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42973.56133.11299.837_200803261859

FOR INFORMATION

08.03.18

Rev.

Date

S.W.KANG

First Issued

S.H.SONG

Prepared Coordinated Checked

Details of Revision

Client :

COASTAL GUJARAT POWER LIMITED

(A WHOLLY OWNED SUBSIDIARY OF THE TATA POWER COMPANY LIMITED)
Engineer :

Contractor :

Sub Suplier :

Project Title :

Orig-Pc

4000 MW ULTRA MEGA POWER PROJECT

AT MUNDRA, GUJARAT, INDIA
Date
Prepared

08.03.18

Pc

Name
N/A
Scale
S.W.KANG DOC. TITLE

Type

SY

Contents

Coordinated

Code

Checked

08.03.18

S.H.SONG

Approved

08.03.18

S.C.SONG

Dept.

T07073

PROCESS AND SYSTEM

DESCRIPTION

BOILER BASIC
DESIGN TEAM

Doosan Heavy Industries &

Construction Co. Ltd.

Document No. :
Owner Document No. :

HAY
Reg. No.

M001
Dept.

UNID

Version

Rev

P
T07073-HAY-SY -M001
TCE.5146A-510-00-1189

Page-No.

1/53

UMPP Mundra ( 800MW x 5 Units )

Process and System Description

DEFINITIONS

1.1

Plant Description

This is a document, derived from the clients plant requirements, which covers the following:
Basic plant description with expected performance in the base load operation.
It outlines the design basis of the plant and the basis of more detailed documents such as the
individual System Operating Philosophies.
1.2

Process Flow Diagram (PFD)

General
The Process Flow Diagram (PFD) is the universal way to present the Heat and Material
balances needed to meet the requirements described in the Plant Description
Heat and Material balances are required to enable: Specifications to be prepared for pipes/flues, equipment, instruments.
Preparation of Operating and Maintenance manuals/operator training.
Commissioning/Plant performance.
Reference PFDs
The Process Flow Diagrams cover the main processes involved in Power generation Systems,
and incorporate the scope necessary to meet the requirements for Mundra(5x800MW),
4000MW Ultra Mega Project.
1.3

System Operating Philosophies

A Boiler Plant comprises numerous systems, such as, Steam and Water, Air & Gas and
Combustion. The Operating Philosophies for each of these systems describe the required
degree of mechanical operation on selected parameters.
1.4

Piping and Instrumentation Diagram (P&ID)

Piping and Instrumentation Diagrams (P&IDs) define the engineering and construction
requirements for the sections of the plant in Doosans scope of supply.
P&IDs which are attached in the technical specification cover all the processes involved in
Power Generation Systems, and incorporate the scope necessary to meet the Doosans
requirements for Mundra UMPP(5x800MW) Project.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

2.0

PROCESS AND INSTRUMENT DIAGRAM DESCRIPTION

2.1

PROCESS FLOW DIAGRAMS

The Process Flow Diagram (PFD) is the universal way to present Heat and Material balances.
Heat and Material balances are required to enable:

Specifications to be prepared for pipes/flues, equipment, instruments.

Preparation of Operating and Maintenance manuals/operator training.
Commissioning/Plant performance

The PFD should treat the boiler as an item of equipment, with a number of inputs and outputs
linked to all the other equipment required to support the boiler. There are basically two sets of
Heat and Material balances to be prepared, which have the following inputs and outputs with
the boiler:

Water/Steam flows Economiser/Reheater inlet and Superheater/Reheater outlet.

Air/Gas flows Fans inlet and Stack inlet(EP outlet).

The PFD output data is a diagram of each part of the system with design and normal operating
conditions and associated pipe sizes, pipe thicknesses, pipe class and insulation code.
2.1.1

CONFIGURATION OF SUPERHEATER SYSTEM

DESCRIPTION
Two spray-type superheater(SH) desuperheaters for stage-1 (10HAH40-BR023A,B) are installed
in the connecting links (10HAH40BR024) between the primary superheater(LTSH) outlet
header(10HAH30) and division panel inlet headers(10HAH42), and two additional spray-type
superheater (SH) desuperheaters for stage-2(10HAH50-BR029A,B) are installed in the connecting
links between the division panel outlet headers(10HAH47) and the SH finishing inlet
header(10HAH55) to reduce steam temperature, when necessary, and to maintain the
temperatures at design values, within the limits of the nozzle capacity.
Temperature reduction is accomplished by spraying water into the path of the steam through a
nozzle at the inlet end of the desuperheater. It is essential that the spray water be chemically pure
and free of suspended and dissolved solids, containing only approved volatile organic treatment
material, in order to prevent chemical deposition in the superheater and carry-over of solids to the
turbine.
CAUTION: During start-up of the unit, if desuperheating is used to match the outlet steam
temperature to the turbine metal temperatures, care must be exercised so as not to spray down
below a minimum of 11C (20F) above the saturation temperature at the existing operating
pressure. Desuperheating spray is not particularly effective at the low steam flows of start-up.
Spray water may not be completely evaporated but be carried through the heat absorbing
sections to the turbine where it can be the source of considerable damage. During start-up,
alternate methods of steam temperature control should be considered.
The locations of the desuperheaters(Stage-1, 10HAH40-BR023A, B , Stage-2, 10HAH50-BR029A,
B) between the Primary superheater (LTSH) and SH division panel section and between the SH
division panel section and the SH finishing section, help ensure that water carry-over to the turbine
does not occur. It also eliminates the necessity for high temperature resisting materials in the
desuperheater construction.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES

Each desuperheater is fitted with a renewable liner to take the wear of erosion from the spray
water stream, thus protecting the main desuperheater shell. Excessive noise from within a
desuperheater usually indicates a worn liner and the Service Department of this Company should
be contacted when this or any such abnormal conditions may arise. Sufficient clearances should
be provided around the desuperheaters for replacing liners.
MAINTENANCE
The spray water lines should be blown out before using the desuperheaters on a new unit and
after repairs on the spray water lines have been made. They may also be blown when there
appears to be any indication of plugging. Always have full pressure on the boiler when blowing out
the desuperheaters.
Each desuperheater should be blown out in the following sequence:
Firstly close the isolating valves(10LAE52AA041, 10LAE52AA001) in the main spray line and
open the blowoff(drain) valves(10LAE52AA401/2), and then open the valves in the bypass line
(10LAE52AA002, 10LAE52AA042, 10LAE52AA071) for 1 minute.
Secondly Close the bypass line valves(10LAE52AA001, 10LAE52AA041, 10LAE52AA071) and
open the main spray line isolating valves(10LAE52AA041, 10LAE52AA001) and control
valve(TCV,10LAE52AA071) but leave the blowoff valves(10LAE52AA401/2) open for another
minute to clear the waste line before restoring the system to its operating status.
Repeat the above blowing sequence for the other spray stations. When blow the bypass station do
the same condition. Above is shown by only one spray station.
NOTE: The blowoff valves should be installed close to the spray water piping and with no
bends intervening, if possible.

SUPERHEATER SCHEMATIC DIAGRAM

S-24
S-23

S-1

S-28

S-29

S-27

S-30
S-8

S-33
S-32B

S-22

S-21

S-5

S-20B

S-6

S-31
S-32A

S-25

S-2

S-26A

S-26B

S-3

S-4
S-32

S-26

S-16
S-9
S-7
S-20
S-10

S-17
S-19

S-11

S-15

Separator
S-12
S-14

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S-13

S-18

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UMPP Mundra ( 800MW x 5 Units )

S-2

Separator

S-5

Process and System Description

S-13

S-6

S-18 S-21

S-1

S-25

S-22

S-31

S-27

S-7

S-23
S-3,4

S-9,10

S-12

S-15,16,17

S-29

S-24
S-8

S-11

S-14

S-19,20,20B

Tag No.

Circuit Name

S-33
S-32b
S-32
S-32a
S-31
S-30
S-29
S-28
S-27
S-26b
S-26
S-26a
S-25
S-24
S-23
S-22
S-21
S-19,20,20b
S-18
S-15,16,17
S-14
S-13

SH Final Outlet Header

SH Final Outlet Term. Tubes
SH Final Tubes
SH Final Inlet Term. Tubes
SH Final Inlet Header
Links to SH Final Inlet Header
SH Desuperheater #2
Links to SH Desuperheater #2
SH Panel Outlet Header
SH Division Panel Outlet Term. Tubes
SH Division Panel Tubes
SH Division Panel Inlet Term. Tubes
SH Panel Inlet Header
Links to SH Panel Inlet Header
SH Desuperheater #1
Links to SH Desuperheater #1
Low Temperature SH Outlet Headers
Low Temperature SH Tubes
Backpass Lower Rear Header
Backpass Front,Roof & Rear Wall Tubes
Backpass Lower Front Header
Backpass Lower Side Header
Extended Wall Outlet Link to
Backpass Lower Front Header
Extended Wall Outlet Header
Extended Wall Side & Floor Tubes
Extended Wall Inlet Header
Backpass Side Wall Tubes
Backpass Side Wall Inlet Headers
Furnace Roof Outlet Header
Furnace Roof Tubes
Furnace Roof Inlet Header
Links to Roof Inlet Header

S-12
S-11
S-9,10
S-8
S-7
S-6
S-5
S-3,4
S-2
S-1

S-33

S-28

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S-26A,26,26B

S-30
S-32A,32,32B

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

2.1.2 CONFIGURATION OF REHEATER SYSTEM

DESCRIPTION
A spray-type reheater (RH) desuperheater(10LBC31-BR001, 10LBC32-BR001) is installed in the
cold reheat piping to Platen Reheater inlet header(10HAJ10) to reduce steam temperature, when
necessary, and to maintain the temperatures at design values, within the limits of the nozzle
capacity.
Temperature reduction is accomplished by spraying water into the path of the steam through a
nozzle at the inlet end of the desuperheater. It is essential that the spray water be chemically pure
and free of suspended and dissolved solids, containing only approved volatile organic treatment
material, in order to prevent chemical deposition in the reheater and carry-over of solids to the
turbine.
CAUTION: During start-up of the unit, if desuperheating is used to match the outlet steam
temperature to the turbine metal temperatures, care must be exercised so as not to spray
down below a minimum of 11 C (20F) above the saturation temperature at the existing
operating pressure. Desuperheating spray is not particularly effective at the low steam flows of
start-up. Spray water may not be completely evaporated but be carried through the heat
absorbing sections to the turbine where it can be the source of considerable damage. During
start-up, alternate methods of steam temperature control should be considered.
The location of the desuperheaters, at inlet of RH low temperature inlet header(10HAJ10), help
ensure that water carry-over to the turbine does not occur. It also eliminates the necessity for high
temperature resisting materials in the desuperheater construction.
MAINTENANCE
Each desuperheater(10LBC31BR001, 10LBC32BR001) is fitted with a renewable liner to take the
wear of erosion from the spray water stream, thus protecting the main desuperheater shell.
Excessive noise from within a desuperheater usually indicates a worn liner and the Service
Department of this Company should be contacted when this or any such abnormal conditions
may arise. Sufficient clearances should be provided around the desuperheaters for replacing
liners.
BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES
The spray water lines should be blown out before using the desuperheaters on a new unit and
after repairs on the spray water lines have been made. They may also be blown when there
appears to be any indication of plugging. Always have full pressure on the boiler when blowing
out the desuperheaters.
Each desuperheater should be blown out in the following sequence :
Firstly close the isolating valves(10LAF52AA041, 10LAF52AA001) in the main spray line and open
the blowoff(drain) valves(10LAF52AA401/2), and then open the valves in the bypass line
(10LAF52AA002, 10LAF52AA042, 10LAF52AA071) for 1 minute.
Secondly Close the bypass line valves(10LAF52AA001, 10LAF52AA041, 10LAF52AA071) and
open the main spray line isolating valves(10LAF52AA041, 10LAF52AA001) and control
valve(TCV,10LAF52AA071) but leave the blowoff valves(10LAF52AA401/2) open for another
minute to clear the waste line before restoring the system to its operating status.
Repeat the above blowing sequence for the other spray stations. When blow the bypass station do
the same condition. Above is shown by only one spray station.
NOTE: The blow-off valves should be installed close to the spray water piping and with no
bends intervening, if possible.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

REHEATER SCHEMATIC DIAGRAM

R-1

R-8

R-2

R-4a

R-7

R-5

R-3

R-6a

R-4b

R-6b

R-6

R-4

R-1

R-8

R-2

R-5
R-4

R-6

R-7

R-3

R-1

R-2

R-8

Tag No.

Circuit Name

R-7
R-6b
R-6
R-6a
R-5
R-4b
R-4
R-4a
R-3
R-1

Reheater Outlet Header

Reheater Final Outlet Term. Tubes
Reheater Final Tubes
Reheater Final Inlet Term. Tubes
Reheater Intermediate Header
Reheater Platen Outlet Term. Tubes
Reheater Platen Tubes
Reheater Platen Inlet Term. Tubes
Reheater Inlet Header
Reheater Desuperheater

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

ECONOMIZER SCHEMATIC DIAGRAM

E-7

E-6
E-5

E-4

E-3
E-1
E-2

E-8,9,10

E-2

E-8
E-4

E-10

E-6

E-1
E-3

E-5

Tag No.
E-10
E-9
E-8
E-7
E-6
E-5
E-4
E-3
E-2
E-1

E-7

Circuit Name
Economizer Waterwall Inlet Links
Economizer Mixing Line
Economizer Outlet Links
Economizer Hanger Tube Outlet Header
Economizer Hanger Tubes
Economizer Junction Headers
Economizer (Bank2) Tubes
Economizer (Bank1) Tubes
Economizer Inlet Header
Economizer Inlet Leads
Feedwater Line

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E-9

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2.2

Process and System Description

PIPING AND INSTRUMENT DIAGRAMS

Piping and Instrumentation Diagrams (P&IDs) are key items in the documentation, which
define the engineering and construction requirements for the sections of the plant in Doosans
scope of supply.

2.3

PIPING AND INSTRUMENT DIAGRAMS DESCRIPTIONS STEAM AND WATER

Each diagram in the design series has an associated diagram description, which has a System
Purpose and Description of the P&ID.
2.3.1

P&ID Drawing Title:

Economiser System and Feed Inlet Pipework

Drawing Number:

Doosan : T07073-XG02-PI-D001
Owner : TCE.5146A-510-00-0612
IBR / ASME

Design Basis:
System Purpose

The transfer of feedwater from the Boiler Design Code boundary to the Furnace inlet header.
The extraction of useful heat from the flue gas by water flow in the economiser(s)
Prevent from evaporating the water at economizer outlet
Description of Drawing
The function of the economizer is to preheat the boiler feedwater before it is introduced into the
furnace waterwalls by recovering some of heats of the flue gases leaving the boiler. The flow path
and arrangement of the economizer circuits is shown on P&ID drawing T07073-XG02-PI-D001
and the Boiler General Arrangement drawings T07073-CC02-GA-A002.
Feedwater is supplied to the economizer system via feed check valve(10LAB50AA002), which is
used during dry mode operation, no BRP operation. But during wet mode operation feedwater is
supplied through the another check valve(10HAG20AA003) which is located in the start-up bypass
system(P&ID No. T07073-XG02-PI-D008).
The feedwater flow is upward through the economizer sections, that is, in counter flow to the hot
flue gases. Most efficient heat transfer is thereby accomplished, while the possibility of steam
generation within the economizer is minimized by the upward water flow.
During start-up and low load before steam produced, minimum 5% load of feedwater excluding
feedwater minimum recirculation flow is introduced to the economizer tube to prevent from
steaming at economizer horizontal tube section. The water temperature of each economizer
outlet string is measured using a quick response temperature transmitter(10HAC30CT101,102).
The measured temperature is transmitted to the control system to be monitored whether or not
evaporating at the economizer water at the economizer outlet.
There is flow measurement(FE,10LAB50CF001) upstream of economizer system to measure
the economizer inlet supply water quantity. Three flow transmitters(FT,10LAB50CF101,
102,103) control the feedwater flow that is deducted SH spray water from feedwater pump
discharge flow. In case feedwater flow at economizer inlet falls below the low set points, alarm
or trip signals are generated by the DCS based on the feedwater transmitters
(FT,10LAB50CF101/2/3) signal. In case trip signal happens, all the fuel must be automatically
tripped with a maximum time delay.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

Feedwater with required flow rate, pressure and temperature is delivered to the boiler boundary
by a pump system.
Pressure tapping points with isolating valve for test(PP,10LAB50CP401) and analogue
transmitters (PT,10LAB50CP101,102) are included for monitoring and transmitting the
economiser inlet pressure to the DCS, and for differential measurements where pressure loss
guarantees from the economiser inlet to the superheater outlet are part of the specification
requirements. Also temperature transmitters(TT,10LAB50CT101,102) are installed to monitor
and transmit to the DCS. A drain line(MOV,10LAB50AA441) is branched out at the economiser
inlet link(10LAB50BR001) and a branch for chemical cleaning service is provided on the drain
line. Normally drain valve is closed except for maintenance.
The economizer is located at the last stage of heat recovery in the back pass of the boiler. The
economizer is arranged in four banks horizontally and made of bare tubes. The economizer banks
are arranged in such a manner that each row is in line in relation to the row above and below. All
tube circuits originate from the economizer inlet header(10HAC10BB001), and discharge into
three economizer junction headers(10HAC20BB001-003). A set of economizer hanger tubes
connect the junction headers to the economizer outlet header(10HAC25BB001).
From the economizer outlet header (10HAC25BB001), the fluid flows through the two outlet links
(10HAC30BR008), mixing link (10HAC30BR009), two water wall inlet links (10HAC30BR010) into
the both of furnace lower side wall headers (10HAD10BB001). See the P&ID, No. T07073-XG02PI-D002.
A low point drain connection via the start-up flash tank(Drawing No. : T07073-XG02-PI-D009,
Boiler Drain & Vent System, 10LCQ20BB001) in boiler area is provided for removal of water
during dry storage.
The vent line(10HAC30BR502) which is connected on the economizer outlet header
(10HAC25BB001) has motorized vent valve(MOV,10HAC30AA541) and manual isolating
valve(10HAC30AA501). The motorized vent valve is closed in time delay from detected the
economizer inlet flow reaches over 10 ton/hr.
The air vent release provides a convenient point for nitrogen gas injection for blanketing or
inerting during periods of wet or dry storage respectively. An isolating(10HAC30AA201) and a
screw down non-return valve(10HAC30AA202) are included for nitrogen supply isolation.
One pressure part thermowell(TW,10LAB50CT401) is provided for performance testing. The
temperature is sensed by a thermocouple(TT,10LAB50CT101,102), and the resultant signal is
either transmitted directly to the DCS through a transmitter to a 4 20mA high level analogue
input. The measured temperature is used for indication, and Top Feed Heater Out of Service
operation (THOS). For availability reasons the feedwater temperature should be measured
twice especially when the measured signal is used for control function manipulation.
The frequency with which soot blowers are used depends entirely on local conditions. When the
economizer is first placed in operation, the economizer soot blowers(Tag No. : 221-238, See P&ID
No. T07073-XG-PI-D020) should be blown about once every shift. Observation of the increase in
draft loss between blow outs will determine how long an interval may be set as a standard. In
many cases, it has been found that blowing the economizer soot blowers once a day or less is
sufficient.

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2.3.2

Process and System Description

P&ID Drawing Title:

Evaporation System

Drawing Number:

Doosan : T07073-XG02-PI-D002
Owner : TCE.5146A-510-00-0613
IBR / ASME

Design Basis:
System Purpose

Source of water for the evaporative circuits (i.e. the furnace walls).
Source of 1. two phase mixture from the evaporative circuits into water and saturated steam.
2. overheated steam from evaporative circuits into superheater section
Description of Drawing
The referenced drawing shows furnace system from furnace lower header(10HAD10BB001) to
riser pipe(10HAD30BR009) of furnace outlet. During start-up and low load condition two-phase
flow is circulated in the furnace with assistance by boiler recirculation pump(10HAG20AP001,
P&ID No.T07073-XG-PI-008) and separated by four separators(10HAD40,42,43,45 BB031).
But during normal operation the fluid is superheated in the furnace and separator has no
separation. It is just the path of superheated steam which is produced in the furnace.
Transfer of sub-cooled water from the economiser outlet header side connecting pipes
(10HAC30BR008) to the furnace lower side headers(10HAD10BB001) through economiser
outlet mixing line(10HAC30BR009). This incoming sub-cooled water is distributed to furnace
wall tubes which are connected to the furnace lower front and rear header as a ring header
configuration. All the furnace tubes which are divided evenly are originated from front and rear
lower header. Furnace wall is consisted as spiral wall that has inclination with 17.3 degree.
There are four intermediate headers(10HAD15BB001-004) at the transition area in the furnace,
which is junction point of spiral wall and vertical wall tubes. The ratio of spiral wall
tube(10HAD12) numbers to vertical wall(10HAD20) tube numbers are 1 to 3. That means
vertical tube numbers are 3 times of spiral wall tube number.
There are four furnace outlet headers(10HAD25BB001-004) and each header has four riser
pipes(10HAD30BR009,BR020,BR029) these are arranged and connected with considering
temperature distribution to the separators (10HAD40,42,43,45 BB031) respectively.
Extraction of heat from the combustion process in the furnace through the spiral tube walls to
the fluid. The heat transferred to the fluid causes density change that induces natural circulation
of fluid from the separator storage tank(10HAD50BB033) to the furnace walls via the
downcomers(10HAG10BR001), and back to the separators(10HAD40,42,43,45 BB031) as a
two-phase mixture. The mixture of steam and water is collected at the top of the walls in outlet
headers and transferred to the separators, which separate the steam and water by using
centrifugal force at the separators(10HAD40,42,43,45 BB031). Regarding separator and
storage tank, see the P&ID No. T07073-XG-PI-D003.
Furnace lower ring header has two drain connections at the front(10HAD50BR402) and rear
(10HAD50BR401) headers, and each intermediate header(10HAD15) has drain connections
(10HAD15BR401,402,403,404). The drain lines are linked as a group of lower header
(10HAD50BR403) and intermediate header(10HAD15BR405) respectively. This combined
drain lines that discharge through isolating valve(lower ring header : MOV,10HAD50AA441 /
Intermediate header : MOV,10HAD15AA441) to the manifold(10LCQ20BR402) which is located
in front of boiler start-up flash tank. See P&ID No. T07073-XG02-PI-D009.

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Process and System Description

Capped chemical cleaning and drain connections are fitted on the dedicated lower wall drains.
The drain system of lower ring headers(10HAD10BB001) is in addition used to fill the boiler for
hydrostatic testing. Filling water through the drains reduces the possibility of air pockets forming
especially during hydrostatic testing. The present trend is for operators to fill the water in the
boiler using the start up feed pump and a filling line.
The warm-up line(10HAG30BR001) is activated to warm-up the start-up lines (10LCT10BR002,
BR003, 10HAG10BR002,BR003. See P&ID No. T07073-XG02-PI-D008) to reduce the
temperature deviation between metal and fluid in preparation of starting boiler during dry
mode(once through mode) operation. It extracted from economiser outlet mixing line(10HAC35)
and discharged(10HAG15BR001) to upstream(10LAE51BR002, 10LAE52BR002) of the 1st
stage desuperheater separately. The motor operated valve(MOV,10HAG30AA041) is opened
automatically by control logic when dry mode operation.
These valves should be in their positions before changing to dry mode operation. (See P&ID
No. T07073-XG02-PI-D008)
- BRP(10HAG20AP001) off
- LL Line(10HAG10BR003) MOV(10HAG10AA042) Close
- UG Line(10HAG20BR002) LCV(UG, 10HAG20AA041) Open
- BRP Inlet(MOV,10HAG20AA041)/Outlet(MOV,10HAG20AA042) MOV Close
- BRP Line(10HAG10BR004) Vent MOV(MOV,10HAG10AA041) Close
- Pre Warm-up Stop MOV(MOV,10HAG30AA041) Open
- WR/ZR Line Isolation MOV(MOV,10LCT10AA041) & LCV(ZR,10LCT10CG091,
WR,10LCT10CG092) Close
Thermo-elements are attached on the unheated tube at the spiral wall tube outlet
(TE,10HAD12CT001-CT116) and vertical wall tube outlet(TE,10HAD20CT001-CT076) to detect
the unheated tube surface metal temperature, which is regarded as the same of steam
temperature. The temperatures are monitored continuously and sent to the DCS.
Alarm and trip(MFT) setting value is set for protecting from furnace wall tube overheating. In
case high temperature is detected through the signal from settled thermo-element alarm signal
is shown on the monitor. If a few numbers of thermo-element detect high temperature than trip
set value and the detected high temperatures do not return to usual temperature after time
delay, the boiler get the MFT signal by the DCS.
Trip and alarm temperature is decided by considering allowable metal temperature and design
metal temperature and tube thickness and operational circumstances.
Temperature transmitters(TT,10HAD30CT101 -108) are installed on the two connection pipes
out of four pipes(10HAD30) of each furnace outlet header(10HAD25BB001-004).

2.3.3

P&ID Drawing Title:

Water separation system

Circulation & Start-up system

Drawing Number:

T07073-XG02-PI-D003 & T07073-XG02-PI-D008

TCE.5146A-510-00-0614 & TCE.5146A-510-00-0619
IBR / ASME

Design Basis:
System Purpose

- This system is divided start-up and low load operation and Normal operation, that means wet
mode type(recirculation mode) and dry mode type(once through mode).
- Wet Mode(Recirculation mode) : start-up and low load condition.
Drain water from separator returns to the economizer inlet pipe.

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Process and System Description

Boiler recirculation pump operation

Boiler minimum flow rate to prevent from over heating
High quality steam flows to the superheater section.
- Dry Mode(Once through mode) : Normal operation
Description of Drawing
1) Description for Start-up and Low Load Circulation System
A supercritical Once Through Boiler operates under Two modes-Dry Mode (Once Through
Mode) and Wet Mode (Recirculation Mode).
Transfer of two phase flow from the riser pipes(10HAD30) of furnace outlet headers(10HAD25)
to the separators(10HAD40BB031, 10HAD42BB031, 10HAD43BB031, 10HAD45BB031) to
separate water and steam by centrifugal force. Separated water goes through the storage tank
(10HAD50BB033) and the Boiler recirculation pump(10HAD20AP001) discharges the drain
water to the economizer inlet pipe(10LAB50BR001) and separated steam goes to the furnace
roof inlet header(10HAH12).
Water from separator storage tank(10HAD50BB033) drain line and from feed water pump
discharge combines in the mixing piece(10HAG10AM001) to increase NPSH of boiler recirculation pump(10HAG20AP001) by mixing hot and cold water.
The minimum boiler water flow should be kept 35% load flow to prevent from furnace overheating in order to ensure adequate cooling of the furnace waterwall tubes during start-up and
low load operation. As a result, wet conditions prevail in the waterwall tubes of the evaporator,
water separator and therefore, the saturated water is recirculated by means of the boiler
circulation system.
Boiler re-circulation pump(10HAG20AP001) assists to circulate mixed return water from mixing
piece(10HAG10AM001) to save the plant energy, to keep minimum water quantity 35% load at
the furnace.
In other words, the primary purpose of the boiler recirculation system is to ensure a minimum
flow of 35% load through the furnace tubes and thus protect them from overheating during
start-up and low load operation of the boiler namely Wet mode.
2) Boiler Circulation System-Major Equipments
The boiler circulation system consists of the following major equipments:
z
z
z
z
z
z
z

Water Separators(10HAD40,42,43,45BB031)
Separator Storage Tank(10HAD50BB033)
Mixing Piece(10HAG10AM001)
UG Valve(LCV,10HAG20AA091)
Boiler Recirculation Pump(10HAG20AP001)
Separator Drain Valves(WR: LCV,10LCT10AA092 / ZR:LCV,10LCT10AA091)
Flash Tank(10LCT20BB001)

In addition, associated piping, valves and fittings as required to make the system complete are
envisaged.
3) Water Separator System & Storage Tank
The water separator system consists of four(4) vertical vessels with four(4) tangential inlet
pipes which consist 4 riser pipes per one separator to receive the steam/water from furnace
waterwall tubes via riser pipes(10HAD30BR009,BR020,BR029). Each Separator has one

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Process and System Description

steam outlet pipe(10HAH10BR001). This outlet pipe(10HAH10BR001) is also located at the top
of the water separator to lead the steam to the Roof inlet header(10HAH12BB001).
Each separator is designed to handle over 25% BMCR steam flow. The capacity of separator
storage tank is designed to accommodate the BMCR water quantity for 10 seconds. Also it has
drain nozzle at the lower part. The separation of water and steam is done in the separator and
the storage water is controlled by drain valves(WR, LCV,10LCT10AA092 / ZR :
LCV,10LCT10AA091) and UG valve(LCV,10HAG20AA091).
The storage tank drain water is connected to the drain line(10HAG10BR001) supplying the
water either to the BRP(10HAG20AP001) or to the boiler start-up flash tank(10LCQ20BB001)
via separator drain valves(MOV,10LCT10AA041, LCV, 10LCT10AA091/2)
The storage tank height from tap to tap is 16444 mm and its inside diameter is 555 mm.

- SEPARATOR STORAGE TANK LEVEL CONTROL

a) Overview
Storage tank water level is controlled by three level control valves, WR(LCV,10LCT10AA092),
ZR(LCV,10LCT10AA091), UG(LCV,10HAG20AA091).
The purpose of circulating water control valve (UG valve) is to control the level with some range
in the storage tank level, thus accurate and fast positioning is a prerequisite. It situated just
downstream the BRP. It is also the hot start which determines the sizing of the UG valve.
Normally the drain flow from the separator storage tank is recirculating through evaporator by
boiler circulation pump(BRP,10HAG20AP001) assistant via control valve(UG) located
downstream of BRP into the economizer.
UG valve is used for storage tank level control within some setting range and additionally UG
valve has functions like control of limited BRP flow capacity and controls economizer inlet flow
not to exceed dry mode flow. At the starting stage the full opened UG valve
(LCV,10HAG20AA091) is closed as minimum opening position(15% to 23%) when
BRP(10HAG20AP001) is ready to start. And after BRP starting the UG valve is controlled
automatically and follows the set flow, minimum water wall flow of 35%TMCR, at economizer
inlet.
Even though the boiler is dry mode the start-up control system is allowed to be controlled by
the DCS but steam re-circulation at the start-up system must be protected. When BRP is being
operated at dry mode, Motor operated valve(MOV,10HAG10AA042) upstream of mixing
piece(10HAG10AM001) must be at the close position and BRP must be stopped within
40%TMCR. Even though the boiler is operated as a dry mode condition, the storage
tank(10HAD50BB033) becomes wet mode condition that means water column in storage tank
increases wet mode set level(around over 3 meter) at over 40% load by abnormal problem, the
BRP(10HAG20AP001) will not be started and the water level is controlled by ZR and WR
(LCV,10LCT10CG091, 092) control valve.
ZR and WR valves are used for controlling the storage tank level from boiler water filling also.
When the storage tank water level decreases down to 3 meters from lower tap level, the UG
valve opening position sets to 30%. If BRP operation is stopped the shut-off valve
(MOV,10HAG10AA042) which located inlet of mixing piece(10HAG10AM001) will be closed
fully with around 20 seconds time delay. When water level down to 1 meter the mixing piece
inlet shut-off valve(MOV,10HAG10AA042) gets the lock signal from DCS. And UG valve gets
full open signal by DCS with 30 seconds time delay after shut-off valve full close.

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Process and System Description

In case BRP is stopped, UG valve is being fully opened but when the water level reaches 3
meter the UG valve opening gets to the 30% of set value.
At the water filling period if normal water level(NWL) of storage tank is maintained automatically
for two minutes with over 65% ZR valve opening and over 15% WR valve opening, it is
assumed that the boiler water filling is over. The drained water through WR and ZR valve
during filling up the boiler is drained to the sump via overflow line(10LCQ40BR401) in the
condensate receiving tank(10LCQ40BB001).
A set of two return valves (WR, ZR valve) is used to control the flow of saturated water from the
separator storage tank(10HAD50BB033) into the boiler flash tank(10LCT20BB001). They are
designed to accommodate the swell flow during start-up, assuming that the BRP is available for
every start.
Especially during start-up larger amounts of water (swell flow) need to be drained from the
separator(10HAD40,42,43,45BB031). For this purpose additional drain capacity is provided,
dumping the excess water into the flash tank(10LCQ20BB001) located in the boiler area. The
respective control valves are situated near the flash tank and open when the separator level
exceeds a certain threshold lying above the normal set value applicable for normal recirculation
via BCP(10HAG20AP001) and control valve(WR, ZR) (split range control).
To control the storage tank water level two control valves(ZR, WR) get the level signal by level
transmitters(LT,10HAD50CL101,102,103) via DCS. The respective control valves are usually
located near the boiler flash tank and open when the separator level exceeds a certain
threshold lying above the normal set value applicable for normal recirculation via BRP and
control valve (split range control). Before operated the control valves(ZR, WR) the mixing piece
inlet shut-off valve(MOV,10LCT10AA041) should be remained open position.
When ZR valve opens 80% of opening position the WR valve starts opening. The normal water
level of storage tank is around 8.4 meter. These data may be changeable during detail process.
The Storage tank Level control logic is designed to control the liquid level in the separator
storage tank during boiler start-up and upset conditions to prevent liquid from overflowing into
the superheaters. Control is accomplished with two split range drain valves. After start-up, a
separate warming control valve(LCV,10HAG15AA071) will control the level of liquid in the
separator wet leg.
b) Demand Development
The three (3) Storage tank level transmitter(LT,10HAD50CL101,102,103) signals are pressure
compensated and then averaged to develop the process variable for the control loop. This
value is compared to a set point and the resulting error signal is sent to the WR
(LCV,10LCT10AA092) and ZR(LCV,10LCT10AA091) drain valves. These are split range valves
(ZR : 11.4 13.5 meter, WR: 13.1-15.3 meter, Normal water Level : 8.4 meter. The basis level
is lower tap level) with the ZR valve providing control from 0 to 50% and the WR valve starting
to open at 50%. The WR valve is normally closed position, and is probably only opened when
the water begins to boil, thereby causing a decrease in density and a corresponding rapid
increase in water level.
The water flow into the Separator during boiler start-up will be controlled by the UG valve. The
economizer inlet flow will be compared to an operator adjustable set point. The set point will be
low limited by the maximum BRP(10HAG20AP001) capabilities and high limited by the
minimum required economizer inlet flow. The resulting error signal will be acted upon by a
proportional plus integral controller to position the UG valve(LCV,10HAG20AA091). The UG
valve is also used to protect the BRP from too low of an outlet pressure. The differential

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Process and System Description

pressure across the BRP is measured and compared to a set point. The resulting error is sent
to a proportional plus integral controller. The output of this controller is used to low limit the
valve position.
c) Interlocks
The ZR valve(LCV,10LCT10AA091) will be interlocked closed when the Separator outlet
temperature is superheated by at least 20 C and the Unit load is larger than 40% load. The
WR valve(LCV,10LCT10AA092) will be interlocked closed by the same conditions as the ZR
plus the feedback that the ZR valve is closed.
The mixing piece(10HAG10AM001) inlet isolation valve(MOV,10HAG10AA042) is interlocked
open when there is no fire in the boiler. When the Separator outlet temperature is superheated
by at least 20 C and the Unit load is larger than 40% load, the mixing piece inlet isolation valve
will be interlocked closed to prevent steam from recirculating through the BRP
(10HAG20AP001).
The UG valve(LCV,10HAG20AA041) will be interlocked open when the BRP is off or when the
mixing piece inlet isolation valve(MOV,10HAG10AA042) is closed. When the BRP is ready to
start, the UG valve will be positioned about 15% to 23% open which represents an
approximation of the initial position required by the UG valve to control the economizer inlet
flow.
The Warming valve(MOV,10HAG30AA041) will be interlocked closed while the BRP is running
and then released to control the Separator Wet Leg Level which is controlled by level control
valve(LCV,10HAG15AA071) once the BRP is turned off.
d) M/A Control Stations
Each of the control valves will be supplied with M/A control station. The WR and ZR control
stations will be rejected to and locked into manual if two out of three of the Separator level
transmitters display bad quality. The UG valve control station will be rejected and locked into
manual if the economizer inlet flow displays bad quality. The Warming valve control station will
be rejected to and locked into manual' if the Separator Wet Leg level displays bad quality.

4) Recirculation Pump (10HAG20AP001)

One(1) No. Boiler recirculation pump(10HAG20AP001) of glandless, wet motor, vertical type is
envisaged to assure water recirculation below minimum once thru load of 35%TMCR, wet
mode. The pump will be supported through the downcomers which in turn are supported by
separator storage tank(10HAD50BB033). Pump and motor foundations are not required. The
boiler recirculation pump is sized for hot-start with high separator pressure. The pump head has
to overcome the pressure loss from economizer inlet to the water separator at a flow of
approximately 35% TMCR, which is the minimum evaporator flow.
The boiler recirculation pump (BRP) is situated in the main stream of start-up feed line,
meaning that the entire water flow to the economizer is passing through the BRP at low load.
Thus the saturated water from the separator is mixed with cold boiler feedwater upstream of the
BRP. This configuration has a number of advantages :
z
z
z

Better NPSH due to mixing of cold feedwater with the saturated water from the
separator
No need for special NPSH control
Higher rates of pressure decrease in the boiler can be tolerated

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z
z

Process and System Description

The idling BRP is kept warm with no need for additional components
Lower thermal stress for the BRP casing

5) Mixing Piece (10HAG10AM001)

In the mixing piece the hot, slightly sub-cooled water from the separator is mixed with cold
feedwater. The purpose of the mixing piece is to avoid formation of hot or cold water jets
striking pipe walls in uncontrolled manner. The mixing piece consists of a vertical casing with
the axial inlet for the hot water at the top and the outlet for the mixed water at the bottom. The
cold feedwater enters radially through an elbow into the central pipe, which has many holes.
The design is optimized for low pressure drop in the recirculation line, particularly in the case
when there is little feedwater flow.

6) Warm-up System(See P&ID No. T07073-XG02-PI-D008)

When the boiler load is approx. 35%TMCR and above, the recirculation system is not in service
and is kept warm by a system using hot water from the economizer outlet mixing
link(10HAC30BR009) and keeping the piping from separator storage tank(10HAD50BB033)
level control valves(drain valves-WR/ZR) up to the level-tanks warm. The BRP
(10HAG20AP001) with mixing piece(10HAG10AM001) and valves are kept warm because a
small amount of feedwater will flow through these.
The warm-keeping system is activated by opening of the motor operated valve
(MOV,10HAG30AA041) on warm water supply line(10HAG30BR001). The flow is restricted by
the orifices(FO,10HAG30BP001, 10HAG30BP002, 10HAG10BP002) in combination with the
manually activated trim valve. The distribution of the warm-keeping water is shown in P&ID
drawing, the start up system configuration. The water is fed into the recirculation
line(10HAG30BR401) and drain line (10LCT10BR003) to flash tank(10LCT20BB001) through
nozzles in the body of the gate valve (MOV,10LCT10AA041) which is installed at the upstream
of WR/ZR. The third feed point is directly into the recirculation line(downcomer)
(10HAG10BR003) above recirculation isolation valve(MOV,10HAG10AA042). The two feedpoints(10HAG30BR002, BR003) are combined as one line(10HAG30BR004) which equipped
with an orifice as well as a non-return valve to assure equal flow in the two warm water supply
lines(10LCT10BR001, 10HAG10BR005). The warm-keeping water from economizer outlet
mixing line(10HAC30BR009) is slowly rising upwards through the above mentioned lines and is
removed from the system through the spray water line(10LAE51BR002, 10LAE52BR002) to 1st
superheater de-superheater.
The remaining part of the recirculating system up to the Storage tank(10HAD50BB033) is kept
warm by condensing steam at sub-critical conditions by supercritical fluid from the
separators(10HAD40,42,43,45BB031), flowing very slowly downwards.
Just above the junction point which is connected from downcomer(10HAG10BR002) to spray
water line(10HAG15BR001), the condensate water level, wet leg level, is measured and its
signal(LT,10HAG10CL101, 102) is primarily a pressure difference and is used directly for the
water leg level control valve(LCV,10HAG15AA071) which is controlling the outflow from the
warm-keeping system. In this way the function of the control valve(LCV,10HAG15AA071) is
assured for sub-critical as well as for supercritical operation. The start up system including
warm-keeping system shows the. on the P&ID No. T07073-XG02-PI-D008.
The most appropriate solution satisfying all functional requirements will be better determined
during actual operation and experience.

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Process and System Description

The warming control valve(LCV,10HAC15AA071) is used to maintain a warm condition in the

piping between the Separator storage tank(10HAD50BB033) and mixing piece
(10HAG10AM001) inlet isolation valve(MOV,10HAG10AA042), WR(LCV,10LCT10CG092), and
ZR(LCV,10LCT10CG091) valves. This is accomplished by modulating the Warming control
valve to adjust the flow water from the separator storage tank through the associated piping to
the desuperheater spray header. The valve is controlled by comparing the Separator Wet Leg
Level with an operator adjustable set point. The resulting error drives a proportional plus
integral controller to position the warming valve.
7) Wet to Dry Mode
Changing from wet to dry mode means that the control basis is changed from separator water
level control to separator outlet steam temperature control.
During the transfer two opposite storage events take place in the boiler, on one hand the
energy content increases on the other the content of flow medium, wet content, decreases. To
realize that, the fire intensity and the waterwall flow temporarily have to come apart. In the
control conception this shifting is reached by first increasing the fire intensity and later the
waterwall flow is increased.
A load increase starting from low load with water recirculation system operation (automatic
level control) and ending in the load range with pure once through operation(automatic
temperature control). The following processes take place during this transfer in operation mode
and the change mode is explained based on the feedwater flow is assumed as constant. :
- Step 1 : The rising firing rate with constant minimum feedwater flow increases the steam
production and decreases the water return flow through separators. The wet steam
enthalpy at separator inlet increases.
The steam quality at separator inlet reaches X(dryness) = 1 ; saturated steam flows
into the separator; no water is separated anymore causing the water return valve
(ZR,LCV,10LCT10CG091) to close.
- Step 2 : The further increase in firing rate still constant minimum feedwater flow effects a slow
superheating of the steam at separators(10HAD40,42,43,45).
The boiler internal control is completely blocked feedwater flow on minimum value;
temperature control inactive because the actual steam temperature is still below its
set point.
A good deal of the fire increase is not used for steam generation but for getting the
boiler on the higher energy level required for once through operation.
The steam temperature at the separator reaches the set point value.
- Step 3 : The further increase of the fire intensity causes the steam temperature to exceed the
set point. The temperature controller reacts by increasing the feedwater flow, which
is allowed by the max-choice. The temperature control is fully active.
8) Feedwater control System
The feedwater system and at least one feedwater pump, including the instrumentation and
equipment, has been checked out and is available for operation. During a start-up, the
feedwater flow should be controlled remote-manually until a continuous flow is established.
The deaerator auxiliary steam supply is operational and de-aerated feedwater at 105 is
available. To avoid oxygen corrosion in the boiler, the use of de-aerated feedwater with a
temperature of greater than 102 is recommended.

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Process and System Description

9) Normal operation
During normal operation the pressure moves as a sliding pressure mode from around 90
kg/cm2g of 35% load to 255 kg/cm2g of 90% load. From 90% to 100% load it is operated with
constant pressure. It is called as a modified sliding operation.
The feedwater entered Economiser is sub-cooled condition and the sub-cooled water is
changed to superheated steam in the furnace at normal operation. Dry mode operation applies
to the load range from 35% load upto full load.
Separator outlet temperature by detecting four temperature transmitters (TT,10HAH10CT101CT104) is used for controlling the feedwater flow.
Four(4) spring loaded safety valves(PSV,10HAH10AA101,102,103,104) are installed on the
separator outlet links(10HAH10BR001A-D) to prevent from over-pressure. They have the same
set pressure and temperature as 304.9 bar(g) and 431.5. The separated vent pipes from
each riser pipe from the same separator are combined as one pipe, which is connected to the
flash tank inlet manifold(10LCQ10BR502) via motorized shut-off valve(MOV,10HAD30AA541AA544). See the P&ID No.T07073-XG02-PI-D003 for more detail layout of vent pipes.
Other vent pipes(10HAH10BR501-504) from separator outlet connection pipe
(10HAH10BR001A-D)
also combine as one pipe. The pipe(10HAH10BR506) is also
connected to the flash tank inlet manifold(10LCQ10BR502). The manifold is connected to the
flash tank vent stack (10LCQ10BR501)
.
The vent pipes allow trapped air to be vented during hydraulic testing, boiler start-up and for
vacuum breaking when blowing down and emptying the boiler.
The common air release provides a convenient point for nitrogen gas injection for blanketing or
inerting during periods of wet or dry storage respectively. An isolating(10HAH10AA201) and a
screw down non-return valve(10HAH10AA202) are included for nitrogen supply isolation.
A sample point incorporating a probe, and complete with isolating valves(10HAH10AA601,
AA602) is provided for steam extraction and subsequent analysis. This is required to ensure
that saturated/superheated steam quality is of suitable for the operating pressure. The sampling
line is extracted from vent line(10HAH10BR505) of separator outlet connection pipe
(10HAHBR001A-D).
To comply with ASME SEC.1 design code requirements, separator outlet connection pipe is
fitted with four(4) numbers of safety valve(PSV,10HAH10AA101,102,103,104). These valves
are designed to be discharged over 65% BMCR

2.3.4

P&ID Drawing Title:

Superheater System (Roof inlet link to LTSH outlet

connection pipe)

Drawing Number:

T07073-XG02-PI-D004
TCE.5146A-510-00-0615
IBR / ASME

Design Basis:
System Purpose

Transfer of superheated steam from separator tank(10HAD50BB033) to Furnace roof inlet

header(10HAH12) through four connection pipes(10HAH10).

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Process and System Description

Transfer of superheated steam from Furnace roof inlet header to Roof outlet header(10HAH14)
& Backpass inlet(upper) header(10HAH14).
Transfer of superheated steam backpass inlet(upper) header to outlet(lower) header(10HAH18)
via extended side wall tube and backpass side wall tubes.
Transfer of LTSH inlet header(10HAH20) to LTSH outlet header(10HAH30) via LTSHs
horizontal tubes and vertical tubes.
Description of Drawing
From the roof inlet headers(10HAH12), steam flows along with the furnace roof tubes to the
roof outlet header. Furnace roof tubes are revealed to the furnace radiant area but outlet side is
in the radiant and convection area. Furnace roof outlet header(10HAH14) is connected to the
both backpass side wall inlet headers(10HAH14).
The roof outlet header is located above backpass section and the header divides the rear
backpass area as a backpass sidewall inlet header(10HAH14) and extended wall inlet
header(10HAH14). The above two headers are connected by the medium of roof outlet
header . Therefore the same condition of steam from roof outlet header distributes to the
backpass sidewall inlet header and extended wall inlet header. Extended side wall is located
nose outlet vestibule section.
Backpass lower side wall headers(10HAH18) have drain branches, which are connected to the
manifold(10LCQ10BR502) of in front of boiler flash tank(10LCQ20BB001). Motorized shutoff
valve(MOV,10HAH20AA441) and manual shutoff valve(10HAH20AA401) are installed at the
common drain line. This drain valve(MOV,10HAH20AA441) can be closed when separator
pressure reaches 3.5 bar(a). But the set pressure can be raise to satisfy no condensate water
remains in the backpass header. The manual shut-off valve is always open condition except
MOV maintenance.
The steam flows from common header, roof outlet header, backpass side wall inlet header
(10HAH14) and extended side wall inlet header(10HAH14), to backpass lower side wall outlet
header(10HAH18) and backpass front wall lower header(10HAH18), which headers are
combined as one header. But there is a extended wall outlet header(10HAH17) between roof
outlet header and backpass lower front header. The extended outlet link (10HAH17) connects
between two headers.
The steam which flows down to the backpass side lower header goes to the LTSH(primary
superheater) inlet header(10HAH20), which located in the bottom of backpass rear wall,
adjacent to the backpass sidewall lower header. Through the LTSH tubes the steam heated
more and goes to the LTSH outlet header(10HAH30) via LTSH horizontal(10HAH22) and
pendent tubes(10HAH25).
Metal temperature elements(TE,10HAH25CT001-CT033) for permanent are attached on the
unheated tube surface at LTSH outlet section to check the stub metal temperature.

2.3.5 P&ID Drawing Title:

Drawing Number:
Design Basis:

Superheater System (LTSH outlet connection pipe to Panel

SH Outlet connection pipe)
T07073-XG02-PI-D005
TCE.5146A-510-00-0616
IBR / ASME

System Purpose
The primary superheater(LTSH) outlet connection pipe(10HAH40) reaches to the Panel SH
inlet header(10HAH42). Between two SH sections the long pipes provide an ideal location for

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

the first stage attemperators. The length is long enough to be mixed completely of the injected
spraywater with the superheated steam before entry to the Panel superheater(10HAH45).
The primary superheater outlet steam temperature is measured for control and monitoring
purposes in each attemperator inlet pipe(10HAH40) using temperature transmitters
(TT,10HAH40CT101-104). The measurements are used by the DCS to provide redundant
inputs for the steam temperature control system.
The temperatures are transmitted to those of the inlet measurements. To reduce the steam
temperature entering the panel superheater, spray water is added in the connecting pipes
(10HAH40) between the primary SH outlet and the panel SH inlet. The source of this water is
economiser inlet.
The flow is sensed by a venturi type flow element that generates a differential pressure.
A pressure differential is converted as a measured differential into a 4-20mA analogue signal
as an input to the DCS. As the flow conditions do not necessarily match the element design
parameters, compensation for pressure and temperature deviations is required. The
temperature
transmitter(TT,10LAB50CT101/2),
and
the
pressure
transmitter
(PT,10LAB50CP101/2) which is located at the feedwater line provide the required inputs to the
DCS for compensation of the spray flow.
The temperature transmitters(TT,10HAH40CT101-8) send temperature values as an analogue
inputs to DCS to reduce the steam temperature difference which is input in the control logic.
The detected temperature values from the upstream transmitters (TT,10HAH40CT101/2/3/4)
and downstream transmitters(TT,10HAH40CT105/6/7/8) of desuperheating stations are sent to
the DCS to be compared with input value.
Following flow measurement, the spray water line divides, with one line serving the 1st and 2nd
stage attemperators on the A side(10LAE51BR002) of the boiler, and the other B
side(10LAE52BR002) attemperators.
Each spray station is made up of an actuated inlet
isolating
valve(10LAE51AA001,2
10LAE52AA001,2),
modulating
control
valve
(TCV,10LAE51AA071,072, 10LAE52AA071,072), and motorized discharge isolating valve
(10LAE51AA041,
042,
10LAE52AA041,042).
A
double
isolated
drain
valve(10LAE51AA401,2,3,4, 10LAE52AA401,2,3,4) between the motorized isolating and
control valves is used to check for isolating valve leakage. The chosen pneumatic control
valves are complete with intelligent I/P converters, fail fix devices, and valve position
transmitters. 100% of redundancy spray station is provided at each spray line for emergency
and for continuous spray use.
On every installation it is necessary to ensure sufficient pressure exists to inject the spraywater
into the steam stream. Therefore a study of the prevailing pressures related to boiler load is
required. This generally shows that at the maximum spray flow there is insufficient feedwater
pressure to inject the spray into the steam. This is of no consequence on boilers with dedicated
spraywater booster pumps, feedwater pumps with additional spray booster stages, or
conventional feedwater control valves at either the feed pump or feed heater discharge. The
differential across the feed valves is adjusted by modulation of the valves to attain a suitable
spraywater pressure.
The steam line(10LAE50BR503) for sootblowing is extracted from LTSH outlet common line.
The steam condition is enough for sootblowing and has enough superheated margin compared
sootblowing steam.
The warm-up line(10HAG15BR001) for maintaining the start-up system as a warm condition
during normal operation is separated and associated with both desuperheater spray
header(10LAE51/52BR002) and injected to the main stream(10HAH40).

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

Each LTSH outlet header connection pipe(10HAH40) is fitted with an air release, which vents
are common together to atmosphere through manual isolating valve(10HAH40AA501) and
motorized isolating valve(MOV,10HAH40AA541). This allows trapped air to be vented during
hydraulic testing, boiler start-up and for vacuum breaking when blowing down and emptying the
boiler.
The common air release provides a convenient point for nitrogen gas injection for blanketing or
inerting during periods of wet or dry storage respectively. An isolating and screw down nonreturn valve(10HAH40AA201) are included for nitrogen supply isolation.
The permanent metal temperature elements(TE,10HAH45CT001-CT012) for monitoring are
attached on the unheated tube surface at Pendent SH outlet section to check the stub metal
temperature. These temperature measurements are transmitted as converted to high level
analogue inputs in transmitters.

2.3.6

P&ID Drawing Title:

2nd Attemperator and Final Superheater

Drawing Number:

T0073-XG02-PI-D006
TCE.5146A-510-00-0617
IBR / ASME

Design Basis:
System Purpose

Transfer of superheated steam from the panel superheater outlet by way of the second stage
attemperators(10HAH50) to the final superheater inlet header(10HAH55).
Collection of steam from the final superheater outlet header(10HAH60).
Attemperation of the steam entering the final superheater to the conditions required to maintain
the final steam temperature at the design condition over the specified load range.
Description of Drawing
The steam from panel SH outlet goes through 2nd stage attemperators and the temperature is
adjusted as the required steam temperature to meet the final shperheater outlet temperature.
As the steam flow has already been divided into two streams on exit from the panel
superheater. The purpose of this connective configuration is to be considered the effect of
combustion imbalance on the heat pick up of each steam stream at the tangential firing boiler
characteristics, thereby attempting to naturally equalise the steam temperature at the outlet of
each stream. Each final SH inlet connection pipe(10HAH50) is fitted with an air release, which
when commoned together vents to atmosphere through manual isolating valve
(10HAH40AA401) and motorized isolating valve(MOV,10HAH40AA441). This allows trapped
air to be vented during hydraulic testing and boiler start-up.
After suitable attemperation, the steam flow enters the final superheater inlet header, travels
through the final SH loops(10HAH58) and emerges at the final superheater outlet
header(10HAH60) with desired temperature, having extracted the required energy from the
combustion process. The outlet connection pipe connects both steam streams and is across
the entire boiler width as it is assumed that there will be two steam legs from the boiler to the
turbine(supplied by others). The connection pipe of final superheater outlet header extends
through the remote casing on each side of the boiler to provide a suitable connection for the
turbine steam legs.
To comply with ASME SEC.1 design code requirements, the superheater outlet connection
pipe (supplied by others) is fitted with four(4) numbers of safety valve
(PSV,10LBA11/12AA201,301). These valves are designed to be discharged over 35% BMCR.
And ERVs which capacity is over 10% BMCR are settled. The combined capacity of the

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

separator outlet connection pipe and superheater valves with ERV shall not be less than the
maximum designed steaming capacity of the boiler. The valves discharge to atmosphere
through pipework, stacks and silencers(SH outlet safety valves only) with suitable expansion
provisions. Each valve has a body vent discharging to atmosphere. Silencer design is
dependent on the international code requirements such as near and far field and steam
releasing time is individually selected for the application.
To reduce the steam temperature entering the final superheater, spray water is added in the
connecting pipes between the panel SH outlet and the final SH inlet. The source of this water is
a continuation of the piping supplying the 1st stage attemperators. Generally this will be the
feed pump discharge (Economiser inlet).
Each spray station is made up of an motorized inlet isolating valve(10LAE61AA041,042
10LAE62AA041,042), modulating control valve(TCV,10LAE61AA071,072, 10LAE62AA071,
072), and discharge isolating valves(10LAE61AA001/2, 10LAE62AA001/2). A double isolated
drain between the motorized isolating and control valves is used to check for isolating valve
leakage. The chosen pneumatic control valves are complete with intelligent I/P converters, fail
fix devices, and valve position transmitters.
Many valves such as temperature transmitter(TT,10LBA11/12CT101/2/3) thermowell
(TW,10LBA11/12CT401/2), pressure transmitter(PT,10LBA11/12CP103/4/5/6), pressure
tap(PP, 10LBA11/12CP401), safety valve(PSV,10LBA11/12AA201,301) and electric power
operated valve(ERV,10LBA11/12AA192), are installed on the main steam pipe(supplied by
others) for controlling, monitoring, and guarantee. Pressure tapping(PP,10LBA11/12CP401),
complete with isolating valves(10LBA11/12 AA401/2), is available for the test gauge used
during safety valve floating, and verification of inlet to superheater outlet pressure loss where
this is a guarantee requirement.
Start-up vent with two isolating valves(MOV,10LBA11/12AA541, 10LBA11/12AA001) and
silencer is settled on the main steam line for air and steam release during boiler start-up.
Motorized isolating valve(MOV,10LBA11/12AA541) for start-up vent is closed by DCS signal
when boiler pressure( reaches approx. 3.5 to 5kg/cm2g. But when HP-Bypass system is used
for boiler start-up the start-up vent closing set pressure can be changeable.
Three pressure transmitters(PT,10LBA12CP104/5/6, PT,10LBA11CP104/5/6) on each final
superheater outlet steam pipe are installed. These transmitters are not required for boiler/unit
pressure control as the correct point for all pressure control is the main steam leg pressure
adjacent to the turbine. Motor operated block valve on each side is installed on the final
superheater outlet connection pipe by IBR code requirement.
Main steam stop valve(MOV,10LBA12AA041) which is on the main steam line is provided for
boiler itself hydraulic test and is used for isolating boiler from turbine.
Thermo-elements are attached on the final SH outlet unheated tube(TE,10HAH58CT001CT057) to detect the unheated tube surface metal temperature, which is regarded as the same
of steam temperature. The temperatures are monitored continuously and sent to the DCS.
Alarm and trip(MFT) setting value is set for protecting from furnace wall tube overheating. In
case high temperature is detected through the signal from settled thermo-element alarm signal
is shown on the monitor. If a few numbers of thermo-element detect high temperature than trip
set value and the detected high temperatures do not return to usual temperature after some
time delay, the boiler get the MFT signal by the DCS.
Trip and alarm temperature is decided by considering allowable and design metal temperature
and tube thickness and operational circumstances.

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UMPP Mundra ( 800MW x 5 Units )

2.3.7

Process and System Description

P&ID Drawing Title:

Reheater System

Drawing Number:

T07073-XG02-PI-D007
TCE.5146A-510-00-0618
IBR / ASME

Design Basis:
System Purpose

Transfer of steam from the inlet header through the pendent banks, intermediate header
between pendent tubes, and outlet headers to the reheater outlet to the hot reheater legs
Extraction of heat from the flue gases through predominantly radiant transfer in the pendant
banks.
Description of Drawing
Steam from the HP turbine exhaust is transferred to the boiler through pipework known as the
Cold Reheat Pipes. These legs connect to the full width reheater inlet header(10HAJ10), and
it is assumed that the pipes deliver a nominally equal quantity of steam. The pipe is fitted with a
drip pot attached drains discharging to pit with double isolated valves(supplied by others). The
steam temperature and pressure entering the reheater is measured for information and control
purposes at each end of the inlet header using pressure transmitters(PT,10LCB31/32CP101)
and temperature transmitters(TT,10LBC31/32CT101/2) . Two thermowells(TW,10LBC31/32
CT401/2) between reheater desuperheater in each pipe is installed for performance test
performance. In addition a pressure test tap(PP,10LBC31/32CP401) is provided at each end of
the inlet header for performance test purposes and for pressure measurement where pressure
loss guarantees are required.
The reheater steam flow is parallel with gas flow. Reheater inlet(10HAJ10) and outlet
headers(10HAJ30) are over the roof tubes and between two headers intermediate
header(10HAJ22) is located to mix the steam temperature and to get the even steam
temperature at both ends of outlet header. The connection pipe from each side of header
leads to the hot reheat legs that deliver reheated steam to the IP turbine inlet.
Burner tilt is used as a reheater temperature control and its inclination is 30 degrees. But for
emergency attemperation, spray water system is installed at the cold reheat pipe. The spray
water comes from Boiler feed water pump inter-stage step.
Following flow measurement(FE,10LAF50CF001), the spray water line(10LAF50BR001)
divides with two lines for two cold reheat pipes(supplied by others). Spray station is made up of
a motorized inlet isolating valve(10LAF51/52AA041/2), modulating control valve(TCV,10LAF
51/52AA071/2) at both branches, and discharge isolating valve (10LAF51/52AA001/2). 100% of
redundancy spray station is provided at both sides. A double isolated drain
(10LAF51/52AA401/2/3/4) between the motorized isolating and control valves is used to check
for isolating valve leakage. The chosen pneumatic control valves are complete with intelligent
I/P converters, fail fix devices, and valve position transmitters.
Double isolated air releases on the intermediate and outlet headers allow trapped air to be
vented during hydraulic testing and boiler start-up. The common air release provides a
convenient point for nitrogen gas injection for blanking or inerting during periods of wet or dry
storage respectively. An isolating(10LBB20AA201) and screw down non-return
valve(10LBB20AA202) are included for nitrogen supply isolation.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

In compliance with ASME SEC.1 design code requirements, the cold reheat pipes and hot
reheat pipes are fitted with safety valves. These valves discharge 100% of the reheater design
capacity. The valves discharge to atmosphere through pipework, stacks and silencers which is
supplied only the lowest set pressure safety valve(PSV,10LBC31/32CP103) (where fitted) with
suitable expansion provisions. Each valve has a body vent discharging to atmosphere. The
discharge elbow and expansion chamber are drained to a hinged and lockable lid tundish,
which in turn is connected to the boiler drains vessel vent. Silencer design is dependent on the
international code requirements and contract specification such as near and far field and steam
releasing time is individually selected for the application. 100% of Safety valve capacity is
separated as 60% at cold reheat pipe(PSV,10LBC31/32AA101/2/3) and 40% at hot reheat pipe
(PSV,10LBB11/12 AA101/2).
At each end of the reheater outlet connection pipe, three temperature transmitters(TT,
10LBB11/12CT101/2/3) are installed for measurement and control of the final reheat steam
temperature. One thermowell(TW,10LBB11/12CT401) at each end is available for performance
test measurements.
Pressure tappings(PP,10LBB11/12CP401), complete with isolating valves(10LBB11/12
AA303/4) are fitted on each end of the reheater outlet pipes(RHP is supplied by others).
Pressure tapping is available for the test gauge used during safety valve floating, and
verification of inlet to reheater outlet pressure loss where this is a guarantee requirement.
Thermo-elements are attached on the intermediate header inlet tube stub(TE,10HAJ20CT001052) and final RH outlet unheated tube(TE,10HAJ25CT020-043) to detect the unheated tube
surface metal temperature, which is regarded as the same of steam temperature. The
temperatures are monitored continuously and sent to the DCS. The alarm and trip set values is
used by the thermo-element temperature at the final RH outlet tube stub.
Alarm and trip(MFT) setting value is set for protecting from furnace wall tube overheating. In
case high temperature is detected through the signal from settled thermo-element alarm signal
is shown on the monitor. If a few numbers of thermo-element detect high temperature than trip
set value and the detected high temperatures do not return to usual temperature after time
delay, the boiler get the MFT signal by the DCS.
Trip and alarm temperature is decided by considering allowable and design metal temperature
and tube thickness and operational circumstances.

2.3.9

P&ID Drawing Title:

Boiler Drain and Vent System

Drawing Number:

T07073-XG02-PI-D009
TCE.5146-510-00-0620
IBR / ASME

Design Basis:
System Purpose

Collection of boiler drains and vents, soot blowers, steam coil air heater drains.
Collection of boiler water by separator storage tank lowering during start-up.
Discharge of condensate to condensate receiving tank.
Discharge of condensate water in the tank to condenser via condensate drain transfer pump.
Discharge of flash steam to safe level.
Discharge of steam air heater to flash tank
Description of Drawing
Each boiler is provided with a complete drain system.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

The boiler start-up flash and blowdown tank(10LCQ20BB001) is a vertical cylindrical type
vessel located at a level to have a gravity that the water in the flash tank drops in the
condensate receiving tank(10LCQ40BB001).
The flash tank is also provided with its own drain manifold connections(10LCQ20BR401/2) from
different sources and a vent stack(10LCQ10BR501). Many vent pipes from boiler proper are
joined into a single line near the flash tank vent stack and the steam in the single line
discharges to the vent stack. The discharged steam is separated by flashing as steam and
water. An anti-siphon pipe(10LCQ30BR401) is provided to ensure that the overflow pipework
maintains a level of water at all times.
Emergency drain line(10LCQ30BR402) is also provided at the bottom of the vessel with
isolating valve(10LCQ30AA401) to dump directly at the sump area. Flash tank is designed to
accumulate the furnace swelling flow during start-up and overflow drain from storage tank
during wet mode operation by WR and/or ZR control valve.
The tank receives drains from Gas airheater sootblower lines, boiler sootblower lines, auxiliary
steam lines, and SCAH drain line and water wall headers.
Drains flow from sootblowing system and SCAH drain line drain during normal operation and
especially boiler proper drains during start-up and low load operation.
To prepare the light-off and to fill up the boiler water the following conditions should be ready.
- Backpass(MOV,10HAH12/18/20AA441), superheater(MOV,10HAH55AA441), and reheater
drain valves are open, and all vent valves(separator outlet : MOV,10HAH10AA541,
10HAD30AA541/2/3/4, furnace roof outlet :MOV,10HAH14AA541, panel SH inlet :
MOV,10HAH40AA541, final SH inlet :MOV,10HAH50AA541, start-up vent, MOV,10LBA11/12
AA541) are closed. The economizer(MOV,10LAB50AA441) and furnace wall drain
valves(MOV,10HAD15/50AA441) are closed, and economizer vent valves(MOV,10HAC30
AA541) are open.
- Close economizer outlet vent valve 20 seconds later than detecting the economizer inlet water
flow reaches over 10 ton/hr.
After light-off open the panel SH vent valve(MOV,10HAH40AA541), final SH vent valve
(MOV,10HAH50AA541), start-up vent valve(MOV,10LBA11/12 AA541), and RH outlet vent
valves.
The backpass drain valve can be closed when separator pressure reaches 3.5 bar(a). But the
set pressure can be raise to satisfy no condensate water remains in the backpass header.
Close the RH outlet vent valves when RH pressure reaches 3.5 bar(a)
The condensate receiving tank(10LCQ40BB001) is a horizontal type vessel, which is located
under the flash tank(10LCQ20BB001) and it has a space below the tank to settle the drain
transfer pump(10LCQ50AP001/2) on the ground. The condensate receiving tank receives the
flash tank drain water. With attached level transmitter(LT,10LCQ40CL101) the detected drain
water level is sent to the DCS and its normal water level is maintained by the funnel and the
funnel line(10LCQ40BR401) is connected to the boiler sump area.
One steam vent line(10LCQ40BR501) for condensate receiving tank is connected over the
flash tank vent stack. Installed two(2) drain transfer pump lead the drain water to the
condenser.
Drain transfer pump operation control logic is input in the logic so that it is operated
automatically by the water level deviation.
The pump capacity is 50%load and it is considered the worst condition at the start-up period.
During the boiler start up drains from separator storage tank, furnace headers and auxiliary
steam discharge saturated water and steam to the boiler flash tank. A large quantity of flash
steam needs to be vented to atmosphere through vent stack during start up which will cause a
great deal of noise pollution. Hence, to reduce the sound level to acceptable limits of the plant,
a noise reducing device is provided in the vent stack.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

All the drain lines to the boiler drains tank must be provided with an adequate slope (1:100
boiler hot) to ensure complete drainage back to the drains vessel.
The vessel must be designed to accept the total flow of drains that could occur during
operation, and the possibility that they may be operated at full pressure and temperature.
Steam Airheater is operated to meet the required average cold end metal temperature of Gas
Airheater(10HLD10/20). The average cold end metal temperature is set to prevent GAHs cold
end side from erosion due to sulphuric acid dew point.
After heat up the primary and secondary air which pass through the SAHs the Condensate
water drains to the SAH drain tank. The drained water goes to the flash tank(10LCQ20BB001)
via SAH drain pump(10HLC80AP001/2). The pump capacity covers the drain water 100% of
drain water and another is for stand-by.
The tank level is controlled by the control valve(LCV,10HLC90CP441) which receives the
signal from the level transmitters(LT,10HLC70CL101/2)
The minimum recirculation line for drain pump is supplied to protect the motor cavitations. The
strainer is inserted in the pump suction line not to enter the debris to the pump. It may be
removed after start-up or in some time operation.

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2.4

Process and System Description

PIPING AND INSTRUMENT DIAGRAMS DESCRIPTIONS AIR AND GAS

Each diagram in the design series has an associated diagram description, which has a System
Purpose and Description of the P&ID

2.4.1

P&ID Drawing Title:

Combustion Air & Flue Gas System

Coal feeder & Pulverizer System
Primary air Sealing & Cooling air System

Drawing Number:

T07073-XG02-PI-D010/11/12/17/18
TCE.5146A-510-00-0622/623/628/629

Design Basis:

NFPA 85 and DOOSAN in-house Design Rules

System Purpose
Provision of Total Air at the required temperature, pressure, and flow for combustion and
pulverised fuel (PF) transport purposes.
Heating of ambient air to the required temperature for meeting of cold end of gas air heater.
Provision of suitable isolation of system components during start up, shutdown, and on fault
conditions.
Crossover duct between Secondary air duct.
Provision of primary air at the required temperature, pressure, and flow for coal drying and
pulverised fuel (PF) transport purposes.
Removal of useful energy from the flue gas to heat the primary air and secondary air.
Provision of seal air at required pressure, and flow for mill and feeder.
Provision of code compliant ducts for the transport of primary and seal air.
Heating of ambient air to the required temperature for dewpoint prevention in regenerative
gas/airheaters, boiler start up.
Removal of useful energy from the flue gas to heat the primary and secondary air.
Provision of suitable isolation of system components during start up, shutdown, and on fault
conditions.
Provision of secondary air for combustion.
Extraction of useful heat from the flue gas by water walls, super heaters, reheaters and
economisers.
Description of Drawing
The referenced drawing depicts a typical two stream draught plant arrangement, variable pitch
(VP) axial flow Forced Draught (FD) fans(10HLB10/20AN001) and steam airheaters
(SAH,10HLC51/52). It caters for ambient air temperatures in the range 4 OC to plus 45OC. The
steam airheater(10HLC51/52) is placed in a downstream of FD Fan and upstream of Gas Air
Heater(GAH,10HLD10/20), where air heating is required for dewpoint protection of the GAH at
low ambient temperature.
Each FD fan draws air directly from atmosphere through silencer(10HLB10/20BS001). The
dampers(MZ,10HLA10/20AA041) which located between Fans and SAHs are Multi vane,
modulating type with electro-motor actuation.
Steam air heating is required principally when low ambient air temperatures are experienced,
but will also be necessary when operating with top feed heaters out of service, during oil firing
and boiler start-ups.
The ambient air inlet is fitted with Flat mesh screens to inhibit foreign particles entering the
respective ducts. A silencer is provided in the FD fan total air inlet duct, the design of the

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

silencer(10HLB10/20BS001) being dependent on the Noise requirements such as near and far
field and is individually selected for the application.
The temperature of total air to the FD fan(10HLB10/20AN001) is measured for airflow
measurement correction and for monitoring the boiler performance. One transmitter(TT,10HLA
is fitted with duplex thermocouple providing redundant inputs to the DCS, the measurement
being transmitted as converted to high-level analogue inputs in transmitters.
A pressure tapping point with analogue transmitter(PT,10HLB10/20CP101) is included for
monitoring the FD fan air inlet pressure by the DCS, and hence to the Central Control Room
(CCR).
The airflow is measured to account the total combustion air entering into the system with
aerofoil type(FE,10HLA30/40CF001) which is installed both downstream of hot secondary air
duct for FD Fan and venture type(FE,10HFE51CF001) which is at the pulverizer inlet duct for
PA Fan(10HFE15/25AN001). Further, it is also used for fan stall prevention. The measured
airflow is temperature and pressure corrected to design conditions. This signal, after
linearization, is characterised into the axial flow fan stall line, which is used to inhibit the blade
pitch from increasing on both the stalling fan and its parallel partner (if operating) or if the
pressure rise continues and crosses the upper limit, the final control element on both fans will
be tripped to manual, and the vane pitch reduced until the stall condition is cleared. The
pressure differential transmitters(PDT,10HFE15/25CP101/2) for PA Fan and FD fan
(PDT,10HLB10/20CP101/2) that sensed the differential pressure and convert the measured
differential into 4-20 mA analogue signals as an input to the DCS and a further pressure
differential transmitter measures and transmits the static head rise across the fan.
A pressure tapping point with analogue transmitter(PT,10HLA10/20CP101) is included for
performance monitoring of the FD fan and transmitting the FD fan air outlet pressure to the
DCS. This measurement may also be used to inhibit start of second fan if the discharge
pressure limit is exceeded. A test point(PP,10HFE10/20CP402 / PP,10HLA10/20CP402) is
provided for test and verification purposes.
The pressure measurement for the FD fan and PA fan outlet air duct is provided for serving the
secondary air and the primary air.
A cold secondary air cross-over duct located upstream of the SAH, interconnects the A-side
secondary air duct and B-side secondary air duct to permit operation at loads below 50%
BMCR on one air stream. An isolating damper(MOV,10HLA15AA041) with Electric motor
actuator is provided in the cross-over duct. Also at hot secondary air duct of GAH outlet it joins
with hot secondary air cross-over duct for isolation of one stream during single stream
operation the dampers(MZ,10HLA30/40AA041) are settled immediately downstream of GAH.
The chosen Electrical operated damper has no leakage multi louver damper with seal ait fan.
GAH secondary air inlet temperature(TT,10HLA30/40AA101/2) is required for monitoring the
GAH and the boiler performance. The temperature is measured using a duplex thermocouple
fitted in a thermowell. The thermocouple is connected to the DCS as converted in a transmitter
to a 4-20mA high level analogue input in a transmitter. Multiple test points at GAH outlet air
side and GAH inlet gas side are provided for performance testing and verification purposes.
A low point drain is provided in GAH secondary air inlet duct with a normally closed manually
operated isolation valve for draining the water during GAH water washing.
The referenced drawing depicts a typical two stream draught plant arrangement with tri-sector
regenerative gas/air heaters (GAH). GAH is used to recover sensible heat from the economiser
exit flue gas. While cooling the flue gas to an acceptable exit temperature for discharge, the
recovered heat is transferred to the incoming secondary air. The heat is transferred through

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

heating elements by exit flue gas from economiser and subsequent cooling by secondary air.
The preheated secondary air passes into the GAH secondary air outlet duct.
The secondary air temperature(TT,10HLA30/40AA101/2) and pressure(PT,10HLA30/40CP101)
at GAH outlet are measured for monitoring the performance of the GAH. The temperature and
pressure signals are transmitted to DCS by using a duplex thermocouple fitted in thermowell
and the pressure transmitter respectively.
A pressure tapping point with analogue transmitter(PT,10HLA35CP101) is located on the hot
secondary air crossover duct. This pressure transmitter transmits the pressure signal to the
DCS for measuring the hot secondary air crossover pressure, with average normally being
used for FD fan control.
Two thermowells(TT,10HLA30/40AA101/2) are installed in each secondary air A-Side / B-Side
to windbox duct for continuous monitoring of secondary air temperature in DCS. These
thermowells are fitted with duplex thermocouples to provide an average measurement and
redundancy. This averaged temperature measurement is used for temperature compensation
of secondary airflow to wind box.
PA Fan(10HFE15/25AN001) is the same variable pitch (VP) control axial fan as FD fan and
same concept of FD Fan but SAH is not installed upstream of GAH because PA Fan is for coal
firing. When coal fired required cold end metal temperature of GAH is not high that PA fan
outlet air temperature is enough to exceed the required average cold end metal temperature of
GAH. Cold air duct for tempering the pulverizer inlet hot air temperature is branched at the
main coal air duct
Each PA fan draws air from atmosphere via silencer(10HFE15/25BS001) and supplies both
tempering and hot air to the mills in order to dry and then transport the pulverised fuel from the
mills to the burners. The PA fan in conjunction with the Mill Seal Air (MSA, 10HFW10AN001/2)
fans (one working and one stand-by), also supplies the seal air with enough flow and pressure
for the mills and feeders.
To supply the clean seal air to pulverizer and feeder dynavane filter is installed between cold air
cross duct and seal air fan inlet. The debris which is screened by the filter is delivered with cold
air to hot secondary air duct. The control damper(PDCV,10HFW10AA071) controls that the
pressure differential between the dynavane filter outlet and bleed air pipe as zero.
The PA fan outlet pressure is required for monitoring the PA fan performance. A pressure
tapping point with analogue transmitter(PT,10HFE10/20CP101) in the PA fan discharge duct
transmits the primary air fan outlet pressure to the DCS. A test point(PP,10HFE10/20CP402) is
provided for testing purposes.
The PA fan outlet temperature is required for monitoring the performance purposes. A
thermowell(TT,10HFE10/20CT101/2) is fitted with duplex thermocouple provides an input to the
DCS, the measurement is being transmitted as converted to a high level 4-20mA analogue
input by a transmitter.
Following the pressure and temperature measurement, the PA outlet duct splits into two paths,
one to GAH primary air inlet duct and the other to Tempering air cross-over duct.
Multiple test points are provided for performance testing and verification purposes in GAH
primary air inlet duct.
The GAH(10HLD10/20) is used to recover sensible heat from the economiser exit flue gas.
While cooling the flue gas to an acceptable exit temperature for discharge, the recovered heat
is transferred to the incoming primary air. The heat is transferred through heating elements by
exit flue gas from economiser and subsequent cooling by primary air. The preheated primary
air passes into the GAH primary air outlet duct.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

The primary air temperature and pressure at GAH outlet are measured for monitoring the
performance of the GAH. The temperature and pressure signals are transmitted to DCS by
using a duplex thermocouple fitted in a thermowell and the pressure transmitter respectively.
One test point and multiple test points are provided for performance testing and verification
purposes.
A multi-louver damper(MZ,10HEF30/60AA041) with Electric motor actuator is provided in each
GAH primary air outlet duct before it joins with Hot primary air to mills duct to permit operation
at loads below 50% BMCR on one stream. The chosen Electrical operated damper has no
leakage multi louver damper with seal air fan and fail fix device.
The hot primary air is transferred to the mill-bay, where it mixes on an individual mill basis with
tempering air.
An isolating damper(XZ,10HFE30/40AA061) with Electric pneumatic actuator is located in each
Tempering air duct at each PA fan discharge to permit operation at loads below 50% BMCR
on one stream. The chosen Electrical operated damper has a damper open/shut position
indication and fail fix device. The tempering air common duct is extended to the mill bay as a
source for the seal air fans and mill tempering air.
Each boiler is provided with two (one working and one stand-by) motor driven centrifugal mill
seal air(MSA) fans(10HFW10AN001/2), which take their suction from the tempering air duct.
The MSA fan supplies the seal air with required flow and pressure to all the mills and feeders.
The transfer damper for seal air fan is installed to shutoff the stand-by fans flow and the
damper which is in the downstream of fans is used to maintain the fan. The differential pressure
across the dynavane filter is monitored by a pressure differential transmitter
(PDT,10HFW10CP101), which transmits an analogue signal to the DCS for alarm purposes. A
pressure indicator(PI,10HFW10CP501) is provided in the downstream of transfer damper for
local measurement.
Seal air prevents the pulverised material from escaping to atmosphere through openings and
clearances between parts having relative movement. It also protects the seals from abrasion
damage, by preventing pulverised fuel from entering these regions. Seal air to the mill and
feeder is supplied from the mill seal air fans(10HFW10AN001/2).
Pressure differential between mill inlet and mill body and between mill bottom and body is
monitored and transmitted to the DCS. If the pressure differential becomes higher than input
set value, mill will be tripped to protect from mill damages owing to mill overload.
A pneumatic isolating shut off damper(FV,10HFW31AA061), controls the mill seal air supply to
each mill. From primary cold air leads to each feeder and a manual shut off damper
(10HFW51AA001) is located upstream of coal feeder(10HFB11-AF001). When the mill is
removed from service for maintenance, a pneumatic isolating shut off damper
(FV,10HFW31AA061) of each seal line provides complete isolation of the seal air to the mill.
The source of seal air of mill is seal air fan(10HFW10AN001/2) but feeder is supplied from cold
primary air common duct(10HFE37). The raw coal is ground in the mill, and then mixed with the
hot primary air, which acts as a drying medium and transports the pulverised fuel from the mill
to the classifier and thence to the burners.
The Hot primary air to mills duct coming from GAH outlet connects to the mill bay for supplying
correct mill air flow at desired pressure and temperature.
Two pressure tappings with one analogue transmitter(PT,10HFE60CP001) and one pressure
test point(PP,10HFE60CP401) are provided on Hot primary air to mills duct to measure the
hot primary air pressure and transmit the same to the DCS. The pressure test point is at
upstream of damper(MZ,10HFE60AA041) and pressure transmitter is downstream of damper.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

The value of the pressure signal is used for PA fan control purposes. An output signal from the
DCS modulates the variable pitch of PA fan to maintain the hot primary pressure at the desired
value.
The hot primary coming from the GAH outlet is divided equally and supplies primary air to all
the mills. A multi vane Electro-pneumatic actuated(XZ,10HFE51AA062), Hot primary air to mill
modulating damper and is located in each Hot primary air to mill duct. And also electropneumatic actuated shutoff damper(XZ,10HFE51AA061) is located at the upstream of multi
vane(XZ,10HFE31/51AA062) to seal the air pipe.
The tempering air that comes from the PA fan outlet is divided equally and supplies tempering
air to all the mills. A multi vane Electro-pneumatic actuated(XZ,10HFE31AA062), Tempering
air to mill modulating damper is located in each Tempering air to mill duct. And also electropneumatic actuated shutoff damper(XZ,10HFE31AA061) is located at the upstream of multi
vane to seal the air pipe.
The dampers located in each Hot primary air to mill duct and Tempering air to mill duct are
modulated to attain the correct mill airflow and desired mill outlet temperature.
The hot primary airflow to each mill is measured and is used for controlling the fuel air ratio on
a mill basis. The flow is sensed by a primary element as a Venturi type(FE,10HFE51CF001)
that generates a differential pressure.
Two pressure differential transmitters
(TT,10HFE51CT101/2) are provided with each flow element for redundant measurement and
control. The transmitter converts the measured differential into a 4-20 mA analogue signal as
an input to the DCS. As the flow conditions do not necessarily match the element design
parameters, compensation for temperature is required.
Multi test points(PP,10HFE51CP401-7) are located at each Hot primary air to mill duct for
verification and performance testing purposes respectively.
Expansion joints are provided in hot primary air to mill ducts and tempering air to mill ducts to
withstand temperature excursions and thermal expansions.

2.4.2

P&ID Drawing Title:

Combustion Air & Flue Gas System -Air and Gas,

Backpass, Windboxes for Corner Fired Boilers

Drawing Number:

T07073-XG02-PI-D011
TCE.5146A-510-00-0622

Design Basis:

NFPA 85 and DOOSAN in-house Design Rules

Provision of secondary air and over-fired air for combustion.

Extraction of useful heat from the flue gas by water walls, superheaters, reheaters and
economisers.
Provision of code compliant flues and ducts for the transport of air and flue gas.
Description of Drawing
The drawing shows the gas route from GAH(10HLD10/20) inlet air to GAH outlet gas through
the furnace, superheaters, reheaters and back pass with low temperature superheater(Primary
superheater) and economisers. In the chosen example there are six mill groups on the front
side of boiler, with four burners in each group.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

To assist in reducing the amount of NOx formed in the furnace, overfire air is admitted to the
furnace through the three upper levels of furnace main windbox Close Coupled Overfire Air
(CCOFA) nozzles.
Control of unit air flow is obtained by positioning the FD fan blade pitch and the ID fan blade
pitch, while the distribution of secondary air to the windbox compartments is controlled by
secondary air dampers. These are positioned by a sub-loop control system associated with the
DCS.
Flame scanner cooling air is supplied from atmosphere. Two numbers of scanner cooling
air fan(10HHQ10/20AN001) are supplied, one with AC motor and the other with DC motor. Both
of two 100% fans serving the flame scanner air manifold can be used to supply the cooling air
pressure required. A filter upstream of each of the fans helps to assure clean air for
cooling. An alarm system should indicate when a filter requires service. Refer to Scanner Air
System, at Air and Flue Gas System for details. A scanner fan should be in service whenever
a fire is in the furnace and should be kept in service until the unit is shut down and the flame
scanners are cooled to their acceptable high temperature limit.
Two windbox ducts at the same side from front view have connections from each side of duct,
one duct taken from secondary air A-side and the other from secondary air B-side. The over air
supply from each side of the boiler is tapped from hot secondary air and is controlled by
damper(GT,10HHA10CC101-112) that is installed at corner 1 in front of port. The above
arrangement maintains a uniform flow distribution across all the burners, for both secondary
and over air.
A pressure tapping point with analogue transmitter(PT,10HBK10/20CP101/2) is included in
each windbox for monitoring and transmitting the windbox pressure to the DCS. A test
point(PP,10HFE80CP401) is located in windbox for performance testing and verification
purposes.
The pressure differential switches(PDSLL,10HFE30CP204/5/6) are measuring pressure
differential between hot primary air crossover duct and furnace for PA fan control and those
measured values sent to the MBC.
The pressure differential transmitters(PDT,10HFE30CP101/2/3) sense the pressure differential
between hot primary air crossover duct and furnace and the signal is converted with the
measured differential into a 4-20mA analogue signal as inputs to the DCS and in case the
supply pressure is lower than minimum value boiler trip, signal comes from the DCS. This
signal is used for PA Fan control.
The hot gases resulting from combustion in the furnace pass through the superheater and
reheater pendant banks, then downward through the rear pass enclosure, over the low
temperature superheater(primary superheater), and economisers. The water walls, panel
superheater, platen reheater and a part of final reheater absorb heat by predominately radiant
transfer and other sections absorb by convective transfer. Flues transfer the gas from the
economiser exit to the airheaters.
During start up, the superheater metal temperatures must be kept below a safe value. The
value can be inferred by furnace gas temperature measurements using electrical operated
retractable temperature probes located in each sidewall of the furnace below the platen
reheater. The flue gas temperature entering platen reheater is connected to DCS as converted
to a high level 4-20 mA analogue input in a transmitter. The probes are designed to auto retract
on detecting high flue gas temperatures.
The furnace system and associated flues and ducts are designed to meet the requirements of
NFPA. The furnace draft control system is designed to control the furnace draft at the desired

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

value by modulating the ID fan inlet dampers. Four pressure tapping points with analogue
transmitters are located on front and either side of the furnace sidewalls for monitoring and
controlling the furnace draft through DCS.
The flue gas temperature is measured after the economiser for performance monitoring. Three
temperature transmitters(TT,10HNA11/21CT101/2/3) with duplex thermocouple provides an
input to the DCS, the measurement being transmitted as converted to high level analogue input
in a transmitter. Multi test points(TP10HNA11/21CT402-8) are located after the economiser for
verification purposes.
The flue gas, after heat recovery by low temperature superheater and economiser surfaces in
back pass.
A damper(MOV,10HNA10/20AA041) is located in each outlet stream of economiser. The
damper is multi vane isolation with seal air fan for protecting leakage. The chosen damper is
fitted with Electro-motor actuation.
One ash hopper is provided in the stream of the economiser outlet gas pass for collection of
ash. A low point drain is provided for the hopper, which discharges to the ash handling system.
Pressure differential transmitter(PDT,10HFE10CP101/2, 10HNA10CP101) monitors between
GAH ducts whether chocking happens in the GAH or not.

2.4.3

P&ID Drawing Title:

Combustion Air & Flue Gas System (3/3)

Drawing Number:

T07073-XG02-PI-D012
TCE.5146A-510-00-0623

Design Basis:

NFPA 85 and DOOSAN in-house Design Rules

System Purpose
Transfer of flue gas from economiser outlet to chimney inlet.
Recovery of sensible heat from flue gas leaving economiser.
Provision of code compliant flues and ducts for the transport of flue gas.
Description of Drawing
The referenced drawing depicts a typical two stream draught plant arrangement with tri-sector
regenerative gas/air heaters (GAH,10HLD10/20), precipitators and mixed flow ID fans.
The flue gas leaving economiser splits into two equal streams. The flue gas enters each gas air
heater through an interconnecting flue and isolating damper. The gas leaves the gas air
heaters through flues leading to Precipitators, ID fans and on to the stack.
A multi vane isolation damper(MZ,10HLA30/40AA041) is located in the GAH flue gas from
economiser duct for isolation of each stream to permit operation at loads below 50% BMCR on
one stream. Each damper is provided with an Electrical actuator complete with damper
open/close position indication and fail fix device.
The flue gas temperature at the GAH inlet is required to monitor the performance of the boiler
heat absorbing surfaces. Temperature transmitters(TT,10HNA10/20CT101/2) are provided, the
temperature is sensed by a thermocouple, and the resultant signal is either transmitted directly
to the DCS as converted in a transmitter to a 4-20mA high level analogue input.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

Two Oxygen sample probes(AT,10HNA10/20CQ001/2) and one Carbon monoxide

(AT,10HNA10/20CQ003) with analysers are provided for continuously monitoring the oxygen
level and carbon-monoxide in each GAH flue gas inlet duct. The analogue output from the
analysers is transmitted to the DCS, for possible use in an Oxygen trim control loop and
carbon-monoxide trim control loop.
The GAH(10HLD10/20) is used to recover heat from the economiser exit flue gas. While
cooling the flue gas to an acceptable exit temperature for discharge, the recovered heat is
transferred to the incoming secondary and primary air. Heat is transferred to the heating
elements by the exit flue gas. The primary and secondary air streams cause subsequent
cooling of the elements. The cooled flue gas passes to the precipitator of the respective stream.
The flue gas temperature leaving GAH is required for monitoring and controlling the GAH
performance and the boiler thermal efficiency.
Three temperature transmitters(TT,10HNA11/21CT101/2/3) are provided for redundant
measurement of the flue gas temperature. The temperature is sensed by a thermocouple, and
the resultant signal is either transmitted directly to the DCS as converted in a transmitter to a 420mA high level analogue input.
A low point drain is provided in each flue gas outlet duct with a normally closed manually
operated isolation valve for draining effluent during GAH water washing.
A test point is located at the GAH outlet for verification purposes and multiple test points are
provided for performance testing.
Precipitators remove particles from the flue gases using electrical forces to move the particles
out of the flowing gas stream and onto collector plates. The accumulated ash deposits are
removed from the collector plates by rapping in which mechanical devices impact the
electrode frameworks, causing the ash to dislodge and fall into the collecting hoppers below.
The cleaned flue gas exits to the ID fan inlet.
The precipitator in each stream has two parallel paths (two precipitators) enclosed in a single
casing. The flue gas duct leaving the GAH splits into two equal paths and connects to two
precipitators. The two paths coming from the precipitator join together and connect to the ID fan
inlet duct.
A test point is provided in the inlet and outlet ducts of each precipitator for verification purposes.
Multiple test points are also provided in the inlet and outlet ducts for performance monitoring.
A sample probe(AT,10HNA12/22CQ001) with Opacity analyser is provided in each precipitator
exit and is connected to DCS for continuous monitoring of the dust level in the flue gas
discharging to the chimney.
A motor driven, variable pitch (VP) axial flow ID fan, located at ground level, is supplied for
each flue gas stream. The ID fan extracts the products of combustion (flue gas) from the
furnace via the GAH and precipitator and transfers them to the chimney inlet while maintaining
the furnace set pressure at the desired value over the boiler operating range.
A pressure tapping point with analogue transmitter is included for monitoring and transmitting
the ID fan inlet pressure to the DCS and to Central Control Room (CCR). This measurement is
required for monitoring the over all performance of the boiler.
The flue gas temperature at each ID fan inlet is measured using a duplex
thermocouple(TT,10HNA12/22CT101) fitted in thermowell and the resultant signal is either
transmitted directly to the DCS as converted in transmitters to 4-20mA high level analogue
inputs.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

The above measured pressure and temperature are used for compensation of flue gas flow
measured at the ID fan.
A test point is located for verification purposes and multiple test points are also provided for
performance testing.
A test point is located in each ID fan outlet duct for verification purposes.
A multi vane isolating damper(MZ,10HNA13/23AA041) is located in each ID fan outlet duct for
isolation of each stream to permit operation at loads below 50% BMCR on one stream. The
chosen damper is provided with an Electrical actuator and is complete with damper open/shut
position indication. The ID fan outlet duct from each stream joins together and the common
duct connects to the chimney.
Multiple test points are provided for verification and flow meter calibration purposes.
Expansion joints are provided at gas GAH flue gas inlet duct, GAH flue gas outlet duct,
Precipitator flue gas inlet &outlet ducts, ID fan inlet & outlet ducts, Flue gas to chimney duct.

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2.5

Process and System Description

PIPING AND INSTRUMENT DIAGRAMS DESCRIPTIONS COMBUSTION

Each diagram in the reference design series has an associated diagram description, which has
a System Purpose and Description of the P&ID.
2.5.1

P&ID Drawing Title:

Heavy Fuel Oil to Burner Rows with Fuel Oil Return

Drawing Number:

T07073-XG02-PI-D013/014/015
TCE.5146A-510-00-0624/0625/0626

Design Basis:

NFPA 85 and DOOSAN in-house Design Rules

System Purpose
Supply of heavy fuel oil to burner rows.
Provision for oil return to fuel oil tanks.
Provision of a code compliant system for heavy fuel oil firing.
Description of Drawing
The referenced drawing is for a fuel oil system supplying heavy fuel oil to burner rows during
start-up, low load and shutdown. The heavy fuel oil system is designed as 25%BMCR capacity.
The heavy fuel oil from the heavy oil storage tank(00EGB20/30BB001) is pressurized by the
fuel oil pressure pumps(00EGC41/42/43/44AP001) and heated by the fuel oil
heater(00EGT31/32/33/34AC001) as a minimum oil temperature 115 to make the viscosity
lower enough to be injected through burner nozzle. Moreover, the heat tracing is provided
along with the heavy fuel oil pipe lines. The maximum temperature by heat tracing is 130
and it prevents heavy fuel oil from becoming rigid. The fuel oil recirculation line
(10END70BR411/421/431/441) provides rapid circulation of fuel oil during start-ups to raise the
oil temperature and pressure to be met as a fuel firing conditions.
The flow-metering device(FE,10END50CF001) which is located downstream of fuel oil heater
accumulates fuel oil quantity to be introduced to the individual operating burners. The
redundant flow element(FE,10END50CF102) is installed to provide the signal to the control
valve(FCV,10END50AA071 / PCV,10END50AA071) for regulation of flow or pressure. The
header trip valve (XV,10END50AA061), flow control valve (FCV,10END50AA071) and inlet
shut off valve(10END71AA001) before entering the burner rows are installed on the supply line
as in order. The oil flow to the burners is measured to account for fuel oil consumption and
possible incorporation into the combustion control loop.
The header trip valve(XV,10END50AA061) shuts off the supply line to prevent from continuous
oil flow if emergent accident happens during oil firing period. A header trip valve ensures safety
of the boiler; it automatically cuts off the fuel to the boiler during abnormal operating conditions.
The valve is complete with solenoid valve and limit switches for control and status monitoring
by the Mill Burner Control System (MBC).
There are two control valves with parallel location which have different functions respectively.
Pressure control valve(PCV,10END50AA042) is operated during below 30% of oil capacity to
match the desired pressure that is required burner inlet condition. During the burner light-off
with heavy fuel oil, the pressure control valve(PCV,10END50AA042) is throttled to maintain the
oil pressure until the required number of burners are placed in service. Then the control valve is
shifted to the flow control valve(FCV,10END50AA041) and then shut-off valve
(XV,10END80AA061) in the heavy oil recirculation line is closed automatically. Flow control

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

valve (FCV,10END50AA041) controls the oil flow over 30% of oil capacity. During warming-up
of the heavy fuel oil, fuel pressure is maintained and controlled by the minimum flow control
valve (PCV,10END50AA042). At that time fuel is returned to boiler return line. An accumulator
is installed downstream of flow control valves(FCV,10END50AA041 / PCV,10END50AA042) for
compensating the burner inlet pressure.
The ball valve(10END55AA003) located between supply oil line(10END55BR001) and
accumulator is opened during normal operation. On the contrary the block
valve(10END55AA401) located accumulator bypass line (10END55BR401) is closed during
normal operation but for the accumulators maintenance the block valve (10END55AA401) is
opened to drain the remained oil in the pipe to the recirculation line (10END80BR002).
One safety valve(PSV,10END55AA201) is settled on the supply oil line to prevent overpressure due to emergent accident. And overflow of oil by the safety valve
(PSV,10END55AA201) burst is drain to the heavy oil recirculation line(10END80BR002).
The oil flow is measured by a flow element(FE,10END50CF001) and its pressure switches
(PSLL,10END55CP201/2/3) convert the measured differential into a 4-20mA analogue signal
as inputs to DCS and in case the supply pressure is lower than minimum value, boiler trip
signal comes from DCS. As the flow conditions do not necessarily match the element design
parameters, compensation for temperature deviations may be required. The temperature signal
(TT,10END55CT001/2) from the fuel oil to burner line is available for flow compensation.
The fuel oil pressure required at the burners varies with the boiler load. The desired pressure
and flow is achieved by modulating the oil pressure control valve(PCV,10END50AA042) and
flow control valve(FCV,10END50AA041) located down stream of the flow element. The chosen
pneumatic control valves are equipped with I/P converter, valve position transmitter and fail fix
device. A pressure gauge(10END55CP501) is also included for local indication.
Isolation valves upstream of the flow element and down stream of the control valve provide
isolation of the flow element and control valve for maintenance purposes
Temperature transmitters(TT,10END55CT001/2) complete with a duplex thermocouple are
used for monitoring the fuel oil temperature to the burners. The thermocouple transmits the
signal to the DCS directly as converted in a transmitter to a 4-20 mA high level analogue input.
The fuel oil is circulated up to the burner valves, through the fuel oil supply after opening the
supply header trip valve(XV,10END50AA061) and after closing fuel oil return shut-off
valve(XV,10END80AA061). The pneumatic operated return shut-off valve(XV,10END80AA061)
is complete with solenoid valve and limit switches for control and status monitoring in the MBC.
The burner requires the fuel oil at a certain viscosity for proper atomisation. The heavy fuel oil
is heated to bring the viscosity to the desired value. Six thermowells are provided in heavy fuel
oil line. The three pressure switches(PSLL,10END55CP201/2/3) transmit digital signal to the
MBC/DCS and one pressure transmitter(PT,10END55CP101) and two temperature transmitters
(TT,10END55CT001,002) transmit the detecting signal to the DCS directly as converted in a
transmitter to a 4-20 mA high level analogue input. Digital outputs from the DCS may be used
to ensure operation of the burner at the correct oil temperature. The fuel oil temperature to the
burners is measured using two duplex temperature transmitters as a monitor of the fuel
viscosity. It is a critical parameter for effective atomisation of the fuel oil.
All the heavy fuel oil lines are insulated and clad to minimise heat losses to atmosphere. To
allow circulation to recommence after a shutdown period, electric heat tracing is applied
between the pipe and the insulation to maintain the fuel at pumping temperature.
An accumulator prevents from sudden pressure drop at the burner inlet and protect boiler trip
due to the lower pressure. A pressure gauge is also included for local indication.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

Valves(10END50AA003/4, 10END50AA006/7, 10END55AA001/2) upstream of the flow

elements and down stream of the control valve provide isolation of the flow element and control
valve for maintenance purposes.
The flow restrictor limits the return fuel oil flow to the tanks/pump suction. An isolating
(XV,10END80AA061) and a non-return valve(10END80AA002) provide complete isolation of
the return oil lines. The block valve(10END80AA001) which is located upstream of isolating
valve on the recirculation is used for locked in throttle position. It is used for getting the required
burner inlet pressure with adjusting valve opening by manual.
Heat tracing is required to maintain the fuel oil at a temperature that will allow circulation to
recommence following a shutdown. The fuel lines are therefore fitted with a trace heating
system and insulated to minimise heat loss. The preferred heating method is electric type.
The atomizing medium of heavy fuel oil is steam, which supplies from auxiliary steam header to
an individual boiler supply line(10HJM50BR001). It is distributed to the individual burners after
reaching atomizing ring header(10EGD60BR001) at the boiler area via atomizing steam
pressure control valve(FCV,10HJM50AA041).
The atomizing steam has to be maintained desired burner inlet pressure by throttling of
atomizing steam control valve. There are four thermowells are provided in the atomizing steam
line. The three pressure switches (PSLL,10HJM55CP201,202,203) with one pressure
transmitter(PT,10HJM55CP101) transmit digital signal to the MBC/DCS. Also redundant
pressure indicator (PI,10EGC55CP501) is installed.
A temperature transmitter for monitoring in the DCS is in the atomizing steam line downstream
of flow control valve.
The drain trap(ST001) upstream of flow control valve(FCV,10HJM50AA041) is installed at the
drain line(10HJM50BR401) and its drain line leads to the flash tank. For maintenance the drain
trap bypass line with block valve(10HJM50AA401) is applied to.
The drain valve(10HJM60AA404/5, 10HJM50AA402/3) is installed at the lowest point of
atomizing steam ring header and line.

2.5.2

P&ID Drawing Title:

HFO to Burner Rows with Fuel Oil Return

Drawing Number:

T07073-XG02-PI-D013/014/015
TCE.5146A-510-00-0624/0625/0626

Design Basis:

NFPA 85 and DOOSAN in-house Design Rules

System Purpose
Supply of heavy fuel oil to the burner rows.
Provision for oil return from the boiler.
Provision of a code compliant system for fuel oil firing.
Description of Drawing
The referenced drawing is for heavy fuel oil system on corner-fired boilers of supplying fuel oil
to the burner rows.
The heavy fuel oil from the fuel oil pump flows to the oil ring header(10END60BR001) for
splitting heavy oil to each oil burner through four support pipes(10END65BR011,021,031,041)
which connects from oil ring header to each burner level branch pipes. From support pipe
branch pipe leads the oil to the burner (Elevation AB, CD, EF P&ID T07073-XG02-PI-D015,
Fuel System (3/3)).

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

Each stream from each corner support pipe supplies heavy fuel oil to the individual burners
from the bottom row to the top row of burners in order, and finally the left fuel oil joins to the fuel
oil return line. When pressure control valve (PCV,10END50AA042) is operated below 30% of
oil capacity the remained oil returns to the return-support pipes(10END70BR411,421,431,441)
and to the return oil manifold(10END70BR001) and then to the heavy oil service tank via shutoff valve(10END80AA001), fuel oil return shut-off valve(XV,10END80AA061) and non-return
valve(10END80AA002).
But if the oil pressure at burner inlet is acquired minimum required value and several burners
are placed in service and the heavy fuel oil flow is enough to be shifted from pressure control
valve (PCV,10END50AA042) to flow control valve(FCV,10END50AA041) the shut-off valve
(XV,10END80AA061) in the heavy oil recirculation line is closed automatically.
Trapped air in the pipelines is vented through vent valve at the highest points in the fuel oil
lines. This allows venting during hydraulic testing, charging with fuel oil and vacuum breaking
when emptying the fuel oil. Each vent line is provided with an isolation valve.
A thermal relief valve and a valved low point drain are provided in each fuel oil to burners line,
to prevent overpressure due to thermal expansion of trapped fuel oil, and draining the fuel oil
respectively.
All the heavy fuel oil lines are insulated and clad to minimise heat losses to atmosphere. To
allow circulation to recommence after a shutdown period, electric heat tracing is applied
between the pipe and the insulation to maintain the fuel at pumping temperature.
2.5.3

P&ID Drawing Title: Light Fuel Oil Pressure Pumping Equipment

Drawing Number:

T07073-XG02-PI-D013/014/015
TCE.5146A-510-00-0624/0625/0626

Design Basis:

NFPA 85 and DOOSAN in-house Design Rules

System Purpose
Supply of light fuel oil to burner rows.
Provision for oil return to fuel oil tanks.
Provision of a code compliant system for light fuel oil firing.
Description of Drawing
The referenced drawing is for a fuel oil system supplying light fuel oil to the lowest burner rows
(Elevation AB) for ignition purpose and/or warming-up at black start-up. The light fuel oil system
is designed as 7.5%BMCR capacity. This burner row is common for heavy fuel oil and light oil.
The Light fuel oil from the light oil storage tank is pressurized by the light fuel oil pressure
pumps. The light oil recirculation line provides rapid circulation of light oil.
The flow-metering device(FE,10EGD50CF001) which is located downstream of light oil pump is
measured light oil flow. The header trip valve (XV,10EGD50AA061) and flow control valve
(FCV,10EGD50AA041) are settled on the light oil line in order. The oil flow to the lowest
burners is measured to account for fuel oil consumption and possible incorporation into the
combustion control loop.
The header trip valve(XV,10EGD50AA061) shuts off the supply line to prevent from continuous
oil flow if emergent accident happens during oil firing period. A header trip valve ensures safety

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

of the boiler; it automatically cuts off the fuel to the boiler during abnormal operating conditions.
The valve is complete with solenoid valve and limit switches for control and status monitoring
by the Mill Burner Control System(MBC).
The control valve(FCV,10EGD50AA041) controls pressure and flow. Its function is changed
automatically from pressure control to flow control according to the burner situations.
The drain valve (10EGD55AA401) in the light oil drain line is opened only to drain.
The ball valve(10EGD55AA002) which is located between supply oil line(10EGD55BR001) and
accumulator is always opened during normal operation. On the contrary the block
valve(10EGD55AA401) located accumulator bypass line (10EGD55BR401) is closed during
normal operation but for the accumulators maintenance the block valve (10END55AA401) is
opened to drain the remained oil in the pipe to the drain line (10EGD60BR401).
One safety valve(PSV,10EGD55AA201) is settled on the supply oil line to prevent overpressure due to emergent accident. And overflow of oil by the safety valve
(PSV,10EGD55AA201) burst is drain to the light oil drain line(10EGD60BR401).
The oil flow is sensed by a flow transmitter(FE,10EGD50CF001) and its pressure switches
(PSLL,10EGD55CP201/2/3) convert the measured differential into a 4-20mA analogue signal
as inputs to the DCS and in case the supply pressure is lower than minimum value boiler trip,
signal comes from the DCS.
The fuel oil pressure required at the burners varies with the boiler load. The desired pressure
and flow is achieved by modulating the oil pressure control valve(FCV,10EGD50AA042)
located down stream of the flow element. The chosen pneumatic control valves are equipped
with I/P converter, valve position transmitter and fail fix device. A pressure gauge is also
included for local indication.
Isolation valves upstream of the flow element and down stream of the control valve provide
isolation of the flow element and control valve for maintenance purposes
A thermal relief valve, steam cleaning connection and low point drain with isolation valve are
provided in the above pipeline. High point vents may be required depending on layout.
The pressure transmitter transmits the signal to the DCS directly as converted in a transmitter
to a 4-20 mA high level analogue input. The fuel oil is circulated up to the burner valves,
through the fuel oil supply after opening the supply header trip valve(XV,10EGD50AA061). The
pneumatic operated header trip valve(XV,10EGD50AA061) is complete with solenoid valve and
limit switches for control and status monitoring in the MBC/DCS.
The light oil has to be maintained desired burner inlet pressure by control valve. There are four
thermowells are provided in the light oil line. The three pressure switches
(PSLL,10EGD55CP201,202,203) with one pressure transmitter(PT,10EGD55CP101) transmit
digital signal to the MBC/DCS. Also redundant pressure indicator(PI,10EGC55CP501) is
installed.
An accumulator prevents from sudden pressure drop at the burner inlet and protect boiler trip
due to the lower pressure. A pressure gauge is also included for local indication.
Valves upstream of the flow element and down stream of the control valve provide isolation of
the flow element and control valve for maintenance purposes.
The atomizing medium of light oil is air, which is supplied from service air system to an
individual boiler supply line(10HJN50BR001). It is distributed to the individual burners after
reaching atomizing air ring header(10HJN60BR001) at the boiler area via atomizing air flow
control valve (FCV,10HJM50AA041).
The drain valve(10HJM60AA404/5) is installed at the lowest point of atomizing air ring header.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

The atomizing air has to be maintained constant burner inlet pressure by throttling of atomizing
air
control
valve(PCV,10HJN50AA071).
The
three
pressure
switches
(PSLL,10HJN55CP201/2/3) transmit digital signal to the MBC. If the air pressure is lower than
required minimum value the trip signal generated by MBC. Also redundant pressure indicator
(PI,10EGC55CP501) is installed for measuring at site.
The drain trap(10HJN50AT001) upstream of flow control valve(FCV,10HJN50AA041) is
installed at the drain line(10HJN50BR401) and its drain line leads to pit. For maintenance the
drain trap bypass line with block valve(10HJM50AA401) is provided.

2.5.5 P&ID Drawing Title:

Coal Pulverising Equipment-Bowl Mill

Drawing Number:

T07073-XG02-PI-D018
TCE.5146A-510-00-0629

Design Basis:

NFPA 85, IBR / ASME & DOOSAN in house design rules

System Purpose
Provision of coal storage.
Provision of coal feed at required quantity to the mill and boiler.
Provision for drying and grinding of the coal to produce pulverised fuel.
Provision for classifying the pulverised fuel and transport to the burners.
Provision of seal air to the mill and feeder.
Provision of inerting system for the mill.
Provision of code compliant systems.
Description of Drawing
The referenced drawing is for a milling system, for converting the raw coal held in the coal
silos to a fineness suitable for successful combustion, transferring the correct quantity of
pulverised fuel to the boiler, and all associated systems such as seal air & mill inerting.
Each mill has one raw coal storage coal silo, each with an outlet-isolating
gate(HV,10HFB11AA001) located beneath the raw coal silo, on the downspout, prior to the
inlet section to the feeder(10HFB11AF001).
A coal silo is provided with 4(four) micro cells(WE,10HFA11CW001/2/3/4) which are to fulfil
the load measurement and provide the necessary measurement and status information to
DCS for indication in Central Control Room (CCR), and/or coal handling control room.
The isolating gate(HV,10HFB11AA001) in each raw coal pipe provides complete isolation of
the coal flow from the bunker to the feeder(10HFB11AF001) and mill(10HFC11). This gate
valve is electrically actuated, and also is operated both locally and remotely, and in
emergencies by a manual chain wheel. Open/close limit switches provide position indication in
the CCR.
Measurement of the coal flow is required for operator information and feeder controls. The
gravimetric feeder weighs coal on a length of belt between two fixed rollers. The third roller is
located midway in the span and supported at each end by precision load cells
(WE,10HFB11CW001/2). The load cells generate an electrical signal directly proportional to
the weight supported by the centre roller. The flow variation achieved by varying the speed of
the belt.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

Two coal feeder weight transmitters, transmit the analogue signal to local controller and DCS
for flow measurement and control. Two redundant coal feeder flow switches will transmit the
No coal flow signal to the DCS for the mill and feeder control. A coal feeder speed transmitter
sends analogue signals to the local controller and DCS for flow control purposes. Points are
provided for performance testing purposes, such as coal sampling. The clean out conveyor
keeps the coal feeder enclosure clean.
Hot gases from the mill are laden with fine coal particles and moisture, and if allowed to back
flow up to the feeder, and through to the bunker, can cause a hazardous situation and
jeopardise the availability of the plant. In order that situations such as these are avoided, a
minimum coal level must be maintained in the bunker, and the pulverizing plant and feeder
provided with a seal air supply. The seal air prevents back flow of hot gases from the mill up
to the feeder and into the bunker.
Seal air prevents the pulverised material from escaping to atmosphere through openings and
clearances between parts having relative movement. It also protects the seals from abrasion
damage, by preventing pulverised fuel from entering these regions. Seal air to the mill and
feeder is supplied from the mill seal air fans(10HFW10AN001/2).
Pressure differential between mill inlet and mill body and between mill bottom and body is
monitored and transmitted to the DCS. If the pressure differential becomes higher than input
set value, mill will be tripped to protect from mill damages owing to mill overload.
A pneumatic isolating shut off damper(FV,10HFW31AA061), controls the mill seal air supply to
each mill. From primary cold air leads to each feeder and a manual shut off damper
(10HFW51AA001) is located upstream of coal feeder(10HFB11-AF001). When the mill is
removed from service for maintenance, a pneumatic isolating shut off damper
(FV,10HFW31AA061) of each seal line provides complete isolation of the seal air to the mill.
The source of seal air of mill is seal air fan(10HFW10AN001/2) but feeder is supplied from
cold primary air common duct(10HFE37). The raw coal is ground in the mill, and then mixed
with the hot primary air, which acts as a drying medium and transports the pulverised fuel from
the mill to the classifier and thence to the burners.
Electrically operated mill inlet isolating dampers(XZ,10HFE31/51AA061) isolate the relevant
mill end in the event of a feeder or mill failure for maintenance. The pneumatically operated
damper is complete with position indication and control from the DCS. Test
points(PP,10HFE51CP401-7) are located in each duct for verification and analysis purposes.
The Bowl mill consists the gearbox, which is driven by an electric motor, is directly connected
to the bowl hub. A planetary gear arrangement provides the proper reduction between the
motor and the bowl hub to obtain the desired bowl speed.
The millside and its air inlet surround the bowl, the bowl hub and support the separator body.
Air for transporting and drying the coal enters through the air inlet and is directed upward
around the bowl.
The BOWL is the table upon which the coal is crushed. Material to be ground is admitted to
the pulverizer and deposited near the centre of the rotating bowl.
The vane wheel assembly, which is attached to the bowl, manages the coal/air mixture within
the grinding zone of the pulverizer by uniformly distributing the transport air through the bowl
outside diameter and inner cone/separator body annulus.
Three independent, Spring loaded journal assemblies are suspended from the separator body
and overhang the bowl. The journal assembly rolls are free to rotate, and do so, when the coal
being pulverized fills the space between them and bowl.
The separator body and separator top with attached deflector assemblies and the inner cone
and classifier, contain the material after it is pulverized. The separator body and separator top
direct the material and transport air up through the deflector assemblies where larger particles
of material are separated from the transport air and returned to the bowl for further grinding.

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UMPP Mundra ( 800MW x 5 Units )

Process and System Description

The separator top assembly separate the flow of material and transport air into four separate
the flow of material and transport air into four separate, equal streams.
The pulverizer discharge valves are mounted on the port outlet on top of the separator top
assembly. The four valves are used to isolate the pulverizer from an operating furnace during
a unit start-up and when the idle pulverizer contains coal. They are also used to isolate the
pulverizer for maintenance. Orifice is installed on each coal pipe to adjust the coal flow to
burners evenly.
The lubrication system provides oil for the bearings located at journal assembly. Each of the
three journal assemblies has a self contained oil bath lubrication system. The journals are
shipped completely filled with the recommended lubricant I order to protect the bearings and
internal surfaces.
Prior to operation, the oil level in each installed journal must be adjusted to its proper level for
operation. Determine the proper level by using the oil dip stick, measuring from the bottom of
the oil reservoir.
This system provides for continuously lubricated, hydrodynamic operation of the bearings and,
hydrostatic operation for lifting the mill during start-up, eliminating metal to metal contact and
wear.
Pressure differential transmitters(PDT,10HFW31CP03/4) at each classifier inlet and outlet
converts the measured pressure into a 4-20mA analogue signal as an input to the DCS for
monitoring the performance of the mill and classifier. The reject line connects the classifier to
the mill, thereby transferring large coal particles back to the mill for further pulverising.
A mill has a static classifier, four coal pipe at each static classifier. This ensures that the
desired grind quality is delivered to the burners. Each classifier is provided with four outlets
pipes designed to carry pulverised coal to the associated slot burners. A pneumatically
operated isolation valve(FV,10HFE81AA061/2/3/4) in each pulverised fuel pipe provides
isolation between the mill and burner. This isolating valve is complete with solenoid valves,
and limit switches. A segmental orifice plate(FO,10HFE81BP501/2/3) is provided in each coal
pipeline except the longest coal pipe among four coal pipes, which acts as a rope breaker to
re-entrain the pulverised fuel back into the transport air stream. Eight(8) pulverised fuelsampling points(AP,10HFE81CQ401-8) are provided in fuel line to each burner. Additional
coal flow test points(FP,10HFE81CF401-8) are fitted in each pulverised fuel pipe adjacent to
the actuated shut off valve (FZ,10HHA10AA001-6).
Three points(TT,10HFC11CT101/2/3) are provided on each classifier to measure the
pulverised fuel and air mixing temperature. These in turn are used for controlling the primary
air temperature to the mill and as inputs to the mill fire detection system. These thermowells
(TT,10HFC11CT101/2/3) are complete with thermocouples that transmit the signals as a
converted in transmitters to 4-20 mA high-level analogue inputs.
To avoid mill fire hazards, a mill inerting(10HHR61BR001) and fire fighting system
(10SGA61BR001) is provided in accordance with the guidelines in NFPA. The purpose of mill
inerting and fire fighting system is to reduce the oxygen content of the gas within the mill. For
fire fighting the deluge water line(10SGA61BR002) is connected to the downspout also. These
systems provide a method of controlling a fire, and reducing the risk of explosions or fire in a
mill containing a charge of coal, especially during start up and shut down. Digital and
analogue signals from the analyser, in conjunction with temperature measurements
(TT,10HFC11CT101/2/3) inform the CCR operator of the particular mill exhibiting temperature
levels.
The inerting and fire-fighting medium is steam and water, and is sourced from the station
auxiliary steam header and DM water system. A remote motor operated shut off valve
(MOV,10HHR61AA041) for mill is provided in steam inerting line and is connected to the
common air duct.

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UMPP Mundra ( 800MW x 5 Units )

2.5.6

Process and System Description

P&ID Drawing Title:

Instrument Air to Burner Rows

Drawing Number:

T07073-XG02-PI-D024
TCE.5146A-510-00-0635

Design Basis:

IBR / ASME, DOOSAN in house design rules

System Purpose
Supply of instrument air to the burner rows.
Provision of code compliant system for the instrument airlines.
Description of Drawing
The referenced drawing is for the instrument air supply system to burner rows.
The instrument air is sourced from the instrument air boiler house via compressor and
removing moisture facility and enters the boiler area in four each corner burners.
The instrument air pressure is a critical parameter for the proper functioning of the actuated
devices associated with each burner. Pressure transmitter(PT,10SCD50CP101) and pressure
reducing valve(PRV,10SCD60/70/80/90AA071/2/3/4) is provided in front of each instrument air
manifold for regulating the pressure. Each pressure reducing valve is provided with a primary
isolation valve(10SCD60/70/80/90AA001/3/5). A shut-off valve(10SCD50AA001) is provided
upstream of pressure transmitter and pressure indicator(PI,10SCD50AA301).
Each stream further splits into three equal streams, with each stream supplying instrument air
to the individual Local Control Panel (LCP) burner units of the respective row.
The instrument air in this system must be clean and dry with a dew point temperature
significantly lower than the minimum possible site ambient.
As the instrument air(compressed air) contains moisture and oil droplets, there will be some
condensation in the pipelines. The water in the instrument air affects the quality of atomisation
and must be removed. Drain trap(10SCD50AT001) is provided in the lowest location of pipeline
for removing the condensate.
The condensate from all the air trap stations is connected in to a steam trap discharge main
and is led to the waste pit.

2.5.7

P&ID Drawing Title:

Atomising Air to Burner Rows

Drawing Number:

T07073-XG02-PI-D013/14/15
TCE.5146A-510-00-0624/0625/0626

Design Basis:

IBR / ASME, NFPA 85 & DOOSAN In house design rules

System Purpose
Supply of atomising air to the burner row.
Provision of code compliant system for atomising airlines.
Description of Drawing
The referenced drawing shows atomising air system coming from service air system for light oil
firing. Service air is used as a atomizing medium of light oil.

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42973.56133.11299.837_200803261859

UMPP Mundra ( 800MW x 5 Units )

Process and System Description

Three pressure switches(PSLL,10HJN50CP201/2/3) in the atomising air supply line

(10HJN50BR001) transmit digital signals to the MBC for safe operation of burners. The
atomising air pressure, 5.3 kg/cm2g (6.2 bara) is required to be constant over the flow range,
and for all burner-firing combinations. If the supplying air pressure is down to the set value, the
light oil burners will be tripped. The lower air pressure than constant pressure might bring
unstable firing situations.
From the common ring boiler supply, the system splits into four equal streams. Each corner has
equal stream supply. Atomising air is necessary to the LDO system only and first row of burner
is connected to the atomising air system.
As the atomising air(compressed air) contains moisture and oil droplets, there will be some
condensation in the pipelines. The water in the atomising air affects the quality of atomisation
and must be removed. Drain traps(AT001) are provided in each burner common
header(HJN60BR001) for removing the condensate.
The condensate from all the air trap stations is connected in to a steam trap discharge main
and is led to the waste pit.

2.5.8

P&ID Drawing Title:

Atomising Steam to Burner Rows

Drawing Number:

T07073-XG02-PI-D013/14/15
TCE.5146A-510-00-0624/0625/0626

Design Basis:

IBR / ASME, NFPA 85 & DOOSAN In house design rules

System Purpose
Supply of atomising steam to the burner rows at the required pressure.
Condensate removal.
Provision of code compliant system for atomising steam lines.
Description of Drawing
The referenced drawing depicts an atomising steam system to the burner rows.
Steam is sourced from the auxiliary steam header, 15bar(a) and 300degC conditions, where
pipework(10HJM50BR001) takes the atomising steam to the burner common ring header
(10HJM60BR001). The steam pressure is reduced by a modulating control
valve(PCV,10HJM50AA071) to the desired level for atomisation of the fuel oil. The chosen
pneumatic control valve is complete with I/P converter, valve position transmitter and fail fix
device. Manually operated isolation valves(10HJM50AA002/3) upstream and downstream of
the control valve provide isolation for maintenance purposes.
Redundant pressure transmitters(PT,10HJM55CP101/2) downstream of the control valve
provide the required inputs to the DCS. A pressure gauge(PI,10HJM55CP501) is also included
for local indication. The pressure gauge and transmitters are provided with primary isolation
valves.
The atomising steam pressure, 7 kg/cm2g (= 7.9 bar(a)) is a critical parameter for effective
atomisation of the fuel oil. Three pressure switches(PSLL,10HJM55CP201/2/3) downstream of
the control valve transmit digital signals to the MBC.
After the pressure reducing station the flow supplies to the common ring header
(10HJM60BR001) for heavy fuel oil atomising and each four corner pipes are connected to the
common ring header. Each support pipe further splits into three equal streams, connected to

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Process and System Description

the heavy oil burner directly and each stream supplies atomising steam to its own individual
burner.
The steam pipelines are insulated, but condensation still occurs, the quantity in direct
relationship to the source steam quality. Water in the steam affects the quality of atomization
and hence has to be removed. Steam traps(10HJM60ST001/2) are provided at low points in
the pipeline to each burner row for removal of condensate.
Each steam trap station consists of a steam trap (complete with strainer), an inlet and outlet
isolating valve(10HJM60AA401/2/4/5) and a bypass isolating valve(10HJM60AA403/5). The
condensate from all the steam trap stations is connected in to a steam trap discharge main and
is led to the start-up flash tank(10LCQ20BB001).

2.5.9

Reference Drawing Title:

Low NOx Burner

Reference Drawing Number:

Design Basis:

NFPA 85 & DOOSAN in house design rules

System Purpose
Provision of an ignition source for the various fuels.
Provision of code compliant burner ancillaries.
Method of introducing fuel and air to the furnace (combustion zone).
Method of mixing the fuels and combustion air to produce a stable flame.
Connection of pulverised coal transport system to the PF burner.
Connection of heavy fuel oil and/or light fuel oil systems to the fuel oil atomiser.
Connection of atomising steam and/or atomising air systems to the fuel oil atomiser.
Connection of secondary air supply to the burners.
Connection of purge, core and instrument air supplies to the burner.
Description of Low NOx Burner
In tangential and corner firing system, the fuel and air are introduced into the furnace through
windbox assemblies located in the furnace corners. The fuel and air streams from the windbox
nozzles are directed toward concentric firing circles, swirling clockwise from the plan view side.
The description is for a Low NOx PF burner system on corner firing boilers with the capability of
firing light or heavy fuel oil with the option of steam or air atomisation or both. The maximum
light oil firing capacity is 7.5% BMCR and maximum heavy oil firing capacity is 25% BMCR.
Burners are capable of sustaining BMCR load with one pulverizer out of service when firing
design coal and one/no pulverizer out of service when range coal in service. Each burner has
turndown range of at least 2 to 1 based on BMCR load without requiring change of any burner
parts and without evidence of flame instability or other combustion difficulties in this range.
Burners are the Supplier's standard low NOx burner and proven design. Total airflow control to
the boiler is accomplished by regulating the forced draft fan dampers. Combustion air
distribution is accomplished by means of the individual windbox compartment secondary air
dampers. This secondary airflow is labeled as fuel air, auxiliary air, or OFA. They are
pneumatic cylinder operated type and are controlled and interlocked with a flame safeguard
system. By varying the windbox compartment damper position, the air distribution is affected as
follows: Opening the fuel-air dampers or closing the auxiliary air dampers increases the airflow
around the fuel nozzle; Closing the fuel air dampers or opening the auxiliary air dampers
decreases the airflow directly around the fuel stream.

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Process and System Description

Burner has a capability of withstanding the furnace heat with secondary air leakage while not in
service. Burner tip is constructed with high strength material for high temperature service and
low thermal expansion with easy replacement.
Coal pipe slide gate valves are provided in the coal pipes to the windbox coal nozzles to prevent
furnace gases from travelling back into the pulverizer when it is opened for inspection or
maintenance with the boiler in operation.
The fuel oil burner is designed so that full steam generator load cycling range can be
maintained with all burners in service. Turndown range shall be not less than 5 to 1 with all
burners in service when firing heavy fuel oil.
Piping includes oil supply and return piping, and atomizing piping. This includes all valves,
duplex basket type strainers, flow integrators, regulators, accumulators, shut-off valves and
flexible piping required for safe operation of the burners.
Oil valves are designed so that the open or closed position is easily determined. Each
connection to the burner shall have a manual shut-off valve.
A scavenging system for each oil atomizer is provided and is interlocked with the igniter control
system. All flexible spiral stainless steel tubing for oil and air supply piping connected to
burners is provided.
An automatic electric ignition system suitable for operation on 120 volts AC with electrodes,
high voltage cables, transformers, relays, controls, mounting brackets, and all required
accessories is provided. The high energy arc (HEA) igniter is designed to serve as an ignition
torch for adjacent warm-up or load carrying oil guns. It ignites the liquid fuel by use of a high
energy electrical discharge in the fuel/air stream and must be a component of the furnace
safeguard supervisory system.
The electric portions are designed for satisfactory operation in high temperature service.
Interlock with the oil control valve that prevent opening of the fuel valve without the igniter being
energized shall be provided. Openings and tubes for optical flame scanners shall be provided.
Piping is arranged so that a single terminal is provided for each service for connection to
terminal points. Provision is included for thermal expansions of pipe and equipment. Flexible
stainless steel hose shall be provided with the burners for connecting the burner piping to the
fuel and air supply headers. The design of the oil piping and location of the shut-off valves
prevent any oil from leaking into the windbox.
Oil trip valves are furnished. There is one trip valve for each oil burner system. Oil trip valves
shall be solenoid or power cylinder operated.
A single gun cleaning facility shall be provided at each side for each burner level.
The proximity type limit switches(dry contacts) shall be furnished as an integral of each light oil
burner and shall be used to detect the insert and retract position.
Each burner is fitted with an oil burner for lighting up, PF stabilization and boiler load carrying.
Each line from the respective heavy fuel oil and light fuel oil system are connected to form a
dedicated fuel oil to burner line. A manually operated isolation valve, a pneumatically operated
burner shut off valve and a non-return valve are provided in the respective fuel oil supply lines
before connection to the single fuel line.

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2.6

Process and System Description

PIPING AND INSTRUMENT DIAGRAMS DESCRIPTIONS AUXILIARY STEAM

Each diagram in the reference design series has an associated diagram description, which has
a System Purpose and Description of the P&ID including any variants, which may be
applicable.
2.6.1

Drawing Title:

Auxiliary Steam line 1

Reference Drawing Number:

Design Basis:

IBR / ASME

System Purpose
Auxiliary steam supply from the main boiler.
The description is regarding general auxiliary steam system based on Doosans experience
through previous project. The auxiliary steam system is supplied by owner.
Description of Drawing
The auxiliary steam system is provided for the purpose of distributing low-pressure steam to the
following plants.
.
- Mill steam inerting.
- Heavy fuel oil tanks.
- Fuel oil heaters.
- Airheater sootblowing.
- Steam airheaters.
The auxiliary boiler during the periods of station waiting, start up and main boiler light up
provides steam for heavy fuel oil tank, and in line heating, burner atomising and steam
airheaters where required. Turbine ancillaries such as gland steam may also require steam.
Auxiliary steam for deaerator, gland steam, atomising steam, mill fire fighting steam and steam
airheaters are sourced from the auxiliary steam header. Each line is provided with an isolation
valve. The fire fighting/inerting steam line to the mills splits further at the mill bay, in order to
supply steam to all the mills.
If an auxiliary boiler is not prepared at the start-up of boiler and then auxiliary steam is not
available, the boiler should be operated with a black start-up during necessary auxiliary steam
is produced.
And if the steam for airheater sootblowing is not available the compressed air will be used for
blowing instead of steam.
The main boiler will be used as the source until the unit has synchronised and achieved 35%
load. At 35% load the steam supply source changes again; from the LTSH
outlet(10HAH40)/main steam line to the cold reheat pipework.
Steam for airheater sootblowing is sourced from the LTSH outlet/Main steam line or cold reheat
before it enters the desuperheater, to ensure the high temperature steam demanded by the
airheater manufacturers. Before extract the steam for airheater sootblowing the steam condition
should be checked whether it is the same or above than auxiliary steam condition.

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Process and System Description

The steam temperature to the auxiliary steam header is to be maintained at a desired level by
adding spray water in the line before it joins the auxiliary steam header. The source of this
water is generally the condensate extraction pump discharge, as this the only available lowpressure source of good quality water.
The auxiliary boiler/other source also supplies steam to unit 2 auxiliary steam header. Steam
for the fuel oil tanks and heaters are sourced from the auxiliary steam crossover. This can
receive steam from either the auxiliary boiler, unit 1 and/or unit 2 auxiliary steam headers. The
steam lines to fuel oil heaters and fuel oil tanks are provided with isolation valves. A pressure
transmitter located in the auxiliary steam crossover continuously monitors auxiliary steam
pressure.
All the auxiliary steam piping shall be designed with adequate drainage to prevent the
accumulation of condensate.
A low point drain with an isolation valve is provided in each line for draining condensate that
has formed during and after shutdown.

2.6.2

P&ID Drawing Title:

Auxiliary Steam for Steam Air Heater

Drawing Number:

T07073-XG02-PI-D027
TCE.5146A-510-00-0638

Design Basis:

IBR / ASME

System Purpose
Auxiliary steam to the steam air heater.
Description of Drawing
The referenced drawing is typical of auxiliary steam supply to steam air heater located down
stream of the FD Fan.
The steam line(10HLC50BR001) coming from the auxiliary steam header splits equally into two
streams(10HLC51/52BR001). One stream supplies the A-side steam airheater and the other
the B-side steam airheater.
The steam air heater is used when the ambient air is cold enough to bring about condensation
of the flue gas constituents within the gas airheater.
Temperature control valve(TCV,10HLC51/52AA071) upstream of the steam airheater
modulates the steam flow through the steam airheater in order to achieve the desired steam
airheater exit air temperature. And the level control valve(LCV,10HLC90CP441) ensures the
condensate level in the steam coil airheater drain tank. The control valve is complete with I/P
converter; position transmitter and fail fix devices. A manual isolation valve upstream and
downstream of the control valve provides isolation to the control valve for the maintenance
purposes.
The steam shall be completely condensed before it leaves the steam airheater for complete
extraction of heat from the steam.
The condensate from each stream is connected to the drain tank and the accumulated water
transferred to the flash tank through the drain pump(10HLC80AP001/2).

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2.7

Process and System Description

PIPING AND INSTRUMENT DIAGRAMS DESCRIPTIONS SOOTBLOWERS

Each diagram in the reference design series has an associated diagram description, which has
a System Purpose and Description of the P&ID including any variants, which may be
applicable..

2.7.1

P&ID Drawing Title:

Sootblowers

Drawing Number:

T07073-XG02-PI-D020/21
TCE.5146A-510-00-0631/632

Design Basis:

ASME

System Purpose
The supply of steam, at acceptable conditions, for sootblowing furnace, heating surfaces, and
gas airheaters.
Description of Drawing
Sootblowers are installed on the boiler envelope and regenerative airheaters, to provide
periodic cleaning of the heating surfaces, and thus limit the formation of combustion deposits
which can occur during operation.
The blowing medium for the sootblowers is steam, which is sourced from the LTSH outlet
connection pipe. But auxiliary steam is used for gas airheater sootblower during start-up period.
In case auxiliary steam is not available, compressed air is used as a sootblowing medium.
The steam supply to the boiler sootblowers is isolated initially by a manually operated isolating
valve(10HCB15AA001), and then a motorised valve(MOV,10HCB15AA041) in series. The
actuated isolating valve is for remote operation. The motorised valve is complete with limit
switches, and status monitoring by the DCS.
A pressure control valve(PCV,10HCB15AA071), downstream of the motor operated valve,
reduces the inlet steam pressure to the desired pressure value which required for the operation
of the blowers. The kept constant pressure downstream of control valve is adjusted to meet
each kind of sootblower by the poppet valve that is installed in the sootblowing facility itself.
The pneumatic control valve(PCV,10HCB15AA071) is complete with I/P converter; valve
position transmitter and fail fix devices.
To comply with design code requirements, a safety valve(PSV,10HCB15AA101) is provided
downstream of the pressure control valve. This safety valve must discharge to a safe location
above the boiler house roof.
The boiler is sectioned into five distinct areas covering; furnace blowers; pendant surface
blowers, two sets of horizontal surface blowers, and gas airheater blowers. Soot blowing steam
from the boiler supplies the sootblowing steam to seven sections of the boiler. Steam for the
gas airheater sootblowers is sourced from the auxiliary steam header. This will allow the gas
airheater sootblowers to operate during boiler start-up when suitable live steam from LTSH
outlet is not available. A motorised shut off valve(MOV,10HCB90AA041) with non-return
valve(10HCB90AA002) is installed on the auxiliary steam line for boiler start-up period.

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Process and System Description

Manual shut off valves(10HCB20/30/40/50/60/70/80AA001) are installed inlet of each section.

This isolates the sootblowers within the section from the steam supply when they are not
required to operate or maintenance.
Each section is further splits into two paths, one to cover the sootblowers on the A-side of the
boiler and the other the B-side.
The sootblowers are split into seven groups considered with sootblower locations. The
operating order of the sootblowers within a particular group and the order of blowing the groups
will be pre-defined. This ensures that blowing from the top down will clean individual heating
surfaces. Each soot blower is equipped with a motor, two limit switches on retraction, one limit
switch for extension and a manual start stop push button for remote (automatic via a timed
sequence and manual) start and local start.

Drain lines(10HCB20/30/40/50/60/70/80BR401) are provided on each group to remove the

condensate, and to provide leg warming prior to the sootblowing. Two temperature transmitters
(10HCB20/30/40/50/60/70/80CT101/2) are installed on the drain lines to monitor the steam
temperature during warming up the each group before sootblowing. When the steam
temperature rises over the set value the pneumatic drain valve(XV,10HCB20/30/40/50/60/70/80
AA061) is closed automatically. This valve operates automatically based on the steam
temperature in the drain line. The temperature is sensed by a thermocouple, and the resultant
signal is either transmitted directly to the DCS as a converted in a transmitter to a 4-20mA high
level analogue input. The warming-up the pipe before sootblowing prevents condensate water
from entering into the sootblower nozzle with steam together
Each drain line is provided with a restricting orifice(FO,10HCB20/30/40/50/60/70/80BP501) for
limiting the drain flow during sootblower operation.
All sootblower drains are connected to the sootblower common drain line(10HCB60BR401) and
then discharged to the boiler flash tank.
A non-return valve(10HCB90AA002) in gas airheater aux steam line(10HCB90BR002) prevents
any back flow of steam/ condensate.

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2.8

Process and System Description

PIPING AND INSTRUMENT DIAGRAMS DESCRIPTIONS

MISCELLANEOUS (UTILITIES)

Each diagram in the reference design series has an associated diagram description, which has
a System Purpose and Description of the P&ID including any variants, which may be
applicable..

2.8.1

Reference Drawing Title: Closed Cooling Water

Reference Drawing Number:
Design Basis

IBR / ASME

System Purpose
To supply cooling water to various equipment within the main boiler plant
Description of Drawing
The referenced description is typical of cooling water distribution to all the plant services, where
it is necessary.
The cooling water supply enters the boiler house from cooling water source. The Cooling water
supply main and Cooling water return main are provided. Each branch line has isolating valve
at the inlet side.
The cooling water supply to the mills is taken from cooling water supply mains and then
returned back to the cooling water return mains.
The closed cooling water system provides cooling water to the following plant services.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)

Coal mill oil coolers.

Air heater oil coolers.
FD Fans oil coolers.
ID Fan oil coolers.
PA Fan oil coolers.
Furnace Access Door
Furnace Camera (CCTV)
Steam Airheater Drain transfer pump oil cooler
Boiler Recirculation Pump Motor cooler

The cooling water supply to each of the above equipment is sourced from the cooling water
supply and return mains. Each item of equipment can be isolated for maintenance purposes
with the isolating valves provided in the individual supply and return lines. A pressuresustaining valve located at the supply line maintains the cooling water supply pressure.
.

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