PROJECT: FGD FOR

2 x 500 MW MEJIA THERMAL POWER STATION

OWNER:

DAMODAR VALLEY CORPORATION

FGD CONTRACT REF. NO: DVC/FGD-2/MTPS/CA/FC/500

EPC CONTRACTOR: TECHNOLOGY (QFGDM):

LARSEN & TOUBRO LIMITED

FGD DOCUMENT TITLE:

Control Philosophy of FGD system

L&T Doc No: F.MEJI.19-XG07-00-HT-110104 REV.: 01

DVC Doc No: 2109-122-PVM-G-006 REV.: 01

ISSUED FOR:
☒ INFORMATION
☐ ENQUIRY
☐ CONSTRUCTION
☐ APPROVAL
☐ AS BUILT

Prepare Reviewed by Approved by

Rev d by
Date Reason of Revision
No
L&T L&T

SK/SB
00 27th April ‘20 First Issue RS SG
/SM
SK/SB/
01 21st Jan ‘22 Revised as per approved P&ID SM GD
SM

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 2 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 20 Jan’ 22

Table of Contents:

Section-1 Flue Gas System ................................................................................................................. 12

1 REFERENCE DOCUMENTS .......................................................................................................................... 13
2 PROCESS DESCRIPTION ............................................................................................................................. 13
2.1 CONTROL PHILOSOPHY .................................................................................................................... 13
3 CONTROLS AND INTERLOCKS: ................................................................................................................... 13
3.1 FGD FLUE GAS GROUP ..................................................................................................................... 13
3.1.1 FGD FLUE GAS GROUP START .......................................................................................................... 14
3.1.2 FGD FLUE GAS GROUP STOP ............................................................................................................ 15
3.2 BOOSTER FAN (BUF) GROUP SEQUENCE ......................................................................................... 15
3.2.1 BOOSTER FAN-A GROUP START ...................................................................................................... 16
3.2.2 BOOSTER FAN-A GROUP STOP ........................................................................................................ 16
3.3 BOOSTER FANS (TAG: 07HTC11AN001 / 07HTC21AN001) ............................................................. 16
3.4 FGD BYPASS DAMPER (TAG: 07HTA51AA001) ................................................................................ 19
3.5 BOOSTER FAN INLET DAMPERS (TAG: 07HTA11AA001 / 07HTA21AA001) ................................... 20
3.6 BOOSTER FAN OUTLET DAMPERS (TAG: 07HTA12AA001 / 07HTA22AA001) ................................ 21
Section-2 Absorber System ................................................................................................................ 22
1 REFERENCE DOCUMENTS .......................................................................................................................... 23
2 PROCESS DESCRIPTION ............................................................................................................................. 23
2.1 CONTROL PHILOSOPHY .................................................................................................................... 25
3 CONTROLS AND INTERLOCKS: ................................................................................................................... 25
3.1 ABSORBER (JBR) GROUP .................................................................................................................. 25
3.1.1 JBR GROUP START ............................................................................................................................ 26
3.1.2 JBR GROUP STOP.............................................................................................................................. 27
3.2 JBR AGITATORS (TAG: 07HTD01AM001 / 07HTD01AM002 / 07HTD01AM003 /07HTD01AM004)
27
3.3 JBR WASH GROUP ............................................................................................................................ 28
3.4 JBR RISER AND WALL WASH VALVES (TAGS: REFER TABLE-1)........................................................ 32
3.5 JBR UPPER DECK & DUCT WASH VALVES (TAGS: REFER TABLE-1) ................................................. 33
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 3 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

3.6 JBR MIST ELIMINATOR WASH VALVES (TAGS: REFER TABLE-1) ..................................................... 33
3.7 LIMESTONE SLURRY FEED CONTROL VALVES (TAG: 07HTK01AA300 / 07HTK01AA301) .............. 34
3.8 JBR MIST ELIMINATOR WASH ISOLATION VALVE (TAG: 07HTD70AA100)..................................... 35
3.9 JBR DRAIN VALVES (TAG: 07HTT01AA100 / 07HTT01AA101) ........................................................ 35
3.10 LIMESTONE SLURRY FEED ISOLATION VALVE (TAG: 07HTK01AA001) ........................................... 36
3.11 LIMESTONE SLURRY FEED BYPASS VALVE (TAG: 07HTK01AA101) ................................................. 36
3.12 JBR UPPER DECK / RISER / MIST ELIMINATOR WASH FLUSH VALVES (TAG: 07HTD31AA112 /
07HTD41AA116 / 07HTD70AA101 / 07HTD76AA101) ..................................................................................... 37
3.13 GYPSUM BLEED RECIRCULATION TO ABSORBER ISOLATION VALVE (TAG: 07HTL04AA100) ........ 37
Section-3 Gas Cooling System .......................................................................................................... 39
1 REFERENCE DOCUMENTS .......................................................................................................................... 40
2 PROCESS DESCRIPTION ............................................................................................................................. 40
2.1 CONTROL PHILOSOPHY .................................................................................................................... 41
3 CONTROLS AND INTERLOCKS: ................................................................................................................... 41
3.1 GAS COOLING PUMP (GCP) GROUP SEQUENCE .............................................................................. 41
3.1.1 GAS COOLING PUMP-A GROUP START............................................................................................ 41
3.1.2 GAS COOLING PUMP-A GROUP STOP ............................................................................................. 42
3.2 GAS COOLING PUMPS (TAG: 07HTH11AP001 / 07HTH21AP001 / 07HTH31AP001) ..................... 43
3.3 GCP SUCTION ISOLATION VALVES (TAG: 07HTH11AA001 / 07HTH21AA001 / 07HTH31AA001) .. 43
3.4 GCP DISCHARGE ISOLATION VALVES (TAG: 07HTH11AA002 / 07HTH21AA002 / 07HTH31AA002)
44
3.5 GCP DRAIN VALVES (TAG: 07HTH11AA100 / 07HTH21AA100 / 07HTH31AA100) ......................... 44
3.6 GCP WASH VALVES (TAG: 07HTH11AA101 / 07HTH21AA101 / 07HTH31AA101) ......................... 45
3.7 EMERGENCY WATER TANK INLET VALVE (TAG: 07HTQ01AA100).................................................. 45
3.8 EMERGENCY QUENCH WATER TO JBR VALVE (TAG: 07HTD12AA100) .......................................... 46
3.9 JBR MAKE-UP WATER LEVEL CONTROL VALVE (TAG: 07HTD11AA300) ......................................... 46
3.10 JBR MAKE-UP WATER SPRAY HEADER-A ISOLATION VALVE (TAG: 07HTD11AA100).................... 47
3.11 JBR MAKE-UP WATER / EMERGENCY SPRAY HEADER FLUSH VALVE (TAG: 07HTD11AA102 /
07HTD12AA101) ................................................................................................................................................ 48
3.12 EMERGENCY WATER TANK INLET ISOLATION VALVE (TAG: 07HTQ01AA002 / 07HTQ01AA003) . 48

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 4 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

3.13 EMERGENCY WATER TANK INLET VALVE-B (TAG: 07HTQ01AA101) .............................................. 49

3.14 JBR MAKE-UP WATER ISOLATION VALVE (TAG: 07HTD11AA001 / 07HTD11AA002) .................... 49
3.15 JBR MAKE-UP WATER INLET VALVE (TAG: 07HTD11AA101) .......................................................... 50
3.16 EMERGENCY QUENCH WATER TO JBR ISOLATION VALVE (TAG: 07HTD12AA001) ....................... 50
Section -4 Oxidation Air System ...................................................................................................... 52
1 REFERENCE DOCUMENTS .......................................................................................................................... 53
2 PROCESS DESCRIPTION ............................................................................................................................. 53
2.1 CONTROL PHILOSOPHY .................................................................................................................... 53
3 CONTROLS AND INTERLOCKS: ................................................................................................................... 53
3.1 OXIDATION AIR BLOWERS (07HTG01AN001 / 07HTG11AN001) .................................................... 53
3.2 OXIDATION AIR BLOWER DISCHARGE ISOLATION VALVES (07HTG01AA001 / 07HTG11AA001) . 54
3.3 OXIDATION AIR HUMIDIFICATION WATER CONTROL VALVE (07HTQ22AA300) ........................... 54
3.4 OXIDATION AIR HUMIDIFICATION WATER LINE FLUSH VALVE (07HTQ22AA100/00HTQ22AA101)
55

Section-5 Gypsum Bleed system ..................................................................................................... 56

1 REFERENCE DOCUMENTS .......................................................................................................................... 57
2 PROCESS DESCRIPTION ............................................................................................................................. 57
3 CONTROL PHILOSOPHY ............................................................................................................................. 57
4 CONTROLS AND INTERLOCKS: ................................................................................................................... 58
4.1 GROUP DEFINITION: ........................................................................................................................ 58
4.2 GYPSUM BLEED PUMPS (07HTL01AP001/07HTL02AP001) GROUP SEQUENCE: ........................... 58
4.2.1 GYPSUM BLEED PUMP GROUP-1 START ......................................................................................... 58
4.2.2 GYPSUM BLEED PUMP GROUP-1 STOP ........................................................................................... 59
4.3 GYPSUM BLEED PUMPS ( 07HTL01AP001/07HTL02AP001) ........................................................... 60
........................................................................................................................................................................... 60
4.4 GYPSUM BLEED PUMPS SUCTION VALVES (07HTL01AA001/07HTL02AA001) .............................. 60
4.5 GYPSUM BLEED PUMPS DISCHARGE VALVES (07HTL01AA002/07HTL02AA002) .......................... 61
4.6 GYPSUM BLEED PUMPS DRAIN VALVES (07HTL01AA100/07HTL02AA100) .................................. 61
4.7 GYPSUM BLEED PUMPS WASH VALVES (TAG:07HTL01AA101/07HTL02AA101) ........................... 62
4.8 ABSORBER BLEED CONTROL ............................................................................................................ 62

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 5 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

4.8.1 ABSORBER BLEED CONTROL VALVE (Tag: 07HTL03AA300) ............................................................ 62

4.9 ABSORBER EMPTYING PUMPS (07HTL06AP001) GROUP SEQUENCE: ........................................... 63
4.9.1 ABSORBER EMPTYING PUMP GROUP START .................................................................................. 63
4.9.2 ABSORBER EMPTYING PUMP GROUP STOP ................................................................................... 64
4.10 ABSORBER EMPTYING PUMP ( 07HTL06AP001) ............................................................................. 65
4.11 ABSORBER EMPTYING PUMP SUCTION VALVES (07HTL06AA001) ................................................ 65
4.12 ABSORBER EMPTYING PUMPS DISCHARGE VALVES (07HTL06AA002) .......................................... 66
4.13 ABSORBER EMPTYING PUMPS DRAIN VALVES (07HTL06AA100) .................................................. 66
4.14 ABSORBER EMPTYING PUMPS WASH VALVES (TAG: 07HTL06AA101) .......................................... 67
4.15 AUX ABSORBENT PUMPS (00HTL07AP001) GROUP SEQUENCE: ................................................... 67
4.15.1 AUX ABSORBENT PUMP GROUP START .......................................................................................... 67
4.15.2 AUX ABSORBENT PUMP GROUP STOP ............................................................................................ 68
4.16 AUX ABSORBENT PUMP (00HTL07AP001) ...................................................................................... 68
4.17 AUX ABSORBENT PUMPS SUCTION VALVES (00HTL07AA001)....................................................... 69
4.18 AUX ABSORBENT PUMPS DISCHARGE VALVES (00HTL07AA002) .................................................. 70
4.19 AUXILIARY ABSORBENT TANK AGITATOR (00HTL05AM001) ........................................................ 70
4.20 AUXILIARY ABSORBENT PUMPS DISCHARGE VALVES TO JBR (07HTL07AA100 / 08HTL07AA100)
71
Section-6 Filtrate Water System ...................................................................................................... 72
1 REFERENCE DOCUMENTS .......................................................................................................................... 73
2 PROCESS DESCRIPTION ............................................................................................................................. 73
3 CONTROL PHILOSOPHY ............................................................................................................................. 73
4 CONTROLS AND INTERLOCKS : .................................................................................................................. 74
4.1 GROUP DEFINITION: ........................................................................................................................ 74
4.2 FILTRATE WATER PUMPS (00HTL11AP001/00HTL12AP001) GROUP SEQUENCE: ........................ 74
4.2.1 FILTRATE WATER PUMP GROUP START: ......................................................................................... 75
4.2.2 FILTRATE WATER PUMP GROUP STOP ............................................................................................ 75
4.3 FILTRATE WATER PUMPS (00HTL11AP001/00HTL12AP001) .......................................................... 76
4.4 FILTRATE WATER PUMPS SUCTION VALVES (00HTL11AA100/00HTL12AA100) ............................ 76
4.5 FILTRATE WATER PUMPS DISCHARGE VALVES (00HTL11AA101/00HTL12AA101) ........................ 77

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 6 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

4.6 FILTRATE WATER PUMPS DRAIN VALVES (00HTL11AA600/00HTL12AA600) ................................ 78

4.7 FILTRATE WATER PUMPS WASH VALVES (00HTL11AA603/00HTL12AA603) ................................ 78
4.8 PROCESS WATER TO FILTRATE WATER TANK VALVE (00HTQ02AA102) ........................................ 78
4.9 FILTRATE WATER TANK AGITATOR (00HTL10AM001) ................................................................... 78
4.10 FILTRATE WATER RETURN CONTROL .............................................................................................. 79
4.10.1 FILTRATE TANK TO ABSORBER UNIT-7/8 CONTROL VALVE (07HTL18AA300/07HTL18AA300) ... 79
4.11 FILTRATE WATER TO WET BALL MILL FLOW CONTROL .................................................................. 80
4.11.1 FILTRATE TANK TO WET BALL MILL CONTROL VALVE (00HTL14/15AA300) ................................. 81
4.12 FILTRATE WATER TO MILL RECYCLE TANK FLOW CONTROL........................................................... 81
4.12.1 FILTRATE TANK TO MILL RECYCLE TANK FLOW CONTROL VALVE (00HTL14/15AA301) ................ 81
3.1 FILTRATE WATER DISCHARGE MOTORISED VALVE (TAG:00HTL14/15AA001, 00HTL14/15AA002 &
07/08HTL18AA001 ) .......................................................................................................................................... 82

Section -7 Limestone Slurry Feed System .................................................................................. 83

1 REFERENCE DOCUMENTS .......................................................................................................................... 84
2 PROCESS DESCRIPTION ............................................................................................................................. 84
3 CONTROL PHILOSOPHY ............................................................................................................................. 85
4 CONTROLS AND INTERLOCKS : .................................................................................................................. 85
4.1 GROUP DEFINITION: ........................................................................................................................ 85
4.2 LIMESTONE SLURRY FEED PUMPS (07HTK31AP001/07HTK32AP001) GROUP SEQUENCE: .......... 86
4.2.1 LIMESTONE SLURRY FEED PUMP GROUP-1 START: ........................................................................ 86
4.2.2 LIMESTONE SLURRY FEED PUMP GROUP-1 STOP ........................................................................... 87
4.3 LIMESTONE SLURRY FEED PUMPS (07HTK31AP001/07HTK32AP001) ........................................... 87
4.4 LIMESTONE SLURRY FEED PUMPS SUCTION VALVES (07HTK31AA100/07HTK32AA100) ............. 88
4.5 LIMESTONE SLURRY FEED PUMPS DISCHARGE VALVES (07HTK31AA002/07HTK32AA002) ......... 88
4.6 LIMESTONE SLURRY FEED PUMPS DRAIN VALVES (07HTK31AA100/07HTK32AA100) ................. 89
4.7 LIMESTONE SLURRY FEED PUMPS WASH VALVES (07HTK31AA101/07HTK32AA101).................. 89
4.8 LIMESTONE SLURRY RECIRCULATION ON-OFF VALVE (TAG: ((07HTK02AA100/101)/
(07HTK02AA100/101)) ...................................................................................................................................... 90
4.9 LIMESTONE SLURRY FEED TANK AGITATOR (00HTK01AM001/002) ............................................. 90
4.10 LIMESTONE SLURRY FEED TANK INLET VALVE (00HTK11/21AA100/00HTK11/21AA101) ............ 91

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 7 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

Section-8 Primary & Secondary Dewatering System............................................................ 92

1 REFERENCE DOCUMENTS .......................................................................................................................... 93
2 PROCESS DESCRIPTION ............................................................................................................................. 93
3 CONTROL PHILOSOPHY ............................................................................................................................. 93
4 CONTROLS AND INTERLOCKS FOR PRIMARY DEWATERING FEED SYSTEM :........................................... 94
4.1 GROUP DEFINITION: ........................................................................................................................ 94
5 PRIMARY HYDROCYCLONE FEED PUMPS A/B (00HTM02AP001/00HTM03AP001) GROUP SEQUENCE:
94
5.1.1 PRIMARY HYDROCYCLONE FEED PUMP (PHFP) GROUP START: .................................................... 95
5.1.2 PRIMARY HYDROCYCLONE FEED PUMP GROUP STOP ................................................................... 95
5.2 PRIMARY HYDROCYCLONE FEED PUMP ( 00HTM02AP001/00HTM03AP001)............................... 96
5.3 PRIMARY HYDROCYCLONE FEED PUMP SUCTION VALVEs (00HTM02AA001/00HTM03AA001) .. 97
5.4 PRIMARY HYDROCYCLONE FEED PUMP discharge VALVEs (00HTM02AA002/00HTM03AA002) . 97
5.5 PRIMARY HYDROCYCLONE FEED PUMP DRAIN VALVES (00HTM02AA102/00HTM03AA102)...... 97
5.6 PRIMARY HYDROCYCLONE FEED PUMP Wash Valves (Tag: 00HTM02AA002/00HTM03AA002) . 98
5.7 PRIMARY HYDROCYCLONE FEED TANK AGITATOR (00HTM01AM001) ........................................ 98
5.8 PRIMARY HYDROCYCLONE FEED INLET VALVES (00HTM04AA100/00HTM04AA101) .................. 99
5.9 PRIMARY HYDROCYCLONE OVERFLOW VALVE (00HTM06AA100/00HTM05AA100).................... 99
5.10 DEWATERING RECIRCULATION FEED FLOW CONTROL VALVE (00HTM04AA300) ........................ 99
6 CONTROLS AND INTERLOCKS FOR SECONDARY DEWATERING FEED SYSTEM : .................................... 100
6.1 GROUP DEFINITION: ...................................................................................................................... 100
6.2 SECONDARY HYDROCYCLONE FEED PUMPS A/B (00HTM32AP001/00HTM33AP001) GROUP
SEQUENCE:....................................................................................................................................................... 100
6.2.1 SECONDARY HYDROCYCLONE FEED PUMP (SHFP) GROUP START: .............................................. 101
6.2.2 SECONDARY HYDROCYCLONE FEED PUMP STOP ......................................................................... 101
6.3 SECONDARY HYDROCYCLONE FEED PUMPS ( 00HTM32AP001/00HTM33AP001) ...................... 102
6.4 SECONDARY HYDROCYCLONE FEED PUMP SUCTION VALVEs (00HTM32AA100/00HTM33AA100)
102
6.5 SECONDARY HYDROCYCLONE FEED Pumps discharge VALVEs (00HTM32AA101/00HTM33AA101)
103

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 8 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

6.6 SECONDARY HYDROCYCLONE FEED PUMPS DRAIN VALVES (00HTM32AA102/00HTM33AA102)

103
6.7 SECONDARY HYDROCYCLONE FEED PUMPS WASH VALVES (TAG:
00HTM32AA103/00HTM33AA103)................................................................................................................. 104
6.8 SECONDARY HYDROCYCLONE FEED TANK AGITATOR (00HTM31AM001).................................. 104
6.9 SECONDARY HYDROCYCLONE FEED INLET VALVEs (00HTM34-AA100/00HTM34AA101)........... 105
6.10 DEWATERING RECIRCULATION FEED FLOW CONTROL ............................................................... 105
6.10.1 DEWATERING RECIRCULATION FEED FLOW CONTROL VALVE (00HTM34AA300) ..................... 105
Section-9 All Sump & Pump System ............................................................................................ 107
1 REFERENCE DOCUMENTS ........................................................................................................................ 108
2 PROCESS DESCRIPTION ........................................................................................................................... 108
3 CONTROL PHILOSOPHY ........................................................................................................................... 108
4 CONTROLS AND INTERLOCKS : ............................................................................................................... 108
4.1 SUMP PUMPS (07HTT11AP001/00HTT31AP001/00HTT51AP001/00HTT61AP001) INTERLOCKS:
108
4.2 SUMP PUMPS DISCHARGE VALVES (07HTT11AA100/101), (00HTT31AA101),
(00HTT51AA102/103) & (07HTT61AA100/08HTT61AA100) .......................................................................... 109
4.3 SUMP TANK AGITATOR (07HTT11AM001/00HTT31AM001/00HTT51AM001/00HTT61AM001)
110

Section 10 Waste Water System .................................................................................................... 111

1 REFERENCE DOCUMENTS ........................................................................................................................ 112
2 PROCESS DESCRIPTION ........................................................................................................................... 112
3 CONTROL PHILOSOPHY ........................................................................................................................... 112
4 CONTROLS AND INTERLOCKS: ................................................................................................................. 113
4.1 GROUP DEFINITION: ...................................................................................................................... 113
4.2 WASTE WATER PUMPS (00HTL21AP001/00HTL22AP001) GROUP SEQUENCE: .......................... 113
4.2.1 WASTE WATER PUMP GROUP START: .......................................................................................... 113
4.2.2 WASTE WATER PUMP GROUP STOP ............................................................................................. 114
4.3 WASTE WATER PUMPS (00HTL21AP001/00HTL22AP001) ........................................................... 114
4.4 WASTE WATER PUMPS SUCTION VALVES (00HTL21AA100/00HTL22AA100) ............................. 115
4.5 WASTE WATER PUMPS DISCHARGE VALVES (00HTL21AA101/00HTL22AA101) ......................... 115

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 9 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

4.6 WASTE WATER TANK AGITATOR (00HTL20AM001) .................................................................... 116

4.7 WASTE WATR OVERFLOW VALVE (00HTM06AA101/00HTM05AA101) ...................................... 116
4.8 WASTE WATER FLOW CONTROL ................................................................................................... 117
4.8.1 WASTE WATER TANK TO ADD WASTE WATER TANK CONTROL VALVE (00HTL23AA300) .......... 117
4.9 GROUP DEFINITION: ...................................................................................................................... 117
4.10 WASTE WATER BLEED PUMPS (00HTL31AP001/00HTL32AP001) GROUP SEQUENCE: ............... 117
4.10.1 WASTE WATER BLEED PUMP (WWBP) GROUP START: ................................................................ 118
4.10.2 WASTE WATER BLEED PUMP GROUP STOP .................................................................................. 118
4.11 WASTE WATER BLEED PUMPS ( 00HTL31AP001/00HTL32AP001) ............................................... 119
4.12 WASTE WATER BLEED PUMPS SUCTION VALVES (0000HTL31AA100/00HTL32AA100) .............. 119
4.13 WASTE WATER BLEED PUMPS DISCHARGE VALVES (00HTL31AA101/00HTL32AA101) .............. 120
4.14 ADDITIONAL WASTE WATER TANK AGITATOR (00HTL30AM001) .............................................. 120
4.15 WASTE WATER RECIRCULATION VALVE (00HTL33AA101) ........................................................... 121
4.16 WASTE WATER TERMINAL POINT VALVE (00HTL33AA100) ........................................................ 121

Section 11 Process Water System ................................................................................................ 122

1 REFERENCE DOCUMENTS ........................................................................................................................ 123
2 PROCESS DESCRIPTION ........................................................................................................................... 123
3 CONTROL PHILOSOPHY ........................................................................................................................... 123
4 CONTROLS AND INTERLOCKS : ................................................................................................................ 124
4.1 GROUP DEFINITION: ...................................................................................................................... 124
4.2 PROCESS WATER PUMPS (00HTQ11AP001/12AP001/13AP001/14AP001) GROUP SEQUENCE: 124
4.2.1 PROCESS WATER PUMP GROUP START: ....................................................................................... 124
4.2.2 PROCESS WATER PUMP GROUP-1 STOP ....................................................................................... 125
4.2.3 PROCESS WATER PUMPS(00HTQ11AP001/12AP001/13AP001/14AP001).................................. 125
4.3 PROCESS WATER PUMPS DISCHARGE VALVES (00HTQ11AA001/12AA001/13AA001/14AA001)
126
4.4 PROCESS WATER PUMPS RECIRCULATION VALVES (00HTQ02AA100/101) ................................ 127
4.5 PROCESS WATER DISTRIBUTION VALVES (00HTQ02AA001/08HTQ01AA001/07HTQ01AA001) 127
4.1 CW BLOWDOWN TO PROCESS WATER TANK INLET VALVE (00HTQ01AA100/101) .................... 127
Section 12 Clarified Water System ............................................................................................... 128

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL
LIMITED POWER STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104
Page 10 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

1 REFERENCE DOCUMENTS ........................................................................................................................ 129

2 PROCESS DESCRIPTION ........................................................................................................................... 129
3 CONTROL PHILOSOPHY ........................................................................................................................... 129
4 CONTROLS AND INTERLOCKS : ................................................................................................................ 130
4.1 GROUP DEFINITION: ...................................................................................................................... 130
4.2 CLARIFIED WATER PUMPS (00HTQ31AP001/32AP001/33AP001/34AP001) GROUP SEQUENCE:
130
4.2.1 CLARIFIED WATER PUMP GROUP-1 START ................................................................................... 130
4.2.2 CLARIFIED WATER PUMP GROUP-1 STOP ..................................................................................... 131
4.3 CLARIFIED WATER PUMPS (00HTQ31AP001/32AP001/33AP001/34AP001) ............................... 131
4.4 CLARIFIED WATER PUMPS SUCTION VALVES (00HTQ31AA600/32AA600/33AA600/34AA600) 132
4.5 CLARIFIED WATER PUMPS DISCHARGE VALVES (00HTQ31AA601/32AA601/33AA601/34AA601)
132
4.6 CLARIFIED WATER STORAGE TANK DISCHARGE VALVES (00HTQ21AA603/604) ........................ 132
1 REFERENCE DOCUMENTS ........................................................................................................................ 134
2 PROCESS DESCRIPTION ........................................................................................................................... 134
3 CONTROL PHILOSOPHY ........................................................................................................................... 134
4 CONTROLS AND INTERLOCKS .................................................................................................................. 135
4.1 DMCW PUMPS (00HTQ41AP001/00HTQ42AP001/00HTQ43AP001) GROUP SEQUENCE ........... 135
4.1.1 DMCW PUMP GROUP START......................................................................................................... 136
4.1.2 DMCW PUMP GROUP STOP .......................................................................................................... 136
4.2 DMCW PUMPS (00HTQ41AP001/00HTQ42AP001/00HTQ43AP001) ........................................... 137
4.3 DMCW PUMPS DISCHARGE VALVES (00HTQ41AA002/42AA002/43AA002) ............................... 137
4.4 DMCW PUMPS SUCTION VALVES (00HTQ41AA001/00HTQ42AA001/00HTQ43AA001) ............ 138
4.5 DMCW PUMPS RECIRCULATION VALVE (00HTQ48AA001) .......................................................... 138
4.6 NAOH TANK AGITATOR (00HTS11AM001).................................................................................... 139
4.7 COOLING WATER OVERHEAD TANK INLET MOV (00HTQ40AA002) ............................................. 139
4.8 COOLING WATER OVERHEAD EMERGENCY INLET MOV (00HTQ40AA001) ................................. 140
4.9 ACWPUMPS (00HTQ51AP001/52AP001/53AP001/54AP001) GROUP SEQUENCE...................... 140
4.9.1 ACW PUMP GROUP START ............................................................................................................ 140

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110104
Page 11 of 145
Control Philosophy of FGD system
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’ 22

4.9.2 ACW PUMP GROUP STOP .............................................................................................................. 141

4.10 ACWPUMPS (00HTQ51AP001/52AP001/53AP001/54AP001) ..................................................... 141
4.11 ACW PUMPS DISCHARGE VALVES (00HTQ51AA002/52AA002/53AA002/54AA002).................. 142
4.12 ACW PUMPS SUCTION VALVES (00HTQ51AA001/52AA001/53AA001/54AA001) ..................... 142
4.13 ACW PUMPS RECIRCULATION VALVE (00HTQ60-AA001) ............................................................. 143
4.14 PROCESS WATER TANK MAKEUP WATER LEVEL CONTROL VALVE (00HTQ01AA300) ................ 143

Section 14 Compressed Air System ............................................................................................. 144

1 REFERENCE DOCUMENTS ........................................................................................................................ 145
2 PROCESS DESCRIPTION ........................................................................................................................... 145
3 CONTROLS AND INTERLOCKS .................................................................................................................. 145
4 COMPRESSED AIR DISTRIBUTION ........................................................................................................... 145

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

Section-1 Flue Gas System

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-L-001A
(ii) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(iii) P&ID - Flue Gas Ducting and Dampers System, DVC Doc. No. 2109-122-PVM-F-006
(iv) P&ID for Booster Fan, DVC Doc. No. 2109-122-PVM-F-020

2 PROCESS DESCRIPTION

The flue gas from FGD Terminal Point will be taken to the FGD system through the FGD Booster Fans.
The pressure at FGD terminal point is considered as 0 mmWC. The Booster Fans will operate in
tandem with the ID Fan, to compensate the gas pressure drop in the FGD system and maintain the
Booster Fan suction pressure at a pre-defined value. The Flue Gas Duct & Dampers system for each
Unit comprises of –

(i) Booster fans (2 x 50%) – Constant speed, Axial type with variable blade pitch control
(ii) Motorized Inlet and Outlet dampers for each Booster fan
(iii) Pneumatic FGD Bypass damper
(iv) Low Height Wet Stack – with Continuous Emission Monitoring System

2.1 CONTROL PHILOSOPHY

The JBR is ready to receive flue gas after the JBR start is complete. The flue gas path through JBR is
gradually established by starting both Booster fans (and its auxiliaries) one after the other with its
1 blades in minimum position (25° approx.). After the Booster fans are taken in line, the FGD Bypass
damper is gradually closed and both Booster fans start modulating its blade pitch, to maintain the
Booster fan suction pressure at pre-defined set-point.

3 CONTROLS AND INTERLOCKS:

3.1 FGD FLUE GAS GROUP

The FGD Flue Gas Group integrates the operation of the Booster fan groups, Bypass damper and Flue
gas related Absorber controls.

The FGD Flue Gas Group structure is envisaged as shown below –

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

FGD Flue
Gas Group

FGD Bypass JBR Limestone

Booster Fan Groups
Damper JBR Washing Group Feed Control
(similar group is applicable
each for BUF-A/B) (Details included in Section-2,
Absorber System)

BUF Inlet Damper & Auxiliaries Riser & Wall Wash Valves

Booster Fan & Auxiliaries Upper Deck Wash Valves

BUF Outlet Damper & Auxiliaries Mist Eliminator Wash Valves

3.1.1 FGD FLUE GAS GROUP START

(a) Group Start Permissive

(i) Booster fan-A & Booster fan-B Group Start Permissive available AND
(ii) FGD Bypass damper open AND
(iii) Absorber (JBR) Group Start complete AND
(iv) Limestone Slurry Preparation Group Start complete AND
1 (v) Mist Eliminator header wash valve open AND
(vi) FGD ready acknowledge available from Plant DCS

(b) Group Start Command:

The FGD Flue Gas Group Start will be initiated by Operator manually

(c) Group Start Sequence:

(i) Step-1: Booster fan-A Group start command
(ii) Step-2: Booster fan-B Group start command
(iii) Step-3: JBR pH control enable command
(iv) Step-4: JBR Washing Group start command (refer Section-2 Absorber System for JBR Washing
Group details)
(v) Step-5: Gradually release Blade pitch actuator of Booster fan(s) for regulation in feedforward
control mode
(vi) Step-6: Step-6 is a breakpoint. The Group sequence will halt and wait for Operator intervention
to proceed further. Operator shall initiate command to proceed, after checking that all
1 parameters are stabilized and FGD Bypass Damper close can be initiated. On receiving this
signal, the Group startup sequence will issue FGD Bypass damper close command (closing time
shall be set during commissioning, in tandem with Booster fan blade opening rate)

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

If Booster fan suction header pressure deviates more than xx mmWC from the set-point value,
shift Booster fan Blade pitch control to Feedforward + Feedback control mode, till the Booster
fan suction pressure reaches within the permissible limit
(vii) Step-7: After FGD Bypass damper is fully closed, shift Booster fan Blade pitch control to
Feedforward + Feedback control mode

The FGD Flue Gas Group Start will be considered complete when all the above sequenced steps are
completed successfully.

3.1.2 FGD FLUE GAS GROUP STOP

(a) Group Stop Permissive: None

(b) Group Stop Command:

The FGD Flue Gas Group Stop will be initiated by Operator manually OR automatically in either of
the following conditions:
(i) FGD Bypass Damper opens OR
(ii) Boiler load > 60% and one BUF trips

(c) Group Stop Sequence:

(i) Step-1: FGD Bypass damper Actuator open command. Shift Booster fan(s) blade pitch actuator
to feedforward control mode. If Booster fan suction header pressure deviates more than xx
mmWC from the set-point value, shift Booster fan Blade pitch control to Feedforward +
Feedback control mode, till the Booster fan suction pressure reaches within the permissible
limit.
(ii) Step-2: After FGD Bypass damper is fully opened, Booster fan-A Group stop command
(iii) Step-3: Booster fan-B Group stop command
(iv) Step-4: JBR pH control disable command
(v) Step-5: JBR Washing Group stop command (refer Section-2 Absorber System for JBR Washing
Group details)

The FGD Flue Gas Group stop will be considered complete when all the above sequenced steps are
completed successfully.

3.2 BOOSTER FAN (BUF) GROUP SEQUENCE

The Booster Fan (BUF) Group Sequence integrates the operation of the Booster fan and all its
auxiliaries, along with the Booster fan Inlet and Outlet damper. Below listed is the sequence of
operation for Booster Fan-A Group. Similar sequence will be applicable for Booster Fan-B also.

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

3.2.1 BOOSTER FAN-A GROUP START

1
(a) Group Start Permissive:
(i) BUF-A Start Permissive Set-1 (refer Clause 3.3 (a) (i)) available AND
(ii) BUF-A Outlet damper closed & healthy
(b) Group Start Command:
BUF-A Group Start can be initiated by Operator manually or on receiving Auto-start command from
FGD Flue Gas Group start (refer Clause 3.1.1) sequence.

(c) Group Start Sequence:

(i) Step-1: BUF-A Outlet damper open command
(ii) Step-2: BUF-A Blade pitch set to fixed minimum position
(iii) Step-3: BUF-A motor start command
(iv) Step-4: After preset time (15 secs), BUF-A Inlet damper open command
The BUF-A Group Start will be considered complete when all the above sequenced steps are
completed successfully. Accordingly, ‘BUF- A in service’ signal will be generated when BUF-A is
running and its inlet & outlet dampers are open.

3.2.2 BOOSTER FAN-A GROUP STOP

(a) Group Stop Permissive:

None

(b) Group Stop Command:

BUF-A Group Stop can be initiated by Operator manually or on receiving Auto-stop command from
FGD Flue Gas Group Stop (refer Clause 3.1.2) sequence.

(c) Group Stop Sequence:

(i) Step-1: BUF-A Blade pitch set to fixed minimum position
(ii) Step-2: BUF-A Inlet damper close command
(iii) Step-3: BUF-A motor stop command
1 (iv) Step-4: After preset time, BUF-A Outlet damper close command
The BUF-A Group Stop will be considered complete when all the above sequenced steps are
completed successfully.

3.3 BOOSTER FANS (TAG: 07HTC11AN001 / 07HTC21AN001)

(a) Start Permissive:

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

Booster fan will get Start Permissive when all conditions listed below in Start Permissive Set-1 & Set-
2 are available

(i) Start Permissive Set-1

• Absorber (JBR) Group Start complete
• Respective Booster fan Inlet Damper closed & healthy AND
• Respective Booster fan motor ready to start AND
• Respective Booster fan Drive end Radial bearing temperature not high (≤ 85 Deg. C) AND
• Respective Booster fan Non-Drive end Radial bearing temperature not high (≤ 85 Deg. C) AND
• Respective Booster fan Non-Drive end Thrust bearing temperature not high (≤ 85 Deg. C) AND
• Respective Booster fan blade pitch actuator healthy AND
• Respective Booster fan Blade Pitch Actuator in minimum position AND
• Respective Booster fan External regulating arm - Blade Pitch Torque switch not activated AND
• Respective Booster fan motor Drive end bearing temperature not high (≤ 85 Deg. C) AND
• Respective Booster fan motor Non-Drive end bearing temperature not high (≤ 85 Deg. C) AND
1 • Respective Booster fan motor winding temperature not high (≤ 125 Deg. C) AND
• Respective Booster fan Seal Air fan (any one) running for more than 30 min. AND
• Second booster fan’s Seal Air fan (any one) running AND
• Respective Booster fan oil pump running (any one) for more than 30 mins

(ii) Start Permissive Set-2

• Respective Booster fan Outlet Damper open AND
1 • Respective Booster fan diffuser (between inside cylinder and flue gas path) seal air differential
pressure not low (≥ 25 mmWC) AND
• Respective Booster fan oil pump running (any one) and oil pressure > 7 kg/cm2
• Respective Booster fan lube oil flow not low

(b) Stop Permissive:

Respective Booster fan Blade Pitch Actuator in minimum position

(c) Auto Start Command:

From respective Booster fan Group Start (refer Clause 3.2) Sequence

(d) Auto Stop Command:

From respective Booster fan Group Stop (refer Clause 3.2) Sequence

(e) Override Trip Command:

(i) FGD Inlet (Booster Fan suction header) pressure very high OR
(ii) FGD Inlet (Booster Fan suction header) pressure very low OR

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

(iii) JBR Inlet Plenum temperature very high (>69 Deg. C) OR

(iv) All Gas cooling pumps stopped for more than preset time OR
(v) JBR Emergency Quench valve in open condition and Booster fan blades in minimum position for
more than 17 mins, OR
(vi) Respective Booster fan Stall protection activated (Stall measurement Differential pressure > 50
mmWC for more than 120 sec) OR
(vii) Respective Booster fan Drive end Radial bearing temperature very high (> 100 Deg. C) OR
(viii) Respective Booster fan Non-Drive end Radial bearing temperature very high (> 100 Deg. C) OR
(ix) Respective Booster fan Non-Drive end Thrust bearing temperature very high (> 100 Deg. C) OR
(x) Respective Booster fan bearing vibration very high (> 7.2 mm/s) OR
(xi) Respective Booster fan motor Drive end bearing temperature very high (> 90 Deg. C) OR
(xii) Respective Booster fan motor Non-Drive end bearing temperature very high (> 90 Deg. C) OR
1 (xiii) Respective Booster fan motor winding temperature very high (> 130 Deg. C) OR
(xiv) Respective Booster fan motor bearing vibration very high (> 7.1 mm/s) OR
(xv) Booster Fan Inlet Damper not open for more than preset time OR
(xvi) Booster Fan Outlet damper not open for more than preset time

(f) Modulating Control:

Control Action – Direct Acting

The flue gas flow rate to the Absorber will be controlled by adjusting the variable blade pitch of the
Booster fans, to meet the required Booster fan suction header pressure with feedforward control
based on Boiler air flow (FD Fan air flow), Boiler draft control signal and Absorber (JBR) level.
i. Set-point – Preset Pressure value (0 mmWC)
ii. Feedback – Booster fan suction header pressure

The Booster Fan Blade pitch control will be shared between both the Booster fans, and will have the
following control modes:
(a) Minimum position mode: In this mode, the Booster fan blades will be given minimum position
command (25° approx.). This mode will be in operation in either of the following conditions –
(i) During Booster fan start (as per command from respective BUF Group start sequence) OR
1 (ii) During Booster fan stop (as per command from respective BUF Group stop sequence) OR
(iii) JBR Inlet Plenum temperature rises > 67 Deg. C OR
(iv) Emergency Quench Water to JBR Valve (07HTD12AA100) open
(v) Boiler Master Fuel Trip (MFT) condition occurs
(vi) Respective Booster Fan Inlet Damper not open
(vii) Respective Booster Fan Outlet Damper not open

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

(b) Feedforward Control mode: In this mode, the BUF blade pitch will be operated in feedforward
control based on Boiler air flow (FD Fan air flow), Boiler draft control signal and Absorber (JBR)
level. This mode will be in operation when the Bypass damper is not closed
(c) Feedforward + Feedback Control mode: In this mode, the BUF blade pitch will be controlled
based on feedback of the Booster fan suction pressure, in addition to the Feedforward control
action. This mode will be in operation in either of the following conditions –
(i) FGD Bypass damper is completely closed
(ii) FGD Bypass damper closing / opening in progression & Booster fan suction header pressure
deviates more than xx mmWC from the set-point value.
(d) Stall Protection mode: This mode will be activated in case of Stall warning alarm in either of the
Booster fans. In this mode, the blade pitch angle of both Booster fans will be reduced till the Stall
warning alarm ceases. (During this condition, it is recommended to reduce the Boiler load in
proportion to the reduction in BUF blade pitch angle, for stable operation OR to initiate FGD
Bypass)

3.4 FGD BYPASS DAMPER (TAG: 07HTA51AA001)

Fail condition: Fail Open

(a) Open Permissive:

None

(b) Close Permissive:

(i) JBR Inlet Plenum temperature not high AND
(ii) JBR Emergency quench not in operation (Emergency Quench valve closed) AND
(iii) FGD in service i.e.
a. Boiler load < 60% AND BUF-A or B in service OR
b. Boiler load > 60% AND both BUFs in service

(c) Auto Open Command:

From FGD Flue Gas Group Stop (refer Clause 3.1.2) Sequence

(d) Auto Close Command:

From FGD Flue Gas Group Start (refer Clause 3.1.1) Sequence

(e) Override Open Command:

(i) Booster fan suction pressure high OR
(ii) Booster fan suction pressure low OR
(iii) All Booster Fans stopped OR
(iv) JBR Inlet Plenum temperature high (> 67 Deg. C) OR

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

(v) All ID fans stopped OR

(vi) All FD fans stopped OR
(vii) Boiler Master Fuel Trip (MFT) generated OR
(viii) Stall warning alarm generated in any BUF OR
(ix) Boiler load > 60% AND any one Booster fan not in service OR
(x) Boiler load > 60% and one BUF trips

(If during Boiler load > 60%, one BUF trips and Bypass damper does not within 20secs, Boiler runback
may need to be initiated)

(f) Override Close Command:

1
None
(Controls of Damper auxiliaries shall be as specified in Damper vendor documents)

3.5 BOOSTER FAN INLET DAMPERS (TAG: 07HTA11AA001 / 07HTA21AA001)

Fail condition: Fail-In-Place

(a) Open Permissive:

Respective Booster Fan running (Motor ON) AND

(b) Close Permissive:

(i) Respective Booster Fan not running OR respective Booster Fan running with Blade pitch at
minimum position AND
(ii) FGD Bypass damper open OR Alternate Booster fan in line (Booster fan running with inlet &
outlet dampers open)

(c) Auto Open Command:

From respective Booster fan Group Start (refer Clause 3.2) Sequence

(d) Auto Close Command:

From respective Booster fan Group Stop (refer Clause 3.2) Sequence

(e) Override Open Command:

None

(f) Override Close Command:

1 Respective BUF tripped (electrical trip or BUF motor stopped due to BUF Override trip command)

(Controls of Damper auxiliaries shall be as specified in Damper vendor documents)

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DVC DOC NO. 2109-122-PVM-G-006 Section-1 Flue Gas System Rev. 01 21 Jan’ 22

3.6 BOOSTER FAN OUTLET DAMPERS (TAG: 07HTA12AA001 / 07HTA22AA001)

Fail condition: Fail-In-Place

(a) Open Permissive:

None

(b) Close Permissive:

Respective Booster Fan not running (Motor OFF)

(c) Auto Open Command:

From respective Booster fan Group Start (refer Clause 3.2) Sequence

(d) Auto Close Command:

From respective Booster fan Group Stop (refer Clause 3.2) Sequence

(e) Override Open Command:

None

(f) Override Close Command:

Preset time after respective BUF tripped (electrical trip or BUF motor stopped due to BUF Override
1 trip command)

(Controls of Damper auxiliaries shall be as specified in Damper vendor documents)

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DVC DOC NO. 2109-122-PVM-G-006 Section-2 Absorber System Rev. 01 21 Jan’ 22

Section-2 Absorber System

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DVC DOC NO. 2109-122-PVM-G-006 Section-2 Absorber System Rev. 01 21 Jan’ 22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-L-001A
(ii) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109‐121‐POM‐A‐001
(iii) P&ID of Absorber System, DVC Doc. No. 2109-122-PVM-F-004A
(iv) P&ID of Mist Eliminator, DVC Doc. No. 2109-122-PVM-F-004E

2 PROCESS DESCRIPTION

The Chiyoda Thoroughbred – 121 (CT‐121) process Absorber is known as the Jet Bubbling Reactor
(JBR). The adiabatically cooled flue gas from the Gas Cooler enters the JBR’s inlet plenum, then flows
down through multiple gas Sparger Tubes into the Jet Bubbling Zone.

Five processes occur simultaneously in the JBR:

1. Absorption of SO2
2. Oxidation of Sulfurous Acid to Sulfuric Acid
3. Limestone dissolution
4. Neutralization of acid sulfates to form Gypsum
5. Growth of Gypsum crystals
All the above processes take place inside the slurry tank of the JBR. The tank may be divided into two
zones viz. Jet Bubbling zone and Reaction zone.

The SO2 laden gas coming out of the Gas Sparger tubes bubbles through the slurry and gets dissolved
in water forming H2SO3 in the Jet Bubbling zone. The aqueous Oxygen present in the slurry (through
continuous sparging of Oxidation Air) in Jet Bubbling zone transforms Sulphate (𝑆𝑂3− ) to Sulphate
(𝑆𝑂42− ). Calcium ion from dissolved Limestone reacts with Sulphate producing Gypsum (CaSO4.2H2O)
and Carbon dioxide. Oxygen present in the Oxidation Air drives away the dissolved Carbon dioxide
from the slurry which increases the reaction rate of limestone. In JBR, unlike Spray tower process,
simultaneous perfect oxidation produces directly Calcium Sulphate (𝐶𝑎𝑆𝑂4 ) without formation of
1
Calcium Sulphate (𝐶𝑎𝑆𝑂3 . 2 𝐻2 𝑂) in bubbling zone.

Different reactions that take place in the two zones are mentioned below.

Chemistry in Jet Bubbling Zone:

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𝑆𝑂2 (𝑔)  𝑆𝑂2 (𝑎𝑞)

𝑆𝑂2 (𝑎𝑞) + 𝐻2 𝑂  𝐻2 𝑆𝑂3

𝐻2 𝑆𝑂3  𝐻𝑆𝑂3− + 𝐻 +
1
𝐻𝑆𝑂3− + 𝑂 (𝑎𝑞)  𝑆𝑂42− + 𝐻 +
2 2
𝐶𝑎𝐶𝑂3 (𝑆)  𝐶𝑎𝐶𝑂3 (𝑎𝑞)

𝐶𝑎𝐶𝑂3 (𝑎𝑞) + 2𝐻 +  𝐶𝑎2+ + 𝐶𝑂2 (𝑔) + 𝐻2 𝑂

𝐶𝑎2+ + 𝑆𝑂42− + 2𝐻2 𝑂  𝐶𝑎𝑆𝑂4 . 2𝐻2 𝑂

Chemistry in Reaction Zone

𝑂2 (𝑔)  𝑂2 (𝑎𝑞)
1
𝐻𝑆𝑂3− + 𝑂 (𝑎𝑞)  𝑆𝑂42− + 𝐻 +
2 2
𝐶𝑎𝐶𝑂3 (𝑆)  𝐶𝑎𝐶𝑂3 (𝑎𝑞)

𝐶𝑎𝐶𝑂3 (𝑎𝑞) + 2𝐻 +  𝐶𝑎2+ + 𝐶𝑂2 (𝑔) + 𝐻2 𝑂

𝐶𝑎2+ + 𝑆𝑂42− + 2𝐻2 𝑂  𝐶𝑎𝑆𝑂4 . 2𝐻2 𝑂

𝐶𝑎𝑆𝑂4 . 2𝐻2 𝑂  𝐶𝑟𝑦𝑠𝑡𝑎𝑙 𝐺𝑟𝑜𝑤𝑡ℎ

HCl, HF and SO3 in the flue gas also reacts with limestone solution inside JBR producing Calcium
Chloride, Calcium Fluoride and Calcium Sulphate. Almost complete (~ 100%) HCl and HF present in
the gas and around 50% of SO3 is removed in the JBR.

𝐶𝑎𝐶𝑂3 (𝑎𝑞) + 2𝐻𝐶𝑙  𝐶𝑎𝐶𝐿2 + 𝐶𝑂2 (𝑔) + 𝐻2 𝑂

𝐶𝑎𝐶𝑂3 (𝑎𝑞) + 2𝐻𝐹  𝐶𝑎𝐹2 + 𝐶𝑂2 (𝑔) + 𝐻2 𝑂

The fine Ash particles in the flue gas coming out of ESP enters the JBR and JBR is very efficient in
collecting even the sub-micron dust due to the improved solid-liquid contacting created by high gas
side pressure drop and large gas-liquid contacting area of bulk of fine bubbles. Unlike Spray tower,
the collection efficiency of dust is typically more than 70%. However, higher dust collection reduces
the quality of Gypsum produced.

Oxidation air for gypsum formation is provided by Oxidation Air Blowers and is distributed
throughout the reaction zone of the JBR. Water is continuously injected into each oxidation air lines

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just before it enters the JBR to humidify the air in order to prevent scale formation at the oxidation
air outlets.

The JBR is equipped with top-entry agitators for suspending gypsum and circulating fresh limestone
slurry into the froth zone.

The flue gas leaving the jet bubbling zone passes upward through Gas Risers into the Outlet Plenum,
and further into the Mist Eliminator.

In the outlet plenum, the entrained mist in the flue gas is minimized by disengagement mechanism
derived from gravity.

The JBR inlet plenum (Gas Riser and JBR side wall) and Upper Deck floor are intermittently washed
with process water to prevent the built up of slurry solids. The wash water is drained to the JBR
reaction zone. The Lower Deck floor is continuously washed with slurry from the discharge of the gas
cooling pumps. The slurry flows down inside of the Sparger tubes to the reaction zone.

A portion of gypsum slurry in the JBR is discharged to the primary hydrocyclone feed tank by the
gypsum bleed pump and the slurry concentration in the JBR is maintained around 20 weight percent.

2.1 CONTROL PHILOSOPHY

As SO2 absorption occurs in the JBR, the JBR slurry pH decreases. The pH value in JBR Jet bubbling
zone is maintained at pre-set value, by modulating the Limestone Slurry feed to the JBR. Control
valves 07HTK01AA300 & 07HTK01AA301 operate in split-range mode to control the Limestone slurry
feed to JBR to maintain the required pH. During JBR operation, the JBR internals are intermittently
washed using process water. The wash valves of Riser & walls, Upper Deck & Mist Eliminator will be
opened and closed one after the other in an iterative sequence, throughout the JBR operation.

3 CONTROLS AND INTERLOCKS:

3.1 ABSORBER (JBR) GROUP

The Absorber (JBR) Group integrates the operation and control of the Absorber (JBR) and all its
auxiliaries. The JBR Group structure is envisaged as shown below –

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JBR Group

Gas Cooling Pump Groups Oxidation Air

Oxidation Air Blowers Humidifcation Water
(similar group is applicable JBR Agitators
& its Auxiliaries Valve
each for GCP-A/B/C)

GCP Suction Valve

Gas Cooling Pump

GCP Discharge Valve

GCP Drain Valve

GCP Wash Valve

3.1.1 JBR GROUP START

(a) Group Start Permissive:

(i) FGD Flue Gas group in stopped condition
(ii) Any one Limestone Slurry feed pump running AND Limestone Slurry pump header pressure
normal, AND
(iii) Any one Gypsum Bleed pump running AND Gypsum Bleed header pressure normal, AND
(iv) Any one Process water pump running AND Process water header pressure normal, AND
(v) Any one Filtrate water pump running AND Filtrate water header pressure normal, AND
(vi) Any one Clarified water pump running AND Clarified water header pressure normal, AND
(vii) Any one DMCW pump running AND DMCW header pressure & temperature normal, AND
(viii) Instrument Air pressure normal AND
(ix) Gas Cooling pump (any two) Group Start Permissive available AND
(x) Oxidation Blower (any one) healthy AND
(xi) JBR level > xx mm AND
(xii) All JBR agitators healthy AND
(xiii) Emergency Tank level High AND Emergency tank outlet manual valve (07HTD12AA603) open
(xiv) JBR Limestone Slurry Distributor Vent Valve (07HTD51AA600) open
(xv) JBR Upper Deck-wash Isolation Valve (07HTD31AA600) open

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DVC DOC NO. 2109-122-PVM-G-006 Section-2 Absorber System Rev. 01 21 Jan’ 22

(xvi) JBR Riser & Wall wash Isolation Valve (07HTD41AA600) open

(b) Group Start Command:

The JBR Group Start will be initiated by Operator manually

(c) Group Start Sequence:

(i) Step-1: Primary Gas Cooling Pump (GCP) Group start command (refer Section-3, Gas Cooling
System for GCP Group details)
(ii) Step-2: Secondary Gas Cooling Pump (GCP) Group start command
(iii) Step-3: After any two Gas Cooling Pumps are running & GCP header pressure is normal,
Oxidation Air Humidification Water Isolation Valve open command
(iv) Step-4: Primary Oxidation Air Blower start command
(v) Step-5: All JBR Agitators start command
The JBR Group Start will be considered complete when all the above sequenced steps are completed
successfully.

3.1.2 JBR GROUP STOP

(a) Group Stop Permissive:

FGD Flue Gas group in stopped condition

(b) Group Stop Command:

The JBR Group Stop will be initiated by Operator manually

(c) Group Stop Sequence:

(i) Step-1: All JBR Agitators stop command
(ii) Step-2: After preset time, Oxidation Blower stop command
(iii) Step-3: Oxidation Air Humidification Water Isolation Valve close command
(iv) Step-4: After preset time, Primary Gas Cooling Pump (GCP) Group stop command (refer Section-
3, Gas Cooling System for GCP Group details)
(v) Step-5: Secondary Gas Cooling Pump (GCP) Group stop command
The JBR Group Stop will be considered complete when all the above sequenced steps are completed
successfully.

3.2 JBR AGITATORS (TAG: 07HTD01AM001 / 07HTD01AM002 / 07HTD01AM003 /07HTD01AM004)

(a) Start Permissive:

1 (i) JBR level > xx mm

(b) Stop Permissive:

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DVC DOC NO. 2109-122-PVM-G-006 Section-2 Absorber System Rev. 01 21 Jan’ 22

None

(c) Auto Start Command:

From JBR Group Start Sequence

(d) Auto Stop Command:

From JBR Group Stop Sequence

1 (e) Override Trip Command:

JBR Level < xx mm

3.3 JBR WASH GROUP

The JBR Wash Group integrates the operation of the complete group of JBR wash valves consisting
of –
(i) Riser & Wall Wash valves
1 (ii) Upper Deck & Duct Wash valves
(iii) Mist Eliminator wash valves

(a) Group Start Permissive:

JBR Mist Eliminator Wash Isolation Valve 07HTD70AA100 open

(b) Group Start Command:

From FGD Flue Gas Group Start Sequence (refer Section-1, Flue Gas & Damper System for FGD Flue
Gas Group details)

(c) Group Stop Command:

From FGD Flue Gas Group Stop Sequence (refer Section-1, Flue Gas & Damper System for FGD Flue
Gas Group details)

(d) Group Operation Sequence:

The JBR Wash Group sequence is an iterative time-based sequence.
It shall start on receiving Group start command and continue repeating the complete sequence till
the Group stop command is received.
The JBR Washing will be implemented in following sequence –
Riser & Wall Wash Group → Upper Deck & Duct Wash Group-1 → Riser & Wall Wash Group → Mist
1 Eliminator 1st Stage Front side Wash Group → Riser & Wall Wash Group → Upper Deck & Duct Wash
Group-2 → Riser & Wall Wash Group → Mist Eliminator 1-2 Stage and 2-3 Stage Wash Group
The valves included in each group are detailed in Table-1 below.

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DVC DOC NO. 2109-122-PVM-G-006 Section-2 Absorber System Rev. 01 21 Jan’ 22

The valves of the JBR Wash Group shall open and close sequentially (one after the other), as per
below timing sequence (Table-1). The Valve close time (Tc) for each valve depends on the Boiler load
operation. At low Boiler load, the valves shall follow close time as per time Tc1 (as indicated in Table-
1). When the Boiler air flow > xx, the valve close time shall be changed to time Tc2 (as indicated in
Table-1).
If any valve fails to open or close on receiving command, an Alarm will be generated for Operator’s
attention, however, the sequence of operation will continue.
(The proposed sequence and Valve open/close time may be revised further based on Mist Eliminator
vendor recommendation)

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Table-1: JBR Wash Group Sequence

Sl. No. Descript Valve Tag Nos. Low Boiler Load High Boiler Load
ion Operation Operation

To (sec) Tc1 (sec) To (sec) Tc2 (sec)

RW-1 07HTD41AA100 30 100 30 50

RW-2 07HTD41AA101 30 100 30 50

RW-3 07HTD41AA102 30 100 30 50

RW-4 07HTD41AA103 30 100 30 50

RW-5 07HTD41AA104 30 100 30 50

RW-6 07HTD41AA105 30 100 30 50

Riser & Wall Wash Group

RW-7 07HTD41AA106 30 100 30 50

RW-8 07HTD41AA107 30 100 30 50

RW-9 07HTD41AA108 30 100 30 50

RW-10 07HTD41AA109 30 100 30 50

RW-11 07HTD41AA110 30 100 30 50

RW-12 07HTD41AA111 30 100 30 50

RW-13 07HTD41AA112 30 100 30 50

RW-14 07HTD41AA113 30 100 30 50

RW-15 07HTD41AA114 30 100 30 50

RW-16 07HTD41AA115 30 100 30 50

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DVC DOC NO. 2109-122-PVM-G-006 Section-2 Absorber System Rev. 01 21 Jan’ 22

UD-1 Upper Deck & Duct Wash 07HTD31AA100 40 140 40 70

UD-2 07HTD31AA101 40 140 40 70

Group-1

UD-3 07HTD31AA102 40 140 40 70

UD-4 07HTD31AA103 40 140 40 70

UD-5 07HTD31AA104 40 140 40 70

UD-6 07HTD31AA105 40 140 40 70

Repeat ‘Riser & Wall Wash Group’ sequence (Sl. No. RW-1 to RW-16)

ME-1 07HTD71AA100 30 140 30 70

Mist Eliminator 1st Stage Wash Group

ME-2 07HTD71AA101 30 140 30 70

ME-3 07HTD71AA102 30 140 30 70

ME-4 07HTD71AA103 30 140 30 70

ME-5 07HTD71AA104 30 140 30 70

ME-6 07HTD71AA105 30 140 30 70

ME-7 07HTD71AA106 30 140 30 70

ME-8 07HTD71AA107 30 140 30 70

Repeat ‘Riser & Wall Wash Group’ sequence (Sl. No. RW-1 to RW-16)

UD-7 07HTD31AA106 40 140 40 70

Upper Deck & Duct Wash

UD-8 07HTD31AA107 40 140 40 70

Group-2

UD-9 07HTD31AA108 40 140 40 70

UD-10 07HTD31AA109 40 140 40 70

UD-11 07HTD31AA110 40 140 40 70

UD-12 07HTD31AA111 40 140 40 70

Repeat ‘Riser & Wall Wash Group’ sequence (Sl. No. RW-1 to RW-16)

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DVC DOC NO. 2109-122-PVM-G-006 Section-2 Absorber System Rev. 01 21 Jan’ 22

ME-9 Mist Eliminator 1st - 2nd Stage Wash Group 07HTD72AA100 30 140 30 70

ME-10 07HTD72AA101 30 140 30 70

ME-11 07HTD72AA102 30 140 30 70

ME-12 07HTD72AA103 30 140 30 70

ME-13 07HTD72AA104 30 140 30 70

ME-14 07HTD72AA105 30 140 30 70

ME-15 07HTD72AA106 30 140 30 70

ME-16 07HTD72AA107 30 140 30 70

Mist Eliminator 2nd – 3rd Stage Wash Group

ME-17 07HTD74AA100 30 140 30 70

ME-18 07HTD74AA101 30 140 30 70

ME-19 07HTD74AA102 30 140 30 70

ME-20 07HTD74AA103 30 140 30 70

ME-21 07HTD74AA104 30 140 30 70

ME-22 07HTD74AA105 30 140 30 70

ME-23 07HTD74AA106 30 140 30 70

ME-24 07HTD74AA107 30 140 30 70

3.4 JBR RISER AND WALL WASH VALVES (TAGS: REFER TABLE-1)
Fail condition: Fail Close

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

From JBR Wash Group

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(d) Auto Close Command:

From JBR Wash Group

(e) Override Open Command:

None

(f) Override Close Command:

None

3.5 JBR UPPER DECK & DUCT WASH VALVES (TAGS: REFER TABLE-1)
1
Fail condition: Fail Close

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

From JBR Wash Group

(d) Auto Close Command:

From JBR Wash Group

(e) Override Open Command:

None

(f) Override Close Command:

None

3.6 JBR MIST ELIMINATOR WASH VALVES (TAGS: REFER TABLE-1)

Fail condition: Fail Close

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

From JBR Wash Group

(d) Auto Close Command:

From JBR Wash Group

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(e) Override Open Command:

None

(f) Override Close Command:

None

3.7 LIMESTONE SLURRY FEED CONTROL VALVES (TAG: 07HTK01AA300 / 07HTK01AA301)

Fail condition: Fail-In-Place

(a) Open Permissive:

Limestone Slurry feed Isolation Valve 07HTK01AA001 Open (this permissive is applicable only for
1 Control Valve 07HTK01AA300)

(b) Close Permissive:

None

(c) Override Open Command:

None

(d) Override Close Command:

None

(e) Modulating Control:

Control Action – Reverse Acting

The Limestone Slurry Feed Control Valves will operate in split control mode to maintain JBR liquid
pH at pre-set value of xx.

(i) Standalone mode – This valve will be given a preset Flow set-point (0 m3/hr), when all Booster
fans are in stopped condition.
(ii) Cascade mode – This valve will be in Cascade mode if any of the Booster fans are running. In
cascade mode, JBR pH control will be the master loop, and the Limestone slurry feed flow
control will be the slave loop.

a. Master control – JBR pH control:

i. Set-point – The set-point for JBR pH control will be xx.
ii. Feedback – JBR pH
The pH controller gain will be modulated based on feedforward signal of Boiler Air flow & JBR
Inlet SO2 value

b. Slave control – Limestone slurry feed flow control

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i. Set-point – JBR pH master controller output biased with feedforward signals based on
Boiler Air flow rate, JBR Inlet SO2 & rate of change of Generator Output (demand)
ii. Feedback – Limestone Slurry feed flow to JBR
Control valves 07HTK01AA300 & 07HTK01AA301 will operate in split control mode. Small capacity
Valve 07HTK01AA301 will operate till xx% controller output. Beyond xx%, the control will be
bumplessly transferred to large capacity Valve 07HTK01AA300 for further control.

Control valve freeze protection: Both control valves will be full opened twice in a day for 20 secs, to
prevent the Control valves from freezing.

Alarm for Higher Limestone Consumption: If the Limestone slurry flow rate (moving average value
for 10 mins) to JBR is more than twice of the theoretical Limestone demand (calculated based on the
Boiler air flow & JBR Inlet SO2 value), an Alarm indicating Limestone Higher demand will be generated.

3.8 JBR MIST ELIMINATOR WASH ISOLATION VALVE (TAG: 07HTD70AA100)

Fail condition: Fail Close

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

None

(d) Auto Close Command:

None

(e) Override Open Command:

None

(f) Override Close Command:

None

3.9 JBR DRAIN VALVES (TAG: 07HTT01AA100 / 07HTT01AA101)

1 Fail condition: Fail Close

(a) Open Permissive:

None

(b) Close Permissive:

None

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(c) Auto Open Command:

None

(d) Auto Close Command:

None

(e) Override Open Command:

None

(f) Override Close Command:

None

3.10 LIMESTONE SLURRY FEED ISOLATION VALVE (TAG: 07HTK01AA001)

1 Fail condition: Fail-In-Place

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

None

(d) Auto Close Command:

None

(e) Override Open Command:

None

(f) Override Close Command:

None

3.11 LIMESTONE SLURRY FEED BYPASS VALVE (TAG: 07HTK01AA101)

1 Fail condition: Fail-In-Place

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

None

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(d) Auto Close Command:

None

(e) Override Open Command:

None

(f) Override Close Command:

None

3.12 JBR UPPER DECK / RISER / MIST ELIMINATOR WASH FLUSH VALVES (TAG: 07HTD31AA112 /
1 07HTD41AA116 / 07HTD70AA101 / 07HTD76AA101)
Fail condition: Fail Close

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

These valves will be auto opened sequentially once in every 12 hours for few seconds (timing will
be decided during commissioning)

(d) Auto Close Command:

These valves will auto close inline with auto operation specified in ‘Auto Open command' above.

(e) Override Open Command:

None

(f) Override Close Command:

None

3.13 GYPSUM BLEED RECIRCULATION TO ABSORBER ISOLATION VALVE (TAG: 07HTL04AA100)

1 Fail condition: Fail in Place

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

None

(d) Auto Close Command:

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110104 Control Philosophy of FGD system Page 38 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-2 Absorber System Rev. 01 21 Jan’ 22

None

(e) Override Open Command:

None

(f) Override Close Command:

None

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

Section-3 Gas Cooling System

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(iii) P&ID - Gas Cooling system, DVC Doc. No. 2109-122-PVM-F-004F

2 PROCESS DESCRIPTION

The Absorber System consists of horizontal Gas Cooler at the inlet of the Absorber. The hot flue gas
from the Boiler is pressurized by Boost-Up Fans, and is introduced into the Gas Cooler, to quench
and saturate the flue gas with water.

The Gas Cooler is a horizontal flow, inclined duct with spray banks installed inside for co‐current
spraying of cooling liquid. The Gas Cooler mainly uses absorbent slurry for cooling of the gas. Inside
the Gas Cooler, the gas temperature will be reduced from the design inlet temperature to the
saturation temperature. The Gas Cooler is a co‐current spray chamber using one stage of makeup
water sprays, one stage of emergency quench sprays, and two stages of slurry quenching sprays.

The flue gas entering the Gas Cooler is first contacted with makeup water from the makeup water
spray headers. This water keeps the walls and downstream spray headers free of solids build-up. The
amount of makeup water spray is determined by the overall water balance of the FGD system. The
makeup water spray bank in Gas Cooler is divided into two groups – supply header-A & B, to maintain
optimum spray pattern. The supply header-A has an on‐off valve (07HTD11AA100). When the make-
up water flow requirement increases above the set point, the valve (07HTD11AA100) on supply
header-A is opened, and water flows through both supply headers. When the flow requirement
drops below the set point, the valve (07HTD11AA100) is closed, and water flows through supply
header-B only.

In normal operating condition, quenching of the flue gas is consummated by two stages of gypsum
slurry quenching sprays which are the 3rd and 4th bank of spray headers in the Gas Cooler. The Gas
Cooling Pumps (3 X 50%) provide slurry to both these spray headers, and also for JBR lower deck
washing.

The emergency quench sprays are used only in the following emergency conditions:
(v) Temperature sensors located in inlet plenum of JBR detect a rise above 67°C set point
(vi) All gas cooling pumps stopped
(vii) All power source become not available (Black Plant event)
When emergency condition occurs, all the makeup spray headers and all the emergency quench
spray headers will spray at the same time. That is, makeup spray shall also have the role of
emergency quenching.

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

The required amount for emergency quench is designed as the sum of the full capacity of makeup
spray and emergency quench spray. And it is approximately three times of the stoichiometric flow
rate required to quench the flue gas at normal operation condition, considering an excursion
temperature of 300 °C for 15 minutes. The emergency water tank is filled with process water by the
process water pump during normal operating condition.

When Black Plant Event happens, the emergency quench water reserved in the emergency water
tank will be supplied to all the spray headers (makeup header and emergency quench header)
spontaneously by opening the normally closed and failure open valves. Simultaneously, the process
water pump (powered by Emergency backup power system) will start to supply the water shortly.

The Gas Cooler is horizontally mounted and its floor is sloped towards the inlet of the Jet Bubbling
Reactor (JBR). Majority of the sprayed water / slurry is collected on the bottom of the Gas Cooler
and flows by gravity to the JBR via several drain connections provided on the Gas Cooler floor. The
quenched and saturated flue gas and a small amount of the sprayed water / slurry enter the JBR inlet
plenum.

2.1 CONTROL PHILOSOPHY

Flue gas cooling in JBR is achieved through slurry spray in Gas Cooler section, by Gas cooling pumps.
The Gas cooling pumps (2W + 1S) are started during JBR start-up. Slurry spray in Gas Cooler section
starts when the Gas Cooling pumps are taken in line and continues with constant slurry flow, till JBR
shutdown is initiated.

During emergency condition, the JBR Emergency Quench valve (07HTD12AA100) is opened and
water from Emergency tank is supplied to the Gas cooler.

The Gas Cooler section also includes spray header for JBR make-up water. The make-up water is
controlled by modulating the JBR Make-up water level control valve (07HTD11AA300), to maintain
1
JBR level at a set level, as required to meet the SO2 removal efficiency.

3 CONTROLS AND INTERLOCKS:

3.1 GAS COOLING PUMP (GCP) GROUP SEQUENCE

The Gas Cooling Pump (GCP) Group Sequence integrates the operation of the complete train of
respective Gas cooling pump including its suction valve, discharge valve, drain valve and wash valve.
Below listed is the sequence of operation for Gas Cooling Pump-A Group. Similar operation
philosophy will be applicable for Gas Cooling Pumps-B / C and their corresponding valves also.

3.1.1 GAS COOLING PUMP-A GROUP START

(a) Group Start Permissive:

(i) GCP-A Suction valve closed & healthy AND

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

(ii) GCP-A start permissive available (except for GCP suction valve open status)

(b) Group Start Command:

GCP-A Group Start can be initiated by Operator manually or on receiving Auto-start signal in either
of the following conditions –
(i) From JBR Group Start-up sequence OR
(ii) GCP-A on standby and Running GCP trips (electrical trip or GCP stop due to Override Trip
command)

(c) Group Start Sequence:

(i) Step-1: GCP-A suction valve open command
(ii) Step-2: GCP-A start command
(iii) Step-3: After preset time (as per GCP OEM recommendation), GCP-A discharge valve open
command
The GCP-A Group Start will be considered complete when all the above sequenced steps are
completed successfully.

3.1.2 GAS COOLING PUMP-A GROUP STOP

(a) Group Stop Permissive:

None

(b) Group Stop Command:

GCP-A Group Stop can be initiated by Operator manually or on receiving Auto-stop signal in either
of the following conditions –
(i) From JBR Group Shutdown sequence OR
(ii) JBR level < xx mm OR
1 (iii) GCP-A stopped

(c) Group Stop Sequence:

(i) Step-1: GCP-A discharge valve close command
(ii) Step-2: GCP-A stop command
(iii) Step-3: GCP-A suction valve close command
(iv) Step-4: GCP-A drain valve open command
(v) Step-5: GCP-A wash valve open command
(vi) Step-6: GCP-A wash valve close command after xx secs
(vii) Step-7: GCP-A drain valve close command
GCP-A group stop shall be considered complete when all the above sequenced steps are completed
successfully.

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

3.2 GAS COOLING PUMPS (TAG: 07HTH11AP001 / 07HTH21AP001 / 07HTH31AP001)

(a) Start Permissive:

(i) JBR level > xx mm AND
(ii) GCP-A Suction valve open AND
(iii) GCP-A Discharge valve closed & healthy AND
(iv) GCP-A Drain valve closed AND
(v) GCP-A Wash valve closed AND
(vi) GCP-A Bearing temperature not high (< xx DegC) AND
1 (vii) GCP-A Motor bearing temperature not high (< 100 DegC) AND
(viii) GCP-A Motor winding temperature not high (< 140 DegC)

(b) Stop Permissive:

None

(c) Auto Start Command:

From respective Gas Cooling pump (GCP) Group Start Sequence

(d) Auto Stop Command:

From respective Gas Cooling pump (GCP) Group Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than xx secs
OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) JBR level < xx mm OR
(iv) GCP-A Bearing temperature very high (> xx DegC) OR
(v) GCP-A Bearing vibration very high (> xx mm/s) OR
(vi) GCP-A Motor bearing temperature very high (> 105 DegC) OR
1 (vii) GCP-A Motor winding temperature very high (> 160 DegC) OR
(viii) GCP-A Motor vibration very high (> xx mm/s)

3.3 GCP SUCTION ISOLATION VALVES (TAG: 07HTH11AA001 / 07HTH21AA001 / 07HTH31AA001)

Fail condition: Fail-In-Place

(a) Open Permissive:

None

(b) Close Permissive:

Respective GCP not running

(c) Auto Open Command:

From respective Gas Cooling pump (GCP) Group Start Sequence

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

(d) Auto Close Command:

From respective Gas Cooling pump (GCP) Group Stop Sequence

(e) Override Open Command:

None

(f) Override Close Command:

None

3.4 GCP DISCHARGE ISOLATION VALVES (TAG: 07HTH11AA002 / 07HTH21AA002 / 07HTH31AA002)

Fail condition: Fail-In-Place

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

From respective Gas Cooling pump (GCP) Group Start Sequence

(d) Auto Close Command:

From respective Gas Cooling pump (GCP) Group Stop Sequence

(e) Override Open Command:

None

(f) Override Close Command:

None

1 3.5 GCP DRAIN VALVES (TAG: 07HTH11AA100 / 07HTH21AA100 / 07HTH31AA100)

Fail condition: Fail Close

(a) Open Permissive:

Respective pump not running

(b) Close Permissive:

(c) Respective wash valve closed Auto Open Command:

From respective Gas Cooling pump (GCP) Group Stop Sequence

(d) Auto Close Command:

From respective Gas Cooling pump (GCP) Group Stop Sequence

(e) Override Open Command:

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

None

(f) Override Close Command:

None

1 3.6 GCP WASH VALVES (TAG: 07HTH11AA101 / 07HTH21AA101 / 07HTH31AA101)

Fail condition: Fail Close

(a) Open Permissive:

Respective Pump not running and corresponding drain valve open

(b) Close Permissive:

None

(c) Auto Open Command:

From respective Gas Cooling pump (GCP) Group Stop Sequence

(d) Auto Close Command:

From respective Gas Cooling pump (GCP) Group Stop Sequence

(e) Override Open Command:

None

(f) Override Close Command:

None

1 3.7 EMERGENCY WATER TANK INLET VALVE (TAG: 07HTQ01AA100)

Fail condition: Fail Open

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

Emergency water tank level < x1 mm

(d) Auto Close Command:

Emergency water tank level > y1 mm

(e) Override Open Command:

Emergency water tank level < x2 mm

(f) Override Close Command:

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

Emergency water tank level > y2 mm

3.8 EMERGENCY QUENCH WATER TO JBR VALVE (TAG: 07HTD12AA100)

Fail condition: Fail Open

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

Each day for 30 secs (as per timer sequence), to keep the spray nozzles clean and prevent plugging

(d) Auto Close Command:

As per Timer sequence specified for Auto Open command.
If the Valve opening is due to Override open command, it shall be auto closed when below conditions
are met –
(i) JBR Inlet Plenum temperature < 67 Deg. C for more than 16 minutes or
(ii) Both BUF stopped

(e) Override Open Command:

(i) JBR Inlet Plenum temperature high (> 67Deg. C) OR
(ii) Boost-Up Fan running AND all Gas Cooling Pumps stopped for more than xx secs, OR
(iii) Black Plant Event

(f) Override Close Command:

None

3.9 JBR MAKE-UP WATER LEVEL CONTROL VALVE (TAG: 07HTD11AA300)

1 Fail condition: Fail Open

(a) Open Permissive:

JBR Make-Up Water Level Isolation Valve (07HTD11AA001) open

(b) Close Permissive:

None

(c) Override Open Command:

(i) JBR Inlet Plenum temperature high (> 67 Deg. C) OR
(ii) Boost-Up Fan running AND all Gas Cooling Pumps stopped for more than xx secs, OR
(iii) Black Plant Event

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

(d) Override Close Command:

None

(e) Modulating Control:

Control Action – Reverse Acting

The JBR level will be adjusted to a set level, as required to meet the SO2 removal efficiency by supply
of makeup water at the Gas Cooler.

(i) Manual mode – This valve will be in manual mode when all Boost-Up fans are in stopped
condition. Set-point will be as configured by Operator.
(ii) Cascade mode – This valve will be in Cascade mode if one or both Boost-Up fans are in service.
In cascade mode, the initial set-point will be set at 0m3/hr till Oxidation Blower starts. After
Oxidation Blower (any one) is in service, the set-point will be set based on cascade loop. The
JBR level control will be the master loop, and the Make-up water flow control will be the slave
loop.
b. Master control – JBR level control:
i. Set-point – The set-point for JBR level control will be generated from functional curve
f1(x) based on the JBR Inlet SO2 measured value.
(functional curve f1(x) gives the JBR level set-point value corresponding to the varying JBR
Inlet SO2 value, as required to meet SO2 removal efficiency of 94.25%)
ii. Feedback – JBR level
c. Slave control – Make-Up water flow control
i. Set-point – JBR Level Controller output biased with feed forward signal from functional
curve f2(x) based on Boiler Air flow rate (FD Fan Air flow rate).
(Function curve f2(x) gives the feedforward correction of the estimated make-up water
required for the corresponding to the Boiler air flow)
ii. Feedback – Make-up water flow

3.10 JBR MAKE-UP WATER SPRAY HEADER-A ISOLATION VALVE (TAG: 07HTD11AA100)
Fail condition: Fail Open

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

Make-up water flow requirement > xx m3/hr

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

(d) Auto Close Command:

Make-up water flow requirement < xy m3/hr. If the Valve opening is due to Override open command,
it shall be auto closed when below conditions are met –
(i) JBR Inlet Plenum temperature < 65 Deg. C for more than 16 minutes or
(ii) Both BUF stopped

(e) Override Open Command:

(i) JBR Inlet Plenum temperature high (> 67 Deg. C) for more than xx secs, OR
(ii) Boost-Up Fan running AND all Gas Cooling Pumps stopped for more than xx secs, OR
(iii) Black Plant Event

(f) Override Close Command:

None

3.11 JBR MAKE-UP WATER / EMERGENCY SPRAY HEADER FLUSH VALVE (TAG: 07HTD11AA102 /
1 07HTD12AA101)
Fail condition: Fail Close

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

These valves will be auto opened sequentially once in every 12 hours for few seconds (timing will
be decided during commissioning)

(d) Auto Close Command:

These valves will auto close inline with auto operation specified in ‘Auto Open command' above.

(e) Override Open Command:

None

(f) Override Close Command:

None

3.12 EMERGENCY WATER TANK INLET ISOLATION VALVE (TAG: 07HTQ01AA002 / 07HTQ01AA003)
1 Fail condition: Fail-In-Place

(a) Open Permissive:

None

(b) Close Permissive:

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

None

(c) Auto Open Command:

None

(d) Auto Close Command:

None

(e) Override Open Command:

None

(f) Override Close Command:

None

3.13 EMERGENCY WATER TANK INLET VALVE-B (TAG: 07HTQ01AA101)

1 Fail condition: Fail Open
(a) Open Permissive:
None
(b) Close Permissive:
None
(c) Auto Open Command:
None
(d) Auto Close Command:
None
(e) Override Open Command:
None

(f) Override Close Command:

None

3.14 JBR MAKE-UP WATER ISOLATION VALVE (TAG: 07HTD11AA001 / 07HTD11AA002)

1 Fail condition: Fail-In-Place

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

None

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

(d) Auto Close Command:

None

(e) Override Open Command:

None

(f) Override Close Command:

None

3.15 JBR MAKE-UP WATER INLET VALVE (TAG: 07HTD11AA101)

1 Fail condition: Fail Open`

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

None

(d) Auto Close Command:

None

(e) Override Open Command:

None

(f) Override Close Command:

None

3.16 EMERGENCY QUENCH WATER TO JBR ISOLATION VALVE (TAG: 07HTD12AA001)

1 Fail condition: Fail-In-Place

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Auto Open Command:

None

(d) Auto Close Command:

None

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DVC DOC NO. 2109-122-PVM-G-006 Section-3 Gas Cooling System Rev. 01 21 Jan’ 22

(e) Override Open Command:

None

(f) Override Close Command:

None

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DVC DOC NO. 2109-122-PVM-G-006 Section-4 Oxidation Air System Rev. 01 21 Jan’ 22

Section -4 Oxidation Air System

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DVC DOC NO. 2109-122-PVM-G-006 Section-4 Oxidation Air System Rev. 01 21 Jan’ 22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(iii) P&ID - Oxidation Blower & System, DVC Doc. No. 2109-122-PVM-F-004B

2 PROCESS DESCRIPTION

The Oxidation Air System is provided to supply Oxidation air for Gypsum formation in the Absorber
(JBR). It also helps to agitate the JBR liquid.

The Oxidation Air system for each Unit comprises of –

(iv) Oxidation Blowers (2x 100%) –
(i) Oxidation Air distribution header & nozzles – to distribute Oxidation air throughout the
reaction zone of JBR
(ii) Oxidation Air Humidification water distribution network – for air humidification, in order to
prevent scale formation at the oxidation air outlets, by continuous injection of clarified water
into each oxidation air-line just before it enters the JBR

2.1 CONTROL PHILOSOPHY

Oxidation air to JBR is supplied through Oxidation Blowers (1W +1S). Before starting the Oxidation
Blowers, Oxidation air humidification water supply is started. Subsequently, the Oxidation Blower is
started.

3 CONTROLS AND INTERLOCKS:

3.1 OXIDATION AIR BLOWERS (07HTG01AN001 / 07HTG11AN001)

(a) Start Permissive:

(i) Clarified water flow for humidification is above set value (value to be fixed during
commissioning), AND
(ii) JBR level > xx mm AND
(iii) Atleast one exhaust fan in operation for more than 2 mins. and enclosure temperature < 50
1 DegC, AND
(iv) Respective Oxidation Blower suction filter DP < 300 mmWC AND
(v) Respective Oxidation Blower discharge valve open AND
(vi) Respective Oxidation Blower bearing temperature not high (< 90 Deg C)

(b) Stop Permissive:

None

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110104 Control Philosophy of FGD system Page 54 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-4 Oxidation Air System Rev. 01 21 Jan’ 22

(c) Auto Start Command:

(i) From JBR Group Start sequence OR
(ii) Standby Oxidation Blower auto-start if –
a. Running Oxidation Blower trips (electrical trip or Blower stop due to Override Trip
command)
b. Oxidation Blower running and Oxidation air discharge header pressure becomes low

(d) Auto Stop Command:

From JBR Group Stop sequence

(e) Override Trip Command:

(i) Enclosure temperature >= 55 DegC, OR
(ii) Respective Oxidation Blower bearing temperature very high (> 100 Deg C) OR
1 (iii) Respective Oxidation Blower bearing vibration very high (> 11 mm/s) OR
(iv) Respective Oxidation Blower discharge pressure very high (> 0.4000 mmWC) OR
(v) Respective Oxidation Blower discharge temperature very high (> 100 Deg C)
Note: Periodic change-over of Oxidation Blowers is recommended for trouble-free operation. The
same shall be manually initiated by Operator.

3.2 OXIDATION AIR BLOWER DISCHARGE ISOLATION VALVES (07HTG01AA001 / 07HTG11AA001)

Fail condition: Fail-In-Place
(a) Open Permissive:
None

(b) Close Permissive:

Respective Oxidation Blower not running

(c) Auto Open Command:

None
1
(d) Auto Close Command:
Respective Oxidation Blower stopped

(e) Override Open Command:

None

(f) Override Close Command:

None

3.3 OXIDATION AIR HUMIDIFICATION WATER CONTROL VALVE (07HTQ22AA300)

Fail condition: Fail-In-Place
(a) Open Permissive:

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DVC DOC NO. 2109-122-PVM-G-006 Section-4 Oxidation Air System Rev. 01 21 Jan’ 22

None

(b) Close Permissive:

No Oxidation Blower running

(c) Auto Open Command:

From JBR Group Start sequence

(d) Auto Close Command:

From JBR Group Stop sequence

(e) Override Open Command:

None

(f) Override Close Command:

None

(g) Modulating Control:

None

1 3.4 OXIDATION AIR HUMIDIFICATION WATER LINE FLUSH VALVE (07HTQ22AA100/00HTQ22AA101)

Fail condition: Fail Close
(a) Open Permissive:
None

(b) Close Permissive:

None

(c) Auto Open Command:

These valves will be auto opened sequentially once in every 12 hours for few seconds (timing will
be decided during commissioning)

(d) Auto Close Command:

These valves will auto close inline with auto operation specified in ‘Auto Open command' above.

(e) Override Open Command:

None

(f) Override Close Command:

None

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110104 Control Philosophy of FGD system Page 56 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

Section-5 Gypsum Bleed system

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DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

1 REFERENCE DOCUMENTS
(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
(iii) Process Flow Diagram of Limestone Grinding and Slurry Preparation System, DVC Doc. No. 2109-
122-PVM-F-001A
(iv) P&ID Gypsum Bleed pumps, DVC Doc. No. 2109-122-PVM-F-004C
(v) P&ID Auxiliary absorbent Tank & Pump System DVC Doc No. 2109-122-PVM-F-035
(vi) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(vii) Tender – Scheme of FGD – Gypsum Dewatering System, DVC Doc. No. 2109-121-POM-A-003

2 PROCESS DESCRIPTION

The SO2 absorption in the absorber and subsequent oxidation results in the formation of gypsum
crystals, which will result in an increase of the solids concentration of the absorber slurry.
The FGD byproduct solids (gypsum, unreacted limestone, inert material, and fly ash) are pumped as
around 15 - 25 weight percent slurry from JBR to Primary Hydro cyclone Feed Tank by the Gypsum
Bleed Pump. Bleed rate is monitored by the flow transmitter placed in the Primary Hydro cyclone feed
tank feeding and recirculation line. The bleed line recirculates back to the JBR. The recirculation flow
is maintained by the control valve located on the top of the hydro cyclone feed tank. The limestone
slurry mixed with recycled gypsum slurry from the discharge loop are fed into the Absorber through
Limestone Slurry Distributor which is located at the top of Absorber to absorb the SO2 and to control
the pH level.
During normal operation valve 07HTL05AA100/07HTL05AA101 remain close. However at the time of
Absorber maintenance, Valve 07HTL05AA100/07HTL05AA101 will be opened to bypass slurry to
Auxiliary Absorbent Storage tank which is used to store the slurries from absorber.

3 CONTROL PHILOSOPHY

The group level shall control a set of functional sub-groups of drives. Appropriate start-up and shut
down commands shall be issued to the sub-group control and various check-backs shall be received
from sub-groups or drives. Each sub-group shall execute the sequential start-up and shut down
programs of a set of inter-related drives along with system interlocks and protections associated with

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110104 Control Philosophy of FGD system Page 58 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

that sub-group as well as basic interlocks and protections related to individual drive falling under that
sub-group.
GYPSUM Slurry will be transferred to Primary & Secondary Dewatering system with the help of two
gypsum bleed pumps. The Gypsum bleed flow is controlled by Gypsum Control valve 07HTL03AA300.
The Gypsum concentration is measured by Density Meters (01HTL03CD101/102). The control valve
opening will be controlled by Gypsum bleed flow measured by 07HTL03CF101 together with Gypsum
slurry concentration. During shut down condition of bleed pump, gypsum bleed line will be flushed
with process water. Absorber Emptying Pump 07HTL06AP001 is used to empty slurry from absorber
during Shut down operation of Absorber.

At the time of Absorber maintenance, Valve 07HTL05AA100/07HTL05AA101 will be opened to bypass

slurry to Auxiliary Absorbent Storage tank which is used to store the slurries from absorber. The
detailed control logic will be provided based on this process description and interlock Write up.

4 CONTROLS AND INTERLOCKS:

4.1 GROUP DEFINITION:

The gypsum Bleed Pump Group integrates the operation of the complete train of respective Gypsum
Bleed Pump including its suction valve, discharge valve, drain valve and wash valve. Below listed is the
sequence of operation for Gypsum Bleed Pump-A Group. Similar operation philosophy will be
applicable for Gypsum Bleed Pump -B and their corresponding valves also.

4.2 GYPSUM BLEED PUMPS (07HTL01AP001/07HTL02AP001) GROUP SEQUENCE:

The Gypsum Bleed Pump-A and corresponding suction, discharge, flushing and draining line valves will
be operated manually or auto based on Overall group Start/Stop condition. Same is applicable to
Gypsum Bleed Pump-2 with proper tag number change.

4.2.1 GYPSUM BLEED PUMP GROUP-1 START

(a) The Gypsum Bleed Pump group start will be allowed only if the following conditions are
satisfied

(i) JBR SLURRY Level NOT LOW . 1

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110104 Control Philosophy of FGD system Page 59 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

(ii) Pump-A Suction Valve 07HTL01AA001 closed AND

(iii) 07HTL05AA100 Valve Closed
(iv) GBP-A START Permissive available (except for GBP suction Valve open status)

(b) Group Start Command:

GBP-A Group Start can be initiated by Operator manually or on receiving Auto-start signal in either
of the following conditions –

(i) GBP-A on standby and Running GBP trips (electrical trip or GBP stop due to Override Trip
command)
(ii) GBP-A on standby and GBP Discharge Header Pressure remains low for more than predefined
time decided at the time of commissioning.

(c) Group Start Sequence:

(i) Step-1: GBP-A suction valve open command

(ii) Step-2: GBP-A start command
(iii) Step-3: After preset time (as per GBP OEM recommendation), GBP-A discharge valve open
command
(iv) The GBP-A Group Start will be considered complete when all the above sequenced steps are
completed successfully.

4.2.2 GYPSUM BLEED PUMP GROUP-1 STOP

(a) Group Stop Permissive and Command:

GBP-A Group Stop can be initiated by Operator manually or on receiving Auto-stop signal in
either of the following conditions –
(i) JBR level low low (Set Point low low will be defined at the time of commissioning)

(b) Group Stop Sequence:

(i) Step-1: GBP-A discharge valve close command
(ii) Step-2: GBP-A stop command
(iii) Step-3: GBP-A suction valve close command
(iv) Step-4: GBP-A drain valve open command
(v) Step-5: GBP-A wash valve open command
(vi) Step-6: GBP-A wash valve close command after time decided at the time of commissioning
(vii) Step-7: GBP-A drain valve close command

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110104 Control Philosophy of FGD system Page 60 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

GBP-A group stop shall be considered complete when all the above sequenced steps are completed
successfully.

4.3 GYPSUM BLEED PUMPS ( 07HTL01AP001/07HTL02AP001)

a) Start Permissive:
(i) JBR SLURRY Level NOT LOW 1
(ii) Pump-A Suction Valve 07HTL01AA001 open AND
(iii) Pump-A Discharge valve 07HTL01AA002 Closed AND
(iv) Pump-A wash valve 07HTL01AA101 Closed
(v) Pump-A drain valve 07HTL01AA100 Closed
b) Stop Permissive:
None

c) Auto Start Command:

From respective Gypsum Bleed Pump (GBP) Group Start Sequence

d) Auto Stop Command:

From respective Gypsum Bleed Pump (GBP) Group Stop Sequence

e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined time decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) JBR level very low OR
(iv) As per GBP (and its Motor) OEM’s recommendation if any.

4.4 GYPSUM BLEED PUMPS SUCTION VALVES (07HTL01AA001/07HTL02AA001) 1

a) Open Permissive :

The Gypsum Bleed pump-A Suction valve will be opened only if the following condition is satisfied

- Pump A drain valve and Wash valve is CLOSED

b) Close Permissive :

The Gypsum Bleed pump-A Suction valve will be closed only if the following condition is satisfied

- Pump-A is not running

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104 Control Philosophy of FGD system Page 61 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

c) Auto Open & Close :

The Gypsum Bleed Pump suction VALVEs will OPEN & CLOSE automatically by respective gypsum
bleed pump group START and STOP sequence activation.

4.5 GYPSUM BLEED PUMPS DISCHARGE VALVES (07HTL01AA002/07HTL02AA002) 1

a) Open Permissive :
The Gypsum Bleed pump-A discharge valve will be opened only if the following condition is
satisfied

- Pump-A is running.

b) Close Permissive :
The Gypsum Bleed pump-A discharge valve will be closed only if the following condition is
satisfied

- Pump-A is not running

c) Auto Open :
The Bleed Pump-A discharge valves will open automatically by respective Bleed Pump group
START sequence activation.

d) Auto Close :
The Bleed Pump-A discharge valves will close automatically if any of the following takes place:

- Close command received from respective Bleed Pump-A group STOP sequence
- Pump-A trips / not running

4.6 GYPSUM BLEED PUMPS DRAIN VALVES (07HTL01AA100/07HTL02AA100)

Fail condition: Fail Close 1

a) Open Permissive :
- Pump-A not running
- Suction Valve and Discharge Valve Closed.
b) Close Permissive :
- Wash Valve is CLOSED.

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104 Control Philosophy of FGD system Page 62 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

c) Auto Open & Close :

The Pump drain VALVEs will open & close automatically by respective gypsum bleed pump group
START and STOP sequence activation.

4.7 GYPSUM BLEED PUMPS WASH VALVES (TAG:07HTL01AA101/07HTL02AA101)

Fail condition: Fail Close

a) Open Permissive:
- Drain Valve is OPEN
b) Close Permissive :
- None
c) Auto Open & Close :

The Pump wash valves will open & close automatically by respective gypsum bleed pump group
START and STOP sequence activation.

4.8 ABSORBER BLEED CONTROL

Gypsum Slurry concentration in the JBR is maintained within an appropriate range, 15-25 wt%
to keep lower level of gypsum super-saturation of absorbent in the JBR. Bleeding rate of gypsum
slurry from JBR is determined by feed forward signal of limestone slurry feed rate. Flow rate of
bleeding gypsum slurry is automatically controlled by cascade control according to determined
bleeding rate and feedback signal of flow rate from flow meter. Gypsum bleed rate is controlled by
the signal of feed rate of limestone slurry. The set values of bleed rate will be adjusted by the signal
of actual slurry concentration.

4.8.1 ABSORBER BLEED CONTROL VALVE (Tag: 07HTL03AA300)

Fail condition: Fail-to-Close

(a) Open Permissive:

- Oxidation Blower running (means Absorber is on working condition)

(b) Close Permissive:

None

(c) Override Close Command:

None

(d) Modulating Control:

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110104 Control Philosophy of FGD system Page 63 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

Control Action – Reverse Acting

The Control mode shall be shifted as follows by the Booster Fan operational Status

(i) MAN mode – Manual mode will be selected in case that all Booster Fan are stopped.
(ii) CASCADE mode (Cascade means one linked to the other. Process target is the set point to
the master controller. Comparing the set point and a process parameter an output is
generated. This output is a set-point to the slave controller.) – Cascade Mode will be
selected in case that one or more Booster Fan is in Operation.
d. Master control – JBR bleed control:
Set point – The set point for Gypsum Bleed control will be generated from functional curve f1(x)
based on the JBR Limestone slurry feed rate, and from functional curve f2(x) JBR gypsum slurry
concentration.

(functional curve f1(x) gives the Gypsum Bleed rate value in terms of JBR limestone slurry feed
rate and also functional curve f2(x) gives Gypsum Bleed rate correction factor in terms of
Gypsum Slurry and same has been shown in the below diagram. The Control logic will be
submitted as a later)
Gypsum Bleed Rate

Gypsum Bleed Rate

correction factor
(m3/Hr)

JBR limestone Slurry feed

20
rate(m3/hr)
JBR gysum Slurry Conc.(wt%)
(Function(FX1) (Function(FX2)

4.9 ABSORBER EMPTYING PUMPS (07HTL06AP001) GROUP SEQUENCE:

The absorber emptying pump and corresponding suction, discharge, flushing and draining line
valves will be operated manually or auto based on Overall group Start/Stop condition.

4.9.1 ABSORBER EMPTYING PUMP GROUP START

(a) The Absorber Emptying Pump group start will be allowed only if the following conditions are
satisfied
(i) JBR is stopped. 1
(ii) JBR SLURRY Level NOT LOW.

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104 Control Philosophy of FGD system Page 64 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

(iii) Pump Suction Valve 07HTL06AA001 closed AND

PUMP START Permissive available (except for GBP suction Valve open status)

(b) Group Start Command:

Absorber Emptying Pump Group Start can be initiated by Operator manually from Control Room.

(c) Group Start Sequence:

(i) Step-1: Pump suction valve open command

(ii) Step-2: Pump start command
(iii) Step-3: After preset time (as per GBP OEM recommendation), Pump discharge valve open
command

Pump Group Start will be considered complete when all the above sequenced steps are
completed successfully.

4.9.2 ABSORBER EMPTYING PUMP GROUP STOP

(a) Group Stop Permissive and Command:

Pump Group Stop can be initiated by Operator manually or on receiving Auto-stop signal in
either of the following conditions –
(i) JBR level low low (Set Point low low will be defined at the time of commissioning)

(b) Group Stop Sequence:

(i) Step-1: Pump discharge valve close command
(ii) Step-2: Pump stop command
(iii) Step-3: Pump suction valve close command
(iv) Step-4: Pump drain valve open command
(v) Step-5: Pump wash valve open command
(vi) Step-6: Pump wash valve close command after time decided at the time of commissioning
(vii) Step-7: Pump drain valve close command

Pump group stop shall be considered complete when all the above sequenced steps are completed
successfully.

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110104 Control Philosophy of FGD system Page 65 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

4.10 ABSORBER EMPTYING PUMP ( 07HTL06AP001)

a) Start Permissive:
(i) JBR SLURRY Level NOT LOW
(ii) Pump Suction Valve OPEN AND
(iii) Pump Discharge valve Closed AND
(iv) Pump wash valve Closed
(v) Pump drain valve Closed
b) Stop Permissive:
None

c) Auto Start Command:

None

d) Auto Stop Command:

None

e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined time decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) JBR level low low OR
(iv) As per absorber emptying pump (and its Motor) OEM’s recommendation if any.

4.11 ABSORBER EMPTYING PUMP SUCTION VALVES (07HTL06AA001)

Fail condition: Fail-In-Place 1

(a) Open Permissive:

The Absorber Emptying Pump Suction valve will be opened only if the following condition is satisfied

- Pump drain valve and Wash valve is CLOSED

(b) Close Permissive :

The Absorber Emptying Pump Suction valve will be closed only if the following condition is satisfied

- Pump is not running

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104 Control Philosophy of FGD system Page 66 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

(c) Auto Open & Close :

The Absorber Emptying Pump suction VALVE will OPEN & CLOSE automatically by Absorber
Emptying Pump group START and STOP sequence activation.

4.12 ABSORBER EMPTYING PUMPS DISCHARGE VALVES (07HTL06AA002)

Fail condition: Fail-In-Place 1

(a) Open Permissive :

The Absorber Emptying Pump discharge valve will be opened only if the following condition is
satisfied

- Pump is running.
(b) Close Permissive :
The Absorber Emptying Pump discharge valve will be closed only if the following condition is
satisfied

- Pump is not running

(c) Auto Open :
The Absorber Emptying Pump discharge valves will open automatically by Pump group START
sequence activation.

(d) Auto Close :

The Absorber Emptying Pump discharge valves will close automatically if any of the following
takes place:

- Close command received from Pump group STOP sequence

- Pump trips / not running

4.13 ABSORBER EMPTYING PUMPS DRAIN VALVES (07HTL06AA100) 1

Fail condition: Fail Close

(a) Open Permissive:

- Pump not running
- Suction Valve and Discharge Valve Closed.
(b) Close Permissive:
- Wash Valve is CLOSED.

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110104 Control Philosophy of FGD system Page 67 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

(c) Auto Open & Close :

The Pump drain VALVEs will open & close automatically by respective gypsum bleed pump group
START and STOP sequence activation.

4.14 ABSORBER EMPTYING PUMPS WASH VALVES (TAG: 07HTL06AA101) 1

Fail condition: Fail Close

(a) Open Permissive:

- Drain Valve is OPEN

(b) Close Permissive :

- None

(c) Auto Open & Close :

The Pump wash valves will open & close automatically by respective gypsum bleed pump group
START and STOP sequence activation.

4.15 AUX ABSORBENT PUMPS (00HTL07AP001) GROUP SEQUENCE:

The Aux Absorbent Pump and corresponding suction, discharge, flushing and draining line
valves will be operated manually or auto based on Overall group Start/Stop condition.

4.15.1 AUX ABSORBENT PUMP GROUP START

(a) The Aux Absorbent Pump group start will be allowed only if the following conditions are
satisfied

(i) Aux Absorbent Tank SLURRY Level NOT LOW

(ii) Pump Suction Valve 00HTL07AA001 closed AND
(iii) Aux Absorbent Pump START Permissive available (except for Pump suction Valve open
status)

(b) Group Start Command:

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110104 Control Philosophy of FGD system Page 68 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

Aux Absorbent Pump Group Start can be initiated by Operator manually or on receiving Auto-start
signal for Group Start sequence:

(c) Group Start Sequence:

(i) Step-1: Aux Absorbent Pump suction valve open command

(ii) Step-2: Aux Absorbent Pump start command
(iii) Step-3: After preset time (as per Aux absorbent Pump OEM recommendation), GBP-A
discharge valve open command
(iv) The Aux Absorbent Pump Group Start will be considered complete when all the above
sequenced steps are completed successfully.

4.15.2 AUX ABSORBENT PUMP GROUP STOP

(a) Group Stop Permissive and Command:

Aux Absorbent Pump Group Stop can be initiated by Operator manually or on receiving Auto-
stop signal in either of the following conditions –
(i) Aux Absorbent Tank SLURRY Level LOW LOW

(b) Group Stop Sequence:

(i) Step-1: Aux Absorbent Pump discharge valve close command
(ii) Step-2: Aux Absorbent Pump stop command
(iii) Step-3: Aux Absorbent Pump suction valve close command
(iv) Step-4: Aux Absorbent Pump drain valve open manually
(v) Step-5: Aux Absorbent Pump wash valve open manually
(vi) Step-6: Aux Absorbent Pump wash valve close manually after predefined time decided at
the time of commissioning
(vii) Step-7: GBP-A drain valve close manually
Aux Absorbent Pump group stop shall be considered complete when all the above
sequenced steps are completed successfully

4.16 AUX ABSORBENT PUMP (00HTL07AP001)

(a) Start Permissive:

Start permissive will be imitated based on Aux absorbent Pump Start if the following conditions
satisfied.

(i) Aux absorbent SLURRY Level NOT LOW

(ii) Pump Suction Valve Open AND

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DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

(iii) Pump Discharge valve Closed AND

(iv) Pump wash valve Closed manually.
(v) Pump drain valve Closed manually.

(b) Stop Permissive:

None

(c) Auto Start Command:

From respective Aux absorbent Pump Start Sequence

(d) Auto Stop Command:

From respective Aux absorbent Pump Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined time decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) Aux absorbent tank level low low OR
(iv) As per Aux absorbent Pump (and its Motor) OEM’s recommendation if any.

4.17 AUX ABSORBENT PUMPS SUCTION VALVES (00HTL07AA001)

1
(a) Open Permissive :

The Aux absorbent Pump Suction valve will be opened only if the following condition is
satisfied

- Pump drain valve and Wash valve is CLOSED manually

(b) Close Permissive :

The Aux absorbent Pump Suction valve will be closed only if the following condition is satisfied

- Pump is not running

(c) Auto Open & Close :

The Aux absorbent Pump suction valves will open & close automatically by respective Aux
absorbent Pump START and STOP sequence activation.

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DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

4.18 AUX ABSORBENT PUMPS DISCHARGE VALVES (00HTL07AA002) 1

(a) Open Permissive :

The Aux absorbent Pump discharge valve will be opened only if the following condition is
satisfied

- Pump is running
(b) Close Permissive :
The Aux absorbent Pump discharge valve will be closed only if the following condition is
satisfied

- Pump is not running

(c) Auto Open :
The Aux absorbent Pump discharge valves will open automatically by respective Aux
absorbent Pump group START sequence activation.

(d) Auto Close :

The Aux absorbent Pump discharge valves will close automatically if any of the following takes
place:
- Close command received from respective Aux absorbent Pump group STOP sequence
- Pump trips / not running

4.19 AUXILIARY ABSORBENT TANK AGITATOR (00HTL05AM001)

(a) Start Permissive :

The Auxiliary Absorbent tank (00HTL05BB001) agitator (00HTL05AM001) will be allowed to

start if the following condition is satisfied
- Auxiliary Absorbent Tank Level (00HTL05CL101) NOT LOW (will be defined during
commissioning stage)

(b) Stop Permissive : None

Notes: LOW and LOW LOW values will be defined during commissioning stage.

(c) Auto Start & Stop :

Agitator will be automatically managed by DCS based on level in Auxiliary Absorbent tank.
Once Auxiliary Absorbent tank Level is higher than a LOW Level, the agitator will be

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DVC DOC NO. 2109-122-PVM-G-006 Section-5 Gypsum Bleed System Rev. 01 21 Jan’22

automatically started. The Auxiliary Absorbent tank agitator will auto stop when the Auxiliary
Absorbent Tank Level LOW LOW.

4.20 AUXILIARY ABSORBENT PUMPS DISCHARGE VALVES TO JBR (07HTL07AA100 /

08HTL07AA100)

1 The Aux absorbent Pump discharge valves will open & close manually by operator as per the
process requirement.

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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

Section-6 Filtrate Water System

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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
(iii) Process Flow Diagram of Limestone Grinding and Slurry Preparation System, DVC Doc. No. 2109-
122-PVM-F-001A
(iv) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(v) Tender – Scheme of FGD – Gypsum Dewatering System, DVC Doc. No. 2109-121-POM-A-003
(vi) Filtrate Water System - DVC Doc. No. 2109-122-PVM-F-004D

2 PROCESS DESCRIPTION

The by-product solids are dewatered by using the vacuum belt filter to produce a filter cake with free
moisture of less than 10 weight percent. The filter cake from vacuum belt filter is discharged to gypsum
handling system. The filtrate recovered from the by-product solids is transferred to the Filtrate water
tank. The Filtrate water tank provides storage of the filtrate produced by the vacuum belt filters,
secondary hydro cyclone underflow and a portion of primary hydro cyclone and waste water tank
overflow. The Filtrate water will contain approximately 4-5 weight percent solids. The Filtrate water
is transferred from the Filtrate water tank to the ABSORBER and to the Limestone Slurry Preparation
System by the Filtrate water pump.

A part of overflow from the Primary Hydro cyclone is routed to the Secondary Hydro cyclone via
Secondary Hydro‐Cyclone Feed Tank and pump. The secondary hydro‐cyclone overflow is taken to the
waste water tank. A portion of the waste water in the waste water tank is discharged to maintain
required concentration of chlorides and soluble salts in liquid throughout the FGD System. The waste
water is delivered to the waste water terminal point from additional waste water tank after the pH
adjustment by lime dozing system. .

3 CONTROL PHILOSOPHY

The group level shall control a set of functional sub-groups of drives. Appropriate start-up and shut
down commands shall be issued to the sub-group control and various check-backs shall be received
from sub-groups or drives. Each sub-group shall execute the sequential start-up and shut down
programs of a set of inter-related drives along with system interlocks and protections associated with

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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

that sub-group as well as basic interlocks and protections related to individual drive falling under that
sub-group.
Filtrate water, collected from waste water tank, vacuum receiver will be transferred to ABSORBER and
limestone Slurry Tank with the help of two Filtrate Water Pump. The distribution of reclaim water to
each ABSORBER will be determined by the gypsum bleed rate from each ABSORBER. The opening of
the control valve will be governed by Filtrate water flow rate and ABSORBER bleed rate. Filtrate water
tank level will be determined by the average value from the two-Level transmitters
(00HTL10CL101/102). During shutdown condition of filtrate water pump, filtrate line will be flushed
with process water. Process water to Filtrate Water tank Valve (00HTQ02-AA102) is for initial filling,
but also for supplying process water just in case water balance could not be kept for some reason. The
valve will open and close by the following logic. This valve will open if Filtrate tank level goes down
lower than LL and will close when the Filtrate tank level goes up higher than H. The detailed control
logic will be provided based on this process description and interlock Write up.

4 CONTROLS AND INTERLOCKS :

4.1 GROUP DEFINITION:

The Filtrate water Pump Group integrates the operation of the complete train of respective Filtrate
water including its suction valve, discharge valve, drain valve and wash valve. Below listed is the
sequence of operation for Filtrate water Pump-A Group. Similar operation philosophy will be
applicable for Filtrate water Pump-B and their corresponding valves also.

4.2 FILTRATE WATER PUMPS (00HTL11AP001/00HTL12AP001) GROUP SEQUENCE:

The Filtrate water Pump-A and corresponding suction, discharge, flushing and draining line valves will
be operated manually or auto based on Overall group Start/Stop condition. Similar operation
philosophy will be applicable for Filtrate water Pump-B and their corresponding valves also.

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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

4.2.1 FILTRATE WATER PUMP GROUP START:

(a) The Filtrate water Pump-A group start will be allowed only if the following conditions are
satisfied

(i) Filtrate water tank Level NOT LOW

(ii) Pump-A Suction Valve 00HTL11AA100 Closed
(iii) Filtrate water Pump-A START Permissive available (except for filtrate water pump suction valve
open status)

(b) Group Start Command:

Filtrate water Pump-A Group Start can be initiated by Operator manually or on receiving Auto-start
signal in either of the following conditions –

(i) Filtrate water Pump-A on standby and Running Filtrate water Pump trips (electrical trip or
Filtrate water Pump stop due to Override Trip command)
(ii) Filtrate water Pump-A on standby and Filtrate water Pump Common Discharge Header
Pressure remains low for predefined time decided during commissioning stage.

(c) Group Start Sequence:

(i) Step-1: Filtrate water Pump-A suction valve open command

(ii) Step-2: Filtrate water Pump-A start command
(iii) Step-3: After preset time (as per Filtrate water Pump OEM recommendation),
Filtrate water Pump-A discharge valve open command

The Filtrate water Pump-A Group Start will be considered complete when all the above
sequenced steps are completed successfully.

4.2.2 FILTRATE WATER PUMP GROUP STOP

(a) Group Stop Permissive: None

(b) Group Stop Command:

Filtrate water Pump-A Group Stop can be initiated by Operator manually or on receiving Auto-
stop signal in either of the following conditions –
(i) Filtrate Water Tank level low low (value will be decided during commissioning stage)
(c) Group Stop Sequence:
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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

(i) Step-1: Filtrate water Pump-A discharge valve close command

(ii) Step-2: Filtrate water Pump-A stop command
(iii) Step-3: Filtrate water Pump-A suction valve close command
(iv) Step-4: Filtrate water Pump-A drain valve open manually.
(v) Step-5: Filtrate water Pump-A wash valve open manually.
(vi) Step-6: Filtrate water Pump-A wash valve close manually after predefined time decided
during commissioning stage.
(vii) Step-7: Filtrate water Pump-A drain valve close manually.

Filtrate water Pump-A group stop shall be considered complete when all the above sequenced
steps are completed successfully.

4.3 FILTRATE WATER PUMPS (00HTL11AP001/00HTL12AP001)

(a) Start Permissive:

(i) Filtrate water tank Level NOT LOW
(ii) Pump-A Suction Valve 00HTL11AA100 Open
(iii) Pump-A Discharge valve 00HTL11AA101 Closed 1
(iv) Pump-A wash valve 00HTl11AA603 Closed manually
(v) Pump-A drain valve 00HTL11AA600 Closed manually
(b) Stop Permissive:
None

(c) Auto Start Command:

From respective Filtrate water Pump Group Start Sequence

(d) Auto Stop Command:

From respective Filtrate water Pump Group Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined times decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) Filtrate water tank level low low OR
(iv) As per Filtrate water Pump (and its Motor) OEM’s recommendation if any.

4.4 FILTRATE WATER PUMPS SUCTION VALVES (00HTL11AA100/00HTL12AA100)

Fail condition: Fail-In-Place

(a) Open Permissive :

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The Filtrate water Pump-A Suction valve will be opened only if the following condition is satisfied

- Pump-A drain valve and Wash valve is CLOSED

(b) Close Permissive :

The Filtrate water Pump-A Suction valve will be closed only if the following condition is satisfied

- Pump-A is not running

(c) Auto Open & Close :

The Filtrate water Pump-A suction valves will OPEN & CLOSE automatically by respective Filtrate
water Pump group START and STOP sequence activation.

4.5 FILTRATE WATER PUMPS DISCHARGE VALVES (00HTL11AA101/00HTL12AA101)

Fail condition: Fail-In-Place

(a) Open Permissive :

The Filtrate water Pump-A discharge valve will be opened only if the following condition is
satisfied

- Pump-A is running

(b) Close Permissive :

The Filtrate water Pump-A discharge valve will be closed only if the following condition is satisfied

- Pump-A is not running

(c) Auto Open:

The Filtrate water Pump-A discharge valves will open automatically by respective Filtrate
water Pump group START sequence activation.

(d) Auto Close :

The Filtrate water Pump-A discharge valves will close automatically by respective Filtrate
water Pump group STOP sequence activation.

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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

4.6 FILTRATE WATER PUMPS DRAIN VALVES (00HTL11AA600/00HTL12AA600)

Filtrate water drain valves will be opened and closed manually based on the process requirement.

4.7 FILTRATE WATER PUMPS WASH VALVES (00HTL11AA603/00HTL12AA603)

1
Filtrate water wash valves will be opened and closed manually based on the process
requirement.

4.8 PROCESS WATER TO FILTRATE WATER TANK VALVE (00HTQ02AA102)

Fail condition: Fail to Close

This valve is for initial filling, but also for supplying process water just in case water balance could
not be kept for some reason.

(a) Open Permissive:

This valve will be opened only if the following condition is satisfied

- When the Filtrate tank level goes down lower than LOW LOW (value will be decided during
commissioning stage)

(b) Close Permissive:

This valve will be closed only if the following condition is satisfied

- When the Filtrate tank level goes up to HIGH (value will be decided during commissioning
stage)

(c) Auto Open:

None

(d) Auto Close :

None

4.9 FILTRATE WATER TANK AGITATOR (00HTL10AM001)

(a) Start Permissive:

The Filtrate water tank (00HTL10BB001) agitator (00HTL10AM001) will be allowed to start if the
following condition is satisfied
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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

-Filtrate water Tank Level (00HTL10CL101/00HTL10CL102) NOT LOW.

-Addition Level transmitter (00HTL10CL102) has been added Based on DVC technical
specification. However operator may select any of two Level transmitter based on
Process requirement.
(b) Stop Permissive : None

(c) Auto Start & Stop :

Agitator will be automatically managed by DCS based on level in Filtrate water tank. Once Filtrate
water tank Level is higher than a LOW Level, the agitator will be automatically started.
The Filtrate water tank agitator will auto stop when the Filtrate water Tank Level LOW LOW.

Notes: LOW and LOW LOW values will be defined during commissioning stage.

4.10 FILTRATE WATER RETURN CONTROL

The filtrate from Filtrate tank is distributed to limestone slurry preparation tank, wet ball mill & mill
recycle tank and to ABSORBERS. Since the amount of filtrate water returned to ABSORBER from filtrate
water pump is total of Unit-7 and 8, it needs to be distributed to each ABSORBER properly. Distribution
of the filtrate water to each ABSORBER is determined by the gypsum bleed rate from each ABSORBER.
The return flow rate of filtrate water is controlled by feed forward set value and the feedback signal
of the filtrate water return to ABSORBER. The feed forward set value is determined by the function
which is estimated by total water balance.

4.10.1 FILTRATE TANK TO ABSORBER UNIT-7/8 CONTROL VALVE (07HTL18AA300/07HTL18AA300)

Fail condition: Fail in Place

(a) Open Permissive:

- 07/08 HTL18AA600 are in OPEN condition.

(b) Close Permissive:

None

(c) Override Open Command:

None

(d) Override Close Command:

None

(e) Modulating Control:

Control Action – Reverse Acting
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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

The Control mode shall be shifted as follows by the filtrate water pump operational Status

(i) MAN mode – Manual mode will be selected in case that all filtrate water pumps are stopped.
(ii) CASCADE mode (Cascade means one linked to the other. Process target is the set point to
the master controller. Comparing the set point and a process parameter an output is
generated. This output is a set-point to the slave controller.) - Cascade Mode will be selected
in case that filtrate water pumps is in Operation.
e. Master control – filtrate water return control:
(i) Set point – The set point for filtrate water return control will be generated from functional
curve f1(x)/ f2(x) based on the ABSORBER (Unit7/8) bleed rate. There is a linear relationship
between ABSORBER filtrate return rate and gypsum bleed rate which is represented below.
Detail Control logic will be submitted later.
(ii) Feedback- Unit7/8 ABSORBER filtrate water return flow rate measured with Flow
Transmitters
(07HTL18CF101/08HTL18CF101).
Unit-1 JBR Filtrate
Unit-1 JBR Filtrate

Return(m3/Hr)
Return(m3/Hr)

Gypsum Bleed Rate (m3/Hr) Gypsum Bleed Rate (m3/Hr)

Function(FX1) Function(FX2)

4.11 FILTRATE WATER TO WET BALL MILL FLOW CONTROL

Filtrate water will be distributed to Wet Ball Mill. The amount of filtrate water required at wet ball mill
will be controlled by output signal from filtrate water flow transmitter 00HTL14/15CF101 whose set
point is governed by limestone weight measured at weigh feeder (Ball mill Vendor Scope).

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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

4.11.1 FILTRATE TANK TO WET BALL MILL CONTROL VALVE (00HTL14/15AA300)

Fail condition: Fail in Place

(a) Open Permissive:

- Discharge valve, 00HTL19AA600, is in OPEN condition.

(b) Close Permissive:

None

(c) Override Open Command:

None

(d) Override Close Command:

None

(e) Modulating Control:

Control Action – Reverse Acting

The Control mode shall be shifted as follows by the filtrate water pump operational Status

(i) MAN mode – Manual mode will be selected in case that all filtrate water pumps are stopped.
(ii) CASCADE mode (Cascade means one linked to the other. Process target is the set point to
the master controller. Comparing the set point and a process parameter an output is
generated. This output is a set-point to the slave controller.) - Cascade Mode will be selected
in case that filtrate water pumps is in Operation.
a. Master control – filtrate water to ball mill flow control:
(i) Set point – The set point for filtrate water flow will be generated from weigh feeder o/p
signals.
(ii) Feedback- Filtrate water flow rate will be measured with Flow Transmitters
(00HTL14/15CF101)

4.12 FILTRATE WATER TO MILL RECYCLE TANK FLOW CONTROL

Filtrate water will be distributed to Mill recycle Tank. The amount of filtrate water required at mill
recycle tank will be controlled by output signal from filtrate water flow transmitter whose set point
is governed by limestone slurry density measured at mill recycle pump common discharge header.

4.12.1 FILTRATE TANK TO MILL RECYCLE TANK FLOW CONTROL VALVE (00HTL14/15AA301)
Fail condition: Fail in Place

(a) Open Permissive:

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DVC DOC NO. 2109-122-PVM-G-006 Section-6 Filtrate Water System Rev. 01 21 Jan’22

- Discharge valve, 00HTL19AA600, is in OPEN condition.

(b) Close Permissive:

None

(c) Override Open Command:

None

(d) Override Close Command:

None

(e) Modulating Control:

Control Action – Reverse Acting

The Control mode shall be shifted as follows by the filtrate water pump operational Status

(i) MAN mode – Manual mode will be selected in case that all filtrate water pumps are stopped.
(ii) CASCADE mode (Cascade means one linked to the other. Process target is the set point to
the master controller. Comparing the set point and a process parameter an output is
generated. This output is a set-point to the slave controller.) - Cascade Mode will be selected
in case that filtrate water pumps is in Operation.
b. Master control – Filtrate water to mill recycle tank flow control:
(i) Set point – The set point for filtrate water flow will be generated from density transmitters
at mill recycle pump common discharge header
(ii) Feedback- Filtrate water flow rate will be measured with Flow Transmitters at inlet of Mill
Recycle Tank

3.1 FILTRATE WATER DISCHARGE MOTORISED VALVE (TAG:00HTL14/15AA001, 00HTL14/15AA002 &

07/08HTL18AA001 )

This valve will always keep open during normal operation condition.

(a) Open Permissive: None

1
(b) Close Permissive: None
(c) Override Close Command: None

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Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

Section -7 Limestone Slurry Feed System

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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L&T DOC.NO.: F.MEJI.19-XG07-00-HT- Control Philosophy of FGD system
110104
Page 84 of 145
Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
Process Flow Diagram of Limestone Grinding and Slurry Preparation System, DVC Doc. No. 2109-
122-PVM-F-001A
(iii) P&ID Limestone slurry Feed Tank & Pump, DVC Doc. No. 2109-122-PVM-F-026
(iv) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-122-POM-A-001
(v) Tender – Scheme of FGD – Gypsum Dewatering System, DVC Doc. No. 2109-121-POM-A-003
(vi) Tender – Scheme of FGD – Milling System, DVC Doc. No. 2109-121-POM-A-002

2 PROCESS DESCRIPTION

Crushed limestone (~20 ‐ 25.4 mm lump) is transferred to Limestone day silos by suitable material
handling system. Limestone is transferred from the limestone silo to the Wet Ball Mill by Weigh Feeder
Conveyor. The Wet Ball Mill grinds the limestone with the Filtrate Water distributed from the Filtrate
Water tank. The Filtrate water is added at the feed chute of the ball mill in proportion to the feed of
the limestone. The slurry from the Wet Ball Mill is fed to Mill recycle tank from where the slurry is
pumped to the Hydro cyclone. The overflow from the hydro cyclone containing fine limestone slurry
(30% solid content, 90% passing through 200 mesh) is transferred to the Limestone slurry tank and
the underflow slurry with coarse limestone is returned to Wet Ball Mill for further grinding.
A complete system of limestone grinding and slurry preparation is supplied as standby. The Ball Mills
with all accessories are housed in Ball Mill building.
The limestone slurry stored in the limestone slurry storage tank is transferred to the Absorber by the
limestone slurry pump. The limestone slurry feed rate into the Absorber is controlled by split control
valve near to the Absorber. The limestone slurry is mixed with gypsum slurry which is recycled from
the discharge loop of Gypsum Bleed Pump and are fed into the Absorber through Limestone Slurry
Distributor..

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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L&T DOC.NO.: F.MEJI.19-XG07-00-HT- Control Philosophy of FGD system
110104
Page 85 of 145
Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

3 CONTROL PHILOSOPHY

The group level shall control a set of functional sub-groups of drives. Appropriate start-up and shut
down commands shall be issued to the sub-group control and various check-backs shall be received
from sub-groups or drives. Each sub-group shall execute the sequential start-up and shut down
programs of a set of inter-related drives along with system interlocks and protections associated with
that sub-group as well as basic interlocks and protections related to individual drive falling under that
sub-group.
Limestone Slurry from limestone slurry preparation system will be stored in limestone slurry storage
tank. The Level is measured by two level transmitters installed in each of the two limestone slurry
tank. Limestone Slurry will be transferred to Absorber-1 & 2 from Limestone slurry storage tank
through limestone slurry feed pump. During shut down condition of limestone slurry feed pump,
limestone slurry line will be flushed with process water.
The detailed control logic will be provided based on this process description and interlock Write up.

4 CONTROLS AND INTERLOCKS :

4.1 GROUP DEFINITION:

The LIMESTONE SLURRY FEED Pump Group Sequence integrates the operation of the complete train
of respective LIMESTONE SLURRY FEED including its suction valve, discharge valve, drain valve and
wash valve. The below control write up is for Pump Group-1 constituting Pump-A (07HTK31AP001)
and including their suction valve, discharge valve, drain valve and wash valve. The same write up is
applicable for Pump Group-2 constituting Pump-B (07HTK32AP001) for absorber Unit-07. Same will
be applicable for absorber Unit-08. PUMP-A (07HTK31AP001) of Unit-07, Pump-A (08HTK31AP001) of
Unit-08 will be supplying limestone slurry from Limestone slurry storage tank to Absorber unit-07 and
08 respectively.
During running condition of limestone slurry Feed Pump, the respective limestone slurry feed tank
interconnected outlet valve to other regent tank (not operating) will be kept close.

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104
Page 86 of 145
Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

4.2 LIMESTONE SLURRY FEED PUMPS (07HTK31AP001/07HTK32AP001) GROUP SEQUENCE:

The Limestone Slurry feed Pump-A and corresponding suction, discharge, flushing and draining line
valves will be operated manually or auto based on Overall group Start/Stop condition. Same is
applicable for other Limestone Slurry Feed Pumps with proper tag number change.

4.2.1 LIMESTONE SLURRY FEED PUMP GROUP-1 START:

(a) The LIMESTONE SLURRY FEED Pump-A group start will be allowed only if the following conditions
are satisfied

(i) LIMESTONE SLURRY FEED TANK SLURRY Level NOT LOW 1

(ii) Pump-A Suction Valve 07HTK31AA001 Closed AND
(iii) LIMESTONE SLURRY FEED Pump-A START Permissive available (except for suction Valve open
status)

(b) Group Start Command:

LIMESTONE SLURRY FEED Pump Group-1 Start can be initiated by Operator manually or on receiving
Auto-start signal in either of the following conditions –

(i) LIMESTONE SLURRY FEED Pump on standby and Running LIMESTONE SLURRY FEED Pump
trips (electrical trip or LIMESTONE SLURRY FEED Pump stop due to Override Trip
command)
(ii) LIMESTONE SLURRY FEED Pump on standby and LIMESTONE SLURRY FEED Pump
Discharge Header Pressure remains low for more than predefined time decided at the
time of commissioning.

(c) Group Start Sequence:

(iv) Step-1: LIMESTONE SLURRY FEED Pump-A suction valve open command
(v) Step-2: LIMESTONE SLURRY FEED Pump-A start command
(vi) Step-3: After preset time (as per LIMESTONE SLURRY FEED Pump OEM
recommendation), LIMESTONE SLURRY FEED Pump-A discharge valve open
command
(vii) The LIMESTONE SLURRY FEED Pump Group-A Start will be considered complete
when all the above sequenced steps are completed successfully.

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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L&T DOC.NO.: F.MEJI.19-XG07-00-HT- Control Philosophy of FGD system
110104
Page 87 of 145
Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

4.2.2 LIMESTONE SLURRY FEED PUMP GROUP-1 STOP

(a) Group Stop Permissive:

None
(b) Group Stop Command:

LIMESTONE SLURRY FEED PUMP-A Group Stop can be initiated by Operator manually or on receiving
Auto-stop signal in either of the following condition –
(i) LIMESTONE SLURRY FEED tank level very low (Set Point Very low will be defined at the
time of commissioning)
(c) Group Stop Sequence:
(i) Step-1: LIMESTONE SLURRY FEED PUMP-A discharge valve close command
(ii) Step-2: LIMESTONE SLURRY FEED PUMP-A stop command
(iii) Step-3: LIMESTONE SLURRY FEED PUMP-A suction valve close command
(iv) Step-4: LIMESTONE SLURRY FEED PUMP-A drain valve open command
(v) Step-5: LIMESTONE SLURRY FEED PUMP-A wash valve open command
(vi) Step-6: LIMESTONE SLURRY FEED PUMP-A wash valve close command after time decided
at the time of commissioning
(vii) Step-7: LIMESTONE SLURRY FEED PUMP-A drain valve close command
LIMESTONE SLURRY FEED PUMP-A group stop shall be considered complete when all the above
sequenced steps are completed successfully.

4.3 LIMESTONE SLURRY FEED PUMPS (07HTK31AP001/07HTK32AP001)

(a) Start Permissive:

Start permissive will be initiated based on LIMESTONE SLURRY FEED Pump group Start.

(i) LIMESTONE SLURRY FEED SLURRY Level NOT LOW LOW

(ii) Pump-A Suction Valve 07HTK31AA001 Open AND
(iii) Pump-A Discharge valve 07HTK31AA002 Closed AND
(iv) Pump-A wash valve 07HTK31AA101 Closed
(v) Pump-A drain valve 07HTK31AA100 Closed

(b) Stop Permissive:

None

(c) Auto Start Command:

From respective LIMESTONE SLURRY FEED Pump Group Start Sequence

(d) Auto Stop Command:

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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Page 88 of 145
Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

From respective LIMESTONE SLURRY FEED Pump Group Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined time decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) LIMESTONE SLURRY FEED tank level very low OR
(iv) As per LIMESTONE SLURRY FEED Pump (and its Motor) OEM’s recommendation if any.

4.4 LIMESTONE SLURRY FEED PUMPS SUCTION VALVES (07HTK31AA100/07HTK32AA100)

(a) Open Permissive:

The LIMESTONE SLURRY FEED Pump-A Suction valve will be opened only if the following condition
is satisfied

- Pump A drain valve and Wash valve is CLOSED

(b) Close Permissive:

The LIMESTONE SLURRY FEED Pump-A Suction valve will be closed only if the following condition is
satisfied

- Pump-A is not running

(c) Auto Open & Close :

The LIMESTONE SLURRY FEED Pump-A suction valves will open & close automatically by respective
LIMESTONE SLURRY FEED Pump group START and STOP sequence activation.

4.5 LIMESTONE SLURRY FEED PUMPS DISCHARGE VALVES (07HTK31AA002/07HTK32AA002)

(a) Open Permissive :

The LIMESTONE SLURRY FEED Pump-A discharge valve will be opened only if the following condition
is satisfied

- Pump-A is running

(b) Close Permissive :

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

The LIMESTONE SLURRY FEED Pump-A discharge valve will be closed only if the following condition is
satisfied

- Pump-A is not running

(c) Auto Open :

The Bleed Pump-A discharge valves will open automatically by respective Bleed Pump group
START sequence activation.

(d) Auto Close :

The Bleed Pump-A discharge valves will close automatically if any of the following takes place:

- Close command received from respective Bleed Pump-A group STOP sequence
- Pump-A trips / not running

4.6 LIMESTONE SLURRY FEED PUMPS DRAIN VALVES (07HTK31AA100/07HTK32AA100)

1
Fail condition: Fail Close

(a) Open Permissive :

- Pump not running
- Suction Valve and Discharge Valve Closed.

(b) Close Permissive :

- Wash Valve is CLOSED.

(c) Auto Open & Close :

The LIMESTONE SLURRY FEED Pump-A drain valves will open & close automatically by respective
LIMESTONE SLURRY FEED Pump group START and STOP sequence activation.

4.7 LIMESTONE SLURRY FEED PUMPS WASH VALVES (07HTK31AA101/07HTK32AA101)

Fail condition: Fail Close 1

(a) Open Permissive :

- Drain Valve is OPEN

(b) Close Permissive :

- None

(c) Auto Open & Close :

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

The Pump wash valves will open & close automatically by respective LIMESTONE SLURRY FEED Pump
group START and STOP sequence activation.

4.8 LIMESTONE SLURRY RECIRCULATION ON-OFF VALVE (TAG: ((07HTK02AA100/101)/

(07HTK02AA100/101))
Fail condition: Fail-to-Open 1
(a) Open Permissive: None

(b) Close Permissive: None

(c) Override Close Command: None

(d) Auto Open:

These valves will open automatically when respective tank level is not HIGH and respective
Limestone Slurry Feed Pump Start.

(e) Auto Close:

These valves will close automatically when respective Limestone Slurry Feed Pump Stops.

4.9 LIMESTONE SLURRY FEED TANK AGITATOR (00HTK01AM001/002)

(a) Start Permissive :

The LIMESTONE SLURRY FEED tank (00HTK01BB001) agitator (00HTK01AM001) will be allowed to
start if the following condition is satisfied
- LIMESTONE SLURRY FEED Tank Level (00HTK01CL101/00HTK01CL102) NOT LOW.

(b) Stop Permissive :

- None

(c) Auto Start & Stop :

Agitator will be automatically managed by DCS based on level in LIMESTONE SLURRY FEED tank. Once
LIMESTONE SLURRY FEED tank Level is higher than a LOW Level, the agitator will be automatically
started.
The LIMESTONE SLURRY FEED tank agitator will auto stop when the LIMESTONE SLURRY FEED Tank
Level LOW LOW.
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110104
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Section-7 Limestone Slurry Feed
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 Jan’22
System

4.10 LIMESTONE SLURRY FEED TANK INLET VALVE (00HTK11/21AA100/00HTK11/21AA101)

Fail condition: Fail-In-Place
(a) Open permissive: None

(b) Close permissive: None

(c) Auto Open: This valve will open if respective Pump suction valve is OPEN

(d) Auto Close: This valve will close if both Pump suction valve is CLOSE

(e) Override Close: These valve will be Closed when respective Tank Level is VERY HIGH.

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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

Section-8 Primary & Secondary Dewatering

System

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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
(iii) Process Flow Diagram of Limestone Grinding and Slurry Preparation System, DVC Doc. No2109-
122-PVM-F-001A
(iv) P&ID Primary & Secondary Dewatering, DVC Doc. No.2109-122-PVM-F-011
(v) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(vi) Tender – Scheme of FGD – Gypsum Dewatering System, DVC Doc. No. 2109-121-POM-A-003

2 PROCESS DESCRIPTION

The FGD byproduct solids (gypsum, unreacted limestone, inert material, and fly ash) are pumped as
around 15-25 weight percent slurry from JBR to Primary Hydrocyclone Feed Tank by the Gypsum Bleed
Pump. A portion of the gypsum bleed pump discharge is returned to JBR mixed with limestone slurry
as described before. The byproduct solids are directed from the Primary Hydrocyclone Feed Tank to
the Primary Hydrocyclone by the Primary Hydrocyclone Feed Pump. The slurry enters the primary
hydrocyclone tangentially and centrifugal forces separate the feed slurry into a high‐solids underflow
and low‐solids overflow. The concentrated underflow from the primary hydrocyclone, at maximum 45
weight percent solids, is discharged to the Vacuum Belt Filter. The overflow from the Primary
Hydrocyclone is routed to the Secondary Hydrocyclone via Secondary Hydro‐Cyclone Feed Tank and
pump. The secondary hydro‐cyclone overflow is routed to the waste water tank.

3 CONTROL PHILOSOPHY

The group level shall control a set of functional sub-groups of drives. Appropriate start-up and shut
down commands shall be issued to the sub-group control and various check-backs shall be received
from sub-groups or drives. Each sub-group shall execute the sequential start-up and shut down
programs of a set Of inter-related drives along with system interlocks and protections associated

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104
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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

with that sub-group as well as basic interlocks and protections related to individual drive falling under
that sub-group.
Gypsum Slurry will be transferred to Primary Hydro cyclone with the help of two Primary hydro cyclone
feed pumps. The Slurry will be recirculated to primary hydro cyclone feed tank if the discharge
pressure of Slurry in the common header line goes beyond some specified limit. Further Primary Hydro
cyclone underflow will be transferred to Vacuum belt filter & overflow to Second Hydro cyclone Feed
Tank & Waste water Tank. Then Overflow will be transferred to Secondary Hydro cyclone with the
help of two Secondary Hydro cyclone feed pumps. Gypsum Slurry will be recirculated to secondary
hydro cyclone tank to maintain the specified discharge pressure to secondary hydro cyclone.. Further
Secondary Hydro cyclone overflow will be transferred to Waste water Tank & underflow to Filtrate
water tank.

4 CONTROLS AND INTERLOCKS FOR PRIMARY DEWATERING FEED SYSTEM :

4.1 GROUP DEFINITION:

The Primary Hydrocyclone Feed Pump Group integrates the operation of the complete train of
respective Primary Hydrocyclone Feed Pump including its suction valve, discharge valve, drain valve
and wash valve. Below listed is the sequence of operation for Primary Hydrocyclone Feed Pump -A
Group. Similar operation philosophy will be applicable for Primary Hydrocyclone Feed Pump -B and
their corresponding valves also.

5 PRIMARY HYDROCYCLONE FEED PUMPS A/B (00HTM02AP001/00HTM03AP001) GROUP SEQUENCE:

The primary hydrocyclone feed pumps Group Sequence integrates the operation of the complete train
of respective primary hydrocyclone feed pumps including its suction valve, discharge valve, drain valve
and wash valve. Below listed is the sequence of operation for primary hydrocyclone feed pump-A
Group. Similar operation philosophy will be applicable for primary hydrocyclone feed pump-B and
their corresponding valves also.

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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

5.1.1 PRIMARY HYDROCYCLONE FEED PUMP (PHFP) GROUP START:

(a) The primary hydrocyclone feed pump group start will be allowed only if the following conditions
are satisfied

(i) Primary Hydrocyclone Feed Tank Level NOT LOW LOW 1

(ii) Pump-A Suction Valve 00HTM02AA001 closed AND
(iii) primary hydrocyclone feed pump-A START Permissive available (except for its
suction Valve open status)

(b) Group Start Command:

Primary Hydrocyclone Feed Pump-A Group Start can be initiated by Operator manually or on
receiving Auto-start signal in either of the following conditions –

(i) Primary Hydrocyclone Feed Pump-A on standby and Running Primary Hydrocyclone
Feed Pump trips (electrical trip or PHFP stop due to Override Trip command)
(ii) PHFP-A on standby and PHFP Discharge Header Pressure remains low for more than
predefined time decided at the time of commissioning.
(iii) Start Command received from Changeover Sequence

(c) Group Start Sequence:

(i) Step-1: PHFP-A suction valve open command

(ii) Step-2: PHFP Overflow Valve open command
(iii) Step-3: PHFP-A start command
(iv) Step-4: After preset time (as per PHFP OEM recommendation), PHFP-A discharge
valve open command
(v) The PHFP-A Group Start will be considered complete when all the above sequenced
steps are completed successfully.

5.1.2 PRIMARY HYDROCYCLONE FEED PUMP GROUP STOP

(a) Group Stop Permissive: None
(b) Group Stop Command:

PHFP-A Group Stop can be initiated by Operator manually or on receiving Auto-stop signal in
either of the following conditions –
(i) From PHFP Group Shutdown sequence OR

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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

(ii) Primary HC Feed Tank level low low (Set Point low low will be defined at the time of
commissioning
(c) Group Stop Sequence:
(i) Step-1: PHFP Overflow Valve close command
(ii) Step-2: PHFP-A discharge valve close command
(iii) Step-3: PHFP-A stop command
(iv) Step-4: PHFP-A suction valve close command
(v) Step-5: PHFP-A drain valve open command
(vi) Step-6: PHFP-A wash valve open command
(vii) Step-7: PHFP-A wash valve close command after predefined time decided at the time
of commissioning.
(viii) Step-8: PHFP-A drain valve close command
PHFP-A group stop shall be considered complete when all the above sequenced steps are
completed successfully.

5.2 PRIMARY HYDROCYCLONE FEED PUMP ( 00HTM02AP001/00HTM03AP001)

(a) Start Permissive:
(i) Primary HC Feed Tank Level NOT LOW
(ii) Pump-A Suction Valve 00HTM02AA001 open AND
(iii) Pump-A Discharge valve 00HTM02AA002 Closed AND 1
(iv) Pump-A wash valve 00HTM02AA103 Closed
(v) Pump-A drain valve 00HTM02AA102 Closed
(b) Stop Permissive:
None
(c) Auto Start Command:

From respective Primary Hydrocyclone Feed pump (PHFP) Group Start Sequence

(d) Auto Stop Command:

From respective Primary Hydrocyclone Feed pump (PHFP) Group Stop Sequence
(e) Override Trip Command:
(i) Pump running and respective pump discharge isolation valve not opened for more
than Predefined time decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) Primary HC Feed Tank Level low low OR
(iv) Vacuum pump motor trip OR
(v) Belt filter deviation signal is active
(vi) As per PHFP (and its Motor) OEM’s recommendation if any.

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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

5.3 PRIMARY HYDROCYCLONE FEED PUMP SUCTION VALVEs (00HTM02AA001/00HTM03AA001)

(a) Open Permissive :

The Primary Hydrocyclone Feed Pump-A Suction valve will be opened only if the following
condition is satisfied

- Pump A drain valve and Wash valve is CLOSED

(b) Close Permissive :

The Primary Hydrocyclone Feed Pump-A Suction valve will be closed only if the following
condition is satisfied

- Pump-A is not running

(c) Auto Open & Close :

The Primary Hydrocyclone Feed Pump suction VALVEs will OPEN & CLOSE automatically by
respective Primary Hydrocyclone Feed Pump group START and STOP sequence activation.

5.4 PRIMARY HYDROCYCLONE FEED PUMP discharge VALVEs (00HTM02AA002/00HTM03AA002)

(a) Open Permissive :

The Primary Hydrocyclone Feed Pump-A discharge valve will be opened only if the following
condition is satisfied

- Pump-A is running

(b) Close Permissive :

The Primary Hydrocyclone Feed Pump-A discharge valve will be closed only if the following
condition is satisfied

- Pump-A is not running

(c) Auto Open & Close :

The Pump suction VALVEs will start & stop automatically by respective Primary Hydrocyclone
Feed Pump group START and STOP sequence activation.

5.5 PRIMARY HYDROCYCLONE FEED PUMP DRAIN VALVES (00HTM02AA102/00HTM03AA102)

Fail condition: Fail Close

(a) Open Permissive :

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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

- Pump not running

- Suction Valve and Discharge Valve Closed.

(b) Close Permissive :

- Wash Valve is CLOSED.

(c) Auto Open & Close :

The Pump drain VALVEs will open & close automatically by respective Primary Hydrocyclone
Feed Pump group START and STOP sequence activation.

5.6 PRIMARY HYDROCYCLONE FEED PUMP Wash Valves (Tag: 00HTM02AA002/00HTM03AA002)

Fail condition: Fail Close

(a) Open Permissive :

- Drain Valve is OPEN

(b) Close Permissive :

- None

(c) Auto Open & Close :

The Pump wash valves will open & close automatically by respective Primary Hydrocyclone Feed
Pump group START and STOP sequence activation.

5.7 PRIMARY HYDROCYCLONE FEED TANK AGITATOR (00HTM01AM001)

(a) Start Permissive :

The Primary Hydrocyclone Feed tank (00HTM01BB001) agitator (00HTM01AM001) will be

allowed to start if the following condition is satisfied
- Primary Hydrocyclone Tank Level (00HTM01CL101/102) NOT LOW.

(b) Stop Permissive : None

(c) Auto Start & Stop :

Agitator will be automatically managed by DCS based on level in Primary Hydrocyclone tank.
Once Primary Hydrocyclone tank Level is higher than a LOW Level, the agitator will be

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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

automatically started. The Primary Hydrocyclone tank agitator will auto stop when the
Primary Hydrocyclone Tank Level LOW LOW.
Notes: LOW and LOW LOW values will be defined during commissioning stage.

5.8 PRIMARY HYDROCYCLONE FEED INLET VALVES (00HTM04AA100/00HTM04AA101)

Fail condition: Fail-In-Place

(a) Open Permissive :

- None
(b) Close Permissive :
- None
1
(c) Auto Open & Close :
The Primary Hydro Cyclone Feed Inlet valves will OPEN if
- PHFP-1 OR 2 is running for x secs (x will be defined at the time of commissioning)
AND
- VBF-1 is ON (00HTM11GH001-XB08) (for Valve 00HTM04AA100)
OR VBF-2 is ON (00HTM21GH001-XB08) (for Valve 00HTM04AA101)
The Primary Hydro Cyclone Feed Inlet valves will CLOSE if
- VBF-1 OFF TRACKING ALARM (00HTM11CG705-XG01& 00HTM11CG706XG01) IS
INITIATED
(for Valve 00HTM04AA100)
- VBF-2 OFF TRACKING ALARM (00HTM21CG705-XG01& 00HTM21CG706XG01) IS
INITIATED
(for Valve 00HTM04AA101)

5.9 PRIMARY HYDROCYCLONE OVERFLOW VALVE (00HTM06AA100/00HTM05AA100)

Fail condition: Fail-In-Place
(a) Open Permissive :
- None

(b) Close Permissive :

- None

(c) Auto Open & Close :

The Primary Hydrocyclone Overflow valve will OPEN & CLOSE automatically by respective
Primary Hydrocyclone Feed Pump group START and STOP sequence activation.

5.10 DEWATERING RECIRCULATION FEED FLOW CONTROL VALVE (00HTM04AA300)

Fail condition: Fail to open
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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Override Open Command:

None

(d) Override Close Command:

None

(e) Modulating Control:

Control Action – Forward Acting

The Control mode shall be shifted as follows by the Primary hydrocyclone feed pump
operational Status
(i) If gypsum slurry pressure is increased beyond desired limit, then the control valve needs
to be opened. % opening of control valve is dependent on the controller output.

6 CONTROLS AND INTERLOCKS FOR SECONDARY DEWATERING FEED SYSTEM :

6.1 GROUP DEFINITION:

The Secondary Hydrocyclone Feed Pump Group integrates the operation of the complete train of
respective Secondary Hydrocyclone Feed Pump including its suction valve, discharge valve, drain valve
and wash valve. Below listed is the sequence of operation for Secondary Hydrocyclone Feed Pump-A
Group. Similar operation philosophy will be applicable for Secondary Hydrocyclone Feed Pump-B and
their corresponding valves also.

6.2 SECONDARY HYDROCYCLONE FEED PUMPS A/B (00HTM32AP001/00HTM33AP001) GROUP

SEQUENCE:

The Secondary Hydrocyclone Feed Pump Group Sequence integrates the operation of the complete
train of respective Secondary Hydrocyclone Feed Pump including its suction valve, discharge valve,
drain valve and wash valve. Below listed is the sequence of operation for Secondary Hydrocyclone
Feed Pump-A Group. Similar operation philosophy will be applicable for Secondary Hydrocyclone Feed
Pump-B and their corresponding valves also.
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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

6.2.1 SECONDARY HYDROCYCLONE FEED PUMP (SHFP) GROUP START:

(a) The Secondary Hydrocyclone Feed Pump group start will be allowed only if the following
conditions are satisfied

(i) Secondary HC Tank Level NOT LOW

(ii) Pump-A Suction Valve 00HTM32AA100 closed AND
(iii) SHFP-A START Permissive available (except for SHFP suction Valve open status)

(b) Group Start Command:

SHFP-A Group Start can be initiated by Operator manually or on receiving Auto-start signal
in either of the following conditions –

(i) SHFP-A on standby and Running SHFP trips (electrical trip or SHFP stop due to
Override Trip command)
(ii) SHFP-A on standby and SHFP Discharge Header Pressure remains low for more than
predefined time decided at the time of commissioning.
(c) Group Start Sequence:

(i) Step-1: SHFP-A suction valve open command

(ii) Step-2: SHFP-A start command
(iii) Step-3: After preset time (as per SHFP OEM recommendation), SHFP-A discharge
valve open command
(iv) The SHFP-A Group Start will be considered complete when all the above sequenced
steps are completed successfully.

6.2.2 SECONDARY HYDROCYCLONE FEED PUMP STOP

(a) Group Stop Permissive: None

(b) Group Stop Command:

SHFP-A Group Stop can be initiated by Operator manually or on receiving Auto-stop signal
in either of the following conditions –
(i) From Secondary HC Feed Pump Group Shutdown sequence OR
(ii) Secondary HC Tank level very low
(c) Group Stop Sequence:
(i) Step-1: SHFP-A discharge valve close command
(ii) Step-2: SHFP-A stop command
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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

(iii) Step-3: SHFP-A suction valve close command

(iv) Step-4: SHFP-A drain valve open command
(v) Step-5: SHFP-A wash valve open command
(vi) Step-6: SHFP-A wash valve close command after predefined time decided at the
time of commissioning.
(vii) Step-7: SHFP-A drain valve close command
(viii) SHFP-A group stop shall be considered complete when all the above sequenced
steps are completed successfully.

6.3 SECONDARY HYDROCYCLONE FEED PUMPS ( 00HTM32AP001/00HTM33AP001)

(a) Start Permissive:

(i) Secondary HC Tank Level NOT LOW
(ii) Pump-A Suction Valve 00HTM32AA100 open AND 1
(iii) Pump-A Discharge valve 00HTM32AA101 Closed AND
(iv) Pump-A wash valve 00HTM32AA103 Closed
(v) Pump-A drain valve 00HTM32AA102Closed
(b) Stop Permissive: None

(c) Auto Start Command:

From respective Secondary Hydrocyclone Feed pump (SHFP) Group Start Sequence

(d) Auto Stop Command:

From respective Secondary Hydrocyclone Feed Pumps (SHFP) Group Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more
than predefined time decided at the time of commissioning. OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) Secondary HC Tank level very low OR
(iv) As per SHFP (and its Motor) OEM’s recommendation if any.

6.4 SECONDARY HYDROCYCLONE FEED PUMP SUCTION VALVEs (00HTM32AA100/00HTM33AA100)

Fail condition: Fail-In-Place

(a) Open Permissive :

The Secondary Hydrocyclone Feed pump-A Suction valve will be opened only if the following
condition is satisfied
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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

- Pump A drain valve and Wash valve is CLOSED

(b) Close Permissive :

The Secondary Hydrocyclone Feed pump-A Suction valve will be closed only if the following
condition is satisfied

- Pump-A is not running

(c) Auto Open & Close :

The Secondary Hydrocyclone Feed Pump Suction VALVEs will OPEN & CLOSE automatically by
respective gypsum bleed pump group START and STOP sequence activation.

6.5 SECONDARY HYDROCYCLONE FEED Pumps discharge VALVEs (00HTM32AA101/00HTM33AA101)

Fail condition: Fail-In-Place

(a) Open Permissive :

The Secondary Hydrocyclone Feed pump-A discharge valve will be opened only if the
following condition is satisfied

- Pump-A is running

(b) Close Permissive :

The Secondary Hydrocyclone Feed pump-A discharge valve will be closed only if the
following condition is satisfied

- Pump-A is not running

(c) Auto Open & Close :

The Pump suction VALVEs will start & stop automatically by respective Secondary
Hydrocyclone Feed pump group START and STOP sequence activation.

6.6 SECONDARY HYDROCYCLONE FEED PUMPS DRAIN VALVES (00HTM32AA102/00HTM33AA102)

Fail condition: Fail Close

(a) Open Permissive :

- Pump not running
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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

- Suction Valve and Discharge Valve Closed.

(b) Close Permissive :
- Wash Valve is CLOSED.
(c) Auto Open & Close :

The Pump drain valves will open & close automatically by respective gypsum bleed pump group
START and STOP sequence activation.

6.7 SECONDARY HYDROCYCLONE FEED PUMPS WASH VALVES (TAG: 00HTM32AA103/00HTM33AA103)

Fail condition: Fail Close

(a) Open Permissive :

- Drain Valve is OPEN
(b) Close Permissive :
- None
(c) Auto Open & Close :

The Pump wash valves will open & close automatically by respective gypsum bleed pump group
START and STOP sequence activation.

6.8 SECONDARY HYDROCYCLONE FEED TANK AGITATOR (00HTM31AM001)

(a) Start Permissive :

The secondary hydrocyclone Feed tank (00HTM31BB001) agitator (00HTM31AM001) will be allowed
to start if the following condition is satisfied
- Secondary Hydrocyclone Tank Level (00HTM31CL101/102) NOT LOW.

(b) Stop Permissive : None

(c) Auto Start & Stop :

Agitator will be automatically managed by DCS based on level in Secondary Hydrocyclone tank.
Once Secondary Hydrocyclone tank Level is higher than a LOW Level, the agitator will be
automatically started. The Secondary Hydrocyclone tank agitator will auto stop when the
Secondary Hydrocyclone Tank Level LOW LOW.
Notes: LOW and LOW LOW values will be defined during commissioning stage.

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

6.9 SECONDARY HYDROCYCLONE FEED INLET VALVEs (00HTM34-AA100/00HTM34AA101)

Fail condition: Fail-In-Place

(a) Open Permissive :

- None
(b) Close Permissive :
- None
(c) Auto Open & Close :

The Secondary Hydro cyclone Feed Inlet valves will OPEN if

- SHFP-1 OR 2 is running for x secs (x will be defined at the time of commissioning)
AND
- VBF-1 OR VBF-2 is ON (00HTM11/21GH001-XB08 )

The Primary Hydro cyclone Feed Inlet valves will CLOSE if

- If both secondary Hydrocyclone feed pump are OFF

6.10 DEWATERING RECIRCULATION FEED FLOW CONTROL

The overflow from the Primary Hydrocyclone is routed to the Secondary Hydrocyclone via Secondary
Hydro‐Cyclone Feed Tank. The feed-rate flow is monitored by magnetic flow transmitter
00HTM34CF101, installed in the discharge line of Secondary Hydrocyclone Feed tank to Secondary
Hydrocyclone. Slurry will be recycled back to secondary hydrocyclone to maintain the desired pressure
in the discharge line to secondary hydrocyclone. % opening of recirculation valve 00HTM34AA300 will
be controlled by the discharge Pressure 00HTM34CP101.

6.10.1 DEWATERING RECIRCULATION FEED FLOW CONTROL VALVE (00HTM34AA300)

Fail condition: Fail to OPEN

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Override Open Command:

None
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Section-8 Primary & Secondary
DVC DOC NO. 2109-122-PVM-G-006 Rev. 01 21 jan’22
System

(d) Override Close Command:

None

(e) Modulating Control:

Control Action – Forward Acting

The Control mode shall be shifted as follows by the secondary hydrocyclone feed pump
operational Status
(ii) If gypsum slurry pressure is increased beyond desired limit, then the control valve needs
to be opened. % opening of control valve is dependent on the controller output.

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DVC DOC NO. 2109-122-PVM-G-006 Section-9 All Sump & Pump System Rev. 01 21 Jan’22

Section-9 All Sump & Pump System

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DVC DOC NO. 2109-122-PVM-G-006 Section-9 All Sump & Pump System Rev. 01 21 Jan’22

1 REFERENCE DOCUMENTS
(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
(iii) Process Flow Diagram of Limestone Grinding and Slurry Preparation System, DVC Doc. No. 2109-
122-PVM-F-001A
(iv) P&ID Sumps & Pumps, DVC Doc. No. 2109-122-PVM-F-012

2 PROCESS DESCRIPTION

The JBR/DEWATERING/LIMESTONE/AUX ABSORBER area sump system includes the relevant area
trenches, the collecting sump with agitator and the pump and associated instrumentation and piping.
All the overflow line will be connected to the nearby trench and trench will be connected to the
respective area sump. The JBR area sump system collects all the process drains of the area by means
of a network of trenches that ends up in the sump. The drains collected in the sump are kept agitated
by the sump agitator to prevent solids from settling. The sump pumps return the collected drains to
the process, namely to the JBR or to the auxiliary storage tank for JBR Sump Pump, namely to the
Primary Hydrocyclone Feed Tank for DEWATERING Sump Pump, namely to Mill recirculation Tank &
lime stone slurry tanks common to unit 7 and 8 for LIMESTONE Sump Pump, namely to Absorber Unit-
7 & 8 for aux absorbent sump Pump.

3 CONTROL PHILOSOPHY

There are four Sump Pumps in FGD projects. They are Absorber Sumps, Limestone Grinding Sumps
Dewatering sumps and Aux absorbent Sumps. Level transmitters are installed in the Sumps in order
to measure the Sump Level Also Agitator is given in order to continuous agitating of medium.

4 CONTROLS AND INTERLOCKS :

4.1 SUMP PUMPS (07HTT11AP001/00HTT31AP001/00HTT51AP001/00HTT61AP001) INTERLOCKS:

(a) Start Permissive:

(i) ABS /GYP DWTR /LIMSTONE/AUX ABS SUMP SLURRY Level NOT LOW
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L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104 Control Philosophy of FGD system Page 109 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-9 All Sump & Pump System Rev. 01 21 Jan’22

(ii) Absorber Sump Pump-A START Permissive available

(b) Stop Permissive:

None

(c) Auto Start Command:

From respective SUMP Pump Start Sequence

(d) Auto Stop Command:

From respective SUMP Pump Stop Sequence

(e) Override Trip Command:

None

(f) SUMP PUMP START UP SEQUENCE:

Step-1: Start permissive satisfied

Step-2: Start Sump pump
Step-3: Open Sump Pump discharge valve after predefined Time
Step-4: Sequence ends.
(g) SUMP Pump SHUT DOWN SEQUENCE:

Step-1: STOP Sump Pump

Step-2: After Sump Pump is detected close for xx secs, close discharge valve.
Step-3: Sequence ends

4.2 SUMP PUMPS DISCHARGE VALVES (07HTT11AA100/101), (00HTT31AA101), (00HTT51AA102/103)

& (07HTT61AA100/08HTT61AA100)
Fail condition: Fail In Place

(a) Open Permissive :

SUMP PUMP DISCHARGE valve will be opened only if the following condition is satisfied

- Respective Pump is running

(b) Close Permissive :

SUMP PUMP DISCHARGE valve will be closed only if the following condition is satisfied
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DVC DOC NO. 2109-122-PVM-G-006 Section-9 All Sump & Pump System Rev. 01 21 Jan’22

-Respective Pump is not running

(a) Auto Open & Close :
The Pump DISCHARGE VALVEs will start & stop automatically by respective Sump Pump START
and STOP sequence activation.

4.3 SUMP TANK AGITATOR (07HTT11AM001/00HTT31AM001/00HTT51AM001/00HTT61AM001)

(b) Start Permissive :

The SUMP agitator will be allowed to start if the following condition is satisfied
- SUMP Level NOT LOW.

(c) Stop Permissive : None

- Notes: LOW and LOW LOW values will be defined during commissioning stage.

(d) Auto Start & Stop :

Agitator will be automatically managed by DCS based on level in SUMP. Once SUMP Level is higher
than a LOW Level, the agitator will be automatically started. The SUMP agitator will auto stop when
the SUMP Level LOW LOW.

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DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

Section 10 Waste Water System

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DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
(iii) P&ID of Wastewater Neutralization and Discharge, DVC Doc. No. 2109-122-PVM-F-504
(iv) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(v) Tender – Scheme of FGD – Gypsum Dewatering System, DVC Doc. No. 2109-121-POM-A-003

2 PROCESS DESCRIPTION

A part of overflow from the Primary Hydrocyclone is routed to the Secondary Hydrocyclone via
Secondary Hydro‐Cyclone Feed Tank and pump. The secondary hydro‐cyclone overflow is taken to the
waste water tank. A portion of the waste water in the waste water tank is discharged to maintain
required concentration of chlorides and soluble salts in liquid throughout the FGD System. The waste
water is delivered to the waste water terminal point after the pH adjustment by lime dozing system
in Additional waste water tank. The remaining portion of waste water overflow transferred to the
Filtrate water tank.

3 CONTROL PHILOSOPHY

The group level shall control a set of functional sub-groups of drives. Appropriate start-up and shut
down commands shall be issued to the sub-group control and various check-backs shall be received
from sub-groups or drives. Each sub-group shall execute the sequential start-up and shut down
programs of a set

Of inter-related drives along with system interlocks and protections associated with that sub-group as
well as basic interlocks and protections related to individual drive falling under that sub-group.

Waste Water will be transferred to Additional Waste Water Tank with the help of two Waste Water
pumps. The Waste Water flow is controlled by Control valve 00HTL23AA300. The control valve
opening will be controlled by Waste Water flow measured by 00HTL23CF101. During shut down
condition of Waste Water pump, waste water line will be flushed with process water. After the pH
adjustment by lime dozing system, Waste Water will be transferred to waste water terminal point
with the help of Waste Water bleed pump. During shut down condition of Wastewater Bleed Pump,
wastewater bleed line will be flushed with process water.

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DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

4 CONTROLS AND INTERLOCKS:

4.1 GROUP DEFINITION:

The Waste Water Pump Group integrates the operation of the complete train of respective Waste
Water Pump including its suction valve, discharge valve, drain valve and wash valve. Below listed is
the sequence of operation for Waste Water Pump -A Group. Similar operation philosophy will be
applicable Waste Water Pump -B and their corresponding valves also.

4.2 WASTE WATER PUMPS (00HTL21AP001/00HTL22AP001) GROUP SEQUENCE:

The Waste water Pump Group Sequence integrates the operation of the complete train of respective
Waste water pump including its suction valve, discharge valve, drain valve and wash valve. Below
listed is the sequence of operation for Waste water Pump-A Group. Similar operation philosophy will
be applicable for Waste water Pump-B and their corresponding valves also.

4.2.1 WASTE WATER PUMP GROUP START:

(a) The Waste water Pump-A group start will be allowed only if the following conditions are satisfied

(i) Waste water tank Level NOT LOW

(ii) Pump-A Suction Valve 00HTL21AA100 Closed AND
(iii) Waste water Pump-A START Permissive available (except for Waste water pump suction valve
open status)

(b) Group Start Command:

Waste water Pump-A Group Start can be initiated by Operator manually or on receiving Auto-start
signal in either of the following conditions –

(i) Waste water Pump-A on standby and Running Waste water Pump trips (electrical trip or
Waste water Pump stop due to Override Trip command)
(ii) Waste water Pump-A on standby and Waste water Pump Discharge Header Pressure remains
low for more than predefined time decided at the time of commissioning.
(iii) Start Command received from Changeover Sequence

(c) Group Start Sequence:

(i) Step-1: Waste water Pump-A suction valve open command

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110104 Control Philosophy of FGD system Page 114 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

(ii) Step-2 Waste water Pump-A start command

(iii) Step-3: After preset time (as per Waste water Pump OEM recommendation), Waste water Pump-
A discharge valve open command
(iv) The Waste water Pump-A Group Start will be considered complete when all the above sequenced
steps are completed successfully.

4.2.2 WASTE WATER PUMP GROUP STOP

(a) Group Stop Permissive:

None

(b) Group Stop Command:

Waste water Pump-A Group Stop can be initiated by Operator manually or on receiving Auto-
stop signal in either of the following conditions –
(i) Waste Water Tank level very low (Set Point Very low will be defined at the time of
commissioning)
(c) Group Stop Sequence:
(i) Step-1: Waste water Pump-A discharge valve close command
(ii) Step-2: Waste water Pump-A stop command
(iii) Step-3: Waste water Pump-A suction valve close command

Waste water Pump-A group stop shall be considered complete when all the above sequenced steps
are completed successfully.

4.3 WASTE WATER PUMPS (00HTL21AP001/00HTL22AP001)

(a) Start Permissive:

(i) Waste water tank Level NOT LOW LOW
(ii) Pump-A Suction Valve 00HTL21AA100 Closed AND
(iii) Pump-A Discharge valve 00HTL21AA101 Closed AND
(iv) Pump-A Drain valve 00HTL21AA600 Closed Manually
(v) Pump-A Wash valve 00HTL21AA602 Closed Manually
(b) Stop Permissive:
None

(c) Auto Start Command:

From respective Waste water Pump Group Start Sequence

(d) Auto Stop Command:

From respective Waste water Pump Group Stop Sequence

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110104 Control Philosophy of FGD system Page 115 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more
than predefined time decided at the time of commissioning. OR
(ii) Pump running and respective pump suction isolation valve OPEN feedback lost OR
(iii) Waste water tank level very low OR
(iv) As per waste water Pump (and its Motor) OEM’s recommendation if any.

4.4 WASTE WATER PUMPS SUCTION VALVES (00HTL21AA100/00HTL22AA100)

Fail condition: Fail-In-Place

(a) Open Permissive :

The Waste water Pump-A Suction valve will be opened only if the following condition is satisfied

- Pump A drain valve and Wash valve is CLOSED

(b) Close Permissive :

The Waste water Pump-A Suction valve will be closed only if the following condition is satisfied

- Pump-A is not running

(c) Auto Open & Close :

The Waste water Pump-A suction valves will open & close automatically by respective waste water
Pump group START and STOP sequence activation.

4.5 WASTE WATER PUMPS DISCHARGE VALVES (00HTL21AA101/00HTL22AA101)

Fail condition: Fail-In-Place

(a) Open Permissive :

The Waste water Pump-A discharge valve will be opened only if the following condition is satisfied

- Pump-A is running

(b) Close Permissive :

The Waste water Pump-A discharge valve will be closed only if the following condition is satisfied

- Pump-A is not running

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DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

(c) Auto Open & Close :

The Waste water Pump-A discharge valves will open & close automatically by respective waste
water Pump group START and STOP sequence activation.

4.6 WASTE WATER TANK AGITATOR (00HTL20AM001)

(a) Start Permissive :

The Waste water tank (00HTL20BB001) agitator (00HTL20AM001) will be allowed to start if the
following condition is satisfied

- Waste water Tank Level (00HTL20CL101) NOT LOW.

(b) Stop Permissive : None

(c) Auto Start & Stop:

Agitator will be automatically managed by DCS based on level in waste water tank. Once Waste water
tank Level is higher than a LOW Level, the agitator will be automatically started.
The Waste water tank agitator will auto stop when the Waste water Tank Level LOW LOW.

Notes: LOW and LOW LOW values will be defined during commissioning stage.

4.7 WASTE WATR OVERFLOW VALVE (00HTM06AA101/00HTM05AA101)

Fail condition: Fail-In-Place 1
(d) Open Permissive :
- None

(e) Close Permissive :

- None

(f) Auto Open & Close :

The Primary Hydrocyclone Overflow valve will OPEN & CLOSE automatically by respective
Waste Water Pump group START and STOP sequence activation.

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104 Control Philosophy of FGD system Page 117 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

4.8 WASTE WATER FLOW CONTROL

Waste water flow to additional waste water tanks needs to be controlled. Flow transmitter
00HTL23CF101 will measure waste water flow and control valve 00HTL23AA300 opening will be
controlled based on desire flow rate. Rest amount of Waste water will be recycled to waste water
tank.

4.8.1 WASTE WATER TANK TO ADD WASTE WATER TANK CONTROL VALVE (00HTL23AA300)
Fail condition: Fail in place

(a) Open Permissive:

None

(b) Close Permissive:

None

(c) Override Open Command:

(i) None

(d) Override Close Command:

None

(e) Modulating Control:

Control Action – Reverse Acting

The Control mode shall be shifted as follows by the Waste water pump operational Status

(i) If waste water flow rate is increased beyond desired flow, then the control valve needs
to be closed. % of closing is dependent on the controller output.

4.9 GROUP DEFINITION:

The Waste Water Bleed Pump Group integrates the operation of the complete train of respective
Waste Water Bleed Pump including its suction valve, discharge valve, drain valve and wash valve.
Below listed is the sequence of operation for Waste Water Bleed Pump -A Group. Similar operation
philosophy will be applicable Waste Water Bleed Pump -B and their corresponding valves also.

4.10 WASTE WATER BLEED PUMPS (00HTL31AP001/00HTL32AP001) GROUP SEQUENCE:

The Waste Water Bleed Pump Group Sequence integrates the operation of the complete train of
respective Waste Water Bleed Pump including its suction valve, discharge valve, drain valve and wash
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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104 Control Philosophy of FGD system Page 118 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

valve. Below listed is the sequence of operation for Waste Water Bleed Pump-A Group. Similar
operation philosophy will be applicable for Waste Water Bleed Pump -B and their corresponding
valves also.

4.10.1 WASTE WATER BLEED PUMP (WWBP) GROUP START:

(a) The Waste Water Bleed Pump group start will be allowed only if the following conditions are
satisfied

(i) Additional Waste Water Tank Level 00HTL30CL101/00HTL30CL102 NOT LOW

(ii) Pump-A Suction Valve 00HTL31AA100 closed AND
(iii) Pump-A START Permissive available (except for WWBP suction Valve open status)

(b) Group Start Command:

WWBP-A Group Start can be initiated by Operator manually or on receiving Auto-start signal in either
of the following conditions –

(i) WWBP-A on standby and Running WWBP trips (electrical trip or WWBP stop due to Override
Trip command)
(ii) WWBP-A on standby and WWBP Discharge Header Pressure remains low for more than
predefined time decided at the time of commissioning.

(c) Group Start Sequence:

(i) Step-1: WWBP-A suction valve open command

(ii) Step-2: WWBP-A start command
(iii) Step-3: After preset time (as per WWBP OEM recommendation), WWBP-A discharge valve open
command
(iv) The WWBP-A Group Start will be considered complete when all the above sequenced steps are
completed successfully.

4.10.2 WASTE WATER BLEED PUMP GROUP STOP

a) Group Stop Permissive: None
b) Group Stop Command:

WWBP-A Group Stop can be initiated by Operator manually or on receiving Auto-stop signal in either
of the following conditions –
(i) From Waste Water Group Shutdown sequence OR
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DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

(ii) Waste Water Tank level very low

c) Group Stop Sequence:
(i) Step-1: WWBP-A discharge valve close command
(ii) Step-2: WWBP-A stop command
(iii) Step-3: WWBP-A suction valve close command
(iv) Step-4: WWBP-A wash valve closed manually.
(v) Step-5: WWBP-A drain valve closed manually.
WWBP-A group stop shall be considered complete when all the above sequenced steps are
completed successfully.

4.11 WASTE WATER BLEED PUMPS ( 00HTL31AP001/00HTL32AP001)

a) Start Permissive:
(i) Additional Waste Water Tank Level 00HTL30CL101/00HTL30CL102 NOT LOW
(ii) Pump-A Suction Valve 00HTL31AA100 open AND
(iii) Pump-A Discharge valve 00HTL31AA101 Closed AND
(iv) Pump-A wash valve 00HTL31AA603 Closed manually.
(v) Pump-A drain valve 00HTL31AA600 Closed manually.

b) Stop Permissive: None

c) Auto Start Command:

From respective Waste Water Bleed Pump (WWBP) Group Start Sequence

d) Auto Stop Command:

From respective Waste Water Bleed Pump (WWBP) Group Stop Sequence

e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined time decided at the time of commissioning. OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) Additional waste water tank level very low OR
(iv) As per WWBP (and its Motor) OEM’s recommendation if any.

4.12 WASTE WATER BLEED PUMPS SUCTION VALVES (0000HTL31AA100/00HTL32AA100)

Fail condition: Fail-In-Place

a) Open Permissive :

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DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

The Waste Water Bleed pump-A Suction valve will be opened only if the following condition is
satisfied

- Pump A drain valve and Wash valve is CLOSED

b) Close Permissive :

The Waste Water Bleed pump-A Suction valve will be closed only if the following condition is
satisfied

- Pump-A is not running

c) Auto Open & Close :

The Waste Water Bleed Pump suction VALVEs will OPEN & CLOSE automatically by respective Waste
Water bleed pump group START and STOP sequence activation.

4.13 WASTE WATER BLEED PUMPS DISCHARGE VALVES (00HTL31AA101/00HTL32AA101)

Fail condition: Fail-In-Place

a) Open Permissive :

The Waste Water Bleed pump-A discharge valve will be opened only if the following condition is
satisfied

- Pump-A is running

b) Close Permissive :

The Waste Water Bleed pump-A discharge valve will be closed only if the following condition is
satisfied

- Pump-A is not running

c) Auto Open & Close :

The Pump discharge VALVEs will start & stop automatically by respective Waste Water bleed pump
group START and STOP sequence activation.

4.14 ADDITIONAL WASTE WATER TANK AGITATOR (00HTL30AM001)

a) Start Permissive :
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DVC DOC NO. 2109-122-PVM-G-006 Section-10 Waste Water System Rev. 01 21 Jan’22

The additional Waste water tank (00HTL30-BB001) agitator (00HTL30AM001) will be allowed to
Start if the following condition is satisfied
Additional Waste water Tank Level (00HTL30CL101/00HTL30CL102) NOT LOW.

b) Stop Permissive : None

c) Auto Start & Stop :

Agitator will be automatically managed by DCS based on level in waste water tank. Once Waste
water tank Level is higher than a LOW Level, the agitator will be automatically started.
The Waste water tank agitator will auto stop when the Waste water Tank Level LOW LOW.

Notes: LOW and LOW LOW values will be defined during commissioning stage.

4.15 WASTE WATER RECIRCULATION VALVE (00HTL33AA101)

(a) Open Permissive: None
(b) Close Permissive: None
(c) Auto OPEN & CLOSE: Valve will OPEN once
- Pump-A OR Pump-B is running
- & Wastewater discharge PH <7.2 for x secs. (x secs will be decided at the time of
commissioning)
Valve will CLOSE once
- Wastewater discharge PH >7.2

4.16 WASTE WATER TERMINAL POINT VALVE (00HTL33AA100)

a) Open Permissive: The Waste Water Terminal Point valve will be opened only if the following
condition is satisfied
- Recirculation Valve (00HTL33AA101) is closed AND

- Pump A or B is Running.
b) Close Permissive: None
c) Auto Start & Stop None.

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DVC DOC NO. 2109-122-PVM-G-006 Section-11 Process Water System Rev. 01 21 Jan’22

Section 11 Process Water System

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DVC DOC NO. 2109-122-PVM-G-006 Section-11 Process Water System Rev. 01 21 Jan’22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
(iii) Process Flow Diagram of Limestone Grinding and Slurry Preparation System, DVC Doc. No. 2109-
122-PVM-F-001A
(iv) P&ID Process Water Tank and Pump System, DVC Doc. No. 2109-122-PVM-F-500
(v) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(vi) Tender – Scheme of FGD – Gypsum Dewatering System, DVC Doc. No. 2109-121-POM-A-003

2 PROCESS DESCRIPTION

Two (2) Process water Storage tanks (each tank catering to the requirements of 2 x500 MW units)
along with Four ( 4 Nos.) numbers of 4x100 % Process water pumps, along with all necessary piping,
valves, control & instrumentation to feed the tank from terminal point. Process water Storage level is
automatically controlled at operating level by controlling the water flow from the Cooling Tower Blow
down System from terminal point. Each of the two tanks shall be interconnected with an isolation
valve.

3 CONTROL PHILOSOPHY

The group level shall control a set of functional sub-groups of drives. Appropriate start-up and shut
down commands shall be issued to the sub-group control and various check-backs shall be received
from sub-groups or drives. Each sub-group shall execute the sequential start-up and shut down
programs of a set of inter-related drives along with system interlocks and protections associated with
that sub-group as well as basic interlocks and protections related to individual drive falling under that
sub-group.
Process water system will be stored in process water tank. The Level is measured by two level
transmitters installed in each of the two process water tank. Process water will be transferred to
different process systems as mentioned in P&ID from process water tank through process water
pump. The detailed control logic will be provided based on this process description and interlock Write
up.

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DVC DOC NO. 2109-122-PVM-G-006 Section-11 Process Water System Rev. 01 21 Jan’22

4 CONTROLS AND INTERLOCKS :

4.1 GROUP DEFINITION:

The Process Water Pump Group Sequence integrates the operation of the complete train of respective
feed including its suction valve, discharge valve, drain valve and wash valve. The below control write
up is for Pump Group-1 constituting Pump-A (00HTQ11AP001) and including their suction valve,
discharge valve, drain valve and wash valve. The same write up is applicable for Pump Group-2
constituting Pump-B (00HTQ12AP001). Same will be applicable for Pump Group-3 constituting
Pump-C (00HTQ13AP001) and Pump Group-4 constituting Pump-D (00HTQ14AP001).
During running condition of Process water Pump, the respective process water tank interconnected
outlet valve to other tank (not operating) will be kept close. Based on the Process water level and
system requirement, operator will select the Process water Tank by opening the discharge valve
manually.

4.2 PROCESS WATER PUMPS (00HTQ11AP001/12AP001/13AP001/14AP001) GROUP SEQUENCE:

The process water Pump Group Sequence integrates the operation of the complete train of respective
Process water Pump including its suction valve, discharge valve. Below listed is the sequence of
operation for Process water Pump group. Similar operation philosophy will be applicable for other
Process water Pumps and their corresponding valves also.

4.2.1 PROCESS WATER PUMP GROUP START:

(a) The Process water pump group start will be allowed only if the following conditions are satisfied

(i) Process Water tank level NOT LOW. (Set Point LOW will be defined at the time of
commissioning)
(ii) PWP START Permissive available (except for PWP suction Valve open status)

(b) Group Start Command:

Process water pump Group Start can be initiated by Operator manually or on receiving Auto-start
signal in either of the following conditions –

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DVC DOC NO. 2109-122-PVM-G-006 Section-11 Process Water System Rev. 01 21 Jan’22

(i) Process water pump on standby and Running PWP trips (electrical trip or PWP stop
due to Override Trip command)
(ii) Process water pump on standby and PWP common discharge Header Pressure
remains low for more than predefined time decided at the time of commissioning.
(c) Group Start Sequence:

(i) Step-1:Check Suction Valve OPEN Status

(ii) Step-1: PWP start command
(iii) After preset time (as per Process water Pump OEM recommendation), PWP-A
discharge valve open command
(iv) Process water pump Group-1 Start will be considered complete when all the above
sequenced steps are completed successfully.

4.2.2 PROCESS WATER PUMP GROUP-1 STOP

(a) Group Stop Permissive :

None

(b) Group Stop Command:

PWP Group-1 Stop can be initiated by Operator manually or on receiving Auto-stop signal in
either of the following conditions –
(i) Process Water Tank level low low (Set Point low low will be defined at the time of
commissioning)
(c) Group Stop Sequence:
(i) Step-1: PWP-A discharge valve close command
(ii) Step-2: PWP-A stop command
(iii) Process water Pump group-1 stop shall be considered complete when all the above
sequenced steps are completed successfully.

4.2.3 PROCESS WATER PUMPS(00HTQ11AP001/12AP001/13AP001/14AP001)

(a) Start Permissive:

(i) Process water tank Level 00HTQ01CL101/102 NOT LOW
(ii) Pump-A suction valve 00HTQ11AA600 Opened
(iii) Pump-A Discharge valve 00HTQ11AA001 Closed

(b) Stop Permissive:

None

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DVC DOC NO. 2109-122-PVM-G-006 Section-11 Process Water System Rev. 01 21 Jan’22

(c) Auto Start Command:

From respective Process water Pump (PWP) Group Start Sequence

(d) Auto Stop Command:

From respective Process water Pump (PWP) Group Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined time decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) Process Water Tank Level low low
(iv) As per PWP (and its Motor) OEM’s recommendation if any.

4.3 PROCESS WATER PUMPS DISCHARGE VALVES (00HTQ11AA001/12AA001/13AA001/14AA001)

Fail condition: Fail-In-Place

(a) Open Permissive :

The PWP-A discharge valve will be opened only if the following condition is satisfied

- Pump-A is running

(b) Close Permissive :

The PWP-A discharge valve will be closed only if the following condition is satisfied

- Pump-A is not running

(c) Auto Open :

The PWP-A discharge valves will open automatically by respective Bleed Pump group START
sequence activation.

(d) Auto Close :

The PWP-A discharge valves will close automatically if any of the following takes place:

- Close command received from respective Pump group STOP sequence

- Pump-A trips / not running

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DVC DOC NO. 2109-122-PVM-G-006 Section-11 Process Water System Rev. 01 21 Jan’22

4.4 PROCESS WATER PUMPS RECIRCULATION VALVES (00HTQ02AA100/101)

Fail condition: Fail-In-Place

(a) Open Permissive:

- None
(b) Close Permissive:
- None
(c) Auto Open & Close:
Process water pump recirculation valve will be opened automatically when the common header
process water flow is lower than low (will be specified at the time of commissioning). Similarly,
the respective valve will be closed automatically when the Process Water Flow is higher than
Low flow.

4.5 PROCESS WATER DISTRIBUTION VALVES (00HTQ02AA001/08HTQ01AA001/07HTQ01AA001)

This valve will always keep open during normal operating condition.

(a) Open Permissive:

None

(b) Close Permissive: 1

None

(c) Override Close Command:

None

4.1 CW BLOWDOWN TO PROCESS WATER TANK INLET VALVE (00HTQ01AA100/101)

Fail condition: Fail-in-Place

(a) Open permissive:

None 1
(b) Close permissive:
None
(c) Auto Open & Auto Close :
This valve will open or close if respective Tank discharge valve is opened or closed.

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DVC DOC NO. 2109-122-PVM-G-006 Section-12 Clarified Water System Rev. 01 21 Jan’22

Section 12 Clarified Water System

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DVC DOC NO. 2109-122-PVM-G-006 Section-12 Clarified Water System Rev. 01 21 Jan’22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
(iii) Process Flow Diagram of Limestone Grinding and Slurry Preparation System, DVC Doc. No. 2109-
122-PVM-F-001A
(iv) P&ID Clarified water Storage Tank, DVC Doc. No. 2109-122-PVM-F-499
(v) Tender – Scheme of FGD – Absorber System, DVC Doc. No. 2109-121-POM-A-001
(vi) Tender – Scheme of FGD – Gypsum Dewatering System, DVC Doc. No. 0011-109-POM-A-003
(vii) Tender – Scheme of FGD – Milling System, DVC Doc. No. 2109-121-POM-A-002

2 PROCESS DESCRIPTION

Two (2) Clarified water Storage tanks (each tank catering to the requirements of 2x500 MW units)
along with two numbers of 2x100 % clarified water pumps, along with all necessary piping, valves,
control & instrumentation to feed the tank from terminal point. The two tanks shall be interconnected
with an isolation valve and 4 pumps are connected in the common header along with all necessary
piping, valves, control & instrumentation. 1 x 100% pump catering to clarified water requirement of
both units.

3 CONTROL PHILOSOPHY

The group level shall control a set of functional sub-groups of drives. Appropriate start-up and shut
down commands shall be issued to the sub-group control and various check-backs shall be received
from sub-groups or drives. Each sub-group shall execute the sequential start-up and shut down
programs of a set of inter-related drives along with system interlocks and protections associated with
that sub-group as well as basic interlocks and protections related to individual drive falling under that
sub-group.
Two (2) Clarified water Storage tanks (each tank catering to the requirements of 2 x500 MW units)
along with of 4x100 % clarified water pumps, all necessary piping, valves, control & instrumentation..
The Level is measured by level transmitter installed in each of the two Clarified water Storage tank.

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DVC DOC NO. 2109-122-PVM-G-006 Section-12 Clarified Water System Rev. 01 21 Jan’22

Clarified water will be transferred for oxidation air quenching for unit-07 & 08 and vacuum line sealing
through clarified water pump.
The detailed control logic will be provided based on this process description and interlock Write up.

4 CONTROLS AND INTERLOCKS :

4.1 GROUP DEFINITION:

The Clarified water Pump Group Sequence integrates the operation of the complete train of
respective clarified water Pump including its suction valve and discharge valve. Below listed is the
sequence of operation for Clarified water Pump group-1 constituting Pump-A (00HTQ31AP001) and)
including their suction valve, discharge valve, drain valve and wash valve. The same write up is
applicable for Pump Group-2 constituting Pump-B (00HTQ32AP001),Pump Group-3 constituting
Pump-C (00HTQ33AP001), Pump Group-4 constituting Pump-D (00HTQ34AP001).

4.2 CLARIFIED WATER PUMPS (00HTQ31AP001/32AP001/33AP001/34AP001) GROUP SEQUENCE:

The Clarified water Pump-A and corresponding suction, discharge, flushing and draining line valves
will be operated manually or auto based on Overall group Start/Stop condition. Same is applicable
for other Clarified Water Pumps with proper tag number change.

4.2.1 CLARIFIED WATER PUMP GROUP-1 START

(a) The Clarified water pump group start will be allowed only if the following conditions are satisfied

(i) Selected Clarified Water tank level (00HTQ21CL101) not Low.

(ii) Any of the Clarified Water Tank outlet isolation valve (00HTQ21AA603/604) open.
(iii) START Permissive available for Clarified Water Pump-A (except for Clarified Water
Pump suction Valve open status)
(b) Group Start Command:

Clarified water pump Group-1 Start can be initiated by Operator manually or on receiving Auto-start
signal in either of the following conditions –

(i) Clarified water pump on standby and Running pump trips (electrical trip or Pump
stop due to Override Trip command)

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DVC DOC NO. 2109-122-PVM-G-006 Section-12 Clarified Water System Rev. 01 21 Jan’22

(ii) Clarified water pump on standby and Pumps common discharge Header Pressure
(00HTQ22CP101) remains low for more than for more than predefined time decided
at the time of commissioning.
(iii) Start Command received from Changeover Sequence
(c) Group Start Sequence:
(i) Step-1 : Clarified Water Pump-A suction Valve OPEN feed back
(ii) Step-2 : Clarified Water Pump-A start command
1 (iii) Step-3 : After preset time (as per Clarified water Pump OEM recommendation),
corresponding clarified water Pump discharge valve open command.
(iv) Clarified water pump Group Start will be considered complete when all the above
sequenced steps are completed successfully.

4.2.2 CLARIFIED WATER PUMP GROUP-1 STOP

(a) Group Stop Permissive:

None

(b) Group Stop Command:

Clarified Water Pump Group Stop can be initiated by Operator manually or on receiving Auto-
stop signal in either of the following conditions –
(i) Selected Clarified Water Tank level (00HTQ21CL101) low low (Set Point Very low
will be defined at the time of commissioning)
- Both Clarified Water Tank outlet isolation valve closed
(c) Group Stop Sequence:
(i) Step-1: Clarified water Pump discharge valve closed by operator.
(ii) Step-2: Clarified water Pump stop command
(iii) Step-3: Clarified water Pump suction valve closed by operator.
(iv) Clarified water Pump group stop shall be considered complete when all the
above-mentioned steps are completed successfully.

4.3 CLARIFIED WATER PUMPS (00HTQ31AP001/32AP001/33AP001/34AP001)

(a) Start Permissive:

(i) Selected Clarified water tank Level (00HTQ21CL101/102) Not Low
(ii) Pump-A Suction valve 00HTQ31AA600 Open. 1
(iii) Any one tank outlet valve (00HTQ21AA603/604) Opened
(iv) Pump-A Discharge valve 00HTQ31AA601open
(b) Stop Permissive:
None

(c) Auto Start Command:

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DVC DOC NO. 2109-122-PVM-G-006 Section-12 Clarified Water System Rev. 01 21 Jan’22

The pumps shall be automatically started in sequence (i.e. A>B>C>D) i.e. if pump A trips or due
to any reason discharge pressure is not sufficient and Pump A is running then Pump B will start.
01 Or if Auto start command for A is issued but due to some reason it did not start within stipulated
time, then pump B will start. Similarly if B tripped then C only will start. and then command will
shift to D. But never shift directly from A>C or A>D.

(d) Auto Stop Command:

From respective Clarified water Pump Group Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined time decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve open feedback lost OR
(iii) Tank outlet valve (00HTQ21AA603/604) Open feedback lost OR
(iv) Clarified Water Tank Level low low OR
(v) As per Pump (and its Motor) OEM’s recommendation, if any.

4.4 CLARIFIED WATER PUMPS SUCTION VALVES (00HTQ31AA600/32AA600/33AA600/34AA600)

(a) Open Permissive:

- None
(b) Close Permissive:
The Clarified water Pump-A suction valve will be closed only if the following condition is satisfied

- Pump-A is not running

4.5 CLARIFIED WATER PUMPS DISCHARGE VALVES (00HTQ31AA601/32AA601/33AA601/34AA601)

(a) Open Permissive :
The Clarified water Pump-A discharge valve will be opened only if the following condition is
satisfied

- Pump-A is running

(b) Close Permissive :

The Clarified water Pump-A discharge valve will be closed only if the following condition is
satisfied

- Pump-A is not running

4.6 CLARIFIED WATER STORAGE TANK DISCHARGE VALVES (00HTQ21AA603/604)

Clarified water Tank Discharge valve will be opened or closed manually as per the process requirement and
Tank selection.

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L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104 Control Philosophy of FGD system Page 133 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

Section 13 ECW System

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104 Control Philosophy of FGD system Page 134 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

1 REFERENCE DOCUMENTS

(i) Process Flow Diagram of Absorber System, DVC Doc. No. 2109-122-PVM-F-001A
(ii) Process Flow Diagram of Gypsum Dewatering System, DVC Doc. No. 2109-122-PVM-F-001A
(iii) Process Flow Diagram of Limestone Grinding and Slurry Preparation System, DVC Doc. No. 2109-
122-PVM-F-001A
(iv) P&ID ECW System, DVC Doc. No. 2109-122-PVM-F-079
(v) Tender – Scheme of FGD – Absorber System, DVC Doc. No.2109-121-POM-A-001
(vi) Tender – Scheme of FGD – Gypsum Dewatering System, DVC Doc. No. 2109-121-POM-A-003

2 PROCESS DESCRIPTION

Principal components of the ECW system are:

a) Three (3) x 50 % capacity DM cooling water pumps
b) Three (3) x 50 % capacity cooling water plate heat exchangers
c) Four (4) x 50 % capacity Auxiliary cooling water pumps
d) One (1) x100% capacity Cooling Water overhead tank
e) One (1) x100% capacity alkali dosing tank along with agitator, motor, piping, valves etc.
f) System piping with associated valves and instruments
g) One Overhead DM Water Storage Tank (ECW Overhead tank)
h) 2 x 100 % Automatic Self-cleaning strainers in secondary side

3 CONTROL PHILOSOPHY
The group level shall control a set of functional sub-groups of drives. Appropriate start-up and shut
down commands shall be issued to the sub-group control and various check-backs shall be received
from sub-groups or drives. Each sub-group shall execute the sequential start-up and shut down
programs of a set of inter-related drives along with system interlocks and protections associated with
that sub-group as well as basic interlocks and protections related to individual drive falling under that
sub-group.

The unit equipment cooling water (ECW) system is a closed loop cooling water system, which removes
heat generated by coolers of various plant equipment. The system uses passivated demineralized
water as cooling medium. The heat picked up by the demineralized cooling water is rejected in the
auxiliary cooling water system through unit plate heat exchangers (PHE) before the water is
recirculated to the plant coolers.

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110104 Control Philosophy of FGD system Page 135 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

Three (3) X 50% capacity unit DMCW PUMPs (00HTQ41AP001, 00HTQ42AP001 & 00HTQ43AP001) are
provided to continuously supply cooling water to the primary circuit of three (3) X 50% capacity plate
heat exchangers (00HTQ61AC001, 00HTQ62AC001 & 00HTQ63AC001). A motor operated valve
(00HTQ41AA001 / 00HTQ42AA001 / 00HTQ43AA001) are provided at each DMCW pump suction.
Check valves (00HTQ41AA500 / 00HTQ42AA500 / 00HTQ43AA500) followed by motor operated valves
(00HTQ41AA002 / 00HTQ42AA002 / 00HTQ43AA002) are provided at each DMCW pump discharge.

An overhead tank (00HTQ40BB001) shall be provided to accommodate any system surges, fluid
expansion due to temperature rise in equipment coolers and to provide system make-up to
compensate system losses. Necessary corrosion inhibitor shall be added in the system through NaOH
dosing tank (00HTS11AM001). Normal and emergency ECW system make-up to unit ECW overhead
tank shall be provided from DM cycle make-up system and condensate transfer system respectively.

The common ACW system is an independent closed cooling circuit comprising of 4 x 50% ACW pumps
(00HTQ51AP001 / 00HTQ52AP001 / 00HTQ53AP001 / 00HTQ54AP001) which pumps cold water
through the 3 x 50% capacity plate heat exchangers where it picks up heat rejected by the common
ECW system. A motor operated valve (00HTQ51AA001 / 00HTQ52AA001 / 00HTQ53AA001 /
00HTQ54AA001) are provided at each ACW pump suction. Check valves (00HTQ51AA500 /
00HTQ52AA500 / 00HTQ53AA500 / 00HTQ54AA500) followed by motor operated valves
(00HTQ51AA002 / 00HTQ52AA002 / 00HTQ53AA002 / 00HTQ54AA002) are provided at each ACW
pump discharge. 2 x 100 % Automatic Self-cleaning strainers (00HTQ41AT001/00HTQ41AT002) are
provided at the inlet of PHE, which will operate in auto mode based on high differential pressure
measured in DPT provided across the strainers.

4 CONTROLS AND INTERLOCKS

4.1 DMCW PUMPS (00HTQ41AP001/00HTQ42AP001/00HTQ43AP001) GROUP SEQUENCE

The DMCW Pump Group Sequence integrates the operation of the complete train of respective
DMCW Pump including its suction valve and discharge valve. Below listed is the sequence of
operation for DMCW Pump group. Similar operation philosophy will be applicable for other DMCW
Pumps and their corresponding valves also.

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110104 Control Philosophy of FGD system Page 136 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

4.1.1 DMCW PUMP GROUP START

(a) The DMCW pump group start will be allowed only if the following conditions are satisfied

(i) Cooling Water Overhead tank level (00HTQ40CL101/102) not Low Low. (Set Point low
low will be defined at the time of commissioning)
(ii) START Permissive available for DMCW Pump-1 (except for DMCW Pump suction Valve
open status)

(b) Group Start Command:

DMCW pump Group Start can be initiated by Operator manually or on receiving Auto-start signal in
either of the following conditions –

(i) DMCW pump on standby and Running pump trips (electrical trip or Pump stop due to
Override Trip command)
(ii) DMCW pump on standby and DMCW Pump Discharge Header Pressure
(00HTQ48CP101/102/103) remains low for more than predefined time decided at the
time of commissioning.

(c) Group Start Sequence:

- Step-1 : DMCW Pump-1 suction Valve OPEN command

- Step-2 : DMCW Pump-1 start command
- Step-3 : After preset time (as per DMCW Pump OEM recommendation to be decided at
the time of commissioning), corresponding DMCW Pump discharge valve open command
- DMCW pump Group Start will be considered complete when all the above sequenced
steps are completed successfully.

4.1.2 DMCW PUMP GROUP STOP

(a) Group Stop Permissive:

None

(b) Group Stop Command:

DMCW Pump Group Stop can be initiated by Operator manually or on receiving Auto-stop
signal in either of the following conditions –
(i) Cooling Water Overhead Tank level (00HTQ40CL101/102) low low (Set Point low low
will be defined at the time of commissioning)

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110104 Control Philosophy of FGD system Page 137 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

-
(c) Group Stop Sequence:
- Step-1: DMCW Pump discharge valve close command
- Step-2: DMCW Pump stop command
- Step-3: DMCW Pump suction valve close command
- DMCW Pump group stop shall be considered complete when all the above mentioned
steps are completed successfully.

4.2 DMCW PUMPS (00HTQ41AP001/00HTQ42AP001/00HTQ43AP001)

(a) Start Permissive:

(i) Cooling Water Overhead tank Level (00HTQ40CL101/102) Not Low Low
(ii) Pump-1 Suction valve 00HTQ41AA001 Open.
(iii) As per Pump (and its Motor) OEM’s recommendation, if any.

(b) Stop Permissive:

None

(c) Auto Start Command:

From respective DMCW Pump Group Start Sequence

(d) Auto Stop Command:

From respective DMCW Pump Group Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
for more than predefined time decided at the time of commissioning. OR
(ii) Pump running and respective pump suction isolation valve not opened OR
(iii) Cooling Water Overhead Tank Level low low OR
(iv) Pump discharge header pressure high high
(v) As per Pump (and its Motor) OEM’s recommendation, if any.

4.3 DMCW PUMPS DISCHARGE VALVES (00HTQ41AA002/42AA002/43AA002)

(a) Open Permissive :

The DMCW Pump-1 discharge valve will be opened only if the following condition is satisfied

- Pump-1 is running

(b) Close Permissive :

The DMCW Pump-1 discharge valve will be closed only if the following condition is satisfied

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110104 Control Philosophy of FGD system Page 138 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

- Pump-1 is not running

(c) Auto Open :

The DMCW Pump-1 discharge valves will open automatically by respective DMCW Pump
group START sequence activation.

(d) Auto Close :

The DMCW Pump-1 discharge valves will close automatically if any of the following takes
place:
- Close command received from respective DMCW Pump group STOP sequence
- Pump-1 trips / not running

4.4 DMCW PUMPS SUCTION VALVES (00HTQ41AA001/00HTQ42AA001/00HTQ43AA001)

(a) Open Permissive :

- None

(b) Close Permissive :

The DMCW Pump-1 suction valve will be closed only if the following condition is satisfied

- Pump-1 is not running

(c) Auto Open & Close :

The DMCW Pump-1 suction valves will open & close automatically by respective DMCW Pump
group START and STOP sequence activation.

4.5 DMCW PUMPS RECIRCULATION VALVE (00HTQ48AA001)

Fail condition: Fail Close

In order to maintain diff. header pressure across DMCW header, this recirculation valve has been
provided.

(a) Open Permissive :

- None

(b) Close Permissive :

- None

(c) Auto Open:

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110104 Control Philosophy of FGD system Page 139 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

- None

(d) Auto Close :

- None

4.6 NAOH TANK AGITATOR (00HTS11AM001)

(a) Start Permissive:
The NAOH tank (00HTS11BB001) agitator will be allowed to start if the following condition is
satisfied
- NAOH Level (00HTS11CL101) NOT LOW. (Set Point low will be defined at the time of
commissioning)
(b) Stop Permissive:
The NAOH tank (00HTS11BB001) agitator will be allowed to stop if the following condition is
satisfied
- NAOH Level (00HTS11CL101) LOW LOW. (Set Point LOW LOW will be defined at the time
of commissioning)
(c) Auto Start & Stop:
Agitator will be automatically managed by DCS based on level in NAOH tank. Once NAOH tank
Level is higher than a LOW Level, the agitator will be automatically started. The NAOH tank
agitator will auto stop when the Auxiliary Absorbent Tank Level LOW LOW.

4.7 COOLING WATER OVERHEAD TANK INLET MOV (00HTQ40AA002)

Two Level transmitters (00HTQ40CL101 & 00HTQ40CL102) are installed in cooling water overhead
tank (00HTQ40BB001) to measure the tank level. Motor operated Valve (00HTQ40AA002) is installed
in the emergency supply line which is required to maintain the constant flow to the Cooling Water
Overhead tank.

(a) Open Permissive:

- None
(b) Close Permissive:
- None
(c) Auto Open:
- Cooling Water Overhead Tank Level (00HTQ40CL101 & 00HTQ40CL102) Very low (Set Point
Very low will be defined at the time of commissioning)
(d) Auto Close:
- Cooling Water Overhead Tank Level (00HTQ40CL101 & 00HTQ40CL102) High (Set Point High
will be defined at the time of commissioning)

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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110104 Control Philosophy of FGD system Page 140 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

4.8 COOLING WATER OVERHEAD EMERGENCY INLET MOV (00HTQ40AA001)

(a) Open Permissive:

- None 1
(b) Close Permissive:
- None
(c) Auto Open:
Cooling water overhead emergency inlet MOV will be opened if
- 00HTQ40AA002 is OPENED and cooling water overhead tank Level is low.
(d) Auto Close:
Cooling water overhead emergency inlet MOV will be closed if
- 00HTQ40AA002 is OPENED and Cooling water overhead tank Level is high.

4.9 ACWPUMPS (00HTQ51AP001/52AP001/53AP001/54AP001) GROUP SEQUENCE

The ACW Pump Group Sequence integrates the operation of the complete train of respective ACW
Pump including its suction valve and discharge valve. Below listed is the sequence of operation for
ACW Pump group. Similar operation philosophy will be applicable for other ACW Pumps and their
corresponding valves also.

4.9.1 ACW PUMP GROUP START

(a) The ACW pump group start will be allowed only if the following conditions are satisfied
(i) Pump common discharge header pressure not low (00HTQ60CP101/102/103)
(ii) START Permissive available for ACW Pump-1 (except for ACW Pump suction Valve
open status)

(b) Group Start Command: ACW pump Group Start can be initiated by Operator manually or on
receiving Auto-start signal in either of the following conditions –
(i) ACW pump on standby and Running pump trips (electrical trip or Pump stop due to
Override Trip command)
(ii) ACW pump on standby and ACW Pump common Discharge Header Pressure low for
more than predefined time decided at the time of commissioning.

(c) Group Start Sequence:

- Step-1 : ACW Pump-1 suction Valve OPEN command

- Step-2 : ACW Pump-1 start command

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110104 Control Philosophy of FGD system Page 141 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

- Step-3 : After preset time (as per ACW Pump OEM recommendation), corresponding ACW
Pump discharge valve open command
- ACW pump Group Start will be considered complete when all the above sequenced steps
are completed successfully.

4.9.2 ACW PUMP GROUP STOP

(a) Group Stop Permissive:

None

(b) Group Stop Command:

ACW Pump Group Stop can be initiated by Operator manually or on receiving Auto-stop signal
in either of the following conditions –
(i) Pump suction header pressure low low (00HTQ01CP101/102/103)
(c) Group Stop Sequence:
- Step-1: ACW Pump discharge valve close command
- Step-2: ACW Pump stop command
- Step-3: ACW Pump suction valve close command
- ACW Pump group stop shall be considered complete when all the above mentioned
steps are completed successfully.

4.10 ACWPUMPS (00HTQ51AP001/52AP001/53AP001/54AP001)

(a) Start Permissive:

(i) Pump suction header pressure not low
(ii) Pump-1 Suction valve 00HTQ51AA001 Open.
(iii) As per Pump (and its Motor) OEM’s recommendation, if any

(b) Stop Permissive:

None

(c) Auto Start Command:

From respective ACW Pump Group Start Sequence

(d) Auto Stop Command:

From respective ACW Pump Group Stop Sequence

(e) Override Trip Command:

(i) Pump running and respective pump discharge isolation valve not opened for more than
predefined time decided at the time of commissioning OR
(ii) Pump running and respective pump suction isolation valve not opened OR

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104 Control Philosophy of FGD system Page 142 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

(iii) Pump suction header pressure low low (00HTQ01CP101/102/103) OR

(iv) Pump discharge header pressure high high (00HTQ60CP101/102/103) OR
(v) As per Pump (and its Motor) OEM’s recommendation, if any.

4.11 ACW PUMPS DISCHARGE VALVES (00HTQ51AA002/52AA002/53AA002/54AA002)

(a) Open Permissive :

The ACW Pump-1 discharge valve will be opened only if the following condition is satisfied

- Pump-1 is running

(b) Close Permissive :

The ACW Pump-1 discharge valve will be closed only if the following condition is satisfied

- Pump-1 is not running

(c) Auto Open :

The ACW Pump-1 discharge valves will open automatically by respective ACW Pump group
START sequence activation.

(d) Auto Close :

The ACW Pump-1 discharge valves will close automatically if any of the following takes place:
- Close command received from respective ACW Pump group STOP sequence
- Pump-1 trips / not running

4.12 ACW PUMPS SUCTION VALVES (00HTQ51AA001/52AA001/53AA001/54AA001)

(a) Open Permissive :

- None

(b) Close Permissive :

The ACW Pump-1 suction valve will be closed only if the following condition is satisfied

- Pump-1 is not running

(c) Auto Open & Close :

The ACW Pump-1 suction valves will open & close automatically by respective ACW Pump
group START and STOP sequence activation.

©THIS DOCUMENT IS A PROPERTY OF LARSEN & TOUBRO LTD AND MUST NOT BE COPIED OR LENT WITHOUT THEIR PERMISSION IN WRITING.
 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
LIMITED STATION
TECHNOLOGY:
(QFGDM)
FGD Package
L&T DOC.NO.: F.MEJI.19-XG07-00-HT-
110104 Control Philosophy of FGD system Page 143 of 145
DVC DOC NO. 2109-122-PVM-G-006 Section-13 ECW System Rev. 01 21 Jan’22

4.13 ACW PUMPS RECIRCULATION VALVE (00HTQ60-AA001)

Fail condition: Fail in Position
In order to maintain diff. header pressure across ACW header, this recirculation valve has been
provided.

(a) Open Permissive:

- None

(b) Close Permissive :

- None

(c) Auto Open:

- None

(d) Auto Close :

- None
(e) Modulating Control :
In order to maintain DMCW pumps header temperature (00HTQ48CT101), this recirculation valve
has been provided. The valve is Inching MOV.
This valve directly controls the ACW inlet flow to PHE to maintain the DMCW discharge header
temperature within predefined set value (The exact set point value will be decided at the time of
commissioning). The valve opening is inversely proportion to header temperature i.e. increase the
valve opening decrease the header temperature.
1

4.14 PROCESS WATER TANK MAKEUP WATER LEVEL CONTROL VALVE (00HTQ01AA300)
Control Action: Reverse Acting
This control valve will maintain the water level of both the Process water tanks. Depending on the
tank which is in operation the inlet On-Off valve (00HTQ69AA100 or 00HTQ69AA101) will be kept
opened at tank side. Accordingly, the control valve will select respective tank level to monitor and
control. The set value of desired level for each tank shall be given to the controller at the time of
commissioning.

The control valve will be fully closed when both the inlet On-Off valves are closed
1

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
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FGD Package
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DVC DOC NO. 2109-122-PVM-G-006 Section-14 Compressed Air System Rev. 01 21 Jan’20

Section 14 Compressed Air System

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 LARSEN & TOUBRO 2 x 500 MW MEJIA THERMAL POWER
LIMITED STATION
TECHNOLOGY:
(QFGDM)
FGD Package
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DVC DOC NO. 2109-122-PVM-G-006 Section-14 Compressed Air System Rev. 01 21 Jan’20

1 REFERENCE DOCUMENTS
(i) P&ID Compressed Air System, DVC Doc. No. 2109-122-PVM-F-001

2 PROCESS DESCRIPTION
The compressed air system provided to cater the requirement of all the units of stage 3 and stage 4.
Compressed air system includes the following:
a) Two (2) no. (1W + 1S) oil free rotary screw type air compressors for Instrument air & Service air
application, including drives and other accessories.
b) Two (2) nos. (1W+1S) Air dryers suitable for connecting to individual instrument air compressor.
c) Respective Intake air filters.
d) Two (2) nos. air receivers, i.e. one (1) for each compressor near compressor house of 2 m3 capacity.
e) Complete instruments, control system with panels as required for compressed air system.
f) Complete compressed air and piping network for service air and instrument air application.

3 CONTROLS AND INTERLOCKS

Please refer the Compressed Air system Vendor documents for further details.

4 COMPRESSED AIR DISTRIBUTION

As shown in the P&ID, following are the major distribution areas for Compressed Air:
a) Flue gas & Booster fan area
b) Absorber area
c) Gypsum Dewatering area
d) Limestone slurry preparation area
e) ECW system area
f) Wet Ball Mill area
g) Filtrate Water system area
h) Mist Eliminator area
i) Gas cooling Pump area
j) DE & Air blasting system
k) Gypsum bleed pump area
l) Oxidation Air blower area
m) Process water area
For certain areas like Flue gas area, Absorber area & Wet Ball Mill area, additional Air Receivers are
provided in the respective areas as shown in the P&ID.

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