Document Code: 1 (12)

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Project :

WEST OFFALY POWER

Author: Approved: Language:

JJA
Document title:

SYSTEM DESCRIPTION

HP -PREHEATING SYSTEM

Submitted for: Customer reference: Other information:

 Document Code: 2 (12)

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TABLE OF CONTENTS

1 GENERAL................................................................................................................................... 3

2 DESIGN DATA ........................................................................................................................... 3

3 EQUIPMENT DATA.................................................................................................................. 4
3.1 HP 1 Preheater .............................................................................................................................. 4
3.2 HP 2 Preheater .............................................................................................................................. 5
3.3 HP 3 Preheater .............................................................................................................................. 6
3.4 Feed water line .............................................................................................................................. 7
3.5 Safety valve HP –preheater 1........................................................................................................ 7
3.6 Safety valve HP –preheater 2........................................................................................................ 7
4 AUTOMATION AND INSTRUMENTATION ....................................................................... 8
4.1 HP1 Preheater level control .......................................................................................................... 8
4.2 HP2 Preheater level control .......................................................................................................... 8
5 OPERATION .............................................................................................................................. 9
5.1 Start-up.......................................................................................................................................... 9
5.2 Normal operation ........................................................................................................................ 11
5.3 Operating disturbances................................................................................................................ 12
6 CONNECTED SYSTEMS ....................................................................................................... 12
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1 GENERAL

The function of the high-pressure feed water preheating system is to preheat the feed water
pumped from the feed water tank to the temperature required by the boiler in order to reach
full load operation. The purpose of preheating feed water before boiler with turbine extrac-
tion steam is to increase power plant’s thermal efficiency.

HP-preheating system is shown in diagram S1 LAD__-MFB1001_.

HP feed water preheating is performed in three stages. In the HP3 preheater (S1LAD30
AC001) feed water is heated with steam from turbine extraction 5 before leading to HP1
preheater. In the HP2 preheater (S1LAD20 AC001) the feed water is heated with steam
from the cold reheat steam line. Pressure in turbine extraction 5 and cold reheat is sliding
according to steam turbine load. High pressure preheaters are vertical, tube and shell heat
exchangers.

Normally secondary condensate from HP2 preheater is returned to HP1 preheater and HP1
condensate is returned to the feed water tank. Condensate level in the HP2 preheater is kept
with control valve S1 LCH10 AA201 and condensate level in the HP1 preheater is kept with
control valve S1 LCH30 AA201.

In case of disturbances, during start-up and very low load situations, while pressure differ-
ence between HP1 preheater and feed water tank is not enough to lead condensate to feed
water tank, condensate is led to the condenser. In these cases condensate level in the HP1
preheater is kept with control valve S1 LCH40 AA201. This means, that S1 LCH30 and 40
AA201 are connected to the condensate level measurement S1 LAD10 CL901.

The HP-preheaters are equipped with a bypass line with quick acting bypass valves for pro-
tection of the turbine in case of tube bundle damage or abnormal condensate level rise in the
heater. HP-preheaters are located to the turbine hall.

2 DESIGN DATA

The high pressure preheating system is designed to be able to preheat feed water to the tem-
perature required by the boiler. At full load operation temperature of feed water entering the
boiler is 250 °C. At boiler minimum load feed water temperature after HP3 preheater is
about 200 °C
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3 EQUIPMENT DATA

3.1 HP 1 Preheater
KKS Code S1 LAD10 AC001.

The heater is vertical shell - U-tube heat exchanger equipped with steam desuperheating,
condensing and drain cooling sections. Steam/secondary condensate on the shell side and
feed water on the tube side. HP 1 -preheater is getting its heating energy from the HP 2- and
3 –preheaters condensate.

HP1 preheater is designed as follows at BMCR. (Boiler Maximum Continuous Rate)

− Number of units 1 x 100%

Cooling side Heating side

(Feed water) (Steam/sec. condensate)
− Temperature IN °C 161.5 271
− Temperature OUT °C 200.4 169.7
− Pressure bar(g) 200 15.2
− Mass flow kg/s 113 7.7
− Pressure drop bar 0.5
− Heat exchanged kW 19 079

Construction data
− Manufacturer Andritz
2
− Heating surface m 580
− Design pressure bar(g) 355 22 / full vacuum
− Design temperature °C 280 / 20 470 / 20
− Piping connections inlet/outlet DN250/DN250 DN250/DN150
− Piping material 15NiCuMoNb5 15Mo3
− Volume m3 2.0 5.4

− Shell 16Mo3
− Tube plates 15NiCuMoNb5

− Tubes
− Number 606
− Material 15Mo3
− Do x s mm 18 x 2.4

− Diameter mm 1180
− Total height mm 10800
− Operation weight kg ca. 24500
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3.2 HP 2 Preheater
KKS Code S1 LAD20 AC001.

The heater is vertical shell - U-tube heat exchanger equipped with steam desuperheating,
condensing and drain cooling sections. Steam/secondary condensate on the shell side and
feed water on the tube side. Steam into HP 2 -preheater is taken from the boiler cold reheat.

HP2 preheater is designed as follows at BMCR. (Boiler Maximum Continuous Rate)

− Number of units 1 x 100%

Cooling side Heating side

(Feed water) (Steam/sec. condensate)
− Temperature IN °C 200.4 348
− Temperature OUT °C 244.3 208.8
− Pressure bar(g) 199.5 35.8
− Mass flow kg/s 113 10.2
− Pressure drop bar 0.5
− Heat exchanged kW 22 393

Construction data
− Manufacturer Andritz
− Heating surface m2 542
− Design pressure bar(g) 355 50 / full vacuum
− Design temperature °C 280 / 20 450 / 20
− Piping connections inlet/outlet DN250/DN250 DN200/DN125
− Piping material 15NiCuMoNb5 15Mo3
− Volume m3 2.0 5.4

− Shell 15NiCuMoNb5
− Tube plates 15NiCuMoNb5

− Tubes
− Number 369
− Material 15Mo3
− Do x s mm 18 x 2.5

− Diameter mm 1180
− Total height mm 10250
Operation weight kg ca. 24500
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3.3 HP 3 Preheater
KKS Code S1 LAD20 AC001.

The heater is vertical shell - U-tube heat exchanger. Steam on the shell side and feed water
on the tube side. Steam into HP 3 -preheater is taken from the turbine extraction No.5.

HP2 preheater is designed as follows at BMCR. (Boiler Maximum Continuous Rate)

− Number of units 1 x 100%

Cooling side Heating side

(Feed water) (Steam)
− Temperature IN °C 244.3 445
− Temperature OUT °C 250 271.2
− Pressure bar(g) 199 15.5
− Mass flow kg/s 113.2 7.7
− Pressure drop bar 0.2
− Heat exchanged kW 3006

Construction data
− Manufacturer Andritz
2
− Heating surface m 114
− Design pressure bar(g) 355 22 / full vacuum
− Design temperature °C 280 / 20 470 / 20
− Piping connections inlet/outlet DN250/DN250 DN250/DN250
− Piping material 15NiCuMoNb5 15Mo3
− Volume m3 0.8 2.1

− Shell 16Mo3
− Tube plates 15NiCuMoNb5

− Tubes
− Number 109
− Material 15Mo3
− Do x s mm 25 x 3.5

− Diameter mm 960
− Total height mm 6400
Operation weight kg ca. 11000
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3.4 Feed water line

Design values of the feed water line (S1 LAB BR010..040) are the following:
− Design pressure 355 bar
− Design temperature (BR010) 200 °C
− Design temperature (BR020..040) 280 °C
− Nominal diameter DN250
− Do x s 273 x 28 mm
− Material 15NiCuMoNb5

3.5 Safety valve HP –preheater 1

S1 LAD10 AA401

On the shell side each HP preheater is designed for the maximum steam pressure which can
prevail during operation of the steam turbine.

Design basis of HP1 preheater safety valve S1 LAD10 AA401 is maximum steam flow from
HP2 preheater (HP2 preheater condensate control valve S1 LCH10 AA201 failure).

Safety valve is also dimensioned according to maximum flow if one tube in the heat ex-
changer is totally broken. (2 open tube ends).

− Capacity
− Steam, 350 °C 10 kg/s
− Water, 200 °C 56.6 kg/s
− Set pressure 22 bar(g)

3.6 Safety valve HP –preheater 2

S1 LAD20 AA401

HP2 preheater safety valve S1 LAD20 AA401 is dimensioned according to maximum flow
if one tube in the heat exchanger is totally broken. (2 open tube ends).
− Capacity (water, 240 °C) 37.3 kg/s
− Set pressure 50 bar(g)
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4 AUTOMATION AND INSTRUMENTATION

4.1 HP1 Preheater level control

Normally condensate level in the HP1 preheater is kept with control valve S1 LCH30
AA201. If the pressure difference between HP1 preheater and feed water tank is not ade-
quate, condensate is led to the condenser and condensate level in the HP1 preheater is kept
with control valve S1 LCH40 AA201.

4.2 HP2 Preheater level control

Condensate level in the HP2 preheater is kept with control valve S1 LCH10 AA201.
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5 OPERATION

5.1 Start-up

In start-up the HP preheaters and the connecting piping are filled with feed water carefully
and vented. Before taking HP preheating system in operation it has to be checked, that all
instrumentation of the system is in operation as well all the check valves are (f.e. drains are
closed) in correct positions.

Procedure to take HP –preheaters feed water side in operation are following:

1. Check, that HP preheater three- and two way, so called quick acting, valves (S1LAB30
AA101 and S1LAB30 AA102) hand wheels’ locking is on and that they are locked to the
bypass mode. When preheaters are in a bypass operation, quick acting valves are
closed.

Note: HP -preheater quick acting bypass valves (S1LAB30 AA101 and S1LAB30
AA102) pressure hold pipe actuator (S1LAX10 AA901) is needed to be ener-
gized. Otherwise it is not possible to take preheaters in operation, because feed
water will push through pipe (S1LAX10 BR210) in question to the blow down
tank.

2. Check, that the main hand check valves (S1 LAB30 AA001 and 002) are still closed.

3. Open the venting valves (S1LAB30 AA803 & 804) after the HP 3 –preheater. Venting
valves have two purposes, which are to remove the air from the pipe and to avoid the
hydrostatic (pressure) hammer effect during preheaters’ filling.

4. Open the main hand check valves before (S1 LAB30 AA001) and after (S1 LAB30 002)
preheaters.

5. Open fill up pipe’s (S1LAB32 BR010) valves (S1LAB32 AA001…002) slowly and fill
the preheaters feed water side.

6. Preheaters’ feed water side is filled full, when feed water has come through venting
pipe over 30 seconds. Close valves S1LAB32 AA001 and 002.

Three- and two way valves (quick acting valves) can be taken in operation at least two
different ways. Here below is explained two examples to do it:

Situation is, that boiler drum has been filled and kept at the normal water level (NWL)
and feed water pump is running in a minimum output. Walk-around worker has con-
nection to the control room’s boiler operator.
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However, preheater can be taken in operation also during the boiler operation, but then
it is strongly recommended to do it with two man, whom also has connection to the
control rooms boiler operator.

a) One worker is taking preheaters in operation.

Note: Preheater has been filled full as mentioned in the earlier page.

- Open slightly two way valve (S1LAB30 AA102) venting valves (S1LAB30 AA805
and 806), which is the two way valves piston’s upper side.
- Release the hand wheel locking of the two way valve (S1LAB30 AA102).
- Open fully the two way valve (S1LAB30 AA102) manually. Check from the boiler
operator, that the open limit switch has signal.
- Close the two way valve (S1LAB30 AA102) venting valves (S1LAB30 AA805 and
806), when feed water is coming through.
- Open slightly three way valve (S1LAB30 AA101) venting valves (S1LAB30 AA807
and 808), which is the two way valves piston’s upper side.
- Release the hand wheel locking of the two way valve (S1LAB30 AA101).
- Open fully the three way valve (S1LAB30 AA101) manually. Check from the
boiler operator, that the open limit switch has signal.
- Close the three way valve (S1LAB30 AA101) venting valves (S1LAB30 AA807 and
808), when feed water is coming through.
- Preheaters’ feed water side is now in operation.
- Check, that feed water side has no leakages (for example at a safety valve).

b) One worker is taking preheaters in operation. Same procedures as mentioned

above, but instead of turning the three – and two way valves hand wheels manu-
ally, they can be opened with the help of feed water line pressure is enough high.
This quick acting function (closing, but also opening) needs, that feed water line pres-
sure is over 70 bar(g).

Note: Preheater has been filled full as mentioned in the earlier page.

- Open slightly three- and two way valves (S1LAB30 AA101…102) venting valves
(S1LAB30 AA805…806 and S1LAB30 807…808).
- Release both valves hand wheel’s locking (S1LAB30 AA101…102).
- When feed water line pressure is now over 70 bar(g), quick acting valves (three-
and two way) opens automatically. Check from the boiler operator, that both
valves came to the open limit.
- Close three- and two way valves (S1LAB30 AA101…102) venting valves (S1LAB30
AA805…806 and S1LAB30 807…808).
- HP –preheaters feed water side is now in operation.
- Check, that feed water side has no leakages (for example at a safety valve). Pre-
heaters’ feed water side is now in operation.
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Procedure to take HP –preheaters steam side in operation is as described in next:

1. Check, that all instrumentation of the system is normally in operation as well all the
check valves (f.e. drains are closed) are in correct positions.

2. After steam turbine is started and steam pressure in extraction 5 and cold reheat is ade-
quate, steam side motor operated bypass valves S1LBQ12 AA101 and S1LBC51
AA101 are opened. Heat the exchangers slowly and control the temperature and pres-
sure raise. Note, that exchanger is a pressure vessel, and it is needed follow normal
heating procedures (manufacturer operating manual).

3. The HP preheaters level control valves are set to auto mode.

4. After steam pipelines are heated, motor operated steam valves S1 LBQ10 AA101 and
S1 LBC50 AA101 are opened and motor operated bypass valves are closed. If pre-
heaters have venting pipes (S1LBG11 AA801) also in the steam side, steam side should
also vented.

5. If possible, let the first 5…10 min condensate to go to the sewage / blow down system.

6. Control, that pressures and condensate levels at a preheaters’ are normalized and stays
steady.

NOTE: Check all preheaters visually, that there are no leakages.

5.2 Normal operation

In normal operation feed water is pumped with one feed water pump through the pre-
heaters.

Steam to HP preheater 1 comes through from the (desuperheater) HP 3. Steam to HP prehea-

ter 3 is taken from turbine extraction 5 and steam to HP preheater 2 is taken from cold re-
heat. Steam side pressures are sliding according to the steam turbine load.

Condensate from the HP 1 preheater is returned to the feed water tank. The water level in
the HP -preheater 1 is controlled with control valve S1 LCH30 AA201. Condensate from
the HP 2 preheater is returned to the HP 1 preheater.

The water level in the HP 2 preheater is controlled with control valve S1 LCH10 AA201.

During low load situations condensate from HP 1 preheater is led to the condenser. In these
cases condensate level in the HP 1 preheater is kept with control valve S1 LCH40 AA201.
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5.3 Operating disturbances

− The water level in the HP 1 preheater rises above the high limit 1 → the condensate flow
is directed to the condenser.

− The water level in the HP 2 preheater rises above the high limit 1 → the condensate con-
trol valve is fully opened to HP 1 and condensate flow is directed to the condenser.

− The water level in the HP 1 preheater rises above the high limit 2 → steam valves
(S1LBQ10 AA101 and S1LBG50 AA101) to HP3 and to HP2 closes, and quick acting by-
pass is activated by de-energizing the pressure hold line’s actuator (S1LAX10 AA901).
Also condensate control valve S1 LCH10 AA201 from HP2 to HP1 closes. If needed, the
condensate flow is directed to the condenser.

− The water level in the HP 2 preheater rises above the high limit 2 → steam valves
(S1LBQ10 AA101 and S1LBG50 AA101) to HP3 and to HP2 closes, and quick acting by-
pass is activated by de-energizing the pressure hold line’s actuator (S1LAX10 AA901).
Condensate control valve S1 LCH10 AA201 from HP2 to HP1 opens fully. If needed, the
condensate flow is directed to the condenser.

− The water level in the HP3 preheater rises above the high limit 2 → steam valves
(S1LBQ10 AA101 and S1LBG50 AA101) to HP3 and to HP2 closes, and quick acting by-
pass is activated by de-energizing the pressure hold line’s actuator (S1LAX10 AA901).
Also condensate control valve S1 LCH10 AA201 from HP2 to HP1 closes.

− The water level in the HP 1 preheater lowers below the low limit → condensate control
valve S1LBQ30…40 AA201 closes. Condensate flow to condenser direction is also
closed.

− The water level in the HP 2 preheater lowers below the low limit → condensate control
valve S1 LBC10 AA201 closes. Condensate flow to condenser direction is also closed.

6 CONNECTED SYSTEMS

− Feed water system S1LA___-MFB1001_

− Condenser S1LC___-MFB1001_
− HP -steam system S1LB___-MFB1001_
− HP –preheater drains S1LAD__-MFB1002_
− Boiler water S1HA___-MFB0001_