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DOCUMENT SUBMISSION STATUS: FOR CONSTRUCTION

7 02.10.2018 FOR CONSTRUCTION Y.G.SOHN H.W.NAM J.H.PARK


6 21.11.2017 FOR CONSTRUCTION S.C.KANG H.W.NAM K.H.KIM
5 30.08.2017 FOR CONSTRUCTION S.C.KANG H.W.NAM K.H.KIM
4 17.07.2017 FOR CONSTRUCTION S.C.KANG H.W.NAM K.H.KIM
3 06.04.2017 FOR CONSTRUCTION H.J.LEE H.W.NAM K.H.KIM
2 05.09.2016 FOR CONSTRUCTION H.J.LEE H.W.NAM K.H.KIM
1 26.05.2016 FOR CONSTRUCTION H.LEE H.W.NAM J.HWANGBO
0 24.12.2015 FOR CONSTRUCTION H.LEE H.W.NAM J.HWANGBO
REV DATE DESCRIPTION PREPARED CHECKED APPROVED

PROJECT TITLE

SONG HAU 1 THERMAL POWER PLANT (2x600MW)

OWNER OWNER’S CONSULTANT

VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING

EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT

VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES


CORPORATION (LILAMA) COMPANY LIMITED - TEPSCO
SUB-CONTRACTOR

DATE NAME SIGN DOCUMENT TITLE

PREPARED 02.10.2018 Y.G.SOHN

System Description -
CHECKED 02.10.2018 H.W.NAM
Feedwater system
APPROVED 02.10.2018 J.H.PARK

DOCUMENT NO. REV.


SH1-DHI-P1LAB-M-M01-PHL-5306 7
SONG HAU 1 THERMAL POWER PLANT PROJECT

CONTENTS

1. INTRODUCTION................................................................................................................ 2
2. SYSTEM / COMPONENT DESCRIPTION ..................................................................... 2
3. DESIGN CRITERIA ........................................................................................................... 6
4. MODE OF OPERATION ................................................................................................... 8
5. INSTRUMENTATION AND CONTROLS .................................................................... 12
6. ELECTRICAL SERVICES .............................................................................................. 18
7. CODES & STANDARDS .................................................................................................. 18
8. REFERENCES ................................................................................................................... 19

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1. INTRODUCTION

This document provideds a general system description for the Feed Water System for Song Hau 1
Thermal Power Plant Project. This document shown for one(1) unit only, Unit#2 is identical to the
Unit#1.

2. SYSTEM / COMPONENT DESCRIPTION

2.1. System Function and Flow Path Description

The Feedwater System supplies the required quantity of high pressure feedwater to the boiler
during start-up, shutdown, and normal unit operation. The boiler feed water start up pump and
booster pumps of main boiler feed pumps obtain their individual suction supply from Feedwater
storage tank. The booster pumps of main boiler feed pumps then supply suction flow to the main
boiler feed pumps, which increase the fluid pressure to meet the required system head.

The feedwater flows through three high-pressure feed water heaters where extraction steam heats
the feed water. This results in improved cycle efficiency:

The Feed water system provides the following functions:

 Receives water from condensate system and removes dissolved gases from condensate
by elevating its temperature in the Deaerator and stored in the feedwater storage tank.
The initial filling of the feed water storage tank will be done through condensate
transfer pump.

 Delivers feed water to the economiser section of the boiler at start up, low load, normal
and shutdown conditions through high pressure feed water heaters to recover heat from
the extraction steam and adds the same as sensible heat.

 Provides feedwater to the superheater attemperators from upstream of economizer inlet

 Provides feedwater from the start-up & main boiler feed pump interstages to the
reheater attemperators.

 Provides feedwater from the start-up & main boiler feed pump discharge header to the
HP BYPASS spray.

The Feedwater System supplies the required quantity of high pressure feedwater to the boiler
during start

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2.2. Chemical dosing Description for Feedwater System

Concentrated ammonia solution is Diluted to 0.5% for OT mode and 10% for AVT mode in
ammonia solution Tanks. Line P1QCD41BR001(Ammonia) is used to dose diluted ammonia to
the Main BFP suction Line with the help of 3x50% Ammonia dosing Pumps. When unit is
operated according to OT mode sufficient ammonia will be dosed to maintain feed water line to
maintain pH in the range of 8 - 8.5.when the unit is operated according to the AVT mode then
sufficient ammonia is dosed to maintain pH in the range of 9.2 -9.5.

When the unit is operated according to OT mode oxygen will flow out of cylinders connected to
the manifold. Line P1QCE41BR001(Oxygen) will be dosed to the feed water line and feed water
oxygen concentration will be automatically maintained in the range of 30 to 150 parts per billion.
No oxygen will be dosed in AVT mode.

2.3. Major Equipment

Feed water system will have the following major components:

 Deaerator with Feedwater storage tank.


 Motor driven start-up boiler feed pump (1 x 30%)
 Steam turbine driven main boiler feed pumps (2 x 50%).
 High pressure feed water heaters (HPH-6, 7 and 8)
 Start-up feedwater control valve

2.3.1. Deaerator

The deaerator provides the following functions;

 Deaerator will be provided to remove dissolved gases, primarily oxygen and carbon
dioxide from the incoming condensate.
 Heat the condensate to saturated conditions with steam extracted from the turbine, thus
improving cycle efficiency

Deaerator will be horizontal spray-tray type heater in which inlet water will be sprayed into
steam atmosphere and falls onto a bank of trays through which the steam passes. And Spray-Tray
type deaerator has utilizing the two stage method.

 1st stage : The Condensate flows through Accu-spray valve and reaches the tray stack.
Virtually almost dissolved oxygen and non-Condensable gas have removed.

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 2nd stage : The Condensate flows over the tray assembly passing through a counter-
current pure steam. Then, condensate flows into a storage tank.
A vent condenser provided will be integral with deaerator to minimize steam loss.

The deaerator will be supplied with extraction steam from the turbine IP stage and will normally
operate at a variable pressure depending on the extraction pressure at different loads. A steam
connection from the auxiliary steam header / cold-reheat pipe will be provided for initial
heating( = warming) and deaeration at start-up, low load operation, HP Bypass operation as well
as Pegging at low extraction steam pressure. The Deaerator will have a material of Carbon Steel
and designed as per latest edition of HEI standard for deaerators.

2.3.2. Feedwater Storage Tank

Primary Function of Feed water storage tank will be to provide storage at feed pump suction so
that disturbances at the upstream of the pumps will be accommodated.

Feed water storage tank will be a horizontal cylindrical steel vessel with dished ends located
below the deaerator which contains a specified volume of deaerated water. Deaerated water flows
from deaerator outlet to the feedwater storage tank through downcomers and maintains equal
pressure between the deaerator and storage section by equalizers. The start-up pump & booster
pump of main boiler feed pumps take suction from the feed water storage tank separately.

Deaerator and its storage tank assembly will be provided with two (2) supports – one will be
fixed type and the other will be sliding type. This is to allow the assembly to have free linear
expansion along one direction maintaining stability on supporting structure/ floor.

The Feed water storage tank will be having material of Carbon steel and will be designed as per
HEI standard. The storage capacity will be of five (5) min at VWO condition.

When operating in AVT (All Volatile Treatment) mode the design dissolved O2 content of
deaerated feedwater at the feedwater storage tank will be maintained under 7ppb without any
chemical dosing.

The chemical dosing (to control the pH) will be controlled in demi. water system before you fill
with demi.water in the deaerator. also, The pH can be adjusted by BFPM minimum recirculation
operation before initial filling. In case of normal operation, the chemical dosing will be adjusted
in condensate system before entering the water to the deaerator. And if do not meet the pH 9 in
the condensate system, the chemical dosing will be adjusted in BFP suction line before pumping
the feedwater to the boiler.

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2.3.3. Start-up Boiler Feed Pump – Motor Driven

One (1) x 30% capacity motor driven, variable speed start-up / back-up boiler feed pump is
provided. The pump will be horizontal, multistage, centrifugal type. Feed pump is provided with
a minimum recirculation flow control to protect the pump under low load operation.

The start-up feed pump shall take suction from the deaerator storage tank to provide boiler
feedwater during start-up and other operating conditions. The start-up pump will be operated in
parallel with a single main boiler feed pump as a back-up for the non-operating main pump set.

Pump has a self-contained forced lubricating oil system for the bearings. The lubricating oil and
the sealing arrangement of the feed pump are cooled by a closed cooling water system. All
necessary protective and supervisory system provides safe and trouble-free operation of the feed
pump.

All necessary connecting pipes, supports, base plates, supporting steel structures, mountings, and
fittings, vent and drain valves, strainers etc will be provided.

2.3.4. Main Boiler Feed Pump – Turbin Driven

The boiler feed pump turbine driver will be designed such that the maximum operating efficiency
(optimum thermal performance) will be at the normal 100% TMCR with drive extraction steam
from the Intermediate-Pressure main plant turbine. During start up, low load condition and
during any abnormal condition extraction steam will be supplied from auxiliary steam header /
cold-reheat pipe. Also, steam is supplied from cold reheat line when load rejection. If for any
reason BFPT require higher driving force, main steam system will supply main steam to BFPT.
The boiler feed pump turbines will be condensing type with the steam exhaust to the main
condenser.

To reduce pressure of feedwater leaked into bush seal, gland by-pass line is supplied between
BFP to BP suction.

Each Main BFP will be directly coupled with respective auxiliary steam turbine drive and
reduction gear box will be installed between auxiliary steam turbine drive and booster pump.
Hence the booster pump runs at a reduced speed (RPM) with respect to auxiliary turbine drive
speed and help in maintaining required NPSH to booster pump of Main Boiler feed pump under
all conditions.

2.3.5. High Pressure Feedwater Heaters

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There are three (3) Nos. HP heaters provided in the circuit between boiler feed pumps &
economizer. Feedwater is passed through tubes and absorb heat by convection while extraction
steam passing on shell side.

Each HP heater will be provided with an individual bypass line on the feedwater side, so that the
heaters can be taken out of the service without disturbing the plant operation.

The HP heaters shall be shell & tube type (horizontal orientation) with feedwater flowing through
the tubes.

Each HP heater is having three (3) zones namely desuperheating, condensing & sub cooling
zones on shell side and having two (2) passes on tube side

2.3.6. Start-up Feedwater Control Valve


Start-up feedwater control valve with isolation MOV at upstream and manual isolation valve is
provided.
During low loads when start up boiler feed pump is in service, the feed water to boiler will be
controlled by start-up control valve at downstream of HP heater # 8.

2.3.7. System Piping

The following table represents the operating parameters for the various feedwater piping.

Design Design
Size Flow1) Velocity
KKS no. Description Temperature Pressure
(DN) (ton/hr) (m/s)
(℃) (bar.a)
P1LAB11BR001 Startup BFP Suction 500 178 13.0 151.68 0.88
P1LAB12/13BR001 Main BFP A/B Suction 650 178 13.0 252.79 0.88
P1LAB21BR001 Startup BFP Discharge 300 184 350 151.68 3.38
P1LAB22/23BR001 Main BFP A/B Discharge 450 184 350 252.79 3.53
P1LAB50BR001 BFP Disch. HDR 600 184 350 505.59 3.47
P1LAB50BR002 HTR No.6 to HTR No. 7 600 310 350 505.59 3.63
P1LAB50BR003 HTR No.7 to HTR No. 8 650 310 350 505.59 3.31
P1LAB50BR004 HTR No.8 to Eco. Inlet 650 310 350 505.59 3.56
HDR
Note 1) VWO condition.

3. Design Criteria

3.1. Design Pressure


3.1.1. Main BFP Suction Pipe Pressure

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The design pressure of feed pumps suction piping is the sum of design pressure of deaerator and
static pressure at pump suction (HHWL of storage tank – CL of main BFP pump suction of main
feed water pump) at deaerator operating temperature at VWO condition.

3.1.2. Start-up BFP Suction Pipe Pressure

The design pressure of feed pumps suction piping is the sum of design pressure of deaerator and
static pressure at pump suction (HHWL of storage tank – CL of start-up BFP suction) at
deaerator operating temperature at VWO condition.

3.1.3. Discharge Pipe Pressure

The design pressure at discharge side will be as follows:

 Upstream of main boiler feed pump(turbine driven) discharge shut-off MOV–


105% of the main BFP shut-off pressure at hot condition at 110% overspeed ÷ 1.2.
Applicable suction pressure will be added to this.

The above is assuming that the 10% over-speed condition will occur concurrently with maximum
head for no more than 1 hour at any one time and not more than 80 hours per year.

 Downstream of boiler feed pump discharge shut-off MOV –


Maximum sustained pressure (Lowest SH outlet safety valve set pressure + Pressure
loss from BFP shut off MOV downstream to SH outlet safety valve at VWO+ static
pressure) plus a 5% design margin.

In order to allow the reduction of pressure from the boiler feedwater pump discharge
isolation valve up to and including the final feedwater heater discharge isolation valve
and bypass valve, interlocks shall exist ensuring that the feedwater heater outlet
isolation valves open before the inlet isolation valves, ensuring that bypass valves open
prior to closing feedwater heater isolation valves, and ensuring that feedwater heater
bypass valves close only after opening of both feedwater heater inlet and outlet
isolation valves.

 Upstream of start-up feed pump discharge shut-off MOV –


The bigger of Downstream of boiler feed pump discharge shut-off MOV and Start-up
BFP shut-off pressure at cold condition + applicable suction pressure.

3.2. Design Temperature


3.2.1. Suction Pipe Temperature

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The design temperature of the feed pumps suction line is the saturation temperature
corresponding to deaerator design pressure.

3.2.2. Discharge Pipe Temperature

The design temperature of the feed pumps discharge line shall be as follows:

 BFP discharge to HP Heater # 6 Inlet.


The design temperature of feed pump discharge line to HP Heater # 6 inlet is the sum
of BFP suction line design temperature and temperature rise across the BFP train at
VWO condition plus a margin of 5.560C (10’F).

 HP Heater # 6 Outlet to HP Heater # 7 Inlet


The design temperature of Heater # 6 outlet to Heater # 7 Inlet reducer is the saturation
temperature corresponding to 115% pressure of HP Heater # 6 extraction pressure at
VWO.

 HP Heater # 7 Outlet to HP Heater # 8 Inlet


The design temperature of Heater # 7 outlet to Heater # 8 Inlet reducer is the saturation
temperature corresponding to 115% pressure of HP Heater # 7 extraction pressure at
VWO.

 HP Heater # 8 Outlet to Economizer Inlet


The design temperature of Heater # 8 outlet to economizer inlet is the saturation
temperature corresponding to 115% pressure of HP Heater # 8 extraction pressure at
VWO.

3.3. Design Flow

The design flow is the maximum flow through the respective sections at VWO condition.

3.4. Design Velocity

The velocity of the feedwater in the pipe at the discharge of the boiler feed pump is not to exceed
4m/s. The velocity of the feedwater in the boiler feed pump suction pipe is not to exceed 1 m/s.

4. MODE OF OPERATION

4.1. Normal Plant Start-Up

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Initial Fill
During initial fill of the Feed water System, the low point drain valves will be closed and the
high point vents will be opened to remove air from the piping. System fill will be provided from
the condensate transfer pumps to deaerator. Once the system is filled, the high point vents as well
as the stop valve located on the fill lines will be to be closed.

Start-up
Motor-driven Start-up Boiler Feed pump provides feedwater to the system during start-up until
sufficient steam will be available to operate turbine-driven Boiler Feed pumps.

During start-up and 30% load variation the feed flow control is provided by one (1) start-up feed
control valve with motor-driven start-up boiler feed pump. Beyond 30% and up to 100% load
variation the feed flow control is provided by operating turbine-driven main boiler feedwater
pump and main line motor operated valve for feedwater control.

During start-up / low load operations one (1) Start-Up feed control valve will be provided in
parallel to the main line motor operated valve for feedwater control.

RPM of MD BFP shall be controlled by variable speed hydraulic coupling, which receive the
control impulse from the pressure difference of the Boiler economizer inlet FCV. As per Boiler
load increased, feedwater flow control valve shall be more open to provide more feedwater to
Boiler economizer, then differential pressure across FCV shall be decreased due to FCV opening
position is increased. To maintain a constant differential pressure across FCV, MD BFP RPM
shall be increased. In case of Boiler load decreased, MD BFP RPM shall be controlled in the
opposite way.
In case of Boiler Economizer inlet flow is over 500 t/h and position of Economizer inlet FCV is
over 90%, then Boiler Economizer inlet MOV will be AUTO OPEN. Then Feedwater control
shall be changed over from FCV to MOV.
When plant load reaches 25%, MD Start-up BFP to TD BFP transfer shall be proceeded in the
following order;
Start TD BFP while MD BFP in operating. RPM of TD BFP shall be increased to match the
discharge pressure of MD BFP and TD BFP to be equalized. Increse RPM of TD BFP more so
that discharge pressure of TD BFP is higher than that of MD BFP. As per discharge pressure
increased, MD BFP discharge flow shall be decreased according to the pump characteristic curve.
MD BFP shall be operated under minimum recirculation point due to discharge flow decreased,
then MD BFP is stopped.

4.2. Normal Operation

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During normal operation, the boiler will be supplied with feedwater by 2x50 % turbine-driven
main boiler feed pumps. And the motor driven pump will be on standby duty.

Booster Pumps of turbine driven main Boiler Feed pumps take suction from feedwater storage
tank, which will be located at a higher elevation than the pumps. Turbine-driven main boiler
feedwater pumps take suction from respective Booster pumps discharge.

Start-up boiler feed pump and turbine driven main boiler feed pumps will be provided with
minimum recirculation line from discharge line to feedwater storage tank for protecting the
pumps during low system flows. A minimum recirculation modulating type valve will be
provided in the recirculation line which will be controlled based on the suction flow of respective
pumps. A manual shut-off valve will also be provided in the recirculation line, which will be
locked open normally and closed only when the corresponding pump is out of service for
maintenance and must be isolated. Manual bypass valves with limit switch will be provided
tapping from inlet and outlet of minimum recirculation modulating valve isolation valves and it
will be locked closed normally. In case of the bypass valve is not closed, the respective BFP will
operate at the minimum RPM. An anti-flash orifice will be installed in each recirculating line at
the inlet nozzle to feedwater storage tank to suppress flashing in the piping between the
minimum flow recirculation valve and the feedwater storage tank.
Manual isolation valves and bypass valves of minimum flow control valves have bypass valves
for balance upstream and downstream pressure.

The discharge lines from the turbine-driven Boiler Feed pumps and motor-driven Start-up Boiler
Feed pump join into a common high-pressure feedwater pipe header to HP Feedwater Heaters 6,
7, and 8. Each boiler feed pump discharge has a check valve and a motor-operated stop valve
arranged in series. A line will be tapped off from start up BFP discharge line and a tap off from
each pump discharge line of main BFPs for warming the boiler feed pump when pump is not in
operation. An orifice will be provided in each warming line to reduce the pressure of water
flowing back into the pump. Pumps should be warmed as per Boiler Feed pump Operating
Instructions.

Motor-operated isolation valves will be provided at the inlet and outlet of the HP Feedwater
Heaters 6, 7, and 8 respectively. Motor-operated bypass valves will be provided in bypass lines
across heaters 6, 7, and 8 respectively to permit feedwater to bypass HP Feedwater Heaters. The
motor-operated valves will be operated by the plant operator via the DCS. A bypass will be
provided around the heater isolation valves to refill the respective feedwater heater following a
feedwater heater repair while the unit is in operation.

In order to remove any of the HP Feedwater Heaters from the Feedwater System during
operation of the unit, the motor-operated valve in the respective feedwater heater bypass line will

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be opened first. To bring the feedwater heater string back into service, the HP Feedwater Heater
outlet valve will be opened first followed by the opening of the HP Feedwater Heater inlet valve.
The HP Feedwater Heater bypass valve will not be closed until the HP Feedwater Heater outlet
valve and HP Feedwater Heater inlet valve are both fully open. This operation sequence will be
necessary to prevent the feedwater heaters from being subject to full boiler feed pump discharge
shutoff pressure, which could damage the feedwater heaters. The feedwater heater inlet and
outlet valves will be interlocked to prevent this from happening.

A tap-off will be provided from start-up BFP and main BFP interstage to supply spray water to
reheater attemperator. This interstage piping has a check valve and a motor operated shut-off
valve at the boiler feed pump intermediate stage discharge connection. Pipe from each boiler feed
pump intermediate stage will be headered to a single pipe to supply spray water to reheater
attempetator.

4.3. Normal Plant Shut Down

i) Normal plant shutdown will be accomplished by reducing the load on BFPs and stopping
either of turbine driven Boiler Feed pump when the main plant turbine load is down to 50%.
ii) Stop the selected boiler feed water pump from DCS.
iii) Discharge MOV gets closed.
iv) Lube Oil pump will be stopped after a time delay to arrive at a acceptance temperature
condition of bearings which can be determined / set during commissioning.
v) Remaining Main Boiler feed pump must remain in operation until boiler shutdown.

To prevent oxygen contamination of water stored in de-aeration storage tank during plant shut
down periods following procedure shall be maintained,

For Shorter shut down periods the storage tank shall be filled with feedwater to normal level
from initial fill line and shall be dosed with oxygen scavengers. After filling to avoid any O2
ingress deaerator shall be remain pressurized with N2 gas or by closing all the vents /
connections to deaerator.

For longer shut down periods deaerator shall be dry preserved by draining the water and
blanketing with steam or nitrogen.

4.4. Abnormal Operation

If one of the turbine-driven boiler feed pumps is out of service, The start-up pump will be
operated in parallel with a single main boiler feed pump as a back-up and 80% rated plant load

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can be maintained by operating the remaining one (1) turbine-driven boiler feed pump and start-
up motor-driven boiler feed pump.

If there is any leakage in any of the high-pressure feedwater heaters, the steam space in the high-
pressure feedwater heater can become flooded with feedwater. Level transmitters will indicate
high water levels in the feedwater heaters. Feedwater flow to the feedwater heaters can be
diverted to the bypass line and the feedwater heater(s) isolated from the Feedwater System. This
will be accomplished by opening the motor operated bypass valve and closing motor-operated
inlet and outlet valves of respective HP Feedwater Heater.

Malfunction of the Deaerator level controls or a rapid unit load decrease could cause flooding of
Deaerator. A high-high water level in Deaerator will actuate the deaerator emergency overflow
control. The overflow control opens an overflow control valve that will drain excess water in
Deaerator to the condenser and avoid flooding.

5. INSTRUMENTATION AND CONTROLS

The primary control operations associated with the Feedwater System include feedwater flow
control and boiler feed pump controls.

5.1. Feed Water Flow Control

Feedwater Flow Demand will be determined from the Boiler Input Demand (BID). Minimum
Feedwater Flow set will be tracked to actual Feed Water Flow when BFP control is in manual
mode during plant startup.

Feedforward signal and control gain will be modified according to the quantity of BFP in
automatic mode. Feedwater Flow demand will be biased to prevent the economizer steaming
condition when the Separator Drain Tank Pressure is sub-critical. During the unit startup, startup
feedwater control valve controls feedwater flow. During normal operation, BFPTs will be used
for Feedwater Flow control by changing the turbine speed.

5.2. Start-up Boiler Feed Pump Contol

The start-up boiler feed pump will be started and stopped by the operator from the DCS operator
interface console. Start / Stop controls will be provided through the DCS.

The following DCS control signals will be associated with Startup Boiler Feed pump

Trip Conditions

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 Start-up BFP Lube oil pressure low low


 Start-up BFP Suction pressure low low
 Start-up BFP Suction flow low low
 Feedwater storage tank Level low low
 Start-up BFP & pump motor bearing temperatures high high
 Start-up BFP vibration high high
 Start-up BFP discharge valve not fully open within a preset time after pump being
started.
 Startup pump discharge pressure high high
 Start-up BFP motor winding temperature high high
 Start-up BFP suction flow High High

Start Permissive
 Start-up BFP Suction valve open.
 Start-up BFP discharge valve closed.
 Start-up BFP lube oil pressure normal.
 Feed water storage tank level not low

Stop Permissive
 None

Auto Start Interlock


 None

Auto Stop Interlock


 None

Startup BFP Discharge Valve.

The following DCS control signals will be associated with the Startup BFP Discharge Valve.

Open Permissive
 No Auto close Interlock

Close Permissive
 Start-up BFP recirculation valve opened
 Startup BFP has stopped

Auto Open Interlock

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 Startup BFP running for a preset time period

Auto Close Interlock


 Start-up BFP Stop Command or Start-up BFP stopped
 Feedwater header pressure high

5.3. Main Boiler Feed Pump Control

Main Booster pumps and Boiler feed pumps will be started and stopped from the DCS. Start /
Stop controls for the same will be provided in DCS.

Following DCS control signals will be associated with Main Booster and Boiler Feed pumps

Trip Conditions
 Corresponding BFP Lube oil pressure low low
 Corresponding BFP Suction pressure low low
 Corresponding Suction flow low low.
 Feedwater storage tank level low low
 Corresponding BFP bearing temperatures high high
 Corresponding Pump vibration high high
 Corresponding Pump discharge valve not fully open within a preset time after pump
start
 Corresponding BFP discharge pressure high high.
 Corresponding BFP suction flow high high

Start Permissive
 Corresponding BFP suction valve open.
 Respective BFP discharge valve closed.
 Respective BFP lube oil pressure normal.
 Feed water storage tank not low
 Lube Oil tank level not low

Stop Permissive
 None

Auto Start Interlock


 None

Auto Stop Interlock


 None

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Based on the above mentioned process conditions, signals will be generated by DCS
appropriately and sent to BFPT Control system through hardwired interface for operation of
respective Main Booster and Boiler feed pumps.

Main BFP Discharge valves

The Discharge valves for each BFP can be controlled manually or in Auto via the DCS.
Following DCS control signals will be associated with the BFP Discharge valves

Open Permissive
 No Auto close Interlock

Close Permissive
 Corresponding BFP stopped
 Corresponding BFP recirculation valve opened

Auto Open Interlock


 Preset time after respective BFP start

Auto Close Interlock


 Corresponding BFP

5.4. High Pressure Feed Water heater Isolation and Bypass valves

The isolation valves for each feedwater heater can be controlled manually or in AUTO via DCS.

Heater Inlet Valves

Following DCS controls will be associated with the HP Feedwater Heater 6, 7 & 8 Inlet Valves

Open Permissive
 At least one of the BFP’s will be running and the corresponding heater outlet valve is
open

Close Permissive
 No Main BFP running
 Bypass valve for corresponding heater open

Auto Open Interlock

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 None

Auto Close Interlock


 Corresponding heater bypass valve opened.

Heater Outlet Valves

The following DCS controls will be associated with the HP FW Heater 6, 7 & 8 Outlet Valves

Open Permissive
 None

Close Permissive
 No Main BFP running
 Bypass valve for corresponding heater open

Auto Open Interlock


 None

Auto Close Interlock


 Corresponding heater bypass valve opened.

Heater Bypass Valves

The following DCS controls will be associated with the HP Feedwater Heater’s Bypass Valves

Open Permissive
 None

Close Permissive
 No Main BFP running
 Inlet and outlet valves of corresponding heater are open

Auto Open Interlock


 Respective Heater level high high

Auto Close Interlock


 None

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5.5. Motorised Valve across Feed Control Valve

Open Permissive
 None

Close Permissive
 No Main BFP running

Auto Open Interlock


 None

Auto Close Interlock


 None.

5.6. Pump Minimum Flow Control

Each pump will be provided with its own modulating type minimum flow recirculation control
valve. For each boiler feed pump, the recirculation control valve will be controlled via DCS
based on the pump suction flow (Booster pump discharge flow in case Main BFP).

5.7. Alarms, Interlocks and Instrumentation

In addition to all trip related process conditions, following Feedwater System alarms will be
monitored from the DCS operator interface console alarm graphic display.

 HP Feedwater Heater 6 Shell-side water level High


 HP Feedwater Heater 7 Shell-side water level High
 HP Feedwater Heater 8 Shell-side water level High
 Start-up BFP / Main BFPs suction flow low
 BFP Suction Pressure low
 Feedwater storage tank level low
 Differential Pressure across suction strainer high
 Respective BFP discharge valve not open within a preset time after corresponding
pump being started
 Respective Startup pump / Start pump Motor / Main BFPs / BFPTs bearing
temperature High
 Start up pump Motor winding temperature high
 Respective BFP discharge pressure low
 Differential temperature across pump high

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 Start up BFP / Main BFPs Lube oil pressure low.


 Lube oil tank level low

5.8. Automatic Protection

The controls must protect the unit from being overfired in case of feed pump limitations. On loss
of one of the operating boiler feed pumps, the control will automatically run back the load and
operational limits of the unit without undue upset to the system and with requiring a boiler or unit
trip.

Generally, auxiliary turbine tripping system provide to trip the stop, control valves, in the event
of the following conditions, as a minimum ;

1) Overspeed
2) Excessive axial rotor movement
3) High back pressure
4) Low bearing oil pressure
5) High vibration
6) High eccentricity,
7) Loss of hydraulic fluid supply pressure

The details of boiler feed pump turbine operation & control description will be covered in
respecteve vendor document.

6. ELECTRICAL SERVICES

Start-up Boiler Feed Pump


 Start-up Boiler Feed Pump fed from both 11 kV unit switch gear.

Valves
 Motor-operated valves will be fed from 400V respective MCC / Distribution Boards.
 All Low Voltage drives will be fed from respective 400V switch gear / MCC

7. CODES & STANDARDS

The feedwater system will be designed in accordance with the latest edition of the following
codes and standards

 American Society of Mechanical Engineer (ASME)


 ASME B 31.1 Power Piping Code

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 ASME Section VIII, Div.1 Pressure Vessels


 ASME Section I Power Boiler
 ASME Section IX Welding Qualification
 American National Standard Institute (ANSI)
 American Society for testing of material (ASTM)
 International Organization for Standardization (ISO)
 Hydraulic Institute (HI)
 American Petroleum Institute (API)
 Heat Exchange Institute (HEI)
 Crane Technical Paper 410

8. REFERENCES

 Heat Balance Diagram (Contract Document, Book 24, Vol. 1, Section 3)


 P&I Diagram: Feed Water system (SH1-DHI-P1LAB-M-M01-PID-5311 to 5313)
 Datasheet for Deaerator & Feedwater Storage Tank (SH1-DHI-P1LAA-M-M01-DAS-
3605)
 System Description for Chemical Dosing System (SH1-DHI-P0QC-M-M01-PHL-
5401)
 P&ID for Start-up Boiler Feed pump (Motor driven) (SH1-DHI-P1LAC-M-M01-PID-
5201)
 P&ID for Main Boiler Feed pump (Turbine driven) (SH1-DHI-P1LAC-M-M01-PID-
5202)
 P&ID Drawing for Fluid Coupling of Start-up Boiler Feed Pump (Motor driven) (SH1-
DHI-P1LAC-M-M01-PID-5203)

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