MI NI STRY OF ENERGY

IRAN POWER DEVELOPMENT CO.

I P D C


PROJ ECT :
22 COMBINED CYCLE POWER PLANTS
YAZD COMBINED CYCLE POWER PLANT
SYSTEM DESCRIPTION
FOR
CONDENSATE SYSTEM

E REVISED BY MAPNA COMMENT DATED NOV. 07, 2005 Nov.07,05 Y.K.CHOI Nov.07,05 H. C. YOO Nov.07,05 C.H. LEE Nov.07,05
D REVISED Sep.29,05 Y.K.CHOI Sep.29,05 H. C. YOO Sep.29,05 C.H. LEE Sep.29,05
C IN CORPORATED MOM DATED 27~31 AUG. AND 08~12 SEP. 04 Nov.09,04 Y.K.CHOI Nov.09,04 H. C. YOO Nov.09,04 W. Y. LEE Nov.09,04
B FOR CONSTRUCTION J uly 5,04 Y.K.CHOI J uly 5,04 H. C. YOO J uly 5,04 W. Y. LEE J uly 5,04
A First Issue Dec.5,03 D.C.KIM Dec.5,03 H. C. YOO Dec.5,03 W. Y. LEE Dec.5,03
REV DESIGNATION DATE DESIGN DATE CHKD DATE APPROVED DATE
DOCUMENT NO. : MP-YZC-GA-04-HN0-001 REV. E
MAPNA C o .
( PRIVATE J OINT STOCK )
IRAN POWER PLANT PROJ ECTS MANAGEMENT Co.
CONTRACT NO. : 22-0701/BA/TL PAGE 1 OF 9
ORIGINATOR NO. : YZC-A-SP-470-SDE-003 A4
ORIGINATOR
DOOSAN HEAVY INDUSTRIES &
CONSTRUCTION CO.,LTD. ORIG
LOC.
ORIG.
DEPT.
PROJ .
NAME
DISC.

DOC.
TYPE
AREA
TYPE
SYS.
FA.N
SEQ.
N.
SH.
N.
REV. E

FOR CONSTRUCTION

MI NI STRY OF ENERGY
IRAN POWER DEVELOPMENT CO.
I P D C


PROJ ECT :
22 COMBINED CYCLE POWER PLANTS
YAZD COMBINED CYCLE POWER PLANT


REVISION REVISION

PAGE
A B C D E F G H
REMARKS PAGE
A B C D E F G H
REMARKS

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DOCUMENT NO. : MP-YZC-GA-04-HN0-001 REV. E
MAPNA C o .
( PRIVATE J OINT STOCK )
IRAN POWER PLANT PROJ ECTS MANAGEMENT Co.
CONTRACT NO. : 22-0701/BA/TL PAGE 2 OF 9
ORIGINATOR NO. : YZC-A-SP-470-SDE-003 A4
ORIGINATOR
DOOSAN HEAVY INDUSTRIES &
CONSTRUCTION CO.,LTD. ORIG
LOC.
ORIG.
DEPT.
PROJ .
NAME
DISC.

DOC.
TYPE
AREA
TYPE
SYS.
FA.N
SEQ.
N.
SH.
N.
REV. E

YAZD
Combined Cycle
SYSTEM DESCRIPTION
CONDENSATE SYSTEM
DOOSAN
Changwon, KOREA
Contract No. :
22-0701/BA/TL
Doc. No. : MP-YZC-GA-04-HN0-001
Originator No. : YZC-A-SP-470-SDE-003
Revision : E
Date : Nov. 07, 05
Page: 3 / 9





CONDENSATE SYSTEM



CONTENTS



CLAUSE NO. DESCRIPTION PAGE


1.0.0 REFERENCE DRAWINGS 4

2.0.0 INTRODUCTION 4

3.0.0 CONDENSATE SYSTEM CONFIGURATION 4

4.0.0 DESIGN BASIS OF CONDENSATE EXTRACTION 6
PUMP

5.0.0 OPERATION 6

6.0.0 GENERAL CONTROL DESCRIPTION 8



YAZD
Combined Cycle
SYSTEM DESCRIPTION
CONDENSATE SYSTEM
DOOSAN
Changwon, KOREA
Contract No. :
22-0701/BA/TL
Doc. No. : MP-YZC-GA-04-HN0-001
Originator No. : YZC-A-SP-470-SDE-003
Revision : E
Date : Nov. 07, 05
Page: 4 / 9




CONDENSATE SYSTEM


1.0.0 REFERENCE DRAWINGS

HRSG Feedwater storage section P & I diagrams (MP-YZC-GA-02-HL0-003)
Condensate system P & I diagrams (MP-YZC-GA-02-HN0-001)


2.0.0 INTRODUCTION

2.1.0 The condensate system consists of the following main components;

Two (2) x 100 % centrifugal, vertical can type condensate extraction pumps
(LCB11/21AP001) for two (2) HRSGs.
Condensate polishing plant (supplied by others).
Ejector condensers (supplied by others).
Gland steam condenser (supplied by others).
Two (2) x 100% level control valves (LCB80AA151/AA152) for each HRSG
Each of the above named components is provided with the necessary piping,
fittings and instrumentation.


3.0.0 CONDENSATE SYSTEM CONFIGURATION

3.1.0 The purpose of the condensate system is

Return condensate to thermal cycle from the condenser hotwell to the deaerator
(HAD80BB002) through condensate polishing plant, ejector condenser, gland
steam condenser and condensate preheater maintain the operating level in the
feedwater storage tank (HAD80BB001).
To supply condensate to auxiliary steam system.
To supply condensate to condensate extraction pump (LCB11/21AP001) for
pump sealing in normal operation. The initial seal water for condensate extraction
pump is to be supplied from the condensate transfer pump.
To supply condensate for valve water sealing.
To supply condensate to flash tank (LCM30BB001).
To supply condensate to steam turbine service (HP/LP bypass attemperators, ST
flash/stand pipe filling, sealing water of ST consumers & permanent filling of HP-
bypass, Gland steam condenser).
To supply condensate to chemical dosing




YAZD
Combined Cycle
SYSTEM DESCRIPTION
CONDENSATE SYSTEM
DOOSAN
Changwon, KOREA
Contract No. :
22-0701/BA/TL
Doc. No. : MP-YZC-GA-04-HN0-001
Originator No. : YZC-A-SP-470-SDE-003
Revision : E
Date : Nov. 07, 05
Page: 5 / 9



3.2.0 Condensate flow paths:

Each condensate extraction pump (LCB11/21AP001) takes suction from the
condenser hotwell through the condensate common suction line. Only one pump
operates at a time. The second pump is in standby.
Condensate flows from condenser hotwell to the suction of condensate extraction
pump (LCB11/21AP001) through a 16 inch pipeline.
Each pump suction is having a relief valve (LAC10/20AA191), basket type
strainer (LCB10/20AT001) with pressure differential switch (LCB10/20CP001)
and manual isolating valve (LCB10/20AA201) with limit switch (LCB10/20CG001).
The condensate extraction pumps (LCB11/21AP001) discharge into common
header.
Each discharge circuit is fitted with a check valve (LCB14/24AA201) and manual
isolation valve (LCB14/24AA252).
Condensate from the pump discharge is piped to the shaft seals of each pump
after the check valve (LAC14/24AA201) to prevent air-in leakage when the
condensate extraction pump (LCB11/21AP001) is on "auto" standby mode and to
provide shaft lubrication. In addition, each pump has a suction vent line (LCB12/
22AA401) / discharge vent line (LCB12/22AA402) piped to the condenser.
A branch off from condensate extraction pump (LCB11/21AP001) discharge line
prior to condensate polishing plant is provided for supplying sealing water to
pump/valves with sealing arrangement.
A branch off from condensate extraction pump (LCB11/21AP001) discharge line
prior to condensate polishing plant is provided for supplying of auxiliary steam
system, flank tank (LCM30BB001) and turbine services water.
A flow measurement device (LCB60CF102) is provided for measuring the total
flow of condensate between gland steam condenser outlet and HRSG inlet.
The minimum flow recirculation system including flow control valve
(LCB61AA151) is branched off from the downstream of the gland steam
condenser. A minimum flow recirculation to the condenser is controlled by the
minimum flow recirculation control valve (LCB61AA151) which protects the
condensate extraction pumps (LCB11/21AP001) from overheating by keeping the
minimum flow rate requirements, when the system demand is lowered than the
minimum flow rate.
A branch off from condensate line after flow measurement device (LCB60CF102)
is provided for supplying of condensate water to chemical dosing system.
Two (2) x 100% feed water storage tank level control valves (LCB80AA151/
AA152) in parallel, two upstream motor operated valves (LCB80AA053/AA054),
two (2) downstream manual valves (LCB80AA253/AA256) are provided for each
HRSG.
Motor operated valves (LCB80AA052) with its integral manual bypass valve
(LCB80AA259) is provided for each HRSG before condensate preheater. Motor
operated valve (LCB80AA051) is used to bypass the condensate preheater to
prevent corrosion of the condensate preheater.
YAZD
Combined Cycle
SYSTEM DESCRIPTION
CONDENSATE SYSTEM
DOOSAN
Changwon, KOREA
Contract No. :
22-0701/BA/TL
Doc. No. : MP-YZC-GA-04-HN0-001
Originator No. : YZC-A-SP-470-SDE-003
Revision : E
Date : Nov. 07, 05
Page: 6 / 9



4.0.0 DESIGN BASIS OF CONDENSATE EXTRACTION PUMP

4.1.0 Guarantee point
(19 ambient temperature, 32% relative humidity, Supplementary firing, Natural gas,
base load without bypass mode)

Flow kg/s 157.83*
Temperature at pump suction Deg.C 49
Discharge Pressure bara 21.51
Suction Pressure bara 0.117
TDH mH 220
NPSHA @ 1st impeller mH 4.65
NPSHR @ 1
st
Impeller mH 2.6
BHP kW 452
Aux. Power Consumption kW 470
* Pump self sealing water is not included in this flow

5.0.0 OPERATION

5.1.0 Condensate Extraction Pumps

5.1.1 Preparation for Start-up
The condensate extraction pumps (LCB11/21AP001) are to be started and
operated in co-ordination with the HRSG start-up and operation.
Fill-up the condenser to the normal level.
Fill-up the feed water storage tank (HAD80BB001) to the normal level by running
the condensate transfer pump and then close the motorized isolating valves
(LCB80AA053/AA054) in the suction of the feed water storage tank
(HAD80BB001).
Fill-up the condensate extraction pump discharge piping including ejector
condenser, gland steam condenser, minimum flow recirculation line, etc., using
condensate system fill-up line with the help of the condensate transfer pump.
Fill-up the LP & HP drums, economizers, evaporators and related piping by
running the condensate transfer pump.
Check the readiness of the condensate extraction pump and its integral system
such as seal water, electrical and instrumentation system as per pump
manufactures O&M manual.
The pump can be kept running through the minimum flow recirculation control
line till the HRSG is ready for start-up.

5.1.2 Starting the first condensate extraction pumps (LCB11/21AP001)

Preselect the pump as the first running pump (LCB11AP001). In case of other
pump (LCB21AP001), its relative valves and switches shall be considered in
the following sequence.
When a particular pump is selected for running, the following permissive are to be
satisfied.
i) Condenser water level is not low.
YAZD
Combined Cycle
SYSTEM DESCRIPTION
CONDENSATE SYSTEM
DOOSAN
Changwon, KOREA
Contract No. :
22-0701/BA/TL
Doc. No. : MP-YZC-GA-04-HN0-001
Originator No. : YZC-A-SP-470-SDE-003
Revision : E
Date : Nov. 07, 05
Page: 7 / 9



ii) Suction valve (LCB10AA201) with limit switch (LCB10CG001) is opened.
iii) Suction Vent valve (LCB12AA401) is opened. Discharge vent valve
(LCB12AA402) shall be closed after 2 seconds from pump (LCB11AP001)
start up.
iv) When GT is running on natural gas firing, the motorized valve (LAC80AA051) in
CPH (Condensate Preheater) bypass is closed and When GT is running on gas
oil firing, it is required to bypass the CPH.
v) The inlet and outlet isolation valves for Condensate polishing plant/Gland steam
condenser/Ejector condenser are kept open.
vi) Minimum recirculation control valve (LCB61AA151) is in Auto-mode and its
isolation valve (LCB61AA251) is opened.
vii) The feed water storage tank level control valve (LCB80AA151/AA152) is in Auto-
mode and its isolation valves (LCB80AA053/AA054) are opened.
viii) All isolation valves on main condensate line to deaerator are opened.
ix) No trip condition exists.

5.1.3 Tripping of the condensate extraction pump

The running condensate extraction pump shall trip when any of the following
condition is true:
i) A low alarm is considered in case condensate flow decreases to reach minimum
flow. If the flow decreases to reach a flow lower than minimum flow, after a time
delay the condensate extraction pump will trip and valve of minimum flow will be
closed.
ii) Condenser level Low-Low.
iii) Motor bearing temperature High-High.
iv) Motor winding temperature High-High.

5.1.4 Alarm of the condensate extraction pump

Condensate extraction pumps will alarms for the following conditions
i) Condensate extraction pump failed to start.
ii) Condensate extraction pump failed to stop.
iii) Condensate extraction pump has electrical fault.
iv) Condensate extraction pump tripped.
v) Condensate extraction pump Motor bearing temperature High.
vi) Condensate extraction pump Motor winding temperature High.
vii) Differential pressure across the suction strainer (LCB10AT001) High.
(Trip of pump will be decided by operator after a time delay of suction strainer
differential pressure switch alarm activated.)
5.1.5 Change-over of the pumps

YAZD
Combined Cycle
SYSTEM DESCRIPTION
CONDENSATE SYSTEM
DOOSAN
Changwon, KOREA
Contract No. :
22-0701/BA/TL
Doc. No. : MP-YZC-GA-04-HN0-001
Originator No. : YZC-A-SP-470-SDE-003
Revision : E
Date : Nov. 07, 05
Page: 8 / 9



The changeover of the condensate extraction pumps can be automatically carried out
from DCS.
The standby pump is kept ready for start-up during normal operation. The standby
pump starts automatically in case of the following:

i) If discharge header pressure is at the low alarm;
Two pumps (LCB11/21AP001) will be delivering the condensate together during
the short time period. And then, if the discharge header pressure is not low, the
existing running pump will be automatically tripped and selected as the standby
pump.
ii) If running condensate extraction pump trip signal is initiated;
The standby pump shall be started immediately. And then, the running pump will
be tripped.


6.0.0 GENERAL CONTROL DESCRIPTION

6.1.0 Minimum Flow Recirculation Control

A pneumatic operated control valve (LCB61AA151) ensures the minimum flow
through the condensate extraction pump. Flow device (LCB60CF101) measures the
discharge flow of condensate extraction pump. At low loads and start-up, a portion of
the condensate flow is recirculated to the condenser to maintain the minimum
required flow through the condensate extraction pump, gland steam condenser,
steam air ejector.

6.2.0 Condensate Flow Control

Condensate water flow control system is to maintain the feed water storage tank
(HAD80BB001) level within the allowable limits by modulating the feed water storage
tank level control valve (LCB80AA151/AA152). The feed water storage tank level
control station consists of two(2) 100% control valves (LCB80AA151/AA152). One
serves as the backup to the other.

6.2.1 Operation with two (2) HRSGs

The condensate water is supplied to two (2) deaerators by one (1) of condensate
extraction pump.
Heat is recovered in gland steam condenser, ejector condenser and condensate
preheater.
Feed water storage tank level is kept constant by level control valve.
The minimum flow recirculation control valve is closed.
The gland steam condenser bypass is closed
Condensate extraction pump discharge isolation valve (LCB14/24AA252) is
opened by manual.
YAZD
Combined Cycle
SYSTEM DESCRIPTION
CONDENSATE SYSTEM
DOOSAN
Changwon, KOREA
Contract No. :
22-0701/BA/TL
Doc. No. : MP-YZC-GA-04-HN0-001
Originator No. : YZC-A-SP-470-SDE-003
Revision : E
Date : Nov. 07, 05
Page: 9 / 9



The sealing water circuit is in operation.

6.2.2 Operation with a single HRSG

The same operation as in paragraph above except the condensate preheater of the
stopped HRSG is isolated.

6.3.0 Excess Condensate Dump Control

During plant load change or abnormal operation. The excess condensate water shall
be controlled by main cooling water system (Heller) in order to prevent the condenser
level high.