Beruflich Dokumente
Kultur Dokumente
INDEX
SR. CHAPTERS PAGE
NO. NO.
1
2
DESCRIPTION:
GENERAL DESTRIPTION OF THE SYSTEM:
• Normal make-up to the condenser (8 t/h) is ensured by a spraying rack running over the condenser tube bundle; this
arrangement allows proper deaeration of the make-up water.
• Quick make-up (20t/h) is ensured to the condenser hotwell directly.
• A pump (101PO) allows the filling of the water circuit (60m³/hr) of the cycle on start up.
• The condensate storage tank constitutes a water reserve for condenser make-up and stores the water coming from the
cycle (discharge of CEX system to the condenser).
• The make-up to CST tank is ensured from the demineralised water tanks.
OPERATION:
NORMAL MAKE-UP:
Normal make-up to condenser is by gravity through normal make-up valve (LV-001).
QUICK MAKE-UP:
Quick make-up to the condenser is by gravity through quick make-up valve (UV-001).
2
3
Start pump 101 PO for hotwell filling by keeping LV 001 & UV 001 open. At normal level close the UV
001 valve.
3
4
4
5
ADG LSL003
FEED WATER TANK
LOW LEVEL
<2200 MM
5
6
HSN101
101 PO STARTING
ORDER
ZSH 101
SUCTION V/V
HV 101 OPEN
LSLL 100
001 BA LOW LOW
LEVEL
START PUMP
101 PO
ZSH 101
SUCTION V/V
HV 101 OPEN
STOP PUMP
101 PO
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7
To supply:
• Desuperheating water to the HP and LP bypass of the HRSGs.
Water to the spraying system of turbine LP cylinder exhaust and the steam turbine gland
sealing desuperheating system.
• Water to the chemical injection tanks.
• Water to the stuffing box of the condensate extraction pump.
• Water to the vacuum pump separator tank.
Condensation system:
• It includes a surface type condenser: heat sink is a closed type tower circuit.
• Half condenser can be isolated on the circulation waterside for on load inspection
• Condensate water is recovered in the hotwell so as to provide a suitable suction head for the condensate extraction
pumps and a sufficient storage capacity during transient operation during insufficient admission of steam into the
condenser or opening of the bypass valve.
Extraction system:
It includes three identical electrically driven pump sets. Each pump set is having 50% capacity; therefore 2
sets normally on duty and third on automatic standby in case of failure of either of running both pump
sets.
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8
It supplies the deareator feed water tank with condensate water and is discharged into the reserve feed
water tank by a power-operated valve.
Demineralised water discharge system:
If the condenser hot well level is too high, the condensate water is discharged into the reserve feed water
tank by a power-operated valve.
DESCRIPTION OF EQUIPMENT AND CIRCUITS:
Condenser:
It is mainly composed of:
• A turbine-condenser connecting neck.
• Tube bundles (18400 nos.).
• Condensate water storage hot well.
• Three condensate water outlet pipes.
• A make-up water pipe.
• The HP and LP turbine bypass devices.
Main data:
Condensate water volume stored in hotwell under rated load About 30 m3
Heat exchange area 13,014 m2
Pressure at nominal load 92 mbar abs.
Number of passes 2
Number of water by passes 2
Motor:
• Axis vertical
• Speed 1 500 rpm
• Power 132 kW
• Voltage 415 V
• The suction circuits of the pumps are independent and each of them includes strainer and a manually operated isolating
valve.
• Each discharge circuit is fitted with a non-return valve and power operated isolating valve.
• Condensate water feeds the turbine gland sealing steam condenser. The recirculation system to the condenser is
branched off form the downstream side off the gland steam condenser.
• A pneumatic operated valve FCV 001 allows the re-circulating flow to reach the condenser. A backpressure orifice-
plate arranged at condenser inlet avoids spraying in the pipes. The set point of the valve FCV 001 is 125 t/h.
• A non-return valve arranged on the de-superheating line supply branch pipe at the condensate water header tapping
point, prevents the de-superheating line to be partially drained during condensate extraction pump shutdown.
Condenser discharge:
• Condenser discharge is into the reserve feed water tank through the pneumatic operated regulating valve LCV 001.
8
9
OPERATION:
NORMAL OPERATION:
Normal operation with 2 HRSGs:
• The condensate water is supplied to the feed water tank by 2 condensate extraction pumps.
• The water is heated in the boiler condensate pre-heaters: the minimum temperatures at boiler inlet and maximum
temperature at feed water inlet are regulated by the recirculation pump and the bypass valve (see FLP system).
• The condenser level is kept constant by the regulating valve LCV 001.
• The recirculation valve FCV 001 is closed.
• The condenser over flow valve (LV 001) is closed
• The isolating valves at pumps discharge (UV 101, 201, 301) are open.
• The gland steam condenser bypass (HV 012) is closed.
• The sealing water circuit is in operation.
• The condensate extraction pump thrust bearing is fed with SRI cooling water.
• The water losses from the water/steam circuit are automatically compensated by the normal make-up valve (CAP LV
001). Normal make-up is sprayed above the tube bundle to allow proper deaeration.
Special Operation:
If condensate water flow rate is too low, the recirculation valve FCV 001 opens. This ensures correct
operation of the pumps a well as sufficient feeding of the gland steam condenser.
TRANSIENT OPERATIONS:
Starting of the condensate extraction pumps:
• Before starting up the condensate extraction pumps the circuit must be filled in by means of make-up pump.
• The hotwell must be filled up to regulation level (900 mm)
• The pumps thrust bearings must be fed with cooling water (SRI)
Changeover of pumps:
• The changeover of the two-condensate extraction pumps is carried out from the control room. This is carried out with
an overlap period, the 3 pumps delivering together for a short time into the circuit.
INCIDENTS:
Abnormal level in the condenser hot well:
• In the case of an excessive rise in the condenser water level, the condenser hot well dump valve (LV 001) opens
automatically.
• In the case of low level, the normal and quick make-up valves are opened (CAP LV 001 and CAP UV 001).
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10
• The condenser level is kept at working level by a proportional and integral action controller, which
governs the control valve LCV 001.
• The control valve opening is limited by over flow of the condensate pumps for protection of this
pumps, this protection is initiated by the condensate water flow through a proportional and integral
controller. In case of flow limitation an alarm is initiated.
• A changeover system by means of a manual loading station (HIC 001) allows the selection of the
type of operation of the loop, either automatic or manual. Manually operator controls the valve
directly. On Auto, the valve is controlled by the analog signal initiated by the control loop.
• The control valve is closed in case of high level in the feed water tank or by stopping of the three-
condensate pumps.
After the starting-up of the pump selected, the discharge valve of all three pumps open and the condenser
level control valve (LCV 001) goes into regulating mode.
Condensate extraction pump starting by using sub-group control:
The operator can start-up a condensate extraction pump using the sub group control if the start conditions
are fulfilled. The pump starts up and its discharge valve opens.
Shutdown of condensate extraction pumps:
• Discharge valve staying closed for three seconds after the pump start up
• Discharge valve not open in 30 seconds after the pump start up
• Very high temperature of pump thrust bearing
• Very high vibration of pump thrust bearing
• Electrical fault in motor.
• Shutdown from sub group control
Following signal causes the condensate extraction pump in question to stop, and discharge valve to
close.
• Discharge valve staying close three second after the pump start-up.
• Discharge valve not open 30 seconds after the pump start-up.
• Very high temperature of the Pump thrust bearing.
• Very high vibration of pump thrust bearing.
• Electrical fault in motor.
• Shutdown from sub-group control
• Very high level in the feed water tank.
• Very low level in the condenser.
• Shutdown from group control.
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11
Changeover of pumps
By group control:
The operator deselects the pumps in operation and selects another using the selector HSU 001 and
confirms this new choice with the group control HSN 001. The changeover of the pumps is going to be
achieved with an overlap period with three pumps in operation.
Individual controls:
Each actuator (pump-discharge valve) can be controlled by an individual control.
LSL 001
CONDENSER LOW
LEVEL <800MM
ZSH 111
SUCTION VALVE
HV101 OPEN
ZSL 101
DISCHARGE V/V PSH 001
UV101 CLOSED DISCHARGE
PRESSURE
CORRECT
CONDENSATE
PUMPS 101 PO
STARTING
CONDITION
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12
HSU 002
TAKING OVER AUTO
HSU 001 CUT OUT
101PO
SELECTED IN NORMAL
SELECTION STATUS
CORRECT
SELECTION STATUS
CORRECT
ON OFF
PUMP SELECTED IN
NORMAL STOPPED
HSN011
101PO SET
STARTING ORDER
HSU 001
101 PO
SELECTED IN STAND-BY
HSN 101
101 PO
INDIVIDUAL STARTING
ORDER
STARTING CONDITIONS
FROM FOLIO 2
PUMP 101 PO
ON
PUMP 101 PO
ON
12
13
CONDENSATE
PUMP
101 PO
IN OPERATION
50 SEC 3 SEC
ZSL 101
DISCHARGE V/V UV101
ZSH 101 CLOSED
DISCHARGE VALVE UV 101
OPEN
TSHH 101
ELECTRIC FAILURE THRUST BEARING
101 MO HIGH HIGH TEMPERATURE
CONDENSATE P/P
101 PO
TRIPPING CONDITIONS
GROUP
TRIPPING
CONDITIONS
13
14
HSN 011
SUB GROUP
STOPPING ORDER
PUMP 101 PO
IN OPERATION ON
GROUP LEVEL
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15
TRIPPING SIGNAL
ELABORATATION FROM
ADGLSHH 101 & 201
TRIPPING SIGNAL
ELABORATION FROM
ADG LSHH 101 & 201
ADGLSHH 001
F.W.T. HHL
1 CONDENSATE PUMP
IN OPERATION
ENERGIZE LCVX
001VALVE LCV 001 IN
MODULATING
15
16
16
17
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18
The water coming from the condensate extraction pumps is injected into the deaerator after passing
through the condensate preheaters.
Feed water tank:
• The feed water tank receives the condensate coming from the deaerator.
• A LP steam injection rack allows the tank warming-up on start-up.
• The LP and HP feed pumps draw water from the tank through six separate pipes.
• The tank overflow pipe is directed towards the drain tank (ACO).
OPERATION:
NORMAL OPERATION:
• The feed water tank is kept at a constant pressure (1.21 bar abs.) by the pressure control valve situated on the turbine
bleed steam pipe (PCV 001). The LP steam valve (PCV 002) is closed.
• The preheating line is closed.
• The water level in the feed water tank is kept at a level corresponding to a water volume of 100 m³.
• The overflow valve is closed.
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19
SPECIAL OPERATIONS:
Low load operations:
• When operating at full load, a pressure controller (set point = 1.21b abs.) works on the bleed steam valve (PCV 001).
• If the bleed steam flow rate is not sufficient (approx. less than 60% of the steam turbine load) the tank pressure will
droop slightly and the second pressure controller (set point=1.11.b abs) will work on the LP steam valve (PCV 001).
The bled steam valve (ADG PCV 001) is full open. If this steam is also not sufficient PCV003 valve in the same LP
header will maintain the D/A pressure.
Cold start-up
• The operator starts the feed water tank system by means of the sub-group control; the isolating valve (UV 003 and UV
004) are open, the pressure control valve (PCV 001 and PCV 002) are unlocked, however the pressure set point is
maintained to zero.
• The tank-preheating valve (UV 005) is open.
• When the condenser pressure is less than 200 mbar the ventilation is directed towards the condenser.
• When the pressures in the LP steam header reaches 5 bar abs, the pressure control is automatic.
• The LP steam valves controls the tank pressure at 1.11 bar abs.
• The bled steam valve is full open but bled steam cannot feed the system as long as bled steam pressure is not
sufficient.
• When the bled steam pressure is sufficient (>1.11 abs.) the steam flow changes over progressively to the bled steam
and at approx. 60% of the steam load, the LP steam valve PCV 002&3 are fully closed.
• The bled steam valve controls the pressure of the feed water tank at 1.21 b abs.
Hot start-up:
• The feed water tank is activated by the sub-group control.
• The isolating valves on LP steam and bled steam pipes open.
• The feed water tank pressure regulation switches to automatic.
• The tank ventilation is automatically directed towards the atmosphere or towards the condenser
according to the pressure of the later.
Shutdown:
• The feed water system is put out of operation by the sub-group control.
• The isolating valves on steam supply lines are closed.
• The ventilation valves are closed.
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20
20
21
21
22
LSHH 001
Tripping signal F.W.T. HIGH
Elaboration from LEVEL 1
<3100MM
LSHH 101 & 201
Tripping signal
Elaboration from LSHH 001. HIGH
HIGH LEVEL 1
LSHH 101 & 201 <3100MM
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23
LSHH 001
Tripping signal F.W.T. HIGH HIGH LEVEL 1
Elaboration from
LSHH 101 &201
TRIPPING SIGNAL
ELABORATION FROM
LSHH 101 &201 LSHH 001
F.W.T. HIGH HIGH
LEVEL 1
<3100 MM
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24
HSN 005
OPENING ORDER
OPEN VALVE
UV 005
CLOSE VALVE
UV 005
24
25
LSHH 001
F.W.T. HIGH HIGH
LEVEL 1
UV 006-UV 007
OPENING MEMORY
SET
CV 1 PSHH 001
CONDENSER
PRESSURE
>200 M BAR
ZSL 007
VALVE UV 007
CLOSED
25
26
UV 006- UV 007
OPENING MEMORY
SET
CV 1 PSHH 001
CONDENSER PRESS
>200 MBAR
ZSL 006
VALVE UV 006
CLOSED
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27
HSZ 003
RESET OF CHECK
VALVES
LSH 001
F.W.T. HIGH HIGH
LEVEL 1
DE-ENERGIZE UVX
DE-ENERGIZE UVX
002 LOCKING OF
001LOCKING OF CHECK
CHECK VALVE UV 002
VALVE UV 001
27
28
LSH 001
F.W.T. HIHG LEVEL 1
GSE US 095
TURBINE SET
28
29
UNLOCK ZERO
PRESSURE
SET POINT
(SEE ANALOG
DIAGRAM)
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30
LSH 003
HSN 008
F.W.T. HIGH LEVEL 3
OPENING ORDER
LSH 004
HSN 008
F.W.T. HIGH LEVEL 4
CLOSING ORDER
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31
3400 MM
100 NORMAL MAKE UP LT01A
LSH 002 100 M³ 2400 MM TO CONDENSER LT01B
LT01C
200 QUICK MAKE UP
TO CONDENSER
LSL 002 2300 M³
L1 01B
2200 MM
LSL 003 2900 M³
LSLL 001
20 M³ 700 MM
200 MM 4mA
BOTTOM
0 M³ 0 MM
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32
PURPOSE:
Feed water system consisting of LP feed water pumps and feed regulating station is to maintain fluid
balance in LP boiler during operation.
DESCRIPTION:
GENERAL DESCRIPTION OF THE SYSTEM:
The system is composed of 3x50% LP feed water motor pump sets, each including:
• One driving 415 V motor
• One double-stage centrifugal pump.
Each pump draws water from the feed water tank by means of a separate suction piping.
The pumps discharge is fed in a common header, from which the flow is taken towards the LP economiser
of each boiler.
DESCRIPTION OF EQUIPMENT AND CIRCUITS:
One LP feed water pump set supply one boiler LP economiser:
Main Data:
Pump:
• Axis horizontal
• Number of stage 2
• Fluid conveyed feed water
• Nominal manometeric head 177 m
• Nominal flow 40.2 m³/h
• Temperature 105°C
• Rotation speed 3000 rpm
• Lubrication oil bath
• Cooling fluid water (SRI)
MOTOR:
• Power 55 kW
• Voltage 415 V AC
• Cooling fluid air
• The pumps suction is taken by means of separate piping, each of them includes a strainer (101 / 201 / 301 FI)
and a manually operated isolating valve (HV 101 / 201 / 301).
• At discharge of each feed water pump, there are:
• A recirculation line with an on-off pneumatic valve (FV 102/202/302), which remains open till 8 t/hr flow, is
established in the pump.
• A check valve (YV 101/201/301).
• A flow measurement device (FE 101/201/301)
• A motor-operated isolating valve (UV 101/201/301)
• The three LP feed water pumps discharge in a common header.
• For each HRSG economiser branch, there are:
• One 25% flow line with one control valve LCV 003, one upstream isolating motorized valve UV 003 and one
downstream manual valve HV 003.
• Two 100% flow line each with having one control valve, one upstream isolating motorized valve, one
downstream manual valve.
• A flow measurement device FE 101.
• An inlet economiser isolating motorized valve UV 004.
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OPERATION:
NORMAL OPERATION:
• The economisers are supplied from the feedwater tank two LP feedwater pumps. The third one is on standby.
• The re-circulating valves of the pumps on duty (FV 102.FV 202 or FV 302) are closed if the flow is more than 8 t/hr.
• The three discharge motorized valves (UV 101, UV 201, UV 301) are opened.
• The inlet economiser motorized valves UV 004 are opened.
• The HRSGs LP dumps levels are controlled by a three-element regulation governing by one 100% control valve (LCV
001 or LCV 002) and its associated motorized valve. The other control and motorized valves are fully closed.
Special operation:
• If there is a low LP feed water flow rate at a pump discharge, the corresponding re-circulating valve opens. This flow
is ensured back to the feed water tank.
• During start up or low load operation (up to about 25% load), the HRSGs drum water level is controlled buy one
element regulation (water level only) governing the 25% feed water control valve LCV 003 and its associated
motorized valve.
• A LP feed water pump stopping by its individual control induces an emergency take-over of standby pump.
• The LP feed water line up-to LP feed water control station is filled by gravity and line up to an including HRSG drum
by using one LP feed water pump and the 25% flow line.
TRANSIENT OPERATION:
Startup:
During the system startup, the HRSG is supposed to be full of water. The starting order is given by the
operator from the control. This order can be a group level control or an individual control.
INCIDENTS AND ACCIDENTS:
• The trip of one pump causes the startup of the standby pump, if the emergency take-over is valid.
• It is allowed to restart the tripped pump only after the fault has disappeared, on voluntary order from the operator.
• One startup refusal of the standby pump causes the automatic trip of the boiler, which has the lowest HP steam flow.
In normal operation:
• The water level is kept constant by means of a three-element control loop (water level, LP water flow, LP steam flow).
A proportional and integral action controller governs a feed water control valve (0 – 100%)
• The other identical valve (0 –100%) is on standby. This one can be put into service by an operator selection and
automatic changeover is realized.
• The changeover of the two (0-100%) feed control valves is realise as follows:
• Selection by the operator of the new control valve activation.
• ON confirmation on the sub-group “Feed water valves”.
• After opening of the upstream-motorized valve of the second control valve, the first control valve closes and the
second control valve monitors the drum level automatically.
• The control valve operation is limited by an overflow limitation loop of the LP feedwater pump for protection of
pump. This protection is initiated by the feedwater flow through a proportional and integral controller.
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35
FAILURE OF T 20:
Al controller power supply:
• No change for the control of the plant.
• Actuators remain in position.
• Drives remain in operation.
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36
LP FEED WATER PUMPS. STARTING CONDITIONS: 101 PO, 201 PO, 301 PO
ZSH 003
SUCTION VALVE
HV 101 OPEN
ZSL 101
DISCHARGE VALVE
UV 101 CLOSED
PSH 101
DISCHARGE
COMMON
HIGH PRESSURE
PUMP 101 PO
STARTING
CONDITIONS
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37
HSU 002
HSU 001 TAKING OVER AUTO
101PO CUT OUT
SELECTED IN NORMAL
SELECTION STATUS
CORRECT
SELECTION STATUS
CORRECT
ON OFF
TAKING OVER MEMORY
P/P SELECTED IN
NORMAL STOPPED
HSN011
PUMP101PO
SUB-GROUP
STARTING ORDER HSU 001 PUMP 101 PO
SELECTED IN STAND-BY
HSN 101
PUMP 101 PO
INDIVIDUAL STARTING
ORDER
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38
ELECTRIC FAILURE
101 MO
PUMP 101 PO
TRIPPING CONDITION
TRIPPING SIGNAL
ELABORATION FROM
ADGLSLL 101 & 201
HSX 001
ADGLSHH 001 LP FEEDWATER GROUP
FEEDWATER TANK EMERGENCY STOPPING
VERY LOW LEVEL
GROUP TRIPPING
CONDITIONS
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39
HSN 011
HSN 101 PO
SUB GROUP
INDIVIDUAL
STOPPING ORDER
ORDER
PUMP
TRIPPING
CONDITIONS
PUMP 101 PO
IN OPERATION ON
GROUP LEVEL
HEATING
GROUP SUB GROUP STOPPING PUMP RESISTANCE
TRIPPING ORDER TRIPPING ORDER 101 PO 101 RS ON
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1. DESCRIPTION:
Each pump draws water from the feed water tank by means of a separate piping.
The pumps discharges supply a common header, in which the flow is taken towards
the HP economiser and the HP desuperheater of each boiler.
Motor:
• Power 850 kW
• Voltage 6600 V
• Cooling fluid water (SRI)
• Lubrication oil bath
• The pumps suction is taken by means of separate piping, each of them includes a strainer (101/201/301 FI) and a
manually operated isolating valve (HV 101/201/301).
• At discharge of each feed water pump, there are:
• A re-circulating line with an on-off pneumatic valve (FV 012/202/302).
• A check valve (YV 101/201/301).
• A flow of measurement device (FE 101/201/301).
• A motor operating isolating valve (UV 101/201/301).
• The three HP feedwater pumps discharge in a common header.
• For each HRSG economiser branch, there are:
• One 25% flow line with one on control LCV 003, one upstream isolating motorized valve UV 003 and one
downstream manual valve HV 003.
• Two 100% flow lines, each with having one control valve, one upstream isolating motorized valve & one downstream
manual valve.
• A flow measurement device FE 001
• One isolating valve UV 006 before Economiser.
• For each HRSG super heater branch, there are:
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2x100% de-super heater lines with its control valves TCV 004 and TCV 005, one upstream isolating
motorized valve UV 004 and one filter FI 001 and its bypass line.
Cooling system:
The cooling system (SRI: demineralised water cooling system) ensures the cooling of the following
exchangers per HP water pump.
• 2 lube oil coolers
• 1 motor cooler.
• 2 casing coolers.
2. OPERATION:
NORMAL OPERATION:
Normal operation with two HRSGs:
The HP Economisers are supplied feed water from the feed water tank by two feed water pumps. The third
one is standby.
The recirculating valve of the pumps on duty (FV 102, FV 202 or FV 302) is closed.
The three discharge motorized valve (UV 101,UV 201, UV 301) are opened.
The cooling water (SRI) valve 9FV 101,FV 201, FV301), corresponding to the pumps in operation, are
opened.
The HRSGs HP drum level is controlled by a three-element regulation, governing one 100% control valve
(LCV 001 or LCV 002) and its associated motorized valve. The other control and motorized valves are
fully closed.
The HRSG isolating valves UV 006 are opened.
The HRSG HP super heater temperature limitations are controlled by a cascade control loop governing
one-control valve TCV 004 or TCV 005. The upstream-motorized valve UV 004 is open.
Operation with single HRSG.
Same operation as in paragraph above except:
• One single HP feed water pump is in operation.
• The stopped HRSG is isolated.
Special operation:
If there is low HP feed water flow rate at a pump discharge (<40t/hr), the corresponding re-circulating
valve opens. This flow is ensured back to the feed water tank.
During start-up or low load operation (up to about 25% load), the HRSGs drum water level is controlled
by one element regulation (water level only) governing the 25% feed water control valve LCV 003 and its
associated motorized valve.
The HP feed water line up to HP feed water control station is filled by gravity and line up to HRSG drum
by using one HP feed water pump and the 25% flow line.
Starting of the three HP feed water pumps:
It is not recommended to start the three HP feed water pumps simultaneously.
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TRANSIENT OPERATION:
Startup:
During system startup, the HRSG is supposed to be full of water. The starting order is given by the
operator from the control room. This order can be a group level control, a sub-group level control or an
individual control.
Voluntary changeover of feed water pump:
The changeover of the two feed water pumps is carried out from the control room. This is carried out with
an overlap period, the three pumps delivering together for a short time into the circuit.
INCIDENT AND ACCIDENTS:
The trip of one pump causes the start-up of the standby pump, if the emergency take-over is valid.
It is allowed to restart the tripped pump only after the fault is removed.
The start-up refusal of the standby pump causes the automatic trip of the boiler, which has the lowest HP
steam flow.
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case of trip order or closing order by operator, the control valve closes and then, the motorized valve
closes.
1. ANALYSIS OF THE LOSS OF MOTIVE OR CONTROL FLUID:
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45
ZSH 103
SUCTION VALVE
HV 101 OPEN
ZSL 101
DISCHARGE VALVE
UV 101
PSH 001
DISCHARGE
COMMON HIGH
PRESSURE
HSU 001
PUMP 101 PO
SELECTED IN
NORMAL
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46
HSU 002
HSU 001 TAKING OVER AUTO
PUMP 101PO CUT OUT
SELECTED IN NORMAL
SELECTION STATUS
CORRECT
SELECTION STATUS
CORRECT
ON OFF
TAKING OVER MEMORY
PUMP SELECTED IN
NORMAL STOPPED
HSN011
FROM FOLIO 8
PUMP101PO
SUB-GROUP
STARTING ORDER HSU 001
101 PO
SELECTED IN STAND-BY
HSN 101
PUMP 101 PO
INDIVIDUAL STARTING
ORDER
46
47
30 SEC
47
48
GROUP TRIPPING
CONDITIONS
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49
HSN 001
GROUP TRIPPING
H GROUP
CONDITIONS
TRIPPING ORDER
FROM FOLIO 7
PUMP
TRIPPING
CONDITIONS
PUMP 101 PO
IN OPERATION ON
GROUP LEVEL
PUMP 101 PO
GROUP SUB GROUP STOPPING PUMP STARTING LUBE
TRIPPING ORDER TRIPPING ORDER 101 PO OIL MOTOR PUMP 1
PUMP 101
STOPPED
5min
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LP drum:
The following pipes are connected to the LP drum:
• Inlet from LP economizer
• Outlet to the evaporator
• Return circuit form the evaporator
• Outlet to the LP super heater
• Blow down circuits
The evaporator:
After entering the drum, feed water is circulated through evaporator coils by LP circulating pump each
pump consists of:
• A pump 374 Po (374 Po) cooled by DM water.
• A check valve 060 VV/061 VV
• A flow transducer
These lines are linked to the economizer inlet through the check-valve 053 VV.
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The superheater:
The saturated steam in the drums sent by a pipe in the superheater. This pipe is equipped with a motorized
vent valve FLB UV 079 with open/closed limit switches.
At the superheater outlet, the steam flows to the LP heater (VVP system) through a pipe, which is having:
• A motorized vent valve UV 037 with limit switches.
• A safety valve 161 VV.
• The instrumentation pressure/temp. Sensors.
• A check-valve 093 VV.
3. OPERATION
NORMAL OPERATION:
When the gas turbine exhaust is supplied to the boiler:
• One LP circulation pump is running to ensure water circulation through the evaporator.
• The water level in the LP drum is kept constant by the 3 elements control loop at operating level.
• The vent valves are closed.
• The economizer circulation valves are closed.
SHUTDOWN:
• The LP circulation pumps continue to run 30 min after stoppage of the boiler to stabilize all temperatures in the
evaporator circuit.
• The vent valves are opened. The drum vent valve connects the LP circuit to atmosphere.
51
52
ECO.RECIR
ECTCV 109
CONT.VALVE
ON AUTO MODE HSU 001 PUMP SELECTED
IN NORMAL 370 PO/375 PO
a b
52
53
TRIPPING SIGNAL
ELABORATION FROM
LSVL 170 &270 LP DRUM LEVEL LSVL
070 VERY LOW LEVEL
10 10
SEC SEC
EC EC
FSLB FSLB
094 095
STOP PUMP 374 PO STOP PUMP
375 PO
53
54
FLB CIRCULATING PUMPS 374 & 375 PO. TAKING OVER MEMORY
A B
HSU 002
TAKING
OVER AUTO
CUT OUT
54
55
PUMP 375 PO
25 SEC
TO TTA SYSTEM US EC
BOILER
TTA US 003 001
TRIPPING
• ORDER NO LP CIRCULATING PUMPS
IN OPERATION *
TO TTA SYSTEM
LP CIRCULATING
TTA US 002
PUMPS IN
CONFIGURATION
US 002
55
56
1.PURPOSE:
• This system enables optimum heat recovery by HP boiler from exhaust flue gas.
2.SYSTEM DESCRIPTION:
• The system comprises mainly:
• The feed water circuit and the economizer
• The HP drum
• The evaporator
• The 2 superheaters and the desuperheating line
• The HP superheated circuit
HP drum
The following pipes are connected to the HP drum:
• Inlet from the HP economizer
• Outlet to the evaporator
• Return circuit from the evaporator
• Outlet to the HP-1 super heater
• Blow down circuit
The evaporator:
The water suction is taken from the HP drum by pumping set with two identical lines. Each one
comprising:
• A pump 378 Po (379Po) cooled by SRI water
• A check valve 267 VV /268 VV
• A flow transducer (FT 092/093)
56
57
The superheater:
The saturated steam in the drum is sent by a pipe in the HP-1 superheater. This is equipped with two
motorized vent valves in series FLH UV 286/UV 287 with open/closed limit switches.
At the HP-1 superheater outlet, the superheater steam is mixed with desuperheating water coming from the
HP feed water pumps. The water circuit is equipped with a check-valve 292 VV.
Instrumentation between HP-1 and HP -2 superheaters:
• Steam temperature before and after desuperheating (TE 088/089)
At he HP-2 superheater outlet, the steam flows to the HP header (VVP steam) through a pipe on which
there are following equipments.
• Two motorized vent valves in series UV 168/UV169 with limit switches
• A safety valve 164 VV
• The instrumentation FLH 164 VV
• A check-valve 302 VV
3. OPERATION:
NORMAL OPERATION:
When the gas turbine output supplies the boiler:
• One HP circulation pump is running to ensure water circulation through the evaporator
• The water level in the HP drum is kept constant by the 3 elements control loop at operating level.
• The vent valves are closed
• The economizer circulation valves are closed.
SHUTDOWN:
• The HP circulation pumps continue to run after stoppage of the boiler to stabilize all temperature in evaporator circuit.
The vent valves are opened which connect the HP circuit to atmosphere.
57
58
ECO.RECIR CONTROL
VALVEECTCV 111 HSU 001 PUMP SELECTED
ON AUTO MODE IN NORMAL 378 PO/379 PO
a b
58
59
TRIPPING SIGNAL
ELABORATION FROM HP DRUM LEVEL LSVL
LSVL 180 & 280 080 VERY LOW LEVEL
10 10
SEC SEC
EC EC
STOP PUMP 378 PO FSLB FSLB STOP PUMP
092 093 379 PO
59
60
FLH CIRCULATING PUMPS 378 & 379 PO. TAKING OVER MEMORY
A B
HSU 002
TAKING OVER
AUTO CUT OUT
60
61
30 30
MIN MIN
61
62
PUMP 379 PO
ON
10
Sec
US EC
TO TTA SYSTEM BOILER 001
TTA US 003 TRIPPING
SIGNAL
HP CIRCULATING
PUMPS IN
CONFIGURATION US 002
TO TTA SYSTEM
TTA US 002
62
63
HSN 288 HSN 285 HSN 274 ECO.RECIR. HSN 246 ECO. RECIR
ECO RECIR INLET ECO.RECIR.IN LET.ISOL. INLET .ISOL.VALVE .INLET.ISOL. VALVE
ISO. VALVE UV 288 VALVE UV 285 UV 274 UV 246
OPENING ORDER OPENING ORDER OPENING ORDER OPENING ORDER
ECO.RECIR ECO.RECIR.
.INLET.ISOL.VL. INLET.ISOL.VL.
UV 288 OPEN UV 247 OPEN
ZSH 288 ZSH 247
ECO. RECIR.CONTROL
ECO.RECIR. CONTROL ECO.RECIR.CONTROL ECO.RECIR.CONTROL VL TCV 111 ZSL
VL TCV 110 VL TCV 110 VL TVC 111 111CLOSED
ZSL 110 CLOSED ZSL 110 CLOSED ZSL111 CLOSED
63
64
HSN 210 HSN 210 INDIVIDUAL HSN 211 INDIVIDUAL HSN 211 INDIVIDUAL
INDIVIDUAL CLOSING OPENING ORDER CLOSING ORDER OPENING ORDER
ORDER
HP DRUM VENT VL. HP DRUM VENT VL. HP DRUM VENT VL. HP DRUM VENT VL.
FLH UV 210 FLH UV 210 FLH UV 211 FLH UV 211
CLOSING ORDER OPENING ORDER CLOSING ORDER OPENING ORDER
HSN 286 INDIVIDUAL HSN 286 INDIVIDUAL HSN 287 INDIVIDUAL HSN 287 INDIVIDUAL
CLOSING ORDER OPENING ORDER CLOSING ORDER OPENING ORDER
HP DRUM VENT VL. HP DRUM VENT VL. HP DRUM VENT VL. HP DRUM VENT VL.
FLH UV 286 FLH UV 286 FLH UV 287 FLH UV 287
CLOSING ORDER OPENING ORDER CLOSING ORDER OPENING ORDER
64
65
HP SUPERHEATER
FLH PSL 090
PRESSURE >8 BAR
HP SUPER HEATER
OUTLET
VVP FSL 008
FLOW >15 T/H
HP SUPERHEATER
OUTLET FLH PSL 090
PRESSURE >8 BAR
HP SUPERHEATER
OUTLET VVP FSL 008
FLOW >15 T/H
65
66
2 SYSTEM DESCREPTION:
The system comprises mainly:
• The HP and LP superheater drain lines.
• The drain tank (FPU 372 BA).
The drains are sent into the boiler drains tank (372 BA).
LP drum blow down lines:
Same circuits as for the LP lines.
• The continuous blow down lines is equipped with an ON/OFF motorized v/v UV045.
• A manual regulating v/v to control blowdown.
• The emergency line is equipped with UV 044.
The drains are sent to 372 BA.
HP superheater drain line:
The drains are sent to 372 BA through the ON/OFF motorized v/v UV 296 & UV 337.
LP superheater drain line:
Same as above with UV 081.
Boiler drains tank 372 BA:
It is fitted witha level transmitter LT 091.
The overflow is sent to the sewer.
3. OPERATION:
NORMAL OPERATION:
WHEN THE BOILER IS OPERATIONAL:
• The continuous blow down valve UV245/258/045 are closed.
• The Emergency blow down valves are closed.
• The superheater drain valves are closed.
START-UP OF BOILER:
• As soon as boiler damper is opened, the continuous blow down valves open in sequence.
• The superheater drain valves are open to remove water during heating periods.
• The emergency blows down valves are normally closed.
SHUT DOWN:
• The continuous blow downs close automatically as soon as the boiler is isolated.
66
67
• The superheater drain valves open on low steam flow criteria <20T/Hr & <8T/Hr for HP & LP.
• The emergency blow downs remain closed.
EMERGENCY OPERATION:
The emergency blow down valves UV 244/044 open if the water level in their respective drum becomes to
high, for instance during start-up.
FPU HP DRUM CONTINUOUS BLOW DOWN VALVES UV 245 & 258
HP DRUM PRESSURE
HP DRUM LEVEL FLH FLH PSL 011
LSH 080 HIGH LEVEL PRESSURE >20 BAR
(1494 MM)
HP DRUM HP DRUM
HP SHT. OUTLET VENT
EMERG. BL.D.VL EMERG. BL.D.VL.
VL. FLH UV 169
FPU UV 244 FPU UV 244
CLOSING ORDER
CLOSING ORDER OPENING ORDER
67
68
LP STEAM FLOW
LP STEAM FLOW VVP VVP FSL 001
FSL 001 FLOW< 8 T/H
FLOW <8 T/H
LP SUPERHEATER
DRAIN VL.FPU UV 081 LP SUPERHEATER
CLOSING ORDER DRAIN VL.FPU UV 081
OPENING ORDER
HP SUPERHEATER
DRAINVL. FPU UV 296 HP SUPERHEATER
CLOSING ORDER DRAIN VL. FPU UV 296
OPENING ORDER
68
69
HSN 045
HSN 045 INDIVIDUAL INDIVIDUAL OPENING
CLOSING ORDER ORDER
HRSG DAMPER
CLOSED
TTA ZSL X10
69
70
HP SUPERHEATER
DRAIN VL. FPU UV HP DRUM CONT.
296 OPENED ZSH 296 BLOW DN. VL.
FPU UV 258 OPENED
ZSH 258
70
71
1. PURPOSE:
3. OPERATION:
72
73
73
74
10
min
A US 001
A HSN 001 SATURATION TEMP.
CLOSING ORDER DETECT.
OPENING ORDER TO
A UV 001
CLOSE VALVE
A UV 001
74
75
C US 001
SATURATION A TTA ZSL X 10 B TTA ZSL X 10
TEMP.DETECT HRSG A DAMPER HRSG B DAMPER
(SEE ANALOG CLOSED CLOSED
DIAGRAM)
OPENING VALVE
C UV 001
A TTA ZSL X 10
HRSG A DAMPER
CLOSED
GRE
STEAM TURBINE
POWER>25%
B TTA ZSL X 10
HRSG A DAMPER
CLOSED
C US 001
SATURATION
TEMP. DETECT.
HSN 003
CLOSING ORDER
OPENING ORDER
TO C UV 001
CLOSE VALVE
C UV 001
75
76
OPEN VALVE A UV
002
10 min
ALSHH 001
DRAIN POT HIGH
HIGH LEVEL
OPENING ORDER
TO A UV 002
CLOSE VALVE
A UV 002
SAME SEQUENCE FOR B UV 002
76
77
C LSHH 001
DRAIN POT HIGH
HIGH LEVEL
GRE
STEAM TURBINE
POWER>25%
HSN 006
OPENING ORDER
OPEN VALVE
C UV 002
A TTA ZSL X 10
HRSG A DAMPER
CLOSED
GRE
STEAM TURBINE
POWER>25%
B TTA ZSL X 10
HRSG B DAMPER
CLOSED
C US 001
DRAIN POT HIGH
LEVEL
HSN 003
CLOSING ORDER
C LSHH 001
DRAIN POT HIGH
HIGH LEVEL
OPENING ORDER
C UV 002
CLOSE VALVE
C UV 002 77
78
GRE
STEAM TURBINE ADG ZSH 003
LOAD > 60% VALVE UV 003 OPEN
GRE
TURBINE LOAD > 60%
78
79
ALL DRAIN
VALVES CLOSED
TSH 001
TANK HIGH
TSH 001 TEMPERATURE
TANK HIGH
TEMPERATURE
EC1
ENERGIZE C TVX
001 VALVE CTV 001
CLOSING
79
80
HSN 008
CLOSING ORDER
TSH 002
FLASH TANK
HIGH TEMP.
ENERGIZE C TVX
002 VALVE C TV
OO2 CLOSING
80
81
(E)
OPEN VALVE
C UV 005
A TTA ZSL X 10
HRSG A DAMPER
CLOSED
B TTA ZSL X 10
HRSG B DAMPER
CLOSED
OPENING ORDER TO
C UV 005
CLOSE VALVE
C UV 005
81
82
OPEN VALVE
C UV 006
A TTA ZSL X 10
HRSG A DAMPER
CLOSED
B TTA ZSL X 10
HRSG B DAMPER
CLOSED
OPENING ORDER TO
C UV 006
CLOSE VALVE
C UV 006
82
83
OPEN VALVE
A UV 005
CLOSE VALVE
A UV 005
83
84
OPEN VALVE A
UV 006
CLOSE VALVE
A UV 006
84
85
A VVP A VVP
FSL 004 FSL 001
10 Min 10 Min
ALSH 001
A US 001 VALVE A UV 001
HIGH LEVEL
&
DRAIN VALVES
A 001 & UV 002
OPEN AUS 003
SAME SEQUENCE FOR BUS 002, BUS 003 & BUS 004
85
86
C ZSH 005
VALVE C UV 005
C US 001 SATURATED C LSH 001 OPEN
TEMPERATURE. DRAIN POT HIGH
DETECTION LEVEL
&
DRAIN VALVES
C UV 001,002,005 &
UV 006 OPEN C US 003
86
87
2. GENERAL DESCRIPTION:
Each manifold receives the steam produced by each boiler through a power-operated valve (A/B-UV ½) as
associated with its bypass valve (A/B-UV003/4).
The following outgoing lines are respectively branched off from these manifolds.
• LP manifold
• Main steam line to the LP steam turbine
• Steam line for supply to the deaerator (ADG system)
• HP manifold
• Main steam line to the LP steam turbine
• Steam line for supply to the turbine gland seals (CET system)
• Steam line for preheating of the deaerator (ADG system)
• The HP and LP bypass lines (GBP-GHP system) are branched off from the steam manifold upstream side.
3. OPERATION:
87
88
NORMAL OPERATION:
Boiler shutdown:
At least one isolating valve is open in order to supply the turbine gland seals, in case of a short time
shutdown.
Operation with only one boiler as the other is in shutdown:
The valves on the manifold corresponding to the boiler in service are open.
The valves on the manifold corresponding to the boiler in shutdown are closed.
LP manifold:
The opening sequence of the section valve and its bypass valve is identical to the one of the HP manifold
using the following criterion:
• Pressure balance ensured: A/B VVP PDSL 001.
When both the HRSG are running in parallel. Both HP bypass valves receive a set point value, which
depends on the sum of the HRSG steam flows. When the HP steam turbine inlet valve is fully open, the
actual HP steam pressure follows the sliding pressure curve. The HP bypass valves which receive a
slightly higher set point are consequently closed.
LP manifold:
The opening sequence of the section valve and its bypass valve is identical to the one of the HP manifold
valves, using the following criteria:
• The temperature of the boiler under start-up is greater than 175 ºC.
• Pressure balanced (A/B VVP PDSL 003).
88
89
89
90
HRSG B
DAMPER CLOSED
B TTA ZSL 100
HRSG A HEADER
V/V CLOSED AZSL
002
90
91
STEAM TEMP.
>175 ºC
A TSH 001
HRSG B HEADER
VALVE CLOSED
B ZSL 001;B ZSL 003
OPENING OF
UV 001
91
92
STEAM
TEMPERATURE >
450 ºC A TSH 002
OPENING ORDER
UV 002 INDIVIDUAL HRSG A HEADER
CONTROL A HSN BY-PASS V/V OPEN
002 A ZSH 004
HRSG A HEADER
BY-PASS V/V OPEN
A ZSH 004
DIFFERENTIAL
PRESS <20 BAR
APDSL 002
92
93
HRSGs ON DUTY
HP HEADER
VALVE A UV 002
(E) CLOSED
DIVERTER DAMPER
CLOSED
A TTA ZSL X 10
HRSG A TRIP
ORDER A TTA US
008
HRSG A ON
SAME SEQUENCE FOR HRSG B DUTY
A US 001
LP B.P.V/V A UV LP B.P.V/V A UV
003 OPENED 003 CLOSED
AZSH 003 A ZSL 003
93
94
STEAM
TEMPERATURE
>450ºC
A TSH 002
STEAM
TEMPERATURE
>175ºC
A TSH 001
(E) SATURATION
TEMP. DETECTION
A ACO TDSL 001
94
95
HRSG A SUB-GROUP
DAMPER “OFF” ORDER
CLOSED A HSN 010
A TTA ZSL X10
HRSG B
DAMPER
CLOSED
B TTA ZSL X 10
HRSG A HEADER
V/V CLOSED
A ZSL 001
CLOSING OF CLOSING OF
UV 003 UV 001
95
96
OPENING OF CLOSING OF
C UV 005 C UV 005
HP STEAM TEMP.
VERY HIGH
A TSHH 004
30 Min
96
97
The system describes the operation of the boiler diverter damper with its auxiliaries. It is by operating the diverter damper
the combined cycle operation of GT is done.
The weather damper, on the top of the boiler which is operated by instrument air, is also comprised in this system. This
damper is closed during boiler shutdown to ensure weather protection of boiler as well as for heat preservation if the boiler
is to be started immediately.
2. DESCRIPTION:
Two identical boilers are provided in one module. Only one is described in this volume. The other is identical.
The system comprises mainly:
• The diverter damper itself.
• Its auxiliaries.
• The hydraulic oil station.
• The air barrier system.
• The weather damper.
• Temperature measurements of the flue gases inside the boiler.
• Two mechanical lock pins to gag the diverter flap.
The diverter damper is operated by a hydraulic ram. The hydraulic power is provided by the oil
station. The following orders can be issued by operator:
• Normal operating order, (operating time 70 sec.)
• Normal closing order, (closing time 70 sec.)
The damper is fitted with two position transmitters for measurement and regulation.
THE HYDRAULIC OIL STATION:
The diverter is operated by hydraulic power supplied by two pumps:
• A main pump 441 PO fitted with an output pressure switch PSL 101 and a check-valve. This pump is designed to
actuate the diverter flap.
97
98
• An auxiliary pump 442 PO fitted with an output pressure switch PSL 1022 and a check-valve. This pump is designed
for accumulator charging. However, these two pumps provide mutual back up and charging of accumulator. One
Pump is able to actuate the flap, though at a lower operating speed.
On the common discharge header of the pumps, there is a pressure switch to start the charging pump on
low-pressure criteria and to stop it on high pressure.
THE AIR BARRIER SYSTEM:
When the damper is fully closed or fully open, seal air is blown by either of the two air barrier fans
(451/452 ZV through a 3 way change over valve UV 453. The air is discharged to the relevant seals by
means of two isolation valves UV 454/UV 455.
THE WEATHER DAMPER:
The double flap damper TTA 382 FV is used during standstill to protect the boiler against corrosion by
rainwater. The damper must be opened prior to start of the boiler.
3. OPERATION:
STANDSTILL:
The gas turbine is shutdown.
The diverter damper is kept closed.
The hydraulic oil station and air barrier system are off.
The weather damper is closed to protect the boiler against corrosion by rainwater.
GAS TURBINE START-UP:
The air barrier sub-group has to be put-up in service prior to start of the gas turbine, to ensure a tight
isolation of the boiler against hot gases.
The diverter damper is kept closed. The oil sub-group is ON and the charging pump ensures the pressure
at the header.
BOILER START-UP:
The boiler has been filled up to the start up level and the water plant is in service.
The weather damper is opened prior to start of the boiler.
The air barrier sub-group is running and a fan is in service as soon as the gas turbine is in service and as
long as long as the diverter is closed.
The oil sub-group is in service in this configuration. The operator or the sequence are able to run in
combined cycle by action on the sub-group opening order to the diverter flap.
The diverter flap opens step by step with corresponding holding time and conditions.
As soon as the opening order is given, the oil main pump starts and the air barrier fan stops when the
closing switch is no more actuated.
The sequence is completed, i.e. the diverter is full open, when the steam turbine load has reached 15%.
The oil main pump stops and the auxiliary pump monitor the header pressure. The air barrier fan starts
again when the full open position is reached, to ensure proper sealing on the stack side.
The diverter is hold open.
CAUTION: Ensure that diverter lock pins are removed before opening of damper.
NORMAL SHUTDOWN OF THE BOILER:
The operator or the sequence gives a closing order to the diverter:
• The main oil pump starts immediately and the barrier air fan stops, when the opening switch is not actuated.
• The diverter rejoins its closing position without intermediate stop.
• When it is fully closed, the main pump stops and the air barrier fan starts if the gas turbine is still running. The auxiliary
pump monitors the accumulator pressure. The
Holding closed valve ZVX 447 is de-energized.
• For a quick restart, the operator can keep the boiler warm while reducing the heat losses during standstill, by closing of the
weather damper.
• If the gas turbine is shutdown, the operator stops the function group.
98
99
INCIDENTS:
In case of air barrier failure, the duty air barrier fan is backed-up by the stand-by fan with changeover on
three way valve.
The two oil pumps are backed-up to each other, but in case of failure of the main pump, the actuating time
of the diverter damper is increased.
Limitation:
• During boiler start-up the opening of the diverter is blocked at 72% until the steam turbine load reaches 15%. Nevertheless,
this limitation does not act any more as soon as the opening is more than 72% and the flap remains open even if the steam
turbine load decreases under 15%.
• In case of limitation by high LP or HP steam pressure, the diverter closes until the next lower opening step, if the limitation
has disappeared. If not, the diverter closes completely.
Boiler trip: in case of a boiler trip, the diverter closes emergency by de-energiation of ZVX 447.
Boiler ready to start conditions:
If the diverter damper is closed, the boiler is ready to start if
• There is no shutdown or trip condition of the HRSG.
• GT should be synchronised to grid.
• The HP steam desuperheating is available.
• The LP feed water pumps are in configuration.
• The HP feed water pumps are in configuration
• The weather damper is open.
• One LP circulating pump and it’s recirculation control valve are in service.
• One HP circulating pump and it’s recirculation control valve are in service.
• One condensate preheater pump is running.
• The boiler preheater outlet valves should be in open position.
• The LP drum is at start-up level.
• The Hp drum is at start-up level.
• The sub-group memory of the oil station is ON and the oil header pressure is correct.
If the diverter damper is not closed, then last three conditions do not apply.
Boiler shutdown and trip:
The boiler will shutdown if:
• There is a voluntary shutdown order.
99
100
5
SEC
DIVERTER DAMPER
ZSH X 10
OPEN POSITION
DIVERTERDAMPER
ZSH 100 DIVERTER DAMPER
CLOSED POSITION ZSH 10A
CLOSED POSITION
5
SEC
DIVERTER DAMPER
ZSL X10
CLOSED POSITION
X3 < X <=100%
LIMITATION BY
STEAM TURBINE
LOAD < 15%
100
101
HRSG
TRIP MEMORY ON
US 003
HRSG
READY TO START US
002
D
LIMITATION BY
STEAM PRESSURE
DIVERTER DAMPER
CLOSE ZSL X 10
S/GROUP HSN 100
OPENING ORDER
AUTO CUT-OUT
HSU 101
S/GROUP
C HSN 100
CLOSING ORDER
101
102
HRSG TRIP
MEMORY ON
HRSG TRIP US 003
MEMORY ON
US 003
DIVERTER DAMPER
CLOSED
ZSL X 10
DIVERTER DAMPER
DIVERTER DAMPER CLOSED
OPENING ORDER ZSL X 10
DIVERTER DAMPER
OPENING ORDER
ENERGIZING DE-ENERGIZING
(CLOSING)
102
103
HP CIRCULATION
PUMP IN
CONFIGURATION
FLH US 002
CONDENSATE
PREHEATER PUMP IN
CONFIGURATION
FLP US 002
LP B.F..P.
IN CONFIGURATION
APB US 002
HP BFPs IN
CONFIGURATION
APH US 002
HP DESUPERHEATING
VALVE AVAILABLE
APH US 005
WEATHER DAMPER:
DIVERTER OPENING
PERMISSIVE
HYDRAULIC OIL
STATION OIL HEADER
LOW PRESSURE
PSL 100
DIVERTER DAMPER
QUICK CLOSING
ORDER US 003
BOILER READY TO
START
US 002
103
104
DIVERTER DAMPER
30Min CLOSED
TTA ZSL X 10
HP HEADER VALVE
LP HEADER VALVE CLOSED
CLOSED 1A VVP ZSL 002
1A VVP ZSL 001
105
106
The purpose of GBP system is to monitor the pressure and temperature of both boilers during transient.
Startup:
The bypass circuit are brought on stream to bring the LP steam to the rated temperature and pressure
before it is led to LP turbine.
Steam turbine Tripping or house load operation:
In case of steam turbine tripping or house load operation, the bypass circuits are in operation so that ST
can be restarted immediately.
2. DESCRIPTION OF THE SYSTEM:
GENERAL DESCRIPTION:
• The LP bypass circuit is composed of two pipes connecting the LP steam manifold to the condenser.
Desuperheating circuit:
The desuperheating circuit is composed of one pipe supplying nozzles arranged inside the condenser neck.
The pipe is equipped with an on-off pneumatic desuperheating valve, which is actuated by a solenoid
valve.
3.OPERATION:
STEADY-STATE MODE OF OPERTION:
• During power station shutdown, in steady stage regime (2GT +1 ST*) or (1 GT +1 ST), The LP bypass valves are closed.
TRANSIENT OPERATION:
Startup:
Startup of the first gas turbine (boiler):
• The section valve on LP steam manifold corresponding to the boiler under starting opens as soon as the HRSG damper
start to open.
• The section valve (UV 101) upstream of the bypass valves has been already opened by the operator.
• The bypass valve remains closed as long as vacuum has not been built up in the condenser.
• Once the condenser is under vacuum, the bypass v/v takes up the position required to adjust the boiler LP steam pressure.
106
107
• The pressure set point is the constant pressure set point displayed in control cubicle (steam turbine constant pressure set
point increased by some value).
• The turbine is run by opening of the HP steam inlet valves.
• When the steam turbine load is more than 25% the LP steam inlet valves open fully.
• The pressure in the LP manifold drops because of steaming to the LP cylinder and then the LP bypass closes.
• The steam turbine loading is completed when the steam turbine control valves adjust the constant pressure displayed in
control cubicle.
• When the steam turbine loading is completed the bypass valve is normally closed but continues to monitor the steam
pressure.
Once the boiler control damper is no longer closed, the bypass takes up the position required to adjust the
LP steam pressure of the starting boiler.
The pressure set point is given by control system which is the set point displayed in the control cubicle.
The isolating valve on the steam manifold being closed, the steam coupling operation is started with
following condiions:
• The boiler pressure has reached the pressure set point.
• The steam temperature is >175°C
108
109
POSITIONING LOOP
DISTURBANCE
GBP US 005
CONDENSATE WATER
PRESSURE > 8 BAR
CEX PSH 001
CONDENSER PRESSURE
HIGH CVI PSHH 002
350 M BAR
BY-PASS
DOWNSTTREAM
TEMPERATURE HIGH
A TSH 001
LP BY-PASS
FAULT A GBP US
010
LP BY-PASS AVAILABLE
AGBP US 100
A PCV 001
IN REGULATION
109
110
CONDENSATE
CONDENSER WATER PRESSURE
PRESSURE HIGH >CEX PSH 001
CVI PSHH 002
3”
BY-PASS
DOWNSTEAM
TEMP.HIGH
A TSH 001
LP BY-PASS FAULT
A GBP US 010
POSITIONNING
LOOP
DISTURBANCE
A GBP US 005
2”
LP BY-PASS
UNAVAILABLE
A GBP US 100
CLOSING OF
APCV 001
110
111
HYDRUALIC GROUP
FAILURE
AGHP US 003
POSITIONNING RACK
ELECTRIC FAILURE
A GHP US 002
LOSS OF CONTROL
SIGNAL
A GBP US 001
LP BY-PASS FAULT
A GBP US 010
111
112
OPENING ORDER
AUV 101
INDIVIDUAL CONTROL
A HSN 101
OPENING OF
UV 101
CLOSING ORDER
AUV 101 INDIVIDUAL
CONTROL
A HSN 101
CLOSING OF
UV 101
112
113
10”
ENERGIZING OF DEENERGIZING OF
A UVX 102 A UVX 102
CLOSING OF OPENING OF
A UV 102 A UV 102
113
114
The pressurized oil necessary for operation of the boiler bypass actuators is applied by one driving oil
plant per boiler.
This driving oil plant supplies:
• 1 HP bypass valve A GHP PCV 001.
• 1 LP bypass valve A GBP PCV 001.
It is actuated by a double action hydraulic jack fed with oil via a slide valve.
The actuator is equipped with a position transmitter (ZT 001).
The valve is equipped with a closing limit switch (ZSH 001).
Operating time in the control mode: adjustable from 3 to 10 seconds.
Isolating valve (UV 101):
The isolating valve is of the cage type with an electric actuator.
The valve is equipped with two limit switches: Opening (ZSH 101), Closing (ZSL 101).
Operating time: 47 seconds.
Desuperheating circuit:
The desuperheating circuit is composed of two valves, TCV 004, and 005.
• One pipe supplying the first crown in the desuperheater.
• A second pipe supplying to second crown.
114
115
Each pipe is equipped with an on-off pneumatic desuperheating valve, which is actuated by a solenoid
valve.
Driving oil plant:
For each boiler, a driving oil plant supplies driving oil to the actuators of the valves associated with the
HP and LP bypass valves.
This driving plant is composed of:
• 1 discharge filter with electric indicator of fouling.
• 2 submerged motor-driven oil pumps (1 on duty and 1 on standby), each fitted with:
• 1 non- return valve.
• 1 hand- operated pump.
• 1 oil cleaning circuit fitted with one pump and three filters.
• 1 oil cooling pump with an exchanger oil/water.
• 1 oil tank (200 litres capacity) with:
• 1 low-level switch.
• 1 high temperature switch.
• 1 vent with filter.
• 2 pressure switches (low and very low pressure).
• 1 accumulator.
• 1 pressure guage at pumps discharge.
• 1 box grouping together all the signals, which are sent by the sensors, mounted on the driving oil plant.
3.OPERATION:
STEADY STATE MODE OF OPERATION:
• During power station shutdown or in steady-state regime (2GT+1ST) or (1 GT+1ST) the HP bypass valves are closed.
• In sliding pressure mode of operation, the steam turbine operates in the pressure control mode.
TRANSIENT OPERATION:
Startup:
Startup the first gas turbine & boiler:
Section valve on the HP steam manifold corresponding to the boiler under starting opens as soon as the
HRSG damper starts opening.
• The section valve (UV 101) upstream of the bypass valve has been already opened by the operator.
The bypass valve remains closed as long as vacuum has not been built up in the condenser
(<380 m bar.)
Once the condenser is under vacuum, the bypass valve takes up the position required to adjust the boiler
HP steam pressure.
The pressure set point is the sliding pressure set point (elaborated by the control system from the starting
boiler flow).
The steam turbine is run up by opening of the HP steam inlet valve & once steam turbine loading is
completed, the bypass valve is normally closed and it continues to monitor the steam pressure.
The bypass valve opens again in case of a limitation causes the steam turbine control valves to close again,
or in order to limit the quick pressure rise.
Startup the second gas turbine & boiler:
The pressure set point freezing keeps the bypass valve closed as long as the boiler control damper is
closed.
Once the boiler control damper is no longer closed, the bypass valve takes up the position required to
adjust the HP steam pressure of the starting boiler.
The pressure set point is elaborated by the control system which determines a sliding pressure set point as
a function of the steam flow of the boiler under starting.
115
116
The isolating valve on the steam manifold being closed, the coupling operation is started when:
• The boiler pressure has reached the ST inlet pressure.
• The steam superheating is satisfactory.
• The steam temperature is higher than 450°C.
• The steam coupling operation progresses according to the following sequence:
• The pressure set point takes the value of the pressure upstream of the steam turbine inlet valves increased by
few %.
• When the pressure of the boiler under starting equals the pressure upstream of the steam turbine, the section
valve on the manifold opens.
• Once the HP manifold section valve is no longer closed, the steam coupling operation is completed. The
pressure set point is the sliding pressure set point elaborated by the control system by adding the steam flows
of the two boilers (in the sliding pressure mode).
Note: As the same pressure set point applies to every HP bypass, the bypass of the boiler that is already on
duty opens, and the bypass of the boiler under starting closes again partly. Consequently, both HP bypass
operates similarly and both of them contribute to pressure adjustment.
• Both HP bypass closes again fully and progressively.
• Both HP bypass monitor then the steam pressure. Both bypass valves open again in case a limitation causes
the re-closing of the steam turbine control valves, or in order to limit quick pressure rise.
INCIDENTS-ACCIDENTS:
Tripping of a gas turbine or a boiler:
When a gas turbine trips, the steam manifold section valve corresponding to the boiler
tripped closes and the ST inlet valves take-up the 50% load position.
The HP bypass set point of the boiler tripped is kept at the value it had before the tripping in
order to keep the boiler under pressure.
Tripping of the steam turbine when condenser is available:
When a ST trips, the turbine inlet valves close, the steam manifold section valves
remain open and the bypass valves adjust the pressure in the HP steam manifold at the sliding
pressure set point elaborated by the control system from the boiler flows.
The exhaust gas dampers at the gas turbine exhaust take-up such a position as to maintain a
partial exhaust gas flow to the boiler.
116
117
The sliding pressure set point is kept at the value of the tripping in case of:
- Gas turbine tripping.
- Boiler tripping.
- Demand of closing of the boiler control damper.
- Besides, the opening of the bypass valves depends on a control loop, which limits the pressure
downstream of the bypass (PT 001) to a maximum value.
- The control system monitors the pressure gradient of each boiler. The bypass valve opens to limit the
positive pressure gradient to 4 bar/min.
Condenser protection:
• A closing order is given to the bypass valves PCV 001 by the following signals:
• Very high pressure in the condenser (CVI PSHH 002) (> 350 m bar)
• Low pressure of desuperheating water (CEX PSH 001) (< 8 bar)
• HP bypass fault (US 010) – (Hydraulic oil system)
• High pressure downstream the reducing valve (PSH 001) (> 18 bar)
• High temperature downstream the Pressure Reducing Valve (TSH 001) (>180 ºC)
117
118
DESCRIPTION-HYDRAULIC SYSTEM:
The hydraulic system is divided in three major parts:
• Hydraulic supply unit (HSU)
• Piping system (PS)
• Actuator System including valves and cylinders (AS)
118
119
The hydraulic supply logic system, HSL monitors and control the condition of the HSU. The pump control
during normal operation is already mentioned above. In case of malfunctions, the HSL utilizes two levels
of actions.
• Warning signal means that there is time to correct faults.
• Alarm signal means serious fault.
The HSL is based on a programmable microcomputer. It also contains a warning and alarm panel on
which the instruments connected are indicated. When a warning or alarm is actuated, the panel shows
what causes the signal. The HSL is only communicating with the HSU, except for a some warning signal
and a some alarm signal which can be connected to the bypass control panel or similar.
Filtration:
The HSU is equipped with four oil filters:
• Two high-pressured filters, one after each pump
• One low-pressure filter in a continuously running filter circuit. The circuit includes a three-way valve, which is used when
filling the tank with oil. This is the only way to fill the tank with oil.
• One low-pressure filter for use during cleaning of the pipe system. During normal operation,
this filter is to be bypassed.
• The tank is also equipped with an air filter.
119
120
Alarm:
The following conditions are responsible for the ALARM signal:
- Pressure too low
- Emergency stop.
- Oil level too low.
120
121
POSITIONNING LOOP
DISTURBANCE
A GHP US 005
CONDENSATE WATER
PRESSURE >8 BAR
CEX PSH 001
CONDENDER
PRESSURE HIGH
CVI PSHH 002
> 350 M BAR
BY-PASS DOWNSTEAM
PRESSURE HIGH
A PSHH 00118 BAR HP
1BAR LP
BY-PASS DOWNSTEAM
TEMP.HIGH
A TSH 001
>180ºC HP & 100ºC LP
HP BY-PASS
AVAILABLE
A GHP US 100
A PCV 001
IN REGULATION
121
122
HYDRAULIC GROUP
FAILURE
A GHP US 003
POSITIONNING RACK
ELECTRIC FAILURE
A GHP US 002
LOSS OF CONTROL
SIGNAL
A GHP US 001
HP BY-PASS FAULT
A GHP US 010
122
123
CONDENSER PRESSURE
HIGH
CVI PSHH 002
> 350 M BAR
CONDENSATE WATER
PRESSURE >8 BAR
CEX PHS 001
BY=PASSDOWNSTEAM
TEMPERATURE HIGH
A TSH 001 3”
>180ºC
BY-PASS DOWNSTEAM
PRESSURE HIGH
A PSHH 001
>18 BAR
POSITIONNING LOOP
DISTURBANCE
A GHP US 005
HP BY-PASS FAULT
A GHP US 010
2”
HP BY-PASS
UNAVAILABLE
A GHP US 100
CLOSING OF
A PCV 001
123
124
1”
CLOSING OF OPENING OF
AUV 102 AUV 102
124
125
ENERGIZING OF DEENERGIZING OF
A UVX 103 A UVX 103
CLOSING OF
AUV 103 OPRNINH OF
A UV 103
125
126
OPENING ORDER A UV
101 INDIVIDUAL
CONTROL A HSN 101
OPENING OF
UV 101
CLOSING ORDER A UV
101 INDIVIDUAL
CONTROL AHSN 101
CONTROL OF
UV 101
126
127
The aim of the condensate preheated is to recover optimum heat from the flue gas of the boiler for the condensate water in
the following low and high limits:
• The temperature of the condensate entering the boiler has to be sufficient to avoid the flue gas reaching the dew point,
which leads to acid corrosion of heat exchanger tubes.
• The water temperature at the downstream of preheated must not exceed the deaerator temperature minus 10 ºC, to
avoid steaming in the exchanger and to allow proper deaeration in the deaerator.
2. GENERAL DESCRIPTION:
PREHEATER:
Downstream of TCV 107 inlet circuit is fitted with:
• A check valve 095 VV.
• The return circuits from the recirculation pumps.
The preheater outlet is linked to the deaerator through the CEX system. On this branch is connected the
recirculation pumps suction circuits.
RECIRCULATION CIRCUIT:
There are two 100% duty pumps in the system with following components:
• A pump 404/405 Po,
• A flow transducer FT 138/FT 139,
• A check valve 124 VV/125 VV.
LOGIC CONTROL:
Starting in sub-group level:
The sub-group starting order sent for preheater system will be acknowledged if the preheater pump suction
pressure is more than 3 bar.
Shutdown of preheated pumps:
Shutdown of all CEX pumps or loss of suction pressure will lead to automatic shutdown of the running
pump.
128
129
HSN 001
SUB/GROUP
STARTING
HSU 001
PUMP SELECTED IN
NORMAL
404 PO/405 PO
A B
TAKING OVER
MEMORY ON
129
130
INLET CONDENSATE
PRES. PSL 068
LOW PRES.
10sec. 10sec.
EC EC
FSLB FSLB
138 139
130
131
FLP RECIRCULATING PUMPS 404 & 405 PO. TAKING OVER MEMORY
A B
HSU 002
TAKING OVER
AUTO CUT OUT
TAKING OVER
ON OFF
MEMORY MEMORY
131
132
PUMP 404 PO
“ON”
404 JA 1
PUMP 405 PO
“ON”
405 JA 1
15
Sec.
US EC
FLP ALARM 001 3
PREHEATER SYSTEM
IN CONFIGURATION
To TTA system US 002
TTA US 002
132
133
2. DESCRIPTION:
GENERAL DESCRIPTION OF THE SYSTEM:
Pumping station:
It is composed of a circulating water pumps whose discharges are interconnected. two pumps (50%
capacity) are attached to one block (in normal operation), with the possibility of fifth common pumpto
either block in emergency.
Distribution system:
The distribution system comes from the circulating water pump house and is divided into one main line,
per block. These main lines are subdivided into:
• One line for each half condenser.
• One line supplying the heat exchangers in the demineralised cooling water circuits.
Main data:
Flow:
• Condenser flow 23 151 m³/h
• Exchanger flow 670 m³/h
Temperature:
• Circulating water at condenser inlet 36 °C
• Circulating water at condenser outlet 41.3 °C
• Circulating water at the outlet of the 40.7 °C
Demineralised cooling water exchanger
Pressure:
• Maximum allowable pressure on raw waterside 7 bar abs
• Maximum allowable pressure on demineralised waterside. 7 bar abs
133
134
The five circulating pumps discharge in a common header.The common circulating pump OC 001 PO is
isolated by two motor-operated valves on its discharge pipe.
Lubricating circuit:
The lubrication of the circulating water pumps shaft bearing is issue done by the lubricating water pumps
103 PO, 203PO. These 2x100 % pumps draw water from a storage tank to a circuit equipped with 2 x 100
% filters and a separate pipe for each circulating water pump.
The make-up valve LV 004 controls the level in the storage tank.
Condenser line:
Each of the two half condenser can be isolated both at inlet and outlet by means of a set of power-operated
butterfly valve (UV 004, 005, 006, 007).
The condenser water boxes are fitted with vent valves.
Auxiliary raw cooling water pump 3 x 50 %:
Two parallel pumps make the raw water circulate through the demineralised cooling water heat
exchangers.
Main data:
• Flow 335 m³/h
• Man metric -
• Motor power 45 kW
• Voltage 415 V
Each pump is provided with a manual butterfly valve at suction and discharge and with a check valve at
discharge.
Filters (2 x 100 %):
Two filters are arranged in parallel at the auxiliary cooling water pump discharge header.
Each of the exchanger can be individually isolated by 2 butterfly valves.
EQUIPMENT INSTALATION:
All the circulating water equipment items are installed at the zero meter level in the pumping station. The
auxiliary raw cooling water pumps and their filters are installed in the steam turbine building.
The lubricating water pumps are installed at the zero meter level in the pumping station.
4. OPERATION:
NORMAL OPERATION:
Under rated load:
• Two circulating water pump supply in one block & two others supply in the second one.
• Two condenser-isolating valves are fully open.
• Two of the auxiliary cooling water pumps supply to cooling water to one of the two heat exchangers.
• One lubricating water pump supplies the lubricating circuit of all the circulating water pumps.
Normal shutdown:
In case of normal shutdown, the discharge valve first closes to 30 % before the respective motor is de-
energized. The valve goes to its closed position when the motor is de-energized.
Tripping:
When motor trips the pump discharge valve goes directly to its closed position.
Change over of circulating water pumps:
In case of Change over of the pumps, the standby pump is taken into operation. After few seconds, when
the flow is stabilized, the pump to be shutdown is switched off.
Parallel operation of the 3 circulating water pumps is allowed only for a short time corresponding to the
normal switch over procedure, from one pump to the standby one.
Operation of one circulating water pump in the complete circuit:
In case of failure of a circulating water pump, the standby pump must be put into operation by the
operator.
136
137
DISCHARGE VALVE
CLOSED ZSL 101
SUCTION BASIN
VERY LOW LEVEL
LSLL 101 (4200)
137
138
3sec
LOCAL/REMOTE LOCAL /REMOTE LUB. WATER LOW
SELECTOR ON SELECTOR ON FLOW
REMOTE LOCAL FSL 101 DISCHARGE VALVE
HSU 101 HSU 101 UV 101 CLOSED
20
ZSL 101
Sec 70sec
DISCHARGE VALVE
UV 101 30% LOCAL CLOSING
OPENED ORDER HSZ 141
ZSL 100
LOCAL/REMOTE
SELECTOR ON
C.W. .PUMP 101 PO LOCAL HSU 101
SHUTDOWN
101 JAO
CLOSING ORDER
1sec HSN 104
DISCHARGE VALVE UV
101 CLOSING ORDER
138
139
DISCHARGE VALVE
CLOSED ZSL 01 A
2C COND. INLET VALVE 2C COND. INLET VALVE 1C COND. INLET VALVE 1C COND. INLET VALVE
OPEN OPEN OPEN OPEN
2C ZSH 004 2C ZSH 005 1C ZSH 004 1C ZSH 005
LUBRICATING WATER
LOW FLOW FSL 001
LOCAL/REMOTE LOCAL/REMOTE
SELECTOR ON REMOTE SELECTOR ON LOCAL
HSU 001 HSU 001
139
140
3HEADER
sec VALVE UV 003 HEADER VALVE. UV 003 LUB. WATER LOW FLOW
CLOSED OPENED FSL 001
ZSL 003 ZSH 003
DISCHARGE VALVE
UV 001
CLOSED ZSL 01 A
LOCAL STOPPING 20 sec
ORDER 70 sec
HSZ 021
DISCHARG VALVE UV 001 LUB. WATER VALVE UV C.W. PUMP 001 PO LOCAL/REMOTE
CLOSSING ORDER TO 30% 008 CLOSING ORDER STOPPING ORDER SELECTOR ON REMOTE
140
141
PUMP 102 PO
SELECTED IN TAKING OVER AUTO
NORMAL CUT-OUT
HSU 202 HSU 102
SELECTION STATUS
SELECTION STATUS CORRECT
CORRECT
TAKING OVER
MEMORY
“ON”
PUMP SELECTION IN
NORMAL STOPPED
STARTING ORDER
HSN 102
SUCTION PRESSURE
LOW PSL 001
(1.8 BAR)
PUMP 102 PO
STARTING ORDER
141
142
SUB/GROUP
STOPPING ORDER
HSN 402
SUCTION PRESSURE
LOW
PSL 001
(<1.8 BAR)
ELECTRICAL
FAILURE
C.W. PUMP
102 PO
SUB/GROUP TRIPPING
STOPPING ORDER
ORDER
142
143
SUB/GROUP CONTROL
STARTING ORDER PUMP 203 PO
HSN 100 TRIPPED
NO CIRCULATING WATER
PUMP IN OPERATION
NO CIRCULATING
AUTO CUT-OUT WATER PUMP IN
HSU 103 OPERATION
143
144
144
145
A closed cycle demineralised water system is used as the primary coolant for steam turbine, boiler and
generator auxiliaries.
2. DESCRIPTION OF THE SYSTEM:
GENERAL:
• One elevated emergency and expansion tank 001 BA (demineralised water).
• Three cooling water pumps 101 PO-201 PO-301 PO, each ensures 50% flow.
• Two identical heat exchangers 101 RF – 201 RF, each capable of accommodating 100% flow.
• One piping network with valves supplying and recovering the demineralised cooling water of the miscellaneous
auxiliaries.
DESCRIPTION OF EQUIPMENT:
Emergency and expansion tank 001 BA:
The emergency and expansion tank 001 BA is a tank under atmospheric pressure, which is located at 12.5
m level. It is filled with demineralised water from the SER system and it is provided with an overflow, two
level transmitters and one level gauge.
The capacity of the overhead tank is 15 m³.
Cooling water pumps 101 PO –201 PO-301 PO:
The cooling water pumps are of the centrifugal type.
They are driven by the electric motors 101 MO-201 MO-301 MO.
Unit capacity of pump : 315 m³/hr
Total manometric head: 40 m
DESCRIPTION OF CIRCUITS:
Make-up and loading circuits:
Make-up is given from the demineralised water transfer pumps 101 PO and 201 PO (SER system) and it
flows into the elevated emergency and expansion tank 001 BA. The emergency and expansion tank 001
BA is located at 12.5 meter level in order to provide sufficient head for emergency circuits.
Auxiliaries water distribution and recovery circuit:
The demineralised water discharged by the cooling water pumps in operation cools the equipment or the
circuit of the unit.
Cooling water circuit chemical conditioning:
Di-sodium and trisodium phosphates are manually injected at suction of the cooling water pumps in order
to adjust the water PH to a suitable value (PH=10.5 to 11).
145
146
STEADY-STATE OPERATION:
Rated operation:
• Two cooling water pumps cool the auxiliaries of the unit.
• The water capacity in the emergency and expansion tank 001 BA is maintained by the pneumatic demineralised water
make-up control valve (LCV 001), which is controlled by the electronic control loop.
TRANSIENT OPERATIONS:
Emergency cooling of particular equipment:
• Emergency cooling of the HRSG HP circulating pump seat (see system FLH).
If three cooling water pumps are tripped at a time, the emergency cooling valves (see system FLH) are
automatically opened to change the cooling water route for emergency cooling purposes. In this case,
water is supplied by gravity from the emergency and expansion tank 001 BA whose water reserve
guarantees the cooling of the equipment.
Start-up:
The start-up order is given from the control room.The cooling water pumps do not start if the emergency
and expansion tank 001 BA level is very low (<1000mm).
Shutdown of cooling water pumps:
The cooling water pumps can be stopped intentionally only if the main auxiliaries and especially the
HRSG HP circulating pumps are not running. The action remains at the operation initiative in line with the
plant operation.
Cooling water circuit make-up:
The cooling water circuit make-up is ensured in the emergency and expansion tank 001 BA by the
demineralised water production and distribution system. The pneumatic make-up control valve LCV 001
is controlled by an electronic level control loop.
BEHAVIOUR OF THE CIRCUIT CASE OF INCIDENTS OR ACCIDENTS:
• If one cooling water pumps in normal operation trips, the standby pump is automatically started provided the
subgroup control is on.
• In case of complete tripping of the cooling water pumps, automatic discharge to the sewer is ensured by opening of the
emergency cooling valves for the HRSG HP circulating pumps.
• The cooling water pumps will trip with very low level in emergency & expansion tank 001 BA.
146
147
HSU 001
101 PO / 201 PO
SELECTED IN
NORMAL
SELECTION STATUS
CORRECT
SELECTION STATUS
CORRECT
TAKING OVER
MEMORY
ON
ON OFF
TAKING OVER MEMORY
PUMP SELECTED IN
NORMAL
STOPPED
HSU 001
101 PO /201 PO
SELECTED IN
STAND-BY
HSN 101
101 PO
INDIVIDUAL
STARTING ORDER
STARTING STARTING
CONDITIONS FROM CONDITIONS
FOLIO 2 FROM FOLIO 2
HEATING HEATING
START PUMP RESISTANCE 201 RS START PUMP RESISTANCE
201 PO OFF 101 PO 101 RS
OFF
(CARRIED OUT IN MCC ) SAME SEQUENCE FOR 201 PO.301 PO. (CARRIED OUT IN MCC)
147
148
101 MO
ELECTRIC FAILURE
PUMP 101 PO
TRIPPING CONDITION
LSLL 001
HEAD TANK LOW
LOW LEVEL
SUB/GROUP
TRIPPING CONDITION
148
149
HSN 001
SUB/GROUP SUB/GROUP TRIPPING
STOPPING ORDER CONDITIONS
(FROM F.4)
HEATING
SUB/GROUP TRIPPING STOP PUMP RESISTANCE
ORDER 101 PO 101 RS
ON
149
150
Each pump draws air from the condenser through a common pipe.
DESCRIPTION OF EQUIPMENT AND CIRCUITS:
Air extraction pumps:
Main data:
Pump:
• Number of stages 2
• Fluid conveyed air with water vapour
• Design flow 25.5 kg/hr
• Nominal temp. of mixture extracted 40 °C
• Nominal suction pressure 84 mbar
Motor:
• Power 55 KW
• Voltage 415 V AC
• Cooling fluid air
• Rotation speed 730 rpm
NORMAL OPERATION:
In normal configuration the vacuum pumps are controlled by group control.
Each vacuum pump can be controlled by an individual control device. Similarly, an individual control
device is available for the seal water pump. Each vacuum pump sucks air from condenser through a
common pipe. When the first pump is started and the differential pressure switch PDSH 101/201 measures
a pressure difference less than 34 mbar, the corresponding suction valve opens & the condenser pressure
begins to decrease. During this operation, if the condenser pressure abnormally increases: p> 135 mbar,
the pressure switch PSH 001 starts the standby pump (only in case of group level control).
In case of a second pump starting the second suction valve will open when the differential pressure is
established (PDSH <34 mbar).
If the two pumps are on duty and the condenser pressure decreases (P<100 mbar), the pressure switch PSL
001 stops the second pump (selected in standby on group level control).
TRANSIENT OPERATION:
Start up:
During standstill, the two suction valves are closed and the pressure in the condenser is nearly atmospheric
pressure. The two pumps can be used for initial evacuation (hogging).
Voluntary changeover:
The changeover of two vacuum pumps is carried out from the control room with an overlap period.
INCIDENTS AND ACCIDENTS:
When two pumps run simultaneously and the pressure continues to rise, an alarm signal PSHH 001 is
provided in the control room. The trip of one pump causes the start up of the standby pump, if the
emergency take-over is valid. It is allowed to restart a tripped pump only after the fault has disappeared,
on voluntary order from the operator.
1. LOGIC CONTROL LOOPS:
151
152
152
153
PRESSURE
1013 mbar abs Initial pressure in condenser = atmospheric pressure
153
154
ZSL 101
SUCTION VALVE FV
101 CLOSED
FSL 105
SEAL WATER
LOW FLOW
PUMP 101 PO
SAME SEQUENCE FOR 201 PO STARTING
CONDITIONS
FSL 105
VACUUM PUMPS 101 SEAL WATER
PO IN OPERATIONS LOW FLOW
10 sec 10 sec
TAKING OVER
ZSH 101
MEMORY
SUCTION VALVE FV
ON
101 OPEN
US PSL 001
US 002 FOR FV 201 NOT OPEN CONDENSER
001
LOW PRESSURE
201 PO IN OPERATION
SELECTED IN
NORMAL
HSU 001
ELECTRIC FAILURE
101 MO 101 PO IN OPERATION
SELECTED IN
STANDBY
HSU 001
TRIPPING CONDITION
SAME SEQUENCE VACUUM PUMP
101 PO SUB-GROUP
FOR 201 PO
TRIPPING CONDITION
VACUUM PUMP
101 PO
154
155
C HSU 002
C HSU 101 PO PUMP TAKING OVER AUTO
101 PO SELECTED IN CUT OUT
NORMAL
SELECTION STATUS
SELECTED STATUS CORRECT
CORRECT
TAKING OVER
MEMORY ON
ON OFF
PSH 001
CONDENSER HIGH
TAKING OVER MEMORY PRESSURE
PUMP 101 PO IN
OPERATION
STARTING
CONDITIONS
PUMP 101 PO IN
OPERATION
PUMP 101 PO IN PUMP 101 PO IN SEAL WATER PUMP STARTING PUMP 101
OPERATION GROUP OPERATIONSUB- 102 PO SUB-GROUP PO
LEVEL GROUP LEVEL STARTING ORDER
155
156
C HSN 101
See folio 3 PUMP 101 PO PUMP 101 PO
TRIPPING CONDITIONS INDIVIDUAL ORDER
156
157
STOPPING
STARTING PUMP 102 PO
PUMP 102 PO
157
158
AT LEAST ONE
FOR KCS SYSTEM CONDENSER VACUUM
SC STEP 030 PUMP IN OPERATION C
US 003
158
159
The purpose of the chemical feed equipment is to condition the steam water loop so as to minimize corrosion and to limit
the fouling of Waste Heat Boilers Heat-exchangers inner surfaces.
2. DESCRIPTION:
Dosing pumps:
Ammonia pumps:
Main data:
• Flow 0 – 13 L/hr
• Motor power 0.55 KW
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160
Hydrazine pumps:
Main data:
• Flow 0 – 13 L/hr
• Motor power 0.55 KW
Phosphate pumps:
Main Data for LP and HP phosphate pumps:
• Flow 0 – 20 L/hr
• Motor power 0.55 KW
Circuits:
Each pump is fitted with:
At suction:
• A filter
• An isolating valve.
At discharge:
• A damping accumulator
• A non-return valve
• An isolating valve.
A recirculating line with relief valve, from the ammonia and hydrazine pumps discharge, is put into
service in case of low flow. This flow is forced back to the corresponding solution tank.
In case of phosphate pump flow low, this one is forced back to a pit.
Ammonia solution is injected in to the condenser water circuit downstream of the pumps. The injection
point is fitted with a manual isolating valve and non-return valve.
Hydrazine solution is injected into the feed water tank. The injection line is fitted with a manual isolating
valve and a non-return valve.
Phosphate solution is injected into the HRSG drum, one LP phosphate pump injects phosphate into the
HRSG LP drums. The same is for HP phosphate pump.
3. OPERATION:
AMMONIA:
Normal operation:
The ammonia injection is realised by one 100 % pump selected in normal in automatic control, locally by
the operator. The second one is on standby. The operator starts this pump locally in case of fault on the
other pump.
The pump on duty sucks the ammonia from the solution mixer is in service. The pump is automatically
started and stopped according to PH thresholds.
The flow rate is adjustable manually on the pumps in case of ammonia concentration is low & the
recirculating safety valve opens and the solution is forced back to the solution tank.
If the selector is on individual control, the pumps start and shutdown by push-button actions.
Transient operation:
Before ammonia solution injection gets into the solution tank, the operator must dose the mixing. This
operation is done in the ammonia preparation tank. Ammonia is poured into the ammonia-measuring tank;
the corresponding demineralised water (SER) dose is injected in the ammonia preparation tank. Then the
solution is mixed in the ammonia preparation tank and then transferred by gravity into the solution tank. A
demineralised water injection can be done for rinsing pumps before stopping. The pump flow can be
measured by a pump calibration column. The operator fills this column, closes the solution tank discharge
valve, start a pump and measures the column employing time. Then he should calculate the flow rate, and
adjust it locally on the pump.
INCIDENT AND ACCIDENT:
The ammonia solution tank low level induces the ammonia pumps and the solution mixer tripping.
In case of the condensate pumps stopping or tripping, the ammonia pumps also stop.
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In case chemical analysis system fault, the ammonia pumps remains in the same status they were before
the fault is developed. The ammonia preparation tank low level induces the preparation mixer tripping.
HYDRAZINE:
Normal operation:
The hydrazine injection is realized by one 100 % pump. The second one is on standby. The operator starts
the pump locally in case of fault on the other pump. The pump on duty sucks the hydrazine from the
hydrazine solution tank. The solution mixer is in service. The pump and the mixers are controlled by push
buttons. The hydrazine injection is continuous in to the feed water tank. The flow rate is adjustable by a
servomotor.
In case of hydrazine flow low, the recirculating safety valve opens and the solution is forced back to the
solution tank.
Transient operation:
Before hydrazine solution injection in the solution tank, the operator must dose the mixing. This operation
is done in the hydrazine preparation tank, as it is done for the ammonia system.
A demineralised water injection can be done for rinsing pumps, before stopping pumps. The pump flow
can be measured by a pump calibration column.
Incident and Accident:
The hydrazine solution tank low level induces the hydrazine pumps and the solution mixer tripping.
The hydrazine preparation tank low level induces the preparation mixer tripping.
PHOSPHATE:
Normal operation:
The phosphate injection into a boiler LP drum is realised by one 100 % LP phosphate pumps and into a
boiler HP drum by one 100 % HP phosphate pump. An interconnection line at the discharge of HP (or LP)
phosphate pump allows a “cross-over “ operation. Two manual valves, after the “cross-over” set, allow the
HRSG selection. Then the phosphate solution is injected in one or the other both HRSG drums. The
pumps and the mixers are controlled locally by push buttons. The phosphate solution is injected into the
boiler drums according to the analysis results or instruction from chemist in order to keep the desired
water qualities. The flow rate is adjustable manually on the pumps. In case if phosphate low flow, the
reciruculating safety valve opens and the solution is forced back to the sewer.
Transient operation:
Before phosphate solution injection gets into the solution tank, the operator must dose the mixing.
This operation is done in the phosphate preparation tank Phosphate bags are mixed with the corresponding
demineralised water in the preparation tank. Then it is mixed and transferred by gravity into the solution
tank. A demineralising water injection can be done for rinsing pumps before stopping. The pump flow can
be measured by a pump calibration column.
Incident and Accident:
The phosphate solution tank low level induces the phosphate pumps and the solution mixer pump tripping.
The phosphate preparation tank low level induces the preparation mixer pump tripping.
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HSZ 113
STARTING ORDER SIT ASL 116
PUMP 103 PO LOW PH
CEX US 002
ONE CONDENSATE
PUMP IN OPERATION
LSL 203
AMMONIA SOLUTION
LOW LEVEL
STARTING AMMONIA
SOLUTION PUMP
103 PO
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163
STOPPING AMMONIA
SOLUTION PUMP 103 PO
163
164
LSL 103
LSL 203 AMMOIA AMMONIA
SOLUTION LOW LEVEL PREPARATION LOW
LEVEL
HSZ 226 STAOPPING LSL 203 AMMONIA LSL 103 AMMONIA HSZ 126 STOPPING
ORDER MIXER SOLUTION LOW LEVEL PREPARATION ORDER MIXER
206 MO LOW LEVEL 106 MO
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165
HSZ 225 LSL 202 HYDRAZINE LSL 102 HYRAZINE HSZ 125
STOPPING ORDER SOLUTION PREPARATION STOPPING ORDER
MIXER 205 MO LOW LEVEL LOW LEVEL MIXER 105 MO
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166
LSL 201
PHOSPHATE
SOLUTION LOW
STARTING LP STOPPING LP
PHOSPHATE PUMP PHOSPHATE PUMP
101 PO 101 PO
STARTING HP STOPPING HP
PHOSPHATE PUMP PHOSPHATE PUMP
301 PO 301 PO
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167
HSZ 224 LSL 201 HOSPHATE LSL 101 PHOSPHATE HSZ 124 STOPPING
STOPPING ORDER SOLUTION LOW PREPARATION LOW MIXER 104 MO
MIXER 204 MO LEVEL LEVEL
STOPPING PHOSPHATE
PREPAARATION MIXER
STOPPING PHOSPHATE 104 MO
SOLUTION MIXER
204 MO
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168
EC 2
LP PHOSPHATE PUMPS FAULT
EC 2
HP PHOSPHATE PUMPS FAULT
EC 2
AMMONIA PUMPS FAULT
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169
Lubrication:
Vertical pumping unit:
This unit consist of three identical pumps submerged in the tank, and driven as follows:
• The pump GGR-001 PO is driven by an A.C. motor.
• The pump GGR- 002 PO is driven by an A.C. motor
• The emergency pump GGR-003 PO is driven by a D.C. motor (it is used for feeding the lube-oil system during the turbine
generator unit coasting down to stop, or in case of malfunctioning or electrical failure of A.C. motor driven pumps).
A manostat is mounted at each pump delivery pipe to indicate which pump is working.
A pressure gauge is also mounted at each pump delivery pipe in order to check the pressure.
All the electrical pumps are installed on the lube oil tank. They are provided with a check-valve at their
discharge pipes. Pump casings are submerged into lube-oil and lube-oil flows through a suction strainer.
Lube-oil tank GGR-001 BA:
This tank is installed close to the turbine generator unit. It is used for lube oil demulsification.
It is provided with an inlet and an outlet for the oil treatment station, and with two drain valves.
Following instruments are fitted on the tank:
• A sight level gauge
• A high and low level alarm in the lube-oil tank. Moreover, a low level-switch controller disables the starting of the lube-oil
pumps GGR-001 PO or GGR – 002 PO.
• A level electrical detector trips the turbine if oil reaches the very low level in the tank.
• A thermostat of heater resistors (when temperature <45°C).
• A direct reading thermometer.
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170
Turning gear:
At idle speed, the shafting is normally driven by an electric turning gear GGR-008 MO through a self-
engaging and disengaging clutch coupling mechanism.
The turning gear is installed on the turbine consists of:
• An electric motor connected to an A.C. supply.
• A worm wheel reduction gear with tangential wheel.
• A SSS automatic clutch.
• A position switch showing that the clutch is engaged on the turbine shaft and another one showing that the clutch is
disengaged on the turbine shaft.
• A position switch that disables the remote starting of the turning gear when the flywheel is engaged on the turning gear
motor for manual operation.
170
171
171
172
STEAM TURBINE – LUBE OIL SYSTEM GGR LUBE OIL PUMPS STARTING: 001PO, 002
PO
HSN 001 SUB GROUP
SUB GROUP TRIPPING
STARTING
HSU 001-001PO
SLECTED IN
NORMAL
PUMP 001 PO IN
OPERATION
ON OFF
PUMP SELLECTED IN
GGR PSL 044 LUBE OIL NORMAL STOPPED
MANIFOLDN PRESSURE
1.2 BAR OFF
STARTING CONDITIONS
001 PO
HSU 001- 001 PO
SELECTED IN NORMAL
START PUMP
001 PO
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173
TEST OPERATING
HSN 001 ON GGR US 006
SUB GROUP STARTING
HSU 001-001 PO
SELECTED IN STAND BY
001 MO
ELECTRIC FAILURE
PUMP 001 PO
TRIPPING CONDITION
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174
TEST OPERATING
HSN 001 ON GGR US 006
SUB GROUP STARTING
HSU 001-002 PO
SELECTED IN STAND BY
PUMP 002 PO
TRIPPING CONDITION
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175
GRE US 002
STEAM TURBINE CASING
TEMP. >100 oC
SUB-GROUP
TRIPPING ORDER STOP PUMP 001 PO
175
176
176
177
177
178
HSN 103
INDIVIDUAL
STOPPING ORDER
STARTING ORDER
003 PO
STOP PUMP
003 PO
178
179
179
180
- STEAM TURBINE – LIFTING OIL PUMPS SYSTEM GGR LIFTING OIL PUMPS
- STARTINGS: 004 PO, 005 PO, 006 PO, 007 PO, 008 PO, 009 PO
GRE US 002
HSN 002 TURBINE CASING
SUB GROUP STARTING TEMPERATURE > 100ºC SUB GROUP TRIPPING
IS
DT
GRE SSH 001 TURNING GEAR
45’
STARTING CONDITIONS TURBINE SPEED NOMINAL SPEED
> 600 RPM GGR SSH 001
ON OFF
GGR PT 200
STUFFING MANIFOLD
PRESSURE > 0.1 BAR OFF
GGR PT 200
STUFFING MANIFOLD
PRESSURE > 3.5 BAR OFF
START PUMPS
GGR PO 004
GGR UY 200 GGR PO 005
SOLENOID VALVE
OPENING ORDER
DT
3s
START PUMPS
GGR PO 006
GGR PO 007
DT
3s
START PUMPS
GGR PO 008 GGR PO 009
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181
DT
10’
GRE SSL 001
TURBINE SPEED
< 33 RPM
HSN 105
TURNING GEAR MOTOR INDIVIDUAL STOPPING
NOMINAL SPEED ORDER
GGR SSH 001
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182
DI
10Sec
LIFTING PUMPS
MANIFOLD PRESSURE
CORRECT
182
183
HSN 104
LIFTING PUMPS GRE SSH, 001 TURNING GEAR
MANIFOLD PRESSURE TURBINE SPEED INDIVIDUAL STARTING
CORRECT > 600 RPM ORDER
TURNING GEAR
TRIPPING ORDER
GGR ZS 521
MANUAL GEAR
FLYWHEEL ENGAGED
START
TURNING GEAR
008 MO
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184
LIFTING PUMPS
MANIFOLD PRESSURE
CORRECT
HSN 002
SUB GROUP STOPPING
ORDER
GER US 002
TURBINE CASING
TEMPERATURE > 100ºC
184
185
The sealing piping provided at rotor bores is divided into two complementary systems:
Vacuum system:
The external chambers are connected to the gland steam condenser CET 001 CS that is maintained in
partial vacuum by means of a centrifugal fan CET 001 ZV and CET 002 ZV that discharges non-
condensable gas into the atmosphere. Condensates are discharged from the gland steam condenser to main
condenser.
Tight system:
The last chambers are connected to the regulated pressure system in which a constant pressure is
maintained slightly higher than the atmospheric pressure. The turbine exhaust gland (LP turbine) supply
system is provided with a desuperheating system with water/gland steam operation.
This system consists of:
• A desuperheating CET 001 DE reduces the steam temperature by adjustable water injection valve (CET TCV 003 )
• A water/steam separator CET 001 ZE is mounted downstream of the super heater
3. OPERATION:
Steady rating:
When the turbine is running, the rotor gland packing on inlet side (over-pressurized area) are crossed by
the internal leaks that enters into the gland steam system, where as gland packing on outlet side are feed
through this system.
The total amount of steam leaks that feed the regulated pressure system (tight system) is higher than the
flow rate required for ensuring low-pressure labyrinth gland sealing. Therefore this steam is in excess and
the surplus steam must be discharged to the drain flash tank through an over flow valve CET PCV 002.
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186
Therefore, in normal operation, this over flow valve CET PCV002 regulates the system pressure.
From stop and control valve rod bores, steam leaks are sucked by the gland steam condenser manifold.
Transient rating:
When the turbine runs at part load or is being started, the tight system flow is insufficient and needs
additional feeding. Make up is ensured by live steam taken from the main steam whose pressure is reduced
by a control valve CET PCV 001. The system can be into service when the pressure of HP steam is >20
bar.
4.ANALYSIS IN CASE OF OPERATING OR CONTROL FLUID SHORTAGE:
Control air shortage:
Opening of the control valves CET PCV 001, PCV 002, TCV 003
Control 220 V A.C. shortages
Opening of the control valves CET PCV 001,CET PCV 002,CET TCV 001.
415 V A.C. shortages:
Stoppage of the centrifugal fan CET 001 ZV, or CET 002 ZV.
The motors operated for vacuum breaker valve CET UV 100 keeps in position.
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187
GLAND STEAM
CONDENSER FANS
STARTING CONDITIONS
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188
HSU 001
001 ZV HSU 002
SELECTED IN NORMAL
AUTO CUT OUT
FAN 001 ZV IN
OPERATION
ON OFF
FAN SELECTED IN
NORMAL STOPPED
HSU 001
001 ZV
SELECTED IN STAND BY
HSN 101
STARTING CONDITIONS 001 ZV
INDIVIDUAL STARTING
ORDER
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189
At low steam flow, the last stage LP blades can be subjected to churning that might lead to heat release. In order to
avoid overheating, water is sprayed at the periphery of outer diffusers placed at the last stage outlet.
2. DESCRIPTION OF THE SYSTEM:
The turbine exhaust casing walls are cooled through a series of nozzles that spray which sprays water on the upper
exhaust half-casing sheets.
Sprayed water is de-ionised. It is supplied from the condensate discharge.
The spraying water flows to the condenser under the gravity effect. This system is provided with:
• one hand shut –off valve CAR HV 112
- one “ON/OFF” pneumatic valve CAR TV 040 controlled by a 3 way solenoid valve UY 040.
- A spray ring header with nozzles.
- A thermostate.
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190
- STEAM TURBINE – GLAND SEAL SYSTEM CET GLAND SEAL CONTROL LOOPS
STARTING: PIC 075A, PIC 075B, TIC 170
CET US 002
TO STEAM TURBINE
CONTROL CABINET
STARTED STARTED
190
191
DEENERGIZED ENERGIZED
SOLENOID VALVE SOLENOID VALVE
CAR UY 040 CAR UY 040
OPENING VALVE CLOSING VALVE
CAR TV 040 CAR TV 040
191
192
101 MO
ELECTRIC FAILURE
FAN 001 ZV
TRIPPING CONDITION
192
193
HSN 001
SUB GROUP
STOPPING ORDER
MAIN CONDENSER
PRESSURE C CVI PSHH 004
> 0. 9 BAR ABS
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194
Pumping unit:
It consists of two reciprocating pumps GFR 011 PO and GFR 012 PO driven by A.C. motors.
In normal operation, only one pump is working, where as the other one is as standby.
• A pressure regulator, which comprises a servo valve GFR PCV 004, GFR PCV 005 and an actuator that adjusts the
pump plunger stroke. It maintains a constant pressure in the system under flow variations.
• A pressure relief-valve GFR PSV 004 & 005.
Fluid oil coolers GFR 003 FR, GFR 004 FR running in parallel:
Coolers can be shifted manually using the shifting level GFR HV 053, GFR HV 056. A filling pipe is
provided between the two coolers in order to make-up fluid oil before using the emergency cooler.
A 3 way temperature control valve GFR TCV 007 is provided down-stream the coolers to maintain the
control fluid temperature in the tank.
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196
PUMP 011 PO
IN OPERATION
ON OFF
TAKING OVER MEMORY
HSU 001
HSN 011 011 PO
011 PO SELECTED IN STAND BY
INDIVIDUAL STARTING
ORDER
STARTING CONDITIONS
START PUMP
011 PO
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197
HSU 001
011 PO
SELECTED IN STAND BY
PUMP 011 PO
TRIPPING CONDITION
197
198
HSU 001
012 PO
SELECTED IN STAND BY
PUMP 012 PO
TRIPPING CONDITION
198
199
SUB GROUP
TRIPPING CONDITION
199
200
200
201
HSN 010
010 PO INDIVIDUAL
STARTING ORDER
START PUMP
010 PO
HSN 102
RESISTANCE HEATER 002 RS
GFR TSL 132 FLUID OIL
INDIVIDUAL STARTING ORDER
TANK TEMP. < 25ºC
201
202
HSN 010
010 PO INDIVIDUAL
STOPPING ORDER
STOPPING PUMP
010 PO
202
203
1. PURPOSE:
The draining system has the following functions:
• To drain condensate when saturated steam is released during start-up.
• To ensure the machine thermal conditioning through steam flow, in order to reduce heat stresses that might affect metal
conditions.
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204
TURBINE GENERATOR
TUBINE GENERATOR UNIT UNIT
OUT PUT < 25% 0UT PUT < 25%
AUTO CLOSING
AUTO OPENING ORDER
ORDER
204
205
AUTO CLOSING
AUTO ORDER
OPENING ORDER
AUTO
OPENING ORDER
30’
ENERGIZED
SOLENOID VALVE
GPV UY 107 CLOSING
VALVE GPV UV 107
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206
B TTA ZSL X 10
HRSG B
DAMPER CLOSED
AUTO OPENING
FROM FOLIO 2
AUTO CLOSING ORDER
FROM FOLIO 2
GPV UV 102
AUTO OPENING ORDER
GPV UV 102
AUTO OPENING ORDER
DEENERGIZED ENERGIZED
SOLENOID VALVE GPV SOLENOID VALVE
UY 102 OPENING VALVE GPV UY 102
GPV UV 102 CLOSING VALVE
GPV UV 102
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♦ Warm up period starts at 1750 rpm. Unit remains at this speed, till the average of HP casing top and bottom temperature
is minimum 352.5oC or the end of 40 minutes warm up timer, whichever comes last. In case of Warm-start, the warm-up
timer is for 10 minutes. After Warm up period, excitation speed is authorized.
♦ Press EXCITATION SPEED. Now the HP Control valves further open and speed goes up to 2850 rpm. After this speed,
the synchronization speed is authorized.
♦ Press SYNCHRONIZATION SPEED. The speed increases to 3000 rpm.
♦ Press SYNCHRONIZATION( After authorization). Now the Unit is synchronized.
♦ PRESS HP /LP LOAD MODE Selection
♦ Select the LOAD RATE as follows:
Rate 1: For Cold start up (When HP casing average temp. < 330 oC)
Rate 2: For Warm start up. (When HP casing average temp. 330 – 410 oC)
Rate 3: For Hot start up. (When HP casing average temp. > 410 oC)
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208
The steam turbine loading is complete when the ST load corresponds with the energy recovered in the
HRSGs and the HP bypass is completely closed.
Now the ST is operated in sliding pressure mode and the minimum HP steam pressure of 30 bar is
maintained by ST inlet control valves and /or HP bypass control valve.
HP speed controller has a wide dead band (+3% nominal speed). So during normal operation when ST is
connected to the grid, the ST speed control doesn’t act and the power delivered by the turbine depends
only on inlet steam temperature, pressure and flow conditions.
SLIDING PRESSURE OPERATION:
The boiler and Steam Turbine work on sliding pressure mode i.e. the ST control valves are fully open and
the pressure depends on steam flow. To avoid excessive steam velocity in steam pipes, the minimum
pressure setting is kept 30 bar. The sliding pressure set point varies from 30 bar to 70 bar depending on
HP steam flow.
The maximum allowable gradient for increase / decrease of HP steam pressure is:
p (bar / min) ≤ 1.2 + 0.2p, if P < 17 bar
p ≤ 3.5 + 0.2 p, if p > 17 bar
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209
Any of the
above No
All yes
START ORDER
ALL YES
209
210
GT START-UP - 2
A
HYD. OIL PUMP START CRANKING MOTOR START TORQUE CONVERTOR AT MAX 65%
GT COOLER FAN 1-6 START 2 SEC LOAD COMPT. FAN 88VG START
10 SEC
FSR & SPEED INCREASE
88 TK-2 START
SPEED 50 % 14 HA
SPEED 60% 14 HC
CRANKING MOTOR STOP IGV OPEN 34 Deg TO 54 Deg GEN WATER PUMP START GEN WATER FAN 1-3 START
210
211
SPEED 95% 14 HS
SPEED CONTROL
Yes
SPEED MATCHING VOLTAGE MATCHING
4.5 MW
IF NO LOAD SELECTION
SPINNING RESERVE
211
212
GT START UP: 4
C
IF IGV CONTROL
ON IF IGV CONTROL
OFF
PRESELECTED
BASE OR PEAK LOAD REACHED
LOAD REACHED SPEED CONTROL
TEMP. CONTROL
END
END
212
213
STOP ORDER
TNR DECRESES
LOAD DECRESES
FSR SET AT MIN FSR COMPRESSOR BLEED GT COOLER FANS 7,8,9 GEN. COOLER FANS
VALVES OPEN STOP 4 TO 9 STOP
94% SPEED 14 HS
213
214
GT SHUTDOWN-2 A
50% SPEED 14 HC
5 Sec
LOSS OF FLAME DETECTED
IF LOAD COMPT. TEMP. LOW 14 HM SPEED 9.5% SUPER PACKAGE VENT 88 BT FAN STOPS
VENTILATION FAN 88 VG STOP
214
215
GT SHUTDOWN –3
B
14 Hrs.
WHEEL SPACE TEMP. AUX. LUB OIL PUMP LUB OIL MIST JAKING OIL PUMP
LOW STOP SEPARATOR STOP
OFF SELECTED
TURBINE STANDBY
215
216
216
217
4. At least one LP BFP running. For this the conditions are same as those for HP BFP.
5. At least one FLH pump running.
For this:
♦ HP drum level should be minimum 300 mm.
♦ HP Economizer re circulation valve should be in auto mode.
♦ Discharge flow should be above 250 tons/hr.
LP bypass valve:
♦ Condenser pressure should be less than 350 mbar.
♦ LP bypass valve downstream steam pressure less than 1 bar.
♦ Bypass valve downstream steam temperature less than 100 oC.
♦ No position loop disturbance.
♦ No LP bypass fault.
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219
2. EXCITATION SYSTEM:
The excitation system in Generator is of brush less type with rotating diode exciter.
The rotating diodes are directly coupled with generator. The diodes are directly connected with the Rotor
(armature) of the exciter feeding D.C. supply directly to the rotor of main generator. The stator (field) of
the exciter is being fed by the excitation supply. This excitation supply is tapped from the generator
terminals, step down by the excitation transformer and rectified by the Thyrister Bridge placed in
excitation and regulation panel.
For field flashing and excitation, the supply comes from 125 V D.C. unit battery systems. During startup,
when there is no voltage at the generator terminals, field flashing is done to build up the voltage. Once the
stator voltage is built up, the power for excitation is taken from the excitation transformer.
The Thyrister Bridge is under the dependence of the voltage regulator, which includes two channels, auto
and manual. A follow up device ensures smooth transfer from auto to manual & vice versa.
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221
The circuit breaker must be closed when the pointer reaches at the twelve o’clock position. There is also a
check synchronising relay, which gives, permissive to the breaker-closing coil.
SPECIFICATION OF GENERATOR TRASNFORMERS:
Generator transformer for GT:
Total Quantity 4 Nos.
Specification of each -
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222
• The voltage protections; they receive a signal which is an image of the stator voltage.
• The power protection: they receive the voltage and the current images,
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223
The purpose of the TVR system is to draw water from the demineralised water storage tanks to the water skids
injection. This water is injection in the combustion chamber of the gas turbine for NOX control.
2. DESCRIPTION OF THE SYSTEM:
GENERAL DESCRIPTION:
The system is composed of 3 x 50 % water skids transfer pumps, each includes:
• 1 single stage centrifugal pumps.
• 1 driving motor.
• 4 reserve water tanks.
Each skid draws water by means of a common piping from demineralised water storage tanks.
The pumps discharge supplies to a common header, from which the flow is sent to the 4 reserve water
tanks (one per gas turbine).
DESCRIPTION OF EQUIPMENT AND CIRCUITS:
Motor pumps:
• Number 3 x 50%
• Design flow 25 m³/h
• Design man metric head 25 m
• Motor power 4 KW
Reserve tank:
• Number 4
• Capacity 3 m³
OPERATION:
NORMAL OPERATION:
The number of water skids transfer pump in operation is according to the number of gas turbine in
operation. For one or two gas turbine in operation, one transfer pump is in operation.
For three or four gas turbine in operation, two transfer pumps are in operation.The level of each reserve
tank is kept constant by the level control valves at the inlet of the tank.
TRANSIENT OPERATION:
Changeover of the pumps:
The changeover of the pumps is carried out from the control room. It is carried out with an overlap period.
INCIDENTS:
The trip of one pump causes the start-up of the standby pump.
It is allowed to restart the tripped pump only after the fault is rectified or voluntary order from the
operator.
4. DESRIPTION OF INSTRUMATION AND CONTROL LOOP:
LOGIC CONTROL LOOPS:
Starting in sub-group level control:
In normal configuration, the water skids transfer pumps are controlled by the sub-group control. The
operator selects the pump to be started up (HSU 001) and confirms the starting-up by using the sub-group
control command (HSN 001).
Starting in individual control:
Each pump can be controlled by an individual control device (HSN 101/201or 301). The starting
conditions must always be fulfilled.
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224
In case of one transfer pump tripping the emergency taking-over by the standby pump is only
possible under the following conditions:
• The operator has authorized the emergency taking-over from the operating device “ taking-over auto-out” (HSU 002).
• There is no discrepancy between the pumps and the choice of the pump in operation.
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225
WATER SKIDS TRANSFER PUMPS. STARTING CONDITIONS: 101 PO. 201 PO. 301 PO.
PUMPS STARTING
CONDITIONS
225
226
HSN 001
SUB-GROUP STARTING SUB-GROUP
ORDER TRIPPING ORDER
FROM FOLIO 5
SELECTED STATUS
CORRECT
SELECTED STATUS
CORRECT
PUMP
SELECTED IN NORMAL
STOPPED
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227
SUB-GROUP TRIPPING
CONDITIONS
ELECTRIC FAILURE
101 MO
PUMP 101 PO
TRIPPING CONDITION
WATER SKIDS TRANSFER PUMPS. STOPPING: 101 PO, 201 PO, 301 PO
227
228
HSN 101
PUMP 101PO
INDIVIDUAL
STOPPING ORDER
PUMP 101 PO
TRIPPING
CONDITION FROM
FOLIO 4
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229
(26) PROTECTIONS
The start-up permissive and protection logics of different auxiliary system and main equipments were
already discussed in the proceeding sessions. Consolidated system wise summary of all protections and
interlocks with threshold/limit values are provided for quick reference.
Tripping Conditions:
• Electrical failure
• Emergency tripping order
• Discharge valve not open (After 30 Sec. Time delay)
• Discharge valve stayed close (After 3 Sec. Time delay)
• Thrust bearing temp. Hi-Hi (95°C)
• Thrust bearing vibration Hi-Hi (120 microns)
• Condenser level very low (500 mm)
• Feed water tank level Hi-Hi
Tripping Conditions:
• Electric failure
• Feed water tank level very low (700 mm)
• Emergency tripping order
Tripping Conditions:
• Electric failure
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230
• Emergency stopping
• Lube Oil pressure very low (less than 0.5 bar)
• Bearing temp. Very high (90° C) (Six channels)
• Cooling valve not open and pump running
• Bearing vibration very high (Pump: 70 microns) (Motor: 150 microns)
• Motor winding temp. Very high (150°C)
• Feed water tank very low (700 mm).
Tripping Conditions:
• Electric failure
• LP drum level very low (300 mm)
• Pump running with discharge flow low (10 sec.time delay)
• EPB trip order
Tripping Conditions:
• HP Drum level very low (300 mm)
• Pump running with discharge flow low. (After 10 seconds time delay)
• EPB trip order.
• Low cooling water flow.
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Tripping Conditions:
• Electric failure.
• Vacuum P/P in operation and suction valve not open for 10 sec.
• Seal water flow low (10 sec. Time delay)
7. CW PUMPS (CRF):
Start Permissives:
• Discharge valve closed
• Suction basin level not very low (4000 mm)
• Condenser inlet & out let valve open
• Lube water flow normal
• No trip order
Tripping Conditions:
• Electric failure
• Lube water flow very low (20 sec. Time delay)
• Discharge valve closed (3sec. Time delay)
• Discharge valve not open (70 sec. Time delay)
• Emergency push button
• Motor bearing temperature very high (75°C)
• Motor thrust bearing temp. Very high (150°C) (3 channels)
• Thrust bearing vibration Hi-Hi (120 microns)
• Suction basin level very low (4000 mm)
Tripping Conditions:
• Suction pressure low
• Electric failure
Tripping Conditions:
• Tank level very low
• Electric failure
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Tripping Conditions:
• Electric failure
• Tank level low low (0.5 m)
• Suction valve not open
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STRESS COMPUTER
OBJECTS OF STRESS COMPUTER
THE MAIN OBJECTS OF THE STRESS COMPUTER ARE:
1) TO QUANTIFY STRESS LEVELS IN THE ROTOR AND STATOR MASS:
2) THE CRITICAL AREAS OF THE STEAM TURBINE, DURING STABLE OR TRANSIENT
CONDITIONS.
3) TO MAINTAIN PERMANENTLY STRESS LEVELS WITHIN PREDEFINED LIMITS
WHAAATEVER THE ST RUNNING WAY MAY BE.
4) TO ASSIST THE DCS AND ESPECIALLY THE REC 920 SYSTEM BY CORRECTING THE
DRIVI IN THE REAL TIME.
5) TO PROVIDE MANUAL ASSISTANCE WHEN ST RUNNING IS CARRIED OUT IN
MANUL MODE
GAP
PICK UP MEASURE
THE ELECTRONIC GENERATES A VHF ELECT SIGNAL ON THE TIP OF THE PICK UP.
THIS GENERATES A MAGNETIC FIELD. THE ROTATING SHAFT ABSORBS SOME ENERGY
THIS ABSORBTION EFFECT PLACES AN ELECTRICAL LOAD ON THE ELECTRICAL SIGNAL
THEREBY REDUCING ITS STRENGTH. THE AMOUNT OF LOADING IS INVERSLY
PROPORTIONAL TO THE DISTANCE BETWEEN THE COIL AND THE SHAFT. THE CLOSER
THE SHAFT THE GREATER THE LOADING EFFECT AND THE SMALLER THE AMOUNT OF
CARRIER SIGNAL.
AS THE SHAFT MOVES RELATIVE TO THE TIP OF THE PICK UP THE STRENGTH OF THE
ELECTRICAL SIGNAL CHANGES PROPORTIONAL TO THE MOVEMENT. THE SIGNAL
SENSOR PROVIDES AN AC SIGNAL VOLT PROPORTIONAL TO VIBRATION AND A DC
SIGNAL PROPORTIONAL TO THE GAP.
THSES PROBES ARE FITTED WITH THE TIP OF THE TRANSDUCER IN CLOSE PROXIMITY TO
THE ROTATING SHAFT. THIS DISTANCE BETWEEN THE TIP O F THE TRANSDUCER AND
THE SHAFT IS CALLED THE GAP. THIS GAP IS VERY CRITICAL AS IT DETERMINES
CALIBRATION OF THE SYSTEM, AT KAWAS THIS GAP IS KEPT AT 1 MM.
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In KGPP there are different A.C. and D.C. voltage levels to meet the power and control requirements of
various systems. A.C. system consist of 230 V, 415 V, 6.6 KV, 11.5 KV and 220 KV.
230 V AC system is used mainly for lighting, UPS and space/motor heating purpose.
415 V systems are used for Auxiliary motors in Gas turbine and Steam Turbine including common station
auxiliaries.
6.6 KV systems can be called as main source of power for complete powerhouse. We are having 2 Nos.
6.6 KV bus namely 1CLGA & 2CLGA getting power through 220 KV/6.6KV Station transformer I & II
respectively. From 6.6 KV systems we are having various step down transformer for 415 V systems of
GTs, STs and common plant auxiliaries. A few 6.6 KV motors are also there, namely cranking motors for
Gas Turbines, CW motors and HP BFP motors for Steam Turbines.
11.5 KV is the generator (GTs and STs) rated terminal voltage. The output voltage of generators in turns
stepped up to 220 KV by Generator Transformers and connected to the 220 KV systems.
220 KV systems are used for the transmission of bulk power being generated by our power station.
D.C. system consist of 220 V, 125 V& 48 V levels:
220 V D.C. systems are used for emergency lighting purpose, in case of complete black out.
125 V D.C. systems are used as control voltage for complete power plant except the process controllers/
computers and also to power emergency motor drives.
48 V D.C. system is used for process controllers/ solenoid valves of STs and GTs
Batteries:
• Batteries used for DC system is of Electrolytic type.
• Each battery is of 2.2 V and specific gravity of electrolyte used is of 1260.
• Numbers of batteries are connected in series to form the required system voltage.
In normal condition the plant batteries are floating on the chargers. Charger takes the load requirement of
system in normal condition. In case of emergency i.e. total A/C power failure, batteries come to supply the
load of the system. So batteries are the most vital equipment in emergency. Therefore
• Regular maintenance and condition monitoring of batteries is very important aspect of plant operation and maintenance.
• Room for batteries is to be maintained clean and well ventilated with proper arrangement of fire fighting/ detection system.
Each UPS is designed to supply the total load of both the switchboards.
• In normal operation individual switchboard is charged by respective UPS with two inverters in parallel operation.
• In case of one inverter failing, the other can supply total load of the switchboard.
• Each battery system is sized to supply the normal load of two inverters for one hour or the load of two UPS system for half
an hour.
• Each charger is capable of supplying the load of two inverters and also to charge batteries.
• Total no. of cells for each UPS DC system is 108.
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In normal configuration station transformer 1 and 2 independently feed power to bus A and B respectively.
In this condition the breakers A, B, C and D are closed, bus coupler breaker E – open, DG incomer
breaker F&G to both buses open.
Once the change over selector switch is in auto mode, the auto-changeover healthiness is indicated by a
lamp in the panel.
Now if one transformer trips on some fault (except on bus fault) the tiebreaker closes and feeds the load.
The tiebreaker has two closing modes:
1.1 QUICK CHANGEOVER:
In this mode, the tiebreaker closes almost immediately after one transformer tripping. Thus none of the
running feeders trip during the changeover transient. But this scheme will be enabled only when the
voltage level in the tripped bus has not fallen below 90% and vector shift between two buses is less than a
certain permissible value. Otherwise only slow changeover will occur.
1.2 SLOW CHANGEOVER:
In this mode, the tiebreaker closes after the voltage level in the tripped bus has fallen below 70% of
normal value. This is a delayed changeover inevitably result in tripping of the motor feeders on under
voltage protection. If slow changeover also fails, DG set starts and corresponding incomer breaker will
close.
One 6.6 KV, 3 MVA Diesel generator (Black start) installed in the station works as emergency power
source during network failure or total station A/C failure. Beside it can also meet the start-up power
requirement of one GT.
The control system of the black start senses under voltage in any of 6.6 KV bus to initiate a start order
with 15 sec time delay.
415 V System:
In 415 V MCC with bus coupler arrangement, the automatic changeover is simple. If one of the auxiliary
transformer trips (except on over current or MCC fault) the tiebreaker closes automatically.
Note:
i) The control scheme for 6.6 KV and 415 V systems does not allow paralleling of two transformers in auto or manual mode.
ii) Paralleling of black start with line station transformer is allowed in the control scheme.
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a) Close the Transfer Bus Isolator of generator feeder (D). Before closing we have to confirm that there is no other feeder
connected to T.B.C. Also confirm healthiness of Transfer Bus.
b) Now close the transfer Bus isolator (G) of Transfer Bus Coupler.
c) Close Bus-II Isolator either (E) or (F) of Transfer Bus Coupler.
d) Now close the Transfer Bus Coupler breaker (2), by putting synchronising switch in check position. Before this the bus
transfer switch at Generator is to be made ON.
e) Confirm the operation done is all right and generator output is being shared by generator Feeder and Bus Coupler Feeder.
This can also be confirmed by seeing the ammeters.
f) After confirmation, trip the Generator Breaker (1) and open the respective Bus Isolator (either (A) or (B) and line isolator
(C) of Generator Feeder.
Above described procedure is true for all the feeder connected to 220 KV Switchyard. The only difference
between generator feeder with line feeder is that generators can only be synchronised from CCR/LCR.
Whereas lines are to be synchronised from switchyard control room.
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On fulfilling the above starting conditions, start one CRF pump at sub group level. On giving start order,
the lubricating water valve to CRF pump opens; then pump would start, followed by automatic opening of
its discharge valve.
The condenser water box vent valves are to be closed after venting of CW discharge system.
4. START-UP OF ARCW SYSTEM:
Line up:
• ARCW pumps suction valves are open.
• Suction pressure is above 0.5bar.
• Heat exchanger inlet/outlet valve for ARCW systems in open
• Discharge valve open
When the above conditions are fulfilled, two ARCW pumps can be started and 3rd pump can be kept
standby.
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ELECTRICAL SYSTEM
NORMALISATION
APH/APB START
TURNNING GEAR
START
HP & LP BOILER-A
FILLING
GFR START
ST RESET
HRSG- B START
HRSG – B COUPLING
ST LOAD TO 100 %
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With the above conditions satisfied, one AC lube oil pump may be started at sub group level. Check for
any oil leakage in the field. See the lube oil header pressure is maintained about 2 bar by the pressure
control valve.
Now steam turbine turning gear can be switched on at sub-group level.
After the start order, all the six jacking oil pumps will take start, followed by starting of turning gear
motor. Then, the coupling between steam turbine and turning gear motor will get engaged. Once the
turbine normal speed is reached, then the jacking oil pumps will stop automatically.
Ensure from field that no abnormal sound is detected from turbine after starting turning gear.
6. MAKEUP WATER (CAP) SYSTEM STARTUP:
Check:
• CAP tank make up filling line is lined up.
• Condenser hot well drains are closed.
• Hot well level transmitter vessel; isolating valve are open.
• Manual isolating valves in the Hotwell filling and dump line are open.
Starts the CAP pumps for hot well filling & keep emergency and normal make up valves open. Once the
normal level is reached close the emergency make up valve UV001.
After proper line up of CEX system, two condensate extraction pumps can be started one by one in
subgroup or group level. When a pump is started, discharge valve of the running pump open
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automatically. (If the operation is done at group level, then the discharge valve of standby pumps also
open after starting of first pump).
Ensure that a minimum flow of 125 t/hr is established through the condensate recirculation valve. Now
start ADG (feed storage tank) filling by manually regulating the hot well level control valve. Fill the ADG
tank to 2200 mm level. Prior to ADG tank filling, confirm that the tank over flow line manual isolating
valve is open, tank drain valve is closed and the level transmitter vessel in charged.
When condensate system is in operation, chemical dozing system must be started in consultation with the
plant chemist to maintain the water quality.
After fulfilling the above conditions, one APH pump can be started at subgroup level.
On group/sub group start order; the lube oil pump starts first, followed by main pump.
Simultaneously pneumatic cooling water valve opens. The discharge valve also opens automatically and
thus the pump runs on recirculation. Once an APH pump is in service, the shaft driven lube oil pump
develops sufficient lube oil pressure. So the auxiliary lube oil pumps stops.
Before HP boiler drum filling, hot well level control can be selected on auto.
HP BOILER FILLING:
PRE START CHECKS:
• Drum vents and super heater vents & drains open
• EBD valve is closed.
• Economiser inlet valve open.
• Motorised isolating valves of both high range feed regulation streams closed.
• Drum level transmitters charged.
Now open the inlet/outlet motorised valves of low range feed control valve (LRFCV). Gradually open the
LRFCV to charge the feed line. Feed line vent valve can be closed as soon as water starts coming out.
Fast opening of feed control valve before filling the economizer may cause severe water hammering. This
may result in valve actuator failures and breakage of hanger support of pipelines. Hence feed line charging
should be always done by low range control valve cautiously.
Once the economiser is filled, drum level starts building up. On reaching about 800 mm level the feed
control valve is to be closed (During filling period it is advisable to operate all controls manually, as the
controller response during the transient phase is not smooth). Watch ADG tank level and hot well level
during boiler filling.
Along with boiler filling HP dozing may be started according to chemist advice.
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Now open the motorised inlet/outlet valve of LRFCV. Open the low range feed control valve gradually in
manual mode for economiser charging. Once the feed lines are vented, the manual vents can be closed.
Bring the LP drum level up to about 800mm, then close the feed control valve.
PRESTART CHECKS:
• Suction and discharge valve open.
• Cooling water inlet/outlet valves open.
• Suction line is vented.
• Drum level is about 800 mm.
• Economiser recirculation valve on auto mode.
• Start one FLH pump in subgroup level.
Following the start order, the economiser recirculation line inlet & outlet motorised valve opens.
Simultaneously the pump would take start. The selected HP economiser recirculation valve opens to
100%. When evaporator is empty, then with the pump running there will be initial drop in the drum level.
This needs to be supplemented by the feed control station.
The function of economiser recirculation valve is to maintain minimum flow through the HP economiser
at low boiler load. Otherwise it may lead to steaming in economiser tubes, which subsequently causes
hammering when the feed control valve opens to supply water to boiler. As the boiler load increases the
recirculation control valve is closed.
PRESTART CHECKS:
• LP drum level is about 800 mm.
• Suction and discharge valve open.
• Economiser recirculation valve is on auto mode.
• Vent the FLB suction line.
Start one FLB pump in subgroup level. Economiser recirculation motorised valves and control valve opens
automatically also, the LP economiser recirculation control valve opens. LP economiser recirculation
valve performs the similar task as HP economiser recirculation valve.
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LP superheated drain will close automatically when steam flow reaches 8 t/hr in LP circuit and HP
superheated drains close automatically when steam flow in HP steam line reaches 20 t/hr.
• ADG subgroup can be switched on. Deaerator heating will start on manual opening of UV
005 with steam from LP circuit.
• When condenser pressure reaches 350 m bar absolute, open the HP/LP bypass isolating valves.
• HP steam pressure on reaching 32 bars, HP bypass control valve starts opening followed by opening of one spray valve.
• Similarly LP bypass control valve opens when LP steam pressure reaches 5 bar.
• HP bypass control works on sliding pressure set point mode i.e. the upstream pressure set point increases with main steam
flow. (Sliding pressure set point characteristics is different for one boiler configuration from two boilers configuration).
• LP bypass controller works on constant pressure set point mode and maintains 5 bars.
If the downstream pressure of HP bypass reaches 11 bar, second spray valve opens to maintain the
downstream temperature within limits.
• Water level in the drum decreases as steam flow reaches about 25% of the design flow, the level control system will switch
over from low range control valve (single element control) to high range control (Three element control) and drum level
set point will automatically shift from 800 mm to 1100 mm gradually. (Level set point evolution takes place only when
auto set point is selected, for manual set point automatic evolution does not occur).
• As the steam flow increases the economiser recirculation control valve starts closing & at about 35% rated feed water flow
to economiser, the recirculation control valve closes fully .
• ADG tank pressure is maintained at 1.15 abs bar by LP steam control valve.
• Open the LP header valves in subgroup level.
• Check water and steam quality from SWAS table and through chemical analysis, only when required purity has reached,
steam turbine start up should be attempted. Otherwise continue steam dumping in condenser through HP/LP bypass and
carry out continuous blow down from HP/LP drum till water/steam quality improves.
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PRESTART CHECKS:
• Control fluid pump in service at subgroup level and control oil pressure more than 80 bar.
• Lube oil manifold pressure more than 1.6 bar.
• All HP/LP manual-isolating valves of turbine drains (GPV) open, also pneumatic drain valves.
• LP exhaust hood spray manual isolating valve open.
• All HP/LP turbine control valves closed.
• Turbine speed more than 33 rpm.
• Stress computer influence in service.
• All turbo supervisory parameters instrumentation healthy.
• One boiler in services with its LP/HP header valves open.
Depending on HP turbine metal temperatures, turbine start-up is broadly classified into three
categories. As:
COLD STARTUP: HP casing temperature less than 330°C
i.e. about 20 hrs after shutdown.
The start-up of steam turbine can be accomplished in different modes viz. Automatic,
Semiautomatic or Manual.
AUTOMATIC MODE:
Once the start order is initiated by the operator through KCS controller, following sequence of operation
will occur.
• Steam turbine reset, HP/LP stop valves are opened and warming up of HP stop valve and control valve body begin.
• When stop/control valve body metal temperature reaches 310 °C, warm up is authorised & turbine speed increases to warm
up speed. The accelaration rate is controlled by stress computer.
• As the turbine accelerates from turning gear speed, the centrifugal clutch of turning gear is disengaged and at 600 rpm
turning gear motor stop automatically.
When warming up period has elapsed, (this period is about 40 minutes for cold start up & 10 minutes for
warm start up. In case of hot start up turbine does not stay at warm up level but accelerates to excitation
speed without any halt) excitation speed will be selected by the controller and turbine accelerates towards
excitation speed (2850 rpm).
• The turbine stress computer does not exert any influence on accelaration during the evolution through critical speed
(exclusion zone is 1900 to 2700 rpm).
• A too high metal stress detection from stress computer stops the speeding of turbine until the stress is low again (This is
inhibited in critical speed zone).
The operator has to constantly monitor the following turbo supervisory parameters during the startup
process.
1) HP/LP diff. expansion
2) Axial shift
3) Vibrations
4) Bearing temperature
5) HP/LP turbine exhaust temperature
6) HP turbine casing metal temperatures
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• On reaching the excitation speed generator field breaker closes automatically and rated voltage develop across the
generator terminals (11.5 KV).
• If the stress margin allows, synchronising speed will be selected and turbine accelerates to rated synchronising speed (3000
rpm).
• On reaching synchronising speed synchroniser will be activated and automatic coupling will take place after matching
generator parameters with grid.
• After synchronision a minimum load of 5 MW is taken by the generator, thereafter turbine load increases according to the
selected slope depending on the turbine metal condition (Three load rate ramps are shown in CGRE-41 view. Of which the
first one is for cold condition, middle ramp for warm and the last one will be selected when turbine casing becomes hot
enough).
• As the HP control valves open gradually, HP bypass valve starts closing as per the sliding pressure set point
characteristics.
• At 15% turbine load diverter damper of boiler in service opens from 75% to 100%.
• At 25% steam turbine load, LP control valve opens and limits the LP steam pressure below the constant pressure set point
of LP bypass valve. So LP bypass control valve starts closing.
• Also all turbines drains (GPV) closes provided condensation is not detected in any drain pot except LPCV/Line drains
which will close after 30mins time delay. Further, LP turbine exhaust spray solenoid valve is to be closed provided exhaust
temperature is normal above 30MW Load.
• When ST load reaches 50% both HP & LP bypass control valves will have closed (considering that one boiler is in
service). Further load raise is possible only when 2nd GT and HRSG are brought in service.
Also seal steam supply control valve PCV 001 closes fully and leak steam control valve PCV 002 starts
opening. With this change over, seal steam pressure set point will move from 1.15 abs bar to 1.25 abs bar.
As the ST load reaches 100% the start-up process of one module comprising of two GT, two HRSG and
one ST can be considered completed.
SEMI AUTOMATIC MODE STEAM TURBINE START-UP:
In this mode Steam Turbine start-up also, the stress computer influence regulates the speeding and loading
of steam turbine. But in this start-up, the operator has to perform the following actions according the
authorisation messages displayed on the CRT screen by stress computer.
1) Turbine reset
2) Turbine warm-up speed
3) Turbine excitation speed
4) Excitation breaker closing
5) Synchronising speed
6) Synchronising
7) HP/LP load mode selection
MANUAL MODE:
In this mode, the operator has to reset the turbine through manual order and roll the turbine by manually
raising the speed set point. All the steps described in auto and semi auto mode have to be performed
manually in this case.
CAUTION: IN THIS MODE, THE STRESS COMPUTER DOES NOT CONTROL THE
ACCELATATION OF TURBINE. HENCE TO AVOID THE RISK OF CROSSING THE TURBINE
STRESS LIMITS, OPERATOR IS ADVISED TO FOLLOW THE STRESS COMPUTER MESSAGES
DISPLAYED ON CRT SCREEN BEFORE ADVANCING FROM ONE STEP TO ANOTHER.
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In manual mode, the stress computer does not act on the steam turbine control. However, the stress
computer elaborates the same messages as in the automatic/ semi-automatic mode to guide the operator for
his decision.
The range of rotor/stator stress margin displayed on operator terminal from –1 to +1. The value –1
corresponds to worst condition. +1 corresponds to the best condition. In normal operation, the stress
margin has a positive value between 0 to 1.
The rotor stress margin is a function of:
- Centrifugal stress owing to its angular velocity.
- Thermal stress due to temperature gradient.
The stator stress margin is a function of the following:
- Pressure stress
- Thermal stress due to temperature gradient.
Authorisation request
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Temperature gradient:
Under severe conditions caused by steam temperature drop; the TG must be MANUALLY TRIPPED in
order to avoid any major damage.
TG Unit Sped:
The machine can run from 94 to 101% its nominal speed without danger.
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During the tests, it is advised to check the valves trouble free operation not only from CCR signals but
also locally by an observer who can readjust an inoperative limit-switch if necessary.
These tests shall be carried-out once a week, by resetting turbine, irrespective of unit is running or not.
-(D) and (E) tests shall be performed as per instructions given in document.
It is clear that the “ lube-oil” sequence must run for (D) tests and “control fluid” sequence for (E) tests,
irrespective of unit is running or not.
- (F) tests shall be performed once a day at least, by resetting turbine, irrespective of unit is running or not.
The tests described hereinafter must be carried-out in presence of the operator locally:
• Either to perform the required operations for test progress,
• Or for breaking off the tests for safety’s sake.
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Like the level tests at lube-oil tank, these tests must be carried-out for “control fluid” once a year at least,
during the “control fluid” sequence restart after a shutdown but before starting the unit again.
Turning- gear safety test:
The purpose of this test is to check the turning gear stoppage when the lube-oil pressure detected by PSLL
035 pressure-switch is below 0.4 bars.
The following test procedure shall be applied:
• Close the shut-off valve on the pressure-switch.
• Drain the pressure-switch.
• Then locally check the stoppage of the turning gear.
• Shut the drain valve on the pressure-switch & then open the shut-off valve.
• Start the turning-gear again.
This test must be performed once a year at least, with the turning-gear engaged.
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6. SUMMARY:
The following table summaries all the tests to be performed, with their periodicity and
references.
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PDSH 034 High pressure drop at Shift to the other filter-Clean the filter that was
F double filter ½ FI running
p < 0.8 bar
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PSLL 048 Very low lube-oil pressure Same action as PSL 044 (G) above.
p< 0.8 bar
Starts the emergency pump
PO2
PSLL 045 Very low lube-oil pressure
PSLL 046 p< 0.8 bar
PSLL 047 Automatic trip of turbine
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BEARING-BLOCKS
High temp at counter- Watch the evolution of these temperature s
TE 151 thrust bearing metal 1-Problem at lube-oil
TE 152 Thrust bearing (alarm 2-Problem at thermostatic valve
TE 153 HP journal bearing temp 3-Excessive thrust-bearing load –at next
TE 154 (t> 70°C) shutdown, disassemble the thrust-bearing and
TE 155 Manual trip if t > 105°C check the free motion of lifting pads
4-Too tight clearance at thrust or journal bearing
Increase the pressure
I TE 156- 184 Reduce the temperature (if possible-replace the
TE 157- 185 Inlet journal bearing- thrust shim). Replace the journal-bearing
TE 158 temp high alarm t> 85°C ( recondition the damaged journal bearing)
TE 158 5-Babbit metal chipping due to foreign matters
-Replace the thrust or journal bearing after
TE 175 shutdown.
To Manual trip if t >95°C -Check the lube –oil system cleanliness
TE 180 -Recondition the faulty thrust or journal-
bearing
6-Misalignment (refer to vibration level) adjust
the alignment at next shutdown.
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STEAM SYSTEM
Item no. Function Cause & Required action
CET TSH 135 High temp at turbine 1-Operation at low load with poor turbine
exhaust t > 80°C. efficiency.
Start the LP casing 2-Poor vaccum. Refer to condenser and
spraying system circulating pump operation. Detect air
ingress into condenser.
GSE TSHH 141 Very high exhaust 3-Check LP gland supply steam temperature
P GSE TSHH 142 temperature t > 100°C on TE 170 valve and the operation of TY
GSE TSHH 143 Automatic trip of the 003 desuperheating valve: shift it to
steam turbine manual operation in case of problem in
automatic mode.
GSE PSHH 066 Very high exhaust
GSE PSHH 067 pressure p > 0.2bar
GSE PSHH 068 absolute.
Automatic trip of the
steam turbine
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R VE 314 High turbine shaft eccentricity > Turning gear is engaged; keep it running
80 microns until the high eccentricity alarm stops
Very High eccentricity > 120 before starting the unit again.
microns. If the eccentricity is very high, stop the
Stop the turning gear turning gear and turn the unit manually
by 1/3 of a turn every 15 min on lifting
pumps, until the alarm stops.
S ZE 352 Thrust-bearing wear 1-Slow increase, without abnormal temp
High <-0.59 mm or raise. Wait for very high alarm to trip
>+0.59 mm the unit and replace the thrust shoes.
Very High <-0.945 mm or 2-Fast increase with temperature rise:
>+ 0.945 mm Trip the turbine immediately, inspect
Manually trip turbine and repair the thrust bearing.
T ZE Absolute Expansion Excessive inlet steam temperatures:
High >14.5 mm alarm Watch boiler superheater outlet temp and
Very High>15.5 mm adjust desuperheating.
Manually trip turbine
U ZE HP Differential Expansion 1-Fast variations of inlet temperature:
High <-5.5 mm & >+2 mm refer to boiler superheating, or correct
Very High <-6 mm & >+2.2 mm the turbine speedup at startup.
Manually trip turbine 2-Too fast load variations; correct, read
stress computer
3-Casing strains due to metal temperature
differences: read stress computer
4-Sliding surfaces badly lubricated:
check it at next shut down and
lubricate with molybdenum disulphide
5- Poor casing heat lagging: make
another lagging at next shutdown
6-Exhaust temperature rise: refer to P
above.
If the over current result in the tripping of the turning motor, manually turn by 1/3 of a turn every
20 minutes.
3 - Electrical problems in the start up cubicle: refer to the turning gear documentation. Detect the anomally and repair.
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