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TRIVENI TURBINES LIMITED, BANGALORE.

CLIENT : STEEL AUTHORITY OF INDIA LIMITED,

COOLING WATER SYSTEM CONTROL PHILOSOPHY-25 MW STG PROJECT DOC. NO : BSP-TEIL-05-011-01B-06-001-

BHILAI STEEL PLANT, BHILAI.

15-BD-00001

COOLING WATER SYSTEM CONTROL PHILOSOPHY (25MW) Objective: This document furnishes the details of the operation and control philosophy of Cooling Water System for 2 X150TPH Boilers, 3 nos. of Turbo Blowers and 25MW Steam Turbo generator main and auxiliary cooling water requirements for Bhilai Steel Plant under 7 MT expansion. The scope of work includes the necessary monitoring and control equipment required for the safe and reliable operation of the plant. The control and monitoring of the cooling tower will be directed from the PLC based control system located at the cooling tower cum recirculation pump house control room. The offered automation is sufficient to perform all the functions in accordance with the process requirements and is suitable for continuous and reliable operation. The PLC system based automation system shall cater for both process control and drive control/interlock functions. The system shall have all the hardware and software features to ensure plant safety and ease of operation. The following areas are interfaced with PLC system. Cooling Tower Recirculation Pump house. Side stream filtration. Make up water circuit. Blow down circuit Chemical dosing system Cooling Tower: The return hot water from Boiler auxiliaries, 25MW Steam Turbo generator condenser, auxiliaries and three (3) nos. of Turbo blower is discharged at the top of the induced draught counter flow cooling tower via 2 nos of return headers (Return header 1 & 2). The temperatures of hot return water from all the above units are measured using RTD (25TE5005- 5006 at condenser outlet, 25TE5007-5008 at 25 MW TG

TRIVENI TURBINES LIMITED, BANGALORE. CLIENT : STEEL AUTHORITY OF INDIA LIMITED,

COOLING WATER SYSTEM CONTROL PHILOSOPHY-25 MW STG PROJECT DOC. NO : BSP-TEIL-05-011-01B-06-001-

BHILAI STEEL PLANT, BHILAI.

15-BD-00001

auxiliaries and 25TE5009-5010 at Boiler) for and the signals transmitted to the PLC system. The water then gets cooled in the cooling tower and collected in the cooling tower basin. Cooling tower drives shall be operated through HMIs located in the control room. Ten (10) nos. (25 CT 5001- 5010)(9 working + 1 stand-by) of cooling tower cells are considered to meet the cooling water requirement. Two (2) nos. of RTD temperature sensors (25TE5001-5002) are provided in the outlet of the cooling tower basin to measure the cold water temperature. If the temperature is within the pre-set range, number of fans of the cooling tower cells will operate as per the requirement. In case the temperature falls below the pre-set limit, the cooling tower cell fan operation will be stopped (stopping through auto operation or by manual intervention).If the temperature increases beyond the set point the stand-by cell will start automatically to meet the desired cooling water temperature . Each cooling tower fan motor (25 CT 5001- 5010) shall be interlocked with vibration monitoring system (vibration switch 25VS50015010) as well as oil level switch (25LS5001-5010) in the gear box. In the event of excessive vibration, the respective fan motor will trip. Also a signal will be generated from the PLC to trip the fan motor at low oil level in the gear box. When any of the fan motors trips, alarm as well as trip indication will be generated in the PLC HMI. When any one of the fan motor trips (25 CT 5001- 5010), the stand by cell fan motor (25 CT 5001- 5010) will start automatically. The PLC HMI has the facility that the operator can select the fan motor of any one cell as stand by. We can run the total system either in AUTO/ MANUAL in Remote manual/Auto mode. Recirculation Pump house: The fore bay of the recirculating water pump house is provided with two (2) nos (25 LIT 5001 -5002) of ultrasonic type level measurement to monitor the water level. Five (3W +2S) (25CWP5001-5005) nos of vertical turbine pump are provided in the recirculating water pump house to supply cooled water from the cooling tower to boilers auxiliaries, three (3) nos of turbo blower , 25 MW steam turbo generator condenser and 25MW steam turbo

TRIVENI TURBINES LIMITED, BANGALORE. CLIENT : STEEL AUTHORITY OF INDIA LIMITED,

COOLING WATER SYSTEM CONTROL PHILOSOPHY-25 MW STG PROJECT DOC. NO : BSP-TEIL-05-011-01B-06-001-

BHILAI STEEL PLANT, BHILAI.

15-BD-00001

generator auxiliaries. Drainage pumps are provided for dewatering the sump. A part (5%) of hot return water from all the units is diverted to the side stream filters (25 SSF5001-5006) for improvement of water quality and after filtration the water is led to the fore bay. Make up water from the terminal point is added to the fore bay of the pump house. Chemical dosing is carried out at the fore bay to improve the quality of water. Required field instruments will be provided to meet the process requirement/ approved P&I diagram and same shall be monitored in PLC system. Operating sequence of pumps in recirculation water pump house: The vertical pumps located in the recirculating water pump house are provided with motorised gate valve with modulating motorised actuator at the delivery line for each pump (25V5025-5029). When the pump is in off condition the motorised gate valve in the delivery side will be in fully closed condition. The operator can start any one the pump out of five (5) pumps with discharge motorised valve in fully open condition (100% open) .When the running pump trips, its discharge valve will close automatically (100% close). The level transmitters (25LIT 5001-5002) in the fore bay are interlocked with all the pumps. At low low level in the fore bay, all the running pumps will trip automatically. Pressure is monitored in delivery side of each pump (25PIT5001-5005). Temperature element will be provided in the common discharge header (ring type header) (25TE 5003 at supply header-1 and 25TE5004 at supply header-2). At high temperature in the common discharge header an alarm will be generated in the PLC to check the performance of the cooling tower. Flow elements (25FE5001 at supply header-1 and 25FE5002 at supply header-2) with flow indicating transmitters (25FIT5001 at supply header-1 and 25FIT5002 at supply header-2) are provided in the discharge headers to monitor and record the flow. Vibration sensors (25VE 5001-5005) with transmitters (25 VT50015005) are provided to monitor vibrations in the HT motors (25CWP5001-

TRIVENI TURBINES LIMITED, BANGALORE. CLIENT : STEEL AUTHORITY OF INDIA LIMITED,

COOLING WATER SYSTEM CONTROL PHILOSOPHY-25 MW STG PROJECT DOC. NO : BSP-TEIL-05-011-01B-06-001-

BHILAI STEEL PLANT, BHILAI.

15-BD-00001

5005). Vibration transmitters having multiple sensors with single display are provided which will have a provision to take these signals to PLC. In case of excess vibration the respective running motor will trip automatically. Six (6) nos of winding RTD (25TE5050-A/B/C/D/E/F to 25TE5055- A/B/C/D/E/F) and two (2) nos of bearing RTD (25TE5050-G/H to 25TE5055-G/H) are provided in HT motor. When the temperature exceeds the pre-set limit the motor will trip automatically. Vibration monitoring will be provided in single point and in both the direction (X-Y). The offered PLC system has the facility that the operator can select any pump as working and any pump as stand by. Side Stream Filtration (SSF): Side stream filtration system is provided to improve the physical quality of recirculation water by removing the suspended particles from a part of the total flow. Required field instruments will be provided as per the supplier recommendation to meet the process requirement. The SSF filters will get the 5% of total flow from two hot water return lines, with motorised isolation valve (25V5011-5012). The common inlet line will connected to SSF units with flow element (25FE 5003) and flow indicating transmitter (25FIT5003). Separate overhead tank is considered for SSF back wash arrangement. The outlet from the SSF units will be fed back to cooling tower basin. The SSF units will be operated in automatic/semiautomatic mode. Operating sequence of SSF units: To meet the side steam filtration requirement, the Six (6) numbers of horizontal filters (25 SSF5001-5006) shall be provided in parallel. Timer based backwash system and Differential pressure indicating transmitter (25 DPIT5001-5006) provided across each filter for emergency backwash/ auto sequence are considered. Following are the modes of operation of the side stream filters: Back wash cycle. A. Drain down.
B. Backwash.

C. Air scouring

TRIVENI TURBINES LIMITED, BANGALORE. CLIENT : STEEL AUTHORITY OF INDIA LIMITED,

COOLING WATER SYSTEM CONTROL PHILOSOPHY-25 MW STG PROJECT DOC. NO : BSP-TEIL-05-011-01B-06-001-

BHILAI STEEL PLANT, BHILAI.

15-BD-00001

Service Cycle. A. Filling. B. Filtration/service. Filling: During the filling sequence all the valve status as follows. Inlet filling valve: Open Outlet valve: Close Air scouring valve: Close Vent valve: Close Backwash inlet valve: Close Backwash outlet valve: Close Filtration/Service: During the filtration/service sequence all the valve status as follows. Inlet filling valve: Open Outlet valve: Open Air scouring valve: Close Vent valve: Close Backwash inlet valve: Close Backwash outlet valve: Close Drain down: During the drain down sequence all the valve status as follows. Inlet filling valve: Close Outlet valve: Close Air scouring valve: Close

TRIVENI TURBINES LIMITED, BANGALORE. CLIENT : STEEL AUTHORITY OF INDIA LIMITED,

COOLING WATER SYSTEM CONTROL PHILOSOPHY-25 MW STG PROJECT DOC. NO : BSP-TEIL-05-011-01B-06-001-

BHILAI STEEL PLANT, BHILAI.

15-BD-00001

Vent valve: Open Backwash inlet valve: Close Backwash outlet valve: Open Backwash: During the backwash sequence all the valve status as follows. Please note that any one of the filter only will go for backwash and all other filters in normal operation. The backwash will be enabled based on the differential pressure across the filter or operator intervention. For filter backwash separate storage tank with level transmitter (25LIT5003) and motorised operated isolation valve (25V5165) in the discharge line. When the level is low the isolation valve in the discharge line will close automatically. Before enabling the backwash during the auto/semiautomatic mode level shall be not in low. Inlet filling valve: Close Outlet valve: Close Air scouring valve: Close Vent valve: close Backwash inlet valve: Open Backwash outlet valve: Open Air scouring: During the air scouring sequence all the valve status as follows. For air scouring purpose two (2) nos. (2 X 100%) of blowers are considered. During the air scouring any one of the blower will operate, during the operation if running blower trips the stand by blower will start automatically to cater the requirement. Inlet filling valve: Close Outlet valve: Close Air scouring valve: Open Vent valve: Open

TRIVENI TURBINES LIMITED, BANGALORE. CLIENT : STEEL AUTHORITY OF INDIA LIMITED,

COOLING WATER SYSTEM CONTROL PHILOSOPHY-25 MW STG PROJECT DOC. NO : BSP-TEIL-05-011-01B-06-001-

BHILAI STEEL PLANT, BHILAI.

15-BD-00001

Backwash inlet valve: Close Backwash outlet valve: Close (Please note that the tag nos will be finalised after placement of order) Makeup Water circuit: The makeup water will be tapped from the terminal point as agreed in the contract. Motorised isolation valve (25V5157) will be provided in the makeup water line to fore bay with flow measurement (25FE 5011 & 25FIT5011) to monitor the flow. The motorised valve with modulating actuator on the makeup water inlet to fore bay will be interlocked with the level transmitters (25 LIT 5001-5002) provided in the fore bay. At low water level the valve will fully open and at high water level the valve will be in fully closed position. The makeup water line is continuously monitored using differential pressure transmitter with flow element (25FE 5011 & 25FIT5011) and the flow value being transmitted to the PLC. Blow down circuit: A part of the return hot water coming to the cooling tower will be led in to existing gravity return network near PBS-1, TG-0 to maintain the cycle of concentration (COC) of the circulating cooling water at 5. This system will have flow measurement (25FE 5004 & 25FIT5004) and a motorised valve (25V5013) to control the flow. The quantity of blow down will depend upon the evaporation loss from the cooling tower and the COC. Chemical dosing system: A chemical dosing system is provided to maintain the quality of the circulating cooling water so that it will neither corrode nor form scales on the surfaces of the parts being cooled or the pipes through which it flows. It will also prevent fouling of heat exchanger elements and growth of algae in the cooling tower. Chemical dosing system usually consists of dosing tank, agitator (25M---) and two nos of transfer pumps (25M---). The actual details will depend upon the design of the chemical dosing system supplier.

TRIVENI TURBINES LIMITED, BANGALORE. CLIENT : STEEL AUTHORITY OF INDIA LIMITED,

COOLING WATER SYSTEM CONTROL PHILOSOPHY-25 MW STG PROJECT DOC. NO : BSP-TEIL-05-011-01B-06-001-

BHILAI STEEL PLANT, BHILAI.

15-BD-00001

Level switch (25LS---) are provided in the dosing tank for monitoring and interlock purpose. If level of the dosing chemical goes low, the PLC will generate a signal to trip the agitator automatically; when the level reaches low low the respective running pump will trip automatically. The operator can select any one of the pump as working and the other as standby. (Please note that the tag nos will be finalised after placement of order)

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