1

8
th
SEMESTER INDUSTRIAL TRAINING REPORT
(January 2010 to June 2010)



Alstom Projects India Ltd.
Piping Engineering Department (Mechanical)
Plot No. 06, Sector 127,
Noida 201301 (India)






























Ashwani Kumar
B. Tech. 4
th
year
(Mechanical Engg.)
D.A.V. Institute of Engg. & Technology
University. Roll No. 7026111252
Class Roll. No. 564/06
Ashwani872@yahoo.com
Gas Coal Oil
Hydro Nuclear (Conv. Island) Wind
2


ACKNOWLEDGEMENT

First of all, I wish to extend my heartfelt gratitude to Mr. Balmiki Mishra (Sr, Manager
Human Resources), Ms. Anshu Sharma (Sr. Officer Human Resources), Ms.Preethi
Balan (Assistant Manager Human Resources), Mr. Naveen Sharma (Former H.O.D
Plant Arrangement & Piping) and Mr. Ahobala Rao (H.O.D Plant Arrangement & Piping)
for giving me an opportunity to undergo training at Alstom Power, Noida.

I thank my advisor Mr. Naveen Sharma for his continuous in my six months training. He
was always there, to listen and to give advice. He taught me how to ask questions and
express my ideas. He showed me different ways to approach a problem and the need to
be persistent to accomplish any goal. He taught me when I doubted myself, and brought
out the good ideas in me. One thing more, he gives me a golden opportunity to attend
all workshop trainings, which is organized by Alstom.

I would also like to thanks Mr. Ajay Bansal (Sr. Executive at Siemens Power) for guiding
me and boosting me morale at all time. He is man who providing me an opportunity to
build my career in power sector. Thank you Sir.

I am also grateful to my Project Guides Mr. Debashis Biswas (Manager Arrangement &
Piping), and Mr. Tribesh Choudhuri (Manager Arrangement & Piping), Ms. Srujana
Saduvala (lead Engineer Arrangement & Piping), Mr. Avuluri Nagaraju (lead Engineer
Arrangement & Piping) for giving me the opportunity to work under their able
supervision.

A special thanks goes to my Project Guide Mr. Debashis Biswas With his
encouragement and constant guidance, I am able to complete my training successfully.
He was always there, to meet and talk about my ideas and my problems.

Once again I thanks to Mr. Avuluri Nagaraju providing me there own Computer system
to learn P.D.M.S software.

I would also like to thank Mr. Pavan K Devaki (lead Engineer Arrangement & Piping),
Mr. Tarun Kumar Srivastava (lead Engineer Arrangement & Piping), Mr. Vankayala
Jaya Krishna (Engineer), for their required inputs for my projects.

I also extend my sincere thanks to (lead Engineer Arrangement & Piping) Mr. Nadeem
Ahmed (lead Engineer Arrangement & Piping), Mr. Awani Srivastava (lead Engineer
Arrangement & Piping), Mr. Anupam Sengupta (lead Engineer Arrangement & Piping),
Mr. C Chandraiah (lead Engineer Arrangement & Piping), Ashish Dhawan (Engineer
Arrangement & Piping) and (Engineers) Mr. Santosh Das, Mr. Vishwanath Sharma and
Mr.Nipun Goyal, for providing me valuable information for my project.

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I am also grateful to each and every member of the staff of the Piping Engineering
Department in Alstom Power, who have helped me in every way possible during my
training here. Their motivation & help was the key to success of my project.

I sincerely thanks to all my Alstom friends who made my training at Alstom a wonderful
and memorable. I shell always remember these wonderful and memorable time and my
Alstom friends.








Date: 1 July 2010 Ashwani Kumar
4

S. No.

Contents Of Table


Page No.

1.
Introduction about ALSTOM

6
2.
ALSTOM In India

8
3.
Power Plant Cycles

11
4.
Brayton cycle

11
5.
Rankine cycle

13
6.
Combined Cycle Power Plant

16
7.
System Configuration of a Combined Cycle Power
Plant

18
8.
Layout of Combined Cycle Power Plant

18
9.
Introduction to Tallawarra Combined-cycle power plant

19
10.
Tallawarra Single Shaft CCPP-KA26 Power Plant

21
11.
Components used in Combined Cycle Power Plant

22
12.
Heat Balance Diagram

33
13.
Systems

34
14.
Abbreviations and Acronyms

35
15.
KKS: Kraftwerks Kennzeichnungs System

36
16.
KKS Function Key

38
17.
How to read KKS No.

41
18.
Main Steam System

42
19.
Main Condensate System

49
20.
Air Removal System

58
21.
HP Turbine Bypass System

65
22.
IP Turbine Bypass System

70
5

S. No.

Contents Of Table


Page No.

23. LP Turbine Bypass System

75
24. Feed Water Storage and Deaeration System 79
25. Feed Water Preheater System 85
26. HP Feed Water Pump System 90
27.
Fuel Gas Pre Heating System

96
28.
GT Air Cooling System

100
29.
Close Cooling Water System

107
30.
Fuel Gas System

117
31.
Clean Drain System 127
32.
Carbon Dioxide Supply System 133
33.
Hydrogen Supply System 135
34.
Water Supply System 137
35.
Demineralised water Supply system 141
36.
Phosphate Dosing System 145
37.
Ammonia Oxygen Scanveger Dosing 149
38.
Hotwell Sampling Monitoring System 153
39.
Main & Secondary Cooling Water System 157
40.
Water-Steam Cycle Sampling Monitoring System 165







6
Introduction about ALSTOM

ALSTOM, the global leader in power and rail transport, is in the business of designing,
building and servicing technologically advanced products and systems for the world's
energy and transport infrastructure. It builds Power Plants and has supplied around
20% of the worlds total installed capacity in power generation.

ALSTOM builds trains, which run on every continent. It has engineered and built the
TGV, the worlds fastest train, Singapores automatic metro and almost the entire fleet
of metros for the city of Paris.

ALSTOM builds highly complex ships, which includes the recently completed Queen
Mary 2, the largest cruise ship in the world.

ALSTOM's annual sales are around 17 billion. It employs 76,000 people in over 70
countries worldwide. The company serves the energy market through its activities in the
fields of power generation, power transmission and distribution, power conversion and
electrical contracting and the transport market through its activities in rail and marine.

ALSTOM offers its customers a complete range of innovative components, systems and
services covering design and manufacture as well as commissioning and long-term
maintenance and has unique expertise in systems integration, management of projects
and application of advanced technologies.

The ability to offer the broadest scope of power generation systems and equipment in
the industry allows ALSTOM Power to deliver global solutions, from boilers, turbines
and generators to the control systems, pollution control equipment, transformers and all
the other systems needed to make a Power Plant run reliably, efficiently and with low
emissions. In addition to state-of-the-art equipment and systems, ALSTOM Power
provides extended core competencies in services and solutions.

The control system technology is a corner stone of an efficient service support all along
the plant life. ALSTOM offers a comprehensive capability, possessing the broadest
scope of power generation systems, equipment and services in the industry. ALSTOMs
customers enjoy the maximum of options plus the most economical, environmentally
friendly and advanced technologies.

ALSTOM provides a wide range of new energy technologies. E.g. CFB boiler
technology, low emissions firing systems, selective catalytic reduction, and flue gas
desulphurisation and supercritical cycles. Environmentally friendly solutions are also
available for noise control and effluents, which meet the most stringent worldwide
regulations.


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Delivering the products and services, whether a utility, an independent power producer,
or you are in industry, ALSTOM can deliver the products and services.


1. Turnkey Plants
Gas/steam/hydro
2. Turbines
Gas/steam/hydro
3. Generators
Gas/steam/hydro
4. Boilers
For power generation and industry
5. Air Preheater and Heat Exchangers

6. Air Pollution Control Systems

7. Power Plant Control

8. Customer Services
Complete portfolio of service products
Modernization of Power Plant
Long-term operation and maintenance
























8
ALSTOM In India

ALSTOM is the majority shareholder in ALSTOM Projects India Ltd. In India, ALSTOM
is active in two major areas of businesses i.e. Power and Transport.

Commencing its operations in Calcutta in the 1910s and later in Chennai in the 1950s,
ALSTOM in India traces its lineage to English Electric, CEGELEC, AEI, GEC
ALSTHOM, ASEA, HBB, FLAKT and ABB, drawing its strengths from technologies
developed over the years by these companies.

ALSTOM has been a long-term player in India in the energy and transport infrastructure
business, supplying critical electrical and industrial equipment including boilers and
turbines and pollution control equipment for Power Plants, and transmission &
distribution equipment. With its significant presence in the transport sector in India,
ALSTOM provides railway equipment and technology solutions. The Industrial
equipment division with annual sales of 15 Million Euros manufactures rotating
machinery, motors, industrial and domestic fans.

ALSTOM in India helps generate nearly 40% of the total power produced in the country.
In India, ALSTOM companies have together a turnover of about 280 Million Euros with
about 6,500 employees.

In India, ALSTOM is active in two major areas of businesses:

Power:

In Karnataka the Power Sector forms a major part of ALSTOM's business operations in
India, accounting for 59 per cent of its total revenue through its activities as an
Equipment Supplier, Engineering Procurement and Construction Contractor and
Products/Services supplier for central and state public sector utilities or Independent
Power Producers.

ALSTOM's power sector in India specializes in designing & supplying integrated and
cost efficient Steam, Combined Cycle and Hydro Power Plants.

This includes their engineering, procurement & construction; development and supply of
air pollution control systems and equipment. In addition, it also offers a full range of
services in spare parts, repairs & maintenance to improve the reliability and availability
of the plants.

ALSTOMs power sector also offers a complete range of utility & industrial boilers in
India. It has manufacturing locations at Durgapur in West Bengal and Shahabad

With manufacturing location at Kolkata for environment control systems, Alstom's power
sector in India employs more than 1800 people, with annual sales in excess of 125
million euro.
9

A joint venture between Alstom and NTPC has a mandate for the total renovation and
modernization (R&M) business in India and the SAARC countries for thermal Power
Plants and thermal based utilities.

Transport:

ALSTOM's Transport sector is among the leaders in rail transport in the world. Its TGV
needs no introduction.

ALSTOM's transport sector in India is equipped with RDSO approved 'state-of-the-art'
factory at Coimbatore equipped for manufacture, supply, assembly and testing of Power
Electronics & Traction Equipment, Signaling products such as Point Machines, Audio
Frequency Track Circuits etc. The company manufactures world-class traction drives,
auxiliary converters, control electronics, electro-mechanical products and safety
systems.

The factory is ISO 9001- 2000 and ISO - 14001 certified and is located in the industrial
belt with access to component suppliers. The company also has a world-class software
centre at Bangalore handling design of Train Control System and Application Software.
Being members of the ALSTOM Transport Group, there is access to global
technologies. ALSTOM's global transport product range includes TGVs and High Speed
Tilting Train for industry operations, tramways and metros for urban transit and
locomotives, and freight wagons. It also provides train control systems, train life
management services, the railroad maintenance and turnkey or full concession
transportation system solutions.

Research & Innovation:

ALSTOM regards competitive technology as a key element of its business strategy,
both to meet the quality and efficiency expectations of its customers and to achieve its
own financial targets. Research and Development efforts are driven essentially by
current and future market needs in our product areas. This is why our R&D resources
are managed by our businesses, with programs and priorities being defined and refined
by them.

We are continuously improving the performance, functionality and cost-effectiveness of
our products, both through developing new technical solutions or innovative application
of existing elements. Current examples include:

Information and communication technologies are enabling major advances in the
large systems we design, including new means of train signaling, novel designs of
electrical substation monitoring and control, and new services such as remote
maintenance or trading in de-regulated electricity markets.
Power electronic systems are already well known, but development of new circuit
concepts continues to expand their application and penetration, while new materials
10
such as silicon carbide and diamond promise further step changes in the future. We
can now see the real possibility that a majority of the world's electricity will be
actively managed by power electronics in the future.
New materials continue to emerge. Gaining understanding on their behavior remains
a key technological activity, and their application to our product is a critical factor in
improving performance and cost-effectiveness.

Advanced engineering simulation systems, which are key to rapid design and
development timescales. Developments made here are enabling us to improve the
lifetime of mechanical components in steam turbines, and the power outputs of
electrical machines, all of which translate into lower costs for our clients. We continue to
reduce the environmental impact of our products. Specific examples include:
1. Reducing atmospheric emissions through improved power generation efficiencies,
novel combustion systems which inhibit NOx formation in gas turbines, new boiler
schemes for clean coal combustion, and even genuinely zero-emission systems
which capture all the CO2 from fuel,
2. Finding ways to minimise the noise generated by the operation of plant and trains,
by understanding how it is generated so it can be efficiently inhibited,
Protecting the marine environment through initiatives such as the 'clean' passenger
ship which avoids the dumping of waste, or the Oil Sea Harvester which can
efficiently collect spilt oil,
3. Making more efficient, more accessible, more reliable public transport systems
which can provide an attractive travel option to other means,
Embedding environmental impact analysis into the design process, so that products can
be designed for minimal whole life environmental cost
















11
Power Plant Cycles


Brayton cycle:


The Brayton cycle is a thermodynamic cycle that describes the workings of the gas
turbine engine, basis of the jet engine and others.
Brayton cycle has more recently been given to the gas turbine engine. This also has
three components:
A gas compressor
A burner (or combustion chamber)
An expansion turbine




Ideal Brayton cycle:
Isentropic process - Ambient air is drawn into the compressor, where it is
pressurized.
Isobaric process - The compressed air then runs through a combustion
chamber, where fuel is burned, heating that aira constant-pressure process,
since the chamber is open to flow in and out.
Isentropic process - The heated, pressurized air then gives up its energy,
expanding through a turbine (or series of turbines). Some of the work extracted
by the turbine is used to drive the compressor.
Isobaric process - Heat rejection (in the atmosphere).

12
Actual Brayton cycle:
Adiabatic process - Compression.
Isobaric process - Heat addition.
Adiabatic process - Expansion.
Isobaric process - Heat rejection.
Methods to increase power:
Reheat, wherein the working fluidin most cases airexpands through a series of
turbines, then is passed through a second combustion chamber before expanding to
ambient pressure through a final set of turbines. This has the advantage of increasing
the power output possible for a given compression ratio without exceeding any
metallurgical constraints (typically about 1000 C). The use of an afterburner for jet
aircraft engines can also be referred to as reheat; it is a different process in that the
reheated air is expanded through a thrust nozzle rather than a turbine. The metallurgical
constraints are somewhat alleviated enabling much higher reheat temperatures (about
2000 C). Reheat is most often used to improve the specific power (per throughput of
air) and is usually associated with a reduction in efficiency; this is most pronounced with
the use of afterburners due to the extreme amounts of extra fuel used.
Methods to improve efficiency:
Intercooling, wherein the working fluid passes through a first stage of
compressors, then a cooler, then a second stage of compressors before entering
the combustion chamber. While this requires an increase in the fuel consumption
of the combustion chamber, this allows for a reduction in the specific volume of
the fluid entering the second stage of compressors, with an attendant decrease
in the amount of work needed for the compression stage overall. There is also an
increase in the maximum feasible pressure ratio due to reduced compressor
discharge temperature for a given amount of compression, improving overall
efficiency.
Regeneration, wherein the still-warm post-turbine fluid is passed through a heat
exchanger to pre-heat the fluid just entering the combustion chamber. This
directly offsets fuel consumption for the same operating conditions improving
efficiency; it also results in less power lost as waste heat. However, at higher
pressure ratios, the compressor discharge temperature can exceed the exhaust
temperature. Under these conditions, regeneration would be counterproductive.
Therefore, regeneration is only an option when the pressure ratio is sufficiently
low that the exhaust temperature is higher than the compressor discharge
temperature.
A Brayton engine also forms half of the combined cycle system, which combines
with a Rankine engine to further increase overall efficiency.
13
Cogeneration systems make use of the waste heat from Brayton engines,
typically for hot water production or space heating

Rankine cycle:

Common heat sources for power plants using the Rankine cycle are the combustion of
coal, natural gas and oil, and nuclear fission.





The Rankine cycle is sometimes referred to as a practical Carnot cycle as, when an
efficient turbine is used, the TS diagram begins to resemble the Carnot cycle. The main
difference is that heat addition and rejection are isobaric in the Rankine cycle and
isothermal in the theoretical Carnot cycle. A pump is used to pressurize liquid instead of
gas. This requires a very small fraction of the energy compared to compressing a gas in
a compressor (as in the Carnot cycle).
The efficiency of a Rankine cycle is usually limited by the working fluid. Without the
pressure reaching super critical levels for the working fluid, the temperature range the
cycle can operate over is quite small: turbine entry temperatures are typically 565C
(the creep limit of stainless steel) and condenser temperatures are around 30C. This
gives a theoretical Carnot efficiency of about 63% compared with an actual efficiency of
42% for a modern coal-fired power station. This low turbine entry temperature
(compared with a gas turbine) is why the Rankine cycle is often used as a bottoming
cycle in combined cycle gas turbine power stations.
The working fluid in a Rankine cycle follows a closed loop and is re-used constantly.
The water vapor with entrained droplets often seen billowing from power stations is
generated by the cooling systems (not from the closed loop Rankine power cycle) and
represents the waste heat that could not be converted to useful work. Note that cooling
towers operate using the latent heat of vaporization of the cooling fluid. The white
14
billowing clouds that form in cooling tower operation are the result of water droplets
which are entrained in the cooling tower airflow; they are not, as commonly thought,
steam. While many substances could be used in the Rankine cycle, water is usually the
fluid of choice due to its favorable properties, such as nontoxic and unreactive
chemistry, abundance, and low cost, as well as its thermodynamic properties.
One of the principal advantages the Rankine cycle holds over others is that during the
compression stage relatively little work is required to drive the pump, the working fluid
being in its liquid phase at this point. By condensing the fluid to liquid, the work required
by the pump consumes only 1% to 3% of the turbine power and contributes to a much
higher efficiency for a real cycle. The benefit of this is lost somewhat due to the lower
heat addition temperature. Gas turbines, for instance, have turbine entry temperatures
approaching 1500C. Nonetheless, the efficiencies of actual large steam cycles and
large modern gas turbines are fairly well matched.
Processes of the Rankine cycle:



There are four processes in the Rankine cycle, these states are identified by number in
the diagram to the right.
Process 1-2: The working fluid is pumped from low to high pressure, as the fluid
is a liquid at this stage the pump requires little input energy.
Process 2-3: The high pressure liquid enters a boiler where it is heated at
constant pressure by an external heat source to become a dry saturated vapor.
Process 3-4: The dry saturated vapor expands through a turbine, generating
power. This decreases the temperature and pressure of the vapor, and some
condensation may occur.
Process 4-1: The wet vapor then enters a condenser where it is condensed at a
constant pressure to become a saturated liquid.
15
In an ideal Rankine cycle the pump and turbine would be isentropic, i.e., the pump and
turbine would generate no entropy and hence maximize the net work output. Processes
1-2 and 3-4 would be represented by vertical lines on the T-S diagram and more closely
resemble that of the Carnot cycle. The Rankine cycle shown here prevents the vapor
ending up in the superheat region after the expansion in the turbine,[1] which reduces
the energy removed by the condensers.

Rankine cycle with reheat:





In this variation, two turbines work in series. The first accepts vapor from the boiler at
high pressure. After the vapor has passed through the first turbine, it re-enters the boiler
and is reheated before passing through a second, lower pressure turbine. Among other
advantages, this prevents the vapor from condensing during its expansion which can
seriously damage the turbine blades, and improves the efficiency of the cycle, as more
of the heat flow into the cycle occurs at higher temperature.

Regenerative Rankine cycle:
The regenerative Rankine cycle is so named because after emerging from the
condenser (possibly as a subcooled liquid) the working fluid is heated by steam tapped
from the hot portion of the cycle. On the diagram shown, the fluid at 2 is mixed with the
fluid at 4 (both at the same pressure) to end up with the saturated liquid at 7. This is
called "direct contact heating". The Regenerative Rankine cycle (with minor variants) is
commonly used in real power stations.


16
Another variation is where 'bleed steam' from between turbine stages is sent to
feedwater heaters to preheat the water on its way from the condenser to the boiler.



These heaters do not mix the input steam and condensate, function as an ordinary
tubular heat exchanger, and are named "closed feedwater heaters".
The regenerative features here effectively raise the nominal cycle heat input
temperature, by reducing the addition of heat from the boiler/fuel source at the relatively
low feedwater temperatures that would exist without regenerative feedwater heating.
This improves the efficiency of the cycle, as more of the heat flow into the cycle occurs
at higher temperature.
Combined Cycle Power Plant:

When two thermal cycles are combined in a single power plant, the efficiency that can
be achieved is higher than that of one cycle alone.

Normally, when two cycles are combined, the cycle operating at higher temperature
level is called the topping cycle. The waste heat it produces is then used in a second
process that operates at a lower temperature level and is therefore called the bottoming
cycle.

The flue gas leaving the gas turbine after expansion in an open process still contains a
lot of thermal energy, which should be used efficiently. This can be done by installing a
water/steam circuit with a steam turbine downstream of the gas turbine process.

The Combined Cycle Power Plant (CCPP) utilizing the Brayton Cycle gas turbine and
the Rankine Cycle steam system with air and water as working fluids achieves efficient,
17
reliable, and economic power generation. The combination of the gas turbine Brayton
Cycle and the steam power system Rankine Cycle complement each other to form



efficient combined-cycles. The Brayton Cycle has high source temperature and rejects
heat at a temperature that is conveniently used as the energy source for the Rankine
Cycle. Other working fluids (organic fluids, potassium vapor, mercury vapor, and others)
have been applied on a limited scale.











18

System Configuration of a Combined Cycle Power Plant



Layout of Combined Cycle Power Plant








19



Introduction to Tallawarra Combined-cycle power plant




TRU energys Tallawarra combined-cycle plant

The Tallawarra project was commissioned shortly after Kwinana, achieving handover to
the owner TRUenergy in January of this year. Headquartered in Melbourne, TRUenergy
has more than 1.2 million electricity and gas customers. In addition to Tallawarra, it
owns the Yallourn power plant and the Hallett power station.

The plant is the first baseload plant to be built in New South Wales (NSW) in 25 years,
and built on a 600 ha site where a coal-fired plant was decommissioned in the 1990s.
The new plant, however, has a much smaller footprint and blends in with the beautiful
landscape around Lake Tallawarra.

The project was given the Notice To Proceed in June 2006. On site, there was a high
level of involvement from local construction companies. During construction, one
challenge was to ensure that a green layer, which covered rubble potentially containing
asbestos from the old power station was not penetrated. Construction works had to
closely follow a careful design of underground services, deep foundations and pump
pits.
20

The plant is built on part of the original site and uses the existing cooling water
structures of the old power station. This created further challenges in meeting, for
example, the requirements of the Building Code of Australia in terms of safety distances
and access. Nevertheless, high standards for health and safety were demonstrated
during plant construction. Environmental performance is a top priority for TRUenergy,
which is committed to reducing its greenhouse gas emissions by 60 per cent by 2050.
The company therefore wanted the most efficient combined-cycle gas fired power plant
possible.


Tallawarra uses the latest GT26 turbine rating. This unit has an improved compressor
for increased mass flow and better seals for reduced leakage of air to deliver an
additional 7 MW compared to the previous machine.

The GT26 is connected to a hydrogen-cooled generator and a steam turbine on a single
shaft. The plant is connected to the local distribution 132 kV grid, which is
interconnected to the NSW 330 kV grid via substations.

The gas turbine has a rated output of 288 MW. Exhaust gas leaving the gas turbine is
fed into a triple pressure reheat HRSG, which generates the steam that is fed to a triple
casing steam turbine to generate an additional 160 MW. The steam turbine is a three-
casing design with HP, IP and LP sections that are connected to the generator via a
self-synchronizing clutch.

The steam turbine has a direct seawater cooled condenser, which uses water from Lake
Tallawarra the lake is a coastal lagoon.























21
Tallawarra Single Shaft CCPP-KA26 Power Plant






















22
Components used in Combined Cycle Power Plant


1. Heat Recovery Steam Generator (HRSG):
A heat recovery steam generator or HRSG is an energy recovery heat exchanger that
recovers heat from a hot gas stream. It produces steam that can be used in a process
or used to drive a steam turbine.
HRSGs consist of three major components. They are the Evaporater, superheater and
Economizer. The different components are put together to meet the operating
requirements of the unit. See Modular HRSG.




HRSG


A common application for an HRSG is in a combined-cycle power station, where hot
exhaust from a gas turbine is fed to an HRSG to generate steam, which in turn drives a
steam turbine.

This combination produces electricity more efficiently than either the gas turbine or
steam turbine alone.


23
2. Turbine:

A steam turbine is a mechanical device that extracts thermal energy from pressurized
steam, and converts it into rotary motion. The basic parts of a turbine are the rotor,
which has blades projecting radially from its periphery; and nozzles, through which



Turbine

the gas is expanded and directed. The conversion of kinetic energy to mechanical
energy occurs on the blades.


3. Main Condenser component:

The major parts of the main condenser are the condenser neck, Hotwell and the
condenser shell with the condenser tubes arranged in tube bundles and the water
boxes.
The condenser is designed with divided water boxes. This allows one half of the
condenser to be taken out of operation for inspection or cleaning, while the other half of
the condenser is in operation.
Sacrificial anodes are installed in the water boxes for corrosion protection. The
condenser tubes are cleaned with sponge balls on the waterside by an automatic
condenser tube cleaning system. The condensate is collected in the hotwell, which is
large enough to ensure trouble-free operation of the condensate pumps at any ST load.
24
4. Condenser:
In thermal power plants, the primary purpose of a surface condenser is to condense the
exhaust steam from a steam turbine to obtain maximum efficiency and also to convert
the turbine exhaust steam into pure water (referred to as steam condensate) so that it
may be reused in the steam generator or boiler as boiler feed water.

Condenser


The main heat transfer mechanisms in a surface condenser are the condensing of
saturated steam on the outside of the tubes and the heating of the circulating water
inside the tubes.

Thus for a given circulating water flow rate, the water inlet temperature to the condenser
determines the operating pressure of the condenser. As this temperature is decreased,
the condenser pressure will also decrease. As described above, this decrease in the
pressure will increase the plant output and efficiency.

Due to the fact that a surface condenser operates under vacuum, non-condensable
gases will migrate towards the condenser. The non-condensable gases consist of
mostly air that has leaked into the cycle from components that are operating below
atmospheric pressure (like the condenser). These gases can also form by the
decomposition of water into oxygen and hydrogen by thermal or chemical reactions.
In vacuum condition or at low pressure the boiling temperature of water is decrease.

These gases must be vented from the condenser for the following reasons:

1. The gases will increase the operating pressure of the condenser. Since the total
pressure of the condenser will be the sum of partial pressures of the steam and
the gases, as more gas is leaked into the system, the condenser pressure will
rise. This rise in pressure will decrease the turbine output and efficiency.
25

2. The gases will blanket the outer surface of the tubes. This will severely decrease
the heat transfer of the steam to the circulating water. Again, the pressure in the
condenser will increase.

3. The corrosiveness of the condensate in the condenser increases as the oxygen
content increases. Oxygen causes corrosion, mostly in the steam generator.
Thus, these gases must be removed in order to extend the life of cycle
components.



5. Vacuum system:
For water-cooled surface condensers, the shell's internal vacuum is
most commonly supplied by and maintained by an external steam jet ejector system.
Such an ejector system uses steam as the motive fluid to remove any non-condensable
gases that may be present in the surface condenser. The

Venturi effect, which is a particular case of Bernoulli's principle, applies to the operation
of steam jet ejectors. Motor driven mechanical vacuum pumps, such as the liquid ring
type, are also popular for this service.

6. Start-up Ejector:

The start-up ejector is a quick start-up single stage steam jet air
ejector with a silencer. It is able to reduce the pressure in the vacuum system within
short time, to allow a quick start-up of the steam turbine bypass.






26
7. Service Ejector:

The service ejector is a two stage steam jet air ejector with inter and
after condenser. It is able to continuously improve and maintain the vacuum after the
start-up ejector achieved the suitable operating vacuum. The condensed motive steam
and adhered steam of the suction flow is recovered in the inter and after condenser.
The condensate of the second stage is returned through a steam trap back to the first
stage condenser and the condensate of the first stage is returned via a siphon to the
flash box.

8. Shutoff valves:

Safety shutoff valves are safety valves used to close a line and stop the flow of material.
Some types are manually closed; others are automated to act when a preset condition
(such as a failure in the system) occurs.
9. Condensate extraction pump:
Condensate extraction pumps to extraction the condensate from the
condenser hot well and feed it into the feed water tank.

10. Flash box:
High-energy water and steam flows from drains are expanded and
separated into steam and condensate in the separate flash box. The flash box is
connected to the steam and condensate side of the condenser.
27
11. Control valves:


Through a single seat, two-port globe valve
Control valves are valves used to control conditions such as flow, pressure,
temperature, and liquid level by fully or partially opening or closing in response to
signals received from controllers that compare a "set point" to a "process variable"
whose value is provided by sensors that monitor changes in such conditions.
The opening or closing of control valves is done by means of electrical, hydraulic or
pneumatic systems. Positioners are used to control the opening or closing of the
actuator based on Electric, or Pneumatic Signals.
12. Feed water Tank and Deaerator:

The feedwater tank and the deaerator are a combined unit. The deaerator dome is
arranged on top of the cylindrical, horizontally mounted feedwater tank. The feedwater
tank serves as the storage tank for the water steam cycle. The elevation of the
feedwater tank ensures the net positive suction head (NPSH) of pump required by the
feedwater and feedwater preheating pumps. With the direct contact deaerator in the
deaerator dome, condensate is heated up and deaerated with steam (evaporated
feedwater when entering the feedwater tank) from the feedwater preheating system and
with pegging steam.

28








































Feedwater Tank and Deaerator





29
13. Feedwater Temperature:

The feedwater needs to be preheated for two reasons.

1
st
:
The temperature in the feedwater tank has to be higher than the condensate
temperature in order to enable the deaeration of the condensate sprayed into the
feedwater tank.

2
nd
:
The cooling down of the GT exhaust gas at the HRSG economizer below the sulfuric
acid dew point has to be avoided because of corrosion issues.
The feedwater temperature setpoint is automatically adjusted accordingly. In normal
operation, the deaerated condensate is preheated in the HRSG economizer and
circulated by means of the feedwater preheating pumps. If required during special
operation modes of the power plant (i.e. start-up) and for redundancy purposes to the
feedwater preheating system, steam will be taken from the cold reheat line and used as
pegging steam.


14. Feedwater Preheater Pump:

The feedwater preheater pump is a horizontal, single stage centrifugal pump. It is
connected by a coupling to the electric motor. The electric motor is a three-phase
induction type and is powered by the plant low voltage board. Motor cooling is ensured
by the motor internal ventilation device. The feedwater flow through the feedwater pump
also contributes to cooling of the pump. For sufficient cooling, the required minimum
feedwater flow through the pump is ensured by the automatic recirculation check valve.


15. Priming of centrifugal pump:

All centrifugal pumps must be primed by filling them with water before they can operate.
The objective of priming is to remove a sufficient amount of air from the pump and
suction line to permit atmospheric pressure and submergence pressure to cause water
to flow into the pump when pressure at the eye of the impeller is reduced below
atmospheric as the impeller rotates.
If you don't prime the pump and start the pump, then you will not get the flow, pump will
run dry and ultimately damage the mechanical seal or gland packing.



30
16. Fuel Gas Heaters:
Fuel Gas Heaters can be used to preheat natural gas to keep gas above the dew point
before combustion.
Preheating of the fuel gas in order to achieve a higher thermal efficiency of the gas
turbine.

17. Once Through Cooler:

The OTC is a surface heat exchanger. The hot air entering the vessel is cooled down.
The cooling water entering the vessel is heated up, evaporated, and superheated. The
OTC is designed with helically winded tubes. The air flows on the outside of the tubes
and transfers the heat to the water and steam inside the tubes.

18. Fuel Gas Main Inlet Valve (EKA):

The purpose of valve EKA01 is to isolate the plant system from the pipeline system. For
emergency cases, this spring-loaded quick shut-off valve can be closed directly from the
main control room emergency board.

For opening it is necessary to open first the bypass valve in order to equalize the
pressure of the pipeline system and the plant fuel gas system.

To prevent damages to the system, the valve can only be opened locally. The
RELEASE TO OPEN signal must be sent from the DCS first. The valve closes
automatically at a fuel gas pressure of approximate 7 bars due to low pipeline pressure.
A high-pressure alarm is indicated in the control room at 180 bar a, low pressure at 36
bar a.

19. Fuel Gas Liquid Dust Separators (Gas Scrubber) (EKB):

The fuel gas liquid dust separators (EKB) are equipped with a condensate-collecting
tank (EKR).

The redundant liquid dust separators with vane pack and a cartridge filter stage
(EKB10/20) used for liquid and dust separation (efficiency: liquids and dust 99.5% 5
m).

Any liquid separated in the babble plate or in the coalescer filter stage is automatically
discharged via a condensate trap to the condensate-collecting tank.





31
20. Fuel Gas Dew Point Heater Station (EKC10/20)


The redundant fuel gas dew point heaters are installed upstream the gas pressure-
reducing station. The gas is heated up to fulfill dew point design criteria of the system
and to meet the gas turbine requirements regarding the fuel gas temperature.





The dew point heating system mainly consists of:
1. Water-bath
2. Gas burners
3. Burner gas reducing system
4. Gas temperature control valve
5. Local control system

To heat up the fuel gas, hot water generated by the gas burner is kept on a constant
temperature of 90C.

The heaters (one in operation and one standby) are driven by natural gas from the gas
pipeline that is reduced to the required level.

Each gas/water heat exchanger is equipped with vent and drain possibilities, gas-in-
water detection device (level indication), local gas pressure indication, local gas
temperature indication, thermal relief valve.



32
21. Fuel Gas Pressure Reducing Station (EKD)

The redundant fuel gas pressure reducing station mainly consists of two pressure
control valves and a overpressure slam-shut valve each run.

In case of high supply pressure, the pressure control valves regulate the downstream
pressure to gas turbine requirements.

22. Fuel Gas Dust Filter (MBP)

The fuel gas dust filters are designed as 2100% cartridge type filter and act as a final
barrier for the gas turbine. All parts downstream the filter elements are made from
stainless steel.

23. Fuel Gas Efficiency Pre-Heater (EKC10)

The fuel gas efficiency pre-heater is designed as tube/shell water/gas heat exchanger. It
is used to heat-up the fuel gas to about 150C for efficiency increase.
Hot water from the water/steam cycle is used as heating medium. The heat-input is
controlled by the DCS.
To prevent fuel gas entering the water/steam cycle in case of a tube break a gas
separator is installed in the hot water return line. Separator and heat exchanger are
equipped with gas detection devices used to give alarm in case of a tube break.

24. Protection System:

The fuel gas system is protected against overpressure by mechanical devices (slam-
shut valve and monitor pressure control valve fail safe close)

25. Over pressure Protection:

The maximum gas pressure at the plant boundary is defined at 166 bar a. Therefore,
the system is designed for 180 bar a from the plant boundary up to the skid outlet valve
of the pressure-reducing skid. Downstream the pressure-reducing skid, the system is
designed for 61 bar a.

The following protection measures are installed:
1. All components are equipped with safety valves for thermal expansion.
2. Upstream each pressure-reducing valve (EKD) slam-shut valves are installed.
3. Over-temperature Protection at the dew point heater


33
Heat Balance Diagram

34














































S. No.

Systems

1.

Main Steam System
2.

Main Condensate System
3.

Air Removal System
4.

HP Turbine Bypass System
5.

IP Turbine Bypass System
6.

LP Turbine Bypass System
7.

Feed Water Storage and Deaeration System
8.

Feed Water Preheater System
9.

HP Feed Water System
10.

Fuel Gas Pre Heating System
11.

GT Air Cooling System
12.

Close Cooling Water System
13.

Fuel Gas System
14.

Clean Drain System
15.

Carbon Dioxide Supply System
16.

Hydrogen Supply System
17.

Water Supply System
18.

Dematerialized water Supply system
19.

Phosphate Dosing System
20.

Ammonia Oxygen Scanveger Dosing
21.

Howell Sampling Monitoring System
22.

Main & Secondary Cooling Water System
23.

Water-Steam Cycle Sampling Monitoring System
35
Abbreviations and Acronyms

1 FWT Feedwater Tank
2 GT Gas Turbine
3 HP High Pressure
4 HRSG Heat Recovery Steam Generator
5 IP Intermediate Pressure
6 LP Low Pressure
7 MCW Main Cooling Water
8 PFUP Process Function Plans
9 ST Steam Turbine
10 WSC Water Steam Cycle
11 CCW Closed Cooling Water
12 LCP Local Control Panel
13 PLC Programmable Logic Control
14 OTC Once Through Cooler
15 PLS Protective Load Shedding
16 PFUP Process Function Plans
17 PHR Preheater
18 FG Function Group
19 SCWS Secondary Cooling Water System
20 CCWS Closed Cooling Water System
21 H2 Hydrogen Gas cooled GT/St Generator
22 Air Air cooled (GT/ST) Generator
23 MCR Main Control Room
24 P&ID Process and Instrumentation Diagram
25 PLST Protective Load Shedding Trip
26 KKS Kraftwerks Kennzeichnungs System
27 WTP Water Treatment Plant
28 RWTP Raw Water Treatment Plant
29 DMWTP Decimalized Water Treatment Plant
30 WWTP Waste Water Treatment Plant
31 DCS Distributed Control System

36
KKS: Kraftwerks Kennzeichnungs System


KKS relevant symbols in P&ID's and principle sketches:

In P&I diagrams the following symbols to indicate KKS code and limit functions and
piping sections are recommended.

S.No Symbols Description
1

The symbol "pin with empty head" is
used to identify the limits of functions
and sub-functions

2
The symbol "pin with full head" is used to
identify the limits of piping sections

3

Reducers are assigned to the piping with
the larger diameter.They need not be
shown on P&ID`s.


4

The symbol "flag" is used for the
identification of pipings,

The direction of the flag shows the
directionof the medium flow.

5

The extended "flag" symbol is used for
the identification of a pipe where medium
flow direction alters according to the
operating conditions

6

The symbol pointer between connected
systems represented on different P&IDs
Breakdown level Function of the
connected system as minimum
information.


37
7

The symbol "I & C - circuits" (DIN 19227,
sheet 1)
Is used to represent measuring
circuits.
KKS-code for measuring circuits



KKS-Introduction (Identification System for Power Stations)

1 Purpose and Area of application:

The power plant identification system is applied to clearly identify plants, systems, parts
and components to their purpose, type and location. The contents are in accordance
with "KKS identification systems for Power Stations" issued by VGB Kraftwerkstechnik
GmbH Essen.

2. Requirements:

In order to perform the set tasks the identification system must be capable of satisfying
the following requirements:
1. Uniform identification for all types of power stations and any connected processes
2. Sufficient capacity and detail for identification of all systems, components and
structures
3. Sufficient capacity for extension to accommodate new technologies
- Consistent identification for planning, licensing, construction, operation, maintenance
and waste management
4. Interdisciplinary applicability to mechanical engineering, civil engineering, electrical
and instrument & control engineering combined with ability to identify according to
process functions, points of installation and locations
5. Consideration of national and international standards,
6. Non-language-based coding to ensure international usability,
7. Application in computer data processing

3. Structure and application:

The KKS consists of three types of identification:
1. The process-related code identifies installations and equipment according to their
assigned task in the power plant process,
2. The point of installation code identifies the points of installation within an installation
unit (e.g. cubicles, consoles, panels),
3. The location code identifies the rooms and floors, or other installation sites, for
installations and equipment in building structures.
38
A uniform identification structure, with a maximum of four breakdown levels, was
created for all three types; the units referred to becoming smaller from left to right.



KKS Function Key


S.No. Key
Description

1.
G Water supply and disposal

2.
GA Raw water supply

3.
GAC Piping and channel system.

4.
GAD Storage system

5.
GCK Piping system, temporary storage system, pump system for main fluid

6.
GHC Distribution systems after treatment (demineralization)

7.
GKB Storage, forwarding, distribution system

8.
L Steam water cycle

9.
LAA Storage, deaeration (incl. feedwater tank)

10.
LAB Feedwater piping system (excl. feedwater pump and feedwater
heating system)

11.
LAC Feedwater pump system

12.
LAF IP desuperheating spray system

13.
LAE HP desuperheating spray system

14.
LBA Main steam piping system

15.
LBB Hot reheat piping system

16.
LBC Cold reheat piping system

17.
LBD Extraction piping system

39
18.
LBF Overpressure limitation and safety equipment incl. water injection and
pressure measuring device

19.
LBH Start-up steam system, shutdown steam system

20.
LBS Extraction steam piping system for main condensate heating

21.
LBG Auxiliary steam piping system

22.
LCA Main condensate piping system (excl. main condensate pump
system, LP feedwater heating system, condensate polishing plant)

23.
LCB Main condensate pump system

24.
LCC Main condensate heating system

25.
LCH HP heater drains system.

26.
LCJ LP heater drains system.

27.
LCE Condensate desuperheating spray system

28.
LCQ Steam generator blow down system

29.
LCM Clean drains system (collecting and return system)

30.
LFN Proportioning system for feedwater, condensate system, incl.
proportioning in boiler and turbine area

31.
M Main Machine sets

32.
MAG Condensing system

33.
MAJ Air removal system

34.
MAN Turbine bypass station, incl. desuperheating spray system

35.
MAL Drain and vent systems

36.
MBH Cooling and sealing gas system

37.
MBN Fuel supply system (liquid)

38.
MBP Fuel supply system (gaseous)


40
39. E
Conventional fuel supply and residual disposal

40. EKT
Heating medium system

41. EKR
Residues removal system

42. P
Cooling water system

43. PAB
Circulating (main cooling) water piping and culvert system

44. PAH
Condenser tubes cleaning system, incl. all appurtenances

45. PCB
Piping and culvert system

46. PGA
Closed cooling water piping system (forward)

47. PGB
Closed cooling water piping system (return)

48. PGC
Closed cooling water pump system.

49. PGF
Pressure system

50. PGL
Closed cooling water system for main groups *G*, *L* and *P*

51. PGM
Closed cooling water system for main groups *B*, *M*, and *X*

52. PGQ
Closed cooling water system for main groups "Q" and "S"

53. PUN
Proportioning equipment

54. PUG
Debris filter equipment

55. QJK
Gas supply and distribution system CO2 (carbon dioxide)

56. QJF
Chilled water systems for conventional area

57. QLC
Condensate system

58. QLA
Feedwater system

59. QCC
Hydrazine supply and distribution

60. QCE
Ammonia supply and distribution

61. QCD
Phosphate supply and distribution

41
How To Read KKS No.














---------------------------------------------------------------------------------------------------------------------















---------------------------------------------------------------------------------------------------------------------














42
1. Main Steam System


43





44

45



46

1. Main Steam System

Purpose:

The system fulfils the following tasks:
1. Transferring of the HP steam from the HRSG to the steam turbine
2. Transferring of the IP steam from the HRSG to the steam turbine
3. Transferring of the LP steam from the HRSG to the steam turbine
4. Transferring of the cold reheat steam from the HP steam turbine outlet and the
HP bypass discharge line to the HRSG reheat section
5. Providing the ejector system with motive steam
6. Providing the gland steam system of the steam turbine with steam
7. Providing the deaerator with pegging steam

Description of Main Steam System:

The HP steam taken from the HRSG HP superheater is fed through the HP steam line to
the HP Steam turbine.

This HP steam expands in the HP steam turbine and leaves the turbine as cold reheat
steam.

While the steam turbine is not able to take over the whole steam. The HP steam is fed
to the HP steam bypass station. In the HP bypass station the HP steam is conditioned
down to the cold reheat steam pressure and temperature level. The steam is also fed
into the cold reheat steam line.

The cold reheat steam is fed back to the HRSG where it is mixed to the IP steam and
reheated in the IP superheater.

The hot reheat steam (IP steam level) taken from the HRSG IP superheater is fed
through the IP steam line to the IP section of the steam turbine where it expands and
leaves to the LP section of the turbine.

While the steam turbine is not able to take over the whole steam (for example during
start-up) the IP steam is fed to the IP steam bypass station and dumped into the
condenser.

The LP steam taken from the HRSG LP superheater is fed through the LP steam line to
the LP section of the steam turbine where it expands and leaves to the condenser.

While the steam turbine is not able to take over the whole steam (for example during
start-up) the LP steam is fed to the LP steam bypass station and dumped into the
condenser.

47



Table: 1






Sr.
No.

KKS

Name

Fluid

Dia.
mm
Design
Pr.(bar)
Oper.
Pr.
(bar)
Design
Temp.
( C)
Temp
Oper.
( C)

Material

1.

18LBA50BR001
High
Pressure
Steam
Line

Steam

300

153

138.4

572

566
9Cr-
1Mo-V
Alloy
Steel

2.

18LBC10BR001

Cold
Reheat
Steam
Line

Steam

500

39

31

460

351
2
Cr Mo
Alloy
Steel

3.

18LBC10BR004

Cold
Reheat
Steam
Line

Steam

500

39

31

420

351
1
Cr Mo
Alloy
Steal

4.

18LBA41BR001
Intermedi
ate Pr.
Steam
Line
(HRS)

Steam

450

34

28

572

566
9Cr-
1Mo-V
Alloy
Steel

5.

18LBA41BR001
Intermedi
ate Pr.
Steam
Line
(HRS)

Steam

450

34

28

572

566
9Cr-
1Mo-V
Alloy
Steel

6.

18LBA10BR001
Low
Pressure
Steam
Line

Steam

350

7.50

4.97

305

289
Carbon
Steel
48
Interface to other Systems:


1. HP steam coming from the HRSG at the HP superheater steam outlet.
2. HP steam exits to the HP steam turbine.
3. HP steam exits to the HP bypass station (LBF).
4. IP steam coming from the HRSG at the IP superheater steam outlet.
5. IP steam exits to the IP steam turbine.
6. IP steam exits to the IP bypass station (MAN40).
7. Cold reheat steam coming from the HP steam turbine outlet.
8. Cold reheat steam coming from the HP bypass station (LBF).
9. Cold reheat steam exits to gland steam system of the steam turbine
(System MAW).
10. LP steam coming from the HRSG at the LP superheater steam outlet.
11. LP steam exits to the LP steam turbine.
12. LP steam exits to the LP bypass station (MAN10).

Main steam lines:

The system consists of the following main steam lines:

1 HP steam lines.
18LBA50BR001
18LBA50BR002
2 IP steam lines (HRH).
18LBA40BR001
18LBA40BR002
18LBA41BR001
18LBA41BR002
18LBA42BR001
18LBA42BR002
3 Cold reheat steam lines.
18LBC10BR001
18LBC10BR002
18LBC10BR003
18LBC10BR004
18LBC10BR005
4 LP steam lines.
18LBA10BR001
18LBA10BR002
18LBA10BR003




49
2. Main Condensate System


50








51







52




53








54
2. Main Condensate System

Purpose:

The system fulfils the following tasks:
1. Condensing the steam from the steam turbine exhaust and bypass stations
2. Delivering the main condensate from the hot well to the deaerator / feedwater
tank
3. Delivering condensate to the bypass stations for injection
4. Delivering condensate to the flash box and the steam turbine exhaust hood spray
system for injection
5. Collecting non-condensable gases for the extraction to atmosphere
6. Collecting condensate from the steam turbine drains, the ejector system and the
gland steam system
7. Compensating water losses with demineralized water (make-up water)
8. Controlling the water level in the hot well
9. Ensuring the required minimum flow rate through the condensate pumps
10. Ensuring the required minimum flow rate through the service ejector steam
condenser.

Description of Main Condensate System:


The steam produced in the HRSG enters mainly trough the ST or the bypass stations
into the condenser neck and is guided to the condenser tubes.
The cooling water is forced by the pumps of the main cooling water system through the
condenser tubes.

The steam condenses on the outside of the condenser tubes and transfers its heat to
the cooling water. The condensate is collected in the hot well.

Condensed water from the steam turbine drains, the gland steam system and the
service ejectors is collected in the flash box and is guided also into the hot well. The
condensate is delivered from the hotwell to the deaerator / feed water tank by 2 x 100%
condensate pumps. The part of the condensate extracted as injection water for the
steam conditioning in the bypass stations, the flash box and the ST returns back to the
hotwell.

The main amount of the condensate is fed through the two stage condensers of the
service ejector in operation (2 x 100% service ejectors) in order to remove the
condensation heat of the motive steam for the service ejectors. Downstream the service
ejector the condensate is fed through the condenser of the gland steam system.

Downstream the gland steam condenser the condensate flow is split into the discharge
flow transferred to the deaerator / feed water tank and the recirculation flow returned to
the hotwell via the flash box.
55

The discharge flow is controlled by condensate discharge control valve depending on
the water level in the hotwell.

The recirculation flow is adjusted by the condensate recirculation control valve
depending on the position of the discharge control valve, ensuring the required
minimum flow through the condensate pump and the service ejector and gland steam
condenser.

Finally the condensate is fed into the deaerator / feed water tank, from there it is
delivered again to the HRSG for steam production.



The system consists of the following main components:

1 Main condenser (18MAG01AC001)
2 Hot well (18MAG03BB001)
3 Condensate pumps
18LCB10AP001
18LCB20AP001
4 Flash box 18MAG04AC001
5 Pump vent lines
18LCB10BR201
18LCB20BR201
18LCB40BR201
6 Pump discharge line shut-off valves
18LCA11AA002
18LCA12AA002
7 Condensate discharge control valve (18LCA30AA002)
8 Condensate recirculation control valve (18LCA31AA002)
9 Service make-up water shut-off valve (18LCP30AA001)











56
Sr.
No.

KKS

Name

Fluid

Dia.
mm
Design
Pr.(bar)
Oper.
Pr.
(bar)
Design
Temp.
( C)
Temp
Oper.
( C)

Material

1.

18LBA10BR001
Low
Pressure
Steam
Line

Steam

350

7.50

4.97

305

289
Carbon
Steel

2.

18LCA01BR001
Inlet to
Condensat
e pump


Steam/
Water

400

1.50

0.04

95

28.3

Carbon
Steel

3.

18LCA01BR002
Inlet to
Condensat
e pump


Steam/
Water

300

1.50

0.04

95

28.3

Carbon
Steel

4.

18LCA11BR001
Outlet of
Condensat
e pump


Steam/
Water

200

16

15

95

28.4

Carbon
Steel

5.

18LCA20BR001

Inlet to
service
Ejector

Steam/
Water

250

16

15

95

28.4

Carbon
Steel

6.

18LCA20BR002

Inlet to
service
Ejector


Steam/
Water

200

16

15

95

28.4

Carbon
Steel

7.

18LCA20BR022

Outlet of
service
Ejector


Steam/
Water

200

16

15

95

28.4

Carbon
Steel

8.

18LCA30BR002


Outlet of
Gland
steam
condenser


Steam/
Water


200


16

15

95


28.4

Carbon
Steel


9.

18LCA30BR003


Inlet to
feed water
tank

Steam/
Water


200


16

15

95

28.4

Carbon
Steel

57

10.

18MAJ20BR01
1

Inlet to
flash tank

Steam/
Water


50

0.40

0.50

110

60

Carbon
Steel



11.



18LCE11BR001

Condensat
e
desuperhe
ating spray
line

Steam/
Water


25


16



95



Stainles
s Steel
316L


12.

18LCB40BR201


Inlet to
flash tank

Steam/
Water

25

1.50 10

110

28.4

Carbon
Steel

13.

18LCB10BR201

Inlet to
flash tank

Steam/
Water

25

1.50 10 110 28.4

Carbon
Steel


Table: 2



Interfaces to other Systems:

1. LP steam enters into the condenser neck from the steam turbine exhaust.
2. Expanded and desuperheated IP/LP steam enters into the condenser neck
from the IP Bypass station and the LP Bypass Station.
3. Non-condensable gases exit through the condenser evacuation line to the
start-up ejector and service ejectors.
4. Cooling water is fed from and returned to the Main Cooling Water System
(PAB) through the condenser tubes.
5. Steam and water enters from the steam turbine internal drains into the flash
box.
6. Demineralized water enters into the condenser from the Demineralized Water
System (GHC) through the service make-up water line and into the flash box
through the emergency make-up water line.
7. The condensate flows through the inter/after condensers of the service
ejectors (MAJ) and through the condenser of the gland steam system
(MAW30) and exits to the deaerator / feedwater tank (LAA). The excess
condensate exits to the waste water system (GMA).





58
3. Air Removal System


59


60




61
3. Air Removal System

Purpose:

The system fulfils the following tasks:
1. Evacuating of the steam turbine, condenser neck, condenser, flash box,
deaerator and feedwater tank during start-up of the plant
2. Venting of non-condensable gases from the deaerator and the condenser during
normal operation

Description of Air Removal System:

The air removal system (ejector system) sucks the non-condensable gases out of the
condenser and vents them to atmosphere.
The single stage start-up ejector is used for start-up evacuation. It serves
for the fast removal of higher amounts of non-condensable gases and the pressure
reduction in the condenser from atmospheric pressure down to the operation range of
the service ejector.
The service evacuation is carried out by one of the 2 x 100% two stage service ejector,
with inter and after condenser. The service ejector serves to vent the non-condensable
gases entering the water steam cycle during normal operation.
Start-up and service ejector require motive steam with a certain pressure
for their operation. This motive steam is taken from the cold reheat steam line and
throttled down to the required pressure by the related steam control valves upstream
the ejectors. The motive steam of the start-up ejector is vented together with the non-
condensable gases to atmosphere. The motive steam of the service ejector condenses
in the two-stage condenser. The condensed steam is returned to the process via the
flash box and the condenser hotwell.


Interfaces to other Systems:

1. Motive steam coming from the cold reheat steam line of the main steam
system (LBA).
2. Non-condensable gases enter from the condenser (LC).
3. Steam/non-condensable gases mixture exits through the start-up ejector
silencer to atmosphere.
4. Drain condensate form the start-up ejector silencer exits to the waste water
system (GMA).
5. Non-condensable gases exit through the exhaust pipe with flap at the service
ejector to atmosphere.
6. Condensed motive steam and adhered steam of the suction flow exit form the
service ejector to the flash box of the main condensate system (LC).
7. Main Condensate enters from and exits to the main condensate system (LC).

62





Sr.
No.

KKS

Name

Fluid

Dia.
mm
Desig
n
Pr.(ba
r)
Oper.
Pr.
(bar)
Design
Temp.
( C)
Temp
Oper.
( C)

Material

1.

18MAJ50BR001
Coming
from
CRH
line

Steam

150

39

32

420
351
1 Cr
Mo Alloy
Steel

2.

18MAJ50BR002
Going
to Start
up
ejector

Steam

150

39

8

420
171
1 Cr
Mo Alloy
Steel

3.

18MAJ09BR001
Going
to
Service
Ejector

Steam

25

39
11.60

420
351
1 Cr
Mo Alloy
Steel

4.

18MAJ15BR001
Air
Remov
al
Line
Steam/
Water

250

0.40

1

110
60
Carbon
Steel

5.

18MAJ10BR001
Coming
From
Conden
ser
Steam/
Water

300

0.40

1

110
60
Cabon
Steel

6.

18MAJ01BR001
Coming
From
Conden
ser
Steam/
Water

200

0.40

1

110
60
Carbon
Steel

7.

18MAJ02BR001
Coming
From
Conden
ser
Steam/
Water

200

0.40

1

110
60
Carbon
Steel

8.

18MAJ11BR001
Air
Remov
al
Line
Going
to
Service
Ejector

Steam/
Water

300

0.40

1

110

60
Carbon
Steel
63

11.


18LCE11BR001

Conden
sate
desupe
rheatin
g
spray
line



Steam/
Water




25




16







95









Stainless
Steel
316L




12.



18LCB40BR201


Inlet to
flash
tank

Steam/
Water

25

1.50


10



110



28.4

Carbon
Steel

13.


18LCB10BR201


Inlet to
flash
tank

Steam/
Water

25


1.50


10


110


28.4


Carbon
Steel




Table-3


















64



Main Components:

The system consists of the following main components:

1. 1 x 100 % Start-up ejector (18MAJ50BN001)
2. Start-up ejector silencer (18MAJ50BS001)
3. Start-up ejector steam shut-off valve (18MAJ50AA001)
4. Start-up ejector steam control valve (18MAJ50AA002)
5. Start-up ejector air shut-off valve (18MAJ15AA010)
6. 2 x 100% Service ejectors
18MAJ20BN001
18MAJ30BN001
7. Service ejector steam shut-off valve (18MAJ09AA001)
8. Service ejector steam control valve (18MAJ09AA002)
9. Service ejector air shut-off valve for both ejectors (18MAJ11AA001)
10. Service ejector air shut-off valve for ejector 1 (18MAJ12AA001)
11. Service ejector air shut-off valve for ejector 2 (18MAJ13AA001)

























65
4. HP Turbine By Pass System


66



67





68
4. HP Turbine By Pass System

Purpose:

1. Take over of the produced HP steam of the heat recovery steam generator during
start-up and shutdown while the steam turbine is not in operation.
2. Take over of the produced HP steam of the heat recovery steam generator in case
of a steam turbine trip or load rejection.
3. Keeping the HP steam pressure and pressure gradient within defined limits.

Description of HP Turbine By Pass System:

The HP bypass system guides the HP live steam,
bypassing the HP steam turbine, into the cold reheat line.
The live steam is conditioned by expanding and desuperheating with HP feedwater
injection in the bypass control valve.

The HP bypass control valve is continuously kept warm by a small steam flow
through the warm-up line. This reduces the thermal stress at a fast take-over of the
hot HP steam in case of a steam turbine trip.

The HP bypass system comes into operation after the steam pressure in the HP
steam line has reached a minimum value.
During normal operation, the HP bypass system remains in stand-by mode, meaning
it is ready to take over the HP steam of the HRSG in case of a steam turbine
limitation or trip.

Interfaces to Other Systems:

1. HP steam enters from the HP steam line of the Main Steam System (LBA).
2. HP feedwater enters for injection from the common HP feedwater line of the HP
Feedwater Pump System (LAC50).
3. Desuperheated steam leaves to the cold reheat steam line of the Main Steam
System (LBA).








69

Table: 4

Main Components:

1. HP bypass control valve (18LBF10AA001)
2. HP bypass steam lines (18LBA55BR001), (18LBC15BR001), and
(18LBC15BR002)
3. HP bypass water injection shut-off valve (18LBF11AA001)
4. HP bypass water injection control valve (18LBF11AA002)
5. Injection water lines (18LBF11BR001), (18LBF11BR002)
6. HP bypass warm-up line (18LBF10BR601)
7. Injection water line drain (18LBF11BR201)






Sr.
No.

KKS

Name

Fluid
Dia.
mm
Design
Pr.(bar)
Oper.
Pr.
(bar)
Design
Temp.
( C)
Temp
Oper.
( C)

Material

1.

18LBA55BR001
H.P
Main
Steam
pipe line

Steam

250

153


138


572

566
9Cr-
1Mo-V
Alloy
Steel

2.

18LBF10BR601
Warm-
up line
Steam

50

153

138.4

572

566
9Cr-
1Mo-V
Alloy
Steel

3.

18LBC15BR001
Cold
Reheat
Pipe line
System

Steam

400

39

33.50

560

350
9Cr-
1Mo-V
Alloy
Steel

4.

18LBC15BR002
Cold
Reheat
Pipe line
System

Steam

400

39

33.50

420

350
2
Cr Mo
Alloy
Steel

5.

18LBF11BR002
De-
Supper
heating
line

Water

80

230

175

127

62
Carbon
Steel
70
5. IP Turbine By Pass System


71





72











73
5. IP Turbine By Pass System

Purpose:
The system fulfils the following tasks:

1 Taking over of the produced IP steam of the HRSG during start-up and shut-
down while the ST is not in operation
2 Taking over of the produced IP steam of the HRSG in case of a ST trip or load
rejection.
3 Keeping the HP steam pressure and pressure gradient within defined limits.

Description of IP Turbine By Pass System:


The IP bypass guides the IP steam, bypassing the IP/LP steam turbine, into the
condenser.

The IP steam is conditioned by expanding and de-superheating with condensate
injection in the bypass control valve.

The IP bypass control valve is continuously kept warm with a small steam flow through
the warm-up line. This serves to reduce the thermal stress at a fast take-over of the hot
IP steam in case of a steam turbine trip.

The bypass shut-off valve, the bypass control valve and the bypass water injection
control valve have pneumatic actuators.

The IP turbine control valves open according the run-up and load control of the steam
turbine, also keeping the fixed pressure and the allowed pressure gradients. The
bypass control valve closes accordingly.

The IP bypass remains in stand-by, ready to take over the IP steam in case of a steam
turbine limitation or trip.

Interfaces to other Systems:

1 IP steam enters from the IP steam line of the main steam system (LBA).
2 Injection water enters from the main condensate system (LC).
3 De-superheated steam exits through the perforated plate to the main
condenser (MAG).




74
Sr.
No.

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp.
( C)
Temp
Oper.
( C)

Material

1.
18LBH40BR001
Coming
from I.P
Steam
Line

Steam

500

34

30.60

572

559
9Cr-
1Mo-V
Alloy
Steel

2.

18MAN40BR001
Coming
from
shutoff
valve

Steam

500

34

30.60

572

559
9Cr-
1Mo-V
Alloy
Steel

3.

18MAN40BR002
Going to
Condens
er

Steam

1000

6

4.62

565

149
2
Cr Mo
Alloy
Steel

4.

18MAN40BR003
Going to
Condens
er

Seam

1000

6

4.62

400

149
1
Cr Mo
Alloy
Steel

5.


18MAN40BR004
Going to
Condens
er
Seam/
Water

1000

6

4.62

400



149
Carbon
Steel


6.


18MAN41BR001

De-
Superhea
ting
Line
Steam/
Water

150

16

15

95

28.4
Carbon
Steel

7.

18MAN40BR601

Worm Up
Line

Seam

50

34

28.5

572

566
9Cr-
1Mo-V
Alloy
Steel

Table: 5



Main Components:

1 IP bypass shut-off valve (18MAN40AA001)
2 IP bypass control valve (18MAN40AA002)
3 IP bypass water injection control valve (18MAN41AA001)
4 IP bypass warm-up shut-off valve (18MAN40AA601)
75
6. LP Turbine By Pass System


76




77
6. LP Turbine By Pass System

Purpose:

The system fulfils the following tasks:
1. Taking over of the produced LP steam of the HRSG during start-up and
shutdown while the ST is not in operation.
2. Taking over of the produced LP steam of the HRSG in case of a ST trip or load
rejection.
3. Keeping the LP steam pressure and pressure gradient within defined limits.



Description of LP Turbine By Pass System:

The LP bypass guides the LP steam, bypassing the LP steam turbine, into the
condenser.

The LP steam is conditioned by expanding and de-superheating with condensate
injection in the bypass control valve.

The bypass shut-off valve, the bypass control valve, and the bypass water injection
control valve have pneumatic actuators.

The LP bypass remains in stand-by, ready to take over the LP steam in case of a steam
turbine limitation or trip.

The LP turbine control valves open according the run-up and load control of the steam
turbine, also keeping the fixed pressure and the allowed pressure gradients. The
bypass control valve closes accordingly.


Main Components:

The system consists of the following main components:
1. LP bypass shut-off valve 18MAN10AA001
2. LP bypass control valve 18MAN10AA002
3. LP bypass water injection control valve 18MAN11AA001







78



Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp
( C)
Temp
Oper.
( C)

Material
1. 18LBH10BR001
Coming
from L.P.
Steam
Line
Steam/
Water
250 7.50 6 305 291
Carbon
Steel
2. 18LBH10BR202
Connect
to Drain
Steam/
Water
25 7.50 6 305 291
Carbon
Steel
3. 18MAN10BR001
Coming
from Shut
off valve
Steam/
Water
250 7.50 6 305 291
Carbon
Steel
4. 18MAN10BR003
Going
into
Condens
er
Steam/
Water
400 6 3 305 80
Carbon
Steel
5. 18MAN11BR001
De-
Superhea
ting
Line
Steam/
Water
25 16 15 95 28.4
Carbon
Steel

Table: 6



Interfaces to other Systems:

1. LP steam enters from the LP steam line of the main steam system (LBA).
2. Injection water enters from the main condensate system (LC).
3. De-superheated steam exits through the perforated cone to the main condenser.










79
7. Feedwater Storage And Deaeration System


80


81

7. Feedwater Storage And Deaeration System

Purpose:

The system fulfils the following tasks:
1. Storage of feedwater for the HRSG
2. Controlling the feedwater tank level by compensating water losses with
Demineralized water ("make-up water") via the condenser.
3. Controlling the pressure/temperature in the feedwater tank by recirculating the
feedwater through the feedwater preheating coil of the HRSG. and with pegging
steam from the cold reheat line in the main steam system.
4. Separating non-condensable gases in the deaerator.

Water Tank and Deaerator:

The feedwater tank and the deaerator are a combined unit. The deaerator dome is
arranged on top of the cylindrical, horizontally mounted feedwater tank. The feedwater
tank serves as the storage tank for the water steam cycle. The elevation of the
feedwater tank ensures the net pressure suction head (NPSH) required by the
feedwater pumps. In the direct contact deaerator, steam from the feedwater preheating
loop return or pegging steam from the cold reheat line is
physically mixed with the entering condensate. The condensate is heated up and
consequently the soluble non-condensable gases leave the water and the condensate
is deaerated. The non-condensable gases collect at the top of the deaerator where they
are sucked through the feedwater tank evacuation vent to the condenser. From there
the non-condensable gases are extracted by the start-up- or service ejectors.

Water tank Level:

The feedwater tank level control is activated and starts to control the supply and
discharge of the demineralized water ("make-up water") in the main condensate system,
in order to keep the feedwater tank level between the minimum level MIN1 and the
maximum level MAX1

During system operation, the level is always slowly increasing and decreasing between
these two points.

If the level in the feedwater tank falls below minimum level MIN1, service make-up
water shut-off valve (18LCP30AA001) opens and demineralized water is sprayed into
the condenser.
82

.
At rising level, the valve closes again if the maximum level MAX1 is reached.
In exceptional cases,
if the feedwater tank level falls below minimum level MIN2, emergency make-up water
shut-off valve (18LCP31AA001) opens in addition to the service make-up water valve.

Demineralized water is filled direct into the flash box until the feedwater tank level
reaches minimum level MIN1, at which point the emergency make-up water shut-off
valve closes.

In very rare cases, if the level in the feedwater tank rises above maximum level MAX2,
the condensate emergency drain valve (18LCA90AA002) opens and drains water to
the waste water system. When the level reaches maximum level MAX1, the condensate
emergency drain valve closes.

The feedwater level control includes a part of the condenser hotwell level control: the
service and the emergency make-up water shut-off valve only open according to the
above conditions as long as the condenser hotwell level is below maximum level MAX1.
The emergency make-up water shut-off valve opens also if the condenser hotwell level
is lower than minimum level MIN1.





83

Table: 7


Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp
( C)
Temp
Oper.
( C)

Material

1.

18LBS50BR001
From
Cold Re-
Heat

Steam

200

39
31

420
351
1
Cr Mo
Alloy
Steel

2.

18LBS50BR003
From
Cold Re-
Heat

Steam

800

1
0.20

420
319
1
Cr Mo
Alloy
Steel

3.

18LBS50BR004
Going
into
Deaerato
r

Steam

800

1
0.20

420
319
1
Cr Mo
Alloy
Steel
4. 18LAA10BR201
Vent to
Condens
er


Steam/
Water
100 1 0.20 120 121
Carbon
Steel
5. 18LAA10BR202
Vent to
Condens
er


Steam/
Water
100 1 0.20 120 121
Carbon
Steel

6.

18LBS50BR020
Vent to
Atmosph
ere

Steam

300

1
2

420
120
1
Cr Mo
Alloy
Steel

7.

18LBS50BR021
Vent to
Atmosph
ere

Steam

300

0.50
1

420
115
1
Cr Mo
Alloy
Steel

8.


18LCQ10BR002

From
HRSG
Flash
Vessel


Steam



350



1

0.20


420

100
1
Cr Mo
Alloy
Steel

9.

18LAA10BR210

Process
Drainage
System

Steam/
Water


100


2

0.20

120

60
Carbon
Steel

84

Feedwater Temperature:

The feedwater needs to be preheated for two reasons.
1
st
:
The temperature in the feedwater tank has to be higher than the condensate
temperature in order to enable the deaeration of the condensate sprayed into the
feedwater tank.

2
nd
:
The cooling down of the GT exhaust gas at the HRSG economizer below the sulfuric
acid dew point has to be avoided because of corrosion issues.

The feedwater temperature setpoint is automatically adjusted accordingly. In normal
operation, the deaerated condensate is preheated in the HRSG economizer and
circulated by means of the feedwater preheating pumps. If required during special
operation modes of the power plant (i.e. start-up) and for redundancy purposes to the
feedwater preheating system, steam will be taken from the cold reheat line and used as
pegging steam.

Interfaces to other Systems:

1. Main condensate enters the deaerator from the Main Condensate System (LC).
2. Cold reheat pegging steam enters from the Main Steam System (LBA).
3. Feedwater exits to the HP Feedwater Pumps.
4. Feedwater exits to the Feedwater Preheater Pumps.
5. Aqueous solutions of conditioning chemicals enter from the dosing systems
(LFN).
6. Drain condensate exits to the clean drain system (LCM)
7. Non-condensable gases leave to the condenser neck of the condenser in the
Main Condensate System (LC).

Main Components:
The system consists of the following main components:

1. Feedwater tank (18LAA10BB001)
2. Deaerator (18LAA10AC001)
3. FWT evacuation shut-off valve (18LAA10AA201)
4. Cold reheat pegging steam shut-off valve (18LBS50AA001)
5. Cold reheat pegging steam control valve (18LBS50AA002)
6. HRSG flash tank vent regulator (18LCQ10AA001)
7. FWT / Deaerator safety valve (18LBS50AA020)
8. Service make-up water shut-off valve (18LCP30AA001)
9. Emergency make-up water shut-off valve (18LCP31AA001)
10. Condensate emergency drain valve (18LCA90AA002)
85
8. Feedwater Preheater Pump System


86

87

8. Feedwater Preheater Pump System

Purpose
The Feedwater Preheater Pump System fulfils the following task:
1. Temperature Control of the HRSG Feedwater in the Feedwater Tank.

Description of Feedwater Preheater Pump System:

During all normal plant operation modes the 2 x 50 % feedwater preheater pumps
recirculate feedwater from the feedwater tank and force it through the feedwater
preheater coil of the HRSG. In HRSG, feedwater takes heat from GT exhaust gas.
Feedwater goes to feedwater tank through return line (18LAA75BR75).
Each pump supplies feedwater from feedwater tank through suction line
(18LAA51BR001) to the common feedwater preheater line. The feedwater flow rate to
the HRSG is controlled by the Feedwater Preheater Return Control Valve (installed on
top of the feedwater tank) according to the feedwater tank pressure respectively
temperature.

Following conditions lead to an emergency shutdown of the feedwater preheater
pumps.
1. If the level in the feedwater tank falls below minimum level MIN4.
2. If the pressure in the common discharge line drops below minimum pressure
MIN2.
3. In case of a not fully open suction valve (limit switch not in open position).
4. If the motor winding (stator) temperature exceeds maximum temperature MAX2.


Interfaces to other Systems:

1. From the feedwater tank (LAA) the feedwater enters in suction line connections.
2. Minimum flow returns back to the feedwater tank.
3. Feedwater leaves the system through the common pump discharge line to the
Feedwater Preheater (HRSG). It comes back to the system (heated-up) through
the connection line between Feedwater Preheater (HRSG) and feedwater tank
(LAA) where it finally returns.


88



Table: 8








Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp
( C)
Temp
Oper.
( C)

Material
1. 18LAA75BR001
Coming
from
HRSG
exhaust
Condens
ate/
Feed
Water
200 20 10 212 93.4
Carbon
Steel
2. 18LAA75BR002
Connect
to Feed
Water
tank at
pt. J
Steam/
Water
300 20 10 212 93.4
Stainles
s Steel
3. 18LAB51BR001
Suction
line of 1
st

pump
Steam/
Water
300 2 0.20 120 60
Carbon
Steel
4. 18LAA52BR002
Discharg
e line of
1
st
pump
Condens
ate/
Feed
Water
150 20 10 120 62
Carbon
Steel
5. 18LAA52BR201 Drain line
Condens
ate/
Feed
Water
25 20 10 120 62
Carbon
Steel
6. 18LAA70BR002
Going to
HRSG
exhaust
Condens
ate/
Feed
Water
200 20 10 120 62
Carbon
Steel
7. 18LAA53BR001
Min. flow
return
line
Condens
ate/
Feed
Water
80 20 10 120 62
Carbon
Steel
89
Main Components:

The system consists of the following main components:
1. Feedwater Preheater Pumps
a. 18 LAA50AP001
b. 18 LAA60AP001
2. Suction Valve Feedwater Preheater
a. 18 LAA51AA001
b. 18 LAA61AA001
3. Shut Off Valve Feedwater Preheater Pump Discharge
a. 18 LAA52AA002
b. 18 LAA62AA002
4. Automatic Recirculating Check Valve
a. 18 LAA50AA001
b. 18 LAA60AA001
5. Shut Off Valve Feedwater Preheater Return
a. 18 LAA75AA001
6. Control Valve Feedwater Preheater Return
a. 18 LAA75AA002

























90
9. H.P Feedwater Pump System


91

92
9. H.P Feedwater Pump System

Purpose:
The system fulfils the following task:
1. From feed water tank, HP feed water feed into HP drum of the HRSG.
2. Feeding of the Once Through GT Air Coolers (OTC) with HP feed water.
3. Providing the HP bypass station with HP feed water for water injection.
4. Providing the HP live steam attemperator of the HRSG with HP feed water
for water injection.

Description of H.P Feedwater Pump System:

Feed water enters at the HP / IP pump suction lines LAB51/ LAB61 from the feed water
storage tank (system LAA). Each pump has its own suction line, Downstream of the
suction line shut-off valves there are strainers 18LAB50AT001/ 18LAB60AT001
installed in order to prevent dirt from entering the pumps.

The filtered feed water is fed to the suction nozzle of HP feed water pump
18LAC50AP001/ 18LAC60AP001. The HP feed water pump increases the fluid
pressure depending on the feed water flow demand.

The IP feed water is extracted from intermediate stage of the feed water pump. The LP
feed water is extracted from the IP feed water line downstream of the common IP/LP
economizers of the HRSG.

The minimum required flow rate through each operating HP feed water pump is ensured
by the automatic recirculation check valve 18LAB50AA001 / 18LAB60AA001, which is
installed downstream of the HP pump discharge nozzle. The HP recirculation flows are
fed back into the feed water storage tank.
To prevent steaming out there are throttling orifices 18LAB53BP001/ 18LAB63BP001
inserted in the recirculation line on top of the feed water tank.

Before start of the first pump the common feed water line LAB95 might be empty or at
least not pressurized. To ensure the minimum required back pressure at the pump
discharge, the motorized discharge shutoff valves remain closed during start-up and the
feed water lines are filled and pressurized via the filling bypass 18LAB54BR001 /
18LAB64BR001.

The automatic recirculation check valve also prevents reverse rotation of the stand by
pump by back feed through the main line.

Back-feed through the filling line is prevented by means of the check valve
18LAB54AA001 / 18LAB64AA001.

Back-feed through the IP line is prevented by means of the check valve 18LAB22AA001
/ 18LAB32AA001.
93

The HP pump lines downstream of the discharge shut-off valves are connected to the
common HP feed water line (18LAB95BR001). The common HP feed water line is
connected to the various feed water consumers such as the HP part of the HRSG and
the OTC.

The IP pump lines downstream of the pump extraction are connected to the common IP
feed water line (18LAB45BR001). The common IP feed water line is connected to the IP
part of the HRSG.
During filling the main HRSG shut off valve 11LAB95AA052 shall be closed. The HRSG
economizer is pressurized via filling bypass line LAB95BR063.

The shut off valve can be opened as soon as the HRSG economizer and the HP
feedwater line to the HRSG are pressurized.


Interfaces to other Systems:

1. Feedwater enters at the HP/IP pump suction line connections from the
feedwater tank (LAA) and exits through the feedwater line to the HP
economizer of the HRSG.
2. Minimum flow returns back to the feedwater tank.
3. A part of the feedwater leaves as injection water to the HP bypass station
(LBF).
4. A part of the feedwater leaves to the distribution line (18QUL40BR001) of
the sampling system.

Main Components:
The main components of each HP feed water pump line are:
1. HP feed water pumps.
a. 18 LAC50AP001
b. 18 LAC60AP001
2. Suction line shut-off valve
a. 18 LAB51AA001
b. 18 LAB61AA001
3. Suction line strainer
a. 18 LAB50AT001
b. 18 LAB60AT001
4. Discharge line shut-off valves
a. 18 LAB52AA002
b. 18 LAB62AA002
5. Automatic minimum flow recirculation check valves
a. 18 LAB50AA001
b. 18 LAB60AA001
94
Table: 9
Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp
( C)
Temp
Oper.
( C)

Material
1. 18LAB95BR001
Common
HP feed
water line
Water 200 229 175 127 62
Carbon
Steel
2. 18LAB95BR401

Sampling
Line

Steam/
Water
15 229 175 127 62
Stainles
s Steel
3. 18LAB51BR001

Suction
Line of
1
st
pump

Steam/
Water
300 2 0.20 120 60
Carbon
Steel
4. 18LAB52BR201

Drain
Line

Water 25 229 165 127 62
Carbon
Steel
5. 18LAB54BR001

By Pass
Line

Water 50 229 165 127 62
Carbon
Steel
6.

18LAB53BR001

Return
line

Water 100 229 10 127 62
Carbon
Steel
7.

18LAB22BR001

I.P
Discharg
e line
Coming
From 1
st

pump
Feed
Water
100

75

40

127

60.4
Carbon
Steel
8. 18LAB45BR001
Common
IP feed
water line
Feed
Water
100 75 40 127 60.4
Carbon
Steel
9.

18LAC50BR252


Drain
Line

Steam/
Water
50

1


40


Carbon
Steel
10.

18LAB22BR201


Drain
Line

Feed
Water

25


75

40

127

60.4
Carbon
Steel
95
The common feed water line:

1. Common HP feed water line (18 LAB95BR001)
2. Connection to the water injection system of the HP steam-bypass
3. Sampling probe extraction line (18 LAB95BR401)
4. HP feed water suction lines
a. 18 LAB51BR001
b. 18 LAB61BR001
5. HP feed water discharge lines
a. 18 LAB52BR001
b. 18 LAB62BR001
6. Filling bypass lines
a. 18 LAB54BR001
b. 18 LAB64BR001
7. Minimum flow recirculation line
a. 18 LAB53BR001
b. 18 LAB63BR001
With shut off valve
a. 18 LAB53AA001
b. 18 LAB63AA001
And orifice
a. 18 LAB53BP001
b. 18 LAB63BP001
8. Vent lines
a. 18 LAB51BR201
b. 18 LAB61BR201
9. Drain lines
a. 18 LAC50BR252
b. 18 LAC60BR252

















96
10. Fuel Gas Preheating System


97

98
10.0 Fuel Gas Preheating System

Purpose:

Preheating of the fuel gas in order to achieve a higher thermal efficiency of the gas
turbine

Description of Fuel Gas Preheating System:

The fuel gas preheating system preheats the fuel gas to a constant Pressure with feed
water taken from an extraction point downstream of the IP economizer of HRSG.
Finally the water returns to the feed water tank via gas preheating control valve.

The gas preheating control valve is located right upstream of the feed water tank inlet to
prevent evaporation of gas preheater water.

The preheater and the water line downstream of the gas preheater is equipped with a
gas detection device in order to protect the water /steam cycle from gas ingress.

The fuel gas preheating system is taken into service when exhaust gas temperature at
stack exceeds a certain value and fuel gas is selected.

The flow of the feed water depends on the fuel gas flow and its target temperature.

Main Components:

The system consists of the following main components:
1. Fuel gas preheater (11EKC10AC001) equipped with gas detection device
(11EKC10CL001) and safety valve (11EKC10AA001).
2. Fuel gas separator (11EKC10AT001) downstream of the fuel gas preheater
equipped with gas detection device (11EKC10CL002)
3. Straightway shut-off valve (11HAC24AA002) downstream of HRSG
extraction point.
4. Straightway shut-off valve (11EKT10AA001) downstream of fuel gas
Separator.
5. Electric motor-actuated gas preheater water shut-off gate valve
(11EKT10AA002).
6. Gas preheater angle control valve (11EKT10AA003).







99
Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp
( C)
Temp
Oper.
( C)

Material
1. 11EKT10BR010
Coming
from
HRSG
Steam/
Water
50 75 38 252 219.7
Carbon
Steel
2. 11EKT10BR001
Coming
From
Fuel
Gas
Preheat
er
Steam/
Water
50 75 38 252 65.8
Carbon
Steel
3. 11EKT10BR002
Return
line
(Separa
tor to
FWT)
Steam/
Water
50 75 38 252 65.8
Carbon
Steel
4. 11EKT10BR003

Inlet
line of
FWT

Steam/
Water
50 1 0.20 252 65.8
Stainless
Steel
5. 11EKT10BR820

Spool
piece

Steam/
Water
50 75 38 252 219.7
Carbon
Steel

Table: 10

Main Lines:

1. Feed water extraction line (11EKT10BR010) from HRSG to fuel gas
preheater.
2. Connection line (11EKT10BR001) between fuel gas preheater and fuel gas
separator.
3. Return lines (11EKT10BR002/3) from fuel gas separator to FWT.

Interface to other Systems:

1. Fuel gas enters from the fuel gas fine filter.
2. Fuel gas goes to the GT.
3. Feed water comes from extraction point downstream of the IP economizer of
HRSG.
4. Feed water goes to the FWT.


100
11. Gas Turbine Air Cooling System.


101


11. Gas Turbine Air Cooling System

Purpose
The system fulfils the following tasks:

1. Cooling of the HP GT air to the required temperature by controlling the HP
feedwater flow through the HP OTC.
2. Cooling of the LP GT air to the required temperature by controlling the HP
feedwater flow through the LP OTC.
3. Producing of HP superheated steam additionally to the HRSG.

Description of Gas Turbine Air Cooling System:

As soon as the GT starts to roll, hot air is loaded from the GT compressor to the GT air
coolers, where it is cooled down to required temperature. After cooling, the air is led
back into the GT.

The water used to cool down the hot air is extracted from the HRSG HP economizer
and routed through the feed water lines to the air coolers.

It is evaporated and superheated through the coolers by means of the air-extracted
heat. The generated steam is led back into the HRSG super heater through the steam
lines. The superheated conditions of the steam are supervised at the HP OTC and LP
OTC steam outlets.

The feed water flows to the air coolers are controlled based on the air temperature at
the coolers air outlet.














102

103

104
Once Through Cooler (OTC):

The OTC is a surface heat exchanger. The hot air entering the vessel is cooled down.
The cooling water entering the vessel is heated up, evaporated, and superheated. The
OTC is designed with helically winded tubes. The air flows on the outside of the tubes
and transfers the heat to the water and steam inside the tubes.

Interfaces to other Systems:

1. HP feedwater comes from the HRSG.
2. HP feedwater goes to the HP OTC and to the LP OTC.
3. HP superheated steam comes from the HP OTC and LP OTC.
4. HP superheated steam goes to the HRSG.

105
Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp
( C)
Temp
Oper.
( C)

Material
1. 11LAB90BR001
Coming
from
HRSG
Water 100 230 171 370 278.2
Carbon
Steel
2. 11LAB91BR001
Inlet Line
of LP
OTC
Water 80 230 171 370 278.2
Carbon
Steel
3. 11LAB91BR002
Inlet Line
of LP
OTC
Water 80 167 144 370 278.2
Carbon
Steel
4. 11LAB91BR003
Inlet Line
of L.P
OTC
Water 80 167 144 370 278.2
Carbon
Steel
5. 11LBG91BR001
Discharge
line of L.P
OTC
Steam 100 165 144 500 474
9 Cr-
1Mo-V
Alloy
Steel
6. 11LAB92BR001
Inlet Line
of H.P
OTC
Water 80 230 143 370 474
Carbon
Steel
7. 11LAB92BR002
Inlet Line
of H.P
OTC
Water 80 167 143 370 278.2
Carbon
Steel

8.

11LBG92BR001
Discharge
line of
H.P OTC

Steam

100

165

143

580

474
9 Cr-
1Mo-V
Alloy
Steel


9.



11LBG95BR001


Common
Discharge
Line


Steam



150



163


141


580


474
9 Cr-
1Mo-V
Alloy
Steel


10.


11MBH30BR201

To
Drainage
system

Steam/
Water


25


21

20

390

370
Carbon
Steel


11.


11MBH30BR211

To
Drainage
system

Steam/
Water


80


1

1

120

370
Carbon
Steel

12. 11MBH30BR001 Vent Line

Steam/
Water


150 1 1 390 370
Carbon
Steel

106

Main components:

The system consists of the following main components:

1. Feedwater shut-off valve HP OTC (11LAB92AA001)
2. Feedwater control valve HP OTC (11LAB92AA003)
3. Feedwater drain shut-off valve HP OTC (11LAB92AA201)
4. Feedwater shut-off valve LP OTC (11LAB91AA001)
5. Feedwater control valve LP OTC (11LAB91AA003)
6. Feedwater drain shut-off valve HP OTC (11LAB91AA201)
7. HP OTC (GT HP air cooler) (11MBH40AC001)
8. LP OTC (GT LP air cooler) (11MBH30AC001)

































107
12. Close Cooling Water System


108



109



110
12. Close Cooling Water System

Purpose:

The closed cooling water (CCWS) fulfils the following tasks:

1. Transferring waste heat from various heat sources to the once through Main
(MCWS) & Secondary (SCWS) cooling water system via the CCW Intercooler
water/water.
2. Keeping the CCW pressure below the GT/ST generator H2 coolers operational
gas pressure.

Description of Close Cooling Water System:

The CCWS is a closed circuit protected with inhibitor against corrosion. The water of the
CCWS is circulated by the CCW pumps (PGC10/20AP001) to the various heat sources.
The heated water is returned to the CCW Intercooler water/water (PGD10/20 AC001)
for cooling down by the MCWS.

Transferring waste heat from various heat sources to the once through Main (MCWS) &
Secondary (SCWS) cooling water system via the CCW Intercooler water/water.
The CCW pumps (PGC10AP001) and (PGC20AP001) are used to circulate water
through the CCW intercooler, MCW pumps, Attemperation pumps, Condenser water
box evacuation pumps, Lube oil cooler, Sampling cooler, H.P feedwater pump,
Sampling hot well, Seal oil cooler, Generator cooler.

CCW pumps:

The CCW pumps (PGC10AP001) and (PGC20AP001) are used to circulate water
through the CCWS, heat source coolers, and the CCW Intercooler. During normal
operation only one of the two CCW pumps shall be in operation. The CCW pumps are
controlled by the plant DCS.

CCW Intercooler Water/Water:

The tube & shell type CCW water/water Intercoolers (PGD10AC001) and
(PGD20AC001) are used to cool down the Closed Cooling Water. During normal
operation only one of the two cooler units is in operation. The CCW Intercoolers are not
controlled by the DCS.

CCW head tank (PGF10BB001):

The CCW head tank provides the necessary buffer volume for thermal expansion and
maintains a constant pressure in the CCWS.

CCWS chemical dosing sluice (PUN90BR002):
111

The CCWS chemical dosing sluice provides dosing facility for CCWS chemical
conditioning.

CCW filling valve (PGF01AA003):

The CCW filling valve controls the water supply from the demineralised water supply
system in order to replenish possible water losses in the CCWS.

H2 gas separator tank (18PGM25AT001):

This tank provides the necessary separating volume if H2 is leaking into the CCWS
form the ST/GT generator H2 coolers. The H2 gas separator tank is vented via an open
pipe over the roof.
Or
In order to prevent dangerous concentration of H2 gas in CCWS a H2 gas separator is
installed. The H2 gas separator is fitted with a vent pipe routed over the building roof.

CCW flushing filter (19PGA09AT001):

The flushing filter provides filtering facility for the CCWS initial cleaning procedures.


Tube & shell type CCW Intercoolers (PGD10AC001) and (PGD20AC001):

The tube & shell water/water CCW Intercoolers transfer the heat from the CCWS to the
(MCWS&SCWS.)


Main Components:

The system consists of the following main components:

1. CCW pumps (PGC10AP001) and (PGC20AP001)
2. CCW head tank (PGF10BB001)
3. CCW chemical dosing sluice (PUN90BR002)
4. CCW filling valve (PGF01AA003)
5. H2 gas separator tank (PGM25AT001)
6. CCW flushing filter (PGA09AT001)








112

Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp
( C)
Temp
Oper.
( C)

Material
1. 19PGB90BR004
Common
line
(At top)
Water
Cold
350 6 5.50 60 59
Carbon
Steel
2. 19PGF11BR001
Connect
to CCW
head
tank(N1)
Water 50 6 5.50 60 65
Stain
Less
Steel
3. 19PGF10BR201
Connect
to CCW
head
tank(N2)
Water 50 10 5.50 60 59
Stain
Less
Steel
4. 19PGB90BR005
Inlet to
CCW
pump
Water
Cold
350 6 5.50 60 59
Carbon
Steel
5. 19PGA01BR001
Outlet of
CCW
pump
Water
Cold
300 6 5.50 60 59
Carbon
Steel
6. 19PGB90BR201

By Pass
line

Water
Cold
50 6 5.50 60 59
Carbon
Steel
7. 19PGA09BR001
By Pass
line
Water
Cold
40 6 5.50 60 59
Carbon
Steel
8. 19PGA10BR201

Vent line

Water
Cold
25 6 5.50 60 59
Carbon
Steel
9. 19PGA11BR001
Inlet to
CCW
Intercool
er
Water
Cold
350 6 5.50 60 59
Carbon
Steel
10. 19PGA11BR003
Inlet to
CCW
Intercool
er
Water
Cold
350 6 5.50 60 59
Carbon
Steel
11. 19PGA11BR004
Outlet of
CCW
Intercool
er
Water
Cold
350 6 5.50 60 59
Carbon
Steel
12. 19PGA11BR002
Outlet of
CCW
Intercool
er
Water
Cold
350 6 5.50 60 59
Carbon
Steel
113
13. 19PGA20BR001
Outlet of
CCW
Intercool
er
Water
Cold
350 6 5.50 60 59
Carbon
Steel
14. 19PGL02BR010
Inlet line
of MCW
Pumps
Water
Cold
50 6 5.50 60 59
Carbon
Steel
15. 19PGL02BR001

Inlet line
of MCW
Pumps

Water
Cold
25 6 5.50 60 59
Carbon
Steel
16.
19PGL11BR001

Inlet line
of MCW
Pumps

Water
Cold
25 6 5.50 60 59
Carbon
Steel
17. 19PGL11BR002
Discharg
e line of
MCW
Pump
Water
Cold
25 6 5.50 60 59
Carbon
Steel
18.

19PGL92BR001

Discharg
e line of
MCW
Pump
Water
Cold


20


6

5.50

60

59
Carbon
Steel
19.

19PGL92BR010

Common
Discharg
e line of
MCW &
Attemper
ation
Pump
Water
Cold


50


6

5.50

60

59
Carbon
Steel
20.

19PGL03BR001
Inlet line
of
Attemper
ation
Pumps
Water
Cold


25


6

5.50

60

59
Carbon
Steel
21.

19PGL41BR001

Inlet line
of
Attemper
ation
Pumps
Water
Cold


25


6

5.50

60

59
Carbon
Steel
22.

19PGL41BR002

Discharg
e line of
Attemper
ation
Pump
Water
Cold


25


6

5.50

60

59
Carbon
Steel
114
23.

19PGL93BR001


Discharg
e line of
Attemper
ation
Pump
Water
Cold


25


6

5.50

60

59
Carbon
Steel
24.

18PGM12BR001

Inlet to
Condens
er Water
Evacuati
on
pumps

Water
Cold


25


6

5.50

60

59
Carbon
Steel
25.

18PGM12BR002

Discharg
e of
Condens
er Water
Evacuati
on
pumps

Water
Cold


25


6

5.50

60

59
Carbon
Steel
26.

18PGM15BR001

Common
Discharg
e of
Condens
er Water
Evacuati
on
pumps
Water
Cold


25


6

5.50

60

59
Carbon
Steel
27.

11PGM50BR001
Inlet line
of lube
oil
cooler
Water
Cold
150

6

5.50

60

59
Carbon
Steel

28.

11PGM50BR002
Outlet
line of
lube oil
cooler
Water
Cold
150 6 5.50 60 59
Carbon
Steel
29.

19PGQ31BR001

Inlet line
of
Sampling
cooler
Water
Cold
50

6

5.50

60

59
Carbon
Steel

30.

19PGL51BR001
Inlet line
of H.P
Feed
Water
Pump
Water
Cold
50

6

5.50

60

59
Carbon
Steel

115
31.

18PGL96BR001

Common
outlet line
of Feed
Water
tank
Water
Cold

100

6

5.50

60

59
Carbon
Steel

32.

19PGQ41BR001

Inlet to
Sampling
Hot Well
Water
Cold
25

6

5.50

60

59
Carbon
Steel

33.
11PGM20BR001

Common
Inlet line
of
Generato
r Cooler
Water
Cold
250

6

5.50

60

59
Carbon
Steel

34.

11PGM20BR003

Inlet line
of
Generato
r Cooler
No-2
Water
Cold
250

6

5.50

60

59
Carbon
Steel

35.

11PGM24BR001

Inlet line
of
Generato
r Cooler
No-1
Water
Cold
150

6

5.50

60

59
Carbon
Steel

36.

11PGM24BR002

Outlet
line of
Generato
r Cooler
No-1
Water
Cold
150

6

5.50

60

59
Carbon
Steel

37.

11PGM23BR002

Outlet
line of
Generato
r Cooler
No-2
Water
Cold
150

6

5.50

60

59
Carbon
Steel

38.

11PGM22BR002

Outlet
line of
Generato
r Cooler
No-3
Water
Cold
150

6

5.50

60

59
Carbon
Steel

39.

11PGM21BR002


Outlet
line of
Generato
r Cooler
No-4

Water
Cold
150

6

5.50

60

59
Carbon
Steel

116
40.

11PGM25BR002

Common
outlet line
of
Generato
r Cooler

Water
Cold
150

6

5.50

60

59
Carbon
Steel

41.

11PGM25BR010


Inlet line
of H2 gas
separator
Water
Cold
250

6

5.50

60

59
Carbon
Steel

42.

11PGM26BR001

Outlet
line of
H2 gas
separator

Water
Cold
250

6

5.50

60

59
Carbon
Steel

43.

11PGM30BR001

Inlet line
of Brush
gear
cooler
Water
Cold
50

6

5.50

60

59
Carbon
Steel

44.

11PGM39BR001

Inlet line
of Brush
gear
cooler
Water
Cold
50

6

5.50

60

59
Carbon
Steel

45.

11PGM20BR002

Inlet line
of
Generato
r Cooler
No-4

Water
Cold
250

6

5.50

60

59


Carbon
Steel


Table: 12

Heat Sources:

The CCWS provides cooling to the following heat sources:

1. GT generator air coolers and lubrication oil coolers (MKP10AC100)
2. KA26 GT/ST generator H2 coolers (MKA13AC100), (MKA13AC200),
(MKA13AC300), (MKA13AC400)
3. ST/GT Generator H2 seal oil coolers (MKW25AC001), (MKW26AC001)
4. H2 Generator brush gear cooler units (MKB40AC001)
5. Sampling coolers for the HRSG boilers and water steam cycle QUL01
6. HP feed water pumps coolers (LAC50AC001), (LAC60AC001)
7. Condenser water box evacuation system coolers (MAJ61/62AC001)


117
13. Fuel Gas System


118



119



120

121

122
13.0 Fuel Gas System

Purpose:

Purpose of the fuel gas supply system is it to transfer the contractual fuel gas received
at the plant boundary from the distribution net (terminal point 1) into the condition
required by the gas turbines in regards of mass flow, pressure, temperature and content
of dust and liquids.

Description of Fuel Gas System:

Fuel gas is delivered according to the contractual design data.

At the gas supply tie-in point, an insulation joint and a fuel gas main inlet valve (EKA)
with quick shut-off function is provided. The gas supply interface pressure and
temperature are measured for remote indication.

Redundant fuel gas liquid dust separators (EKB) 1st stage baffle plate, 2nd stage
coalescer elements are provided for liquid and dust separation. Both stages are
equipped with level indicator, level alarm, pressure indicator, and differential pressure
alarm.

Liquids are drained automatically to the condensate collection tank (EKR).

To keep the gas temperature above dew point and to heat up the fuel gas to the level
required by the gas turbines, a redundant fuel gas dew point heating system
(EKC10/20) is installed downstream the liquid and dust separators. The fuel gas dew
point heaters are designed as indirect gas-fired water-bath heaters. They consist of a
hot water-bath with natural gas burner.

To obtain the required gas temperature within the fuel gas supply system, the dew point
heaters are equipped with a temperature control using a bypass installation.

The fuel gas pressure reducing station consists of redundant pressure control valves
monitor type and overpressure protection devices (slam-shut valve, safety valve, etc.).
Purpose of the fuel gas pressure reducing station is it to supply the gas turbines with the
required fuel gas pressure.

Downstream the fuel gas pressure reducing station, the fuel gas dust filter (MBP01) are
installed. The cartridge type filters are designed 2x100%. They act as a final barrier
upstream the gas turbine.

After that the fuel gas enters the fuel gas flow meters, 1x100 % per GT (MBP05 CF001)
and 1x100 % for the EV chamber line (MBP05CF002)

123
Before entering the GT fuel gas system the gas passes the fuel gas efficiency pre-
heater (EKC10). The pre-heater is designed as a water/gas heat exchanger. Hot water
will be supplied from the water steam cycle.

The complete equipment of the fuel gas supply system is grounded to the overall plant
grounding net to obtain the same electrical potential.

Components of the common Fuel Gas System:

1. 1100% fuel gas main inlet valve (EKA)
2. 2100% fuel gas liquid dust separators EKB (Gas Scruber) incl. one condensate
collecting tank (EKR)
3. 2100% fuel gas dew point heaters (EKC10/20)
4. 2x100% fuel gas pressure reducing lines (EKD)

Turbine related fuel gas system:

1. 2100% fuel gas dust fine filter (MBP01)
2. 1x100% fuel gas efficiency pre-heater (EKC10)
3. 1x100% GT-fuel gas meter (MBP05CF001)
4. 1x100% EV chamber fuel gas meter (MBP05CF002)


Components:

Fuel Gas Main Inlet Valve (EKA) F25:

The purpose of valve EKA01 is to isolate the plant system from the pipeline system. For
emergency cases, this spring-loaded quick shut-off valve can be closed directly from the
main control room emergency board.

For opening it is necessary to open first the bypass valve in order to equalize the
pressure of the pipeline system and the plant fuel gas system.

To prevent damages to the system, the valve can only be opened locally. The
RELEASE TO OPEN signal must be sent from the DCS first. The valve closes
automatically at a fuel gas pressure of approximate 7 bar due to low pipeline pressure.
A high-pressure alarm is indicated in the control room at 180 bar a, low pressure at 36
bar a.







124

Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp
( C)
Temp
Oper.
( C)

Material
1. 11EKG10BR001
Inlet to
Gas
Scruber
Fuel
Gas
200 179 166 60 50
Carbon
Steel
2. 11EKG20BR001
Outlet to
Gas
Scruber
Fuel
Gas
200 179 166 200 50
Carbon
Steel
3. 11EKG21BR001
Inlet to
Dew
Pont
Heater
Fuel
Gas
200 179 166 100 50
Carbon
Steel
4. 11EKG23BR001
Outlet of
Dew
point
heater
Fuel
Gas
200 179 166 100 70
Carbon
Steel
5. 11EKG30BR001
Inlet to
Pressure
reducing
Station
Fuel
Gas
200 179 166 100 70
Carbon
Steel
6. 11EKG50BR003

Inlet to
fine filter

Fuel
Gas
250 60 49 80 22
Carbon
Steel
7. 11EKG60BR001

Outlet of
fine
Filter

Fuel
Gas
200 60


47


80 22
Stainless
steel
8. 11EKG90BR001
Outlet of
Gas
Preheate
r
Fuel
Gas
200 60 46 170 150
Stainless
steel
9. 11EKG90BR012

Inlet to
GT-11

Fuel
Gas
150 60 47 170 150
Stainless
steel
10. 11EKG91BR001

Inlet to
GT-11

Fuel
Gas
150 60 46 170 150
Stainless
steel

Table: 13

125


Fuel Gas Liquid Dust Separators (Gas Scruber) (EKB) F24:

The fuel gas liquid dust separators (EKB) are equipped with a condensate-collecting
tank (EKR).

The redundant liquid dust separators with vane pack and a cartridge filter stage
(EKB10/20) used for liquid and dust separation (efficiency: liquids and dust 99.5% 5
m).

Any liquid separated in the babble plate or in the coalescer filter stage is automatically
discharged via a condensate trap to the condensate-collecting tank.


Fuel Gas Dew Point Heater Station (EKC10/20) F22

The redundant fuel gas dew point heaters are installed upstream the gas pressure-
reducing station. The gas is heated up to fulfill dew point design criteria of the system
and to meet the gas turbine requirements regarding the fuel gas temperature.


The dew point heating system mainly consists of:
6. Water-bath
7. Gas burners
8. Burner gas reducing system
9. Gas temperature control valve
10. Local control system

To heat up the fuel gas, hot water generated by the gas burner is kept on a constant
temperature of 90C.

The heaters (one in operation and one standby) are driven by natural gas from the gas
pipeline that is reduced to the required level.

Each gas/water heat exchanger is equipped with vent and drain possibilities, gas-in-
water detection device (level indication), local gas pressure indication, local gas
temperature indication, thermal relief valve.

Fuel Gas Pressure Reducing Station (EKD) F26

The redundant fuel gas pressure reducing station mainly consists of two pressure
control valves and a overpressure slam-shut valve each run.

126
In case of high supply pressure, the pressure control valves regulate the downstream
pressure to gas turbine requirements.

Fuel Gas Dust Filter (MBP)

The fuel gas dust filters are designed as 2100% cartridge type filter and act as a final
barrier for the gas turbine. All parts downstream the filter elements are made from
stainless steel.

Fuel Gas Efficiency Pre-Heater (EKC10) F27

The fuel gas efficiency pre-heater is designed as tube/shell water/gas heat exchanger. It
is used to heat-up the fuel gas to about 150C for efficiency increase.
Hot water from the water/steam cycle is used as heating medium. The heat-input is
controlled by the DCS.
To prevent fuel gas entering the water/steam cycle in case of a tube break a gas
separator is installed in the hot water return line. Separator and heat exchanger are
equipped with gas detection devices used to give alarm in case of a tube break.

Protection System:

The fuel gas system is protected against overpressure by mechanical devices (slam-
shut valve and monitor pressure control valve fail safe close)

Over pressure Protection:

The maximum gas pressure at the plant boundary is defined at 166 bar a. Therefore,
the system is designed for 180 bar a from the plant boundary up to the skid outlet valve
of the pressure-reducing skid. Downstream the pressure-reducing skid, the system is
designed for 61 bar a.

The following protection measures are installed:

4. All components are equipped with safety valves for thermal expansion.
5. Upstream each pressure-reducing valve (EKD) slam-shut valves are installed.
6. Over-temperature Protection at the dew point heater.









127
14. Clean Drain System


128
14. Clean Drain System

Purpose:

The system fulfils the following tasks:
1. Draining of condensate out of the steam lines and the steam turbine.
2. Initial warm-up of steam lines.
3. Steam and condensate separation.
4. Collecting the condensate and forwarding to the blow down system (external
drains) respectively returning to the process (internal drains).


Description of Clean Drain System:

The clean drain system mainly acts during start-up of the water steam cycle. During
these periods, large amounts of steam condense in the piping of the water steam cycle.
The condensate is collected either in the ADV or in the blow down tank.

During normal operation of the plant, the clean drain system acts with little amounts of
condensate.

There are two different groups of drains: external drains and internal drains.

External Drains

External drains are the drains of all lines where steam can flow while the steam turbine
is not in operation and the condenser is not evacuated. The external drains are guided
to the relevant collectors on the ADV respectively to the blow down tank.

The steam drains of the HRSG and the intermittent and continuous blow down drains
are routed to the blow down tank. The connection of some drains of the main steam
system and GT air-cooling system to the blow down tank of the HRSG is done due to
arrangement reasons. The condensate/steam mixture expands and is separated in the
ADV respectively in the blow down- / flash-tank.

The flashed-out steam in the ADV is discharged via the exhaust lines to the atmosphere
outside of the main hall building.

The flashed out steam of the flash tank is recovered in the feed water tank and the
steam from the blow down is routed to safe location in HRSG area.

The condensate is transferred by the ADV pump respectively the blow down tank
pumps to the waste water system.



129
Internal Drains

Internal drains are all drains where steam can flow only if the steam turbine is in
operation. Generally, these are all steam turbine internal drain lines downstream of the
steam turbine control valves. These drain lines are connected to the flash box of the
condenser system. The condensate/steam mixture is cooled down by water injection in
the flash box. The flashed-out steam is discharged to the condenser neck. The
condensate is returned to the process via the main condensate system.

ADV

The ADV is a vertical cylinder vessel. The instruments for monitoring and controlling of
the level are mounted on the outside of the vessel.

ADV Pump

The ADV pump is a single stage pump. It is connected by a coupling to the electric
motor. The electric motor is a three-phase induction type and is powered by the plant
low voltage board. Motor cooling is ensured by the motor internal ventilation device.

Main Components

The system consists of the following main components:
1. Drain lines including drain shut-off valves, steam traps and orifices.
2. Warm-up lines including warm-up shut-off valves and orifices.
3. HP/IP/LP drain collectors.
19LCM20BR001
19LCM30BR001
4. Atmospheric drain vessel 19LCM10AC001
5. Atmospheric drain vessel silencer 19LCM10BS001
6. Atmospheric drain vessel pump 19LCM10AP001

Drain lines, steam traps, orifices and drain valves of various steam lines are indicated
by a 2 following.
The letters BR/BP/AA (for example: 18LBA50BR201).

Warm-up lines, orifices and warm-up valves of various steam lines are indicated by a 6
following

The letters BR/BP/AA (for example: 18LBA45BR601).
Steam turbine drains to the flash box are not part of this system.

Steam line drains from the HRSG enter into the blow down- / flash-tank, but are not part
of this system,


130


Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Oper.
Pr.
(bar)
Design
Temp.
( C)
Temp.
Oper.
( C)

Material

1.

19LCM20BR001
HP/IP/LP
drain
collectors

Steam

400

2

3

564

523
2
Cr Mo
Alloy
Steel

2.

19LCM30BR001
HP/IP/LP
drain
collectors

Steam

400

2

3

564

523
2
Cr Mo
Alloy
Steel


3.


18LBA40BR212
Drain
coming
from IP
Steam
line

Steam

50

34

28.50

572

566
9 Cr-
1Mo-V
Alloy
Steel


4.


18LBA10BR222
Drain
coming
from LP
Steam
line


Steam/
Water

25

7.50

4.97

305

289


Carbon
Steel

5.

18LBC10BR225
Drain
coming
from
CRH line

Steam

50

39

31

420

351
1
Cr Mo
Alloy
Steel

6.

18LBC10BR212
Drain
coming
from
CRH line

Steam

25

39

31

420

351
2
Cr Mo
Alloy
Steel


7.


18LBA50BR201
Drain
coming
from
High Pr.
Steam
line

Steam

50

153


138


572

566
9 Cr-
1Mo-V
Alloy
Steel

8.

19LCM10BR002

Vent
Line

Steam

600

0.20

1.20

563

520
9 Cr-
1Mo-V
Alloy
Steel

9.

18MAL70BR201
Drain
coming
from LP
Steam
line

Steam/
Water

25

7.50

4.97

305

289


Carbon
Steel
131


10.


18LBA50BR231
Drain
coming
from
High Pr.
Steam
line

Steam

50

153

138

572

566

9 Cr-
1Mo-V
Alloy
Steel


11.




18MAN40BR202


Darin
Coming
from
Worm Up
line (IP
by pass)


Steam



25


34

30.60

572

559

9 Cr-
1Mo-V
Alloy
Steel


12.


18LBA41BR201


Drain
coming
from IP
Steam
line


Steam




50




34


28.50


572


566
9 Cr-
1Mo-V
Alloy
Steel


13.



18LBA42BR601

Drain
coming
from IP
Steam
line
Steam


50




34


28.50


572


566
9 Cr-
1Mo-V
Alloy
Steel

14.



19LCM10BR010


Inlet to
ADV
Pump

Steam/
Water



100




0.40


1.20


105


104

Carbon
Steel

15.


19LCM10BR003

Outlet to
ADV
Pump

Steam/
Water



50



9

5

105

104

Carbon
Steel


16.


11LAB91BR201
Inlet to
HRSG
Blow
down
Tank
Water 25 167 144 370 278.2


Carbon
Steel
17. 11LAB92BR201
Inlet to
HRSG
Blow
down
Tank
Water 25 167 143.10 370 278.2
Carbon
Steel

18.

18LBC10BR231
Drain
coming
from
CRH line
Steam 50 39 31 420 351
1
Cr Mo
Alloy
Steel
132



19.


18LBS50BR211
Drain
coming
from HP
Steam
line


Steam 25 39 31 420 351
1
Cr Mo
Alloy
Steel

Table 14




Interface to other Systems

1. Steam and condensate enters though the various drain lines and warm-up lines
from the Main Steam System (LBA), the Air Removal System (MAJ), the IP Bypass
(MAN40), the LP Bypass (MAN10), the GT Air cooling system (MBH), the feedwater
deaeration steam piping (LAA), and the steam turbine.

2. Steam exits trough the vent lines of the atmospheric drain vessel to atmosphere.

3. Condensate collected in the flash box returns to the process via the condenser
hotwell (LC).

4. Condensate collected in the atmospheric drain vessel is further directed to the hot
wastewater collecting pit 90GMP20BB001 of the Waste Water System (GMA).


















133
15. Carbon Dioxide Gas Supply System


134
15. Carbon Dioxide Gas Supply System

Purpose

The system fulfils the following tasks:
1. Storage of the auxiliary gases Carbon Dioxide (CO2).
2. Pressure reduction from storage pressure to transfer pressure.
3. Distribution of auxiliary gases from storage area to consumer interfaces.

Description of Co2 Gas Supply System:

The auxiliary gas supply system consists of individual supply systems for carbon
dioxide. Each of these systems consists of the storage system, the pressure reduction
system and the distribution system.

The gas storage of the three gas systems is centralized in a common shelter. The
hydrogen storage section is separated and declared as a separated hazardous area.

The carbon dioxide supply system provides carbon dioxide to the ST generator cooling
system.

Metastable carbon dioxide is stored in bottle racks consisting of 6 bottles of each 40
liters volume, total 8 racks. The maximum storage pressure is 50 barg. The required
minimum carbon dioxide purity is >99.5 %.

The bottle racks are connected to the high-pressure manifold by flexible hoses.

The redundant heaters will evaporate the carbon dioxide prior entering the 2 redundant
pressure reduction valves. Downstream of this manifold 2 redundant pressure reduction
valves are installed.

Main Equipment:

1. Bottle racks filled with metastable carbon dioxide.
2. 2x 100 % pressure reduction rack with pressure gage and safety valves.
3. 2x 100 % evaporation heaters installed at the pressure reduction racks.
4. Distribution piping with check valves and safety valves.

Interface to other Systems:

The Co2 gases will be transferred via the distribution piping to the ST generator gas
cooling system.



135
16. Hydrogen Gas Supply System


136
16.0 Hydrogen Gas Supply System

Purpose
The system fulfils the following tasks:
1. Storage of the auxiliary gases) Hydrogen (H2).
2. Pressure reduction from storage pressure to transfer pressure.
3. Distribution of auxiliary gases from storage area to consumer interfaces.

Description of H2 Gas Supply System

The auxiliary gas supply system consists of individual supply systems for hydrogen.
Each of these systems consists of the storage system, the pressure reduction system
and the distribution system. The gas storage of the three gas systems is centralized in a
common shelter. The hydrogen storage section is separated and declared as a
separated hazardous area.

The hydrogen supply system provides hydrogen to the ST generator cooling system.

Pressurized hydrogen is stored in bottle racks consisting of 12 bottles of each 50 liters
volume, total 10 racks. The maximum storage pressure is 200 barg.

The required minimum hydrogen purity is >99.9 %. The bottle racks are connected to
the high-pressure manifold by flexible hoses. Downstream of this manifold 2 redundant
pressure reduction valves are installed. The hydrogen is fed with approx. 10 barg into
the distribution piping serving the generator cooling system.

Main Equipment:

1. Bottle racks filled with pressurized hydrogen.
2. 2x 100 % pressure reduction rack with pressure gage and safety valves.
3. Distribution piping with check valves and safety valves.

Interface to other Systems:

The H2 gases will be transferred via the distribution piping to the following consumers:

Hydrogen supply system:

1. ST generator gas cooling system
2. Losses for geno cooling





137
17. Water supply system


138
17.0 Water supply system

Purpose

The system fulfils the following tasks:
1. Providing the combined cycle power plant of Tallawarra with fire fighting water.
2. Providing the combined cycle power plant of Tallawarra with service water.
3. Providing the combined cycle power plant of Tallawarra with potable water.
4. Providing the combined cycle power plant of Tallawarra with demineralised
water.

Description of Water Supply System:

Raw Water Supply:

The raw water supply from TP-D is done via the raw water supply line 19GAC10BR001
to the raw water tank 19GAD10BB001/2. The tank have a capacity of 200 m3.

Raw Water Treatment Plant:

The raw water treatment plant is fed by 2 x 100 % raw water supply pumps from the raw
water tank.
Further treatment steps to reach service water quality are 2 x 100 % ultrafiltration units,
2 x 50 % reverse osmosis units (2 stage) with an afterwards EID section. Integrated to
reach service water quality is the water steam cycle blowdown water treatment plant
(WSCWTP), mainly consisting of: 2 x 100 % chiller with air/water precooler, 1 x 100 %
conventional clarifier, 2 x 100 % multimedia filter and 2 x 100 % ultrafiltration.

Service and Fire Fighting Water System:

The both fire fighting water tanks are excisting with a total capacity of 1000 m3 each.
The tanks are fed via the raw water treatment plant. The tanks are provided with a
connection for inlet, outlet, fire fighting outlet, vent, overflow and drain.
Control of the tank filling is achieved by the use of two level transmitters
(19GAD20/30CL001 and 19GAD20/30CL002). Out of these two independent level
transmitters setpoints prevent the pumps in the demin water treatment plant from
running dry.
Other setpoints control the service water supply. The various consumers of the service
water are shown on P&ID TWA/19/M/G---------/FD/003.
139

Sr.
No

KKS

Name

Fluid
Dia.
mm
Pr.
(bar)
Temp
( C)

Material


1.


19GAC10BR001
Coming from
existing raw
water tank.


Water
(Cold)


300


10


40
High
Density
Poly
Ethylen
e

2.

19GKB10BR002
Coming from city
water

Water
(Cold)

180

10

40
High
Density
Poly
Ethylen
e

3.

19GKB52BR001

Going to
Laibotatory

Air /
Water

25

10

40
Galvani
zed
Carbon
steel

4.

19GKB11BR001
Going to Raw
Water Tank.

Air /
Water

150

10

40
Galvani
zed
Carbon
steel

5.

19GKB54BR001
GT/ST Building

Air /
Water

25

10

40
Galvani
zed
Carbon
steel

6.

19GKB53BR001
Admin. / Control

Air /
Water

25

10

40
Galvani
zed
Carbon
steel

7.

19GAC40BR001
Inlet to Water
Treatment Plant

Water

80

10

40

Stain
less
Steel


8.
19GAC01BR001

Inlet to Pump

Water 100 10 40
Stain
less
Steel


9.
19GAC45BR001

Outlet to Pump

Water 80 10 40
Stain
less
Steel



10.



19GAC42BR001
Outlet of Water
Treatment Plant
& Inlet to Raw
Water Tank



Water



25



10



40



Stain
less
Steel
140

Potable Water System:

Potable Water Distribution System (19GKB) All connected users of the potable water
distribution system (19GKB) use the potable water mainly for the WTP, drinking and
flushing purposes. The supply is from interface point TP-2.


System Filling:

1. The raw water basins are filled via the raw water supply piping.
2. The raw water treatment plant is fed by the raw water supply pumps.
3. Filling of the service and fire fighting water tanks is accomplished by the raw
water treatment plant.
4. The potable water distribution system is fed by the potable water supply line.































141
18. Demineralized Water Supply


142

18. Demineralised Water Supply

Purpose:

The system fulfils the following tasks:
1. Providing the combined cycle power plant of Tallawarra with demineralised
water.


Description of Demineralised water Supply System:


Demin Water Treatment Plant:

The DMWTP consists of the treatment steps 2 x 100 % cation exchanger, 2 x 100 %
anion exchanger and 2 x 100 % polishing mixed bed units and serves the demineralised
water tank.

Demineralised Water Tank (19GHC10BB001)

The demineralised water tank is approximately 8.0 m high with a total capacity of 500
m3. The tank is fed by the forwarding pumps (2 x 100 %) of the demin water treatment
plant via the demineralised water pipe.

The tank is provided with a connection for inlet, outlet, regeneration outlet, recirculation,
vent, overflow and drain.

Control of the tank filling is achieved by the use of two differential pressure transmitters
(19GHC10CL001 and 19GHC10CL002). Out of these two independent level
transmitters setpoints prevent the regeneration pumps in the demin water treatment
plant from running dry.

Other setpoints control the demin water treatment plant and prevent the demin water
forwarding pumps from running dry.


Demin Water Forwarding Pumps (19GHC10/20AP001)

2 x 100 % forwarding pumps supply demineralised water to the respective consumers.
Each pump train is mainly provided with a centrifugal pump, isolating valve and check
valve, a suction pressure gauge and a discharge pressure gauge. A continuous
minimum bypass for pump protection feeds back into the demin water tank.

143

Table: 18









Sr.
No

KKS

Name

Fluid
Dia.
mm
Design
Pr.
(bar)
Design
Temp.
( C)

Material
1. 19GCK01BR001
Coming from
Water Treatment
Plant
Water 80 10 40
Stainless
Steel
2. 19GHC01BR001
Outlet of Demin
tank
Water 200 10 40
Stainless
Steel
3. 19GHC41BR002
Outlet of pump &
Inlet to Demin
Water tank
Water 80 10 40
Stainless
Steel
4. 19GHC45BR001 Outlet of Pump Water 150 10 40
Stainless
Steel
5. 19GHC54BR010
Going to
Laboratory
Water 25 10 40
Stainless
Steel
6. 19GHC53BR010
Going to GT
Wash Skid
Water 25 10 40
Stainless
Steel
7. 18GHC52BR010
Going to
Sampling
Water 50 10 40
Stainless
Steel
8. 18GHC51BR010
Going to Lube oil
Cooler
Water 25 10 40
Stainless
Steel
9. 18GHC55BR010
High GT Fogging
Steam
Water 100 10 40
Stainless
Steel
10. 18GHC54BR010
ST Brushgear
Cooler
Water 25 10 40
Stainless
Steel
11. 18GHC52BR010
Phosphate
dosing
Water 50 10 40
Stainless
Steel
12. 18GHC53BR010
Ammonia /
Oxygen
scavenger
Water 25 10 40
Stainless
Steel
13. 18GHC51BR010
Closed Cooling
system
Water 25 10 40
Stainless
Steel
14. 18GHC55BR010 LC 17C Water 100 10 40
Stainless
Steel
144
Waste Water Treatment Plant:

The WWTP recycles waste water from the RO of the RWTP and neutralised waste
water from the regeneration of the DMWTP. It consists of 2 x 50 % reverse osmosis
units, 2 x 100 % activated carbon filters.
The recycled waste water is fed to the filtered water tank after the ultrafiltration of the
RWTP.


System Filling:

1. The demin water treatment plant is fed by gravity from the service and fire
fighting water tanks.
2. Filling of the demin tank is accomplished via the demin water treatment plant.
3. The demin water lines to the demin water forwarding pumps as well as the line
to the deminwater treatment plant for regeneration and flushing purposes are
filled by gravity from the demin water tank.
4. The demin water piping system to the consumers as well as the minimum flow
line back to the demin water tank shown on the P&ID TWA/19/M/GHC----
/FD/001 are filled by starting one demin water forwarding pump.


























145
19.0 Phosphate Dosing


146
19.0 Phosphate Dosing

Purpose:

Phosphate is dosed into the low, intermediate, and high-pressure boiler drums for the
purpose of maintaining the required pH value of the plant boiler water.

Storage and Dilution Tank:

If the level in the storage tank 18LFN01 BB002 drops below <MIN 1 (CL003), new
dosing medium must be prepared.

Chemical Preparation:
Chemical will be supplied in solid form for preparation of a solution in the mixing/dosing
tank.

The solution will be prepared by adding a pre-determined amount of water using the
solution storage tank-level-gauge. For the filling a solenoid valve is installed. The valve
will be opened and closed to manually at the local control panel.

For safety reason the valve closes at level >MAX 1 (CL004) and Level > MAX 2 to
prevent the dosing tank for overfilling. After the water has been filled into the tank, a
specified amount of Phosphate is added.

Then the stirrer can be started. The stirrer runs for approx. 15 minutes, or for a sufficient
time to assure complete dissolving of the chemical. During the dissolving operation no
dosing should take place otherwise solid material to could enter the suction line and
disturb the dosing.

During the preparation of the reagent the tank outlet-isolating valve should be closed.

Level gauge:

The level gauge (calibration column) indicates the level of the tank contents and gives
the opportunity to check the delivery rate of the dosing pumps. The level measurement
points can be easily changed by adjusting the position of the switching points.
The level gauge has 2 scales, one shows the contents of the tank in m3 and the other
the volume of the pipe. The pipe is used as calibration column to check the delivery rate
of the dosing pumps. When during the removal the level drops below <MIN2 (CL003),
the dosing is interrupted.





147
Equipments:



S.No


KKS

Description

1.


11LFN01 BB001

Storage tank (Phosphate) 1200 L, stainless steel


2.


11LFN01 CL001

Bypass Level control storage tank with 3 level switches.
CL002 <MIN 2 low low level alarm (pumps OFF)
CL003 <MIN 1 low level; alarm (Chemical refill)
CL004 >MAX 1 high level; filled
(Water filling valve OFF)

3.


11LFN01 AM001

Stirrer 750 rpm, 0.25 kW, 3 x 400V, 50 Hz

4.


11LFN01 AA007

Solenoid valve brass nickel plated for make up water , 24 VDC

5.


11LFN01 CL005

Built in Level switch Overfilled.


6.



11LFN05 AP001


Dosing Pump, Spare Pump with automatic stroke length
adjustment, Meta HK 21610SST, 10 l/h, 216 bar (1500 rpm)


7.


11LFN10 AP001

Dosing Pump, LP BOILER with automatic stroke length adjustment,
Meta HK 21603SST, 3 l/h, 216 bar (750 rpm)

8.


11LFN10 CP001

Pressure indicator to LP BOILER (0 - 16 bar)

9.


11LFN10 BB001

Pulsation damper, Stainless steel, (0,15 L, 250 bar)
Expansion vessel Nitrile


10.



11LFN30 AP001


Dosing Pump, IP BOILER with automatic stroke length adjustment,
Meta HK 21603SST, 3 l/h, 216 bar (750 rpm)


11.


11LFN30 CP001

Pressure indicator to IP BOILER (0 - 60 bar)

12.


11LFN30 BB001
Pulsation damper, Stainless steel, (0,15 l, 250 bar)
Expansion vessel Nitrile
148

13.


11LFN50 AP001

Dosing Pump, HP BOILER with automatic stroke length
adjustment, Meta HK 21610SST, 10 l/h, 216 bar (1500 rpm)

14.


11LFN50 CP001

Pressure indicator to HP BOILER (0 - 250 bar)

15.


11LFN50 BB001

Pulsation damper, Stainless steel, (0,15 l, 250 bar)
Expansion vessel Nitrile

Dosing:

Duty dosing pumps are installed for LP / IP / HP Boilers and one standby
pump.
For the duty pumps of the boiler drums (LP / IP / HP) a key switch (Remote -
Local) is installed.
For the standby pump a key switch (Local 0 LP IP HP) is installed.

It is possible to change from the duty to the standby pump on remote operation.
If the key switches of the duty pumps is set to Remote, the system (dosing pumps) can
be switched on and off from the DCS with a pulse (one shot) signal.
In local operation the dosing pumps can be started and stopped at the Local Control
Panel (LCP) with the push-bottoms.

Stroke length controller:

The output of the dosing pumps is adjusted with a stroke length controller.
In remote mode can the stroke length be adjusted from the DCS.
In manual mode can the stroke length be adjusted on the LCP with a manual
controllers (4 20 mA).
The set and actual value of the stroke length controllers can be read for each pump on
individually displays.

Standby Pump (11LFN05 AP001):

If a duty-dosing pump becomes faulted or has to be overhauled, the standby pump will
take over its function. The standby pump is turned on locally at the LCP as follows:

Electrically: Pre selection of LP / IP / HP Pump
Hydraulically: Depending on the desired dosing point, the necessary valves of
Standby pump needs to be opened and the valve at the duty pumps needs to be closed.





149
20. Ammonia / Oxygen Scanveger Dosing



150
20. Ammonia / Oxygen Scanveger Dosing

Purpose:

Feed-water and condensate of the plant water/steam circuit an the fluid of the plant
circuit is alkalized by dosing of Oxygen Scavenger and/or ammonia. The plant will
normally operate continuously dosing either dilute Oxygen Scavenger or/and dilute
ammonia solution.


Equipments:




S.No

KKS

Description


1.

18LFN20 BB001


1 Storage tank (Ammonia), 1200L, stainless steel




2.



18LFN20 CL001

1 Bypass Level control storage tank with 3 level switches
CL002 <MIN 2 low low level alarm (pumps OFF)
CL003 <MIN 1 low level; alarm
(Chemical refill; Chemical preparation)
CL004 >MAX 1 high level; filled
Make up Water filling valve,
Barrel pump OFF

3.

18LFN20 AM001

1 Stirrer 750 rpm, 0.25 kW, 3 x 400V, 50 Hz, Stainless steel blades

4.

18LFN20 AA002

1 Solenoid valve brass nickel plated for make up water , 24 VDC

5.


18LFN20 AT001


Carbon filter 3L (for Ammonia)


6.


18LFN40 BB001


1 Storage tank: Oxygen Scavenger, 1200L, stainless steel




7.



18LFN40 CL001

Bypass Level control storage tank with 3 level switches
CL002 <MIN 2 low low level alarm (pumps OFF)
CL003 <MIN 1 low level; alarm
(Chemical refill; Chemical preparation)
CL004 >MAX 1 high level; filled
Make up Water filling valve,
Barrel pump OFF

151

8.


18LFN40 AM001


1 Stirrer 750 rpm, 0.25 kW, 3 x 400V, 50 Hz, Stainless steel blades


9.


18LFN40 AA002


1 Solenoid valve brass nickel plated for make up water , 24 VDC


10.


18LFN40 AT001


Carbon filter 3L (for Oxygen Scavenger)


11.

18LFN21 AP001


Dosing Pump; Ammonia, 10 L/hr, 216 bar (1500 rpm)


12.

18LFN22 AP001


Dosing Pump; Ammonia, 10 L/hr, 216 bar (1500 rpm)


13.


18LFN25 CP001


Pressure indicator (0 - 40 bar)


15.

18LFN41 AP001

Dosing Pump; Oxygen
10 L/hr, 216 bar (1500 rpm)


16.

18LFN42 AP001


Dosing Pump; Oxygen, 10 L/h, 216 bar (1500 rpm)


17.

18LFN45 CP001


Pressure indicator
0 - 40 bar


Table: 20


Chemical Preparation:

If the level in storage tank 18LFN20 BB001 or 18LFN40 BB001 drops below < MIN 1
(CL003), new dosing medium must be prepared.

Both chemicals will normally be supplied in a concentration that is higher than that
required for dosing.

The solution will be prepared by adding a pre-determined amount of water using the
solution storage tank-level-gauge. For the filling a solenoid valve is installed. The valve
will be opened and closed manually at the local control panel.

For safety reason the valve closes at level >MAX 1 (CL004). Also the barrel pump is
switched of. Overfilling is not possible. Additionally a level >MAX2 (CL005) is directly
152
built into the dosing tank as overfilling protection. Water is filled into the tank. Then the
required amount of Ammonia or Oxygen Scavenger will be added to the tank with the
portable electric barrel pump. The barrel pumps are electrically connected to the Local
control panel.


Dosing:

Duty and standby dosing pumps are installed for the dosing, the output is adjusted with
the stroke length.

A key switch (Remote-Local) is incorporated for the dosing set. If the key switch is set at
Remote, the system (dosing pumps) can be switched on and off from the DCS with a
pulse (one shot) signal.
The changeover of the dosing pumps is made by a timer in the Local Control Panel
(LCP) or failure of one of the dosing pump.

In local operation the dosing pumps can be started and stopped at the LCP with the
push-bottoms.

Stroke length controller:

The output of the dosing pumps is adjusted with a stroke length controller.
In remote mode can the stroke length be adjusted from the DCS.
In manual mode can the stroke length be adjusted on the LCP with manual
current controllers (4 20 mA).

The set and actual value of the stroke length controllers can be read for each pump on
individually displays.

















153
21. Hotwell Sampling Monitoring System


154
21.0 Hotwell Sampling Monitoring System


Sampling Conditioning System

In general, all incoming steam/water samples shall be sample-conditioned such that the
steam/water sample can be measured accurately & handled by the analyzers. Typically,
every sample line has the following sample conditioning equipments;
1) Sample Cooler.
2) Relief valve at Cooling Water Outlet from Sample Cooler (setting at 8 10 bar-
g).
3) Sample Line Flow Regulator (To regulate sample flow at 20 LPH).


Sample Cooler

All sample cooler are designed & sized up to 20 LPH sample water flow-rate as
indicated in the Heat Load Data List. Based on cooling water flow-rate at 750 LPH and
maximum temperature at 47oC, all sample water shall be cooled down to temperature
approximately at 48 dg. Cl from samples designed temperature at 95 dg. Cl.


Relief valve at Cooling Water Outlet from Sample Cooler:

When the cooling water supply is disrupted, some of the water/steam sample will
remain inside the sample cooler. When this occurs, the remnants of water/steam
sample will also pre-heat the remnants of cooling water along the cold side of the
sample cooler. Thus, pressure will build up along the cold side and the sample cooler
may rupture as a result.


Sample Line Flow Regulator:

The flow regulator is actually a rotameter with needle valve. It can regulate sample
flowrate from 8 to 88 LPH. In this application, the sample flow-rate shall be set at 20
LPH in order to achieve sample temperature after sample cooler.









155
Analyzer:

Measuring Parameter in each stream for Hotwell.


BNF STREAM
NO.


STREAM
M KKS

STREAM

PARAMETER

MEASURING
RANGE

1.

18 QUL21


CONDENSATE


Cation Conductivity


0-10 uS/cm

2.

18 QUL 23


CONDENSATE


Cation Conductivity


0 - 10 uS/cm


Cation Conductivity:

Analyzers used are from ABB with the following models for its controller and sensor
Type.
Controller : AX410
Sensor: AC221

Controller Description:

This analyzer is wall-mounted type with conductivity measurable from 0 to 10,000 uS
cm-1. The display is dual 5-digit with 7 segment backlit LCD. This backlit LCD can be
configured as ON or Auto-off after 60 seconds.

As standard, this analyzer provides 2 analogue outputs and 3 relay outputs. Analogue
output can be programmed to any value between 0 and 22 mA. For WSC system, it
shall be programmed as 4-20 mA signal to DCS. Relay outputs are rated 5A at 230
VAC or 5A DC. Analogue output shall be bi-linear of 0 1 10 uS cm-1 (0 50 100%
output).

Accuracy of reading is at 0.01% of span at 0 100 uS cm-1 and 1% of measurement
up to 10,000 uS cm-1.


Sensor Description:

This sensor body comes together with conductivity & temperature sensors integrated.
The sensor used is Pt-100 with reference temperature at 25oC and temperature
compensation allowable from -10 to 200oC. Cell constant is 0.01. This sensor will be
mounted at a stainless steel flow chamber with 3/8 FNPT inlet & outlet for sample.
Sensor Cable length provided is 1 meter or 3.3 feet. Cable connection method is
terminal head type. 4 Maximum operating temperature and pressure are 110oC and 20
156
bar-g respectively. Flowrate of sample prior to this analyzer shall be regulated by flow
regulator at 20 LPH.

Sample Pump Dry-run Protection System (DPS) for Hotwell Sampling Monitoring
System:

Basically, samples pump DPS for each sampling line has the following components;

1. 2 units of 3/8 Solenoid valve.
2. 1 unit of Low Flow Switch.

Sample pump used is gear pump type with IP65 motor with max flow-rate of 150 LPH.
The gear pump used is able to withstand liquid medium at max. 95oC. This gear pump
is designed to have suction length of 5 meters horizontal and 5 meters vertical.
However, gear pump is prone to damages due to dry-run conditions. To protect the
sample pump, a flow switch is placed after the cation conductivityanalyzer. At flow-rate
less than 2 LPH, the flow switch will shut-off the sample pump and 2 units of solenoid
valve to ensure the gear pump in wet condition prior to start-up. This flow switch will
also give out a dry contact signal to DCS via the Hotwell Sampling Control Box.



























157
22. Main And Aux. Cooling Water System


158



159



160

22. Main And Aux. Cooling Water System

Purpose

The purpose of the main (MCWS) and Secondary (SCWS) cooling water system is to
transfer the waste heat to the passing once through cooling water.

Heat sources are the steam turbine/condenser and the parallel stream SCWS located
CCW intercooler of the closed cooling water system (CCWS) with its various heat
sources.

Description of Main And Aux. Cooling Water System:

The MCWS & SCWS is an once through type. From the open water source (Lake
Tallawarra), the cooling water (MCW) pumps (PAC10/20) take suction via the intake
structure, the mechanical cleaning device and bring cold water to the condenser
(MAG02) and to the closed cooling water (CCW) intercooler PGD10/20.

The heated up MCWS & SCWS water is then routed to the seal pit/outfall structure for
discharge into the outlet channel. If applicable the hot discharged water will be cooled
down by the attemperation system. With the attemperation pumps (PAC40/50) cold
water is routed to the seal pit/outfall structure. It is mixed with the hot discharged water
from the MCWS & SCWS.


Main components:

The following equipment is also part of the MCWS & SCWS & ATTS:

The MCWS & SCWS & ATTS consists of the following main components:

Onshore Intake structure PAA01, the coarse bar screen (PAA 01 AT001/002), the
stop gate (PAA01 AB001) and with its intake channel to the mechanical cleaning
device.

Mechanical cleaning device with a fine bar rake (PAA30 AT001), automatically
cleaned for attemperation system.

Mechanical cleaning devices with motorized penstocks (PAA 10/20 AA001) stop
gates (PAA 10 AB001/002/003), the Multi Disc Screens (PAA 10/20 AA001) and a
mechanical fine bar screen (PAA 10/20 AT003).

Fish removal system


161
2 x 50% MCW pumps (PAC 10/20 AP001), MCW pump combined check/control
valves (PAB 01/02 AA001)

Debris filter (PUG10/20)

CCW intercooler (PGD 10/20 AC001)

Condenser inlet valves (PAB 10/20 AA001)

CCW intercooler inlet isolation valves (PCB 21/22 AA001)

CCW intercooler outlet isolation valves (PCB 23/24 AA001)

Condenser tube cleaning system (PAH 10/20/30)

Condenser water box evacuation pumps (MAJ 61/62 AP001)

Condenser outlet valves (PAB 30/40 AA001)

ThermoShock Bypass Valve (PAB 51 AA001)

Condenser Outlet Valve (PAB 50 AA001)

Vacuum breaker valves (MAJ 60 AA007/008)

Seal pit / outfall structures (PAB 90)

2 x 50% Attemperation pumps (PAC 40/50 AP001), Attemperation pump combined
check/control valves (PAB 04/05 AA001)

Sampling facilities (QUP)

MCWS&SCWS and Attemperation Piping or channel system as shown on the P&ID
including instrumentation, hangers, supports, thermal expansions as required











162
Components:

1. MCWS & SCWS & ATTS Intake structure (PAA01):

The Intake structure allow suction/provide intake for adequate amount of cooling water
from the open water source.
Coarse bar screen (PAA01 AT001/002) to protect the system from big debris and to
keep the fishes out. Stop gate (PAA01 AB001) are used to isolate the intake channel.

2. MCWS & SCWS Mechanical cleaning devices / guides
/stop gates (PAA10/20):

The Mechanical cleaning devices (Multi Disc Screen) provide adequate cleaning for the
required amount of cooling water. The gate guides / stop gates (PAA 10
AB001/002/003) allow isolation of one intake/ mechanical cleaning equipment lane or
one MCW pump in case of maintenance/repair needs.

3. ATTS Mechanical cleaning devices / guides /stop gates
(PAA30):

The Mechanical cleaning devices (Fine bar rake) provide adequate cleaning for the
required amount of attemperation water. The gate guides / stop gates (PAA 10
AB001/002/003) allow isolation of one intake/ mechanical cleaning equipment lane or
both attemperation pumps in case of maintenance/repair needs.

4. MCW pumps (PAC10 / 20AP001):

The 2 x 50 % MCW pumps maintain the condenser and CCW intercooler required flow.

5. Attemperation pumps (PAC40/50AP001):

The 2 x 50 % attemperation pumps to maintain the guaranteed water temperature in the
outfall canal.

6. MCWS & SCWS combined check/control valves (PAB
01/05 AA001):

These valves maintain the 2 x 50 % MCW pumps to run within its allowable operating
range.

7. ATTS combined check/control valves (PAB 04/05 AA001):

These valves maintain the 2 x 50 % MCW pumps to run within its allowable operating
range.

8. Condenser inlet valves (PAB10/20AA001):
163

The motor operated condenser inlet valves are used to isolate condenser inlet water
box during maintenance

9. Debris filter (PUG10/20):

The debris filters provide final cleaning for the condenser and CCW intercooler required
flow.

10. Condenser tube cleaning system (PAH10/20/30):

It provides sponge ball cleaning to the cooling waterside of the condenser tubing.

11. Condenser outlet valves (PAB30/40AA001):

The motorized condenser outlet valves are used to isolate condenser outlet water box
during maintenance. They are designed and used to provide sufficient flow to the CCW
intercooler during one MCW pump operation/start-up.


12. ThermoShock Bypass Valve (PAB51AA001):

The motor operated ThermoShock Bypass Valve is used to operate the ThermoShock
Operation Mode

13. MCW Outlet Valve (PAB50AA001):

The motor operated MCW outlet valve is used to isolate the MCW System from the
MCW seal pit/outfall structure during ThermoShock Operation Mode.

14. CCW intercooler inlet or outlet isolation valves (PCB
21/22/23/24AA001):

The manual CCW intercooler inlet or outlet isolation valves are used to isolate CCW
intercooler during operation or maintenance.

15. Tube and Shell type CCW intercoolers (PGD10/ 20AC001):

It transfers the waste heat from CCWS into the MCWS&SCWS


16. Condenser water box evacuation system (MAJ61/62):

The water ring type Condenser water box evacuation pumps assure the removal of
dissolved air and the complete filling of the condenser water boxes.
164

17. Seal pit / outfall structures (PAB90):

The seal pit/weir crest provides the required hydraulic leg for siphon operation. The
outfall structures rout/distribute the discharged MCWS&SCWS into the open water
source.

18. Sampling facilities (QUP):

Samples are taken to analyze the chemical quality of MCWS&SCWS.


19. MCWS & SCWS&ATTS Piping or channel system:

Complete MCWS&SCWS&ATTS Piping or channel systems as shown in the P&ID with
instrumentation, hangers, supports, thermal expansion as required and are mainly used
to route the MCWS&SCWS from intake to the condenser / CCW Intercooler to the seal
pit/outfall area.




Interfaces to other Systems:

MCWS & SCWS intake/outfall structures to open water sources:

Mechanical cleaning incl. fish removal system.
Mechanical cleaning devices of the Attemperation System coarse trash routed to
trash moulds exchange/handling/disposal.
Condenser water box evacuation pumps are connected to (GHC) Distribution
system.
Sampling including Grab Sampling (QUP).
MCWS & SCWS Drain valves enter/discharge to WWS (GM).
Debris filter Backwash is routed through the Backwash valve (PUG10/20AA010)
and enter the condenser discharge to seal pit.











165

23. WSC Sampling Conditioning System



166






167





168



169



170



171

23. Water Steam Cycle (WSC) Sampling Monitoring System

Overview:

System overview shall describe sampling conditioning system, analyzers and thermal
protection system. WSC sampling monitoring system generally consists of 2 sections.
Wet panel
Dry panel.
Wet panel in general contains most of the sampling conditioning equipments while Dry
panel includes analyzers and grab samples.

Sampling Conditioning System:

In general, all incoming steam/water samples shall be sample-conditioned such that the
steam/water sample can be measured accurately & handled by the analyzers. Typically,
every sample line has the following sample conditioning equipments;

1) Sample Cooler
2) Relief valve at Cooling Water Outlet from Sample Cooler (setting at 8-10bar-g)
3) Cooling Waters Relief Valve (setting at 8-10 bar-g)
4) Self-cleaning In-line Filter (100 micron)
5) Pressure Reducing Station
6) Sample Line Relief Valve (Setting at 5 bar-g)
7) Sample Line Flow Regulator (To regulate sample flow at 60 LPH)
8) Backpressure Regulator (preset at 1.36 bar-g)

Sample Cooler:

All sample cooler are designed & sized up to 60 LPH sample water flow-rate as
indicated in the Heat Load Data List. With cooling water at maximum 33oC (the chiller
will ensure incoming cooling water maintained at max. 33oC), all sample water shall be
cooled down to temperature varying from 33.8oC to 37.9oC. Temperature of sample
water after sample cooler must not exceed 45oC. The lowest operating temperatures by
analyzers are Sodium and Dissolved Oxygen at 55oC.

Relief valve at Cooling Water Outlet from Sample Cooler:
When the cooling water supply is disrupted, some of the water/steam sample will
remain inside the sample cooler. When this occurs, the remnants of water/steam
sample will also pre-heat the remnants of cooling water along the cold side of the
sample cooler. Thus, pressure will build up along the cold side and the sample cooler
may rupture as a result.

Cooling Waters Relief Valve:

172
To ensure no pressure build-up at cooling water inlet & outlet header, each header is
equipped with relief valve at pre-set pressure from 8 to 10 bar-g.


Self-cleaning In-line Filter:

The design of this in-line filter is to ensure no large sediments entering the sampling
system and the analyzers especially during initial plant commissioning. The size of
filtering element is 100 microns. Another feature of this in-line filter is self-cleaning.
Utilizing the pressure from the sample, the filtering element is back pressured and all
sediments or contaminants are removed via the drain port to the common drain.


Pressure Reducing Station:

All sampling lines are equipped with VREL (Variable Pressure Reducing Element) from
Sentry. Typically, VREL is placed in sampling line where pressure is at least 10 bar-g.
Initial sample pressure is reduced to the range of 3 to 5 bar-g depending on the
distance from Wet panel to Dry panel. In this application, the sample pressure shall be
reduced to 3 bar-g.


Sample Line Relief Valve:

In the event of VREL failure, the sample relief valve will release excessive pressure by
draining to the common drain when the sample pressure exceeds 5 bar-g.


Sample Line Flow Regulator:

The flow regulator is actually a rotameter with needle valve. It can regulate sample flow
rate from 8 to 88 LPH. In this application, the sample flow-rate shall be set at 60 LPH in
order to achieve sample temperature after sample cooler.


Backpressure Regulator:

After VREL, the sample pressure will be around 3 to 5 bar-g. Typically, analyzers
operate in pressure range between 1.0 and 1.5 bar-g. Thus, the function of
backpressure regulator is to ensure sample pressure is between 1.0 and 1.36 bar-g
prior to entering the analyzers. In excess of 1.36 bar-g pressure, the backpressure
regulator releases sample to the common drain.




173
Analyzers:

At HRSG block, the parameters are being measured;
1. Cation Conductivity
2. Direct Conductivity
3. pH
4. Dissolved Oxygen
5. Sodium


BNF
STREAM
NO.
STREAM KKS

STREAM


PARAMETER

MEASURING
RANGE

Direct
Conductivity

0 - 20 uS/cm

Cation
Conductivity

0 - 2 uS/cm

1.
18 QUL40

HP
FEEDWATER


Dissolved
Oxygen

0 - 2000 ug/kg

Cation
Conductivity

0 - 2 uS/cm

2.
18 QUL30

CONDENSATE

Sodium

0 - 2000 ug/kg

Direct
Conductivity

0 - 300 uS/cm

3.
11 QUL01

LP DRUM
BLOWDOWN
PH

7 - 12

Direct
Conductivity

0 - 300 uS/cm

4.
11 QUL03

IP DRUM
BLOWDOWN
PH

7 - 12

Direct
Conductivity

0 - 300 uS/cm

5.
11 QUL05

HP DRUM
BLOWDOWN
PH

7 - 12

6.
11 QUL11

LP LIVE
STEAM/
LP SAT
STEAM
Cation
Conductivity

0 - 2 uS/cm

174
7.
11 QUL14

REHEAT
STEAM/
IP SAT STEAM
Cation
Conductivity

0 - 2 uS/cm

Cation
Conductivity
0 - 2 uS/cm

8.
11 QUL16

HP LIVE
STEAM/
HP SAT
STEAM

Sodium

0 - 1000 ug/kg








Prepared By:















Ashwani Kumar
ashwani872@yahoo.com
6
th
Months Training Report
+91-9911137304, +91-9464338557, +91-9569329450