Sop HRSG

WI/OPS/ HRSG-01
STANDARD OPERATING PROCEDURE

1. SYSTEM NAME: HEAT RECOVERY STEAM GENERATOR.
2. OBJECTIVE:
The Heat Recovery Steam Generators (HRSG) utilized in the Combined Cycle
Plants, carries out the function to produce steam to supply the Steam Turbines
(ST), utilizing the thermal energy of the Gas-Turbines (GT) exhaust gas, before
discharging it to atmosphere by means of the boiler stack.
3. SYSTEM DESCRIPTION:
To carry out this function, the HRSG are located downstream the GT and are
contained in casings to forming an extension of the GT gases exhaust ducts.
The steam generators are of multitubular type and steam drum, natural or
activated water circulation, with economizer and super heater.
The exhaust gases coming from the GT crosses, in sequence, the distinct
components of steam generators to transfer to them the heat for convection
mode.
The feed water pre-heated in the economizer, flows in the evaporator and the
saturated steam produced is collected in the steam drum, located in the upper
zone of the steam generator. The steam crosses then the super heater and is
delivered to the ST.
To control the boiler outlet steam temperature, the super heater is provided with
desuperheater, which may be of water spray type or surface type.
In the combined cycle unit of large capacity, for technique and economic reasons,
the steam generators are subdivided in two or three sections, of high,
intermediate and low pressure, and the relevant heat exchanger elements are
conveniently distributed along the course of the GT exhaust gas. The
superheated steam produced by the different sections of the steam generators, is
conveyed, respectively, to the high, intermediate and low sections of ST.
In some cases the HRSG are provided with supplementary firing, located in the
exhaust gas duct upstream of the superheated to increase the superheated
steam temperature.
The Heat Recovery Steam Generator is a dual steam pressure type, natural
circulation, without supplementary firing. The superheated steam produced at
different pressure is utilized to feed the high and low pressure of Steam Turbine
sections. A diverter damper. Located at the entrance of the GT exhaust gas of
the HRSG, permits to exclude the boiler discharging the exhaust gas directly to
atmosphere, whenever it is necessary.
Initial Issue Date: 01.12.2005
Current Revision: 0
Reliance Energy Limited, Samalkot Power Station
Revision Date: 01.12.2005
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WI/OPS/ HRSG-01
The HRSG heating surfaces are divided in the following sections, in the direction
of the exhaust gas flow:
- HP super heater 2
HP super heater 1
- HP evaporator
- HP economizer 2
- LP super heater
- LP evaporator
- HP economizer 1 in parallel with LP economizer
The heating surfaces are assembled in modules, separated by cavities.
In the inlet duct a pressure transmitter, a pressure indicator and two pressure tapping
point are provided.
Six temperature tapping point, one occupied by a thermocouple, are provided
upstream HP super heater 2.
In each cavity six temperature tapping point are provided, three each side, one
occupied by a thermocouple fitted for supervision of the gas temperature profile along
the heating surfaces.
Downstream the banks, at the inlet of the stack, six temperature tapping point, one
occupied by a thermocouple, are provided. Four pressure-tapping points are also
provided, one occupied by a local pressure indicator and one by a pressure
transmitter to control room.
All the instruments provided for the exhaust gas system have the only purpose of
local or remote supervision.
HRSG HIGH PRESSURE LEVEL
The HRSG high-pressure level has the purpose to generate HP steam at the
correct pressure, temperature, and quality in accordance with the heat available
from the GT exhaust gas and requirements of the ST.
For this purpose, it will be supplied with the due amount of feed water at any time
during its operation: steady load, start-up or load changes.
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The HP superheated steam will be supplied to the ST through the HP main steam
piping system.
The HP system is equipped with intermediate desuperheater to control the main
steam outlet temperature at the desired value in any operating condition.
The HP drum level control station is located downstream the HP economizer to
prevent from steaming in the economizer itself, for feed water low flow during the
start-up.
HP SECTION STEAM GENERATOR
The high pressure section of steam generator is located downstream the exhaust
gas inlet to the HRSG and its heating surface is made of finned tubes, crossed by
he hot gas in the following order:
-
HP Super heater 2
HP Super heater 1
HP Evaporator
HP Economizer 2
HP Economizer 1.
Water from the HP feed water line enters the HP economizer 1 and 2, in counter
flow with respect to the exhaust gas, where it is heated up to the appropriate
economizer outlet temperature and is then delivered to the HP drum.
The HP economizers 1 and 2 are equipped with manual drains and vents.
A drum level control station is located downstream the HP economizer and
consists of two main feed water control valves suitable to control the HP drum level
in the range 30-100% MCR (one in stand-by) and a low load feed water control
valve suitable for loads below 30% MCR.
Each level control valve is provided with one intercepting motorized on-off valve
upstream and one intercepting manual on-off valve downstream. Suitable manual
drains are also provided between the intercepting valves and the control valves
to empty the lines in case of control valves maintenance.
Upstream the control station a safety valve is provided.
Once water has entered the HP drum, it falls down through the down comers and
reaches the inlet header of the HP evaporator. The HP evaporator bank
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generates steam heating the water with the hot gas, which passes through the
bank in cross-flow. The resulting water and steam mixture can go up through a
natural circulation loop to the evaporator outlet headers and then again to the HP
drum through some connecting pipes (called risers), uniformly distributed along
the drum length.
The boiler drum has the aim to:
-
Ensure a good mixing between inlet feed water and boiler water
Constitute a water reserve required for the circulation system
Allow water expansion during start-up
Ensure good water and steam separation.
The drum capacity is selected to ensure a stable and safe operation under all the
nominal operative conditions. The steam and water separation is achieved by
means of appropriate primary (cyclone type) and secondary scrubbers
(corrugated plates type). In the cyclones a mechanical centrifugal separation
occurs in the mixture of saturated water and steam coming from the risers.
Separated water falls down in the cyclones to the drum while saturated
Steam is conveyed to the secondary scrubbers where a tortuous path makes it
virtually dry.
A chemical dosing line for phosphates are foreseen in the HP drum in order to
control boiler water pH to a suitable value. A blow-down line, equipped with a
motorized on-off valve (with double manual by-pass valve) and a manual control
valve, is foreseen to control boiler water conductivity. A blow-off line, equipped
with a manual on-off valve and a motorized inching type valve, is also fitted to
control drum swelling during the start-up.
A dedicated line also ensures sampling of the blow-down water.
The HP drum is equipped with two safety valves with silencers, three level
transmitters pressure compensated for control, alarm and trip purposes, and six
skin metal temperature thermocouples, for supervision and alarm. Two hydra
step type level indicators to control room and two level gauges (local drum level
indicators) are provided for remote and local supervision.
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Saturated steam flows from the HP drum to HP super heater 1 inlet through
connecting piping. For the conductivity monitoring of the saturated steam is
foreseen a sampling line, while a motorized on-off vent valve is provided in the
connecting piping, to be closed during the beginning of the pressurisation.
From the HP super heater 1 the steam, flowing in counter flow with respect to the
exhaust gas, enters the intermediate desuperheater, used to limit the main steam
temperature (downstream HP super heater 2) at the desired value in any
operating condition and then reaches the HP super heater 2.
Seven skin metal thermocouples are fitted at the outlet of this bank to monitor
and alarm the relevant metal temperature.
Both HP super heater 1 and 2 are equipped with motorized drain valves, to be
used during start-up or load variations to ensure no condensate remain inside the
super heater tubes.
HP MAIN STEAM PIPING
Main steam piping is provided with:
-
A safety valve with silencer;
A flow meter, equipped with double transmitters, double temperature and
pressure transmitters for flow measurements compensation.

-
Local temperature and pressure indicators.
The two temperature transmitters are also used for main steam temperature control
purposes.
A sampling line is provided for the superheated steam quality monitoring.
A start-up motorized inching type vent, complete with relevant silencer, is
foreseen to limit the HP drum pressure gradient during HRSG start-up. An
electrometric valve, complete with an intercepting manual on-off valve and
silencer, is provided to prevent from HP super heater safety valve opening.
A motorized on-off valve, gate type, is located in HRSG area to intercept main
steam piping and boiler isolation. This valve is equipped with a motor operated
by-pass valve for the steam line warming.
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Downstream of the HRSG isolating valve, the branch for the turbine by-pass is
provided.
Chemical cleaning connection in the main steam pipe is also provided.
HRSG LOW PRESSURE LEVEL
The HRSG low-pressure level has the purpose to generate LP steam at a correct
pressure, temperature and quality to the low-pressure stage of the ST.
For this purpose, it will be supplied with the due amount of feed water at any time
during its operation: steady load, start-up or load changes.
The LP superheated steam will be supplied to the ST through the LP main steam
piping system.
The LP drum level control station is located downstream the LP economizer to
prevent from steaming in the economizer itself.
LP SECTION STEAM GENERATOR
The low pressure section of steam generator is located downstream the exhaust
gas inlet to the HRSG behind the HP level and its heating surface is made of
finned tubes, crossed by he hot gas in the following order:
-
LP Super heater
LP evaporator
LP Economizer
Water from the LP feed water line enters the LP economizer, in counter flow with
respect to the exhaust gas, where it is heated up to the appropriate economizer
outlet temperature and is then delivered to the LP drum.
The LP economizer is equipped with manual drains and vents.
A drum level control station is located downstream the LP economizer and
consists of two main feed water control valves suitable to control the LP drum
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level in the range 0-100% MCR (one in stand-by). Each level control valve is
provided with one intercepting motorized on-off valve upstream and one
intercepting manual on-off valve downstream.
Upstream the control station a safety valve is provided.
Once water has entered the LP drum, it falls down through the down comers and
reaches the inlet header of the LP evaporator. The LP evaporator bank generates
steam heating up the water with the hot gas which pass through the bank in
cross-flow. The resulting water and
Steam mixture can go up through a natural circulation loop to the evaporator
outlet headers and then again to the LP drum through some connecting pipes
(called risers) uniformly distributed along the drum length.
The boiler drum has the aim to:
-
Ensure a good mixing between inlet feed water and boiler water
Constitute a water reserve required for the circulation system
Allow water expansion during start-up
Ensure good water and steam separation.
The drum capacity is selected to ensure a stable and safe operation under all the
nominal operative conditions. The steam and water separation is achieved by
means of appropriate primary (cyclone type) and secondary scrubbers
(corrugated plates type). In the cyclones a mechanical centrifugal separation
occurs in the mixture of saturated water and steam coming from the risers.
Separated water falls down in the cyclones to the drum while saturated steam is
conveyed to the secondary scrubbers where a tortuous path makes it virtually
dry. A chemical dosing line for phosphates is foreseen in the LP drum in order to
control boiler water pH to a suitable value. A blow-down line, equipped with a
motorized on-off valve (with manual by-pass valve) and a manual control valve, is
foreseen to control boiler water conductivity. A blow-off line, equipped with a
manual on-off valve and a motorized inching type valve, is also fitted to control
drum swelling during the start-up.
A dedicated line also ensures sampling of the blow-down water.
The LP drum is equipped with two safety valves with silencers, three level
transmitters pressure compensated for control, alarm and trip purposes, and a
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skin metal temperature thermocouple (for supervision and alarm). Two hydra step
type level indicators to control room and two level gauges (local drum level
indicators) are provided for remote and local supervision.
Saturated steam flows from the LP drum to LP super heater inlet through
connecting piping. For the conductivity monitoring of the saturated steam is
foreseen a sampling line, while a motorized on-off vent valve, is provided in the
connecting piping, to be closed during the beginning of the pressurisation.
From the LP super heater outlet the steam is conveyed to the LP main steam
piping.
The LP super heater is equipped with a motorized drain valve, to be used during
start-up or load variations to ensure no condensate remain inside the super
heater tubes.
No temperature control is necessary on the LP super heater as the LP main
steam temperature is very low and remains stable in the normal boiler operative
range.
LP STEAM PIPING
The aim of this pipe is to lead the low pressure steam to the low pressure stage
of the ST.
Steam piping is provided with:
-
A safety valve with silencer;
A flow meter, equipped with double transmitters, double temperature and
pressure transmitters for flow measurement compensation;

-
Local temperature and pressure indicators.
A sampling line is provided for the superheated steam quality monitoring.

A start-up motorized inching type vent, complete of silencer, is foreseen to limit
the LP drum pressure gradient during HRSG start-up.
A motorized on-off valve, complete with relevant motorized by-pass, is located in
HRSG area to intercept main steam piping.
HRSG DRAINS AND VENTS SYSTEM
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The system fulfils the following requirements:
-
Collects and discharges blow-off water from the drums during start-up to the
atmospheric flash tank

-
Collects water from the super heater drains to the atmospheric flash tank
Collects water from the economizer and evaporator drains to the atmospheric
flash tank, when this operation is necessary to empty the boiler

-
Collects and discharges blow-down water from the drums during normal
operation to the atmospheric flash tank

-
Collects drum and economizer vents and safety and electrometric valve
drains to the atmospheric flash tank

-
Delivers collected water in the flash tank to the plant drainage system.
FUNCTIONAL DESCRIPTION
The water collected inside the atmospheric tank flashes and is splitted in two
parts: steam is conveyed to a silenced vent and then is discharged to the
atmosphere; the remaining water is collected to the plant drainage system.
HRSG NITROGEN FILLING SYSTEM
The system fulfils the requirement to carry out HRSG wet conservation (lay-up) in
case of long shutdown.
FUNCTIONAL DESCRIPTION
The system consists of a nitrogen tank connected to LP and HP saturated steam
pipes (the highest HRSG points) and fed by a nitrogen pipe connected to a
nitrogen bottles set complete of a safety valve and a pressure reducing valve.
Demineralised water is used to fill the HRSG up to the middle of the nitrogen
tank; nitrogen is then introduced in the tank at a very low pressure (~ 2 bar).
Pressure and water level in the tank can be easily monitored by means of
dedicated local instruments.
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Once water level or pressure decrease, water or nitrogen have to be further
introduced.
RATING
The quantity of superheated steam generated (both LP & HP) Under GT load of
100% and 29oC ambient are as follows:
a. HP steam 62.5 Kg/sec at 84.1 KG/cm2 and 528oC
b. LP steam 15.5 Kg/sec at 5.87 KG/cm2 and 208oC
PRE-REQUISITES:
No PTW pending for HRSG (HP/LP system) and maintenance activity,
which could impact the start-up operations, is over.

Ensure that the needed inspections following to a long period of inactivity
after shutdown have been carried out.
All MOVs megger values should be O.K.

All equipments properly earthed.
All control valves functional checked completed.
All the instruments are lined up and supervision system and the
recorders are in service.
Ensure HRSG sump pump is auto available.
DM water storage tank level is normal for startup.
Ensure DM water distribution pump, CEP, LPBFP, HPBFP is available for
operation.
Ensure that the electrical automation system and the relevant transducers
are in service.
Ensure that the safety rules are correctly met.

Ensure that all the main manual valves are in their correct position.
Check that the fire protection system is available.
Check that electrical supplies are available.
Ensure that all the instrument impulse line-isolating valves are open and
the equalizing valves are closed.
Check that the Natural gas or Naphtha/HSD fuel systems are available.
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Ensure that the Waste Water Treatment System and the HVAC System are
normally operating.
Perform all the detailed pre-checks specified by the manufactures and put
the relevant drives in AUTO mode.
Ensure that all the valves, including cock valves, are not under
maintenance and in the correct position.
Ensure that all the safety valves are disengaged and their relevant spring
action is efficient.
Ensure that the HRSG drums level is at least at start-up level and fill them,
if necessary.
Check that the Chemical Dosing System is ready.
Check that the HRSG drain and vent valves are in automatic mode
SAFETY CHECKS:
1.Fire detection and Fire alarm system for all areas should be available.
2.Fire hoses should place all hose boxes.
3.All the valves should be free for operation.
HYDRO TEST OF HP SYSTEM:
Open the economizer 1&2 vent valve.

Open drum vent valve with isolation valve.
Open evaporator vent valve.
Open super heater 1& 2 vent valve.
Close the blow down and blow off isolation valve.
Lock the hp economizer, hp drum (both), and hp supper heater safety
valve for preventing the popup.
Keep the ERV in manual mode.
Close the HPMS shutoff valve and its bypass valve.
Open the hp eco inlet valve.
Open the initial filling valve from DM water distribution pump.
Keep the feed control valves (2*100% +1*30%)in manual operation
mode.
Start the one DM water distribution pump and open the discharge valve
of the pump.
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If continuous water is coming from the eco vent, close the eco vent.
Stop the DM water distribution pump and close the discharge valve of
the pump.
Close the initial filling valve from DM water distribution pump.
Start one HPBFP with chemical injection as per chemical requirement.
Open the manual isolation valve and MOV of 30% control valve.
Slowly open the 30% control valve manually maximum up to 30%.
Observe the HPBFP discharge pressure.
Open or close the 30% control valve by keeping the HPBFP discharge
pressure more than 120 bar.
If continuous water is coming from the supper heater 1&2 vents, close
the respective vent.
If hp drum level reached high- high value (350 mm) and continuous
water is coming from the HP drum vent, close the vent.
Observe the drum pressure if it is more than 130 bar, close the 30%
control valve and its MOV.
Stop the HPBFP and close the discharge and its bypass valve.
Observe the drum pressure for 30 minutes.
If drum pressure is holding 130 bars up to 30minutes than it is
concluded that hydro test is completed successfully and system is leak
proof.
HYDRO TEST OF LP SYSTEM:
Open the economizer vent valve.

Open drum vent valve with isolation valve.
Open evaporator vent valve.
Open super heater vent valve.
Close the blow down and blow off isolation valve.
Lock the LP economizer, LP drum (both), and LP supper heater safety
valve for preventing the popup.
Keep the ERV in manual mode.
Close the LPMS shutoff valve and its bypass valve.
Open the LPECO inlet valve.
Keep the feed control valves (2*100%)in manual operation mode.
of the pump.
If continuous water is coming from the eco vent, close the eco vent.
the pump.
Start one LPBFP with chemical injection as per chemical requirement.
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Open the manual isolation valve and MOV of one control valve.
Slowly open the control valve manually maximum up to 15%.
Observe the LPBFP discharge pressure.
Open or close the control valve by keeping the LPBFP discharge
pressure more than 20 bar.
If continuous water is coming from the supper heater vents, close the
respective vent.
If hp drum level reached high- high value (200 mm) and continuous
water is coming from the HP drum vent, close the vent.
Observe the drum pressure if it is more than 12 bars; close the control
valve and its MOV.
Stop the LPBFP and close the discharge and its bypass valve.
Observe the drum pressure for 30 minutes.
If drum pressure is holding 12 bars up to 30minutes than it is concluded
that hydro test is completed successfully and system is leak proof.
HYDRO TEST OF CPH SYSTEM:

Open the CPH vent valve.
Close the deaerator feed water inlet manual valve, MOV and its bypass
valve.
of the pump.
Charge the GSC from waterside after doing proper venting.
Charge the LP heater from waterside after doing proper venting.
Close the both CPH pump suction and discharge valve.
Open the manual isolation valve and MOV of the CPH coil and close
manual isolation valve and MOV of the CPH coil bypass line.
If continuous water is coming from the CPH vent, close the vent.
the pump.
Start one CEP with chemical injection as per chemical requirement.
Ensure CEP discharge valve open in auto.
Observe the CEP discharge pressure.
Observe the CPH coil outlet pressure if it is more than 16 bars; Stop the
CEP and close the discharge and its bypass valve.
Observe the CPH coil pressure for 30 minutes.
If pressure is holding 16 bars up to 30minutes than it is concluded that
hydro test is completed successfully and system is leak proof.
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STARTUP PROCEDURE
COLD START- UP PROCEDURE (ST metal temperature < 150C; HP drum at
atmospheric pressure)
PRE-REQUISITES:
No PTW pending for HRSG (HP/LP system) and maintenance activity,
which could impact the start-up operations, is over.

Ensure that the needed inspections following to a long period of inactivity
after shutdown have been carried out..
All the instruments are lined up and supervision system and the
recorders are in service.
Ensure HRSG sump pump is auto available.
Ensure ACW pump is in service.
DM water storage tank level is normal for startup.
Ensure at least one CEP, HPBFP, LPBFP are in-service and other is auto
available.
Ensure condenser and deaerator level is normal.
Ensure chemical dosing pumps are running as per chemical requirement.
Ensure that the electrical automation system and the relevant
transducers are in service.
Ensure that all safety valves are in service i.e. all safety valves are in
unlocked position.
Ensure that the safety rules are correctly met.
Ensure that all the main manual valves are in their correct position.
Check that the fire protection system is available.
Check that electrical supplies are available.
Ensure that all the instrument impulse line-isolating valves are open and
the equalizing valves are closed.
Ensure GT is synchronized with grid.
Ensure that the Waste Water Treatment System and the HVAC System are
normally operating.
Perform all the detailed pre-checks specified by the manufactures and put
the relevant drives in AUTO mode.
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Ensure that all the valves, including cock valves, are not under
maintenance and in the correct position.
Ensure that all the safety valves are disengaged and their relevant spring
action is efficient.
Ensure that the HRSG drums level is at least at start-up level(-100mm)
and fill them, if necessary.
Ensure the HP and LP feed control station all control valves are in auto
and HP 30% valve is in service.
Check that the HRSG drain and vent valves are in automatic mode.
Ensure HP and LP blow down and blow off isolation valves are in open
condition.
Ensure HP and LP drum vents are in open condition and kept in auto.
Ensure HP and LP supper heater vents are in open condition and kept in
auto.
Ensure HPSH pray isolation valve is open and control valve is in auto.
Procedure
Set the GT load set point 15MW.
Reset the HRSG trip from back up panel.
Partially open the HP and LP MS drain valve.
Open the HP and LP main steam shutoff valve.
Open the diverter damper manually by giving the gas flow target value
10%.
Maintain the drum level 100mm, if required essentially than give the blow
down or blow off.
Open the HRSG sump water-cooling valve.
For maintaining the drum level 100mm if required change the level
biasing.
Open the diverter damper by taking care of following parameters.
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a) Maintain the drum metal temp rise less than 6 0 C /Min.
b) Maintain the HP steam temp rise less than 120 C /Min.
c) Drum top and bottom metal temp difference less than 100 oC
Observe the HP drum pressure if it is more than 3.5 bar drum vent closed
in auto, if not closed manually.
Observe the HPSH pressure if it is more than 3.5 bar drum vent closed in
auto, if not closed manually.
Observe the LP drum pressure if it is more than 2.5 bar drum vent closed
Observe the LPSH pressure if it is more than 2.5 bar drum vent closed in
Start at least one CW pump as per pump starting procedure.
If HPMS pressure come up to 10 bar start the main steam deaerator
pegging line heating by crack opening of the first pressure control valve
and its isolation valve.
Open the main steam deaerator pegging de supper heating line isolation
valve and keep the de supper heating control valve in auto at 250 0 C set
value.
Observe the main steam deaerator pegging line temperature if it come up
to 2000 and HP drum pressure come up to 13 bar start the deaerator
pegging charging by manual opening of 1st and 2nd pressure control valve
and maintain the line pressure after the 1 st control valve at 6.0 bar.
Open the GSC drain valve.
If deaerator pressure is maintaining 1.0 bar keep the both pressure control
valve in auto.
Start one GSC blower as per checklist.
If HP drum pressure comes up to 20 bars open the first pressure control
valve and its isolation valve manually.
Open the second pressure control valve slowly and open the first pressure
control valve in manual mode for maintaining the pressure15 bar.
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Keep the seal steam temp control valve in auto at 180 oC set value.
If seal pressure comes up to 25mbar than keep the both pressure control
valve in auto.
Close the vacuum breaker valve.
Start both vacuum pumps as per startup procedure.
If condenser pressure comes up to 200 mbar open the HP and LP bypass
control valve partially in manual mode.
Ensure the opening of the HP and LP bypass cooling line isolation valve.
Set the HP and LP bypass pressure control valve slightly less than the up
actual up streamline pressure and keep the HP and LP bypass pressure
control valve in auto.
Maintain the up streamline pressure by slowly changing the pressure set
point and taking care of HP and LP drum level as per steam turbine rolling
condition.
Keep the diverter damper in auto.
WARM START- UP PROCEDURE (ST metal temperature < 350C; HP drum pr. = 4 bar)
Permissive conditions:
Instruments and service air available;
Demi water available (tank level not low);
Circulating water and closed cooling system in service;
Condenser level and deaerator level not low;
HRSG trip reset;
By-pass system hydraulic supply in service.
Procedure
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10%.
Increase the GT load up to 35MW in 25 min.
down or blow off.
Open the HRSG sump water cooling valve.
biasing.
Open the diverter damper by taking care of following parameters.
d) Maintain the drum metal temp rise less than 6 0 C /Min.
e) Maintain the HP steam temp rise less than 120 C /Min.
f) Drum top and bottom metal temp difference less than 100 oC
Observe the LP drum pressure if it is more than 2.5 bar drum vent closed
Observe the LPSH pressure if it is more than 2.5 bar drum vent closed in
If HPMS pressure come up to 10 bar start the main steam deaerator
pegging line heating by crack opening of the first pressure control valve
and its isolation valve.
Open the main steam deaerator pegging de supper heating line isolation
valve and keep the de supper heating control valve in auto at 250 0 C set
value.
Observe the main steam deaerator pegging line temperature if it come up
to 2000 and HP drum pressure come up to 13 bar start the deaerator
pegging charging by manual opening of 1st and 2nd pressure control valve
and maintain the line pressure after the 1 st control valve at 6.0 bar.
Open the GSC drain valve.
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If deaerator pressure is maintaining 1.0 bar keep the both pressure control
valve in auto.
Start one GSC blower as per checklist.
If HP drum pressure comes up to 20 bars open the first pressure control
valve and its isolation valve manually.
Open the second pressure control valve slowly and open the first pressure
control valve in manual mode for maintaining the pressure15 bar.
Keep the seal steam temp control valve in auto at 180 oC set value.
If seal pressure comes up to 25mbar than keep the both pressure control
valve in auto.
Close the vacuum breaker valve.
Start both vacuum pumps as per startup procedure.
condition.
Keep the diverter damper in auto.
HOT START- UP PROCEDURE (ST metal temperature > 350C; HP drum pr. = 75 bar)
Instruments and service air available;
Demi water available (tank level not low);
Circulating water and closed cooling system in service;
Current Revision: 0
Page 19
WI/OPS/ HRSG-01
Condenser level and deaerator level not low;
HRSG trip reset;
By-pass system hydraulic supply in service.
Procedure
30%.
Increase the GT load up to 60MW @11MW/min.
down or blow off.
Open the HRSG sump water-cooling valve.
biasing.
Put the diverter damper in auto.
Start both vacuum pumps (if required) as per startup procedure.
Current Revision: 0
Page 20
WI/OPS/ HRSG-01
condition.
SHUTDOWN PROCEDURE
All necessary plant drives available and in Auto mode;
GT in service;
Diverter damper HRSG fully open;
HRSG HP & LP steam by-pass in Auto.
Start of procedure
Switch HP pressure set-point to Manual mode (HP steam by-pass of HRSG
and ST control valves will maintain the pressure at the actual value);
If the steam flow from HRSG is greater than 75% of nominal value (depending
on the actual GT
load), partial closure request (70% opening) to diverter
damper
Close the diverter damper Slowly by taking care of:
g) Maintain the drum metal temp decreasing rate not less than 4.7 0 C
/Min.
h) Maintain the HP steam temp decreasing rate not less than 9.6 0 C /Min.
IF ST HP CV position comes down up to 20% trip the steam turbine manually.
Close the diverter damper fully.
CHEMICAL PARAMETERS AND OPERATING LIMITATIONS
CHEMICAL PARAMETERS
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Page 21
WI/OPS/ HRSG-01
In order to permit the set of the monitoring field instrument and to perform the main
chemical analysis, we supply the recommended main chemical parameters on the
following basis:
The steam O2 and pH values corrections, will be checked through alkaline
scavenger, supplied by means of the chemical plant.
Feed water hardness leakage, will be checked using phosphate injection plant into
boiler drum, if required.
Maximum pH and conductivity values, in the boiler water, will be maintained by
means of the use of the blow-down system.
In the annex diagram n 12, is showing the boiler silica repartition pressure rate
curve.
The blow-down flow adjustment will maintain the SiO 2 maximum value.
Sampling point
Measure
Range
Feed water conductivity *

S/cm
max 0,2
Feed water pH
9,0
Blow-down conductivity *
S/cm
3 HP; 5 LP
Steam SiO2
ppm
max 0,02
Steam conductivity *
S/cm
0,2 ( 0,5**)
Oxigen O2 at deaerator out
ppm
max 0,04
Hydrazine N2H4 feed water
ppm
0,02
Iron (Fe) in feed water
ppm
max 0,02
* Thecontent
conductivity value takes in consideration the sample after cationic
exchange (acid conductivity)
Safety valve setting:
Actual setting at the side is as follows:
HRSG SAFETY V/V SET / RESET VALUE
SET
SAFETY V/V
RESET VALUE
SR. NO.
VALUES IN
DESCRIPTIONS
IN BAR
BAR
1
ERV
92.9
88.72
2
HP SUPER HEATER
96.4
93.91
3
HP-DRUM-I
103.88
102.12
4
HP-DRUM-II
103.31
98.71
5
HP ECO II
N.A.
168.5
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WI/OPS/ HRSG-01
6
7
8
LP SUPER HEATER
LP DRUM
LP DRUM
7.94
10
10
7.73
9.55
9.55
Prepared by
Reviewed by
DY manager. - Operation
Head (Operation)
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Page 23

Sop HRSG

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WI/OPS/ HRSG-01

STANDARD OPERATING PROCEDURE

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

Constitute a water reserve required for the circulation system

Allow water expansion during start-up

Ensure good water and steam separation.

Initial Issue Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

A safety valve with silencer;

A flow meter, equipped with double transmitters, double temperature and

pressure transmitters for flow measurements compensation.

Local temperature and pressure indicators.

Initial Issue Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

Constitute a water reserve required for the circulation system

Allow water expansion during start-up

Ensure good water and steam separation.

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

A safety valve with silencer;

A flow meter, equipped with double transmitters, double temperature and

pressure transmitters for flow measurement compensation;

Local temperature and pressure indicators.

A sampling line is provided for the superheated steam quality monitoring.

Initial Issue Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

atmospheric flash tank

flash tank, when this operation is necessary to empty the boiler

operation to the atmospheric flash tank

drains to the atmospheric flash tank

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

No PTW pending for HRSG (HP/LP system) and maintenance activity,

which could impact the start-up operations, is over.

All MOVs megger values should be O.K.

Ensure that the safety rules are correctly met.

Initial Issue Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

Open the economizer 1&2 vent valve.

Initial Issue Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

Open the economizer vent valve.

Initial Issue Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

HYDRO TEST OF CPH SYSTEM:

Initial Issue Date: 01.12.2005

Reliance Energy Limited, Samalkot Power Station

Revision Date: 01.12.2005

No PTW pending for HRSG (HP/LP system) and maintenance activity,