Steam Turbine Manual

1
STEAM TURBINE MANUAL
INDEX
SR. CHAPTERS PAGE
NO. NO.
1 Condenser Make up System (CAP) 2 to 6

2 Condensate Extraction System (CEX) 7 to 17
3 Feed Water Tank (ADG) 18 to 31
4 LP Feed Water System (APB) 32 to 40
5 HP Feed Water System (APH) 41 to 50
6 LP Circulating System (FLB) 51 to 55
7 HP Circulating Pumps (FLH) 56 to 65
8 Boiler Drains and Blow downs (FPV) 66 to70
9 Main System Drains (ACO) 71 to 86
10 Main Steam Circuit (VVP) 87 to 96
11 Boiler Flue Gas System (TTA) 97 to 105
12 LP Bypass System (GHP) 106 to 113
13 HP Bypass System (GHP) 114 to 126
14 Condenser Pre-heater System (FLP) 127 to 132
15 Condenser Circulating Water System (CRF) 133 to 144
16 DM Water Cooling System (SRI) 145 to 149
17 Condenser Vacuum System (CVI) 150 to 158
18 Chemical Dozing System (SIR) 159 to 168
19 Lubricating and Turning System (GGR) 169 to 184
20 Turbine Gland Seal System & LP Exhaust Hood Spray (CAN) 185 to 193
21 Steam turbine Control Fluid (GFR) 194 to 202
22 Steam Turbine Drains (GPV) 203 to 206
23 Steam Turbine Start Up 207 to 208
24 Generator and Excitation System 219 to 222
25 Nox Control System 223 to 228
26 Protection 229 to 237
27 Electrical System at Kawas Plant 238 to 240
28 Block Start-up Procedure 241 to 250
29 Safety Tests 251 to 253
30 Trouble Shooting 254 to 261
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2
(1) CONDENSER MAKE -UP SYSTEM (CAP)

PURPOSE OF THE SYSTEM:
THE CAP SYSTEM ENSURES:
• Water reserve storage for the cycle.
• Normal make-up to the condenser.
• Quick make-up to the condenser.
• Water filling of the cycle by means of a pump.
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.
DESCRIPTION OF THE EQUIPMENT:

Condensate storage tank:
Total capacity 250 m³
Diameter 6m
Height 9.2 m
Filling pump:
Flow rate 60 m³/hr

Manometer head 40 m
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).
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3
Filling of the water circuits of the cycle:

The filling pump (101 PO) is in operation and fills the condensate water circuits (condenser + condensate
water line) and the feed water circuits (feed water tank HP and LP feed water lines. HP and LP boiler
drums).
DESCRIPTION OF INSTUMENTATION AND CONTROL LOOPS:
LOGIC CONTROLS:
Normal make-up valve (LV 001):
This valve is controlled normally by the feed water tank level (2300mm), and exceptionally by the water
level in the condenser hot well.
Quick make up valve (UV 001):
The principle of operation of this valve is identical to that of the normal make-up valve. It is controlled as
follows:
• Normally, by the feed water tank level. (<2200mm)
• Exceptionally, by the condenser level.
• By its individual control (HSN 001).
Filling pump control (101 PO):

• This pump is started by the operator from its individual control.
• Safety devices (very low level in the tank and suction valve not open) makes this pump trip.
ANALYSIS OF THE LOSS OF MOTIVE OR CONTROL FLUID:

INSTRUMENT AIR LOSS:
• Normal make-up valve LV 001 closes. (Air to open)
FAILUR OF 48 V DC CONTROL VOLTAGES:

• The filling pump remains on duty.
• The motor operated valve UV 001 remains in the same position as before the voltage failure.
FAILURE OF 415 V DC POWER VOLTAGES:

• The fillings pump stops.
• The motor operated valve UV 001 remains in the same position as before the voltage failure.
CAP SYSTEM START-UP

• Cap tank make up filling line is lined up (SER LV 001)
• Condenser drain valves should be closed.
• Hot well level transmitter vessel isolating valve are open.
• Manual isolating valve in the hotwell filling and pump line are open.
Start pump 101 PO for hotwell filling by keeping LV 001 & UV 001 open. At normal level close the UV
001 valve.
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4
MAKE UP VALVE CONTROL: LV001
CEX LSL 001

CONDENSER LOW
LEVEL
<800 MM
ADGLSL002 ADG LSH 002

FEEDWATER TANK FEEDWATER
LOW LEVEL TANK HIGH LEVEL
<2300 MM <2400 MM
ENERGISE LVX 001 DE-ENERGIZE

VALVE LV 001 LVXOO1
OPENING VALVE LV001
CLOSING
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5
QUICK MAKE UP VALVE CONTROL: UV001
ADG LSH 002

FEED WATER TANK
HIGH LEVEL
<2400 MM
CEX LSL 001

CONDENSER
LOW LEVEL
<800 MM
ADG LSL003
FEED WATER TANK
LOW LEVEL
<2200 MM
HSN 001 HSN 001

OPENING CLOSING
ORDER ORDER
OPEN VALVE CLOSE VALVE

UV 001 UV 001
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6
FILLING PUMP CONTROL: 101 PO
HSN101
101 PO STARTING
ORDER
ZSH 101
SUCTION V/V
HV 101 OPEN
LSLL 100
001 BA LOW LOW
LEVEL
START PUMP
101 PO
HSN 101 LSLL100

101 PO 001 BA
STOPPING ORDER LOW LOW LEVEL
ZSH 101
SUCTION V/V
HV 101 OPEN
STOP PUMP
101 PO
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7
(2) CONDENSATE EXTRACTION SYSTEM (CEX)

PURPOSE OF THE SYSTEM:
• To condense the turbine LP cylinder exhaust steam and the HP and LP bypass steam.
• To supply the condensate to deaerator feedwater tank.
• To keep the level in the condenser hotwell constant, by adding demineralised water from (CAP system) or
condensate water discharge from outside.
• To ensure condensate extraction pump recirculation
• To ensure the cooling of the turbine gland steam condenser.
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.
DESCRIPTION OF THE SYSTEM:

GENERAL DESCRIPTION:
It is composed of:
• a condensation system
• a extraction system
• a condensate water discharge system.
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.
On water side, the condenser recovers:

• The drains from the turbine gland sealing steam condenser.
• The condensate extraction pump recirculating water.
• The make-up water from the reserve feedwater tank (CAP).
• The various clean drains (ACO & GPV).
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
Condensate extraction pumps:

The condensate pumps are of the vertical axis type.
The feedwater tank supply pipe is provided with a recirculation system, which is composed of a flow
measuring (FT 001) and a control loop. The recirculation system protects the condensate extraction pumps
and the gland steam condenser delivering the minimum flow necessary for operating these systems.
Main data:
Pumps:
• Number of stages 4
• Fluid conveyed condensate water
• Design flow 310 m³/h
• Manometric head 90 m
• Flow under rated load 210 t/h
• Temperature 44°C
• Rotation speed 1500 rpm
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.
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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.
Operation with single HRSG:

Same operation as in paragraph above except.
• 1 single condensate extraction pump in operation.
• The stopped HRSG is isolated by closing preheater outlet valve.
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).
DESCRIPTION OF INSTRUMENTATION AND CONTROL LOOPS:

ANALOG CONTROL LOOP:
Condenser level control loop:
• The condenser level control valve LCV 001 is controlled by an electronic control loop.
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• 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.
Reciculating flow control loop:

• The control loop opens the valve FCV 001 and allows a minimum flow at 125 m3/h.
LOGIC CONTROL LOOPS:

Starting-up using group control:
In normal configuration the condensate extraction pumps are controlled by the group control. The operator
selects the pumps to be started up and confirms the starting-up using the group control.
The starting-up conditions must be fulfilled. These are:
1. Correct level in the feed water tank (< Very high level (3100mm)).
2. Correct level in the condenser (>low level (800mm))
3. Pump suction valve open.
4. Discharge valve closed or correct pressure in the discharge header.
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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Emergency takeover of pumps

Emergency takeover is only possible at group control level.
In the case of condensate extraction pump tripping, the emergency takeover by another pump is
possible if:
• Operator has authorised the emergency takeover.
• There is no discrepancy between the state of the pumps and the choice of the pumps in operation.
• There is no tripping order at group level (very high feed water tank level, very low condenser
level).
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.
CONDENSATE PUMPS STARTING CONDITIONS: 101 PO 201PO 301 PO

TRIPPING SIGNAL
ELABORATION FROM
ADG LSHH 101 & 201
ADG LSHH001
FEED WATER TANK
HIGH HIGH LEVEL
(3100MM)
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
SAME SEQUENCE FOR 201PO. 301PO
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CONDENSATE PUMPS.STARTING: 101PO 201PO 301PO

GROUP TRIPPING
HSN 001
ORDER FROM FOLIO 5
GROUP STARTING
HSU 002
TAKING OVER AUTO
HSU 001 CUT OUT
101PO
SELECTED IN NORMAL
SELECTION STATUS
CORRECT
SELECTION STATUS
CORRECT
TAKING OVER MEMORY

ON
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
PUMP 101 PO PUMP 101 PO START PUMP HEATING

IN OPERATION IN OPERATION 101 PO RESISTANCE 101RS
GROUP LEVEL SUB-GROUP LEVEL OFF
(CARRIED OUT IN MCC)
SAME SEQUENCE FOR 201PO 301PO
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13
CONDENSATE PUMPS TRIPPING CONDITIONS: 101PO 201 PO 301PO
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
HSX 101 VSHH 101

101 PO EMERGENCIES THRUST BEARING
TRIPPING ORDER HIGH HIGH VIBRATION
CONDENSATE P/P
101 PO
TRIPPING CONDITIONS
Tripping signal Tripping signal

Elaboration from Elaboration from
ADG LSHH 101 &201 LSLL 101 &201
ADG LSHH 001 FEED HSX 001 LSLL 0 01

WATER TANK HIGH GROUP EMERGENCY CONDENSER
HIGH LEVEL TRIPPING LOW LOW LEVEL
<3100 MM
GROUP
TRIPPING
CONDITIONS
SAME SEQUENCE FOR 201 PO .301PO
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14
CONDENSATE PUMPS STOPING: 101PO 201PO 301PO
HSN 001 GROUP

GROUP TRIPPING
HTRIPPING ORDER CONDITIONS
FROM FOLIO 4
HSN 011
SUB GROUP
STOPPING ORDER
HSN 101 PUMP

INDIVIDUAL TRIPPING
STOPPING ORDER CONDITIONS
PUMP 101 PO
IN OPERATION ON
GROUP LEVEL
GROUP SUB GROUP STOP PUMP HEATING

TRIPPING ORDER TRIPPING ORDER 101 PO RESISTANCE
101 RS ON
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CONDENSATE WATER VALVE CONTROL: LCV001
TRIPPING SIGNAL
ELABORATATION FROM
ADGLSHH 101 & 201
ADGLSHH 001 3 CONDENSATE PUMPS

F.W.T. HHL STOPPED
CONTROL VALVE LCV

001 ZERO SET POINT
DE-ENERGIZE LCVX 001

VALVE LCV 001
CLOSING
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
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ISOLATING VALVE CONTROL: A UV 001

AHSN 001 AHSN 001
OPENING ORDER CLOSING ORDER
AUV 001 AUV 001
OPEN VALVE CLOSE VALVE

AUV 001
AUV 001
SAME SEQUENCE FOR BUV 001
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HOTWELL DUMP VALVE CONTROL:LV 001

LSH 003 LSH 002
CONDENSER HIGH LEVEL CONDENSER HIGH LEVEL
ENERGIZE LVX 001 DE-ENERGIZE LVX 001

VALVE OPENING VALVE CLOSING
LV 001 LV 001
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(3) FEED WATER TANK (ADG)

PURPOSE OF SYSTEM:
The purpose of the deaerator feed water tank system is:
• To ensure a water reserve in the feed water tank, as well as the heating and the deaeration of this water.
• To serve as feed water flow break between the condensate extraction pumps and feed water pumps .
• To provide the required suction head to the feed water pumps.
DESCREPTION OF THE SYSTEM

GENERAL DESCRIPTION
The system consist of a feed water storage tank and tray deaerator
Deaerator:
The deaerator is fed with steam from two different sources:
• LP steam from the waste heat recovery boiler header.
• Bleed steam from the steam turbine.
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).
Steam supply pipes:

The bleed steam pipe from the turbine is equipped with:
• 2 check-valve assisted on closing to protect the turbine from steam backflow.
• One isolating valve.
• One pressure-reducing valve for regulating the feed water tank pressure (PCV 001).
The LP stream pipe is equipped with:

• One Check valve.
• One isolating valve.
• One pressure-reducing valve for regulating the feed water tank pressure (PCV 002)
Additionally PCV003 was installed after Liquid Fuel commissioning as preheater is to be bypassed sometimes and
quantity of steam coming from PCV002 may be insufficient.
DESCREPTION OF EQUIPMENT:
Principal characteristics of the feed water tank:
• Total capacity 150 m³
• Working capacity 100 m³
• Operating pressure 1.21 bar abs.
• Feed water temperature 105°C
• Design pressure 5 bar g
• Installation level: axis 13.3 m
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.
DESCRIPTION OF INST5RUMENTATION AND CONTROL LOOPS:

Regulation of feed water tank pressure:
• When operating at full load, a pressure controller (set point=1.21 bar abs.) work on the bled system valve.
• If the bled steam flow rate is insufficient, the tank pressure will drop slightly and the second pressure controller (set
point=1.11 bar abs.) will work on the LP steam valve.
• Upon shutdown of the system, the control valves get closed.
Bled steam isolation valve control (UV 003):

• On the start-up, this valve opens automatically using the sub-group control, on condition that the feed water tank level
is less than very high-level (3100 mm).
• Sub-group shutdown or very high level in the feed water tank closes the valve.
• This valve can also be operated by its individual control.
LP steam isolation valve control (UV 004):

• The control logic of this valve is identical to that of valve UV 003.
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Preheating valve control (UV 005):

• This valve is operated by individual control.
• Low level or high temperature in the feed water tank closes the valve.
Vent valve control (UV 006- UV 007):

• Start-up by sub-group control puts the valves onto automatic operation dependent on condenser vacuum.
• The tank vent is directed towards the atmosphere then towards the condenser when the pressure there in is less than
200 mbar abs.
• Shutdown by sub-group control closes the vent valves.
• The vent valve can also be operated using their individual controls.
Assisted check-valves control (UV 001- UV 002):

• High or very high level in the feed water tank or turbine tripping causes the closure of the assisted check-valves.
• Very high level locks the closure of the check-valves: Unlocking can only be ensured after a local reset by the
operator.
• A local push-button allows the testing of the check-valves to check their operation.
Overflow valve control (LV 001):

• This valve is controlled automatically by two level switches or manually by individual control.
ANALYSIS OF THE LACK OF MOTIVE OR CONTROL FLUID:

LACK OF INSTRUMENT AIR:
• The pressure control valves PCV 002 closes.
• The check-valves UV 001, UV 002 are assisted to close.
• The overflow valve LV 001 closes.
FAILURE OF 48 V. DC CONTROL VOLTAGES:

• The check-valves UV 001, UV 002 are assisted to close.
• The motor-operated valves remain in the same position as before the voltage failure.
FAILURE OF 125 V. DC ON SWITCHBOARD:

FAILURE OF 415 V POWER VOLTAGES:

• The motor operated valves remains in the same position as before the voltage failure.
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FEED WATER TANK LEVEL 001 BA

Functional code Capacity Level Corresponding action
TOP 150 m³ 3800 mm
LSHH 001 130 m³ 3100 mm Locking of check valves UV
001& UV002 valves closing
of UV 003, UV004 & CEX
pumps tripping
LSH 003 2750
LSH 001 2700 mm Closing of check valve
LSL 004 2650
LSH 002 100 m³ 2400 mm
LSL 002 2300
LV 001 Normal 8 tons/hr 2200 mm Low condensor level opens
make-up this valve.
LSL 003 UV 001 20 tons/hr D/A level not high&
Quick make-up Condensor level low opens
this valve.
LSL 001 75 m³ 1900 mm Start permissive for pumps
LSLL 001 20 m³ 700 mm Tripping of running pumps.
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BLEEDING ISOLATING VALVE CONTROL: UV003
HSN 001 HSN 003

SUB GROUP OPENING ORDER
STARTING
LSHH 001
Tripping signal F.W.T. HIGH
Elaboration from LEVEL 1
<3100MM
LSHH 101 & 201
OPEN VALVE UV UNLOCK PCV 001

003 ZERO SET POINT
HSN 001 SUB HSN 003

GROUP STOPPING CLOSING ORDER
Tripping signal
Elaboration from LSHH 001. HIGH
HIGH LEVEL 1
LSHH 101 & 201 <3100MM
CLOSE VALVE PCV 001

UV 003 ZERO
SET POINT
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23
LP STEAM ISOLATING VALVE CONTROL:UV 004

HSN 001 HSN 004
SUB GROUP OPENING ORDER
STARTING
LSHH 001
Tripping signal F.W.T. HIGH HIGH LEVEL 1
Elaboration from
LSHH 101 &201
OPEN VALVE UNLOCK PCV

UV 004 ZERO
SET POINT
HSN 001 HSN 004

SUB GROUP CLOSING ORDER
STOPPING
TRIPPING SIGNAL
ELABORATION FROM
LSHH 101 &201 LSHH 001
F.W.T. HIGH HIGH
LEVEL 1
<3100 MM
OPEN VALVE PCV 002

UV 004 ZERO
SET POINT
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F.W.T. PREHEATER VALVE CONTROL: UV 005
HSN 005
OPENING ORDER
LSL 001 F.W.T.

LOW LEVEL 1
(1900 MM)
TSH 001 F.W.T.

HIGH
TEMPERATURE
OPEN VALVE
UV 005
HSN 005 TSH 001 LSL 001

CLOSING ORDER F.W.T. HIGH F.W.T.LOW LEVEL 1
TEMPERATURE
CLOSE VALVE
UV 005
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25
VENT TO ATMOSPHERE VALVE CONTROL: UV006
HSN 001 HSN 001

SUB GROUP SUB GROUP STOPPING
STARTING
(D) TRIPPING SIGNAL

ELABORATION FROM
LSHH 101 &201
LSHH 001
F.W.T. HIGH HIGH
LEVEL 1
UV 006-UV 007 UV 006-UV 007

SETTING OF RESETTING OF OPENING
OPENING MEMORY
MEMORY
HSN 006 HSN 006

UV 006-UV 007
OPENING MEMORY
SET
CV 1 PSHH 001
CONDENSER
PRESSURE
>200 M BAR
ZSL 007
VALVE UV 007
CLOSED
OPEN VALVE UV CLOSE VALVE UV

006 006
25
26
VENT TO CONDENSER VALVE CONTROL: UV007
HSN 007 HSN 007

UV 006- UV 007
OPENING MEMORY
SET
CV 1 PSHH 001
CONDENSER PRESS
>200 MBAR
ZSL 006
VALVE UV 006
CLOSED
OPEN VALVE CLOSE VALVE UV

UV 007 007
26
27
LOCKING OF BLEEDING CHECK VALVES: UV 001 UV 002
TRIPPING SIGNAL TRIPPING SIGNAL

ELABORATION FROM ELABORATION FROM
LSHH 101 &201 LSHH 101 & 201
LSH 001 LSHH 001

F.W.T. HIGH HIGH F.W.T. HIGH HIGH
LEVEL 1 LEVEL 1
HSZ 003
RESET OF CHECK
VALVES
SET OF FAULT RESET OF FAULT

MEMORY MEMORY
LSH 001
F.W.T. HIGH HIGH
LEVEL 1
FAULT MEMORY GSE US 058

SET TURBINE TRIPPED
HSZ 001 HSZ 002

UV 001 TEST OF UV 002 TEST OF
CHECK VALVE CHECK VALVE
DE-ENERGIZE UVX
DE-ENERGIZE UVX
002 LOCKING OF
001LOCKING OF CHECK
CHECK VALVE UV 002
VALVE UV 001
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28
UNLOKING OF BLEEDING CHECK VALVES: UV 001 UV 002
FAULT MEMORY SET
LSH 001
F.W.T. HIHG LEVEL 1
GSE US 095
TURBINE SET
HSZ 001 HSZ 002

TEST CHECK VALVE TEST CHECK VALVE
UV 001 UV 002
ENERGIZE UVX 001 ENERGIZE UVX 002

UNLOCKING OF CHECK UNLOCKING OF CHECK
VALVE UV 001 VALVE UV 002
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29
ZERO PRESSURE SET POINT
A TTA ZSL X 10 B TTA ZSL X 10

HRSG A DAMPER HRSG B DAMPER
(D) CLOSED CLOSED
VVP PSH 001

LP STEAM PRESSURE
>5 BAR ABSOLUTE
UNLOCK ZERO
PRESSURE
SET POINT
(SEE ANALOG
DIAGRAM)
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30
OVERFLOW VALVE CONTROL: LV 001
LSH 003
HSN 008
F.W.T. HIGH LEVEL 3
OPENING ORDER
ENERGIZE LVX 001

LV 001 VALVE OPENING
LSH 004
HSN 008
F.W.T. HIGH LEVEL 4
CLOSING ORDER
DE-ENERGIZE LVX 001

LV 001 VALVE CLOSING
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31
FEED WATER CONTROL LEVEL 001BA
FUNCTIONAL CAPACITY LEVEL CORRESPONDING

CODE ACTION
20 mA
TOPTOP
TOP LOCKING OF150
CHECK
M³ VALVE UVMM
3800 001
UV002 VALVES, CLOSING OF UV003
UV004 & CEX PUMPS TRIPPING, ST TRIPPING
LSHH
LSHH 001 130 M³ 3100 MM
LSH 003 2750 M³ CLOSING OF 100 OVERFLOW 2200 MM

CHECK VALVES V/V CONTROL
LSH 001 2700 MM
LSL 004 2650 M³
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
LSL 001 75 M³ 1900 MM
LSLL 001
20 M³ 700 MM
200 MM 4mA
BOTTOM
0 M³ 0 MM
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32
(4) LP FEED WATER SYSTEM (APB)
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.
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
• 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.
Operation with a single HRSG:

Same operation as in paragraph above except:
• One single LP feedwater pump is in operation.
• The stopped HRSG is isolated.
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.
DESCRIPTION OF INSTRUMENTATION AND CONTROL LOOPS:

HRSG drum level control loop:
• The drum level set point is adjustable by the operator from the control room.
• A changeover system by means of a manual loading station allows the selection of the operation type: either automatic
or normal. On manual operation, the operator controls the valve directly. On automatic operation, the valves are
controlled by the analog signal initiated by the control loop.
• Stopping of the three-feedwater pumps closes the control valves.
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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Start-up or low operation:

During start up or low load operation (up to about 25% load) of the HRSG, LP drum level is kept constant
by a single element control loop (water level only), and proportional & integral action controller,
governing a 25% feed water control valve LCV 003.
Control of feed water pump:
Starting group control level:
• In normal configuration, the LP feed water pumps are controlled by the group control. The operator selects one or two
pumps to be started by using the group control command.
• The starting conditions must be fulfilled. After the start-up of the selected pump, the discharge valves of the three
pumps open and the HRSG LP drum level goes to regulating mode.
• Starting in sub-group control level:
• The operators can start a feed water pump by using the sub-group control command if the starting conditions are
fulfilled.
• The pump start-up and its associated discharge valve open.
Shutdown of LP feed water pumps:

• In case of LP feed water sub-group, tripping order by a pump tripping condition or a voluntary sub-group stopping
order by operator, the pump stops. Its discharge valve closes only in sub-group level and not in-group level.
• In case of LP feed water group tripping order, by a group tripping condition or a voluntary group stopping order by
operator, the three pumps stop and all the discharge valves close.
• In case of LP feed water pump stopping by an individual control, the pump stops, but its discharge valve remains in
the same position.
Emergency take-over of pumps:

• Emergency taking over is only possible at the level of group control.
• In case of feed water pump stopping, the emergency taking over by another pump is only possible under following
conditions.
• The operator has authorized the emergency take-over with the operating device “ taking-over auto cut off”
• There is no tripping order at group level.
Control of HRSG LP drum level valves:

• As soon as the operation conditions are correct (pump in operation, normal pressure, inlet economiser valve opened,
auto/manual loading station in automatic position), the operator put the LP feed water valves sub-group in service.
• If one selected control valve is on manual position, an alarm is given in the control room.
• During start-up or low load operation, the 25% flow control line is automatically selected. The isolating motorized
valve UV 003 opens and the control valve LCV 003 is in regulation. The other lines are closed.
• As soon as the flow reaches 25%, the selected 100% flow control line is put into operation in auto and its motorized
valve opens and the associated modulating valve controls the LP drum level. The 25% control valve LCV 003 closes
and 25% motorized valve UV 003 closes.
• The LP feed water valves sub-group can be put out of service by the operator only in case of the HRSG is not in
operation.
ANALYSIS OF THE LACK OF MOTIVE OR CONTROL FLUID:

INSTRUMENT AIR LACK:
• Minimum flow valves FV 102, FV 202, FV 302 open.
• The control valves LCV 001, LCV 002, LCV 003 close.
FAILURE OF 48 V DC CONTROL VOLTAGE (on logic controller output):

• The motor-operated valves remain in the position, where they were before voltage failure.
• The solenoid valves FVX 102, FVX 202, FVX 302 are de-energized which cause the opening of valves FV 102, FV
202, FV 302.
• The LP feed water pumps remain in operation.
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35
FAILURE OF 125 V. DC OR 48 V. DC LV SWITCH BOARD.

• The LP feed water pumps are trips.
• The motor operated valves stop in the position they were before the voltage failure.
FAILURE OF 240 V. AC VOLTAGES:

• Shutdown of the heating resistances of the motors.
FAILURE OF 415 V. AC VOLTAGES:

• The LP feed water pumps stop.
• The motor operated valves stop in the position they were before voltage failure.
FAILURE OF T 20:
Al controller power supply:
• No change for the control of the plant.
• Actuators remain in position.
• Drives remain in operation.
A controller power supply:

• Actuator remains in position.
• Individual command remains available.
• Interlocks and protections remain operative.
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36
LP FEED WATER PUMPS. STARTING CONDITIONS: 101 PO, 201 PO, 301 PO
ADG LSL 001

FEEDWATER TANK
LOW LEVEL
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
SAME SEQUENCE FOR 201 PO. 301 PO
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37
LP FEED WATER PUMPS.STARTING: 101PO 201PO 301PO

HSN 001 GROUP TRIPPING
GROUP STARTING ORDER
ORDER
HSU 002
HSU 001 TAKING OVER AUTO
101PO CUT OUT
SELECTED IN NORMAL
SELECTION STATUS
CORRECT
SELECTION STATUS
CORRECT
TAKING OVER MEMORY

ON
ON OFF
TAKING OVER MEMORY
P/P SELECTED IN
NORMAL STOPPED
HSN011
PUMP101PO
SUB-GROUP
STARTING ORDER HSU 001 PUMP 101 PO
HSN 101
PUMP 101 PO
INDIVIDUAL STARTING
ORDER
PUMP 101 PO STARTING CONDITIONS

PUMP101 PO IN OPERATION
IN OPERATION
PUMP 101 PO PUMP 101 PO HEATING

IN OPERATION IN OPERATION STARTING RESISTANCE 101RS
GROUP LEVEL SUB-GROUP LEVEL PUMP101 PO OFF

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38
LP FEEDWATER PUMPS. TRIPPING CONDITIONS: 101PO, 201 PO, 301 PO
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
SAME SEQUENCE FOR 201 PO. 301 PO
38
39
LP FEED WATER PUMPS STOPPING: 101PO 201PO 301PO
HSN 001 GROUP

H
GROUP TRIPPING
TRIPPING ORDER CONDITIONS
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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40
(5) HP FEED WATER SYSTEM (APH)

PURPOSE:
3 x 50% duty HP feed water pumps and feed regulating station together maintain fluid balance in HP
boiler.
1. DESCRIPTION:

The system is composed of 3 x 50% HP feed water motor pump sets, each including:
Driving 6.6 kV motor,
1 multi-stage centrifugal pump,
Lubricating oil system
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.

HP Feed water circuit:
One HP Feed Water pump supply water to HP economiser and superheater in a boiler
Pump:
• Axis horizontal
• Number of stages 10 +1 double (suction)
• Fluid conveyed feed water
• Nominal manometric head 1100 m
• Nominal flow 182.2 m³/h
• Rotation speed 3 000 rpm
Motor:
• Power 850 kW
• Voltage 6600 V
• 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.
Lubricating oil system:

The lubricating oil system for a HP water pump, consists of:
• An oil reservoir.
• A main shaft-driven oil pump
• An electric motor-driven auxiliary oil pumps
• Duplex filters
• Two oil 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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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.
3. DESCRIPTION OF INSTRUMENTAYTION AND CONTROL LOOPS:

HRSG drum level Control loop:
The drum level set point (HIK 001) can be adjusted by the operator from control room.
In normal operation:
The water level is kept constant by means of a three-element control loop (water level, HP water flow, HP
steam flow). A proportional, integral and derivative controller action govern 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 an automatic changeover is realized.
The control valve opening is limited by over flow limitation loop of the HP feed water pump for
protection of this pump. This protection is initiated by the feed water flow through a proportional and
integral controller.
Startup or low load operation:
During start-up or low load operation (up to about 25% load), the HRSG HP Drum level is kept constant
by a single element control loop (water level only) and proportional, integral and derivative controller
action, governs 25% feed water control valve LCV 003.
HP STEAM TEMPERATURE LIMITATION:
The steam temperature at desuperheater outlet must be kept constant, as this superheating steam is sent to
the steam turbine.
The steam temperature set point is adjustable by the operated (HIK 002) from the control room. The
minimum and maximum values are imposed in the control loop. The designed value is compared to the
real value of the superheating steam by means of a proportional, integral and derivative action controller
(PID) and then corrected by the second superheated outlet temperature by means of a second PID which
governs a control valve TCV 004 or TCV 005.
The control valve is closed if the steam flow < 50 t/hr.
Starting in group control level
In normal configuration, the HP feed water pumps are controlled by the group control. The operator
selects one or two pumps to be started up and confirms the starting up by using the group control
command.
The starting conditions must be fulfilled. After the start up of the pump(s) selected, the discharge valves of
the three pumps open and the HRSG HP drum level goes into regulating mode.
Starting in sub-group control level:
The operators can start-up a feed water pump by using the sub-group control command if the starting
conditions are fulfilled.
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The pump starts and its associated discharge valve opens.

Shutdown of HP feed water pumps:
In case of HP feed water sub-group pump order, pump tripping conditions or a voluntary sub-group
stopping order by operator, the pump stops and its discharge valve closes.
In case of HP feed water group tripping order, in a group tripping conditions or a voluntary group stopping
order by operator, the pump stops and its discharge valve closes.
In case of HP feed water pump stopping by an individual control, the pump stops but its discharge valve
stays in position.
Emergency take-over of pumps:
Emergency taking over is only possible at level of group control.
In the case of feed water pump stopping, the emergency taking-over by another pump is only possible
under following conditions:
• The operator has authorized the emergency take-over from the operating drive taking over auto cutout.
• There is no tripping order at group level.
Control of recirculation valve:

This valve opens by low flow and closes by normal flow at the discharge of feed water pumps.
Control of cooling valve:
In-group or sub-group operation:
• At a pump starting order, the corresponding valve opens.
• At pump stopping the corresponding valve closes after a time delay of 5 minutes.
Control of oil lubricating system:

In normal operation the main shaft-driven oil pump lubricates the bearings and the thrust bearings of the
associated HP feed water pump.
During HP feed water pump start-up, if oil pressure is low, the electric motor-driven auxiliary oil pump
starts. It runs until a very high pressure (PSHH) is reached. Then the auxiliary pumps stops.
At the HP feed water pump shutdown, the auxiliary oil pumps is put in operation for 5 minutes.
Abnormal operation: If the main shaft driven oil pump fails, the pressure decreases and the auxiliary oil
pump starts. If the pressure (PSLL) decreases again to very low level, the HP feed water pump trips.
Control of HRSG HP drum level valves:
As soon as the operation conditions are correct for pump(s) in operation, normal discharge pressure inlet
economiser valve opens, (auto/manual loading station in automatic position), the operator puts the HP
feedwater valves sub-group in service.
If one selected control valve is on manual position an alarm is given in the control room.
At the start-up or low load operation, the 25% flow control line is automatically selected. The isolating
motorized valve UV 003 opens and the control valve LCV 003 is in regulation. The other lines are closed.
As soon as the flow reaches 25% the selected 100% flow control line is taken into service, the motorized
valve opens and the associated modulating valve control the HP drum level. The 25% control valve LCV
003 closes and the 25% motorized valve UV 003 closes.
In case of a new selection by the operator, the new selected 100% line is service as described above. The
precedent line in operation closes at the same time, the control valve closes immediately, and then
isolating motorized valve closes.
The HP feed water valves sub-group can be put out of service by the operator only if HRSG is not in
operation.
Control of economiser inlet valve:
This valve is used for the boiler isolation. It opens by an individual control device and closes by a HRSG
tripping order or an individual control device.
Control of steam desuperheating:
As soon as one HP feed water pump is started and there is high pressure in a common header, the
motorized valve UV 004 opens and then the control valve TCV 004 & TCV 005 is put in regulation. In
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44
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:
INSTRUMENT AIR LOSS:

• Minimum flow valves FV 102, FV 202, FV 302 open.
• The control valves LCV 001, LCV 002, LCV 003, TCV 004, TCV 005 close.
• The pneumatic valves FV 101, FV 201, FV 301 open.
FAILURE OF 48 V DC CONTROL VOLTAGE (on logic controlled out put):

• The motor-operated valves stays in the position they were before voltage failure.
• The solenoid valve FVX 101, FVX 201, FVX 301 and FVX 102, FVX202, FVX 302, FVX 302 are de-energized
which cause the opening of valves FV 101, FV201, FV301and FV102, FV 202, FV302.
FAILURE OF 125 V DC or 48 V DC LV SWITCHBOARDS:

• The HP feedwater pumps and its lubricating system are shutdown.
• The motor-operated valves stay in the position they were before the voltage failure.
FAILURE OF 240 V DC VOLTAGES:

• Shutdown of the heating resistances of the motors.
FAILURE OF 415 V AC VOLTEGE:

• The oil motor pump sets stop.
• The motor-operated valve stay in the position they were before voltage failure.
FAILURE OF 6.6 kV VOLTAGES:

• The HP feedwater pumps stop.
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45
HP FEED WATER PUMPS STARTING: 101PO 201PO 301PO

ADG LSL 001
FEEDWATER TANK
ZSH 103
SUCTION VALVE
HV 101 OPEN
ZSL 101
DISCHARGE VALVE
UV 101
PSH 001
DISCHARGE
COMMON HIGH
PRESSURE
STANDBY PUMP HSN 001 GROUP HSN 011 PSH 101

101 PO STARTING STARTING ORDER PUMP 101PO SUB- LUBE OIL HIGH
ORDER GROUPSTARTING PRESSURE
ORDER
HSU 001
PUMP 101 PO
SELECTED IN
NORMAL
DE ENERGIZED PUMP 101 PO

FVX 101 OPENING STARTING LUBE- STARTING
VALVE FV 101 OIL PUMP 102 PO CONDITIONS
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46
HP FEED WATER PUMPS.STARTING: 101PO 201PO 301PO

HSN 001 GROUP TRIPPING
GROUP STARTING ORDER FROM
FOLIO 8
HSU 002
HSU 001 TAKING OVER AUTO
PUMP 101PO CUT OUT
SELECTED IN NORMAL
SELECTION STATUS
CORRECT
SELECTION STATUS
CORRECT
TAKING OVER MEMORY

ON
ON OFF
TAKING OVER MEMORY
PUMP SELECTED IN
NORMAL STOPPED
HSN011
FROM FOLIO 8
PUMP101PO
SUB-GROUP
STARTING ORDER HSU 001
101 PO
HSN 101
PUMP 101 PO
INDIVIDUAL STARTING
ORDER
PUMP 101 PO PUMP 101 PO STARTING STANDBY PUMP

IN OPERATION IN OPERATION CONDITIONS 101 PO STARTING
ORDER
PUMP 101 PO PUMP 101 PO HEATING

IN OPERATION IN OPERATION STARTING PUMP RESISTANCE 101RS
GROUP LEVEL SUB-GROUP LEVEL 101 PO OFF

46
47
HP FEED WATER PUMPS.TRIPPING CONDITIONS: 101PO, 201PO, 301PO
HSX 101 PUMP 101 PO PSLL 104 LUBE-OIL

EMERGENCY STOPPING VERY LOW PRESSURE
ELECTRIC FAILURE VSHH 101 VERY HIGH

101 MO VIBRATION BEARING 101 PO
TSHH 101 VERY HIGH TSHH 106 VERY HIGH

TEMPERATURE BEARING 101 TEMPERATURE WINDING 101
PO MO
TSHH 102 VERY HIGH VSHH 102 VERY HIGH

TEMPERATURE BEARING 101 VIBRATION BEARING 101 PO
PO

TEMPERATURE BEARING 101 VIBRATION BEARING 101 MO
MO

TEMPERATURE BEARING 101 VIBRATION BEARING 101 MO
MO
TSHH 105 VERY HIGH TSHH 107 VERY HIGH

TEMPERATURE BEARING 101 TEMPERATURE WINDING 101
PO MO
PUMP 101 PO IN SERVICE TSHH 108 VERY HIGH

TEMPERATURE WINDING 101
MO
COOLING VALVE FV 101 NOT TSHH 113 VERY HIGH

OPEN ZSH 104 TEMPERATURE BEARING 101
PO
30 SEC
PUMP 101 PO TRIPPING

CONDITIONS
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HP FEED WATER PUMPS. GROUP TRIPPING CONDITIONS: 101PO, 201PO, 301PO
TRIPPING SIGNAL ELABORATION FROM

ADGLSLL 101 &201
ADGLSLL 001 HSX 001 HP FEEDWATER

FEEDWATER TANK GROUP EMERGENCY
VERY LOW LEVEL STOPPING
GROUP TRIPPING
CONDITIONS
SAME SEQUENCE FOR 201PO, 301PO
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HP FEED WATER PUMPS STOPING: 101PO 201PO 301PO
HSN 001
GROUP TRIPPING
H GROUP
CONDITIONS
TRIPPING ORDER
FROM FOLIO 7
HSN 011 HSN 101 PO

SUB GROUP INDIVIDUAL
STOPPING ORDER STOPPING ORDER
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
ENERGIZED FVX 101 HEATING RESISTANCE

CLOSING VALVE FV 101 101 RS ON

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50
(6) LP CIRCULATIN PUMPS (FLB)
1. PURPOSE OF THE SYSTEM:

This System enables optimum heat recovery by boiler from exhaust flue gas.
2. SYSTEM DESCRIPTION:
The system comprises mainly:

• The feed water circuit and the economizer.
• The LP drum,
• The evaporator
• The superheater and LP superheater circuit.
COMPOSITION OF THE EQUIPMENTS AND CIRCUITS:

Feed water circuit:
At he LP feed water pumps outlet upstream the economizer, are fitted:
• A check-valve FLB 094 VV
• The measuring devices PT 056 and TE 049,
• The economizer re-circulation circuit return
Downstream the economizer, on the line to the LP drums:

• Measurement of water temperature FLB TE 058.
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
On the drum itself there are:

• A safety valve FLB 160 VV
• A vent valve FLB UV 012 with limit switches
• Level and pressure measurement devices.
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
The suction line is equipped with a pressure device PT 074

The water is discharge to:
• The evaporator. The water returns then to the drum.
• The 2 identical economizer circulation lines, each one provided with:
• An upstream isolating economizer valve UV 033 (UV 046) with open/closed limit switches.
• A control valve TCV 108 (TCV 109) with closed limit switch.
• A down stream isolating motorized valve UV 032 (UV 047) with open/closed limit switches:
These lines are linked to the economizer inlet through the check-valve 053 VV.
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51
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.
START-UP OF THE BOILER:

• One LP circulation pump has to be put in service prior to start the boiler.
• During start-up and low load, the LP drum level is adjusted at 800 mm level by single element control loop, to
prevent a high level trip due to swelling.
• During start-up, the LP drum vent valve is opened to remove all gases, which were present in the boiler. The LP
superheater vent valve is kept opened to remove the initial steam produced by the boiler while ensuring a steam flow
in the superheater tubes and headers for cooling.
• One economizer circulation line is opened to maintain constantly a water flow through the economizer during start-up
and low load of the boiler.
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.
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FLB CIRCULATING PUMPS 374 & 375 PO. STARTING ORDER
ECO. RECIR CONT.

VALVE TCV 108 ON HSN 001 SUB/GROUP
AUTO MODE STARTING
ECO.RECIR
ECTCV 109
CONT.VALVE
ON AUTO MODE HSU 001 PUMP SELECTED
IN NORMAL 370 PO/375 PO
a b
TAKING OVER MEMORY

ON
PUMP 375 PO PUMP 374 PO

SELECTED IN SELECTED IN
NORMAL NORMAL STOPPED
HSU 001 374 PO HSU 001 375 PO

STANDBY STANDBY
HSN 374-374 PO HSN 375-375 PO

INDIVIDUAL INDIVIDUAL
STARTING ORDER STARTING ORDER

OFF OFF
LP DRUM LEVEL LP DRUM LEVEL

LSVL 070 VERY LSVL 070 VERY
LOW LEVEL LOW LEVEL
LSVL 170 & 270 LSVL 170 &270
START PUMP START PUMP

374 PO 375 PO
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53
FLB CIRCULATING PUMPS 374 & 375 PO. STOPPING ORDER
HSX 001 SUB GROUP HSN 001 SUB GROUP

EMERGENCY STOPPING EMERGENCY STOPPING
TRIPPING SIGNAL
ELABORATION FROM
LSVL 170 &270 LP DRUM LEVEL LSVL
070 VERY LOW LEVEL

ON ON
10 10
SEC SEC

DISCHARGE FLOW LOW DISCHARGE FLOW LOW
FSL 094 FSL 095
HSN 374-374 PO HSN 375-375 PO

INDIVIDUAL STOPPING INDIVIDUAL STOPPING
ORDER ORDER
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

ON ON

FSL 094 FSL 095
HSU 002
TAKING
OVER AUTO
CUT OUT
TAKING OVER ON OFF

MOMORY
54
55
FLB. HRSG TRIPPING ORDER

PUMP 374 PO
ON
LSVL 170 & 270 LSVL 170 &270
LP DRUM LEVEL LSHH LP DRUM LEVEL LSVL
070 HIGH HIGH LEVEL 070 VERY LOW LEVEL
1872 MM 250 MM
PUMP 375 PO
25 SEC
TO TTA SYSTEM US EC
BOILER
TTA US 003 001
TRIPPING
• ORDER NO LP CIRCULATING PUMPS
IN OPERATION *
FLB CIRCULATING PUMPS IN CONFIGURATION

PUMP 374 PO IN PUMP 375 PO IN
OPERATION 374 JA 1 OPERATION 375 JA 1
ECO. RECIR CONTROL ECO RECIR CONTROL

VALVE TCV 108 VALVE TCV 109
MODULATING RELEASE MODULATING RELEASE
TO TTA SYSTEM
LP CIRCULATING
TTA US 002
PUMPS IN
CONFIGURATION
US 002
55
56
(7) HP CIRCULATIN PUMPS (FLH)
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
COMPOSITION OF THE EQUIPMENT AND CIRCUITS:

Feedwater circuit:
At the HP feedwater pumps outlet upstream the economizer, following equipments are
fitted:
• A check valve FLH 307 VV
• The measuring device PT 079 and TE 080
• The economizer re-circulation circuit return
Downstream the economizer, on the HP drum:

• Measurement of water temperature (FLH TE 081)
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
On the drum itself there are:

• A safety valve FLH 162 VV
• 2 vent valves in series: FIH UV 210 and UV 211 with limit switches ZSH/ZSL 211/210
• Level and pressure devices: LT 083 and PT 018.
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)
The suction line is equipped with a pressure device (PT 086)

The water is discharge to:
• The evaporator. Then water returns to the drum
• 2 identical economizer circulation lines, each one provided with:
• An upstream isolating motorized valve UV 247/UV 228 with open/closed limit switches
• A control valve TCV 111 (TCV 110) with close limit switch (ZSL 111/110)
• A downstream isolating motorized valve UV 246/ UV 285 with open/closed limit switches. These are the linked to the
economizer inlet through the check valve 243 VV
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.
START-UP OF THE BOILER:

• One HP circulation pumps has to be put in service prior to start the boiler.
• During start-up and low load, the HP drum level is adjusted at a level close to the low level alarm by the single element
control loop, to prevent high level trip due to swelling, or a drum drain.
• During start-up the HP drum vent valves are opened to remove all gases, which were present in the boiler. The HP
superheater vent valves are kept opened to remove the initial steam produced by the boiler while ensuring a steam flow in
the superheater tubes and headers.
• One economizer circulation line is opened to maintain constantly a water flow through the economizer during start up and
low load of the boiler.
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.
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FLH CIRCULATING PUMPS 378 & 379 PO. STARTING ORDER
ECO. RECIR CONTROL HSN 001 SUB/GROUP

VALVE TCV 110 STARTING
ON AUTO MODE
ECO.RECIR CONTROL
VALVEECTCV 111 HSU 001 PUMP SELECTED
ON AUTO MODE IN NORMAL 378 PO/379 PO
a b
TAKING OVER MEMORY

ON

NORMAL STOPPED NORMAL STOPPED
HSU 001 378 PO HSU 001 379 PO

SEECTED IN SELECTED IN
STAND BY STANDBY
HSN 378-378 PO HSN 379-379 PO


OFF OFF
LP DRUM LEVEL LP DRUM LEVEL

LSVL 080 VERY LSVL 080 VERY
LOW LEVEL TRIPPING SIGNAL TRIPPING SIGNAL LOW LEVEL
LSVL 170 & 270 LSVL 170 & 270
PUMP 378 PO LOW PUMP 379 PO LOW

COOLING WATER COOLING WATER
FLOW FSL 378 FLOW FSL 379

378 PO 379 PO
58
59
FLH CIRCULATING PUMPS 378 & 379 PO. STOPPING ORDER

HSX 001 SUB/GROUP HSN 001 SUB/GROUP
EMERGENCY STOPPING EMERGENCY STOPPING
TRIPPING SIGNAL
ELABORATION FROM HP DRUM LEVEL LSVL
LSVL 180 & 280 080 VERY LOW LEVEL

ON ON
10 10
SEC SEC

FSL 092 FSL 093
HSN 378-378 PO HSN 379-379 PO

INDIVIDUAL STOPPING INDIVIDUAL STOPPING
ORDER ORDER

LOW COOLING LOW COOLING
WATER FLOW WATER FLOW
FSL 378 FSL 379
EC EC
STOP PUMP 378 PO FSLB FSLB STOP PUMP
092 093 379 PO
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60
FLH CIRCULATING PUMPS 378 & 379 PO. TAKING OVER MEMORY
A B

ON ON

ON ON

DISCHARGE FLOW LOW DISCHARGE FLOW LOW PUMP 379 PO PUMP 378 PO
FSL 092 FSL 093 LOW COOLING LOW COOLING
WATER FLOW WATER FLOW
FSL 379 FSL 378
HSU 002
TAKING OVER
AUTO CUT OUT
TAKING OVER ON OFF

MEMORY
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61
FLH. COOLING WATER VALVES SRI FVX 199 & 200
PUMP 378 PO HP DRUM PUMP 379 PO

LOW COOLING WATER SATURATED PRES. HIGH LOW COOLING WATER
FLOW FSL 378 PSH 086 FLOW FSL 379
PUMP 378 PO LOW PUMP 379 PO

COOLING WATER FLOW LOW COOLING WATER
FSL 378 FLOW FSL 379
30 30
MIN MIN
SRI HSN 199 SRI HSN 200

SRI HSN 199 OPERNING OPERNING SRI HSN 200
INDIVIDUAL ORDER ORDER INDIVIDUAL
CLOSING CLOSING
ORDER ORDER
ENERGIZING DE- DE- ENERGIZING

ENERGIZING ENERGIZING
PUMP 378 PO PUMP 378 PO PUMP 379 PO PUMP 379 PO

COOLING COOLING COOLING WAT COOLING WAT
WAT. FLOW WAT.FLOW FLOW VL. FLOW VL.
VL VL. SRI FVX 200 SRI FVX 200
SRI FVX 199 SRI FVX 199
61
62
FLH. HRSG TRIPPING ORDER

LSHH 180 & 280 LSVL 180 &280 PUMP 378 PO
ON
HP DRUM LEVEL LSHH HP DRUM LEVEL LSVL
080 HIGH HIGH LEVEL 080 VERY LOW LEVEL
1644 MM 250 MM
PUMP 379 PO
ON
10
Sec
US EC
TO TTA SYSTEM BOILER 001
TTA US 003 TRIPPING
SIGNAL
FLH HP CIRCULATING PUMPS IN CONFIGURATION

PUMP 378 PO IN
PUMP 379 PO IN
OPERATION 378 JA 1
OPERATION 379 JA 1
ECO.RECIR CONTROL ECO RECIR CONTROL

VALVE TCV 110 VALVE TCV 111
MODULATING RELEASE MODULATING RELEASE
HP CIRCULATING
PUMPS IN
CONFIGURATION US 002
TO TTA SYSTEM
TTA US 002
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FLH HP ECONOMISER CIRCULATING VALVES

HP DRUM LEVEL
LSVL 080
VERY LOW LEVEL
HSU 003 ECO.RECIR.VIS.

SELECTION
TCV 110/TCV 111
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.CONTROL ECO. RECIR. CONTROL ECO RECIR. CONTROL ECO.RECIR.CONTROL

VL.TCV 110 VL.TCV 110 VL. TCV 111 VL.TCV 111
ZSL 110 CLOSED ZSL 110 CLOSED ZSL 111 CLOSED ZSL 111 CLOSED
ECO.RECIR.INLET.ISOL. ECO.RECIR.INLET.ISOL. ECO.RECIR ECO.RECIR.

VL. UV 288 VL. UV 285 INLET.ISOL.VL. INLET.ISOL.VL.
OPENING ORDER OPENING ORDER UV 247 UV 246
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. OUTLET ECO.RECIR.OUTLET.ISO

ISOL.VL. UV 285 OPEN L.VL. UV 246 OPEN
ZSH 285 ZSH 246
ECO. RECIR.CONTROL ECO.RECIR.CONTROL

VL. TCV 110 VL. TCV 111
MODULATING MODULATING RELEASE
RELEASE
C
ECO. RECIR. CONTROL

ECO. RECIR.VL. VL.TVC 111
TVC 110 CLOSING ORDER
CLOSING ORDER
HSN 247 HSN 246

HSN 288 ECO. RECIR. HSN 285 ECO.RECIR. ECO.RECIR.INLET.ISOL. ECO. RECIR.INLET VL
INLET ISOL.VL UV 288 INLET ISOL.VL VL UV 247 CLOSING UV 246 CLOSING ORDER
CLOSING ORDER UV 285 CLOSING ORDER ORDER
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
ECO.RECIR.INLET ECO.RECIR. ECO.RECIR.INLET.ISOL ECO.RECIR.INLET.ISOL

ISOL.VL UV 288 OUTLET.ISOL.VL UV 285 VL UV 247 VL UV 246
CLOSING ORDER CLOSING ORDER CLOSING ORDER CLOSING ORDER
63
64
FLH HP DRUM VENT VALVES UV 210 & 211
HSN 210 HSN 210 INDIVIDUAL HSN 211 INDIVIDUAL HSN 211 INDIVIDUAL
INDIVIDUAL CLOSING OPENING ORDER CLOSING ORDER OPENING ORDER
ORDER
HP DRUM PRESSURE HP DRUM PRESSURE

FLH PSL 010 FLH PSL010
PRESSURE > 2 BAR PRESSURE > 2 BAR
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
FLH HP DRUM OUT LET VENT VALVES UV 286 & 287
HSN 286 INDIVIDUAL HSN 286 INDIVIDUAL HSN 287 INDIVIDUAL HSN 287 INDIVIDUAL
HP DRUM PRESSURE HP DRUM PRESSURE

FLH PSL 010 FLH PSL 010
PRESSURE > 2 BAR PRESSURE > 2 BAR
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
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65
FLH. HP SUPERHEATER OUTLET VENT VALVES 168 & 169
HSN 168 HSN 168

INDIVIDUAL CLOSING INDIVIDUAL OPENING
ORDER ORDER
HP SUPERHEATER
FLH PSL 090
PRESSURE >8 BAR
HP SUPER HEATER
OUTLET
VVP FSL 008
FLOW >15 T/H
HP SHT. OUTLET VENT HP SHT. OUTLET VENT

VL FLH UV 168 VL FLH 168
CLOSING ORDER OPENING ORDER
HSN 169 HSN 169

ORDER ORDER
HP SUPERHEATER
OUTLET FLH PSL 090
PRESSURE >8 BAR
HP SUPERHEATER
OUTLET VVP FSL 008
FLOW >15 T/H
HP SHT. OUTLET VENT HP SHT. OUTLET VENT

VL. FLH UV 169 VL. FLH UV 169
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66
(8) BOILER DRAINS AND BLOWDOWNS (FPU)

1.PURPOSE:
• Warm up the steam pipelines and draining of condensate.
• Blowdown of boiler water to maintain boiler silica.
• Blowdown of boiler water to limit drum level in emergency.
2 SYSTEM DESCREPTION:
• The HP and LP superheater drain lines.
• The drain tank (FPU 372 BA).
COMPOSITION OF THE EQUIPMENTS AND CIRCUITS:

HP drum blow down lines:
It comprises:
• A continuous blow down line fitted with two ON/OFF motorized valves (UV 245/258) in series with the open/close limit
switches.
• A manual regulating valve to control blow down.
• An emergency line fitted with the ON/OFF motorized valve (UV 244) with the open/close limit switches
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.
WHEN THE BOILER IS STOPPED:

• The continuous blow down valves is closed to avoid spilling of water.
• The emergency blows down valves are closed.
• The superheater drain valves UV 081/296 are open.
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.
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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
HSN 245 HSN 245 HSN 258 HSN 258

INDIVIDUL CLOSING INDIVIDUAL OPENING INDIVIDUAL CLOSING INDIVIDUAL OPENING
ORDER ORDER ORDER ORDER
HRSG DAMPER CLOSED HRSG DAMPER CLOSED

TTA ZSL X 10 TTA ZSL X 10
HP DRUM HP DRUM HP DRUM HP DRUM CONT

CONT.BL.D.VL. CONT.BL.D. VL. CONT. BL.D VL. BL.D.VL.
FPU UV 245 FPU UV 245 FPU UV 258 FPU UV 258
FPU HP DRUM EMERGENCY BLOW DOWN VALVE UV 244
HSN 244 HSN 244

ORDER ORDER
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
67
68
FPU LP DRUM SUPERHEATER DRAIN VALVE UV 081
HSN 081 HSN 081

ORDER ORDER
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
FPU HP SUPERHEATER DRAIN VALVE UV 296
HSN 296 HSN 296

ORDER ORDER
HP STEAM FLOW HP STEAM FLOW

VVP FSL 006 VVP FSL 006
FLOW < 20 T/H FLOW < 20 T/H
HP SUPERHEATER
DRAINVL. FPU UV 296 HP SUPERHEATER
CLOSING ORDER DRAIN VL. FPU UV 296
OPENING ORDER
68
69
FPU LP DRUM CONTINUOUS BLOW DOWN VALVE UV 045
HSN 045
HSN 045 INDIVIDUAL INDIVIDUAL OPENING
CLOSING ORDER ORDER
HRSG DAMPER
CLOSED
TTA ZSL X10
LP DRUM CONT. LP DRUM CONT.

BL.D.VL.FPU UV 045 BL.D.VL. FPU UV 045
FPU LP DRUM EMERGENCY BLOW DOWN VALVE UV044
HSN 044 HSN 044

ORDER ORDER
LP DRUM LEVEL FLB

LSH 070
HIGH LEVEL
(1722 MM)
LP DRUM EMERG. LP DRUM EMERG.

BL.D.VL. FPU UV 044 BL.D.VL. FPU UV 044
69
70
FPU. DRAIN VALVES OPEN CONDITIONS HP DRUM CONT.

BL.D.VL.FPU UV 245
OPENED ZSH 245
HP SUPERHEATER
DRAIN VL. FPU UV HP DRUM CONT.
296 OPENED ZSH 296 BLOW DN. VL.
FPU UV 258 OPENED
ZSH 258
LP DRUM CONT BL. D.

LP SUPERHEATER VL. FPU UV 045
DRAIN VL. FPU UV OPENED ZSH 045
081 OPENED ZSH 081
HP/LP SUPERHEATER HP/LP

TO KCS D.VL.OPENED
SYSTEM FPU CONT.BL.D.VL.OPENED
US 001 FPU US 002
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(9) MAIN STEAM DRAINS (ACO)
1. PURPOSE:
The purpose of ACO system is to:

• Reheat the piping line during start-up.
• Drain the condensates, which is collected in the piping.
• Collect the condensates and drain and send them towards the condenser after desuperheating.
DESCRIPTION OF THE SYSTEM:

The system is composed of:
• A drain tank, which collects
• HP and LP steam piping drains
• HP and LP turbine admission drains upstream the stop valves
The heating steam of the piping upstream the turbine.

• The feed water tank overflow.
• A flash tank, which collects.
• Turbine inlet valves drains
• Turbine drains
• Turbine bled steam-piping drains.
DESCRIPTION OF LINES AND EQUIPMENT:

Drain lines:
The drain lines are equipped with a motorized valve and a flow limiting diaphragm.
Drain tank:
The horizontal drain tank discharges into the atmosphere by a chimney
A pipe fitted with a regulating valve discharges the drains to the condenser.
• Total capacity: 10 m³
• Useful capacity 7.5 m³
Flash tank:
The vertical flash tank is connected to the condenser by two pipes:
• At its upper part, the steam line which is equipped with an orifice plate.
• At its lower part, with the water line.
3. OPERATION:
OPERATION AT RATED LOAD:

The piping drain valves closed:
The piping warm-up valves are closed.
The HP and LP bypass pipes are heated by steam circulating towards the turbine admissions (valves A and
B UV 005 and A and B 006 are opened).
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OPERATION AT LOW LOAD:

At low load:
• The piping and turbine drain valves are open (up until approx. 25% of the rated load).
• The warm-up valves of the turbine inlet pipes are open (up until approx. 20% of the rated load).
• The bleed pipe drain valves are open (up until approximately 60% of the rated load).
• The desuperheating water valves are open.
4.DESCRIPTION OF INSTRUMENTATION AND CONTROL LOOPS:

ANALOG CONTROLS:
Regulation of the drain tank level.
The level in the drain tank is kept constant by the regulation valve LCV 001.
LOGIC CONTROL:
Control of drain valves A UV 001 & B UV 001:
These valves are open when the steam temperature is near the saturation temperature or when the steam
flow from the boiler is less than 40 t/h.
They close if the steam temperature is correct and the stem flow is more than 40 t/h.
An individual control allows the valves to be controlled from the control room.
Control of the drain valve C UV 001:
This valve opens when the steam temperature nears the saturation temperature or when the turbine load is
less than 25% of the rated load.
It closes if the steam temperature is correct and the turbine load is greater than 25%.
An individual control allows the valve to be operated from the control room.
Control of the drain valve A UV 002 – B UV 002:
These valves open when water is detected in the drain pot or when the steam flow from the boiler is less
than 8 t/h.
They close if there is more water in the drain pot and if the steam flow is more than8 t/h.
An individual control allows the valve to be operated from the control room.
Control of the drain valve C UV 002:
This valve opens when water is detected in the drain pot or if the turbine load is less than 25% of the rated
load.
It closes if there is no more water in the drain pot and if the turbine load is more than 25%.
An individual control allows the valve to be controlled from the control room.
Control of the bleed line drain valves –C UV 004:
These valves opens if the turbine load is less than 60% of the rated load or if an isolating valve on the
bleed line is closed. They close if the turbine load is more than 60% and if the isolating valves on the
bleed line are open. An individual control allows the valve to be controlled from the control room.
Control of the desuperheating valve TV 001:

This valve opens following the opening of a drain valve or a low level or a high temperature in the drain
tank.
It closes if all the drain valves are closed and if the level and the temperature in the drain tank is correct.
Control of the desuperheating valve TV 002:

This valve is opened due to high temperature in the flash tank.
It is closed by an individual control in the control room and if the temperature is correct.
Control of the warm-up valves C UV 005- C UV 006:

These valves open with turbine load <20% of the rated load.
They close when the turbine load is more than 20% or when the two boilers are shutdown.
An individual control allows the valve to be controlled form the control room.
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5. ANALYSIS OF THE LACK OF MOTIVE OR CONTROL FLUID:
LACK OF INSTRUMENT AIR:

• The level control valve LCV 001 closes.
• The desuperheating valve TV 001-TV 002 open.
FAILURE OF 48 V DC CONTROL VOLTAGES:

• The desuperheating valves TV 001- TV 002 gets open.
• The motor operated valves remain in the same position as before the voltage failure.
FAILURE OF 125 V DC SWITCHBOARDS:

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DRAIN VALVE CONTROL: A UA001-B UV 001

A US 001SATURATION A TTA ZSL X 1`0
TEMP. DETECT (SEE HRSG A DAMPER
ANALOG DIAGRAM) CLOSED
AVVP FSL 004

A HSN 001 HP STEAM FLOW < 40
OPENING ORDER T/H
OPEN VALVE AUV 001
ATTA ZSL X10 A VVP FSL 004

HRSGA DAMPER HP STEAM FLOW
CLOSED < 40 T/H
10
min
A US 001
A HSN 001 SATURATION TEMP.
CLOSING ORDER DETECT.
OPENING ORDER TO
A UV 001
CLOSE VALVE
A UV 001
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DRAIN VALVE CONTROL: C UV 001
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)
HSN 003 GRE

OPENING ORDER STEAM TURBINE
POWER>25%
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
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DRAIN VALVES CONTROL: A UV 002- BUV 002
A LSHH 001 ATTA ZSL X10

A LSHH 001 DRAIN POT HIGH HRSG A DAMPER
DRAIN POT HIGH HIGH LEVEL CLOSED
HIGH LEVEL
A HSN 002 A VVP FSL 001

OPENING ORDER LP STEAM
FLOW < 8 T/H
OPEN VALVE A UV
002
A TTA ZSL X 10 A VVP FSL 001

HRSG DAMPER LP STEAM
CLOSED FLOW < 8 T/H
10 min
HSN 002 ALSH 001

CLOSING ORDER DRAIN POT HIGH
HIGH LEVEL
ALSHH 001
DRAIN POT HIGH
HIGH LEVEL
OPENING ORDER
TO A UV 002
CLOSE VALVE
A UV 002
SAME SEQUENCE FOR B UV 002
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DRAIN VALVE CONTROL: C UV 002
C LSH 001 DRAIN POT A TTA ZSL X 10 B TTA ZSL X 10

HIGH LEVEL HRSG A DAMPER HRSG B DAMPER
CLOSED CLOSED
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
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BLEEDING DRAIN VALVE CONTROL: C UV 003 C UV 004
GRE
STEAM TURBINE ADG ZSH 003
LOAD > 60% VALVE UV 003 OPEN
ADG ZSL 001 ADG ZSL 002

CHECK VALVE UV 001 CHECK VALVE UV 002
LOCKED LOCKED
HSN 009 HSN 010

OPEN VALVE OPEN VALVE

C UV 003 C UV 004
GRE
TURBINE LOAD > 60%
ADG ZSH 003

VALVE UV 003 OPEN
ADG ZSH 001

CHECK VALVE UV 001
UNLOCKED
ADG ZSH 002

HSN 009 CHECK VALVE UV 002 HSN 010
CLOSING ORDER UNLOCKED CLOSING ORDER
CLOSE VALVE C UV CLOSE VALVE C UV

003 004
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DRAIN TANK DESUPERHEATING VALVE CONTROL: C TV 001
A ZSL 001 A ZSL 002

VALVE A UV 001 VALVE A UV 002
CLOSED CLOSED
B ZSL 001 B ZSL 002

VALVE B UV 001 VALVE B UV 002
CLOSED CLOSED
C ZSL 001 C ZSL 002

VALVE C UV 001 VALVE C UV 002
CLOSED CLOSED
GPV ZSL 102 GPV ZSL 106

VALVE UV 102 VALVE UV 106
CLOSED CLOSED
C ZSL 005 C ZSL 006

VALVE C UV 005 VALVE C UV 006
CLOSED CLOSED
HSN 007 LSLL 001 TANK

OPENING ORDER LOW LOW LEVEL
TSH 001 TANK

HIGH
DE-ENERGIZE CTVX 001

VLAVE C TV 001
OPENING
ALL DRAIN
VALVES CLOSED
TSH 001
TANK HIGH
TSH 001 TEMPERATURE
TANK HIGH
TEMPERATURE
LSLL 001 1min

TANK LOW LOW
LEVEL
EC1
ENERGIZE C TVX
001 VALVE CTV 001
CLOSING
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DRAIN FLASH TANK DESUPERHEATING VALVE CONTROL: C TV 002
HSN 008 TSH 002

OPENING ORDER FLASH TANK HIGH
TEMP.
DE-ENERGIZE C TVX 002

VALVE C TV 002
OPENING
HSN 008
CLOSING ORDER
TSH 002
FLASH TANK
HIGH TEMP.
ENERGIZE C TVX
002 VALVE C TV
OO2 CLOSING
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WARM UP VALVE CONTROL: C UV 005

A TTA ZSL X10
B TTA ZSL X 10
HRSG A DAMPER
HRSG B DAMPER
CLOSED
CLOSED
C VVP TDSL 002

HP STEAM
SATURATED
TEMP.DETECTION
HSN 011
OPENING ORDER
(E)
OPEN VALVE
C UV 005
A TTA ZSL X 10
HRSG A DAMPER
CLOSED
B TTA ZSL X 10
HRSG B DAMPER
CLOSED
C VVP TDSL 002

HSN 011 HP STEAM
CLOSING ORDER SAATURATED TEMP.
DETECTION
(E)
OPENING ORDER TO
C UV 005
CLOSE VALVE
C UV 005
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WARM UP VALVE CONTROL: C UV 006
A TTA ZSL X 10 B TTA ZSL X10

HRSG A DAMPER HRSG B DAMPER
CLOSED CLOSED
C VVP TSL 001

HSN 014 LP STEAM
OPENING ORDER LOW TEMP.
OPEN VALVE
C UV 006
A TTA ZSL X 10
HRSG A DAMPER
CLOSED
B TTA ZSL X 10
HRSG B DAMPER
CLOSED
C VVP TSL 001

HSN 014 LP STEAM LOW
CLOSING ORDER TEMPERATURE
OPENING ORDER TO
C UV 006
CLOSE VALVE
C UV 006
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ISOLATING VALVES CONTROL: A UV 005-B UV 005
AHSN 005 A VVP ZSH 002

OPENING ORDER VALVE AVVP
UV002 OPEN
OPEN VALVE
A UV 005
A HSN 005 A VVP ZSL 002

CLOSING ORDER VALVE AVVP UV
002 CLOSED
CLOSE VALVE
A UV 005
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ISOLATING VALVES CONTROL: A UV 006-B UV 006
A HSN 006 A VVP ZSH 001

OPENING ORDER VALVE A VVP
UV 001 OPEN
OPEN VALVE A
UV 006
A HSN 006 A VVP ZSL 001

CLOSING ORDER VALVE A VVP
UV 001 CLOSED
CLOSE VALVE
A UV 006
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INTERCONNECTION WITH KCS SYSTEM (START UP CONTROLER)
A VVP A VVP
FSL 004 FSL 001
10 Min 10 Min
ALSH 001
A US 001 VALVE A UV 001
HIGH LEVEL
AZSH 001 ALSHH 001 AZSH 002

VALVE UV 001 VALVE A UV 001 VALVE A UV 002
OPEN HIGH HIGH LEVEL OPEN
&
DRAIN VALVES
A 001 & UV 002
OPEN AUS 003
A ZSH 005 A ZSL 005

VALVE A UV 005 VALVE A UV 005
OPEN CLOSED
AZSH 006 VALVE A ZSL 006 VALVE

A UV 006 OPEN A UV 006
CLOSED
DRAIN VALVES DRAIN VALVES

A 005 & UV 006 A005 & UV 006
OPEN CLOSED
AUS 004 A US 002
SAME SEQUENCE FOR BUS 002, BUS 003 & BUS 004
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INTERCONNECTION WITH KCS SYSTEM (START UP COTROLER)
GRE C VVP TDSL 002

STEAM TURBINE HP STEAM
>25% SATURATED TEMP.
DETECTION
C ZSH 005
VALVE C UV 005
C US 001 SATURATED C LSH 001 OPEN
TEMPERATURE. DRAIN POT HIGH
DETECTION LEVEL
C LSHH 001 C VVP TSL 001

DRAIN POT HIGH LP STEAM LOW
HIGH LEVEL TEMPERATURE
C ZSH 002 DRAIN

C ZSH 001 VALVE C UV 002 C ZSH 006
DRAIN VALVE C UV OPEN VALVE C UV 006
001 OPEN OPEN
&
DRAIN VALVES
C UV 001,002,005 &
UV 006 OPEN C US 003
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(10) MAIN STEAM CIRCUIT (VVP)

1. PURPOSE:
The purpose of the VVP system is to:

• Supply the steam turbine with LP steam and HP steam for parallel operation of the waste heat boilers.
• Supply the feed water tank with LP steam.
• Supply HP steam for the turbine gland sealing system.
2. GENERAL DESCRIPTION:
The system is mainly composed of two main manifolds:

• One manifold for low pressure steam supply.
• One manifold for high pressure steam supply.
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.

Main manifolds:
Every steam line from the boiler is equipped with:
• One non-return valve.
• One flow-measuring nozzle.
• One drain pot at the lower point.
• Steam pressure and temperature measuring points.
• One branch pipe for bypass pipe.
Every main manifold is equipped with:

• Steam pressure and temperature points.
• One header section valve and one bypass valve on each side.
Main steam lines to the steam turbine:

Every pipe is equipped with:
• One drain pot at the lower point.
• Steam and temperature measuring points.
3. OPERATION:
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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.
Operation with both boilers:

All the valves on the manifolds are open.
Transient operation:
Start-up:
Start-up only one boiler as the other is at shutdown:
The operator has to close (if not already closed) the header section valve of the HRSG, which will remain
shutdown or will start in second. The opening (if not already done) of the isolating valve of the HRSG,
which starts, will be made automatically as soon as the HRSG damper starts to open.
HP manifold:
The bypass valve of the section header valve opens to condition the downstream pipe as soon as the
HRSG damper is no more closed (TTA ZSL 100).
When pressure upstream and downstream of the section valves are partly balanced (A/B VVP PDSL 002),
the main valve opens:
• Final admission of HP and then LP steam to the turbine depends on the control valves peculiar to the turbine.
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.
Starting of one boiler, when the other is already on duty

HP manifold
The second boiler is brought on steam:
• When there is no more steam saturation temperature detection (ACO TDSL 001)
• The HP steam temperature is higher than 450 ºC (VVP TSH 002)
• When pressure of the boiler under start-up is almost equal to the ST up steam pressure (A/B VVP PDSL 004- end of the
steam sequence), the bypass valve and then the main section valves are opened on the manifold.
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).
Tripping of one HRSG (or one gas turbine):

• If two HRSGs are running in parallel, isolating valve of the boiler, which trips closes.
• If only one HRSG is in operation and tripped, the isolating valve remains open. The steam turbine trips but the turbine seal
are always fed by the HRSG residual steam pressure, down to 20-bar g.
Tripping of the steam turbine only:

The HRSG(s) continue(s) to operate via the bypass.
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The following valves are kept in open position:

• On the manifold: in order not to deprive gland seal feeding.
• On the LP manifold: to preserve the feedwater tank heating.
4. DESCRIPTION OF INSTRUMENTATION AND CONTROL LOOPS:

ANALOG CONTROL LOOPS:
Condensate water detection in the pipes
Refer to ACO system (drain and condensate recovery system).
HP steam pressure control
Sliding pressure mode operation

The ST inlet valves do not control the steam pressure. They take up the 100% or 50% open position
depending on the number of boilers on duty.
The position is defined by the position open or closed of the isolating valves on the HP header.
Limitations:
In order to protect the waste heat boilers, the steam turbine control system causes the ST HP inlet valves to
close for:
• Keeping the HP steam pressure at a minimum value of 30-bar abs.
• Limiting the negative steam pressure gradient to 3.5 bar/min.
• Over speed protection.
LP steam pressure control:

Constant pressure mode operation:
The steam turbine LP inlet valves adjust the steam pressure to the value given and this set point can be
changed internally in the steam turbine control cubicle.
FAILURE OF 48 V DC CONTROL VOLTAGES ON LOGIC CONTROLLER OUTPUT:
• The motor-operated valves remain in same position.
FAILURE OF 125 V DC OR 48 V DC ON LV SWITCHBOARD:

• The motor-operated valves remain in same position
FAILURE OF 415 V VOLTAGES:

FAILURE OF T20 AI CONTROLLER POWER SUPPLY:

FAILUR OF T20 AA CONTROLLER OPWER SUPPLY:

• Individual commands remain available.
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90
HP HEADER VALVES A UV 002- UV 004 OPERATION
HRSG A SUB-GROUP “OFF”

DAMPER CLOSED ORDER A HSN 020
A TTA ZSL 100
HRSG B
DAMPER CLOSED
B TTA ZSL 100
CLOSING ORDER HRSG B HEADER CLOSING ORDER

UV 004 INDIVIDUAL VALVE CLOSED UV 002 INDIVIDUAL
CONTROL B ZSL 002 CONTROL
A HSN 004 A HSN 002
HRSG A HEADER
V/V CLOSED AZSL
002
CLOSING OF UV 004 CLOSING OF UV 002
SAME SEQUENCE FOR B UV 002-UV 004
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LP HEADER VALVES A UV 001- UV 003 OPERATION

STARTUP ORDER SUB-GROUP
FROM KCS “ON” ORDER
A HSN 010
STEAM TEMP.
>175 ºC
A TSH 001
HRSG B HEADER
VALVE CLOSED
B ZSL 001;B ZSL 003
HRSG B HEADER HRSG B HEADER DIFFERENTIAL OPENING ORDER

VALVE CLOSED VALVE CLOSED PRESSURE <0. 5 UV 003 INDIVIDUAL
B ZSL 001; B ZSL 001; BAR A PDSL 001 CONTROL
B ZSL 003 B ZSL 003 A HSN 003
HRSG B HEADER HRSG B HEADER OPENING OF

HRSG A VALVE CLOSED VALVE CLOSED UV 003
COUPLING ORDER B ZSL 001; B ZSL 001;
B ZSL 003 B ZSL 003
HRSG A HEADER HRSG A HEADER

BY-PASS VALVE BY-PASS V/V
OPEN A ZSH 003 OPEN A ZSH 003
DIFFERENTIAL OPENING ORDER

PRESS<4 BAR UV 001 INDIVIDUAL
A PDSL 003 CONTROL
A HSN 001
OPENING OF
UV 001
SAME SEQUENCE FOR B UV 001-UV 003
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HP HEADER VALVES A UV 002- UV 004 OPERATION

STARTUP ORDER SUB-GROUP “ON”
FROM KCS ORDER A HSN 020
STEAM
TEMPERATURE >
450 ºC A TSH 002
HRSG B HEADER SATURATION

VALVE CLOSED TEMP. DETECTION
B ZSL 002; BZSL 004 A ACO TDSL 001
HRSG B HEADER HRSG B HEADER DIFFERNTIAL OPENING ORDER

VALVE CLOSED VALVE CLOSED PRESSURE < 3 BAR UV 004 INDIVIDUAL
B ZSL 002; B ZSL B ZSL 002; B ZSL APDSL 004 CONTROL
004 004 A HSN 004
HRSG A HRSG B HEADER HRSG B HEADER OPENING OF

COUPLING ORDER VALVE CLOSED VLAVE CLOSED UV 004
B ZSL 002;B ZSL 004 B ZSL 002;B ZSL 004
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
SAME SEQUENCE FOR B UV 002-UV 004 OPENING OF

UV 002
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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
POSITION OF HP/LP ISOLATING HEADER VALVES

LP HEADER V/V LP HEADER A UV
AUV 001 OPENED 001 CLOSED
A ZSH 001 A ZSL 001
LP B.P.V/V A UV LP B.P.V/V A UV
003 OPENED 003 CLOSED
AZSH 003 A ZSL 003
HP HEADER V/V HP HEADER V/V A

A UV 002 OPENED UV 002 CLOSED
A ZSH 002 A ZSL 002
HP B.P. V/V UV 004 HP B.P. V/V A UV

OPENED 004 CLOSED
A ZSH 004 A ZSL 004
HRSG A HP/LP HRSG A HP/LP

HEADER V/V OPEN HEADER V/V
A US 002 CLOSED A US 003
SAME SEQUENCE FOR HRSG B
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HP/LP STEAM CONDITION FOR HRSG COUPLING
STEAM
TEMPERATURE
>450ºC
A TSH 002
STEAM
TEMPERATURE
>175ºC
A TSH 001
(E) SATURATION
TEMP. DETECTION
A ACO TDSL 001
HRSG A HP STEAM HRSG A LP STEAM

CONDITION CONDITION
CORRECT CORRECT
A US 005 A US 004
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LP HEADER VALVES A UV 001- UV 003 OPERATION
HRSG A SUB-GROUP
DAMPER “OFF” ORDER
CLOSED A HSN 010
A TTA ZSL X10
HRSG B
DAMPER
CLOSED
B TTA ZSL X 10
CLOSING ORDER UV HRSG B HEADER CLOSING ORDER UV

003 INDIVIDUAL V/V CLOSED 001 INDIVIDUAL
CONTROL B SZL 001 CONTROL A HSN 001
A HSN 003
HRSG A HEADER
V/V CLOSED
A ZSL 001
CLOSING OF CLOSING OF
UV 003 UV 001
SAME SEQUENCE FOR B UV 001 – UV 003
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STEAM TURBINE SEAL ISOLATING VALVE C UV 005

C UV 005 C UV 005
HSN 005 HSN 005
OPENING OF CLOSING OF
C UV 005 C UV 005
HRSG A STEAM TEMP VERY HIGH PROTECTION
HP STEAM TEMP.
VERY HIGH
A TSHH 004
30 Min
SEE TTA SYSTEM (TTA US 003) TRIPPING OF

SAME SEQUENCE FOR HRSG B HRSG A
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(11) BOILER FLUE GAS SYSTEM (TTA)

1. PURPOSE:
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 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 FV 396:

It is a single flap, which can close the boiler side or the stack side to the hot gases of the gas turbine while
rotating around its horizontal shaft.
The damper is considered open if gas can flow to the boiler (combined cycle)
The damper is considered closed if boiler is isolated from the gas turbine (open cycle)
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.)
Emergency closing, (closing time 20 sec.)

• Holding when there is none of the above orders.
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.
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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.
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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.
The boiler will trip if:

• No LP circulation pump is ON.
• No HP circulating pump is ON
• There is a LP feed water pump protection against over flow i.e. due to any leakage etc.
• There is a HP feed water pump protection against over flow.
• The LP drum level is very low or high <300 mm or >1870 mm
• The HP drum level is very low or high <300 mm or >1640 mm
• The gas turbine is not ON (unit circuit breaker is not closed)
• The steam temperature is very high 535°C (delay 30 min)
• There is no steam exhaust or flow (the HP (GHP) or LP (GBP) bypass is unavailable and the steam turbine is tripped) and
the diverter opening is more than 33%
• Weather damper not open.
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100
DIVERTER DAMPER: OPEN & CLOSED POSITIONS

DIVERTER DAMPER
DIVERTER DAMPER ZSH 10A
ZSH 100 OPEN POSITION
OPEN POSITION
DIVERTER DAMPER DIVERTER DAMPER DIVERTER DAMPER

ZSH 10A ZSH 10B ZSH 10B
OPEN POSITION OPEN POSITION OPEN POSITION
5
SEC
DIVERTER DAMPER
ZSH X 10
OPEN POSITION
DIVERTERDAMPER
ZSH 100 DIVERTER DAMPER
CLOSED POSITION ZSH 10A
CLOSED POSITION
DIVERTER DAMPER DIVERTER DAMPER DIVERTER DAMPER

ZSH 10A ZSH 10B ZSH 10B
CLOSED POSITION CLOSED POSITION CLOSED POSITION
5
SEC
DIVERTER DAMPER
ZSL X10
CLOSED POSITION
DIVERTER DAMPER: LIMITATION

STEAM TURBINE
<15%
X3 < X <=100%
LIMITATION BY
STEAM TURBINE
LOAD < 15%
100
101
DIVERTER DAMPER: AUTOMATIC OPENING & CLOSING MEMORIES
HRSG
TRIP MEMORY ON
US 003
HRSG
READY TO START US
002
D
CLOSING INDIVIDUAL ORDERS G

OPENING H
STOPPING F
LIMITATION BY
STEAM TURBINE
LOAD < 15%
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
AUTOMATIC OPENING MEMORY AUTOMATIC CLOSING MEMORY

ON OFF
ON OFF
101
102
DIVERTER DAMPER: EMERGENCY CLOSING VALVE
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)
EMERGENCY CLOSING VALVE

ZVX 447
102
103
BOILER READY TO START: SIGNAL ELABORATION

DIVERTER DAMPER
SEE APB, APH; FLB; FLH &
CLOSED
FLP OPERATION NOTICES
ZSL X 10
LP CIRCULATING
PUMP IN
CONFIGURATION
FLB US 002
HP CIRCULATION
PUMP IN
CONFIGURATION
FLH US 002
CONDENSATE
PREHEATER PUMP IN
CONFIGURATION
FLP US 002
HP DRUM START-UP LEVEL

FLH LSL 080 (600 MM)
LP DRUM START-UP LEVEL

FLB LSL 070 (600 MM)
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
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104
DIVERTER DAMPER QUICK CLOSING ORDER (HRSG TRIP MEMORY)

SEE APB, APH, FLB, FLH, GBP,
GHP & VVP OPERATION NOTICES
BLOCK EMERGENCY TRIP WEATHER DAMPER NOT

P-B OPEN
C KSC HSX 001 A US 001
EMERGENCY P-B DAMPER LP DRUM VERY LOW

QUICK CLOSING ORDER LEVEL
A HSX 001 A FLB LSVL 070
GT A HP DRUM VERY LOW

CONNECTED TO THE GRID LEVEL
TEV L 52 GX 2 A FLH LSVL 080
HP BFPs PROTECTION LP DRUM VERY HIGH

AGAINST OVERFLOW LEVEL
A APH US 003 A FLB LSHH 070
LP BFPs PROTECTION HP DRUM VERY HIGH

AGAINST OVERFLOW LEVEL
A APB US 003 A FLH LSHH 080
HRSG A CIRCULATING PUMPS OFF

NO STEAM EXHAUST FLB 374 & 375 PO
A US 006 A FLB US 001
STEAM PRESSURE VERY CIRCULATING PUMPS OFF

HIGH (535º C) FLH 378 & 379 PO
AVVP TSH 004 A FLH US 001
DIVERTER DAMPER
30Min CLOSED
TTA ZSL X 10
HRSG TRIP MEMORY TTA US 003 ON OFF

FREEZING ORDER
TWO HRSG STOPPED
BOILER DAMPER QUICK BOILER DAMPER QUICK

CLOSING ORDER CLOSING ORDER
1A TTA US 003 1B TTA US 003
HRSG B DIVERTER HRSG A DIVERTER

DAMPER CLOSED DAMPER CLOSED
1B TTA ZSL X 10 1A TTA ZSL X 10
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105
TWO HRSGS STOPPED TWO HRSGS STOPPED

1A TTA US 004 1B TTA US 004
HRSG A DAMPER CLOSING FAULT HRSG A: NO STEAM EXHAUST

SAME SEQUENCE FOR HRSG B SAME SEQUENCE FOR HRSG B
BOILER DAMPER QUICK ST TRIPPED

CLOSING ORDER 1C GSE US 058
A US 003
40SEC. HP BY-PASS AVAILABLE LP BY-PASS AVAILABLE

1A GHP US 001 1A GBP US 100
HRSG DIVERTER DAMPER BOILER START-UP

CLOSED COMPLETED
A ZSL X 10 X> X 1
HRSG A CLOSING FAULT HRSGA

TO TRE SYSTEM (GT TRIP
A ORDER)
US 005 NO STEAM EXHAUST
A US 006
HRSG A : STEAM TURBING GENERATOR TRIP

TWO HRGs STOPPED 1A LP DRUM VERY HIGH HP DRUM VERY HIGH

TTA US 004 LEVEL LEVEL
A FLB LSHH 070 A FLH LSHH 080
HP HEADER VALVE
LP HEADER VALVE CLOSED
CLOSED 1A VVP ZSL 002
1A VVP ZSL 001
TO GSE & KCS SYSTEM HRSG A STEAM TURBINE

(S.T. TRIP ORDER) GENERATOR TRIP
1A TTA US 034
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106
(12) LP BY PASS SYSTEM

1. PURPOSE OF SYSTEM:
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:
• The LP bypass circuit is composed of two pipes connecting the LP steam manifold to the condenser.
Each circuit is fitted with:

• A pressure-reducing valve (hydraulic actuator type)
• An isolation valve upstream of the pressure-reducing valve.
• A piping from the CEX system supplies a desuperheating water system arranged in the condenser neck.
• Pressurized oil necessary for operation of the pressure reducing valve actuator is supplied by two driving oil sets (one per
boiler). These plants also supply the oil necessary for operation of HP/LP bypass valves.
DESCRIPTION OF EQUIPMENT AND CIRCUIT:

PRESSURE REDUCING VALVE (PCV 001):
The pressure-reducing valve is of the cage type with fluid tending to open it.
It is actuated by a double action hydraulic ram 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 (ZSL 001) and an open limit switch (ZSH 001).
Operating time in the control mode: adjustable from 3 to 10 sec.
Isolating valve (UV 001):
The isolating valve is of the parallel seat type with an electric actuator.
The valve is equipped with two limit switches: opening (ZSH 101) & closing (ZSL 101).
Operating time: 30 sec.
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.
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.
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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.
Start-up the second GT & Boiler:

• The pressure set point freezing keeps the bypass valves closed as long as the boiler control damper is closed.
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
The steam coupling operation progresses according to the following sequences:

• When the pressure of the boiler under starting equals the pressure up steam of the steam turbine, the section
valve on the manifold opens.
• Once the LP manifold section valve is no longer closed, the steam coupling operation is completed. The
pressure set point is the constant pressure set point of the steam turbine plus a few %.
Operation of the desuperheating water system inside the condenser:

Detection of the LP bypass valve not closed position causes the desuperheating valve UV 102 to open
automatically.
This valve remains open as long as the LP bypass valve is not fully closed. It recloses only when the LP
bypass valve is fully closed.
Condenser protection:
The condenser is protected by safety devices, which close the bypass valve in emergency.
Operation of the bypass valve driving oil plant:
This has been discussed in HP bypass system:
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 adequate position to a maintain the pressure set point displayed in the
control cubicle.
The LP bypass set point of the boiler tripped is kept at the value it was before the tripping, in order to keep
the boiler under pressure.
Tripping of the steam turbine with condenser available:
When ST trips; the turbine inlet valves close, the steam manifold section valves remain open and the
bypass valves adjust the pressure in the LP steam manifold at the constant pressure set point
The exhaust gas damper at the gas turbine exhaust take up such a position as to maintain a partial exhaust
gas flow to the boiler.
Tripping of the steam turbine with condenser unavailable:
When ST trips and the condenser pressure reach the tripping value, the bypass valve will close
automatically.
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108
Start-up after ST trip:

As the manifold section valves have remained open, both boilers are simultaneously brought on stream
again. Loading is symmetrical for both boilers. The bypass valves adjust the pressure in the LP steam
manifold.
The steam turbine is run up by opening of the HP inlet valves and when the ST load is more than 25% the
LP inlet valves open.
The steam pressure drops because of steam flow into the LP cylinder and the LP bypass valves close.

Regulation:
• The regulation function is ensured by the bypass valve PCV 001.
• The pressure controller governing the bypass valve receives a set point displayed in the control cubicle.
• The pressure measurement taken into account is the HRSG outlet pressure when the HRSG is not coupled and the ST
upstream pressure when the HRSG is coupled (depending on the LP steam manifold valves position).

CONDENSER PROTECTION:
A closing order is given to the bypass valves PCV 001 by the following signals:
• Very high pressure in the condenser (350 m bar)
• Low pressure of desuperheating water (<8 bar)
• LP bypass fault.
• High temperature downstream of the pressure-reducing valve >100°C
• Positioning loop disturbance.
Desuperheating water valves (UV 102):

Spray water is injected into the condenser by means of a valve GBP UV 102, which opens for not closed
position of the LP bypass valves.
4. ANALYSIS OF LOSS OF MOTIVE OR CONTROL FLUIDS:
LOSS OF INSTRUMENT AIR:

• The desuperheating valve opens.

• The desuperheating valve opens & the bypass valve close.
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109
LP BY-PASS VALVE OPERATION PCV 001
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
SAME SEQUENCE FOR B PCV 001
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110
LP BY-PASS VALVE OPERATION A PCV 001
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
ELABORATION OF SIGNAL “ LP BY-PASS FAULT”
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
BY-PASS ISOLATING VALVE OPERATION A UV 101
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
DESUPERHEATING VALVE A UV 102
BY- PASS VALVE PCV

001 CLOSED
A ZSL 001
10”
ENERGIZING OF DEENERGIZING OF
A UVX 102 A UVX 102
CLOSING OF OPENING OF
A UV 102 A UV 102
113
114
(13) HP BYPASS SYSTEM

1.PURPOSE OF THE SYSTEM
The purpose of HP Bypass system is to monitor the pressure and temperature of the both boilers and the
steam turbine during transients.
Start-up
The bypass circuit is brought on stream to bring the steam to the correct temperature and pressure on
startup before it is led to the turbine.
Steam turbine Tripping and house load operation:
In case of steam turbine tripping or house load operation, the bypass circuit is brought on stream to enable
the boiler to go on operating in order to restart steam turbine rapidly.
Normal operation:
The bypass circuit limits the pressure gradient to the value admitted. The bypass valves open and relieve
boiler pressure during ST load throw off.

The HP bypass circuit is composed of two pipes connecting the outlet of each boiler to condenser (steam
is taken off from the HP manifold, upstream of the section valves).
Each circuit is fitted with:
• A pressure-reducing valve (hydraulic actuator type).
• A motorized isolating valve upstream of the pressure-reducing valve.
• A desuperheater and associated equipment.
• One desuperheating pneumatic on-off valves.
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.
The same applies for boiler B.

The pressure-reducing valve is of the cage type.
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.
Section valves upstream of the bypass valves are open.
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.
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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.
OPERATION OF THE BYPASS VALVES DRIVING OIL PLANT:

- Each block is composed of 2 driving oil plants, each associated with a boiler.
- Each driving oil plant includes 1 oil pump on duty and 1 on standby.
- Each driving oil plant actuates 1 LP bypass valve, 1 HP bypass valve.
- Each pump of the variable displacement type pressurizes the valve control circuit.
- The oil pump on duty operates continuously. A safety valve at the pumps discharge opens when the
pressure reaches high in the control circuit and thus allows the no-load operation of the pump with oil
returns to the tank.
- When the control circuit pressure is low the safety valve closes and thus allows the accumulator filling.
- In a case, when pressure in the control circuit decreases to 140 bars, a pressure switch causes the start up
of the pump selected on emergency take-over mode.
- In a case, when pressure in the control circuit increases to 180 bars a pressure switch causes the hydraulic
valves to take up the safety position. The oil quantity required is supplied by the accumulator.
OPERATION OF THE DESUPERHEATING WATER SYSTEM:

- Desuperheating water is injected downstream of the HP bypass valves by two on-off pneumatic valves.
- The first valve UV 102 opens when the bypass valve PCV 001 is no more closed.
- The second valve UV 103 opens on a bypass steam pressure criterion
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.
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117
Tripping of the steam turbine with condenser unavailable:

Should the ST trip and the condenser pressure reaches the tripping threshold, the bypass valve
gets closed.
Start up after ST trip:
As the manifold section valves have remained open, both boilers are simultaneously brought on
stream again. The bypass valve adjusts the pressure in the HP steam manifold.

Bypass valves:
- In normal operation, the pressure controller governing the bypass valve PCV 001 may
depend on the set point, which is elaborated by the control system From the steam flows of each boiler.
• The control system adds the flow of the boilers whose section valve is no longer closed and generates a function, which
gives the required pressure.
- The pressure set point is different according to the number of boiler on duty (one or two section valves
no longer closed on the steam manifold).
- On start up, the pressure controller receives a set point elaborated by the control system from the HP
steam flow of the boiler considered.
- During the steam coupling operation, the controller as a set point the pressure upstream of the steam
turbine HP inlet valves plus by a few %.
- The start up pressure set point is used when the section valve on the steam manifold is closed.
- The normal operation pressure set point is used when the section valve on the steam manifold is no
longer closed.
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.

Driving oil plants control:
• The pump of the driving oil plant on duty operates continuously.
• The pumps are governed by the low and very low pressures of oil circuit and the very low level of the oil tank.
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)
Desuperheating valves (UV 102, UV 103):

• An opening order is given to the desuperheating valve UV 102 in case of PCV 001 not closed.
• An opening order is given to the desuperheating valve UV 103 in case of high pressure (> 18 bar) downstream of the
bypass valve (PSH 001).
ANALYSIS OF LOSS OF MOTIVE OR CONTROL FLUIDS:

• The desuperheating valves open.
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118

• The desuperheating valves open.
• The bypass valves close.
• The hydraulic oil pumps remain in operation.
FAILURE OF 125 V DC OR 48 V DC ON SWITCHBOARD:

• The motor-operated valves remain in position.
• The hydraulic oil pumps are shutdown.
FAILURE OF 240 V AC VOLTAGES:

• The bypass valves close.
• The hydraulic oil pump stops.

• The motor-operated valves remain position.
• The hydraulic oil pumps stop.
FAILURE OF T20 AI CONTROLLER:

• The motor-operated valves remain in position.
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)
Hydraulic supply unit:

The HSU is compact and built on a base frame which makes it easy to transport and install. All hydraulic
equipment forms one unit.
Each HSU is controlled by a separate hydraulic supply logic system. HSL is mounted in a cabinet.
Operation:
Pumps with variable displacement have been chosen to obtain favourable operation conditions. The
pressure level in the system will be as constant as possible.
The pump capacity is chosen to meet the requirement of a normal control operation during a control time
of 20 seconds.
One pump is chosen to be operating as a continuously running pump. The other pump will be acting as a
standby pump, which will be started only if the system pressure falls below the set point. The standby
pump will then be running during a preset 5 minutes time. If 5 minutes are exceeded, then warning RTTL
will be given. If the pressure is above the starting limit, the standby pump will stop, but if the pressure still
is on or below the set point after 30 seconds, alarm be given.
The hydraulic supply logic system will switch off running standby pumps after a preset 20 hours time. The
reason for this is to achieve same total running time for both pumps.
The accumulator(s) are of piston type. The accumulator(s) are recharged with nitrogen to achieve the
necessary driving force in case of quick opening or closing operations. The accumulator’s primary task is
to provide necessary hydraulic supply in emergency situations such as quick actions, but secondary task is
to level out the hydraulic supply in control mode.
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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 “warning” is activated when:

• RTTL. Running time too long on one motor.
• Filter is bypassed.
• Oil temperature is too high
• Oil level in tank reaches a low level
• Oil pressure reaches a too high level (pumps stop)
• The motor safety switch has tripped
The “alarm” is activated when:

• Oil pressure reaches a too low level
• Oil level in the tank reaches a too low level (pumps stop) (<<150 mm)
• Pumps are emergency stopped
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.
HYDRAULIC SUPPLY LOGIC:

Application:
The hydraulic supply logic (HSL) serves to control and monitor one hydraulic supply unit, with two
pumps. In case of deviation from normal operation, an alarm is produced. The latter is signalised on two
different priority levels: WARNING (WA), if the personnel has sufficient time for correcting actions, and
ALARM (AL), if immediate interlocking actions are required.
Stopping the pump:
The following conditions lead to the PUMP OFF signal:
• Emergency stop
• Loss of motor supply
• Oil level too low
• Control switch in position OFF
• Discharge Pressure is exceeded
Warnings:
The following conditions lead to the WARNING signal:
- Motor Over Current .
- Filter not ok
- Pressure too high.
- Oil temperature too high.
- Running time too long RTTL.
- Oil level low.
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Alarm:
The following conditions are responsible for the ALARM signal:
- Pressure too low
- Emergency stop.
- Oil level too low.
Input signals from the hydraulic supply unit:

P<< Pressure too low Alarm valves close
P< Pressure low 140 Bar Start back-up pump
P= normal 160 Bar ok
P> Pressure high 180 Bar Warning Stop pumps
L< Oil level low 250 mm Warning
L<< Oil level too low 150 mm Alarm Stop pumps
I> Over current 16 A Warning Start next pumps
T> Oil temp. too high 60 C Warning
F> Filter failure dp > 3,5 bar Warning
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121
BY-PASS VALVE OPERATION A PCV 001
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 FAULT

A GHP US 010
HP BY-PASS
AVAILABLE
A GHP US 100
A PCV 001
IN REGULATION
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122
ELABORATION OF SIGNAL “ HP BY-PASS FAULT”
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
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123
BY-PASS VALVE OPERATION A PCV 001
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
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124
DESUPERHATING VALVE A UV 102
BY-PASS VALVE PCV

001 CLOSED
A ZSL 001
1”
ENERGIZING OF A UVX DEENERGIZING OF

102 A UVX 102
CLOSING OF OPENING OF
AUV 102 AUV 102
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125
DESUPERHETING VALVE A UV 103
BY-PASS DOWN STEAM

PRESSURE HIGH
>18 BAR HP
>1 BAR LP
A PSH 001
ENERGIZING OF DEENERGIZING OF
A UVX 103 A UVX 103
CLOSING OF
AUV 103 OPRNINH OF
A UV 103
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126
BY-PASS ISOLATING VALVE OPERATION A UV 101
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
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(14) CONDENSATE PREHEATER SYSTEM (FLP)

1. PURPOSE:
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:

- A 3-way valve to bypass the preheater.
• The preheater
- The circulation pumps set.
BY PASS VALVE TCV 107:

This valve opens in the two following cases:
• To mix cold condensate water with preheated water when the temperature of the latter exceeds the deaerator
temperature minus 10 C, before it reaches the deaerator.
• To avoid sending cold water to the preheater if the circulation is not sufficient to maintain the minimum temperature.
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.
On the common header discharge, there are:

• A pressure transmitter PT 069.
• A regulating valve TCV 106 which opens to ensure the minimum temperature limit of 40 °C of the condensate
entering the boiler.
• In parallel to TCV 106, a minimum flow valve FV 196 protects the pumps in case of TCV 106 closure.
The circuit ends at the preheater inlet:

• TCV 107 maintains the condensate inlet temperature to D/A 10 °C below feed storage tank temperature.
3. INSTUMENTATION AND CONTROL LOOPS:

• TCV 106 and TCV 107 are two-temperature control valves in preheater system controlled by two independent controls
loop. The set point and purpose of the control loop are already discussed.
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128
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.
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129
FLP CIRCULATING PUMPS 404 & 405 PO. STARTING ORDER
HSN 001
SUB/GROUP
STARTING
HSU 001
PUMP SELECTED IN
NORMAL
404 PO/405 PO
A B
TAKING OVER
MEMORY ON

NORMAL STOPPED NORMAL STOPPED
HSU 001 HSU 001

404 PO SELECTED IN 405 PO SELECTED IN
STAND BY STAND BY
HSN 404-404 PO HSN 405-405 PO


“OFF” “OFF”
INLET CONDENSATE INLET CONDENSATE

PRES. PSL 068 LOW PRES. PSL 068 LOW
PRES. PRES.

404 PO 405 PO
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130
FLP CIRCULATING PUMPS 404 & 405 PO. STOPPING ORDER

HSX 001 SUB-GROUP HSN 001 SUB-GROUP
EMERGENCY EMERGENCY
STOPPING STOPPING
INLET CONDENSATE
PRES. PSL 068
LOW PRES.
PUMP 404 PO PUMP 405

“ON” “ON”
10sec. 10sec.

DISCHARGE FLOW DISCHARRGE FLOW
LOW LOW
FSL 138 FSL 139
EC EC
FSLB FSLB
138 139
HSN 404-404 PO HSN 405-405 PO

STOPPING ORDER STOPPING ORDER
STOP PUMP STOP PUMP

404 PO 405 PO
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131
FLP RECIRCULATING PUMPS 404 & 405 PO. TAKING OVER MEMORY
A B

“ON” “ON”

DISCHARGE FLOW DISCHARGE FLOW
LOW LOW
FSL 138 FSL 139
HSU 002
TAKING OVER
AUTO CUT OUT
TAKING OVER
ON OFF
MEMORY MEMORY
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132
FLP. NO RECICULATING PUMPS IN OPERATION
PUMP 404 PO
“ON”
404 JA 1
PUMP 405 PO
“ON”
405 JA 1
15
Sec.
US EC
FLP ALARM 001 3
( C ) FLP. RECIRCULATING PUMPS 404 & 405 PO IN CONFIGURATION
PUMP 404 PO “ON” PUMP 405 PO

404 JA 1 “ON”
405 JA 1
PREHEATER SYSTEM
IN CONFIGURATION
To TTA system US 002
TTA US 002
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133
(15) CONDENSER CIRCULATING WATER SYSTEM (CRF)

The purpose of the circulating water system is to cool the condenser and the closed cycle cooling water
exchangers.
Circulating water is cooled in cooling towers.
2. DESCRIPTION:
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.
This line includes:

• 3 auxiliary raw cooling (3 x 50%) water pumps 102 PO, 202 PO, 302 PO.
• 2 filters.
• 1 distribution line to the exchangers.
• 2-Heat exchanger 2 x 100 % (SRI 101 RF, 201 RF).
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

Circulating water pump:
2 x 50 % parallel pumps make the raw water circulation through one block of the condenser.
Main data of each pump:
• Flow 11910 m³/h
• Man metric head 22.3 mWC
• Motor rated power 930 KW
• Voltage 6600 V
The motors are cooled by the raw water.

Each pump is provided with a motor-operated valve at discharge.
The pumps are equipped with a non-reverse ratchet to prevent shaft reverse rotation on loss of electric
power.
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134
Circulating water pumps discharge circuit:

At discharge of each circulating pump there are:
• An expansion joint
• A motor-operated isolating valve UV 001,101,201.
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.
Special operation conditions:

Operation with only one half condenser.
Either half condenser can be isolated for maintenance.
The load of the turbine-generator set will be reduced to approximately 60% of the rated power when half
condenser is isolated.
TRANSIENT:
Circulating water pump start up:
The circulating water pumps are started with the condenser isolating valves fully open.
The starting order is given either from the control room or local.
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135
The lubricating circuit is in service, the discharge valve is closed.

The discharge valve begins to open as soon as the pump starts and it goes directly to its open position.
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.
5. DESCRIPTION OF INSTRUMENTATION AND CONTROL

LOOPS:
Circulating water pumps control:
The start up and the shutdown of a circulating water pump are initiated by the operator from the control
room or local.
The motor heating resistance are automatically put into operation when the motor is shutdown.
The motor-operated valve at the pump discharge opens automatically during the start up of the associated
pump.
The circulating water pumps shutdown automatically in case of:
• Electrical failure
• Loss of 6.6 kV
• Very low level at the pump suction (LSLL)
• Motor bearing temperature very high (TSHH 107,108)
• Motor thrust bearing temperature very high (TSHH 109)
• Lubricating water flow low (FSL 101).
• Discharge valve closed 3 second after pump start up.
• Discharge valve not open 70 second after pump start up.
• Pump vibration very high (VSHH 103).
• Motor vibration very high (VSHH 101,102).
• Motor winding temperature very high (TSHH 101, 103, 105).
• Motor top Bearing Casing vibration very high.
Lubricating water pump control:

The start up and the shutdown of a lube water pump is initiated by the operator from the control room on
the common service panel or locally.In case of tripping of one pump, the other starts automatically only if
the operator has authorized the take-over.
These pumps shutdown automatically in case of:
• Very low level in the storage tank (LSLL 001)
• Electrical failure.
Auxiliary raw cooling water pump control:
The operation of Auxiliary raw cooling water pump is initiated from the control room.
The operator selects two pumps in operation and the standby one. In case of tripping of one pump, the
standby pump restarts automatically if the operator has authorized the take-over.
The pumps shutdown automatically in case of:
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136
- Pump suction pressure low (PSL 001)

- Electrical failure.
Circulating water header valves:

These valves are remotely controlled from block 1 or block 2. They cannot be opened both together.
As soon as one valve is not closed, the other one cannot be operated anymore.
Condenser isolating valve:

These valves are remotely operated from the control room.
Circulating water pump discharge valve:
These valves are in sequence with the pump operation and individually controlled from the control room
or locally.
6. ANALYSIS OF LOSS OF MOTIVE OR CONTROL FLUIDS:
• The lubricating storage tank make-up valve opens.
• The lubricating water valves open.
FAILURE OF 48 V CONTROL VOLTAGES ON LOGIC CONTROLLER OUTPUT:

• All the pumps remain in operation.
• All the solenoid valves are reenergized which cause the opening of the lube water valve and the lube storage tank make-up
valve.
FAILURE OF 125 V DC OR 48 V DC LV SWITCHBOARDS:

• The auxiliary raw cooling water pumps are shutdown.
• The lubricating water pumps are shutdown.
FAILURE OF 125 V DC ON MV SWITCH BOARD:

• The circulating water pumps are shutdown.

• Shutdown of the heating resistance of the motors.

- The motor-operated valves remain in same position.
• The auxiliary raw cooling water pump stops.
• The lubricating water pump stops.
FAILURE OF 6.6 KV VOLTAGES:

• The circulating water pump stops.
FAILURE OF T20 AI CONTROLLER POWER SUPPLY:

• Actuators remain in same position
• Drives remain in operation
FAILURE OF T20 AA CONTROLLER POWER SUPPLY:

• Actuators remain in same position
• Drives remain in operation
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137
C.W. PUMP 101 & 201 PO OPERATION
LOCAL STARTING STARTING ORDER

ORDER SUB/GROUP
HSZ 111 CONTROL
HSN 101
LOCAL/REMOTE LOCAL/ REMOTE

SELECTOR ON LOCAL SELECTOR ON
HSU 101 REMOTE
HSU 101
DISCHARGE VALVE
CLOSED ZSL 101
SUCTION BASIN
VERY LOW LEVEL
LSLL 101 (4200)
CONDENSER INLET CONDENSER INLET

VALVE OPEN VALVE OPEN
ZSH 004 ZSH 005
CONDENSER OUTLET CONDENSER OUTLET

VALVE OPEN VALVE OPEN
ZSH 006 ZSH 007
LUBRICATING LUBRICATING OPENING ORDER

WATER VALVE UV WATER LOW FLOW HSN 104
102 OPENING ORDER FSL 101
LOCAL/REMOTE LOCAL OPENING

SELECTOR ON ORDER HSZ 131
REMOTE
HSU 101
C.W.PUMP 101 PO LOCAL/REMOTE

IN OPERATION SELECTOR ON
101 JA 1 LOCAL
HSU 101
C.W. PUMP 101 PO DISCHARGE VALVE

SAME SEQUENCE FOR C 201 PO STARTING ORDER UV 101
OPENING ORDER
137
138
C.W. PUMP 1C 101 & 201 PO OPERATION
MOTOR BEARING ELECTRICAL

VERY HIGH TEMP. FAILURE
TSHH 107
MOTOR BEARING MOTOR WINDING

VERY HIGH TEMP. TEMP. VERY HIGH
TSHH 108 TSHH 101/103/105
MOTOR THRUST MOTOR VIBRATION

BEARING VERY VERY HIGH
HIGH TEMP. VSHH 101/102
TSHH 109
SUCTION BASIN PUMPVIBRATION

VERY LOW LEVEL VERY HIGH
LSLL 101 VSHH 103
STOPPING ORDER LOCAL STOPPING SHUTDOWN ORDER C.W. PUMP 101 PO

SUB/GROUP ORDER LOCAL PUSH- IN OPERATTION
CONTROL HSZ 121 BUTTORN 101 JA 1
HSN 101 HSX 101
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
C.W. PUMP 101 PO

SHUTDOWN DISCHARGE VALVE
101 JAO UV 101 OPENED
ZSH 101
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
C.W. PUMP 101 PO

LUB. WATER STOPPING ORDER LOCAL/REMOTE
DISCHARGE VALVE SELECTOR ON
VALVE UV 102
UV 101 CLOSING REMOTE HSU 101
CLOSING ORDER
ORDER TO 30%
DISCHARGE VALVE UV
101 CLOSING ORDER
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139
C.W. PUMP OC 001 PO OPERATION
STARTING ORDER FROM LOCAL STARTING STARTING ORDER FROM BLOCK 2

BLOCK 1 1C HSN001 ORDER OC HSZ 011 2C HSN 001
LOCAL/REMOTE LOCAL/REMOTE LOCAL/REMOTE

SELECTOR ON REMOTE SELECTOR ON LOCAL SELECTOR ON
HSU 101 HSU 101 REMOTE HSU 101
DISCHARGE VALVE
CLOSED ZSL 01 A
SUCTION BASIN VERY

LOW LEVEL(4000)
OC LSLL 002
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
2C COND.OUTLET 2C COND.OUTLET 1C COND.OUTLET 1C COND.OUTLET

VALVE OPEN VALVE OPEN VALVE OPEN VALVE OPEN
2C ZSH 006 2C ZSH 007 1C ZSH 006 1C ZSH 007
HEADER VALVE UV 002 HEADER VALVE UV 003

CLOSED CLOSED
ZSL 002 ZSL 003
HEADER VALVE UV 003 HEADER VALVE UV 002

OPENED OPENED
ZSH 003 ZSH 002
LUBRICATING WATER
LOW FLOW FSL 001
OPENING ORDER LOCAL OPERNING ORDER

HSN 010 HSZ 031
LOCAL/REMOTE LOCAL/REMOTE
SELECTOR ON REMOTE SELECTOR ON LOCAL
HSU 001 HSU 001
C.W. PUMP 001 PO IN

OPERATION 001 JA 1
LUB. WATER VALVE C.W. PUMP OC 001 PO DISCHARGE VALV UV 001

UV 008 OPENING ORDER STARTING ORDER OPENING ORDER
139
140
C.W. PUMP OC 001 PO OPERATION

MOTOR BEARING
NDE.VERY HIGH ELECTRICAL
TEMP.TSHH 007 (90ºC) FAILURE
MOTOR BEARING VERY MOTOR WINDING TEMP.

HIGH TEMP. TSHH 008 VERY HIGH
75ºC TSHH 001/003/005 (150ºC)
STOPPING ORDER STOPPING ORDER MOTOR THRUST MOTOR VIBRATION

BLOCK 1 SUB/GROUP BLOCK 2 SUB/GROUP BEARING VERY HIGH VERY HIGH VSHH
CONTROL 1C HSN 001 CONTROL 2C HSN 001 TEMP. TSHH 009 (95ºC) 001/002 350 M
LOCAL/ REMOTE LOCAL/REMOTE SUCTION BASIN VERY PUMP VIBRATION VERY

SELECTOR ON REMOTE SELECTOR ON REMOTE LOW LEVEL HIGH VSHH 003 (215 M
HSU 001 HSU 001 OC LSLL 002 4000 MM ALARM) ( 320 M TRIP)
HEADER VALVE HEADER VALVE SHUTDOWN ORDER C.W. PUMP 001 PO

UV 002 OPENED UV 002 CLOSED LOCAL PUSH-BUTTON IN OPERATION
ZSH 002 ZSL 002 HSX 001 001 JA 1
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
LOCAL/REMOTE DISCHARGE VALVE UV

SELECTOR ON LOCAL 001 OPENED ZSH 001
HSU 001
LOCAL CLOSING ORDER

HSZ 041
C.W.PUMP 001 PO DISCHARRGE VALVE

SHUTDOWN 001 JAO UV 101 30% OPENED
ZSL 01 B
LOCAL/REMOTE
SELECTOR ON LOCAL
HSU 001
C.W. PUMP 001 PO

SHUTDOWN 001 JAO
CLOSING ORDER
HSN 010
1sec
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
DISCHARGE VALVE UV 001

CLOSING ORDER
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141
AUXILIARY RAW C.W. PUMP 102 PO OPERATION

SUB/GROUP
STARTING ORDER SUB/GROUP
HSN 402 TRIPPING ORDER
SEE FOLIO 6
PUMP 102 PO
SELECTED IN TAKING OVER AUTO
NORMAL CUT-OUT
HSU 202 HSU 102
SELECTION STATUS
SELECTION STATUS CORRECT
CORRECT
ON OFF TAKING OVER MEMORY
TAKING OVER
MEMORY
“ON”
PUMP SELECTION IN
NORMAL STOPPED
PUMP 102 SELECTED

IN STAND-BY
HSU 202
STARTING ORDER
HSN 102
SUCTION PRESSURE
LOW PSL 001
(1.8 BAR)
PUMP 102 PO
STARTING ORDER
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142
AUXILIARY RAW C.W. PUMP 102 PO OPERATION
SUB/GROUP
STOPPING ORDER
HSN 402
SUCTION PRESSURE
LOW
PSL 001
(<1.8 BAR)
5sec STOPPING ORDER

HSN 102
ELECTRICAL
FAILURE
C.W. PUMP
102 PO
SUB/GROUP TRIPPING
STOPPING ORDER
ORDER
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143
LUBRICATING WATER PUMP OC 103 PO OPERATION
SUB/GROUP CONTROL
STARTING ORDER PUMP 203 PO
HSN 100 TRIPPED
PUMP 103 PO SELECTED LOCAL STARTING TAKING OVERY

IN NORMAL STARTING ORDER ORDER MEMORY
HSU 101 HSN 103 HSZ 113 ON
LOCAL/REMOTE LOCAL/REMOTE LOCAL/REMOTE PUMP 103 PO

SELECTOR IN REMOTE SELECTOR IN REMOTE SELECTOR IN LOCAL SELECTED IN
HSU 104 HSU 104 HSU 104 EMERGENCY
HSU 101
LUB. WATER TANK

VERY LOW LEVEL
LSLL 001
LUB. WATER PUMP 103 PO LUB. WATER PUMP 103 PO

IN OPERATION 103 JA 1 STARTING ORDER
SUB/GROUP CONTROL ELECTRICAL FAILURE

STOPPING ORDER HSN 100
NO CIRCULATING WATER
PUMP IN OPERATION
LOCAL/REMOTE LOCAL STOPPING

SELECTOR IN REMOTE STOPPING ORDER ORDER
HSU 104 HSN 103 HSZ 123
LUB. WATER TANK LOCAL/REMOTE LOCAL/REMOTE

VERY LOW LEVEL SELECTOR IN REMOTE SELECTOR IN LOCAL
LSLL 001 HSU 104 HSU 104
NO CIRCULATING
AUTO CUT-OUT WATER PUMP IN
HSU 103 OPERATION
TAKING OVER MEMORY

LUB. WATER PUMPS 103
ON OFF PO STARTING ORDER
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LUBRICATING WATER STORAGE TANK MAKE-UP VALVE LV 004 OPERATION
MAKE-UP VALVE LV 004

OPENING ORDER
HSN 004
MAKE-UP VALVE LV 004 SUB/GROUP CONTROL LOCAL/REMOTE

CLOSING ORDER STARTING ORDER SELECTOR IN REMOTE
HSN 004 HSN 100 HSU 004
LOCAL/REMOTE LOCAL/REMOTE LUB. WATER TANK

SELECTOR IN REMOTE SELECTOR IN REMOTE VERY HIGH LEVEL
HSU 004 HSU 004 LSHH 001
LUB. WATER TANK LUB. WATER TANK LOW

HIGH LEVEL LEVEL LSL 001
LSH 001
LUB. WATER TANK

VERY HIGH LEVEL
LSHH 001
SUB/GROUP CONTROL MAKE-UP VALVE LV 004 MAKE-UP VALVE LV 004

STOPPING ORDER LOCAL CLOSING ORDER LOCAL OPENING ORDER
HSN 100 HSZ 024 HSZ 014
LOCAL/REMOTE LOCAL/REMOTE LOCAL/REMOTE

SELECTOR IN REMOTE SELECTOR IN LOCAL SELECTOR IN LOCAL
HSU 004 HSU 004 HSU 004
MAKE-UP VALVE LV 004

CLOSING ORDER MAKE-UPVALVE LV 004
OPENING ORDER
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(16) DM WATER COOLING SYSTEM (SRI)

1. PURPOSE:
A closed cycle demineralised water system is used as the primary coolant for steam turbine, boiler and
generator auxiliaries.
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
Heat exchangers 101 RF – 201 RF:

The heat exchanger is identical. Each heat exchanger is of the plate type.
Demineralised water flow : 630 m³/hr
Circulating water flow :670 m³/hr
Demineralised water outlet nominal temperature: 38 °C.
Valve LCV 001 and control devices:
The system includes:
• The pneumatic demineralised water make-up control valve LCV 001 of the emergency and expansion tank 001 BA.
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).
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Cooling water circuit recirculation:

A recalculating line is connected to the emergency and expansion tank 001 BA to ensure the recirculation
of the cooling water pumps and also to keep the tank water at the same temperature as the one of the
cooling circuit.
1. OPERATION:
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.
Each cooling water pump trip for:

• Electric fault.
• Low reserve tank level.
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COOLING WATER PUMPS. STARTING: 101 PO 201 PO 301 PO

HSN 001
SUB GROUP SUB GROUP TRIPPING
STARTING ORDER FROM FOLIO 5 HSU 002
TAKING OVER
AUTO CUT OUT
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)
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COOLING WATER PUMPS. TRIPPING CONDITIONS: 101PO 201PO 301PO
101 MO
ELECTRIC FAILURE
PUMP 101 PO
TRIPPING CONDITION
LSLL 001
HEAD TANK LOW
LOW LEVEL
SUB/GROUP
TRIPPING CONDITION
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149
COOLING WATER PUMPS. STOPPING: 101PO 201PO 301PO
HSN 001
SUB/GROUP SUB/GROUP TRIPPING
STOPPING ORDER CONDITIONS
(FROM F.4)
HSN 101 INDIVIDUAL PUMP TRIPPING

STOPPING ORDER CONDITIONS FROM
FOLIO 4
HEATING
SUB/GROUP TRIPPING STOP PUMP RESISTANCE
ORDER 101 PO 101 RS
ON
SAME SEQUENCE FOR 201 PO. 301 PO.
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150
(17) CONDENSER VACUUM SYSTEM (CVI)

1.PURPOSE OF THE SYSTEM:
The condenser vacuum pumps are used for initial condenser vacuum built up (hogging) and for continues
removal of non-condensable gases from the condenser (holding), when it is operating at normal vacuum.
2. DESCRIPTION:

The system is composed of 2x100% vacuum motor pump sets, each mainly including:
• 1 double stage liquid ring pumps 101/201 PO.
• 1 driving 415 V AC motor 101/201/MO.
• 1 pneumatic suction valve FV 101/201.
• 1 separator 101/201 BA.
• 1 heat exchanger 101/201 RF.
• 1 seal water circulating motor pump set 102/202 PO.
Each pump draws air from the condenser through a common pipe.
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
Air extraction circuit:

An air-operated block valve FV 101/201 is installed on the suction pipe of each vacuum pump.
Each pump discharges in its separator.
The air-operated block valve ensures pump isolation during shutdown period.
Air discharge circuits:

Air is discharge through its own isolating valve and silencer in to the turbine hall. It is possible to measure
the airflow using a flow device (rota meter) installed in parallel.
Seal water circulation circuit:
Seal water drawn from separator by a circulating pump 102/202 PO and by the vacuum pump itself
is cooled through a heat exchanger.
Seal water separator level:

The make-up of each separator is made by a float valve. Overflows are routed to drain water system.
3.OPERATION:
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151
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).
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:
Starting in group level control:

In normal configuration, the vacuum pumps are controlled by the group control. The operator selects the
pump to be started up and confirms the starting-up by using the group control command.
The starting conditions must be fulfilled. The seal water pump associated to the selected vacuum pump
starts and then, the selected vacuum pump starts.
During initial start-up, second vacuum pump will start when condenser pressure is high > 135 mbar (PSH
001), and it will stop when the condenser pressure is low <100mbar (PSL 001).
Starting in sub-group control level:

The operation can start-up a vacuum pump and its associated seal water pump by using the sub-group
control command if the starting conditions are fulfilled.
Starting in individual control:
Each vacuum pump can be controlled by an individual control device.
Shutdown of the pumps:
Whatever the operation, hogging or holding, the pumps can be stopped by individual control or by using
the group control command or sub-group control command (HSN 011/021).
In case of low seal water flow or suction valve not open after a time delay of (10 sec) the pump in
operation trips.
INSTUMENT AIR LOSS:

The pneumatic suction valves FV 101/201 close.
FAILURE OF 48 V DC CONTROL VOLTAGE (on logic controller output):
The vacuum valves FVX 101/201 are de-energised which causes the closing of valves FV 101/201.
FAILURE OF 125 V DC OR 48 V DC ON LV SWITHBOARD:
The vacuum pumps and the seal water pumps are shutdown.
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152

The vacuum pumps and the seal water pumps stop.
FAILURE OF T20:
A1 controller power supply:
- No change for the control of the plant.
- Actuators remain in same position.
- Drives remain in operation.
AA controller power supply:

- Actuators remain in position.
- Drives remain in same operation
- Individual command remain available
- Interlocks and protection remain operative.
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153
CONDENSER PRESSURE SCALE
PRESSURE
1013 mbar abs Initial pressure in condenser = atmospheric pressure
900 mbar abs-PSHH 002 CET system
350-mbar a-PSHH 002 HP&LP steam bypass valves LOCKED (GBP&GBPsystems)
GSE PSHH 066

270 mbar a steam turbine trip (GSE system) -- GSE PSHH 067 ©
GSE PSHH 068
200-mbar a- PSHH 001 alarms EC1: condenser vacuum very high, Deaerator vent-valve
CADG UV006 to atmosphere closes & CADG UV007 open towards
condenser
135-mbar a-PSH 001 starting standby vacuum pump
100-mbar a- PSL 001 stopping standby vacuum pump
92 mbar a Nominal vacuum: based load 27 ºC
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VACUUM PUMPS. STARTING CONDITION: 101PO, 201PO
ZSL 101
SUCTION VALVE FV
101 CLOSED
SEAL WATER PUMP

102 PO IN OPERATION
FSL 105
SEAL WATER
LOW FLOW
PUMP 101 PO
SAME SEQUENCE FOR 201 PO STARTING
CONDITIONS
VACUUM PUMPS. TRIPPING CONDITIONS: 101 PO, 201 PO
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
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155
VACUUM PUMPS STARTING: 101 PO; 201 PO

C HSN 001 START-UP CONTROLLER GROUP STOPPING
GROUP STARTING STARTING ORDER ORDER
ORDER KSC SYSTEM, STEP 030
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
C HSN 011 PUMP 101 PUMP SELECTED IN VACUUM PUMPS 201

POSUB-GROUP NORMAL STOPPED PO IN OPERATIONS
STARTING ORDER
C HSU 001 PUMP 101

PO SELECTED IN
STAND-BY
C HSN 101 PUMP 101

PO INDIVIDUAL
STAARTING ORDER
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
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156
VACUUM PUMPS. STOPPING: 101PO, 201PO
C HSN 001 C HSX 001

GROUP STOPPING CONDENSER VACUUM
ORDER SHUTDOWN COMMAND
C HSN 011 SUB-GROUP TRIPPING

PUMP 101 PO CONDITIONS VACUUM
SUB-GROUP STOPPING PUMP 101 PO
ORDER
DEENERGIZED FVX 101

SUCTION VALVE FV CLOSING ORDER
101 CLOSED SUCTION VALVE
FV 101
C HSN 101
See folio 3 PUMP 101 PO PUMP 101 PO
TRIPPING CONDITIONS INDIVIDUAL ORDER

GROUP SUB-GROUP SUB-GROUP STOPPING
STOPPING ORDER STOPPING ORDER STOPPING ORDER PUMP 101 PO
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PNEUMATIC SUCTION VALVES OPERATION: FV 101, FV 201.

SUCTION VALVE
VACUUM PUMP 101 PO VACUUM PUMP 101 PO FV 101
IN OPERATION OUT OF OPERATION CLOSING ORDER
PDSH 101 HSN 104 HSN 104

SUCTION VALVE FV 101 INDIV. OPENING ORDER INDIV. CLOSING ORDER
DIFF. PRES.<= 34 MBAR SUCTION VALVE FV 101 SUCTION VALVE FV 101
ENERGIZED FVX 101 DEENERGIZED FVX 101

OPENING CLOSING
SUCTION VALVE FV 101 SUCTION VALVE FV 101
SAME SEQUENCE FOR FV 201
SEAL WATER PUMPS OPERATION: 102 PO, 202 PO.

HSN 102 HSN 102
SEAL WATER PUMP 102 SEAL WATER PUMP 102
PO INDIVIDUAL PO INDIVIDUAL
STARTING ORDER STOPPING ORDER
SEAL WATER PUMP SEAL WATER PUMP 102

102 PO SUB GROUP PO
STARTING ORDER SUB GROUP STOPPING
ORDER
GROUP OR S/GROUP VACUUM PUMP

STARTING ORDER
LSL 107
GROUP S/GROUP VACUUM PUMP SEAL WATER
STOPPING ORDER. SEPARATOR STOPPING ORDER
LOW LEVEL
STOPPING
STARTING PUMP 102 PO
PUMP 102 PO
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CONDENSER VACUUM PUMPS IN OPERATION: 101 PO, 201 PO.
VACUUM PUMP VACUUM PUMPS 201 PO

101 PO IN OPERATION IN OPERATION
101 JA 1 201 JA 1
SUCTION VALVE FV 101 SUCTION VALVE FV 201

OPENED OPENED
ZSH 101 ZSH 201
SEAL WATER PUMP 102 SEAL WATER PUMP

PO IN OPERATION 202 PO IN OPERATION
102 JA 1 202 JA 1
AT LEAST ONE
FOR KCS SYSTEM CONDENSER VACUUM
SC STEP 030 PUMP IN OPERATION C
US 003
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(18) CHEMICAL DOZING SYSTEM (SIR)
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:

The chemical feed equipment consists of 3 injection sets:
The ammonia injection set is mainly composed of:
• 1 ammonia preparation tank (103 BA) with its mixer (106 MO).
• 1 ammonia solution tank (203 BA) with its mixer (206 MO).
• 2 x100% dosing pumps (103 PO/203 PO).
The hydrazine injection set is mainly composed of:

• 1 hydrazine preparation tank (102 BA) with its mixer (105 MO).
• 1 hydrazine solution tank (202 BA) with its mixer (205 MO).
• 2 x 100 % dosing pumps (102 PO/202 PO).
The phosphate injection set is mainly composed of:

• 1 phosphate preparation tank (101 BA) with its mixer (104 MO).
• 1 phosphate solution tank (201 BA) with its mixer (203 MO).
• 2 x 100 % dosing pumps (101 PO/201 PO) for LP drums injection.
• 2 x 100 % dosing pumps (301 PO/ 401 PO) for HP drums injection.

Reagent preparation tanks:
Capacity:
• Ammonia 600 Litres
• Hydrazine 600 Litres
• Phosphate 1000 Litres
Reagent solution tanks:

Capacity:
• Ammonia 600 Litres
• Hydrazine 600 Litres
• Phosphate 1000 Litres
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
Phosphate pumps:
Main Data for LP and HP phosphate pumps:
• Flow 0 – 20 L/hr
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.
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.
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.
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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AMMONIA PUMPS 103 PO, 203 PO STARTING
HSU 001 AUTOMATIC

HSU 001 CONTROL PUMP
INDIVIDUAL CONTROL 103 PO SELECTED
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
SAME SEQUENCE FOR AMMONIA PUMP 203 PO
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163
AMMONIA PUMPS 103 PO, 203 PO STOPPING
HSU 001 HSU 001 AUTOMATIC

INDIVIDUAL CONTROL PUMP 103
CONTROL PO SELECTED
SHZ 123 STOPPING

ORDER PUMP SIT ASH 116 HIGH PH
103 PO
CEX US 002 NO LSL 2203

CONDENSATE PUMP AMMONIA SOLUTION
IN OPERATION LOW LEVEL
STOPPING AMMONIA
SOLUTION PUMP 103 PO
SAME SEQUENCE FOR AMMONIA PUMP 203 PO
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164
AMMONIA SOLUTION AND PREPARATION MIXERS

106 MO, 206MO OPERATION
HSZ 2216 STARTING HSZ 116STARTING
ORDER MIXER ORDER MIXER
206 MO 106 MO
LSL 103
LSL 203 AMMOIA AMMONIA
SOLUTION LOW LEVEL PREPARATION LOW
LEVEL
STARTING AMMONIA STARTING AMMONIA

SOLUTION MIXER PREPARATION MIXER
206 MO 106 MO
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
STOPPING AMMONIA STOPPING AMMONIA

206 MO 106 MO
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HYDRAZINE SOLUTION AND PREPARATION

MIXERS 105MO, 205 MO OPERATION
HSZ 215 STARTING HSZ 115 STARTING

ORDER MIXER ORDER MIXER
205 MO 105 MO
LSL 2202 HYDRAZINE LSL 102 HYDRAZINE

SOLUTIN PREPARATION LOW
LOW LEVEL LEVEL
STARTING HYDRAZINE STARTING HYDRAZINE

205 MO 105 MO
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
STOPPING HYDRAZINE STOPPING HYDRAZINE

SOLUTION PREPARATION
MIXER 205 MO MIXER 105 MO
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166
LP AND HP PHOSPHATE PUMPS

101PO, 201 PO, 301 PO, 401 PO OPERATION
HSZ 111 STARTING HSZ 121 STOPPING LSL 201

ORDER PUMP 101 ORDER PUMP 101 PHOSPHATE
PO PO SOLUTION LOW
LSL 201
PHOSPHATE
SOLUTION LOW
STARTING LP STOPPING LP
PHOSPHATE PUMP PHOSPHATE PUMP
101 PO 101 PO
SAME SEQUENCE FOR LP SPHATE PUMP
HSZ 311 HSZ 321 LSL 201

STARTING ORDER STOPPING ORDER PHOSPHATE SOLUTION
PUMP 301 PO PUMP 301 PO LOW LEVEL
LSL 201 PHOSPHATE

SOLUTION LOW
LEVEL
STARTING HP STOPPING HP
PHOSPHATE PUMP PHOSPHATE PUMP
301 PO 301 PO
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167
PHOSPHATE SOLUTION AND PREPARATION

MIXER 104 MO; 204 MO OPERATION
HSZ 214 HSZ 114 STARTING

STARTING ORDER ORDER MIXER
MIXER 204 MO 104 MO
LSL 201 PHOSPHATE LSL 101 PHOSPHATE

SOLUTION LOW LEVEL PREPARATION LOW
LEVEL
STARTING PHOSPHATE STARTING PHOSPHATE

SOLUTION MIXER 204 SOLUTION PREPARATION
MO MIXER 104 MO
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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CHEMICAL REAGENT INJECTION ALARMS
ELECTRIC FAILURE ELECTRIC FAILURE MOTOR PUMPS LOCAL

101 MO 201 MO CONTROL BOX SUPPLY
FAULT
EC 2
LP PHOSPHATE PUMPS FAULT

FAULT
EC 2
HP PHOSPHATE PUMPS FAULT

FAULT
HYDRAZINE PUMPS FAULT EC 2

FAULT
EC 2
AMMONIA PUMPS FAULT
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(19) STEAM TURBINE LUBRICATION (GGR)

This system has following functions:

Lube oil supply that ensures:
• The lubrication of journal bearings & thrust bearing of the turbine generator unit.
• Discharge of heat dissipated in journal bearings and thrust bearings.
• The shaft line turning (turning gear operation).
Which ensures the even distribution of temperatures along the whole shaft when the turbine has stopped or
turbine starting due to its rotation at constant speed.
• The lifting of rotor during turbine turning operation.
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.
A centrifugal electric fan GGR-001 ZV:

Used as an oil separator for exhausting oil vapours, it creates a slight depression in the lube-oil tank. The
fan is driven by an A.C. motor.
Lube-oil coolers:
Each cooler is able to cool the whole lube-oil capacity in the tank. Coolers can be shifted manually using
the shifting lever, a shifting pipe is provided between the two coolers in order to make-up lube-oil before
using the emergency cooler. The lube oil temperature in the manifold is maintained by 3 ways thermo
static v/v mounted on the cooler outlet pipe.
Each cooler is fitted with one thermo well at lube-oil outlet. A thermometer is mounted upstream of the
cooling and another is mounted downstream of the cooling station for checking lube-oil temperature.
Double fitter GGR-001 FI:
Provided with a change over 3-way valve for shifting lube-oil flow from one filter to the other (one filter
should be in operation under normal conditions).
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This double filter is fitted with:

Header pressure control valve:
The lube-oil header pressure control valve PCV that maintains 2 bar header pressure by a local controller
during operation.
• A differential pressure gauge, which measures locally the fouling/choking of the working filter.
• A differential manostat that triggers an alarm when the working filter gets fouled.
Lube-oil inlet manifold:

It lubricates the journal and thrust bearings of the generator unit.
At turbine side end is fitted:
• A pressure gauge for checking lube-oil pressure locally.
• A pressure transmitter for checking lube-oil pressure (Remote).
• Three manostat that trip the turbine if the lube-oil pressure drops abnormally (<0.8 bar).
• A manostat that prohibit the shaft line turning when pressure drops below 0.4 bars.
• A manostat that enable the automatic start of the pump GGR-001 PO or GGR-002 PO when the pressure drops under 1.2
bar.
• A manostat that gives the pressure in the lube oil pipe (>1.6 bar). It allows the lube-oil sequence.
• A manostat that enables the automatic start of the emergency pump GGR-003 PO when the pressure drops below 0.8 bars.
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.
Lifting system for moving parts:

The turbine generator unit includes a lifting system for lifting the turbine and generator rotor during
starting sequences of the turbine generator unit.
This system is equipped with six jacking oil pumps (GGR 004 PO, GGR005 PO, GGR 006 PO, GGR 007
PO, GGR 008 PO, GGR 009 PO) driven by three A.C. motors GGR 005 MO, GGR 006 MO, and GGR
007 MO.
Each pump delivery is fitted with:
• A pressure- guage
• A pressure switch
• A check valve
• A cut-off valve.
• A manostat (on the discharge manifold for the six pumps).
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STEAM TURBINE – LUE OIL SYSTEM GGR

- STTING CONDITIONS: 001 PO
GGR LSL 222

LOW LEVEL IN
OIL TANK
LUBE OIL PUMPS

STARTING CONDITIONS
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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
GGR PSH 043 LUBE

OIL PRESSURE
>1.6 BAR OFF
GGR PSH 031 DISCHARGE

PRESSURE PUMP
001 PO> 3.5 BAR OFF
TAKING OVER MEMORY

ON
ON OFF
PUMP SELLECTED IN
GGR PSL 044 LUBE OIL NORMAL STOPPED
MANIFOLDN PRESSURE
1.2 BAR OFF
HSU 001 \001

PO SELECTED IN
STAND BY
HSN 101 GSE ZSH 531,GSE ZSH GGR 008 JAI

OO1 PO INDIVIDUAL 533,GSE ZSH 535 TURNING GEAR IN
STARTING ORDER STEAM TURBINE SET OPERATION
GGR PSH 043

LUBE OIL PRESSURE
>1.6 BAR OFF
STARTING CONDITIONS
001 PO
HSU 001- 001 PO
SELECTED IN NORMAL
START PUMP
001 PO
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173
STEAM TURBINE LUBE OIL SYSTEM GGR

TRIPPING CONDITIONS :001 PO
TEST OPERATING
HSN 001 ON GGR US 006
SUB GROUP STARTING
HSU 001-001 PO
SELECTED IN STAND BY
GGR PSH 032

DISCHARGE PRESSURE LUBE
OIL PUMP 002PO >3.5 bar OFF
GFR PSH 043 LUBE OIL

PRESSURE >1.5 bar. OFF
001 MO
ELECTRIC FAILURE
PUMP 001 PO
TRIPPING CONDITION
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174
STEAM TURBINE LUBE OIL SYSTEM GGR

TRIPPING CONDITIONS: 002 PO
TEST OPERATING
HSN 001 ON GGR US 006
SUB GROUP STARTING
HSU 001-002 PO
GGR PSH 031 DISCHARGE

PRESSURE LUBE OIL PUMP
001 PO>3..5 BAR OFF
GGR PSH 043

FLUID OIL PRESSURE > 1.6
BAR. OFF
002 MO
ELECTRIC FAILURE
PUMP 002 PO
TRIPPING CONDITION
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175
STEAM TURBINE – LUBE OIL SYSTEM GGR

STOPPING CONDITIONS: 001 PO, 002 PO
HSN 001 SUB GROUP

STOPPING ORDER
GRE US 002
STEAM TURBINE CASING
TEMP. >100 oC
GRE SSL 001 STEAM HSN 101 INDIVIDUAL

TURBINE SPPED <33 rpm STOPPING ORDER TRIPPING CONDITIONS
SUB-GROUP
TRIPPING ORDER STOP PUMP 001 PO
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- STEAM TURBINE – LUBE OIL SYSTEM GGR STARTING CONDITION:

001 RS- 002 RS- 003 RS- 001 ZV, 002 ZV, 003 ZV
LUBE OIL MANIFOLD

PRESSURE > 1.6 BAR OFF
GGR PSH 043
HSN 301 GGR TSL 131 LUBE OIL HSN 301

HEATERS IND. COMMAND TANK TEMPERATURE HEATERS IND. COMMAND
OFF < 45ºC ON
LUBE OIL TANK LUBE OIL TANK

HEATERS 001 RS-002RS- HEATERS 001RS-002RS-
OO3RS SWITCH OFF 003RS SWITCH ON
HSN 201 SUB GROUP HSN 001 HSN 201

IND STOPPING TRIPPING ORDER LUBRICATION S/ GROUP INDIVIDUAL STARTING
ORDER STARTING ORDER ORDER
HSN 202 002 ZV HSN 202 002 ZV

HSN 203 003 ZV HSN 203 003 ZV
STOP EXTRACTOR START EXTRACTOR

001 ZV 001 ZV
002 ZV { SAME SEQUENCE FOR } 002 ZV

003 ZV 003 ZV
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- STEAM TURBINE – LUBE OIL SYSTEM GGR

EMERGENCY LUBE OIL PUMP STARTING: 003 PO
TAKING OVER MEMORY

ON
HSN 103 GGR PSLL 048

INDIVIDUAL STARTING LUBE OIL PRESSURE
ORDER < 0.8 BAR OFF
START PUMP STATRTING ORDER

003 PO 003 PO
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- STEAM TURBINE – LUBE OIL SYSTEM GGR

EMERGENCY LUBE OIL PUMP STOPPING: 003 PO
HSN 103
INDIVIDUAL
STOPPING ORDER
GGR PSH 032 GGR PSH 031

DISCHARGE PRESSURE DISCHARGE PRESSURE
PUMP 002 PO > 3.5 BAR OFF PUMP 001 PO > 3.5 BAR OFF
GGR PSH 043 HSN 103 GGR US 007

LUBE OIL PRESSURE INDIVIDUAL TEST IN OPERATION
. 1.6 BAR OFF STOPPING ORDER
TAKING OVER MEMORY TAKING OVER MEMORY

ON OFF
STARTING ORDER
003 PO
STOP PUMP
003 PO
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- STEAM TURBINE – LIFTING OIL PUMPS SYSTEM GGR STARTING CONDITIONS:

004 PO, 005 PO, 006 PO, 007 PO, 008 PO, 009 PO
GGR LSL 222

LOW LEVEL IN OIL TANK
GGR PSH O43

LUBE OIL
LIFTING OIL PUMPS

STARTING CONDITIONS
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- 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
HSN 105 TURNING GEAR

INDIVIDUAL STARTING ON
ORDER GGR 008 JA 1
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
GGR PT 200
STUFFING MANIFOLD
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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STEAM TURBINE – LIFTING OIL PUMPS SYSTEM GGR

STOPPING CONDITIONS:004 PO. 005PO. 006 PO. 007 PO. 008 PO. 009 PO.
SUB GROUP TRIPPING

LIFTING AND TURBINE ORDER
GEAR SUB GROUP
MEMORY ON
DT
10’
GRE SSL 001
TURBINE SPEED
< 33 RPM
HSN 105
TURNING GEAR MOTOR INDIVIDUAL STOPPING
NOMINAL SPEED ORDER
GGR SSH 001
GRE SSH 001

TURBINE SPEED
> 600 RPM
STOPPING GGR UV 200

LIFTING PUMPS SOLENOID VALVE
CLOSING ORDER
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182

TUNNING GEAR STARTING COINDITIONS: 008 MO
GGR PSH 036

LIFTING OIL PUMP 004 PO
DISCHARGE PRESSURE > 45 BAR OFF
GGR PSH 037

GGR PSH 038

GGR PSH 039

GGR PSH 040

DISCHARGE PRESSURE. 100 BAR OFF
GGR PSH 041

DI
10Sec
LIFTING PUMPS
MANIFOLD PRESSURE
CORRECT
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STEAM TURBINE- LUBE OIL SYSYEM GGR

TUNNING GEAR STARTING: 008 MO
HSN 104
LIFTING PUMPS GRE SSH, 001 TURNING GEAR
MANIFOLD PRESSURE TURBINE SPEED INDIVIDUAL STARTING
CORRECT > 600 RPM ORDER
LIFTING AND TURNING LIFTING PUMPS GER SSL 001

GEAR SUB GROUP MANIFOLD PRESSURE TURBINE SPEED
MEMORY ON CORRECT < 33 RPM
TURNING GEAR
TRIPPING ORDER
GGR PSLL 035

LUBE OIL PRESSURE <
0.4 BAR OFF
GGR ZS 521
MANUAL GEAR
FLYWHEEL ENGAGED
START
TURNING GEAR
008 MO
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184

TURNNING GEAR STOPPING: 008 MO
LIFTING AND TURNING HSN 104 TURBINE SPEED

‘ SUB GROUP MEMORY INDIVIDUAL STOPPING < 33 RPM
ON ORDER GER SSL 001
TURBINE SPEED TURNING GEAR

> 600 RPM NORMAL SPEED
GER SSH 001
GGR PSLL 035 TURNING GEAR

VERY LOW LUBE OIL ON
PRESSURE < 0.4 BAR GGR 008 JA 1
LIFTING PUMPS
MANIFOLD PRESSURE
CORRECT
HSN 002
SUB GROUP STOPPING
ORDER
TURBINE SPEED > 600 RPM

GER SSH 001
GER US 002
TURBINE CASING
TEMPERATURE > 100ºC
TURNING GEAR STOPPING SUB GROUP

TRIPPING ORDER TURNING GEAR TRIPPING
008 MO ORDER
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185
(20)TURBINE GLAND SEAL SYTEM & LP EXHAUST HOOD SPRAY

1. PURPOSE OF THE SYSTEM (CET):
This system ensures the steam turbine sealing at turbine glands.

The turbine casings and inlet valves chambers pressure is different from the atmospheric air.
The function of the gland steam turbine sealing is to isolate the steam contained in the chambers formed
by inlet valves and turbine casings:
• To prevent any steam leaking outwards.
• To prevent atmospheric air ingress into the turbine casing which is under vacuum.

General description:
This system has two main functions:
Steam seal:
Since the areas of the inlet valve chamber are pressurized, steam outlets are limited by sealing and
packings and then sucked into a chamber maintained under atmospheric pressure. This partial vacuum is
maintained by the gland steam manifold connected to the gland seal condenser
CET 001 CS.
Rotor shaft seal:
At the casings shafts outlets, sealing is ensured by labyrinth glands provided with several sealing strips
separated by annular chambers where leaks are recovered. In order to avoid steam leaking outwards, the
gland steam external chambers are maintained under a partial vacuum.
Main technical data:
• The gland stream pressure is maintained at 1.3 bar abs. through a pressure regulating system (valves CET PCV 001 and
CET PCV 002).
• The gland steam condenser is maintained at about 0.95 bar abs through the centrifugal fan CET 001 ZV or CET 002 ZV
fitted at the gland steam condenser.
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.
186
187
- STEAM TURBINE – GLAND SEAL SYSTEM CET

STARTING CONDITIONS: 001 ZV, 002 ZV
MAIN STEAM ISOBARE

CVVPT DS 002
SUPERHEATER > 50 ºC
MAIN STEAM PRESSURE

CVVPT PSH 002
> 20 BAR ABS
GRE SSL 001

TURBINE SPEED < 33 RPM
GLAND STEAM
CONDENSER FANS
STARTING CONDITIONS
187
188
- STEAM TURBINE – GLAND SEAL SYSTEM CET

GLAND STEAM CONDENSER FANS STARTING: 001 ZV, 002 ZV.
HSN 001 SUB GROUP TRIPPING
SUB GROUP STARTING
HSU 001
001 ZV HSU 002
SELECTED IN NORMAL
AUTO CUT OUT
FAN 001 ZV IN
OPERATION
TAKING OVER MEMORY

ON
ON OFF
TAKING OVER MEMORY
FAN SELECTED IN
NORMAL STOPPED
HSU 001
001 ZV
HSN 101
STARTING CONDITIONS 001 ZV
INDIVIDUAL STARTING
ORDER
SAME SEQUENCE START FAN

001 ZV
FOR 002 ZV
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189
LP EXHAUST HOOD SPRAY

1. PURPOSE OF THE SYSTEM (CAR):
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.
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.
3. ANALYSIS IN CASE OF OPERATING OR CONTROL FLUID SHORTAGE:
Control air shortage.

“ON/OFF” air valves open.
Control 220 V A.C. shortage.
Power shortage solenoid-valve “ON/OFF”
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190
- STEAM TURBINE – GLAND SEAL SYSTEM CET GLAND SEAL CONTROL LOOPS
STARTING: PIC 075A, PIC 075B, TIC 170
MAIN STEAM ISOBARE

SUPERHEATER > 50 ºC
MAIN STEAM PRESSURE

> 20 BAR ABS
CET US 002
TO STEAM TURBINE
CONTROL CABINET
FAN 001 ZV FAN 002 ZV
STARTED STARTED
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191
STEAM TURBINE – EXHAUST HOOD SPRAY SYSTEM CAR
CAR TSH 136 CAR TSH 136

TURBINE EXHAUST CASING TURBINE EXHAUST CASING
TEMPERATURE > 80ºC TEMPERATURE > 80 ºC
TURBINE GENERATOR UNIT TURBINE GENERATOR UNIT

OUT PUT < 20% OUT PUT < 20%
HSH 001 HSN 001

INDIVIDUAL OPENING ORDER INDIVIDUAL CLOSING ORDER
DEENERGIZED ENERGIZED
SOLENOID VALVE SOLENOID VALVE
CAR UY 040 CAR UY 040
OPENING VALVE CLOSING VALVE
CAR TV 040 CAR TV 040
191
192
- STEAM TURBINE – GLAND SEAL SYSTEM CET GLAND STEAM CONDENSER

FAN TRIPPING CONDITIONS: 001 ZV, 002 ZV
101 MO
ELECTRIC FAILURE
FAN 001 ZV
TRIPPING CONDITION
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193
STEAM TURBINE – GLAND SEAL SYSTEM CET

STOPPING CONDITIONS: 001 ZV, 002 ZV
HSN 001
SUB GROUP
STOPPING ORDER
MAIN CONDENSER
PRESSURE C CVI PSHH 004
> 0. 9 BAR ABS
STEAM TURBINE TRIPPED HSN 101

GSE ZSL 530 & GSE ZSL 532 INDIVIDUAL FAN TRIPPING
& GSE ZSL 534 STOPPING ORDER CONDITIONS
SUB GROUP STOP FAN

TRIPPING ORDER 001 ZV
SAME SEQUENCE FOR 002 ZV
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194
(21)STEAM TURBINE CONTROL FLUID SYSTEM(GFR):

The fluid station generates the required driving power for the governing and casing stop valve hydraulic
actuators.
The control fluid used is atmost non-ignitable (phosphate ester); which reduces the fire hazard if hydraulic
systems around the turbine develops any leaks.
In order to ensure the trouble free operation, specific properties of the fluid must be maintained during
operation.
• Purity (ensured by filtering)
• Stability (through a continuous chemical treatment).
2.DESCRIPTION OF THE SYSTEM:

Fluid tank GFR 002 BA:
It consists of two sections:
• A settling tank connected to the fluid return pipes.
• A tank from which the fluid is pumped.
The fluid tank is provided with:

• A sight level gauge.
• Three level detectors that trigger an alarm if fluid level in the tank reaches the low or high value.
• A direct reading locally mounted thermometer.
• An air filter mounted at the top.
• A filter mounted on the fluid return pipe.
• A drain valve at the lowest point of each tank section.
• A sampling cock with a cut-off valve.
• A connection, at the top, provided with a pressure relief-valve GFR PCV 008 for scavenging dry air during stand still
periods with cut-off valve.
• A fluid return pipe from the treatment station.
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.
A double filter GFR 004 FI – GFR – 005 FI:

Provided with a hand selector GFR HV 068 – GFR HV 070 for shifting oil flow from one filter to the
other (1 single filter should be in service under normal conditions), and a balance pressure valve HV 069.
• A differential pressure gauge GFR PDI 014.
• A differential pressure gauge GFR PDSH 050 that gives an alarm when the working filter gets choked.
It filters the fluid supplied to the inlet and safety systems.
Distribution manifold:
It includes:
• A fluid outlet to the relevant components.
• A fluid outlet to the treatment system provided with a shut-off valve and a diaphragm used as a flow regulator.
A hydro pneumatic accumulator GFR 003 – BA with the following functions:

• Antipulses
• Power reserve for (10 seconds) time, which is required for the stand by pump power sources to come into service.
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195
Treatment unit: It consists of:

• A reciprocating pump GFR 010 PO driven by A.C. motor and used for feeding the treatment station through filters, during
stoppage of both control oil pumps.
• A filter GFR 006 FI provided with a polymerised impregnated paper cartridge. It ensures the filter desiccation.
• A filter GFR 007 FI provided with fuller earth cartridges. It eliminates dirty particles in the system and maintains the fluid
acid number at a normal value.
• A filter GFR 008 FI with pleated paper & glass cartridges. It ensures the fine filtration of fluid.
• A mobile tank fill-in system.
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.
- STEAM TURBINE – E.H.C FLUID OIL SYSTEM GFR

STARTING CONDITIONS: 011 PO, 012 PO
GFR LSL 225

LOW LEVEL IN FLUID
TANK
E.H.C FLUID OIL PUMPS

STARTING CONDITIONS
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196
- STEAM TURBINE – E.H.C FLUID OIL SYSTEM GFR

E.H.C FLUID OIL PUMPS STARTING: 011 PO, 012 PO
HSN 001 SUB GROUP TRIPPING
SUB GROUP STARTING
HSU 001 HSU 002

011 PO TAKING OVER
SELECTED IN NORMAL AUTO CUT OUT
PUMP 011 PO
IN OPERATION
GFR PSH 051

FLUID OIL PRESSURE
> 80 BAR OFF
GFR PSH 048

DISCHARGE PRESSURE
PUMP 011 PO > 70 BAR OFF
TAKING OVER MEMORY

ON
ON OFF
TAKING OVER MEMORY
GFR PSL 055

FLUID OIL PRESSURE PUMP 012 PO SELECTED IN
< 70 BAR OFF NORMAL STOPPED
HSU 001
HSN 011 011 PO
011 PO SELECTED IN STAND BY
INDIVIDUAL STARTING
ORDER
STARTING CONDITIONS
START PUMP
011 PO
SAME SEQUENCE FOR 102 PO
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197
STEAM TURBINE – E.H.C. FLUID OIL SYSTEM GFR

TRIPPING CONDITION: 011PO.
HSN 001 TEST OPERATING ON

SUB GROUP STARTING GFR US 001
HSU 001
011 PO
GFR PSH 049

DISCHARGE PRESSURE E.H.C
PUMP 012 PO >70 BAR OFF.
GFR PSH 051

FLUID OIL PRESSURE > 80
BAR OFF
011 MO
ELECTRIC FAILUARE
PUMP 011 PO
TRIPPING CONDITION
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198

TRIPPING CONDITIONS: 012PO.
HSN 001 TEST OPERATING ON

SUB GROUP STARTING GFR US 001
HSU 001
012 PO
GFR PSH 048

DISCHARGE PRESSURE E.H.C
PUMP 011PO>70BAR OFF.
GFR PSH 051

FLUID OIL PRESSURE>80
BAR.OFF
012 MO
ELECTRIC FAILUARE
PUMP 012 PO
TRIPPING CONDITION
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199

TRIPPING CONDITION: 011PO. 012PO.
GFR LSLL 226

VERY LOW LEVEL
IN FLUID OIL TANK
SUB GROUP
TRIPPING CONDITION
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200
STEAM TURBINE – E.H.C. FLUID OIL SYSTEM

STOPPING CONDITIONS: 011 PO. 012 PO
HSN 001 SUB GROUP

SUB GROUP TRIPPING CONDITION
STOPPING ORDER
GSE ZSL 530, 532, 534 HSN 011 INDIVIDUAL TRIPPING

STEAM TURBINE STOPPING ORDER CONDITIONS
TRIPPED
SUB GROUP STOP PUMP

TRIPPING ORDER 011 PO
SAME SEQUENCE FOR 012 PO
200
201

STARTING CONDITION: 010 PO. 002 RS
HSN 010
010 PO INDIVIDUAL
STARTING ORDER
START PUMP
010 PO
FLUID OIL MANIFOLD

PRESSURE > 80 BAR OFF
GFR PSH 051
HSN 102
RESISTANCE HEATER 002 RS
GFR TSL 132 FLUID OIL
INDIVIDUAL STARTING ORDER
TANK TEMP. < 25ºC
FLUID OIL TANK

HEATER 002 RS
STARTING ORDER
201
202

STOPPING CONDITIONS: 010 PO. 002 RS
HSN 010
010 PO INDIVIDUAL
STOPPING ORDER
STOPPING PUMP
010 PO
FLUID OIL MANIFOLD

PRESSURE > 80 BAR OFF
GFR PSH 051
HSN 102 RESISTANCE GFR TSL 132 FLUID OIL

HEATER 002 RS INDIVIDUAL TANK TEMP. < 25 ºC
STOPPING ORDER
FLUID OIL TANK

HEATER 002 RS
STOPPING ORDER
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(22) STEAM TURBINE DRAINS (GPV)
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.

The turbine is provided with nine drains points. Each one is provided with an “ON/OFF” pneumatic valve.
Drains are discharged to the drain tank or flash tank.
OPERATION:
When the turbine generator is at stand still or when the unit output is low, all the drains are opened.
DESCRIPTION OF THE LOGIC CHAINS:
All the drain valves actuate together on automatic criteria. Besides, each valve has its own individual
control for operation. The opening order always has priority over the closing ones.
Automatic opening orders:
All the drain valves are kept open if:
• The turbine generator output is less than 25% OR
• The steam turbine is tripped. OR
• The metal casing temperature is less than 100 ºC.
Individual opening orders:

Each valve can be opened at any moment by its individual control at any time
Closing orders:
All the valves receive a closing order on appearance of the information “ turbine generator unit output
more than 25% AND steam turbine set AND casing metal temperature more than 100 ºC ”.
For UV 102 & UV 109, this closing order is only effective if there has not been any automatic opening
order for 30 minutes.
Each valve can be closed individually by manual command. These closing orders are only effective
if there is no opening order present.
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• STEAM TURBINE – DRAINS SYSTEM GPV
TURBINE CASING TEMP TURBINE CASING TEMP.

> 100 ºC GRE US 002 > 100ºC GRE US 002
TURBINE GENERATOR
TUBINE GENERATOR UNIT UNIT
OUT PUT < 25% 0UT PUT < 25%
TURBINE TRIPPED TURBINE SET

GSE ZSL 530 & GSE ZSL 532 GSE ZSH 531 & GSE ZSH
& GSE ZSL 534 533 & GSE ZSH 535
AUTO CLOSING
AUTO OPENING ORDER
ORDER
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STEAM TURBINE- DRAINS SYSTEM GPV

VALVE GPV UV 101. GPV UV 103. GPV UV 104. GPV UV 105. GPV UV 107 GPV UV 108
AUTO CLOSING
AUTO ORDER
OPENING ORDER
HSN 001 HSN 001 INDIVIDUAL

INDIVIDUAL CLOSING ORDER
OPENING ORDER
AUTO
OPENING ORDER
DEENERGIZED GRE ZSL 540 ENERGIZED

SOLENOID VALVE LP CONTROL VALVE SOLENOID VALVE
GPV UY 101 OPENING CLOSED GPV UY 101 CLOSING
VALVE GPV UV 101 VALVE GPV UV 101
SAME SEQUENCE FOR UV 103,UV

104 UV 105 UV 108
30’
ENERGIZED
SOLENOID VALVE
GPV UY 107 CLOSING
VALVE GPV UV 107
SAME SEQUENCE FOR UV 109
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STEAM TURBINE – DRAINS SYSTEM GPV

VALVE GPV UV102, GPV 106
B TTA ZSL X 10 A TTA ZSL X 10 A TTA ZSL X 10

HRSG B DAMPER CLOSED HRSG
DAMPER CLOSED DAMPER CLOSED
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
HSN 102 INDIVIDUAL GPV UV 102 HSN 102

OPENING ORDER AUTO OPENING ORDER HRSG A
CLOSING 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
SAME SEQUENCE FOR UV 106
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(23) STEAM TURBINE START UP

Reset conditions for the Steam Turbine:
9 Lube oil manifold pressure more than 1.6 bar.
9 Control oil manifold pressure more than 80 bar.
9 All drain valves open. ( Pneumatic drain valves)
9 HP & LP steam stop valve close limit switch picked up
9 HP & LP steam control valves close limit switches picked up.
9 Turbine speed more than 33 rpm.
♦ Start hydraulic oil sub-group (CGFR41)
♦ Start lube oil system sub-group. (CGGR 41)
♦ Start Jacking / turning gear sub-group (CGGR 42).
♦ After turning gear starts automatically (turning gear speed is 50 rpm), press SAFETY RESET. The HP stop valves open
and after 10 seconds delay LP stop valves open for increasing their metal temperature.
♦ For Warm up Speed authorization, the stop valve temperature should be more than 300o C.
♦ Press WARM UP after warm up speed authorization. Now the HP control valves open slightly (0.1 to 0.3%) gradually
increasing the turbine speed to 1750 rpm for soaking.
• The following important Turbine Parameters are to be constantly monitored during start-up processes:
1) HP/LP DIFF. EXPANSION

2) AXIAL SHIFT
3) VIBRATIONS( SHAFT/BEARINGS)
4) BEARING TEMPERATURES
5) HP/LP TURBINE EXHAUST TEMPERATURES
6) HP TURBINE CASING METAL TEMPERATURES
♦ 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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STEAM TURBINE SPEED AND LOAD CONTROL:

The steam turbine load & speed control functions are provided by the steam turbine control system (REC
920). The ST speed control enables automatic speeding up to 3000 rpm with a slope and temperature
stabilization periods of the thermal stack of the turbine. The speed control system governs the turbine HP
control valves.
After synchronization of the Generator, the ST load increases following a pre-determined slope, which
depends on its thermal stack.
The loading rates in various ST conditions are as follows:
Cold Between 0-10% 0.125 % per minute
Above 10% 1.5 % per minute
Warm 2.375 % per minute
Hot 3.167 % per minute
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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GAS TURBINE START-UP

AUTO OR REMOTE
GAS TURBINE READY TO START PERMISSIVES
Any of the
above No
All yes
NOT READY TO START READY TO START START
START ORDER
30 SEC AUTO VENT
AOP START GT WATER PUMP START SUPER PACKAGE FAN START 88 BT
LUB OIL PRESSURE
JACKING OIL PUMP START
1 -No lube Oil pressure low trip

2 -Jacking oil pressure OK
3 -Super package vent complete
4 -Jacking oil pump motor run
ALL YES
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GT START-UP - 2
A
HYD. OIL PUMP START CRANKING MOTOR START TORQUE CONVERTOR AT MAX 65%
SPEED DETECTED 14 HR (0.06%)
SPEED INCREASE 14 HT (8.4%)

OIL MIST SEPERATOR START
SPEED INCREASE 14 HM (10%)

EXHAUST COOLING FAN
MOTOR START 88 FX
JACKING OIL PUMP STOP TORQUE CONVERTOR 50%
SPEED INCREASE TO VENT SPEED TURBINE PURGING ( 1 min)
PURGE TIMER PICK UP
SPEED DECREASES TORQUE CONVERTOR 15%
SPEED BOGGED DOWN TO 14 MF 12% (FIRING SPEED)
FSR FIRING LEVEL (19. 8%)

SPARK PLUG 1 min
FLAME DETECTION 2 OUT OF 4
GT COOLER FAN 1-6 START 2 SEC LOAD COMPT. FAN 88VG START
FSR TO WARM UP LEVEL (9.5%) EXHAUST FAN 88 TK-1 START

TORQUE CONVERTOR 65%
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
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SPEED 95% 14 HS
AOP STOP AUX HYD OIL PUMP STOP GEN EXCITATION ON
SPEED CONTROL
COMPRESSOR BLEED VALVES CLOSE
SPEED SET POINT 100.3%

SYNCRO ON AUTO
Yes
SPEED MATCHING VOLTAGE MATCHING
GEN CIRCUIT BREAKER CLOSE
4.5 MW
IF NO LOAD SELECTION
SPINNING RESERVE
GT COOLING WATER FAN 7, 8, 9 START GEN COOLING WATER FAN 7, 8, 9 START
IF COOLING WATER TEMP HIGH FAN

10, 11, 12, START IF COOLING WATER TEMP HIGH FAN
10, 11, 12, START
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GT START UP: 4
C
BASE FOR PEAK PRESELECTED

LOAD SELECTED LOAD SELECTED
TNR & LOAD TNR & CONTROL

INCREASES INCREASES
IF IGV CONTROL
ON IF IGV CONTROL
OFF
AT 80% LOAD AT 25% LOAD

IGV WILL MOVE IGV WILL MOVE
54 Deg TO 84 Deg 54 Deg TO 84 Deg
PRESELECTED
BASE OR PEAK LOAD REACHED
LOAD REACHED SPEED CONTROL
TEMP. CONTROL
END
END
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GAS TURBINE NORMAL SHUTDOWN

GT SHUTDOWN -1
BASE OR PEAK LOAD
STOP ORDER
TNR DECRESES
LOAD DECRESES
IF IGV CONTROL ON IF IGV CONTROL OFF
AT 80 % LOAD IGV WILL MOVE AT 25% LOAD IGV WILL MOVE

FROM 84 Deg. TO 54 Deg FROM 84 Deg TO 54 Deg
TNR & LOAD DECREASES
REVERSE POWER DETECTOR - 4.5 MW
GEN. CIRCUIT BREAKER OPENS
FSR SET AT MIN FSR COMPRESSOR BLEED GT COOLER FANS 7,8,9 GEN. COOLER FANS
VALVES OPEN STOP 4 TO 9 STOP
FIRED COASTING DOWN
94% SPEED 14 HS
AUX. LUB. OIL PUMP START

EXHAUST BASE PLENUM FAN STOP AUX. HYD.PUMP START
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GT SHUTDOWN-2 A
IGV CLOSE FROM 54 TO 34 Deg.
50% SPEED 14 HC
40% SPEED 14 HA IF GEN COOLING WATER TEMP. LOW
BLOWOUT SPEED 35%

GEN. WTR. FAN 1 TO 3 STOP GEN COOLING WTR. P/P STOP
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
IF GT COOLING WTR. TEMP LOW 14 HT SPEED 6% JAKING OIL

PUMP START SUPER PACKAGE VENT
FAN 88 BT START
GT COOLER FAN 1 TO 6 STOP EXHAUST COOLING FAN 88FX STOP
14 HP SPEED DECREASING 3.3 %
BARRING MOTER START EXHAUST FRAME COOLING FAN 88 TK - 1&2 STOP
TORQUE CONVERTER AT 34%
COOL DOWN TIMER 62 CD ON
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GT SHUTDOWN –3
B
14 Hrs.
COOLDOWN OFF FROM LOCAL
BARING MOTER STOP
ZERO SPEED 14 HR 0.06% TORQUE CONVERTOR 65%
WHEEL SPACE TEMP. AUX. LUB OIL PUMP LUB OIL MIST JAKING OIL PUMP
LOW STOP SEPARATOR STOP
SUPER PACKAGE GT COOLING WATER PUMP

VENT FAN STOP
88 BT STOP
OFF SELECTED
TURBINE STANDBY
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MECHANICAL DATA OF STEAM TURBINE

TYPE: IMPULSE, TANDEM COMPOOUNDED, NON-HEAT, AND SINGLE FLOW
HP CYLENDER & DOUBLE FLOW LP CYLENDER.
NO OF STAGES: HP 13 STAGES & LP 05 STAGES
GOVERNING: THROTTLE GOVERNING
TURNING GEAR: MOTOR OPERATED AT 49 RPM
HP CASING: CAST STEEL, LP CASING: WELDED STEEL
CRITICAL SPEED: 2150 – 2750 RPM

DESIGN FLOW: HP=346 t/h, LP – 420 t/h
DESIGN PRESSURE: HP = 68 kg/cm², LP =4.35 kg/cm²
CONTROL: ELECTRO HYDRAULIC CONTROL BY OIL AT 100 bars
SAFETY: HP = 2 STOP VALVE, LP = 1 STOP VALVE
CONTROL: HPT 2 CONTROL VALVES, LPT 1 CONTROL VALVE
VIBRATION EXPANSION MEASUREMENT: 3300 SYSTEMS SUPPLIED BY BENTLY
NEVADA (NON-CONTACT PICKUPS)
SAFETY PHILOSOPHY: 125 V DC SOLENOID DE ENERGISE TO TRIP
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PERMISSIVES FOR DIVERTER DAMPER OPENING

UPTO 50% OPENING:
1. Diverter damper closed signal from limit switch.
2. At least one CEX pump should be running.
For CEX start up:
♦ Condenser level should be minimum 800mm.
♦ Deaerator level should not be more than 3100 mm.
♦ Discharge valve closed or discharge header pressure more than 7 bar.
3. At least one HP BFP running.

For BFP start up:
♦ Deaerator level should be minimum 1900 mm.
♦ Pump Discharge valve should be closed or there should be sufficient pressure in discharge header.
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.
6. At least one FLB pump running.

For this:
♦ LP drum level should be minimum 250 mm.
♦ LP Economizer re circulation valve should be in auto mode.
♦ Discharge flow should be above 55 tons/hr.
7. At least one FLP pump running.

For this:
♦ Pressure at suction of the FLP pump should be at least 4 bar i.e. CEX pump should be running.
8. HP & LP drum levels normal (600mm each)

9. HP feed regulating control valve sub group ON and one of the lines selected. The sub group cannot be made ON unless HP
Economiser inlet valve is open.
10. LP feed regulating control valve sub group ON and one of the lines is selected. The sub group cannot be made ON unless
LP Eco inlet valve is open.
11. De superheating sub-group ON.
12. Weather damper open.
13. Diverter hydraulic oil sub group ON and oil pressure normal.
14. No Diverter Damper closing order.
FOR 50 TO 75% OPENING:

HP and LP bypass should be available (unlocked). For unlocking of these systems, following conditions
should be fulfilled:
HP bypass valve:
♦ Pressure in de superheating spray water line should be minimum 8 bar abs. i.e. CEX pump should be running.
♦ Condenser pressure should be less than 350 mbar.
♦ HP bypass valve downstream steam pressure less than 18 bar.
♦ Bypass valve downstream steam temperature less than 180o C.
♦ No position loop disturbance.
♦ No HP bypass fault.
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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.
FOR 75% TO 100% OPENING:

ST should be synchronized and should have a minimum load of 15% i.e. 17 MW.
(Now it is modified to ST synchronized & 3 minutes there-after).
HALT OF DIVERTER DAMPER AT 3 POSITIONS (33%, 50% 72%):

15, 10 and 12 minutes respectively.
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(24) GENERATOR AND EXCITATION SYSTEM

1.GENERATOIR:
In KGPP there are 4 nos. Gas Turbines each having 134 MVA rating Synchronous Generators and 2 Steam Turbines each
having 145 MVA rating Synchronous Generators. These generators are 2 pole machines with a generating frequency of 50
Hz. Generators are directly coupled with turbines.
Major components of the generator are as discussed bellow:
Housing/Frame:
The frame is a single block. It holds by clamping the magnetic core along with stator bars, their wedges
and connections. The frame forms the outer casing of the turbogenetator.
Stator Magnetic Core:
The magnetic core is made up of a stack of special grain oriented magnetic steel segment, or laminations.
These laminations are characterised by their method of manufacturing-cold rolling- their low loss and high
permeability, and their carlite coating. Each segment is further insulated with a thin coat of oil varnish
containing coloidal silica.
Rotor/Shaft:
The generator shaft is made of a single forging, whose ingot is made in an electric furnace and then
vacuum cast. The steel used is a high fracture resistant alloy. The longitudinal slots of the field’s coils are
milled into the shaft body and are arranged so as to generate a magneto motive force wave approaching a
sine wave.
Stator Winding:
It is composed of conductors wedged into the magnetic core. It is in the winding that the electrical energy
is generated. There are two distinct parts of winding.
a) The straight part, which is within the magnetic core.
b) The end winding which are outside the core and which serve to connect bars of different slots together,
thereby completing the winding.
Rotor winding:
The rotor winding which is unevenly arranged around the body thus produces a dissymmetry of inertia
with respect to both of the main planes of the rotor. Slot milled perpendicular to the axis of rotation restore
this equilibrium. The rotor winding has two distinct parts.
a) The part contained in the shaft body - the slot portion.
a) b) The part outside the shaft body-the end winding
b) The rotor winding comprises a number of turns stacked inside the rotor slots that constitute
the field coils, which make up the poles of the rotor.
Cooler and cooling arrangement:

The coolers are mounted vertically in the generator, the water being supplied from the bottom, underneath
the generator. They are four in numbers and are placed at four corners of the generator and are
symmetrically positioned within the air circuit.
The complete generator is cooled by air and air in turn is cooled by the 4 coolers as mentioned above. The
air being driven by two axial fans fitted on both ends of rotor. Air is circulated inside the generator in
closed path. A small amount of fresh air is sucked through an opening with filter mounted at the exciter
end to make up for the leakages.
Specification of Generators:
Gas Turbine Generator:
Total quantity 4 Nos.
Specifications:
a) Rated MVA 134
b) Rated MW 107.2
c) Rated voltage 11.5 KV +10%
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220
d) Rated stator current 6728 A

e) Rated power factor 0.8
f) Maximum Reactive MVAR (Lagging) 75
g) Minimum Reactive MVAR (Leading) 72
h) Excitation system Brush less; Rotating Diode type
Steam Turbine Generators:

Total quantity 2 Nos.
Specifications:
a) Rated MVA 145
b) Rated MW 116.078
c) Rated voltage 11.5 KV +10%
d) Rated stator current 7285 A
e) Rated power factor 0.8
f) Maximum Reactive MVAR (Lagging) 70
g) Minimum Reactive MVAR (Leading) 75
h) Excitation system Brush less; Rotating Diode type
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.
The voltage regulator also performs:

a) Normal limitation of the excitation current (1.1 x 1 nominal)
b) Temporary limitation at ceiling value in case of short circuit.
c) Voltage drop compensation (if necessary)
d) Under excitation Limitation.
e) Stator voltage/frequency limitation.
f) Power stabilisation.
3.GENERATOR CONTROL SYSTEM:

The control system of generator permits the driving of the generator by
• Measuring the main parameters as voltage, currents, active and reactive power.
• Acting on these parameters through the operating switches.
• Manual synchronisation.
Brief description of manual synchronisation:

The manual synchronisation control system needs three indicators
• A differential voltmeter, which helps to equalise the generator voltage upon network by operating voltage control
switch.
• A double frequency meter 48 to 52 Hz range is used to adjust the generator to the same frequency as the network by
operating the raise/lower speed control switch.
• A differential phase difference between generator and network system. The rotation speed of the pointer of
synchroscope is the frequency drift between F (Grid) & F (Generator).
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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 -
a) Rated MVA 115
b) Voltage ratio 229 KV/11.5 KV
c) Vector group Ynd 11
d) Type of Grounding Solid
e) Type of Tap changer&% variation Offload (-5% to + 5%)
f) % Age Impedance 12.23%
g) Type of cooling OFAF
Generator transformer for ST:

Total Quantity 2 Nos.
Specification of each
a) Rated MVA 140
b) Voltage ratio 229 KV/ 11.5 KV
c) Vector Group Ynd 11
d) Type of grounding Solid
e) Type of Tap changer& % variation off load (-5 % to + 5%)
f) % Age Impedance 14.92%
g) Type of cooling OFAF
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GENERATOR PROTECTION SYSTEM:

The purpose of the generator electrical protection system is to avoid any abnormal operation (due to
internal or external-disturbance), which could have damaging effects on the machine. This is done by
giving an alarm or by automatically tripping the unit.
The generator protection can be classified with the nature of the input circuit signal, as follows:
• The protection operated by current, they receive a signal, which is the “image” of the stator currents.
87 G : Generator differential protection
46 : Stator current unbalance protection
51 G : Stator over current protection
87 B : Overall differential protection
• The voltage protections; they receive a signal which is an image of the stator voltage.
27 : Under voltage protection
59 : Over voltage protection
81 : Under frequency protection
95 : Generator over fluxing protection.
• The power protection: they receive the voltage and the current images,
27 : Reverse power protection

40 : Loss of excitation protection
21 : Back-up impednece protection
• The ground /earth protection:
54 F : Rotor earth fault protection

54 G : Stator voltage protection
64 TP: Generator transformer back-up E/F protection.
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(25) NOX CONTROL SYSTEM:
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.
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).
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.
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:
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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Shut down of the pumps:

The pump in operation stops:
• In case of a sub-group tripping order (in a sub-group tripping condition or a voluntary sub-group stopping order by the
operator).
• In case of a pump tripping order (in a tripping conditions or a voluntary pump stopping order by the operator).
Emergency taking-over of the pumps:

• Emergency taking-over is only possible at level of sub-group control.
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.
Changeover of the pumps:

By sub-group control: the operator, with the selector HSU 001, realizes his new choice of pumps and
confirms with the sub-group control device HSU 001.
The changeover of the sub-group is realizes with an overlap period.
FAILURE OF 125 V DC OR 48 V DC ON LV SWITCHBOARD:

The transfer pumps are shutdown.
The transfer pumps stop.
FAILURE OF T20:
A1 controller power supply:
• Actuators remain in same position.
AA controller power supply:

• Actuators remain in same position.
• Individual command remains available.
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WATER SKIDS TRANSFER PUMPS. STARTING CONDITIONS: 101 PO. 201 PO. 301 PO.
SER LSL 001 SER LSL 002

DEMINERALIZED WTR. TANK DEMINERALIZED WTR.
1 LOW LEVEL TANK 2 LOW LEVEL
SER ZSH 001 SER ZSH 002

VALVE SER HV 001 VALVE SER HV 002
OPENED OPENED
PUMPS STARTING
CONDITIONS
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WATER SKIDS TRANSFER PUMPS. STARTING: 101 PO.201 PO. 301 PO
HSN 001
SUB-GROUP STARTING SUB-GROUP
ORDER TRIPPING ORDER
FROM FOLIO 5
HSU 002 TAKING OVER

AUTO CUT OUT
HSU 001
PUMP 101 PO
SELECTED IN NORMAL
SELECTED STATUS
CORRECT
SELECTED STATUS
CORRECT
TAKING OVER MEMORY

ON
TAKING OVER MEMORY ON OFF
PUMP
SELECTED IN NORMAL
STOPPED
HSN 101 PUMP 101 PO HSU 001

INDIVIDUAL STARTING PUMP 101 PO
ORDER SELECTED IN STAND-BY
PUMP 101 PO STARTING CONDITIONS

IN OPERATION FROM FOLIO 2
PUMP 101 PO STARTING

IN OPERATION PUMP 101 PO
SUB-GROUP LEVEL
SAME SEQUENCE FOR 201 PO, 301 PO
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WATER SKIDS TRANSFER PUMPS. TRIPPING CONDITIONS: 101

PO, 201 PO, 301PO
SER LSLL 001 SER LSLL 002 SER ZSH 001

DEMINERALIZED WTR. DEMINERALIZED WTR. VALVE SER HV 001
TANK 1 VERY LOW TANK 2 VERY LOW OPENED
LEVEL LELVEL
SER ZSH 001 SER ZSH 002 SER ZSH 002

VALVE SER HV 001 VALVE SER HV 002 VALVE SER HV 002
OPENED OPENED OPENED
SUB-GROUP TRIPPING
CONDITIONS
ELECTRIC FAILURE
101 MO
PUMP 101 PO
TRIPPING CONDITION
WATER SKIDS TRANSFER PUMPS. STOPPING: 101 PO, 201 PO, 301 PO
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228
HSN 001 SUB-GROUP

SUB-GROUP TRIPPING
STOPPING ORDER CONDITION
FROM FOLIO 4
HSN 101
PUMP 101PO
INDIVIDUAL
STOPPING ORDER
PUMP 101 PO
TRIPPING
CONDITION FROM
FOLIO 4
SUB-GROUP PUMP 101 PO

TRIPPING ORDER TRIPPING ORDER
SAME SEQUENCE FOR 201 PO, 301 PO
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(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.
1. CONDENSATE PUMPS (CEX):

Start Permissives:
• Feed water tank level not Hi-Hi (<3100 mm)
• Condenser level not low (>800 mm)
• Suction valve open
• Discharge valve closed or discharge header pressure normal
• Not trip order
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
2. LP FEED WATER PUMPS (APB):

Start Permissives:
• Feed water tank level not low (1900 mm)
• Discharge valve closed or discharge header pressure normal
• No trip order
• Electric failure
• Feed water tank level very low (700 mm)
• Emergency tripping order
3. HP FEED WATER PUMPS (APH):

Start Permissives:
• Feed water tank level not low (1900 mm)
• Discharge valve closed or discharge header pressure OK.
• Lube oil pressure normal
• No trip order
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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).
4. L.P.CIRCULATING PUMPS (FLB):

Start Permissives:
• Both economizer recirculatation control valve on auto mode
• LP drum level not very low
• No trip order
• LP drum level very low (300 mm)
• Pump running with discharge flow low (10 sec.time delay)
• EPB trip order
5. HP CIRCULATING PUMPS (FLH)

Start Permissives:
• Both economizer recirculation valves on auto mode.
• HP Drum not very low.
• No trip order present.
• 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.
6. PREHEATER CIRCULATING PUMPS: (FLP)

Start Permissives:
• Inlet condensate pressure OK. (4 kg/cm²)
• No trip condition.
• Tripping conditions:
• Condenser pressure low (4 kg/cm²)
• Pump on but discharge flows low (15T/H) (After 10 sec. Time delay)
7. VACUUM PUMPS (CVI):

Start Permissives:
• Suction valve closed.
• Seal water pump in operation.
• Seal water flow not low.
• No trip order present.
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231
• 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
• 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)
9. ARCW PUMPS (CRF):

Start Permissives:
• Suction pressure OK.
• No trip order
• Suction pressure low
10. DM COOLING WATER PUMPS (SRI):

Start Permissives:
• Tank level normal
• No trip order
• Tank level very low
11. DM MAKE-UP PUMPS (CAP):

Start Permissives:
• Tank level above (0.5 m)
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232
• Tank level low low (0.5 m)
• Suction valve not open
12. DIVERTER DAMPER (TTA):

Damper opening permissives:
• Damper closed
• One LP circulating pump in service
• One HP circulating pump in service
• One condensate-preheater circulating pump in service
• HP Drum level normal
• LP Drum level normal
• LP BFP in service
• HP BFP in service
• HP desuperheating valve available
• Weather damper open
• Diverter hydraulic oil pressure normal and sub group on
• No diverter closing order
Diverter damper quick closing conditions:

• Block emergency trip
• EPB closing order
• GT breaker trip
• HP BFP protection against over flow
• LP BFP protection over flow
• No steam flow from HRSG
• Steam temp. Very high (30min. time delay)
• Weather damper not open
• LP drum level very low (300 mm)
• HP drum level very low (300 mm)
• LP drum level very high (1872 mm)
• HP drum very high (1644 mm)
• Both LP circulating pumps off
• Both HP circulating pumps off
If the diverter damper does not close following a trip order, then the corresponding GT will be
tripped after 40 sec. Time delay.
13. HP BYPASS SYSTEM (GHP):

Valve open permissives:
• No position loop disturbance
• Condensate water pressure OK (8 Bar)
• Condenser pressure less than 350 m bar
• Bypass valve down stream pressure less than 10 bar
• Bypass valve down stream steam temp. less than 120°C
• HP bypass no fault
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233
Valve closing Protections:

• Condenser pressure high (350 m bar)
• Bypass down steam temp. High 250 °C
• Position loop disturbance (After 2 sec. Time delay)
• Condensate water pressure low (after 3 sec. Time delay) (8 bar)
• Down stream water pressure high (18 bar)
• HP bypass fault.
14. LP BYPASS VALVE:

Valve open Permissives:
• No position loop disturbance
• Condensate water pressure normal 8 bar
• Condenser pressure less than 350 m bar
• Bypass valve down stream steam pressure less than 1 bar
• LP bypass no fault.
Valve Closing Interlocks:

• Condenser pressure high > 350 mbar.
• Bypass down stream steam temp. High (100 °C)
• Position loop disturbance (After 2 Sec. Time delay)
• Condensate water pressure low (less than 8 bar) (After 3 Sec. Time delay)
• LP bypass fault.
15. STEAM TURBINE SAFETY SYSTEM:

Reset Conditions:
• Lube oil manifold pressure more than 1.6 bar
• Control fluid manifold pressure more than 80 bar
• All drain valves open (9 pneumatic drain valves open)
• Steam turbine tripped (Close limit switch contact of HP&LP control & stop valves).
• Turbine speed more than 33 rpm
OR
• Turning gear motor on with normal speed.
• No trip conditions
• Internal setting authorised (power & speed set point is zero)
Turbine tripping conditions:

• Lube oil pressure very low (0.8 bar)
• Condenser vacuum very low (0.27 bar absolute)
• Control fluid pressure very low (60 bar)
• LP exhaust temp. Very high (100°C)
• Turbine lube oil tank Level very low (-460 mm)
• Shaft vibration at bearings and 200 microns for generator bearings)
• Both HRSG A&B tripped)
• Deaerator level very high (3100 mm)
• Condenser level very high (1250 mm)
• Generator breaker tripped
• Steam turbine over speed (Electrical 3300 rpm)
• Steam turbine over speed (Mechanical)
• Very high shaft eccentricity (120 microns)
• Very high axial shift (0.945 mm)
• HP differential expansion very high (-3 mm & 6.4 mm)
• LP shaft absolute expansion very high (4.5 mm)
• Emergency local shutdown.
• Emergency remote shutdown.
• Emergency back-up desk shutdown.
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STEAM TURBINE TRIPPING CONDITION

Shaft vibration at GMA VSHH 100 Microns Any one will trip
steam turbine 302,303,304,305,
bearing 306,307,308,309
Shaft vibration at GMA VSHH 200 Microns Any one will trip
generator bearing 310,311,312,313
Shaft eccentricity GMA VSHH 120 Microns Applicable up to
very high 314 600 RPM
Axial shift very GMA ZSHH +0.945 mm & Only one sensor
high 352 - 0.945 mm
HP differential GMA ZSHH - 3.0 mm & HP Rotor to HP
expansion very 355 + 6.4 mm Casing diff. Exp.
high
STEAM TRIPPING CONDITION
LP shaft absolute GMA ZSHH - 1.5 mm & Only one sensor
Expansion very 353 + 4.2 mm
high
Deaerater level ADGLSHH 3100 MM From 3 level
very high 001 Transmitters
Condenser hot CEXLSHH 1250 MM From 3 level Transmitters
well 001
Both HRSG ATTA/BTTA Limit Switch Two Limit Switches &
tripped One position Feedback
Transmitter
Both HP Stop GSE US 027 Limit Switch Both valve Limit Switches
Valve closed
Boiler header VVP US 034
valve open &
drum level very
high

Over speed trip GSE US 003 3300 RPM From 3 speed sensors
(electrical) (110%)
Over speed trip GSE PSLL 3270 RPM From 3 Lub Oil Pressure
(Mechanical) 045,046,047 (109 %) Switches
Generator From Elect. Protection
protection trip Panel (Group)
Emergency remote GSE HSX From CRT
shut down 003
Emergency GSE HSX Push Button
backup desk shut 001
down
Emergency shut GSE HSX Push Button
down LOCAL 002
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235
STEAM TAG NO SET POINT REMARKS

TURBINE
TRIPPING
CONDITIONS
Lube oil pressure GGR PSLL 0.5 Bar 2/3 Logic voting
very low 045,046,047 (Falling)
Condenser GSE PSHH 0.27 Bar 2/3 Logic voting
vacuum very low 066,067,068 (abs) (Rising)
Control fluid GFR PSLL 60 Bar 2/3 Logic voting
prressur3e very 052.053,054 (Falling)
low
LP exhaust temp. GGR LSHH 100 °C 2/3 Logic voting
very high 140,141,142 (Rising)
Turbine lube oil GGR LSLL - 460 mm From the top of the tank
tank very low 223
STEAM TURBINE PROTECTIONS: INTERLOCK:

1) LUBE OIL LEVEL VERY LOW.
2) LUBE OIL PRESSURE <8.5 BAR
1) ALL DRAIN VAQLVE OPEN
3) CONTROL OIL PRESSURE <68 BAR
4) EXHAUST CASING TEMP. >88 deg C 2) TG ON AND SPEED >33 rpm
5) VERY HIG BEARING VIBRATIONS
a) 188 Micron ST BRG 3) CONTROL/STOP VALVE
b) 288 Micron GEN BRG
6) WATER PLANT TRIP:
CLOSED
a) DEAERATOR LEVEL > 3100 mm
b) CONDENSER LEVEL >1250 mm 4) NO TRIPING ORDER PRESENT
c) HP DRUM LEVEL >1644 mm & header valve Open
d) LP DRUM LEVEL >1872 mm & header valve open. 5) CONTROL SYSTEM HEALTHY
7) EXHAUST CASING PRESSURE >270 m bar
8) VERY HIGH SHAFT ECCENTRICITY >200
micron 6) STRESS COMPUTER OK
9) VERY HIGH DIFFERENTIAL EXP - 3/6.5 mm
10) VERY HIGH LP DIFFERENTIAL EXP –1.6/4 mm
11) MECHANICAL OVER SPEED >109 %
12) ELECTRICAL OVER SPEED >110%
13) GENERATOR BREAKER TRIP CONDITIONS
14) BOTH STOP VALVES CLOSED.
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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
STRESS COMPUTER FUNCTIONAL LAYOUT

STRESS PLC PLC T 20
COMPUTR FULL AUTO
C100
MODE
REC MICRO CENTRALOG

Z SEMIAUTO/MAN
920
THEORY OF OPERATION OF NON-CONTACT PICK-UPS
GAP
PICK UP MEASURE
OSCILLATOR DETECTOR AMPLIFIER

SHAFT
TO REMOTE MONITOR
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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INSTRUMENT IN STEAM TURBINE COLD JUCTION COMPENSATION
1) BEARING TEMP –THERMOCOUPLE

2) SPEED-5 PICK UPS2 FOR CONTROL HOT JN
3) VIBRATION – NON CONTACT t°C COLD

JN BOX
PICK UPS 60°C
4) HP CASING EXPAN
5) LP ROTOR EXPANSION
6) HP ROTOR EXPANSION
7) AXIAL SHIFT
8) ECCENTRICITY PICK UP <600 rpm (t - 60) °C
9) KEY PHASOR
10) GENERATOR AIR TEMP –TRD
11) LVDT – CONTROL V/V POSITION The cold junction box is kept at a
12) PRESSURE TRANSMITTER constant temp or 68 deg C irrespective of
13) TEMP GAUGES stomas temp thus eliminating ambient
temp effects the resulting deficit is taken
care of by the temp measuring cards in
REC 920.
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(27) ELECTRICAL SYSTEM AT KAWAS PLANT
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.
UNINTERRUPTIBLE POWER SYSTEM (UPS):

In KGPP, we are having 240 V AC UPS system connected with 220 V DC batteries to supply to the
computers and microprocessor based control system. Some of the important features of UPS system of
KGPP are as follows:
• Two UPS are provided to supply the secured 240 V A/C.
• One UPS set is provided for each of the switchboards, namely 1CLNA and 2CLNA.
Each UPS system consists of:

a) Two rectifiers
b) One set of batteries of 240V.
c) Two inverters.
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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CHANGE OVER SCHEME OF 6.6 KV/415 V SYSTEMS:

Automatic quick changeover facility is provided with 6.6 KV switchgear & 415 V MCC. This ensures
continuity in power supply to plant auxiliary feeders during tripping of one power supply source
(transformer).
1. 6.6 KV SYSTEM :
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.
220 KV SWITCHYARD SYSTEMS:

Kawas Power Project has 220 KV systems for the transmission of Bulk Power being generated. The
switchyard is of 2 Bus and 1 transfer Bus system, between two buses, we are having Bus-coupler to couple
both the Bus in normal operation. There is only one Transfer Bus coupler (TBC), so at one time only one
feeder can be transferred. Normally transfer Bus is not charged. But in case of problem of any feeder
breaker, we can use transfer Bus Coupler and transfer bus in service. In turn we can bypass the feeder
breaker. Thus transfer of load can be done ON-load without taking any shutdown.
In normal operation the Generator will be connected to either Bus-I or Bus-II through its respective
Isolator (i.e. (A) or (B)). The generator Breaker (1) will be closed/synchronised with the 220 KV Bus from
central control room.
In case of problem in Generator Breaker (1), we can shift the load from Generator Feeder to transfer bus
coupler feeder on load. The steps are to be followed during this changeover are as follows:
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240
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.
Operational procedure for Major equipments:

220 KV Breakers:
It is double break SF6 breaker. This breaker can be operated manually or electrically. Manual operation is
only possible at local and off line. Manual operation is done for maintenance purpose only. From remote
i.e. from switchyard control room or central control room, breaker can be operated. On line/load closing of
breaker is always with synchronising mode. Tripping can be manual or automatic with protection circuit.
Horizontal breaker Isolator:
It is air break off load switch. Isolator can be operated mechanically as well as electrically. Mechanical
operation of the isolators are possible only at local. Electrical operation is possible from local as well as
from switchyard control room. It is having interlocks with Earth Switch & Breaker. On load operation is
strictly prohibited.
Air Break Earth Switch:
This is only used to earth the circuit during maintenance work. This can only be used off load and from
local. Through it also can be operated mechanically & electrically. It is having interlocks with isolators
and Breakers.
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(28) BLOCK START-UP PROCEDURE

Start-up and operation of combined cycle module involves line up and start-up of various auxiliaries to
systems in a sequence. The flow diagram of a general block start-up is illustrated on next page.
1. ELECTRICAL SYSTEM LINE UP:
• Check 220 KV/6.6 KV station transfer 1 & 2 charged.
• Check 415 V unit and station MCC’s are powered.
• 125 V station DC supply available.
• 48 V DC control supply available.
• 240 V AC UPS supply available.
• 240 V DC emergency lighting supply available.
• DG set available on auto.
• All essential auxiliaries drive power supply available.
2. GAS TURBINE START-UP:

Start-up the gas turbine and select base load operation
(See GT start-up procedure in training manual 1).
3. START-UP OF COOLING WATER SYSTEM (CRF)

• Check the following line up
• Condenser inlet/outlet valves of atleast one CW pass open.
• Cooling water lump level is above 4600 mm (When CW discharge duct is empty, starting of first CW pump would cause
about 500 mm drop in CW sump level).
• CW lube water tank is normal and level control valve is on remote.
• Service water pump in the DM plant is running to provide continuous make up to lube water tank.
• Manual isolating valve before make up control valve is open.
• One lube water pump is running and second pump is available as standby.
• Condenser water box vents open.
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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BLOCK START UP SEQUENCE
ELECTRICAL SYSTEM
NORMALISATION
GT-A START-UP GT-B START-UP
CAP START CRF & ARCW

UP PUMPS START
CEX START SRI SYSTEM

UP AFTER SRI START
AFLP START GGR START
APH/APB START
TURNNING GEAR
START
HP & LP BOILER-A
FILLING
GFR START
FPU/ACO LINE UP BFLP START
AFLB/AFLH START HP/LP BOILER- B

FILLING
TTA-A LINE UP &

ADG SUB-GROUP ON FPU/ACO- B LINE UP
HRSG-A START FLB/FLH- B START
CVI START TTA – B LINE UP
ST RESET
ROLLING & SYNCHRNISATION
HRSG- B START
HRSG – B COUPLING
ST LOAD TO 100 %
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243
5. DM COOLING WATER SYSTEM (SRI):

Line up:
• Suction and discharge valves are open.
• SRI tank make up system is OK.
• Heat exchanger inlet/outlet valve is open
(The same heat exchanger must be charged from ARCW side also)
Now two DM water pumps can be started at sub group level.
6. STEAM TURBINE TURNING GEAR OPERATION:

Line up:
• Ensure all lube oil pressure switches transmitter and local guage isolating valve are opened
• Lube oil tank level is normal
• Lube oil cooler inlet and outlet waterside valves are open.
• Both AC lube oil pump discharge valves are open.
• Thrust bearing filter drain and lube oil cooler oil side drains are closed.
• Isolating valves before and after lube oil pressure control valves are open.
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.
08 CONDENSATE SYSTEM START UP (CEX)

Check:
• Condensate pumps suction valves are open.
• Open the CEX system-filling valve from CAP. Once the discharge of CEX system is primed. Close the filling line valve.
• Ensure CEX pump’s suction strainer drain valves are closed.
• CEX discharge line drains are closed.
• CEX pumps gland sealing water isolating valves open.
• Vacuum balancing line valves of CEX pumps open.
• DM cooling water valves of CEX pumps open.
• All isolating valves in condensate line to Deaerator, like gland steam cooler inlet/outlet valve, preheater inlet /outlet valves
are open.
• CEX common recirculation valve is open FV001.
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.
09 STARTING OF PREHEATER CIRCULATING SYSTEM:

Once the CEX system is charged, preheater circuit inlet/outlet valves are open and preheater circulating
pumps suction & discharge valves open. First preheater pump can be started in subgroup level.
When boiler is running the temperature control valve TCV 106 maintains the preheater inlet temperature
above 45°C in case of GAS fuel & 69°C in case of Liquid Fuel to avoid Cold end corrosion, Whereas
TCV 107 temperature control valve maintains preheater outlet temperature about 95°C.
10. STARTUP OF HP FEED WATER SYSTEM (APH):

Line up:
• ADG tank level is about 2300 mm.
• Suction valve of APH pumps open.
• Discharge valve of all three APH pumps closed.
• Feed pump and feed line all drains closed.
• Feed line vent valve open.
• APH motor and lube oil cooler manual cooling water valves open.
• Lube oil tank level is OK.
• Recirculation line manual valve and pneumatic valve open.
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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11. LP FEED PUMP START UP AND LP BOILER FILLING (APB):
Prior to ABP pump start up, ensure that:

• The suction valve is open
• Recirculating line manual and pneumatic valve open.
• Suction and discharge drains are closed.
• All C&I impulse lines are charged.
• Discharge valve are closed (This is required only when all pumps are stopped).
• AGD tank is about 2300 mm, start one APB pump in group or sub group mode.
• On start-up of an APB pump the corresponding discharge valve opens automatically and the pump runs on recirculation.
Following line up needs to be checked before LP boiler filling.

• LP drums vents and super heater vents & drains open.
• EBD valve closed.
• Feed line vents open.
• Economiser inlet valve open.
• Both high range feed regulating station motorised valves closed.
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.
12. HP CIRCULATING SYSTEM START-UP (FLH):
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.
13. LP CIRCULATING PUMP START UP (FLB):
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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14. BOILER START-UP:
PRE CONDITIONS TO BE FULFILLED:

• FLP, FLB, FLH systems in service at sub group level.
• HP desuperheating subgroup is on.
• HP & LP feed control valves are in auto mode.
• HP/LP drum levels are OK. (800 mm).
• Weather damper open.
• Diverter damper hydraulic stations operating at subgroup.
• Diverter damper seal air fan subgroup on.
• GT of the boiler to be started is in synchronised condition.
• Steam turbine is on turning gear.
• Main steam and boiler drains (ACO & FPU) are open.
• HP/LP bypass spray valve isolating valves open.
• Seal steam spray isolating valves open.
• HP header valve of the incoming boiler open (this require only when two boilers are out of service)
• Close vacuum breaker valve and start two vacuum pumps for condenser vacuum pulling in-group level/sub group level.
• Start moving diverter damper in subgroup mode. Initially the diverter opens to 30 Deg. for 15
minutes, then it opens to 45 Deg. for 10 minutes then it opens to 75 Deg. for 12 minutes and
finally to 90 Deg. when steam turbine load has reached 15%.
• Gradually the boiler water temperature increases. When the temperature in the evaporator reaches 100 °C the water level in
the drum increases quickly and can reach high-level alarm. In this case, EBD valve will be operated to maintain the level
with in acceptable limits.
• As the pressure and temperature increases, drum vents in HP/LP circuit closes automatically when pressure reaches 2 bars.
The drum water is considered deaerated.
• Pressure and temperature go on increasing.
• The LP superheated vent will close automatically when pressure is more than 4 bar and steam flow is more than 5 t/hr and
HP superheated vents will close automatically when the relevant steam pressure is more than 5 bar and steam flow more
than 15t/hr.
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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15. STEAM TURBINE START UP:
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.
WARM STARTUP: HP casing temperature between 330 °C and 410°C i.e.

about 8 hrs. After shutdown but before 20 hrs.
HOT STARTUP: HP casing temperature above 410°C i.e. within 8 hrs

of 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.
16. 2ND GT AND HRSG STARTUP:

Second GT of module could be started in parallel with first GT or after complete loading of first GT.
• For 2nd GT & Boiler start-up, 2nd APB,APH and CEX pumps are to be started. Follow the line up and start-up procedure as
mentioned in the case of first boiler. But VVP header valves of 2nd boiler (HP & LP header valves) should remain closed.
• Bring the pressure and temp. parameters of the new boiler matching with the first one in operation.
• Couple the HP & LP header valves of the incoming boiler with the running one.
• On coupling second boiler with main steam side, Steam turbine load gradually increases to 100%.
• At about 60% ST load, the deaerator pressure control valve from LP steam closes fully and bleeding steam from LP turbine
maintains the rated steam pressure 1.2 abs bars. Prior to this change over, ADG tank pressure is 1.15 abs bar.
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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TURBINE STRESS EVALUATOR:

The turbine stress margins are calculated by a stress computer and exchanges information/ authorisation
with steam turbine control REC –920. In normal operation stress computer determines the stress margins
for ST rotor and stator. This calculation is used for:
- To stop speeding up
- To decrease loading and stop loading up
- To authorise the cross over of critical range
- To authorise synchronisation
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.
Rotation speed Rotor stress margin

S
First stage steam pressure T Stator stress margin
R
First stage steam temp. E Loading slope
S
Inner flange metal temp. S Stress calculation start
Outer flange metal temp. Alarm

C
Inner casing metal temp. O Speed slope
M
Outer casing metal temp. P Speed up stopping
U
Speed position from critical range T Critical range authorisation
E
Critical range cross over R Synchronisation authorisation
Authorisation request
Synchronisation authorisation Request
Main circuit breaker status
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BLOCK MASTER LOAD CONTROL:

The simplified analog control diagram of block master control is shown in next page.
Block master control operation is possible for one GT/ST combination or two GT/ST combinations or two
GT on open cycle combination.
The block load set point comes either from operator workstation or from B.U.D. (Back Up Desk) in the
central control room. ST load follows the GT load variations with a time delay depending mainly on the
HRSG inertia. Therefore, after a block load set point change, the GTs try to take more or less their final
stabilized values. In this case, there will be some oscillations in the block load during the transient period
when ST load increases.
There exists an anti over shoot system in the control loop, which will suppress the transient oscillations if
the anti over-shoot is on. This system calculates the theoretical Steam Turbine load from the block load set
point and compensates the actual Steam Turbine load. After stabilisation of Steam Turbine load, this loop
has no influence.
When both Gas Turbines are in operation, each Gas Turbine receives a set point, which is half of the
difference between the block load set point and the steam turbine actual load compensated by the antiover
shoot system. But if one Gas Turbine cannot produce this load (due to an internal limitation), the other
Gas Turbine receives in addition to its own set point the load deficit of the other as far as it does not cross
its maximum permissible load.
In this case, the maximum unbalanced operation allowed corresponds to a temperature difference of two
HRSGs out of 30 °C.
When only one Gas Turbine is in operation, it receives a set point value, which is the block load minus the
Steam Turbine actual load compensated by anti-overshoot system.
OPERATION UNDER ABNORMAL CONDITIONS:
The turbine must withstand some deviations from the normal condition, provided they remain within the
limits mentioned below.
Pressure:
The average pressure at turbine inlet, for a whole operating period of 12 months, must not exceed the
nominal value.
Assuming that this average value is complied with the pressure must not exceed 110% of the nominal
pressure, through it may momentarily raise at 120% of the nominal pressure, provided that the total
duration of this over pressure periods does not exceed 12 hours for the whole operating period (effective
running) of 12 months.
Steam temperature maximum limits:
The average steam temperature at any turbine inlet point must not exceed the nominal temperature for the
whole operating period (nominal operation) of 12 months.
Assuming that this average value is complied with:
• As a general rule, the temperature must not exceed the nominal value by more than 8.3°C.
• If, in exceptional cases, the temperature exceeds the nominal value by more than 8.3°C, the instantaneous temperature
value may vary between this value and 14°C (25°F) above the nominal value, provided that the totalised duration of the
operating periods between these two limits does not exceed 400 hours for the whole operating period (effective running) of
12 months.
• Operation between 14 °C and 28 °C above the nominal temperature is allowed, provided that the total duration of the
operation periods within those limits does not exceed 80 hours for the whole operating period (effective running of 12
months).
• In no case, temperature should exceed the nominal temperature by more than 28 °C.
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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(29) SAFETY TESTS

1. TYPES OF TESTS:
Normally 3 Main test series shall be periodically performed:
- Tests on operator’s order
- Automatic tests without operator’s action
- Other tests under operator’s action
- Local control
2. TESTS ON OPERATOR’S ORDER:

Six series of tests shall be carried-out on operator’s order given from the control room (CCR) through the
REC 920 cubicle, during every turbine cold start-up but also at the periodicity mentioned in table
hereafter.
• Tests (A) HP 1 stop valve-channels ½ (2 tests)
• Tests (B) HP 2 stops valve- channels ½ (2 tests)
• Tests © LP stop-valves on bleedings (2 tests)
• Tests (D) 1st and 2nd emergency lube-oil pump (2 tests)
• Tests (E) Emergency control fluid pump (1 test)
• Tests (F) on main safeties channels 1 and 2 (2 tests)
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.
3. AUTOMATIC TESTS WITHOUT OPERATOR’S ACTION:

These tests apply to over speed, which is automatically performed from REC 920 cubicle periodically as
soon as the unit runs.
They allow for checking on the one hand that the detectors trip the unit when necessary and on the other
hand, the accuracy of the tripping value/threshold.
4. OTHER TESTS UNDER OPERATOR’S LOCAL CONTROL:
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.
Over speed tests in real conditions:

These tests must be carried-out not only at the first turbine commissioning, but also at restart following an
overhaul, or every two years at least.
For these overspread tests in real conditions, the turbine speed-up is controlled manually by actuating the
+/- control.
An operator close to the turbine speed indicator should be ready to press the local “emergency” stop push-
button if required.
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Level Sensors Tests:

Level sensors in the lube-oil tank.
These tests must be carried-out once a year at least, after a shutdown, during the “lubricating” sequence
restart, but before starting the unit again.
Level sensors in the control fluid tank
The following procedure should be applied:
• First of all, check on the level side, that the fluid level is correct and corresponds to the position of the magnetic plunger on
the level sensors float rods.
• Mark the position of the level sensor LSH 224, then loosen its fixing clamp to the sleeve tube above the float, then slide the
sensor downwards along the sleeve until the “high level” alarm trigger, this being controlled from CCR or locally by the
switching of “ON-OFF” switch at the sensor terminals.
• Restore the sensor to its initial position.
• Repeat the same procedure with the low level sensor LSL 225 and the very low level sensors LSLL 226 by moving them
upwards.
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.
“Emergency Stop” tests:

The emergency stop remote (in CCR) and local (push-button) devices must be tested twice a year during
shutdown after resetting turbine.
5. OTHER TESTS AND ROUTINE CHECKS:
Turbine generator unit slowing-down:
Once a year, during a scheduled shutdown, the unit slowing-down shall be measured from the unit trip
until the turning-gear clutches-in & also unit slowing-down curve to be plotted.
The comparison of the times or slowing-down curves with the previous ones will point-out some
deteriorations of the unit condition.
Turbine generator unit cooling.
Likewise, once a year at least, after a shutdown at full load, the turbine casing-cooling curve will be
plotted by recording the evolution of the casing temperatures as a function of time, through
TE 2533 High point at HP upper casing and
TE 2534 Low point at LP lower casing
The comparison between the various cooling curves denotes the turbine heat insulation deterioration.
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6. SUMMARY:
The following table summaries all the tests to be performed, with their periodicity and
references.
TESTS SUMMARY TABLE

Right HP stop-valve 2 Control room 1+2+ weekly 4.3.4.6 + 4.9.2
Left HP stop-valve 2 Control room 1 + 2 + weekly 4.3.4.6 + 4.9.2
LP stop-valve 2 Control room 1 + 2 + weekly 4.4.8.8 and 4.9.2
Bleeding valves
Control-valves
1st emergency lube-oil pump 1 Control room 1+2+ 4.3.7.1.2 + 4.9.2
monthly
2nd 1 Control room 1+2+ 4.3.7.1.2 + 4.9.2
emergency lube-oil pump
monthly
Control fluid emergency pump 3 Control room 1+2+ 4.3.7.2 + 4.9.2
monthly
Main safeties 1 Control room 1 + 2 + daily 4.9.2
Actual over speeds 2 Control room + locally 1 + 2 x year 4.9.4.1
Lube –oil tank levels 3 Locally + Control 1 + 2 + yearly 4.3.7.1.1 + 4.9.4.2.1
room
Control fluid tank levels 2 Locally + Control 1 + 2 + yearly 4.3.7.2 + 4.9.4.2.2
room
Turning-gear safety 2 Locally + Control 1 + 2 + yearly 4.3.7.1.6 + 4.9.4.3
room
Emergency stop in CR 1 Locally + Control 1+2+2x 4.3.8.8 and 4.9.4.4
room year
Local “ emergency stop “ push- 1 Locally + Control 1+2+2x 4.9.88.and 4.9.4.4
button room year
Slowing-down time and curve 1 Control room 3 4.9.5.1
Cooling curve 1 Control room 3 4.9.5.1
P/tº - switch threshold check Locally 2 x year 4.9.5.3
1 = first startup, 2 = any cold start up; 3 = schedule hot shutdown>60h
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(30) TROUBLE SHOOTING

MAIN ANOMALIES:
These anomalies may be:
• Excessive differential expansion
• Lube-oil pressure drop
• Journal-bearing temperature rise
• Sudden vibration increase
• Water content in oil
• Lube-oil level decrease in the tank
• Control fluid system malfunction
• Turbine gear inoperative
• LP casing cover temperature rise
• Exhaust pressure increase
• Synchronization impossible
• Abnormal absolute expansion of front bearing-block
Generally, these malfunctions are signalled by alarms.

In the following pages, the table shows the actions to be taken when these alarms trigger.
1. ANOMALIES, WHICH ARE NOT SIGNALLED BY ALARMS:
Water content in lube-oil:

a) Steam flowing out of shaft ends and coming into the bearing-blocks: check the gland sealing supply pressure which is too
high, the trouble free operation of the gland steam condenser and of the overflow valve.
b) Tube pierced on the running lube-oil cooler: replace the cooler and repair the pierced cooler.
In both cases, start the centrifuge.
2. ANOMALIES ON THE CONTROL FLUID SYSTEMS:
A stop-valve or a control valve is seized:

• Immediately stop the system if the seizing has caused control problems. Repair the valve as soon as the valve cage is cool
down.
• If a stop-valve has seized in mid position and if the steam flow rate has not reduced, the unit shutdown can be postponed.
Repair the valve as soon as the valve block has cooled.
The servo valves are fouled:

The control fluid system should be cleaned at next shutdown and the filters upstream and downstream of
control boxes to be replaced if necessary.
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LUBE-OIL SYSTEM (GGR)

Item no. Function Cause & Required action
LSH High level at lube-oil tank- Probably. Water content in oil
221 z> 12 000 1it. Cause: 1- Gland supply steam:
- Extraction fans on gland steam condenser stopped.
- Maladjustment of gland pressure- refer to pressure
A control system.
Cause: 2 Tube stack of the running cooler is pierced.
Shift to the other cooler. Repair the damaged
cooler. Centrifuge the oil.
LSL 222 Low level at lube-oil tank 1-Insufficient filling of the tank Make up oil to the
– < 8 450 1it. normal level.
Impedes Start-up and lube oil 2-Lube-oil leak on the system:
sequence but does not stop it a) Leak at running cooler; shift to the other cooler and
if it runs repair the damaged one & Centrifuge the oil.
b) Slight leaks on the systems: seal off the leaks and
repair at the shutdown. Make up the tank level.
B c) Some oil leaks at the running lube-oil system,
which cannot be repaired. Trip the unit. When it has
stopped completely, stop the lube-oil system. Start
the lifting pumps. Turn the unit manually by 1/3 of
a turn every 15 minutes during the whole repair
time. Make up the tank level. Start: lube-oil turning
gear and turbine-generator unit.
LSLL Very low level at lube-oil Important leaks on lube-oil systems. Refer to the
C 223 tank – z < 7 900 1it. above procedure. The fast slowing down procedure
Immediate manual tripping can be applied during the shutdown.
TI 101 High temp at lube-oil tank Check that 001/RS heaters for lube-oil tank have
D TI 102 t > 90°C stopped.
TI 103 High temp at lube-oil tank 1-Problem at lube-oil cooler:

TSH 132 t > 65°C -Check air vent on water and oil pipes
TI 181 -Check water inlet temperature (EB)
-Check pressure drop
-Increase the cooling water flow if possible
E -Shift to the other cooler, clean the cooler
Very high oil to at cooler 2-Problem at TCV 300 thermostatic valve

outlet t > 70°C - Reduce set point valve
Manual turbine trip -Check the valve at next shutdown
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
255
256
PSL 044 Low lube-oil pressure 1-Lube oil leaks on system

p< 1.2 bar 2-Main pump alarm: inspect the pump in shutdown
Emergency pump starts 3-Alarm for main pump discharge check valve. Check
G the valve at next shutdown
4-Cooler is fouled: shift to the other cooler and clean
the fouled one.
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
256
257
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.
LIFTING- TURNING GEAR (GGR)

PSLL 224 Very low lube-oil Refer to PSL 044 (G) above
pressure
J Turning gear trip
Turning gear interlock
If P<0.4 bar
257
258
CONTROL FLUID (GFR)

K LSH 224 High level at oil tank Excessive tank filling. Drain the excess of fluid
z> 1 through HV 087/088 valve before unit stops .
LSL 225 Low level at oil tank 1-Insufficient filling of the tank. Make up oil to
z<1 upto the normal level
TG Fluid system start 2-Oil leaks on control fluid system-detect the
interlock does not stop leaks
the system, if it is Refer to B.2a and 2b if slight leaks. 2c if
L running important leaks that cannot be repaired on the
control fluid system that runs:
- Trip the unit
- Stop the control fluid system
- Repair leaks and make up the oil level
- Restart the Control fluid system and the unit
PSL 055 Low control fluid 1-Lube-oil leaks on the system
pressure p < 70 bar - Refer to L above (LSL 225)
- Refer to the ageing of rapid discharge solenoid
M Control Fluid valves on safety valve blocks and Moog servo
emergency pump starts valves, leading to abnormal leaks
2-Main pump alarm: inspect the pump at next
shutdown
PSLL 052 Turbine trip Channel 1
PSLL 053 Turbine trip channel 2 Refer above
N PSLL 054 Turbine trip channel 3
If very low Control fluid
pressure p < 60 bar
TSH 160 High temperature in Make sure 002 RS heater on the fluid tank is
fluid tank for t > 80°C stopped
258
259
STEAM SYSTEM
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
259
260
OTHER ANOMALIES DETECTED THROUGH ALARMS - TRIGGERING

VE 304 High turbine rotor 1-Low increase of vibratory level
vibrations > 75 microns. a) Casing strain due to the blocking of HP casing
Watch their evolution bolt washers on inlet bearing. Check their free
motion.
Very high turbine rotor b) Unbalancing due to dissymmetrical erosion of
vibrations > 100 microns blading or heat unbalancing of the generator
turbine automatic trip or turbine rotor. Readjust balancing if
required.
High generator rotor C) Water content in lube-oil: have tank oil
To vibrations > 75 microns analysed; start the centrifuge.
Watch their evolution d) Thrust or journal-bearing damaged watch the
Very High generator rotor evolution of the relevant bearing temperature,
vibrations > 100 microns. then inspect and repair the faulty ones.
Turbine automatic trip 2-Fast increase of vibration level
a) A blade has broken: open the casing
replace the blading.
VE 313 b) Water stroke: watch the evolution of HP and
Q
LP temperatures, boiler problem: trip turbine.
c) Rotor strain: when the Turning Gear is
engaged, check the eccentricity and keep the
turning gear engaged as long as necessary.
d) Poor turbine-generator alignment: check it
when the unit has stopped and re-adjust it if
required.
e) A thrust or journal bearing has broken: check
all these bearings as well as the shaft line.
Also refer to lubricating procedure (A to I
above inclusive).
260
261
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.
2. TURNING GEAR MALFUNCTION:

1 - The manual turning flywheel is installed: refer to signalling and remove the flywheel.
2 - Over current on turning gear motor: the lifting pumps are still running; check the lifting pressures and the rotor
lifting values at each bearing block, in order to check if the lifting is not excessive and there is no contact between
the rotor and the casing.
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.
261

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1

STEAM TURBINE MANUAL

1 Condenser Make up System (CAP) 2 to 6

(1) CONDENSER MAKE -UP SYSTEM (CAP)

DESCRIPTION OF THE EQUIPMENT:

Flow rate 60 m³/hr

Filling of the water circuits of the cycle:

Filling pump control (101 PO):

ANALYSIS OF THE LOSS OF MOTIVE OR CONTROL FLUID:

FAILUR OF 48 V DC CONTROL VOLTAGES:

FAILURE OF 415 V DC POWER VOLTAGES:

CAP SYSTEM START-UP

MAKE UP VALVE CONTROL: LV001

CEX LSL 001

ADGLSL002 ADG LSH 002

ENERGISE LVX 001 DE-ENERGIZE

QUICK MAKE UP VALVE CONTROL: UV001

ADG LSH 002

CEX LSL 001

HSN 001 HSN 001

OPEN VALVE CLOSE VALVE

FILLING PUMP CONTROL: 101 PO

HSN 101 LSLL100

(2) CONDENSATE EXTRACTION SYSTEM (CEX)

DESCRIPTION OF THE SYSTEM:

On water side, the condenser recovers:

Condensate extraction pumps:

Operation with single HRSG:

DESCRIPTION OF INSTRUMENTATION AND CONTROL LOOPS:

Reciculating flow control loop:

LOGIC CONTROL LOOPS:

Emergency takeover of pumps

CONDENSATE PUMPS STARTING CONDITIONS: 101 PO 201PO 301 PO

SAME SEQUENCE FOR 201PO. 301PO

CONDENSATE PUMPS.STARTING: 101PO 201PO 301PO

TAKING OVER MEMORY

PUMP 101 PO PUMP 101 PO START PUMP HEATING

(CARRIED OUT IN MCC)

SAME SEQUENCE FOR 201PO 301PO

CONDENSATE PUMPS TRIPPING CONDITIONS: 101PO 201 PO 301PO

HSX 101 VSHH 101

Tripping signal Tripping signal

ADG LSHH 001 FEED HSX 001 LSLL 0 01

SAME SEQUENCE FOR 201 PO .301PO

CONDENSATE PUMPS STOPING: 101PO 201PO 301PO

HSN 001 GROUP

HSN 101 PUMP

GROUP SUB GROUP STOP PUMP HEATING

(CARRIED OUT IN MCC)

SAME SEQUENCE FOR 201PO 301PO

CONDENSATE WATER VALVE CONTROL: LCV001

ADGLSHH 001 3 CONDENSATE PUMPS

CONTROL VALVE LCV

DE-ENERGIZE LCVX 001

ISOLATING VALVE CONTROL: A UV 001

OPEN VALVE CLOSE VALVE

SAME SEQUENCE FOR BUV 001

HOTWELL DUMP VALVE CONTROL:LV 001

ENERGIZE LVX 001 DE-ENERGIZE LVX 001

(3) FEED WATER TANK (ADG)

DESCREPTION OF THE SYSTEM

Steam supply pipes:

The LP stream pipe is equipped with:

DESCRIPTION OF INST5RUMENTATION AND CONTROL LOOPS: