3.7 Step 7
6.3.8 Step 8
rest.
be disabled.
Date: 24/01/11
pipeline is sealed.
time period.
interrogated.
fault alarm.
clearing timer level probes (11ETG31 LS01), (11ETG32 seconds
LS01) , (11ETG33 LS01) or (11ETG34
down is initiated.
Date: 24/01/11


The Ash vessel will be controlled by a PLC located in the main electrical control panel.
period timer.
(11ETG31 LS01), (11ETG32 LS01), (11ETG33 LS01) or (11ETG34 LS01) in the
feed hopper outlet is covered.
Valve open solenoid (11QFB31 AA201-Y01), (11QFB32 AA201-Y01), (11QFB33
AA201-Y01) or (11QFB34 AA201-Y01) is energised and the seal pressure is < 5
Barg (11QFB31 PS01), (11QFB32 PS01), (11QFB33 PS01) or (11QFB34 PS01).
level probes (11ETG31 LS01), (11ETG32 LS01), (11ETG33 LS01) or (11ETG34
Date: 24/01/11
LS01) in the ESP outlets remain covered for more than 30 minutes (while the Ash
vessel system is running).
reached.
progress.
not in progress.

The indications associated with the ash silos are described in section 7 & 8 – 350m3
Ash Storage Silo & 175m3 Fly Ash Storage Silo.
The indications associated with Dome switch valve are described in section 21.4 -
Operator Controls & Indications
Date: 24/01/11

Definition:
Inlet Dome Valve open solenoid (11QFB31 AA201-Y01), (11QFB32 AA201-Y01),
(11QFB33 AA201-Y01) or (11QFB34 AA201-Y01) energised and seal pressure > 5.0 Barg
(11QFB31 PS01), (11QFB32 PS01), (11QFB33 PS01) or (11QFB34 PS01) for more than 5
seconds.
Control Action:
Visual alarm only.

Definition:
(11QFB33 AA201-Y01) or (11QFB34 AA201-Y01) de-energised and seal pressure < 5.0
Barg (11QFB31 PS01), (11QFB32 PS01), (11QFB33 PS01) or (11QFB34 PS01) for more
than 5 seconds.
Control Action:

Definition:
OR
Control Action:

Definition:
The “START” command is active and one or more of the low level probes (11ETG31 LS01),
(11ETG32 LS01), (11ETG33 LS01) or (11ETG34 LS01) in the ESP outlets is covered for
more than 30 minutes.
Control Action:
Visual alarm only.

Definition:
Control Action:
Date: 24/01/11

Definition:
close and seal.
OR
open.
Control Action:
Date: 24/01/11
7.1 INDICATIONS

stations.
(11ETH01 LS01 or 11ETH01 LS02) in the ash silo is covered.

Definition:
11ETH01 PD03)
OR
Control Action:
Date: 24/01/11
8.1 INDICATIONS

stations.

Definition:
OR
Control Action:
Date: 24/01/11
9.1 OVERVIEW
rate.
During filling, the open Dome switch valve leg will be closed to prevent air from being drawn
through the conveying pipeline by the vacuum in the ESP.
When all of the inlet Dome Valves have closed and sealed, and the relevant Dome switch
valve leg has opened, air will be introduced into the master ash vessel. The material will then
be discharged from all of the vessels into the conveying pipeline and will be conveyed to the
ash silo.
vented.
Date: 24/01/11
9.2 SYSTEM AT REST

(11ETG41 AA201Q01)
(11ETG44 AA201Q01)
(11ETG42 AA201Q01)
(11ETG43 AA201Q01)
(11ETG41 AA203Q03)
(11ETG41 AA202Q02)
Date: 24/01/11
(11QFB43 PS01) & (11QFB44 PS01).
OR

OR
The target ash silo high level probes are uncovered

(11ETH01 LS01, 11ETH01 LS02) or (10ETH01 LS01, 10ETH01 LS02)
proceed as follows:
9.3.1 Step 1
minimum cycle period timer (105 seconds - adjustable) will be started. Material will fall
under gravity into the master ash vessel.
9.3.2 Step 2
Date: 24/01/11
9.3.3 Step 3
9.3.4 Step 4
9.3.5 Step 5
When the outlet Dome Valve close delay timer has expired and the 350m3 silo is the selected
route the Y Dome Switch valve will be closed by de-energising solenoids (11QFB40 AA202-
Y02A) and energising (11QFB40 AA202-Y02B) - see section 19.
or
When the Dome Switch Valve close delay timer has expired and the 175m3 Fly ash silo is the
selected route the X dome switch valve will be closed by de-energising solenoids (11QFB40
AA201-Y01A) and energising (11QFB40 AA201-Y01B) - see section 19
Y01), (11QFB43 AA201-Y01) or (11QFB44 AA201-Y01). When the outlet vessel inlet
Dome Valve open timer expires the outlet vessel inlet Dome Valve will be closed by
de-energising solenoid (11QFB44 AA201-Y01).
Note 2: If the 350m3 silo is the selected route the X Dome Switch Valve will be opened by
energising solenoids (11QFB40 AA201-Y01A) and de-energising (11QFB40 AA201-
Y01B) - see section 19.
or
If the 175m3 Fly ash silo is the selected route the Y Dome Switch Valve will be opened
by energising solenoids (11QFB40 AA202-Y02A) and de-energising (11QFB40
AA202-Y02B) - see section 19.
9.3.6 Step 6
PS01), (11QFB43 PS01) & (11QFB44 PS01) and the relevant Dome Switch Valve leg is
open (11ETG40 ZS02 or 11ETG40 ZS01), the conveying air valve (11ETG41 AA203Q03)
and supplementary air valve (11ETG41 AA202Q02) will be opened by energising solenoid
(11QFB41 AA202-Y02) and (11QFB41 AA203-Y03) respectively. Simultaneously, the
convey secure timer (20 seconds) will be started. Air will enter the master ash vessel and the
material will be discharged into the conveying pipe.
Date: 24/01/11
9.3.7 Step 7
The material will be conveyed through the pipeline to the target ash silo.
9.3.8 Step 8
rest.
be disabled.
Date: 24/01/11
pipeline is sealed.
time period.
interrogated.
fault alarm.
LS01) , (11ETG43 LS01) or (11ETG44
down is initiated.
Date: 24/01/11


period timer.
(11ETG41 LS01), (11ETG42 LS01) (11ETG43 LS01) or (11ETG44 LS01) in the
Date: 24/01/11
reached.
progress.
not in progress.

The indications associated with the ash silos are described in section 10 & 11 –
350m3 Ash Storage Silo & 175m3 Fly Ash Storage Silo.
The indications associated with Dome switch valve are described in section 21.4 -
Operator Controls & Indications
Date: 24/01/11

Definition:
seconds.
Control Action:
Visual alarm only.

Definition:
than 5 seconds.
Control Action:

Definition:
OR
Control Action:

Definition:
Control Action:
Visual alarm only.
CONVEYING PIPE PRESSURE TRANSMITTER FAILED ALARM

Definition:
Control Action:
Date: 24/01/11

Definition:
close and seal.
OR
open.
Control Action:
Date: 24/01/11
10.1 INDICATIONS

stations.

Definition:
11ETH01 PD03)
OR
Control Action:
Date: 24/01/11
11.1 INDICATIONS

stations.

Definition:
OR
Control Action:
Date: 24/01/11
12 UNIT 2- MODEL 3.0/8 ASH VESSELS – AIR PRE-HEATERS
12.1 OVERVIEW
During normal operation of the system, ash will accumulate in the outlets from the Air
preheaters. The ash will be discharged into the line of ash vessels mounted beneath the ESP
hoppers and will then be pneumatically conveyed to the ash silo. The ash vessel system
transfers ash in batches at a frequency set to achieve the system design transfer rate.
be opened and ash will gravity discharge into the vessel. After a short time delay, the inlet
Dome Valves on the outlet ash vessel will be opened.
Conveying air will also be introduced into the conveying pipe after each vessel to ensure
smooth conveying.
vented.
Date: 24/01/11
12.2 SYSTEM AT REST

(12ETG21 AA201Q01)
(12ETG22 AA201Q01)
(12ETG22AA202Q02)
(12ETG21 AA203Q03)
(12ETG21 AA202Q02)
Date: 24/01/11
All vessel inlet Dome Valves are closed and sealed (12QFB21 PS01) & (12QFB22
PS01).
Low level probe in one or more of the ESP * outlets is covered (12ETG21 LS01) or
(12ETG22 LS01)
OR

OR
The ash silo high level probes are uncovered (10ETH01 LS01) and (10ETH01 LS02)
proceed as follows:
12.3.1 Step 1
AA201-Y01). The master vessel inlet Dome Valve open timer (10 seconds), outlet vessel inlet
Dome Valve open delay timer (1 second), cycle watchdog timer (90 seconds), and minimum
cycle period timer (115 seconds - adjustable) will be started. Material will fall under gravity
into the master ash vessel.
12.3.2 Step 2
12.3.3 Step 3
Date: 24/01/11
Y01). When the outlet vessel inlet Dome Valve open timer expires the outlet vessel
inlet Dome Valve will be closed by de-energising solenoid (12QFB22 AA201-Y01)
and the outlet Dome Valve will be opened by de-energising solenoid (12QFB22
AA202-Y02).
12.3.4 Step 4
PS01) and the outlet Dome Valve has opened (12ETG22 ZS01), the conveying air valve
(12ETG21 AA203Q03) and supplementary air valve (12ETG21 AA202Q02) will be opened
by energising solenoids (12QFB21 AA202-Y02) and (12QFB21 AA203-Y03) respectively.
Simultaneously, the convey secure timer (20 seconds) will be started. Air will enter the
master ash vessel and the material will be discharged into the conveying pipe.
12.3.5 Step 5
The material will be conveyed through the pipeline to the ash silo.
12.3.6 Step 6
rest.
Date: 24/01/11
be disabled.
Date: 24/01/11
pipeline is sealed.
time period.
interrogated.
fault alarm.
clearing timer level probes (12ETG21 LS01) or (12ETG22 seconds
down is initiated.
Date: 24/01/11


period timer.
(12ETG21 LS01) or (12ETG22 LS01) in the feed hopper outlet is covered.
Valve open solenoid (12QFB21 AA201-Y01) or (12QFB22 AA201-Y01) is
energised and the seal pressure is < 5 Barg (12QFB21 PS01) or (12QFB22 PS01).
Date: 24/01/11
level probes (12ETG21 LS01) or (12ETG22 LS01) in the ESP outlets remain
covered for more than 30 minutes (while the Ash vessel system is running).
reached.
progress.
not in progress.

The indications associated with the ash silo is described in section 13 – 175m3 Fly
Ash Storage Silo.
Date: 24/01/11

Definition:
Inlet Dome Valve open solenoid (12QFB21 AA201-Y01) or (12QFB22 AA201-Y01)
energised and seal pressure > 5.0 Barg (12QFB21 PS01) or (12QFB22 PS01) for more than 5
seconds.
Control Action:
Visual alarm only.

Definition:
Inlet Dome Valve open solenoid (12QFB21 AA201-Y01) or (12QFB22 AA201-Y01) de-
energised and seal pressure < 5.0 Barg (12QFB21 PS01) or (12QFB22 PS01) for more than 5
seconds.
Control Action:

Definition:
Control Action:

Definition:
Control Action:
Visual alarm only.

Definition:
OR
Control Action:

Definition:
The “START” command is active and one or more of the low level probes (12ETG21 LS01)
or (12ETG22 LS01) in the ESP outlets is covered for more than 30 minutes.
Control Action:
Visual alarm only.
Date: 24/01/11

Definition:
Control Action:

Definition:
close and seal.
OR
open.
Control Action:
Date: 24/01/11
13.1 INDICATIONS

stations.

Definition:
OR
Control Action:
Date: 24/01/11
14.1 OVERVIEW
vented.
Date: 24/01/11
14.2 SYSTEM AT REST

(12ETG31 AA201Q01)
(12ETG34 AA201Q01)
(12ETG32 AA201Q01)
(12ETG33 AA201Q01)
(12ETG34 AA202Q02)
(12ETG31 AA203Q03)
(12ETG31 AA202Q02)
Date: 24/01/11
(12QFB33 PS01), & (12QFB34 PS01).
OR

OR
The target ash silo high level probes are uncovered (10ETH01 LS01) and (10ETH01
LS02)
proceed as follows:
14.3.1 Step 1
minimum cycle period timer (65 seconds - adjustable) will be started. Material will fall under
gravity into the master ash vessel.
14.3.2 Step 2
14.3.3 Step 3
Date: 24/01/11
14.3.4 Step 4
14.3.5 Step 5
Y01), (12QFB33 AA201-Y01), (12QFB34 AA201-Y01). When the outlet vessel inlet
de-energising solenoid (12QFB34 AA201-Y01) and the outlet Dome Valve will be
opened by de-energising solenoid (12QFB34 AA202-Y02).
14.3.6 Step 6
PS01), (12QFB33 PS01) and(12QFB34 PS01) and the outlet Dome Valve has opened
(12ETG34 ZS01), the conveying air valve (12ETG31 AA203Q03) and supplementary air
valve (12ETG31 AA202Q02) will be opened by energising solenoid (12QFB31 AA202-Y02)
and (12QFB31 AA203-Y03) respectively. Simultaneously, the convey secure timer (20
seconds) will be started. Air will enter the master ash vessel and the material will be
discharged into the conveying pipe.
14.3.7 Step 7
Date: 24/01/11
14.3.8 Step 8
rest.
be disabled.
Date: 24/01/11
pipeline is sealed.
time period.
interrogated.
fault alarm.
LS01) , (12ETG33 LS01) or (12ETG34
down is initiated.
Date: 24/01/11


period timer.
Date: 24/01/11
reached.
progress.
not in progress.

The indications associated with the ash silo is described in section 15– 175m3 Fly
Ash Storage Silo.
Date: 24/01/11

Definition:
seconds.
Control Action:
Visual alarm only.

Definition:
than 5 seconds.
Control Action:

Definition:
Control Action:

Definition:
Control Action:
Visual alarm only.

Definition:
OR
Control Action:

Definition:
Date: 24/01/11
Control Action:
Visual alarm only.

Definition:
Control Action:

Definition:
close and seal.
OR
open.
Control Action:
Date: 24/01/11
15.1 INDICATIONS

stations.
(10ETH01 LS01, or 10ETH01 LS02) in the ash silo is covered.

Definition:
OR
Control Action:
Date: 24/01/11
16.1 OVERVIEW
vented.
Date: 24/01/11
16.2 SYSTEM AT REST

(12ETG41 AA201Q01)
(12ETG44 AA201Q01)
(12ETG42 AA201Q01)
(12ETG43 AA201Q01)
(12ETG44 AA202Q02)
(12ETG41 AA203Q03)
(12ETG41 AA202Q02)
Date: 24/01/11
(12QFB43 PS01) & (12QFB44 PS01).
OR

OR
The target ash silo high level probes are uncovered (10ETH01 LS01) and (10ETH01
LS02)
proceed as follows:
16.3.1 Step 1
AA201-Y01 ). The master vessel inlet Dome Valve open timer (10 seconds), slave vessel 1
minimum cycle period timer (65 seconds - adjustable) will be started. Material will fall under
gravity into the master ash vessel.
16.3.2 Step 2
16.3.3 Step 3
Date: 24/01/11
16.3.4 Step 4
16.3.5 Step 5
will be closed by de-energising solenoids (12QFB41 AA201-Y01) (12QFB42 AA201-
Y01) (12QFB43 AA201-Y01) (12QFB44 AA201-Y01). When the outlet vessel inlet
de-energising solenoid (12QFB44 AA201-Y01) and the outlet Dome Valve will be
opened by de-energising solenoid (12QFB44 AA202-Y02).
16.3.6 Step 6
PS01), (12QFB43 PS01) & (12QFB44 PS01) and the outlet Dome Valve has opened
(12ETG44 ZS01), the conveying air valve (12ETG41 AA203Q03) and supplementary air
valve (12ETG41 AA202Q02) will be opened by energising solenoid (12QFB41 AA202-Y02)
and (12QFB41 AA203-Y03) respectively. Simultaneously, the convey secure timer (20
seconds) will be started. Air will enter the master ash vessel and the material will be
discharged into the conveying pipe.
16.3.7 Step 7
Date: 24/01/11
16.3.8 Step 8
rest.
be disabled.
Date: 24/01/11
pipeline is sealed.
time period.
interrogated.
fault alarm.
LS01) , (12ETG43 LS01) or (12ETG44
down is initiated.
Date: 24/01/11


period timer.
Date: 24/01/11
reached.
Conveying pressure is > 0.3 Barg (12ETG41 PT01) and a conveying cycle is not in
progress.

The indications associated with the ash silo is described in section 17– 175m3 Fly
Ash Storage Silo.
Date: 24/01/11

Definition:
seconds.
Control Action:
Visual alarm only.

Definition:
than 5 seconds.
Control Action:

Definition:
Control Action:

Definition:
Control Action:
Visual alarm only.

Definition:
OR
Control Action:

Definition:
Date: 24/01/11
Control Action:
Visual alarm only.

Definition:
Control Action:

Definition:
close and seal.
OR
open.
Control Action:
Date: 24/01/11
17.1 INDICATIONS

stations.

Definition:
OR
Control Action:
Date: 24/01/11
C06293 – Rio Turbio, Santa Cruz Power plant Issue: 04
Switch valve- Unit 1 Air Preheater system By: F Patel
18 CONVEYING ROUTE CONTROL- UNIT 1, AIR PREHEATER SYSTEM
18.1 OVERVIEW
The material from the Ash Vessels will be routed to the either the 350m3 Storage silo or the
175m3 Fly ash storage silo by means of a Dome Switch Valve to physically set the route.
To permit the route to be changed the conveying cycle must be “at rest”.
For each conveying pipe a 2 position switch for each ash storage silo will enable the operators
to select that silo for filling. The two positions will be labelled “DISABLE” and “ENABLE”.
When the switch is in the “ENABLE” position then that silo will be filled until the silo high
level switch is covered. When the silo has been filled and the high level switch is covered, or
if the “DISABLE/ENABLE” switch is set to the “DISABLE” position then any current
Conveying cycle will be permitted to continue and end. The control system will then change
the routing to another silo that is set to “ENABLE” and whose high level switch is uncovered.
If another silo is not available the control system will inhibit further operation of the Ash
Vessels/MD-Pump vessels.
System Target location Dome Switch Valve

Dome Valve X Dome Valve Y
Ash vessels 350m3 Storage Silo Open Closed
175m3 Fly Ash Closed Open
Storage Silo
Prior to the Ash vessel operating cycle the control system will check the position of the
associated dome switch valve to ensure that the route is correctly set. In the event of a switch
valve fault the control system will inhibit the operation of the Ash vessels until the fault has
been rectified. This is referred to as the “conveying route confirmed” requirement in the
Conveying cycle start interlocks.
Prior to the Ash vessel operating cycle the control system will check the status of the high
level switch in the target reception silo to ensure that there is sufficient space available for a
charge of material. In the event that the high level switch in the current target silo is covered
then the control system will change the routing to the other available silo, or inhibit the
operation of the Ash vessels.
Date: 24/01/11
18.2 DOME SWITCH VALVE
18.2.1 GENERAL
The Dome Switch Valve comprises a Y shaped junction with a Dome Valve mounted on each
of the branches. The material is routed through the appropriate branch by opening the Dome
Valve on that branch and closing the Dome Valve on the other branch.
A position switch provides confirmation that a Dome Valve has fully opened. A pressure
switch, connected to the inflating seal of the Dome Valve, provides a signal that the valve has
closed and sealed.
The position of the Dome Valves may only be changed when the Ash vessel cycle has been
completed and the system is at rest.
The routing valves cannot change if the Ash vessel is in cycle and the cycle can not start until
the route valve positions are confirmed.
18.2.2 CHANGING THE DOME SWITCH VALVE POSITION
18.2.2.1 Provided the Ash vessel cycle is complete and the system is at rest, the Dome
Valve open and closed solenoids (11QFB AA202-Y02A/B and 11QFB20 AA201-Y01A/B)
will be energised/de-energised to open and close the appropriate valves for the selected route.
18.2.2.2 When the seal pressure switch (11QFB20 PS02 or 11QFB20 PS01) indicates
that the appropriate valve has closed and sealed, and when the open position switch
(11ETG20 ZS02 or 11ETG20 ZS01) indicates that the other valve has fully opened, the Dome
Switch Valve position is confirmed as correct.
18.2.2.3 In the event that the solenoids are energised/de-energised for more than 5
seconds and the appropriate valve position is not confirmed, then the required target silo
“selected” indication will flash to alert the operators of a route valve fault.
Date: 24/01/11
Dome Valve fault This allows a delay for the Dome 5 seconds 0 – 20 seconds
timer Valve to open or close before
initiating a Dome Valve fault alarm.
Date: 24/01/11

A pneumatic control panel is provided at each of the Switch Valves which houses the
solenoid valves and pressure switch associated with that valve.

The following describes the operator controls, indications and alarms available at the local
and remote control stations.
Storage silo “DISABLE/ENABLE” command. The silo will be filled if this

command is set to the “ENABLE” position until the high level switch is covered.
When the high level switch is covered, or if the command is set to “DISABLE” then
any current conveying cycle will be permit to continue and end. The control system
will then change the routing to the other available silo, or inhibit further operation of
the Ash vessels.
Switch Dome Valve open / fault indication. The indication will be “on” when the
switch Dome Valve open solenoid (11QFB20 AA202-Y02A or 11QFB20 AA201-
Y01A) is energised and the close solenoid (11QFB20 AA202-Y02B or 11QFB20
AA201-Y01B) is de-energised and the switch Dome Valve seal pressure switch
(11QFB20 PS02 or 11QFB20 PS01) is made. The indication will flash in the event
of the switch Dome Valve failing to open or failing to close and seal. See summary
of alarm conditions.
Date: 24/01/11
18.5.1 DOME SWITCH VALVE FAULT ALARM (1 per switch valve)

Definition:
Dome Switch Valve open solenoid (11QFB20 AA202-Y02A or 11QFB20 AA201-Y01A)
energised for more than 5 seconds and open position switch (11ETG20 ZS02 or 11ETG20
ZS01) not made.
or:
Dome Switch Valve close solenoid (11QFB20 AA202-Y02B or 11QFB20 AA201-Y01B)
energised for more than 5 seconds and seal pressure < 5.0 barg (11QFB20 PS02 or 11QFB20
PS01).
Control Action:
Date: 24/01/11
19.1 INDICATIONS

stations.

Definition:
11ETH01 PD03)
OR
Control Action:
Date: 24/01/11
20.1 INDICATIONS

stations.

Definition:
OR
Control Action:
Date: 24/01/11
Switch valve- Unit 1 Dust collectors Row 1 & 2 By: F Patel
21 CONVEYING ROUTE CONTROL- UNIT 1, DUST COLLECTOR ROW 1 & 2
21.1 OVERVIEW
The material from the Ash Vessels will be routed to the either the 350m3 Storage silo or the
175m3 Fly ash storage silo by means of a Dome Switch Valve to physically set the route.
To permit the route to be changed the conveying cycle must be “at rest”.
For each conveying pipe a 2 position switch for each ash storage silo will enable the
operators to select that silo for filling. The two positions will be labelled “DISABLE” and
“ENABLE”. When the switch is in the “ENABLE” position then that silo will be filled until
the silo high level switch is covered. When the silo has been filled and the high level switch
is covered, or if the “DISABLE/ENABLE” switch is set to the “DISABLE” position then
any current Conveying cycle will be permitted to continue and end. The control system will
then change the routing to another silo that is set to “ENABLE” and whose high level switch
is uncovered. If another silo is not available the control system will inhibit further operation
of the Ash Vessels/MD-Pump vessels.
System Target location Dome Switch Valve

Dome Valve X Dome Valve Y
Ash vessels 350m3 Storage Silo Open Closed
175m3 Fly Ash Closed Open
Storage Silo
Prior to the Ash vessel operating cycle the control system will check the position of the
associated dome switch valve to ensure that the route is correctly set. In the event of a
switch valve fault the control system will inhibit the operation of the Ash vessels until the
fault has been rectified. This is referred to as the “conveying route confirmed” requirement
in the Conveying cycle start interlocks.
Prior to the Ash vessel operating cycle the control system will check the status of the high
level switch in the target reception silo to ensure that there is sufficient space available for a
charge of material. In the event that the high level switch in the current target silo is covered
then the control system will change the routing to the other available silo, or inhibit the
operation of the Ash vessels.
Date: 24/01/11
21.2 DOME SWITCH VALVE
21.2.1 GENERAL
The Dome Switch Valve comprises a Y shaped junction with a Dome Valve mounted on
each of the branches. The material is routed through the appropriate branch by opening the
Dome Valve on that branch and closing the Dome Valve on the other branch.
A position switch provides confirmation that a Dome Valve has fully opened. A pressure
switch, connected to the inflating seal of the Dome Valve, provides a signal that the valve
has closed and sealed.
The position of the Dome Valves may only be changed when the Ash vessel cycle has been
completed and the system is at rest.
The routing valves cannot change if the Ash vessel is in cycle and the cycle can not start
until the route valve positions are confirmed.
21.2.2 CHANGING THE DOME SWITCH VALVE POSITION
21.2.2.1 Provided the Ash vessel cycle is complete and the system is at rest, the Dome
Valve open and closed solenoids (11QFB30 AA202-Y02A/B & 11QFB30 AA201-Y01A/B
or 11QFB40 AA202-Y02A/B & 11QFB40 AA201-Y01A/B) will be energised/de-energised
to open and close the appropriate valves for the selected route.
21.2.2.2 When the seal pressure switch (11QFB30 PS02 or 11QFB30 PS01, 11QFB40
PS02 or 11QFB40 PS01 ) indicates that the appropriate valve has closed and sealed, and
when the open position switch (11ETG30 ZS02 or 11ETG30 ZS01, 11ETG40 ZS02 or
11ETG40 ZS01) indicates that the other valve has fully opened, the Dome Switch Valve
position is confirmed as correct.
21.2.2.3 In the event that the solenoids are energised/de-energised for more than 5
seconds and the appropriate valve position is not confirmed, then the required target silo
“selected” indication will flash to alert the operators of a route valve fault.
21.2.3 THE DOME SWITCH VALVE ACTING AS OUTLET VALVE
21.2.3.1 When conveying cycle is at step 5 (see section 6.3.5 or 9.3.5) and the Dome
Switch Valve close delay timer has expired both valves (11ETG30 AA202Q02 & 11ETG30
AA201Q01 or 11ETG40 AA202Q02 & 11ETG40 AA201Q01) will be closed.
21.2.3.2 When the outlet vessel inlet Dome Valve has closed (see section 6.3.6) then
both valves (11ETG30 AA202Q02 & 11ETG30 AA201Q01 or 11ETG40 AA202Q02 &
11ETG40 AA201Q01) will be opened by energising solenoid (11QFB30 AA202-Y02A &
11QFB30 AA201-Y01A or 11QFB40 AA202-Y02A & 11QFB40 AA201-Y01A) and de-
energising (11QFB30 AA202-Y02B & 11QFB30 AA201-Y01B or 11QFB40 AA202-Y02B
& 11QFB40 AA201-Y01B) .
Date: 24/01/11
Dome Valve fault This allows a delay for the Dome 5 seconds 0 – 20 seconds
timer Valve to open or close before
initiating a Dome Valve fault alarm.
Date: 24/01/11

A pneumatic control panel is provided at each of the Switch Valves which houses the
solenoid valves and pressure switch associated with that valve.

The following describes the operator controls, indications and alarms available at the local
and remote control stations.
Storage silo “DISABLE/ENABLE” command. The silo will be filled if this

command is set to the “ENABLE” position until the high level switch is covered.
When the high level switch is covered, or if the command is set to “DISABLE” then
any current conveying cycle will be permit to continue and end. The control system
will then change the routing to the other available silo, or inhibit further operation
of the Ash vessels.
Switch Dome Valve open / fault indication. The indication will be “on” when the
switch Dome Valve open solenoid (11QFB30 AA202-Y02A or 11QFB30 AA201-
Y01A OR 11QFB40 AA202-Y02A or 11QFB40 AA201-Y01A) is energised and
the close solenoid (11QFB30 AA202-Y02B or 11QFB30 AA201-Y01B OR
11QFB40 AA202-Y02B or 11QFB40 AA201-Y01B) is de-energised and the switch
Dome Valve seal pressure switch (11QFB30 PS02 or 11QFB30 PS01 OR 11QFB40
PS02 or 11QFB40 PS01) is made. The indication will flash in the event of the
switch Dome Valve failing to open or failing to close and seal. See summary of
alarm conditions.
Date: 24/01/11
21.5.1 DOME SWITCH VALVE FAULT ALARM (1 per switch valve)

Definition:
Dome Switch Valve open solenoid (11QFB30 AA202-Y02A or 11QFB30 AA201-Y01A
OR 11QFB40 AA202-Y02A or 11QFB40 AA201-Y01A) energised for more than 5 seconds
and open position switch (11ETG30 ZS02 or 11ETG30 ZS01 OR 11ETG40 ZS02 or
11ETG40 ZS01) not made.
or:
Dome Switch Valve close solenoid (11QFB30 AA202-Y02B or 11QFB30 AA201-Y01B
OR 11QFB40 AA202-Y02B or 11QFB40 AA201-Y01B) energised for more than 5 seconds
and seal pressure < 5.0 barg (11QFB30 PS02 or 11QFB30 PS01 OR 11QFB40 PS02 or
11QFB40 PS01).
Control Action:
Date: 24/01/11
22.1 INDICATIONS

stations.

Definition:
11ETH01 PD03)
OR
Control Action:
Date: 24/01/11
23.1 INDICATIONS

stations.

Definition:
OR
Control Action:
Date: 24/01/11
Bed Ash transfer System By: F Patel
24 BED ASH TRANSFER SYSTEM
24.1 OVERVIEW
Unit 1 and unit 2 have identical bed ash systems. Each unit transfers coarse bed ash via
rotary valves to their individual storage silos (unit 1- 350m3 silo & unit 2- 175m3 Fly ash
storage silo) using 2 x 160kw blower units on each side. There are 5 blowers in total with the
remaining blower on standby duty.
The coarse ash will first be fed through two D.D (Delta Ducon) rotary valves which will
meter the bed ash at atmospheric pressure. A further two rotary valves are set in series of the
D.D rotary valves to provide an airlock between the pressurised environment of the
conveying pipe below and the atmospheric pressure above the D.D rotary valves
When all of the start interlocks are met the conveying sequence will continue as follows:
The blowers will be started. (The blower isolation butterfly valves are manually open/closed
by the operator) When the blowers are confirmed running the rotary valve will be started.
The system will convey until stopped by the operator.
The above rotary valve arrangement will be identical for units 1 & 2
Date: 24/01/11
24.2 SYSTEM AT REST

Blower motor Stopped Stopped Stopped
(11SCA02 AN001-M01,
11SCA03 AN003-M01)
Blower cooling fan motor Stopped Stopped Stopped
(11SCA02 AN002-M01,
11SCA03 AN004-M01)
Rotary Valve Motor Stopped Stopped Stopped
(11ETD11 AF001-M01,
11ETD12 AF001-M01)
Date: 24/01/11
LPA ASH HANDLING OPERATING SEQUENCE
At the start of ash transfer cycle the control system will check that the following cycle start
The ash transfer “START” command has been set at the HMI.
The Delta Ducon Rotary valve "run request" signal is enabled
The Rotary valve motor is healthy (available) (see summary of alarm conditions
section 24.5)
All relevant blower motors are healthy (available) (see summary of alarm conditions
section 24.5)
Conveying pressure is < 0.3 Barg
E/STOP button has not been activated for the any associated equipment
or (10ETH01 LS01, 10ETH01 LS02) or (12ETE01 LS01, 12ETE01 LS02)
Target Silo filter differential pressure is not high (11ETH01 PD01, 11ETH01 PD02,
11ETH01 PD03 or 10ETH01 PD01 or 12ETE01 PD01, 12ETE01 PD02)
Providing the start interlock conditions above are true an ash transfer cycle will be initiated
and will proceed as follows:
24.2.1 Step 1
If the Local / Remote selection switch is set to "Remote", the Blowers (11SCA02 AN001 &
11SCA03 AN003, 12SCA02 AN007 & 12SCA03 AN009) and blower cooling fans
(11SCA02 AN002 & 11SCA03 AN004, 12SCA02 AN008 & 12SCA03 AN010) will be
started. (see section 25 for motor control)
or
If the Local / Remote selection switch is set to "Local", the sequence will continue from step
2.
Note: On a blower failure or blower start up the appropriate manual valves need to be
open/closed by the operator. The cooling fans will be interlocked with its blower motors.
There is no Remote facility for the Standby blower and cooling fan
24.2.2 Step 2
If the Local / Remote selection switch is set to "Remote" and the Blowers and associated
fans are confirmed running and the conveying pressure is < 0.3 Barg (11ETD11
AF001CP01, 12ETD11 AF001CP01) the rotary valves will be started. (see section 25 for
motor control).
or
Date: 24/01/11
If the Local / Remote selection switch is set to "Local", and unit 1 blower 1 and unit 1
blower 2 or unit 1 blower 1 and standby blower or unit 1 blower 2 and standby blower (same
for unit 2) are confirmed running with their associated cooling fans and the conveying
pressure is <0.3 Barg (11ETD11 AF001CP01, 12ETD11 AF001CP01), the rotary valves will
be started and the sequence will continue from step 3.
Note: If during the cycle the conveying pressure becomes greater than 0.85 Barg, the
sequence will be stopped and reset to its At-Rest condition (the "run permit" signal will be
removed).
24.2.3 Step 3
When the Rotary valve has been confirmed running (11ETD11 AF001XT01, 11ETD12
AF001XT01 & 12ETD11 AF001XT01, 12ETD12 AF001XT01) the "run permit" signal will
be energised, the Delta Ducon rotary valve will start (client control system).
Note: If any one of the rotary valves fail the bed ash system for that unit will shut down and
reset to its at rest condition.
24.2.4 Step 4
When the ash transfer "disable" command is set the "run permit" signal will be removed (the
Delta Ducon rotary valve will stop) and the in flight timer (20 seconds) will be started
Note: If the run request signal from the Delta Ducon valve is lost the ash transfer system for
that unit will stop
24.2.5 Step 5
When the in flight timer has expired the Rotary valve, blowers and fans will be stopped (see
section 25 for motor control)
24.2.6 Step 6
When the Rotary valve, blowers and fans are confirmed stopped the system will be at rest.
Note:
If a Blower motor not running alarm OR motor not healthy alarm becomes true, the motor
will be stopped (see section 25 for motor control), the sequence will be stopped and reset to
its At-Rest condition (the "run permit" signal will be removed).
If the Rotary valve motor not running alarm OR motor not healthy alarm becomes true, the
motor will be stopped (see section 25 for motor control), the sequence will be stopped and
reset to its At-Rest condition (the "run permit" signal will be removed).
If a motor is stopped due to an alarm condition then the motor will not automatically restart
when the alarm returns to a healthy condition, but will need to be re-started by re-initiating
the “ENABLE” command.
Date: 24/01/11
In-Flight timer Allows the Rotary valve pockets to be 20 seconds 0 - 120 seconds
emptied of ash
Date: 24/01/11

The Bed ash transfer will be controlled by a PLC located in the main electrical control panel.
Enable / Disable command / indication. This will permit the operators to start and
stop the rotary valves. When the command is set to “ENABLE” position the system
will start provided the relevant interlocks are true.
Rotary valve jog reverse command / indication. This indication will be “on” when
the Rotary valve running reverse signal (11ETD11 AF001XT02, 11ETD12
AF001XT02, 12ETD11 AF001XT02, 12ETD12 AF001XT02) is received. This
facility is intended for use to clear a blockage, the motor is not intended to run
continuously in reverse (see section 25 for motor control).
Rotary valve running / fault indication. This indication will be “on” when the rotary
valve “STOP” contact (11ETD11 AF001XJ03, 11ETD12 AF001XJ03, 12ETD11
AF001XJ03 or 12ETD12 AF001XJ03) is energised and the “RUNNING” signal
(11ETD11 AF001XT01, 11ETD12 AF001XT01, 12ETD11 AF001XT01, 12ETD12
AF001XT01) is received. The indication will flash in the event of an alarm. See
summary of alarm conditions.
Blower running / fault indication. This indication will be “on” when the blower
“STOP” contact (11SCA02 AN001XJ02, 11SCA03 AN003XJ02, 10SCA02
AN005XJ02, 12SCA02 AN007XJ02 or 12SCA03 AN009XJ02) is energised and
the “RUNNING” signal (11SCA02 AN001XT01, 11SCA03 AN003XT01,
10SCA02 AN005XT01, 12SCA02 AN007XT01, 12SCA03 AN009XT01) is
received. The indication will flash in the event of an alarm. See summary of alarm
conditions.
Blower cooling fan running / fault indication. This indication will be “on” when the
cooling fan “STOP” contact (11SCA02 AN002XJ02, 11SCA03 AN004XJ02,
10SCA02 AN006XJ02, 12SCA02 AN008XJ02, 12SCA03 AN010XJ02) is
energised and the “RUNNING” signal (11SCA02 AN002XT01, 11SCA03
AN004XT01, 10SCA02 AN006XT01, 12SCA02 AN008XT01, 12SCA03
AN010XT01) is received. The indication will flash in the event of an alarm. See
summary of alarm conditions.
calibrated against the 4-20 mA signal from the pressure transducer (11ETD11
AF001CP01, 12ETD11 AF001CP01).

pressure (11ETD11 AF001CP01, 12ETD11 AF001CP01) over time.
Date: 24/01/11
24.5.1 ROTARY VALVE MOTOR NOT HEALTHY ALARM

Definition:
Tripped signal (11ETD11 AF001XT03, 11ETD12 AF001XT03, 12ETD11 AF001XT03
or12ETD12 AF001XT03) is received for more than 3 seconds.
Control Action:
Visual alarm, discharge sequence start inhibited / controlled shutdown.
24.5.2 ROTARY VALVE MOTOR NOT RUNNING ALARM

Definition:
The rotary valve has been started (see section 25 for motor control) for more than 3 seconds
and the running signal (11ETD11 AF001XT01, 11ETD12 AF001XT01, 12ETD11
AF001XT01 or 12ETD12 AF001XT01) has not been received.
Control Action:
Visual alarm, discharge sequence controlled shutdown.
24.5.3 BLOWER MOTOR NOT HEALTHY ALARM

Definition:
Tripped signal (11SCA02 AN001XT02, 11SCA03 AN003XT02, 10SCA02 AN005XT02,
12SCA02 AN007XT02 or 12SCA03 AN009XT02) is received for more than 3 seconds.
Control Action:
24.5.4 BLOWER MOTOR NOT RUNNING ALARM

Definition:
The blower has been started (see section 25 for motor control) for more than 3 seconds
and the running signal (11SCA02 AN001XT01, 11SCA03 AN003XT01, 10SCA02
AN005XT01, 12SCA02 AN007XT01 or 12SCA03 AN009XT01) has not been received.
Control Action:
24.5.5 COOLING FAN MOTOR NOT HEALTHY ALARM

Definition:
Tripped signal (11SCA02 AN002XT02, 11SCA03 AN004XT02, 10SCA02 AN006XT02,
12SCA02 AN008XT02 or 12SCA03 AN010XT02) is received for more than 3 seconds.
Control Action:
Date: 24/01/11
24.5.6 COOLING FAN MOTOR NOT RUNNING ALARM

Definition:
The cooling fan has been started (see section 25 for motor control) for more than 3 seconds
and the running signal (11SCA02 AN002XT01, 11SCA03 AN004XT01, 10SCA02
AN006XT01, 12SCA02 AN008XT01 or 12SCA03 AN010XT01) has not been received.
Control Action:
24.5.7 BLOWER OUTLET HIGH PRESSURE ALARM SWITCH

Definition:
Blower outlet pressure >14.5 PSIG (11SCA02 AN001PS01, 11SCA03 AN003PS01,
10SCA02 AN005PS01, 12SCA02 AN007PS01, 12SCA03 AN009PS01)
Control Action:
Visual alarm and conveying cycle start inhibited, discharge sequence controlled shutdown

Definition:
Conveying pressure transmitter signal (11ETD11 AF001CP01, 12ETD11 AF001CP01) has
been less than 3.5 mA for more than 5 seconds or greater than 20.5 mA for more than 5
seconds.
Control Action:
24.5.9 CONVEYING PRESSURE HIGH ALARM

Definition:
Conveying pressure is > 0.85 Barg (11ETD11 AF001CP01, 12ETD11 AF001CP01).
Control Action:
24.5.10 BLOWER UNIT HIGH TEMPERATURE ALARM

Definition:
Acoustic enclosure temperature is > 50oC (11SCA02 AN002 CP01, 11SCA03 AN004 CP01,
10SCA02 AN006 CP01, 12SCA02 AN008 CP01, 12SCA03 AN010 CP01).
Control Action:
Date: 24/01/11
25.1 INDICATIONS

stations.

Definition:
11ETH01 PD03)
OR
Control Action:
Date: 24/01/11
26 175m3 BED ASH STORAGE SILO
26.1 INDICATIONS

stations.
(12ETE01 LS01) or (12ETE01 LS02) in the ash silo is covered.

Definition:
Silo filter differential pressure greater than a set pressure (12ETE01 PD01, 12ETE01 PD02)
OR
Control Action:
Date: 24/01/11
27 MOTOR STOP/START
27.1 OVERVIEW
The motors will be controlled via the PLC. Each motor will have the following controls:
The MCC will have a selector switch to select between Local and Remote operation.
Remote This mode of control is from the PLC. The motors will be started during the
operating sequence by energising the STOP contact and pulse the RUN
MOTOR FORWARD contact for 3 seconds. The motor will be stopped by de-
energising the STOP contact and de-energising the RUN MOTOR FORWARD
contact if energised.
There will also be the facility for the CBD rotary valve to jog the motor in
reverse with a Jog Reverse command. The jog facility is intended for use to
clear a blockage, the RUN MOTOR REVERSE contact will be energised as
long as the Jog Reverse button is pressed on the PLC. Once the button is
released the motor will be stopped by de-energising the RUN MOTOR
REVERSE contactor.
Local Controlled by buttons on the MCC. Run motor forward and Stop motor
commands will be available for the CBD Rotary valve, blowers and cooling
fans. There will also be the facility to jog the motor in reverse with a Jog
Reverse command. The jog facility is intended for use to clear a blockage, the
RUN MOTOR REVERSE contact will be energised as long as the Jog Reverse
button is pressed on the MCC. Once the button is released the motor will be
stopped by de-energising the RUN MOTOR REVERSE contactor.
Date: 24/01/11
Silo Discharge System By: F Patel
28 SILO DISCHARGE EQUIPMENT
28.1 OVERVIEW
During normal operation of the boilers, Fly Ash and/or Bed Ash will accumulate in the 350m3
storage silo, 175m3 Fly Ash storage silo and the 175m3 Bed Ash storage silo. Discharge of the
ash from each of the silos will be via a single outlet, material flow will be assisted by the
fluidisation system on the 350m3 storage silo and the 175m3 Fly Ash storage silo.
Each outlet will be fitted with a manual isolation valve, pneumatic isolation valve, rotary
valve and a ash conditioner. This equipment will discharge conditioned ash to belt conveyors
(supplied by others).
The manual isolation valve will be used for maintenance only to isolate the silo from the
discharge equipment.
28.1.1 MIXING AND DISCHARGE

When the discharge sequence is initiated the ash conditioner will be started followed shortly
by the rotary valve. After a short delay the pneumatic isolation valve will be opened and after
a further delay, the ash conditioner water valve will also be opened. The conditioned ash will
gravity discharge from the ash conditioner to the conveyor belts (provided by others). When
the discharge sequence is stopped the pneumatic isolation valve will be closed and after a
short delay the rotary valve will be stopped and after a further short delay, the water valve
will be closed. The ash conditioner will continue to run for a preset time to remove some
residual ash before being stopped.
Date: 24/01/11
28.2 SYSTEM AT REST

When the silo discharge system is stopped and at rest the status of the equipment will be as
follows:
Control air Off Control air On Control air On

Electrical power Off Electrical power Off Electrical power On
PLC mode Off PLC mode Off PLC mode Run
Pneumatic isolation valve Last position Closed Closed
(11ETH01 AA202Q02,
10ETH01 AA202Q02,
12ETE01 AA201Q01)
Rotary valve Stopped Stopped Stopped
(12ETH04 AM002, 10ETH04
AM002, 12ETE04 AM002)
Ash conditioner Stopped Stopped Stopped
(11ETH04 AM001, 10ETH04
AM001, 12ETE04 AM001)
Ash conditioner water valve Last position Closed Closed
(11ETH04 AA201Q01,
10ETH04 AA201Q01,
12ETE04 AA201Q01)
Washout valve Closed Closed Closed
(11ETH04 AA401Q01,
10ETH04 AA401Q01,
12ETE04 AA401Q01)
Date: 24/01/11
28.3 CONDITIONED ASH DISCHARGE SEQUENCE
Prior to a conditioned ash discharge sequence start, the PLC will check that the following
The discharge "ENABLE" command has been set at the HMI.
Pneumatic isolation valve is closed (11ETH01 ZS02, or 10ETH01 ZS02, or 12ETE01

ZS02).
The rotary valve motor is healthy (see summary of alarm conditions)
The ash conditioner motor is healthy (see summary of alarm conditions)
A shutdown sequence is not underway (steps 6 to 9)
E/STOP button has not been activated for the ash conditioner
Providing the above conditions are true the ash conditioner cycle will be initiated and will
proceed as follows.
28.3.1 Step 1
The ash conditioner will be started by energising the “STOP” contact (11ETH04
AM001XJ02, 10ETH04 AM001XJ02, 12ETE04 AM001XJ02) and pulsing the “START”
contact (11ETH04 AM001XJ01, 10ETH04 AM001XJ01, 12ETE04 AM001XJ01) for 3
seconds.
28.3.2 Step 2
When the ash conditioner motor is confirmed running (11ETH04 AM001XT01, 10ETH04
AM001XT01, 12ETE04 AM001XT01) the rotary valve will be started by energising the
“STOP” contact (11ETH04 AM002XJ02, 10ETH04 AM002XJ02, 12ETE04 AM002XJ02)
and pulsing the “START” contact (11ETH04 AM002XJ01, 10ETH04 AM002XJ01,
12ETE04 AM002XJ01) for 3 seconds.
28.3.3 Step 3
When the rotary valve is confirmed running (11ETH04 AM002XT01, 10ETH04
AM002XT01, 10ETH04 AM001XT01) the material feed delay timer (5 seconds) will be
started.
28.3.4 Step 4
When the material feed delay timer has expired the pneumatic isolation valve will be opened
by energising solenoid (11QFB01 AA202-Y02, 10QFB01 AA202-Y02, 12QFB01 AA201-
Y01) and ash will discharge from the silo via the rotary valve into the ash conditioner.
Simultaneously the water feed delay timer (5 seconds) will be started.
Date: 24/01/11
28.3.5 Step 5
When the water feed delay timer has expired the water valve will be opened by energising
solenoid (11QFB04 AA201-Y01, 10QFB04 AA201-Y01, 12QFB04 AA201-Y01). The
conditioner will feed conditioned ash onto the selected belt conveyor (BY OTHERS).
28.3.6 Step 6
When the start / stop command is set to “D ISABLE”, the pneumatic isolation valve will be
closed by de-energising solenoid (11QFB01 AA202-Y02, 10QFB01 AA202-Y02, 12QFB01
AA201-Y01) and the in-flight timer (10 seconds) will be started.
28.3.7 Step 7
When the in-flight timer has expired the rotary valve will be stopped by de-energising the
“STOP” contact (11ETH04 AM002XJ02, 10ETH04 AM002XJ02, 12ETE04 AM002XJ02)
and de-energising the “START” pulsed contact (11ETH04 AM002XJ01, 10ETH04
AM002XJ01, 12ETE04 AM002XJ01) if energised. The water valve close delay timer (5
seconds) will be started.
28.3.8 Step 8
When the water valve close delay timer has expired the water valve will be closed by de-
energising solenoid (11QFB04 AA201-Y01, 10QFB04 AA201-Y01, 12QFB04 AA201-Y01)
and the ash conditioner over-run timer (20 seconds) will be started.
28.3.9 Step 9
When the ash conditioner over-run timer has expired the ash conditioner will be stopped by
de-energising the “STOP” contact (11ETH04 AM001XJ02, 10ETH04 AM001XJ02,
12ETE04 AM001XJ02) and de-energising the “START” pulsed contact (11ETH04
AM001XJ01, 10ETH04 AM001XJ01, 12ETE04 AM001XJ01) if energised.
Note:
If a motor not running alarm becomes true or a motor becomes unhealthy, that motor will be
stopped by de-energising the “STOP” contact and de-energising the pulsed “START” contact
if energised.
Note:
If a motor is stopped due to an alarm condition then the motor will not automatically restart
when the alarm returns to a healthy condition, but will need to be re-started by re-initiating
the “ENABLE” command.
Date: 24/01/11
28.4 ASH CONDITIONER WASHOUT SEQUENCE
Prior to an conditioner washout sequence, the PLC will check that the following interlock
conditions are fulfilled:
Washout sequence "start" is initiated.
The ash conditioning system is at rest
Providing the above conditions are true the ash conditioner washout cycle will be initiated
and will proceed as follows.
28.4.1 Step 1
The ash conditioner will be started by energising the “STOP” contact (11ETH04
AM001XJ02, 10ETH04 AM001XJ02, 12ETE04 AM001XJ02) and pulsing the “START”
contact (11ETH04 AM001XJ01, 10ETH04 AM001XJ01, 12ETE04 AM001XJ01) for 3
seconds.
28.4.2 Step 2
When the ash conditioner motor is confirmed running (11ETH04 AM001XT01, 10ETH04
AM001XT01, 12ETE04 AM001XT01) the main header water valve will be opened by
simultaneously energising solenoid (11QFB04 AA201-Y01, 10QFB04 AA201-Y01,
12QFB04 AA201-Y01) and energising the washout valve solenoid (11ETH04 AA401Q01,
10ETH04 AA401Q01, 12ETE04 AA401Q01). The washout maximum run timer (10 minutes)
will be initiated.
28.4.3 Step 3
When the washout maximum run timer has expired the main header water valve will be
closed simultaneously by de-energising solenoid (11QFB04 AA201-Y01, 10QFB04 AA201-
Y01, 12QFB04 AA201-Y01) and de-energising the washout valve solenoid (11ETH04
AA401Q01, 10ETH04 AA401Q01, 12ETE04 AA401Q01). The system will then be at rest
Date: 24/01/11
Ash conditioner Provides a timed pulse for the motor start 3 second 0 – 30 seconds
motor start contact contact.
pulse timer.
Rotary valve Provides a timed pulse for the motor start 3 second 0 – 30 seconds
motor start contact contact.
pulse timer.
Material feed Allows time for any residual material to start 5 seconds 0 – 60 seconds
delay timer. flowing before introducing new material.
Water feed delay Allows time for material feed to become 5 seconds 0 – 60 seconds
timer. established before introducing water.
In-flight timer. Allows time for the rotary valve to run 10 seconds 0 – 60 seconds
empty before stopping feeder.
Water valve close Provides a light washout when stopping the 5 seconds 0 – 60 seconds
delay timer conditioner after a conditioning cycle.
Ash conditioner Allows time for the conditioner to run 20 seconds 0 – 60 seconds
over-run timer. without ash or water being added in order to
remove some residual ash.
Valve fault timer Allows a delay for the valve to open / close 5 seconds 0 – 20 seconds
before initiating a valve fault alarm.
Water pressure Allows a delay for manifold pressure to rise 5 seconds 0 – 20 seconds
fault timer after the water valve is opened before
initiating and alarm
Motor running Allows a delay for the motor contactor to 3 seconds 0 – 60 seconds
secure timer. pull in before initiating an alarm.
Washout Allows time for washing of the ash 10 minutes 0 - 3600 second
maximum run conditioner
timer
Date: 24/01/11
Enable / Disable selection command / indication. This will permit the operator to
start and stop the discharge sequence. When the command is set to “ENABLE”
position the discharge sequence will start provided the relevant interlocks are true.
Note:
If the “crash stop” or “shut down alarm” is initiated (see alarms section). The
command is set to “DISABLE”.
Washdown sequence Start / stop selection command / indication. This will permit the
operator to start and stop the discharge sequence. When the command is set to
“START” position the discharge sequence will start provided the relevant interlocks
are true.
Pneumatic isolation valve open / fault indication. The indication will be “on” when
the pneumatic isolation valve open solenoid (11QFB01 AA202-Y02, 10QFB01
AA202-Y02 or 12QFB04 AA201-Y01 ) is energised and the pneumatic isolation
valve open limit switch (11ETH01 ZS01, 10ETH01 ZS01 or 12ETE01 ZS01) is
made. The indication will flash in the event of the pneumatic valve failing to open or
close. See summary of alarm conditions.
Rotary valve running / fault indication. This indication will be “on” when the rotary
valve “STOP” contact (11ETH04 AM002XJ02, 10ETH04 AM002XJ02 or
12ETE04AM002XJ02) is energised and the “RUNNING” signal (12ETH04
AM002XT04, 10ETH04 AM002XT04 or 12ETE04 AM002XT04) is received. The
indication will flash in the event of an alarm. See summary of alarm conditions.
Ash conditioner running / fault indication. This indication will be “on” when the ash
conditioner “STOP” contact (11ETH04 AM001XJ02, 10ETH04 AM001XJ02 or
12ETE04 AM001XJ02 ) is energised and the “RUNNING” signal (11ETH04
AM001XT01, 10ETH04 AM001XT01 or 12ETE04AM001XT01) is received. The
indication will flash in the event of an alarm. See summary of alarm conditions.
Water valve open indication. The indication will be “on” when the water valve open
solenoid (11QFB04 AA201-Y01, 10QFB04 AA201-Y01 or 12QFB04 AA201-Y01)
is energised.
Water pressure switch indication. This indication will be “on” when the water low
pressure switch (11ETH04 PS01, 10ETH04 PS01 or 12ETE04 PS01 ) is made.
Date: 24/01/11
Discharge sequence in progress indication. The indication will be “on” when a

discharge sequence is in progress (discharge sequence steps 1 to 5).
Shutdown sequence in progress indication. The indication will be “on” when a

shutdown sequence is in progress (discharge sequence steps 6 to 9).
Silo low level indication. The indication will be “on” when an ash storage silo low
level switch (11ETH01 LS03, 10ETH01 LS03 or 12ETE01 LS03) is uncovered.
Silo high level indication. The indication will be “on” when an ash storage silo high
level switch (350m3 silo- 11ETH01 LS01 or 11ETH01 LS02, 175m3 Fly ash silo-
10ETH01 LS01 or 10ETH01 LS02, 175m3 Bed ash silo- 12ETE01 LS01 or
12ETE01 LS02) is covered.
Washout cycle in progress indication. The indication will be "on" when valve
(11ETH04 AA004H04, 10ETH04 AA401Q01, 12ETE04 AA401Q01) open solenoid
is energised
Date: 24/01/11
28.7.1 PNEUMATIC ISOLATION VALVE NOT OPEN ALARM

Definition:
Pneumatic isolation valve open solenoid (11QFB01 AA202-Y02, 10QFB01 AA202-Y02 or
12QFB01 AA201-Y01) energised and open limit switch (11ETH01 ZS01, 10ETH01 ZS01 or
12ETE01 ZS01) not made for more than 5 seconds.
Control Action:
Visual alarm & mixing cycle start inhibited.
28.7.2 PNEUMATIC ISOLATION VALVE NOT CLOSED ALARM

Definition:
Pneumatic isolation valve open solenoid (11QFB01 AA202-Y02, 10QFB01 AA202-Y02 or
12QFB04 AA201-Y01) de-energised and close limit switch (11ETH01 ZS02, 10ETH01 ZS02
or 12ETE01 ZS02) not made for more than 5 seconds.
Control Action:
Visual alarm and mixing cycle start inhibited.
28.7.3 ROTARY VALVE MOTOR NOT HEALTHY ALARM

Definition:
Tripped signal (11ETH04 AM002XT02, 10ETH04 AM002XT02 or 12ETE04 AM002XT02)
is received for more than 3 seconds.
Control Action:
28.7.4 ROTARY VALVE MOTOR NOT RUNNING ALARM

Definition:
The rotary feeder motor has been started for more than 3 seconds and the running signal
(12ETH04 AM002XT01, 10ETH04 AM002XT01 or 12ETE04 AM002XT01) has not been
received.
Control Action:
28.7.5 ASH CONDITIONER MOTOR NOT HEALTHY ALARM

Definition:
Tripped signal (11ETH04 AM001XT02, 10ETH04 AM001XT02 or 12ETE04 AM001XT02)
is received for more than 3 seconds.
Control Action:
Visual alarm, discharge sequence start inhibited / crash stop.
Date: 24/01/11
28.7.6 ASH CONDITIONER MOTOR NOT RUNNING ALARM

Definition:
The ash conditioner motor has been started for more than 3 seconds and the running signal
(11ETH04 AM001XT01, 10ETH04 AM001XT01 or 12ETE04 AM001XT01) has not been
received.
Control Action:
Visual alarm, discharge sequence crash stop.
28.7.7 WATER PRESSURE LOW ALARM

Definition:
The water valve open solenoid (11QFB04 AA201-Y01, 10QFB04 AA201-Y01 or 12QFB04
AA201-Y01) energised for more than 5 seconds and the ash conditioner water pressure
(11ETH04 PS01, 10ETH04 PS01 or 12ETE04 PS01) is < 1.5 barg.
Control Action:
Visual alarm.
28.7.8 ASH LEVEL LOW ALARM

Definition
Any of the silo low level switches (11ETH01 LS03, 10ETH01 LS03 or 12ETE01 LS03) are
uncovered.
Control Action:
Visual alarm.
28.7.9 DISCHARGE SEQUENCE SHUTDOWN ALARM

Definition:
Rotary valve not healthy alarm
OR
Rotary valve not running alarm
Control Action:
Visual alarm, begins shutdown sequence.
Date: 24/01/11
28.7.10 DISCHARGE SEQUENCE CRASH STOP ALARM

Definition:
Ash conditioner not healthy alarm
OR
Ash conditioner not running alarm
Control Action:
Visual alarm, resets all steps and puts discharge system AT REST.
The PLC / SCADA start / stop commands are set to “STOP”
28.7.11 WASHOUT VALVE NOT OPEN ALARM

Definition:
Pneumatic water valve open solenoid (11QFB04 AA201-Y01, 10QFB04 AA201-Y01 or
12QFB04 AA201-Y01) energised and open limit switch (11ETH04 ZS01, 10ETH04 ZS01 or
12ETE04 ZS01) not made for more than 5 seconds.
Control Action:
Visual alarm
28.7.12 WASHOUT VALVE NOT CLOSED ALARM

Definition:
Pneumatic water valve close solenoid (11QFB04 AA201-Y01, 10QFB04 AA201-Y01 or
12QFB04 AA201-Y01) de-energised and close limit switch (11ETH04 ZS02, 10ETH04
ZS02 or 12ETE04 ZS02) not made for more than 5 seconds.
Control Action:
Visual alarm
Date: 24/01/11
29.1 INDICATIONS

stations.

Definition:
11ETH01 PD03)
OR
Control Action:
Date: 24/01/11
30.1 INDICATIONS

stations.

Definition:
OR
Control Action:
Date: 24/01/11
31 175m3 BED ASH STORAGE SILO
31.1 INDICATIONS

stations.
(12ETE01 LS01) or (12ETE01 LS02) in the ash silo is covered.

Definition:
Silo filter differential pressure greater than a set pressure (12ETE01 PD01, 12ETE01 PD02)
OR
Control Action:
Date: 24/01/11
Motors By: F Patel
32 MOTOR STOP/START
32.1 OVERVIEW
The motors will be controlled via the PLC. Each motor will have the following controls:
The MCC will have a selector switch to select between Local and Remote operation.
Remote This mode of control is from the PLC. The motors will be started during the
operating sequence by energising the STOP contact and pulse the RUN MOTOR
FORWARD contact for 3 seconds. The motor will be stopped by de-energising
the STOP contact and de-energising the RUN MOTOR FORWARD contact if
energised.
Local Controlled by buttons on the MCC. Run motor forward and Stop motor
commands will be available for the ash conditioners.
Date: 24/01/11
Compressor System By: F Patel
33 COMPRESSOR SYSTEM

The compressor system will be Enabled/Disabled at the local compressor management unit
X8I system controller. The compressor system will provide the conveying air and control air
requirements of the plant. The compressor system consists of three compressors in total, two
working and one standby. There are also three Refrigerant dryers and two Desiccant dryers.
Operator Interface will be via a HMI operator terminal located to the front of the PLC panel,
and also remotely at the clients SCADA control system
The following describes the operator indications and alarms which should be made available
at the HMI.
X8I Controller General alarm indication. This will be "on" when there is an X8I
general alarm
Refrigerant Dryer 1 Healthy. This will be "on" when Refrigerant Dryer 1 Healthy
signal is true
Compressor 1 Running indication. This will be "on" when compressor 1 Running

signal is true
Compressor 1 Healthy indication. This will be "on" when compressor 1 Healthy

signal is true
signal is true

signal is true

signal is true
signal is true

signal is true

signal is true
Conveying pressure system indication

Date: 24/01/11
Re-Issue notes By: F Patel
34 RE-ISSUE NOTES
ISSUE NO DATE PAGE DESCRIPTION OF CHANGE

00 26/10/10 All Original Issue.
01 15/11/10 P94-95 Blower sequence updated steps 1 & 2
02 23-11-10 P95 Step 3 note added, minimum cycle period timer note
removed
03 20-12-10 P94,P95, E/Stop interlocks to bed ash & silo discharge systems
P99, added, remote facility removed from standby blower,
P102, Blower acoustic enclosure high temp alarm added,
P105, Bed ash rotary valve remote jog reverse facility
P113, added and ash conditioner washout valve not
P119 open/closed alarms added. Compressor section added
04 24-01-11 P119 Pressure transmitter added , System pressure
indication

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FUNCTIONAL DESIGN SPECIFICATION

Document No C062930114-R04 FDS.doc

Rio Turbio, Santa Cruz Power Plant

Fly Ash and Bed Ash Conveying Systems

Telephone: +44 (0) 1302 552200

2 CONTROL SYSTEM ................................................................................................................... 9

2.1 OVERVIEW – UNIT 1 & UNIT 2 ......................................................................................... 9

3 UNIT 1- MODEL 3.0/8 ASH VESSELS – AIR PRE-HEATERS .......................................... 10

3.1 OVERVIEW ......................................................................................................................... 10

3.2 SYSTEM AT REST.............................................................................................................. 11

3.3 ASH VESSEL OPERATING SEQUENCE ......................................................................... 12

3.4 TIMER DEFINITIONS AND VALUES .............................................................................. 15

3.5 OPERATOR CONTROLS AND INDICATIONS ............................................................... 16

3.6 SUMMARY OF ALARM CONDITIONS ........................................................................... 18

4 350M3 ASH STORAGE SILO ................................................................................................... 20

4.1 INDICATIONS ..................................................................................................................... 20

5 175M3 FLY ASH STORAGE SILO .......................................................................................... 21

5.1 INDICATIONS ..................................................................................................................... 21

6 UNIT 1- MODEL 8.0/12 ASH VESSELS- DUST COLLECTOR, ROW 1........................... 22

6.1 OVERVIEW ......................................................................................................................... 22

6.2 SYSTEM AT REST.............................................................................................................. 23

6.3 ASH VESSEL OPERATING SEQUENCE ......................................................................... 24

6.4 TIMER DEFINITIONS AND VALUES .............................................................................. 27

6.5 OPERATOR CONTROLS AND INDICATIONS ............................................................... 28

6.6 SUMMARY OF ALARM CONDITIONS ........................................................................... 30

7 350M3 ASH STORAGE SILO ................................................................................................... 32

7.1 INDICATIONS ..................................................................................................................... 32

8.1 INDICATIONS ..................................................................................................................... 33

9 UNIT 1- MODEL 8.0/12 ASH VESSELS- DUST COLLECTOR, ROW 2........................... 34

9.1 OVERVIEW ......................................................................................................................... 34

9.2 SYSTEM AT REST.............................................................................................................. 35

9.3 ASH VESSEL OPERATING SEQUENCE ......................................................................... 36

9.4 TIMER DEFINITIONS AND VALUES .............................................................................. 39

9.5 OPERATOR CONTROLS AND INDICATIONS ............................................................... 40

9.6 SUMMARY OF ALARM CONDITIONS ........................................................................... 42

10 350M3 ASH STORAGE SILO ................................................................................................... 44

10.1 INDICATIONS ..................................................................................................................... 44

11 175M3 FLY ASH STORAGE SILO .......................................................................................... 45

11.1 INDICATIONS ..................................................................................................................... 45

12 UNIT 2- MODEL 3.0/8 ASH VESSELS – AIR PRE-HEATERS .......................................... 46

12.1 OVERVIEW ......................................................................................................................... 46

12.2 SYSTEM AT REST.............................................................................................................. 47

12.3 ASH VESSEL OPERATING SEQUENCE ......................................................................... 48

12.4 TIMER DEFINITIONS AND VALUES .............................................................................. 51

12.5 OPERATOR CONTROLS AND INDICATIONS ............................................................... 52

12.6 SUMMARY OF ALARM CONDITIONS ........................................................................... 54

13 175M3 FLY ASH STORAGE SILO .......................................................................................... 56

13.1 INDICATIONS ..................................................................................................................... 56

14 UNIT 2- MODEL 5.0/12 ASH VESSELS- DUST COLLECTOR, ROW 1........................... 57

14.1 OVERVIEW ......................................................................................................................... 57

14.2 SYSTEM AT REST.............................................................................................................. 58

14.4 TIMER DEFINITIONS AND VALUES .............................................................................. 62

14.5 OPERATOR CONTROLS AND INDICATIONS ............................................................... 63

14.6 SUMMARY OF ALARM CONDITIONS ........................................................................... 65

15 175M3 FLY ASH STORAGE SILO .......................................................................................... 67

15.1 INDICATIONS ..................................................................................................................... 67

16 UNIT 2- MODEL 5.0/12 ASH VESSELS- DUST COLLECTOR, ROW 2........................... 68

16.1 OVERVIEW ......................................................................................................................... 68

16.2 SYSTEM AT REST.............................................................................................................. 69

16.3 ASH VESSEL OPERATING SEQUENCE ......................................................................... 70

16.4 TIMER DEFINITIONS AND VALUES .............................................................................. 73

16.5 OPERATOR CONTROLS AND INDICATIONS ............................................................... 74

16.6 SUMMARY OF ALARM CONDITIONS ........................................................................... 76

17 175M3 FLY ASH STORAGE SILO .......................................................................................... 78