HRSG

000

09-Sep-11

ISSUE FOR INFORMATION

B.H.Park

C.R.Kim

J.S.Kim

REV

DATE

DESCRIPTION

CHKD.

CERT.

APPD.

Project Title

CONVERSION OF QURAYYAH OPEN CYCLE POWER PLANT TO COMBINED CYCLE POWER PLANT PROJECT C

Client

Consultant

Contractor

Document Title

O&M MANUAL FOR HRSG CREATED BY:

CHECKED BY:

DATE STARTED:

DATE COMPLETED:

OPR'G. DEPT.:

ENG. DEPT.: APPROVAL/CERTIFICATION INFORMATION

THIS DOCUMENT IS NOT TO BE USED FOR CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL CERTIFIED AND DATED

DOC. NO.

QURAYYAH

REV. NO.

SAUDI ARABIA JOB ORDER NO.

1-0923053.01 JOB NO.

PROJECT SUBDIVISION

DOCUMENT TYPE CODE

DOCUMENT NUMBER

REV. NO.

30621127

000

3DT

00019

000

30621127-000-3DT-00019-000 Page 1 of 248

Qurayyah CCPP HRSG

1.0

GENERAL

1.1 Purpose 1.2 Introduction

Chapter 1.0

General

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Qurayyah CCPP HRSG 1.1

Purpose This technical document provides the necessary instruction for the operation and maintenance of the Heat Recovery Steam Generators (HRSG), installed in the Qurayyah

Add-on Combined Cycle Power Plant 30 & 40, Saudi Arabia.

1.2

Introduction

9

The triple pressure heat recovery steam generator (HRSG) with reheater based on the natural circulation principle is located downstream of combustion gas turbine for use in a combined cycle power plant which is installed in the Qurayyah

Add-

on Combined Cycle Power Plant 30 & 40, Saudi Arabia. 9

The Qurayyah plant consists of five (5) blocks and each block consists of three(3) gas turbine generator units(GT Model GE 7FA), three(3) unfired HRSGs utilizing the exhaust heat of the gas turbine and one(1) steam turbine generator unit (STG).

9

The gas turbines and associated components have been installed as part of previous Qurayyah open cycle project. Exhaust gas diverter dampers is provided and able to divert flow to either the bypass stack for open cycle operation, or to the HRSG for combined cycle operation.

9

Each HRSG operates independently with its own gas turbine and produced steam to be fed into a common steam header to drive the steam turbine.

9

The HRSG is unfired, reheat, three (3) pressure levels of high pressure (HP), intermediate pressure (IP) and low pressure (LP), natural circulation and vertical gas flow design. The low pressure drum is provided with feedwater storage function. The integrated deaerator is mounted on the LP drum.

Chapter 1.0

General

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Qurayyah CCPP HRSG

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1 HRSG SYSTEM OVERVIEW This document describes the Heat Recovery Steam Generator (hereafter HRSG) system for the Qurayyah Combined Cycle Power Plant. The Qurayyah plant consists of five (5) blocks and each block consists of three(3) gas turbine generator units(GT), three(3) unfired HRSGs utilizing the exhaust heat of the gas turbine and one(1) steam turbine generator unit (STG). The gas turbines and associated components have been installed as part of previous Qurayyah open cycle project. Exhaust gas diverter dampers is provided and able to divert flow to either the bypass stack for open cycle operation, or to the HRSG for combined cycle operation. Each HRSG operates independently with its own gas turbine and produced steam to be fed into a common steam header to drive the steam turbine. The HRSG is unfired, reheat, three (3) pressure levels of high pressure (HP), intermediate pressure (IP) and low pressure (LP), natural circulation and vertical gas flow design. The low pressure drum is provided with feedwater storage function. The integrated deaerator is mounted on the LP drum. The HRSG is designed to have the following output at Guarantee condition; Load Case

N-1(Guarantee)

D-1 (Guarantee)

GT Load

100 %

100 %

Ambient temperature

33 deg.C

33 deg.C

Fuel type

Natural Gas

Distillate Oil

HP Steam pressure at superheater outlet

132.19 bara

107.92 bara

HP Steam temperature at superheater outlet

567 deg.C

527.7 deg.C

HP Steam flow at superheater outlet

53 kg/s

44.3 kg/s

HRH Steam pressure at reheater outlet

36.34 bara

30.59 bara

HRH Steam temperature at reheater outlet

566 deg.C

523.5 deg.C

HRH Steam flow at reheater outlet

58.6 kg/s

50.7 kg/s

IP Steam pressure at superheater outlet

37.66 bara

31.73 bara

IP Steam temperature at superheater outlet

339.7 deg.C

322.8 deg.C

IP Steam flow at superheater outlet

7.5 kg/s

8.2 kg/s

LP Steam pressure at superheater outlet

6.34 bara

4.04 bara

LP Steam temperature at superheater outlet

252.1 deg.C

LP Steam flow at superheater outlet

6.6 kg/s

0 kg/s

Stack Exhaust Gas temperature

107.2 deg.C

153.7 deg.C

2.0 General Description

N.A

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Qurayyah CCPP HRSG

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1.1 High Pressure (HP) system Reference P&ID ; - P&I Diagram – HRSG H.P Superheater Section [Dwg No. EA-685640] - P&I Diagram – HRSG H.P Econ. & Evap. Section [Dwg No. EA-685642] The high pressure steam generation system generates HP steam of specific quality, which means of correct pressure and temperature, from the thermal energy contained in the Gas turbine exhaust gas. The steam is produced in the HRSG and fed to the HP main steam system. - Heating surface information of HP system; Design Pressure

Design Temperature

(barg)

(Deg.C)

SA210C

210

371

HP Economizer 2

SA210C

210

371

HP Evaporator

SA210C

153

360

HP Superheater 1

SA213-T11

153

451

HP Superheater 2

SA213-T91

153

564

HP Superheater 3

SA213-T91

153

599

Component

Tube Material

HP Economizer 1

- Safety valves information of HP system; Description

Tag. No.

Set Pressure (barg)

Capacity (kg/s)

HP S.H ERV

LBA-90-AA-191

145.5

9

HP S.H SV

LBA-90-AA-192

146

14.9

HP Drum 1st SV

HAD-90-AA-191

153

22.4

HP Drum 2nd SV

HAD-90-AA-192

157.6

22.4

HP Economizer SV

HAC-90-AA-191

210

19.1

The system fulfils the following object: z Delivers feedwater to the high pressure drum during start-up, shut-down and power operation of the combined-cycle unit. z Shuts off feedwater supply during feedwater control malfunction in order to prevent overfeeding of the HRSG. z Supplies HP steam produced by the HRSG to the HP main steam system during normal operation. z Supplies HP feedwater to the HRSG HP desuperheating system. z Maintains and safeguards the HP superheated steam temperature within the allowable main steam system limit during part load operation at high ambient temperatures. 2.0 General Description

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Qurayyah CCPP HRSG

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HP Feedwater System The HP feedwater line is equipped with a check valve to prevent back-streaming from the HRSG into the feed water pumps. The line can be isolated by a motorized stop valve. The HP feedwater control valve station is located downstream of the HP economizer to prevent steaming of feedwater in the economizer. A relief valve is installed downstream of economizer to prevent overpressure in the economizer if the HP feedwater control valve is closed and HRSG in operation. From the HP feedwater line, the spray water line to the HP desuperheating spray system branch off. The HP desuperheating spray system delivers water into the HP interstage desuperheater located between HP superheater heating surfaces. It can limit the HP steam temperature within the design value during part load or normal operation at high ambient temperature. The Max. spray flow is approximately 8% of the steam flow. HP Steam Generation The high pressure system is located downstream the exhaust gas inlet of the HRSG. The heating surfaces are fabricated mainly from finned tubes. The high pressure system is subdivided into the following sections, listed in the order in which exhaust gas flows through them; z HP Superheater 3/2/1 z HP Evaporator z HP Economizer 2/1 The HP economizer recovers the remaining heat contained in the exhaust gas at the HP evaporator outlet. The HP evaporator generates steam through a natural circulation loop from and to the HP drum. The HP superheater heats the saturated steam from HP drum temperature to superheated steam. The HP superheater and the HP economizer are cross counter flow heat exchangers and the HP evaporator flow is cross to the exhaust gas flow. The HRSG is of vertical design. The feedwater is fed by the HP/IP feedwater pumps from the LP drum to the HP economizers, where it is heated up to economizer outlet temperature and then delivered to the HP drum. Water is fed from the HP drum through downcomers to the inlet header of the HP evaporator. Water partly evaporates in the HP evaporator and the water/steam mixture is fed via natural convection in the tube risers from the outlet header back to the HP drum. The connection piping between the outlet header and drum is distributed uniformly over the length of the drum. 2.0 General Description

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The HP drum has the following functions: z ensure good mixing of feedwater and HP Drum water z reserve a water required for the circulation system z allow water expansion during start-up z ensure a thorough water and steam separation z Deliver saturated steam of specified purity ( 10 : < 0.5 mg/kg - Chloride (Cl ) - Ammonia : > 10 mg/kg

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Recommended HRSG Hydrostatic Test Procedure QURAYYAH COMBINED CYCLE POWER PLANT 2.5

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PAG. 9 OF 22

Temporary Piping

1) Filing and blow-off lines (a) HP Economizer The filling and blow-off lines shall be connected to the feed water pipe line and header drain line. (b) HP Evaporator and Superheater The filling and blow-off lines shall be connected to the HP Evaporator supply pipe line and HP steam pipe line. (c) IP Economizer The filling and blow-off lines shall be connected to the feedwater pipe line and header drain line. (d) IP Evaporator and Superheater The filling and blow-off lines shall be connected to the IP Evaporator supply pipe line and IP steam pipe line. (e) LP Evaporator and Superheater The filling and blow-off lines shall be connected to the LP Evaporator supply pipe line and LP steam pipe line. (f) CPH The filling and blow-off lines shall be connected to the Condensate supply pipe line and header drain line. 2) Pressurizing line and location of sampling The pressurizing lines shall be connected to the above related parts. Notes: 1) Depending on the specific hydrostatic test methodology that the HRSG erector will issue, HRSG OEM can provide required advice in selecting the filling and blow-off lines, as well as the pressurizing lines and sampling location. 2) The third party inspector requirements(if have) shall also be considered by HRSG erector.

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Recommended HRSG Hydrostatic Test Procedure QURAYYAH COMBINED CYCLE POWER PLANT 3.0

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PAG. 10 OF 22

HYDROSTATIC TEST STEP 3.1

Preliminary Hydrostatic Test

1) Water-filling Water shall be introduced into the boiler. NOTES : Depending on the specific Hydrostatic Test methodology that the specialized contractor will issue, HRSG OEM can provide the required advice in selecting the filling lines. The Third Party Inspector requirements shall also be considered by HRSG erector. Fill with treated condensate or treated demineralized water. Refer to Section 2.4 CAUTION: The use of fill water, treated with solid chemicals, should be avoided. Deposits of solid materials in superheaters can be detrimental from heat transfer and corrosion standpoints. Superheaters containing stainless steel tubing are particularly vulnerable to stress corrosion cracking in the presence of such chemicals as caustic and chlorides. 2) Feed water system HRSG feed water pump must be allowed to operate normally. In case feed water system is not in service, HRSG Erector shall conduct water filling using a separate filling pump referred in section 2.0. 3) NDT To confirm performing the Radiographic Examination and Stress Relieving Test to all pressure and welding parts. 4) Pipe Support To check whether all the hanger supports are in locked condition. 5) Cleaning Before starting to fill the boiler make sure all drums and headers are cleared of foreign material. Close all drains. Open all vents normally used when filling the HRSG (such as superheater link vents, economizer link vents, drum vents). 6) Operator and Inspector Operators and inspectors are requested to be placed in the position as required.

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PAG. 11 OF 22

7) Pressurizing Pressurizing shall be performed with the pressurizing pump, connected to the pressurizing line. The pressurizing rate of 3∼5 bar per minute is recommended. When the pressure has reached 80% of the safety valve setting pressure, the pressurizing pump must be stopped and the gags shall be set on the safety relief valves. Then, the pressurizing shall continue again, up to the test pressure. 8) Inspection The HRSG shall be inspected for leakage 2-3 times during the pressurizing process. During the inspection, the pressurizing pump shall be shut-off. When the test pressure has been reached, the pressure shall be maintained for a minimum 10 minutes. NOTES : (a) close visual inspection is not required during this stage, in the interest of safety of the inspector. (b) at near the design pressure(maximum working pressure), the pressurizing shall be performed at a lower rates, so as not to exceed the test pressure. 9) Pressure decreasing After reaching the test pressure, the pressure is then reduced to design pressure using the relief valve of the pressurizing pump, special pressure relief valve or other drain valves. NOTES : (a) The pressure decreasing rate shall be 3-5 bar per minute. (b) The pressure relief valve or drain valve must not be opened too fast. When the pressure has decreased to design pressure, the pressure reducing valve must be closed, in order to carry out the official inspection for leakage. After inspection, pressure decreasing shall be continued. When the pressure has decreased to 80% of the safety valve setting pressure, the pressure reducing valve must be closed, in order to remove the gags from the safety relief valves. After the removal of the safety relief valve gags, the pressure decrease shall continue. 3.2

Official Hydrostatic Test

The HRSG shall be pressurized and depressurized in the same manner as in the preliminary test. The HRSG shall be maintained under the specified hydrostatic test pressure for required time

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PAG. 12 OF 22

The official leakage inspection shall be carried out at the design pressure during pressure decreasing stage.. If no leakage has identified, the hydrostatic test can be considered completed. General Notes The hydrostatic test shall be conducted using water at no less than ambient temperature, but in no case less than 21 oC as per PG-99. At no time during the hydrostatic test shall any part of the boiler be subjected to a general primary membrane stress greater than 90% of its yield strength (0.2% offset) at test temperature as per PG-99. The hydrostatic test pressure shall be under proper control at all times so that the required test pressure is never exceeded by more than 6% and close visual inspection for leakage is not required during this stage as per PG-99.1 It is recommended the boiler metal temperature shall be less than 49 oC during the close examination during the pressurizing status as per PG-99.2

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Recommended HRSG Hydrostatic Test Procedure QURAYYAH COMBINED CYCLE POWER PLANT 4.0

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PAG. 13 OF 22

PRESERVATION AFTER HYDROSTATIC TEST -

Introduce nitrogen through the drum vent to pressure the unit to approximately 0.2~0.4 barg.

-

Remove all hydrostatic test plugs and gags from the safety valves prior to starting up the unit

Note: Since there is generally some time delay between the hydrostatic test and the chemical cleaning of the boiler, the unit should remain full of water; air should not be allowed to enter. Note: If there is a chance of freezing, the water in the drainable circuits can be displaced with nitrogen and the unit can laid up under nitrogen pressure. Temporary heating equipment should be provided to keep the non-drainable superheater elements above freezing temperature. The preservation after the hydrostatic test shall be in accordance with the recommended HRSG Conservation Procedure.

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Recommended HRSG Hydrostatic Test Procedure QURAYYAH COMBINED CYCLE POWER PLANT 5.0

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PAG. 14 OF 22

HYDROSTATIC TEST PRESSURIZING CHART

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Recommended HRSG Hydrostatic Test Procedure QURAYYAH COMBINED CYCLE POWER PLANT 5.1

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PAG. 15 OF 22

Package No.1, HPSH / HPEVA / HPSTM Piping

Holding Time Min. 10 Minutes at 219 barg

Inspection Time Min. 10 Minutes at 146 barg

Safety Valve Gagging at ca. 108 barg

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PAG. 16 OF 22

Package No.2, HPECO / HPFWT Piping

Holding Time Min. 10 Minutes at 315 barg

Inspection Time Min. 10 Minutes at 210 barg

Safety Valve Gagging at ca. 168 barg

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PAG. 17 OF 22

Package No.3, RH / HRH, CRH Piping

Holding Time Min. 10 Minutes at 67.5 barg

Inspection Time Min. 10 Minutes at 45 barg

Safety Valve Gagging at ca. 29.5 barg

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PAG. 18 OF 22

Package No.4, IPSH / IPEVA / IPSH Piping

Holding Time Min. 10 Minutes at 68.2 barg

Inspection Time Min. 10 Minutes at 45.5 barg

Safety Valve Gagging at ca. 31 barg

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PAG. 19 OF 22

Package No.5, IPECO / IPFWT Piping

Holding Time Min. 10 Minutes at 112.5 barg

Inspection Time Min. 10 Minutes at 75 barg

Safety Valve Gagging at ca. 51 barg

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PAG. 20 OF 22

Package No.6, LPSH / LPEVA, LPSTM Piping

Holding Time Min. 10 Minutes at 15 barg

Inspection Time Min. 10 Minutes at 10 barg

Safety Valve Gagging at ca. 5 barg

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PAG. 21 OF 22

Package No.6, CPH / CPH Piping

Holding Time Min. 10 Minutes at 60 barg

Inspection Time Min. 10 Minutes at 40 barg

Safety Valve Gagging at ca. 27 barg

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Recommended HRSG Hydrostatic Test Procedure QURAYYAH COMBINED CYCLE POWER PLANT 6.0

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PAG. 22 OF 22

ATTACHMENT

30621127-000-3DT-00019-000 Page 150 of 248

HRSG HYDROSTATIC TEST PACKAGE NO.1 - PART1 HPSH SECTION

SEE TO PACKANGE NO.1 PART2 DWG

REFER TO BOP PACKAGE DWG

REFER TO BOP PACKAGE DWG

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HRSG HYDROSTATIC TEST PACKAGE NO.1 - PART2 HPEVA SECTION

SEE TO PACKAGE NO.1 PART1 DWG

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HRSG HYDROSTATIC TEST PACKAGE NO.2 HPECO SECTION

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HRSG HYDROSTATIC TEST PACKAGE NO.3 HR SECTION

REFER TO PACKAGE NO.4 DWG

REFER TO BOP PACKAGE DWG

SEE TO BOP PACKAGE DWG

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HRSG HYDROSTATIC TEST PACKAGE NO.4 IPSH/IPEVA SECTION

SEE TO PACKAGE NO.

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HRSG HYDROSTATIC TEST PACKAGE NO.5 IPECO SECTION

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REFER TO BOP PACKAGE DWG

HRSG HYDROSTATIC TEST PACKAGE NO.6 LPSH/LPEVA SECTION

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HRSG HYDROSTATIC TEST PACKAGE NO.7 - PART.1 CPH SECTION

SEE TO PACKAGE NO.7 PART.2 DWG

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SEE TO PACKAGE NO.7 PART.1 DWG

HRSG HYDROSTATIC TEST PACKAGE NO.1 - PART.2 CPH SECTION

30621127-000-3DT-00019-000 Page 159 of 248

0

2011.08.26

First Issue

BJ Park

IS Kim

SG Jung

REV NO.

DATE

DESCRIPTION

CHKD.

CERT.

APPD.

Project Title

CONVERSION OF QURAYYAH OPEN CYCLE POWER PLANT TO COMBINED CYCLE POWER PLANT PROJECT C Client

Consultant

Contractor

Document Title

RECOMMENDED HRSG LAYUP PROCEDURE CREATED BY:

CHECKED BY:

DATE STARTED:

DATE COMPLETED:

OPR'G. DEPT.:

ENG. DEPT.:

THIS DOCUMENT IS NOT TO BE USED FOR CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL CERTIFIED AND DATED

QURAYYAH

APPROVAL/CERTIFICATION INFORMATION DOC.NO.

REV.NO.

SAUDI ARABIA JOB ORDER NO.

1-0923053.01 Job No.

Project Subdivision

Document Type Code

Document number

Revision

30621127

000

GAP

EE-XXXXX

0

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Recommended HRSG Layup Procedure QURAYYAH COMBINED CYCLE POWER PLANT

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PAG. 2 OF 10

TABLE OF CONTENTS

1.0

GENERAL

2.0

SELECTION OF LAYUP METHODS

3.0

DRY LAYUP METHOD

4.0

WET LAYUP METHOD 4.1

Hot Wet Layup Method

4.2

Cold Wet Layup Method

5.0

MONITORING

6.0

MISCELLANEOUS RECOMMENDATIONS

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PAG. 3 OF 10

GENERAL The purpose of layup is to minimize corrosion (pit corrosion or oxygen pitting) as well as to reduce the subsequent start up after shutdown. This procedure is for water and steam side, not for gas side. For gas side, refer to chapter 6 miscellaneous recommendation in this procedure. There are three kinds of key factors for corrosion such as the water, the oxygen and the metal. In case of the metal, it is unavoidable in HRSG. There are two choices which are to eliminate water or oxygen. If remove water, it is dry layup method and if remove oxygen, it is wet layup method. a)

Dry Layup method

b)

Wet Layup method

The concept of dry layup is to fully fill the nitrogen at the inside of tubes, pipes and drums. The concept of wet layup is to fully fill the water with pH 10 ~ 11 and a low conductivity uniformly throughout the inside of tubes, pipes and drums. All chemicals herein should be followed the manufacturer’s instructions.

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PAG. 4 OF 10

SELECTION OF LAYUP METHODS Desiccant method can be used for transportation before install on site. If delay starting of erection, it needs to discuss with DOOSAN. During erection, it should be considered the attack by corrosion environments such as rainy. After mechanical completion in field, it shall the hydro pressure test in field in accordance with hydrostatic pressure test procedure. Before hydro test and after hydro test, it shall follow layup method on hydro pressure test procedure. After chemical cleaning, HRSG shall be conserved wet or dry layup method depending on the site conditions such as the below maintenance, freezing and availability. There are many factors to select layup method to protect the HRSG heat transfer internal surfaces: Maintenance If expect maintenance during the outage, it shall select dry layup method. However, if maintenance is anticipated, the dry air method shall be used. Freezing If expect freezing during the outage, it shall select dry layup method. Availability If expect not to be operated properly the chemistry, it shall select dry layup method. Outage period If expect the subsequent start up during the outage, it shall select wet layup method. Because HRSG can not be successfully dried, wet layup method is strongly recommended.

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PAG. 5 OF 10

DRY LAYUP METHOD The Dry Layup method, which requires nitrogen sealing, is a typical and effective method used for a long outage period (more than 48 hours). The following are mandatory requirements for the nitrogen gas sealing method: a)

After the HRSG pressure has reached the 1.5 barg, the water existing in the HRSG shall be gradually drained by opening the blow off valves.

b)

The heat remaining in the HRSG metal will dry the moisture at the inside of tubes. Due to this reason, the vent is to open and to close. It must be initiated around 1.5 barg.

c)

Charge nitrogen gas from nitrogen gas injection system of each drum.

d)

When nitrogen gas, instead of water, starts to come out from the blowdown tank outlet (to the sump), drums blow off valves shall be closed.

e)

After all HRSG sections have been filled with nitrogen gas, all valves shall be closed.

f)

The nitrogen pressure in all sections shall be maintained at 0.5 barg (min. 0.2 barg). Nitrogen gas shall be recharged when the pressure reaches 0.3 barg. The nitrogen gas pressure in all sections shall be checked with the related existing pressure gauges.

g)

Nitrogen gas pressure shall be checked daily at the pressure gauges.

h)

As the HRSG cools to the ambient temperature, the nitrogen gas pressure shall be checked frequently because HRSG cooling will decrease nitrogen pressure.

Alternatively, the circulating dehumidified air is able to use instead of nitrogen under maintaining below 30% related humidity. Maximum 0.1% volume percentage nitrogen is recommended. Caution: Nitrogen is a hazard to personnel and can not be used if maintenance on the systems is going to be proceeded. If there are any leaks from the inside of tubes and piping to the gas side, anyone on the gas side of HRSG should be left because of a lethal environment. If repair works are anticipated, dry air instead of nitrogen has to inject to the inside of tubes and piping. The related humidity levels should be checked at the drain or vent less than 30%.

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WET LAYUP METHOD

4.1

Hot Wet Layup Method

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PAG. 6 OF 10

It is “bottle up” by closing stack damper and drain/vent valve. The water chemistry shall be kept from the normal value to maximum value. If the pressure in drum is less than 1.5 barg, it needs to fill nitrogen from steam drum to superheater to preventing air ingress into the inside of tubes, piping and drums. The following are mandatory requirements for the hot wet layup method: a)

Keep drum level from start up level to normal level.

b)

The temperature will gradually down by heat loss.

c)

The pressure will be up and down for the time being and then it will gradually down.

If the pressure in drum approaches to 1.5 barg, the followings are mandatory requirements. d)

If the pressure approaches to 1.5 barg, the steam drum pressure shall be pressurized by nitrogen on the connection of steam drum.

e)

Nitrogen gas pressure shall be maintained at 0.3 barg at any time.

f)

Close the nitrogen connections until start up HRSG. Also, close the level gages on the steam drums if lasts over 3 days layup.

g)

Before put in service, the drain valves are opened to blow off any water. Also, open the level gages.

Caution: Nitrogen is a hazard to personnel and can not be used if maintenance on the systems is going to be proceeded. If there are any leaks from the inside of tubes and piping to the gas side, anyone on the gas side of HRSG should be left because of a lethal environment. 4.2

Cold Wet Layup Method The wet layup method requires the HRSG, except the superheater, to be completely filled with feedwater. The wet layup method, which requires nitrogen sealing in superheater and which requires water sealing in evaporator / economizer, is a typical and effective method used for a long

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outage period (more than 48 hours). The following are mandatory requirements for the Wet Layup method: a)

When the HRSG is required to be shutdown, the chemicals shall be added 30 minutes before taking the HRSG out of service.

b)

The water quality shall be the same or similar to normal deaerated feedwater/condensate treated with chemicals. The recommended chemicals are hydrazine (or an alternative) for eliminating oxygen and ammonia(or amine) for maintaining pH value between 10 ~ 11.

c)

Keep drum level from start up level to normal level.

d)

The temperature will gradually down by heat loss.

e)

The pressure will be up and down for the time being and then it will gradually down.

f)

If the pressure approaches to 1.5 barg, the steam drum pressure shall be pressurized by nitrogen on the connection of steam drum.

g)

Purge the superheater. The nitrogen shall be vented downstream the superheater.

h)

After the HRSG complete filling, all valves shall be closed, to avoid any air flow into the HRSG sections

i)

Nitrogen gas pressure shall be maintained at 0.3 barg at any time.

j)

The hydrazine (or an alternative) concentration in the HRSG water shall be tested weekly. The chemical sampling system should be used for these tests. Hydrazine (or an alternative) shall be added, as required, to maintain the proportion of 100 to 200 ppm.

k)

HRSG water level shall be checked. If required, additional feedwater shall be filled in. Also, hydrazine (or an alternative) shall be filled in, in order to maintain the required proportion.

l)

Close the nitrogen connections until start up HRSG. Also, close the level gages on the steam drums if lasts over 3 days layup.

m)

During wet layup, the recirculation of fluid is required for maintaining the chemicals intended every week for one hour. The temporary layup recirculation pump shall be connected to the evaporator downcomer and economizer inlet.

n)

If not action l), drain the water under 0.3 barg of nitrogen pressure and refill the economizer and evaporator up to drum level high high with deaerated water, pH 10~11, hydrazine (or an alternative) concentration 200 ppm.

o)

Before put in service, the drain valves are opened to blow off any water. Also, open the level gages.

The Requirement for Post Hydrostatic Test Layup Demineralized water or Condensate treated with Ammonia -

pH

: > 10

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-

Ammonia

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: > 10 mg/kg

Caution : Nitrogen is a hazard to personnel and can not be used if maintenance on the systems is going to be proceeded. If there are any leaks from the inside of tubes and piping to the gas side, anyone on the gas side of HRSG should be left because of a lethal environment.

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MONITORING Short term layup (four days) is required to monitor four hours basis and long term layup (over four days) is required to monitor every day basis. DRY LAYUP It should be monitored nitrogen pressure. . WET LAYUP It should be monitored pH, conductivity and nitrogen pressure.

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MISCELLANEOUS RECOMMENDATIONS At the beginning of the "Lay Up" method, the combustion gas side shall also be inspected. Soot, etc. must be removed. The surface of the drums, tubes and the combustion gas side should be inspected for corrosion. Gas side corrosion typically occurs when moist air is present with tube deposits containing sulfuric acid or other fuel-borne contaminants. The gas side can only be laid up dry, if necessary Electrical Heaters will be used to prevent condensate. And also silica gel can be placed inside the gas side. The quantities are 0.5 kg / m3. Periodic inspection of the gas side should be performed to ensure that conditions promoting rapid corrosion are not present. Under warm high humidity environment below the ambient dew point, a rust / flaky scale in finned tube will occur. The desired relative humidity is less than 30%. If find the gas side corrosion, cleaning of flaky deposits from finned tubes is recommended. -

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9.0

HRSG WATER CHEMISTRY REQUIREMENTS 9.1

General

9.2

Water Treatment

9.3

Requirement for HRSG Feedwater

9.4

Requirement for HRSG Drum Water (Boiler Water)

9.5

Requirement for Steam Quality (Reference)

9.6

Sampling/Monitoring Recommendation

9.7

Caution

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9.0

HRSG WATER CHEMISTRY REQUIREMENTS

9.1

General The purpose of this requirement is to minimize corrosion, erosion and deposits under good industry practices. In order to protect all components of the steam water cycle against corrosion, erosion and deposits and so not to affect the plant efficiency, it is essential to control the water chemistry within the values in this requirement. This requirement is limited to drum type HRSG.

Copper-tubed condenser, brass-

tubed condenser and air cooled condenser is not permitted to use this requirement. These requirements are generally in accordance with published guidelines from EPRI, VGB, EN, ASME and ABMA. The plant water chemistry control requirements provided by plant engineering company are preferred. The aim of minimizing corrosion / erosion and avoiding deposits is reached by - Using de-mineralized water - Controlling the pH value by ammonia - Reducing the oxygen content within recommended ranges - Blowing off the drum water During normal operation, the maximum rate of make up water is one percentage. During upset condition, up to five percentage of make up water is allowed. Special attention is required when HRSG is in use for cogeneration purposes because of a wide range of make up water demand. During commissioning, this requirement should be verified by the plant operator. Generally, the quality of the steam is proportional to the quality of the water. Due to frequently start up and shut down, well skilled chemical operators are required.

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9.2

Water Treatment HRSG OEM is not responsibility for water treatment.

The type of chemical

treatment will be selected depending on the variety of material, system supplied, etc. This requirement is to provide based on all volatile treatment.

pH value is high

enough so that any copper containment at the feed water system is not allowed. If there is any copper containment, oxygenated treatment can be selected under high purity water, lower pH value. Organic treatment chemicals is not permitted in order to minimize the potential flow accelerated corrosion.

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9.3

Requirement for HRSG Feedwater The feedwater is from out of our boundary such as steam turbine condenser or external deaerator storage tank.

The feedwater is pumped to HP/IP drums by the

feedwater pump from LP storage tank.

The feedwater is used to spray system.

The following requirements are valid for continuous operation. and shutdown, the following requirements will deviate.

During start up

The following

requirements are the maximum allowable values except pH.

Parameter

Unit

Required value

μS/cm

< 0.2

-

9.4 ~ 9.8

Silica as SiO2 @ 25deg. C

ppb

< 20

Iron as Fe @ 25deg. C

ppb

< 20

Sodium as Na @ 25deg. C

ppb

< 10

Copper as Cu @ 25deg. C

ppb

15 barg; Intermediate (20%) open.

5) IP Steam line drain MOV (LBA-95-AA-003) Open drain valve when IP Drum pressure (HAD-94-CP-001/002/003) above 1 barg. Close after 5 minutes time delay, if IP Drum pressure reaches or higher than 5 barg and IP Steam PCV (LBA-95-AA-081) open more than 10 %. Then, place into auto operation mode monitoring the drain pot level switches. - Open when High or High/High level switch detect any condensate. - Close when High level switch detect no condensate. Chapter 10 Operating Procedure

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This valve shall have opening limit to prevent excess drain flow. When open demand is initiated, the valve open position shall be determined as following. - IP Drum Pressure < 15 barg; full open. - IP Drum Pressure > 15 barg; Intermediate (20%) open.

6) LP Steam line drain MOV (LBD-90-AA-004) Open drain valve when LP Drum pressure (HAD-97-CP-001/002/003) above 0.5 barg. Close after 5 minutes time delay, if LP Drum pressure reaches or higher than 2 barg. Then, place into auto operation mode monitoring the drain pot level switches. - Open when High or High/High level switch detect any condensate. - Close when High level switch detect no condensate.

2.10

Steam Start up Vent Control

The function of these valves is to remove non condensable gas like an air from the HRSG steam side. HRSG start-up shall be initiated with closed these vent valves. Then vent valves operation shall be initiated as followings.

1) HP start up vent MOV (LBA-90-AA-002) Open vent valves when HP Drum pressure (HAD-90-CP-001/002/003) above 0.5 barg. Close when HP Drum pressure reaches 2 barg.

2) RH start up vent MOV (LBB-90-AA-001) and PCV (LBB-90-AA-081) * Pressure increasing mode during start up ; The RH start up vent will control the RH pressure increasing rate, if RH steam bypass system (Condenser vacuum) is not ready condition. Open RH start up vent isolation MOV (LBB-90-AA-001) when RH steam pressure (LBB-90-CP001/002/003) above 0.5 barg.

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The RH start up vent PCV (LBB-90-AA-081) will control the RH pressure change rate within allowable range (1 bar/min). Close RH start up vent MOV and PCV when the RH steam bypass system (Condenser vacuum) is available. Then vent valve will be placed into the pressure control mode. * Pressure control mode during normal operation; If the RH steam pressure(LBB-90-CP-001/002/003) is reached to the set point (39.5 barg), the HP start up vent PCV (LBB-90-AA-081) open initiated and control the steam pressure, not to over than the set point. The set point is slightly lower than safety valve setting pressure. The isolation MOV will open first when the RH steam pressure is reached to 39 barg.

3) IP start up vent MOV (LBA-95-AA-001) Open vent valves when IP Drum pressure (HAD-94-CP-001/002/003) above 0.5 barg. Close when IP Drum pressure reaches 1.5 barg.

4) LP start up vent MOV (LBD-90-AA-001) and PCV (LBD-90-AA-081) * Pressure increasing mode during start up ; The LP start up vent will control the LP Drum pressure increasing rate, if LP steam bypass system (Condenser vacuum) is not ready condition. Open LP start up vent isolation MOV (LBD-90-AA-001) when LP Drum pressure (HAD-97-CP001/002/003) above 0.5 barg. The LP start up vent PCV (LBD-90-AA-081) will control the LP Drum pressure change rate within allowable range (0.3 bar/min). Close LP start up vent MOV and PCV when the LP steam bypass system (Condenser vacuum) is available. Then vent valve will be placed into the pressure control mode. Pressure control mode during normal operation; If the LP steam pressure (LBD-90-CP-001/002/003) is reached to the set point (8 barg), the LP start up vent PCV (LBD-90-AA-081) open initiated and control the steam pressure, not to over than the set point. The set point is slightly lower than safety valve setting pressure. The isolation MOV (LBD-90-AA-001) will open first when the LP steam pressure is reached to 7.5 barg.

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5) Deaerator vent MOV (HAD-97-AA-001) This vent MOV will be opened when HRSG start initiated and always opened during HRSG operation. This valve can be closed after HRSG shutdown completed (Stack Damper close).

2.11

Drum Continuous Blowdown Control

Continuous blowdown basically controls the T.D.S and silica level of the drum water. Blowdown flow of drum water is continuous and controlled manually by the operator in the control room based on the feed back of drum and steam quality. An isolation MOV for tight shut off and an manual blowdown valve for fine control in series are provided for this control.

1) HP Continuous Blowdwon MOV (HAD-91-AA-002) The HRSG start up will be initiated with closed blowdown MOV. The blowdown MOV shall be opened after HP steam flow (LBA-90-CF-001/002) is higher than 20 % MCR flow and also shall be automatically closed when the HP steam flow is not higher than open permissive value. This valve shall be protectionally closed if following happen; * When HP drum level (HAD-90-CL-001/002/003) fall below the low water level (-685 mm from C.L).

2) IP Continuous Blowdwon MOV (HAD-95-AA-002) The HRSG start up will be initiated with closed blowdown MOV. The blowdown MOV shall be opened after IP steam flow (LBA-95-CF-001/002) is higher than 20 % MCR flow and also shall be automatically closed when the IP steam flow is not higher than open permissive value. This valve shall be protectionally closed if following happen; * When IP drum level (HAD-94-CL-001/002/003) fall below the low water level (-530 mm from C.L).

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2.12

Intermittent Blowdown Control

This valve is used to control the drum level in abnormal condition. If the water level is abnormally high, the intermittent blowdown valves open and the excess volume of water is discharged to the blowdown tank.

1) HP intermittent blowdown MOV (HAD-91-AA-001) There are two opening set point, namely start up set point and normal set point. The set point change will be done when HP steam production has reached about 25% MCR. Opening set point; * Start up set point (below 25% M.C.R); N.W.L (0mm from C.L). * Normal operation set point (above 25% M.C.R); High water level (+180mm from C.L). This valve shall be closed whenever drum level fall below set points. This valve shall have opening limit to prevent excess blowdown flow. When open demand is initiated, the valve open position shall be determined as following. Opening limit; * HP Drum Pressure < 15 barg; full open. * HP Drum Pressure > 15 barg; Intermediate (20%) open. This valve shall be protectionally closed if following happen; * When HP drum level (HAD-90-CL-001/002/003) fall below the low water level (-685 mm from C.L).

2) IP intermittent blowdown MOV (HAD-95-AA-001) There are two opening set point, namely start up set point and normal set point. The set point change will be done when IP steam production has reached about 25% MCR. Opening set point; * Start up set point (below 25% M.C.R); N.W.L (0mm from C.L). * Normal operation set point (above 25% M.C.R); High water level (+180mm from C.L). This valve shall be closed whenever drum level fall below set points.

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This valve shall have opening limit to prevent excess blowdown flow. When open demand is initiated, the valve open position shall be determined as following. Opening limit; * IP Drum Pressure < 15 barg; full open. * IP Drum Pressure > 15 barg; Intermediate (20%) open. This valve shall be protectionally closed if following happen; * When IP drum level (HAD-94-CL-001/002/003) fall below the low water level (-530 mm from C.L).

3) LP intermittent blowdown MOV (HAD-98-AA-001) There are two opening set point, namely start up set point and normal set point. The set point change will be done when condensate flow has reached about 25% MCR. Opening set point; * Start up set point (below 25% M.C.R); N.W.L (500mm from C.L). * Normal operation set point (above 25% M.C.R); High water level (+680mm from C.L). This valve shall be closed whenever drum level fall below set points. This valve shall be protectionally closed if following happen; * When LP drum level (HAD-97-CL-001/002/003) fall below the low water level (-1065 mm from C.L).

2.13

HRSG Feedwater and Condensate line stop MOV

Following valves can be used to make HRSG isolation from the BOP system for HRSG shutdown or maintenance period. The stop valve shall be always opened from HRSG initial start up and not be closed when HRSG is in service.

1) HP Feedwater Main (LAB-90-AA-001) and Bypass (LAB-90-AA-002) stop MOV. Due to the high pressure difference between the running feedwater pumps and the HRSG, small bypass MOV is provided. As preparation activity for HRSG start, these valves will be used to pressurize the economizer zone by the running feedwater pumps.

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First, the small bypass MOV will be opened. Then, if the pressure difference across the main MOV is less than 5 bar, the main MOV is opened. The small bypass MOV will be closed after the main MOV is fully opened. These valves shall be protectionally closed if following happen; * When HP drum level (HAD-90-CL-001/002/003) reaches the High/High water level (230 mm from C.L).

2) IP Feedwater Main (LAB-94-AA-001) and Bypass (LAB-94-AA-002) stop MOV. Due to the high pressure difference between the running feedwater pumps and the HRSG, small bypass MOV is provided. As preparation activity for HRSG start, these valves will be used to pressurize the economizer zone by the running feedwater pumps. First, the small bypass MOV will be opened. The, if the pressure difference across the main MOV is less than 5 bar, the main MOV is opened. The small bypass MOV will be closed after the main MOV is fully opened. These valves shall be protectionally closed if following happen; * When IP drum level (HAD-94-CL-001/002/003) reaches the High/High water level (230 mm from C.L).

3) Condensate Stop MOV (LCA-90-AA-001) As preparation activity for HRSG start, this valve will be opened before HRSG start. This valve shall be protectionally closed if following happen; * When LP drum level (HAD-97-CL-001/002/003) reaches the High/High water level (725 mm from C.L).

2.14

HRSG Steam line stop MOV

These valves make HRSG isolaton from the steam header in case of HRSG not in service. Also these valves are used to connect the HRSG into the operation steam header during start-up. During the plant start up, shutdown and trip, pressure builds in the HRSG will be controlled by HP steam bypass system, IP steam line PCV, HRH steam bypass system and LP steam bypass

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system. The HP steam bypass steam will be admitted to the CRH piping. The HRH and LP steam bypass is routed to the condenser respectively.

1) HP Steam Main (LBA-90-AA-003) and Bypass (LBA-90-AA-004) stop MOV. 1.1) For HRSG Start up Mode. * Lead HRSG HP steam stop MOV ; The Main stop MOV is opened at the initiation of the HRSG start while the bypass stop MOV is closed. And the HP main steam header is warmed, drained and pressurized along with the HRSG. * Lag HRSG HP steam stop MOV ; The lag HRSG is started with closed steam stop valves. When the following conditions are satisfied, Open small bypass stop valve first. z Temperature difference between lag HRSG steam and operation header steam is lower than 50 deg.C. z The lag HRSG (HP) steam pressure is higher (Approximately, 2 bar) than the operation header pressure. After small bypass stop valve open, then open the main stop valve and close the small bypass stop valve. * Last HRSG HP steam stop MOV ; The last HRSG HP steam stop MOV’s operation is the same with lag HRSG.

1.2) For HRSG shutdown mode. * Lead HRSG HP steam stop MOV ; With HRSG shutdown command, the diverter damper will be closed with normal speed (60 seconds). Then the HP steam bypass system will open to control HP steam pressure and the HRH steam bypass system will open as a result of the HP steam bypass system opening. The HP steam stop valve will be closed when HRSG shutdown initiated and HP steam bypass system open sufficiently (about 10%). The HP steam bypass set point of the HRSG is slowly ramped below (about 2 bar) the operating pressure, thereby diverting steam from the HP steam through the HP steam bypass system.

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* Lag HRSG HP steam stop MOV ; The lag HRSG HP steam stop MOV’s operation is the same with lead HRSG. * Last HRSG HP steam stop MOV ; During the last unit shutdown, the Steam turbine MCV is ramped closed. The Steam turbine continues to unload and finally the Steam turbine valves are tripped closed. When the ST is tripped, the last HRSG HP and HRH steam stop valves are closed.

2) CRH Steam Stop MOV (LBC-90-AA-001) 2.1) For HRSG Start up Mode. * Lead HRSG CRH steam stop MOV ; The CRH steam stop MOV is opened at the initiation of the HRSG start. And the CRH steam header is warmed, drained and pressurized along with the HRSG. * Lag HRSG CRH steam stop MOV ; The lag HRSG reheater is started with closed steam stop valves. Thus, the reheater is initially isolated from the steam header. Steam from the HP steam bypass system passes through the reheater to the condenser via the HRH steam bypass system. When the steam conditions are satisfied, the lag HRSG HRH steam isolation valve open initiated. At this moment, the CRH steam stop valve will be opened simultaneously. * Lag HRSG CRH steam stop MOV ; The last HRSG CRH steam stop MOV’s operation is the same with lag HRSG.

2.2) For HRSG shutdown mode. * Lead HRSG CRH steam stop MOV ; With HRSG shutdown command, the diverter damper will be closed normal speed. Then the HP steam bypass system will open to control HP steam pressure and the HRH steam bypass system will open as a result of the HP steam bypass opening. The HP steam stop valve will be closed when HRSG shutdown initiated and HP steam bypass system open sufficiently (about 10%). The HP steam bypass set point of the HRSG is slowly ramped below (about 2 bar) the operating pressure, thereby diverting steam from the HP steam through the HP steam bypass system. The lead HRSG HP steam is isolated from the HP header.

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At this moment, the HRH, CRH and LP steam stop valve will be closed simultaneously. * Lag HRSG CRH steam stop MOV ; The lag HRSG CRH steam stop MOV’s operation is the same with lead HRSG. * Last HRSG CRH steam stop MOV ; During the last unit shutdown, the Steam turbine MCV is ramped closed. The Steam turbine continues to unload and finally the Steam turbine valves are tripped closed. When the ST is tripped and HP steam bypass system is completely closed, the last HRSG CRH steam stop valve is closed.

3) LP Steam Main (LBD-90-AA-002) and Bypass (LBD-90-AA-003) stop MOV. 3.1) For HRSG Start up Mode. * Lead HRSG LP steam stop MOV ; The Main stop MOV is opened at the initiation of the HRSG start while the bypass stop MOV is closed. And the LP main steam header is warmed, drained and pressurized along with the HRSG. * Lag HRSG LP steam stop MOV ; The lag HRSG is started with closed steam stop valves. When the following conditions are satisfied, Open small bypass stop valve first. z Temperature difference between lag HRSG steam and operation header steam is lower than 30 deg.C. z The lag HRSG (LP) steam pressure is higher (Approximately, 0.5 bar) than the operation header pressure. After small bypass stop valve open, then open the main stop valve and close the small bypass stop valve. * Last HRSG LP steam stop MOV ; The last HRSG LP steam stop MOV’s operation is the same with lag HRSG.

3.2) For HRSG shutdown mode. * Lead HRSG LP steam stop MOV ;

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With HRSG shutdown command, the diverter damper will be closed with normal speed. Then the LP steam bypass system will open to control LP steam pressure. The HP steam stop valve will be closed when HRSG shutdown initiated and HP steam bypass system open sufficiently (about 10%). The HP steam bypass set point of the HRSG is slowly ramped below (about 2 bar) the operating pressure, thereby diverting steam from the HP steam through the HP steam bypass system. The lead HRSG HP steam is isolated from the HP header. At this moment, the HRH, CRH and LP steam stop valve will be closed simultaneously. * Lag HRSG LP steam stop MOV ; The lag HRSG LP steam stop MOV’s operation is the same with lead HRSG. * Last HRSG LP steam stop MOV ; During the last unit shutdown, the ST LP control valve is placed in position control and ramped closed. At this moment, the HRSG LP steam stop is closed.

3 HRSG PROTECTION DESCRIPTION The HRSG protection fulfils all requirements to ensure the safe operation with high availability of the HRSG and its main components and the affected/linked plant aggregates. Besides the prevention of personal hazards the HRSG, protection shall avoid failure of major parts of the plant with high financial risk and strong reduction in lifetime of components. The following items are implemented for HRSG protection.

3.1 HP Drum Level > H.H The HP drum level is protected against impermissible high water level to avoid water carry over into the superheater, the main steam line and in an extreme case also into the steam turbine. In this case temperature shocks with damages to the superheater and main steam line might occur. Water droplets to the steam turbine might result in mechanical damages to the blades. 1) Signal; High/High(+230 mm from C.L) by 2 out of 3 HP drum level (HAD-90-CL-001/002/003). 2) Actions after time delay of 2 sec; * HRSG Trip by Fast close of diverter damper. * Close HP feedwater stop valves (LAB-90-AA-001/002). * Trip HP/IP feedwater pumps, if the HP feedwater stop valves (LAB-90-AA-001/002) is not closed within 50 seconds.

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3.2 HP Drum Level < L.L The HP evaporator has to be protected from running dry to avoid local overheating on evaporator due to missing feed water. 1) Signal; Low/Low (-785 mm from C.L) by 2 out of 3 HP drum level (HAD-90-CL-001/002/003). 2) Actions after time delay of 2 sec; * HRSG Trip by Fast close of diverter damper.

3.3 IP Drum Level > H.H The IP drum level is protected against impermissible high water level to avoid water carry over into the superheater, the main steam line and in an extreme case also into the steam turbine. In this case temperature shocks with damages to the superheater and main steam line might occur. Water droplets to the steam turbine might result in mechanical damages to the blades. 1) Signal; High/High (+230 mm from C.L) by 2 out of 3 IP drum level (HAD-94-CL-001/002/003). 2) Actions after time delay of 2 sec; * HRSG Trip by Fast close of diverter damper. * Close IP feedwater stop valves (LAB-94-AA-001/002). * Trip HP/IP feedwater pumps, if the IP feedwater stop valves (LAB-94-AA-001/002) is not closed within 50 seconds.

3.4 IP Drum Level < L.L The IP evaporator has to be protected from running dry to avoid local overheating on evaporator due to missing feed water. 1) Signal; Low/Low (-630 mm from C.L) by 2 out of 3 IP drum level (HAD-94-CL-001/002/003). 2) Actions after time delay of 2 sec; * HRSG Trip by Fast close of diverter damper.

3.5 LP Drum Level > H.H The LP drum level is protected against impermissible high water level to avoid water carry over into the superheater, the main steam line and in an extreme case also into the steam turbine. In this case temperature shocks with damages to the superheater and main steam line might occur. Water droplets to the steam turbine might result in mechanical damages to the blades. Chapter 10 Operating Procedure

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1) Signal; High/High (+725 mm from C.L) by 2 out of 3 LP drum level (HAD-97-CL-001/002/003). 2) Actions after time delay of 2 sec; * HRSG Trip by Fast close of diverter damper. * Close condensate stop valves (LCA-90-AA-001). * Trip Condensate pumps, if the condensate stop valves (LCA-90-AA-001) is not closed within 50 seconds.

3.6 LP Drum Level < L.L The LP evaporator has to be protected from running dry to avoid local overheating on evaporator due to missing feed water. The feedwater pumps also have to be protected from cavitations in case of extreme low level of LP drum. 1) Signal; Low/Low (-1165 mm from C.L) by 2 out of 3 LP drum level (HAD-97-CL-001/002/003). 2) Actions after time delay of 2 sec; * HRSG Trip by Fast close of diverter damper. * Trip HP/IP feedwater pumps.

3.7 HP Steam Temperature > H.H In case of failure of the HP desuperheater steam temperature control, the HRSG has to be protected to avoid impermissible high temp. 1) Signal; High/High (582 deg.C) by 2 out of 3 HP steam temperature (LBA-90-CT-001/002/003) 2) Actions after time delay of 60 sec; * HRSG Trip by Fast close of diverter damper.

3.8 Hot Reheat Steam Temperature > H.H In case of failure of the Reheater desuperheater steam temperature control, the HRSG has to be protected to avoid impermissible high temp. 1) Signal; High/High (581 deg.C) by 2 out of 3 RH steam temperature (LBB-90-CT-001/002/003) 2) Actions after time delay of 60 sec; Chapter 10 Operating Procedure

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* HRSG Trip by Fast close of diverter damper.

3.9 HRSG Inlet Duct Temperature > H.H The HRSG inlet duct has to be protected against impermissible high exhaust gas temperature. 1) Signal; High/High (659 deg.C) by 2 out of 3 Gas temperature (HNA-90-CT-001/002/003) 2) Actions after time delay of 120 sec; * HRSG Trip by Fast close of diverter damper.

3.10

HRSG Stack Closure Damper Failure

In case of failure of the HRSG stack damper, the HRSG has to be protected to avoid HRSG duct or HRSG wall over pressurization or rupture caused by closure of the stack damper. 1) Signal; Two out of three open limit switches (HNE-90-CG-081/082/083) do not indicate the stack damper fully open. 2) Actions; * HRSG Trip by Fast close of diverter damper.

3.11

All HP/IP Feedwater Pumps OFF

In case of failure of all HP/IP feedwater pumps, the HRSG (HP and IP Drum) has to be protected to avoid missing feedwater. 1) Signal; by logic. 2) Actions after time delay of 60 sec; * HRSG Trip by Fast close of diverter damper.

3.12

All Condensate Extraction Pumps OFF

In case of failure of all condensate extraction pumps, the HRSG (LP Drum) has to be protected to avoid missing condensate. 1) Signal; by logic. 2) Actions after time delay of 60 sec; * HRSG Trip by Fast close of diverter damper. Chapter 10 Operating Procedure

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3.13

Gas Turbine Trip

In case of a GT trip, the HRSG has also to be tripped to avoid cooling of HRSG by running down GT. 1) Signal; by logic 2) Actions; * HRSG Trip by Fast close of the diverter damper.

3.14 HRSG Trip Command from C.C.R HRSG shall be tripped when trip command from C.C.R. decided by the operator. 1) Signal; by logic 2) Actions; * HRSG Trip by Fast close of the diverter damper.

3.15 HRSG Trip and Diverter damper Not Closed In case that the diverter damper is not closed within required time, the GT shall be tripped. 1) Signal; by logic (The diverter damper is not closed within 20 seconds after HRSG trip initiated). 2) Actions; * HRSG Trip by the GT trip

3.16 Steam bypass system trip and bypass operation required In this case the produced HRSG steam cannot be routed completely to the condenser. To avoid steam pressure increase and blowing of the safety valves, the HRSG has to be protected. 1) Signal; by logic. 2) Actions; * HRSG Trip by Fast close of the diverter damper.

Chapter 10 Operating Procedure

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3.17 CW (Circulation Water) System Trip In this case the produced HRSG steam cannot be routed completely to the condenser due to the lack of condenser vacuum. To avoid steam pressure increase and blowing of the safety valves, the HRSG has to be protected. 1) Signal; by logic. 2) Actions; * HRSG Trip by Fast close of the diverter damper.

4 Alarm and Set Point List Item. No. 1

Tag.No.

Service Description

HNA-90-CT-

HRSG inlet duct

001/002/003

Gas Temperaure

Set Point ≥ 659 deg.C

Required Action * Alarm H,H * HRSG Trip (Time delay 120 sec).

≥ 655 deg.C

* Alarm H * Gas Turbine Run Back until alarm disappeared.

2

LAB-90-CP-001

HP Econ. Pressure

≥ 210 barg

* Alarm H * Econ. Safety valve Set Pressure.

3

HAD-90-CL001/002/003

HP drum level

≥ + 230mm

* Alarm H,H

From Center Line

* HRSG Trip (Time delay 2 sec). * Protective close F.W stop MOV (LAB-90-AA-001/002). * HP/IP F.W pumps Trip, if F.W stop MOV is not closed within 50 seconds.

≥ + 180mm

* Alarm H

From Center Line

* Open set point of HP IBD MOV (HAD-91-AA-001) for Normal operation.

= 0mm

* Normal Water Level.

From Center Line

* Open set point of HP IBD MOV (HAD-91-AA-001) for start up operation.

= - 200mm

* High Start up Water Level, when

From Center Line

Drum Press > 40 barg.

= - 550mm

* Low Start up Water Level, when

From Center Line

Drum Press < 40 barg.

Chapter 10 Operating Procedure

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Item.

Tag.No.

No.

Service Description

Set Point

Required Action

≤ - 685mm

* Alarm L.

From Center Line

* Protective close HP CBD MOV (HAD-91-AA-002) & IBD MOV (HAD91-AA-001).

4

5

6

≤ - 785mm

* Alarm L,L

From Center Line

* HRSG Trip (Time delay 2 sec).

≥ 50 deg.C

* Alarm H.

HAD-90-CT-001

Wall differential

Vs

temperature at HP

* limiting GT load change during load

HAD-90-CT-002

Drum lower side.

change.

HAD-90-CT-003

Wall differential

Vs

temperature at HP

* limiting GT load change during load

HAD-90-CT-004

Drum upper side.

change.

HAD-90-CP-

HP drum pressure

≥ 50 deg.C

≥ 153 barg

001/002/003

* Alarm H.

* Alarm H. * Drum Safety valve Set Pressure.

≥ 40 deg.C

HAH-90-CT-008

* Alarm H.

Vs

* limiting GT load change during load

HAH-90-CT-009.

change.

or HAH-90-CT-010 Vs

7

HAH-90-CT-011.

Wall differential

or

temperature at HP

HAH-90-CT-012

S.H outlet Header.

Vs HAH-90-CT-013. or HAH-90-CT-014 Vs HAH-90-CT-015. 8

LBA-90-CT-

HP final steam

001/002/003

temperature

≥ 582 deg.C

* Alarm H.H * HRSG Trip (Time delay 60 sec).

≥ 575 deg.C

* Alarm H. * Gas Turbine Run Back until alarm disappeared.

Chapter 10 Operating Procedure

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Item. No.

Tag.No.

Service Description

Set Point = 567 deg.C

Required Action * Set Point of HP desuperheater control

9

LBA-90-CP-

HP steam pressure

≥ 146 barg

001/002/003 10

LAE-90-CP-101

* Alarm H. * S.H Safety valve Set Pressure.

Strainer Del.

≥ 0.5 bar

* Alarm H * For strainer blocking warning.

Pressure on HP DESH. Spray line 11

LBC-90-CP-001

CRH steam

≥ 42.5 barg

pressure 12

LBB-90-CT-

RH final steam

001/002/003

temperature

* Alarm H. * CRH Safety valve Set Pressure.

≥ 581 deg.C

* Alarm H.H * HRSG Trip (Time delay 60 sec).

≥ 574 deg.C

* Alarm H. * Gas Turbine Run Back until alarm disappeared.

= 566 deg.C

* Set Point of RH desuperheater control

13

LBB-90-CP-

Hot RH steam

001/002/003

pressure

≥ 40.5 barg

* Alarm H. * HRH Safety valve Set Pressure.

≥ 39.5 barg

* Set point of RH start up vent PCV control (LBB-90-AA-081)

≥ 39 barg

* Open Set point of RH start up vent isolation MOV (LBB-90-AA-001)

14

LAF-90-CP-101

Strainer Del.

≥ 0.5 bar

* Alarm H * For strainer blocking warning.

Pressure on RH DESH. Spray line 15

LAB-94-CP-001

IP Econ. Pressure

≥ 75 barg

* Alarm H * Econ. Safety valve Set Pressure.

16

HAD-94-CL001/002/003

IP drum level

≥ + 230mm

* Alarm H,H

From Center Line

* HRSG Trip (Time delay 2 sec). * Protective close F.W stop MOV

Chapter 10 Operating Procedure

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Item. No.

Tag.No.

Service Description

Set Point

Required Action (LAB-94-AA-001/002). * HP/IP F.W pumps Trip, if F.W stop MOV is not closed within 50 seconds.

≥ + 180mm

* Alarm H

From Center Line

* Open set point of IP IBD MOV (HAD-95-AA-001) for Normal operation.

= 0mm

* Normal Water Level.

From Center Line

* Open set point of IP IBD MOV (HAD-95-AA-001) for start up operation.

= - 200mm

* High Start up Water Level, when

From Center Line

Drum Press > 10 barg.

= - 450mm

* Low Start up Water Level, when

From Center Line

Drum Press < 10 barg.

≤ - 530mm

* Alarm L.

From Center Line

* Protective close IP CBD MOV (HAD-95-AA-002) & IBD MOV (HAD95-AA-001).

17

HAD-94-CP-

IP drum pressure

≤ - 630mm

* Alarm L,L

From Center Line

* HRSG Trip (Time delay 2 sec).

≥ 45 barg

* Alarm H.

001/002/003 18

LBA-95-CP-

* Drum Safety valve Set Pressure. IP steam pressure

≥ 43 barg

001/002 19

LCA-90-CP-101

* Alarm H. * S.H Safety valve Set Pressure.

CPH Pressure

≥ 40 barg

* Alarm H. * C.P.H Safety valve Set Pressure.

20

LCA-92-CP-101

Strainer Del.

≥ 0.1 bar

* Alarm H * For strainer blocking warning.

Pressure on CPH Recirculation Pump 21

LCA-93-CP-101

Strainer Del. Pressure on CPH

≥ 0.1 bar

* Alarm H * For strainer blocking warning.

Recirculation Pump

Chapter 10 Operating Procedure

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Item. No.

22

23

Tag.No.

Service Description

LCA-90-CT-

CPH inlet

003/004

Temperature

LCA-94-CF-

CPH Recirculation

001/002

flow

Set Point

= 70 deg.C

Required Action

* Set Point of CPH recirculaiton temp. control

≤ 67 deg.C

* Alarm L

≥ 330,000 kg/hr

* Alarm H.H * Stop the operation pump and Start the standby pump.

≥ 300,000 kg/hr

* Alarm H. * Limit further opening of TCV(LCA94-AA-081).

≤ 65,000 kg/hr

* Alarm L. * Limit further closing of TCV(LCA-94AA-081).

≤ 60,000 kg/hr

* Alarm L.L * Stop the operation pump and Start the standby pump.

24

HAD-97-CL001/002/003

LP drum level

≥ + 725mm

* Alarm H,H

From Center Line

* HRSG Trip (Time delay 2 sec). * Protective close Condensate stop MOV (LCA-90-AA-001). * Condensate extraction pumps Trip, if Condensate stop MOV is not closed within 50 seconds.

≥ + 680mm

* Alarm H

From Center Line

* Open set point of LP IBD MOV (HAD-98-AA-001) for Normal operation.

= + 500mm

* Normal Water Level.

From Center Line

* Open set point of LP IBD MOV (HAD-98-AA-001) for start up operation.

Chapter 10 Operating Procedure

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Item. No.

Tag.No.

Service Description

Set Point

Required Action

= + 300mm

* High Start up Water Level, when

From Center Line

Drum Press > 2 barg.

= - 100mm

* Low Start up Water Level, when

From Center Line

Drum Press < 2 barg.

≤ - 1065mm

* Alarm L.

From Center Line

* Protective close LP IBD MOV (HAD98-AA-001).

≤ - 1165mm

* Alarm L,L

From Center Line

* HRSG Trip (Time delay 2 sec). * HP/IP feedwater pumps Trip.

25

HAD-97-CP-

LP drum pressure

≥ 10 barg

001/002/003

* Alarm H. * Drum Safety valve Set Pressure.

≥ 7 barg

* Protective close pegging stop MOV (LBA-96-AA-001).

= 3 barg

* Set Point of LP Drum pegging control

26

LBD-90-CP-

LP steam pressure

≥ 9 barg

001/002/003

* Alarm H. * S.H Safety valve Set Pressure.

≥ 8 barg

* Set point of LP start up vent PCV control (LBD-90-AA-081)

≥ 7.5 barg

* Open Set point of LP start up vent isolation MOV (LBD-90-AA-001)

Chapter 10 Operating Procedure

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5 HRSG Water Chemistry Requirements The main objectives of water chemistry control are to insure the long term integrity of the materials of construction and the successful operation of the water & steam cycle. The particular types of chemical treatment may vary depending on many factors such as the variety of materials, operating conditions, system design, etc. These guidelines are generally in accordance with published guidelines from EPRI, VGB, ASME, as well as ABMA (American Boiler Manufacturers Association).

- Demineralized Water (at Demineralizer Water Plant Outlet) Target (See table for Maximum Annual Exposure to Contaminant Conditions and Action Level Criteria) Parameter

Unit

Normal

Specific conductivity

μS/cm

< 0.2

Silica as SiO2

ppb

< 20

Sodium + Potassium as Na+K

ppb

< 10

Iron as Fe

ppb

< 20

Copper as Cu

ppb

< 3

TOC

ppb

< 300

- Condensate (at Condensate Pump Discharge) Target (See table for Maximum Annual Exposure to Contaminant Conditions and Action Level Criteria) Parameter

Unit

Cation Conductivity pH-value

Normal

Level 1

Level 2

Level 3

μS/cm

< 0.2

< 0.4

< 0.8

-

9.0 - 9.6

-

-

-

> 0.8

Silica as SiO2

ppb

< 20

> 20

-

-

Iron as Fe

ppb

< 20

> 20

-

-

Sodium as Na

ppb

< 10

< 20

< 40

>40

Copper as Cu

ppb

3

-

-

Oxigen

ppb

< 10

< 20

> 20

-

- Feedwater (at Feedwater pump Discharge) Chapter 10 Operating Procedure

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Target (See table for Maximum Annual Exposure to Contaminant Conditions and Action Level Criteria) Parameter

Unit

Cation Conductivity pH-value

Normal

Level 1

Level 2

μS/cm

< 0.2

< 0.4

< 0.8

-

9.0 - 9.6

-

Level 3 > 0.8

-

-

Silica as SiO2

ppb

< 20

> 20

-

-

Iron as Fe

ppb

< 20

> 20

-

-

Sodium as Na

ppb

< 10

< 15

< 30

>30

Copper as Cu

ppb

3

-

-

Oxigen

ppb

< 10

< 15

< 20

>20

- Boiler Water (HP, IP and LP Drum) Note:

These guidelines do not apply to the Low Pressure (LP) drum because LP drum acts as

a feedwater tank. In such a case, the feedwater guidelines are applicable to the LP boilerwater. Target (See table for Maximum Annual Exposure to Contaminant Conditions and Action Level Criteria) Parameter

Unit

Normal

Level 1

Level 2

Level 3

Immediate shutdown

Specific Conductivity (HP drum)

μS/cm

< 40

< 50

> 50

-

-

Cation Conductivity (HP drum)

μS/cm

< 30

< 40

> 40

-

-

-

9.1 - 9.6

-

-

-

2.4

-

Phosphate as PO4 (HP drum)

ppm

60

-

-

Cation Conductivity (IP drum)

μS/cm

< 40

< 50

> 50

-

-

-

9.1 - 9.6

-

-

-