PT PLN Sulut-1 Coal Fired Steam Power Plant Project

2 x 50 MWe CFB Boiler

Pressurized and Instrument Air System

 TASK OF THE SYSTEM

 The task of pressurized (transport/ service) and instrument air system in

boiler area is to distribute air within the boiler area according to agreed scope
of supply.

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 Mechanical Description

INSTRUMENT AND PRESSURIZED AIR; S1-SH-100-SYS-PID-00090

 Distribution piping for service air
 Isolation valves for consumers
 Service air pressure measurement
 Distribution piping for instrument air
 Instrument air distribution boxes
 Instrument air pressure measurements for SIS

TRANSPORT AIR; S1-SH-100-SYS-PID-00091

 Distribution piping for transport air

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 Mechanical Description

 Air pressure (instrument as well as pressurized) is measured in the inlet to

SUMITOMO Heavy Industries, Ltd. scope of supply and divided and led to
both sides of the boiler. The vertical distribution lines are located on opposite
sides of boiler building for individual consumers. The distribution lines are
equipped with the connections for the air hoses including shut-off valves on
each level.
 The main instrument air pipeline is divided and led to both sides of the boiler.
The distribution lines are equipped with connections including shut-off valves
on necessary levels. The instrument air distribution boxes are connected in
series on needed levels.

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 Mechanical Description

 Main instrument air consumers:

 Limestone system
 Bed material system
 Burners system
 Pneumatic control valve/damper
 Instrument purge/ reference air

 Main pressurized (service) air consumers:

 Bottom Ash Screw
 Air Pulse Valve, Ash Drain Cleaning
 Air Cannon
 Wall Screw, Shaft Sealing Air
 Purge Air For Lift Legs
 Startup Burner Purge Air
 Ammonia Purge Air

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 Mechanical Description

 Main pressurized (transport) air consumers:

 Sand Silo Hopper Fluidization
 Limestone Silo Hopper Fluidization
 Limestone Feeding Rotary Valve Sealing Air
 Sand Blow Air
 Startup Burner Atomizing Air
 Startup Burner cooling Air
 Ammonia Atomizing Air

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 P&ID - INSTRUMENT AND PRESSURIZED AIR

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 P&ID – TRANSPORT AIR

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 Functional Description

 To avoid unnecessary downtime pressurized and instrument air quality,

produced by compressors and treated by necessary filter and dryers, fills the
buffer tank/tanks. Pressurized or instrument air compressors, tanks, dryers
and buffers are not in SUMITOMO Heavy Industries, Ltd. scope of supply.
 When instrument or pressurized air is needed during shutdown back-up air
compressor will be used for providing air into instrument/ pressurized air
network.

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 MAIN CONTROLS AND INTERLOCKING
Interlocking

 Instrument air pressure is measured with the three pressure transmitters. If

two of the pressures go below the low limit (LLL) the boiler trip is activated via
SIS
 Start-up burners are stopped (and start is prevented) if instrument air is <L
limit.
 Start-up burners while burning oil are stopped (and start is prevented) if
atomizing air (pressurized air) is <L limit.

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 GENERAL OPERATING CONDITIONS
Preparation of the System

 Before boiler start-up the following inspections and procedures shall be done:
 Verify that manual shut off valves are open
 Verify if measurements are operated

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 GENERAL OPERATING CONDITIONS
Start-up of the System

 Switch ON absorption dryers and verify that dew point control unit is
operational (dryers not in SUMITOMO Heavy Industries, Ltd. scope of supply)
 Start compressor. Switch the other compressor to stand-by mode for
automatic start (compressors not in SUMITOMO Heavy Industries, Ltd. scope
of supply).
 Open shut-off valves to all consumers.

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 GENERAL OPERATING CONDITIONS
Normal Operation

 During normal operation verify that dew point and instrument air pressure are
in set point.
 Verify that local pressure measurements and pressure measurements in DCS
are on same level.

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 General Operating conditions
Shutdown of the System

 For the normal boiler shut down the system is not needed to shut down. If
the system needs to be shut down, shut down the compressors and switch of
the dryers (dryers and compressors not in SUMITOMO Heavy Industries, Ltd.
scope of supply). Before starting up the maintenance works verify that the
pressure is released from the all parts of the system.

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 General Operating conditions
Abnormal Operating Conditions

 If there are problems with adsorption dryer and dew point of air is increasing,
drain air lines carefully to get water out from the air lines.
 For instrument air, avoid pressure drop below interlocking limit of the
instrument air.

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