2_1!01!02_basic operation concept for turbine and auxiliary plant_r00

Owner

P. T. CENTRAL JAVA POWER

Employer

Project

TANJUNG JATI ‘B’ COAL-FIRED POWER STATION UNIT 3 & 4 2 x 660MW(NET)

Document Title :

BASIC OPERATION CONCEPT FOR TURBINE AND AUXILIARY PLANT

Document No. : Owner's Document No. : A-00-M-TS-7610 Rev.2 TOSHIBA’s Document No. : PCD-GMH-XIT3-0002 Rev.2

Date Revision Prepared by Reviewed by Issued by TO Purpose Status

SC For Approval 26 Dec, 2008 1 H.Tao K.Kawamoto T.Konishi

SC For Approval Final 10 Nov, 2009 2 H.Tao N.Kada J.Tajiri

Submitted By :

LOT 2

PCD-GMH-XIT3-0002

2 10 Nov, 2009 Added the system design description focusing functional logic parts as per design progress. J.Tajiri H.Tao N.Kada

1 26 Dec., 2008 Added customer document No. for release to relative parties. T.Konishi K.Kawamoto H.Tao

0 23 Jun., 2008 First Issue - - -

変

更 REVISIONS

回数 REV.NO.

日付 DATE

記事 CONTENTS

承認 APROVED BY

調査 CHECKED BY

担当 REVISED BY

配布先

DISTRIBUTION (タ設) 1 (火IX) 1

Sumitomo 1 (制御) 1 (火EX) 1

発行課

ISSUED BY

Thermal Power Plant Engineering Div.

Plant Engineering Dept. Global Plant Engineering

Lot1 1 (熱設) 1 (火IC) 1 承認 APPROVED BY

T.Konishi

Lot4 1 (タ配) 1 (火計Ｔ) 1 調査 CHECKED BY

T.Kiyokuni / K.Kawamoto

(発Ｄ) 1 (火CV) (火PX) 控担当 PREPARED BY

E. Iwata / Tao

TOSHIBA CORPORATION

FINAL

客先名

CUSTOMER

プラント名

PLANT

発行日付

DATE ISSUED 23 June, 2008

製造／見積番号

JOB/QUOT.NO. M210463/M210464

P. T. CENTRAL JAVA POWER TANJUNG JATI ‘B’ COAL-FIRED POWER STATION

UNITS 3 & 4 2 x 660MW(NET)

Rev 2 A - 0 0 - M - T S - 7 6 1 0

The information in this material is confidential and contains Toshiba’s intellectual property including know-how. It shall not be disclosed to any third party, copied, reproduced, used for unauthorized purposes nor modified without prior written consent of Toshiba.

Toshiba Corporation

P.T. CENTRAL JAVA POWER

TANJUNG JATI ‘B’ COAL-FIRED POWER STATION UNIT 3 & 4 2 x 660 MW (NET)


PCD-GMH-XIT3-0002

Page 2 of 58 TOSHIBA CORPORATION Proprietary Information © Toshiba Corporation 2009, All Rights Reserved

CONTENT

Clause No. Description Page No.

1 Introduction 3

1.1 Turbine Island Balance of Plant (BOP) 4

1.2 Control Configuration 5

2 Operating Condition 5

2.1 Steam Turbine Operation 6

2.2 Plant Operation 7

3 Main Line and Main Equipment 16

3.1 Make Up Line 16

3.2 Condensate Line 19

3.3 Feedwater Line 21

3.4 Extraction Line and Heater Drain Line 29

3.5 Circulating Water Line 36

3.6 Auxiliary Cooling Water Line 41

3.7 Closed Cycle Cooling Water Line 44

3.8 Lube Oil Line 47

4 Failure Action and Valve set for Control Valve (TG island) 49

5 Special Operation 51

5.1 House Load Operation 51

5.2 Boiler Single Operation 51

5.3 Condenser Half Tube Bundle Operation 51

5.4 CW Traveling Band Screen Operation 51

5.5 Feed Water Pump Parallel Operation 51

5.6 Load Runback 52

5.7 HP and LP Feedwater Heaters Bypass Operation 53

6 Reference Documentation 54

Annexure-I Typical BFP Turbine Start-up Curve & Shut-down Curve 55

Annexure-II Typical Sequence of Manual Turbine Start-up Time Chart 57

Annexure-III Mismatch Chart 58

2

2

PCD-GMH-XIT3-0002



1. INTRODUCTION:

The Plant consists of two identical 660 MW Capacity Coal fired Thermal Power plant. Coal is used as a primary fuel for normal operation and Light fuel oil is used during startup, low load operation and shutdown condition. Steam Turbines, Hydrogen Cooled Generators and their auxiliaries are supplied by Toshiba. Two Coal fired Steam Generators are supplied by MHI. And their auxiliaries are supplied by BVI.

Specification of Main Turbine: Steam Turbine make = Toshiba TCDF-42

MS Stop – 2 Nos and MS CV – 4 Nos

RH Stop / ICV – 2 Nos

B-MCR = 729.5 MW (at Gen output)

T-MCR = 708.3 MW (at Gen output)

100% ECR = 695.7 MW (at Gen output)

Main Steam Pressure = 166 barg (Turbine inlet 100%ECR)

Main Steam Temperature = 538 degC (Turbine inlet 100%ECR)

Reheat Temperature = 538 degC (Turbine inlet 100%ECR)

Reheat pressure = 34.3 barg (Turbine inlet 100% ECR)

Type of Turbine = Reheat condensing steam Turbine

No of Cylinders = One HP / one IP / two LPs

Normal Operating speed = 3000 rpm

Turning gear speed = 6 rpm

Governing Control system = D-EHC

Specification of Generator:

Type = TAKS, TOSHIBA (Three phase, 2-poles, Totally

enclosed synchronous Generator)

Capacity = 802 MVA

Power Factor = 0.9 lagging

Frequency = 50 HZ

PCD-GMH-XIT3-0002


Specification of Steam generator: Steam Generator Make = MHI

Type = Single Drum, Reheat,

Coal Fired type

Oil fired (up to 25%B-MCR load)

Main Steam Flow = 2285.00 t/h (at B-MCR)

Main Steam Pressure (Final SH outlet) = 174.3 barg (at B-MCR)

Main Steam Temperature(Final SH outlet) = 538 degC (at B-MCR)

HRH steam flow = 1905.45 t/h (at B-MCR)

HRH Steam Pressure(HRH outlet) = 38.58 barg (at B-MCR)

HRH Steam Temperature(HRH Outlet) = 538 degC(at B-MCR)

1.1 Turbine Island Balance of Plant (BOP) Turbine Balance of Plant comprises the following major Systems/Equipments

A Systems Steam Condensate System

1 Feedwater System 2 Main Steam and Turbine Bypass System 3 Reheat Steam and Turbine Bypass System 4 Extraction Steam and Heater Drain System 5 Auxiliary Steam System 6 Main Turbine / BFP Turbine Gland Seal System 7 Turbine Generator Lubrication Oil System 8 Control Oil System 9 Boiler Feedwater Pump Lubrication Oil System

10 Air Evacuation System 11 Makeup Water system 12 Closed Cycle Cooling Water System 13 Circulating Water System 14 Compressed Air System 15 Closed Cycle Cooling Water Chemical Dosing System 16 Intake Screen 17 Chlorination System 18 Desalination System 19 Demineralized Water System 20 Waste Water Treatment System 21 Sampling System 22 CO2 / H2 System

B Equipments 1 Steam Turbine components 2 Generator and Auxiliaries 3 Steam Valves 4 Condensers 5 Condensate Extraction Pumps 6 LP Feedwater Heaters 7 Deaerator and Feedwater Tanks 8 Turbine Driven Boiler Feedwater Pumps

PCD-GMH-XIT3-0002


9 Motor Driven Boiler Feedwater Pumps 10 HP Feedwater Heaters 11 Condenser Vacuum Pumps 12 Closed Cycle Cooling Water Pumps 13 Closed Cycle Cooling Water Heat Exchanger 14 Circulating Water Pumps 15 Seawater Booster Pumps 16 Condenser Tube Ball Cleaning Pumps & Strainers 17 Service Water Pumps 18 Potable Water Pump 19 Make Up Water Pump 20 Make Up Water Tanks 21 Sump Pumps 22 Air Compressor 23 Piping and Valves

1.2 Control Configuration.

Turbine startup and shutdown automatic operation will be controlled by Plant automation system (PAS). Turbine and its auxiliaries are controlled by DCS system. Following BOPs shall have their own dedicated control system and interfaced with DCS system for overall monitoring.

o Desalination and Demineralized Water Plant o Waste Water Treatment Plant o Chlorination Plant o Intake Screen (Raking Machine) o Air Compressor o H2 Generator Plant

2. OPERATING CONDITION: The Plant can be operated up to the Maximum load (T-MCR) or can be operated at any

intermediate Load Set point between Minimum Load and the Maximum Load as desired by the operator. It can also run without load (without connected to Grid) at Full Speed No Load (FSNL). The Unit is capable to operate with a minimum load of 25% B-MCR design capacity.

Specific Design Data :

(a) Ambient air temperature:

Annual Average (Design) (degC) 27.0 Monthly average temperature (degC) 25.4-31.9

(b) Relative air humidity:(%) 50 - 92

(c) Cooling Water (Seawater) Temperature

Inlet Design (degC) 29.2 Outlet Design (degC) 36.2

Temperature rise between Circulating Water Condenser inlet and discharge is 7degC.

PCD-GMH-XIT3-0002


2.1 Steam Turbine operation

The Steam Turbine operation concept includes Basic operation, Special operation, main equipment operation, Failure action and runback operation. Boiler and Turbine unit startup and shutdown automatic operation will be controlled by Plant automation system (PAS).

2.1.1 Sliding Pressure Operation and D-EHC Turbine Control The Steam Turbine consists of several stages with each stage consisting of the High Pressure (HP), Intermediate Pressure (IP) and Low Pressure (LP) stages. The Boiler and Turbine Generator units are operated with sliding pressure mode. While MSV is fully opened in any load operation and opening of CVs are depends on the required load. Steam Turbine is controlled by Digital Electro-Hydraulic-Control (D-EHC) system. The Main Functions of D-EHC is to control Turbine speed, load, load limit, line speed matching, FA/PA Valve transfer, CV Chest warming, Automatic Turbine startup, Thermal stress calculation, Turbine trip, Test Turbine valves, test Turbine over speed and backup over speed governors. During turbine startup, main steam is controlled by four CVs whose openings are equal in each other. Exchange point FA to PA operation is at 25% B-MCR load. CVs No1,2,3 & 4 are opening simultaneously during start up conditions, At approx. 59% ECR load condition these three CVs (1,2,3) will open fully to control load & speed of the Turbine. CV 4 will starts closing at 25％B-MCR load and will be standby for fluctuation of grid

frequency. Over approx. 90％ECR gross load CV4 starts open to control load & speed of the Turbine ( Ref Fig-1) Constant pressure {108 bar(g)} operation shall be up to 59%ECR load and sliding Pressure{ 108 to 166 bar(g)} operation shall be greater than 59%ECR load. Minimum operating load is 25%B-MCR (coal fired, without by pass conditions).

Sliding Pressure Pattern and CV control pattern for static condition

(Fig-1)

100

50

0

166

108

CV Position % Pressure bar (g)CV #1,#2,#3

CV #4

90%

CV#1,2,3

CV#4

FA/PA FA

FA/PA at 25%B-MCR

Sliding pressure (approx.59%)

(FA/PA)

PCD-GMH-XIT3-0002


2.2 Plant operation 2.2.1 Start up Start up of Turbine and its auxiliaries systems will be performed always to ensure

operational reliability and economy. Each of the 660 MW boiler-Turbine sets has an automatic startup and shutdown sequence logic, which may be used in the normal start–stop operation of the unit. This sequence logic includes the equipment and control variable sequencing steps necessary to take the Boiler -Turbine unit from Ready-to-Start condition to the desired load level and back to shutdown condition. Each 660MW unit is designed to shutdown efficiently and to maintain the boiler-Turbine in a condition which will shorten start-up or load up times by use of HP/LP Bypass, Boiler single operation or house load operation. To Establish Ready to Start conditions, certain operations are to be done by manual or sequenced actions initiated by the operator for some cases from the DCS and in other cases from the respective Local equipment. Simultaneous start up of Unit 3 and 4 is not considered in the operating philosophy and design condition. Start up of each unit shall be done sequentially.

The Period of Startup after shutdown is indicated in table-1 & 2. To maintain operational safety, reliability, and economy, certain test (Turbine protection/valve test) shall be performed during all phases of Turbine operation.

A) The following Pre-start conditions are to be established to bring the Turbine to ready to

start conditions.

1) Power Receiving Ready and Electrical System are in Available

2) HVAC system in service

3) Fire Detection, Alarm and Fighting systems are ready

4) DCS system in service

5) Waste Water Treatment plant in service

6) Plant water supply systems incl. Desalination Plant and Demineralized Water Plant in service

7) Make up water system for condensate and closed cycle cooling water are in service

8) CCCW Chemical Dosing System is in available

9) Make up water system, and related tanks / basins and their water level, Make up water tanks, and Emergency Diesel Generator Day Tank normal level

10) Circulating Water system and Intake Screen system are in service

11 Chlorination plant is in service

12) Condenser Tube Cleaning System is in service

13) Auxiliary Cooling Water system is in service

14) Closed Cycle Cooling Water system is in service

15) Compressed air system in service

PCD-GMH-XIT3-0002


16) Condenser Hot-well filling complete

17) LP Feedwater Heaters, Deaerator and Feedwater Tank, and HP Feedwater Heaters filling complete

18) Boiler filling complete

19) Turbine Lube Oil and EHC Oil Systems are in service

20) DC power for Emergency Oil Pumps and Emergency Seal Oil Pump in service

21) Main Turbine Turning Gear is in service

22) HP Turbine Bypass Control Valve Oil Supply Unit is in service and auto.

23) LP Turbine Bypass Control is in auto

24) BFPT Lube Oil System is in service

25) BFPT Turning Gear is in service

26) Auxiliary steam system is in service and check the condition of steam source and Aux. steam header

27) Generator Seal Oil System is in service

28) Generator H2 filing complete and H2 pressure normal

29) Generator stator cooling water unit is in service

Note) When checking and establishing the systems in service as mentioned in those above items, selection and change over the line by manually for the duty and stand-by equipment are required. After the confirmation of pre-Start condition, Turbine Start Preparation

B) The following Manual operations are to be confirmed by operator or operated by operator manually.

1) Turbine rub check

2) Water quality check

3) All operation required during normal operation (such as lube oil filter change over, lube oil cooler change over and stand by pump selection)

4) N2 Seal operation (if required)

5) BFP/CEP shutdown operation

6) Necessary operation prior to start/stop (includes Boiler Feedwater Pump, Condensate Extraction Pump, Circulating Water Pump, Closed Cycle Cooling Water Pump, Air compressors)

PCD-GMH-XIT3-0002


C) The following Turbine protection /valve test shall be performed.

Device to be tested Schedule Unit conditions

Turbine Trip test Before start-up

Testing of over speed trip system Once in a week and /or each startup

Off line (every 6-12 months) No load

MSV, CRV test Once in a day In service

CV test Once in a week In service

EHC oil pump stand by automatic starting Once in a week In service

Stand by oil pump and emergency oil pump automatic start

Once in a week or month or every 6

months In service

Extraction steam non return valve Once in 3 days In service

Turbine lube oil tank level switch high/low alarm Once in a week In service

(Table-1) Description Start up time for each type

Type of Start-up

Definition of outage Period (Note1)

Boiler Firing to ST roll off

(min)

ST roll off to synchronizat

ion (min)

Synchronization to

100%load (min)

Total (min)

Cold start-up

After an outage of 150hrs

Approx. 250

Approx. 130

Approx. 220

Approx. 600

Warm start After an outage of 36hrs

Approx. 90

Approx. 50

Approx. 145

Approx. 285

Hot start After an outage of 8hrs

Approx. 70

Approx. 24

Approx. 81

Approx. 175

Very Hot Start

After an outage of 2hrs

Approx. 70

Approx. 14

Approx. 81

Approx. 165

Note 1: Definition of outage period is “From Generator Circuit Breaker Open to Turbine run-up(rolling off)”. Note 2: All the time in above table does not include the minimum check & confirmation time.

2.2.2 Total Number of Start up per unit During life time of 30 years are indicated in table-2

(Table-2)

Cold start 120

Warm start 1100

Hot start 4500

Very hot start 50

PCD-GMH-XIT3-0002


2.2.3 Start up Criteria:

Plant Startup Criteria consists of the following Conditions & type of start and Turbine startup

criteria consists of 1st stage metal temperature.

a) Plant startup conditions :

a-1) In case of Aux. steam from other unit is not in available

• Start-up using MBFP without aux steam from other unit

a-2) In case of Aux. steam from other unit is in available

• Start-up using MBFP

• Start-up using TBFP with aux steam from other unit in case of MBFP is in failure

(Aux. steam source condition and establishment of the related system line shall be done in the pre-start preparation work by manually)

Type of Startup : Cold / Warm/ Hot & Very Hot

b) Boiler and Turbine unit startup automatic operation will be controlled by Plant automation system (PAS) based on the Boiler and Turbine conditions. (Ref. Annexure-II). In case of the start-up after condenser vacuum break, condenser vacuum up shall be done as the first step for the steam turbine start preparation.

PCD-GMH-XIT3-0002


(Table-3) System Name Condenser Vacuum Up and Vacuum Break Description This master sequence system is provided automatic operation of

related auxiliaries for vacuum up and vacuum break operation. This sequence basically comprises of each command signals for each auxiliaries of gland steam system and vacuum system.

Permissive Start(Vacuum up): CWP running SWBP running CEP running Gland steam exhauster & condenser vacuum pump selected Auxiliary steam header pressure normal Main Turbine, and BFP turbine Tripped Turning gear in-service

Stop(Vacuum break): Main Turbine, and BFP turbine Tripped

Turbine speed <2350rpm MFT Operation

Auto Start(Vacuum up) PAS signal Stop(Vacuum break) PAS signal

Manual from DCS OPS(Operator Station) Local N/A

Sequence Step Vacuum up

GLND STM PKG ULND CV BV and STM SL FD BV close BFPT CSG DV/EXHD DV/SSD DV open DEA&FW TK VAC DEAERTN VLV close DEA&FW AIR VENT VLV open => GLND STM EXH start / GLAND STM SUPL PIPE WARMG

VLV open => (60sec) => GLAND STM SUPL PIPE WARMG VLV close => STM SL FD ISLN VLV inching open =>CONDR VAC PMP start (sequentially two pump operation) => CONDR VAC BRK VLV close => (CONDR VAC normal) => DEA&FW TK VAC DEAERTN VLV open DEA&FW AIR VENT VLV close => Non-duty CONDR VAC PMP stop

Vacuum break

Duty CONDR VAC PMP stop => DEA&FW TK VAC DEAERTN VLV close DEA&FW AIR VENT VLV open => CONDR VAC BRK VLV open => STM SL FD ISLN VLV close => (10min) => duty GLND STM EXH stop

Failure Conditions Electrical Failure for each Auxiliaries

2

PCD-GMH-XIT3-0002


(Table-4)

System Name Condenser Vacuum Pump Description The 2 x 100% Condenser Vacuum Pump located in the turbine

house ground floor level is provided for removing the incondensable gases and air-in-leakage from the condenser and thereby maintain the desired vacuum. The vacuum pumps are of liquid ring type, double stage. The vacuum pump comprises of the condenser vacuum connection pipe with isolation valve at the condenser and pneumatic isolation valve at each vacuum pump suction.

Permissive Start: SWBP running CEP running CONDR VAC PMP SEP TK LVL not low-low

Stop: CONDR VAC PMP INL VLV not closed (at manual operation)

Operation Auto Start Master sequence demand vacuum low

Back-up start demand by condenser Stop Master sequence demand


Override Start: N/A Stop: N/A

Protection Condition Electrical Failure (SWGR)

CONDR VAC PMP SEP TK LVL Level Low-Low Failure Conditions Electrical Failure

2

PCD-GMH-XIT3-0002


c) Turbine startup conditions: The Admission steam temperature should meet the 1St stage metal temperature as

shown in the Annexure-III (mismatch chart) in order to start and load the Turbine in shortest possible time. On the recommended starting time and sequence (by Mismatch chart), the suggested Turbine speed acceleration rate, Low/high speed heat soak time, loading up rate and holding time at initial load, and requirement of HP Turbine warming are determined by the mismatch chart.

(Table-5) System Name HP Turbine WARMING Description This master sequence system is provided automatic operation of

related auxiliaries for HPT warming operation. This sequence basically comprises of each command signals for each valves of steam system around HP turbine.

Permissive Start: Condenser vacuum normal Turbine Tripped ICVs close Turning In Operation

Auto Start PAS signal Stop PAS signal (HPT 1st stage temp >180deg C or 2 hour passed

Over 150deg C) Manual from DCS OPS(Operator Station) Local N/A

Sequence Step Start CRH CKV INL DV open, HP FW HTR 7 EXTRSTM CKV INL DV open MS LEAD PIPE DV open => (30sec) => CRH CKV INL DV throttling position HP FW HTR 7 EXTRSTM CKV INL DV throttling position MS LEAD PIPE DV throttling position => HPT WARMG VLV inching open

Stop => HPT WARMG VLV close CRH CKV INL DV open HP FW HTR 7 EXTRSTM CKV INL DV open MS LEAD PIPE DV open


2

PCD-GMH-XIT3-0002


2.2.4 Shut down

a) Plant Shutdown Criteria consists of the following Conditions & types.

Plant Shut down conditions:

• Shutdown using TBFP with aux steam from other unit

• Shutdown using MBFP (with aux steam is in available)

• Shutdown using MBFP (without aux steam from other unit)

The shut down time will vary depends on operator intervention during normal or load through off or emergency Turbine trip or emergency Boiler trip.

Type of shut down :

• Condenser Vacuum Maintain

The plant shut down with the maintaining the condenser vacuum is generally applied to the case of expecting the next short term Turbine outage up to 10 hours such as overnight shut-down so as to desire to shorten the start-up duration for the next coming plant re-start considering water quality.

• Condenser Vacuum break

Plant shut down with condenser vacuum break is generally applied to the case of expecting the next longer term outage so as to desire to reduce the amount of waste consumption fuel, water and power consumptions during outage. In case of shut down for Turbine inspection and/or maintenance, vacuum break may be requested regardless of outage period. Boiler and Turbine shutdown automatic operation will be controlled by Plant Automation System (PAS) based on the Boiler and Turbine conditions.

b) Turbine Generator Shutdown. The Turbine Generator shall be shutdown according to operating instruction. If an emergency occurs, the Turbine generator unit may be rapidly unloaded and or be shutdown by operating the trip push button from any operating conditions. After shutdown of the Turbine, Turbine shall be natural cooled.

PCD-GMH-XIT3-0002


2.2.5 Ramp Rate (Load up MW / time = Δ L / Δ T)

Each unit shall be able to achieve the following dispatch ramp rates as specified in the Table-6.

(Fig-2)

(Table-6)

Type of Start-up Load Rage

Cold Warm Hot

0 – 25%B-MCR 3.5MW/min (Approx. 0.5%/min)

3.5MW/min (Approx. 0.5%/min)


25%B-MCR – 50%ECR


7MW/min (Approx. 1%/min)


50% – 75%ECR 7MW/min (Approx. 1%/min)



75 – 100%ECR 7MW/min (Approx. 1%/min)



2.2.6 HP/LP Turbine Bypass

Each Unit provided with High pressure (HP) turbine bypass system which is driven by own hydraulic oil unit, and Low pressure (LP) turbine bypass system which is driven Electro Hydraulic Oil Unit (EHC) same as for other major valves like as MSV, CV, CRV. These bypass systems are provided so as to reduce the unit startup time during Hot/very hot/cold and warm startup. The Turbine bypass system serves to remove surplus steam from the Main steam line and Hot Reheat line during the following conditions. Steam from the Main steam line is dumped into the Cold Reheat line and steam from Hot reheat line is dumped into the condenser during Bypass operation. The Capacity of HP/LP bypass systems is selected based on 35% of B-MCR condition. The Possible phases of operation of HP/LP bypass

• Boiler Single Operation (BSO) • Startup /shutdown • Turbine trip • Fast cut back (FCB) • Load rejection to House load operation (HLO)

2.2.7 Scope of Automation

Refer to “Plant Automation Concept for DCS Controls (A-DCS-I-TS-7653 / SPC-GCH-XIT3-0004)”

ΔL

ΔT

Actual MW MW Demand

2

PCD-GMH-XIT3-0002


3.0 MAIN LINES AND MAIN EQUIPMENT 3.1 Make up line

The make up system is the common system for plant and is provided to supply make up (Demineralized) water from Make Up Water Tank to Condenser, Condensate & Feedwater System, CCCW System, Generator Stator Cooling Water System, Chemical Dosing System, and Hydrogen Generator System. (Ref Schematic diagram Fig-3)

Make up line consists of two (2) x 100% duty Make Up Water Pumps, one normal make up control valve and one emergency make up valve. Emergency makeup Valve (motorized) is located in the bypass line of the normal make up control valve. Normal make up valve supplies Demineralized water to the condenser when condenser is under vacuum.

(Table-7) Description Qty x Capacity

Remarks

Make Up Water Tank 2 x 1,000 m3 per plant Common for Unit-3 and Unit-4

Make Up Water Pump (Ref:Table-8)

2 x 100% per plant each 7m3/min (Including Min. Flow)

Common for Unit-3 and unit-4

(Table-8) Equipment Name Make Up Water Pump Description Two (2) of 1000 m3 Make Up Water Tanks are provided located at

near side of Demineralized Water Plant. Permissive Start: both make up water tank level not low-low

Stop: N/A

Operation Auto Start Back-up start demand by duty pump fail or required flow high

Stop N/A Manual from DCS OPS(Operator Station) Local N/A


Protection Condition Electrical Failure (SWGR) Both make up water tank level low-low

Failure Conditions Electrical Failure

2

PCD-GMH-XIT3-0002


3.1.1 Normal makeup and Condensate water filling Operation

(Fig-3)

Make up water pump head is considered based on the required pressure during normal plant operation, and not considered static head of boiler top for boiler initial water filling. Condensate extraction pump or boiler feedwater pump can be used for initial water filling of boiler. Regarding water initial filling except boiler, simultaneous filling more than one system is not considered for this plant. However, operators might conduct simultaneous filling up by manually with the second pump in operation.

Demineralized Water Plant

Make Up Water Tank

Make Up Water Pumps

Condenser

Condensate & Feedwater

System

CCCW System

Generator Stator Cooling Water

System

Chemical Dosing System

H2 Generator

System

UNIT 3 UNIT 4 Common

PCD-GMH-XIT3-0002


Make Up Water Tank (2 x 1,000m3)

LLWL

LWL

NWL

Overflow Level

HWL

C.L.

DEA & FW TK

HP FW HTR 7

BFP & BOOSTER PUMP

CEP

LP FW HTR 3

CONDENSER

DEA Inlet Header

Make Up Water Pump

CCCWP

CCCW HEAD PIPE HWL

LWL

LLWL

NWL

To BOILER

HP FW HTR 6

HP FW HTR 5

LP FW HTR 2

LP FW HTR 1

MHI

Toshiba

(Fig-4)

PCD-GMH-XIT3-0002


3.2 Condensate Line

3.2.1 Each Unit Condensate Line consists of 2 x 100 % condensate extraction pump, Gland steam condenser, LP Feedwater heater 1,2 & 3 and Deaerator and Feedwater tank. Condensate extraction pump take suction from condenser hotwell and deliver to Deaerator and Feed water Tank (through the gland steam condenser and Low pressure heaters), LP Turbine Bypass Spray, Auxiliary steam spray, Condenser Water Curtain spray, LP Turbine Casing Spray, Seal water for Condenser Vacuum Pump, Boiler Feed Water Pumps and Valves sealing connected to the Condenser.

A Chemical dosing system (Hydarzine and Ammonia) is provided at Condensate Extraction pump discharge to maintain condensate water quality such as dissolved Oxygen and PH.

(Table-9)

Description Qty x Capacity Remarks

Condensate Extraction Pump (CEP)

2 x 100% per unit 30 m3/min each

In case of FCB, Standby pump need to cut in.

Gland Steam Condenser(GSC)

1 x 100% per unit Horizontal surface type

LP FW HTR 1 1 x 100% per unit With common Bypass with LP

FW HTR 2

LP FW HTR 2 1 x 100% per unit With common Bypass with LP FW HTR 1

LP FW HTR 3 1 x 100% per unit With Individual Bypass

Deaerator & Feed Water tank (DEA FWTK)

1 x 100% per unit

Single barrel type

3.2.2 Condensate Extraction Pump (CEP) Operation

(Table-10)

Plant Start up Plant Shut down

1 x 100 % CEP Start: Before MBFP start

Stop: After MBFP stopped (manual)

2 x 100 % CEP Start: stand by CEP at FCB operation (auto)

Stop: stand by CEP (Manual) and stop duty CEP after MBFP stopped (Manual)

PCD-GMH-XIT3-0002


(Table-11) Equipment Name Condensate Extraction Pump Description There are 2 x 100% capacity Condensate Extraction Pumps (CEP)

for each unit. Each of CEP takes suction independently from the Condenser Hotwell. The suction line is also provided with a temporary strainer and isolation valve. Discharge from CEP is provided with check valve and motor operated isolation valve respectively.

Permissive Start: Condenser hotwell level not Low Not motor winding temp High-High CEP outlet valve closed or duty pump running/outlet valve open

Stop: N/A

Operation Auto Start Backup start demand by duty pump fail or CEP outlet press

Low Stop N/A



Protection Condition Trip condition Electrical Failure (SWGR) Mmotor winding temp High-High

Condenser hotwell level Low-Low CEP outlet valve closed after pump running

5sec.

Failure Condition Electrical Failure, Earth Fault

2

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3.3 Feedwater Line 3.3.1 Each Unit Feed water line consists of Two (2) x 50% duty Turbine Driven Boiler Feed water

Pumps (TBFP), one (1) x 50% duty Motor Driven Boiler Feed water Pump (MBFP) and HP Feedwater heater 5,6 & 7. The Boiler Feed water system is provided to supply feed water from Deaerator and Feed water Tank to Boiler Steam Drum via High Pressure Heaters and Boiler Economizer, and HP Turbine Bypass / HP spray water. Reheater Steam spray water will be supplied from intermediate stage extraction of Boiler Feed water Pumps. (Ref Schematic diagram Fig-5)

(Table-12) Equipment Qty X Capacity Remarks

TBFP 2 x 50% per

unit Q=23 m3/min Directly coupled with BFPT

TBFP BSTR PMP 2 x 50% per unit

Coupled with TBFP through reducing gear

MBFP 1 x 50% per unit

2×25% Motors for one pump Q=23 m3/min Coupled with Motor through Fluid Coupling

MBFP BSTR PMP

1 x 50% per unit

Direct Coupled with MBFP motor

MBFP Fluid Coupling

1 per unit

HP FWHTR 5 1 x 100% per unit

With common Bypass with HP FW HTR 6

HP FW HTR 6 1 x 100% per unit

With common Bypass with HP FW HTR 5

HP FWHTR 7 1 x 100% per unit

With Individual Bypass

PCD-GMH-XIT3-0002


C.L.

Center Level

BLR STM DRUM

ECO

HP FW HTR 7

HP FW HTR 6

HP FW HTR 5

DEA Inlet

Motor Driven Boiler Feedwater Pump (1 x 50%)

NWL LWL HWL

HHWL

LLWL DEA & FW TK

From LP FW HTR 3

BFPT BFP GB

BP

BFPTBFP GB

BP

BFP

BP

H/C -M01-M02

Turbine Driven Boiler Feedwater Pump (2 x 50%)

C.L.

B/T Terminal Point

MHI

TSB

to DEA (Min. Flow) to DEA (Min. Flow)

to DEA (Min. Flow)

(Fig-5)

FEED WATER LINE –SCHEMATIC DIAGRAM

PCD-GMH-XIT3-0002


3.3.2 Boiler Feed Water Pump Operation

a) Unit start up

MBFP shall be used for the starts of unit as a regular routine startup and keep in service up to 25 % B-MCR load. TBFP shall be used for the starts of unit as back up purpose for only the case when MBFP is not available due to unusual reasons. In this case of using TBFP for the unit starts, it is essential for the operator to pre-check and establish the feed source condition of the auxiliary steam which is to be fed from the other unit thru the auxiliary steam header.

b) TBFP Start up/Shut down Normal Operation

Ref Annexure-I for BFP startup and shutdown operation.

(Table-13) Plant Start up Plant Shut down

First TBFP

(Ref:Table-14) In service: Before 25% Load

Stop : below 50% Load

Second TBFP In service: Before 50% Load

Stop : Below 25% load or After TBFP to MBFP Changed over

PCD-GMH-XIT3-0002


(Table-14) Equipment Name Turbine Driven Boiler Feedwater Pump/Booster Pump Description There are 3x 50% capacity Feedwater Pumps, two (2) nos are

turbine driven (TBFP) and one (1) no is motor driven(MBFP). Each of the BFPs takes suction independently from the Deaerator and Feedwater Tank. The suction line is also provided with a permanent strainer, temperature element and isolation valve. The permanent strainer is provided with differential pressure transmitter for monitoring. The suction pipe is next connected to the Booster pump suction. Discharge from the booster pump is provided with a flow transmitter and connected to the suction of the Main Boiler Feedwater Pump. Discharge from the Main Boiler Feedwater Pump is provided with check valve and motorized isolation valve.

Permissive Start: not Trip condition DC-MCC control voltage normal BFPT speed under 102%

Stop: N/A

Operation Auto Start Master sequence demand

Stop Master sequence demand Manual from DCS OPS Local Trip PB


Protection Condition Trip condition Manual Trip from CCR or Local Dea&FW tank level not low-low Lub oil press. Low-Low Condenser Vacuum Low-Low Over Speed Thrust Bearing Wear position Bearing Vibration Hi-Hi Inlet Flow Low-Low DEHC Major Fault

2

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c) MBFP Start up/Shut down (Table-15)

Plant Start up

Plant Shut down

MBFP (Ref:Table-16)

In service: Before Boiler Firing

Stop : After All Boiler Equipment stopped (manual)

MBFP In service: Stand by (manual)

Stop

(Table-16) Equipment Name Motor Driven Boiler Feedwater Pump Description There are 3x 50% capacity Feedwater Pumps, two (2) nos are turbine

driven (TBFP) and one (1) no is motor driven(MBFP. Each of the BFPs takes suction independently from the Feedwater tank. The suction line is also provided with a permanent strainer, temperature element and isolation valve. The permanent strainer is provided with differential pressure transmitter for monitoring. The suction pipe is next connected to the Booster pump suction. Discharge from the booster pump is provided with a flow transmitter and connected to the suction of the Main Boiler Feedwater Pump. Discharge from the Main Boiler Feedwater Pump is provided with check valve and motorized isolation valve.

Permissive Start: not Fail condition Dea&FW tank level not low-low Lub oil press. not Low-Low Motor winding temp. not hi-hi

Outlet valve not close MBFP AOP run MBFP min flow valve open MBFP hydro-coupling min position

Stop: N/A

Operation Auto Start Master sequence command

Stop Master sequence command Manual from DCS OPS(Operator Station) Local directly at SWGR (Commissioning use only)


Protection Condition Electrical Failure (SWGR) Fail condition Dea&FW tank level not low-low

Lub oil press. Low-Low Motor winding temp. High-High

Failure Conditions Electrical Failure, Earth Fault

2

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d) BFP Turbine Operation

BFP Turbine shall be driven by any one of the following three sources of steam and Exhaust is connected to the condenser. • No.4 Extraction steam for normal operation. • Auxiliary steam for Startup and after Turbine trip . • CRH steam / Auxiliary steam during fast cut back. BFP Turbine is controlled by D-EHC. The main function of D-EHC are acceleration control, speed holding, Deceleration control, over speed trip test, speed control and CV position control. Acceleration ratio : 800 rpm. Critical speed range :1400 to 1850 rpm Rub check at : 400 rpm Low speed Heat soak at : 1000 rpm Turning gear speed : 7 rpm

e) TBFP/MBFP Operation Normal starts of Unit shall be done by MBFP operation. In case Unit start up with TBFP when steam from another Boiler via auxiliary steam system available, TBFP start up flow control valve (*FW-FCV001) will be used for feedwater control when unit load is low.

In general MBFP shall be used for unit start up and MBFP Outlet Flow Control Valve(*FW-FCV301) will be used for feedwater control. MBFP speed will be controlled by UCS according to feed water demand. MBFP Fluid Coupling speed range is between 1490 to 5600 rpm.

During plant start up MBFP will be taken in to service and loaded up to 25 %. First TBFP will be taken into service and MBFP will be unloaded simultaneously between 15 to 25 % load. Before 50% load, second TBFP will be taken in to service. Finally both the TBFPs will be loaded together up to total 100 % load.(Ref Fig -5)

Temporary suction strainer with 60 mesh will be applied during the first half of commissioning stage so that any foreign particles from various systems connected to the Deaerator to be removed, and permanent suction strainer with 20 mesh will be applied after temporary mesh removal.

Parallel operation by using one (1) TBFP and one (1) MBFP is possible within the extent of allowable load range is possible, however this shall not be the regular routine operation and shall be the case only when it is required by the reason of one BFPT or one TBFP is in trouble conditions.

Regular routine operation and starts shall be based on the Fig.6.

PCD-GMH-XIT3-0002


(Table-17) System Name MBFP SERVICE IN, 1ST TBFP SERVICE IN, 2ND TBFP SERVICE IN Description This master sequence system is provided automatic operation of

related auxiliaries for hand-over to feed water control under boiler control This sequence basically comprises of each command signals for MBFP/TBFP, MBFP its auxiliaries, related motor valves and other control systems.

Permissive Start: BFP operation condition selected Permissive condition from UCS

Stop: N/A

Operation Auto Start PAS signal


Sequence Step MBFP (Plant start up using MBFP (auto/manual), plant shutdown (T+T=>T=>M)) MBFP start => (MW demand <25% (plant shutdown operation only)) => MBFP service in 1ST TBFP (Plant start up (auto/manual)) 1ST BFPT reset => (40 min after Main turbine control mode changed to UCS

mode (Plant start up using MBFP only)) => 1ST BFPT start => (MW demand >25% (Plant start up using MBFP only)) => 1ST TBFP service in 2ND TBFP (Plant start up (auto/manual)) 2ND BFPT reset => (60 min (plant start up (auto) only) => 2ND BFPT start => (MW demand > 50% (plant start up (auto) only) => 2ND TBFP service in


2

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(Table-18) System Name BFP SERVICE OUT (T+M=>T, T+M=>M, T+T=>T) Description This master sequence system is provided automatic operation of

related auxiliaries for service out the BFP feed water control from boiler control. This sequence basically comprises of each command signals for MBFP/TBFP, its auxiliaries, related motor valves and other control systems.

Permissive Start: BFP operation condition selected Permissive condition from UCS

Stop: N/A



Sequence Step BFP SERVICE OUT (T+M=>T) MBFP service out => MBFP stop BFP SERVICE OUT (T+M=>M) TBFP service out => BFPT stop BFP SERVICE OUT (T+T=>T) TBFP service out => BFPT stop


BFP Basic operation at normal Start up

Light off synchronization

(Fig-6)

Unit load

TBFP B TBFP A

MBFP

FLOW 25 % load

50 % load

2

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3.4 Extraction Steam line and Heater Drain Line 3.4.1 Steam is extracted from different stages from HP Turbine, IP Turbine and LP Turbine and

supply for feed water heating. The Extraction Steam lines from the Turbines are listed in table -19.

(Table-19)

3.4.2 Cascades drains are provided from a higher pressures heater to a lower pressure heaters. Each feedwater heater, including Deaerator is provided with venting system, thus allowing of non-condensable gas from each heat exchanger shells. Gases from HP feedwater heaters normally flow to Deaerator and Feedwater Tank. Gases from the Deaerator and Feedwater Tank flow to condenser. Gases from LP feedwater heaters flow to condenser. Heater Drain line details are listed in table-20. (Ref Schematic diagram Fig-7)

(Table-20)

Equipment Normal

Discharge To

Emergency Discharge To

HP FW HTR 7 HP FW HTR 6 Condenser HP FW HTR 6 HP FW HTR 5 Condenser HP FW HTR 5 DEA & FW TK Condenser LP FW HTR 3 LP FW HTR 2 Condenser LP FW HTR 2 LP FW HTR 1 Condenser LP FW HTR 1 Condenser Condenser

DESCRIPTION APPLICATION No.1 Extraction from LP Turbine A LP FW HTR 1 feed water heating

No.2 Extraction from LP Turbine B LP FW HTR 2 feed water heating

No.3 Extraction from LP Turbine A LP FW HTR 3 feed water heating

No.4 Extraction from IP Turbine Turbine driven Boiler feedwater pump

No.4 Extraction from IP Turbine Deaerator pegging steam

No.5 Extraction from IP Turbine HP FW HTR 5 feed water heating

No.6 Extractionfrom CRH line HP FW HTR 6 feed water heating

No.7 Extraction from HP Turbine HP FW HTR 7 feed water heating

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(Table-21)

Drain Discharge

Before startup During startup Before shut down During shutdown

HP FW HTR 7 toCondenser HP FW HTR 7 to

HP FW HTR 6

HP FW HTR 7 to

HP FW HTR 6

HP FW HTR 7 to

Condenser


HP FW HTR 5

HP FW HTR 6 to

HP FW HTR 5

HP FW HTR 6 to

Condenser


DEA & FW TK

HP FW HTR 5 to

DEA & FW TK

HP FW HTR 5 to

Condenser

LP FW HTR 3 to condenser LP FW HTR 3 to

LP FW HTR 2

LP FW HTR 3 to

LP FW HTR 2

LP FW HTR 3 to

condenser


LP FW HTR 1

LP FW HTR 2 to

LP FW HTR 1

LP FW HTR 2 to

condenser


Condenser

LP FW HTR 1 to

Condenser

LP FW HTR 1 to

condenser

3.4.3 Heater Service conditions during startup and shutdown

During Startup, when the Main Turbine load reaches to greater than 10% Turbine load, the extraction steam isolation valves are opened one by one in the order from lower pressure extraction steam line to higher pressure extraction steam line.

During Shutdown, when the main Turbine load comes down less than 15% Turbine load, the extraction steam isolation valves are closed from High pressure extraction steam line to low pressure extraction steam line.

(Table-22)

Equipments *Start-up (In Service)

*Shut down (Out Service)

HP FW HTR 7 > 10% Load < 15% Load HP FW HTR 6 > 10% Load < 15% Load HP FW HTR 5 > 10% Load < 15% Load DEA & FW TK > 10% Load < 15% Load LP FW HTR 3 > 10% Load < 15% Load LP FW HTR 2 - - LP FW HTR 1 - -

* Typical Generator Load for Heater In service/Out Service

PCD-GMH-XIT3-0002


(Table-23) System Name HP EXTRACTION Description This master sequence system is provided automatic operation of

related auxiliaries for HP feed water heater to in-service condition during turbine start-up operation. This sequence basically comprises of each command signals for each extraction steam isolation valves.

Permissive Start: Generator Load >73MW Each HP heater level not high

Stop: Generator Load <109.4MW


Stop PAS signal Manual from DCS OPS(Operator Station) Local N/A

Sequence Step Start HP FW HTR 5 DRAIN CLEANG ZONE VENT VLV open

=> HP FW HTR 5 INL EXTRSTM VLV inching open => HP FW HTR 6 INL EXTRSTM VLV inching open => HP FW HTR 7 INL EXTRSTM VLV inching open

Stop HP FW HTR 7 INL EXTRSTM VLV close => HP FW HTR 6 INL EXTRSTM VLV close => HP FW HTR 5 INL EXTRSTM VLV close => HP FW HTR 5 DRAIN CLEANG ZONE VENT VLV close


2

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(Table-24) System Name LP EXTRACTION Description This master sequence system is provided automatic operation of

related auxiliaries for LP feed water heater to in-service condition during turbine start-up operation. This sequence basically comprises of each command signals for each extraction steam isolation valves.

Permissive Start: Generator Load >73MW LP heater level not high Deaerator and feedwater tank level not high Not Water Induction condition

Stop: Generator Load <109.4MW


Stop PAS signal Manual from DCS OPS(Operator Station) Local N/A

Sequence Step

Start LP FW HTR 3 INL EXTRSTM VLV inching open => DEA&FW TK INL EXTRSTM VLV inching open

Stop DEA&FW TK INL EXTRSTM VLV close => LP FW HTR 3 INL EXTRSTM VLV close


2

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3.4.3 Water Induction Protection

The basic concept for the water induction protection are as follows: 1) Alarm :

Each Feedwater heater provided with High water level alarm (HWL) and High-High water level alarm (HHWL)

2) Protection action:

Design concept for minimum protection action: - Double protection consists of the following a) and b). for LP FW HTR3, Deaerator and Feedwater Tank, HP FW HTR5,6,7. - Double protection consists of the following a) and c). for LP FW HTR1,2.

a). Automatic drain system from the feedwater heater shell to condenser b). Automatic shutoff in extraction line to feedwater heater. c). Automatic shutoff in all sources of water entering the feedwater heater shell and tubes.

3) Heater drain :

All Feed water heater and Deaerator emergency drain lines are directly connected to the Condenser. These emergency drain valves will open at HWL (NWL+50mm) by automatically split controls with the normal drain controls. For the deaerator and feedwater tank drainage, a single emergency drain is utilized to open at HWL.

4) In case of water induction detected, the following action should be taken. (ref table-25)

PCD-GMH-XIT3-0002


(Table-25) a) HP FW HTR 7

HWL Alarm High Emergency drain control valve open HHWL Alarm High- High Extraction steam isolation valve and

Extraction steam NRV force to close. (Heater trip)

Operator Remote Manual

HP FW HTR 7 inlet / outlet valve force to close. Heater bypass valve force to open

b) HP FW HTR 6

HWL Alarm High Emergency drain control valve open HHWL Alarm High- High Extraction steam isolation valve close (Heater trip) Operator Remote

Manual HP FW HTR 5 inlet, HP FW HTR 6 outlet valve force to close. Heater bypass valve force to open.

b) HP FW HTR 5

HWL Alarm High Emergency drain control valve open HHWL Alarm High- High Extraction steam isolation valve and

Extraction steam NRV force to close. (Heater trip)

Operator Remote Manual

HP FW HTR 5 inlet, HP FW HTR 6 outlet valve force to close. HP FW HTR 5/6 bypass valve force to open

c) LP FW HTR 3

HWL Alarm High Emergency drain control valve open HHWL Alarm High- High Extraction steam inlet isolation valve close (Heater trip)

Operator Manual at Local Feedwater inlet / outlet valve force to close. Heater bypass valve force to open

d) LP FW HTR 1, 2

HWL Alarm High Heater drain line to condenser to open HHWL Alarm High- High LP FW HTR1 inlet, LP FW HTR 2 outlet valve close

LP FW HTR 1/2 bypass valve open Gland steam diverting valve to condenser side (for LP FW HTR 1)

d) Deaerator and Feedwater Tank

HWL Alarm High Deaerator emergency blow down isolation valve open to condenser

HHWL Alarm High- High Extraction isolation valve and Extraction check valves force to close

PCD-GMH-XIT3-0002


HP / LP HEATER DRAINS AND VENTS SCHEMATIC DIAGRAM (Fig-7)

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3.5 Circulating Water Line

Circulating water line consists of Two (2) x 50% duty Circulating Water Pumps (CWP) and pipes to each unit, and these pumps are installed at the downstream of seawater screening plant in seawater intake structure. (Ref Schematic diagram Fig-8)

The discharge of the CW pumps is provided with a motorized butterfly valve. The CW pipe further continues to the condenser inlet water box and discharge to culvert. Cold seawater pumped by CWPs up to the condenser inlet, and the seawater booster pump suction in auxiliary cooling water system as well, Return hot water from the condenser and auxiliary cooling water system circuit outlet is discharged to outer sea through the same CW discharge line. Circulating Water line filling shall be done by CW pump manually. Condenser outlet valve and CW pump outlet valve shall be kept partial open during line filling, and CW pump outlet valve will be fully opened after filling. The water filling tie by CW pump with gravity filling will be approx. 3 to 5 min according to commissioning result of the reference plant.

Note): The circulating water system is independently installed system in each unit of Unit3 and Unit4, which does not utilize a Tie-in-connection between each other circulating water piping system.

(Fig-8)

PCD-GMH-XIT3-0002


(Table-26) System Name Circulating Water System Description This master sequence system is provided automatic operation of

related auxiliaries for circulating water system in normal operation condition. This sequence basically comprises of each command signals for CWP, Condenser, Sea water booster pump, CCCW heat exchanger strainer and other related valves.

Permissive Start: Each Auxiliaries in Auto mode Permissive condition from UCS

Stop: N/A

Operation Auto Start N/A


Sequence Step Start: Condenser inlet valve open/ condenser outlet vale 30% open/ condenser water box vent valve open => CWP-A start => CWP-A outlet valve open by inching operation/CWP-A

motor cooling water booster pump start => (240sec) => Condenser water box vent valve close => CWP-B start => CWP-B outlet valve open/CWP-B motor cooling water

booster pump start/ condenser outlet valve 50% open => Sea water booster pump start => Complete

Stop Condenser outlet valve 30% open/sea water booster pump stop => CWP-A outlet valve closing => CWP-A stop/CWP-A motor cooling water booster pump

stop => Chrolination System stop => CWP-B outlet valve closing => CWP-B stop/CWP-B motor cooling water booster pump stop => Condenser water box vent valve open => (40sec) => Condenser water box vent valve close => Complete


2

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3.5.1 Equipments

(Table-27) Equipment Type or Specification

2 x 50%, each 920 m3/min per one unit, Vertical Turbine type Inlet Vane Control: None (Fix)

Circulating WaterPump

Bearing: without external water seal

Type: Horizontal, single shell with double pass, divided water box, surface condenser Condenser

Tube Material: Titanium tube

Condenser tube cleaning system

Type Sponge ball cleaning system: Ball cleaning type

PCD-GMH-XIT3-0002


3.5.2 Operation of Circulating Water Pump

• Two x 50 % Circulating Water Pumps are in operation in the circulating water systems per unit continuously.

• CW pump intake traveling band screen is operated periodically by timer or the difference in the water level across the screen.

• In case all the Circulating water pump trips, the Turbine will trip automatically due to poor vacuum reaches at pre determined level.

(Table-28) Equipment Name Circulating Water Pump Description There are 2 x 50 % CWP pumps for each unit located in the intake

area and pump sump for pumping sea water through the once circulating water system. The discharge of the CWP is provided with hydraulically controlled outlet valve. Each unit 2x50% CW pumps combined into a single pipe and deliver the cooling water to the respective unit condenser and coolers.

Permissive Start: Not CWP Motor cooling water Leakage Not motor winding temp High-High

Stop: Outlet valve closing (at manual operation)


Stop Master sequence demand Manual From DCS OPS(Operator Station) Local Directly at SWGR (Commissioning use only)


Protection Condition Electrical Failure (SWGR) Motor winding temp. High-High Motor cooling water loss Outlet valve not opened


2

PCD-GMH-XIT3-0002


3.5.3 Condenser tube cleaning system:

Condenser tube ball cleaning system operates once a day: The standard recommended number of circulating sponge balls is specified as approximately 10% of the total number of condenser cooling tubes per pass.

(Table-29) System Name Condenser Tube Cleaning System Description The condenser tube cleaning system is provided for On-Line

cleaning of the condenser tubes by the passage of slightly oversized rubber sponge ball through the condenser tubes. This system ensures that the cooling water side fouling is prevented in the condenser tubes. The system basically comprises of tube ball feed pump, collector, counter, sorter and ball strainer. The balls are injected at the condenser inlet with the help of one ball feed pump. The ball feed pump picks up the balls collected at the ball strainer screen along with water and pumps it to a ball collector vessel and finally into the respective condenser inlet pipe injection V-pipe. The system is provided with ball undersize sorter and ball counter monitor in parallel to measure the size of the balls and if they are smaller to be replaced.

Operation Auto Start N/A

Stop N/A Manual from DCS OPS Local N/A

Permissive Start: Circulating Water System in Normal condition Stop: N/A


Protection Condition Strainer Differential Press. Hi-Hi Each Auxiliaries Fault Circulating Water System Stopped

Sequence Step Ball Strainer Close => Collector Outlet Valve Open => Ball Feed Pump Start => Collector Inlet Valve Open => Ball Collector Open

(Cleaning Mode) => Ball Collector Close

(Ball Counting Preparation) => Ball Collector Open => Ball Collector Close

(Ball Collection Mode) => Collector Inlet Valve Close => Ball Feed Pump Stop => Collector Outlet Valve Close => Ball Strainer Open

2

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3.6 Auxiliary Cooling Water Line Each unit Auxiliary Cooling water line consists of two (2) x100% Seawater Booster Pumps (SWBP) and two (2) x100% CCCW Heat Exchanger. Seawater booster Pumps takes suction from Circulating water line ( upstream of condenser ) and pumped up to CCCW Heat Exchangers and Condenser Vacuum pump seal water coolers. Return hot water from the CCCW heat exchangers and Condenser Vacuum pump seal water Coolers are connected to the Circulating water line (down stream of condenser) (Ref Schematic diagram Fig-9)

3.6.1 Equipments

(Table-30) Equipments Quantity X Capacity

for each unit

Remarks

Sea water Booster pump 2 x 100% per unit, each 52 m3/min

1 working + 1 stand by

CCCW Heat Exchanger Strainer

2 x 100%

CCCW Heat Exchanger 2 x 100%

Plate type 1 working + 1 stand by

Condenser Vacuum Pump Seal Water Coolers

2 x 100% 1 working during normal operation, 2 working for vacuum up of condenser

PCD-GMH-XIT3-0002


3.6.2 Sea Water Booster Pump Operation

(Table-31)

Plant Start up Plant Shut down

Pump (Ref:Table-32)

Start: After CWP start

Stop: Before CWP stop

(Table-32) Equipment Name Sea Water Booster Pump Description There are 2 x 100 % SWB pumps for each unit located in the turbine

house and discharge from the booster pump passes through 2x100% self cleaning strainer and then is supplied to the vacuum pump seal water cooler and the CCCW Heat Exchanger cooler.

Permissive Start: Not Motor winding temp high-high CWP running

Stop: N/A


Back-up start demand by duty pump fail or required flow high Stop Master sequence demand

Manual from DCS OPS(Operator Station) Local Yes(commissioning use only)

Override Start: N/A

Stop: N/A Protection Condition Electrical Failure (SWGR)

Motor winding temp. High-High Both CWP stopped


2

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AUXILIARY COOLING WATER LINE SCHEMATIC DIAGRAM (Fig-9)

PCD-GMH-XIT3-0002


3.7 Closed Cycle Cooling Water Line

Each Unit Closed Cycle Cooling Water(CCCW) Line consists of 2 x 100% Closed Cycle Cooling Water Pumps (CCCWP) and 2 x 100% CCCW heat exchangers, common 2 x 100% Make Up Water pumps and CCCW Chemical dosing system. Demineralized water in CCCW system is pumped by CCCWPs up to the Boiler, Boiler auxiliary, Turbine and common auxiliary cooling system through CCCW heat Exchangers and return hot water from each cooler shall be discharged to the suction of the CCCWPs to be cooled again in CCCW heat exchangers. CCCWPs are provided with suction side temporary strainer. A head pipe is provided at the suction of the CCCWPs for buffer and to keep the.pump suction head The make up water is provided from the Make Up Water pumps. The chemical dosing line is connected to CCCW pump suction for corrosion inhibition. (Ref Schematic diagram Fig-10)

3.7.1 Equipments

(Table-33) Equipment Quantity X Capacity

For each unit

Remarks

CCCWP 2 x 100% each 51 m3/min

CCCW head pipe (back pressure control)

1 x 100%

3.7.2 Closed Cycle Cooling Water line Operation

(Table-34) Start Stop

CCCWP (Ref:Table-35)

Manual start : One CCCWP.

Manual stop in case unit under maintenance

Make Up Water

Remote manual (For Initial filling) Interlock (by signal of LWL of CCCW head pipe)

Remote auto (By signal of NWL of of CCCW head pipe)

CCCW Chemical Injection

Manual Start At Low corrosion inhibitor Concentration

Manual Stop

PCD-GMH-XIT3-0002


(Table-35) Equipment Name Closed Cycle Cooling Water Pump Description There are 2x100% CCCW Pumps taking suction from various

coolers return water common pipe and the Head Tank. The CCCW Pumps are provided with suction side temporary strainer. The discharge from the CCCW pump is sent to the 2x100% CCCW heat exchanger (CCCW HE). Cold cooling water from the CCCW HE is branched off to various coolers of the boiler/turbine and the BOP equipment coolers as per the flow diagram. The return from all these coolers is fed to the suction of the CCCW pump to complete the cycle.

Permissive Start: not motor winding temp. high-high Stop: N/A

Operation Auto Start Back-up start demand by duty pump fail or CCCWP Press Low



Protection Condition Electrical Failure (SWGR) Motor winding temp. High-High


2

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CLOSED CYCLE COOLING WATER LINE SCHEMATIC DIAGRAM

(Fig-10)

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3.8 Lube Oil Line

Each Unit Lube Oil Line consists 2 x 100% Main Oil Pumps with AC motors for normal use, and 1 x 100% Emergency Oil Pump with DC motor for emergency use. The Oil system is provided for feeding the lubricating oil Turbine and Generator bearings. The Vapour Extractor is installed the Main Oil Tank top surface, and discharges gas of the Main Oil Tank inside to the atmosphere. EHC control oil line is referred to following documents.

• System Design Description for Main Turbine D-EHC(A-EHC-I-TS-7522 / 5B2K0800) • System Design Description for BFP Turbine D-EHC(A-EHC-I-TS-7523 / 5B2K0801)

3.8.1 Equipment

(Table-36) Equipment Quantity X Capacity

Remarks

Main Oil Pump 2 x 100% per unit

5270L/min each Vertical Type

Emergency Oil Pump

1 x 100% per unit 4321L/min

Vertical TypeDC Motor

Main Oil Tank

1 x 100% per unit Nor:40,000LTR Max:59,000LTR

Main Oil Tank Vapour Extractor 2 x 100% per unit 24m3/min

(Table-37)

Equipment Quantity X Capacity

Remarks

BFPT Main Oil Pump 2 x 100% per BFPT 720L/min each

Vertical Type

BFPT Emergency Oil Pump

1 x 100% per BFPT 530L/min

Vertical TypeDC Motor

BFPT Main Oil Tank

1 x 100% per BFPT Nor:3870LTR Max:5340LTR

BFPT Main Oil Tank Vapour Extractor

1 x 100% per BFPT 8m3/min

3.8.2 Oil Pump Operation

(Table-38) Start Stop

Main Oil pump Start:

Before Turbine Startup Manual Stop

Emergency Oil Pump Start: Main Oil Pump Backup

Manual Stop

BFPT Main Oil Pump Start: Before BFPT Startup

Manual Stop

BFPT Emergency Oil Pump

Start: BFPT Main Oil Pump Backup

Manual Stop

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PCD-GMH-XIT3-0002


(Table-39) System Name LUBE & EHC OIL START Description This master sequence system is provided automatic operation of

related auxiliaries for lubrication and control oil system start-up operation. This sequence basically comprises of each command signals for each auxiliaries of lubricating oil and control oil system.

Permissive Start: Main Oil Tank Level not low EHC Oil Tank Level not low Turbine Tripped Each duty pump/fan selected Operation

Auto Start Master sequence demand Backup start demand by duty pump fail


Sequence Step Duty MN OIL TK VAP EXTRTR start => MN OIL CNDNR FR PMP start => duty EHC OIL PMP start => duty MOP start


(Table-40) System Name Boiler Feed Pump Turbine Oil System Description The BFPT oil system is provided for feeding the lubricating oil to

BFPT and BFP bearings and feeding the hydraulic oil to BFPT major valve control system. The system basically comprises of two(2) AC-motor driven pump, One(1) DC-motor driven pump, one(1) vapor extractor. The oil is maintained the pressure and temperature controlled by regulator, oil cooler and cooling water flow control valve. The system is provided with pressure regulator, oil cooler and cooling water flow control valve to keep related oil condition for bearing and hydraulic control system.

Permissive Start: Each Auxiliaried in Auto mode BFPT Oil Tank Level not Low BFPT Tripped

Stop: N/A


Backup start demand by duty pump fail Stop N/A


Sequence Step Oil Tank Vapor Extractor Start => Oil Conditioner Filter Pump Start => Selected Main Oil Pump Start


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4.0 Failure Action and valve set for Control Valve( TG Island )

Major control valves are tabulated in Table 19 with Failure Action with related isolation valve configuration.

(Table-41)

FO: Fail to Open FC: Fail to Close FL(O): Fail to Lock, finally to Open FL(C): Fail to Lock, finally to Close

Valve Name System Type of Control

Action at Air Failure

Bypass Balve Inlet Valve Outlet

Valve

Condenser Hotwell Level Control Valve

Makeup Modulation FC Applied Applied Applied

Condensate Water Minimum Flow Recirculation Valve

Condensate Modulation FO N/A Applied Applied

Deaerator and Feedwater Tank Level Control Valve

Condensate Modulation FL(O) Applied Applied Applied

LP Turbine Casing Spray Valve Condensate ON-OFF FC Applied Applied Applied Condenser Curtain Spray Valve Condensate ON-OFF FO Applied Applied Applied M-BFP Outlet Flow Control Valve Feedwater Modulation FL(C) N/A N/A Applied MBFP Minimum Flow Control Valve TBFP A Minimum Flow Control Valve TBFP B Minimum Flow Control Valve

Feedwater Modulation FO N/A N/A Applied

TBFP Start Up Flow Control valve Feedwater Modulation FL(C) Applied N/A Applied HP Feedwater Heater No.7 Level Control Valve

Heater Drain Modulation FO N/A N/A Applied

HP Feedwater Heater No.7 Emergency Level Control Valve


HP Feedwater Heater No.6 Level Control Valve




HP Feedwater Heater No.5 Level Control Valve




LP Feedwater Heater No.3 Level Control Valve


LP Feedwater Heater No.3 Emergency Level Control Valve










HP Turbine Bypass Spray Control Valve

Boiler Feedwater

Modulation FL(C) N/A Applied Applied

LP Turbine Bypass Valve A/B Spray Control Valve

Condensate Modulation FO N/A N/A Applied

Auxiliary Steam Header Attemperator Temperature Control Valve

Condensate Modulation FL(C) N/A Applied Applied

Auxiliary Steam Header Inlet Cold Reheat Pressure Control Valve

Aux. Steam Modulation FC Applied Applied Applied

PCD-GMH-XIT3-0002


Valve Name System Type of Control

Action at Air Failure

Bypass Balve Inlet Valve Outlet

Valve

Deaerator and Feedwater Tank Inlet Auxiliary Steam Pressure Control Valve

Aux. Steam Modulation FC N/A Applied Applied

Deaerator and Feedwater Tank Inlet Cold Reheat Steam Pressure Control Valve


BFPT Inlet Auxiliary Steam Pressure Control Valve


BFPT Inlet Cold Reheat Pressure Control Valve

CRH Modulation FC N/A Applied Applied

Lube Oil Temperature Control Valve CCCW Modulation FL(O) Applied Applied Applied BFPT A Lube Oil Temperature Control Valve

CCCW Modulation FL(O) Applied Applied Applied

BFPT B Lube Oil Temperature Control Valve

CCCW Modulation FL(O) Applied Applied Applied

CCCW Head Tank Level Control Valve

CCCW ON-OFF FC Applied Applied Applied

Gland Steam Seal Feed Control Valve Gland Steam Modulation FO Applied Applied Applied Gland Steam Packing Unloading Valve

Gland Steam Modulation FC Applied Applied Applied

PCD-GMH-XIT3-0002


5.0 Special Operation 5.1 House load Operation (HLO):

House load operation will be initiated when there is complete isolation between the facility and the 500kV Grid system. Boiler load will be reduced to equivalent to approx. 25 %B-MCR Load operation, which is a continuous minimum load. The house load operation with assistance of safety valves is able to continuous up to 40 minutes.

5.2 Boiler Single Operation (BSO):

While Plant is running stable and normal operation with coal firing, if Turbine or Generator trips, then the power plant shall be shifted to Boiler single operation and boiler load reduced rapidly to target load of 25% operation. The Boiler is kept in operation independently in preparation for re-synchronization with in two hours, If the cause of Turbine or Generator trip is by miss operation /simple fault, which can be quickly recovered. During BSO, Boiler auxiliary power shall be supplied from other sources (Back feeding power from the 500kV Grid). If the Turbine /Generator is not able to start with in two hours, it is suggested to trip the boiler.

5.3 Condenser half tube bundle operation:

In case condenser tube leakage occurred, the associated tube bundle is isolated from the circulating water system by fully closing condenser water box inlet and outlet isolation valves. The water box vent and drain valves are opened for the inspection and maintenance of the leaked tube. The leaked tube is plugged for further operation. Under half tube bundle operation, one CWP may be stopped where the Turbine continues to operated at the load up to 50% Turbine load.

5.4 CW Traveling band screen operation:

In case one of the traveling band screen will fail, screening line is shut down for maintenance and CWP at the downstream of the screen shall be stopped. The plant load shall be reduced accordingly.

5.5 Feed Water Pump Parallel Operation :

Two TBFPs will be in service during normal operation. In case any one TBFP tripped, MBFP may be operated manually so that 100% load operation can be achieved by parallel operation of a TBFP and MBFP.

PCD-GMH-XIT3-0002


5.6 Load Runback

Runback functions are provided, in case of Quick load reduction and complex of operation is needed when the accident or protection occurs. It is difficult to predict accident or protection, except Turbine trip. Other than Turbine tripping operator can reduced the load due to any accident or protection occurs. The items of run back and load change rates is indicated in table -20.

(Table-42)

Runback Item Consideration Condition Runback

Target LoadLoad Demand decrease rate

Operation mode

BFP Trip Yes

2(two) BFPs Operation, One BFP Tripped

30% Load 100%/min Turbine follow

a) BFP Trip

In case of one of the running BFP trips, Stand by MBFP will start on manual with minimum flow operation and discharge valve open. The remaining Feed water flow is controlled automatically to keep the total feed water flow equal to 50% load. The load can be recovered to 100% load after feed water flow from two BFPs are balanced out and stand by BFP in Auto mode.

PCD-GMH-XIT3-0002


5.7 HP and LP Feed water Heater Bypass Operation

a) The maximum plant load limit at heater bypass operation is indicated in Table-21 respectively.

(Table-43)

Case

LP FW HTR 1

LP FWHTR 2

LP FWHTR 3

HP FWHTR 5

HP FW HTR 6

HP FW HTR 7

Max. LoadMW (NET)

HP FW HTR 7 bypass o o o o o X 660

HP FW HTR 5,6 bypass o o o × × o 462

LP FW HTR 3 bypass o o × o o o 660

LP FW HTR1,2 bypass × × o o o o 594

o：In Operation, x：Out Of Operation

Note: Indicative Possible Max. Load is not for guaranteed. In the event of heaters failure, operator needs to decrease load and perform checking around the heaters. Toshiba recommends to slowly increase the plant load to indicative possible maximum load as indicated in table above. Heater bypass operation cases shown in Table-21 are typical bypass cases only. The maximum plant load at other heater bypass combinations is limited by the design criteria of steam turbine, feedwater heater and/or heater drain system according to heater bypass combination.

DEA & FW TK

HP FW HTR 7

BFP & BOOSTER PUMP

CEP

LP FW HTR 3

Condenser

To BOILER

HP FW HTR 6

HP FW HTR 5

LP FW HTR 2

LP FW HTR 1

M

M

MM

M

M

M

M

M

FEEDWATER HEATER BYPASS SCHEMATIC DIAGRAM (Fig-13)

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6.0 Reference documentation

Title Document/Drawing No.

1 Plant Automation Concept for DCS controls A-DCS-I-TS-7653 SPC-GCH-XIT3-00042 System Design Description for Main Turbine

D-EHC A-EHC-I-TS-7522 5B2K0800

3 System Design Description for BFP Turbine D-EHC

A-EHC-I-TS-7523 5B2K0801

4 Piping and Instrument Diagrams ・Table of Contents B-00-0-TS-1118 1GMH00839 ・Legend A-00-0-TS-1121 2GMH00624 ・Water Balance Sheet B-00-M-TS-1112 1GMH00774 ・Steam Turbine and Steam Turbine

Supervisory Instrument A-MT-0-TS-1117 1GMH00779

・Main/Reheat Steam and Turbine Bypass A-MS-0-TS-1104 1GMH00764 ・Extraction Steam A-ES-0-TS-1105 1GMH00765 ・Auxiliary Steam A-AS-0-TS-1106 1GMH00766 ・Heater Drain and Vent System A-HD-0-TS-1107 1GMH00767 ・Drain to Blowdown Tank A-DVT-0-TS-1126 2GMH00649 ・Condensate System A-CO-0-TS-1108 1GMH00768 ・LP Feedwater Heater / Deaerator and

Feedwater Tank A-CO-0-TS-1109 1GMH00769

・Boiler Feedwater Pump A-FW-0-TS-1110 1GMH00770 ・HP Feedwater Heater A-FW-0-TS-1111 1GMH00771 ・Condenser A-CO-0-TS-1112 1GMH00772 ・Condenser Vacuum Pump A-CAE-0-TS-1122 2GMH00644 ・Cycle Makeup and Storage A-MU-0-TS-1114 1GMH00775 ・Circulating Water System A-CW-0-TS-1100 0GMH00163 ・Closed Cycle Cooling Water System A-CCCW-0-TS-1115 1GMH00776 ・CCCW Chemical Dosing System A-CCCW-0-TS-1127 2GMH00661 ・Chemical Dosing System in Lot2 Area B-CO-M-TS-1129 2GMH00672 ・Turbine Seal & Drain System A-MT-M-TS-1400 0KS001886 ・BFP Turbine Seal Steam & Drain System A-BFT-M-TS-1401 2GMH00646 ・Steam Turbine Generator Lube Oil System A-LOS-M-TS-1504 0KT0028556 ・BFPT Lube Oil System A-LOT-M-TS-1505 1KT003083 ・ST & BFPT Lube Oil Conditioning System A-LO-M-TS-1600 2KW009535 ・Valve Sealing Water system(Turbine Area) A-CO-M-TS-1601 2KW009617

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TYPICAL CHART of BFP-TURBINE AUTOMATIC START Annexure- I (1 of 2)

TYPICAL CHART of BFP-TURBINE AUTOMATIC SHUTDOWN Annexure- I (2 of 2)

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TYPICAL SEQUENCE OF MANUAL TURBINE STARTUP TIME CHART 2

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Annexure-II

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Annexure-III

Mismatch Chart

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2_1!01!02_basic operation concept for turbine and auxiliary plant_r00

Documents