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GAZA POWER GENERATION COMPANY 140 MW CCGT POWER PLANT

GAZA

SOP: 010 REVISION 5 SECTION: CONDENSER SYSTEM (MAG)

______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

1 SAFETY ……………………………………………………..……………………… 3

2 SYSTEM DESCRIPTION …………………………………..…………………….. 4

2.1 Function …………………………………………………………………….. 4

2.2 General System Description …………………………………………….... 4

2.3 Design Basis ……………………………………………………………….. 5

2.4 Dimensioning DATA ………………………………………………………... 5

3 SYSTEM OPERATION AND MAINTENANCE …………………..……………. 6

3.1 Accessibility ………………………………………………………………… 6

3.2 Inspection and testing ……………………………………………………... 6

3.3 System Malfunctions ………………………………………………………. 6

3.4 Monitoring Signals …………………………………………………………. 7

3.5 System Logics ……………………………………………………………… 9

3.5.1 Vacuum breaker valve 10/20MAG10AA010 ……………………. 9

3.5.2 Power supply ………………………………………………….…… 9

4 SYSTEM PREREQUISTES …………………………………..………………….. 10

4.1 Base Position ………………………………………………………………. 10

4.2 Filling of Condenser ………………………………………………………... 11

5 OPERATION PROCEDURES …………………..……………………………….. 12

5.1 Start-up Preparation ……………………………………………………….. 12

5.2 Normal Plant Operation ……………..…………………………………….. 12

5.3 Start of the Plant ……………….…………………………………………... 12

5.4 Shutdown of the System ……...…………………………………………... 12

5.5 Plant in stand-by condition ………………………………………..………. 12

5.6 Emptying of condenser ………………………………………………….... 12


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

6 ABNORMAL PLANT OPERATION ……………………………………………… 13

6.1 Plant trip 13

6.1 Loss of grid power 13

7 DESTURBANCE INSTRUCTIONS ……………………………………………. 14

8 FAULT PROCEDURES …………………………………………………………. 17

9 SYSTEM MODIFICATIONS …………………………………………………….. 23

10 SYSTEM UNTREATED MALFUNCTIONS …………………………………… 24

11 SYSTEM HISTORY ……………………………………………………………… 25

12 HAZOP METHODOLOGY ……………………………………………………… 26

12.1 Risk Matrix ………………………………………………………………….. 26

12.2 HAZOP Matrix ……………………………………………………………… 28

13 SYSTEM P&ID …………………………….…………………………………….. 30

14 SYSTEM REFERENCES ………………………..…………..………………….. 31


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

1 SAFETY

Before operating the condenser System the owners, employers and staff should become familiar with, and comply with, all applicable safety regulations and applicable local codes, recognised international standards and regulations relative to personal protective equipment. This includes eye and face protective equipment, respiratory protective equipment, equipment intended to protect the extremities, protective clothing, protective shields/barriers and electrical protective equipment as well as noise exposure administration and/or engineering controls and/or personal hearing protective equipment.

• Employers to be able to recognize hazardous conditions and to act accordingly. • Do not attempt to operate the pumps with fan, coupling or other guards removed. • Verify system alignment prior to starting any equipment.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

2 SYSTEM DESCRIPTION

2.1 Function The condenser 10/20 MAG10AC010 receive steam and transfer the heat to the main

cooling water, the condensate is collected in the hot well. Secure the steam turbine outlet from high pressure by a rupture disc and a safety valve. The safety valve shall open before the rupture disc. The safety valve shall only take care of

the leakage flow. To be able to break condenser vacuum at steam turbine trips or at steam turbine shutdown

by using a vacuum breaker, 10/20 MAG10AA010.

2.2 General System Description The steam from the steam turbine is condensed in 10/20 MAG10AC010 and the heat is transferred to the main cooling water. The condensate is collected in the bottom of the condenser by the shell and internal hot well. The condenser (10/20 MAG10AC010) is evacuated by the evacuation system MAJ. During steam turbine start up the steam turbine is initially by-passed and the steam is dumped into the condenser. When the steam temperature and pressure allow the warm-up of the steam turbine to be started, steam is both by-passed and led into the steam turbine. The by-pass will be in stand-by for a steam turbine trip. The condenser, 10/20 MAG10AC010, and steam turbine outlet is secured against high pressure through a rupture disc, 10/20 MAG10BP010, and a safety valve, 10/20 MAG10AA235. The safety valve shall open before the rupture disc. The safety valve shall only take care of a possible leakage flow. The rupture disc and safety valve is placed at the condenser. The condenser can not receive steam under following conditions: high pressure, high condensate level or high temperature. In order to reduce the turbine coasting down time, the condenser is equipped with a vacuum breaker valve, 10/20 MAG10AA010. The vacuum breaker consists of a pneumatic shut-off valve mounted vertically, with sealing water from the condensate system on the atmospheric side. The vacuum breaker shall be closed at start-up and during operation. At plant shutdown the vacuum breaker shall be opened, vacuum shall be broken.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

2.3 Design Basis

The condenser 10/20 MAG10AC010 is designed to transfer the heat from the steam coming in to the condenser shell side with a temperature increase in the main cooling water on the condenser tube side. The pressure inside the condenser shell side shall correspond to the temperature of the main cooling water in the tube side. The condenser 10/20 MAG10AC010 is designed for maximum mass flow when steam turbine in by-pass operation. Design pressure shell side: vacuum - 1.0 bar (g) and +1.0 bar (g). Design temperature shell side: 150 ºC. A rupture disc that will open at 1.0 bar (g) +/- 10% secures the condenser. The rupture disc is designed to manage maximum flow through steam turbine by-pass valves. The condenser is also secured against high pressure through a safety valve. The safety valve shall open at 0.50 bar (g). The safety valve shall only take care of 10% of the maximum steam flow. The vacuum breaker is dimensioned to increase the condenser pressure to 0.5 bar (a) in 55 seconds.

2.4 Dimensioning DATA

ST Load 100% ST Load 50% Cooling flow ST Bypass 50% 50 % COOLING WATER SIDE; Mass flow, kg/s 1195 1195 597.5 Inlet temperature, °C 25.5 25.5 25.5 Outlet temperature, °C 37.5 39.7 48.4 Inside velocity in the tube, m/s 2.2 2.2 1.1 Pressure lost, mwc 6.0 6.0 4.0 Cleanliness factor 0.88 0.88 0.88 STEAM SIDE: Turbine exhaust mass flow, kg/s 25.4 25.4 25.4 Inlet enthalpy, kJ/kg 2320 2793.3 2320 Condenser pressure, bar (a) 0.078 0.093 0.137 Saturated temperature, °C 71 44.4 52.1

3 SYSTEM OPERATION AND MAINTENANCE


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

3.1 Accessibility The system is not accessible during normal operation.

3.2 Inspection and testing

Operator has to round the system (together with rest of plant) to check equipment general status and for periodic maneuvers (e.g. change over of redundant equipment, checking of automatic drains etc.), This rounding list does not include any maintenance activities required (for this, see detailed information in equipment manuals).

3.3 System malfunctions

High level gives steam turbine trip respective interlock of the by-pass dumping valves (the dumping valve close).

High pressure gives steam turbine trip respective interlock of the by-pass dumping valves. High temperature on the dumping steam interlocks the by-pass dumping valves. Fault on level, pressure and temperature instrument shall be checked at periodical testing. The condenser is protected by switches (pressure, temperature and level) which are hard

wired.

Malfunction of water injection valve 10/20 LAE10AAOQ2 and 10/20 LAE20AA002 when steam turbine by-pass valve 10/20 MAN10AA001 and 10/20 MAN20AA001 are open cause high temperature in condenser and two out of three (10/20 MAG10CT005, CT010, CT015) closes 10/20 MAN10AA001 and 10/20 MAN20AA001 via the hard wired system.

High pressure in condenser will be measured by 10/20 MAG10CP010, CP015 and CP020

and trip the steam turbine operation via the hard wired system.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

3.4 Monitoring signals

Temperature transmitter 10/20MAG10CT030 indicates temperature in the condenser. At high temperature H1, an alarm is generated.

Temperature transmitter 10/20MAG10CT020 indicates temperature in the condenser

flash box. Temperature switches 10/20MAG10CT005/010/015 protect condenser from high

temperature. At high temperature H2 at any individual transmitter, an alarm is generated. At high level H2 at two out of three transmitters, HP and LP steam bypass valves (10/20MAN10AA001 and 10/20 MAN20AA001) are tripped (ordered to close) by the hardwired safety system.

Pressure transmitter 10/20MAG10CP005 indicates pressure in the condenser.

Signal is hardwired to steam turbine protection system. At high pressure H3 (0.22 bar (a)) an alarm is generated and steam turbine controller will reduce turbine load to keep condenser pressure. The transmitter is used as redundancy for pressure transmitter 10/20 MAG10CP030.

Pressure switches 10/20 MAG10CP010/015/020 protects the steam turbine from high condenser pressure. At high pressure H4 (0.25 bar (a)) at two out of three switches, steam turbine is tripped by the hard-wired safety system.

Pressure transmitter 10/20 MAG10CP030/CP005 indicates pressure in the condenser and is used by steam bypass controller in Main Steam System. At high pressure H1 (0.15 bar (a)) an alarm is generated. When pressure is below H1, condenser hogger 10/20MAJ10AP001 in Condenser Evacuation System is stopped. At high pressure H2 (0.20 bar (a)) an alarm is generated and condenser hogger 10/20MAJ10AP001 is started. At high pressure H5 (0.35 bar (a)) an alarm is generated and the steam bypass valves 10/20MAN10/20AA001 are ordered to close if the speed of the steam turbine is above 70% of normal speed. At high pressure H6 (0.55 bar (a)) an alarm is generated if steam bypass valves are open- At high pressure H7 (0.60 bar (a)) an alarm is generated and steam bypass controller will reduce steam bypass to keep condenser pressure.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

At high pressure H8 (0.70 bar (a)) an alarm is generated and steam bypass valves are ordered to close.

Level switches 10/20 MAG10CL010/025/030 protects the steam turbine and condenser from overfilling. At high level H2 at two out of three switches, steam turbine is tripped and steam turbine bypass valves are tripped (ordered to close) by the hard-wired safety system.

Level transmitter 10/20 MAG10CL005 indicates condensate level in the condenser. At high level HI an alarm is generated and stand-by condensate pump 10/20LCB11/12AP001 in condensate system is started. At low level LI an alarm is generated. The transmitter is used as redundancy for level transmitter 10/20 MAG10CL015.

Level transmitter 10/20 MAG10CL015 indicates condensate level in the condenser and is used by condenser level controller in Condensate System. At high level H1 an alarm is generated and stand-by condensate pump 10/20LCB11/12AP001 in condensate system is started. At low level L1 an alarm is generated.

Level switch 10/20 MAG10CL020 protects the condensate pumps 10/20LCB11/12AP001 (in condensate system) from running dry.

At low level L2 an alarm is generated and condensate pumps 10/20LCB11/12AP001 are stopped.

Conductivity transmitter 10/20MAG10CQ005 measures conductivity at condensate in

hot well. At high conductivity H1 an alarm is generated


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

3.5 System logic

3.5.1 Vacuum breaker valve 10/20MAG10AA010

Vacuum breaker valve 10/20MAG10AA010 is manually maneuvered from the central control room and automatically from Steam Turbine protection system (see System Description Steam Turbine System). Vacuum breaker position (open or closed) is indicated in the central control room.

3.5.2 Power supply

Solenoids and switches in the system are fed with 24VDC. Transmitters are fed with 4-20 mA.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

4 SYSTEM PREREQUISTES

4.1 Base Position

The Condenser System is clean and empty. All equipment are prepared for operation, e.g. instruments are mechanically and electrically connected. The valves for system 10 MAG and 20 MAG are in base position according to the System Base Position List as shown below:

KKS DESCRIPTION OFF STARTUP ON REMARK

10MAG10AA010 VACUUM BREAKER OPEN CLOSED CLOSED 10MAG10AA015 SHUT-OFF VALVE OPEN OPEN OPEN 10MAG10AA205 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA206 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA211 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA212 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA213 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA214 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA215 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA216 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA220 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA221 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA222 SHUT-OFF VALVE CLOSED CLOSED CLOSED 10MAG10AA223 SHUT-OFF VALVE LOSED CLOSED CLOSED 10MAG10AA235 SAFETY VALVE AUTOMATIC OPERATED

10MAG10AA305 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA306 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA310 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA315 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA320 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA325 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA330 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA335 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA340 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA341 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA345 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA346 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA350 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA351 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA355 INSTRUMENT VALVE OPEN OPEN OPEN


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

10MAG10AA356 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA360 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA361 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA365 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA366 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA370 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA371 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA375 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA376 INSTRUMENT VALVE OPEN OPEN OPEN 10MAG10AA380 INSTRUMENT VALVE OPEN OPEN OPEN

4.2 Filling of condenser

The Condenser is filled with de-mineralized water together with filling of Condensate system. See operating instruction for Condensate System, section 2.1, Filling of system.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

5 OPERATION PROCEDURE

5.1 Start-up Preparation The un-condensable gases are evacuated from the condenser 10/20 MAG10AC010 by the evacuation system MAJ. When the necessary vacuum level is reached it is possible to lead steam through the steam turbine by-pass valves into the condenser. At start-up the by-pass will receive the steam until the steam turbine is completely heated and speeded up.

5.2 Normal Plant Operation

At normal operation steam is led through the steam turbine down to the condenser.

5.3 Start of the Plant

The system is read to receive steam after the condenser is evacuated. Gland steam to the steam turbine glands is necessary.

5.4 Shutdown of the System

At a turbine shut off the steam flow will be led through the by-pass station. The steam load from one of the two boilers will be condensed in the condenser. In order not to have a too high condenser pressure or main cooling water temperature, the steam load from the boilers reduced as soon as the steam turbine is shut off.

5.5 Plant in stand-by condition

When the steam turbine and the steam turbine auxiliary systems are not in operation the condenser 10/20 MAG10AC010 is also shutdown.

5.6 Emptying of condenser

The Condenser is emptied and drained from water to allow for maintenance work together with emptying of Condensate system. See operating instruction for Condensate System, section 2.5, Emptying of system


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

6 ABNORMAL PLANT OPERATION 6.1 Plant trip

At a trip of the steam turbine, the steam flow to the steam turbine will be shut off. The steam will be dumped into the condenser through the by-pass valve. At high level, high pressure or high temperature in the condenser, the by-pass dumping valves will be interlocked. The steam will not be admitted to the condenser.

6.2 Loss of grid power

All steam conditioning valves will close and the steam must be blown out through safety valves. The cooling water pumps will be stopped and there is no cooling of the condensers.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

7 DISTURBANCE INSTRUCTION Note: For each alarm, sensors shall always be checked for proper function and setpoints.

Alarm Cause Action

10/20 MAG10 CL901 1. Failure at condensate pump. 1.1. Check that redundant

CONDENSER L AVERAGE pump is automatically started Lim H1 at H1. 2. Failure at level controller 2.1. Check that controller is in automatic mode with correct set value.

2.2 Open manually the level control valve.

10/20 MAG10 CL901 1. Failure at level controller 1.1. Check that level controller CONDENSER L AVERAGE is in automatic mode with Lim L1 correct set value. 1.2 Close manually the level

control valve and open the recirculation valve.

the recirculation valve. 10/20 MAG10 See above for 1.1 Start redundant pump. CL010/025/030 XH21N 10/20 MAG10CL901 Lim H1 Check why redundant pump not has LSH2 CONDENSER been automatically started at H1 Alarm 1. Redundant pump is not Stop formerly running pump when started at H1 level is restored. 1.2 Check that steam turbine is tripped and steam bypass valves are tripped (closed) when 2 of 3 transmitters are >H2. 10/20 MAG10CL020 XL21N See above for 10/20 See above for 10/20 LSL2 CONDENSER MAG10CL901 Lim L1 MAG10CL005 < L1 Alarm 1.1 Check that Condensate Pumps 1. Pumps still running at L2 10/20 LCB11/12 AP001 are stopped 10/20 MAG10 CP901 1. Low cooling water flow 1.1 Check operation of ZH11/ZH21/ZH31/ZH51/ cooling water pumps. ZH61/ZH71/ZH81 1.2 Check adjustment of


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

CONDENSER PRESSURE cooling water flow at valves H1/H2/H3/H5/H6/H7/H8 10/20 PAC20 AA001. Alarm

2. High temperature in cooling 2.1 Increase cooling in cooling

water tower by starting more fans if possible. 3. High steam load to 3.1 Minimise steam bypass condenser operation (if any). 3.2 Reduce boiler load. 4. Condenser evacuation 4.1 Check that condenser failure hogger is started at H2 4.2 Start stand-by ejectors 4.3 Check that steam bypass valves are closed at H5 if the speed of steam turbine is above 70% 4.4 Check that steam bypass is reduced at H7 4.5 Check that steam bypass valves are closed at H8 10/20 MAG10 CP010/015/020 1. See above for 10/20 1.1 See above for 10/20 XH41N MAG10 CP901 ZH11/ZH21.. MAG10 CP901 ZH11/ZH21.. PSH4 CONDENSER Alarm 1.2 Check that steam turbine is

tripped when 2 of 3 transmitters are > H4.

10/20MAG10CQ005 1. Saltwater inleakage from 1.1 Sample and analyse to CONDUCT. HOT WELL condenser tubes determine leakage. Lim. H1 2. High conductivity in boiler 2.1 Check and adjust steam steam condensate. quality according to boiler manual.

10/20 MAG10 1. Low cooling water flow 1.1 Check operation of cooling water pumps.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

CT005/010/015 XH21N 2. High temperature 1.2 Check adjustment of cooling water TSH2 CONDENSER in cooling water flow at valves 10 PAC20 AA001. Alarm 3. High steam load 2.1 Increase cooling in cooling tower to condenser by starting more fans if possible.

4. steam bypass valve 3.1 Minimise steam bypass operation (if any).

fails open 3.2 Reduce boiler load.

4.1 Check that steam bypass valves are closed

when 2 of 3 transmitters are > H2. 10/20 MAG10 CT030 1. Low cooling water flow 1.1 Check operation of TEMP CONDENSER cooling water pumps. Lim. H1 1.2 Check adjustment of cooling

2. High temperature in cooling water flow at valves 10 PAC20 AA001.

water 2.1 Increase cooling in cooling 3. High steam load to tower by starting more fans if possible. condenser 2.2 Increase cooling flow to condenser 3.1 Minimise steam bypass

operation (if any). 3.2 Reduce boiler load.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

8 FAULT PROCEDURES


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

9 SYSTEM MODIFICATIONS


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

10 SYSTEM UNTREATED MALFUNCTIONS

Condenser level sight glass (10/20MAG40CL005) has a false reading.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

11 SYSTEM HISTORY


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

12 HAZOP METHODOLOGY

12.1 HAZOP Methodology

The Hazard and Operability (HAZOP) technique was used to address hazards of the process, previous incidents, which had a likely potential for severe consequences in the work place, engineering and administrative controls and consequences of failures of those controls. Additionally, facilities siting, human factors, and a qualitative evaluation of a range of possible safety and health effects were made.

12.2 Risk Matrix

4 C B A A 3 C B B A 2 D C B B 1 D D C C

1 2 3 4 Consequence • Where A, B, C, and D indicating the risk range

Frequency Range Qualitative Criteria

4 (>1/100yr.)

Single instrument or valve failure; hose leaks; or a human error in everyday activity.

3 (1/100-1/1000 yr.)

Dual instrument or valve failures; hose ruptures; or piping leaks; or human errors.

2 (1/1000-1/10000 yr.)

Combination of instrument failures and human errors; or full-bore failures of small process lines or fittings.

1 (1/10000 yr.)

Multiple instrument or valve failures or human errors; or spontaneous failures of tanks or process vessels.

Frequency


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

Consequence Range

Qualitative Criteria

4 Personnel- Potential for multiple life-threatening injuries or fatalities. Public- Potential for multiple life-threatening injuries or fatalities. Env.- Unconfined release with potential for major environmental impact. Eqpt.- Plant damage/loss value in excess of U.S.$ 100 million.

3 Personnel- Potential for life-threatening injuries or single fatality. Public- Potential for life-threatening injuries or single fatalities. Unconfined release with potential for medium environmental impact. Eqpt.- Plant damage/loss value in the range of U.S.$ 10-100 million.

2 Personnel- Potential for severe injury requiring physician’s care. Public- Potential for severe injuries requiring physician’s care. Env.- Unconfined release with potential for minor environmental impact. Eqpt.- Plant damage/loss value in the range of U.S.$ 1-10 million.

1 Personnel- Potential for injury requiring first aid. Public- odor or noise nuisance to the public. Env.- Contained release with localized impact. Eqpt.- Plant damage/loss value in the range of U.S.$ 100,000-1 million.


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

12.3 HAZOP Matrix: Item No.

Deviation

Cause Consequence Engineering and Administration

Controls

L C R Recommendations

26.23 Maintenance

need to remove condendsate pump from condenser pit

area is inaccessible Unknown 2 4 B 26.23.1: Confirm that a hatch is provided as well as lighting equipment for removal of pumps and other auxiliaries from condenser pit

26.24 Human Factors

high temp in condenser pit

heat stress, potential operator injury

4 2 B 26.24.1: Investigate providing ventilation in condenser pit to ensure adequate ventilation to minimise danger of heat stress to personnel that must enter or work in the condenser pit

26.25 Human Factors

One means of egress is provided from condenser pit

Operating area with potential for personnel to be trapped

4 2 B 26.25.1: Provide an emergency ladder on opposite end of condensate pit from stairs to allow a second means of egress from condenser pit

22.09 Loss of containment

Tube failure in condenser

Salt water in condensate system, contamination, shutdown

Conductivity measurement in hot well QIA MAG10 CQ005 sampling point Continues monitoring on feed condensate system

3 1 C 22.09.1: Ensure preventative maintenance performed on conductivity instruments throughout the plant, maintain warehouse spare instrument, carry out manual sampling and lab analysis every shift

22.21 Wrong material

wrong materials on pump

corrosion, mechanical failures, reduced efficiencies

Periodic cycling of pumps to help prevent corrosion

4 1 C 22.21.1:Vendor to provide verification of homogeneous microstructure of pump material on cooling water system

22.09 Loss of containment

Tube failure in condenser

Salt water in condensate system, contamination, shutdown

Conductivity measurement in hot well QIA MAG10 CQ005 sampling point Continues monitoring on feed condensate system

3 1 C 22.09.1: Ensure preventative maintenance performed on conductivity instruments throughout the plant, maintain warehouse spare instrument, carry out manual sampling and lab analysis every shift

26.01 High flow

both pumps running (2 x100%)

Suck hot well dry on condenser, fill up dearator, blow hot water out of vent dearator, potential personnel injury

LL alarms on hot well, LL switches on hot well (LSMAG10CLO020 shut down pumps), LICA 10

1 2 D 26.01: Team decided no recommendation required


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Item No.

Deviation

Cause Consequence Engineering and Administration

Controls

L C R Recommendations

LAA10CL020 on dearator, three independent HL alarms, control valve in condensate system LCA43AA003 go open

34.03 High flow

bypass to condenser open

Damage turbine Condenser designed for this case HP and LT alarms - 2 out of 3 Dump valve fails closed 10 MAN10AA001

1 2 D 34.03.1: Team decided no recommendation required

47.10 High temperature

fouling of condenser surfaces

loss of heat transfer, bearing wear, lost production

Water treatment of closed water treatment system

1 1 D 47.10.1: Team decided no recommendation required


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13 SYSTEM P&ID


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______________________________________________________________________________ GPGC SOP- 010 of 31 FEB, 2010

14 REFERENCES

This manual should be used in conjunction with the vendor-supplied manuals for the equipment and/or systems. This manual is meant to supplement but never replace or supercede vendor data.

1. P&ID 501088, 501087. 2. System description/ operation instruction (document no. 503221, 501082). 3. Main HAZOP matrix.

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