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CHOI
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Document Title
HEAT RECOVERY STEAM GENERATOR (HRSG)
SYSTEM DESCRIPTION
1-0923053.01
Job No. Project Subdivision Document Type Code Document number Revision
CONTENTS
Reference Drawing ;
Heat And Mass Balance Calculation [Doc No. EE-00001]
P&I Diagram – HRSG H.P Superheater Section [Dwg No. EA-685640]
P&I Diagram – HRSG Reheater Section [Dwg No. EA-685641]
P&I Diagram – HRSG H.P Econ. & Evap. Section [Dwg No. EA-685642]
P&I Diagram – HRSG I.P Section [Dwg No. EA-685643]
P&I Diagram – HRSG L.P Section [Dwg No. EA-685644]
P&I Diagram – HRSG Condensate Preheater Section [Dwg No. EA-685645]
P&I Diagram – HRSG Blowdwon Tank Section [Dwg No. EA-685646]
P&I Diagram – HRSG Flue Gas Section [Dwg No. EA-685661]
P&I Diagram – High Pressure Steam System [Dwg No. EA-682801]
P&I Diagram – Hot Reheat Steam System [Dwg No. EA-682829]
P&I Diagram – Cold Reheat Steam System [Dwg No. EA-682828]
P&I Diagram – Low Pressure Steam System [Dwg No. EA-682803]
P&I Diagram – Feedwater System [Dwg No. EA-682805]
P&I Diagram – Condensate System [Dwg No. EA-682806]
General Arrangement of HRSG [Dwg No. EA-685564]
z Maintains and safeguards the HP superheated steam temperature within the allowable main
steam system limit during part load operation at high ambient temperatures.
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.
The HP drum capacity is selected to ensure safe and stable operation under all normal
operating conditions. The HP drum provides about 3 minutes storage volume between normal
operating water level and the low low trip level when operating at MCR conditions to protect
evaporator surface during short term, intermittent feedwater flow interruptions and also provide
surge volume to accommodate drum level fluctuation caused by the drum water swelling during
start up. The drum water swelling during start up is considered as abnormal condition.
The HP drum is installed outside of the casing thus is not heated by exhaust gas. The
separation of water and steam is achieved by means of water/steam separation system (Two
stage separation system, baffle assisted separator as a primary and chevron type of dryer as a
secondary separator), which restricts carryover of water to the superheater within the limits.
Two safety valves are installed on the HP drum to protect the system against over pressure. The
vent piping from the drum safety valves is routed into the silencer to limit noise level. Sampling
connections are provided in the system for sampling of HP drum water (taken off from the
continuous blowdown line) and saturated steam (taken off from the saturated steam piping) from
the HP drum during operation. Connection for chemical dosing is installed at the HP drum.
The intermittent blowdown line from the HP drum to the HRSG blowdown system is equipped
with a motorized valve.
The continuous blowdown line from the HP drum to the HRSG blowdown system is equipped
with a motorized stop valve and a manual blowdown valve.
Saturated steam flows from the HP drum through connecting piping to the HP superheater. The
HP superheater is divided into three parts. A desuperheater is located between the HP
superheater2 &3 heating surfaces to maintain the HP steam temperature within the design
value during part load operation at high ambient temperature. (For the detail of set point, refer to
the item no.8 in Clause 5.)
Drain station is provided in the system to allow system drainage and warm-up particularly during
start-up. A motorized start up venting system is provided in the piping to remove the non-
condensable gas like an air during start-up.
A safety valve is installed to protect the system against over pressure. In addition, electrically
assisted relief valve (ERV) is provided in the HP main steam piping. The vent piping from the
steam line safety valve, ERV and start up vent valve is routed into the silencer to limit noise
level. Sampling connection is provided in the system for HP steam sampling during operation.
The HP steam line is equipped with a check valve to prevent back-streaming from another
HRSG. The line equipped with motorized main and small stop valve, which is used to isolate or
connect to the common steam header.
IP Feedwater System
The IP 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 IP feedwater control valve station is located downstream of the IP economizer to prevent
steaming of feedwater in the economizer. A relief valve is installed downstream of IP economizer
to prevent overpressure in the economizer if the IP feedwater control valve is closed and HRSG
in operation.
From the IP feedwater line, the spray water line to the RH desuperheating spray system branch
off. The RH desuperheating spray system delivers water into the RH interstage desuperheater
located between Reheater heating surfaces. It can limit the hot reheat steam temperature within
the design value during part load or normal operation at high ambient temperature. The Max.
spray flow is approximately 5% of the steam flow.
IP Steam Generation
The intermediate pressure system is located downstream the exhaust gas inlet of the HRSG
behind the HP part. The heating surfaces are fabricated mainly from finned tubes. The
intermediate pressure system is subdivided into the following sections, listed in the order in
which exhaust gas flows through them;
z IP Superheater
z IP Evaporator
z IP Economizer
The IP economizer recovers the remaining heat contained in the exhaust gas at the IP
evaporator outlet. The IP evaporator generates steam through a natural circulation loop from
and to the IP drum. The IP superheater heats the saturated steam from IP drum temperature to
superheated steam.
The IP superheater and the IP economizer are cross counter flow heat exchangers and the IP
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 IP economizers,
where it is heated up to economizer outlet temperature and then delivered to the IP drum.
Water is fed from the IP drum through downcomers to the inlet header of the IP evaporator.
Water partly evaporates in the IP evaporator and the water/steam mixture is fed via natural
convection in the tube risers from the outlet header back to the IP drum. The connection piping
between the outlet header and drum is distributed uniformly over the length of the drum.
The IP drum capacity is selected to ensure safe and stable operation under all normal operating
conditions. The IP drum provides about 8.8 minutes storage volume between normal operating
water level and the low low trip level when operating at MCR conditions to protect evaporator
surface during short term, intermittent feedwater flow interruptions and also provide surge
volume to accommodate drum level fluctuation caused by the drum water swelling during start
up. The drum water swelling during start up is considered as abnormal condition.
The IP drum is installed outside of the casing thus is not heated by exhaust gas. The separation
of water and steam is achieved by means of water/steam separation system (Two stage
separation system, baffle assisted separator as a primary and chevron type of dryer as a
secondary separator), which restricts carryover of water to the superheater within the limits.
Two safety valves are installed on the IP drum to protect the system against over pressure. The
vent piping from the drum safety valves is routed into the silencer to limit noise level. Sampling
connections are provided in the system for sampling of IP drum water (taken off from the
continuous blowdown line) and saturated steam (taken off from the saturated steam piping) from
the IP drum during operation. Connection for chemical dosing is installed at the IP drum.
The intermittent blowdown line from the IP drum to the HRSG blowdown system is equipped
with a motorized valve.
The continuous blowdown line from the IP drum to the HRSG blowdown system is equipped
with a motorized stop valve and a manual blowdown valve.
Saturated steam flows from the IP drum through connecting piping to the IP superheater.
Drain station is provided in the system to allow system drainage and warm-up particularly during
start-up. A motorized vent valve is provided in the piping to remove the non-condensable gas
like an air during initial start-up.
A safety valve is installed to protect the system against over pressure. The vent piping from the
steam line safety valve and start up vent valve is routed into the silencer to limit noise level.
Sampling connection is provided in the system for IP steam sampling during operation.
A pressure control valve is installed in the IP steam piping and used to control the IP system
pressure within allowable range during start up and shut down period. The IP steam piping can
be isolated by motorized stop valve. A check valve is provided to prevent back streaming from
the cold reheat piping system.
Reheater system
The reheater, which is divided into two parts, is located in high temperature gas zone. During
normal plant operation the exhaust steam from the HP turbine section is routed via the reheater
of the HRSG to the IP turbine inlet. Before entering the reheat section the HP turbine exhaust
steam is mixed with superheated IP steam coming from the IP superheater.
The line from the HP-steam bypass is routed to the cold reheat line during bypass operation.
No active regulation for HRH steam balance. Flow will be balanced as per HRSG back
pressure.
Reheater desuperheating spray system deliver water into the reheater desuperehater located
between the divided reheater heating surfaces. It limits the steam temperature to the allowable
range during part load operation at high ambient temperatures. (For the detail of set point, refer
to the item no.12 in Clause 5.)
Two safety valves are installed upstream and one safety valve downstream of the reheater to
protect the system against overpressure. A sampling connection is provided in the downstream
of the reheater system for steam sampling during operation.
Drain station is provided in the system to allow system drainage and warm-up particularly during
start-up. A motorized stop valve and pneumatic control valve in series is provided in start up
venting system in the Hot reheat piping to control the steam pressure during start-up. The vent
piping from the steam line safety valve and start up vent valve is routed into the separate
silencer to limit noise level.
The low pressure steam generation system generates LP steam of specific quality, which means
of correct pressure and temperature, from the thermal energy contained in the GT exhaust gas.
The steam is produced in the HRSG, supplied to heat the condensate in the deaerator system
and fed to the LP steam system. Condensate through the condensate preheater is fed to the
deaerator where it is heated and deaerated with steam from the LP evaporator. The deaerator is
integrated at the top of the LP drum for the deaeration of condensate.
z Shuts off condensate supply during feedwater control malfunction in order to prevent
overfeeding of the HRSG.
z Supplies LP steam produced by the HRSG to the LP steam system during normal operation.
z Reserves and Supplies feedawater to the feedwater pumps
z Supplies saturated steam from the LP drum to the deaerator for deaeration.
z Remove non condensable gases like CO2 and oxygen from the condensate during
operation of the plant.
z Control the temperature of the condensate entering the condensate preheater.
Condensate System
The condensate line is equipped with a check valve to prevent back-streaming from the HRSG
into the condensate extraction pump. The line can be isolated by a motorized stop valve.
The LP drum level control valve is located downstream of the condensate preheater to prevent
steaming of condensate in the condensater preheater. A relief valve is installed downstream of
condensate preheater to prevent overpressure in the condensate preheater if the LP drum level
control valve is closed and HRSG in operation.
LP Steam Generation
The low pressure system is located downstream the exhaust gas inlet of the HRSG behind the
IP part. The heating surfaces are fabricated mainly from finned tubes. The low pressure system
is subdivided into the following sections, listed in the order in which exhaust gas flows through
them;
z LP Superheater
z LP Evaporator
z Condensate preheater
The condensate preheater recovers the remaining heat contained in the exhaust gas at the LP
evaporator outlet. The LP evaporator generates steam through a natural circulation loop from
and to the LP drum. The LP superheater heats the saturated steam from the LP drum
temperature to superheated steam.
The LP superheater and the condensate preheater are cross counter flow heat exchangers and
the LP evaporator flow is cross to the exhaust gas flow. The HRSG is of vertical design.
The condensate is fed by the condensate extraction pumps to the condensate preheater, where
it is heated up to condensate preheater outlet temperature and then delivered to the deaerator.
The condensate preheater system is equipped with recirculation system which is used to control
the condensate preheater inlet temperature. The condensate preheater recirculation pump
recirculates water from the outlet of the condensate preheater to the inlet of the condensate
preheater. The temperature control valve, which is located in the recirculation pump discharge
line, controls the recirculation flow to maintain the condensate preheater inlet temperature.
To prevent less flow operation, below minimum flow of the recirculation pump, the recirculation
system control must limit the closure of the temperature control valve when the recirculation
pump flow approaches actual min. flow.
The condensate preheater system is also equipped with a condensate bypass system. The
three-way valve sends condensate water flow to the condensate preheater and/or bypass
around the condensate preheater.
The three-way valve can be positioned to ;
1. direct all condensate flow to the condensate preheater,
2. direct all condensate flow through the condensate preheater bypass,
3. direct any portion of the flow to either the preheater or the bypass around the condensate
preheater.
When the recirculation pumps are all failure, the three-way valve is positioned in the fully-closed
position, resulting in all the condensate flow bypassing the condensate preheater so that the
HRSG can be continuously operation without shut down.
The three-way valve is positioned to route a portion of the condensate flow to the condensate
preheater bypass as required to hold a minimum subcooling before entering the deaerator to
ensure an optimum deaeration process.
At the top of the LP drum, a direct contact spray-tray-type deaerator vessel is provided. A spring
loaded spray nozzle is provided for guaranteed operation of deaerating. All condensate through
the condensate preheater is fed to the deaerator where it is deaerated and heated by the
saturated steam from the LP drum and the resulting air is expelled through the vent line to
atmosphere. The deaerated condensate falls down through the deaerator downcomer and
collected in the LP drum.
Water is fed from the LP drum through downcomers to the inlet header of the LP evaporator.
Water partly evaporates in the LP evaporator and the water/steam mixture is fed via natural
convection in the tube risers from the outlet header back to the LP drum. The connection piping
between the outlet header and LP drum is distributed uniformly over the length of the LP drum.
The LP drum capacity is selected to ensure safe and stable operation under all normal
operating conditions. The LP drum provides about 10 minutes storage volume between normal
operating water level and the low low trip level when operating at MCR conditions to protect
evaporator surface during short term, intermittent feedwater flow interruptions and also provide
surge volume to accommodate drum level fluctuation caused by the drum water swelling during
start up. The drum water swelling during start up is considered as abnormal condition.
The LP drum is installed outside of the casing thus is not heated by exhaust gas. The separation
of water and steam is achieved by means of water/steam separation system (Two stage
separation system, baffle assisted separator as a primary and chevron type of dryer as a
secondary separator, which restricts carryover of water to the superheater within the limits.
The steam for the heating of the deaerator/LP drum is supplied by various sources. The main
source of steam is the LP evaporator.
Additionally, the pegging steam is supplied from the IP superheater outlet steam line. This
pegging steam operation is required when the LP drum pressure cannot be maintained above
floor pressure or drops quickly.
Two safety valves are installed on the LP drum to protect the system against over pressure. The
vent piping from the drum safety valves is routed into the silencer to limit noise level. Sampling
connections are provided in the system for sampling of LP drum water (taken off from the BFP
suction line) and saturated steam (taken off from the saturated steam piping) from the LP drum
during operation.
The suction line is provided from the LP drum to provide feedwater into the feedwater pumps.
Connections for the min. recirculation and leak off lines from the feedwater pumps are provided
on the LP drum.
The intermittent blowdown line from the LP drum to the HRSG blowdown system is equipped
with a motorized valve.
Saturated steam flows from the LP drum through connecting piping to the LP superheater.
Drain station is provided in the system to allow system drainage and warm-up particularly during
start-up.
A safety valve is installed to protect the system against over pressure. A motorized stop valve
and pneumatic control valve in series is provided in start up venting system in the LP steam
piping to control the steam pressure during start-up. The vent piping from the steam line safety
valve and start up vent valve is routed into the separate silencer to limit noise level.
Sampling connection is provided in the system for LP steam sampling during operation.
The LP steam line is equipped with a check valve to prevent back-streaming from another
HRSG. The line equipped with motorized main and small stop valve, which is used to isolate or
connect to the common steam header.
The exhaust gas system also includes the HRSG framework, stiffening elements, heating
surface suspension, expansion joints, insulation and instrumentation.
The gas turbine exhaust gas flows through the HRSG exhaust gas inlet ducting and the HRSG
before being routed to atmosphere via the HRSG exhaust gas stack. The HRSG heating
surfaces are divided into the following sections in the direction of the exhaust flow;
z HP superheater 3
z Reheater 2
z HP superheater 2
z Rehater 1
z HP superheater 1
z HP evaporator
z IP superheater
z HP economizer 2
z IP evaporator
z LP superheater
z HP economizer 1 / IP economizer
z LP evaporator
z Condensate preheater
The heating surface mainly consist of horizontal finned tubes joined together to form heating
surface packages. The tube banks are suspended in the HRSG frame and walls. The HRSG is
of vertical design.
The cooled exhaust gas, after it leaves the last heating surface (Condensate Preheater), flows
through the HRSG exhaust gas stack.
A stack damper is provided to reserve a heat in the HRSG casing during shut down period.
A stack silencer is provided to limit noise within allowable value.
The blowdown system is designed to collect the process water from drains, continuous and
intermittent blowdown. The main purpose of the blowdown system is to receive the discharge of
blowdown water in order to control boiler water quality and decrease drum levels. The
continuous blowdown is used to control the water quality. The purpose of the intermittent
blowdown is lowering drum water levels.
The blowdown tank is vertical, cylindrical tank in which drain headers enter tank tangentially
above water level. The tank water level is maintained by an internal loop seal of overflow line.
A drain line is supplied at the bottom of tank to allow complete drain. A silencer is supplied at
exhaust vent line to limit noise level.
Check the HRSG to make sure that all maintenance work has been completed, all tools and
debris have been removed, the handhole plates and manhole covers have been installed and
secured, and all access doors have been installed and secured.
Check all relevant clearance certificates to be obtained and all work permits cancelled and
signed out.
Check the safety valves to see if the gags have been removed, the lifting levers have been
replaced, and the valves are not fouled or hung up.
This section describes the recommended procedure for filling an empty HRSG with water. If the
unit is hot, the unit has to be cooled first to avoid severe temperature strains (Max. allowable
temperature difference is approximately 50 deg.C). Also, since deposits of solids in a
superheater can cause corrosion or inhibit heat transfer, introduction of solids by carryover of
boiler water from the drum during filling should be avoided.
Reference P&ID ;
P&I Diagram – HRSG H.P Superheater Section [Dwg No. EA-685640]
P&I Diagram – HRSG Reheater Section [Dwg No. EA-685641]
P&I Diagram – HRSG H.P Econ. & Evap. Section [Dwg No. EA-685642]
P&I Diagram – HRSG I.P Section [Dwg No. EA-685643]
P&I Diagram – HRSG L.P Section [Dwg No. EA-685644]
P&I Diagram – HRSG Condensate Preheater Section [Dwg No. EA-685645]
Note; The activity of initial filling require manual action from local
or control room.
2. Ready for LP LP Open and prepare the following valves for filling.
drum filling
1. Confirm closed condensate stop MOV (LCA-90-AA-001).
3. Ready for IP IP Open and prepare the following valves for filling.
drum filling
1. Open IP feedwater small stop MOV (LAB-94-AA-002) and Close
main stop MOV (LAB-94-AA-001).
4. Ready for HP Open and prepare the following valves for filling.
HP drum filling
1. Open HP feedwater small stop MOV (LAB-90-AA-002) and
Close main stop MOV (LAB-90-AA-001).
5. LP drum LP 1. Initial water filling is done by separate filling line from the
filling demineralized transfer pump. The filling line is prepared in the
condensate line. The filling from the demi. Water pump is only
used for initial filling (System is in empty case). In case of normal
start up, which mean the system is already filled by water, the
demi. water pump will not be used.
2. Adjust the water flow about 10% of MCR flow by LP drum LCV
(LCA-91-AA-081).
4. Fill LP drum until Low Start up water level (-100 mm from Drum
Center Line) has been reached.
6. IP drum IP 1. Initial water filling is done by separate filling line from the
filling demineralized transfer pump. The filling line is prepared in the
feedwater pump IP discharge line (Refer to BOP P&ID-Feedwater
System dwg.no. EA-682805-003). The filling from the demi. Water
pump is only used for initial filling (System is in empty case). In
case of normal start up, which mean the system is already filled by
water, the demi. water pump will not be used.
2. Adjust the water flow about 10% of MCR flow by IP drum LCV
(HAC-94-AA-081).
4 Fill IP drum until Low Start up water level (-450 mm from Drum
Center Line) has been reached.
7. HP drum HP 1. Initial water filling is done by separate filling line from the
filling demineralized transfer pump. The filling line is prepared in the
feedwater pump HP discharge line (Refer to BOP P&ID-Feedwater
System dwg.no. EA-682805-002). The filling from the demi. Water
pump is only used for initial filling (System is in empty case). In
case of normal start up, which mean the system is already filled by
water, the demi. water pump will not be used.
2. Adjust the water flow about 10% of MCR flow by Low load HP
drum LCV (HAC-90-AA-082).
4. Fill HP drum until Low Start up water level (-550 mm from Drum
Center Line) has been reached.
[EA-685642]
“ LAB-90-AA-002 HP Feedwater small stop MOV Auto(Close) Auto(Close) Auto(Close)
H.P
Superheater.
HAH-91-AA-001 HP SH 1 inlet drain MOV Auto(Close) Auto(Close) Auto(Close)
Section
[EA-685640]
-End-
Reheater
Section LBC-90-AA-001 CRH steam stop MOV Auto(Close) Auto(Open) Auto(Close)
[EA-685641]
-End-
direction)
L.P Section
LCA-91-AA-001 LP Drum LCV bypass MOV Auto(Open) Auto(Close) Auto(Close)
[EA-685644]
-End-
Note ;
* The condensate stop MOV (LCA-90-AA-001) shall be opened after HRSG LP section water
filling completed, if the system was earlier filled using the demineralized transfer pumps.
The HRSG outputs (steam evaporation rates, superheated temperatures, pressures, energy
outputs at HP, IP and LP steam outlets, respectively) varies according to available exhaust heat
from the gas turbines.
Most operations normally required to establish a HRSG ready to start condition after an
overnight shutdown can be accomplished from the central control room. These operations are
remote manual actions by the control room operator. Some activity, such as HRSG water filling
and manual valve alignments for HRSG ready to start condition requires local operator actions.
3) GT Start
Certain conditions must be satisfied prior to the initiations of the HRSG start. All system (Gas
turbine, Steam turbine, Mechanical Auxiliary/BOP equipments and etc) required for the plant
operation must be ready for operation. Followings are HRSG Ready to Start Condition.
* High start up level (If HP drum P > 40 barg); -200mm from C.L.
* High start up level (If IP drum P > 10 barg); -200mm from C.L.
* High start up level (If LP drum P > 2 barg); +300mm from C.L.
z Align HP/IP/LP section valves as shown on the column labeled “Start Up” listed in the table
1,2 and 3.
The HRSG can be started up using either of the two following methods which can be selected
by the operating personnel;
In this case, GT and HRSG are started up commonly with use of the diverter damper system.
In this case, the HRSG is started up by using the diverter damper while the GT is in operation.
Before switch over from simple cycle to combined cycle mode, the GT has to be shutdown (if
the HRSG is not purged) or load decreased and subsequently the GT exhaust gas temperature
reduced to the required condition for the HRSG purging process and temperature matching.
Description Action
2 Plant Purge The purging concept involves that the bypass stack and the HRSG
will be purged prior every GT start (ignition) for both simple cycle and
combined cycle start. Once the purge has been completed, it remains
set in memory if the GT has remained in continuous operation with no
trips. Provided that the purge completed remains set, GT exhaust flow
can re-enter HRSG without re-purge for the HRSG start. HRSG and
bypass stack side shall be purged by GT with 850 RPM (23.6% of
rated GT RPM) and by change the position of the diverter damper.
The purge duration is 15 minutes (GT purge duration is 9 minutes and
HRSG purge duration is 6 minutes). The HRSG purge is performed
for 6 minutes after completion of GT purge with bypass stack side (9
minutes). During GT purge, the diverter damper is in HRSG closed
position and then for HRSG purge, the diverter damper is moved to
the HRSG opened position.
After HRSG has been purged, the diverter damper is moved to HRSG
closed position.
Description Action
3 GT ignition and As soon as bypass stack and HRSG purge completed, the GT ignition
Gas temperature and accelerating is initiated. In case of GT in already operation in
matching simple cycle mode, the GT load decrease and subsequently the GT
exhaust gas temperature reduced to the required condition for the gas
temperature matching.
Description Action
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.
The lag HRSG is started with closed steam stop valves. When the
following conditions are satisfied, Open small bypass stop valve first.
After small bypass stop valve open, then open the main stop valve
and close the small bypass stop valve.
The last HRSG HP steam stop MOV’s operation is the same with lag
HRSG.
Description Action
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.
The lag HRSG reheater is started with closed steam stop valves.
Thus, the reheater is initially isolated from the cold reheat steam
header. Steam from the HP steam bypass system passes through the
reheater to the condenser via the HRH steam bypass system.
When the hot reheat 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.
The last HRSG CRH steam stop MOV’s operation is the same with
lag HRSG.
Description Action
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.
The lag HRSG is started with closed steam stop valves. When the
following conditions are satisfied, Open small bypass stop valve first.
After small bypass stop valve open, then open the main stop valve
and close the small bypass stop valve.
The last HRSG LP steam stop MOV’s operation is the same with lag
HRSG.
Description Action
8 Drain operation Drain will be operated for removing condensate from HRSG steam
(HP) path.
Description Action
9 Drain operation 1. Open CRH steam line drain MOV (LBC-90-AA-002), when RH
(RH) steam pressure (LBB-90-CP-001/002/003) above 1 barg.
Description Action
10 Drain operation 1. Open IP steam line drain MOV (LBA-95-AA-003) when IP Drum
(IP) pressure (HAD-94-CP-001/002/003) above 1 barg.
11 Drain operation 1. Open LP steam line drain MOV (LBD-90-AA-004) when LP Drum
(LP) pressure (HAD-97-CP-001/002/003) above 0.5 barg.
12 Start Up Vent Vent will be operated for extracting any non-condensable gas from
Operation (HP) HRSG steam path.
13 Start Up Vent The RH start up vent will control the RH pressure increasing rate, if
Operation (RH) RH steam bypass system (Condenser vacuum) is not ready condition.
3. Close RH start up vent MOV and PCV when the RH steam bypass
system (Condenser vacuum) is available.
Description Action
14 Start Up Vent Vent will be operated for extracting any non-condensable gas from
Operation (IP) HRSG steam path.
15 Start Up Vent The LP start up vent will control the LP Drum pressure increasing
Operation (LP) rate, if LP steam bypass system (Condenser vacuum) is not ready
condition.
3. Close LP start up vent MOV and PCV when the LP steam bypass
system (Condenser vacuum) is available.
16 Steam Bypass Each Steam Bypass System will be operated to control the HRSG
System Operation Pressure.
Description Action
17 GT and HRSG In line with the admitting of the GT exhaust gas, the metal of the heat
load up transfer surface is heated up and steam is formed in the evaporators,
which leads to a partly water ejection from the evaporators into the
drums.
Description Action
19 LCV set point Drum level set point should be changed from start up water level into
change Normal water level when load greater than 25% MCR flow.
For starting the HRSG from a warm or hot condition, steps are the same with above sequence.
The lag or last HRSG is started in a similar manner to the lead HRSG.
After first GT, HRSG and ST are on-line s lead, succeeding GT and HRSG can be started as lag
by operator’s initiation of remaining GT and HRSG start up. When succeeding GT and HRSG is
initiated for start up, HRSG should already be prepared for start up conditions as summarized in
clause 2.3.2 HRSG Ready to Start Condition above. With the start of HRSG, steam flow will be
established through HRSG steam line. AS ST and Condenser are on-line, produced steam can
be dumped to the condenser through the steam bypass system until each steam can be
equalized to steam lines of leading HRSG.
Steam production increase from the part load to base load is performed by increasing the load
of the GT. HRSG runback is achieved by GT load decrease.
The HRSG operating pressure is operated in natural sliding pressure mode between 100% and
40% of rated pressure depending on the steam mass flow into the steam turbine. In part load
operation, the HRSGs are oeperated in fixed pressure mode, means the pressure is controlled
by the steam turbine throttle oeperation. For the detail of the plant operation characteristic,
please refer to the Heat and Mass Balance Calculation [Doc.no. EE-00001].
The HRSG load is dierectly depending on the GT operation. Generally, 30% of MCR steam flow
load operation as minimum is recommended at which the drum level is relatively stable.
The HRSG shut down is performed by the diverter damper close with normal speed (60
seconds)
2) As the remaining heat in the HRSG, Steam bypass system control the HRSG pressure
5) If there is no demand of feedwater supply, close all feed water stop valves.
Description Action
2 Diverter damper The Diverter damper will be closed with normal speed (60 seconds).
close Now, HRSG can be isolated from the GT.
3 Steam Bypass HP/RH/LP steam bypass system will be operated, thereby diverting
System Operation steam from the HRSG through the associated steam bypass system.
The lag HRSG HP steam stop MOV’s operation is the same with lead
HRSG.
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.
Description Action
5 CRH Steam Stop The CRH steam stop MOV (LBC-90-AA-001) will be closed.
MOV Close
1) Lead HRSG CRH steam stop MOV ;
The HP steam stop valve and CRH steam stop MOV will be closed
when HRSG shutdown initiated.
At this moment, the HRH, CRH and LP steam stop valve will be
closed simultaneously.
The lag HRSG CRH steam stop MOV’s operation is the same with
lead HRSG.
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.
Description Action
The HP steam stop valve and LP steam stop MOV will be closed
when HRSG shutdown initiated.
At this moment, the HRH, CRH and LP steam stop valve will be
closed simultaneously.
The lag HRSG LP steam stop MOV’s operation is the same with lead
HRSG.
7 IP Steam Stop The IP steam stop MOV (LBA-95-AA-002) will be closed after IP
MOV Close steam PCV (LBA-95-AA-081) fully closed.
9 HP feedwater stop The HP feedwater stop MOV (LAB-90-AA-001) can be closed when
MOV Close no demand of feedwater supply. This MOV will be closed after HP
drum LCV(HAC-90-AA-081 and 082) fully closed.
Description Action
10 IP feedwater stop The IP feedwater stop MOV (LAB-94-AA-001) can be closed when no
MOV Close demand of feedwater supply. This MOV will be closed after IP drum
LCV(HAC-94-AA-081) fully closed.
11 Condensate stop The condensate stop MOV (LCA-90-AA-001) can be closed when no
MOV Close demand of condensate supply. This MOV will be closed after LP drum
LCV (LCA-91-AA-081) fully closed.
The HRSG protection item, which cause HRSG trip is summarized in Clause.4. In case of
HRSG protection signal detected, the HRSG is tripped by quick closing of diverter damper
within 20 seconds.
In case of a GT trip, the HRSG has also to be tripped to avoid cooling of HRSG by running
down GT. The HRSG is tripped by quick closing of diverter damper within 20 seconds.
Steam Turbine Trip does not make any impact on the HRSG itself. The HRSG can be operated
by dumping steam generated from the HRSG to the condenser through the steam bypass
system or HRSG can be shutdown decided by operator.
The HRSG Run Back will be achieved by the Gas Turbine Run Back (load reducing) as
following events.
z If HRSG inlet duct Gas temperature (HNA-90-CT-001/002/003) ≥ 655 deg.C (Alarm H), the
GT Run Back until alarm disappeared.
z If HP final steam temperature (LBA-90-CT-001/002/003) ≥ 575 deg.C (Alarm H), the GT
Run Back until alarm disappeared.
z If RH final steam temperature (LBB-90-CT-001/002/003) ≥ 574 deg.C (Alarm H), the GT
Run Back until alarm disappeared.
The drum level/feed water control comprises of a single element drum level control operating on
low load operation and a three element control operating on full load operation. The single
element control is envisaged for controlling the drum level during low load up to 25% MCR. The
three element control is envisaged for drum level control from 25% MCR to 100% MCR.
Valve composition ;
The median value of the drum level (HAD-90-CL-001/002/003) is compensated for the drum
pressure (HAD-90-CP-001/002/003). The compensated output is selected for load less than 25%
MCR. The measured level is compared with the set value and the error is applied to the
controller for positioning the level control valve. The drum level shall have two start up level set
points namely high start up level set point and low start up level set point. The set point should
be changed according to the drum pressure increasing.
* Low start up level set point; -550mm from C.L. (If HP drum pressure is lower than 40 barg)
* High start up level set point; -200mm from C.L. (If HP drum pressure is higher than 40 barg)
These set points will switch over to normal set point from start up set point when load above 25%
MCR.
This control is used for load greater than 25% MCR. It is based on three parameters namely
drum level, steam flow and feed water flow.
The steam flow (LBA-90-CF-001/002) is applied as a feed forward signal to the drum level
controller and the output of the controller is given as the set point for the feed water flow
controller. The feedwater flow (LAB-90-CF-001/002) is added to the controller as a feedback
signal.
The valves controlling the water feed to the drum are in a two valve arrangement consisting of a
30% valve for low load and a 100% valve for full load control.
The low load and full load control valves are arranged in a parallel split-range manner to provide
good flow control through a wide range of control valve pressure drop. The low load valve
handles the smaller flows until it is nearly fully open then full load valve opens to handle the
large flows. The opposite action occurs on decreasing flow. Generally, the flow capacity ratio of
the two valves is chosen to ensure that the drum level control remains as single-element during
start-up and the transfer of control valves occurs after three-element drum level control has
commenced.
For increasing flow, the full load control valve opens when the low load control valve is almost
fully open (approximately 90% stoke). After the transfer, the low load valve is fully closed
ensuring that the full load valve will not operate near to its seat. For decreasing flow, the low
load valve is opened and the larger valve is fully closed at the transfer point.
A motorized isolation valve on the inlet of each control valve is supplied to isolate the control
valve during shutdown/maintenance period and automatically opened when HRSG start initiated.
The drum level/feed water control comprises of a single element drum level control operating on
low load operation and a three element control operating on full load operation. The single
element control is envisaged for controlling the drum level during low load up to 25% MCR. The
three element control is envisaged for drum level control from 25% MCR to 100% MCR.
Valve composition;
The median value of the drum level (HAD-94-CL-001/002/003) is compensated for the drum
pressure (HAD-94-CP-001/002/003). The compensated output is selected for load less than 25%
MCR. The measured level is compared with the set value and the error is applied to the
controller for positioning the level control valve. The drum level shall have two start up level set
points namely high start up level set point and low start up level set point. The set point should
be changed according to the drum pressure increasing.
* Low start up level set point; -450mm from C.L. (If IP drum pressure is lower than 10 barg)
* High start up level set point; -200mm from C.L. (If IP drum pressure is higher than 10 barg)
These set points will switch over to normal set point from start up set point when load above 25%
MCR.
This control is used for load greater than 25% MCR. It is based on three parameters namely
drum level, steam flow and feed water flow.
The steam flow (LBA-95-CF-001/002) is applied as a feed forward signal to the drum level
controller and the output of the controller is given as the set point for the feed water flow
controller. The feedwater flow (LAB-94-CF-001/002) is added to the controller as a feedback
signal.
In the event of failure of the control valve, the inching type motorized bypass valve can be used
by the manual signal from the control room.
The drum level/condensate water control comprises of a single element drum level control
operating on low load operation and a three element control operating on full load operation.
The single element control is envisaged for controlling the drum level during low load up to 25%
MCR. The three element control is envisaged for drum level control from 25% MCR to 100%
MCR.
Valve composition ;
The median value of the drum level (HAD-97-CL-001/002/003) is compensated for the drum
pressure (HAD-97-CP-001/002/003). The compensated output is selected for load less than 25%
MCR (condensate flow). The measured level is compared with the set value and the error is
applied to the controller for positioning the level control valve. The drum level shall have two
start up level set points namely high start up level set point and low start up level set point. The
set point should be changed according to the drum pressure increasing.
* Low start up level set point; -100mm from C.L. (If LP drum pressure is lower than 2 barg)
* High start up level set point; +300mm from C.L. (If LP drum pressure is higher than 2 barg)
These set points will switch over to normal set point from start up set point when load above 25%
MCR (condensate flow).
This control is used for load greater than 25% MCR (condensate flow). It is based on three
parameters namely drum level, summed drum out flow and condensate flow.
The summed drum out flow [LP steam flow(LBD-90-CF-001/002) + HP feedwater flow(LAB-90-
CF-001/002) + IP feedwater flow(LAB-94-CF-001/0020)] is applied as a feed forward signal to
the drum level controller and the output of the controller is given as the set point for the
condensate flow controller. The condensate flow (LCA-90-CF-001/002) is added to the controller
as a feedback signal.
In the event of failure of the control valve, the inching type motorized bypass valve can be used
by the manual signal from the control room.
The HP superheater steam desuperheater function is to control HRSG superheater outlet steam
temperature within allowable condition. The set point is 567 deg.C.
Valve composition ;
To ensure that all water droplets are evaporated and to minimize potential temperature shocks
resulting from the introduction of spray water, the desuperheater is placed at the inlet to the HP
final superheater. The amount of spray water must be limited to avoid driving the HP final
superheater inlet steam into the saturation region.
The output of the outer controller is the temperature setpoint of the inner controller. This
controller positions the HP desuperheater spray water control valve. The feedback of the inner
controller is the steam temperature (HAH-90-CT-002/003/004) at the inlet to the final
superheater. In effect, the outer controller controls the final HRSG HP superheater outlet steam
temperature by adjusting the temperature of the steam entering the final stage of superheating.
Since there is a possibility of overspraying and forcing steam to saturation temperature at the
inlet of the HP final superheater, the setpoint of the inner controller has a minimum limit of the
present saturation temperature plus a margin (+28 deg.C). The saturation temperature is
determined from the saturation temperature from HP drum pressure measurements (HAD-90-
CP-001/002/003).
This steam temperature control is permissive only when the HP steam flow (LBA-90-CF-
001/002) is higher than 20% of MCR flow to avoid any steam condensation in steam path.
A motorized block valve is placed in the spray water line in series with a spray control valve. The
block valve is automatically closed whenever the desuperheater control is not enabled and
automatically opened when enabled.
In the event of failure of the control valve, the inching type bypass valve can be used by the
manual signal from the control room.
The Reheater steam desuperheater function is to control HRSG reheater outlet steam
temperature within allowable condition. The set point is 566 deg.C.
Valve composition;
To ensure that all water droplets are evaporated and to minimize potential temperature shocks
resulting from the introduction of spray water, the desuperheater is placed at the inlet to the final
reheater. The amount of spray water must be limited to avoid driving the final reheater inlet
steam into the saturation region.
Reheater steam desuperheater control utilizes two controllers in a cascade arrangement namely
"outer" controller and “inner” controller. The setpoint of outer controller is the desired HRSG
reheater outlet steam temperature and the feedback is the HRSG reheater outlet steam
temperature (LBB-90-CT-001/002/003) measured at the outlet of the final reheater. The set
point is 566 deg.C at the final reheater outlet.
The output of the outer controller is the temperature setpoint of the inner controller. This
controller positions the reheater desuperheater spray water control valve. The feedback of the
inner controller is the steam temperature (HAJ-90-CT-002/003/004) at the inlet to the final
reheater. In effect, the outer controller controls the final HRSG reheater outlet steam
temperature by adjusting the temperature of the steam entering the final stage of reheater.
Since there is a possibility of overspraying and forcing steam to saturation temperature at the
inlet of the final reheater, the setpoint of the inner controller has a minimum limit of the present
saturation temperature plus a margin (+28 deg.C). The saturation temperature is determined
from the saturation temperature from hot reheat steam pressure measurements (LBB-90-CP-
001/002/003).
This steam temperature control is permissive only when the HP steam flow (LBA-90-CF-
001/002) is higher than 20% of MCR flow to avoid any steam condensation in steam path.
A motorized block valve is placed in the spray water line in series with an spray control valve.
The block valve is automatically closed whenever the desuperheater control is not enabled and
automatically opened when enabled.
In the event of failure of the control valve, the inching type bypass valve can be used by the
manual signal from the control room.
The HRSG is equipped with IP steam pressure control valve and steam stop MOV in series to
Cold Reheater line. Large, rapid variations in IP drum pressure can cause rapid variations in the
drum level. Pressure change causes the void fractions in the evaporator and drum to enlarge
(on rapid pressure decay) or shrink (on rapid pressure rise), causing the water in the drum to
rise above or fall below NWL. Maintaining stable IP drum pressure greatly helps maintaining a
stable IP drum level.
Valve composition ;
HRSG start-up shall be initiated with closed control valve. Then valve operation will be initiated
as followings.
Open control valve to 10 % when the IP steam pressure (LBA-95-CP-001/002) above 3 barg
and hold this position until the IP steam pressure reaches 10 barg. Then the control valve shall
modulate to maintain this pressure (10 barg).
With this control, the control valve will open continuously to full open position when the cold
reheat steam line is pressurized above 10 barg.
Another function is that, during plant transient operation, if the IP steam pressure drops too fast,
the pressure decay rate will be controlled by acting to close this control valve. The control valve
shall control the IP steam pressure (LBA-95-CP-001/002) decay rate within -0.1bar/s.
The IP steam stop MOV will be opened from the initial start up and always open during
operation. During shutdown period, this valve can be closed when IP steam PCV is completely
closed.
Valve composition ;
The pegging steam supply has the following functions. And this control is active only if the IP
drum pressure is higher than 10 barg.
* Mainly Oil firing operation case, It is expected that insufficient flue gas energy available at the
LP evaporator to maintain the LP drum pressure high enough to prevent gas side corrosion.
Pegging steam from the IP steam line maintains a minimum LP drum pressure and a resultant
LP drum water temperature. The set point (3 barg) is compared with the LP drum pressure
(HAD-97-CP-001/002/003). The difference is the input signal for the controller of the control
valve.
* When the feedwater pump suction is taken from the LP drum, pegging steam prevents a rapid
decay of LP drum pressure to limit the generation of steam voids in the drum and BFP suction
line water. If LP drum pressure drops too fast, the pressure decay rate will be controlled by
providing pegging steam. The pegging steam control valve shall control the LP drum pressure
(HAD-97-CP-001/002/003) decay rate within -0.007 bar/s.
The motorized isolation valve at the inlet of control valve is supplied to prevent any possible
leakage of the control valve. Also this valve will provide a tight isolation from the IP steam
system when no demand of steam supply. The motorized isolation valve is automatically closed
whenever the control is not enabled and automatically opened when enabled.
The motorized isolation valve will be protectionally closed when the LP drum pressure (HAD-97-
CP-001/002/003) is higher than 7 barg.
The condensate preheater (CPH) is located outlet of HRSG and heated by exhaust gas before
leaving the main stack. The CPH inlet temperature control is to raise the temperature of the
condensate entering the CPH to avoid flue gas corrosion in the CPH tube. A temperature control
valve modulates the discharge flow of the CPH recirculation pumps to recirculate hot water from
the outlet of the CPH to the inlet of the CPH where it mixes with cold condensate flow.
The design Gas fuel composition used for the plant operation indicates zero sulfur concentration.
The fixed set point of 70 deg.C is enough to prevent corrosion for Gas fuel operation. When the
higher sulfur content fuel used, such as Oil operation, the CPH will be completely bypassed.
Composition ;
One of recirculation pump should be placed into service before starting the HRSG.
The fixed set point, 70deg.C is compared with the CPH inlet temperature (LCA-90-CT-003/004)
signal. The difference is the input signal for the controller of the control valve.
In addition to the above temperature control, following control for recirculation pumps protection
is also incorporated.
To prevent less flow operation of pumps, the recirculation system controls must limit the closure
of control valve when the recirculation pump flow reaches low flow set point (65,000 kg/hr). The
low flow set point would be slightly above the actual minimum flow of recirculation pumps. The
recirculation pump flow is measured using flow transmitter (LCA-94-CF-001/002) located at the
discharge of pump. The operation pump must be tripped if the measured pump flow falls to the
minimum flow trip setting (60,000 kg/hr).
To prevent excessive flow from the pumps, the recirculation high flow set point (300,000 kg/hr)
would be set below the recirculation pump maximum allowable continuous flow in order to limit
the further opening of control valve when the recirculation pump flow approaches the high flow.
The operation pump must be tripped if the pump flow equals or exceeds the maximum allowable
continuous flow setting (330,000 kg/hr).
The condensate preheater system is equipped with a condensate bypass system. The three-
way valve sends condensate water flow to the condensate preheater and/or bypass around the
condensate preheater.
* direct any portion of the flow to either the preheater or the bypass around the condensate
preheater.
Valve composition ;
The 3-way valve is positioned to full open to the bypass direction before HRSG start. During
start up period, no cold condensate would be introduced into CPH tube while all condensate is
bypassed by 3-way valve in order to prevent possible flue gas corrosion in the CPH tube. The 3-
way valve can be positioned to full open to the CPH direction after steam bypass operation is
finished and all steam introduced into the steam turbine.
The three-way valve is positioned to route a portion of the condensate flow to the condensate
preheater bypass as required to hold a minimum subcooling before entering the deaerator to
ensure an optimum deaeration process.
The function of this control is to maintain condensate temperature several degrees below
saturation temperature to achieve a good deaeration performance in the deaerator. It is
accomplished by 3-way valve valve to split the incoming condensate flow between the CPH and
a bypass around the CPH.
If the temperature difference between the saturation temperature calculated from the LP drum
pressure (HAD-97-CP-001/002/003) and the CPH outlet temperature (LCA-91-CT-001/002) is
lower than 8 deg.C, the 3-way valve will be opened partially into the bypass direction in order to
make a cold condensate bypass flow and therefore reduce the temperature of CPH outlet
condensate before entering the deaerator.
The CPH full bypass operation shall be required in some case. When the CPH recirculation
pumps are all failure longer than 10 minutes, the three-way valve is positioned in the fully-closed
position to the CPH, resulting in all the condensate flow bypassing the condensate preheater so
that the HRSG can be continuously operation without shut down.
If HP economizer pressure (LAB-90-CP-001) reaches 188 barg, Auto open the low load LCV
(HAC-90-AA-082) to 20%. The auto open function has to be effective in HRSG operation below
25% MCR and shut down period also.
The auto open command is removed if HP economizer pressure (LAB-90-CP-001) falls below
180 barg.
If IP economizer pressure (LAB-94-CP-001) reaches 65 barg, Auto open the LCV (HAC-94-AA-
081) to 20%. The auto open function has to be effective in HRSG operation below 25% MCR
and shut down period also.
The auto open command is removed if IP economizer pressure (LAB-94-CP-001) falls below 55
barg.
If CPH pressure (LCA-90-CP-002) reaches 32 barg, Auto open the LCV (LCA-91-AA-081) to
20%. The auto open function has to be effective in HRSG operation below 25% MCR and shut
down period also.
The auto open command is removed if CPH pressure (LCA-90-CP-002) falls below 28 barg.
HRSG start-up shall be initiated with closed drain valves. Then drain valves operation shall be
initiated as followings.
Close after 5 minutes time delay, if HP drum pressure reaches or higher than 15 barg.
Then, place MOV (HAH-90-AA-001 and LBA-90-AA-001) into auto operation mode comparing
the drain pot temperature element and the saturation temperature at corresponding drum
pressure measurements.
Place MOV (HAH-91-AA-001) into auto operation mode monitoring the drain pot level switches.
These valves shall have opening limit to prevent excess drain flow. When open demand is
initiated, the valve open position shall be determined as following.
Close after 5 minutes time delay, if HP drum pressure reaches or higher than 15 barg and HP
steam stop MOV (LBA-90-AA-003) open.
Then, place into auto operation mode comparing the drain pot temperature element and the
saturation temperature at corresponding drum pressure measurements.
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.
Open CRH steam line drain MOV (LBC-90-AA-902), when RH steam pressure (LBB-90-CP-
001/002/003) above 1 barg.
Close after 5 minutes time delay, if RH steam pressure reaches or higher than 5 barg and CRH
steam stop MOV (LBC-90-AA-001) open.
Then, place into auto operation mode monitoring the drain pot level switches.
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.
Close after 5 minutes time delay, if RH steam pressure reaches or higher than 5 barg.
Then, place into auto operation mode monitoring the drain pot temperature element and
comparing the saturation temperature at RH steam pressure measurements.
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.
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.
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.
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 vent valves when HP Drum pressure (HAD-90-CP-001/002/003) above 0.5 barg.
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-CP-
001/002/003) above 0.5 barg.
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.
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.
Open vent valves when IP Drum pressure (HAD-94-CP-001/002/003) above 0.5 barg.
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-CP-
001/002/003) 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.
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.
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).
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.
* When HP drum level (HAD-90-CL-001/002/003) fall below the low water level (-685 mm from
C.L).
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.
* When IP drum level (HAD-94-CL-001/002/003) fall below the low water level (-530 mm from
C.L).
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.
* 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;
* When HP drum level (HAD-90-CL-001/002/003) fall below the low water level (-685 mm from
C.L).
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.
* 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;
* When IP drum level (HAD-94-CL-001/002/003) fall below the low water level (-530 mm from
C.L).
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.
* 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.
* When LP drum level (HAD-97-CL-001/002/003) fall below the low water level (-1065 mm from
C.L).
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. 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.
* When HP drum level (HAD-90-CL-001/002/003) reaches the High/High water level (230 mm
from C.L).
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.
* When IP drum level (HAD-94-CL-001/002/003) reaches the High/High water level (230 mm
from C.L).
As preparation activity for HRSG start, this valve will be opened before HRSG start.
* When LP drum level (HAD-97-CL-001/002/003) reaches the High/High water level (725 mm
from C.L).
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
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.
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.
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.
The last HRSG HP steam stop MOV’s operation is the same with lag HRSG.
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 (if
necessary) 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.
The lag HRSG HP steam stop MOV’s operation is the same with lead HRSG.
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.
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.
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.
The last HRSG CRH steam stop MOV’s operation is the same with lag HRSG.
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 (if necessary) and the HRH steam
bypass system will open as a result of the HP steam bypass opening.
The HP steam stop valve and CRH steam stop MOV will be closed when HRSG shutdown
initiated.
At this moment, the HRH, CRH and LP steam stop valve will be closed simultaneously.
The lag HRSG CRH steam stop MOV’s operation is the same with lead HRSG.
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.
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.
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.
The last HRSG LP steam stop MOV’s operation is the same with lag HRSG.
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 if necessary.
The HP steam stop valve and LP steam stop MOV will be closed when HRSG shutdown
initiated.
At this moment, the HRH, CRH and LP steam stop valve will be closed simultaneously.
The lag HRSG LP steam stop MOV’s operation is the same with lead HRSG.
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.
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.
* Trip HP/IP feedwater pumps, if the HP feedwater stop valves (LAB-90-AA-001/002) is not
closed within 50 seconds.
The HP evaporator has to be protected from running dry to avoid local overheating on
evaporator due to missing feed water.
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.
* Trip HP/IP feedwater pumps, if the IP feedwater stop valves (LAB-94-AA-001/002) is not
closed within 50 seconds.
The IP evaporator has to be protected from running dry to avoid local overheating on evaporator
due to missing feed water.
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.
* Trip Condensate pumps, if the condensate stop valves (LCA-90-AA-001) is not closed within
50 seconds.
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.
In case of failure of the HP desuperheater steam temperature control, the HRSG has to be
protected to avoid impermissible high temp.
In case of failure of the Reheater desuperheater steam temperature control, the HRSG has to
be protected to avoid impermissible high temp.
The HRSG inlet duct has to be protected against impermissible high exhaust gas temperature.
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;
2) Actions;
* HRSG Trip by the GT trip
Item. Service
Tag.No. Set Point Required Action
No. Description
Item. Service
Tag.No. Set Point Required Action
No. Description
10 LAE-90-CP-101 Strainer Del. ≥ 0.5 bar * Alarm H
Pressure on HP * For strainer blocking warning.
DESH. Spray line
11 LBC-90-CP-001 CRH steam ≥ 42.5 barg * Alarm H.
pressure * CRH Safety valve Set Pressure.
Item. Service
Tag.No. Set Point Required Action
No. Description
≥ + 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 (HAD-
95-AA-001).
≤ - 630mm * Alarm L,L
From Center Line * HRSG Trip (Time delay 2 sec).
17 HAD-94-CP- IP drum pressure ≥ 45 barg * Alarm H.
001/002/003 * Drum Safety valve Set Pressure.
18 LBA-95-CP- IP steam pressure ≥ 43 barg * Alarm H.
001/002 * S.H Safety valve Set Pressure.
19 LCA-90-CP-101 CPH Pressure ≥ 40 barg * Alarm H.
* C.P.H Safety valve Set Pressure.
Item. Service
Tag.No. Set Point Required Action
No. Description
22 LCA-90-CT- CPH inlet = 70 deg.C * Set Point of CPH recirculaiton temp.
003/004 Temperature control
≤ 67 deg.C * Alarm L
23 LCA-94-CF- CPH Recirculation ≥ 330,000 kg/hr * Alarm H.H
001/002 flow * Stop the operation pump.
≥ 300,000 kg/hr * Alarm H.
* Limit further opening of TCV(LCA-
94-AA-081).
≤ 65,000 kg/hr * Alarm L.
* Limit further closing of TCV(LCA-94-
AA-081).
≤ 60,000 kg/hr * Alarm L.L
* Stop the operation pump.
24 HAD-97-CL- LP drum level ≥ + 725mm * Alarm H,H
001/002/003 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.
= + 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.
Item. Service
Tag.No. Set Point Required Action
No. Description
≤ - 1065mm * Alarm L.
From Center Line * Protective close LP IBD MOV (HAD-
98-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 * Alarm H.
001/002/003 * 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 * Alarm H.
001/002/003 * S.H Safety valve Set Pressure.
≥ 8 barg * Set point of LP start up vent PCV control
(LBD-90-AA-081)
These guidelines are generally in accordance with published guidelines from EPRI, VGB, ASME,
as well as ABMA (American Boiler Manufacturers Association).
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.