Owner:

TRUenergy Tallawarra Pty Ltd

Contractor:
ALSTOM Power Limited

TALLAWARRA Combined Cycle Power Plant

Revision History
Rev.

Revision Date

Created by

Checked by

A
B

04/1/2007
15/01/2007

Alvin Lee
Alvin Lee

Navin Bala
Navin Bala

Approved by

Description

Mohd. Faizal
Mohd. Faizal

Description latest Revision:

Supplier Information

Hotwell Sampling Monitoring System

Optimized Integrated Solution

Replaces

ALSTOM Document Code

TWA/19/M/QUL----B55/DM/010
Responsible dept.

Created by

Design

Alvin Lee

Originator

Power Turbo-Systems /
Power Environment

Checked by

Navin Bala

Approved by

Format

Mohd. Faizal

Document Type

Document Status

Title, Subtitle

Identification number

SYSTEM DESCRIPTION
(HOTWELL)

Rev.

A4

TWA/19/M/QUL----B55/DM/010
B

Date

15/01/2007

Template No.: GGG/00/-/EQA---/FT/302E (released with Work Instruction GGG/00/-/EQA---/WI/306)

ALSTOM 2006. All rights reserved.

Lang.

Sheet

en

1/5

SYSTEM OVERVIEW OF HOTWELL SAMPLING MONITORING SYSTEM

AT TALLAWARRA POWERPLANT

System overview shall describe sampling conditioning system, analyzers and sample
pump dry-run protection system.

A) Sampling Conditioning System

In general, all incoming steam/water samples shall be sample-conditioned such that the
steam/water sample can be measured accurately & handled by the analyzers. Typically,
every sample line has the following sample conditioning equipments;
1) Sample Cooler
2) Relief valve at Cooling Water Outlet from Sample Cooler (setting at 8 10 bar-g)
3) Sample Line Flow Regulator (To regulate sample flow at 20 LPH)

A1) Sample Cooler

All sample cooler are designed & sized up to 20 LPH sample water flow-rate as indicated
in the Heat Load Data List. Based on cooling water flow-rate at 750 LPH and maximum
temperature at 47oC, all sample water shall be cooled down to temperature approximately
at 48oC from samples designed temperature at 95oC.

A2) Relief valve at Cooling Water Outlet from Sample Cooler

When the cooling water supply is disrupted, some of the water/steam sample will remain
inside the sample cooler. When this occurs, the remnants of water/steam sample will also
pre-heat the remnants of cooling water along the cold side of the sample cooler. Thus,
pressure will build up along the cold side and the sample cooler may rupture as a result.

A3) Sample Line Flow Regulator

The flow regulator is actually a rotameter with needle valve. It can regulate sample flowrate from 8 to 88 LPH. In this application, the sample flow-rate shall be set at 20 LPH in
order to achieve sample temperature after sample cooler.

B) Analyzer
At Hotwell block, only cation conductivity is being measured.

Table 1 : Measuring Parameter in each stream for Hotwell.

BNF
STREAM
NO.

STREAM KKS
#

STREAM

18 QUL21

CONDENSATE

Cation Conductivity

0 - 10 uS/cm

18 QUL 23

CONDENSATE

Cation Conductivity

0 - 10 uS/cm

MEASURING
RANGE

PARAMETER

Cation Conductivity
Analyzers used are from ABB with the following models for its controller and sensor
type.
Controller
Sensor

: AX410
: AC221

Controller Description:
This analyzer is wall-mounted type with conductivity measurable from 0 to 10,000 uS
cm-1. The display is dual 5-digit with 7 segment backlit LCD. This backlit LCD can be
configured as ON or Auto-off after 60 seconds.
As standard, this analyzer provides 2 analogue outputs and 3 relay outputs. Analogue
output can be programmed to any value between 0 and 22 mA. For WSC system, it shall
be programmed as 4-20 mA signal to DCS. Relay outputs are rated 5A at 230 VAC or 5A
DC. Analogue output shall be bi-linear of 0 1 10 uS cm-1 (0 50 100% output).
Accuracy of reading is at 0.01% of span at 0 100 uS cm-1 and 1% of measurement
up to 10,000 uS cm-1.

Sensor Description:
This sensor body comes together with conductivity & temperature sensors integrated. The
sensor used is Pt-100 with reference temperature at 25oC and temperature compensation
allowable from -10 to 200oC. Cell constant is 0.01. This sensor will be mounted at a
stainless steel flow chamber with 3/8 FNPT inlet & outlet for sample. Sensor Cable
length provided is 1 meter or 3.3 feet. Cable connection method is terminal head type.

Maximum operating temperature and pressure are 110oC and 20 bar-g respectively. Flowrate of sample prior to this analyzer shall be regulated by flow regulator at 20 LPH.

C) Sample Pump Dry-run Protection System (DPS) for Hotwell Sampling

Monitoring System
Basically, samples pump DPS for each sampling line has the following components;
1. 2 units of 3/8 Solenoid valve.
2. 1 unit of Low Flow Switch.

Sample pump used is gear pump type with IP65 motor with max flow-rate of 150 LPH.
The gear pump used is able to withstand liquid medium at max. 95oC. This gear pump is
designed to have suction length of 5 meters horizontal and 5 meters vertical. However,
gear pump is prone to damages due to dry-run conditions.

To protect the sample pump, a flow switch is placed after the cation conductivity
analyzer. At flow-rate less than 2 LPH, the flow switch will shut-off the sample pump
and 2 units of solenoid valve to ensure the gear pump in wet condition prior to start-up.
This flow switch will also give out a dry contact signal to DCS via the Hotwell Sampling
Control Box.

Power Failure Recovery Mode

In event of power failure, conductivity analyzers can run back automatically according to
prior control mode settings. To indicate loss of power supply to the DCS, a dry contact
signal shall be provided to the DCS via the Main Miniature Circuit Breaker (MCB)s
auxiliary switch. The Main MCBs auxiliary switch shall operate in the following;
i)

When there is power supply, an active signal (energized signal) via the Main
MCBs auxiliary switch will be sent to the DCS.

ii)

Where power failure occurs, there will be a passive signal (de-energized

signal) sent to the DCS via the Main MCBs auxiliary switch.

Prepared by:

Date:

Alvin Lee

15th January 2007

Design & Application Engineer.

BNF ENGINEERING & SUPPLIES (M) SDN BHD