A.

Basics General A1 Features of PAITON Project PAGE1

PAITON EXPANSION PROJECT

COURSE – A （ BASICS GENERAL ）

A1 Features of PAITON Project

TRAINER: Hiroyuki Hattori

MITSUBISHI HEAVY INDUSTRIES, LTD.

MHI BUSINESS
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A. Basics General A1 Features of PAITON Project PAGE2

PROGRAM
A2. Features of PAITON project are...
1. PAITON Project Outline
2. Environmental Features
3. Design Criteria
4. Operating Condition

MHI BUSINESS
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 A. Basics General A1 Features of PAITON Project PAGE3

Contents
1. PAITON Project Outline are...
1.1 Project Summary
1.2 Project Location
1.3 Overall Project Schedule
1.4 Project Organization
1.5 Basic flow diagram
1.6 Plant Layout
1.7 Plant Performance Summary
1.8 Design Concept

MHI BUSINESS
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1.1 Project Summary

Ø Project Name
PAITON Ⅲ Expansion Coal Fired Power Plant Project
Ø Plant type
Coal Fired Supercritical Power Plant
Ø Capacity
1×815MWNET (at 100% Rated Load)
Ø Steam Condition at MSV Inlet
24.4 MPa (g) & 538 deg C at MSV Inlet
566 deg C at RSV Inlet
Ø Fuel
Coal (Main fuel)
No.2 Fuel Oil (Start-up)

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1.1 Project Summary

BOILER:
MANUFACTURER Mitsubishi Heavy Industries, Ltd.
QUANTITY 1 unit
TYPE Supercritical, sliding pressure
operation, once through boiler,
single reheat cycle
MAIN STEAM FLOW
2,695 t/h (B-MCR)
RATE
STEAM CONDITION
25.8MPa(g) x 542 deg C
(at SH Outlet)
STEAM CONDITION
568 deg C
(at RH Outlet)
Burner Arrangement Circular Corner Firing system

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1.1 Project Summary

STEAM TURBINE:
MANUFACTURER Mitsubishi Heavy Industries,
Ltd.
QUANTITY 1 unit
TYPE Tandem compound quadruple
exhaust condensing reheat
(TC4F-35.4)
RATED OUTPUT 865.9 MW
Steam Condition
24.4 MPa(g) x 538 deg C
at MSV Inlet
Steam Condition
566 deg C
at RSV Inlet
RATED SPEED 3000 min-1
No. OF EXTRACTIONS Eight (8)
GOVERNOR SYSTEM Electronic-Hydraulic System

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1.1 Project Summary

GENERATOR:
MANUFACTURER Mitsubishi Electric Corporation
QUANTITY 1 Unit
TYPE Horizontally mounted cylindrical
rotor, rotating field type
RATED CAPACITY 1,045 MVA
COIL COOLING Rotor: Hydrogen
MEDIUM Stator: Water
RATED VOLTAGE 27 kV
POWER FACTOR 0.85 Lagging / 0.90 Leading
SPEED 3000 min-1
FREQUENCY 50 Hz

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Contents
1. PAITON Project Outline are...
1.1 Project Summary
1.2 Project Location
1.3 Overall Project Schedule
1.4 Project Organization
1.5 Basic flow diagram
1.6 Plant Layout
1.7 Plant Performance Summary
1.8 Design Concept

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1.2 Project Location

Ø Project Location : J1. Raya Surabaya-Situbondo Km.
141 Paiton-Probolinggo, INDONESIA

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1.2 Project Location

Nagasaki in Japan

Direct Distance
Approx: 5,000km

PAITON

MHI BUSINESS
Ref. Google earth CONFIDENTIAL
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1.2 Project Location

Coal Storage Yard

Unit-7 Unit-5 Unit-1

Unit-3
Unit-8 Unit-6 Unit-2
Unit-9

Ash Disposal GIS

Area Area

MHI BUSINESS
Ref. Google earth CONFIDENTIAL
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1.2 Project Location

Unit-8 Unit-7 Unit-6 Unit-5 Unit-2 Unit-1

Unit-3

MHI BUSINESS
Ref. Google earth CONFIDENTIAL
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Contents
1. PAITON Project Outline are...
1.1 Project Summary
1.2 Project Location
1.3 Overall Project Schedule
1.4 Project Organization
1.5 Basic flow diagram
1.6 Plant Layout
1.7 Plant Performance Summary
1.8 Design Concept

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1.3 Overall Project Schedule

Ø LNTP Effective Date. : 2008/08/04

Duration: 45 months

Ø Operational Acceptance Date. : 2012/04/22

Ø Final Acceptance Date. : 2012/10/22

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1.3 Overall Project Schedule

2009/01/03
YEAR 2009 2010 2011
MONTH 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

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1.3 Overall Project Schedule

YEAR 2009 2010 2011

MONTH 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

2010/01/14
Boiler First
Column Election

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1.3 Overall Project Schedule

YEAR 2009 2010 2011

MONTH 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

2010/06/30
Water Separator
Lifting

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1.3 Overall Project Schedule

YEAR 2009 2010 2011

MONTH 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

2010/12/02
Generator
On Base

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1.3 Overall Project Schedule

YEAR 2009 2010 2011

MONTH 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

2011/03/31
Power Receiving

2011/09/22
Initial Firing

MHI BUSINESS
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Contents
1. PAITON Project Outline are...
1.1 Project Summary
1.2 Project Location
1.3 Overall Project Schedule
1.4 Project Organization
1.5 Basic flow diagram
1.6 Plant Layout
1.7 Plant Performance Summary
1.8 Design Concept

MHI BUSINESS
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1.4 Project Organization

Ø Major Parties Involved in the Contract:

- “Owner”
P. T. PAITON ENERGY (PE)
- “Contractor”
Mitsui & Co., Ltd. (MBK) And Toa Corporation
- “Equipment Supplier”
Mitsubishi Heavy Industries Ltd. (MHI)

MHI BUSINESS
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Contents
1. PAITON Project Outline are...
1.1 Project Summary
1.2 Project Location
1.3 Overall Project Schedule
1.4 Project Organization
1.5 Basic Flow Diagram
1.6 Plant Layout
1.7 Plant Performance Summary
1.8 Design Concept

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 A. Basics General A1 Features of PAITON Project PAGE23

Stack

500kvGIS SH RH

BOILER FGD
GTR
（Sea Water
Scrubber）
IPB AH IDF
E P #7,8 Fly
Generator L P IP HP Ash Silo

TURBINE Deaerator
Demi LP
RO FDF #7,8 Coal
Heater
Handling
FGD Condenser
HP
Pump/Mix/Aer Conveyor,
Heater
ation/Disch Crusher
BASIN CP
BFP Coal silo
CPS
Screen Coal Feeder

PAF

Absorber Discharge
CWP Desali P No.2 Fuel oil Tank &
Pump Canal Pulverizer Pump
#7,8

5. Basic Flow Diagram MHI BUSINESS

CONFIDENTIAL
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Contents
1. PAITON Project Outline are...
1.1 Project Summary
1.2 Project Location
1.3 Overall Project Schedule
1.4 Project Organization
1.5 Basic flow diagram
1.6 Plant Layout
1.7 Plant Performance Summary
1.8 Design Concept

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1.6 Plant Layout

Unit 3 Area

Plot Plan
Overall
(UnitPlot
3 Area)
Plan

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1.6 Plant Layout

Boiler and Turbine

Boiler

Turbine Building

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General Arrangement 1st Floor

Motor Driven
Boiler Feed Water Pump

Condensate Pump

Condenser Turbine Driven

Boiler Feed Water Pump

Condensate Polisher Area

1.6 Plant Layout MHI BUSINESS

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General Arrangement 1st Floor
Primary Air Fan 3A

Coal Pulverizer

Primary Air Fan 3B

1.6 Plant Layout MHI BUSINESS

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 A. Basics General A1 Features of PAITON Project PAGE29

General Arrangement 1st Floor

Bottom Ash Storage Area

Air Heater 3A
Submerged Scraper Conveyor

Air Heater 3B

1.6 Plant Layout MHI BUSINESS

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1.6 Plant Layout

Intake System

Discharge Canal

Intake Canal

Circulating Water Pump

Intake Electrical Building & Chlorination Area

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1.6 Plant Layout

Flue Gas System

Induced Draft Fan

Fly Ash Transport Building

FGD Absorber

Electrostatic Precipitator

Stack
FGD/EP/Ash Cont.&Elec.Building

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1.6 Plant Layout

Flue Gas Desulfurization (FGD) System
FGD Discharge Basin
FGD Absorber Pump Basin

FGD Mixing Basin

FGD Aeration Basin

FGD Absorber Pump FGD Absorber

FGD Aeration Blower

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1.6 Plant Layout

Water Treatment System

Potable Water Tank

Condensate Make-Up Tank

Product Water Tank
Permeate Water Tank
Desalination Sea Water Pump
Condensate Storage Tank

Desali & Demi Building

Desalination & Demineralizer Plant Area

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1.6 Plant Layout

Fire Fighting System

Fire Pump Station

Service Water Tank

Sea Water Diesel Driven Fire Pump

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1.6 Plant Layout

Coal and Fuel Oil
Coal Handling Conveyor

Coal Crusher House

Coal Handling Building

No.2 Fuel Oil Feed Pump Area

No.2 Fuel Oil Storage Tank

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1.6 Plant Layout

Electrical System

Generator Transformer

Unit Auxiliary Transformer

Unit Auxiliary Transformer (SPARE)

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1.6 Plant Layout

Other Systems

Service Building

Air Compressor Building UNIT 3 Retention Basin

CO2 Storage Tank

H2,O2,N2 Gas Supply House

Emergency Diesel Generator Area

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1.6 Plant Layout

Please see the 3D View.

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Contents
1. PAITON Project Outline are...
1.1 Project Summary
1.2 Project Location
1.3 Overall Project Schedule
1.4 Project Organization
1.5 Basic flow diagram
1.6 Plant Layout
1.7 Plant Performance Summary
1.8 Design Concept

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1.7 Plant Performance Summary

PLANT PERFORMANCE:
Net Electrical Output 815MW
Net Plant Heat Rate at 100% Load 9,574 kJ/kWh

Conditions;
Circulating Water Temperature 29.2℃
Ambient Air Temperature 25.5℃
Ambient Relative Humidity 79%
Ambient Barometric Pressure 1.0333kg/cm2
Generator Power Factor 0.90

MHI BUSINESS
CONFIDENTIAL
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Contents
1. PAITON Project Outline are...
1.1 Project Summary
1.2 Project Location
1.3 Overall Project Schedule
1.4 Project Organization
1.5 Basic flow diagram
1.6 Plant Layout
1.7 Plant Performance Summary
1.8 Design Concept

MHI BUSINESS
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1.8 Design Concept

1. Compliance with Environmental Requirement
2. Enhanced Reliability
3. Enhanced Thermal Efficiency
Ø Supercritical Unit.
4. Easy Operation
Ø Mitsubishi DCS specially customized for Boiler and
Turbine, and PLC control customized for FGD, EP,
and Water treatment etc...
5. Common Utility
Ø Using the Unit-7,8 equipment commonly, such as
waste water treatment system, fly ash silo, coal
receiving system, storage yard and fuel oil storage
tank.
MHI BUSINESS
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PROGRAM
A2. Features of PAITON project are...
1. PAITON Project Outline
2. Environmental Features
3. Design Criteria
4. Operating Condition

MHI BUSINESS
CONFIDENTIAL
A. Basics General A1 Features of PAITON Project PAGE44

Contents
2. Environmental Features are...
2.1 Overall Plan
2.2 Flue Gas Emissions
2.3 Seawater Discharge

MHI BUSINESS
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2.1 Overall Plan

Input Power Plant Output

Coal Electric Power (To PLN)

Air PAITON Flue gas (To Atmosphere)

Sea Water
POWER Waste water (To Unit7&8)

PLANT Ash (To Unit7&8)

Chemical Sea Water (To Sea)

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Contents
2. Environmental Features are...
2.1 Overall Plan
2.2 Flue Gas Emissions
2.3 Seawater Discharge

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2.2 Flue Gas Emissions

Ø Flue Gas Emissions from Stack is in accordance with
the Contract Documents requirement.
PAITON PROJECT
Parameter
Guarantee Value (at BMCR)
Particulate Emission 50mg/Nm3
(average value) at 6% O2 dry
SO2 Emission 92.0%
(average value) Minimum SO2 removal efficiency
NOx Emission
(average value, 50% Rated Load 0.097mg/kJ
or above)
CO Emissions 100ppm
(average value) at 6% O2 dry

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2.2 Flue Gas Emissions

Following methods are adopted to meet the strict
emission norm:

Ø Low NOx Combustion Technology

(3 Technologies are explained by next page)
Ø Electrostatic Precipitator (EP) for arresting
particulate.
Ø Seawater Scrubber Process for Flue Gas
Desulfurization (FGD).
Ø 220m High Stack for dispersing the emission
over wide range.

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2.2 Flue Gas Emissions

Low NOx Combustion Technology
Ø (Circular Corner Firing System)
- CCF System
Ø (Mitsubishi Advanced-Pollution Minimum Burner)
- Mitsubishi A-PM Burner
Ø (Mitsubishi Advanced Combustion Technology)
- MACT

High Combustion Efficiency, Low Excess Air

Low NOX Emission

MHI BUSINESS
Ref: Details will be explained at the training of Basic of Boiler. CONFIDENTIAL
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2.2 Flue Gas Emissions

Clean
Flue Gas Treatment System; Gas

Treated
Flue Gas
Flue Gas

Dust FGD Stack

E P ABSORBER
SO2
SO2

Coal
Air
Fly Ash SEA
Handling WATER
System
Mixing Basin
Boiler EP FGD STACK

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2.2 Flue Gas Emissions

STACK Boiler
IDF EP

FGD

Location of Boiler and Main BOP MHI BUSINESS

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2.2 Flue Gas Emissions

Electrostatic Precipitator (EP) ;
MANUFACTURER Mitsubishi Heavy
Industries Mechatronics
Systems, Ltd.
QUANTITY 1 unit
TYPE HORIZONTAL FLOW
DRY TYPE
GAS FLOW RATE 2,698,000 Nm3/h wet
(Performance Coal) (at BMCR condition)
DESIGN FUEL Coal
COLLECTING
98.3%
EFFICIENCY
(at BMCR condition)
(Performance Coal)
OUTLET DUST 50 mg/Nm3
CONCENTRATION (O2=6% Dry)

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2.2 Flue Gas Emissions

Electrostatic Precipitator (EP) ;
Trans/
Insulator chamber Rapping
Rectifier
motor

Gas Outlet
Discharge Erectrode Duct

Gas Distribution Plate

Collecting Erectrode

(Photo : Reference plant in Mexico) Hopper

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2.2 Flue Gas Emissions

Flue Gas Desulfurization (FGD) ;

MANUFACTURER Mitsubishi Heavy

Industries, Ltd

QUANTITY 1 unit

TYPE Double Contact Flow

scrubber

DESIGN FUEL Coal

SO2 REMOVAL 92.0 %

EFF.

OUTLET SO2 196 mg/l

(at O2 6% dry)

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2.2 Flue Gas Emissions

Flue Gas Desulfurization (FGD) ;

1.8 C-276 B olts

Alloy

(Photo : Reference plant in Saudi Arabia)

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2.2 Flue Gas Emissions

Continuous Emission Monitoring System (CEMS）
Following parameters will be continuously monitored at the
half part of Stack and automatically reported to DCS.

• SO2
DCS
• NOx
• Dust
• CO, CO2
• O2
CEMS
Power Station

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Contents
2. Environmental Features are...
2.1 Overall Plan
2.2 Flue Gas Emissions
2.3 Seawater Discharge

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2.3 Seawater Discharge

SEA WATER DISCHARGE LIMITS.
Parameter Values
(1) Temperature : < 40℃
(2) pH : ≧ 6.0
(3) COD : ≦ 100 mg O2/l
(4) Dissolved Oxygen : ≧ 2.7 O2/l

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PROGRAM
A2. Features of PAITON project are...
1. PAITON Project Outline
2. Environmental Features
3. Design Criteria
4. Operating Condition

MHI BUSINESS
CONFIDENTIAL
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Contents
3. Design Criteria is...
3.1 Applicable Codes and Standards
3.2 Plant Identification

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3.1 Design Codes and Standard

(1) Applicable codes and standards

ØMechanical : ASME, ANSI, ASTM, NFPA, ISO, JIS,

JSME, API, ASHRAE, AISC, AMCA,
AWS, AWWA, OSHA, HEI, TEMA, UL, etc.

ØCivil : ACI, ASCE, AIJ, UBC, etc.

ØI&C Electrical : ANSI, IEC, IEEE, ISA, ICEA, IEC,

JEC, JEAC, NEMA, NEC, etc.

In addition to the above listed standards, Indonesian

standards and Manufacture Standards will also be used.

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Contents
3. Design Criteria is...
3.1 Applicable Codes and Standards
3.2 Plant Identification

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3.2 Plant Identification

(1) Column Numbering Procedure

Priority 1: West to East by number (1,2,3,...)

Priority 2: South to North by alphabet (A,B,C,…)

Main Column Sub-Column

West- South- West- South-
East North East North
ST & Common 1,2,3,… A,B,C,… 1A,1B, A1,A2,
Building, 2A,… B1,…
Boiler House

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WEST

1
2 1A

TURBINE
3 2A

BOILER
4 3A
SOUTH NORTH

A B C D

EAST MHI BUSINESS

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3.2 Plant Identification

(2) Project Document Numbering System
• Engineering & Project Document Numbering Conventions
• Engineering Drawing Numbering Conventions
Ø Format ----------- A123 – 12 – 1234.56 – A123

Project Number
Document Type
Engineering or Project
Subject
Sequential Number

Sample: G101-25-1723.09-L070 ( Boiler Manual )

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3.2 Plant Identification

(2) Project Document Numbering System
• Engineering & Project Document Numbering Conventions
• Engineering Drawing Numbering Conventions
Ø Format ----------- A123 – 12 – 3 AA - AA – A123
Project Number
Drawing Type
Unit
Area / Building
System / Category
Sequential Number
Sample: G101-31-3-05-00-E001 (Plot Plan)
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3.2 Plant Identification

(3) Mitsubishi Numbering System (MNS)

For example;
03LBA01BR001
Sequential
number

Unit Code System Code Equipment Code

01 : Unit 1 LBA01 : Main steam system BR : Pipe
02 : Unit 2 LCA12 : Condensate system AA : Valve
03 : Unit 3 LAB12 : Feed water system AP : Pump

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Contents
3. Design Criteria is...
3.1 Applicable Codes and Standards
3.2 Plant Identification

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PROGRAM
A2. Features of PAITON project are...
1. PAITON Project Outline
2. Environmental Features
3. Design Criteria
4. Operating Condition

MHI BUSINESS
CONFIDENTIAL
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Contents
4. Operating Condition are...
4.1 Load Conditions
4.2 Load Change Rate
4.3 Start up Time

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4.1 Load Conditions

l Operating Condition
- Base load and variable load operation
- Maximum load for continuous operation : BMCR
- Minimum load for continuous operation : 35% load
100% Load 75% Load 50% Load 35% Load BMCR
ELECTRICAL
POWER
OUTPUT
865.9MW 649.5MW 433.0MW 303.1MW 882.9MW
(GROSS)
MAIN STEAM
FLOW RATE
2,630 t/h 1,918 t/h 1,258 t/h 905 t/h 2695 t/h
Pressure 24.5MPa(g) 18.3MPa(g) 12.3MPa(g) 8.97MPa(g) 25.0MPa(g)
@ MSV INLET
Temperature 538 deg C 538 deg C 538 deg C 538 deg C 538 deg C
@ MSV INLET
Temperature 566 deg C 566 deg C 566 deg C 538 deg C 566 deg C
@ RSV INLET

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Contents
4. Operating Condition are...
4.1 Load Conditions
4.2 Load Change Rate
4.3 Start up Time

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4.2 Load change rate

Load Change Operation during normal operation

Pulverizer
Load Rate
Band operation
100%
100% - 70% 12 MW/min 5
70%
70% - 50% 12 MW/min 4
50%
50% - 35% 8 MW/min 3 35%

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Contents
4. Operating Condition are...
4.1 Load Conditions
4.2 Load Change Rate
4.3 Start up Time

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4.3 Start up time

Start-up period as per each mode

Start-up Mode COLD1 COLD2 WARM HOT

(Shutdown period) (> 150hr) (56~150hr) (8~56hr) (< 8hr)
Start-up period (hour) 13 10.2 6.5 4.2
(*1) (13) (13) (6.7) (4.2)

Light off → Steam Admission 300 300 130 70

Steam Admission → Synchro. 155 50 35 15

Synchro. → Full Load 262 203 162 136

(*1):( )is as per contract specification

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A-1 Features of PAITON Project

End

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