Turbine Vol 1
Uploaded by
Sakthi MuruganTurbine Vol 1
Uploaded by
Sakthi MuruganVolume-1
2 X 660MW Jaypee Nigrie Super Thermal Power Project
Operation & Maintenance Manual for STGI Package
BINDER NO. 1 MODULE NO. 1
CONTENT OF ALL VOLUMES
Volume Binder Binder Module Document
Content
No. Sl. No. No. No. No.
Volume-1 1 Binder-1 Module-1 LTSL-M0-00951 O&M manual - STG Island
Compilation of Sub-vendor's O&M Manuals
2 Binder-2 (A) Module-2 LMTG-P0-01033 Instruction Manual for Steam Turbine
3 Binder-2 (B) Module-2 LMTG-P0-01033 Instruction Manual for Steam Turbine
4 Binder-2 (C) Module-2 LMTG-P0-01033 Instruction Manual for Steam Turbine
Instruction Book for Water Cooled
5 Binder-3 (A) Module-3 LMTG-E0-02385
Turbine Generator
Instruction Book for Water Cooled
6 Binder-3 (B) Module-3 LMTG-E0-02385
Turbine Generator
7 Binder-4 (A) Module-4 SIEG-M0-03660 Drive Turbine O&M Manual
8 Binder-4 (B) Module-4 SIEG-M0-03660 Drive Turbine O&M Manual
9 Binder-4 (C) Module-4 SIEG-M0-03660 Drive Turbine O&M Manual
10 Binder-4 (D) Module-4 SIEG-M0-03660 Drive Turbine O&M Manual
11 Binder-4 (E) Module-4 SIEG-M0-03660 Drive Turbine O&M Manual
12 Binder-4 (F) Module-4 SIEG-M0-03660 Drive Turbine O&M Manual
13 Binder-4 (G) Module-4 SIEG-M0-03660 Drive Turbine O&M Manual
Complete Group Instruction Manual
14 Binder-5 (A) Module-5 FPD-M0-03313
MDBFP
Complete Group Instruction Manual
15 Binder-5 (B) Module-5 FPD-M0-03313
MDBFP
Complete Group Instruction Manual
16 Binder-5 (C) Module-5 FPD-M0-03313
MDBFP
Volume-2 Complete Group Instruction Manual
Binder-5 (D) Module-5 FPD-M0-03313
17 MDBFP
Binder-5 (D) Module-6 FPD-M0-03380 Complete Group IOM TDBFP
Instruction Manual for Condensate
18 Binder-6 Module-7 KSB-M0-03546
Extraction Pump
O&M Manuals for C&I and Electrical
19 Binder-7 Module-8 LTCA-OM-001
Packages
20 Binder-8 (A) Module-9 SWTL-P0-00106 CPU O&M Manual
21 Binder-8 (B) Module-9 SWTL-P0-00106 CPU O&M Manual
22 Binder-8 (C) Module-9 SWTL-P0-00106 CPU O&M Manual
O&M Manual for TDBFP Recirculation
23 Binder-9 Module-10 CCI-I0-03570
CV & BFP Feed CV
Binder-10 Module-11 KBLP-Q0-04638 O&M Manual for DMCW Pumps
O&M Manual of Motors for DMCW
Binder-10 Module-12 KBLP-E0-04619
Pumps
O&M Manuals Including Installation
Binder-10 Module-13 GDKL-P0-04228
24 Manual for Vacuum Pump
O&M Instruction Manual for Plate
Binder-10 Module-14 GEA-M0-04414-OM
Type Heat Exchanger
O&M Manual for Condenser On Load
Binder-10 Module-15 GEA-I0-04321
Tube Cleaning System
CONTENT OF ALL VOLUMES
Volume Binder Binder Module Document
Content
No. Sl. No. No. No. No.
O&M Manual for MDBFP Recirculation
Binder-10 Module-16 MIL-IO-03512
Control Valve
QCNRV : Installation, Operation &
Binder-11 Module-17 ADAMS-PO-06051
Maintenance Manual
Binder-11 Module-18 CCI-P0-05536 O&M Manual for LP Bypass Valve
O&M Manual for 2200mm Butt
Binder-11 Module-19 FEIL-P0-04700
Welded Motorised Butterfly Valves
25 O&M manual for Double Flanged
Binder-11 Module-20 FEIL-P0-04701
Manual & Motorised Butterfly Valves
IOM Manual for SB & LB
Binder-11 Module-21 LTV-M0-05071
Gate/Globe/Check Valves (L&T Valve)
O&M Instructions for Safety & Relief
Binder-11 Module-22 B&R-P0-06350
Valve - Spring loaded
Pressure Seal Valves & Auma
Binder-12 Module-23 VEL-P0-04773 Actuators – Installation & Operation
Manual (Velan)
O&M Manual for Low Pressure
Binder-12 Module-24 MIL-I0-03509
Control Valves
O&M Manual for 12.5TX15m lift EHB
Binder-12 Module-25 BRMS-M0-07020
with PT(4F) (CW Butterfly Valve)
O&M Manual for 5.0TX6.3m lift EHB
Volume-2 Binder-12 Module-26 BRMS-M0-07021
with PT(4F) (CCW Pump Motor)
Binder-12 Module-27 BRMS-M0-07022 O&M Manual for Manual Hoists
Metallic Expansion Joints - Installation
Binder-12 Module-28 LSI-P0-06027
and Maintenance Manual
Binder-12 Module-29 CORI-P0-06012 Rubber Expansion Joints - IOM Manual
Binder-12 Module-30 SM-P0-07201 Basket & ‘Y’ type Strainer – IOM
26 Manual
Steam Traps – LP Bypass valve drain
Binder-12 Module-31 GESTRA-P0-08026
line – IOM Manual (GESTRA)
Steam Traps – IOM Manual for TD55,
Binder-12 Module-32 SM-P0-07200
TD62M & FT44
Instruction & Maintenance Manual for
Binder-12 Module-33 CSIL-P0-07801
Site Flow Indicator
Binder-12 Module-34 GIC-P0-07100 Restriction Orifice - IOM Manual
IOM Manual for Spring Loaded Bypass
Binder-12 Module-35 WEIR-P0-06107
Valve for HP Heaters
Installation & Operating instructions
Binder-12 Module-36 LESIGA-P0-06400 for Constant & Spring Hangers &
Supports (LISEGA)
Installation & Maintenance Manual –
Binder-12 Module-37 TI-P0-07251 Small bore Hangers & Supports
(TECHNO)
CONTENT OF ALL VOLUMES
Volume Binder Binder Module Document
Content
No. Sl. No. No. No. No.
O&M Manual for Vacuum Tank Drain
Binder-12 Module-38 FPD-M0-06315
Pump
O&M Manual for Vertical Mounted
Binder-12 Module-39 FPD-M0-06365 Centrifugal Sump Pump for CPU Drain
Pit
O&M Manual and part list for Oil
Binder-12 Module-40 ALIL-M0-07185
centrifuge package
LP Valves – IOM manual (Gate, Globe,
Binder-12 Module-41 WEIR BDK-P0-06250
Check, Ball and Butterfly valves)
O&M Manual for Vibration Monitoring
Binder-13 Module-42 FMPL-I0-03237
& Analysis System
27 O&M Manual of Turbine Preservation
Binder-13 Module-43 MIHC-M0-07857
Volume-2 System
Binder-13 Module-44 KEI-P0-4507 Installation Procedure for Elevators
Binder-14 Module-45 LT-M0-03054 IOM Instructions for LP Heaters
Binder-14 Module-46 LT-M0-03053 IOM Instructions for HP Heaters
28
Binder-14 Module-47 LT-M0-03036 O&M Manual for Condenser
Binder-14 Module-48 LT-M0-03106 O&M Manual for Deaerator
O&M Manual for 115/15T X 31.2M
29 Binder-15 Module-49 AIL-M0-03237
Span TG Hall EOT Crane
O&M Manual for 40/10T X 9M Span
Binder-16 Module-50 AIL-M0-03287
BFP Bay EOT Crane
30 O&M Manual for DT Flash Tank
Binder-16 Module-51 CPSPL-M0-06249
Condensate Pump
Binder-16 Module-52 ANEP-M0-06909 O&M Manual for H2 & CO2 cylinders
JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
STEAM TURBINE GENERATOR & AUXILIARIES PACKAGE
OWNER:
,.t;,YPEE
.--c; R o t.1 r=--....
JAIPRAKASH POWER VENTURES LIMITED
OWNER'S CONSULTANT:
!)m DEVELOPMENT CONSULTANTS PRIVATE LIMITED
CONTRACTOR:e
LARSEN & TOUBRO LIMITED
L&T'S CONSULTANT:
es&.L) L&T-SARGENT & LUNDY LIMITED
L&T-S&L JOB NO.: L 752000 PROJECT NO.: T209001
TITLE:
O&M MANUAL- STG ISLAND- VOLUME 1
TOTAL NO. OF PAGES.: 860
DOC/DRG NO.: LTSL-M0-00951 REV:O
TOTAL NO. OF DRAWINGS. : 97
For Information
I I
REVISION CERTIFICATION
REVISION PREPARED REVIEWED APPROVED
NO.
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
II
0 HNP/SM M~ 13.09.2013 BKG
w 13.09.2013 YDM '~/ -13.09.2013
REVISION SUMMARY SHEET
REV. DETAILS / DESCRIPTION DATE
0 FOR INFORMATION 13.09.2013
Operation & INDEX
Maintenace Volume 1 Steam Turbine
Manual Island
Preface 005
Disclaimer 007
Safety Instructions 009
Emergency Situations 029
Section A. Condensate System 039
Section B. Feedwater System 175
Section C. Closed Cooling Water System 303
Section D. Extraction Steam Sytem 362
Section E. Heater Drain & Vent System 544
Section F. LP Bypass System 628
Section G. Condenser Air Removal System 695
Section H. Water, Air & Nitrogen Distribution System 751
Section I. Start-up Shutdown Procedure 775
JAYPEE O&M MANUAL – VOLUME 1 PREFACE
PREFACE
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JAYPEE O&M MANUAL – VOLUME 1 PREFACE
Preface
Plant O&M manual intends to highlight brief but salient features of the Jaypee Nigrie
STG Island plant for the benefit of Plant Operation Engineers and Operators.
Operation, control and protection systems of the Plant are automated with minimum
operator intervention.
This manual deals with detailed description of the system, plant equipment and
important requirements for operation & control of the plant. Basically this manual is the
elaborative document with the information compilation of system & various equipment
Operation and Maintenance practices. These documents shall be subjected to
modifications / revisions / improvements upon whenever additional information / inputs
are available.
It is prudent to keep abreast of the changes in technology and practice adopted in
modern power plant for efficient and economical operation.
Plant Information:
The 2 X 660 MW JAYPEE Nigrie Super Thermal Power Project is being set up by
Jaiprakash Power Ventures Limited in the district of Sidhi, Madhya Pradesh, India.
The Project is located at village Nigrie of Sidhi district in Madhya Pradesh, Latitude – 24
8’ 25” to 24 10’ 2” N; Longitude - 81 53’ 50” E to 81 55” 6” E. The nearest national
highway is NH-7 running between Sidhi & Rewa at a distance of 40 km from the site.
The plant area is measuring around 433 Ha on the east of the river Gopad near village
Nigrie.
The nearest railway station is Niwas Road at a distance of 8 km from the site on Katni-
Singrauli section of west-central railway. The nearest airport is located at Varanasi & the
nearest Seaport is Vizag.
O&M Manuals’ Content Arrangement:
Volume - 1 : O&M Manual – STG Island
Volume - 2 : Compilation of Sub-vendor’s O&M Manuals
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JAYPEE O&M MANUAL – VOLUME 1 DISCLAIMER
DISCLAIMER
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JAYPEE O&M MANUAL – VOLUME 1 DISCLAIMER
Disclaimer
This manual contains information on the operation & maintenance of the Steam Turbine
Island system. The information has been prepared on the assumption that the operating
& maintenance personnel have a basic knowledge of power plant engineering &
operation.
It is an essential prerequisite for satisfactory operation and maintenance of the Steam
Turbine Island system and its equipment that the operating & maintenance personnel
are fully familiar with the design of the same & receive proper training in operation &
maintenance.
The following cases are excluded from purview of this document:
1. Failure or damage due to improper handling, use or storage of major equipment
2. Failure or damage due to improper and/or inadequate maintenance
3. Failure or damage due to improper modification or repair
4. Reason of force majeure such as fires, earthquakes, storms/floods,
thunder/lightening, or other natural disasters, or disturbance, riots, welfare.
5. Replacement of consumable parts & accessory of major equipment without OEM
consultation
The manual is for reference only and shall be read in conjunction with Plant operational
management systems/ rules / guidelines / instructions to be issued by concerned O&M
personnel / department from time to time.
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
Safety Instruction
General Information
User safety is a major focus for the power plant operation & maintenance staff.
While operating the power plant equipment and systems, safety of operating
personnel and equipment are of prime importance. By understanding the system
and equipment as well as meticulously following operating instructions, maximum
advantage can be derived from the power plant by way of long life and efficient
performance, with no injury to personnel and damage to equipment. The
following features shall be adhered to during startup and operation of a power
plant system.
• The operators should study and be familiar with the operations manual and
other Instruction books supplied by vendors.
• In addition, the operators should obey the instructions and cautions
mentioned in the operation procedures after understanding the specific
function and characteristics of each part of the facility.
• Automatic interlocks are provided for various equipment and drives of the
system in order to protect the equipment. The operator shall not bypass any
such interlocks.
• Lubrication oil for required equipment shall be provided or replaced properly
by specified brand of oil following the individual component manufacturer’s
instruction manual.
• Prior to start of any rotary equipment like fan/pump etc. after a long shutdown,
the free rotation of shaft should be checked.
• Each one of the interlock circuits must be checked to ensure that it has not
been bypassed.
• All steam piping that is in a cold condition shall be gradually warmed up and
properly drained out prior to or during the startup process of a system.
• Routine inspections shall be performed during plant operation in order to
allow for early detection of various abnormalities.
• The local operators should keep in contact with the Central Control Room
(CCR) during their routine local inspections.
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
Definitions
Throughout this manual the words WARNING, CAUTION & ELECTRICAL
HAZARD are used to indicate where special operator attention is required.
Observe all Cautions and Warnings highlighted in this Operation &
Maintenance Manual.
WARNING
This indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
Example: Pump shall never be operated without coupling guard installed
correctly.
CAUTION
This indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
Example: Throttling flow from the suction side may cause cavitation and
pump damage.
ELECTRICAL HAZARD
This indicates the possibility of electrical risks if directions are not followed.
Example: Lock out driver power to prevent electric shock, accidental start-up,
and physical injury.
When installed in potentially explosive atmosphere, the instructions that follow
the ‘Ex’ symbol must be followed. Personal injury and/or equipment damage may
occur if these instructions are not followed.
Example: Improper impeller adjustment could cause contact between the
rotating and stationary parts, resulting in a spark and heat generation.
Furthermore some important terms to be understood by the operators as well as
maintainers in the context of safety are;
(i) SERIOUS INJURY
(ii) MINOR INJURY
(iii) SERIOUS DAMAGE TO PROPERTY
(iv) MINOR DAMAGE TO PROPERTY
These terms are described below:
SERIOUS INJURY: Any injury which leaves lasting effects is classified as a
serious injury. Examples are-
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
a) Loss of eyesight
b) Permanent disability
c) Bone fracture and/or breakage
d) Gas inhalation/asphyxiation
e) Electric shock
f) Any other injury requiring hospitalization or lengthy treatment
All other injuries are termed as MINOR INJURIES.
SERIOUS DAMAGE TO PROPERTY: Any damage to property which calls
for suspension of productive operation for one or more days is termed as
serious damage to property.
Any other type of damage to property is termed as MINOR DAMAGE.
Symbols
Symbols, safety signs and color codes are pictorial representations of important
messages. These are designed in a way as to attract immediate attention and
help protect the health and safety of the employees and workplace visitors.
Symbols and signs are used to:
• Draw attention to health and safety hazards
• Point out hazards that may not be obvious
• Provide general information and directions
• Remind employees where personal protective
• Equipment must be worn
• Show where emergency equipment is located
• Indicate where certain actions are prohibited
Color codes are used as additional safety measures. They help identify nature of
hazard, and the probability of a hazard causing harm. E.g. the color red indicates
a definite hazard, while yellow color indicates a potential hazard.
Sign Categories
As shown in the table below, there are three basic sign categories used in the
workplace:
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
1. Regulatory
2. Warning
3. Information
Category Sub - Category Color
1. Regulatory
A circle indicates that
an order is in force
1.1 Prohibition: Red and black on
Forbids an action white
1.2 Mandatory: White on black
Requires an action
2. Warning
A triangle indicates
caution or danger
2.1 Caution:
Indicates a potential Black on yellow
hazard White on red
2.2 Danger:
Indicates a definite hazard
3. Information
A square indicates
Information
3.1 Emergency:
Indicates first aid, health,
protection against fire, White on green
firefighting and emergency White on blue
equipment
3.2 General information:
Indicates permission or
public information
Signs can be of three main types: a) symbols without text; b) symbols with text
and c) plain text. However, the first two types are the most used types of signs.
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
The following symbols present an easy understanding of the content to be found
besides the DANGER/CAUTION sign:
SYMBOL DESCRIPTION
Possible presence of high voltage; hazard
which may result in shock, burn or
electrocution if safety precautions are neglected
and/or system is handled incorrectly.
Movable section (either under safety covering
or exposed). May inflict lacerations or fractures
on body parts such as hands if they get caught
in the machinery. May also catch clothing.
Parts with hot surfaces. May cause burns if
handled incorrectly.
Take care on placing your feet when moving
around in the area. High probability of injury by
tripping is present near this symbol on account
of unstable surfaces or obstructions such as
scaffolding, temporary pipelines, protrusions
etc.
Possible presence of gas (or gases) which may
be toxic/asphyxiating to personnel. Care should
be taken to ventilate the area properly before
work commences.
Caution against handling of a heavy object or
working in an abnormal position. Avoid working
in postures which may damage one’s back or
waist.
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
SYMBOL DESCRIPTION
Prohibited items or actions during operation
and maintenance of system.
Hot surface: personnel must NOT touch it.
Personnel must NOT enter any are where this
symbol is displaced.
Personnel must NOT enter the area where this
symbol is displayed unless authorized.
Physical contact is prohibited. Do NOT touch or
enter any surface/enclosure where this symbol
is displayed.
Stated items/actions in the warning notices
relative to operation and maintenance are
MANDATORY.
Following are some examples of signs having symbols along with text:
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
NOTE: It should always be remembered that even though warnings, signs,
symbols and color codes are provided at every place of possible hazard, they are
no substitutes for elimination/reduction of hazards. Hazardous situations should
be isolated and rectified after detection as fast as possible.
RISK ASSESSMENT STANDARDS
Risk assessment standards give us the detailed description of the damaging
impact of accidents on each object, as well as their frequency of occurrence.
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
Detailed description of impact on each object
Category Safety Health Environment
• Harmful gas or oil
• Unit shut leakage
down (unit • High pressure and
cannot be temperature
I Catastrophic Death
operated) material leakage
• More than 4 (steam, water, gas,
days of repairs oil etc.)
• Low oxygen
• Unit shut
down (cannot
be operated) Serious
II Critical Same as above
• Repairing can injury
be done within
3 days
• Unit shut
• Same as above.
down (cannot Minor injury
• High temperature
be operated) (with
III Marginal surface
• Can be hospitalizati
• High elevation or
repaired by on)
unstable
consumer
• No harmful/high
Minor injury
temperature/pressur
(without
IV Negligible e leakages
hospitalizati
• Mechanically
on)
protected
TABLE 1: RISK ASSESSMENT STANDARDS
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
Definition Description Detail
Category
(A) Frequent Repeating occurrence 1 time / 1 or 2 months
(B) Probable Known to occur 1 time / 1 year
(C) Occasional Could occur 1 time / 5 years
(D) Remote Not likely to occur 1 time / 10 years
(E) Improbable Practically impossible 1 or 2 times / total life
TABLE 2: RISK ASSESSMENT STANDARDS
Hazard I II III IV
Categories
Catastrophic Critical Marginal Negligible
Frequency
(A) Frequent 1 3 7 13
(B) Probable 2 5 9 16
(C) Occasional 4 6 11 18
(D) Remote 8 10 14 19
(E) Improbable 12 15 17 20
TABLE 3: RISK ASSESSMENT STANDARDS
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
Safety measures
1. Work permit system (lockout/tag out)
The method described herein is a standard generally followed in plants and is
given for reference only.
This system comes into the picture whenever maintenance work is to be carried
out, in order to provide safe condition for work. The system works in the following
flow:
• An application form indicating the content of maintenance work to be done is
filled out by the Maintenance Engineer (hereafter referred to as M. E.) and
submitted to the Shift Charge Engineer (hereafter referred to as S. C. E.).
• This form is passed on to the operator, who studies and finalizes a method to
mechanically and electrically isolate the line in question from the rest of the
operations. He then reports to the S. C. E. with comments on the hazard
conditions for the work.
• The S. C. E. prepares necessary tags displaying the work permit no. and the
status of isolation of valves and power supply.
• The operators set the isolation conditions following the work permit form. This
is done by opening breakers, setting valves to specified conditions and then
locking all safeguards. After this, they return the work permit to the S.C.E.
• After checking the isolation and other safety measures, the S.C.E. issues the
signed work permit to the M. E. or his representative. The maintenance work
can start ONLY AFTER this step.
• After the maintenance work is completed, the work permit is returned to the
S.C.E.
• Operators are sent to check the situation. Once the normal condition of the
system is affirmed, the locks are released and normal operation of the system
resumes.
• The S. C. E. confirms that the work mentioned in the permit is completed
satisfactorily and files the details in the log book.
The work permit system ensures that the maintenance work is carried out in an
organized and orderly manner. It also underlines the responsibility of the
concerned officers and operators at every step of the procedure and eliminates
all ambiguity, thus providing greater safety for everyone involved.
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
2. General safety warnings for works in select areas.
2.1 Caution against rotating equipment-
Care is taken to cover all couplings on rotating equipment and machinery.
However, the shafts are not completely covered. Thus the following warning must
be heeded to very stringently:
2.2 Cautions against high voltage section-
The high voltage live parts are protected by panels and terminal boxes and the
switchgear units have interlocks in the doors. However, to guarantee safety of all
personnel working in high voltage area, the following warning must not be
ignored under any case:
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
2.3 Cautions against high temperature section-
Even after provision of insulation on hot surfaces and pipes to the maximum
degree possible, several hot-spots exist in the system. Also, many vessels and
pipes are not insulated for cooling purposes. Thus this warning is provided:
2.4 Caution against steam leakage-
Steam leakage, with the steam being at very high temperatures, is extremely
dangerous for the personnel working in the area. Thus it should be identified and
repaired as soon as possible. Following are certain indications of steam leakage:
Steam leakage, with the steam being at very high temperatures, is extremely
dangerous for the personnel working in the area. Thus it should be identified and
repaired as soon as possible. Following are certain indications of steam leakage:
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
2.5 Cautions against chemicals
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
2.6 Cautions against combustible materials/storage areas
2.7 Cautions against lack of oxygen
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
2.8 Cautions against lifting heavy objects
2.9 Caution against sharp objects
2.10 Caution while using forklifts
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
2.11 Caution while using crane
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JAYPEE O&M MANUAL – VOLUME 1 SAFETY INSTRUCTIONS
3. Disposal
• Disposal of water including drainage of oil- Waste water is categorized
and discharged depending upon the level of contaminants. The three
categories are rain water, chemical water and oily water.
After treatment, all waste water goes into the public drainage system.
• Chemical disposal- In accordance with the MSDS guidelines, chemicals
must be disposed via a separate chemical drain.
• Solid disposal- Disposal of solids is done from site in accordance with the
local legal regulations.
Disposal of water including drainage of oil, chemical disposal & solid disposal
would be done in a manner so as that it will not be harmful or problematic.
4. Evacuation during emergencies
• Route
a. Each and every building in the plant compound should have at least two
emergency exits in addition to usual exits.
b. All exits should have clear indication lights. Alternate emergency power
supply should be provided specially for said lights.
c. Evacuation routes should be marked throughout with special signals and
signs which should be visible even during conditions of smoke or dust.
d. In case of more than one stories, map of corresponding level should be
provided with the emergency exit routes marked clearly.
e. Evacuation routes should be kept free of any tools, raw materials,
products or any other goods.
• Disabled persons
a. Wheelchairs and stretchers should be kept in specially demarcated
places.
b. In case of accidents, inform the rescue team and try to bring injured
person(s) to the nearest aid station.
• Power house
a. A predetermined ‘gathering point’ must be decided beforehand to
assemble after evacuation form a power house.
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b. Emergency drills must be carried out in advance to prepare for any
contingency.
c. All persons working within the power house must be alerted repeatedly on
a centrally located broadcast facility.
d. As soon as evacuation directive is given out, all persons must stop work
immediately and leave.
e. Once everyone is assembled at the gathering point, a head count should
be done to check whether anyone is missing.
5. Qualification and training
For ensuring greater safety, no personnel other than the ones listed below should
operate/be allowed to operate the equipment:
• Authorized operators
• Maintenance supervisors
• Any other personnel authorized by the customer to operate the equipment.
The following guidelines for the level of training for operators and maintainers
should be strictly adhered to:
• They should be able to read and fully understand the description of this
manual.
• They should be able to understand the related P&I Ds and logic diagrams.
• They should know location of the system equipment, including pipe routes,
valves and instruments.
• They should have fundamental knowledge of the functioning of the
equipment.
• They should be able to operate the equipment and the system manually at
local stations.
• They should be able to operate the system remotely using DCS system.
• They should be able to respond suitably to any kind of alarm.
• They should know location of emergency exits in power house and should
have basic knowledge of first aid treatment.
• They must know how to operate the emergency communication system.
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• Following the Shift Charge Engineer’s instruction, the operators and
maintainers should be aware of the isolation method for mechanical, electrical
and instrumental equipment being prepared for safe maintenance while the
unit is in operation.
• Maintainers must also be able to handle the maintenance tools provided by
the owner and those supplied by the manufacturer.
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EMERGENCY SITUATIONS
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Emergency Situations
Introduction
It is quite normal to come across some emergency conditions during plant
operation. There are some cases which warrant an emergency shutdown of the
plant. The cause of an emergency can be internal or external. Some of the
emergency conditions of the plant are listed below.
A. Blackout
B. Runback
C. Turbine Trip
D. Fast Cut Back (FCB)
E. Earth Quake
F. Fire in Plant
A. Blackout
During plant normal operating condition, unit auxiliaries are fed from Unit
Transformers (UT) connected to generator bus, and station auxiliaries are fed
from Station Transformers (ST) connected to EHV (Extra High Voltage)
switchyard.
Blackout condition refers to the situation where both EHV grid as well as plant
generator trips/fails and no power is available for plant operation. Under this
condition battery system will provide initial supply to DC drives. Emergency
diesel generator is started and emergency board is charged from EDG and all
essential auxiliaries are started sequentially by operator for subsequent safe
shutdown of the plant.
1. Check and ensure
a. Immediate checks
• All emergency DC illuminations are on.
• TG and boiler have tripped and generator-transformer EHV breakers
and generator field circuit breakers have opened.
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• All governor valves and stop valves are closed
• The following DC drives are running :
Emergency Oil Pump of Main Turbine
Generator DC Seal oil Pump (Air side)
EOP for TDBFP
• Turbine internal drain valves, extraction line drain SOVs will open
immediately on detection of turbine trip.
• BFPT inlet steam line drip leg SOVs will open immediately on
detection of respective BFPT trip.
• HP/LP bypass will be quick closed (trip)
Note: For details of Turbine internal drain valves, refer Volume 2 – LMTG-P0-
01033: Steam Turbine O&M Manual. For description of extraction line drain
SOVs, refer Section D in Volume 1 of this O&M manual.
b. Further checks
• 220V and UPS batteries are healthy.
• DCJOP cut in at the pre-set turbine speed (900 RPM).
• LPH 3&4, deaerator and all HP heaters extraction NRVs are shut.
• Fail safe status of drain valves for Turbine & TDBFP once instrument
air supply is exhausted.
2. Actions
a. Immediate actions
• Ensure that gland steam temperature supplied to main turbine and
BFPT are within limits.
Subsequently, break vacuum and stop gland steam supply when
turbine speed is less than 400 rpm or when the condenser vacuum
deteriorates to (-) 0.4 barg.
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• It is important to ensure that the condenser pressure does not rise to
unacceptable limits else it would cause rupturing of the turbine LP
diaphragm. In case, condenser gets pressurized, cut-off the gland steam
and open the vacuum breaker valve.
• Ensure main steam /CRH/ HRH line drain valves leading to condenser are
closed.
• Close DA vent to condenser.
Note: For details of main steam drain valves, refer Volume 2 – LMTG-P0-
01033: Steam Turbine O&M Manual. For description of CRH/ HRH line drain
valves, refer Section D in Volume 1 of this O&M manual.
Once power is available from DG at Emergency MCC, start the following
TG auxiliaries sequentially, if not started on auto:
• MOT, BFPT and generator seal oil vapor extractor fans
• H2 side seal oil pump
• Any one air side seal oil pump (stop DC pump)
• BFPT MOP (Stop DC Pump)
• TOP (stop DCEOP)
• Turning gear of TDBFPs, when rotor comes to standstill
• At 900 rpm, JOP should start. Start AC JOP and stop DC JOP, if
started.
• Turning Gear of main turbine
b. Checks while waiting for startup power
• Monitor DC battery voltages closely.
• Monitor TG eccentricity, differential expansion, vibration etc.
• Monitor all running equipment’s parameter.
• Monitor RH pressure.
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• Make sure that condenser is not pressurized.
• Ensure that CEP, Vacuum pump and all other auxiliaries are not in
AUTO mode.
• Monitor hydrogen pressure and purity for generator
• Monitor level in hotwell, deaerator and feedwater heaters
3. Activity for normalization
a. Action prior to restoration of the system
• Check & ensure that all motor feeder circuit breakers have tripped
• Close/ throttle TDBFP DMCW supply valve
b. Steps for Normalization
1. Ensure that EMB (Emergency Board) is charged from normal source.
2. Follow normal start-up procedure to bring back the unit.
B. Runback
When one of the major operating STG auxiliary (TDBFP, CEP) trips,
operating load shall be reduced to the target load (50 % TMCR) at the set
load change rate (100 % BMCR / min.) Runback will not occur, if unit load <
target load (50 % TMCR)
Following permissive must be satisfied for initiating runback:
• FWF, FF, AF, Furnace pressure controls and Turbine Master on Auto
• MFT not operated
Once runback is initiated, boiler reduces its FW, Fuel and Air flow to bring
Boiler load to target load.
Runback will be initiated if any of the following conditions occurs.
• One TDBFP trip
• Any one CEP trip (Standby CEP under maintenance)
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a. One TDBFP trip
During normal operation two (2) TDBFP are in operation. In case, any one
of the running TDBFP trips, then load has to be reduced to the capacity of
the running TDBFP (50%).
It is to be checked whether tripped TDBFP can be taken back into
operation. If not, one MDBFP will be started to increase the load to
approx. 75% TMCR.
Subsequently, second MDBFP can also be started to restore the load
to 100% TMCR.
When TDBFP and MDBFP are running in parallel, feedwater demand
shall be shared proportionally. FW control will be through speed
control of TDBFP and Hydraulic coupling of MDBFP.
b. One CEP trip (Standby CEP under maintenance)
During normal operation, two (2) CEP are in operation. In case, one of the
running CEP trips and the third pump is under maintenance, then load has
to be reduced to the capacity of the running CEP (50%).
Ensure all operating parameters stabilize within the permissible limits.
Once load is stabilized at target load (50% TMCR), check whether tripped
CEP can be taken back into operation.
C. Turbine Trip
Turbine trip will be initiated by turbine protection system (TPS) in case any of
the following condition occurs:
• Turbine Trip Request (from Generator Protection)
• TCS System / Power Failure
• LP Turbine Exhaust Steam Temp. High
• Rotor Position Abnormal
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• Emergency Oil Pressure Low
• Mechanical Over Speed Trip (MOST) operated
• Electrical Over Speed Trip (EOST) Operated
• Low Condenser Vacuum
• Low Bearing Oil Pressure
• Rotor Vibration Very High
• Turbine Trip Command
• Turbine Trip Push Button
• Turbine Hand Trip Lever (Local)
• TPS Failure
• All CWP stopped
• Main Steam Temperature Very Low / Very High
• Boiler MFT
a. Turbine Trip – Boiler in operation
As soon as turbine trip is initiated, boiler reduces its FW, Fuel and Air flow to
bring boiler load to 60% load automatically.
In case of turbine trip condition following operations should occur on auto:
• Opening of Circuit Breaker (GT EHV and Generator Field)
• Closure of ESV, GV, RSV, ICV, Extraction NRVs & MOV
• Opening of Turbine and Extraction line drains
• Changeover of steam source for Deaerator , BFPTs and gland Steam
• HP and LP Bypass Valve
• Operation of Level Control Valve for Hotwell, Deaerator and Heaters
• Operation of BFP, CEP and GSC Recirculation valves
The following parameters should be monitored closely:
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• Turbine speed and turbo-supervisory parameters
• MS and HRH pressure and temperature
• Condenser vacuum
• Turbine exhaust temperatures
Restoration of normal operation:
The cause of turbine trip should be identified and rectified at the earliest.
Once fault has been rectified, normal start up procedure should be followed to
bring back unit on load.
b. Turbine Trip on Boiler MFT
When turbine trip is initiated on boiler MFT, both boiler and turbine will be
shutdown.
Following operation should be ensured in case of turbine trip on boiler MFT:
• Running TDBFP will trip
• Spray water to maintain HP bypass downstream temperature will not
be available
• Auxiliary steam source for gland steam and Deaerator to be ensured
• Condensate system in operation, Condenser Vacuum kept
Restoration of normal operation:
Once condition is normalized and unit is ready for startup once again, normal
start up procedure should be followed to bring back unit on load.
D. Fast Cut Back (FCB) to House Load
In an event of transmission line trouble, the generator load is reduced
suddenly only to plant requirements (House Load). In order to successfully
shift from normal load to house load, the boiler will rapidly reduce its feed
water flow, fuel flow and air flow.
• Permissive for FCB:
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FWF, FF, AF, Furnace pressure controls, Turbine Control on Auto
MW > 30 %
MFT not operated
• Boiler rapidly reduces its FW, Fuel and Air flow to bring Boiler load to
60 %
• Balance steam generated by boiler is dumped to condenser through
HP-LP bypass
• Both TDBFP and CEP remain in operation
• Steam source changeover for TDBFP and deaerator from IP extraction
to CRH
• Extraction valves close, turbine drains open
• Monitor the turbine exhaust temperature and turbine differential
expansion and ensure that it remain within acceptable limits
OEM guideline, if any on limits of operation of turbine on house load to be
referred It is preferable to restore normalcy at the earliest and synchronize the
unit with grid otherwise proceed for safe shutdown
E. Earthquake
Take care for falling dropping stuff
As the piping is supported by separate structure, the possibilities of the
damages by earthquake are considerably high. Operators must check the
damages of piping as soon as possible after the earthquake.
In addition check for any leakages developed in the lube oil system or seal oil
system. In case of a major earthquake the machine alignments may get
damaged. Consult OEM before attempting a re-start.
F. Fire in the Plant
Inform the fire-fighting team immediately, if you find the fire in the plant. Try
to extinguish the fire using the nearest fire extinguisher. Leave the site to safe
place if fire-fighting team arrives to the site. Trip the unit immediately by
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direction of shift charge engineer, if the fire is near the generator, turbine lube
oil tank, central control room and/or electric equipment room to avoid serious
damages.
In case of fire near the hydrogen system, plant operators must initiate
immediate action for Carbon-Dioxide purging of the generator to avoid an
explosion.
All operators and maintainers must know the position and route of safety exit
of power house and auxiliary buildings.
All persons in the power plant must follow with shift charge engineer’s
direction in emergency case. All operators must know the procedure
concerning the equipment to be stopped and equipment to be kept running
such as lubrication oil pump of main turbine.
Note: Concept and actions to be followed for each of the emergency
conditions as described above are intended for operator’s guidance only.
Periodic review and revision is recommended based on experience.
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Operation & Section A.
Maintenace Volume 1 Condensate
Manual System
Table of Contents 040
1. Overview of Condensate System 043
2. System Description 092
3. Normal Operation, Start-up / Shutdown 114
4. Emergecny Operations & Alarms 124
5. Instrumentation & Process Control 136
6. Interlock & Protection 141
7. Valve Line-up List 151
Abbreviations 155
Exhibits 159
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Table of Contents
1.0 OVERVIEW OF CONDENSATE SYSTEM
Chapter 1
1.1 Purpose
1.2 Specifications
1.2.1 Design Data of Major Equipment
1.2.2 Operation Limit
1.3 References
1.3.1 P & ID
1.3.2 GA Drawings
1.3.3 System documents
1.3.4 Heat Balance Diagram
1.3.5 Vendor Drawings / Documents
2.0 SYSTEM DESCRIPTION
Chapter 2
2.1 Overview
2.2 Flow Path
2.2.1 Condensate from Make-up system to condenser hotwell to CEP suction
2.2.2 Condensate from CEP suction to CEP Discharge Valve
2.2.3 Condensate from CEP discharge to CPU through GSC
2.2.4 Condensate from CPU outlet to deaerator level control station with tapping
to GSC recirculation & dump valve
2.2.5 Condensate from deaerator level control station outlet to deaerator
through LP heaters
2.3 Major Equipment
2.3.1 Condenser & Hot-well
2.3.2 Condensate Extraction Pump
2.3.3 Gland Steam Condenser (GSC)
2.3.4 Condensate Polishing Unit (CPU)
2.3.5 LP Heaters
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3.0 NORMAL OPERATION, START-UP AND SHUTDOWN
Chapter 3
3.1 Start-up and initial fill
3.2 Normal operation
3.3 Normal shutdown
3.4 Checklist
3.4.1 Before CEP Start – up
3.4.2 CEP Running
3.4.3 Stopping CEP
3.4.4 Switching Over CEP
3.4.5 Charging Condensate System
4.0 EMERGENCY OPERATION AND ALARMS
Chapter 4
4.1 Emergency Operation
4.1.1 Loss of a Condensate Pump
4.1.2 Condensate Pump Recirculation
4.1.3 Gland Steam Condenser Recirculation
4.1.4 Turbine Water Induction Prevention (TWIP) Events
4.1.5 Removing LP Heater from Operation
4.1.6 Returning LP Heater to Operation
4.1.7 Abnormal Deaerator Water Levels
4.1.8 Abnormal Condenser Hotwell Water Levels
4.1.9 Loss of Power or Instrument Air
4.2 Alarms
4.3 Cause & Effect Table
5.0 INSTRUMENTATION AND PROCESS CONTROL
Chapter 5
5.1 Instrument and Process Control
5.1.1 Hotwell level control - Makeup Control Valve and Excess condensate
dump Control Valve
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5.1.2 CEP minimum recirculation control valve
5.1.3 GSC minimum recirculation valve
5.1.4 De-aerator level control valve (2 x 100%) (1LCA50AA081, 1LCA50AA082)
5.1.5 Deaerator Overflow On-Off Valve (1LAR05AA081)
5.1.6 Ventilator valve spray control valve (1LCA42AA081)
6.0 INTERLOCKS AND PROTECTION
Chapter 6
6.1 Condensate Extraction Pumps (3 x 50 %)
6.2 CEP discharge MOV
6.3 Condenser curtain spray SOV
6.4 Condensate Cleanup Blow Valve
6.5 De-aerator level control valve bypass MOV
6.6 De-aerator level control valve inlet MOV
6.7 Heater inlet MOV
6.8 Heater inlet MOV integral bypass
6.9 Heater bypass MOV
6.10 Heater bypass MOV integral bypass
6.11 Heater outlet MOV
6.12 Heater outlet MOV integral bypass
6.13 CPU Common Bypass Pneumatic Operated Butterfly Valve
6.14 Solenoid Operated Vent on CEP Discharge side
7.0 VALVE LINE-UP LIST
Chapter 7
Valve Line-Up List
7.1 List
ABBREVIATIONS
EXHIBITS
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1.0 OVERVIEW OF CONDENSATE SYSTEM
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Chapter 1
Overview of Condensate System
1.1 Purpose
The purpose of condensate system O&M manual document is to provide the
operating personnel with necessary information to safely operate and maintain
the condensate system & associated equipment.
The scope of the manual covers an overview of the Condensate System,
description of its major components with associated equipment & devices and
details of the startup, shutdown and normal operation and process control.
The condensate system maintains the condensate level in the system & supplies
condensate to the LP heaters & deaerator with the required quantities and quality
to satisfy unit demands during start-up, shutdown and normal unit operation. The
condensate system stores adequate quantity of de-mineralized water to meet the
makeup water requirements for normal cycle fluctuations and for abnormal
operating conditions when supply of de-mineralized water is interrupted. In
addition, this system will transfer condensate to and from storage tanks as per
requirements of the cycle.
Steam from both LP turbine exhaust, BFPT exhaust and LP bypass gets
condensed in the dual pressure condensers consists of HP & LP shell. The
condenser hotwell is condensate collection vessel, integral with the condenser
shell. Each unit’s 3 x 50% condensate extraction pumps (CEP) obtain their
suction supply from the condenser hotwell. CEP supplies condensate to the
deaerator through gland steam condenser (GSC), condensate polishing unit
(CPU) & 4 (four) nos. of LP heaters. The heater increases the condensate
temperature & it results in improved cycle efficiency.
The main purpose of condensate system is to deliver continuously condensate to
the deaerator, at any load or transient condition considering the flow and
pressure requirements of the condensate system. The system commences from
the dual pressure condenser and extends up to the discharge of LP heater 4.
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The normal make up to the condenser is supplied from the condensate storage
tank. In case of fluctuations in the cycle, condensate will be transferred to and
from the condensate storage tank as required
Notes:
1. It is advisable to read this manual with the equipment O&M manual of the
major equipment of the system i.e. condensate extraction pumps, condenser,
CPU, LP heaters etc.
2. The scope of the document covers the overall system description for the
condensate system, description of its major components and associated
auxiliaries & system startup, shutdown, operation & process control.
3. If the condensate system equipment and components are operated under
conditions different than its design, it is possible that the system may not
achieve its performance objectives.
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1.2 Specifications
1.2.1 Design Data of Major Equipment
A. Condenser
Value / Remark
Condenser 1 Condenser 2
Sr. No. Item description Unit
(for LP-1 (for LP-2
turbine) LP turbine) HP
Shell Shell
1.1 General
L&T – HED
1.1.1 Manufacturer L&T- HED Ltd.
Ltd.
Rectangular Rectangular
1.1.2 Type of condenser
divided type divided type
Orientation of Transverse to Transverse to
1.1.3
condenser tube axis turbine axis turbine axis
Number of surface
1.1.4 No. 1 set 1 set
condensers per ST unit
1.1.5 Number of passes One pass One pass
Shell Side Operating
1.2 Condition
Turbine @ 100%
TMCR - condition at 33
1.2.1 o
C CW inlet temp, 0%
make-up.
Steam from turbine
1.2.1.1 exhaust
a) Quantity kg/hr 585277 585277
kg/cm2
b) Pressure 0.0783 0.1002
(a)
O
c) Temperature C 40.76 45.49
d) Enthalpy kcal/kg 566.8 569.8
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Value / Remark
Condenser 1 Condenser 2
Sr. No. Item description Unit
(for LP-1 (for LP-2
turbine) LP turbine) HP
Shell Shell
Steam from BFP drive
1.2.1.2
turbine
a) Quantity kg/hr 61370.5 61370.5
kg/cm2
b) Pressure (max.) 0.1006 0.1006
(a)
d) Enthalpy kcal/kg 586.9 586.9
Feed water heater
1.2.1.3 drains including seal
steam leak-off
a) Quantity kg/hr 137950.5 137950.5
O
c) Temperature C 49.9 49.9
d) Enthalpy kcal/kg 49.9 49.9
1.2.1.4 Drain from GSC
a) Quantity kg/hr - 2680
d) Enthalpy kcal/kg - 99.1
Condenser parameters
@ 100%
1.3 TMCR 0%MU, CW inlet
temp 33 OC
1.3.1 CW data:
a) Flow rate kg/hr 72176000 72176000
kcal/
b) Specific heat 0.99809 0.99812
kg oC
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Value / Remark
Condenser 1 Condenser 2
Sr. No. Item description Unit
(for LP-1 (for LP-2
turbine) LP turbine) HP
Shell Shell
c) Density kg/m3 994.72 993.07
1.3.2 Design Heat Load kcal/hr 342741538 340784620
Condenser operating
kg/cm2
1.3.3 pressure (considering 5 0.0783 0.1002
(a)
% tubes plugged)
Condensate
O
1.3.4 temperature at hotwell C 43.2 43.2
outlet
Temperature of air O
1.3.5 C 36.59 41.32
vapour mix at air cooler
O
1.3.6 CW inlet temperature C 33 37.76
O
1.3.7 CW outlet temperature C 37.76 42.50
1.3.8 Cleanliness factor % 90 90
Velocity of water in
1.3.9 tubes (considering 5 % m/sec 2.2 2.2
tubes plugged)
Cooling surface area
1.3.10 (inclusive of 5 % m2 25689.8 25108.5
plugging margin)
1.3.11 Tube side pressure drop kg/cm2 0.4 0.4
Heat load @ VWO
condition, 0% MU, CW
1.4 kcal/hr 356091027 353830019
inlet temp 33 oC
(TXH1A-090092 R3):
Condenser back
1.4.1 pressure for 1.4 kg/cm2 0.0787 0.1012
condition (a)
1.4.2 CW temp rise o 4.94 4.91
C
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Value / Remark
Condenser 1 Condenser 2
Sr. No. Item description Unit
(for LP-1 (for LP-2
turbine) LP turbine) HP
Shell Shell
Condenser Design Shell side / Shell side /
1.5 parameter - Tube Side Tube Side
kg/cm2 1.07 & F.V. / 1.07 & F.V. /
1.5.1 Design pressure
(g) 5.0 & F.V. 5.0 & F.V.
O
1.5.2 Design temperature C 120 / 60 120 / 60
Corrosion allowance (on
1.5.3 mm 0.8 / 3.2 0.8 / 3.2
CS parts)
Water box design kg/cm2
1.5.4 5.0 & F.V 5.0 & F.V
pressure (g)
CW flow considering
1.5.6 m3/hr 76200 76200
CW pump margin
Pressure drop across
1.5.7 the tubes with flow given
under clause 1.5.6
Considering 5% tubes
a) kg/cm2 < 0.84 < 0.84
plugged
b) Without plugging tubes kg/cm2 < 0.8 < 0.8
Velocity in tubes with
1.5.8 flow given under clause
1.5.6
Considering 5% tubes
a) plugged m/sec < 2.31 < 2.31
b) Without plugging tubes m/sec < 2.2 < 2.2
Materials of
1.6
Construction
1.6.1 Shell SA 285 GR C SA 285 GR C
1.6.2 Shell flanges SA 285 GR C SA 285 GR C
1.6.3 Condenser neck SA 285 GR C SA 285 GR C
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Value / Remark
Condenser 1 Condenser 2
Sr. No. Item description Unit
(for LP-1 (for LP-2
turbine) LP turbine) HP
Shell Shell
1.6.4 Water boxes SA 285 GR C SA 285 GR C
SA 516M GR SA 516M GR
1.6.5 Tube sheets
485 485
Tubes in condensing & SA 249 TP 304 SA 249 TP 304
1.6.6 air cooling zone (WELDED) (WELDED)
Tubes in impingement SA 249 TP 304 SA 249 TP 304
1.6.7
zone (WELDED) (WELDED)
1.6.8 Tube support plates IS 2062 Gr. B IS 2062 Gr. B
(a) Pipes : SA (a) Pipes : SA
53 53
1.6.9 Structural parts (b) Plates & (b) Plates &
others : IS others : IS 2062
2062 /MS /MS
1.6.10 Bolts SA 193 GR B7 SA 193 GR B7
1.6.11 Nuts SA 194 GR 2H SA 194 GR 2H
Neoprene / Neoprene /
1.6.12 Gaskets on water side
Aramide fiber Aramide fiber
Water box coating and Coal tar epoxy Coal tar epoxy
1.6.13
thickness of paint Paint Paint
SS 304 / CS as SS 304 / CS as
1.6.14 Impingement baffles
required required
Coating material on tube
Coal tar epoxy Coal tar epoxy
1.6.15 sheets and thickness of
Paint Paint
paint
1.6.16 Hot well SA 285 GR C SA 285 GR C
Expansion joint
(between Condenser
1.6.17 SS SS
shell & turbine exhaust
joint)
SA 516M GR SA 516M GR
1.6.18 Internal piping 485 / SA 106 485 / SA 106
GR B GR B
LTSL-M0-00951 REV 0 Page 50 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Value / Remark
Condenser 1 Condenser 2
Sr. No. Item description Unit
(for LP-1 (for LP-2
turbine) LP turbine) HP
Shell Shell
Bosses for anodes of
1.7 Included Included
cathodic protection
1.8 Weights
When equipment
1.8.1 completely filled with kg 1,254,900 1,230,100
water (steam side)
1.8.2 Empty kg 390,300 383,100
1.8.3 Water boxes kg 42,800 42,800
1.8.4 Tubes kg 154,600 151,200
B. Condensate Extraction Pump
Sr.
Item description Unit Value / Remark
No.
1.0 General
1.1 Manufacturer KSB PUMPS LTD.
1.2 Model No. WKTB 9/1+3
1.3 Quantity per unit % 3 x 50
No. of Pumps working
1.4 02
per unit
Vertical can type ring section
1.5 Type of pump pump. 1ST Stage Impeller -
Double Suction Type
1.6 Type of operation Continuous
Direction of rotation of
1.7 pump viewed from top CCW
(motor end)
KSB Germany std.
Following standards considered:
1.8 Design code
1) Technical requirements for
“Centrifugal pumps – Class I” to
LTSL-M0-00951 REV 0 Page 51 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
ISO 9905
2) Safety Norms as per :
- EC Machinery directive
98/37/EC
- EC directive 94/9/EC,
Nonelectric equipment for use in
potentially explosive atmosphere
Design and
2 Performance Data
2.1 Liquid handled
O
a) Operating Temperature C 43.2
Specific gravity of
b) saturated water at 0.9908
operating temperature
O
c) Design temperature C 100
Specific gravity of
d) saturated water at 0.9581
design temperature
O
e) Temperature range C 35 - 100
8.5 to 9.3 normal operation
f) pH value
9.3 to 9.6 during start up
Rated Performance
2.2
(Design Point)
O
(a) Suction Temperature C 43.6
(b) Specific Volume m3/kg 0.0010093
(c) Capacity m3/hr 975
Minimum flow through
(d) m3/hr 245
the pump
Runout flow ( One pump
(e) at design speed) m3/hr 1430
Suction Pressure kg/cm2
(f) 0.44
(a)
LTSL-M0-00951 REV 0 Page 52 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
kg/cm2
(g) Discharge Pressure 28.88
(a)
(h) Total Developed Head m 287
(i) Shut –off head m 365 ± 3%
NPSH available at first 5.77
(j) stage impeller m considering NPSHa = 0 m at
(minimum) pump mounting floor level
NPSH Required at first
(k) stage impeller based on
3% head loss
(a) Design flow m 2.85
(b) Runout flow (One
pump at design speed) m 4.6
NPSH Required at first
(I) stage impeller based on
1% head loss
(a) Design flow m 3.7 @ 975
(b) Run out flow (One
pump at design speed) m 5.2 @ 1430
(m) Efficiency % 81
(n) Rated Pump speed rpm 1487
(o) Power input to pump kW 932.6
(p) Power input to motor kW 991.5
(q) Selected motor rating kW 1170
(r) Suction specific speed
(a) At first stage US Unit 10983
LTSL-M0-00951 REV 0 Page 53 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
(s) Pump specific speed US Unit 1443
Critical speeds for pump
(t) rpm > 125% of rated speed
& motor assembly
80-110% of Qopt - 2.3 mm/s
Maximum Vibration 40-80% of Qopt - 4.2 mm/s
(u) Level mm/sec 110-120% of Qopt - 4.2 mm/s
20-40% of Qopt - 7.1 mm/s
Q > 120% of Qopt - 7.1 mm/s
Maximum possible
speed of CEP unit
(v) during reverse rotation rpm Up to 117% of rated speed
due to back flow of
water
Maximum noise level at
(w) dB 85
1 m from pump outline
Pump Performance at
2.3 100% TMCR 0% MU (at
best efficiency point)
O
(a) Suction Temperature C 43.2
(b) Specific Volume m3/kg 0.0010091
(c) Capacity m3/hr 827
Suction Pressure kg/cm2
(d) 0.44
(a)
Discharge Pressure kg/cm2
(e) 30.16
(a)
(f) Total Developed Head m 300 (268 m at 47.5 Hz)
(g) NPSH Required m 2.75
(h) Efficiency % 80.5
(i) Power input to pump kW 832.2
LTSL-M0-00951 REV 0 Page 54 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
(j) Power input to motor kW 884.7
Operating range
2.4 (Minimum and Maximum m3/hr 245 to 1430
continuous stable flow)
3.0 Construction
Bowl casing type and
3.1 mounting Radially split stage casing
3.2 Type of impeller Enclosed
3.3 Impeller arrangement Between bearing
1+3 = 4
No. of stages (1st Stage Impeller with Double
3.4
Suction type and the next 3 nos.
impellers are single entry type)
3.5 Internal element offered Removable
3.6 Shaft Coupled
3.7 Type of Coupling offered Flexible
Suction and Discharge
3.8 Side
Nozzle location
Type of shaft bearing
3.9 and design life Bush / Sleeve
Type of thrust bearing
3.10 and design life Segmental pad
3.11 Thrust bearing location Pump bearing hsg. - DE
3.12 Suction strainer
(a) Type Simplex Basket
Strainer mesh size,
(b) 40 / 80
coarse / fine
LTSL-M0-00951 REV 0 Page 55 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
(c) Material of mesh SS316
(d) Material of body C.S.
Pressure drop across
(e) strainer during normal kg/cm2 0.097281
operation
Pressure drop across
(f) strainer during 50% 0.122087
/ clean condition kg/cm2
Ratio of Strainer free
(g) >5
area to inlet nozzle size
Design pressure
(h) (kg/cm2(g)) 3.5 and full vacuum
(i) Design temperature(oC) 100
Hydrostatic test
(j) pressure 1.5 times design pressure
Strainer inlet and outlet
(k) nozzle size(mm) DN 550
Mechanical Seals for
3.13 CEP
(a) Type Tandem
(b) Make Flowserve / EagleBurgmann
(c) API classification code BTTFN
(d) Seal size mm IB=120, OB=130
(e) Mechanical seal life hr 40,000
API Plan for cooling
(f) water (flushing) 13, 32
Seal flush water flow
(g) rate requirement (for Lpm 15
start-up)
LTSL-M0-00951 REV 0 Page 56 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
Pressure require for kg/cm2
(h) sealing (for start-up) 3-4
(a)
3.14 Line shaft coupling type Sleeve with split ring
3.15 Coupling
Type and make Flexible, Power & Machinery
(a)
Const. Pvt. Ltd.
(b) Service factor 2
(c) Spacer length Without spacer
3.16 Coupling guard Cover plates
3.17 Lubrication and Grade Sump oil, ISO VG 46
3.18 Thrust bearing
a) Manufacturer Michell or equivalent
b) Type Segmental pad
c) Lubrication Sump oil
Cooling water
d) requirement 25 lpm
Cooling water inlet kg/cm2 1-5 (Pr. drop across cooler is 0.1
e)
(a) kg/cm2)
f) Load at rated flow 40kN
g) Load at run-out flow 36kN
Load at shut off
h) condition 50kN
LTSL-M0-00951 REV 0 Page 57 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
3.19 Thrust bearing capacity
Upward direction 54.9kN
Downward direction 52kN
3.20 Pump Bearing
a) Type Sleeve
b) Lubrication Self
Materials of
4.0 construction
4.1 Suction can IS2062 E250/E350 Gr. A
Pump bowl: A48 CL 35B
4.2 Bowl or casing
Casing: A216 Gr.WCB
Discharge casing Distributor casing:
4.3
A516 Gr.70, A106
4.5 Column pipe A516 Gr. 70
Impellers 1.4008 (ASTM Eq. A743 Gr.
4.6
CA15)
Impeller Wearing rings 1.4024.19 (Hardness: 225 Max.)
4.7
(ASTM Eq. A743 Gr. CA6NM)
Casing Wearing rings Cr. Hard 400 (Hardness: 350 -
4.8
400 Max.)
4.9 Pump Shaft A182 Gr. F6NM Cr. Plated
4.10 Shaft sleeves A276 TY 316
4.12 Base Plate IS 2062 Gr. A
LTSL-M0-00951 REV 0 Page 58 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
4.13 Mounting flange A105
4.14 Coupling Class 4 IS 2004
Diffuser and guide 1.4008 (ASTM Eq. A743 Gr.
4.16 vanes CA15)
4.17 Canister Ref Sr. No.4.1 above
Strainer mesh material SS316 mesh / SS304 perforated
4.18
sheet
4.19 Strainer body material C.S.
Suction and Discharge
4.20 Nozzle A106, A105
4.21 Suction ring A48 CL 35B
Bearing Bearing Sleeve:
4.22
A276 M410H
4.23 Impeller Keys A276 TY 316
Bolts For pressure parts
4.24
SA 193 B7
Nuts For pressure parts
4.25
SA 194 2H
5.0 Physical Data
Miscellaneous Design
5.1 Data
Pump Total Weight
(a) (empty/flooded) kg 16426 / 23246
Largest Weight To Be
Handled (Individual
(b) kg Pump with motor stool = 9090
Piece or Assembly
During Maintenance)
Rotation of pump seen
(c) from Coupling End CCW
LTSL-M0-00951 REV 0 Page 59 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
Distance From Pump
Centre Line To
(d) mm 800
Suction/Discharge
Flange
Moment Of Inertia Of
GD2 = 30.72
(e) Rotating Assembly kg x m2
WR2 = 7.68
Including Pumped Liquid
Suction Connection
(f) (Size/Rating/Type) DN 400 / 150 RF/ Flanged
Discharge Connection
(g) (Size/Rating/Type) DN 300 / 300 RF / Flanged
(h) Column pipe diameter mm 355.6
Drive shaft = 116
(i) Line diameter mm Intermediate shaft = 83
Pump shaft = 83
Impeller diameter –
(j) mm 545 / 454 / 545 & 494
Max/Min/Actual
(k) Shaft span mm 2070, 1198, 898, 2822
Shaft diameter at
(l) impeller and impeller mm 70
shaft coupling
Suction Can Length
(m) mm 5750
(Floor to Bottom)
(n) Suction Can Diameter mm 1150
Diametrical clearance
(o) between impeller and mm 0.45-0.6
casing ring
(p) Impeller vane number
1) Suction 5 nos.
2) Other 7 nos.
(q) Bearing ’TD's
LTSL-M0-00951 REV 0 Page 60 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr.
Item description Unit Value / Remark
No.
1) Type PT-100, 3 wire duplex
2) Quantity 2 nos.
3) Manufacturer/Model
GIC
No.
4) Alarm Set point 85 oC
5) Shutdown Set point 95 oC
C. LP Heaters
Duplex Duplex
Sr. Item LP LP
Unit LP Heater LP Heater
No. description Heater 3 Heater 4
1A/1B 2A/2B
1.0 GENERAL
L&T – L&T –
L&T – L&T –
Manufacturer HED HED
HED Ltd. HED Ltd.
Ltd. Ltd.
Shell and Shell and
tube type tube type
Shell Shell
with 2 with 2
and tube and tube
1.1 Type of heater zones / zones /
type with type with
DUPLEX DUPLEX
2 zones 2 zones
LP LP
HEATER HEATER
1.2 Orientation
Condenser
YES YES --- ---
mounted
Position
Horizont Horizont
(Horizontal/ Horizontal Horizontal
al al
Vertical)
LTSL-M0-00951 REV 0 Page 61 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Duplex Duplex
Sr. Item LP LP
Unit LP Heater LP Heater
No. description Heater 3 Heater 4
1A/1B 2A/2B
COND. COND.
1.3 Location Indoor Indoor
NECK NECK
1.4 Tube type U-tube U-tube U-tube U-tube
No. of tube
1.5 Two Two Two Two
passes
Two Zone Two Zone Two Two
No. of Zones, Zone Zone
1.6 Shell side (One (One
(One (One
Shrouded) Shrouded)
Shrouded) Shrouded)
DESIGN DATA
(SHELL SIDE)
2.0 AT 100% TMCR
0% MU
Extraction
2.1 steam
Flow rate kg/hr 27265 22877 85111 89583
Inlet o
C 69.84 87.92 168.36 268.70
temperature
kg/
Operating
cm2 0.316 0.661 2.086 5.39
pressure
(A)
kcal/
Enthalpy 600.7 625.0 670.3 716.3
kg
Drains
2.2
Entering
Source of drains --- LPH -3 LPH-4 ---
Flow rate kg/hr 110224 87347 89583 ---
kcal/
Enthalpy 72.69 90.77 124.14 ---
kg
2.3 Drains leaving
Flow rate kg/hr 137950.5 110224 174694 89583
o
Temperature C 49.90 72.70 90.70 123.70
kcal/
Enthalpy 49.91 72.69 90.77 124.14
kg
LTSL-M0-00951 REV 0 Page 62 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Duplex Duplex
Sr. Item LP LP
Unit LP Heater LP Heater
No. description Heater 3 Heater 4
1A/1B 2A/2B
kg/
Design
2.4 cm2 3.5 3.5 3.5 6.0
Pressure
(G)
Design
2.5 Vacuum F.V F.V F.V F.V
Design
2.6 temperature
o
Main Shell C 163.0 163.0 239.0 320.0
o
Skirt Shell C 163.0 163.0 239.0 320.0
kg/
2.7 Test Pressure cm2 4.6 4.6 4.6 7.8
(G)
Pressure
drop(Shell kg/
2.8 0.11 0.11 0.20 0.18
Side) cm2
DESIGN DATA
(TUBE SIDE)
3.0 AT 100% TMCR
0% MU
Feed water flow
rate kg/hr 785938.5 785938.5 1571877 1571877
Inlet o
temperature C 44.30 67.10 85.10 118.10
Outlet o
temperature C 67.10 85.10 118.10 151.10
Operating kg/
pressure cm2 28.78 28.78 28.78 28.78
(A)
kg/
Design pressure cm2 42.0 42.0 42.0 42.0
(G)
Design o
temperature C 150 150 150 185
kg/
Test pressure cm2 54.6 54.6 54.6 54.6
(G)
LTSL-M0-00951 REV 0 Page 63 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Duplex Duplex
Sr. Item LP LP
Unit LP Heater LP Heater
No. description Heater 3 Heater 4
1A/1B 2A/2B
Feed water
velocity at sp. m/s 1.45 1.45 1.61 1.93
gravity 1.0
Tube plugging
margin for Qty 2 2 4 4
fabrication
4.0 HEAT DUTY
kcal/ 5234350 5312944
Total heat duty 17840804 14146893
hr 4.1 2.6
HEAT
TRANSFER
5.0 SURFACE
AREA
Desuperheating
zone m2 --- --- NA NA
Condensing
zone m2 694.40 565.04 1249.09 1103.40
Drain cooling
zone m2 157.77 95.00 179.29 86.54
Eff. Area
(Excluding m2 852.22 660.12 1428.40 1190.02
plugging margin
6.0 L.M.T.D
Desuperheating o
zone C --- --- NA NA
Condensing o
C 9.26 8.39 12.14 12.58
zone
Drain cooling o
zone C 11.99 10.86 15.28 15.78
HEAT
7.0 TRANSFER
COEFFICIENT
Desuperheating kcal/
zone h.m2. --- --- NA NA
o
C
Condensing kcal/
zone h.m2. 2354.10 2629.46 3092.73 3612.05
o
C
LTSL-M0-00951 REV 0 Page 64 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Duplex Duplex
Sr. Item LP LP
Unit LP Heater LP Heater
No. description Heater 3 Heater 4
1A/1B 2A/2B
Drain cooling kcal/
zone h.m2. 1449.75 1624.86 1939.92 2024.35
o
C
PERFORMANC
8.0 E DATA
Terminal
o
temperature C 2.8 2.8 2.8 2.8
difference
Drain cooler o
approach C 5.6 5.6 5.6 5.6
Overall pressure
drop on the tube
kg/ <=0.60 <=0.60 <=0.55 <=0.65
side at the avg.
cm2
operating temp.
CONSTRUCTIO
9.0 N FEATURES
9.1 Shell
Shell ID mm 1800 1800 1655 1475
Shell Thickness mm 12 / 12 12 / 12 12 / 12 12 / 12
Overall length of 12250 12206
14500 mm 14500 mm
heater mm mm
Shell side
corrosion mm 3.2 3.2 3.2 3.2
allowance
9.2 Tubes
Tube side
corrosion
allowance
except SS tubes mm 3.2 3.2 3.2 3.2
(T tubes in case
of LP Heaters 3
& 4)
Total number of
647 648 1166 972
U- tubes
Tube OD mm 19.05 19.05 19.05 19.05
Tube Gauge mm 0.90 0.90 0.90 0.90
LTSL-M0-00951 REV 0 Page 65 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Duplex Duplex
Sr. Item LP LP
Unit LP Heater LP Heater
No. description Heater 3 Heater 4
1A/1B 2A/2B
Tube Pitch mm 23.8125 23.8125 23.8125 23.8125
Straight
Effective length mm 10756 8257 9893 9927
of tube
9.3 Tube-sheet
Tube sheet
thickness mm 170 170 163 150
Minimum
overlay mm 0 0 0 0
thickness
Type of joint
between shell
and tube Welded Welded Welded Welded
sheet
Type of joint
between tube
sheet and Welded Welded Welded Welded
channel
Type of joint Grooved Grooved Grooved Grooved
between tube & & & Expansi Expansi
tube sheet Expan. Expan. on on
Nozzle type /
9.4 End
connection
Feed water inlet
nozzle B.W end B.W end B.W end B.W end
Feed water
outlet nozzle B.W end B.W end B.W end B.W end
Steam inlet
nozzle on the B.W end B.W end B.W end B.W end
shell side
Drain outlet
nozzle type on B.W end B.W end B.W end B.W end
the shell side
Relief Valve
9.5 Size
Nos. Of
Ruptured Tubes
For S/S Relief N/A N/A 2 2
Valve Sizing
LTSL-M0-00951 REV 0 Page 66 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Duplex Duplex
Sr. Item LP LP
Unit LP Heater LP Heater
No. description Heater 3 Heater 4
1A/1B 2A/2B
Shell relief
valve(in*in) N/A N/A 4*6 4*6
(Inlet/Outlet)
Flange Rating
(lbs) # 300*# # 300*#
N/A N/A
(Inlet/Outlet) 150 150
Channel side
thermal relief 3/4" * 1" 3/4" * 1" 3/4" * 1" 3/4" * 1"
valve
ASME ASME
ASME ASME
SEC VIII SEC VIII
CONSTRUCTION SEC VIII SEC VIII
10.0 CODE DIV1, DIV1,
DIV1, HEI, DIV1, HEI,
HEI, HEI,
TEMA TEMA
TEMA TEMA
MATERIAL OF
11.0 CONSTRUCTION
Main Shell &
Shell Side SA516 SA516 SA516 SA516
D'End Gr70 Gr70 Gr70 Gr70
Shell skirt SA516 SA516 SA516 SA516
Gr70 Gr70 Gr70 Gr70
Support SA516 SA516 SA516 SA516
plates/Baffles Gr70 Gr70 Gr70 Gr70
Tube sheet SA350 SA350 SA350 SA350
GrLF2 GrLF2 GrLF2 GrLF2
Tubes SA688 SA688 SA688 SA688
TP304 * TP304 * TP304 * TP304 *
Channel/Man SA350 SA350 SA350 SA350
way cover GrLF2 GrLF2 GrLF2 GrLF2
SA106 SA106
Channel & shell SA106 SA106
GrB/SA GrB/SA
nozzles GrB/SA GrB/SA
516 Gr 516 Gr
516 Gr 70 516 Gr 70
70 70
SS SS SS SS
Gaskets on SPWD/ SPWD/ SPWD/ SPWD/
steam side ARAMIDE ARAMIDE ARAMID ARAMID
FIBRE FIBRE E FIBRE E FIBRE
Gaskets on SS SS
water side SS SPWD SS SPWD
SPWD SPWD
Bolts SA 193 SA 193 SA 193 SA 193
B7 B7 B7 B7
LTSL-M0-00951 REV 0 Page 67 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Duplex Duplex
Sr. Item LP LP
Unit LP Heater LP Heater
No. description Heater 3 Heater 4
1A/1B 2A/2B
Nuts SA 194 SA 194 SA 194 SA 194
2H 2H 2H 2H
Spacer Tubes SS 304 SS 304 SS 304 SS 304
Tie rods SA 36 SA 36 SA 36 SA 36
Shell nozzle
flanges SA 105 SA 105 SA 105 SA 105
WEIGHT
(Cumulative of
11.0 all component
units/heaters)
Empty kg 45800 45800 28300 23400
Flooded kg 72000 72000 51400 41800
Operating kg 54900 54900 36600 30000
LTSL-M0-00951 REV 0 Page 68 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
D. Condensate Polishing Unit
1) Service Vessels
Sl. No. ITEM CPP Vessel
1 Type Spherical
2 Numbers Total Six (6 nos.) ( 3 X 50% per unit)
3 Flow rate, m3/hr
3.1 Service 975 m3/hr per Service Vessel
3.2 Design 975 m3/hr per Service Vessel
3.3 Maximum 975 m3/hr per Service Vessel
4 Head loss through bed, mWC
4.1 During service 20 mWC at Clean Condition
4.2 Maximum 33 mWC at Dirty Condition
5 Service cycle
5.1 Normal 12 days (H/OH cycle)
During condenser tube (a) Minor Leak condition - 50 hrs
5.2
leakage condition (b) Major Leakage condition - 5 hrs
6 Exchange Resin Details
6.1 Resin Cation & Anion
Cation - Macroporous /
6.2 Type
Anion - Macroreticular type
6.3 Manufacturer Rohm & Haas (DOW)
LTSL-M0-00951 REV 0 Page 69 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sl. No. ITEM CPP Vessel
6.4 Brand name Rohm & Haas (DOW)
Cation Resin – Amberlite 252RF H &
6.5 Resin Model
Anion Resin – Ambersep 900SO4
Estimated resin life for cation - 5 to 7
years
6.6 Estimated life of resin in years
Estimated resin life for anion – 3 to 5
years
4 – 6% (Estimated) per year for
Attrition loss of resin per year
6.7 Cation
%
6 – 7% (Estimated) per year for Anion
7 Depth of bed, mm
7.1 Effective 1100 ( Average)
Total resin – 10.020 m3 per vessel
Quantity supplied for each
8 (Active Resin – 9.260 m3 &
exchange, m3
Inactive Resin – 0.760 m3)
Regeneration level, kg of
9 100% chemical per m3 of 320gpl for Cation & 160gpl for Anion
resin
**Quantity of chemical
**Acid 2100 kg as 100% HCl (plus
required for each
7% tolerance) & Caustic 583 kg as
10 regeneration of one(1)
100 % NaOH per regeneration per
exchanger, kg of 100%
CP vessel
chemical
Regenerant chemical
HCL – 30 to 33% as per IS 265 &
12 specification (indicate
NaOH – 48% Lye as per IS 252
standard)
Strength of chemical during
13 HCL – 5% & Caustic – 4 %
regeneration (% w/w)
14 Vessel details
Surface flow rate at design
14.1 117 m/hr (Average)
flow (m/hr)
Dimension, mm x mm
14.2 Dia. 3400 mm ( Spherical)
(Diameter x H.O.S)
14.3 Shell SA 516 Gr.70
LTSL-M0-00951 REV 0 Page 70 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sl. No. ITEM CPP Vessel
14.4 Dished end SA 516 Gr.70
14.5 Inside lining Rubber Lining
14.6 Material Natural Rubber
14.7 Thickness, mm 4.5 mm ( in 3 layers)
14.8 Hardness 65 + /- 5% Shore A
15 Design code ASME Section VIII Div. I
16 Design pressure, kg/cm2 43 kg/cm2a
17 Test pressure, kg/cm2 64.5 kg/cm2a
18 Man hole
Davit type on Top & Hinged type on
18.1 Type
Bottom
18.2 Size (dia), mm 500
18.3 Number 2 nos.
19 Influent distributor
19.1 Type Splash Plate
19.2 Material SS 316
20 Under drain system
20.1 Type Strainer on Plate
Plate (dished type) – SS 304,
20.2 Material
Strainer- SS 316 ,
Yes – Manual backwash In – place
Resin trap provided at service
21 type for service outlet, For Rinse &
and rinse/backwash outlet
Backwash – Not Applicable
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
** Note-The specified chemical consumption is only for regeneration and does
not include quantity required towards neutralization of waste.
2) Regeneration Vessels
Cation
Anion Regeneration
Sl. No. Separation
ITEM Regeneration cum Mixed
Vessel
Vessel resin Storage
Vessel
Vertical Vertical Vertical
cylindrical with cylindrical with cylindrical with
1 Type
torrispherical torrispherical torrispherical
dished end dished end dished end
2 Numbers 1 1 1
Regeneration
level, kg of 100%
3 NA 160 gpl 320 gpl
chemical per m3 of
resin
Regenerant
NaOH - 48 % HCL - 30 to
chemical
4 Lye as per IS 33% as per IS
specification
252 265
(indicate standard)
Quantity of
chemical required
for each 2170 kg as
730 kg as
5 regeneration of NA 100% HCl (+
100% NaOH
one(1) exchanger, 7% tolerance)
kg of 100%
chemical
Regenerant
6 chemical NA Caustic HCl
specification
Strength of
chemical during
7 NA 5% 5%
regeneration (%
w/w)
Volumetric 100% on
8 Free board (%) Free Board- 100% Cation Resin
84.6% Volume
Lower Dia
Dimension, 2200mm,
Dia 1800mm X Dia 2400mm X
9 mm(Diameter x H. Straight height
3430mm HOS 3400mm HOS
O.S) 4410mm,
Upper Dia
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Cation
Anion Regeneration
Sl. No. Separation
ITEM Regeneration cum Mixed
Vessel
Vessel resin Storage
Vessel
3100mm,
Straight height
1800mm
Shell – 8, Shell – 8, Shell – 10,
10 Thickness – mm
Dish - 10 Dish - 10 Dish - 10
11 Material
SA516 grade SA516 grade SA516 grade
11.1 Shell
70 70 70
SA516 grade SA516 grade SA516 grade
11.2 Dished end
70 70 70
12 Inside lining Rubber lining Rubber lining Rubber lining
13 Material Natural rubber Natural rubber Natural rubber
4.5 4.5 4.5
14 Thickness, mm
(in 3 Layers) (in 3 Layers) (in 3 Layers)
65± 5deg. 65± 5deg. 65± 5deg shore
15 Hardness
shore A shore A A
ASME section ASME section ASME section
16 Design code
VIII Div. I VIII Div. I VIII Div. I
Design pressure,
17 8.2 8.2 8.2
kg/cm2 (g)
Test pressure,
18 12.3 12.3 12.3
kg/cm2(g)
Mechanical Design
19 Temperature, 60 60 60
Deg. C
20 Man hole
20.1 Type Davit type Davit type Davit type
20.2 Size (dia), mm 500 500 500
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Cation
Anion Regeneration
Sl. No. Separation
ITEM Regeneration cum Mixed
Vessel
Vessel resin Storage
Vessel
20.3 Number 1 1 1
21 Influent distributor
21.1 Type Header lateral Splash plate Splash plate
CSRL-RC with
conventional
21.2 Material strainer in Splash plate Splash plate
SS316
construction
Under drain
22
system
Strainer on Strainer on Strainer on
22.1 Type
plate in CSRL plate in CSRL plate in CSRL
Strainer – Strainer – Strainer –
22.2 Material
SS 316 SS 316 Hastalloy
Resin trap
Yes – Yes – Yes –
provided at service
22.3 Conventional Conventional Conventional
and rinse/
type type type
backwash outlet
3) Air Blowers
Blowers for
Blowers for
Sl. No. ITEM Condensate
Regeneration System
Polishers
Two(2) – units Four (4) – units
1 Number offered (Common for 2 Unit) (2nos per each Unit)
(1W+1S) (2W+2S)
Rotary, Twin lobe
Rotary, Twin lobe type,
type, Oil Free,
2 Type Oil Free, Positive
Positive
Displacement
Displacement
Rated Capacity of
3 1200 m3/hr 1700 m3/hr
each blower, m3/hr
4 Total Head, mWC 5 5
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Blowers for
Blowers for
Sl. No. ITEM Condensate
Regeneration System
Polishers
5 Blower speed, RPM 1500 1500
Material of
6
construction
Cast Iron IS 210 Gr. Cast Iron IS 210 Gr.
a) Casing
FG 260 FG 260
Cast Iron IS 210 Gr. Cast Iron IS 210 Gr.
b) Impeller
FG 260 FG 260
c) Shaft EN-8 EN-8
7 Motor rating, kW 37 55
8 Motor, RPM 1500 1500
4) Acid tanks
Acid
Acid
Bulk Acid metering tank
metering tank
Sl. No ITEM Storage for
for
Tank Neutralizing
Regeneration
Pit
1. Number 1 1 1
Horizontal
Vertical Vertical
cylindrical
cylindrical with cylindrical with
Type and pressure with Torri-
2. removable flat removable flat
class spherical
hinged cover, hinged cover,
dished end,
Over ground Over ground
Over ground
3. Useful capacity, m3 62.9 6.29 1.0
Size in mm Dia x 3500mm X 2400mm X 1200mm X
4.
height or Dia x length 6500mm LOS 2200 mm HT 1300 mm HT
IS2062 Gr. B IS2062 Gr. B IS2062 Gr. B
Material of
Shell - 10, Shell - 6, Shell - 6,
5. construction and
Bottom Bottom Bottom
thickness, mm
Plate - 10 Plate - 6 Plate - 6
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Rubber lining, Rubber lining, Rubber lining,
4.5 mm (in 3 4.5 mm (in 3 4.5 mm (in 3
Inside lining material,
6. layers), layers), layers),
thickness, hardness
65± 5deg. 65± 5deg. 65± 5deg.
shore A shore A shore A
As per As per As per
7. External protection painting painting painting
specification specification specification
8. Design pressure Atm. Atm. Atm.
Thickness
calculations
9. Design Code as per - IS803 IS803
ASME Sec
VIII Div. 1
500mm ,
Man hole size, type &
10. Davit type, 1 NA NA
number
No
5) Alkali tanks
Alkali
Alkali
Bulk Alkali metering tank
metering tank
Sl. No ITEM Storage for
for
Tank Neutralizing
Regeneration
Pit
1. Number 1 1 1
Horizontal
Vertical Vertical
cylindrical
cylindrical with cylindrical with
Type and pressure with
2. removable flat removable flat
class Torrispherical
hinged cover, hinged cover,
dished end,
Over ground Over ground
Over ground
3. Useful capacity, m3 30.53 1.01 2
Size in mm Dia x 2800mm X 1200mm X 1600mm X
4.
height or Dia x length 5000mm LOS 1600mm HT 1500mm HT
IS2062 Gr. B IS2062 Gr. B IS2062 Gr. B
Material of
Shell - 8, Shell - 6, Shell - 6,
5. construction and
Bottom Bottom Bottom
thickness, mm
Plate - 10 Plate - 6 Plate - 6
Rubber lining, Rubber lining, Rubber lining,
Inside lining material, 4.5 mm, 4.5 mm, 4.5 mm,
6.
thickness, hardness 65± 5deg. 65± 5deg. 65± 5deg.
shore A shore A shore A
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Alkali
Alkali
Bulk Alkali metering tank
metering tank
Sl. No ITEM Storage for
for
Tank Neutralizing
Regeneration
Pit
8. Design pressure atm atm atm
Thickness
calculations
9. Design Code as per - IS803 IS803
ASME Sec
VIII Div. 1
Man hole size, type & 500mm, Davit
10. NA NA
number type, 1 No.
6) Chemical handling pumps - horizontal centrifugal
Alkali Unloading/ Acid Unloading/
Sl. No. Item
Transfer Pump Transfer Pump
1. Nos. offered 2 (1W + 1S) 2 (1W + 1S)
Horizontal Horizontal
2. Type
centrifugal centrifugal
As per
3. Design Code IS5120
manufacturer’s std.
4. Manufacturer Mather + Platt Antico
5. Model No. PN ISO 4 EXP- 50CTM
6. Rated Capacity, m3/hr 10 10
7. Maximum flow, m3/hr 12 12
8. Safe minimum flow, m3/hr 7.5 2.0
17 (Discharge 12 (Discharge
9. TDH at rated capacity – mlC
Pressure) Pressure)
10. Shut off head - mlC 21 13.5
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Alkali Unloading/ Acid Unloading/
Sl. No. Item
Transfer Pump Transfer Pump
Pump efficiency at rated
11. 16.7% 25%
capacity
12. Pump speed, rpm 1500 1500
13. BKW at rated condition 6.13 1.35
14 Motor kW rating & RPM 9.3/1500 2.2/2900
NPSH Available, m &
15 12.57 / 1.6 7.6 / 2.0
Required, m
16 Type of sealing Mechanical seal Mechanical seal
18 Material
a) Casing CF8M PP
b) Impeller CF8M PP
c) Shaft SS 410 EN-8
7) Chemical Dosing Pumps – Positive displacement type
Acid Dosing Alkali Dosing
Pump for Pump for
Sl. No. Item
regeneration regeneration
purpose purpose
1. Nos. offered 2 (1W + 1S) 2 (1W + 1S)
Positive Positive
displacement – displacement -
2. Type
Diaphragm Diaphragm
Plunger type Plunger type
3. Design Code API 675 API 675
4. Rated Capacity, m3/hr 5.035 1.220
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Acid Dosing Alkali Dosing
Pump for Pump for
Sl. No. Item
regeneration regeneration
purpose purpose
5. Maximum flow, m3/hr 5.148 1.225
6. TDH at rated capacity, mlC 40 40
7. Pump speed, rpm 1450 1450
8. Motor kW rating 5.5 1.5
9. Material
SS 316 (Wetted
a) Casing PP (Liquid End)
Parts)
b) Impeller NA NA
8) Water handling pumps
Neutralized
Rinse Resin
Sl. Regeneration Waste
Item Recirculati Transfer
No. Water Pump Disposal
on Pumps Pumps
Pumps
4, 2 nos. for
2 2 2
1. Nos. offered each unit
(1W + 1S) (1W + 1S) (1W + 1S)
(1W + 1S)
Horizontal Horizontal Horizontal Horizontal
2. Type
centrifugal centrifugal centrifugal centrifugal
IS1520 / IS1520 / IS1520 /
3. Design Code API 610
IS 5120 IS 5120 IS 5120
Rated Capacity,
4. 50 515 141 50
m3/hr
Maximum flow,
5. 65 710 167 65
m3/hr
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Neutralized
Rinse Resin
Sl. Regeneration Waste
Item Recirculati Transfer
No. Water Pump Disposal
on Pumps Pumps
Pumps
35 33 60 49.2
TDH at rated
6. (Discharge (Differential (Discharge (Discharge
capacity, mWC
Pressure) head) Pressure) Pressure)
Pump speed,
7. 1500 1500 1500 2900
RPM
8. Motor kW rating 11 75 45 15
Mechanical Mechanical Mechanical Mechanical
9. Type of sealing
Seal Seal Seal Seal
10. Material
a) Casing CF8M CF3M CF8M CF8M
b) Impeller CF8M CF3M CF8M CF8M
c) Shaft sleeve SS 316 SS 316L SS 316 SS 316
d) Shaft SS 410 SS 316L SS 410 SS 410
9) Activated carbon filter
Sr. No. Item Activated Carbon Filter
Vertical cylindrical with dished
1.1 Type
end
1.2 Numbers 1
1.3 Flow rate, m3/hr
i Service (Net) 10
ii Design 10
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr. No. Item Activated Carbon Filter
iii Maximum 10
iv Back wash, m3/hr 15.43
v Rinse 10
1.4 Head loss through bed, mWC 8
i During service 6
ii Normal 6
iii Maximum 7
1.5 Guaranteed time (Min), max 20
i Back wash 10
ii Rinse 5 to 10
Total time required for
iii 20
regeneration
Output between two successive
1.6
back wash, m3
i Net 10
ii Gross 10
1.7 Filter media details
i Media type Activated Carbon
ii Iodine Adsorption, mg/gm 900
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr. No. Item Activated Carbon Filter
iii Bulk Density, g /cc 0.4 to 0.6
iv Effective size, mm 0.8 to 0.9
v Carbon Content 90%
vi Ash Content 8%
vii Moisture Content 5% (as packed)
ii Guaranteed Life, yrs. Estimated – 1 yr.
iii Depth of bed, mm
Media (Activated Carbon) 1200
Support (Gravel / Garnet) 300
Quantity supplied for each filter, 0.950 m3 Carbon + 0.191 m3
iv
m3 Garnet
1.8 Vessel details
Surface flow rate at design
i 15
flow, m3/hr/m2
ii Free board – mm 75%
Dimension – mm (Diameter x
iii 1000mm X 2400mm
H.O.S)
Mech. Design Temperature,
iv 60
Deg. C
v Material & thickness – mm Shell - 6, Dish - 8
Shell IS 2062 Gr.B
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sr. No. Item Activated Carbon Filter
Dished IS 2002 Gr B. OR SA 515 Gr.70
v Inside lining
Material Rubber lining
Thickness, mm 4.5 mm (in 3 Layers)
Hardness 65± 5 deg. shore A
vi Design code ASME Section VIII Div. I
vii Design pressure – kg/cm2 6
1.9 UNDER DRAIN SYSTEM
i Type Strainer on plate type in CSRL
ii Material Strainer - PP
Media trap provided at service
1.10 Yes
and back wash outlet (yes/no)
10) Hot water tanks
No. of Tanks One (1) (Common for 2 Units)
Type Vertical Cylindrical with dished end
Tag HWT-1
Material Carbon Steel
Pressure rating 6 Bar
Dimension 2600 mm dia. x 2800 mm HOS
Mech. Design Temperature, Deg. C 75
Shell IS 2062 Gr. B
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Dished SA 515 Gr.70
Design code ASME Section VIII Div. I
Design pressure, kg/cm2 6
Inside lining material, thickness, hardness Rubber lining, 8.0 mm, 65± 5deg.
shore A
External painting As per painting specification
Man hole size, type & number 500mm, Davit type, 1 No.
Electrical heating coil Three (3) sets of 170 kW each
PERFORMANCE PARAMETERS
A. Operation parameters
Sl.
Parameters Units Values Tolerance
No.
Design flow per Service
1.0 m3/hr 975 --
Vessel
Duration of Service Run on
2.0 Hydrogen cycle with following -
condition:
Under normal operating
a) Days 12 (H/OH) -
condition
b) During Start-up / Shut down Hours 50 --
Under minor tube leakage
c) Hours 50 --
condition
Under major tube leakage
d) Hours 5
condition
Average velocity of
3.0 condensate through resin bed m/hr 120 (max)
in service vessel
4.0 Chemical consumption --
Refer Note-5 Consumption of
kg/
Acid for resin one service 2170 (kg as
a) regeneration +7%
vessel (for 100% w/w 100% HCl)
per CP vessel
concentration)
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sl.
Parameters Units Values Tolerance
No.
Refer Note-5 Consumption of
730 (kg as
Alkali for resin one service kg/regeneration
b) 100% -
vessel (100% w/w per CP vessel
NaOH)
concentration )
48 kW –
BKW &
Power consumption for Resin
5.0 kW 75 kW -
transfer pump
(Motor
Rating)
12 kW –
BKW &
Power consumption for
6.0 kW 18 kW -
Regeneration water pump
(Motor
Rating)
Pressure drop across the
polisher service vessels
including losses due to
entrance/exit nozzles, flow
7.0
elements, distributors, drains,
resins, resin traps and losses
in inlet and outlet header
between terminal points:
a) At clean resin bed condition bar 2.0 (max) --
At end of service cycle under
both condition i.e. normal
b) continuous operation bar 3.3 (max) --
condition and start-up
condition.
After separation, anion resin
8.0 < 0.1%
in the cation resin
After separation, cation resin
9.0 < 0.1%
in the anion resin
10.0 Resin life for: --
5 to 7 years
a) Cation resin Year -
(Estimated)
3 to 5 years
b) Anion resin Year -
(Estimated)
11.0 Attrition loss per Year --
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Sl.
Parameters Units Values Tolerance
No.
4 - 6 % per
% of cation
a) Cation resin year -
resin
(Estimated)
6 -7 % per
% of anion
b) Anion resin Year -
resin
(Estimated)
Noise level for all equipment
12.0 at a distance of 1 m from dBA <85 -
equipment
NOTE:-
1. Plant Design (including external regeneration facility) is based on 250 ppb
ammonia concentration in the influent.
2. PG test will be conducted only once based on the design value of ammonia.
3. In case, during regular operation, feed ammonia level is 100 ppb and pH =
8.5 (other inlet conditions and parameters remaining same as mentioned
above), contractor should confirm service (H/OH) cycle duration of 30 days
with outlet quality as above table. Contractor confirmed that external
regeneration facilities are sufficient for 100 ppb ammonia load.
4. In case of abnormal condition, a feed ammonia level of 500 ppb and pH = 9.2
(other inlet conditions and parameters remaining same as mentioned above),
Contractor confirmed service (H/OH) cycle duration of 30 days with outlet
quality as above table. However, contractor has clarified that external
regeneration facility is not available for this load and regeneration frequency.
Contractor also clarified that continuous plant operation would not be possible
with the continuous load of 500 ppb influent ammonia concentration.
5. Chemical consumption is only for regeneration and does not quantity required
towards neutralization of regeneration waste.
B. Effluent quality at outlet of service vessel in normal continuous operation
at design flow and temperature up to process design temperature:
Value in
Sl. No. Parameter Unit Tolerance
Effluent
Total Dissolved Solids (TDS,
1.0 ppb < 25 --
ammonia excluded)
2.0 Suspended solids (Crud) ppb <5 --
3.0 Ammonia ppb BDL --
Total Ferric Iron (soluble) (as
4.0 ppb <2 --
Fe)
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
pH value (polisher runs at 25
5.0 o 6.5 – 7.5 --
C with H/OH mode)
6.0 Chloride (as Cl) ppb <2 --
7.0 Sodium (as Na) ppb ≤2 --
8.0 Relative silica (as SiO2) ppb <5 --
µmho/cm
9.0 Electric conductivity at 25 oC <0.1 --
at 25 oC
10.0 Total copper (soluble) as Cu ppb <1 --
C. Effluent quality at outlet service vessel during start-up/shutdown operation
with design flow and temperature up to process design temperature:
Sl. Value in
Parameter Unit Tolerance
No. Effluent
Total Dissolved Solids
1.0 ppb < 50 --
(TDS, ammonia excluded)
2.0 Suspended solids (Crud) ppb < 100 --
3.0 Ammonia ppb BDL --
Total Ferric Iron (soluble)
4.0 ppb < 10 --
(as Fe)
pH value (polisher runs at
5.0 6.5 – 7.5 --
25 oC with H/OH mode)
6.0 Chloride (as Cl) ppb <10 --
7.0 Sodium (as Na) ppb ≤5 --
8.0 Relative silica (as SiO2) ppb <20 --
Electric conductivity at 25 µmho/cm
9.0 o <0.2 --
C at 25 oC
10.0 Total copper (soluble) as Cu ppb <1 --
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
D. Effluent quality at outlet of service vessel during condenser tube leakage
condition with design flow and temperature up to process design
temperature:
Sl. Value in
Parameter Unit Tolerance
No. Effluent
1.0 Sodium ppb, as ion ≤ 20 --
2.0 Reactive Silica (as SiO2) ppb < 20
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
1.2.2 Operation Limit
Sr. No Parameter Unit Value
Lo Lo - 200
Lo - 275
1 Hotwell Level mm NWL 865
Hi - 940
Hi HI - 1015
0 Hi - 120
2 CEP Motor Brg. Temp. C
Hi HI - 130
0 Hi - 120
3 CEP Motor Stator Temp. C
Hi HI - 130
Hi – 4.5
4 CEP Vibrations mm/s
Hi Hi – 7.1
5 CEP Min. Recirculation Flow m3/hr 245
6 CEP Suction DP Hi kg/cm2(g) 0.3
7 GSC Min. Recirculation Flow TPH 400
Lo – 161
8 LP Heater 1A / 2A Level mm Hi – 200
Hi Hi – 225
Lo – 161
9 LP Heater 1B / 2B Level mm Hi – 200
Hi Hi – 225
Lo – 143
10 LP Heater 3 Level mm Hi – 195
Hi Hi – 220
Lo – 113
11 LP Heater 4 Level mm Hi – 160
Hi Hi – 185
Lo Lo – 870 mm
Lo – 2400 mm
12 Deaerator Level mm Hi – 3000 mm
Hi Hi – 3050 mm
Hi HI Hi – 3100 mm
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
1.3 References
1.3.1 P & ID
a) Condensate System P&ID
Dwg. No. LTSL-M1-00201 (Sheet 1 to 6)
1.3.2 GA Drawings
a) Condenser GA Drawing
Dwg. No. LT-M0-03000/3001
b) LP Heater GA Drawings
Dwg. No. LT-M0-03075/3071
c) Duplex Heater GA Drawing
Dwg. No. LT-M0-03080
d) Condensate Extraction Pump GA Drawing
Dwg. No. KSB-M0-03503
Note: All above drawings are attached as Exhibits.
1.3.3 System documents
a) System Description , Operation & Control
Dwg. No. LTSL-M1-00151 (Condensate System)
1.3.4 Heat Balance Diagram
a) Dwg. No. T3101AAAB110
1.3.5 Vendor Drawings / Documents
a) Data Sheet – Condenser
Dwg. No. LT-M0-03000
b) Datasheet – CEP
Dwg. No. KSB-M0-03533
c) Datasheet – LP Heaters
Dwg. No. LT-M0-03070
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
d) Datasheet – Duplex Heaters
Dwg. No. LT-M0-03079
e) Datasheet – CPU
Dwg. No. SWTL-M0-00103
f) Erection Manual – Condenser
Dwg. No. LT-M0-03013
g) O&M Manual – CEP
Dwg. No. KSB-M0-03546
h) IOM – LP Heaters
Dwg. No. LT-M0-03054
i) Operation Philosophy – CPU
Dwg. No. 62OP-12023-OCL-01
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2.0 SYSTEM DESCRIPTION
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Chapter 2
System Description
2.1 Overview
The main function of the condensate system is to deliver continuously the
condensate to the deaerator, at any load or transient condition considering the
flow and pressure requirements of the system, including the spray water to the
low-pressure turbine.
The system commences from condenser and includes all the equipment and
components up to the entrance of the deaerator.
Steam from both LP turbine exhaust, BFPT exhaust and LP bypass gets
condensed in the dual pressure condensers consists of HP & LP shell.
Condensate from the low pressure and high pressure condenser hot wells is
transported through three (3) condensate pumps (3 x 50%). The main
condensate header directs condensate through several inline components
upstream of the deaerator level control valves such as condensate polisher and
gland steam condenser. Condensate from the deaerator level control valves is
transported to the deaerator through LP heaters 1 to 4. Two (2) nos. of duplex
heaters (1A/2A & 1B/2B) are installed in condenser neck. Condensate flows
through the channel (tube) side of the LP feedwater heaters where it is heated
from the condensing extraction steam on the shell side. Condensate is supplied
to the deaerator spray valve manifold where dissolved non-condensable gases
are removed. The de-aerated condensate is collected in the deaerator.
Individual bypass lines are provided to bypass each LP heater from service by
use of motor operated isolation and bypass valves. The condensate flow to the
deaerator is controlled through deaerator level control station located upstream
of the LP heaters.
The flow diagram for condensate system is as shown in the schematic on next
page.
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
DCS Graphics: Condensate System
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
2.2 Flow Path
Condensate System flow path is described from the condensate system P&IDs
(Attached in Exhibits). The flow paths associated with the System are grouped
as:
• Condensate from Make-up system to condenser hotwell to CEP suction
• Condensate from CEP suction to CEP Discharge Valve
• Condensate from CEP Discharge to CPU through GSC
Condensate from CPU outlet to deaerator level control station with tapings for
GSC recirculation & dump valve
• Condensate from deaerator level control station outlet to deaerator through
LP heaters
2.2.1 Condensate from Make-up system to condenser hotwell to CEP
suction
Steam exhausted from each of the low-pressure turbine stages and BFPT enters
the two condensers, which consists of two shells having steam space and hotwell
cross connections. Condensate from the hotwell flows to a header, which allows
the condensate to be pumped out of both hotwell by any combination of the
3X50% condensate extraction pumps.
Makeup water from the condensate storage tank enters the Condenser (high
pressure shell) through the normal makeup control valve (1GHC10-AA081) &
then to low pressure shell through the condenser hotwell equalizing line. Makeup
to the condenser is required to replace water loss from the plant cycle. Makeup
ensures that the condensate pump suction head requirements are met.
The normal level control valve is positioned by the DCS based upon the level
sensed by redundant condenser hotwell level transmitters. When the condenser
hotwell level will drop below the normal operating limit, the DCS will command
the level control valve to increase the makeup water flow to maintain the required
condensate level. The normal make-up is sized for 3% TGVWO flow. Flow
element is provided on this line to monitor the make up to the cycle. Sampling
point is also provided to check the quality of make-up water to the cycle.
To cater to the emergency or quick fill requirement emergency make up line is
provided with the control valve. The emergency make up control valve
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(1GHC15AA081) will operate on Auto should hotwell level falls below the set
value. For valve trouble / maintenance, both the normal and emergency level
control valves are provided with inching type MOV bypass valve.
2.2.2 Condensate from CEP suction to CEP Discharge Valve
Individual suction lines are branched from the common suction header at the
outlet of both hot wells. During normal operation, taking suction from condenser
hotwell, two condensate extraction pumps operate with one in active standby. If
an operating pump trips, the standby pump will start up automatically. If the
condensate level drops below the minimum hotwell level, it will trip all operating
pumps. Additionally, low level will be a start inhibit if no pumps are running.
(Pump trip due to low hotwell level will override standby pump start.) Each of
these motor driven extraction pumps is provided with suction strainer,
condensate recirculation system, non-return valve (NRV) and motorized
discharge valve. A single recirculation line and flow transmitter is provided on
each condensate extraction pump discharge line before pump’s check valve and
motorized discharge valve. The minimum flow requirement of each condensate
pump is maintained by its individual recirculation flow control valve. The
recirculated condensate is returned to the HP Condenser Shell Hotwell. The flow
in this line is controlled via the condensate pump recirculation control valve to
maintain the minimum continuous stable flow requirements of the respective
condensate pump.
The suction piping to the pumps is vented back to the condenser, to ensure that
the non-operating pump(s) stays completely flooded. These vent lines include
manual valves on the vent for each pump. Each pump is provided with suction
side relief valve, High point vent line at the pump discharge casing is connected
to the condenser via solenoid operated valve.
The shaft seals of these pumps are the water-injected type fed from a header to
prevent the suction of air, particularly the pump that is not operating while the
condenser is under vacuum. Initial sealing water is provided from the DM transfer
/ condensate transfer pump discharge line. Once the condensate pump is
started, self-sealing is provided from the pump itself.
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2.2.3 Condensate from CEP discharge to CPU through GSC
After the condensate pumps discharge to a common header, the gland steam
condenser is the first heat exchanger. The condensate absorbs heat as it flows
through this heat exchanger which condenses the turbine gland leak-off steam.
Manual isolation valves are provided at the inlet, outlet and bypass lines of Gland
Steam Condenser.
The condensate passes through polishers after leaving the gland steam
condenser for removal of dissolved and suspended solids. A recirculation line is
provided at outlet line after CPU. The flow in this line is controlled via GSC
recirculation control valve to maintain the minimum continuous stable flow
requirements of GSC. The recirculated condensate is returned to the HP
Condenser Shell Hotwell. Flow transmitter is located at the outlet line of GSC. In
the event of any condition that results hot well levels in excess of the normal
level, the excess condensate dump control valve opens and condensate is
directed to the condensate storage tank.
Inching type MOV is provided on the bypass lines of GSC minimum recirculation
valve and excess condensate dump control valve to meet the requirements in the
event of trouble / maintenance of the control valve.
Depending upon the feed water quality and type of chemical treatment selected
either Oxygen, hydrazine or ammonia are injected into the condensate piping
after the condensate polisher.
The condensate system also supplies water to the following consumers:
• Condenser water curtain spray to both HP and LP shell of condenser from
GSC outlet
• Make-up to stator coil cooling water system from CPU outlet
• Spray water to LP Bypass valve from CPU outlet
• Desuperheating water to Ventilator Valve
• CCW overhead tank make-up
• Desuperheating water to Gland Steam
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• BFPT butterfly valve sealing
• Auxiliary steam attemperator spray
• Spray water to BFPT Drip pot
• BFPT exhaust hood spray
• LP exhaust hood spray
• Vacuum tank drain pump sealing
• Chemical injection system
• Sealing water for valves (Boiler)
• Sealing water for Vacuum Pump and Vacuum breaker valve
• Water to turbine flash tanks
One tapping with inching type MOV is also provided between GSC and CPU for
start-up clean-up of condensate system.
2.2.4 Condensate from CPU outlet to deaerator level control station with
tapping to GSC recirculation & dump valve
At the outlet of the polishing unit after the tapping of excess dump valve, two
control valves (1LCA50-AA081, -AA082) are piped in parallel (2 x 100%) to
regulate the flow of condensate in the main condensate header. The valves are
controlled via the DCS based on level in the Deaerator. The Deaerator level
control is accomplished using a three-element control utilizing deaerator level,
condensate flow and feedwater flow and single element control for load upto 30%
Deaerator level control valves are provided with MOV (1LCA50AA003) with
inching control. This MOV is provided for controlling deaerator level if both the
deaerator level control valves fail and will be operated manually by the operator
through DCS.
Both the level control valves are provided with isolation valves at inlet (MOV) &
outlet (manual) and drain lines for isolation purpose.
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2.2.5 Condensate from deaerator level control station outlet to deaerator
through LP heaters
Next, the condensate flows parallel through the duplex LP Feedwater Heaters
1A/2A and 1B/2B., Outlet of both duplex heaters merged into common line and
passed through LP heater 3 and 4 in series. These feedwater heaters are shell
and tube type, with condensate flowing through the tubes. Steam is supplied to
the LP heaters from the main turbine extraction points to heat the condensate.
Motor operated inlet, outlet and bypass valves are provided for each Duplex
Heaters 1A/2A, 1B/2B and LP Heaters 3 and 4 which will permit taking the
respective heaters out of service.
Condensate leaving LP Heater 4 is routed to the Deaerator, which heats as well
as removes dissolved oxygen from the condensate. Flow transmitter is provided
at LPH 4 outlet line to measure condensate flow for deaerator level control and
also a tapping is taken for sampling line downstream of the flow element.
2.3 Major Equipment
2.3.1 Condenser & Hot-well
Condenser is used to condense the exhaust steam from LP Cylinder and the
incoming steam from the LP Bypass steam of hot reheat line after pressure
reducing and de-superheating and to produce the deepest possible vacuum in
order to maximize the heat drop and the turbine output. For maintaining the
desired condenser vacuum, the air/non-condensable is continuously removed
from condenser by vacuum pumps. It also facilitates reuse of condensate.
The condenser is a rectangular type, dual shell, double pressure, shell and tube
type, water cooled, single pass, divided water box design for each unit of 2X660
MW Jaypee Nigrie Power Project.
The cooling water design inlet temperature & temperature rise across both the
condenser is 33°C and 9.5°C respectively at 100% TG MCR, 0% MU. The
maximum velocity through the tubes should not exceed 2.2 m/sec; the tube
cleanliness factor is considered as 90%. Tube plugging margin is considered as
5%.
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The water box design pressure is 5 kg/sq.cm (g) and full vacuum. The condenser
shell (steam side) is designed for full vacuum to a maximum of 1.07 kg/cm2(g).
Hot well is a condensate collection vessel, integral with the condenser shell. The
condenser hotwell have a storage capacity of three (3) minutes of condensate
flow at TG VWO, 3% MU, CWT 33°C between normal water level and low-low
water level.
The condenser water chambers have provision for the isolation of half of the
condenser for leak detection of tubes without tripping the plant.
2.3.2 Condensate Extraction Pump
Three (3 x 50%) condensate extraction pumps (CEP) are provided for each unit.
The pump sets are vertical, can-type ring-section, multistage centrifugal type
consisting of pumps, drive, connecting coupling and can. The can is arranged in
a pit below the installation floor. The pump body is lowered into the can by
means of riser pipes.
Each pump is equipped with suction side isolation valve, suction strainer,
Expansion Joint, suction side relief valve, canister vent valve, casing discharge
vent valve, recirculation line with flow control valve; check valve, motorized
discharge valve with integral bypass valve, instruments and necessary
accessories.
Suction side isolation valve is provided with the limit switch to indicate the full
open position of the valve. Full open position of the valve is a start permissive for
the CEP.
Suction strainer of each pump is fitted with the differential pressure (dp)
transmitter to generate an alarm whenever the dp across the strainer exceeds
the preset value. The CEP should not be operated with high dp across the
suction strainer. Standby CEP will be taken into service and running CEP will be
isolated to clean the suction strainer.
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The suction piping to the pumps is vented back to the condenser, to ensure that
the non-operating pump(s) stays completely flooded. These vent lines include
manual valves on the vent for each pump.
Sealing water is provided to prevent air ingress through the condensate pump
seals. During initial start, seal water is provided from condenser make up system.
Once CEP is started, sealing water from the pump is used for the sealing.
Cooling water is provided to the cooling coil of the pump bearings, to cool the
bearing lubricating oil.
2.3.3 Gland Steam Condenser (GSC)
The gland steam condenser maintains a pressure slightly below that of the
atmosphere so as to prevent the escape of steam from the ends of the glands.
The steam and air mixture leaving the outer gland of the turbine is introduced into
a surface type gland steam condenser. The gland steam condenser has two
exhaust fans operated with A.C. motor, one of which is for stand-by.
Main component details:
(1) Gland steam condenser
Type Surface cooling
Number One (1) set
Tube material SA249-TP304
Vacuum -600 mmAq
Cooling water Condensate water
Minimum Flow 400,000 kg/hr
(2) Gland exhaust fan
Type Horizontal centrifugal
Number Two (2) sets
Head 670 mmAq
Rotating speed 2,935 rpm
Motor power 22.0 kW
Rotating speed of motor 2,935 rpm
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2.3.4 Condensate Polishing Unit (CPU)
3 X 50% (2 Working + 1 Standby) per unit Deep Bed Condensate Polisher (CP)
Units will treat the available condensate from the condensate supply header. Two
Condensate Polishers will be in Service all the time and 50% of the flow will be
diverted to standby Condensate Polisher while one goes for resin transfer/
regeneration.
When all three (3) polishers are out of service or under certain pre-set alarm
conditions such as Condensate high temperature, high differential pressure etc.
the Bypass control valve will be opened in order to maintain the appropriate flow
rate.
The system is provided with an automatic bypass valve to ensure continuity of
flow to the boiler and to protect the polisher from damage due to excessive
pressure drop, thermal excess, and from hydraulic damage during start-up of the
Condensate Feed Pumps.
The Deep Bed Condensate Polisher will be removed from Service due to high
pressure drop / reduced flow / an alarm condition resulting from poor polished
water quality, the Polisher should be removed from Service and the resins
regenerated.
The complete Condensate polishing plant package consists of the following:
UNIT #1:
1. Condensate Polisher service vessels - 3 nos. (1LDF01-BB001 / 1LDF01-
BB002 / 1LDF01-BB003)
2. Resin traps (in-place manual backwash type) - 3 nos. (1LDF01-BZ001 /
1LDF01-BZ002 / 1LDF01-BZ003)
3. Rinse Recirculation pumps - 2 nos. (1LDF01-AP001 / 1LDF01-AP002)
4. Air Blower for condensate polishers – 2 nos. (1LDC01-AN001 / 1LDC01-
AN002)
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UNIT #2:
1. Condensate Polisher service vessels - 3 nos. (2LDF01-BB001 / 2LDF01-
BB002 / 2LDF01-BB003)
2. Resin traps (in-place manual backwash type) - 3 nos. (2LDF01-BZ001 /
2LDF01-BZ002 / 2LDF01-BZ003)
3. Rinse Recirculation pumps - 2 nos. (2LDF01-AP001 / 2LDF01-AP002)
4. Air Blower for condensate polishers – 2 nos. (2LDC01-AN001 / 2LDC01-
AN002)
One (1) Common External Regeneration system consisting of:
1. Resin Separation vessel (SPT) – 1 no. (0LDP01-BB001)
2. Anion Regeneration vessel (ART) – 1 no. (0LDP02-BB001)
3. Cation Regeneration cum mixed resin storage vessel (CRT) – 1 no. (0LDP03-
BB001)
4. Air Blower for external regeneration – 2 nos. (0LDC01-AN001 / 0LDC01-AN
002)
5. Resin Hopper with Eductor – 1 no. (0LDP01-BZ001)
6. Sluice / Regeneration Water Pumps – 2 nos. (0GCK02-AP001 / 0GCK02-
AP002)
7. DM water Pumps for Resin Transfer – 2 nos. (0GCK01-AP001 / 0GCL01-
AP002)
8. Acid Unloading cum Transfer Pumps – 2 nos. (0LDN04-AP001 / 0LDN04-
AP002)
9. Bulk Acid Storage Tank- 1 no. (0LDN04-BB001)
10. Acid Measuring Tank – 1 no. (0LDN05-BB001)
11. Acid Dosing Pumps- 2 nos. (0LDN05-AP001 / 0LDN05-AP002)
12. Acid Measuring Tank for N. Pit – 1 no. (0LDN06-BB001)
13. Alkali Unloading cum Transfer Pumps – 2 nos. (0LDN01-AP001 / 0LDN01-
AP002)
14. Bulk Alkali Storage Tank- 1 no. (0LDN01-BB001)
15. Activated Carbon Filter for Alkali- 1 no. (0LDN01-BB002)
16. Alkali Measuring Tank – 1 no. (0LDN02-BB001)
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17. Alkali Dosing Pumps- 2 nos. (0LDN02-AP001 / 0LDN02-AP002)
18. Alkali Measuring Tank for N. Pit – 1 no. (0LDN03-BB001)
19. Dilution water heater for regeneration of Anion Resins (HWT) - 1 no. with 3
nos. electric heating elements (0LDP04-BB001)
20. Neutralized Effluent Waste Water Transfer Pumps – 2 nos. (0LDR01-AP001 /
0LDR01-AP002)
21. Waste water effluent collection Neutralization Pit (Two compartments) by
others (0LDR01-BB001)
22. Isolation Gate (FRP) for Neutralization pit – 2 nos. (0LDR01-BZ001 /
0LDR01-BZ002)
23. Safety Shower (with eye wash fountain) - 1 no. (0GKB01- BZ001)
24. Programmable Logic Control (PLC) Common for CPP package- 1 no. (0LDN-
GH001)
25. Resin charges – First fill of resin for all condensate polisher Mixed Beds,
Mixed resin storage vessel and resin injection hopper.
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2.3.4.1 SYSTEM /COMPONENT DESCRIPTION
A. Condensate Polisher System
The Deep Bed Condensate Polishing System consists of Condensate Polishers
and an External Regeneration System, and is designed to treat a design flow of
1950 m3/hr of condensate per unit. The system includes three (3) x 50% - 2w +
1s per unit capacity Mixed Bed Condensate Polishers with resin traps and
associated valves instrumentation and piping.
Common external regeneration system (common for two units) is provided.
External Regeneration System includes three (3) process-specific pressure
vessels, support systems to supply acid and caustic for regeneration, piping,
associated valves and instrumentation. Demin Water transfer pumps to provide
water flows required for resin transfer and regeneration processes are included.
In normal operation, condensate enters Condensate Polishing System at 1950
m3/hr flow (max.) and passes through a common condensate inlet header. Three
(3) Condensate Polisher pressure vessels are connected in parallel. Each
spherical polisher vessels is 3400 mm in diameter, fabricated of rubber-lined
carbon steel to a design pressure of 43 kg/cm2(a), charged with condensate
grade mixed bed cation and anion resin. Two polishers are normally in service,
each processing 50% of system flow (975m3/hr). The incoming condensate
enters top of spherical vessel, flows down through mixed resin bed and exits
through bottom of vessel. As it passes through resin, cationic and anionic
impurities in condensate are exchanged with hydrogen and hydroxide ions
present on resin beds, removing these impurities from the water and binding
them onto resin. The resin bed also filters suspended solids (Crud). The size of
suspended solids particles is considered to be >75 micron. A resin trap on outlet
of polisher vessel ensures that no resin particles get carried away into treated
condensate exiting the system. Resin trap is having a provision of manual back
flushing facility to remove the trapped resin particles in order to reduce the
pressure drop. The manual back flushing should be done periodically by the
operator based on the indication of differential pressure across the resin trap.
Condensate polisher unit is designed for pressure drop of 2.0 kg/cm2 max under
the clean condition across the inlet & outlet flanges including pressure drop due
to entrance & exit nozzles, distributors, under drain nozzles, resins, effluent resin
trap. & 3.3 kg/cm2 max under the clogged condition across the inlet & outlet
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flanges including pressure drop due to entrance & exit nozzles, distributors,
under drain nozzles, resins, effluent resin trap.
Each polisher is monitored for pressure and flow at the inlet and for resin trap
differential pressure on the outlet. Each polisher outlet is also monitored for pH,
specific conductivity, cation conductivity, silica content and sodium content. The
system feed condensate inlet header is monitored for Specific Conductivity, pH,
flow, temperature. The full system is also monitored for differential pressure. A
bypass line, with pneumatically actuated butterfly modulating control (inching)
wafer type valve sized for the full system flow, provides a direct connection
between the condensate inlet and outlet headers. In normal service, this valve is
closed, directing the full flow of system through two Condensate Polishers in
service.
The condition, or exhaustion, of the resin in an individual polisher vessel is
monitored (as noted above) by a series of instruments at inlet and outlet of
polisher / common header. Throughput, pH, specific conductivity, silica, sodium
and cation conductivity are monitored to ensure quality of polisher effluent. When
most of the resin in polisher vessel is exhausted and can no longer remove ionic
impurities from condensate, it must be chemically regenerated to strip impurities
from resin beads and replace hydrogen cation and hydroxide anion that were
exchanged in service. This process is accomplished in an external Regeneration
System that is connected to, and services, all of the condensate polisher vessels.
B. Regeneration System
The External Regeneration System contains three (3) vessels used to separate
and process the exhausted resins and to mix and rinse the regenerated resins.
These vessels are the Separation Tank (SPT), Anion Regeneration Tank (ART),
and Cation Regeneration cum mixed resin storage Tank (CRT). Regeneration
System also utilizes DM water for separating, scrubbing, and transferring the
resin. Separate DM water transfer pumps are provided for regenerant dilution
and resin transfer. Acid measuring & dosing system supplies dilute acid (HCl) to
CRT. Caustic measuring & dosing system along with Hot Water System supplies
dilute hot caustic (NaOH) to ART. Resin hopper system with eductor helps to add
resin into the system when necessary.
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When instruments monitoring the outlet of a polisher indicate end of service cycle
run, resin in the polisher would require regeneration and this condition is
indicated on screen in PLC control room which will be located in External
regeneration facility. The operator then initiates a sequence of events to transfer
& regenerate the resin of the specific polisher. Before the exhausted polisher can
be taken out of service for regeneration, the particular polisher inlet valve must
be closed and the inlet valve of standby polisher will be opened. This avoids a
disruption in processing that would initiate bypass flow and reduce the
effectiveness of the system. In Offline Mode, the unit's automatic Vent Valve is
opened to depressurize the vessel. When the appropriate set point (less than 4
bar) is achieved; the unit will undergo resin transfer to prepare it for a return to
service.
Following a specific sequence, water from DM Water Pump for resin transfer and
high pressure air are used both separately and together to transfer the exhausted
resin from the polisher to the Separation Tank in the Regeneration System. After
depressurization, in the next step for resin transfer, service air is introduced in
the bottom of the polisher vessel, followed by transfer with both air (through
bottom) and sluice water through bottom plate sluice inlet. The above steps are
repeated once more sequentially. When the transfer is complete, the polisher
vessel is drained and the transfer lines are flushed with water from the DM
Regeneration pump. The exhausted resin that has been transferred to the
Separation Tank must be separated into its cation and anion resin components
before these resins can be regenerated. It is critical that the separation of the
resins be as complete as possible. The separated anion resin is hydro-
pneumatically transferred to the Anion Regeneration Tank from a nozzle in the
side of the SPT vessel. The cation resin is then hydro-pneumatically transferred
to the Cation Regeneration cum mixed resin storage Tank from the bottom of the
SPT tank. The interface resin is left in the SPT tank in preparation for the next
polisher regeneration. Siemens Fullsep external regeneration system is designed
to restrict the resin cross-contamination after separation to <0.1%. Prior to
chemical regeneration, the resins in each tank are 'scrubbed' with air from the
Low pressure air blower and water provided by the DM Regeneration Pump for
resin transfer to loosen and remove suspended solids, or 'crud' that has been
deposited on the beads during the service run. Following the scrubbing, the
resins are chemically treated to replace the ionic impurities bound to the beads
with new supply of hydrogen and hydroxide ions. In the ART, the anion resin is
regenerated with a dilute solution of sodium hydroxide. In the CRT, the cation
resin is regenerated using a dilute solution of Hydrochloric acid. The dilute
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regeneration solutions are supplied through the Acid Mixing Tee and the Caustic
Mixing Tee.
During regeneration, the acid is drawn from the Hydrochloric acid measuring tank
by an Acid Dosing Pump and mixed with DM water to the desired dilution (set by
design at 5% concentration) before flowing into the CRT. Similarly, the caustic is
drawn from the Alkali measuring tank by an Alkali Dosing Pump and mixed with
heated water to the required dilution (set by design at 4% concentration) and
temperature before flowing into the ART. DM water is raised to the needed
temperature in hot water caustic dilution tank. The regeneration wastewater from
each regeneration tank, with its chemical waste and added impurities, is directed
through gravity drain trenches (in RCC construction by others) to the
neutralization pit (in RCC construction by others).
C. Hot Water Tank Operational Philosophy:
In hot water tank, there is one Temperature transmitter provided to control the
temperature of water which is coming out from the hot water tank. Finally upon
mixing of hot water (at 70 ºC) from hot water tank and incoming cooler DM water
(at 10 ºC) mix together we will achieve warm water. Provision of control valve at
upstream of caustic mixing tee will ensure proper power water flow and the
timings on PLC program together will ensure required water volume at 49 ºC
temperature as required.
Location of temperature transmitter after the caustic mixing tee will take into
account the temperature variations due to mixing of hot water & DM water
(thereby called as warm water) as well as heat of dilution of caustic with warm
water.
Three-way temperature control valve will automatically control the proportion in
which these two waters (cold water and hot water) mix with each other, to obtain
desired 49 ºC (warm water required for regeneration) temperature based on the
signal from temperature transmitter which is located after the caustic mixing tee.
When regeneration of both resins is complete, the anion resin is transferred
hydro pneumatically from the ART to the CRT, where it is mixed with the (already
backwashed and rinsed) cation resin by using low pressure air from twin lobe air
blower and rinsed. The mix of regenerated resins is then stored in the CRT
before it is transferred into the empty polisher vessel. If replacement resin is
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needed during the regeneration sequence, fresh resin from a drum can be added
to the charge in the ART or CRT under manual control through the Resin hopper.
DM water is directed through an Eductor to draw the resin and transfer it to the
appropriate vessel through a set of dedicated manual valves.
The External Regeneration System can also be used to scrub and rinse the
transferred resins, without the process of chemical regeneration if the
condensate polisher resin bed is clogged with crud.
DM water is drawn from a demineralization Storage Tank (by others). DM water
is provided by purchaser at the suction of the DM regeneration water pumps.
D. Neutralization System
The waste water generated during regeneration of mixed bed columns is either
acidic or alkaline in nature and it is collected through drain trenches into an
underground neutralization pit. The neutralization of this waste will be done by
either acid (or) alkali addition through separate measuring tanks provided for the
purpose. The neutralized regeneration effluent will be pumped by separate
neutralized effluent pumps (2 x 100%)
The detailed description of the Neutralization Philosophy is provided below:
E. Neutralization pumps control & operation philosophy:
Before transferring neutralized effluent to disposal, adequate amount of alkali will
be added in waste water effluent. & then waste water will be re-circulated by
neutralization pump in pit. The Pit level will be monitored by level transmitter in
neutralization pit. pH of recirculated effluent waste water will be monitored by pH
transmitter.
Based on the pH value monitored, either diluted caustic will be injected in the
neutralization pit or aeration will be done by low pressure air from blower
(common for external regeneration facility) through distributor header for
neutralization. Once pH value reaches the required set point (6.5 to 7.5), the
discharge valve is opened and the recirculation valve will be closed & then the
neutralized water will be discharged out to dispose by discharge pump. In
general, if pH is less than 7, dilute caustic will be dosed into the tank and if pH
valve more than 8, dilute acid will be dosed into the tank.
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F. Rinse Recycle Operational Philosophy:
Once the resin transfer step from polisher to SPT is completed, the fresh or
regenerated resin which is stored after regeneration in CRT will be transferred
hydro pneumatically to respective polisher vessel. Once the regenerated resin is
transferred to the polisher, the whole resin bed is thoroughly rinsed in order to
achieve the treated condensate quality for about 10mins at the flow of 515m3/hr.
The rinse recycle outlet water will be routed to main condensate inlet header
through Rinse Recycle Pump. Rinse outlet water quality is monitored with
conductivity transmitter. Once the treated condensate quality is achieved, the
polisher service outlet valve will open followed by rinse recycle valve being
closed and this will be through the PLC. There steps for rinse recycling sequence
are listed below,
1. Pressurize polisher (Open the small inlet valve for about 3 min to pressurize
the polisher prior to open the service inlet valve to avoid the mechanical
damage to the internals)
2. Pressurize recycle header (Recycle header will be pressurized during this
step)
3. Open Inlet valve (Once the rinse recycle header is pressurized, service inlet
valve will open)
4. Rinse recycle (Rinse recycle outlet will be opened after few minutes the
service inlet valve is opened. Rinse outlet conductivity should be monitored
for 10 min. Once the rinse outlet conductivity is achieved, polisher outlet valve
will open followed by rinse outlet valve closing and then polisher is in service
mode) & CP vessel will be placed in service. If rinse outlet conductivity is not
achieved then it will continued for second rinse recirculation.
2.3.5 LP Heaters
Total four (4) Nos. of LP heaters are provided in the condensate path from the
CEP discharge to deaerator inlet. It includes two (2) Nos. of duplex neck-
mounted heaters (LPH – 1A/2A and LPH – 1B/2B) & two (2) Nos. of single unit
heaters (LPH - 3 and LPH - 4).
All heaters are two zone, horizontal, U-tube shell type heaters. Each has a
removable shell.
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The extraction steam from the LP turbine heats the condensate water flowing to
deaerator. Extraction steam from turbine is entered on the shell side of the unit.
Extraction heat from this exit heats the condensate on the tube side of the unit.
The condensate has two passes on this side.
Outer shell is circumferentially welded onto the skirt which is integral with the
tube sheet. Hoop rings are tack welded to shell outer surface on either side of the
parting line. They act as guide while the shell is being cut.
A Flame Protection Band made of stainless steel is provided behind the welded
joint. This band provides protection to tubes during disassembly as well as re-
welding operations.
There is provision of all-welded closure for channel, with a flanged type access
opening.
A. Duplex heater
The duplex heater is assembled by combining LP1 and LP2 in the shell side. A
divider plate is provided to separate the steam sides of LP1 and LP2.
Two nozzles are provided on the channel side: the bottom half has the
condensate inlet nozzle of LP1, while the top half has the condensate outlet
nozzle of LP2. The duplex heater is mounted inside the condenser neck.
B. Tube bundles
They are divided into two distinct zones on the shell side.
i. Condensing zone
The tubes are separated by carbon steel plates. This helps prevent sagging
and protects against flow induced vibrations.
Steel plates (16 THK) are welded to the support plates to facilitate easy shell
removal.
Steam gets fully condensed in this zone.
ii. Drains cooling zone
The drains cooling zone is of full pass type, where an enveloped shell
encloses all tubes. This shell extends for part the length of the tube.
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Drains are sub-cooled in this zone by two methods. The tubes are flooded
with condensate, and baffles are provided to create high mass velocities
which help in better heat transfer.
Saturated condensate enters through an inlet protruding from the bottom of
the DC zone. Here it gets further sub-cooled. The inlet of this nozzle must
always be immersed in water in order to prevent steam from entering the
zone.
A. Vents and drains
These facilitate start-up, shutdown and trouble-free operation.
Continuous venting of about 0.5% steam is provided. This helps clean all the
non-condensable on the shell side of the heater, and thus helps achieve
maximum thermal efficiency.
B. Parameters governing heater design
i. Terminal temperature difference (TTD)
Terminal temperature difference is defined as the difference between
saturation temperature corresponding to inlet extraction steam pressure, and
the outlet condensate temperature.
For all LP heaters, terminal temperature difference to be 2.8°C.
ii. Drains cooler approach (DCA)
It is defined as the temperature difference between drains leaving the shell
side of the heater, and the condensate entering the tube side.
For all LP heaters, the DCA value is 5.6°C.
iii. Tube side pressure drop
It is the pressure drop due to frictional losses in the tubes and channels.
It has the following values:
For LP3: < 0.55 kg cm-2
For LP4: < 0.65 kg cm-2
For LP1 and LP2: < 0.6 kg cm-2
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3.0 NORMAL OPERATION, START-UP AND
SHUTDOWN
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Chapter 3
Normal Operation, Start-up and Shutdown
3.1 Start-up and initial fill
3.1.1 Initial Fill
The condensate storage tank will provide the initial fill for the condensate system.
The normal make-up control valves will be used to fill the condenser hotwells.
Alternatively, higher capacity quick fill control valves can be used.
Initial system fill of condensate system will be performed by use of one
condensate pump. A motor operated bypass valve of main condensate pump’s
discharge valve is provided to allow a controlled start of a condensate pump. The
pump will run with motor operated bypass valve open to complete system fill up
to the Deaerator Level Control Valves’ inlets. Upon completion of filling the
condensate pipe up to the Deaerator Level Control Valves’ inlets, the piping to
the Deaerator will be filled by partially opening the Deaerator Level Control
Valve. During initial fill all the high point vent valves shall be kept open to vent
any trapped air into atmosphere.
3.1.2 Start-Up
A. Condensate System Preparation
Prior to start-up of the condensate system and condensate pumps, all
condensate pump suction isolation valves corresponding to the pump, should be
in the open position. The pump discharge motor operated valves should be in
the closed position for the first pump starting. For second pump & standby pump
starting, the discharge motor operated valves should be kept in open position.
CEP supplier’s O&M manual should also be adhered to with regards to the
preparation of CEP for start-up. The deaerator level control valves should be
placed in manual operation in the closed position. The condensate polisher skid
should be bypassed by opening the bypass valve and closing the inlet and outlet
isolation valves.
The feedwater heater bypass valves should be in the open position & heaters
inlet and outlet motor-operated isolation valves in closed position so that
condensate flow can be established before placing the heaters in service. The
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channel (tube) side vent valves should be open along with any high point vents
in the condensate piping between the heater bypass and isolation valves.
The condensate system minimum flow individual recirculation valves should be
in auto to maintain operation at flows above the minimum continuous stable flow
for each pump in operation. The condensate pumps should never be operated at
shutoff conditions to avoid damage as per the manufacturer’s recommendations.
When the gland steam condenser is required, the GSC recirculation control
valve maintain a minimum flow through the condensate system which is
adequate to serve as the cold temperature sink for the gland steam condenser
in accordance with manufacturer’s recommendations.
Upon start-up, seal water is provided from the condensate make-up system to
prevent air ingress through the condensate pump seals.
Once all valves have been placed in the correct position and all start
permissives have been achieved, one (1) condensate pump should be started.
After the pump has attained a stable flow condition through the minimum flow
recirculation valve, the condensate polisher may be placed in service. Refer
Condensate Polisher Unit O&M manual (Volume 2, SWTL-P0-00106) in for
further details.
B. Condensate System Warm-Up Operation
When desired, the deaerator level control valves can be opened in manual
mode to allow condensate flow to the deaerator for condensate system warm-
up. For condensate system warm-up operation, the proper throttle and block
valves must be opened to allow controlled drainage of condensate from the
deaerator to the condensate storage tank.
During this operation, the water temperature of the condensate storage tanks
should be monitored and maintained below the maximum allowable working
temperature of the tank. In addition, the temperature of the condensate flowing
through the condensate polisher must not exceed the limits established by the
polishing equipment supplier. If higher temperatures are expected, the polisher
must be put in bypass mode until the condensate temperature drops to within
the allowable temperature range.
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C. Condensate System Operation
After condensate flow to the deaerator has been established, the tube-side of
the LP heaters will be placed in service in sequential order. The motor-operated
integral valve on the motor-operated inlet isolation valve should be opened prior
to opening the main isolation valve. Then, the motor-operated integral valve on
the motor-operated isolation valve downstream of each LP heater should first be
opened to allow filling/pressure equalization of the heaters and associated
piping. Once all air has been evacuated from the heaters and piping, vent valves
should be closed and the isolation valve downstream of the respective heater
should be opened.
After condensate flow through the tube side of the LP heaters has been
established, flow is admitted to the shell side of the LP heaters when the
extraction steam system is ready. For details on shell side LP heater start-up
procedure, refer LP Heaters Vendor Installation and Operation Manual (Volume
2, LT-M0-03054) as well as extraction steam system O&M manual (Section D,
Volume 1).
The deaerator water level is initially controlled manually by the operator. Based
on operator experience, the deaerator level control valves should be switched to
auto once the plant condensate requirements are sufficient for demand following
operation. The CEP and GSC recirculation control valves (in auto) close as the
condensate flow to the deaerator becomes sufficient to maintain the condensate
pumps above their minimum continuous stable flow requirements.
As soon as condensate demand is high enough, the pump discharge motor
operated valves for the remaining pumps should be opened. A second pump
should be started with the third placed in active stand-by.
Manufacturer recommendations should be strictly adhered to with regard to
start-up sequence. For details, refer manufacturer information for Condensate
Extraction Pumps, Feedwater Heaters, and Condensate Polishing Equipment.
3.2 Normal operation
Steam exhausted from each of the low-pressure turbine stages enters the two
condensers, which consists of two shells having steam space and hot well cross
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connections. Condensate from the hot well flows to a header, which allows the
condensate to be pumped out of both hot wells by any combination of the 3X50%
condensate pumps. Each pump is provided with a strainer installed in the suction
piping. During normal operation, two condensate pumps operate with one in
active standby. If an operating pump trips, the standby pump will start up
automatically. If the condensate level drops below the minimum hot well level, it
will trip all operating pumps. Additionally, low level will be a start inhibit if no
pumps are running. (Pump trip due to low hot well level will override standby
pump start.) The minimum flow requirement of each condensate pumps is
maintained by its individual recirculation flow control valve. Each pump is
provided with a strainer permanently installed in the suction piping.
The gland steam condenser is the first heat exchanger after the condensate
pumps discharge to a common header. The condensate absorbs heat as it flows
through this heat exchanger which condenses the turbine gland leak-off steam.
At low unit loads, a portion of the condensate flow downstream from the gland
steam condenser and CPU is recirculated to the condenser. This recirculation is
regulated by a control valve to ensure adequate flow through the gland steam
heat exchanger is maintained. The condensate passes through polishers after
leaving the gland steam condenser for removal of dissolved and suspended
solids.
Two control valves (1LCA50-AA081, 1LCA50-AA082) piped in parallel (2 x
100%) regulate the flow of condensate in the main condensate header. The
valves are controlled via the DCS based on level in the deaerator. The Deaerator
level control is accomplished using a three-element control (above 30% load)
which utilizes deaerator level, condensate flow and feed water flow. For load upto
30%, single element level (from triple redundant level transmitters) control will be
used for controlling deaerator level.
Next, the condensate flows through the LP Feedwater Heaters 1, 2, 3 and 4 in
series. These feedwater heaters are shell and tube type, with condensate flowing
through the tubes. Steam is supplied to the heaters from the main turbine
extraction points to heat the condensate.
A bypass is provided around each Duplex LP Heaters 1A/2A, 1B/2B and Heaters
3 and 4 which will permit taking the respective heaters out of service.
Condensate leaving LP Heater 4 is routed to the Deaerator. Oxygen, hydrazine
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and ammonia are injected into the condensate piping after the condensate
polisher. In some cases Oxygen or hydrazine are also injected at the Deaerator
outlet (Please refer Feedwater System Operation Manual – Volume 1, Section
B).
Makeup to the condenser is required to replace water loss from the plant cycle.
Makeup water maintains the condenser hot well storage level during unit load
increases and ensures that the condensate pump suction head requirements are
met. Makeup water from the condensate storage tank enters the Condenser
(high pressure shell) through the normal makeup control valve (1GHC10-AA081),
& goes to low pressure shell through the condenser hot well equalizing line. This
normal level control valve is positioned by the DCS based upon the level sensed
by redundant condenser hot well level transmitters.
When the condenser hot well level drops below the normal operating range, the
DCS will control the level control valve to increase the makeup water flow and
thereby maintains the required condensate level in the hot well. The normal
make-up is sized for 3% TGVWO flow and emergency make-up/quick fill for 25%
BMCR flow.
3.3 Normal shutdown
Normal condensate system shutdown occurs after the boiler feed pumps have
been tripped and feedwater demand has ceased. As the required condensate
flow demand to maintain water level in the deaerator at safe levels decreases,
the condensate pumps will be tripped in succession. Care should be taken to
ensure that shutoff or run out conditions are not experienced during plant
shutdown. Condensate flow should be maintained through the feedwater heaters
and other condensate equipment until the equipment has cooled sufficiently for
safe shutdown without undue stress and damage. The condensate make-up
system should be maintained in auto until all demineralized water demands have
ceased.
3.4 Checklist
3.4.1 Before CEP Start – up
• Ensure cancellation of any work permit issued for CEP.
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DANGER
Strictly follow the work permit system to avoid unacceptable
troubles or danger.
• Ensure that the power supply is available from the feeder.
• Make sure all interlocks and protections test of CEP are qualified.
• All related instruments are mounted and properly fitted.
• Ensure availability of instrument air supply.
• Ensure cooling water supply line is charged and isolating valves are open.
• Ensure sealing water line to the CEP is lined up and isolating valves are
open and sealing pressure is adequate
• Ensure lubricating oil level is above the low level.
• Ensure the suction line drain, suction filter drain are closed.
• Isolation valves on vent lines, recirculation line and all instrument tapings
are open.
• Open Air vents of suction strainer, pump suction and pump discharge
(solenoid operated); close them after venting.
• Hot well level is adequate and its level control valves are lined up.
3.4.2 CEP Running
• Check the pump for current, pressure, abnormal sound, vibrations etc.
• Check the oil level.
• Check the differential pressure across suction strainer.
DANGER
Operator must change over the CEP in operation to Standby
whenever running CEP suction strainer differential pressure
high alarm appears. After changeover, clogged strainer
should be cleaned.
• Check the bearing temperature, cooling water temperature etc.
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• Check the various parameters are within the range.
CAUTION
Ensure control parameters (pressure, temperature, flow, level
etc.) are controlled as specified
• Check the motor casing temperature.
• Ensure sealing water to the pump is charged over from the DM transfer /
condensate transfer pump to the CEP itself.
• Closure of the pump discharge side solenoid operated vent valve.
• No leakage through the pump gland packing.
3.4.3 Stopping CEP
• After stopping the unit, ensure no demand of Condensate water for the unit.
• Ensure LP exhaust temperature to each condenser is less than 50 0C.
• Change standby pump to manual mode from AUTO.
• Stop the running CEP and ensure closure of its discharge MOV.
• Ensure pump does not rotate in reverse direction after pump is stopped.
3.4.4 Switching Over CEP
• Make sure all check points listed in 3.4.1 above are checked for the standby
pump.
• Ensure start permissions are available for the standby pump.
• Change standby pump to manual mode from Auto
• Start the standby CEP and ensure opening of the discharge MOV. Also,
check the satisfactory operation of recirculation valve
• Check and make sure that the pump current, discharge pressure, sound,
vibrations, level, motor and pump bearing temperatures, gland leakage etc.
are normal and within acceptable limits.
• Ensure the Pump running signal on DCS is right.
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• Stop the former running pump intended to be stopped and ensure the
closure of the discharge MOV.
• Ensure the CEP common discharge header pressure is normal.
• Ensure start permissive of the pump is available and put the stopped pump
in Auto Standby mode, if desired.
• If CEP is to be isolated for maintenance, close its discharge valves, suction
valve, vent valve sealing water valve from the pump as well as from the DM
transfer / condensate transfer pump etc. Open the suction side and canister
drain valve, if required.
• Any kind of mechanical isolation of the respective CEP should be carried
out only after ensuring the electrical isolation of the same. For electrical
isolation, the associated circuit breaker should be kept in OFF position and
breaker will be racked out.
3.4.5 Charging Condensate System
CAUTION
Do not operate valves without proper authorization such as
work permit, as unauthorized operation may lead to serious
injury and damage to the equipment.
• Ensure cancellation of any work permit issued for carrying out maintenance
on the condensate system.
• Ensure all high point vents are open and closure of the same after charging.
• Ensure CPU bypass Pneumatic operated butterfly valve, LP heaters bypass
valves are open.
• Ensure GSC minimum recirculation control valve is lined up and on Auto.
• Ensure deaerator level control station is lined up and control valves are kept
on manual for initial charging.
• Condensate side vents on GSC are kept open for priming.
• All Locked Open (LO) valves as indicated in the P&ID of condensate system
are open.
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• Start CEP in recirculation and ensure opening of its discharge MOV bypass
valve. The condensate system will be charged gradually to inlet of
Deaerator level control station.
• CEP discharge MOV is opened fully and condensate system will be
operated in recirculation through the GSC minimum recirculation valve.
• When condensate water quality is acceptable, line up the deaerator level
control station to put into operation and manually operate the either of the
level control valve to supply condensate to the deaerator.
• Make sure the condensate header pressure remain above the low level.
• When desired, charge the LP heaters from condensate side. Ensure priming
of each LP heaters and close the bypass valve only after opening of inlet
and outlet valve of each LP heaters.
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4.0 EMERGENCY OPERATION AND
ALARMS
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Chapter 4
Emergency Operation and Alarms
4.1 Emergency Operation
4.1.1 Loss of a Condensate Pump
If a condensate pump is tripped or taken out of service for maintenance, full load
plant operation is maintained by the two (2) remaining pumps. However, if the
standby Condensate pump is under maintenance and one out of two running
pump trips, runback will be initiated to bring unit load to 50%. Please refer
Section on “Emergency Situations” of O&M manual in Volume 1 for details on the
runback. The deaerator and hot well levels are to be maintained carefully during
this period.
4.1.2 Condensate Pump Recirculation
At start-up and low plant loads where the condensate demand to maintain
deaerator water level is below the minimum flow for the pump in operation,
recirculation of the additional flow to maintain the pump above their minimum
continuous stable flow limits is required. This is maintained by the condensate
pump individual recirculation control valves.
4.1.3 Gland Steam Condenser Recirculation
At low plant loads where the condensate demand to maintain deaerator water
level is below the minimum flow for the gland steam condenser, recirculation of
the additional flow to maintain the gland steam condenser above their minimum
continuous stable flow limits is required. This is maintained by the GSC
recirculation control valve.
4.1.4 Turbine Water Induction Prevention (TWIP) Events
Due to excessive tube leaks or improper drain operation, the LP heaters may
flood with operating water levels exceeding the high-high alarm limit. To prevent
water from entering the turbine through the extraction piping, the LP heaters are
automatically isolated and bypassed. The extraction steam lines are also
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automatically isolated and drained. This will be further elaborated in the
extraction steam system description for details regarding to TWIP events.
4.1.5 Removing LP Heater from Operation
To manually remove a heater from service (does not apply to Turbine Water
Induction Prevention events), the extraction steam isolation valves should be
closed to prevent admission of steam to the shell side of the heater. Condensate
flow through the tube side of the heaters should be maintained until the unit has
cooled and reached steady state. The heater bypass valves and the isolation
valve will be actuated accordingly.
If inspection or maintenance of the heater is required, all valves in normal
operating vent and drain lines should be closed. Atmospheric vent valves should
be opened. Manual drain valves on shell side and tube side have to be opened to
completely drain the heaters. Further, please refer heater supplier’s Installation
and Operation Manual (Volume 2, LT-M0-03054) for details on preparing the
heaters for maintenance.
4.1.6 Returning LP Heater to Operation
To return a LP heater to service, the same procedure for initial plant start-up
should be followed.
4.1.7 Abnormal Deaerator Water Levels
At high levels the GSC minimum recirculation valve opens to drain condensate to
the condenser so that the deaerator inlet condensate flow can be reduced.
At low condensate levels in the deaerator, condensate flow is increased through
the deaerator level control valves. If water levels continue to drop to unsafe
levels, the boiler feed pumps must be tripped to avoid damage associated with
dry running.
4.1.8 Abnormal Condenser Hotwell Water Levels
At low water levels in the condenser hotwell, the condensate make-up system
provides make-up water from two (2) condensate transfer pumps through the
emergency make-up control valves. During this process the emergency make-up
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control valve starts opening & simultaneously the normal make-up control valve
will start closing.
For high water levels in the hotwell, condensate make-up control valves will
close. If water level continues to rise, the condensate overflow control valve
opens to dump water from the system to condensate storage tank.
4.1.9 Loss of Power or Instrument Air
Upon loss of power or instrument air to any component, the component fails in
place or to its designed safe position.
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4.2 Alarms
CAUTION
Operator must take appropriate corrective action, if any of the
alarms mentioned below appears. Continuous operation without
corrective action may lead to the tripping of equipment and may
lead to the possible damage to the equipment.
The Condensate System alarms can be monitored from the DCS operator
interface console alarm graphic display.
The following system conditions are alarmed through the DCS
Condenser Hotwell Level Hi
Condenser Hotwell Level Hi-Hi
Condenser Hotwell Level Low
Condenser Hotwell Level Low-Low
LP Condenser Pressure Hi
HP Condenser Pressure Hi
CEP Suction Strainer DP Hi
CEP Discharge Pressure Low
CEP Discharge Pressure Hi
CEP Common Discharge Header Pressure Low
CEP Reverse Rotation Switch Activated
CEP Suction Manual Valve Close
CEP motor R-phase Winding Temperature Hi
CEP motor R-phase Winding Temperature Hi-Hi
CEP motor Y-phase Winding Temperature Hi
CEP motor Y-phase Winding Temperature Hi-Hi
CEP motor B-phase Winding Temperature Hi
CEP motor B-phase Winding Temperature Hi-Hi
CEP Thrust Bearing Temperature Hi
CEP Thrust Bearing temperature Hi-Hi
CEP Radial Bearing Temperature Hi
CEP Radial Bearing temperature Hi-Hi
CEP Motor DE Bearing temperature Hi
CEP Motor DE Bearing Temperature Hi-Hi
CEP Motor NDE Bearing temperature Hi
CEP Motor NDE Bearing Temperature Hi-Hi
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CEP Casing Vibration Hi
CEP Casing Vibration Hi-Hi
CEP Motor Casing Vibration Hi
CEP Motor Casing Vibration Hi-Hi
CEP Emergency Push Button Operated
CEP Overload Trip & Alarm
CEP Electric Trip
All Three(3) CEPs are Running
The following information will be provided on the control room display on the CRT
as a function of the DCS.
Make-up Control Valve Status (0-100%)
Emergency Make-up Control Valve Status (0-100%)
Condenser Hotwell Blow Valve Status (OPEN/CLOSE)
CEP Status (ON/OFF)
CEP Start Permissive Not Available
Condenser Hotwell Level HP & LP Shells
Condenser Hotwell Temperature
Condenser Hotwell Conductivity
Condensate Header Pressure
Condenser HP & LP shell Vacuum
Polisher System Inlet/Outlet Valve Status (OPEN/CLOSE)
Polisher System Bypass Valve Status (OPEN/CLOSE)
ALL MOV Status (OPEN/CLOSE)
Condensate Pump Motor Bearing Temperature
Condensate Pump Motor Amperes
Condensate Pump Motor Winding Temperature
Deaerator Level Control Valve and Bypass Valve Position (0-100%)
Condensate Temperature Leaving the Deaerator
Condensate Recirculation Valve Position (0-100%)
Turbine Exhaust Hood Spray Control Valve Status (OPEN/CLOSE)
(to be implemented in the Turbine Control System (TCS). For details, refer
system description for steam turbine)
Condensate Flow to the Deaerator Measured by calibrated orifice
Condensate Flow at pump discharge as well as Deaerator inlet
Deaerator overflow valve status
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pH, conductivity, Na+ concentration & silica at condensate pump
discharge and CPU outlet
Oxygen at deaerator outlet
GSC minimum recirculation valve status
Individual CEP flow & minimum recirculation valve status
Curtain Spray Valve status
Cooling water inlet & outlet temperature
CW inlet/outlet valve position
4.3 Cause & Effect Table
Cause Effect Action
1 Trip of one Condensate Pump
1. Standby pump Identify and eliminate the cause
will start on Auto of the tripping. Put the tripped
and Unit can be pump on Auto after ensuring
run at full load availability of all start permissive.
1. Reduce the unit load; ensure
the parameters of the boiler,
turbine and auxiliaries remains
within normal range in
accordance to the load. Ensure
satisfactory operation of the unit
Any Condition as at part load.
listed in Chapter 7 for 2. If, standby pump 2. Carefully maintain deaerator
CEP Trip is under and hot well level within operating
maintenance, range.
deaerator and hot 3. Identify and eliminate the
well level gets cause of the tripping and put the
disturbed. tripped pump into service. Bring
back unit to the full load.
4. If tripped pump could not be
normalized, verify whether pump
under maintenance could be
taken back into operation. Put it
into service and bring back unit to
the full load operation.
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Cause Effect Action
2 Turbine Trip
1. Check the status of the
standby pump and ensure the
CEPs are run normally.
2. Take deaerator control valves
on manual and regulate
condensate supply to deaerator
as required.
3. Ensure make up to the hotwell
1. Sudden opening
through normal as well as
of Spray water
emergency control valves. Also,
valve to LP bypass
for time being reduce the
attemperation,
condensate to deaerator to
curtain spray water
prevent hotwell level reaching to
valve etc. increase
low-low level.
the condensate
Actuation of any 4. Ensure operation of GSC
demand and
turbine protection minimum recirculation valve and
condensate header
CEP minimum recirculation valve,
pressure low may
if the flow reaches below the set
be actuated.
values.
2. Increase in
5. Maintain level in deaerator and
deaerator level
hotwell around normal level and
3. Decrease in
control it while turbine rolling and
Hotwell level
loading.
6. If turbine could not be restarted
and unit is required to be shut
down for longer period, stop CEP
one after another as per
condensate demand. (Refer
Chapter 3 for the Shutdown
procedure)
3 Turbine Water Induction Prevention (TWIP) Events
1. Opening of 1. When heater level high alarm
Emergency drain appears, check the operation of
1. Tube leakage in control valve on drain control valve and
any Heater heater level high. emergency drain control valve.
2. Mal operation of 2. Respective Also, check the operation of next
respective heater heater gets higher pressure drain control
drain control valve bypassed from valve for abnormal increase in the
3. Mal operation of extraction steam valve PI. If any abnormality
next higher pressure and water side on noticed, try to control the heater
heater drain control Heater level high - level by taking the respective
valve high. For heaters valve on manual.
provided in the 2. If, heater level high - high
condenser neck alarm is noticed, ensure
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Cause Effect Action
receiving the respective heater gets bypassed
cascading drain of from steam as well as water side.
next higher Open the respective heaters drain
pressure heater, valves to empty water from the
the drain valve heater. Check the turbovisory
gets closed. parameters and ensure no undue
variations. Identify and eliminate
the cause and bring back heater
into operation.
3. If tube leakage is suspected
(reflected by drop in condensate
outlet and heater drain
temperature), isolate the
respective heater for the
maintenance and put the same
into operation after attending the
leakage.
4 Abnormal Level in Deaerator
A Deaerator level high high
Mal operation of 1. Check the behavior of
Deaerator level deaerator level control valve in
control valve or operation. If necessary,
turbine trip changeover the control to the
Extraction steam standby level control station.
valve and normal 2. Take deaerator level control on
drain valve of manual and regulate the
upstream heater condensate flow to deaerator to
gets closed. bring down the level to normal.
Deaerator overflow 3. Ensure closure of the bypass
drain valve gets MOV provided across Deaerator
opened. level control station.
Deaerator LCV 4. After bringing the deaerator
Inlet MOV get level to the normal immediately
Running BFP trips
closed. GSC charge the extraction steam to
minimum deaerator. Divert normal drain of
recirculation valve upstream heater to Deaerator.
may open. 5. During above period monitor
the pressure in deaerator.
6. Identify & eliminate cause of
tripping of running BFP. Put BFP
in to operation.
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Cause Effect Action
B Deaerator level low
1. Check the behavior of
deaerator level control valve in
operation. If necessary,
changeover the control to the
standby level control station.
2. Take deaerator level control on
1. Mal operation of
manual and regulate the
Deaerator level
condensate flow to deaerator to
control valve
bring back the level to normal.
Running BFPs Maintain the condensate header
may trip on pressure.
Deaerator level low 3. If necessary, operate the
- low and bypass MOV provided across
eventually Unit will Deaerator level control station.
2. Load increased and trip. 1. Put 2nd CEP into operation or
2nd CEP is not put restrict the Unit load. 2. If one of
into operation or the running CEP trips refer
tripping of one CEP Actions listed in 1 above.
3. Inadvertent opening
Check and ensure the closure of
of Deaerator overflow
Deaerator overflow control valve /
/ GSC minimum
GSC minimum recirculation valve
recirculation / CEP
/ CEP minimum recirculation
minimum recirculation
valve
valve.
5 Abnormal Level in Hot well
A Hot well level high
1. Check the operation of Normal
and emergency hotwell level
control valve. If, necessary take
Mal-operation of
them on manual and control the
Hotwell level control
DM makeup to the hotwell.
valves
At High level 2. Ensure the closure of the
condensate dump bypass MOV provided across
valve to CST will each control valves.
open. 1. Check the behavior of
Drop in Condenser deaerator level control valve in
vacuum. operation. If necessary,
Mal operation of
changeover the control to the
Deaerator level
standby level control station.
control valve
2. Take deaerator level control on
manual and regulate the
condensate flow to deaerator.
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Cause Effect Action
1. Check and monitor the Hotwell
conductivity and feed water
parameters at CPU and deaerator
outlet. If it exceeds the
acceptable limits, shutdown the
unit.
2. Find out the probable zone of
the condenser tube leakage and
isolate the same. Unit can be run
Hotwell
Condenser Tube at part load with one- half
conductivity will
leakage condenser isolated.
increase
3. Attend the tube leakage,
charge the isolated condenser
and bring back the unit to full
load.
4. Monitor the turbo-visory
parameters for abnormality. If
excessive vibrations are noticed,
trip the turbine to check the blade
damage of LP turbine.
B Hotwell level Low
1. Check the operation of Normal
and emergency hotwell level
control valve. If, necessary take
Mal-operation of them on manual and control the
Hotwell level control DM makeup to the hotwell.
valves 2. Open the bypass MOV
provided across each control
valves and close them when
CEP start hotwell level reaches to normal.
permissive 1. Check the behavior of
unavailable on deaerator level control valve in
Hotwell level low. operation. If necessary,
Mal operation of Running CEPs changeover the control to the
Deaerator level may trip on Hotwell standby level control station.
control valve level low low. 2. Take deaerator level control on
manual and regulate the
condensate flow to deaerator.
Refer Action listed in 2 above for
Turbine trip
control of Hotwell level
Sudden increase in 1. If load is increased drastically
demand of during load raising, adjust the
Condensate load.
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Cause Effect Action
2. Open the Hotwell level control
valves fully by taking them on
manual and simultaneously,
regulate the deaerator level
control valve to normalize the
hotwell level. Ensure no tripping
of BFP and CEP during above
action.
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5.0 INSTRUMENTATION AND PROCESS
CONTROL
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Chapter 5
Instrumentation & Process Control
5.1 Instrument and Process Control
5.1.1 Hotwell level control - Makeup Control Valve and Excess condensate
dump Control Valve
Purpose:
The condenser hotwell level will be maintained at a fixed point for all load
conditions to maintain a suitable NPSH for the condensate extraction pumps by
modulating the air-operated level makeup control valves (1GHC10AA081 for
normal make-up or the higher flow control valve 1GHC15AA081 for emergency
make-up) & excess condensate dump control valve (1LCA48AA081) which are
normally controlled automatically from the DCS based on Hotwell level.
Functional Description:
The level control valve can be placed in automatic or manual control via DCS.
The control of the valve is normally placed in automatic and it modulates as
required, to pass the required flow from the condensate storage tank in order to
maintain constant hotwell level. Condenser hotwell level signal (Median selection
of level transmitters located on HP shell - 1LCA02CL001, 1LCA02CL002 &
1LCA02CL003) is used as process variable (PV) for control of Condenser hot
well level. Set point for normal make up CV will be NWL & Set point for
Emergency make up CV will be NWL1 (NWL >NWL1). During the normal
operation, condenser normal make up CV maintains the level of the hotwell at
level NWL (normal level). In case of any disturbances causing the hotwell level to
fall to level NWL1, the emergency make-up CV will start controlling the hotwell
level at the set point.
In the event of any condition that results hot well levels in excess of the normal
level, the excess condensate dump control valve opens and condensate is
directed to the condensate storage tank.
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In case of valve trouble/maintenance, inching type MOV provided at the bypass
of the corresponding valve (1GHC10AA001 for normal make-up control valve;
1GHC10AA081, 1GHC15AA001 for emergency make-up control valve;
1GHC15AA081, 1LCA48AA001 for excess condensate dump control valve) &
can be operated manually from DCS to achieve above mentioned functions.
5.1.2 CEP minimum recirculation control valve
Purpose:
To meet the minimum flow requirement of the respective pump.
Functional Description:
The minimum flow requirement of each condensate extraction pump will be
maintained by individual air-operated recirculation flow control valve
(1LCA17AA081 / LCA18AA081 /1LCA19AA081 respectively for CEP A, CEP B,
& CEP C). The control valve can be placed in automatic or manual control via
DCS. The valve will be normally placed in auto and modulates as required based
on Condensate Extraction Pump discharge flow (1LCA17CF001 /
1LCA18CF001/ 1LCA19CF001 respectively) to maintain a minimum flow for
condensate extraction pump.
5.1.3 GSC minimum recirculation valve
Purpose:
To meet the minimum flow requirement of the Gland Steam condenser, also
ensuring (manual quality checking & modulating the valve by operator) that
required quality water is fed to the Boiler.
Functional Description:
The minimum flow requirement of gland steam condenser is maintained by an
air-operated recirculation flow control valve (1LCA74AA081). The control valve
can be placed in automatic or manual control via the DCS. The valve is normally
placed in automatic and modulates as required to maintain a minimum flow.
When placed in manual control through the DCS, plant operator can manually
modulate the control valve based on GSC minimum flow requirements. The
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condensate flow signals (median value) from the flow transmitters (FT-
1LCA40CF001, 1LCA40CF002 & 1LCA40CF003) at the gland steam condenser
discharge header modulate this recirculation CV. When the flow is more than the
permissible minimum flow through the gland steam condenser, the GSC
minimum recirculation CV remains closed.
Further, in condition of Deaerator level Hi, this valve will be open about 74% to
reduce supply of condensate to deaerator, also during condensate cleanup
recirculation this valve will be fully open.
5.1.4 De-aerator level control valve (2 x 100%) (1LCA50AA081,
1LCA50AA082)
Purpose:
Maintaining deaerator level at a preset value
Functional Description:
Triple redundant level transmitters (1LAA10CL001, 1LAA10CL002,
1LAA10CL003) provided for Deaerator level measurement, Triple redundant flow
transmitters (1LCC70CF001, 1LCC70CF002, 1LCC70CF003) provided at the
outlet of LP heater-4 to measure condensate flow to deaerator & Feed water flow
at boiler inlet (provided by boiler supplier) are used to undergo a three-element
control (above 30% load) for controlling deaerator level. Controller compares
level set point and modulates level control valve using deaerator inlet condensate
flow, feed water flow at boiler inlet and deaerator feed water storage tank level.
For load upto 30%, single element level (from triple redundant level transmitters)
control will be used for controlling deaerator level.
5.1.5 Deaerator Overflow On-Off Valve (1LAR05AA081)
Purpose:
During normal operation if the valve is selected in auto mode, then in the event of
any condition that results de-aerator level Hi Hi (H=3050 mm) the overflow valve
opens and overflow water is directed to the condenser. When de-aerator level
reaches normal level (L=2900 mm) the overflow valve closes automatically.
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Functional Description:
Overflow control valve (1LAR05AA081) is normally controlled automatically from
the DCS based on deaerator level.
In case of valve trouble/maintenance, MOV (1LAR06AA001) provided at the
bypass of the valve can be operated manually from DCS to achieve above
mentioned functions.
5.1.6 Ventilator valve spray control valve (1LCA42AA081)
Purpose:
Ventilator valve spray control valve controls the temperature of the CRH steam
going to the condenser in the event of operation of ventilator valve, by spraying
water based on the temperature feedback of temperature elements (3 nos.)
mounted at the downstream of the de-superheater.
Functional Description:
This is a temperature control valve normally controlled from PID controller in
DCS based on downstream steam temperature. During auto operation, in the
event of any condition that results in the operation of the Ventilator valve in the
CRH line, this valve opens in response to the high temperature (H=187 degree
Celsius) sensed by the temperature elements (Median value of 1LBC01CT004,
1LBC01CT005, 1LBC01CT006.) mounted at the downstream of the de-super
heater. Valve sprays water in to the steam to reduce temperature of the CRH
steam going to the condenser in order to protect the condenser from the effects
of the water hammering.
The valve closes automatically when the set temperature is met by the PID
controller.
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6.0 INTERLOCKS AND PROTECTION
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Chapter 6
Interlock and Protection
6.1 Condensate Extraction Pumps (3 x 50 %)
1LCA13AP001 (CEP A), 1LCA14AP001 (CEP B), 1LCA15AP001 (CEP C)
Purpose:
To pump the condensed steam (condensate) from the condenser hotwell to The
Deaerator
Functional Description:
The condensate extraction pumps (CEP) will be normally started and stopped
automatically from the DCS. Regardless of the number of pumps utilized, one of
the pumps will be in standby and will start automatically upon loss of the primary
pump or header pressure low.
Permissive:
• Corresponding CEP suction valve open.
• CEP recirculation CV in AUTO.
• Corresponding CEP discharge valve closed or any other CEP started with
corresponding discharge valve open.
• Hotwell level not low low.
• Corresponding CEP motor bearing temperature not high.
• Corresponding CEP motor winding temperature not high.
Trip Conditions:
• Hotwell level low-low.
• Corresponding CEP suction valve not open
• Corresponding CEP motor bearing temperatures high-high.
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• Corresponding CEP motor winding temperatures high-high.
• Corresponding CEP vibrations high-high.
• Corresponding discharge MOV not opened within preset time.
Auto Start Interlock of standby pump:
• CEP discharge header pressure low.
• Running CEP trip.
• MW demand (in case of normal start of 2nd CEP).
6.2 CEP discharge MOV
Functional Description:
CEP discharge MOVs (1LCB17AA001, 1LCB18AA001 & 1LCB19AA001) will be
in closed conditions when no CEP is running. Respective MOV at each pump
discharge will open automatically as soon as the pump startup is complete. If any
CEP is running, and the discharge valve of running CEP is open then the
discharge valve of non-running CEP can be auto opened.
A bypass MOV (1LCB17AA002, 1LCB18AA002 & 1LCB19AA002 for CEP
discharge MOVs 1LCB17AA001, 1LCB18AA001 & 1LCB19AA001 respectively)
is provided for opening CEP discharge MOV, thus protecting the CEP discharge
MOV from pressure surge.
The opening sequence for CEP discharge MOV is as follows:
• CEP discharge MOV open sequence is initiated: The bypass MOV opens
automatically.
• Auto open command for CEP discharge MOV is generated 10 seconds after
the bypass MOV fully opens, & CEP discharge MOV open sequence in
service is initiated.
• Bypass MOV closes 10 seconds after CEP discharge MOV is open.
• When CEP discharge MOV is fully opened & bypass MOV is closed, the
CEP discharge MOV open sequence in service is reset.
Auto Open Interlock
• With a time delay after start of corresponding pump.
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• Any CEP running and CEP discharge header pressure above preset value
for standby pump MOV.
Auto Close Interlock
• Corresponding pump trip
• Reverse rotation is detected
6.3 Condenser curtain spray SOV
1LCA22AA051 (FOR LP SHELL), 1LCA24AA051 (FOR HP SHELL)
Functional Description:
Condenser curtain spray SOV (1LCA22AA051 / 1LCA24AA051) will be operated
automatically from the DCS. Condenser curtain spray SOV will open whenever
any turbine trip exists or LP bypass valve position > 5% or WDC valve is not
closed.
Protective Commands:
Condenser curtain spray SOV will be override open whenever any turbine trip
exists or LP bypass valve position > 5% or WDC valve is not closed.
6.4 Condensate Cleanup Blow Valve
Functional Description:
Condensate cleanup Blow valve (1LCA35AA001) will be used to blow out
condensate to atmospheric flash tank during cleanup operation. Refer Volume 1,
Section I, subsection 2 of O&M manual for details.
6.5 De-aerator level control valve bypass MOV
Purpose:
Controlling deaerator level if both the deaerator level control valves fail.
Functional Description:
Deaerator level control MOV (1LCA50AA003) with inching control will be
operated manually by the operator through DCS. This MOV is provided for
controlling deaerator level if both the deaerator level control valves fail. MOV will
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be in closed conditions during the normal operation when either of the deaerator
level control valves is functioning properly.
Protective Commands:
Override close for Deaerator level high-high.
6.6 De-aerator level control valve inlet MOV
1LCA50AA001 for control valve 1LCA50AA081 & 1LCA50AA002 for control
valve 1LCA50AA082
Purpose:
To isolate Deaerator level control valve
Functional Description:
Isolation MOV for the Deaerator level CV is operated automatically from the DCS
as per the sequence mentioned below:
• Isolation MOV open sequence is initiated: The Integral bypass MOV opens
automatically.
• Auto open command for Isolation MOV is generated: 10 seconds after the
integral bypass MOV fully opens, Isolation MOV open sequence in service is
initiated.
• Integral bypass MOV closes 10 seconds after Isolation MOV is open.
• When Isolation MOV is fully opened & integral bypass MOV is closed, the
isolation MOV open sequence in service is reset.
6.7 Heater inlet MOV
1LCC10AA001 for Heater 1A/2A, 1LCC30AA001 for Heater 1B/2B,
1LCC50AA001 for Heater 3, 1LCC60AA002 for Heater 4.
Purpose:
To isolate corresponding heater (working in conjunction with heater bypass, &
heater outlet MOV).
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Functional Description:
• Condensate Inlet MOVs for LP heaters are opened from the DCS during LP
heater water charging when integral bypass MOV of respective MOV are
open OR during respective heater recovery operation.
• These valves will be closed during LP heater water isolation.
Open Permissive:
• Inlet condensate MOV can be opened only if heater O/L MOV is open.
Close Permissive:
• LP heater 1 & 2 Inlet condensate MOV can be closed when feed water
heater bypass MOV is open OR All BFP OFF.
• LP heater 3 & 4 inlet MOV can be closed when respective heater bypass
MOV is open AND respective steam inlet MOV closed OR All BFP OFF.
Protective Commands:
Inlet condensate MOV will be override closed when respective LP heater level is
high-high AND respective heater bypass MOV is open.
Note : For Heater recovery operation, please refer Section D – Extraction Steam
System in this Volume 1.
6.8 Heater inlet MOV integral bypass
1LCC10AA001A for Heater 1A/2A, 1LCC30AA001A for Heater 1B/2B,
1LCC50AA001A for Heater 3, 1LCC60AA002A for Heater 4.
Functional Description:
• Condensate Inlet MOV integral bypass for LP heaters are opened from the
DCS during LP heater water charging when respective inlet MOV is not open
OR during respective heater recovery operation.
• These valves will be closed when respective inlet MOV is open for 10
Seconds OR during LP heater water isolation.
Protective Commands:
Inlet condensate MOV shall be override closed when feed water heater level is
high high for 5 seconds AND respective heater bypass MOV is open.
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6.9 Heater bypass MOV
1LCC10AA002 for Heater 1A/2A, 1LCC30AA002 for Heater 1B/2B,
1LCC50AA002 for Heater 3, 1LCC60AA003 for Heater 4
Purpose:
To bypass corresponding heater (working in conjunction with heater inlet, &
heater outlet MOV)
Functional Description:
• Condensate bypass MOVs for LP heaters are opened from the DCS during
LP heater water isolation when integral bypass MOV of respective Bypass
MOV are open.
• Condensate bypass MOVs for LP heaters are closed from the DCS during
LP heater water charging OR during respective heater recovery operation.
Close Permissive:
• LP heater 1 & 2 Bypass condensate MOV can be closed when respective
Heater inlet & outlet condensate MOV are open OR during MFT.
• LP heater 3 & 4 bypass condensate MOV can be closed when respective
Heater inlet & outlet condensate MOV are open AND Heater inlet steam
MOV is closed OR during MFT.
Protective Commands:
Heater bypass MOV will be override opened when respective LP heater level is
high-high for 5 seconds. Note : For Heater recovery operation, please refer
Section D – Extraction Steam System in this Volume 1.
6.10 Heater bypass MOV integral bypass
1LCC50AA002A for Heater 3, 1LCC60AA003A for Heater 4.
Functional Description:
• Condensate bypass MOV integral bypass for LP heaters are opened from
the DCS during LP heater water isolation
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• These valves will be closed when respective bypass MOV is open for 10
Seconds OR during LP heater water charging OR during respective heater
recovery operation
6.11 Heater outlet MOV
1LCC20AA001 for Heater 1A/2A, 1LCC40AA001 for Heater 1B/2B,
1LCC60AA001 for Heater 3, 1LCC70AA001 for Heater 4
Purpose:
To isolate corresponding heater (working in conjunction with heater bypass, &
heater inlet MOV).
Functional Description:
• Outlet condensate MOV for feed water heaters are opened from DCS during
LP heater water charging when respective integral bypass MOVs are open
OR during respective heater recovery operation.
• These valves will be closed during LP extraction water isolation.
Close Permissive:
• LP heater 1 & 2 Outlet condensate MOV can be closed when feed water
heater bypass MOV is open OR All BFP OFF.
• LP heater 3 & 4 Outlet condensate MOV can be closed when respective
heater bypass MOV is open AND respective steam inlet MOV closed OR all
BFP off.
Protective Commands:
Outlet condensate MOV will be override closed when respective LP heater level
is high-high for 5 seconds AND respective heater bypass MOV is open..
Note : For Heater recovery operation, please refer Section D – Extraction Steam
System in this Volume 1.
6.12 Heater outlet MOV integral bypass
1LCC20AA001A for Heater 1A/2A, 1LCC40AA001A for Heater 1B/2B,
1LCC60AA001A for Heater 3, 1LCC70AA001A for Heater 4.
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Functional Description:
• Outlet condensate MOV for feed water heaters are opened from DCS during
LP heater water charging when respective outlet MOVs are not open OR
during respective heater recovery operation.
• These valves will be closed during LP heater water isolation OR respective
outlet MOV is open for 10 seconds.
Protective Commands:
Outlet condensate MOV integral bypass shall be override closed when respective
feed water heater level is high-high for 5 seconds AND respective heater bypass
MOV is open.
6.13 CPU Common Bypass Pneumatic Operated Butterfly Valve
Purpose:
The CPU is provided with an automatic bypass valve to insure continuity of flow
to the boiler and to protect the polisher from damage due to excessive pressure
drop, thermal excess, and from hydraulic damage during start-up of the
Condensate Feed Pumps.
Functional Description:
The Bypass Modulating butterfly control valve is used to divert condensate to the
Polishers or around the Polisher system (bypass mode). The combination of the
control logic and control valve provides a fail-safe operation of the condensate
flow. This valve has a fail open position. In the event of failure of Air, the valve
will open and the condensate will be bypassed.
For control description, refer CPU O&M manual (SWTL-PO-00106) compiled
under Volume 2.
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6.14 Solenoid Operated Vent on CEP Discharge side
Purpose:
To prime the CEP up to discharge side and pressure equalizing before CEP start
– up.
Functional Description:
The solenoid operated discharge side vent on CEP ensures the pressure
equalizing and priming of the CEP up to discharge line before start of associated
CEP.
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7.0 VALVE LINE-UP LIST
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Chapter 7
Valve Line-Up List
7.1 List
CAUTION
Do not operate valves without proper authorization such as work
permit, as unauthorized operation may lead to serious injury and
damage to the equipment.
Valve line-up list tabulated below provides recommended position of manual
valves of the condensate system for starting the system.
System Pre
Valve Tag no. Description
Start Position
Inlet Isolating valve of NORMAL Make
1GHC10AA102 OPEN
up Control Valve
Outlet Isolating valve of NORMAL
1GHC10AA103 OPEN
Make up Control Valve
Inlet Isolating valve of EMERGENCY
1GHC15AA102 OPEN
Make up Control Valve
Outlet Isolating valve of EMERGENCY
1GHC15AA103 OPEN
Make up Control Valve
1LCA13AA101 CEP A Suction Valve OPEN
1LCA14AA101 CEP B Suction Valve OPEN
1LCA15AA101 CEP C Suction Valve OPEN
Isolation valve on CEP A Recirculation
1LCA17AA101 OPEN
Line
Isolation valve on CEP B Recirculation
1LCA18AA101 OPEN
Line
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System Pre
Valve Tag no. Description
Start Position
Isolation valve on CEP C Recirculation
1LCA19AA101 OPEN
Line
Isolation Valve on Common Sealing
1LCW10AA102 OPEN
water line
Outlet Isolation Valve of SOV on CEP
1LCB50AA105 OPEN
A Discharge Vent to Condenser
Outlet Isolation Valve of SOV on CEP
1LCB60AA105 OPEN
B Discharge Vent to Condenser
Outlet Isolation Valve of SOV on CEP
1LCB70AA105 OPEN
C Discharge Vent to Condenser
Condensate Inlet Isolating valve for
1LCA20AA101 OPEN
GSC
Condensate Outlet Isolating valve for
1LCA21AA101 OPEN
GSC
1LCA20AA102 Condensate Bypass valve for GSC CLOSE
Inlet Isolating Valve for LP Shell
1LCA22AA102 OPEN
Curtain Spray Water Control Valve
Outlet Isolating Valve for LP Shell
1LCA22AA101 OPEN
Curtain Spray Water Control Valve
Inlet Isolating Valve for HP Shell
1LCA24AA102 OPEN
Curtain Spray Water Control Valve
Outlet Isolating Valve for HP Shell
1LCA24AA101 OPEN
Curtain Spray Water Control Valve
Common Isolating Valve for
1LCA25AA104 Condensate to Turbine Flash Tank - 1 OPEN
and 2
Common isolating valve for LP Bypass
1LCE45AA101 OPEN
Spray water Valves
Inlet Isolating Valve for GSC
1LCA47AA101 OPEN
Recirculation Valve
Outlet Isolating Valve for GSC
1LCA47AA102 OPEN
Recirculation Valve
Inlet Isolating Valve for Howell Excess
1LCA48AA101 OPEN
Dump to CST Valve
LTSL-M0-00951 REV 0 Page 153 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
System Pre
Valve Tag no. Description
Start Position
Outlet Isolating Valve for Howell
1LCA48AA102 OPEN
Excess Dump to CST Valve
I isolating valve on initial sealing water
1GHC30AA101 OPEN
from condensate transfer pumps
II isolating valve on initial sealing water
1GHC30AA102 OPEN
from condensate transfer pumps
Isolation valve on Auxiliary Steam
1LCE42AA101 OPEN
Attemperation Spray line
Isolation valve on Gland Steam
1LCE42AA102 OPEN
Desuperheater line
Isolation Valve on BFP Drive Turbine
1LCW42AA101 OPEN
Butterfly Valve Sealing
Isolation valve on Spray water line for
1LCW42AA102 OPEN
Both BFP Turbines
Isolating valve on Gland steam
1LCW42AA103 OPEN
spillover control valve sealing line
Isolation valve on Exhaust Hood Spray
1LCA42AA102 OPEN
line
Isolation Valve on CCW Overhead
1LCA42AA103 OPEN
Tank Make Up
Isolation valve on Ventilator valve
1LCA42AA105 OPEN
Desuperheater line
Isolating valve on Vacuum Breaker line
1LCA46AA103 OPEN
Sealing
Isolating valve on sealing water make
1LCA46AA104 OPEN
up for vacuum pump
Isolating valve for sealing water supply
1LCA46AA106 OPEN
to valves (Boiler Scope)
Outlet isolating Valve for Deaerator
1LCA50AA101 OPEN
LCV (1LCA50AA081)
Outlet isolating Valve for Deaerator
1LCA50AA102 OPEN
LCV (1LCA50AA082)
LTSL-M0-00951 REV 0 Page 154 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
ABBREVIATIONS
LTSL-M0-00951 REV 0 Page 155 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Abbreviations:
Abbreviation Meaning
A/C Air Cooling
AH Auxiliary Heater
ART Anion Regeneration Tank
ASME American Society of Mechanical Engineers
AVG Average
BCP Boiler Circulation Pump
BFP Boiler Feedwater Pump
BFPT Boiler Feed Pump-drive Turbine
BKW Brake-horse Kilo Watt
BWG Birmingham Wire Gauge
CCW Closed Cooling Water/Counter Clock Wise
CEP Condensate Extraction Pump
CPP Condensate Polishing Plant
CPU Condensate Polishing Unit
CP Condensate Pump / Condensate Polisher
CRT Cation Regeneration cum Mixed Resin Storage Tank
CS Condensate System/Carbon Steel
CST Condensate Storage Tank
CV Control Valve
CW Cooling Water/Circulating Water
CWT Combined Water Treatment / Cooling Water Temperature
DC Direct Contact
DCA Drains Cooler Approach
DCS Distributed Control System
DE Drive End
DG Diesel Generator
DM De-Mineralized
DP Differential Pressure
DPT Differential Pressure Transmitter
LTSL-M0-00951 REV 0 Page 156 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Abbreviation Meaning
EOP Emergency Oil Pump
FCB Fast Cut Back
FE Flow Element
FT Flow Transmitter
FV Full Vacuum
FW Feed Water
GA General Arrangement
GSC Gland Steam Condenser
HEI Heat Exchanger Institute
HP High Pressure
HVAC Heating, Ventilation and Air Conditioning
ID Inner Diameter
ISO International Standard Organization
kV Kilo Volt
LC Locked Close
LCV Level Control Valve
LMTD Log Mean Temperature Difference
LP Low Pressure
LPBV Low Pressure Bypass Valve
LPH Low Pressure Heater
LWL Low Water Level
LO Locked Open
MOV Motor Operated Valve
MU Make –up / Million Units
MW Mega Watt
NA Not Applicable
NDE Non- Drive End
NPSH Net Positive Suction Head
NRV Non Return Valve
NWL Normal Water Level
LTSL-M0-00951 REV 0 Page 157 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
Abbreviation Meaning
OD Outer Diameter
O&M Operation & Maintenance
P&IDs Piping & Instrumentation Diagram
PG Pressure Gauge
PID Proportional Integral Differential
PLC Programmable Logic Control
PP Pressure Point
PPB Parts Per Billion
PPM Parts Per Million
PTC Performance Test Codes
PV Process Variable
RPM Revolution Per Minute
SOV Solenoid Operated Valve
SPT Separation Tank
SP Set Point
SS Stainless Steel
ST Steam Turbine
STG Steam Turbine Generator
TCS Turbine Control System
TDH Total Developed Head
TDS Total Dissolved Solids
TTD Terminal Temperature Difference
TGMCR Turbine Generator Maximum Continuous Rating
TGVWO Turbine Generator Valve Wide Open
TMCR Turbine Maximum Continuous Ratings
TOP Turning-gear Oil Pump
TWIP Turbine Water Induction Prevention
UPS Uninterrupted Power Supply
VWO Valve Wide Open
LTSL-M0-00951 REV 0 Page 158 of 860
JAYPEE O&M MANUAL – VOLUME 1 CONDENSATE SYSTEM
EXHIBITS
LTSL-M0-00951 REV 0 Page 159 of 860
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HOTWELL 2'::_TSL-Iol1~0211-01 I ¢ \J!W
DRAWING TITLE DRAWING NUMBER
GA OF LP RECTAGULAR SURFACE CONDENSER LT~-o3000
H GA OF HP AECTAGULAR SURFACE CONDENSER LT-Ioi0-D3001 H
~--------------------------~------------!
STANDPIPE DETAIL ICONOENSER-1 I L T-loi0-D3004
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I- P&ID STEAN & DRAINAGE FOR SFP DRIVE TURBIN SIEG-MO-D3600
SCHEMATIC DIAGRAM FOR STEAl.! & WATER K6A24-I-D08-02
ANALYSIS SYSTEM
G
~--------------------------~------------fG
N
vs 13A vs
Ll LT NOTES
1LCAO 1. FOR INDEX, LEGENDS AND SYII!OLS REFER OWG NO. LTSL-Ioi0-D0200.
CL001 2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15NS WHEREVER
SINGLE ISOLATION VALVE IS PROVIDED & 25NS WHEREVER DOUBLE
ISOLATION VALVE PROVIDED. ALL TEMPERATURE STUB CONNECTION
SIZE SHALL BE OF RC 1 ANO RC 1 1, , FOR SERVICES HAVING PRESSURE F
LESS THAN -40 KG/CW2 AND FOR SERVICES HAVING PRESSURE lMJRE
THAN 40 KC/CM2 RESPECTIVELY AS PER IS-554. THIS HAS BEEN
FOLLOWED BASED ON DCPL/JPVL RECOIKNOATION VIDE MAIL DATED
13.09.2010.
3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST OF I-
ON 25 UNLESS OTHERWISE SPECIFIED.
~. - - - IN JPVL SCOPE
- - - - - IN L&T STG I SCOPE
5. THE CONNECTIONS FOR CONDENSER SHELL ARE SHOWN IN THE
P&ID NO. LTSL-Mt-00201. SHEET NO. 6
E 6. • DENOTES THE VALUES TO BE VERIFIED AFTER RECEIVING FRON E
EQUIPMENT SUPPLIER.
1. SPECIAL INSTRUMENTS FOR PG TEST SHALL BE SUPPLIED BY TGV.
THE SANE SHALL BE TAKEN SACK AFTER COWLETION OF PG TEST.
8. :~LT~~~ ;~~~~~~L~~/~~L~/~~~~::~~~OB~NL~~~NT OCS BY JPVL. --
9. STANDPIPE WITH ISOLATION VALVES. ROOT VALVES FOR
INSTRUMENTS AND ISOLATION VALVES FOR VENT AND DRAIN
SHALL BE SUPPLIED BY L&T-HEO.
10.PDC-PIPING DESIGN COOE
PDT-PIPE DESIGN TABLE
0 t 1-COND.CTIVITt ANALYSER SHALL BE INSERTION TYPE. D
12.JPVL DENOTES INSTRUMENT ARE IN JPVL SCOPE.
REST OF THE INSTRUMENTS WILL BE SUPPLIED BY L&T.
13.ALL HIGH POINTS SHALL HAVE VENTS AND All LOW
POINTS SHALL HAVE DRAINS.
1~. TEMPERATURE MEA.SUREMENT CABLES FOR HOTWELL IIIJUNTED
TEMPERATURE ELEIAENTS WILL BE PROVIDED BY JPVL.
15.DELETEO.
PROJECT'
RELEASE STATUS DATE
c JAYPEE NIGRIE SUPER THERilAL POWER PROJECT, 2 X 660 1111' C
PRELIMINARY
550x750 01 05-DN750 STEAII TURBINE GENERATOR AND AUXILIARIES PACKAGE
FOR INFORMATION
DESIGN DESIGN ~AX OPER. MAX OPER. FIELD TEST
PDC PRESSURE TEMP. PRESSURE TEMP. PIPE POT PRESSURE REMARKS DESIGN DESIGN MAX OPER. MAX OPER. FIELD TEST
j~YPEE
NUMBER kQ/Cm2tc;~l IDEG. CJ kQ/cm21QJ IOEG. Cl CLASS kQ/cm2{ c;~l FOR APPRO¥ AL
PDC PRESSURE TEMP. PRESSURE TEMP. PIPE POT PRESSURE REMARKS JAIPRAKASH POWER VENTURES LIMITED
C0-1 3.5 50 0.694 49.20 JPN 0105 5.25
NUMBER kQ/Cm21Ql IOEG. Cl kQ/cm21Q IOEG. Cl CLASS kQ/Cm2{QI X FOR CONSTRUCT ION 19108113 ...
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B OM-10 10 53 4.60 47.80 JPN 0145
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LTSL-M0-00951 REV 0
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DATE PROJECT'
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t\'- / \'- ~ l.itALXC2AT02W1T
OWNER'
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X FOR CONSTRUCTION 19108/U
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REVISIONS THIS DRAWING AND DESIGN IS THE PROPERTY OF u SES .,.. 29 10<111 SCALE: TITLE 'PIPING S. INSTRUWENTATION DIAGRAW
REV. DATE REP ARE REVIEWED REVISIONS REV. DATE REPARED REVIEWED
A WECH. CIVIl. ELECT.
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12/12/11 Pl/RS swv AYA HNP YOW OR CONSTRUCTION ,.. ..II" AND PIPING LAYOUT AND MUST NOT BE COPIED OR LENT WITHOUT PROJECT NO. :T209001
28/05/12 PL/RS swv AYA HNP YOM OR APPROVAL AS PER .OM DATED 20.0·4.2012 ;v THEIR PERMISSION IN WRITING L&T-S&l JOB NO.: L543000 [,\t~,.ixJ201~-l OWG. NO. :LTSL-141·00201 I SHT 05 OF 06 rT'
16 I 15 I 14 I 13 I 12 11 10 I 9 8 l I 6 I 5 I 4 3 I REVISE THIS owe. USING CAD SYSTEM ONLY
I
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DRAWING TITLE DRAWING NUMBER
TURBINE#A EXHAUST ·: Vl-2 1LBC01 ATTEMPERATOR TURBINE#S EXHAUST GLAND STEAM AND DRAIN PIPING DIAGRAM LMTG-IIO-D1 005
H 125010 ' f----------------------11r.N"'I~ BR064
T ~ i 1------------------.,.-----1 I C0-1 -~LCB50 GA OF LP RECTAGULAR SURF ACE CONDENSER LT-110-03000 H
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2. INSTRUMENT PRESSURE CONNECTION SI2E SHALL BE ISNB WHEREVER
SINGLE ISOLATION VALVE IS PROVIDED & 25NB WHEREVER DOUBLE
~ ~t001-DN150 A~· A02
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1 0001-DN150 ISOLATION VALVE PROVIDED. ALL TEioiPERATURE STUB CONNECTION F
F J
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II TSL-111-D0209-01 PG TEST THERMOWELLS SHALL BE SUPPLIED BY L&T.
f,_-g-~~~01-:-1~0
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W2 1PAB10
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POT-PIPE DESIGN TABLE
BR<03
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r
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sc
D ! poo1-DN80
:~01~ 0001-DNBO~ f M
~ ~000.1-DNSO RECOt.I.ENDATION.
tO.ALL HIGH POINTS SHALL HAVE VENTS ANS ALL LOW POINTS SHALL D
~ ~I I l !
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BR4021 HAVE DRAINS.
! IBR404 BR404 11.TURBINE EXHAUST PRESSURE INSTRUMENTATION & CONTROL IS BY TGV.
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THE SAME IS ALSO INDICATED IN TGV P&JO NO. LMTG""""O-Q1005
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cr.
u BR401 DATE PROJECT'
RELEASE STATUS
c 0001-DN150 ~ CONDENSER HOTWELL EQUALISING LINE
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JAYPEE NIGRIE SUPER THERIIAL POWER PROJECT. 2 X 660 Kll' C
PDC DESIGN DESIGN MAX OPER. MAX OPER. PIPE POT FIELD TEST REMARKS STEAII TURBINE GENERATOR AND AUXILIARIES PACKAGE
NUMBER PRESSURE TEMP. PRESSURE TEMP. CLASS PRESSURE NUMBER PRESSURE TEMP. PRESSURE TEMP. CLASS PRESSURE
kg/cm2(QI <OEG.CI kg/cm2Cgl COEG. Cl kg/cm2Cgl kg/cm2Cgl fOEG.Cl kg/cm2<QI COEG. Cl kg/cm2Cgl FOR INFORMATION
OWNER'
C0-1 3.50 50.0 0.10 .9.2 0 JPN 0105 5.25 ES-11 1.07 120.0 -0.90 79.8 D JPN 0105 5.25 FOR APPROVAL
1- JAIPRAKASH POli'ER VENTURES LIIIITED
CD-12 3.50 120.0 0.00 -1\9.2 D JPN 0105 5.25 FV-1 3.50 260.0 0.30 .9.2 D JPN 0105 5.25 X FOR CONSTRUCTION 19108113
C0-16
C0-2
7.97
41.97
585.0
55.0
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34.00
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49.2
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0
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JPN 0306
11.95
62.95
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3.50
73.50
110.0
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193.0
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5.25
110.25
AS-BUlL T
f-L---'-...,-S~I-G-N-f-D-A-T~E-j rn
OWNER"S CONSULTANT'
DEVELOPMENT CONSULTANTS PRIVATE Lilli TED
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I ~ L&T - SARGENT ~ LUNDY LIIIITED
J-----D_R_A_I_N________________________ ~~~~~~====---------------------------------,-.,.------------------------------~~~~~~~==~---------------------------------r----------------------------------------~~~C~&~I====t==•~•~•==~H~/~~~~~1~1~~~--~~~r;~~~~~~;=;,;~~~;,;~~~~~~~;l
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REV. DATE AEPARE REVIEW£0 APPROVED REVISICWS REV. DATE AEPAREOf-:-:=-r.=,.,.:;~:;,Y:..;I,E;,;WE'iOC...,.,,.,-..,=--lAPPROVEO REVISIONS
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A MECH. CIVIL ELECT. C&l 5£5 MECH. CIVIL UECT. C&l SES U!.T-SARGENT & LUNDY LIMITED APPD. BY ... 2'0/~/11 FOR
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~ ~;~~;~:: :~~:~
w:::c :: :~:wv ~~: ~ ~::~:~~~::: 3 19108113 ,I!Pl/RS 1"-::J,"./ :~~~~~~~~~;~~~TEST VENOOR INPUT AND t.UST NOT BE COPIED OR LENT WITHOUT t~PR;O~J;E~C~T~N;o~·====•~T~2~0~90;0~1=~hS'iiiZrE~:;---t:::=-:::--:-=:-::::-C-;O::N::D::E::N-S_A_T_ETS-::-Y:::T:::E:::W:-::=I[iTI':yJ
2 28/05112 PLIRS swv •u HNP vow OR APPROVAL AS PER"""' DUEo 2o.o~.20I2 . '.t THEIR PERMISSION IN WRITING L&T-S&L JOB NO.:LS43000 E&~~~10Hit·l owe. NO.:LTSL·I.U-00201 I SHT060fD6 IT
16 I 15 I 14 I 13 J 12 11 10 I 9 !. 8 I 7 I 6 I 5 I 4 3 I REVISETHISOWC.USINGCAOSYSTEIIONLY
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• • I •
LTSL-M0-00951 REV 0 Page 166 of 860
LTSL-M0-00951 REV 0 Page 167 of 860
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LTSL-M0-00951 REV 0 Page 169 of 860
LTSL-M0-00951 REV 0 Page 170 of 860
REV PART DATE DRAWN / CHECKED APPROVED
,... .., DETAILS
NO REV BY BY BY
- I :2~~ 20.01.2010
2
12 2
REF.
25
DETAIL-'D2' DETAIL-'D3'
• ADDENDA 09h.
FOR CLOSED FEED WAlER HEATERS- SMNTH Elli110N
-TWO ZONE, HORIZONTAL SHB.l SIDE TUB£ SID£
2. DESK;N PRESSURE (KG/SQ.CM."G") 3.5/F.V. 42
3. OES~N TEMPERATURE tc) SHill 163 I SKIRT 163 150
4. MIN. OESIGN METAL TEMP. tc) 0 0
5. H'IDROTEST PRESSURE (KGISQ.CM."G1 4.5 64.6
f.l.SA H'IDR01EST TEMPERATURE tc 17 TO 48 11m 4ll
~ CORROSKlN ALLOWANCE (WM) 3.2 32 ( EXCEPT TUBES, ;._ NIL FOR TUBES)
7. RADKlGRN'HY FULl : RTI (REFER NOlE-1)
FULl : RTI (REFER NOTE-I)
8. .ONT EFFICIENCY 1.0 1.0
9. POST WELD HEAT TREATNENT NIL YES
I 0. FLUID CIRCULATED STEAM I ORAJNS CONDENSATE
11. NO. Of TUBE PASSES 1WO
12 NO. Of ZONES 1WO
13. TOTAL NO. Of U-TUBES FOR LPIA/IPIB & TUBE O.D. (MW)- 647Us & 19.05 !REFER GENERAL N01E NO. 5)
. TOTAL NO. Of U-TUBES FOR LP2A/LP2B & TUBE O.D. (MM)- 648Us & 19.05 REFER GENERAL N01E NO. 5)
14. HEAT TRANSFER AREA (SQ. M), EFFECTIVE 1512.34 (LPIAtlP2A) (LPIB+LP2B) [852.22 FOR LPIA/IPIB, 650.12 FOR LP2A/lP2BJ
15. INSULATION SHill!: CHANNEL-75Mt.l (NOT IN L&:T HED'S SCOPE)
~~ INSPEC110N l.&T I l.&T POWER/JP'Il/ASME (A,I.).
17. ~ YirnHT OF EQUIPMENT !ENPlY)
b ~GHT OF EQUIPMENT OPERA]NG)
45800 KGS.t:PROX.l
54900 KGS. PRO~ h. IJJ.
._ c WEGHT OF EQ~PIIENT FULl OF WAlER) 72000 KGS. ROX.
l~d u~"fN~~~NDP'k DRGS.) INDICATE WELD SEAM Nl1ilfJl;c:s-(i.PPROX.)
111A. RBMBIENTS :- (UG--84, IJCS-116, lJCS--87)
.&_ b) FOR WELDS 1: HAl
""""""-'
SR. NO. IS PER CODE CLAUSE RlWlMNG .... NOS. ""
1 ucs-67(u) NIL
229 (TYP.) 140 (TYP.) '' 2 ucs-67(b) NIL
~ '
•
ucs-67(c=)
ucs-67(~
10.
NIL
V3
120
' VIEW 'Vl-Vl'l.l. 19. PWHT CYClE FOR CHANNEL ASSEMBLY WITH DRILlED TUBESHEET, CHANNEL FLANGE & NOZZL£ Tl & 1:1 WEl.DEO
I' q Vl 8UT PRIOR TO CHANNEL PASS PARTITlON PLATE &: PARTITlON FLANGE WELDING. ~
I.IWliNG TEMP. • 300'C MAX. SOAKING PERIOD • 2 Hrs MIN. CODE STAMP IS
RATE Of HEA]NG • 511C1Hr MAX.
Sll!KING TEMP. • 601fcC630'c
RATE Of COOUNG • 50'C/Hr MAX.
UNlD!IliNG TEMP. • 300'C MAX. ON FURNI<:E)
AS ME REQUIRED ON
THIS EQUIPMENT
TUBE BUNDL£ REMOVAL L£Nr:rH I 0800 20. WELDING:- ==--===-==::./
CS TO CS: CSTOSS:
SIAAW : ASME SFA 5.1 AWS E7018 <;rAW : ASME SFA 5.9 AWS ER309l
<;rAW : ASME SFA 5.18 AWS ER70S-2
SAW : ASME SFA 5.17 AWS EHIOKIS3 t IN 420 TTR (FWX) SSTOSS:
SIAAW : ASME SFA 5.4 AWS E308l
GENERAL NOTES :- GTAW : ASME SFA 5.9 AWS ER308L
1. IDDIIlONAI. N.D.T.
a) ruBE TO TIJBESHEEr JOINT SfW.l BE flt£l.IM.11CA1.1Y EXAMit£D IJY PRESSURISING SHnl SIDE AT PRESSURE 1.8 KGjSQ.CM "G" AND USING so.t.P SOUJTJJN.
b) ATTACHElENT W8..DS B£IWEEN CHANNB. BARREL &: NOZZLES T1 &: T2. SIWl BE UT &: PT EXMIINED
Nil ATTACHMENT WELDS FOR OTHER NOZZL.ES SIWl BE PT EXAMINED.
c) ALL REitt=ORCDENT PADS SHAll. BE flt£l.IMTIC TESTED AT 1.25 KGjSQ.CM "G" USING AR SCWJ SOLUTION.
2. AU. EXTERNAL CS SURFACES stWl. BE SHOT BLASTED TO Sa 2.5 FINISH AND SHALL BE PAINTED WITH ONE COAT OF INORGNIC ETHYl. ZINC SIUCA.TE PRIER
OF 75 MICRONS OFT AT WORKS.
J. EQUIPI!ENT NME. ITEM No., P.0. No., CliSlllMER'S tw.IE, ADDRESS AND OIPIY WEIGHT SIWl BE PAINTED ON EQUIPMENT WITH 75 MM l..ET1ER HEIGHT.
4-. FOR CARRYING OUT HYDRO TEST, CLEAN WATER HAVING CHURDE CONTENT NOT EXCEEDING 20 PPM stWl.
BE USED Nl1 stW1 CONTAIN A RUSf INHBTOR SUCH N3 0.21 SODIUM NITRITE.
5. 2 NOS. (4 ENDS) OF 'U' TUBES FOR OCH LP1A/LP1B a: LP2A/2B ~ BE PLUGGED DURING FABRICATION AT lA:T t£D'S WORKS IF REQUIRED.
6. MATERIAL OF CONSTRUCTION AS GIVEN IN PART UST MAY BE SUBSTITUTED IN THE
FOL.LOWING DIRECTION OF ARROW -
IS 2062 GR A - IS 2062 GR B -SA 285 GR C - SA 515 GR 60- SA 516 GR 60 -SA 515 GR 70- SA 516 GR 70.
7. EOUIPWENT SIW.l. II: TifOROUGHLY DRAit£D &: DRIED AFTER HTLKliESI.
B. EFFECTlVE HEAT TRANSFER AREA IS EXCI.I.I)N; PLUGGING MAR<* OF 4 NOS. U-TUIES.
9. PRIOR TO DESPATQt EQUIPIIENT SHALL II: PURGED WITH DRY NITROGEN ON B01H SHELL AND T1.ll: Sl)[ AND Tl£N stW.L BE FILLED WITH tfTROGEN
AT 0.5 kG/50. CM ~
10. FOR FABRICATION TOLERANCES REFER DRAWING No. 15-LT014
TUBE PLUGGING DETAIL Lt.
PROJECT: JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
2600
STEAM TURBINE GENERATOR AND AUXILIARIES PACKAGE
50 OWNER: •'
"'sl'i I 170 REF. I lUBE SIJE ~]AYPEE JAIPRAKASH POWER VENTURES LIMITED
u~o u r
6
12
OWN CONSULTANT:
!Jm
6TH.
INSULATION
3
"
~
TUBE TO T/S JOINT
3 IYP.
3 PROJ.
_ 1 167 SIRENGIH EXPANSION
'
CONTRACTOR: e DEVELOPMENT CONSULTANTS PRIVATE LIMITED
LARSEN & TOUBRO LIMITED
VIEW 'V2-V2' CLEAT DETAIL
l.l.SUPP<II!T .... L&T'S CONSULTANT:
(IPVL SCOPB or aomY)
DESIGN DATA CONTD ..... e---~ L&T - SARGENT & LUNDY LIMITED
11. ADDITIONAL LOOSE SUPPLY ITEt.IS TO BE CONNECTED AT SITE BY OTHERS:
a) C~NEL SIDE TI-IERMAI... REUEF' VALVE(PART No. B), TO BE SCREW TIGHTENED AND SEAL WELDED AT SITE BY OTHERS. NOS:
b) STAND PIPES TO BE INSTAll.ED AT SITE BY OTHERS.
UNIT #I UNIT #2
12 All OloENSIONS ARE ~ MM UNL£55 011£R\\1SE SPECIAEO.
13. TUBE TO TUIESHEET JOINTS: STRENGTH EXPANDED (GROOVED EXPANSION)
LPH-IA - lLCClOACOOl LPH-lA - 2LCC10ACOOI
14. ALL WELD DErAILS stWl. CORY ASME SEC. WI 01'1.1 REQUIREMENTS. LPH-2! - 1LCC10AC002 LPH-2! - 2LCC10AC002
15. -rCIP" .t: "BBrrrW" stWl. II: PAINTED ON STAND PIPES WITH SIJTABLE (APPROX. 20 WW) LEITER 1-mfl'. LPH-lB - 1LCC30AC001 LPH-lB - 2LCC30ACOOI
16. * IMRKED NOZZLE w.RKS IN t«lZZl..E SCHEDULES WILl II: USED FOR PG TESTING PURPOSE. LPH-2B - ILCC30AC002 LPH-2B - 2LCC30AC002 Lt.
A, 17.1SYlliNDICATES
&
WElDINGWITH
18. ALL COMPANION Fl.MGES BE PERFORMED AT
TO NUT,BOLT.t:GASKEfS ARESITE BY I...&:T HED.
IN LA:T-HED'S SCOPE. INTEGRAl.. PIPING BETWEEN RELIEf VAL\£ AND HEATER IS IN HW'S SCOPE. PART NOS. ARE 511, 512, 513 .t: 515.
19. MAXIMUM NOISE LEVEL DURING OPERATION WILL BE 85 Dba. AT A DISTANCE OF 1.0 M FROM TI-lE OUTUNE OF EQUIPMENT.
~~jii~ii=~;=li:iii===n=r~ii~==l~;--I<EXii .....iif----t,HHiil---frJ~,...,iiJW--j
20. EFFECTlVE HEAT TRANSFER AREA IS EXa.L.Dt«; lUTAI... 4 NOS. TUBES PR(M)ED FOR PUJGGING DURING FABRICAliDN, IF REal.
.&,21. FOR NITROGEN FIWNG ARRANGEMENT REFER OOAWING NO. 592701-8.
f-;;:;t.iiffiiliifii--liHHiii-LL =-;;;------jf--l;;=;;;;;----1;;=,------+-.---- :::p;jiOiiiiHJii--1
I II:)
2 ±0.4
THERMAL DESIGN DATA
I 355.6 D~ Lt. DESCRIPTION MATERIAL SIZE/REMARKS
NOZZLE BEVEL DETAILS LARSEN & TOUBRO LIMITED
AS PER ASME B16.25
FULL PENETRATION WELD
CPERA11lN :IAYPEE
: LI<T POWER
: 2x660 111r , smm, liP
' IM-Pilm/ftGl-~/lJXIOJIB1
D!'liD 111-111-10011 Lb.
FOR CONNEC110NS FOR CONNECTIONS
<= 50 NB >= 65 NB lUIE SllE PRESSU£ DROP (KG/SO.CU.) < ., < 0.6 STAGE INSPECTION BY ORAWING No. REV.
1EIIIIW. TEMIUAJI.IIE ~ TID ('C)
WELD-Wl WELD-W2 DRAIN SliiCOOI.ER lfPRQIOI, DCA ('C) 5.6
LTSL-M0-00951 REV 0 Page 171 of 860
I 11 I 10 I 9 I 8 I 7 I 6 I 5 4 I 3 I 2 I 1
10' REV
DETAILS
PART DATE DRAWN / CHECKED APPROVED
/: NO
0 FIRST ISSUE
NO
20.01.2010
REV BY
MJ
BY
RR
BY
AllY
1650 TYP. / ! 1 REVISED AS PER CUSTOMER'S COMMENTS. 18.06.2010 Ill AI'S RR
2 REVISED AS PER CUSTOMER'S COMMENTS. 13.10.2010 Ill SP RR
3 REVISED AS PER CUSTOMER'S COMMENTS. 12.01.2011 Ill
G) REVISED AS PER CUSTOMER'S COMMENTS. 07.05.2011 Ill
SP
SP
RR
RR
IH
CODE STAMP IS
REQillRED ON
TillS EQUIPMENT
1-
NOTE :-
1. FOR GENERAL ASSEMBLY OF DUPLEX LP HEATER AND GENERAL NOTES REFER DRG. NO. 592701 SHm 1 OF 2.
1- PROJECT: 1-
.1\ 1650 AFTER ASSEMBLY AT SITE JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
STEAM TURBINE GENERATOR AND AUXILIARIES PACKAGE
OWNER:
•'
']AYPEE JAIPRAKASH POWER VENTURES LIMITED
GROUP
1- OWNER'S CONSULTANT: 1-
!Jm
e
DEVELOPMENT CONSULTANTS PRIVATE LIMITED
CONTRACTOR:
LARSEN & TOUBRO LIMITED
(.t. ST!INIII'll'.l!;-1 I~'Ul< LPH-1A/rnh h.
9CFW L&T'S CONSULTANT:
esay L&T - SARGENT & LUNDY LIMITED 1-
TAG NOS :
\ ·~ ,;;:---u UNIT fl UNIT #2 13 I"I<RI!U 1B jl;"~ 101
c£ _1_ LPH-IA
LPH-2A
-
-
lLCClOACOOl
1LCC10AC002
LPH-IA
LPH-2A
-
-
2LCC10AC001
2LCC10AC002
I
12 1"-''"' HR 1"-m"
1- 1
~·
iii.. .
1"'lllJ
•138 I "' '--l Si __::450:::__19-2-----lREF. LPH-lB - 1LCC30AC001 LPH-lB - 2LCC30AC001 "'~l;ntiiT--ts;:ii<iH..,---i:JlC
~ETAIL-D4
1--i
2LCC30AC002 =I II liD. MIT
NOZZLE~
LPH-2B - 1LCC30AC002 LPH-2B - I"' ,, "
NOZZLE~ 24 loam IIBI .1\ S!--11>11 I0 liD. IDllllJ I B7 f.!- I"' ' 3P ' liD Ill
1- (;\ CFW 22 loam IIBI ' .. ' .. 9 i ""' I'"" r I" ""~ 1-
SINGLE SIDED FULL
PENEJRAAJlON~
I --., WELD~.
15 h. 9 CFW_y iii 21 loam""' '" .JL •>'•IIDU: B I ·- IS!--111011 ~I"''''~'
s. -""b \ 20 oamiiBI S!--11>11 ~ IOEDI 7 "RII~' 1- IO .. IIIIf,Sit
lc ~t .)B- I
~ ' ~/J\ I,,~.~~~~~~HI~~".--t~Lj·•··~'~"~~~-~ii..~~-~·~,.$Ho~---u~••~
...~~~~~~"'llc ...
t + ~~ r-'--;""Joi"'iii<""·iH\1. . .~..---"--t-!---c 'l"' "'" ""'" I"'"" •, " l"' ... ""'"
~ 1~ ,~.....,
61,,~5~biiiiiiorrrriiiiii_,~,._ii=iiii,,.-----j~:Jc,_, ~"'~"
WELD-lH 5 1- '
1 ; 97.8 75 ,._,. . ., -!---- '""'""'·"' 4 1 111111
""'' ,.. f-:!-----1'"'*
1- C0l'''\sof<J'. ••I"'"" ~··~·~- ,1::-~-~- " • ··~·~- r-
Mil'7'7T =TOr.;-; .. 2 1"""",...,..""' " 1- ••~·~'"'
~ ~ ~~~.1 ~
4 ~~••~~~---tt·~~~,~~~~~~sw~il.,il,...,..~,---tsHHITIB--~2~8o~,~~•~ll~lm-j ..
5 CFW t;6\
.~ l --..:;J 9 CFW MATERIAL ~ SIZE/REMARKS I8
2051.-H
w~
19
7 L.&T'S
1.5
"' ~ =r
j_-1)- No.
50325
1
LP1B+LP2B ITWO GENERAL ASSEMBLY !-
~""~"''~CW~,- ,~~f'""'~'~,.~""~"""'~~~~~~:k.~'~~~cn~'g.:•iccumsiTiro;Ji!IRR[EJ : sm~;~:1#------l
1\'P.
75 97.8 100 ~
REF. REF.
....
tIJr"a~~~j!~~~~---~ 2x0oo o . smm.
360 F,Y o.4 ro o.s ::r 11 PURCIIASER:: L&T ElcC.
PROJECT liP
.11
10500 10500 Pr P.O. No. •LOI-PUIIB/OIGHI/-/LDIIOIIIII
NOZZLE/Sii\!Q/SU\ & 0.11 TO 1.11 '1t 1 / TAPPt.IG DlTID 21-olt-IODI
\..!.1\..!!..1
~~1 =i:- '3r '·' ro •• 'Jr STAGE INSPECTION BY DRAWING No. REV.
&HEATER KEY PLAN - A .a. ')r •• 11).. .,r
EDGE '""""'"""
~~~~
SIGNATURE•
DATE •
\WELD SEAM NOS !;" ao ro ,.
I 11 0 I 9 8 I 7 6 I 5 I 3 2 I
LTSL-M0-00951 REV 0 Page 172 of 860
REV DETAILS
PAAT DATE DRAWN / CHECKED APPROVED
NO NO REV BY BY BY
2:1 EWPSOIDAl O'ENO
12 THK. NOMINAL
10 THK. MINIMUM
DESIGN DATA:-
1. DESIGN CODE :- ASME SEC. VIII, OW- 1, 2007 EDITION INCL ADDENDA 2009.
HEI STANDARDS FOR CLOSED FEED WATER HEAlERS- SEVENTH EDmON
TYPE: 'U' TUBE -1WO ZONE, HORIZONTAL
VIEW V5 ,+, SHELL SIDE TUBE SIDE
2. DESIGN PRESSURE (KG/SQ.Ct.t""t)--- J.S / F.V. 42.0
3. DESIGN TEMPERATURE tc)------SHELL-239 It!. 150
SKIRT SHELL-239
4. MIN. DESIGN METAL TEMP. tc)---- 0 D
5. HYDROTEST PRESSURE (KG/SQ.CM;dll)- 4.6 54.6
H'tiAWIESITEMPERATURE tc)--------17 TO 48 17 TO 48
6. CORROSION Al..l.OWANCE (MM)- - - - - 3.2 3.2 ( EXCEPT TUBES, i.e. NIL FOR TUBES)
7. RADIOGRAPHY----------- FULL: RT1 (REFFR NOTE 21) FULL: RT1 (REFFER NOTE 21)
8. JOINT EFACIENCY---------1.0 1.0
9. POST WELD HEAT TREAT\4ENT----- NIL YES
10. FLUID CIRCULAlED- --------STEAM/DRAIN FEEDWATER
757 PITCH 11. NO. OF TUBE PASSES------- 1WO
12. NO. OF ZONES----------lWO (ONE SHROUDED)
lYP. 1J. TOTAL NO. OF U-TUBES &: TUBE 0.0. (Mt.t)-----1166 Us&: 19.05 (REFER NOTE. 25)
14. HEAT TIRANSFER AREA (SQ. M) GROSS/EFFECTIVE---1465.12/1428.40
15. - - - - - - - - - - - - - - - S H E L l & : CHANNEL-75MM (NOT IN L&:T-HED'S SCOPE).
16. -------------L&T/L&T POWER/JPI\/ASME (A.I.). b,.
17. 1 - - - - - - - - 28,300 KGS.!APPROX.~ ~
I - - - - - 36,600 KGS. APPROX.
- -51,400 KGS. APPROX.
6,1 00 KGS. APPROX.
. INDICAlE WElD SEAM NUMBERS.
b) FOR WELDS 41: 1-MZ
75 lYP.
N'PlJC.IIIlf FOR
SR. NO. ItS PER CODE CL.NJSE FOLLOWING SEMI NOS.
1 IJCS-67(a) NIL
2 IJCS-67(b) NIL
J IJCS-67(c) NIL
4 IJCS-67(d)
7000 VIEW V1-V1 h. NIL
~IOli'I'OIITIWL
SECTIONAL ELEVATION (IP9L SCOPI Ill SOPPLY)
CS:
SMAW : ASt.IE SFA 5.1 AWS E7018 CODE STAMP IS
10 Dl 11001YP.
I
Dl l<l
GTAW : ASME SFA 5.18 AWS ER70S-2
SAW : ASME SFA 5.17 AWS EH10K/S3 + UV 420 TTR (FWX)
REQUIRED ON
0'1-------'=-"'-'--------1 THIS EQUIPMENT
I
--,--
' CSTOSS:
GTAW : ASME SFA 5.9 AWS ER309L
---~* 90' I
---~Et- 90'
I
'
SSTOSS:
SMAW : ASME SFA 5.4 AWS E3DBL
I GTAW : ASME SFA 5.9 AWS ER308L
'I CD ~~
:a CiS R. 20. PWIHT CYCLE FOR CHANNEL ASSEMBLY WELDED WITH T1 ,T2 II< CHANNEL FlANGE II< DRILLED TUBESHEET
LDAOING TEMP. = 300'C MAX. SOAKING PERIOD = 1 1/2 Hrs MIN.
-::r--::r
~ ~ ~ RATE OF HEATING =
50'C/Hr MAX. RATE OF COOUNG =
50'C/Hr MAX.
13-a
I
SOAKING TEMP.
21. ADDmONAL N.D.T.
=
600'C-630'C UNLOADING TEMP. =
300'C MAX. (IN FURNACE)
' ~XED SADDLE
a) TUBE TO TUBESHEET JOINT SHAll. BE :
0 ='4==-=-=-_ o...J, FOUNDATION PNEUMA.TlCAlLY EXAWINED BY PRESSURISING SHn.l SIDE AT PRESSURE 1.25 KG/SQ.CW "G" AND USING SOAP SOLUTION.
b) SKIRT SHELl TO SHELl CLOSING SEAM SHALl BE U.T. EXAMINED INSTEAD OF 1U. EXAMINATION.
' c) ATTACHEMENT WELDS BETWEEN CHANNEL Bf.RREL &: NOZZLES T1 &: T2 SHALL BE UT &: PT EXAWINED AND ATTACHMENT
WELDS FOR OTHER NOZZLES SHALl BE PT EXAMINED.
TYP. FOUNDATION BOLT DETAIL d) ALL REINFORCEMENT PADS SHAll. BE PNEUMATIC TESTED AT 1.25 KG/SQ.CM "G" USING ~R SOAP SQLUTION.
180' e) ATTACHMENTS OF NON PRESSURE PARTS TO PRESSURE PARTS &: NON PRESSURE PARTS TO NON PRESSURE PARTS WITH
10
~ Iffi~
SEAIA NOS. SIHAl.L BE PT ~INED.
1550 AFTER ASSEMBLY AT SITE 22. ALL EXTERNAL CS SURFACES SHAll. BE SHOT BLASTEO TO Sa 2.5 ~NISH AND SHAll. BE PAINTED WITH ONE COAT OF
INORGANIC ETHYL ZINC SIUCATE PRIMER OF 75 MICRONS OFT.
23. EQUIPMENT NAME. rial NO., P.O. No., CUSTOMER'S NAME, ADDRESS AND EMPTY WEIGHT SHALl BE PAINTED ON EQUIPMENT
§I~
WITH l.£ll[RS OF 75 Mt.t HEIGHT.
m8
85
-o o
y I
24. FOR CARRYING OUT HYDRO TEST, CLEAN PDTABL£ WATER SHAll. BE USED AND SIHAl.L CONT~N RUST INHIBITOR SUCH AS
0.2~ SODIUM NITRITE.
25. TOTAL NO. OF U-TUBES INDICATED UNDER NOTE No. 13 INCLUDES 4 NOS. FOR PLUGGING (IF REQUIRED) DURING FABRICATION
FOR CONNECTIONS FOR OONNEC110NS AT L&:T WORKS.
JOSA-D <= 50 NB >= 65 NB
TYP. DETAIL OF CAP REMOVAL VIEW V2-V2b. PROJECT: JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
& 11EP. AT SITE BY L&T.
STEAM TURBINE GENERATOR AND AUXILIARIES PACKAGE
26. MATERIAL OF CONSTRUCTION ItS GIVEN IN PART UST MAY BE SUBSTTTUTID IN THE OWNER: o'
FOLLOWING DIRECI10N OF ARROW - -}AY PEE
IS 2062 GR A - IS 2062 GR 8 - SA 285 GR C - SA 515 GR 60- SA 516 GR 60 -SA 515 GR 70- SA 516 GR 70.
GROUP
JAIPRAKASH POWER VENTURES LIMITED
27. ALL WElD DET~LS SHAll. COMPLY ASIAE SEC. V111 DW.1 REQUIREMENTS.
NOZZLE ISiMii\ .t. 28. EQUIPMENT SHALL BE THOROUGHLY DRAINED &: DRIED AFTER HYDROTEST &: SHALl BE PURGm WITH DR'f NITROGEN ON BOTH
\D\.V {STANDPIPE-2.t.) SHELL & TUBE SIDE AND THEN SHAll. BE ~LLED WITH NI1ROGEN (BOTH SHELL SIDE & TUBE SIDE) AT 0.5 KG/SQ.CM G OWN CONSULTANT:
!Jm
PRIOR TO DESPATCH.
29. FOR FABRICATION TOLERANCES REFER DRAWING No. 1S-LT014 DEVELOPMENT CONSULTANTS PRIVATE LIMITED
30. ADDmONAL LDOSE SUPPLY rialS:
a) SHELL SIDE REUEF VALYE(PART No. 8), TO BE INSTALLED AT SITE BY L&T.
b) CHANNEL SIDE THERMAL REUEF VALVE(PART No. 9), TO BE SCREW TIGHTENED AND SEAL WELDED AT SrTE BY LA:T. CONTRACTOR:
c) STAND PIPES TO BE INSTALLED AT SITE BY L&T. LARSEN & TOUBRO LIMITED
d) FOUNDATION BOLTS (PART No. 11 ), HEX. NUT (PART No. 12) 8c P~N WASHER (PART No. 13).
It!. 31. TOP & BOTTOM ON STAND PIPE SHAll. BE P~NTED WITH SUITABL£ (APPROX. 20 MM) LETTER HEIGHT.
&,32. All coti'AhllN FLANGES Y«TH NUT,BOLT~ ARE r. IA:T-HED'S SCOPE ( PART NOS. 485. 486. 4811: 488). 1liS ITEUS WILL BE LOOSE SUPPLIED.
INIEGRAL PIPN; IEIWEEN REI.JEF VILVE AND HEATER IS IH lED'S saH. PART NOS. ME 427, 428, 429, 430, 431, 512, 513, 514, 515, 516 .t 517.
.£ 3J. MAXIMUM NOISE LEVEL DURING OPERATION WILl BE 85 Dba. AT A DISTANCE OF 1.0 M FROM THE OlJTUNE OF EQUIPMENT.
L&T - SARGENT & LUNDY LIMITED
~
192 REF. A 35. EFFECJlYE HEAT THANSFER AREA IS EXCLUDING 4 NOS. TlllES PRCMDED FOR Pl..lJGGN; DURING F~. IF REQD.
.G».J6. FOR NRROGEN Flu.t«; ARWHGEMENT REFER DRAWING NO. 592801-8.
NOZZLE~ /SiMi2\
.t. NOZZLE \l.J\]./
9CFW
20JA-F
1.5
703.8 7918.6 6923.6
0.0 0.0
192 REF. 1630.3 16154.4 8194.8
ORIFICE PLATE FOR S5
DESCRIPTION MATERIAL SIZE/REMARKS
CUSTOIII!R : JAYPEE
FOUNDAll~
PURCHASER : L8cT EII<C. TAG NOS : IOOTflb,.
LPB-S - 1LCC60AC001
PENETRATION WELD. 100Tf2
1 P.O. No.
STAGE INSPECTION BY DRAWING No. REV.
HEATER KEY PLAN
LTSL-M0-00951 REV 0 Page 173 of 860
60' REV
DETAILS DATE DRAWN I
t~
NO REV BY
2:1 EWPSOIDAL D'END DETAIL-'D5' .t.
12 THK. NOMINAL
II
V3 DESIGN DATA:
1. DESIGN OODE :- ASIAE SEC. ~II. OIV- 1, 2007 EDmON INCL. AOOENDA 2009.
VIEW V5 HEI STANDARDS FOR CLOSED FEED WAIIR HEAIIRS- SMNTH EDmON
TYPE: 'U' TUBE -TWO ZONE, HORIZONTAL
,t. SHELl. SIDE TUBE SIDE
2. DESIGN PRESSURE (KG/SQ.CM G}--- 6.0 / F.V. 42.0
3. DESIGN TEMPERATURE {"C)------ SHEli-320 .&, 185 CODE STAMP IS
SKIRT SHEll-320 REQUIRED ON
4. MIN. DESIGN MErAL TEMP. tc)----0 0 TIUS EQUIPMENT
5. HYDROTEST PRESSURE (KG/SQ.CMl1f)- 7.8 54.6
tn'DROTEST TEMPERATURE tc)--------17 TO 48 11 ro 48
. CORROSION AllOWANCE {UW)----- 3.2 3.2 ( EXCEPT TUBES, i.e. NIL FOR TUBES)
• RADIOGRAPHY----------- FULL: RT1 (REFFR NOTE. 21) FULl.! RT1 (REFFER NOTE. 21)
. JOINT EmCIENCY---------1.0 1.0
9. POST WELO HEAT TREA1\4ENT----- NIL YES
10. FLUID CIRCULATED--------- STEAM/DRAIN FEEDWATER
g GRIND AT SITE 11. NO. OF TUBE PASSES-------TWO
100V6 12. NO. OF ZONES----------lWO (ONE SHROUDm)
~
13. TOTAL NO. OF U-TUBES & TUBE 0.0. (MM)-----972 U• & 19.05 (REFER NOTE. 25)
14. HEAT TRANSFER AREA (SQ. M) GROSSjEFFEcTM:---1218.91/1190.02
15. INSULATION-----------------SHEll & CHANNEL-75UM (NOT IN L&:T-HED'S SCOPE).
16. INSPEC110N----------------- L&T/L&T POWER/J~ASME (A.I.).
I ClEAT 17. [WEIGHT OF EQUIPMENT~EMPTY)---------23,400 KGS.~PROX.l b; h.
b WEIGHT OF EQUIPMENT OPERATING}------- 30,000 KGS. APPROX.
,t. c WEIGHT OF EQUIPMENT FULl. OF WAIER)-----41,800 KGS. PROX.
18. /If
MN aw~J/ DRG5.)iNiiiCATE_WElo_SOOA_N8~1f&sKGS. APPROX.
b) FOR WELDS ot HAl
APPLICABLE FOR
SR. NO. AS PER CODE CLAUSE FOLLOWING S£AM NOS.
1180 BOLT 1 UCS-67(a) NIL
1536 = =
2 UCS-67(b) NIL
a. VIEW Vl-Vl 3 UCS-67(c) NIL
4 UCS-67(d) NIL
ai!1JPPOIITIWL
SECTIONAL ELEVATION (li'YL SllOPI or SUPPLY) VIEW V6
Sl Dl I
~----~9~~WP~·~--~~~ M24x3P.
~
45" 19. WELDING:-
CS TO CS: CSTOSS:
GTAW : ASME SFA 5.9 AWS ER309L
_j_ 2'111' SMAW : ASME SFA 5.1 AWS E1018
GTAW: ASME SFA 5.18 AWS ER70S-2
SSTOSS:
90" SMAW : ASME SFA 5.4 AWS E308l.
• SAW : ASME SFA 5.17 AWS EH10K/S3 + lN 420 TIR (FLUX)
I~
GTAW : ASME SFA 5.9 AWS ER308L
dil 20. PWHT CYCLE FOR CHANNEL ASSEMBLY WELDED WITH T1 ,T2 lie CHANNEL FlANGE lie DRILI.ED TUBESHEET
LOADING TEMP. = JOO'C MAX. SOAKING PERIOD = 1 1/2 Hrs MIN.
li
·- ~
0
RATE OF HEATING
SOAKING TEMP.
21. ADDmONAL N.D.T.
=
=
50'C/Hr MAX.
600'C-630'C
a) TUBE TO TUBESHEET JOINT SHALl BE :
RATE OF COOUNG
UNLOADING TEMP.
=
=
50'C/Hr MAX.
JOO'C MAX. (IN FURNACE)
AXED SADDLE PNEUMATICALLY EXAMINED BY PRESSURISING SHELl. SlOE AT PRESSURE 1.25 KG/SQ.CM "G" ANO USING SQAP SOLUTON.
b) SKIRT SHELl. TO SHELl. CLOSING SEAM SHALL BE U.T. EXAMINED INSTEAD OF k.T. EXAMINATION.
c) ATTACHEMENT WELDS BETWEEN CHANNEL eARREL & NOZZLES T1 & T2 SHALL BE UT & PT EXAMINED AND ATTACHMENT
WELDS FOR OTHER NOZZLES SHALL BE PT EXAMINED.
TYP. FOUNDATION BOLT DETAIL d) All REINFORCEMENT PADS SHAll. BE PNEUMATIC TESTED AT 1.25 KG/SQ.CM "G" USING AIR SOAP SOLUTION.
e) ATTACHMENTS OF NON PRESSURE PARTS TO PRESSURE PARTS & NON PRESSURE PARTS TO NON PRESSURE PARTS WITH
Sl
SEAM NOS. SHAll. BE PT EXAMINED.
1400 AFTER ASSEMBLY AT SnE 1400 AFTER ASSEMBLY AT snr 22. ALl EXTERNAL CS SURFACES SHALl BE SHOT BLASTED TO Sa 2.5 RNISH AND SHAll. BE PAINTID WITH ONE COAT OF
INORGANIC ETHYL ZINC SIUCA1E PRIMER OF 75 MICRONS OFT.
23. EQUIPiotENT NAME, nrM NO., P.O. No., CUSTOMER'S NAME, AOORESS AND EMPTY WEIGHT SHAI.I. BE PAJNTED ON EQUIPMENT
WnH LET1ERS OF 75 MM HBGHT.
24. FOR CARRYING OUT HYDRO TEST, Cl.fAN POTABLE WATER SHAI..l BE USED AND SIW.L CONTAIN RUST INHIBITOR SUCH AS 0.2X SODIUM N~:~~~~
25. TOTAL NO. OF U-TUBES INDICATED UNDER NOTE No. 13 INCWDES 4 NOS. FOR PLUGGING (IF REQUIRED) DURING FABRICATION AT l&T WI
26. MATERIAL OF CONSTRUCTION AS GIVEN IN PART UST MAY BE SUBSTITUTED IN THE
FOUOWING DIRECTION OF ARROW -
IS 2062 GR A - IS 2062 GR B - SA 285 GR C - SA 515 GR 60- SA 516 GR 60- SA 515 GR 70- SA 516 GR 70.
PROJECT: JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
VIEW V2-V2
STEAM TURBINE GENERATOR AND AUXILIARIES PACKAGE
DESIGN DATA CONTD ..... OWNER: o'
i_11!...\QH) 27. All WELD DErAILS SIW.l COMPLY ASME SEC. VIII DIV.1 REQUIREMENTS.
27. All WELD DErAILS SIW.l COMPLY ASME SEC. VIII DIV.1 REQUIREMENTS. --J~!'!u;E JAIPRAKASH POWER VENTURES LIMITED
·~ 28. EQUIPMENT SIW..l.. BE THOROUGHLY DRAINED &: DRIED AFTER HYDROTEST &: SHALl BE PURGED WITH DRY NITROGEN ON BOTH
SHELL &: TUBE SIDE AND THEN SHALL BE FILLED WITH NrTROGEN (BOTH SHELL SIDE & TUBE SIDE) AT 0.5 KG/SQ.CM G PRIOR TO DESPATCH.
&. NOZZLE /S1MU\
\.A./\.!..1 29. FOR FABRICATION TOLERANCES REFER DRAWING No. 1S-LT014 OWN CONSULTANT:
30. ADOmoNAL LOOSE SUPPLY nrMS:
SIDE "
150 REF. ' I)1JBE SIDE
a) SHELl. SIDE REUEF VALVE(PART No. 8), TO BE INSTALLED AT snr BY L&T.
b) CHANNEL SIDE THERMAL RELEF VALVE(PART No. 9), TO BE SCREW TIGHTENED AND SEAL WELOEO AT snr BY L&T.
c) STAND PIPES TO BE INSTALLED AT SITE BY l&T.
!Jm DEVELOPMENT CONSULTANTS PRIVATE LIMITED
6 :-- d) FOUNDATION BOLlS (PART No. 11), HEX. NUT (PART No. 12) & PLAIN WASHER (PART No. 13). CONTRACTOR:
12 31. TOP & BOTTOM ON STAND PIPE SHALL BE PAINTED WnH SUrrABLE (APPROX. 20 MM) LET1ER H8GHT. LARSEN & TOUBRO LIMITED
~
~~~~~~~~~;~ b;32. All. COMPANION FlANGES WITH NUT,BOLT&GASKETS ARE IN l&T-HED'S SCOPE ( PART NOS. 480, 481, 462 & 483). THIS nrMS WILl. BE LOOSE SUPPUED.
·-- 33. MAXIMUM NOISE LEVEL DURING OPERATION WILL BE 85 Dba. AT A DISTANCE OF 1.0 M FROM THE OlffiJNE OF EQUIPMENT.
3 TYP.
a. L&T - SARGENT & LUNDY LIMITED
EFFECTIVE HEAT TRANSFER AREA IS EXCLUDING 4 NOS. TUBES P~DED FOR PWGGING DURING FABRICATION, IF REQD.
192 REF. 3
~ " 3 PROJ.
FOR NmRDGEN ~WNG ARRANGEMENT REFER DRAWING NO. 592804-8.
CODE SCOPE IS UMITED TO 1ST CIRCUMFERENTW.. JOINT FOR WElDED CONNECTION.
;;
2 1" ON 25 SW LEVEL SWITCH CONNECTION (LS-HHWL) WnH GLOBE VALVE
147 S1RENGI'H EXP~SION I
NOZZLE~ • 2
2
1"
1"
ON 25
ON25
XXSTR/-
XXSTR/-
SO
SW
LEVEL SW1TCH CONNEC110N (l.S-LWL) ,t.
SPARE CONNECTION
WITH
wrrn
BOO# GLOBE VN..VE
GLOBE VN..VE
2 1" ON25 SW LEVEL GAUGE CONNECTION WITH GLOBE VN..VE
2 2" ON 50 SW LEVEL TRANSMITTER CONNECTION (LT-3) WnH BOO# GLOBE VALVE
0.8 2 2" ON 50 SW LEVEL TRANSMITTER CONNECTION wrrn GLOBE VN..VE
2 2" ON 50 SW LEVEL TRANSMITTER CONNECTION WITH GLOBE VN..VE
1" ON25 SW STAND PIPE DRAIN WnH BOO# GLOBE VALVE
ON25 SO STANO PIPE VENT
ON 50 SW STANO PIPE CONNECTIONS
S9C ON 15 XXSTR/- SW PRESSURE GAUGE CONN. ON SHB.l WITH 800# GLOBE VALVE 21
4TH
59A-B 2 PRESSURE GAUGE CONN. ON NOZ 51 & GLOBE VALVE 18
ORIFICE DETAIL ~ SI1A-C 3 CONNECTION WITH HEX. H£AD PLUG
ORIFICE PLATE FOR S5.t. S7A-B 2 DRAIN
S6 ON25 UP VENT
55 2.5· ON 50 AIR VENT 50 X 12
53 •• ON 100 RF RELIEF VN..VE CONN. 50 X 12
10" ON 250 BW EMERGENCY DRAIN OUTLET 50 X 12
50 X 12 DESCRIPTION
S1 50 X 12
T7 RELIEF VN..VE CONN.
TM-B 2 PRESSURE GAUGE OONN.
T5A-B 2 CONNECTION
T4 2• ON 50 160/- SO DRAIN
T3 ON 25 SO VENT
T2 20• ON 500 BW OU1\£I'
T1 20" h. ON 500 40/- BW INL.IT
f---+-+...::;
NOZ. SCH/11<
SERVICE
MARK
LTSL-M0-00951 REV 0 Page 174 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Operation & Section B.
Maintenace Volume 1 Feedwater
Manual System
Table of Contents 176
1. Overview of Feedwater System 179
2. System Description 206
3. Normal Operation, Start-up / Shutdown 228
4. Emergecny Operations & Alarms 234
5. Instrumentation & Process Control 240
6. Interlock & Protection 247
7. Valve Line-up List 259
Abbreviations 263
Exhibits 266
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Table of Contents
1.0 OVERVIEW OF FEEDWATER SYSTEM
1.1 PURPOSE
1.2 SPECIFICATIONS
1.2.1 Design Data of Major Equipment
1.2.2 Operation limit of the system
1.3 REFERENCES
1.3.1 P & ID
1.3.2 Control and Logic Diagrams
1.3.3 Electrical Single Line Diagrams
1.3.4 Vendor Information
2.0 SYSTEM DESCRIPTION
2.1 OVERVIEW
2.2 FLOW PATH
2.2.1 Feedwater from deaerator to Boiler Feedwater Pumps
2.2.2 Boiler Feedwater Pumps to HP Heater inlet
2.2.3 Boiler feedwater from HP heater no. 6 inlet to economizer inlet
2.3 MAJOR EQUIPMENT
2.3.1 Deaerator
2.3.2 Boiler Feedwater Pump
2.3.3 Booster Pump (BP)
2.3.4 HP Heaters
2.3.5 Hydraulic coupling and oil supply unit for MDBFP
2.3.6 Drive Turbine (BFPT) for TDBFP
2.3.7 Warm-up line
2.3.8 Feedwater control station
2.3.9 System piping
3.0 NORMAL OPERATION, START-UP AND SHUTDOWN
3.1 START-UP AND INITIAL FILL
3.1.1 Initial Fill
3.1.2 Start-Up
3.2 NORMAL OPERATION
3.3 NORMAL PLANT SHUTDOWN
3.4 CHECK LIST
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
4.0 EMERGENCY OPERATION AND ALARMS
4.1 EMERGENCY CONDITIONS OPERATION
4.1.1 One Turbine Driven BFP trip
4.1.2 HP Heater Tube Leakage
4.1.3 Abnormal Deaerator Water Levels
4.2 ALARMS
5.0 INSTRUMENTATION & PROCESS CONTROL
5.1 INSTRUMENTATION & PROCESS CONTROL
5.1.1 Motor Driven Boiler Feed Pumps & Booster pumps (2 x 25 %)
5.1.2 Turbine Driven Boiler Feed Pumps & Booster pumps (2 x 50 %)
5.1.3 Pump minimum recirculation flow Control
5.1.4 Feedwater Control
6.0 INTERLOCKS AND PROTECTION
6.1 INSTRUMENTATION & PROCESS CONTROL
6.1.1 BFP Discharge valves & integral bypass MOV
6.1.2 HP Heater bypass MOV
6.1.3 HP Heater inlet MOV (1LAB40AA001/1LAB43AA001) & integral bypass MOV
(1LAB40AA003/1LAB43AA003):
6.1.4 HP Heater outlet MOV (1LAB41AA001/1LAB44AA001) & integral bypass MOV
(1LAB41AA001A/1LAB44AA001A/1LAB41AA001B/1LAB44AA001B):
6.1.5 Clean up from HTR 8A/8B outlet MOV (1LAB41AA002/1LAB44AA002) & integral
bypass MOV (1LAB41AA002A / 1LAB44AA002A / 1LAB41AA002B /
1LAB44AA002B):
6.1.6 LP/HP HEATER CLEAN UP BLOW MOV (1LAB44AA005):
6.1.7 LP/HP HEATER CLEAN UP RECIRCULATION MOV (1LAB44AA006):
6.1.8 LP CLEAN UP ISOLATION MOV (1LAA20AA003):
6.1.9 BFP Discharge re-heater de-super heater isolation valves
6.1.10 Feedwater Control valve inlet isolation MOV (1LAB29AA001) & integral bypass
MOV (1LAB29AA001A & 1LAB29AA001B)
6.1.11 Feedwater Control valve outlet isolation MOV (1LAB29AA002) & integral bypass
MOV (1LAB29AA002A & 1LAB29AA002B)
6.1.12 Feedwater Control valve bypass MOV (1LAB28AA001) & integral bypass MOV
(1LAB28AA001A & 1LAB28AA001B)
6.1.13 BFP warm up MOV
6.1.14 BFP Blow off MOV
6.1.15 BFP DRIVE TURBINE DRIVES
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
7.0 VALVE LINE-UP LIST
7.1 LIST
ABBREVIATIONS
EXHIBITS
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
1.0 OVERVIEW OF FEEDWATER SYSTEM
LTSL-M0-00951 REV 0 Page 179 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Chapter 1
Overview of Feedwater System
1.1 Purpose
The purpose of feedwater system O&M manual document is to provide the
operating personnel with necessary information to safely operate and maintain the
feed water system & associated equipment.
The scope of the manual covers an overview of the Feed water System,
description of its major components with associated equipment & devices and
details of the startup, shutdown and normal operation and process control.
The feedwater system maintains continuous supply of feedwater to the boiler,
according to the requirements of flow and pressure. After undergoing chemical
treatment, polishing and heating in LP heaters, the condensate enters the
deaerator, where non-condensable gases are removed. After further chemical
treatment, it goes to the Boiler Feedwater Pump, HP feedwater heaters and
ultimately to the Economizer.
Each unit is equipped with 2 X 50 % Turbine Driven BFPs (TDBFP) and 2 X 25 %
Motor Driven BFP (MDBFP). During normal operation both TDBFPs will be in
operation, whereas MDBFP will be used mostly for start up or during normal
operation in case of non-availability of any TDBFP. These pumps transfer the
feedwater from the deaerator to the HP heaters. The spray water for the HP
turbine bypass is also supplied from the pump outlets. Super-heater (SH) spray
water is supplied from economizer outlet header; re-heater (RH) spray water is
supplied from BFP inter-stages.
LTSL-M0-00951 REV 0 Page 180 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Booster Pumps are installed upstream of all TDBFPs and MDBFPs. The ones
used for TDBFPs are driven by the BFPT via a speed reduction gear; the ones for
MDBFPs are directly coupled to main pump motor.
HP heaters (nos. 6, 7 and 8) provide regenerative feedwater heating using
extraction steam from the IP/HP turbine.
LTSL-M0-00951 REV 0 Page 181 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
1.2 Specifications
1.2.1 Design Data of Major Equipment
A. BFP Group Data sheet
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
Main BFP / Main BFP /
1.0 General
Booster Pump Booster Pump
1.1 Manufacturer Flowserve Flowserve
80CHTA-6 6x14CSB-6 /
1.2 Model No.
/10HDX27A 8HDX27B
Quantity per unit x
1.3 2x50% 2X25%
capacity
1.4 Type Horizontal Horizontal
Boiler Feed
1.5 Liquid handled Boiler Feed Water
Water
1.6 Type of drive Turbine Motor
2.0 Design and Performance Data
Rated Performance (Design
Main BFP / Main BFP /
2.1 VWO, 3% M.U, 10% flow
Booster Pump Booster Pump
margin.
Suction
(a) ºC 186.3/186.1 186.4/186.1
Temperature
(b) Specific Volume m3/kg 0.00113 0.00113
Capacity (Booster
(c) includes warm up m3/hr 1498 / 1520.7 749 / 765
flow)
Inlet Flow (Booster
(d) includes warm up m3/hr 1498 / 1520.7 749 / 765
flow)
Minimum flow
through the pump
(e) m3/hr 374.5/ 419.5 206.6/ 227.3
(Booster includes
warm up flow)
Runout flow ( One
pump at design
(f) speed) (Booster m3/hr 1943 / 1965.7 1006.4 /1022.4
includes warm up
flow)
(g) Interstage flow m3/hr 48 24
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
Frequency range for
the operation of the 48.5 Hz to 51.5
(h) m3/hr N/A
pump under rated Hz
flow
(i) Suction Pressure kg/cm2(a) 26.3 / 14.0 27.9 / 14.0
(j) Inter stage Pressure kg/cm2(a) 120.9 126.2
(k) Discharge Pressure kg/cm2(a) 326.2 326.2
Interstage o
(l) C 187.9 188.1
Temperature
Discharge o
(m) C 191.3 191.5
Temperature
Total Developed
(n) m 3400.8 / 152.9 3381.9 / 170.8
Head
Interstage Total
(o) Developed Head m 1073.1 1115
Barrel only
Interconnecting pipe
(p) losses including flow m 13.7 12.7
measuring device
Pressure Drop in
suction strainer of
Booster pump a) a) 0.1kg/cm2 a) 0.1kg/cm2
(q) m
when clean b) at b) 0.15 kg/cm2 b) 0.15 kg/cm2
50% clogged
condition c)
Maximum Shut-off
(s) head (head at m 4247.2 / 173.2 4129.4 / 194.4
design speed)
Maximum Interstage
(t) Shut-off head (head m 1378.6 / 173.2 1376.5 / 194.4
at design speed)
NPSH Required at
(u) 3%, 1% and 0% At 3% At 3%
head break
41.4 (Main
31 (Main pump)
- Design flow m pump) 4.9
2.9 (Booster)
(Booster)
- At run out flow 78 (Main
60.2 (Main pump)
(One pump at m pump)
4.9 (Booster)
design speed) 7 (Booster)
- During Transient
m 6.0 6.0
operation
164.5 (Main 183.2 (Main
NPSHA at design
m pump) pump)
point
25.8 (Booster) 25.8 (Booster)
LTSL-M0-00951 REV 0 Page 183 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
(v) Pump efficiency % 86.9 / 84.0 84.5 / 75.3
Losses in Hydraulic
(w) kW 12 983.2
Coupling + gear box
Overall efficiency of
(x) % 86.8 83.9
the Pump set
Total Power input
required to pump set
(main pump,
(y) kW 14426 8438
booster pump &
hydraulic coupling)
at rated flow & head
(z) Efficiency of Motor % NA 96.9
8708 (Rated
Power input to
(aa) kW 15100 (Rated) mechanical
Turbine / Motor
power: 9710 kW)
Power input required
(ab) kW 15098 8879
at run out flow
Power consumption
(ac) kW 8000 4000
at pump shut-off
(ad) Operating speed RPM 5530 / 1507 5209 / 1492
NPSH Required 41.4 31.0
(ae) m
main pump (rated point) (rated point)
Critical speeds for
(af) pump motor rpm 6914 6649
assembly
Minimum speed
(ag) pump can operate rpm 3100 / 845 1500 / 800
continuously.
Minimum speed
requirement for
(ah) TDBFP during rpm 80/21 NA
barring gear
operation.
Maximum possible
speed of BFP unit
(ai) during reverse rpm 5530 / 1507 5215 / 1492
rotation due to back
flow of water
Maximum Speed at
(aj) rpm 5530 / 1507 5215 / 1537
duty point
Maximum noise
(ak) level at 1.0m from dBA 85 85
pump outline
LTSL-M0-00951 REV 0 Page 184 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
Permissible variation
(al) in load sharing 1% 1%
between pumps
38.7 38.7
(am) Warm up Flow m3/hr TDBFP(22.7) TDBFP(22.7)
MDBFP(16) MDBFP(16)
Head developed per
(an) m 566.8 563.7
stage
Pump Performance 100% Main BFP / Main BFP /
2.2
TMCR 0% MU Booster Pump Booster Pump
Suction o
(a) C 185.3/185.1 185.4/185. 1
Temperature
(b) Specific Volume m3/kg 0.00113 0.00113
(c) Capacity m3/hr 1260 / 1282.7 630.0 / 646.0
(d) Inlet Flow m3/hr 1260 / 1282.7 630.0 / 646.0
(e) Interstage flow m3/hr 42.78 21.39
(f) Suction Pressure kg/cm2(a) 25.6 / 14.0 28.9 / 14.0
(g) Interstage Pressure kg/cm2(a) 117.6 123.4
(h) Discharge Pressure kg/cm2(a) 314.7 / 25.6 314.7 / 28.9
Interstage o
(i) C 186.8 187.1
Temperature
Discharge o
(j) C 190.1 190.5
Temperature
Total Developed
(k) m 3274.7 / 141 3237.8 / 177.2
Head
Interstage Total
(l) Developed Head m 1041.4 1070.4
Barrel only
(m) NPSH Required m 31.6 / 4.0 23.4 / 2.5
(n) Pump efficiency % 86.9 / 81.2 83.0 / 72.5
Losses in Hydraulic
(o) kW 10.8 1244
Coupling + gear box
Overall efficiency of
(p) % 86.7 82.4
the Pump set
Total Power input
required to pump set
(q) kW 11680 7389
(main pump,
booster pump &
LTSL-M0-00951 REV 0 Page 185 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
hydraulic coupling)
at rated flow & head
(r) Efficiency of Motor % N/A 96.7
(s) Power input to motor kW N/A 7641
Power input required
(t) kW 15098 8879
at run out flow
Power consumption
(u) kW 6795 3476
at pump shut-off
(v) Operating speed rpm 5228 / 1425 4960 / 1492
Pump performance at Main BFP / Main BFP /
2.3
Maximum Run out flow Booster Pump Booster Pump
a) Capacity m3/hr 1943 / 1965.7 1006.4 / 1022.4
b) Inlet Flow m3/hr 1943 / 1965.7 1006.4 / 1022.4
c) Interstage flow m3/hr 48 24
d) Suction Pressure kg/cm2(a) 23.6 / 14.0 25.1 / 14.0
e) Interstage Pressure kg/cm2(a) 90.6 98.5
f) Discharge Pressure kg/cm2(a) 242 250.6
Total Developed
g) m 2476.3/ 131.7 2557.7 / 148.4
Head
Interstage Total
h) Developed Head m 760 832.6
Barrel only
i) NPSH Required m 78.0 / 7.0 60.2 / 4.9
j) Pump efficiency % 80 / 84.1 82.8 / 71.8
Total Power
k) kW 15098 8879
consumption
Main BFP / Main BFP /
3.0 Construction
Booster Pump Booster Pump
3.1 Type of casing Barrel / Volute
Type of impeller
3.2 Closed Series / Closed
arrangement
3.3 No. of stages Six / One Six / One
3.4 Volute No / Yes
3.5 Shaft Heavy duty
3.6 Shaft Seal Mechanical. Cartridge type
LTSL-M0-00951 REV 0 Page 186 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
Main Pump
API Plan-23 Double Cooler
(2x100%)
Cooling
3.7
arrangement of seal
Booster Pump
API Plan-23 Single Cooler
(1x100%)
3.8 Coupling Flexible with spacer
Suction and
3.9 Discharge Nozzle Top - Top
location
Type of shaft Sleeve /
3.10 Sleeve / Ball
bearing Sleeve
Tilting pad
Type of thrust
3.11 / Tilting Tilting pad / Ball
bearing
pad
Type of axial Flanged Balancing Drum / Not
3.12
balancing device applicable
3.13 BFP suction strainer
(a) Type NA / Simplex basket
(b) Strainer mesh
NA / 40 - 100 mesh
size coarse / fine
(c) Ratio of Strainer
free area to inlet NA / >5
nozzle size
Seals for Booster
3.14
Pump and BFP
(a) Type Cartridge
(b) Make Flowserve
(c) life hrs 16 000
Time required for
BFP to start (from
zero speed to full
3.15 Sec NA < 15 s
load with discharge
valve in full open
condition)
Main BFP / Main BFP /
4.0 Materials of construction
Booster Pump Booster Pump
A336 F11/ A336 F11/ A487
4.1 Outer casing
A487 CA6NM CA6NM
4.2 Inner casing A487 CA6NM A487 CA6NM
4.3 Impellers A487 CA6NM A487 CA6NM
LTSL-M0-00951 REV 0 Page 187 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
A582 Ty 416
Casing Wearing A582 Ty 416 (352-
(352-415
4.4 rings material/ 415 BHN) / A426
BHN) / A426
hardness (BHN) CPCA15
CPCA15
Impeller Wearing
NA / A426 NA / A426
4.5 rings material/
CPCA15 CPCA15
hardness (BHN)
4.6 Pump Shaft A276 Ty 410 A 276 Ty 410
NA / A276 Ty
4.7 Shaft nuts NA / A 276 Ty 410
410
NA / A276 Ty
4.8 Shaft sleeves NA / A276 Ty 410
410
4.9 Diffuser / Volute A 487 CA6NM A 487 CA6NM
Strainer mesh
material support (a)
316 SS
gauge no. for
a) 40 mesh 316 SS
perforated stainless
4.10 coarse a) 40 mesh coarse
steel supporting
b) 100 mesh b) 100 mesh fine
plate (b) gauge no.
fine
of wire for screen
mesh
Strainer body
4.11 Carbon steel Carbon steel
material
A582 Ty 416 /
4.12 Balance drum A582 Ty 416 / NA
NA
Pressure bolting
4.13 A 193 Gr B7 A 193 Gr B7
studs
4.14 Nuts A194 Gr 2H A194 Gr 2H
Structural
4.15 Base plate Structural Steel
Steel
Main: A217
Main: A217 WC6
WC6 and A
Suction and and A 336 F11
4.16 336 F11
Discharge Nozzle Booster: A 487
Booster: A
CA6 NM
487 CA6 NM
4.17 Coupling Flexible discs - Flender make
4.18 Hydraulic Coupling DIN Materials
a)Coupling wheels G-X5CrNi13
b)Coupling wheels
EN- GJL-300
casing
NA
c)Scoop tube Stellit
d)Step up gear
18CrNiMo7-6
Pinion
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
4.19 Seal casing
Carbon / Carbon / Silicon
a) Faces
Silicon Carbide Carbide
b) Springs Alloy C-276 Alloy C-276
c) Holder Gland 316 L 316 L
d) O-rings Fluorelastomer Fluorelastomer
Main BFP / Main BFP /
5.0 Physical Data
Booster Pump Booster Pump
5.1 Miscellaneous
Empty: 14575 / Empty: 14000 /
Pump Total Weight 2920 2867
(a) kg
(empty / Flooded) Flooded: 14925 Flooded: 14200 /
/ 3220 3098
Largest Weight To
Be Handled
(b) (Individual Piece or kg 14575 / 3200 14000
Assembly During
Maintenance)
Rotation of pump
(c) seen from Coupling CCW / CCW CCW / CCW
end
1479(S) /
Distance From 975(S) / 950(D)
1253(D)
Pump Centre Line
(d) mm
To Suction(S) /
Discharge(D) Flange 630(S) / 630(D) 700(S) / 700(D)
Height Above
Operating Floor Of 2784(P) / 2209(P) /
(e) mm
Pump(P)/Motor(M)/T 5724(T) 3742(M)
urbine(T) Assembly
Moment Of Inertia
Of Rotating 7.16 (WR^2) / 4.64 (WR^2) /
(f) kg x m2
Assembly Including 7.25 7.00
Pumped Liquid
Main: Main:
Suction Connection 18” 600# RF 10” 300# RF
(g)
(Size/Rating/Type) Booster: Booster:
16” 300# RF 12” 300# RF
Discharge Main: 12” BW Main: 8” BW
(h) Connection Booster: Booster:
(Size/Rating/Type) 10” 300# RF 8” 300# RF
Take off Nozzle Main: 4” BW Main: 2.5” BW
(i)
(Size/Rating/Type)
LTSL-M0-00951 REV 0 Page 189 of 860
JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
Balance leak off Main: 2” 600# Main: 1.5” 600#
(j) line(Size/Rating/ RF RF
Type)
Warm up line
Main: 2” BW Main: 2” BW
(k) connection
(Size/Rating/Type)
Suction impeller Main: Single
Main: Single
(l) Type (single / Booster:
Booster: Double
double) Double
Sleeve Tilting
Sleeve Tilting Pad
(m) Pump Bearing Type Pad / Sleeve
/ Ball - Ball
Tilting Pad
(n) Shaft Seal
1) Type Cartridge Cartridge
2) Materials SS 316 L SS 316 L
3) API Plan for API 23 + Plan
API 23 + Plan M
cooling water M
4) Seal Flush Water
Internal Internal
Flow Rate
Pump shaft
(o)
Coupling
Flexible with Flexible with
1) Type
Spacer Spacer
Siemens/
2) Manufacturer Siemens/Rathi
Rathi
(p) Impeller diameter
1) Design 385 / 675 381 / 690
2) Maximum 385 / 675 381 / 690
(q) Bearing ‘TD’ s
PT 100 3 Wire PT 100 3 Wire
1) Type
Duplex Type Duplex Type
2) Manufacturer
Wika Wika
/Model No.
o
3) Alarm Set point C 85 85
4) Shutdown Set o
C 95 95
point
5) Minimum 0.36 to 0.43 0.36 to 0.43
clearance between (main) (main)
stationary rotating 0.65 to 0.75 0.60 to 0.70
parts (Booster) (Booster)
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
Casing
except for Voith
vibration limits
Casing vibration
Maximum peak to are as per ISO
limits are as per
peak vibration i) at 10816-
ISO 10816-
(r) rated condition ii) at microns 7 one A and
7 one A and ISO
other operating ISO
7919-3 for shaft
condition 7919-3 for
vibration limits
shaft vibration
one A.
limits one A.
Pump Speed range 5530 - 3100 / 5215 - 2689 /
(s) rpm
(Max/Min) 1507 - 845 1492-1447
Hydraulic Coupling
5.2
for each MDBFP
Planetary Gear /
(a) Type / Model No. NA
R17K550M
(b) Manufacturer NA Voith
(c) Input motor speed NA 1492
(d) ear ratio NA AGMA 1.4
Range of speed
(e) NA 4÷1
control
Primary start-up
(f) NA 1492
speed
(g) Full load slip NA 2.67%
Secondary speed
(h) NA 5470
(maximum)
Number of bearings
(i) NA 10 / Sleeve
/ type
Material (i) Impeller (i) G-X5CrNi13 (ii)
(j) (ii) Casing (iii) Scoop NA EN-GJL-300 (iii)
Tube Stellit
Lube Oil duplex
(k)
Filter
(i) Type NA DU631
(ii) Make NA Internormen
(iii) Mesh Size NA 25 microns
EN-GJS-400- 18-
(iv) Material - Casing
NA LT / Stainless
- Filtering element
steel
(l) Performance
a) Slip between
impeller and runner NA 7.33%
at normal load
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Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
b) Maximum
possible slip
See Voith
between impeller
NA performance
and runner at design
curve
ratings of driven
equipment
c) Scoop tube min.
position to start the
NA 0%
unit Oil
recommended
d) Response time of
scoop tube element
sec NA ca 10 sec
to move from zero to
100% position
e) Response time of
control element to
move from one sec NA ca 15 sec
extreme position to
other/.
Oil tank storage
(m) NA 3000 litres
capacity
Working Oil cooler a) Shell-tubes
a) Type b) DIN EN 10217
b) Shell material P235
c) Channel material c) EN 10028-2
d) Tube sheet P265GH
material d) CuAl10Ni
(n) NA
e) Tube material (2.0966)
f) Size of the tubes e) X5CrNi1810
g) No. of Tubes (1.4301)
h) No. of coolers f) Dia. =10 mm
(Working+Standby) g) 768
h) 1 + 1
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Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
Lube Oil cooler a) Shell-tubes
a) Type b) DIN EN 10217
b) Shell P235
material c) DIN EN 1561
c) Channel material EN-GJL-250
d) Tube sheet d) CuAl10Ni
(o) NA
material (2.0966)
e) Tube material e) X5CrNi1810
f) Size of the tubes (1.4301)
g) No. of Tubes f) Dia. = 10 mm
h) No. of coolers g) 462
(Working+Standby) h) 1 + 1
Oil Pumps a) 2 + 1
b) 1 shaft driven
a) Numbers working oil pump
(Working+Standby) +
1 shaft driven
b) Type lube oil pump + 1
motor driven aux.
(p) c) Design capacity NA lube oil pump
c) 1000 + 540 +
d) Total head 485 l/min
d) 1.5 + 6 + 6 bar
e) Material - Casing e) Casing EN-
- Impeller - Shaft GJL- 200.
Impeller GGG40.
Shaft C45+N
Cooling water
5.3 See point 8 See point 8
requirement
a) Voith
Hydraulic coupling
b) Electro
5.4 scoop tube actuator NA
Hydraulic
a) Make b) Type
actuated
Main Yes. Multi-plate Yes. Multi-plate
Idle pump warm-up
5.5 Pump Orifice supplied Orifice supplied
system
only loose loose
5.6 Acoustic enclosure Yes Yes
Lubricating Oil
6.0 System for each
MDBFP
Type of pump / Shaft driven + motor driven / Voith-
6.1
Manufacture Rickmeier
6.2 Number of pump 1 shaft driven + 1 Stand by (AC)
6.3 Pump speed rpm 1450
6.4 Motor rating of W 18.5
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Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
pumps
Pump casing
6.5 EN- GJL-200
material
Pump impeller
6.6 GGG40
material
6.7 Shaft material C45+N
Number of full
6.8 capacity lube oil 1+1
coolers (W + S)
6.9 Material
(a) Shell material DIN EN 10217 P235
(b) Channel material DIN EN 1561 EN-GJL-250
(c) Tube sheet material CuAl10Ni (2.0966)
(d) Tube material X5CrNi1810 (1.4301)
6.9 Filler type and make Duplex, in Voith supply.
6.10 Capacity of oil Sump m3 3
Lube oil Grade
6.11 (Common for ISO VG 32
MDBFP set) (ISO)
Lubricating Oil
7.0 requirement for
TDBFP set
(a) Flow m3/hr 9.6
Lube Oil pressure at
(b) Terminal point kg/cm2 1.00 kg/cm2 (a)
(return)
Lube Oil
temperature at o
(c) C 50 to 85 (Normal)
terminal point
(Return)
Cooling water Main BFP / Main BFP /
8.0
requirement Booster Pump Booster Pump
8.1 Lube oil coolers m3/hr NA 40
8.2 Working Oil coolers m3/hr NA 218
8.3 Seal Coolers m3/hr 3.6 / 3 3.6 / 3
Others (Motor air m3/hr
8.4 NA 45
cooler)
Total cooling water
m3/hr 6.6 309.6
requirement
Pressure drop in
cooling water
8.5 kg/cm2 1 1
system between
terminal points
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Sl.
ITEMS UNITS VALUES/REMARKS
No.
TDBFP MDBFP
8.6 Temperature rise
Temperature rise
o
across the lube oil C NA 5
cooler
Temperature rise
o
across the Seal C 5 5
cooler
Temperature rise
o
across the Working C NA 7
oil cooler
9.0 Gear Box for TDBFP
9.1 Casing material FG-300 IS:210 / FE410WA IS:2062
9.2 gear Material 17CrNiMo6 - DIN - 17210
9.3 Pinion Material 17CrNiMo6 - DIN - 17210
9.4 Service Factor 2
9.5 Design code AGMA 6011 - 103
B. BFP Drive Turbine (BFPT)
Technical data Units
Manufacturer Siemens
Turbine model SST-600
Number of drive turbines Two per unit No.
Type of Turbine Condensing
No of Stages 15
Steam admission Single
85 at 1m from outline of
Maximum noise level dBA
equipment
Direction of rotation viewed from steam
Counterclockwise
admission end
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Technical data Units
Power output front / rear
Design output 756 / 14423 kW
Rated output 589 / 11184 kW
Maximum output (turbine coupling) 756 / 14423 kW
Speed
Turbine (design) 5530 rpm
Driven machine 5530 rpm
Minimum continuous operating speed 3100 rpm
Maximum continuous operating speed 5530 rpm
Trip speed electric/electric (controller) 6083 / 6194 rpm
Minimum continuous speed (on turning
gear) Turbine: 80 rpm
Steam pressure
The allowable pressures, whose duration is limited, are only acceptable for
unforeseen fluctuations in operating conditions. It is assumed that these values
will only be tolerated within narrow limits, in particular at maximum pressure and
maximum temperature.
Main steam pressure, maximum 14.78 kg/cm2
Main steam pressure, normal 11.46 kg/cm2
kg/cm2
- allowable deviation as defined by IEC
14.79
45 to (annual average)
- allowable deviation as defined by IEC kg/cm2
45 to (the specified annual average 15.5
may not be exceeded)
- allowable deviation as defined by IEC kg/cm2
45 to (instantaneous value for an 17.74
overall duration of max. 12 hours/year)
Wheel chamber pressure (with mineral kg/cm2
deposits and at maximum load), 14.27
maximum
Exhaust steam, can increase to 0.2 kg/cm2
Cold reheat pressure, standard/max. 53.6 / 63.7 kg/cm2
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Technical data Units
Steam temperature
The allowable pressures, whose duration is limited, are only acceptable for
unforeseen fluctuations in operating conditions. It is assumed that these values
will only be tolerated within narrow limits, in particular at maximum pressure and
maximum temperature.
Main steam (design) 356.8 °C
Main steam, allowable deviation as
defined by IEC 45* to (annual
365 °C
average: top limit permitted without
any time restrictions)
Main steam, allowable deviation as
defined by IEC 45* to (for extended
373 °C
period: the specified annual average
may not be exceeded)
Main steam, allowable deviation as
defined by IEC 45* to (for 400
379 °C
hours/year: the specified annual
average may not be exceeded)
Main steam, allowable deviation as
defined by IEC 45* to (for 80
393 °C
hours/year: the specified annual
average may not be exceeded)
Cold reheat, standard/max. 342.7 / 366 °C
Exhaust steam (normal/zero load) 45 / 43 °C
Startup times for cold startup
The values given are limits.
We recommend longer periods to reduce stress and wear on materials.
Startup time, minimum 27 min.
Load application time, minimum 7 min.
Startup and load application time,
34 min.
minimum
Warmup time period between opening
of trip valve and opening of throttle 5 min.
valve
Oil requirements
Oil type IOS VG 32
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Technical data Units
Oil pressures
The following pressures are given as operating gauge pressures
Viscosity class VG 32
Lube oil 2.55 kg/cm2
Control oil 9.2 kg/cm2
Trip oil 9.2 kg/cm2
Jacking oil 122.4 kg/cm2
Lubricating oil volumetric flow, m3/h
Journal bearing, front (turbine) 5.83 m3/h
Journal bearing, rear (turbine) 9.75 m3/h
Thrust bearing 4.2 m3/h
Oil flow rates
Turbine journal bearing, front 5.83 m3/h
Turbine journal bearing, rear 9.75 m3/h
Turbine thrust bearing 4.20 m3/h
Shaft jacking pump 1.20 m3/h
Safety 10.20 m3/h
Lube oil (total) 31.10 m3/h
Control oil / leakage oil 9.50 m3/h
Total oil flow rate 52.00 m3/h
Oil tank / base frame with heating system
Nominal volumetric capacity 6.30 m3
Initial oil fill 7.80 m3
Highest oil level
(measured from top edge of oil tank 275 mm
during standstill)
Lowest oil level
(measured from top edge of oil tank 375 mm
during operation)
Heating system 7.5 kW
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Technical data Units
Oil cooler with changeover valve and temperature controller
Manufacturer DELMAS
Model SBD-E-30/345
No. each (duty oil coolers / standby oil
2
coolers)
Temperature controller MVA
Oil filter (control oil)
Manufacturer HYDAC
Model AFLD MM502
Allowable differential pressure
0.61 kg/cm2
(alarm/trip) [pe = bar]
Oil filter (lube oil)
Manufacturer HYDAC
Model AFLDG / HC882
Allowable differential pressure (alarm) 0.61 kg/cm2
Main oil pump
Manufacturer Allweiler
Model NSSV 2/50-250
Flow rate 52.0 m3/h
Pressure 10.2 kg/cm2
Speed 2954 rpm
Drive
Auxiliary oil pump
Manufacturer Allweiler
Model NSSV 2/50-250
Flow rate 52.0 m3/h
Pressure 10.2 kg/cm2
Speed 2954 rpm
Drive
Jacking oil pump
Manufacturer Parker
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Technical data Units
Model PHSDEC 0487.790
Flow rate 1.2 m3/h
Pressure 122.4 kg/cm2
Speed 1463 rpm
Drive
Oil mist eliminator
Manufacturer FRANKE
Model FF2-099
Lube oil accumulator
Manufacturer HYDAC
Model SB 330 B accmin
Initial fill pressure 7.3 kg/cm2
Filling and test unit FPU-1-010 F2
Control oil accumulator
Manufacturer OLAER
Model EBV 100 oil acc
Initial fill pressure 5.6 kg/cm2
Filling and test unit VG 3
Steam system
All pressures given as gauge pressures
Steam control valve, admission
Manufacturer HORA
Model DN40 / PN40
Overall dimension DN40
Safety valve, exhaust steam, 10% rupture disk
Manufacturer REMB
Model BT-RODV-FSA-8
Overall dimension DN200
Valve begins to open at 1.35 kg/cm2
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Technical data Units
Flow Pressure
Speed
Oil pump Make Model (m3/h), (kg/cm²) (rpm) Drive
max.
Main oil
Allweiler NSSV 2/50-250 52.0 10.2 2954 AC motor
pump
Auxiliary oil
Allweiler NSSV 2/50-250 52.0 10.2 2954 AC motor
pump
Emergency
Allweiler NSSV 40-250 27 2.55 2000 DC motor
oil pump
Jacking oil
Parker PHSDEC 0487.790 1.2 122.4 1463 AC motor
pump
C. HP HEATERS
Sr.
Description No. 6 No. 7 No. 8
No.
1. No. of heaters Two (2) Two (2) Two (2)
1LAD31A 1LAD21A 1LAD11A
C001, C001, C001,
2. Equipment no.
1LAD32A 1LAD22A 1LAD12A
C001 C001 C001
Desuperheating zone Heating 147.44 164.42 203.18
3.
surface m2 m2 m2
877.04 1152.05 1050.10
4. Condensing zone Heating surface
m2 m2 m2
352.92 282.34 136.09
5. Drain cooling zone Heating surface
m2 m2 m2
6. Shell side design pressure 36.0 74.0 111.0
kg/cm2 "G" kg/cm2 "G" kg/cm2 "G"
Shell side design temperature 533/ 245 383/290 457/320
7. o o o
(Shell skirt/shell) C C C
8. Water side design pressure 346.0 346.0 346.0
kg/cm2 "G" kg/cm2 "G" kg/cm2 "G"
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9. Water side design temperature 265 oC 310 oC 340 oC
Heating Tube
1. Outside diameter 15.9 mm 15.9 mm 15.9 mm
2. Thickness 2.30 mm 2.40 mm 2.40 mm
3. Effective straight length 7876 mm 8802 mm 7720 mm
1679 1750 1724
4. No. of U-tubes
pieces pieces pieces
5. No. of pass (water side) Two (2) Two (2) Two (2)
Material
SA688 SA688 SA688
1. Heating tube
TP304N * TP304N * TP304N *
SA516 SA516 SA516
2. Main Shell & Shell Side D'End
Gr70 Gr70 Gr70
SA387 SA387 SA387
3. Shell skirt
Gr22 Cl2 Gr11 Cl2 Gr11 Cl2
SA516 SA516 SA516
4. Channel Shell
Gr70 Gr70 Gr70
NOTE:
* SA 688 TP 304N is of superior quality than SS 304L.
D. DEAERATOR
Sr. No. Description Details
1. Quantity One (1) set
2. Equipment no. 1LAA10AC001
3. Internal diameter 4140 mm
4. Tan-Tan length 33000 mm
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
5. Overall length 35120 mm
6. Gross Storage capacity 462.8 m3
Normal operating condition (100% TMCR)
Feedwater inlet/outlet
7. 151.1 oC/ 185.1 oC
temperature
8. Heating steam pressure 11.47 kg/cm2(a)
9. Heating steam quantity 87.268 t/hr
Feedwater quantity (Condensate
10. 1571.877 t/hr
inlet)
11. Oxygen at storage tank outlet 7 ppb
12. Design pressure/temperature 14.0 & FV kg/cm2 (g) / 205 oC
Deaerator shell/storage tank
13. SA-516M Gr 485
material
1.2.2 Operation limit of the system
Sr. No. Description Details
1. MDBFP BP minimum flow 227.3 m3/hr
2. TDBFP BP minimum flow 419.5 m3/hr
3. MDBFP Operating Speed Max. / Min.
a. Main Pump 5215 / 1500 rpm
b. Booster Pump 1492 / 800 rpm
4. TDBFP Operating Speed Max. / Min.
a. Main Pump 5530 / 3100 rpm
b. Booster Pump 1507 / 845 rpm
BFPT Operating Speed
5. 5530 / 3100 rpm
(Max. / Min.)
6. Deaerator outlet oxygen 7 ppb*
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Sr. No. Description Details
Lo Lo – 870 mm
Lo – 2400 mm
7. Deaerator Level Hi – 3000 mm
Hi Hi – 3050 mm
Hi Hi Hi– 3100 mm
Lo – 155 mm
8. HPH 6A / 6B Level Hi – 215 mm
Hi Hi – 240 mm
Lo – 140 mm
9. HPH 7A / 7B Level Hi – 200 mm
Hi Hi – 225 mm
Lo – 110 mm
10. HPH 8A / 8B Level Hi – 170 mm
Hi Hi – 195 mm
* during AVT mode of operation
1.3 References
1.3.1 P & ID
a) Feed Water System P&ID _ Rev 2 Dwg. No. LTSL-M1-00202 (Sheet 1 to 5)
b) Start-up System P&ID LMB Dwg. No. 97000-2111-2
1.3.2 Control and Logic Diagrams
a) Basic Plan for I & C LMB Dwg. No. 61000-0111
b) Boiler Automatic Plant Control Diagram LMB Dwg. No. 61110-1001
1.3.3 Electrical Single Line Diagrams
a) Electrical Single Line Diagram for Auxiliary Power Distribution Dwg. No.
K6A24 – DWG – E – 0101 REV.D
1.3.4 Vendor Information
a) Motor driven boiler feed pump & booster pump : Flowserve
b) Turbine driven boiler feed pump & booster pump : Flowserve
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
c) HP Heaters : Larsen & Toubro Ltd.
d) Deaerator : Larsen & Toubro Ltd.
e) BFP Turbine Drive : Siemens
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2.0 SYSTEM DESCRIPTION
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Chapter 2
System Description
2.1 Overview
The main function of the feedwater system is to deliver feedwater to the boiler
continuously. This should occur regardless of the load or the transient conditions
of flow and pressure requirements of the system, including the spray water to HP
turbine bypass and to the RH de-superheaters.
Deaerator receives the condensate water from the outlet of LP heaters. The
degasified water gets stored in the deaerator. During normal operation feedwater
is fed by two (2) steam turbine driven boiler feed pumps (TDBFPs) having 50%
capacity each, whereas for start-up two (2) motor driven boiler feed water pump
(MDBFP) with 25% capacity each are used for feedwater supply.
Booster pumps are installed upstream of the BFPs to take care of the available
NPSH for the pumps. TDBFP booster pumps are connected to main drive shaft
through a speed reduction gear. Booster pumps for MDBFP are connected to the
main pump motor directly through coupling. The boiler feedwater booster pumps
then supply feedwater to the respective boiler feedwater pumps, which increase
the fluid pressure to meet the required system head. A tap off from the feedwater
header upstream of feed control station is provided to the HP Bypass de-
superheater for control of bypass steam temperature. Intermediate stage nozzles
on the boiler feedwater pumps supply spray water to the reheat de-superheater
for control of reheat steam temperature.
The feedwater then splits into two HP heater streams (A and B) each flow through
three high-pressure feedwater heaters (6A&B, 7A&B and 8A&B) where extraction
steam heats the feedwater. This results in improved cycle efficiency. The HP
heaters are protected against overpressure by the safety valves.
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A clean-up line is provided at deaerator outlet. This line is connected to
Atmospheric flash tank and condenser. It is used to discharge the water during
clean-up until the specified water quality is met. Motor operated valves are
installed in this line.
During normal operation, the Boiler Feed Pump Turbines (BFPTs) or Hydraulic
couplings are used for Feedwater Flow control by varying the pump speed. During
the unit startup and low loads, when it is not possible to control the feedwater flow
through speed control, feedwater flow shall be controlled by feedwater control
valve (1LAB29AA081) located at BFP discharge header.
2.2 Flow Path
The system flow path is described from the P&IDs (Attached in Exhibits). They are
grouped as:
• Path for feedwater from deaerator to Boiler Feedwater Pumps
• Path for feedwater from Boiler Feedwater Pumps to HP heater inlet.
• Path of feedwater going from HP heater to economizer inlet.
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Recirculation Recirculation Recirculation Recirculation IP turbine extraction Initial fill + Normal drain from Steam from CRH/aux.
from TDBFP A from TDBFP B from MDBFP A from MDBFP B steam condensate inlet HPH 6A/6B steam header
Deaerator
MDBFP (A) MDBFP (B) TDBFP (A) TDBFP (B)
Overflow line BP BP BP BP
to HP
flashtank Warm-up line
MDBFP (A) BFP BFP Recirc. to
Recirc. to BFP Recirc. to BFP Recirc. to
interstage discharge (M) (M) Deaerator
Deaerator (T) Deaerator (T) Deaerator
To Re-heater MDBFP (B) interstage discharge
Attemperator
TDBFP (A) interstage discharge
TDBFP (B) interstage discharge
BFP discharge header HP bypass system
FCV
HP Heater 6A HP Heater 6B
Process Flow Diagram
for
HP Heater 7A HP Heater 7B
Feedwater System
2x660 MW Jaypee
HP Heater 8A HP Heater 8B
Thermal Power Station
To economiser
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DCS Graphics: Deaerator & BFP
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DCS Graphics: HP Feedwater Heater
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DCS Graphics: BFPT
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
2.2.1 Feedwater from deaerator to Boiler Feedwater Pumps
Deaerator receives the condensate from LPH 4 outlet. The deaerated condensate
is supplied to the Booster pumps of the BFPs through the individual suction lines.
Connections of chemical feeds (Oxygen and Hydrazine) are provided in each
suction line for chemical treatment of the feed water.
The Booster Pump suction line is provided with a manual isolation valve (gear
operated - 1LAB10/11/12/13 AA101), a suction strainer and a relief valve. The
suction strainer has differential pressure indicator switch
(1LAB10/11/12/13CP080) provided across it, which helps in monitoring high
differential pressure alarm at DCS. It has also a drain and vent line with manual
isolation valve. The BP suction pressure is locally monitored by pressure indicator
(1LAB10/11/12/13CP501). Triple redundant pressure transmitters
(1LAB10/11/12/13CP001/002/003) are also provided for monitoring the suction
pressure. Suction temperature is monitored using a temperature element
(1LAB10/11/12/13CT002). The BP discharge line is provided with pressure switch
(1LAB14/15/16/17CP080) for low alarm. The Booster Pump feed water discharge
temperature is monitored through another temperature element
(1LAB14/15/16/17CT001).
The Booster Pump discharge line is connected to the MDBFP and TDBFP
suction. The suction flow of each BFP is measured by flow transmitters
(1LAB14/15/16/17CF001/002).
The tapping from the Booster Pump discharge line are connected to the common
warm up line and are used to warm up standby BFP.
BFP suction pressure and temperature are monitored locally by pressure indicator
(1LAB14/15/16/17CP001) and temperature indicator (1LAB14/15/16/17CT501)
respectively. The redundant pressure transmitters (1LAB20/22/24/26CP001/02)
and temperature sensing element (1LAB20/22/24/26CT001) are also provided for
monitoring.
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The discharge line has an NRV with subsequent motor operated valve
(1LAB20/22/24/26AA001) and joins the BFP common discharge header. Each
motor operated main discharge valve is provided with motor operated equalizing
valve for easy operation of the main valve. Limit switch has been fitted with the
main valve and with the equalizing valve to ensure open/close position feedback
of the valve.
Each BFP has a minimum recirculation flow line connected back to the deaerator
through a flow control valve (1LAB30/32/34/36AA081) and manual isolation
valves at the inlet and outlet of the control valve. The CV outlet pipe is provided
with a multistage orifice for pressure reduction, before it gets connected to
deaerator.
Feed water for RH temperature control (emergency) is tapped off from the
intermediate stage of the BFP. This line has a NRV and a motor operated
isolation valve (1LAF30/32/34/36AA001). The individual lines from interstage of
each BFPs join to form a common RH spray line and supplies the spray water to
the RH DSHs at the boiler end.
2.2.2 Boiler Feedwater Pumps to HP Heater inlet
The common discharge line for both MDBFP & TDBFP has a feed control station
consisting of a MOV (1LAB28AA001) and a low load (35%) control valve
(1LAB29AA081) for flow control. The flow control valve operates during startup
and low load, with MDBFP running at required hydraulic scoop position to
maintain fixed speed. Motor operated isolation valves (1LAB29AA001/002) with
one equalizer valve (also motor operated) are provided at upstream and
downstream of the low load FCV. The MOV (1LAB28AA001) remains full open
during normal operation, with TDBFP running through DEH governor control to
maintain feed water demand.
The common discharge piping is connected to HP heaters No.6A & 6B. Pressure
transmitter (1LAB48CP001) and temperature element (1LAB48CT001) are
provided to monitor the BFP common discharge header pressure and
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temperature. A tap off from the common discharge pipe line is taken for the HP
bypass valve de-superheater spray.
2.2.3 Boiler feedwater from HP heater no. 6 inlet to economizer inlet
The discharge lines from each unit’s Turbine Driven Boiler Feedwater Pumps and
Motor Driven Boiler Feedwater Pumps join into a common high-pressure header
that feeds 2 x 50% trains of high-pressure feedwater heaters. HP Feedwater
Heaters 6A&B, 7A&B and 8A&B have been provided for increasing the cycle
efficiency by heating the feedwater prior to entering the boiler economizer.
Feedwater flows through the tube side of the HP feedwater heaters and extraction
steam flows through the shell side of the HP feedwater heater.
Each 50% stream of HP heaters can be bypassed from feed water side through
motor operated valves provided at upstream (1LAB40/43AA001), downstream
(1LAB41/44AA001) and bypass line (1LAB40/43AA002) of feedwater heater
streams. One spring relief valve is provided across the feed water bypass valve of
each HP heater stream as per IBR requirement to ensure that feedwater system
downstream of Feed control station downstream isolation valve is not subjected to
BFP shut- off condition.
For charging of the HP heater train one motor operated valve (1LAB40/43AA003)
with orifice (1LAB40/43BP003) is provided across the HP heater train inlet MOV
(1LAB40/43AA001).
The inlet pressure and temperature are monitored through local pressure indicator
(1LAB40/43CP501) and temperature indicator (1LAB41/44CT505). For
supervision in DCS, pressure transmitter (1LAB40/43CP001) and temperature
element (1LAB41/44CT004) are also provided. HP heater No.6 outlet is
connected to HP heater No.7 inlet without any isolation valve. Similarly HP heater
No.7 outlet is connected to HP heater No.8 inlet without any isolation valve The
HP heater No.6 & 7 outlet temperatures are monitored by temperature elements
(1LAB41/44CT001 & 002).
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HP heater No.8 outlet is provided with MOV (1LAB41/44AA001) along with
equalizing valve. The HP heater No.8 outlet temperature is monitored by
temperature element (1LAB41/44CT003). HP heater No.8A & 8B outlets are
provided with clean up connections for cleanup and are tapped off before the
outlet MOV. The cleanup lines have been mounted with manual isolation valve
and MOV (1LAB41/44AA002) and join into a common line which goes to the
condenser and Atmospheric Flash tank. The clean-up connection line joins the LP
cleanup line from deaerator and is directed to Atmospheric Flash Tank through
motor operated blow valve (1LAB44AA005) and multiple orifices, and to
condenser through MOV (1LAB44AA006) and multiple orifice. During the clean up
blow, the MOV to Atmospheric Flash Tank is opened and when feed water quality
is OK, during the clean up recirculation, the MOV to condenser is opened. The
clean-up line has a relief valve.
2.3 Major Equipment
Boiler Feed Water System consists of the following major equipment and
components:
• Deaerator
• Boiler Feed Pumps (Motor and Turbine Driven)
• Booster Pumps
• HP Heaters
• Hydraulic Coupling & Oil Supply Unit for MDBFP
• Drive Turbine (BFPT) for TDBFPs
2.3.1 Deaerator
A STORK type deaerator is provided for removing the non-condensable gases
contained in the condensate water. The deaerator continuously supplies de-
gasified water. Steam for heating is supplied to the deaerator either from the
intermediate pressure turbine extraction steam or from the auxiliary steam system
during start-up or cold reheat steam line in case of FCB.
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The Stork feedwater deaerator is designed to extract oxygen out of the feed water
by using steam. The incoming water (condensate / make-up) is put into the
deaerator through a sprayer and at the same time steam is injected under the
water level.
The operation of the deaerator is based on physical deaeration which takes place
in two steps :
• Pre-deaeration in which water is sprayed in a part of the steam space.
• Final deaeration in the water tank where steam is brought in close contact
with the water.
The sprayer and all internals are specifically designed to de-aerate the incoming
water. The deaerator is at the same time used as a mixer / pre-heater and as a
storage tank.
The deaerator is constructed of Carbon-Steel and it consists of a cylindrical shell
provided with two dished ends.
The interior consists mainly of steam-sparger device(s) for injection of steam
under water level and specific baffles.
One manhole is provided to facilitate inspection of the deaerator.
An overflow line with pressure control valve (1LAR05AA081) is provided to divert
excess feed water to HP flash tank. The valve is provided with bypass MOV
(1LAR06AA001). The outlet nozzle of deaerator is extended to the inside of the
tank. This prevents the entry of foreign matter to the feed pump suction.
Fixed as well as sliding saddle supports account for longitudinal shift due to
expansion.
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2.3.2 Boiler Feedwater Pump
There are four (4) horizontal, centrifugal, multistage, double suction, double
casing, variable-speed pumps; of these two are motor driven (MDBFP) and two
are turbine driven (TDBFP).
Turbine Driven BFPs
Each unit’s Feedwater System is equipped with 2x50% turbine-driven pumps.
Each Turbine Driven Boiler Feedwater Pump takes suction directly from its
associated booster pump. A flow element is included at the suction to each
Turbine Driven Boiler Feedwater Pump to measure the total flow to pumps.
Turbine-driven Boiler Feedwater booster pump and turbine-driven boiler
Feedwater pump forms a set with common drive turbine and gearbox
arrangement.
Motor Driven BFPs
The Feedwater System is equipped with 2 x 25% Motor Driven boiler feedwater
pumps. The Motor Driven Boiler Feedwater Pump takes suction directly from its
Boiler Feedwater Booster Pump. The pump is driven with a variable speed
hydraulic coupling. A flow element is included at the suction to the Boiler
Feedwater Pump to measure the total flow to pump. Motor Driven pumps can also
work in parallel with TDBFP if one of the TDBFP fails. Motor Driven Boiler
Feedwater booster pump and Motor Driven boiler Feedwater pump forms a set
with common drive motor and hydraulic coupling arrangement.
In case of TDBFPs, feedwater flow is regulated by controlling the speed of the
steam turbine. In case of MDBFPS, feed water flow is to be regulated by a
hydraulic speed variator. Above mentioned regulation is applicable for load above
35 %. However, for load less than 35 % the feed water flow will be controlled by a
pneumatic feed control valve located on the common BFP discharge header and
MDBFP will run at a fixed speed.
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Each pump is provided with a minimum flow recirculation system. The spray water
to re-heater de-superheaters is tapped from the inter-stage of all the boiler feed
pumps.
Each pump series (booster pump and main pump) is provided with its own
modulating type minimum flow recirculation control valve which returns feedwater
to the unit’s deaerator. Manual shutoff valves are provided in each recirculation
line. These valves shall be locked opened and must be open at all times when it’s
associated pump is operating. The manual shutoff valve should be closed only
when the corresponding pump is out of service for maintenance and the
recirculation line is to be isolated.
Major Components of TDBFP and MDBFP are described below.
2.3.2.1 Rotating Element
Consisting of the shaft, impellers and any sleeves that might be used the
rotating element is pre-assembled for dynamic balance
2.3.2.2 Bundle Assembly
The rotating Assembly (bundle) is made up of the shaft, impellers, with
channel ring and diffusers assemblies. Consisting of the rotating element and
channel ring assemblies, the bundle is pre-assembled prior to insertion into the
barrel. Spiral wound gaskets are used to seal the suction pressure from the
discharge and/or from intermediate stage take off connections.
2.3.2.3 Outer Case and Discharge Head
The forged outer casing encloses the rotating assembly that is held firmly by
the forged discharge head. A spiral wound gasket is used to seal the main
flange joint between the discharge head and barrel.
2.3.2.4 Shaft
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The shaft furnished is machined from the highest quality material selected with
consideration to the service for which the pump is intended. It is machined with
stepped impeller mounting journals for ease in assembly / disassembly.
2.3.2.5 Impellers
Individually mounted impellers of one-piece construction are keyed to the shaft
with keyways on alternate sides. Each impeller is provided with interference fit
to the shaft journal areas of 0.08 mm to 0.13 mm (0.003" to 0.005")
diametrical.
2.3.2.6 Hydraulic balance System
Pumps are maintained in axial balance during operation by a self-
compensating flanged (rotating) balance drum and (stationary) counter
balance disc.
Located at the discharge end of the rotor the balance system effectively
counteracts the normal axial thrust developed by the rotor toward the suction
end of the pump.
During operation, the front end of balance disc is exposed to full discharge
pressure while the chamber at its back, being piped to the suction source, is
exposed to that pressure. With this, a thrust is developed equal in magnitude
and opposite in direction to that on the front side.
2.3.2.7 Wear Rings
Renewable case wear rings and diffuser bushing rings control the leakage rate
between them and the impeller skirt/hub turns.
2.3.2.8 Radial Bearings
Radial bearings are carbon steel backed, babbitt lined, sleeve-type inserts.
The renewable inserts are mounted in bearing bodies and are kept from
rotating by anti-rotation pins
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2.3.2.9 Thrust Bearings
The thrust bearing is of the equalizing type and canvary in size / thrust shoe
count depending on size. Residual thrust loads not carried by the hydraulic
balance system are taken up by the thrust bearing. Thrust is transmitted
through the thrust collar to the shoe segments by way of the shoe-to-shoe
supporting elements and then to the bearing housing and ultimately the
foundation.
2.3.2.10 Shaft Sealing Provisions
Mechanical seals provided are of proven high pressure / high temperature
design. These are provided with a flush system compatible to API Plan 23.
2.3.3 Booster Pump (BP)
BP for TDBFPs
The Feedwater System for each unit is equipped with 2 x 50% turbine-driven
radial split-casing booster pumps. Each Turbine Driven Boiler Feedwater Booster
Pump takes suction from that unit’s Deaerator via a dedicated line provided with
gear operated suction valve which is locked open in normal condition. Suction
pipes to the booster pumps are not cross-tied. At the suction of each booster
pump, a basket/simplex type suction strainer with associated instrumentation is
installed.
The TDBFP BP is mounted on the same shaft of TDBFP through a reduction gear
and is driven by BFPT.
BP for MDBFPs
Each unit’s Feedwater System is equipped with 2 x 25% radial split-case booster
pumps directly coupled to the motor of MDBFP. MDBFP Booster Pump takes
suction from the Deaerator via a dedicated line provided with gear operated
suction valve which is locked open in normal condition. At the suction of each
booster pump, a basket/simplex type suction strainer with associated
instrumentation is installed.
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The booster pumps are single stage, double suction impeller, double volute
radially split casing, centreline mounted, with top nozzles heavy duty process
pumps.
Major Components of booster pumps of TDBFP and MDBFP are described below.
2.3.3.1 Casing
The casing is radially split, dual volute, heavy walled, centerline supported to
achieve the safest and most simple sealing and centerline supported to
maintain alignment at high temperatures. Wall thickness and casing shape are
chosen for the maximum strength against stresses resulting from combined
high working pressure and high allowable external loads on flanges. The
double volute casing minimizes the radial thrust on the pump rotor and gives
longer life to the seals, bearings and wear rings.
2.3.3.2 Impeller
The standard double suction closed type impeller is mounted with an
interference fit and keyed to the shaft, positively secured against axial
movements by a step in the shaft and a threaded shaft nut.
Impellers are designed to handle hot liquids close to their boiling points. The
symmetric pressure distribution acting on impeller shrouds ensures complete
axial balance of the rotor.
2.3.3.3 Wearing Rings
The casing and the impeller are fitted with replaceable wear rings of hardened
material. The rings are held in place by a press fit with locking pins on the
casing and with threaded dowels on the impeller.
2.3.3.4 Rotors
Rotors are of the stiff shaft design. Shafts are of ample diameter, combined
with the minimum bearing span to minimize shaft deflectors especially when
the pump is operating at off peak conditions.
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2.3.3.5 Covers
Two covers, one full size at the outboard pump end which permits rotor
removal and one reduced size cover at inboard end provide circular type joints
and easy pump sealing with confined gaskets.
The metal to metal fit with confined controlled compression gasket insures
proper alignment between casing and cover.
2.3.3.6 Bearings
BP of TDBFP is equipped with babbitted sleeve line bearings and Ball thrust
bearings. Efficient ring oil lubrication systems ensure lubrication to both types
of bearings. The thrust ball bearing is of the double row (mounted back to
back) angular contact type, and is of ample size to carry the thrust loads
encountered in service. Bearing housings and bushings are split horizontally to
facilitate assembly and disassembly. The bearing assemblies are bolted and
doweled at the joint surfaces to prevent displacement and are secured to
support brackets integrally cast with the stuffing box covers. Both the line and
thrust bearing housing are provided with water jackets.
BP of MDBFP are fitted as standard with antifriction bearings. The radial
bearing is a deep groove type, while the thrust bearings are dual single row
angular contact type.
2.3.3.7 Coupling
A spacer type coupling, which permits removal of the Drive End mechanical
seal assembly without disturbing the pipe connection or driver alignment, is
standard. Different types of coupling can be specified.
2.3.4 HP Heaters
Two (2) sets each of HP No.6 heaters, HP No.7 heaters and HP No.8 heaters in
two trains are provided. The heaters are of surface type for horizontal installation,
with a tube bundle in ‘U’ form. The high-pressure heaters have integral de-
superheating and sub-cooling zones. High pressure heaters are designed
according to HEI Standards, ASME Code and manufacturer’s standard.
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Each heater stream can be bypassed from the feed water side in group by the
MOVs provided upstream, downstream as well as on a separate bypass line
across them.
The heaters are shell and U-tube type and mounted horizontally. The feed water
flows through the tubes of the heaters. Extraction steam from different stages of
turbine flows through the shell side of the heaters and it is used to raise the
temperature of the feed water in each heater. The steam is condensed in the
heater shell, and the condensed steam is cascaded to the next lower pressure
heater. This increases the thermal efficiency of the system.
HP heater has three (3) heat exchange sections i.e. de-superheating section,
condensing section, and sub-cooling section. The feed water in tube side flows
first through the sub-cooling section, and then through the condensing section and
finally through de-superheating section. In the heater shell side, the steam comes
in contact with the tube bundle surface for heat transfer through the de-
superheating section, the condensing section and finally the sub-cooling section.
The support plates will be spaced such that vibration and deflection in the tubes is
prevented. Deflector plates are provided to direct the flow within the body and are
of the same material as the support plates. In the steam intake connections and
drains to the body, impact plates are installed to prevent direct shock of the fluid
against the tubes.
To facilitate the installation and maintenance, lifting rings, bolts/lugs firmly secured
to the body is provided.
2.3.5 Hydraulic coupling and oil supply unit for MDBFP
2.3.5.1 Hydraulic Coupling
The speed of MDBFP is varied by hydraulic coupling and is of hydrodynamic,
horizontal mounting type. It consists of the following components:
• A gear incrementer to supply an output speed variation.
• A reverse-turn detector mounted in the output shaft.
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The hydraulic coupling is designed to continuously transmit the maximum
torque produced by the motor. All the rotating elements of the hydraulic
coupling are statically and dynamically balanced. The hydraulic coupling,
including the gear incrementer, is housed in a steel casing of rigid
construction, precisely machined to ensure a precise alignment of all the
components.
The hydraulic coupling unit has an oil system and is provided with an actuation
system. This actuation system is electric, with feedback circuits to correct the
output in relation to the input. The actuation system is designed to receive 4 to
20 mA, DC supply signal from the feedwater control system.
2.3.5.2 Oil Supply Unit
An oil supply unit is provided to supply working oil for the hydraulic coupling
and lube oil for the lubrication of the bearings of the main motor, BFP,
hydraulic coupling shaft, and main part of the hydraulic coupling.
The oil unit has an oil tank with level gauge, coolers, duplex-type filter, full-
capacity pump operated by an AC motor (AOP),shaft driven pump (MOP),
accessories and valves, forming a complete unit, fully assembled, piped and
wired, integral with the hydraulic coupling unit. All the instruments for
supervision and control of the pressure and temperature of the oil and cooling
water to the cooler is mounted in a board integral with the unit.
2.3.6 Drive Turbine (BFPT) for TDBFP
The purpose of the steam turbine is to convert the thermal energy in the steam to
mechanical energy.
The steam passes through the main steam connection, the steam strainer and the
emergency stop valve before the servo valves into the inlet part of the outer
casing. After opening of the servo valves, the steam flows into the steam
chamber, to pass through the jet groups into the expansion area of the turbine, by
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giving off its energy capacity and expanding up to the final pressure in the exhaust
part.
The turbine consists of the main assembly groups
• Turbine casing
• Front and rear bearings
• The turbine rotor with blading
• The blade mounts
• The sealing shells and
• the emergency stop and regulating valves with their actuators.
For more details, refer the Drive Turbine O&M manual (SIEG-MO-03660) in
Volume 2.
2.3.7 Warm-up line
Common warm up system is provided for all BFPs of each unit. A warm-up line
including NRV and Manual valve is tapped off from the discharge line of each
boiler feedwater booster pump and connected to common warm up header. From
common warm up header individual line is provided to each boiler feed pump(s)
drain connection through NRV, two (2) isolation valves and pressure breakdown
orifice. One of the isolation valves is kept as MOV and can be operated from DCS
to warm up the pump in hot standby mode of operation.
2.3.8 Feedwater control station
During normal operation, the Boiler Feed Pump Turbines (BFPTs) or Hydraulic couplings
of MDBFP are used for Feedwater Flow control by varying the pump speed. During the
unit startup and low loads, when it is not possible to control the feedwater flow through
speed control, feedwater flow shall be controlled by feedwater control valve
(1LAB29AA081) located at BFP discharge header. The valve is intended to operate
between 10% to 85% valve positions during its entire operating range.
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2.3.9 System piping
The Feedwater System piping is seamless carbon steel pipe and designed in
accordance with ANSI/ASME B31.1 Power Piping Code. Piping and piping
components are insulated with lightly resin bonded mineral (rock) wool and
covered with aluminum jacketing for heat retention and/or personnel protection.
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3.0 NORMAL OPERATION, START-UP AND
SHUTDOWN
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Chapter 3
Normal Operation, Start-up and Shutdown
3.1 Start-up and initial fill
3.1.1 Initial Fill
During initial fill of the Feedwater System, the low point drain valves are closed
and the high point vents are opened to remove air from the piping. A separate DM
line (1GHC70BR004) is provided, which joins the Condensate inlet line for initial
filling of Deaerator, feed water pumps and feedwater piping. Once the system is
filled, the high point vents needs to be closed.
During initial start-up, the tube-side of the feedwater heaters may be placed in
service in sequential order. The motor-operated equalizing valve across the
motor-operated inlet isolation valve should be opened prior to opening the main
isolation valve. Then, the motor-operated integral valve on the motor operated
isolation valve downstream of each feedwater heater should first be opened to
allow filling/pressure equalization of the feedwater heaters and associated piping.
Once all air has been evacuated from the heaters and piping, vent valves should
be closed and the main isolation valve of the respective feedwater heater should
be opened.
DANGER
Utmost care needs to be taken while operating manual vent valve
as high temperature feedwater may come out from the vents outlet
and gets evaporated. Wear a suitable working wear including
gloves
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During initial - start-up, it is imperative to follow the feedwater pump
manufacturer’s recommendations (Refer Volume-2, FPD-MO-03380 & FPD-MO-
03313) with regards to warming and start-up of the feedwater pumps.
3.1.2 Start-Up
Motor Driven Boiler Feedwater Booster Pump and Boiler Feedwater Pump
provide feedwater to the system during start-ups until sufficient steam is available
to operate turbine-driven Boiler Feedwater Pumps.
3.2 Normal operation
The Feedwater System consists of 2 x 50% turbine-driven boiler feedwater
booster pumps and boiler feedwater pumps, 2 x 25% Motor Driven boiler
feedwater booster pumps and boiler feedwater pumps, and the necessary fittings,
valves and piping to route the feedwater through feed control station and 2 x 50%
high pressure feedwater heater trains to the boiler economizer inlet header.
During normal operation, the boiler is supplied with feedwater by 2x50% turbine-
driven boiler feedwater pump set. The 2x25% Motor Driven boiler feedwater
pump set provides feedwater during a normal unit start and during turbine driven
boiler feed pump set unavailability.
At low system flows, Motor Driven Boiler Feedwater Pumps and Turbine driven
Boiler Feedwater Pumps minimum flow is maintained by recirculation piping from
the respective pump discharge to the deaerator. Each boiler feedwater pump is
provided with its own modulating type minimum flow recirculation valve. Each
minimum recirculation control valve is controlled independently based on the
associated pump suction flow. Each minimum recirculation line is provided with
two manual shut-off valves, which are locked open normally and must be open at
all times when the pump is running. The shut-off valves are closed only when the
corresponding pump is out of service for maintenance and pump must be isolated.
An anti-flash orifice is installed in each recirculation line at the inlet nozzle to the
deaerator to suppress flashing in the piping between the minimum flow
recirculation control valve and the deaerator.
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A line is provided from an intermediate stage of each Boiler Feedwater Pump to
supply water to the reheater desuperheater. Each reheater desuperheater spray
water supply line has a check valve and a motor operated shut-off valve at the
boiler feedwater pump intermediate stage discharge connection. The check valve
prevents water from back-flowing into a non-operating boiler feedwater pump. The
motor operated shut-off valve is closed when it is required to isolate a boiler
feedwater pump for maintenance. Pipes from each boiler feedwater pump
intermediate stage are combined to a single header to supply water to the
reheater desuperheater.
Each boiler feedwater pump discharge has a check valve and a motor-operated
stop valve arranged in series. The discharge lines from the turbine-driven Boiler
Feedwater Pumps and Motor Driven Boiler Feedwater Pump join into a common
high-pressure feedwater header to feed two HP Feedwater Heater Trains A and B
through feed control station.
A line having NRV and manual valve is tapped off from each boiler feedwater
booster pump discharge line and connected to a common warm up header.
Individual connection to each boiler feedwater pump from common warm up
header is provided with one NRV, two isolation valves (one of which is MOV) and
one breakdown orifice for warming up the standby pump with the help of running
pump/s. Standby pumps should be kept warmed as much as possible before
being put into service.
Each 50% stream of HP heaters can be bypassed through motor operated valves
provided at upstream, downstream and bypass line of feedwater heater streams.
3.3 Normal Plant shutdown
Normal plant shutdown is accomplished by stopping either of Turbine-driven
Boiler Feedwater Pump, starting Motor Driven Boiler Feedwater Pump, and then
stopping the remaining Turbine driven Boiler Feedwater Pump. Motor Driven
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Boiler Feedwater Pump will be gradually stopped after both Turbine-driven Boiler
Feedwater Pumps are stopped.
3.4 Check List
Pre-requisites: Check the following before starting up the Boiler Feedwater
System:-
• Electrical Distribution System is in service and all the related Switchgears and
MCC are ready.
• Service Air and Instrument Air system are in service.
• Close Circuit Cooling Water System is in service.
• Auxiliary steam is available.
• Condensate System is in service.
• Deaerator is filled to normal level.
• LP clean-up is completed.
• Initial heating of feedwater in deaerator is completed.
Pre-operational checklist: Before feed water system start-up, the following
should be verified:-
DANGER
Strictly follow the work permit system to avoid unacceptable
troubles or danger.
• All work permits or hold orders for the plant systems are cleared
• All equipment is in a safe condition to operate and is ready for operation.
• All instrumentation and control system (DCS) are available and lined up.
• All annunciations and interlocks are available.
• All rotating equipment guards and safety devices are installed.
• Valve Iine-up is completed as per valve P&ID.
• Lockout relays for all applicable electrical motors are reset.
• Power supply line up is completed.
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• All equipment is aligned for remote operation from CCR. (where applicable)
• Sub-Group and Drive levels are transferred in Auto mode for all the related
equipment (pumps/fans/valves) before Group level operation (DCS)
• All set points on the DCS are normal.
• All nitrogen gas sealing valves are fully closed.
• All isolating valves before protective over pressure valves for high pressure
shall be opened.
• All cooling water for bearing and cooler etc. is in service.
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4.0 EMERGENCY OPERATION AND
ALARMS
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Chapter 4
Emergency Operation and Alarms
4.1 Emergency Conditions Operation
4.1.1 One Turbine Driven BFP trip
If one of the turbine-driven boiler feedwater pumps trips, runback will be initiated &
approximately 50% rated plant load can be maintained by operating the remaining
turbine-driven boiler feedwater pump. Once load stabilizes and steady state is
achieved one standby MDBFP should be started manually so plant load can be
increased. Subsequently, second MDBFP should be started to meet the
feedwater demand in accordance with the load. Refer Section on “Emergency
Situation”, Volume 1 of O&M manual for more details on runback.
4.1.2 HP Heater Tube Leakage
If a leak or tube break occurs in a high-pressure feedwater heater, the steam
space in the high-pressure feedwater heater may be flooded with feedwater.
Level switches will indicate high-high water levels in the feedwater heaters. If
high-high water level in any of the heaters persist for 1 (one) minute, feedwater
flow to the feedwater heaters can be diverted directly to the economizer inlet,
bypassing respective high pressure feedwater trains. This is accomplished by
operating MOVs located at the inlet, outlet and bypass of HP Feedwater Heater
train A and B with following sequence.
If a high-high level condition persists for one minute in any HP heater of either
train A or B, the respective heater train is bypassed by the following sequence:
1. Respective bypass line MOV (1LAB40/43AA002) will open first
2. Then inlet MOV (1LAB40/43AA001) and outlet MOV (1LAB41/44AA001) of the
HP Feedwater heater train are closed.
Refer to feedwater heater Installation and Operation Manual (Volume -2, LT-MO-
03053), O&M manual of Feedwater heater vents and drains system (Volume – 1,
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Section E, Chapter 3 and Extraction steam system (Volume – 1, Section D,
Chapter 3) for further details on preparing the feedwater heaters for maintenance.
After maintenance or after founding non high-high condition; for taking back
heaters into service following sequence is to be followed:
1. Outlet MOV (1LAB41/44AA001) of the respective HP Feedwater heater train is
to be opened first
2. Then HP Feedwater heater inlet MOV (1LAB40/43AA001) is to be opened
3. HP Feedwater heater bypass MOV (1LAB40/43AA002) can be closed only
after fully opening of both i) inlet MOV (1LAB40/43AA001) and ii) outlet MOV
(1LAB41/44AA001).
This sequential operation ensures that during any condition feedwater system
downstream of first isolation valve before HP Heater-6 is not subjected to BFP
shut- off condition. Further one spring relief valve is also provided across each HP
heater stream as per IBR requirement for the same purpose.
When the feedwater heaters are taken out of service, steam that is normally
extracted from the Turbine to the feedwater heaters will instead pass through the
Turbine and tend to increase kilowatt output. The maximum rated kW capability of
the turbine should not be exceeded during this situation. The maximum operating
load should be determined from the turbine-generator instruction book (refer
Instruction manual for Steam Turbine (LMTG-PO-01033) compiled under Volume
2 for more details). Operating efficiency will get reduced when the feedwater
heaters are removed from service. The maximum operating load during any one
feedwater heater train out of service is 100% TMCR.
4.1.3 Abnormal Deaerator Water Levels
Upon high high level in the deaerator, condensate flow to the deaerator will be
shut-off by closure of Deaerator LCV inlet MOV (1LCA50AA001 / 02).
The GSC minimum recirculation valve (1LCA47AA081) opens to divert
condensate to the condenser so that the deaerator inlet condensate flow can be
reduced.
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In the event of any condition that results deaerator level in excess of the normal
level, the overflow control valve (1LAR05AA081) opens and overflow water is
directed to the condenser through HP Flash Tank.
At low condensate levels in the deaerator, condensate flow is increased through
the deaerator level control valves (1LCA50AA081 / 82). If only one condensate
pump is operating, a second should be started. If water levels continue to drop to
unsafe levels, the boiler feed pumps will trip to avoid damage associated with dry
running.
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4.2 Alarms
CAUTION
Operator must take appropriate corrective action, if any of the
alarms mentioned below appears. Continuous operation without
corrective action may lead to the tripping of equipment and may
lead to the possible damage to the equipment.
The Feedwater System alarms will be monitored from the DCS operator interface
console alarm graphic display.
The following system conditions will be alarmed through the DCS:
BFP Booster Pump Discharge Flow Low
BFP Suction Strainer DP High
DANGER
Operator must change over the BFP in operation to Standby
whenever running BFP suction strainer differential pressure
high alarm appears. After changeover, clogged strainer shall
be cleaned.
DA Level Low
DA Level Low-Low
DA Level High
DA Level High-High
BFP Discharge Pressure High
BFP Pump Vibration High
BFP Pump Vibration High-High
BFP Lube Oil Pressure Low
BFP Lube Oil Level Low
BFP Lube Oil Temp High
BFP Lube Oil Temp High- High
BFP Emergency Push Button Operated
BFP Trip
BFP Motor Winding Temperature High
BFP Motor Winding Temperature High-High
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BFP Motor DE Bearing Vibration High
BFP Motor DE Bearing Vibration High-High
BFP Motor NDE Bearing Vibration High
BFP Motor NDE Bearing Vibration High-High
The following information will be provided on the control room display on the CRT
as a function of the DCS.
Feedwater Flow, Pressure and Temperature
BFP Flow and Discharge Pressure
BFP RPM
BFP Vibration
BFP Status (ON/OFF)
BFP Start Permissive Not Available
MDBFP Motor Bearing Temperature
MDBFP Motor Winding Temperature
MDBFP Motor Current TDBFP Booster Pump Status (ON/OFF)
Scoop Tube Position
ALL MOV Status (OPEN/CLOSE)
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5.0 INSTRUMENTATION & PROCESS
CONTROL
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Chapter 5
Instrumentation & Process Control
5.1 Instrumentation & Process Control
5.1.1 Motor Driven Boiler Feed Pumps & Booster pumps (2 x 25 %)
1LAC10AP001+1LAC12AP001 (MDBFP A + Booster Pump),
1LAC15AP001+1LAC17AP001 (MDBFP B + Booster Pump)
Purpose:
To supply feedwater to boiler at required flow & head from Deaerator
Functional Description:
The motor-driven boiler Feedwater pump is driven by an electric motor through
the Hydraulic coupling. Scoop tube of hydraulic coupling receives a 4-20 mA
control signals from plant DCS based on the boiler feedwater demand (BID) and
provides position feedback for use in the plant DCS. MDBFP can be operated
manually by operator or automatically (if placed in Auto) from Plant DCS. Its
auxiliary lube oil pump should be placed in automatic control within the Plant
DCS. The booster pumps and main pumps have only one drive.
Start Permissive
• Pump Suction valve open
• Deaerator Tank Level shall be above 2400 mm
• Lube Oil tank level not low
• Oil Cooler water side inlet valve open
• Oil Cooler water side outlet valve open
• MDBFP Aux lube oil pump started AND Lube oil pressure not low AND
Hydraulic coupling position less than 3%
• Pump Warm up MOV close
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• Corresponding pump discharge valve is closed
• Any one CCW pump is ON/running
• BFP cooling water outlet header flow not low
• Difference between booster pump suction water temperature & Main pump
barrel discharge temp is not greater than 55 degree C
• Difference between booster pump suction water temperature & Main pump
barrel suction temp is not greater than 55 degree C
• Difference between Main pump barrel discharge temperature & Main pump
barrel suction temp is not greater than 28 degree C
• Reverse rotation not detected
Stop Permissive
None
Protection command
Pump shall trip if any of the following conditions occur:
• Pump is running for 60 seconds & Suction flow is very low for 1 second
• Pump suction valve not open
• Pump Lube oil pressure low-low
• Pump bearing temperature high-high
• Motor bearing & Winding temperature high-high
• Wet mode selected AND boiler water separator drain tank level high-high for
30 seconds
• MFT operated
• Control oil cooler inlet oil temperature high-high
• Control oil cooler outlet oil temperature high-high
• Lube oil cooler inlet oil temperature high-high
• Lube oil cooler outlet oil temperature high-high
• Pump is running for 25 seconds & Pump vibration high-high
• Pump discharge flow high-high
• Pump discharge valve is not open AND minimum recirculation FCV is closed
AND Pump is running
• Deaerator Tank Level low low
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5.1.2 Turbine Driven Boiler Feed Pumps & Booster pumps (2 x 50 %)
1LAC20AP001+1LAC22AP001 (TDBFP A + Booster Pump)
1LAC25AP001+1LAC27AP001 (TDBFP B + Booster Pump)
Purpose:
To supply the feedwater to boiler at required flow and head from Deaerator
Functional Description:
The two turbine-driven boiler Feed water pumps are driven by BFP drive turbines.
The BFP turbine controller (governor) receives a 4-20 mA control signals from
plant DCS based on the boiler feedwater demand (BID) and shall provide BFP
turbine speed feedback signal for use in the plant DCS. The pumps can be
operated in both, automatic or manual control mode. The booster pumps and
main pumps have only one drive. Booster pumps are also driven by Drive turbine
through a Gear box.
Start Permissive
• Pump Suction valve open.
• Pump’s lube oil pressure not low.
• Deaerator Tank Level shall be above 2400 mm
• Difference between booster pump suction water temperature & Main pump
barrel discharge temp is not greater than 55 degree C
• Difference between booster pump suction water temperature & Main pump
barrel suction temp is not greater than 55 degree C
• Difference between Main pump barrel discharge temperature & Main pump
barrel suction temp is not greater than 28 degree C
• Pump Warm up MOV close
• Any condensate pump start up complete condition available
• Any one CCW pump is ON/running
• Reverse rotation not detected
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Protection command
Pump shall be tripped/stopped if any of the following conditions occur:
• MFT operated
• Wet mode selected AND boiler water separator drain tank level high-high for
30 seconds
• Pump bearing temperature high-high
• Pump suction flow at corresponding running speed is low for 1 second
• Pump suction valve not open
• Pump is running for 25 seconds & Pump vibration high-high
• Deaerator Tank Level low-low
• Pump discharge flow high-high
• BFPT trip on Exhaust steam pressure high-high
• BFPT trip on Exhaust steam temperature high-high
• BFPT trip on condensate drain tank level high-high
• BFPT trip on lube oil pressure low-low
• BFPT trip from woodward governor505
• BFPT trip from Fire protection system
• BFPT trip from Over speed protection system
5.1.3 Pump minimum recirculation flow Control
(MDBFP-A: 1LAB34AA081; MDBFP-B: 1LAB36AA081; TDBFP-A:
1LAB30AA081; TDBFP-B: 1LAB32AA081)
Purpose:
To meet the minimum flow requirement of the corresponding pump during startup
and when system flow requirement is less than minimum recirculation flow.
Functional Description:
Each pump series is provided with its own modulating type minimum flow
recirculation control valve (1LAB34AA081 for MDBFP A, 1LAB36AA081 for
MDBFP B, 1LAB30AA081 for TDBFP A, 1LAB32AA081 for TDBFP B). This
recirculation control valve is controlled via the plant DCS based on the main pump
suction flow. Minimum flow recirculation control loop will maintain at minimum
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Feedwater flow rate through the corresponding pumps. The minimum flow set
point for each of the boiler Feedwater pumps will be based on boiler Feedwater
pump manufacturer's recommendation. The valve is normally controlled from
plant DCS in auto mode, and provision is also made for opening each of the
minimum flow recirculation valves manually from the plant DCS.
5.1.4 Feedwater Control
Feedwater control valve (1LAB29AA081), Bypass MOV (1LAB28AA001)
Purpose:
To meet the Feedwater demands of Boiler at all loads
Functional Description:
Feedwater Flow Demand will be determined from the Boiler Input Demand (BID).
Feedwater control valve (1LAB29AA081) and MOV (1LAB28AA081) are used to
ensure that feedwater flow demand is met.
Feedwater requirement during Plant cleanup and startup will be fed through
MDBFP with fixed speed and relevant BID requirement will be controlled through
feed control valve.
HP Cleanup and boiler cold cleanup will take place at 25% feedwater flow. After
completion of boiler cold cleanup, Oil burner is light-off and steam begins to generate.
Boiler is cleaned up with system same as Boiler Cold Clean-up. During this process flow
from MDBFP will reduce to 5% BMCR and rest of the 20% will be maintained through
BCP. With gradual increase in steam generation, flow from BCP will reduce and the same
will be compensated through MDBFP.
1st TDBFP will come in service at 30% TMCR and gradually MDBFP out of
service will take place. At 35% TMCR, BID requirement will switch over to TDBFP
speed control and feed control valve will hold its position. At the same point of
time bypass MOV of feed control valve will start opening. Feed control valve will
close when bypass MOV is fully open.
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During normal operation, feedwater flow control is governed by BFP speed control
as per BID requirement and the same is distributed among running BFP as per
predefined bias.
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6.0 INTERLOCKS AND PROTECTION
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Chapter 6
Interlock and Protection
6.1 Instrumentation & Process Control
6.1.1 BFP Discharge valves & integral bypass MOV
(MDBFP-A: 1LAB24AA001 + 1LAB24AA001A + 1LAB24AA001B)
(MDBFP-B: 1LAB26AA001 + 1LAB26AA001A + 1LAB26AA001B)
(TDBFP-A: 1LAB20AA001 + 1LAB20AA001A + 1LAB20AA001B)
(TDBFP-B: 1LAB22AA001 + 1LAB22AA001A + 1LAB22AA001B)
Purpose:
To isolate the BFP from the main feed water discharge header
Functional Description:
The Discharge valves for each BFP can be controlled manually or in auto via the
Plant DCS.
The operating sequence for integral bypass MOV shall be as follows:
When main MOV open command is generated, first the integral bypass MOVs
open automatically.
Auto open command for main MOV is generated 10 seconds after the integral
bypass MOVs fully open.
Integral bypass MOVs close 10 seconds after main MOV is open.
When main MOV is fully opened & integral bypass MOV is closed, the main
MOV open sequence in service is reset
Close Permissive
None
Open Permissive
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• Difference between BFP individual discharge pressure & BFP common header
pressure is less than 1 bar AND any one BFP is running
OR
- Any other BFP is not running AND corresponding BFP is running.
Protective command:
This valve receives over ride close command when corresponding BFP pump is
stopped / Tripped
6.1.2 HP Heater bypass MOV
(1LAB40AA002 / 1LAB43AA002) & Integral bypass MOV (1LAB40AA002A /
1LAB43AA002A / 1LAB40AA002B / 1LAB43AA002B):
Purpose:
To isolate corresponding heater train (heater 6A, 7A and 8A or heater 6B, 7B and 8B),
bypass MOVs with integral bypass MOVs are provided.
Functional Description:
This MOV will open in auto mode during HP heater water side isolation when both
integral bypass MOV are open. This MOV will be closed during HP Heater line
clean up blow OR during HP heater water charging OR during heater recovery
operation*.
Permissive:
Bypass valves can be closed if HP heater Inlet & outlet MOV open OR during
MFT condition.
Protective Commands:
Bypass valves will be override open when any HP Feedwater heater level high-
high.
Note:
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*- For Heater Recovery Operation, Refer O&M manual Volume – 1,
Section D, Chapter 4
In case Heater is bypassed in the event of any abnormal operation, heater
can be taken in to service through heater recovery procedure.
As soon as normal water level is achieved & Operator gives the heater
bypass reset (heater recovery) command, heater recovery operation will be
initiated as per below mentioned sequence.
1. Heater will be charged through water side by opening the feed water
heater inlet/outlet isolation valve.
HP heaters inlet MOV is provided with the equalizing valve and
outlet MOV is provided with the integral bypass valve. During heater
recovery, a command will be issued to the HPH outlet MOV and in
turn, the integral bypass valve will open. Once, integral bypass valve
gets full open, outlet MOV will start opening after 10 seconds. Once
outlet MOV gets full open, a command will be issued to the HPH
intlet MOV and its equalizing line MOV will open. Subsequently inlet
MOV will open. Once Inlet MOV is full open, bypass MOV will be
closed.
2. Once heater is ready for steam admission, Heater will be charged
through steam side by opening motor operated isolation valve (For
further details refer Volume – 1, Section D). At the same time the
cascade drain from upstream heater will be opened. (For further
details refer Volume – 1, Section E)
- Operating sequence of integral bypass MOV will be as mentioned in
Cl.no 6.1.1
6.1.3 HP Heater inlet MOV (1LAB40AA001/1LAB43AA001) & integral bypass MOV
(1LAB40AA003/1LAB43AA003):
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Purpose:
To isolate corresponding heater train (heater 6A, 7A and 8A or heater 6B, 7B and
8B)
Functional Description:
This MOV will open in auto mode during HP Heater line clean up blow OR during
HP heater water charging when integral bypass MOV is open. This MOV will be
closed during HP heater water side is being bypassed
Permissive:
These valves can be closed if HP heater Bypass MOV open OR during MFT
condition.
Protective Commands:
HP heater Inlet valves will be override closed when any HP Feedwater heater
level high-high AND HP heater bypass MOV is open.
Operating sequence of integral bypass MOV will be as mentioned in Cl.no
6.1.1
6.1.4 HP Heater outlet MOV (1LAB41AA001/1LAB44AA001) & integral bypass
MOV (1LAB41AA001A/1LAB44AA001A/1LAB41AA001B/1LAB44AA001B):
Purpose:
To isolate corresponding heater train (heater 6A, 7A and 8A or heater 6B, 7B and
8B)
Functional Description:
This MOV will open in auto mode during HP heater water side charging when both
integral bypass MOVs are open. This MOV will be closed during HP Heater line
clean up blow startup OR during HP heater water side isolation.
Permissive:
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These valves can be closed if HP heater Bypass MOV open OR during MFT
condition.
Protective Commands:
HP heater outlet valves will be override closed when any HP Feedwater heater
level high-high AND HP heater bypass MOV is open.
Operating sequence of integral bypass MOVs will be as mentioned in Cl.no
6.1.1
6.1.5 Clean up from HTR 8A/8B outlet MOV (1LAB41AA002/1LAB44AA002) &
integral bypass MOV (1LAB41AA002A / 1LAB44AA002A / 1LAB41AA002B /
1LAB44AA002B):
Purpose:
To Cleanup HP heaters from water side
Functional Description:
This MOV will open in auto mode during HP heater line cleanup blow when
integral bypass MOVs are open. This MOV will be closed after completing heater
water quality check during HP Heater line clean up recirculation as mentioned in
O&M manual Volume – 1, Section I, sub-section 2.
Operating sequence of integral bypass MOVs will be as mentioned in Cl.no
6.1.1
6.1.6 LP/HP HEATER CLEAN UP BLOW MOV (1LAB44AA005):
Purpose:
To perform LP & HP heaters cleanup blow from water side.
Functional Description:
This MOV will open in auto mode during LP/HP Heater line clean up blow. This
MOV will be closed when heater water quality is achieved as mentioned in O&M
manual Volume – 1, Section I, sub-section 2.
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6.1.7 LP/HP HEATER CLEAN UP RECIRCULATION MOV (1LAB44AA006):
Purpose:
To perform LP & HP heaters cleanup recirculation from water side
Functional Description:
This MOV will open in auto mode during LP/HP Heater line clean up recirculation.
This MOV will be closed when heater water quality is achieved as mentioned in
O&M manual Volume – 1, Section I, sub-section 2.
6.1.8 LP CLEAN UP ISOLATION MOV (1LAA20AA003):
Purpose:
To perform LP heaters cleanup blow from water side.
Functional Description:
This MOV will be open in steps of 5sec at 20sec interval during LP Heater line
clean up blow OR during LP Heater line clean up recirculation. This MOV will be
closed in steps of 5sec at 20sec interval when heater water quality is achieved as
mentioned in O&M manual Volume – 1, Section I, sub-section 2
6.1.9 BFP Discharge re-heater de-super heater isolation valves
(MDBFP-A: 1LAF34AA001; MDBFP-B: 1LAF36AA001; TDBFP-A:
1LAF30AA001; TDBFP-B: 1LAF32AA001)
Purpose:
To isolate the BFP main pump inter stage discharge flow to re-heater
desuperheater.
Functional Description:
This valve isolates the spray water from BFP inter-stage discharge to re-heater
de-super heater. For each BFP this valve can be controlled manually or in Auto
via the Plant DCS. When selected in auto, this valve opens
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• If MFT is reset AND corresponding BFP pump is started/running in case of
MDBFP &
• If MFT is reset AND corresponding BFP turbines speed up is complete in case
of TDBFP.
When selected in auto, this valve is auto closed
• If the corresponding BFP pump is not running/stopped (in case of MDBFP )
• If the corresponding BFP Turbine is tripped (in case of TDBFP)
Close Permissive
None
Open Permissive
None
Protective Command:
None
6.1.10 Feedwater Control valve inlet isolation MOV (1LAB29AA001) & integral
bypass MOV (1LAB29AA001A & 1LAB29AA001B)
Purpose:
To isolate the Feed water control valve
Functional Description:
This valve can be operated manually as well as automatically from plant DCS.
When selected in auto mode from plant DCS. This valve opens during boiler feed
water start up when integral bypass 1 OR 2 is open
When selected in auto, this valve is auto closed when feed water control valve is
closed AND feed water control valve bypass MOV is open.
Operating sequence of integral bypass MOVs will be as mentioned in Cl.no
6.1.1
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Close Permissive
None
Open Permissive
None
Protective command:
None
6.1.11 Feedwater Control valve outlet isolation MOV (1LAB29AA002) & integral
bypass MOV (1LAB29AA002A & 1LAB29AA002B)
Purpose:
To isolate the Feed water control valve
Functional Description:
This valve can be operated manually as well as automatically from plant DCS.
When selected in auto mode from plant DCS this valve opens during boiler feed
water start up when integral bypass 1 OR 2 is open
When selected in auto, this valve is auto closed when feed water control valve is
closed AND feed water control valve bypass MOV is open.
Operating sequence of integral bypass MOVs will be as mentioned in Cl.no
6.1.1
Close Permissive
None
Open Permissive
None
Protective command:
None
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6.1.12 Feedwater Control valve bypass MOV (1LAB28AA001) & integral bypass
MOV (1LAB28AA001A & 1LAB28AA001B)
Purpose:
To bypass the Feed water control valve
Functional Description:
This valve can be operated manually as well as automatically from plant DCS.
When selected in auto mode from plant DCS this valve opens during the speed
control mode operation of BFPT with corresponding integral bypass valves open.
When selected in auto, this valve is auto closed when BFPT operates in fixed
position mode AND feed water control valve bypass MOV is open.
Operating sequence of integral bypass MOVs will be as mentioned in Cl.no
6.1.1
Close Permissive
None
Open Permissive
None
Protective command:
None
6.1.13 BFP warm up MOV
(MDBFP A: 1LAC10M003; MDBFP-B: 1LAC15M003; TDBFP-A: 1LAC20M003;
TDBFP-B: 1LAC25M003)
Purpose:
To supply Feed water for the warm up of Standby BFP pump.
Functional Description:
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This valve can be operated manually as well as automatically from plant DCS.
When selected in auto mode from plant DCS this valve opens:
• If difference between booster pump suction water temperature & Main pump
barrel discharge temp is greater than 50 degree C OR Difference between
booster pump suction water temperature & Main pump barrel suction temp is
greater than 50 degree C OR Difference between Main pump barrel discharge
temperature & Main pump barrel suction temp is greater than 23 degree C
AND
• Pump of the corresponding warm up valve is not running AND any one of the
other pump is running
When selected in auto, this valve is auto closed
• If difference between booster pump suction water temperature & Main pump
barrel discharge temp is less than 47 degree C AND Difference between
booster pump suction water temperature & Main pump barrel suction temp is
less than 47 degree C AND Difference between Main pump barrel discharge
temperature & Main pump barrel suction temp is less than 20 degree C
Close Permissive
None
Open Permissive
None
Protective command:
None
6.1.14 BFP Blow off MOV
(MDBFP A: 1LAB16AA005; MDBFP-B: 1LAB17AA005; TDBFP-A:
1LAB14AA005; TDBFP-B: 1LAB15AA005)
Purpose:
To maintain standby pump suction water temperature same as De-aerator
temperature
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Functional Description:
BFP blow off MOV to condenser can be operated manually as well as
automatically from plant DCS. When selected in auto mode from plant DCS this
valve opens when difference between booster pump discharge temperature &
deaerator temperature is greater than 5 degree C AND corresponding pump is not
running.
When selected in auto, this valve is auto closed if corresponding pump is started
OR IF all CEPs are stopped.
Close Permissive
None
Open Permissive
None
Protective command:
None
6.1.15 BFP DRIVE TURBINE DRIVES
For the logic & description of the drives of BFP drive turbine refer Siemens O & M
manual placed at Volume 2, SIEG – MO-03660.
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7.0 VALVE LINE-UP LIST
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Chapter 7
Valve Line-Up List
7.1 List
CAUTION
Do not operate valves without proper authorization such as work
permit, as unauthorized operation may lead to serious injury and
damage to the equipment.
Valve line-up check list is prepared for the system pre-start condition. Instrument
root valves are not covered in the valve list; they are to be kept open always
except during instrument maintenance. Reference may be made to the P&ID for
the system. Control valves, piston operated valves and motor operated valves are
not listed, since they are operated from DCS according to plant operating
conditions.
System Pre
Valve Tag no. Description Start
Position
1LAB12/13AA101 MDBFP BP (A) / (B) SUCTION VALVE OPEN
1LAB10/11AA101 TDBFP BP (A) / (B) SUCTION VALVE OPEN
MDBFP BP(A) / (B) SUCTION RELIEF
1LAR12/13BR401 SET
VALVE
TDBFP BP(A) / (B) SUCTION RELIEF
1LAR10/11BR401 SET
VALVE
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
System Pre
Valve Tag no. Description Start
Position
MDBFP BP(A) / (B) SUCTION AIR
1LAB12/13AA501 CLOSE
VENT ISOLATION VALVE
MDBFP BP(A) / (B) SUCTION
1LAB12/13AA401 CLOSE
STRAINER DRAIN ISOLATION VALVE
TDBFP BP(A) / (B) SUCTION AIR VENT
1LAB10/11AA501 CLOSE
ISOLATION VALVE
TDBFP BP(A) / (B)) SUCTION
1LAB10/11AA401 CLOSE
STRAINER DRAIN ISOLATION VALVE
MDBFP(A) / (B) RECIRCULATION
1LAB34/36AA101/102 CONTROL VALVE INLET /OUTLET OPEN
VALVE
TDBFP(A) / (B) RECIRCULATION
1LAB30/32AA101/102 CONTROL VALVE INLET/OUTLET OPEN
VALVE
MDBFP (A) / (B) RECIRCULATION
1LAB34/36AA401 CONTROL VALVE OUTLET DRAIN 1ST CLOSE
ISOLATING VALVE
MDBFP (A) / (B) RECIRCULATION
1LAB34/36AA402 CONTROL VALVE OUTLET DRAIN CLOSE
2ND ISOLATION VALVE
TDBFP(A) / (B) RECIRCULATION
1LAB30/32AA401 CONTROL VALVE OUTLET DRAIN 1ST CLOSE
ISOLATION VALVE
TDBFP(A) / (B) RECIRCULATION
1LAB30/32AA402 CONTROL VALVE OUTLET DRAIN CLOSE
2ND ISOLATION VALVE
1LAB440/43AA001 HP HEATER NO.6A/6B WATER INLET OPEN
HP HEATER NO.6A/6B WATER INLET
1LAB40/43AA003 CLOSE
VALVE BYPASS VALVE
HP HEATER NO.8A/8B WATER
1LAB441/44AA001 OPEN
OUTLET
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
System Pre
Valve Tag no. Description Start
Position
HP HEATER NO.8A/8B WATER
1LAB41/44AA003 CLOSE
OUTLET VALVE BYPASS VALVE
HP HEATER NO.8 OUTLET CLEAN-UP
1LAR41AA091 SET
LINE RELIEF VALVE
HP HEATER NO.8 OUTLET SAMPLING
1OUA17AA601/602 OPEN
1ST/ 2ND ISOLATION VALVE
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
ABBREVIATIONS
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Abbreviations:
Abbreviation Meaning
LP Low Pressure
HP High Pressure
BFP Boiler Feed Pump
TDBFP Turbine Driven Boiler Feed Pump
MDBFP Motor Driven Boiler Feed Pump
SH Superheater
RH Reheater
BFPT Boiler Feed Pump Turbine
VWO Valve Wide Open
MU Make Up
TMCR Turbine Maximum Continuous Rating
AVT All Volatile Treatment
BHN Brinell Hardness Number
BP Booster Pump
NPSH Net Positive Suction Head
DCS Distributed Control System
NRV Non-Return Valve
DSH De-Superheater
MOV Motor Operated Valve
FCV Flow Control Valve
DEH Digital Electro Hydraulic
IBR Indian Boiler Regulation
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
Abbreviation Meaning
BCP Boiler Circulation Pump
FCB Fast Cut-Back
HFO Heavy Fuel Oil
MCC Motor Control Chamber
CCR Central Control Room
DA De-aerator
DE Drive End
NDE Non-Drive End
CRT Cathode Ray Tube
BID Boiler Input Demand
CCW Closed Cooling Water
MFT Master Fuel Trip
BMCR Boiler Maximum Continuous Rating
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JAYPEE O&M MANUAL – VOLUME 1 FEEDWATER SYSTEM
EXHIBITS
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JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
STEAM TURBINE GENERATOR & AUXILIARIES PACKAGE
OWNER:
JAIPRAKASH POWER VENTURES LIMITED
OWNER’S CONSULTANT:
DEVELOPMENT CONSULTANTS PRIVATE LIMITED
CONTRACTOR:
LARSEN & TOUBRO LIMITED
L&T’S CONSULTANT:
L&T-SARGENT & LUNDY LIMITED
SUPPLIER:
Flowserve INDIA CONTROLS PVT LIMITED
L&T-S&L JOB NO.: L543000 PROJECT NO.: T209001
TITLE:
COMPLETE GROUP GENERAL ARRNAGMENT DRAWING (TDBFP)
DOC NO: FPD-M0-03372 TOTAL NO. OF PAGES. : 9
REV: E
VENDOR DOC NO : FPD-GAD-GUJ-10-55002&85001-01
AS BUILT
REVISION CERTIFICATION
REVISION
PREPARED REVIEWED APPROVED
NO.
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
P0 SRR 07/16/2010 VKM 07/16/2010 RVS 07/16/2010
A SRR 08/06/2010 VKM 08/06/2010 RVS 08/06/2010
B SRR 11/30/2010 VKM 11/30/2010 RVS 11/30/2010
C SRR 12/22/2010 VKM 12/22/2010 RVS 12/22/2010
D SRR 08/18/2011 VKM 08/18/2011 RVS 08/18/2011
E SRR 12/04/2012 VKM 12/04/2012 RVS 12/04/2012
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JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
STEAM TURBINE GENERATOR & AUXILIARIES PACKAGE
OWNER:
JAIPRAKASH POWER VENTURES LIMITED
OWNER’S CONSULTANT:
DEVELOPMENT CONSULTANTS PRIVATE LIMITED
CONTRACTOR:
LARSEN & TOUBRO LIMITED
L&T’S CONSULTANT:
L&T-SARGENT & LUNDY LIMITED
SUPPLIER:
Flowserve INDIA CONTROLS PVT LIMITED
L&T-S&L JOB NO.: L543000 PROJECT NO.: T209001
TITLE:
COMPLETE GROUP GENERAL ARRNAGMENT DRAWING
DOC NO: FPD-C0-03305 TOTAL NO. OF PAGES. : 11
REV: J
VENDOR DOC NO : FPD-GAD-GUJ-10-55002&85001-02
AS BUILT
REVISION CERTIFICATION
REVISION
PREPARED REVIEWED APPROVED
NO.
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
0 SRR 10/26/2010 VKM 10/26/2010 SRR 10/26/2010
G SRR 5/9/2011 SRR 5/9/2011 SRR 5/9/2011
H SRR 10/21/2011 SRR 10/21/2011 SRR 10/21/2011
I SRR 11/26/2011 SRR 11/26/2011 SRR 11/26/2011
J SRR 04/12/2012 SRR 04/12/2012 SRR 04/12/2012
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JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
STEAM TURBINE GENERATOR & AUXILIARIES PACKAGE
OWNER:
JAIPRAKASH POWER VENTURES LIMITED
OWNER’S CONSULTANT:
DEVELOPMENT CONSULTANTS PRIVATE LIMITED
CONTRACTOR:
LARSEN & TOUBRO LIMITED
L&T’S CONSULTANT:
L&T-SARGENT & LUNDY LIMITED
SUPPLIER:
Flowserve INDIA CONTROLS PVT LIMITED
L&T-S&L JOB NO.: L543000 PROJECT NO.: T209001
Hydraulic Coupling drawing & Operating Area Curve
DOC : FPD-M0-03467 REV:C TOTAL NO. OF PAGES. : 3
FOR Approval
REVISION CERTIFICATION
REVISION
PREPARED REVIEWED APPROVED
NO.
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
T.Balach
C B.Arun BA 25.05.2011 H.Arun HA 25.05.2011 TB 25.05.2011
andar
T.Balach
B B.Arun BA 12.05.2011 H.Arun HA 12.05.2011 TB 12.05.2011
andar
T.Balach
A B.Arun BA 25.02.2011 H.Arun HA 25.02.2011 TB 25.02.2011
andar
T.Balach
P0 B.Arun BA 19.12.2010 H.Arun HA 19.12.2010 TB 19.12.2010
andar
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Rev B 7365.8
Rev B 9710
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Voith Turbo
Voith Turbo GmbH & Co.KG
Voithstraße 1
74564 Crailsheim, Germany
Attachment to Operating Map
Project: Flowserve_Jaypee_S1
Customer: Flowserve_Jaypee_S1
Offer No.: Flowserve_Jaypee_S1_2011-01-11
Description: n.a.
5) Operating Points
Operating ne [rpm] na [rpm] Pa [kW] Pvs [kW] Pvm [kW] Description
point input output output slip mechanical losses
speed speed power losses ± tolerance
1 1492 2689 1038 1145 478 ± 106 -
2 1492 3127 1671 1345 477 ± 104 -
3 1492 3565 2492 1448 468 ± 98 -
4 1492 3492 1886 1161 472 ± 100 -
5 1492 4225 3460 1151 442 ± 88 -
6 1492 4666 4842 996 421 ± 80 -
7 1492 4593 4508 1015 426 ± 81 -
8 1492 4830 5178 852 412 ± 77 -
9 1492 4960 5765 772 399 ± 73 -
10 1492 4994 5974 753 395 ± 72 -
11 1492 5037 6120 712 391 ± 70 -
12 1492 5086 6359 671 384 ± 68 -
13 1492 5114 6439 641 380 ± 67 -
14 1492 5208 7038 560 362 ± 62 -
15 1492 5208 7366 586 359 ± 61 -
16 1447 5215 7062 320 299 ± 48 -
17 1447 5215 7396 336 297 ± 47 -
18 1537 5200 7013 799 412 ± 74 -
19 1537 5200 7334 836 409 ± 73 -
20 ±
21 ±
22 ±
23 ±
24 ±
25 ±
26 ±
27 ±
28 ±
29 ±
30 ±
31 ±
32 ±
33 ±
34 ±
35 ±
Attachment to Operating Map Preliminary Rev. n.a. Page 2/2
SI Units S/RK
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
Operation & Section C.
Maintenace Volume 1
Manual CCW System
Table of Contents 304
1. Overview of CCW System 306
2. System Description 324
3. Normal Operation, Start-up / Shutdown 330
4. Emergency Operations & Alarms 335
5. Instrumentation & Process Control 338
6. Interlock & Protection 343
7. Valve Line-up List 346
Abbreviations 349
Exhibits 351
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
Table of Contents
1.0 OVERVIEW OF CCW SYSTEM
1.1 PURPOSE
1.2 SPECIFICATIONS
1.2.1 Design Data of Major Equipment
1.3 REFERENCES
1.3.1 P & ID
1.3.2 GA Drawings
1.3.3 Vendor Information
2.0 SYSTEM DESCRIPTION
2.1 OVERVIEW
2.2 FLOW PATH
2.3 MAJOR EQUIPMENT
3.0 NORMAL OPERATION, START-UP AND SHUTDOWN
3.1 START-UP AND INITIAL FILL
3.2 NORMAL OPERATION
3.3 NORMAL SHUTDOWN
3.4 CHECK LIST
4.0 EMERGENCY OPERATION AND ALARMS
4.1 EMERGENCY CONDITIONS OPERATION
4.1.1 Closed Cooling Water Pump Trip
4.1.2 Closed Cooling Water Heat Exchanger Outage
4.2 ALARMS
5.0 INSTRUMENTATION & PROCESS CONTROL
5.1 INSTRUMENTATION & PROCESS CONTROL
5.1.1 Closed cooling water Pumps (3 x 50 %)
5.1.2 Recirculation Flow control valve (1PGB10AA081)
5.1.3 CCW Pump Suction Valve
5.1.4 Temperature Control Valves: (By LMTG)
6.0 INTERLOCKS AND PROTECTION
6.1 INSTRUMENTATION & PROCESS CONTROL
6.1.1 CCW Overhead Tank Inlet MOV
6.1.2 Recirculation Bypass MOV
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
6.1.3 CCW Pump discharge MOV
6.1.4 Bypass MOV to lube oil temperature control valve
7.0 VALVE LINE-UP LIST
7.1 LIST
ABBREVIATIONS
EXHIBITS
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1.0 OVERVIEW OF CCW SYSTEM
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
Chapter 1
Overview of CCW System
1.1 Purpose
The purpose of CCW system O&M manual document is to provide the operating
personnel with necessary information to safely operate and maintain the closed
cooling water system & associated equipment.
The scope of the manual covers an overview of the CCW System, description of
its major components with associated equipment & devices and details of the
startup, shutdown and normal operation and process control.
The closed cooling water (CCW) system or demineralised cooling water (DMCW)
system is a closed loop circuit that circulates passivated demineralised water
dosed with a corrosion inhibiter for various coolers of Turbine, generator & other
equipment within the scope of steam turbine generator & auxiliaries’ package. The
heated CCW is in turn cooled in Plate Heat Exchangers by the auxiliary cooling
water system. Passivated demineralised quality water is used in CCW system for
this purpose. The make-up is provided from condensate system. The circulation of
water in the CCW system is maintained by the horizontal centrifugal pumps and
make-up to the system is catered from an overhead tank located at deaerator
floor. One (1) independent CCW system is provided for each unit. All CCW pumps
& PHE’s are located at Ground Floor of Power House Building of each unit.
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
1.2 Specifications
1.2.1 Design Data of Major Equipment
A. DMCW PUMP
SL.
DESCRIPTION UNIT
NO.
1.0 GENERAL
1.1 Pump designation DMCW
Number of pumps
1.2 6 nos - (3 Pumps/Unit)
offered
Name of
1.3 Kirloskar Brothers Limited)
manufacturer
1.4 Model no. UP 300/46
1.5 Type of pump Horizontal Split Casing - Double
Suction
Direction of
rotation of pump
1.6 CW
viewed from driver
(motor) end
1.7 Prime mover Motor
Type of duty/
1.8 Continuous
operation
1.9 Design Code IS 5120
1.10 Test code HIS
Location of Pump
1.11 (Indoor/ Outdoor/ Indoor
Shelter)
1.12 Pumped Liquid DM Water
2.0 DESIGN & PERFORMANCE REQUIREMENTS
2.1 Rated capacity m3/hr 1650
Temperature at 0
2.2 C 43
pump suction
Total head
2.3 developed at rated mLC 45
capacity
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
SL.
DESCRIPTION UNIT
NO.
2.4 Shut-off head mLC 58.5
2.5 Runout capacity m3/hr 2135
2.6 Runout head mLC 12
a) Range of % of a) 40% to 127% of rated discharge
operation within rated
which the pump flow
can operate
continuously
2.7 without any
problem
b) Minimum safe b) Min. safe flow= 660 m3/hr
flow
NPSHR @ duty
2.8 m 8.0 mtr @ 1481 RPM
point
87%
Pump efficiency at Tolerance= +5% (Without
2.9 %
rated capacity application of Performance
enhancement coating)
Efficiency of pump
at rated point
2.10 % 87
without negative
tolerance
The pumps offered
have stable rising
H-Q characteristics
2.11 Yes
from the specified
duty point to the
shut –off
Pump shaft input
2.12 power at rated kW 232.42
capacity
Pump shaft input
2.13 required at runout kW 223
capacity
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
SL.
DESCRIPTION UNIT
NO.
Power
consumption at
rated condition at
motor terminals
2.14 kW 244.13 @ 95.2% Motor efficiency
(Input power at
specified capacity
and head of pump
at motor terminal)
Shaft input power at
2.15 kW 155.0
pump shut off
Duration of
2.16 operation of pump Minutes Less than 2 minutes
for shut-off condition
Max. power 255 @ 95.2% Motor efficiency at
2.17 consumption at kW Full load
motor terminals
Maximum pump
shaft input power 243 (2000 m3/hr, 31.2m with 70%
required within the efficiency)
2.18 kW
working range of
the pump
2.19 Motor rating kW 280
Recommended
2.20 355 with p. f. as 0.87
motor frame size
Range of operation
2.21 ( in terms of % of % 40%-127% of rated discharge
rated capacity)
Tolerance in rated
2.22 head at rated As per HIS
capacity
Pump rated speed
2.23 RPM 1481
(full load Speed)
Suction specific
speed based on
U.S. 2345.42 US Units
2.24 a) NPSHA (39m at
Units 7694.88 US Units
rated point)
b) NPSHR
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
SL.
DESCRIPTION UNIT
NO.
1807
Pump Specific U.S. H =56 m, Q = 1750 cu.mlhr,
2.25 Speed= 1450 rpm which is the
Speed Units
BEP of Full Impeller Dia,i.e.465
mm)
Noise level at a
distance of 1 m from 85
2.26 dB(A)
the pump center
line.
Maximum vibration
at pump & motor
bearing housing at
2.27 microns 120 micron
rated speed and
capacity (Peak-
Peak)
Permissible Max.
Suction lift / min.
suction head
required for pump NPSHR at 127% range of
2.28 mLC
operation at max. operation is 27 m
Discharge point
within the "Range of
Operation ".
3.0 CONSTRUCTION FEATURES
3.1 Type of casing Axially Split
3.2 Type of impeller Closed
3.3 No. of stages Nos Single
3.4 Volute Single
3.5 Shaft size mm 1172 mm
Sealing
3.6 Mechanical Seal
arrangement
Type of Coupling
3.7 between pump and Flexible Spacer Type Coupling
motor
Make of bearing
SKF/FAG
Type of
3.8 Deep Groove ball bearing
thrust/Radial
Hrs. 50,000 hrs
bearing Design Life
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
SL.
DESCRIPTION UNIT
NO.
Type of lubrication
and cooling for
3.9 thrust bearing with Grease Lubricated
pipe and fittings to
make the system
Type of lubricant TRADE MANUFACTURER I.O.C.L
and Description of - SERVOGEM-3
3.10
lubricant H.P.C.L. NATRA-3 OR LITHON-3
arrangement Apply Manually
Suction and
3.11 discharge nozzle Side I Side
orientation
Discharge 300
connection Size, Flange Drilling Standard: ANSI
3.12 flange drilling
B16.5 CL 150FF Pipe size at end
standard and
pressure rating of reducer: DN500
Suction connection 350
Size, flange drilling Flange Drilling Standard: ANSI
3.13
standard and 816.5 CL 150FF Pipe size at end
pressure rating of reducer: DN600
Size of drain Casing Drain, BSP - Rp 1/2
3.14
connection Stuffing box Drain, BSP - Rp 3/8
Critical speed
3.15 1. First 1. 2023 rpm
2. Second 2. 8093 rpm
Is the pump suitable YES but only for max. 3 minutes
3.16 for reversed flow duration. Run away speed is
condition? away from critical speed.
Run away speed of
the pump due to
3.17 reverse flow at RPM 1628 (for reference purpose only)
rated discharge
head
Mode of pump
3.18 DOL
Starting
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
SL.
DESCRIPTION UNIT
NO.
Whether pumps
offered can be
3.19 started with Yes
discharge valve
close
Type and make of
Flexible Spacer Type Coupling and
3.20 coupling between
Rathi make
pump and drive
Moment of Inertia
GD2 of the
3.21 complete rotating kg x cm2 49132 kg.cm2
system including
pump
Pump shaft dia
3.22 mm 81
(under shaft sleeve)
Impeller dia.
Selected a. 465 mm
3.23 mm
-Maximum b. 436 mm
-Rated
Shaft Sealing
3.24 Mechanical Seal
Arrangement
a) Flushing/sealing
plan Mechanical Seal
Diametrical
3.25 clearance between mm 0.791mm-0.460mm
wear rings
4.0 MATERIALS OF CONSTRUCTION
4.1 Casing ASTM A - 351 Gr CF8M
4.2 Impeller ASTM A - 743 Gr CF8M
Casing wearing
4.3 ASTM A - 351 Gr CF8M
ring
4.4 Pump Shaft ST ST ASTM-A276- 316 ANLD
4.5 Shaft sleeve ST ST ASTM-A276- 316 ANLD
4.6 Base plate I frame IS 2062 Fe 410 WA
4.7 Coupling SWQ 2955 - 140 spacer length
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
SL.
DESCRIPTION UNIT
NO.
4.8 Stuffing box ASTM A- 351 Gr CF8M
Mechanical seal
4.9 Stationary ring As per manufacturing standard
Rotating ring
Pump- motor
4.10 Flexible Spacer type
coupling
Fasteners in pump
4.11 SS316
Assembly
4.12 Companion flange SS
External water
inlet and outlet
4.13 No
connection (if
applicable )
5.0 Weight and dimensions data
Weight of the
5.1 kg 1554
pump assembly
weight of the pump
5.2 kg 3574
and drive assembly
5.3 Weight of motor kg 2020
Weight of base
5.4 kg 459
plate
Minimum hook lift
required to from
5.5 6m
floor level to handle
pump and drive
Recommended
capacity of hoist for
5.6 erection, tons 5.0
maintenance of the
pump and motor
Weight of the
largest single
5.7 piece to be handled kg 2020
for: Erection /
maintenance
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
SL.
DESCRIPTION UNIT
NO.
Shipping weight 3
5.8 and volume/ kg & m3 3574 kg & 15m
dimensions
5.9 GD2 of pump 49132 kg cm2
5.10 GD2 of coupling 12524 kg cm2
Dimension and
3.5 m (L) x 2.5 m (B) x 1.5 m (H) &
5.11 weight of largest
2020 kg for Motor
removable piece
B. DMCW PUMP MOTOR
SL. NO. DESCRIPTION
1.0.0 HT MOTORS
1.1.0 General
1.1.1 Quantity 6 Nos.
1.1.2 Make ABB
1.1.3 Frame Size 355L
1.1.4 Applicable Standard IS325,IEC34
1.2.0 Type and Rating HXR & 280 kW
1.2.1 Type of Motor Squirrel-Cage
1.2.2 Service Continuous
1.2.3 Duty Cycle/Designation S1/ Continuous
1.2.4 Rated Continuous Output
At 50°C ambient kW 280
1.2.5 Rated Speed R.P.M. 1481
1.2.6 Rated Voltage & % variation Volt 3300 ±10%
1.2.7 Rated Frequency & % variation Hz 50±5%
1.2.8 Full load current Amps 59
1.2.9 No load current Amps 18
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SL. NO. DESCRIPTION
1.2.10 Rated Power Factor
a) Full load 0.87
b) ¾ load 0.84
c) ½ load 0.77
Efficiency at rated voltage and
1.2.11
frequency
a) Full load 95.2%
b) ¾ load 95.2%
c) ½ load 64.5%
1.3.0 Performance
1.3.1 Method of Starting DOL
Starting Current at rated voltage
1.3.2 600% f.l.c
inclusive of tolerance
1.3.3 Starting Torque at rated voltage 80% of FLT
80% 100% 110%
1.3.4 Starting time at :
Voltage Voltage Voltage
a) Motor with rigid coupling -
i) With Load 2.0 1.0 0.8
ii) Without Load (driven
1.1 0.7 0.6
equipment decoupled)
75% 100% 110%
b) Motor with fluid coupling -
Voltage Voltage Voltage
i) With Primary Side of fluid
coupling and oil content in the Sec - -
chamber
ii) Without load (fluid coupling
Sec - -
decoupled)
Safe stall time at 110% rated
1.3.5
Voltage
a) Hot condition Sec. 12.0
b) Cold condition Sec. 20.0
1.4.0 Construction
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SL. NO. DESCRIPTION
Degree of Protection of
1.4.1 IP55
Enclosure
1.4.2 Method of Cooling IC 411
Insulation Class Class F
1.4.3
a) Stator
Temperature Rise Over 50°C 70 Deg. C
1.4.4
ambient (by resistance
1.4.5 Tropicalized Yes
1.4.6 Winding Connection Star
1.5.0 Bearings D.E. N.D.E
a. Make SKF/FAG SKF/FAG
b. Type Ball Bearing Ball Bearing
c. Recommended lubricant Kluberplex Kluberplex
1.6.0 Motor Terminal Box
a. Type Phase Segregated Terminal Box
b. Fault withstand
i) Current kA 43.7
ii) Time Sec. 0.25
Gland (Yes) / Lug (KBL
c. Cable lugs & glands furnished Yes/No.
Scope)
1.7.0 ACCESSORIES
1.7.1 Space Heaters
a. No. X Watt 1 No. X 200 W
Volt./No
b. Voltage, phase & frequency 220-250V/1 Ph/ 50 Hz
s./Hz
1.7.2 Winding temperature detector
a. Type simplex type
b. Nos. furnished 12
1.7.3 Bearing temperature detector
b. Nos. furnished 1 No./ Bearing
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SL. NO. DESCRIPTION
1.7.4 Temperature Indicators
a. Type Dial Type Thermometers
b. Nos. provided 1 No./ Bearing
c. Locations On Accessories T/Box, RHS from DE
1.7.5 Temperature Alarm Contact
a. Nos. provided 2
b. Locations RTD Box
c. Contact rating 3A, 240V AC
1.7.6 Accessory Terminal Box
1 No for Space Heater and 1no for
a. No. provided
RTD/BTD/DTT
b. Cable glands furnished? Yes/No.
Grounding
1.8.0
No. of grounding pads provided
a. On motor body 2 Nos. of M12 Threads as
shown in GAD
b. On terminal box 2 Nos. as shown in T/box
Drawing
1.9.0 Miscellaneous
1.9.1 Type of mounting IM1001/B3
1.9.2 Overall dimension (LxDxH) mm 1670X1395X1190
1.10.0 MOMENT OF INERTIA (GD2)
a. Stator N.A Kg.m2
b. Rotor kg.m2 28
c. Total Weight kg.m2 28
a. Stator + BODY 1520 Kg
b. Rotor 500 Kg
c. Total 2020 Kg
1.11.0 Noise 85 dB(A) at 1 Meter
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C. Plate Type Heat Exchanger (PHE)
SL.
DESCRIPTION UNIT
NO.
1PGB10AC001/1PGB10AC002/1PG
1.0(A) Tag No. UNIT 1
B10AC003
2PGB10AC001/2PGB10AC002/2PG
1.0(B) Tag No. UNIT 2
B10AC003
Manufacturer model
2.0 NT500
number
3.0 Type Plate type, single pass, water – water
4.0 Quantity 3 x 50%
5.0 Flow pattern Counter flow
6.0 Duty Continues
7.0 Location INDOOR
Hot Side Cold Side
8.0 Design data
(DMCW) (ACW)
8.1 Heat duty kcal/hr 9856387
8.2 Surface per unit m2 550
8.3 Over surface area % 56.74 ((Uc-Ud)/(Ud*100))
8.4 No. of passes Single Single
kcal/hr
8.5 Heat transfer rate
m2 0c
Service 4520
Clean 7085
Hydrostatic test kg/sq.c
8.6 14.25 14.25
pressure m (g)
Duration of hydraulic minute
8.7 30
test s
Hot Side Cold Side
9.0 Plates
(CCW) ( ACW)
passes
x
9.1 Arrangement 1 x 110 1 x 111
chann
els
Quantity / Frame
9.2 1 / 25 % extra
Capacity
9.3 Plate Thickness mm 0.5
Material & chemical
9.4 Stainless steel , AISI-316
composition
No. of plates per heat
exchangers Nos.
222
Theoretical number of Nos.
209
9.5 plates mm x
2503 x 1242
Plate Dimension mm
Area m2 2.5
Type of Corrugation V Type
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SL.
DESCRIPTION UNIT
NO.
Maximum number of
plates that can be
9.6 278
accommodated in
each heat exchangers
Maximum plate pack
9.7 length as per 9.5 Mm 222*4.15 = 921
above
Maximum plate pack
9.8 length as per mm 278*415 = 1154
9.6 above
Average gap between
9.9 mm 4.15
two plates
(LxW
10.0 Overall dimension 2.800 x 1.405 x 3.257
x H) m
Withdrawal space and
10.1 m 2.10 each side
location
Hot side Cold side
11.0 Performance required
(DMCW) (ACW)
11.1 Flow rate ( Design ) m3/hr 1485 2485
Inlet water
11.2 °C 42.64 33
temperature
kcal/
11.3 Specific Heat 0.999595018 0.991588229
kg°C
kcal/
11.4 Thermal conductivity 0.54269 0.53758
mhr°C
Viscosity
centi
11.5 a) Inlet 0.616 0.749
poise
b) Outlet 0.704 0.688
11.6 Velocity at inlet m/s 2.1 3.51
Nominal velocity
11.7 m/s 0.86 1.42
between plates
11.8 Specific gravity 1 1
11.9 Density kg/m3 1000 1000
Outlet water
11.10 °C 36 37
temperature
Pressure drop at kg/sq.
11.11 0.6 0.9
design flow cm (g)
11.12 Design temperature °C 48 48
Normal working kg/sq.c
11.13 4 5
pressure m (g)
kg/sq.c
11.14 Design Pressure 9.5 9.5
m (g)
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SL.
DESCRIPTION UNIT
NO.
Permitted pressure kg/sq.c 0.7 (at 1.1 times 1.0 (at 1.1 times
11.15
drop m (g) design Flow) design Flow)
Calculated pressure
kg/sq. 0.6 (at design 0.9 (at design
11.16 drop including in
cm (g) Flow) Flow)
Nozzles
kcal /
11.17 Film coefficient hr m2 Proprietary
°C
2
m hr°C
11.18 Fouling factor 0.8 x 10-4
/kcal
Heat transfer kcal /
11.19 coefficient of plate hr m2 Proprietary
( dirty ) °C
Overall heat transfer
kcal /
coefficient of plate :
11.20 hr m2 4520
a) Inlet
°C
b) Outlet
11.21 Flow per channel m3/hr 13.5 22.39
Channel cross section
11.22 m2 Plate specific values, proprietary
area
11.23 Corrected LMTD 4.19
kg/
11.24 Test pressure 14.25 14.25
sq.cm
Maximum particle size
11.25 that can pass mm Not more than 2 mm
through
Allowable fouling
factor for a cleaning m2hr°C
11.26 0.8 x 10-4
frequency of once a /kcal
year
Heat load at design
11.27 kcal/hr 9856387
flow
Pressure drop across
Flow
PHE in DMCW
Pressu 1950 3250
11.28 and ACW side for the
re 1.06 bar 1.83 bar
indicated flows
Drop
condition
12.0 Empty weight of PHE kg 10408
Operating (filled)
13.0 kg 11330
weight of PHE
Is variable ‘theta (θ)’
14.0 No
plates
15.0 Hold up volume / side m3 1.07195 1.0817
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SL.
DESCRIPTION UNIT
NO.
Compressed by bolt tightening
Gasket compression
16.0 between frame
arrangement
plate & pressure plates
Cleaning frequency of
Heat exchangers for month
17.0 Not less than a year
the assumed fouling s
factor
Is anti fluid inter-
Yes. We provide double sealing
mixing arrangement
18.0 gasket
incorporated? If so
arrangement.
what?
Yes/N
19.0 ASME code stamp No
o
Inlet Nozzle
Quantity 2
No.
20.0 Size 500
mm
Rating 150#
Facing ANSI B 16.5
Outlet Nozzle
Quantity 2
No.
21.0 Size 500
mm
Rating 150#
Facing ANSI B 16.5
22.0 Additional information -
Recommended
cleaning frequency
22.1 Not less than a year
with respect to design
foul factor
Around 5 years if in use & around 1.5
Gasket replacement
22.2 years if stored in cool (below 20°)
frequency
dark place away from Sunlight
Is back flushing
22.3 No
required
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1.3 References
1.3.1 P & ID
a) CCW System P&ID _ Rev 2 Dwg. No. LTSL-M1-00210 (Sheet 1 to 5)
1.3.2 GA Drawings
a) PHE GA Drawing
Dwg. No. M0-04402-GA
b) DMCW Pump GA Drawing
Dwg. No. KBLP-M0-04601
Note: All above drawings are attached as Exhibits.
1.3.3 Vendor Information
a) CCW/DMCW Pump : Kirloskar Brothers Limited
b) PHE : GEA ECOFLEX (I) Pvt. Ltd.
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2.0 SYSTEM DESCRIPTION
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Chapter 2
System Description
2.1 Overview
The main function of closed cooling water (CCW) system or demineralized cooling
water (DMCW) system is to circulate passivated demineralized water along with a
corrosion inhibiter for various coolers of Turbine, generator & other equipment
within the scope of steam turbine generator & auxiliaries’ package. The heated
CCW is in turn cooled in Plate Heat Exchangers by the auxiliary cooling water
system. Passivated demineralized quality water is used in CCW system for this
purpose with provision for alternate supply from the condensate system. The
circulation of water in the CCW system is maintained by the horizontal centrifugal
pumps and make-up to the system is catered from an overhead tank located at
deaerator floor. One (1) independent CCW system is provided for each unit. All
CCW pumps & PHE’s are located in the Ground Floor of Power House Building of
each unit.
2.2 Flow Path
The closed cooling water system is designed to provide the necessary cooling
water to the following auxiliary coolers:
a) Steam Turbine lubricating oil coolers
b) Steam Turbine control fluid coolers
c) Generator stator water coolers
d) Hydrogen coolers
e) Seal oil coolers
f) Brushless exciter air cooler supply
g) Sampling coolers / SWAS coolers (by others)
h) Motor driven BFP coolers :
• Booster pump stuffing box cooler
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• Motor air cooler
• Working oil cooler
• BFP seal cooler
• Lubricating oil cooler
i) Turbine drive BFP coolers
• BFP turbine oil cooler
• BFP seal cooler
• Booster pump stuffing box cooler.
j) Condensate extraction pump bearing oil coolers.
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From DM water make-up system
Process Flow Diagram for CCW System
2x660 MW Jaypee Thermal Power Station
Make-up line from CEP discharge Carbon dioxide absorber tank
Chemical
NaOH
additive
tank DMCW Expansion cum make-up tank
NaOH
Overflow line
Pump Pump Pump
A B C
MOV FCV
PHE 1 PHE 2 PHE 3 PUMP
RECIRCULATION
LINE
Turbine
oil cooler
EH oil
cooler
CEP CEP CEP
motor motor motor Seal oil
Stator Seal oil Exciter
MDBF BFPT TDBF BFPT TDBF MDBF thrust thrust thrust SWAS cooler Generator
coil cooler air
PA A PA B PB PB bearing bearing bearing room (Hydrogen gas cooler
cooler (Air side) cooler
cooler cooler cooler side)
A B C
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DCS Graphics: Closed Cooling Water System
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2.3 Major Equipment
CCW pumps (1PGB10AP001, 1PGB10AP002, 1PGB10AP003)
There are three (3 x 50%) horizontal, centrifugal CCW pumps for TG auxiliaries
per unit i.e. total six (6) (4W + 2S) nos. pumps for both the units. Pumps are of
horizontal, centrifugal heavy-duty directly connected to motors through flexible
spacer coupling complete with base plate / frame and all accessories.
Plate type Heat Exchangers (1PGB10AC001, 1PGB10AC002, 1PGB10AC003)
There are three (3 x 50%) Plate type Heat Exchangers for TG auxiliaries per unit
i.e. totals six (6) (4W + 2S) nos. PHEs for both the units. In PHEs, passivated DM
water is in primary side and ACW water is in secondary side. Closed cooling
water system rejects heat to the plant auxiliary cooling water system, circulated
through secondary side of the heat exchangers. The heat exchangers are
constructed of material suitable for the auxiliary cooling water / DM water quality.
CCW Expansion cum overhead Tank (1PGB10BB001)
The closed cooling water over head tank is sized to accommodate the total
expansion volume of CCW liquid due to temperature fluctuation in the system and
the selected capacity of the tank is 5 m3. Corrosion inhibition dosing is carried out
in the CCW pump suction line.
Chemical pot feeder (1PGB10BB002)
To control the pH of the DM water, alkali (sodium hydroxide) solution is dosed in
CCW pump suction as well as in overhead expansion tank. For this purpose one
(1) no. chemical pot feeder is provided. Pressurized dosing is envisaged to
passivate the demineralized water in the primary (CCW) circuit with provision for
periodic sampling.
One no. tapping is taken from discharge side of the CCW pump and it is passed
through the chemical pot feeder and the chemical solution is dosed in the suction
line & CCW overhead Tank.
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3.0 NORMAL OPERATION, START-UP AND
SHUTDOWN
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Chapter 3
Normal Operation, Start-up and Shutdown
3.1 Start-up and initial fill
DM water is pumped into system through the DM make-up line into the CCW
expansion tank. During initial filling, some of the selected vent line is to be kept
open to remove the entrapped air completely from the system. Open the suction
valves of the pumps fully and keep the discharge valves of the specific pump in
closed condition. Once the level of cooling water in the expansion tank reaches
high enough to satisfy the pump start permissive, one CCW pump will be started.
After first pump is in service, the second pump will be started and put in service as
per requirement. The third pump will be kept in auto mode. When the pump
reaches the full speed, the discharge valve will be fully opened and the discharge
pressure will be checked. Each equipment cooled by this system is provided with
valves in supply and return line in order to isolate the equipment from the system.
It should be ensured that the circulating cooling water must be flowing through the
CCW Heat Exchanger before these valves are manually adjusted to regulate
cooling water flow through the equipment.
• High point vents in the piping system to be opened during filling to remove
trapped air.
• Initial fill of the system will be stopped by closing the filling valve
(1PGB10AA001) when the CCW overhead tank level reaches high.
• Corrosion inhibitor chemicals are to be added in the chemical tank during the
end of the filling process.
• The chemical tank is to be partially drained before adding the chemicals.
• Subsequent to loading the system, individual discharge throttling valves of
plant coolers are to be adjusted to control the outlet water temperature through
the coolers.
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• The auxiliary cooling water flow through the plate heat exchangers is to be
adjusted by manually operating the heat exchanger discharge (butterfly)
valves, to bring the CCW supply temperature within specified limits.
• Once the temperatures have stabilized, the system is considered to be
balanced.
3.2 Normal operation
The CCW loop is in continuous service during plant operation and functions with
two (2) closed cooling water pumps in operation. The 3rd pump will remain in
standby. The standby CCW pump is arranged for automatic start on an electrical
trip of running pump or low discharge header pressure after main pump running
for a preset time.
During normal operation, the motorized operated valve (1PGB10AA001) at the
inlet of the tank will get open or close signal through DCS for tank level make-up.
If the tank level is at low level the tank inlet valve will be opened and valve will be
closed after the tank level high is reached. The level is controlled through the level
transmitter (LT-1PGB10CL001& 1PGB10CL002).
Pumps have manually operated isolation (butterfly) valves (1PGB10AA102,
1PGB10AA103 & 1PGB10AA104) in their suction and motor operated isolation
(butterfly) valves (1PGB20AA001, 1PGB20AA002 & 1PGB20AA003) with check
valves (1PGB20AA201, 1PGB20AA202 & 1PGB20AA203) provided in the pump
discharge lines.
During system operation, closed cooling water is cooled by two plate heat
exchangers (3 x 50%) to a temperature equal to 36 deg. C by plant auxiliary
cooling water available at 33 deg. C
Temperature indicators are provided on inlet suction header and outlet of each
cooler.
The overhead tank is sized to accommodate the thermal expansion and
contraction of the cooling water in the system, as well as any system surge while
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bringing standby coolers in service. If makeup water is required, it will be
automatically supplied from the CEP discharge or DM water make up system
through a motorized operated valve.
Periodically, a grab sample will be taken for water chemistry analysis from the
head tank and PHE outlet.
Corrosion inhibitor will be added as required into the chemical addition tank. The
drain point connection provided on any nearby cooler may be used to take a grab
sample for evaluating the distribution of corrosion inhibitor in the loop.
3.3 Normal shutdown
If the closed cooling water system is to be shut down, stop the closed cooling
water pumps. During a prolonged outage, the water chemistry of the CCW system
should be monitored periodically and corrosion inhibitor should be added as
required. Operation & Maintenance Manuals of CCW pumps and plate heat
exchangers should be consulted for shutdown maintenance of these equipment.
3.4 Check List
Pre-requisites: Check the following before starting up the CCW System:-
• Electrical Distribution System is in service and all the related Switchgears and
MCC are ready.
• Service Air and Instrument Air system are in service.
• DM Water System is in service
Pre-operational checklist: Before start-up, the following should be verified:-
DANGER
Strictly follow the work permit system to avoid unacceptable
troubles or danger.
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• All work permits or hold orders for the plant systems are cleared
• All equipment is in a safe condition to operate and is ready for operation.
• All instrumentation and control system (DCS) are available and lined up.
• All annunciations and interlocks are available.
• All rotating equipment guards and safety devices are installed.
• Valve Iine-up is completed as per valve P&ID.
• Lockout relays for all applicable electrical motors are reset.
• Power supply line up is completed.
• All equipment is aligned for remote operation from CCR. (where applicable)
• Sub-Group and Drive levels are transferred in Auto mode for all the related
equipment (pumps/fans/valves) before Group level operation (DCS)
• All set points on the DCS are normal.
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4.0 EMERGENCY OPERATION AND
ALARMS
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Chapter 4
Emergency Operation and Alarms
4.1 Emergency Conditions Operation
4.1.1 Closed Cooling Water Pump Trip
If the closed cooling water pump trips due to any reason, an alarm is initiated in
the DCS (common trouble alarm). With the tripping of one CCW pump, standby
pump will come into the service. Operator needs to investigate and rectify the
cause of malfunction. If cause for the tripping identified in the short time, operator
needs to reset pump status from the DCS & pump will be kept on the standby.
However, if the cause has not been identified in short time, operator needs to
isolate the pump.
4.1.2 Closed Cooling Water Heat Exchanger Outage
If more than one CCW heat exchanger out of service, plant load will have to be
reduced to the point that the CCW outlet temperature from PHE does not exceed
36 deg. C.
4.2 Alarms
CAUTION
Operator must take appropriate corrective action, if any of the
alarms mentioned below appears. Continuous operation without
corrective action may lead to the tripping of equipment and may
lead to the possible damage to the equipment.
The CCW System alarms can be monitored from the DCS operator interface
console alarm graphic display.
The following system conditions are alarmed through the DCS:
CCW Overhead Tank Level Low
CCW Overhead Tank Level Low Low
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CCW Overhead Tank Level High
CCW Overhead Tank Level High High
Running Pump Trip
Discharge Header Pressure Low
CCW Temperature at PHE Outlet Header High
CCW Pressure at PHE Outlet Header High
CCW motor R-phase Winding Temperature Hi
CCW motor R-phase Winding Temperature Hi-Hi
CCW motor Y-phase Winding Temperature Hi
CCW motor Y-phase Winding Temperature Hi-Hi
CCW motor B-phase Winding Temperature Hi
CCW motor B-phase Winding Temperature Hi-Hi
CCW Motor DE Bearing Temperature Hi
CCW Motor DE Bearing Temperature Hi-Hi
CCW Motor NDE Bearing Temperature Hi
CCW Motor NDE Bearing Temperature Hi-Hi
CCW Pump DE Bearing Temperature Hi
CCW Pump DE Bearing Temperature Hi-Hi
CCW Pump NDE Bearing Temperature Hi
CCW Pump NDE Bearing Temperature Hi-Hi
The following information will be provided on the control room display on the CRT
as a function of the DCS.
CCW Pump Status (ON/OFF)
CCW Pump Start Permissive Not Available
CCW Overhead Tank Level
Discharge Header Pressure
ALL MOV Status (OPEN/CLOSE)
CCW Pump Motor Bearing Temperature
CCW Pump Motor Amperes
CCW Pump Motor Winding Temperature
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5.0 INSTRUMENTATION & PROCESS
CONTROL
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Chapter 5
Instrumentation & Process Control
5.1 Instrumentation & Process Control
5.1.1 Closed cooling water Pumps (3 x 50 %)
1PGB10AP001 (Pump A)
1PGB10AP002 (Pump B)
1PGB10AP003 (Pump C)
Purpose:
Closed cooling water pumps (2 Working + 1 Standby) are provided to circulate the
passivated demineralised cooling water through equipment coolers and heat
exchangers.
Functional Description:
The closed cooling water pumps (CCWP) will be normally started and stopped
manually from the DCS. Regardless of the number of pumps utilized, one of the
pumps will be in standby and will start automatically upon loss of the running
pump or discharge header pressure low.
The closed cooling water pumps are controlled manually by the operator from the
DCS operator interface console. Start / Stop / Auto soft manual controls are
provided through the DCS.
Permissive
• CCW Overhead tank level not low (not less than 1000mm)
• Pump suction valves fully open.
• Pump discharge valve closed (Except for standby pump, where valve can be
in open position, in order to bring standby pump online quickly in auto mode).
• Pump and motor bearing temperature is not high.
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• Motor winding temperature is not high.
• Emergency stop push button near motor is not operated.
Trip Condition
Pump will be tripped / stopped if any of the following conditions occur:
• CCW Overhead tank level low low.
• Pump suction valve not open.
• Pump discharge valve not fully open within a preset time after pump starting.
• Bearing temperature (either pump or motor) high high.
• Motor winding temperature high high.
• Vibration of the bearing of either pump or motor high high.
• CCW suction pressure is low (0.3 kg/cm2)).
• After starting of CCW Pump if Discharge MOV opening feedback not received
within specified time (10 sec.)
Stand by Pump Auto-start
If any of the following conditions appear, stand by pump will start subject to
availability of start permissive:-
• Running pump Tripped
• One pump running and Pump discharge header pressure low (< 5.1kg/cm2)
for a preset time
5.1.2 Recirculation Flow control valve (1PGB10AA081)
Purpose:
To protect the pump and piping system from high pressure during low flow
conditions and to meet the minimum flow requirement of the pump during startup
and when header flow is less than minimum recirculation flow.
Functional Description:
The minimum flow requirement of each CCW pump will be maintained by air-
operated recirculation flow control valve (1PGB10AA081). The control valve can
be placed in automatic or manual control via DCS. The valve will be normally
placed in auto and will modulate as required based on pressure differential
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between the main supply & return headers of CCW System to maintain constant
pressure differential between the same.
5.1.3 CCW Pump Suction Valve
1PGB10AA102, 1PGB10AA103, 1PGB10AA104
Purpose:
To isolate the Pump
Functional Description:
These valves are provided with open limit switches and should be kept at open for
before startup of those pumps. These switches are wired into the DCS for
monitoring of the same.
5.1.4 Temperature Control Valves: (By LMTG)
Generator Stator coil temperature will be controlled by operation of Temperature
control valve (1PGB30AA081) in CCW line at Generator Stator coil coolers (A &
B) supply header. Operation of the Temperature control valve will be from TCS
based on Generator Stator coil temperature of respective sides.
Generator Seal oil temperature will be controlled by operation of respective
Temperature control valves (1PGE01AA001, 1PGE01AA002) in CCW line at
supply header of Generator Seal oil coolers (A & B). Operation of the
Temperature control valve will be from TCS based on Generator seal oil
temperature of respective sides.
Generator Hydrogen coolers (A & B) temperature will be controlled by operation of
respective Temperature control valve (1PGB40AA081) in CCW line at return
header of Generator hydrogen coolers (A & B). Operation of Temperature control
valve will be from TCS based on hydrogen cooler temperature of respective sides.
Main Turbine Lube oil temperature will be controlled by operation of respective
Temperature control valves (1PGA01AA701) in CCW line at supply header of
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Main Turbine lube oil coolers (A & B). Operation of the Temperature control valve
will be from TCS based on Main Turbine lube oil temperature of respective sides.
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6.0 INTERLOCKS AND PROTECTION
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
Chapter 6
Interlock and Protection
6.1 Instrumentation & Process Control
6.1.1 CCW Overhead Tank Inlet MOV
1PGB10AA001
Functional Description:
During normal operation, the Over-head tank inlet MOV (1PGB10AA001) at the
inlet of the tank will get open or close signal through DCS for tank level makeup. If
the tank is at low level (500 mm) the tank inlet valve will be opened and valve will
be closed after the tank level high (1000mm) is reached. The level is controlled
through the 1 out of 2 Redundant Level transmitters (1PGB10CL001 &
1PGB10CL002).
Protective commands:
Override close for DM Make up tank level high-high (1200mm)
6.1.2 Recirculation Bypass MOV
1PGB10AA005
In case of valve trouble/maintenance, inching type MOV is provided at the bypass
of the corresponding valve (1PGB10AA005 for recirculation flow control valve
1PGB10AA081) and it can be operated manually from DCS to achieve above
mentioned functions.
6.1.3 CCW Pump discharge MOV
1PGB20AA001
1PGB20AA002
1PGB20AA003
Type: Motor operated butterfly valves
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
Functional Description:
It can be controlled manually or in Auto via the DCS.CCW pump discharge MOVs
(1PGB20AA001, 1PGB20AA002 & 1PGB20AA003) will be in closed conditions
when no CCW Pump is running. Respective MOV at each pump discharge will
step open automatically within a preset time after the starting of corresponding
CCW pump. When selected in auto mode, if the selected pumps are running and
the sufficient pressure is available at pump discharge common header, then
discharge valve at the discharge of the non-running CCW Pump will also open (in
order to bring standby pump online quickly).
Close Permissive:
Corresponding CCW Pump stopped
Auto Open Interlock:
Preset time after respective CCW Pump start
6.1.4 Bypass MOV to lube oil temperature control valve
(1PGB30AA004)
In case of valve trouble/maintenance, inching type MOV is provided at the bypass
of the corresponding valve (1PGB30AA004 for temperature control valve
1PGA01AA701) and it can be operated manually from DCS to achieve above
mentioned functions.
Main Turbine EH oil temperature will be controlled by operation of respective
Temperature control valve (1MAY06AA751) in CCW line at supply header of Main
Turbine EH oil coolers (A & B). Operation of the Temperature control valve will be
from TCS based on EH control oil temperature of respective sides.
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7.0 VALVE LINE-UP LIST
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Chapter 7
Valve Line-Up List
7.1 List
CAUTION
Do not operate valves without proper authorization such as work
permit, as unauthorized operation may lead to serious injury and
damage to the equipment.
Valve line-up check list is prepared for the system pre-start condition. Instrument
root valves are not covered in the valve list; they are to be kept open always
except during instrument maintenance. Reference may be made to the P&ID for
the system. Control valves, piston operated valves and motor operated valves are
not listed, since they are operated from DCS according to plant operating
conditions.
System Pre
Valve Tag no. Description Start
Position
DMCW MAKE-UP TANK INLET MOV
1PGB10AA001 OPEN
FROM DM WATER MAKE-UP SYS.
BYPASS MOV TO DMCW MAKE-UP
1PGB10AA117 CLOSE
TANK INLET MOV
CHEMICAL ADDITIVE TANK TO
1PGB10AA120 CLOSE
MAKE-UP TANK ISOLATION VALVE
MAKE-UP TANK DISCHARGE TO
1PGB10AA101 DMCW PUMP SUCTION HEADER OPEN
ISOLATION VALVE
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JAYPEE O&M MANUAL – VOLUME 1 CCW SYSTEM
System Pre
Valve Tag no. Description Start
Position
DMCW PUMP -1/2/3 SUCTION
1PGB10AA102/103/104 OPEN
VALVE
DMCW PUMP -1/2/3 DISCHARGE
1PGB20AA001/002/003 OPEN
VALVE
1PGB20AA102/104/106 PHE -1/2/3 SUCTION VALVE OPEN
1PGB30AA101/103/105 PHE -1/2/3 DISCHARGE VALVE OPEN
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ABBREVIATIONS
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Abbreviations:
Abbreviation Meaning
CCW Closed Cooling Water
DMCW Demineralized Cooling Water
PHE Plate Heat Exchanger
SWAS Steam Water Analysis System
BFP Boiler Feed Pump
DCS Distributed Control System
MOV Motor Operated Valve
TCS Turbine Control System
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EXHIBITS
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JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
STEAM TURBINE GENERATOR & AUXILIARIES PACKAGE
OWNER:
JAIPRAKASH POWER VENTURES LIMITED
OWNER’S CONSULTANT:
DEVELOPMENT CONSULTANTS PRIVATE LIMITED
CONTRACTOR:
LARSEN & TOUBRO LIMITED
L&T’S CONSULTANT:
L&T-SARGENT & LUNDY LIMITED
SUPPLIER:
KIRLOSKAR BROTHERS LIMITED
L&T-S&L JOB NO.: L543000 PROJECT NO.: T209001
TITLE:
GA and Foundation plan drawing for DMCW Pump
TOTAL NO. OF PAGES. : 03
DOC/DRG NO. : KBLP-M0-04601 REV:G
TOTAL NO. OF DRAWINGS. :01
FOR APPROVAL
REVISION CERTIFICATION
REVISION
PREPARED REVIEWED APPROVED
NO.
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
A SSA 22.03.2011 SSA 23.03.2011 SSA 24.03.2011
B SSA 01.04.2011 SSA 01.04.2011 SSA 01.04.2011
C SSA 07.04.2011 SSA 07.04.2011 SSA 07.04.2011
D SMM 20.05.2011 SBP 20.05.2011 JBK 20.05.2011
E SMM 13.06.2011 SBP 14.06.2011 JBK 15.06.2011
F SMM 03.02.2012 SBP 03.02.2012 JBK 03.02.2012
LTSL-M0-00951
PDF processed REV 0evaluation edition www.CutePDF.com
with CutePDF Page 357 of 860
JAIPRAKASH POWER VENTURES LIMITED
JAYPEE NIGRIE SUPER THERMAL POWER
PROJECT, 2 x 660 MW L&T - S&L LIMITED
LARSEN & TOUBRO LIMITED
STEAM TURBINE GENERATOR Rev: G
GA and Foundation Plan Drawing for CCW Pump
AND AUXILIARIES PACKAGE Date: 04.07.2012
SUPPLIER: KBL Document No. KBLP-M0-04601 Page: 2 of 3
G SMM 04.07.2012 SBP 04.07.2012 JBK 04.07.2012
Revision Summary Sheet
Rev. Details / Description Date
P0 Foundation Plan Drawing 11.03.2011
A GA and Foundation Plan Drawing 24.03.2011
B GA and Foundation Plan Drawing 01.04.2011
C GA and Foundation Plan Drawing 07.04.2011
D GA and Foundation Plan Drawing for DMCW Pump 20.05.2011
E GA and Foundation Plan Drawing for DMCW Pump 15.06.2011
F GA and Foundation Plan Drawing for DMCW Pump 03.02.2012
G GA and Foundation Plan Drawing for DMCW Pump 04.07.2012
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JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
Operation & Section D.
Maintenace Volume 1 Extraction
Manual Steam System
Table of Contents 363
1. Overview of Extraction Steam System 365
2. System Description 381
3. Normal Operation, Start-up / Shutdown 394
4. Emergecny Operations & Alarms 398
5. Instrumentation & Process Control 405
6. Interlock & Protection 410
7. Valve Line-up List 428
Abbreviations 435
Exhibits 437
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Table of Contents
1.0 OVERVIEW OF EXTRACTION STEAM SYSTEM
1.1 Purpose
1.2 Specifications
1.2.1 Design Data of Major Equipment
1.3 References
1.3.1 P & ID
1.3.2 System documents
1.3.3 Heat Balance Diagram
1.3.4 Vendor Drawings / Documents
2.0 SYSTEM DESCRIPTION
2.1 Overview
2.2 Major Component
2.2.1 System Piping
2.2.2 Non-Return Valves
2.2.3 Power Operated Isolation valves
2.2.4 Automatic Drain Valves
2.2.5 Low Point Drain Valves
3.0 NORMAL OPERATION, START-UP AND SHUTDOWN
3.1 Description of Operation
3.1.1 Normal Start-up
3.1.2 Normal Operation
3.1.3 Normal Plant Shut Down
3.2 Checklist
4.0 EMERGENCY OPERATION AND ALARMS
4.1 Emergency Operation
4.1.1 Turbine Trip Events
4.1.2 Turbine Water Induction Prevention (TWIP) Events
4.1.3 Removing Heater from Operation
4.1.4 Returning Heater to Operation / Heater Recovery Operation
4.1.5 Loss of Instrument Air/Power
4.2 Alarms
4.3 Cause & Effect Table
5.0 INSTRUMENTATION AND PROCESS CONTROL
5.1 Instrument and Process Control
5.1.1 Extraction Steam Source Changeover and Pressure Control of Deaerator
5.1.2 BFPT Motive Steam Source Changeover
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6.0 INTERLOCKS AND PROTECTION
6.1 Heater Extraction Steam Isolation MOVs
6.2 BFPT Inlet steam inching MOVs
6.3 Deaerator Extraction Steam Isolation MOV
6.4 Extraction Steam Check Valves
6.5 BFPT & Deaerator Extraction Steam Check Valve
6.6 HP heater Extraction Steam Low Point Drain Valves & Drain SOVs
6.7 Extraction Steam Low Point Drain Valves & Drain SOVs
6.8 BFPT & Deaerator Extraction Steam Drain SOVs
6.9 BFPT Extraction Steam Low Point Drain Valves
6.10 BFPT Exhaust MOVs
6.11 CRH to Gland steam header MOV
6.12 Aux steam to Gland steam header MOV
6.13 CRH to BFPT CV
6.14 CRH to BFPT MOV
6.15 Aux steam to BFPT MOV
6.16 BFPT- A / B GLND STM CV I/L DRN MOV
6.17 BFPT MSV I/L AIR VENT VLV
6.18 BFPT CRH CV I/L DRN VLV
6.19 BFPT - A / B I/L STM AUX ISO VLV I/L DRN SOV
6.20 Aux steam header to Atmospheric flash tank MOV
6.21 GS SPIL TO CNSR MOV
6.22 GS SPIL TO LP HTR
6.23 BFPT Exhaust to BFPT FT MOVs
6.24 CRH TO DA PEG STM CV
6.25 AUX TO DA PEG STM CV
6.26 CRH to Deaerator CV Isolation MOV & Integral bypass MOV
6.27 AUX steam to Deaerator CV isolation MOV
6.28 AUX steam to Deaerator CV bypass MOV
6.29 Deaerator steam balance MOV
7.0 VALVE LINE-UP LIST
7.1 List
ABBREVIATIONS
EXHIBITS
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1.0 OVERVIEW OF EXTRACTION STEAM
SYSTEM
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Chapter 1
Overview of Extraction Steam System
1.1 Purpose
The purpose of extraction steam system O&M manual document is to provide the
operating personnel with necessary information to safely operate and maintain the
extraction steam system & associated equipment.
The scope of the manual covers an overview of the Extraction Steam System,
description of its major components with associated equipment & devices and
details of the startup, shutdown and normal operation and process control.
The Extraction Steam System routes steam extracted from various stages of the
main turbine, IP exhaust and cold reheat lines (CRH) to the feed water heaters and
the boiler feed pump turbines. It also provides the capability to drain the excessive
moisture between the Turbine Stages. The main purposes of the Extraction Steam
system are the following:-
• To preheat the condensate & feed water before entering the boiler by turbine
bled steam, thereby increasing overall plant efficiency.
• To deliver bled steam from the steam turbine to the turbine drive of main boiler
feed pumps.
• To supply steam to deaerator for deaeration and feedwater heating.
Extraction steam for HP heaters and LP heaters (except 1 A/B and 2 A/B) flows
through a set of solenoid operated steam check valve (energize to open and fail to
close) and motorized isolation valve. There are two steam check valves and one
motorized isolation valve in the extraction line of Deaerator. Condenser neck
mounted heaters (LP 1A/B and 2 A/B) do not include any valves in extraction lines.
Notes:
1. It is advisable to read this manual carefully to achieve the performance objective.
2. The scope of the document covers the overall system description for the
extraction steam system, description of its major components and associated
auxiliaries & system startup, shutdown, operation & process control.
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3. If the extraction steam system equipment and components are operated under
conditions different than its design, it is possible that the system may not achieve
its performance objectives and is likely to result in serious trouble.
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1.2 Specifications
1.2.1 Design Data of Major Equipment
A. Non Return Valve
Valve description
Valve Tag “LPH 3 Extraction NRV” 1LBS80AA055
Valve Make TYCO FLOW CONTROL (FASANI)
Valve type Swing Check Bolted Bonnet
Operation Non Return Valve
Medium Steam
Design ANSI / ASME B16.31 BS1868
Normal size 38”
Body connection Welding End
Weight without Actuator 5700 kg
Operating Data
Temperature 168.6 °C
Pressure 2.15 kg/cm2 (a)
Flow 85111 kg/hr
Pressure Drop at 100% TMCR 3 mbar
Design Data
Temperature 239 °C
Pressure 3.5 kg/cm2 (g)
Valve description
Valve Tag “LPH 4 Extraction NRV” 1LBS70AA055
Valve Make BABCOCK VALVES
Valve type Swing Check Bolted Bonnet
Operation Non Return Valve
Medium Steam
Design ANSI B16.25
Normal size 30”
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Body connection Welding End
Weight without Actuator 2420 Kg
Operating Data
Temperature 269 °C
Pressure 5.55 kg/cm2 (a)
Flow 89583 kg/hr
Pressure Drop at 100% TMCR 0.02903 kg/cm2
Design Data
Temperature 320 °C
Pressure 5.97 kg/cm2 (g)
Valve description
Valve Tag “BFPT & DA Extraction
1LBD40AA055
NRV”
Valve Make BABCOCK VALVES
Valve type Swing Check Bolted Bonnet
Operation Non Return Valve
Medium Steam
Design ANSI B16.25
Normal size 32”
Body connection Welding End
Weight without Actuator 4970 kg
Operating Data
Temperature 358.8 °C
Pressure 12.07 kg/cm2 (a)
Flow 210009 kg/hr
Pressure Drop at 100% TMCR 0.01156 kg/cm2
Design Data
Temperature 391 °C
Pressure 13.97 kg/cm2 (g)
Valve description
Valve Tag “DA Extraction NRV” 1LBD50AA055
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Valve Make ADAMS
Valve type Swing Check Bolted Bonnet
Operation Non Return Valve
Medium Steam
Design DIN EN 12516
Normal size 26”
Body connection Welding End
Weight without Actuator 1818 kg
Operating Data
Temperature 358.8 °C
Pressure 12.07 kg/cm2 (a)
Flow 87268 kg/hr
Pressure Drop at 100% TMCR 0.006 kg/cm2
Design Data
Temperature 391 °C
Pressure 14 kg/cm2 (g)
Valve description
Valve Tag “HPH 6A/6B Extraction
1LBQ30AA055
NRV”
Valve Make ADAMS
Valve type Swing Check Bolted Bonnet
Operation Non Return Valve
Medium Steam
Normal size 18”
Body connection Welding End
Weight without Actuator 1010 kg
Operating Data
Temperature 496.2 °C
Pressure 30.2 kg/cm2 (a)
Flow 122762 kg/hr
Pressure Drop at 100% TMCR 0.0328 kg/cm2
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Design Data
Temperature 528 °C
Pressure 36 kg/cm2 (g)
Valve description
Valve Tag “HPH 7A/7B Extraction
1LBQ20AA055
NRV”
Valve Make ADAMS
Valve type Swing Check Bolted Bonnet
Operation Non Return Valve
Medium Steam
Normal size 18”
Body connection Welding End
Weight without Actuator 1010 kg
Operating Data
Temperature 349.8 °C
Pressure 60.2 kg/cm2 (a)
Flow 175526 kg/hr
Pressure Drop at 100% TMCR 0.0249 kg/cm2
Design Data
Temperature 383 °C
Pressure 74 kg/cm2 (g)
Valve description
Valve Tag “HPH 8A/8B Extraction
1LBQ10AA055
NRV”
Valve Make BABCOCK VALVES
Valve type Swing Check Bolted Bonnet
Operation Non Return Valve
Medium Steam
Normal size 12”
Body connection Welding End
Weight without Actuator 1115 kg
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Operating Data
Temperature 417.3 °C
Pressure 96.6 kg/cm2 (a)
Flow 186290 kg/hr
Pressure Drop at 100% TMCR 0.15233 kg/cm2
Design Data
Temperature 457 °C
Pressure 110.9 kg/cm2 (g)
B. Motorized Operated Valve
Valve description
Valve Tag 1LBQ11AA001, 1LBQ12AA001
Valve Make L&T VALVE
Valve type Parallel Slide Gate Valve
Operation Inching
Medium Steam
Design ASME B16.34
Normal size 8”
Body connection Buttweld End
Total Weight 625 kg
Design Data
Temperature 457 °C
Pressure 110.97 kg/cm2 (g)
Actuator Details
Service Inching Duty
Power Rating 2.2 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 51 sec
Weight 72 kg
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Valve description
Valve Tag 1LBQ21AA001, 1LBQ22AA001
Valve Make L&T VALVES
Valve type Parallel Slide Gate Valve
Operation Inching
Medium Steam
Design ASME B16.34
Normal size 14”
Body connection Buttweld End
Total Weight 1215 kg
Design Data
Temperature 383°C
Pressure 74 kg/cm2 (g)
Actuator Details
Service Inching Duty
Power Rating 5 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 48 sec
Weight 75 kg
Valve description
Valve Tag 1LBQ31AA001, 1LBQ32AA001
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation Inching
Medium Steam
Design ASME B16.34
Normal size 12”
Body connection Buttweld End
Total Weight 935 kg
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Design Data
Temperature 528°C
Pressure 36 kg/cm2 (g)
Actuator Details
Service Inching Duty
Power Rating 2.2 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 84 sec
Weight 71 kg
Valve description
Valve Tag 1LBD50AA001
Valve Make L&T VALVES
OS & Y, Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation Inching
Medium Steam
Design ASME B16.34
Normal size 26”
Body connection Buttweld End
Total Weight 1955 kg
Design Data
Temperature 391 °C
Pressure 14 kg/cm2 (g)
Actuator Details
Service Inching Duty
Power Rating 5 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 109 sec
Weight 75 kg
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Valve description
Valve Tag 1LBD61AA001, 1LBD62AA001
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation Inching
Medium Steam
Design ASME B16.34
Normal size 24”
Body connection Buttweld End
Total Weight 1950 kg
Design Data
Temperature 391 °C
Pressure 20.5 kg/cm2 (g)
Actuator Details
Service Inching Duty
Power Rating 5 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 109 sec
Weight 75 kg
Valve description
Valve Tag 1LBC20AA001, 1LBC20AA002
Valve Make L&T VALVES
Valve type Pressure Seal Bonnet Globe Valve
Operation Inching
Medium Steam
Design ASME B16.34
Normal size 8”
Body connection Buttweld End
Total Weight 740 kg
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Design Data
Temperature 383°C
Pressure 73.97 kg/cm2 (g)
Actuator Details
Service Inching Duty
Power Rating 4 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 75 sec
Weight 115 kg
Valve description
Valve Tag 1LBD61AA003,1LBD62AA003
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation Inching Duty
Medium Steam
Design ASME B16.34
Normal size 10”
Body connection Buttweld End
Total Weight 565 kg
Design Data
Temperature 391°C
Pressure 21.97 kg/cm2 (g)
Actuator Details
Service On-Off duty
Power Rating 1.25 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 58 sec
Weight 71 kg
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Valve description
Valve Tag 1LBS70AA001
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation Inching Duty
Medium Steam
Design ASME B16.34
Normal size 30”
Body connection Buttweld End
Total Weight 2150 kg
Design Data
Temperature 320 °C
Pressure 5.97 kg/cm2 (g)
Actuator Details
Service Inching duty
Power Rating 4 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 121 sec
Weight 72 kg
Valve description
Valve Tag 1LBS80AA001
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation Inching Duty
Medium Steam
Design ASME B16.34
Normal size 38”
Body connection Buttweld End
Total Weight 3250 kg
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Design Data
Temperature 239°C
Pressure 3.5 kg/cm2 (g)
Actuator Details
Service Inching duty
Power Rating 5 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 104 sec
Weight 75 kg
Valve description
Valve Tag 1LBS70AA441
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation Vacuum Service
Medium Steam
Design ASME B16.34
Normal size 10”
Body connection Buttweld End
Total Weight 225 kg
Design Data
Temperature 383°C
Pressure 3.5 kg/cm2 (g)
Actuator Details
Service On-Off duty
Power Rating 0.55 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 46 sec
Weight 39 kg
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Valve description
Valve Tag 1LBS70AA442, 1LBS80AA441
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation Vacuum Service
Medium Steam
Design ASME B16.34
Normal size 6”
Body connection Buttweld End
Total Weight 130 kg
Design Data
Temperature 383°C
Pressure 3.5 kg/cm2 (g)
Actuator Details
Service On-Off duty
Power Rating 0.55 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 46 sec
Weight 39 kg
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1.3 References
1.3.1 P & ID
a) Extraction Steam System P&ID Dwg. No. LTSL-M1-00203 (Sheet 1 to 7)
Note: P & IDs are attached as Exhibits.
1.3.2 System documents
a) System Description, Operation & Control Dwg. No. LTSL-M1-00153
b) Logic Drawings Dwg. No. LTSL-I1-00200
c) Process Control Function Dwg. No. LTSL-I1-00202
1.3.3 Heat Balance Diagram
a) Dwg. No. T3101AAAB110
1.3.4 Vendor Drawings / Documents
a) Turbine Auxiliary Machine Control Logic Diagram Doc/Drg No. LMTG-I0-01304
b) Control Concept for BFP Drive Turbine Doc/Drg No. SIEG-I0-03661
c) Data Sheet – Forced Closing Non-Return Valve Dwg. No. LMTG-M0-02001
ADAMS-M0-06052
d) GA Drawings – MOV Dwg. No. LTV-M0-04947, LTV-M0-04948, LTV-M0-04953,
LTV-M0-04956, LTV-M0-04916, LTV-M0-05056, LTV-M0-04913, LTV-M0-04983,
LTV-M0-04933, LTV-M0-05054.
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2.0 SYSTEM DESCRIPTION
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Chapter 2
System Description
2.1 Overview
The main function of the extraction steam system is to suitably and efficiently
extract and supply the bleed steam from the various inter stages and/or end stages
of the HP, IP, and LP turbine to the two stream (2 x 50%) of HP feedwater heaters
(6 numbers total, three in each stream), (1 x 100%) Deaerator, one stream (1 x
100%) LP feedwater heater 4 & 3, two streams (2 x 50%) of duplex LP feedwater
heater 1A-2A & 1B-2B and (2 x 50%) turbine-drives for Boiler Feedwater Pumps.
The feedwater is preheated by extraction steam in feedwater heaters before the
feedwater enters into the boiler economizer. This results in the increase of
feedwater temperature which reduces the amount of heat to be added in boiler and
improves the reversibility of the process, thereby increasing plant efficiency.
The various main turbine sections and CRH line supply steam to the eight stages of
feed water heating as follows:
Sl. No. Extractions Turbine Stages Turbine Feed water Heater
LP Heater No. 1A
(1LCC10AC002) &
1. 1st Extraction 8th / 7th LP 1
LP Heater No. 2A
(1LCC10AC001)
LP Heater No. 1B
2nd (1LCC30AC001) &
2. 8th / 7th LP 2
Extraction LP Heater No. 2B
(1LCC30AC002)
LP Heater No. 3
3. 3rd Extraction 5th LP 2
(1LCC50AC001)
LP Heater No. 4
4. 4th Extraction 3rd LP 1
(1LCC60AC001)
Deaerator
(1LAA10AC001) /
5. 5th Extraction ---- IP Exhaust
BFP Turbine (1AXAA10 &
1BXAA10)
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Sl. No. Extractions Turbine Stages Turbine Feed water Heater
HP Heater No. 6A
(1LAD31AC001) &
6. 6th Extraction 5th IP
HP Heater No. 6B
(1LAD32AC001)
HP Heater No. 7A
(1LAD21AC001) &
7. 7th Extraction ---- CRH
HP Heater No. 7B
(1LAD22AC001)
HP Heater No. 8A
(1LAD11AC001) &
8. 8th Extraction 8th HP
HP Heater No. 8B
(1LAD12AC001)
During Normal operating condition, when the unit is running at its rated load, the
extraction steam from turbine is readily available and utilized for feed water heating
and for driving the steam turbine driven Boiler Feed Pumps in the respective
extraction lines.
Auxiliary steam can be used for Boiler Feedwater Pump Turbine drive during plant
startup. When IP Extraction is not available to feed Boiler Feedwater Pump Turbine
Drive, steam will be supplied through CRH (Extraction 7). CRH (Extraction 7) steam
is also used during plant startup and low load operation for Deaerator pegging.
The deaerator is a direct contact (DC) heater which heats and removes entrained
oxygen & other non-condensable gases from the condensate flowing into it, while
the remaining heaters are of the closed shell and tube type with feed water flowing
through the tubes and with steam condensed in the shells. With the exception of LP
Feed water Heaters 1A, 1B, 2A and 2B extraction steam to each closed feed water
heater passes through the pneumatically operated quick closing non-return valve
and motor operated valve.
MSVGV leak off line is connected to Extraction 6 line.
Gland Steam spill over line is connected to Condenser and LP Feedwater Heater 1A
& 1B.
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Pneumatically operated quick closing non-return valve is located as close as
possible to the main turbine connections to prevent the over speed during load
throw-off or turbine trip.
Drains with air-operated drain valves are provided at low points in the Extraction
Steam Piping System. During normal operation, the drain valves are closed.
The flow diagram for extraction steam system is as shown in the schematic on next
page.
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Process Flow Diagram for Extraction Steam System
2x660 MW Jaypee Thermal Power Station
LP Turbine - 1 LP Turbine - 2 IP Turbine HP Turbine
S
S
CRH to
S
boiler
S S
S
From gland
Steam spill
Over line
To
Condenser
LP heater 4 LP Heater 3 HP heater HP Heater HP heater HP Heater HP Heater HP Heater
6A 6B 7A 7B 8A 8B
LP Heater LP Heater To
Deaerator To
1A/2A 1B/2B Deaerator
Legends:
From Auxiliary - NRV (Self actuated)
From Auxiliary
Steam header Steam header S Solenoid Operated
- QCNRV
To To
condenser condenser - MOV
BF BF
Main BFP BFPT Main BFP BFPT
Booster Booster - Control valve
B B A A
pump pump
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DCS Graphics: HP Extraction
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DCS Graphics: LP Extraction
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2.2 Major Component
Extraction steam system is having the following major components:
• System Piping
• Non – Return valves
• Power operated isolation valves
• Automatic Drain Valves
• Low point Drain valves
2.2.1 System Piping
The extraction steam piping used to feed HP Feedwater Heater 7A/B, Deaerator &
associated branch lines, LP Feedwater Heater 4, LP Feedwater Heater 3, LP
Feedwater Heater 2A & 2B and LP Feedwater Heater 1A & 1B are of carbon steel
material. The extraction steam piping used to HP feedwater Heater 8A/B and HP
feedwater Heater 6A/B are of alloy steel ASTM A 335 Gr. P11 and ASTM A 335 Gr.
P22 respectively. Extraction steam piping and piping components are insulated with
mineral wool and covered with aluminum cladding.
Extraction Piping System design includes all requirements dictated by the ASME
Standard No. TDP-1, “Recommended practices for the Prevention of Water Damage
to Steam Turbines Used for Electric Power Generation”
The following table represents the design parameters for the various extraction
piping:-
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Design Design
Sr.
SERVICE Material Pressure Temp.
No.
kg/cm2 (g) 0
C
1. FROM TURBINE NOZZLE TO
HPH 8A/B HEADER
2. HEADER TO HPH 8 A/B
ASTM A
1 3. EXTRACTION 8 DRIPLEG 110.97 457
335 Gr. P11
4. EXTR-8 DRIPLEG TO FLASH
TANK
5. DRAIN & VENT
1. FROM CRH HEADER TO HPH
7A/B HEADER AND HPH 7
HEADER AND DEAERATOR
BFPT COMMON LINE.
2. HEADER TO HPH 7 A/B
3. EXTRACTION 7 DRIPLEG
4. EXTR-7 DRIPLEG TO FLASH
TANK
5. CRH TO DEAERATOR BEFORE
CONTROL VALVE ASTM A
2 73.97 383
6. CRH TO DEAERATOR AFTER 106 GR. B
CONTROL VALVE
7. CRH TO BFPT COMMON LINE
8. CRH TO BFPT BEFORE
CONTROL VALVE
9. CRH TO BFPT AFTER CONTROL
VALVE
10. CRH TO GLAND STEAM
HEADER
11. DRAIN & VENT
1. FROM TURBINE NOZZLE TO
HPH 6A/B HEADER.
2. HEADER TO HPH 6 A/B
3. EXTRACTION 6 DRIPLEG
4. MSV GV HP STEAM LEAK TO
ASTM A
3 EXTR-6 35.97 528
335 Gr. P22
5. EXTR-6 DRIPLEG TO FLASH
TANK
6. DRAIN & VENT
7. INSTRUMENT PRESSURE
CONNECTION
1. FROM TURBINE NOZZLE TO
HPH 5 HEADER.
2. HEADER TO BFPT &
DEAERATOR
3. HEADER TO BFPT ASTM A
4 4. EXTRACTION 5 DRIPLEG 106 13.97 391
5. CRH TO DEAERATOR GR. B
DOWNSTREAM OF CV AFTER
CV ISOLATION VALVE
6. DRAIN
7. DRAIN & VENT
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8. INSTRUMENT PRESSURE
CONNECTION
1. IP EXTRACTION TO BFPT-A/B
BEFORE MOV
2. BFPT-A/B EXTRACTION
DRIPLEG BEFORE MOV
ASTM A
5 3. BFPT-A/B EXTRACTION 13.97 391
106 GR. B
DRIPLEG TO FLASH TANK
4. DRAIN & VENT
5. INSTRUMENT PRESSURE
CONNECTION
1. IP EXTRACTION TO BFPT-A/B
AFTER MOV
2. BFPT-A/B EXTRACTION
DRIPLEG AFTER MOV & IP
EXTRACTION TO BFPT LINE
RELIEF VALVE INLET
3. CRH TO BFPT DOWNSTREAM
OF CV AFTER CV ISOLATION
VALVE
4. AUXILIARY STEAM TO BFPT
ASTM A
6 DOWNSTREAM OF MOV 21.97 391
106 GR. B
5. IP EXTRACTION TO BFPT LINE
RELIEF VALVE OUTLET
6. BFPT A/B EXTRACTION TO
BFPT SEALING
7. BFPT A/B EXTRACTION LINE
VENT TO ATMOSPHERE
8. BFPT-A/B EXTRACTION
DRIPLEG TO FLASH TANK
9. DRAIN, VENT & INSTRUMENT
PRESSURE CONNECTION
1. FROM TURBINE NOZZLE TO
LPH 4 HEADER.
2. LPH 4 HEADER AFTER
REDUCER
ASTM A
7 3. DRIP LEG AFTER NRV 5.97 320
106 GR. B
4. DRAIN BEFORE NRV
5. VENT
6. INSTRUMENT PRESSURE
CONNECTION
1. FROM TURBINE NOZZLE TO
LPH 3 HEADER.
2. LPH 3 HEADER AFTER
REDUCER
ASTM A
8 3. DRIP LEG AFTER NRV 3.5 239
106 GR. B
4. DRAIN BEFORE NRV
5. VENT
6. INSTRUMENT PRESSURE
CONNECTION
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1. AUXILIARY STEAM TO
DEAERATOR UPSTREAM OF
CONTROL VALVE
2. AUXILIARY STEAM TO
ASTM A
9 DEAERATOR DOWNSTREAM 20.4 220
106 GR. B
OF CONTROL VALVE
3. VENT & DRAIN
4. INSTRUMENT PRESSURE
CONNECTION
1. AUXILIARY STEAM TO BFPT
UPSTREAM OF MOV
2. AUXILIARY STEAM TO BFPT
ASTM A
10 LINE DRIP LEG 20.4 360
106 GR. B
3. VENT & DRAIN
4. INSTRUMENT PRESSURE
CONNECTION
2.2.2 Non-Return Valves
The steam turbine extraction steam lines to the regenerative feed water heating
system are provided as follows:
1) Pneumatically operated quick closing swing type non-return valve in common
line with flap type non-return valve in individual line for HP feedwater heaters.
2) Pneumatically operated quick closing swing type non-return valve in series
with flap type non-return valve for LP feedwater heater 3 & 4.
3) The extraction steam line to the deaerator is provided with two pneumatically
operated quick closing non-return valves in series, due to the higher quantity
of energy stored in Deaerator.
Following are the Power assisted Non-Return Valves on the pipeline:
1LBQ10AA055 – In the Extraction line to Heater 8A/8B
1LBQ20AA055 – In the Extraction line to Heater 7A/7B
1LBQ30AA055 – In the Extraction line to Heater 6A/6B
1LBD40AA053 & 1LBD50AA055 – In the Extraction line to Deaerator
1LBS70AA055 – In the Extraction line to Heater 4
1LBS80AA055 – In the Extraction line to Heater 3
4) Extraction steam lines to LP feedwater heater 1A/2A & 1B/2B (Duplex heater
located in the condenser neck) without any valves.
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In order to prevent the over speed trip during the load shut down, the extraction NRV
are installed as close as possible to the main turbine connections, to reduce the
volume of steam which can flow back in to turbine during the load shut down.
Pneumatically operated quick closing non- return valve are located as close as
possible to the main turbine connections to provide analysis of turbine speed
increase after trip for the residual entrained energy in the extraction piping.
A pneumatically actuated quick closing type non-return valve on cold reheat
(individual) line are provided to safeguard against the back flow of steam into HP
turbine through its exhaust side while HP bypass is in operation.
2.2.3 Power Operated Isolation valves
Power operated isolation valves are located downstream of quick closing non-return
valves. These valves are located as close as possible to the feedwater heaters. The
motor operated isolation valves on extraction will be closed on heater high-high
level, to prevent water induction into the steam turbine.
Following are the Motor operated isolation Valves on the pipelines:
• 1LBQ11AA001 & 1LBQ12AA001– In the Extraction line to Heater 8A/8B
• 1LBQ21AA001 & 1LBQ22AA001– In the Extraction line to Heater 7A/7B
• 1LBQ31AA001 & 1LBQ32AA001 – In the Extraction line to Heater 6A/6B
• 1LBD50AA001– In the Extraction line to Deaerator
• 1LBS70AA001 – In the Extraction line to Heater 4
• 1LBS80AA001– In the Extraction line to Heater 3
• 1LBD61AA001 & 1LBD62AA001- In the Individual Extraction line to TDBFP-1& 2
2.2.4 Automatic Drain Valves
A drain with a power operated drain valve is located upstream and downstream of
each pneumatically operated quick closing non-return valve. Each drain point is
connected to the turbine flash tank with a separate connection.
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2.2.5 Low Point Drain Valves
Drains located at low points in the extraction steam pipe routing where automatic
drain valves are not provided as described above are designed with drip legs and
power operated drain valves. Drains located at low points in the piping feeding the
BFP Turbine Drives have drain pots with level switches controlling power operated
drain valves. Low point drains discharges to the turbine flash tank.
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3.0 NORMAL OPERATION, START-UP AND
SHUTDOWN
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Chapter 3
Mode of Operation
3.1 Description of Operation
3.1.1 Normal Start-up
When auxiliary steam header pressure is achieved, auxiliary steam is admitted to
the deaerator by opening isolation valve 1LBG70AA007, and pressure control valve
1LBG70AA081 for initial heating and pegging during start-up. Once required steam
parameters are available from CRH line and when BID flow requirement for BFP is
20%, steam source is switched over to CRH for further pegging by opening valve
1LBC01AA025 & control valve 1LBC01AA090. Once required unit load is reached,
extraction steam from IP turbine is admitted for deaerator pegging by opening
isolation valve 1LBD50AA001, pneumatically operated check valves 1LBD40AA055
& 1LBD50AA055. Drain valves on upstream of QCNRVs to be kept open until the
isolation valve 1LBD50AA001, 1LBD61AA001 and 1LBD62AA001 is full open.
All HP feedwater heaters 6A/B, 7A/B and 8A/B extraction steam drain valves should
be fully open during start-up until the load reaches 18% of rated load. LP Feedwater
heaters 3 & 4 and Deaerator & BFPT extraction steam drain valves should be fully
open during start-up until the load reaches 13% of rated load. The feedwater heaters
should be placed in service sequentially from LP heaters, 3 and 4, and HP heaters
6A, 6B, 7A, 7B, 8A and 8B; the heater manufacturer’s startup and operating
instructions are to be followed. The LP Heaters 1A/2A and 1B/2B are condenser
neck mounted and do not have associated extraction valves or isolation from the LP
Turbine extractions. The feedwater/condensate flow should be established before
extraction steam is admitted to the heaters as identified in the applicable sections of
this Volume 1 as well as the heater manufacturer’s O&M manual (LT-M0-03053/54
in Volume 2).
Once a feedwater heater is ready for steam admission, the continuous shell vent
valve, motorized startup shell vent valve should be fully opened. The extraction
steam isolation valve should be cracked open at first to drain the condensate from
the extraction line after which the valve should be operated into the fully open
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position. The motorized startup vent valve should be closed after the corresponding
extraction steam isolation valve is fully open.
Auxiliary steam from auxiliary steam header should be admitted to Boiler Feedwater
Pump Steam Turbine Drive for sealing purpose and also to run the BFP during plant
startup and low load conditions. Once steam parameters are achieved in CRH line,
source will be switched over to CRH and as the required load is reached, extraction
steam from IP turbine should be admitted to run the drive turbine.
Refer to the Section E in this Volume 1 for miscellaneous feedwater heater vents
and drains as well as the manufacturer’s documentation regarding manual valve
operation and start-up sequence.
3.1.2 Normal Operation
During normal plant operation all feedwater heaters, deaerator and Turbine Driven
BFPs are in operation. Steam is supplied to above equipment by uncontrolled
extractions from the high pressure, intermediate pressure, and low pressure turbine.
Extraction steam flows through a set of extraction steam check and isolation valves
for each extraction for heaters and through two extraction steam check and one
isolation valve for extraction to Deaerator except extractions to LP heaters in the
condenser neck, 1A, 1B, 2A and 2B, which do not include intervening valves.
The deaerator is a direct contact (DC) heater which heats and removes entrained
oxygen & other non-condensable gases from the condensate flowing into it, while
the remaining heaters are of the closed shell and tube type with feedwater flowing
through the tubes and with steam condensed in the shells to raise the feedwater
temperature prior to entering the economizer.
Drain valves in the extraction steam lines are closed when extraction steam reaches
a defined load and remain in the closed position until a turbine trip or plant
shutdown. Drain valves in extraction steam line to boiler feed pump drive turbine will
open on drain pot high level. Drain valve in BFPT exhaust drain line will be closed
when BFPT load is greater than 10% & remain closed during normal operation and
this valve will opened with delay when BFPT main stop valve is closed. All drain line
isolation valves are locked open.
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3.1.3 Normal Plant Shut Down
During normal plant shutdown, the feedwater heaters are to be removed from
service in reverse order (heaters 8 to heater 3) as the unit load is decreased by
closing the extraction steam check valves & isolation valves and opening the shell
vents.
All drain valves in the extraction steam lines to HP feedwater heaters 6A/B, 7A/B
and 8A/B should be open below 16% of rated load. All drain valves in the extraction
steam lines to LP feedwater heaters 3 & 4 and Deaerator & BFPT should be open
below 12% of rated load.
3.2 Checklist
Heater in service
• Ensure cancellation of any work permit issued relevant to extraction steam
system.
DANGER
Strictly follow the work permit system to avoid unacceptable troubles
or danger.
• Ensure that the power supply for MOV is available from the feeder.
• Make sure all interlocks and protections test of Steam Check valve and MOV
are qualified.
• All related instruments are mounted and properly fitted.
• Ensure availability of instrument air supply.
• Ensure all valves are on auto.
• Manual isolating valves of Heater Extraction Steam Low Point Drain Valves &
Drain SOVs are open.
• Heater level is not high.
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4.0 EMERGENCY OPERATION AND
ALARMS
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Chapter 4
Emergency Operation and Alarms
4.1 Emergency Operation
4.1.1 Turbine Trip Events
In the event of a turbine trip, all extraction steam check valves slam shut to prevent
turbine over-speed due to backflow from the extraction steam piping and power
operated isolation valves in the extraction lines will also be closed. Simultaneously,
all drains are opened to remove condensate and steam from the extraction steam
piping.
Motor operated and check valves are not being installed in the low pressure heaters
1A /1B & 2A/2B extraction steam lines because these heaters are installed in the
main condensers extension necks. Anti-flash baffles are provided in these heaters
to retard flashing of water in the heaters and backflow into the turbine on a unit trip.
Steam for Deaerator and Boiler Feedwater Pump turbine drive can be achieved from
CRH line during FCB / Boiler island / House load and Turbine trip.
The MOV (1LBC01AA030) in balancing line between IP extraction line and CRH line
to deaerator is closed during normal operation. The MOV is opened during turbine
trip allowing the steam flow to pass through both the rakes of deaerator.
4.1.2 Turbine Water Induction Prevention (TWIP) Events
Due to excessive tube leaks or improper drain operation, the heaters may flood with
operating water levels exceeding the high-high alarm limit. To prevent water from
entering the turbine through the extraction piping, upon receipt of a high-high alarm
of any of the HP Heater A/B, the extraction steam check valve and isolation valve of
both heaters (of stream A and B) will be closed. Upon receipt of high-high alarm in
the respective LP heater, the extraction steam check valve and isolation valve will be
closed.
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Closing of above valves will automatically result in opening of drain valve in the
extraction steam line. If after 1 min. heater level remain as high-high then only the
inlet/outlet feedwater valves of the heater train will close (Bypassing the train).
Refer to the Section A of condensate system in this Volume 1 for further details
regarding TWIP events.
4.1.3 Removing Heater from Operation
To manually remove a heater from service (does not apply to Turbine Water
Induction Prevention events), the extraction steam isolation valves are closed to
prevent admission of steam to the shell side of the heater. Feedwater flow through
the tube side of the heaters is to be maintained until the unit has cooled and reached
steady state.
If inspection or maintenance of the heater is required, all valves in normal operating
vent, start-up vent and drain lines should be closed. Manual drain valves on shell
side and tube side have to be opened to completely drain the heaters. Please refer
heater supplier Installation and Operation Manual (LT-M0-03053/54 in Volume 2) for
further details on preparing the heaters for maintenance.
4.1.4 Returning Heater to Operation / Heater Recovery Operation
In case Heater is bypassed in the event of any abnormal operation, heater can be
taken in to service through heater recovery procedure.
As soon as normal water level is achieved & Operator gives the heater bypass reset
(heater recovery) command, heater recovery operation will be initiated as mentioned
below sequence.
1. Heater will be charged through water side by opening the feed water heater
inlet/outlet isolation valve. (For further details refer O&M manual Volume 1,
Section A - Condensate system and Section B - Feed Water System)
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2. Once heater is ready for steam admission, Heater will be charged through
steam side by opening motor operated isolation valve (For further details, refer
clause no. 3.1.1 above). At the same time the cascade drain from upstream
heater will be opened. (For further details, refer O&M manual Volume 1,
Section E - Heater drain & vent system).
4.1.5 Loss of Instrument Air/Power
Upon loss of control air, signal, or power, the extraction steam check valves gets
closed (fail safe position) and all drain valves fail in the open position. Pressure
control valves for CRH / Aux steam to deaerator fail in closed condition.
4.2 Alarms
CAUTION
Operator must take appropriate corrective action, if any of the
alarms mentioned below appears. Continuous operation without
corrective action may lead to the tripping of equipment and may
lead to the possible damage to the equipment.
The following alarms related to extraction steam system are generated in the DCS
CRH steam to BFPT MOV closed
BFPT- A inlet steam MOV closed
BFPT- B inlet steam MOV closed
BFPT– A Exhaust steam-vent MOV open
BFPT– B Exhaust steam-vent MOV open
HP heater stream-A out of service
HP heater stream-B out of service
LP heater 4 out of service
LP heater 3 out of service
LP heater 1A/2A out of service
LP heater 1B/2B out of service
Heater Recovery Command
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The following information will be provided on the control room display on the CRT as
a function of the DCS
Extraction NRV Valves’ Status (OPEN/CLOSE)
Heater/deaerator Isolation Motor Operated Valves’ Status (OPEN/CLOSE)
ALL MOV Status (OPEN/CLOSE)
Extraction Steam Pressure Value at Turbine & Heater/Deaerator End
Extraction Steam temperature Value at Turbine End
CRH Steam Pressure/Temperature Value
4.3 Cause & Effect Table
Cause Effect Action
1 Turbine Trip
1. Closing of heaters 1. Check the status of the extraction
extraction line steam low point drain valves and
steam isolation drain SOVs and ensure these are
MOV and steam open.
Actuation of any
check valves
turbine protection
2. Decrease in 2. Check that steam source for
Deaerator Deaerator heating and pressure
pressure and control transferred from IP
temperature. extraction to CRH.
Turbine Water Induction Prevention (TWIP) Events: HP
2
heaters
1. Tube leakage 1. Closing of 1. Check the status of the extraction
in any Heater corresponding steam low point drain valve and
heater extraction drain SOV of corresponding
line steam isolation heater and ensure these are
MOV (Both A&B) open.
and steam check
valve.
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Cause Effect Action
2. Mal operation 2. Closing of 2. Check the Turbo Supervisory
of respective extraction line parameters and ensure no undue
heater drain steam isolation variations.
control valve MOV for other
heaters in the 3. After the stream in which the
same train. faulty heater is present gets
3. Mal operation
3. Respective train isolated both from extraction and
of next higher
gets bypassed feedwater side, the heater of the
pressure
from water side if healthy stream whose extraction
heater drain
level high-high line was isolated previously has
control valve
persist for more to be taken in to service.
than 1 min.
4. Decrease in feed
water I/L
temperature to
Economiser.
Turbine Water Induction Prevention (TWIP) Events: LP
3
heaters
1. Tube leakage 1. Closing of heater
in any Heater extraction line
steam isolation 1. Check the status of the
MOV and steam extraction steam low point drain
check valve. valve and drain SOV of
corresponding heater and
2. Mal operation 2. Heater gets ensure these are open.
of respective bypassed from
heater drain water side if level 2. Check the Turbo Supervisory
control valve high-high persist parameters and ensure no
for more than 1 undue variations.
min.
3. Mal operation 3. Decrease in
of next higher condensate I/L
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JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
Cause Effect Action
pressure temperature to
heater drain Deaerator.
control valve
4 Fast Cut-Back (FCB)
1. Closing of heaters 1. Check the status of the extraction
extraction line steam low point drain valves and
steam isolation drain SOVs and ensure these are
MOV and steam open.
check valves
2. Check that steam source for
2. Decrease in Deaerator heating and pressure
Deaerator control transferred from IP
Actuation of any
pressure. extraction to CRH and D/A
FCB condition
pressure set point tracking as per
logic.
3. Decrease in feed 3. Check that motive steam source
water I/L for BFPT transferred from IP
temperature to extraction to CRH if CRH pressure
Economiser. is healthy otherwise to Auxiliary
steam.
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5.0 INSTRUMENTATION AND PROCESS
CONTROL
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Chapter 5
Instrumentation & Process Control
5.1 Instrument and Process Control
5.1.1 Extraction Steam Source Changeover and Pressure Control of Deaerator
Purpose:
The Deaerator is designed to extract oxygen out of the feed water by using steam.
Steam is supplied from three (Auxiliary steam header, Cold reheat line (CRH) and IP
exhaust) different sources, only one source will be active at any time. Deaerator
pressure control set point will be varied according to load signal index.
Functional Description:
Deaerator is provided with three pressure transmitters (1LAA10CP001,
1LAA10CP002, 1LAA10CP003) for interlock, alarm, control and monitoring. The
controller will compare the pressure with set point & modulate the valve accordingly.
The set point of this valve in normal operation will be varied according to load index
signal.
Deaerator pressure will be controlled through Aux to DA Pegging Steam CV
(1LBG70AA081) when CRH steam AND IP extraction steam is not available. The set
point of this valve in normal operation & cleanup will be 0.5 kg/cm2(a).
In the process gradually CRH pressure will increase, control valve (1LBC01AA090)
will start to open when CRH pressure is higher than 13 kg/cm2(g) and maintain
deaerator pressure as per set point which varies according to the load index signal.
Aux to DA Pegging Steam CV (1LBG70AA081) will be force closed when CRH valve
open position is greater than 2%.
When Generator load is higher than13% IP exhaust to DA NRV (1LBD50AA055) will
be free and DA extraction steam isolation MOV (1LBD50AA001) starts to open. CRH
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to DA pressure control valve (1LBC01AA090) will be force closed after 5 sec when
IP exhaust to DA NRV (1LBD50AA055) open feedback is available, from now steam
will be supplied to DA through uncontrolled extraction.
During Fast Cut Back (FCB) condition, IP exhaust to DA NRV (1LBD50AA055) will
get close command and CRH to DA pressure control valve (1LBC01AA090) will
control DA set pressure which is kept at 1kg/cm2 less than DA pressure just before
FCB for eight minutes. After eight minutes, set pressure will be ramped down at a
rate of 1kg/cm2 per minute.
During Boiler island operation / house load operation, deaerator pressure is
maintained through Boiler Input Demand (BID) with a minimum temperature set
value of 160°C (corresponding to 5.29 kg/cm2 (g)).
During auto operation valves (1LBG70AA081, 1LBC01AA090, 1LBD50AA055,
1LBD50AA001) will be opened automatically from DCS when LP extraction group
and LP extraction steam sub group are active.
5.1.2 BFPT Motive Steam Source Changeover
Purpose:
The Boiler Feed Pump is designed to supply feed water to the Boiler as per Boiler
Input Demand (BID). Turbine of the BFPT (Turbine Driven Boiler Feed Pump) is
driven with the help of steam supplied from three ((Auxiliary steam header, Cold
reheat line (CRH) and IP exhaust) different sources. Only one source will be active
at any time.
Functional Description:
During start-up auxiliary steam will provide steam to BFPT to drive the Turbine.
Auxiliary Steam to BFPT MOV (1LBD61AA003/1LBD62AA003) will open
automatically under following conditions and sequence:
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1. Auxiliary steam supply to BFPT main isolation valve (Common for two BFPT) will
get open command if any one BFPT steam group on is active and auxiliary
steam header pressure is greater than 10 kg/cm2.
2. Auxiliary Steam to BFPT MOV (1LBD61AA003/1LBD62AA003) will get open
command when following conditions will satisfy :
a. Auxiliary steam supply to BFPT main isolation valve open feedback is
available
AND
b. MW demand is less than preset value
OR
(i) BFPT A/B CRH control valve I/L MOV (1LBC20AA001/ 1LBC20AA001)
open feedback is not available AND BFT A/B I/L steam pressure
(1LBD61CP001/1LBD61CP001) not greater than 5.5 Kg/cm2.
OR
(ii) BFPT A/B I/L steam isolating MOV (1LBD61AA001/ 1LBD62AA001)
open feedback is not available AND CRH pressure not greater than 10
kg/cm2.
Initial speed up of BFPT will be done with the help of auxiliary steam. CRH to BFPT
A/B MOV (1LBC20AA001/1LBC20AA002) will be opened automatically from DCS if
all below conditions satisfy:
a) BFPT A/B steam group on is active.
AND
b) Auxiliary steam header pressure is greater than 10 Kg/cm2.
AND
c) BFPT A/B Speed Up completed (Speed > 3100 RPM)
AND
d) MW demand is greater than 30%
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BFPT A/B inlet steam inching MOVs (1LBD61AA001, 1LBD62AA001) will be opened
automatically from DCS when BFPT A/B steam group on mode is active & MW
demand is greater than 35%.
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6.0 INTERLOCKS AND PROTECTION
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Chapter 6
Interlock and Protection
6.1 Heater Extraction Steam Isolation MOVs
(1LBQ11AA001, 1LBQ12AA001, 1LBQ21AA001, 1LBQ22AA001, 1LBQ31AA001,
1LBQ32AA001, 1LBS70AA001, 1LBS80AA001)
Purpose:
This Isolation valve prevents steam turbine from over-speeding due to Backflow of
steam from heater shell & extraction steam lines to steam turbine and also prevents
from turbine water induction in heater flooding situation.
Functional Description:
This valve is normally controlled automatically from DCS. This inching type MOV will
be opened from the DCS during extraction steam start-up when Generator load is
higher than 13% (for LP heaters) / higher than 18% (for HP heaters) in two steps. In
first step, these valves will be cracked opened for 10 seconds after that valve
opening will be hold for 180 seconds to warm–up heater and after completion of hold
up time valve will fully open.
Valve will be closed automatically from DCS during extraction steam shutdown.
Open Permissive:
• Heater is not bypassed (FW inlet, outlet valves are open & bypass valve closed)
Protective Command:
Valve receives Override close command from DCS when
Respective heater* level hi hi
OR
Turbine trip
OR
Generator CB open (52G)
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OR
Respective feed water heater stream is isolated in case of HP heaters
(* In case of HP heaters, respective A OR B stream heater)
6.2 BFPT Inlet steam inching MOVs
(1LBD61AA001, 1LBD62AA001)
Purpose:
This valve will isolate BFPT from IP extraction steam.
Functional Description:
During auto operation valve (1LBD61AA001/1LBD62AA001) will be opened
automatically from DCS when BFPT steam group on mode is active & MW demand
is greater than 35%.
During auto operation valve (1LBD61AA001/1LBD62AA001) will be automatically
closed if following conditions occur:
1. BFPT steam shutdown command is active
OR
2. BFPT steam group ON mode is active & MW demand is less than 20%
AND
i. Auxiliary steam isolation MOV is open
OR
ii. Auxiliary steam header pressure is greater than 10 kg/cm2(g).
6.3 Deaerator Extraction Steam Isolation MOV
(1LBD50AA001)
Purpose:
This Isolation valve prevents steam turbine from over-speeding due to Backflow of
steam from deaerator & extraction steam lines to steam turbine and also prevents
from water induction in deaerator flooding situation.
Functional Description:
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This valve is normally controlled automatically from DCS. This inching type MOV will
be opened from the DCS during extraction steam start-up when Generator load is
higher than 13% in two steps. In first step, this valve will be cracked opened for 10
seconds after that valve opening will be hold for 180 seconds and after completion of
hold up time valve will fully open.
Valve will be closed automatically from DCS during LP extraction steam shutdown.
Protective Command:
Valve receives Override close command from DCS when
Deaerator level emergency high high
OR
Turbine trip
OR
Generator CB open
6.4 Extraction Steam Check Valves
(1LBQ10AA055, 1LBQ20AA055, 1LBQ30AA055, 1LBD50AA055, 1LBS70AA055,
1LBS80AA055)
Please refer the Exhibit – LMTG’s Turbine Auxiliary machine control logic diagram
(Doc no. LMTG-I0-01304) attached in this manual.
6.5 BFPT & Deaerator Extraction Steam Check Valve
(1LBD40AA055)
Please refer the Exhibit – LMTG’s Turbine Auxiliary machine control logic diagram
(Doc no. LMTG-I0-01304) attached in this manual.
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6.6 HP heater Extraction Steam Low Point Drain Valves & Drain SOVs
(1LBQ10AA452, 1LBQ20AA452, 1LBQ30AA452, 1LBQ10AA451, 1LBQ20AA451,
1LBQ30AA451)
Purpose:
This valve will open to drain out the condensate accumulated in extraction steam
pipes.
Functional Description:
These valves are normally controlled automatically from DCS.
During startup, these valves will be opened from DCS until the unit reaches 18% of
rated load and after 18% load, these low point drain valves will be closed.
During shut down, these valves will be opened from DCS when unit load goes below
16% rated load.
When the unit out of service, the plant operator will manually open these valves.
Protective Command:
Valve receives override open command from DCS when
Respective Stream A or Stream B heater level hi hi
OR
Turbine trip
OR
Generator breaker (52G) not on
6.7 Extraction Steam Low Point Drain Valves & Drain SOVs
(1LBD50AA452, 1LBS70AA451, 1LBS80AA451, 1LBS70AA452, 1LBS80AA452)
Purpose:
This valve will open to drain out the condensate accumulated in extraction steam
pipes.
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Functional Description:
These valves are normally controlled automatically from DCS.
During startup, these valves will be opened from DCS until the unit reaches 13% of
rated load and after 13% load, these low point drain valves will be closed.
During shut down, these valves will be opened from DCS when unit load goes below
12% rated load.
Protective Command:
Valve receives override open command from DCS when
Respective heater level hi hi
OR
Turbine trip
OR
Generator breaker (52G) not on
6.8 BFPT & Deaerator Extraction Steam Drain SOVs
(1LBD40AA451, 1LBD40AA452)
Purpose:
This valve will open to drain out the condensate accumulated in extraction steam
pipes.
Functional Description:
During normal operation, these valves will be opened from DCS when inlet steam
MOVs of Deaerator, BFPT- A and BFPT- B are all closed.
These valves will be closed when any one inlet steam MOV among Deaerator,
BFPT-A and BFPT- B is open.
When the unit out of service, the plant operator will manually open these valves.
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Protective Command:
Valve receives override open command from DCS when
Turbine trip
OR
Generator CB open
6.9 BFPT Extraction Steam Low Point Drain Valves
(1LBD61AA451, 1LBD61AA452, 1LBD62AA451, 1LBD62AA452)
Purpose:
These valves will open to drain out the condensate accumulated in extraction steam
pipes to BFPT.
Functional Description:
During auto operation from DCS, these valves will operate based on the level
detected by level switches installed on the drain pipe.
During normal operation, this valve will auto open when level switch 1LBD61CL081/
1LBD62CL081/1LBD61CL083/1LBD62CL083 are actuated on sensing level high in
the drain pot.
This valve will auto close if the Drain pot level high signal is not available for 10
seconds.
Protective command:
Valve receives override open command from DCS when level switch
1LBD61CL082/1LBD62CL082/1LBD61CL084/1LBD62CL084 are actuated on
sensing level very high in the drain pot.
Valve receives override close command if the drain pot level high signal is not
available for 10 seconds.
6.10 BFPT Exhaust MOVs
(1LBD61AA002, 1LBD62AA002)
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Purpose:
This valve allows exhaust steam from BFPT to flow to the condenser.
Functional Description:
This valve will be opened automatically from DCS when it receives open command
during the execution of condenser vacuum start up sequence.
The valve can be closed manually by operator from DCS if the close permissive for
the closing of valves are available.
Open permissive:
BFPT gland steam in service complete
Close permissive:
BFPT is tripped
6.11 CRH to Gland steam header MOV
(1LBC30AA001)
Purpose:
This valve isolates CRH steam from gland steam header.
Functional Description:
When selected in auto mode from DCS, this valve will be opened when CRH
pressure is greater than 10 kg/cm2(g) & MW demand is greater than 30%.
Valve will be auto closed from DCS if Gland seal shutdown command is active OR
Gland seal shutdown permissives are available.
6.12 Aux steam to Gland steam header MOV
(1LBG60AA001)
Purpose:
This valve isolates aux steam from gland steam header.
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Functional Description:
When selected in auto mode from DCS, this valve will be opened when Gland seal
start up command is active & either of Gland steam exhaust condenser fan A OR B
is running & Gland steam condenser vacuum is less than -0.015 kg/cm2(g).
Valve will be auto closed from DCS if Gland seal shutdown command is active OR
Gland seal shutdown permissives are available.
Protective Command:
This valve will be override closed when auxiliary steam header pressure falls below
14 kg/cm2(g).
6.13 CRH to BFPT CV
(1LBC20AA081, 1LBC20AA082)
For the operation philosophy of this valve, refer the Exhibit - Siemens document
“Control concept of BFP drive turbine (SIEG-I0-03661)” attached in this manual.
6.14 CRH to BFPT MOV
(1LBC20AA001/1LBC20AA002)
Purpose:
This valve will open to provide CRH steam to BFPT to drive the turbine; When IP
extraction steam is not available.
Functional Description:
During auto operation valve 1LBC20AA001/1LBC20AA002 will be opened
automatically from DCS when
a. BFPT A/B steam group on mode is active
AND
b. CRH pressure is greater than 10 kg/cm2
AND
c. BFPT A/B Speed Up completed
AND
d. MW demand is greater than 30%
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During auto operation valve 1LBC20AA001/1LBC20AA002 will be automatically
closed if following conditions occur:
a. BFPT is tripped
OR
b. BFPT steam supply valve close command is active.
6.15 Aux steam to BFPT MOV
(1LBD61AA003/1LBD62AA003)
Purpose:
This valve will open to provide Auxiliary steam to BFPT to drive the turbine during
start up.
Functional Description:
In auto operation this valve will be operated automatically from DCS. This valve will
open automatically in following conditions:
1. BFPT steam group on is active and auxiliary steam header pressure is greater
than 10 kg/cm2(g).
AND
2. Auxiliary steam supply valve to BFPT open feedback is available
AND
3. a) MW demand is less than L %
OR
b) BFPT CRH control valve I/L MOV (1LBC20AA001/1LBC20AA002) open
feedback is not available AND BFPT I/L steam pressure not greater than 5.5
kg/cm2
OR
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(i) BFPT I/L steam isolating MOV (1LBD61AA001/1LBD62AA001) open feedback
is not available AND CRH pressure not greater than 10 kg/cm2(g).
This valve will close automatically in following conditions:
1. BFPT steam group on mode is active & MW demand is not less than L%
OR
(i) BFPT CRH control valve I/L MOV (1LBC20AA001/1LBC20AA002) open
feedback is available AND BFT A/B I/L steam pressure greater than 5.5
kg/cm2(g).
OR
(ii) BFPT I/L steam isolating MOV (1LBD61AA001/1LBD62AA001) open
feedback is available AND CRH pressure greater than 10 kg/cm2(g).
OR
2. BFPT steam subgroup shut down command is active.
6.16 BFPT- A / B GLND STM CV I/L DRN MOV
(1LBD61AA441/1LBD62AA441)
Purpose:
This valve will open to drain the condensate accumulated in steam line to Gland
steam header for BFPT.
Functional Description:
During auto operation this valve will be opened automatically from DCS when BFPT
auxiliary steam isolation MOV is closed OR BFPT inlet steam isolation MOV is
closed OR BFPT CRH steam inlet MOV is closed.
During auto operation this valve will be closed automatically if following conditions
occur:
1. BFPT auxiliary steam isolation MOV is open OR BFPT inlet steam isolation
MOV is open OR BFPT CRH steam inlet MOV is open &
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2. BFPT steam group on mode is active.
6.17 BFPT MSV I/L AIR VENT VLV
(1LBD61AA551/1LBD62AA551)
Purpose:
This valve will open to vent the steam/gaseous matter to atmosphere.
Functional Description:
During auto operation, this valve will be operated automatically from DCS during
sequential startup of BFPT for warm up of the main steam stop valves of BFP drive
turbine.
6.18 BFPT CRH CV I/L DRN VLV
(1LBC20AA451/1LBC20AA452)
Purpose:
This valve will open to drain the condensate accumulated in CRH line to BFPT.
Functional Description:
During auto operation this valve will be opened automatically from DCS if the CRH
CV inlet MOV is not open.
During auto operation this valve will be closed automatically if the CRH CV inlet
MOV is open & BFPT steam group on mode is active.
6.19 BFPT - A / B I/L STM AUX ISO VLV I/L DRN SOV
(1LBG55AA451/1LBG55AA452)
Purpose:
This valve will open to drain the condensate accumulated in auxiliary steam line to
BFPT.
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Functional Description:
During auto operation this valve will be opened automatically from DCS if the
auxiliary steam supply valve to BFPT is closed.
During auto operation this valve will be closed automatically if the auxiliary steam
supply valve to BFPT is open & BFPT steam group on mode is active.
6.20 Aux steam header to Atmospheric flash tank MOV
(1LBG60AA005)
Purpose:
This valve drains the steam or condensed steam in the aux steam line to gland
steam header.
Function description:
When selected in auto mode from DCS, this valve will be opened when auxiliary
steam to Gland seal header MOV (1LBG60AA001) is closed.
Valve has to be manually closed by operator from the DCS after checking all the
necessary conditions to close the valve.
Protective commands:
This valve will be override closed when auxiliary steam to Gland seal header MOV
(1LBG60AA001) is open
6.21 GS SPIL TO CNSR MOV
(1LBS70AA441)
Purpose:
This valve drains the steam in the condenser.
Functional Description:
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When selected in auto mode from DCS, this valve will be opened when generator
load is less than 10% AND GS spill to heater 1A & 1B MOVs are closed.
Valve will be auto closed when either GS spill to heater 1A MOV OR GS spill to
heater 1B MOV open.
Open permissive:
None
Close permissive:
Either GS spill to heater 1A MOV OR GS spill to heater 1B MOV open.
6.22 GS SPIL TO LP HTR
(1LBS70AA442/1LBS75AA442)
Purpose:
This valve drains the steam in the LP heater 1A/ 1B.
Functional Description:
When selected in auto mode from DCS, this valve will be opened when generator
load is higher than 10% AND respective LP heater level not hi hi.
Valve will be auto closed when either GS spill to heater 1A MOV OR GS spill to
heater 1B MOV open.
Open permissive:
None
Close permissive:
Either GS spill to CNSR MOV open OR GS condenser fan A & B not running.
Protective commands:
Respective LP heater level hi hi for 3 seconds
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6.23 BFPT Exhaust to BFPT FT MOVs
(1LBD61AA408, 1LBD62AA408)
Purpose:
This valve directs BFPT drain to BFPT flash tank.
Functional Description:
In normal operation this valve will remain close.
Protective commands:
This valve will be override open when BFPT main stop valve is closed for 1 hour
duration & it will be override closed when BFPT load is higher than 10%.
6.24 CRH TO DA PEG STM CV
(1LBC10AA090)
Purpose:
This valve controls CRH steam to Deaerator.
Functional Description:
Deaerator pressure will be controlled through this valve when IP extraction is not
available. Deaerator is provided with three pressure transmitters for interlock,
alarm, control and monitoring. The controller will compare the pressure with set
point & modulate the valve accordingly. The set point of this valve in normal
operation will be varied according to load index signal.
• Before synchronization (52G OFF), deaerator pressure set point is constant at
0.3 kg/cm2 (g).
• After synchronization (52G ON), deaerator pressure set point is varied
according to the load index signal.
• During FCB condition, CRH side pressure set point is kept at 1kg/cm2 less than
previous steam pressure for eight minutes (FCB signal 180 seconds + OFF
delay timer 300 seconds = 8 minutes). After eight minutes, pressure will be
ramped down at a rate of 1kg/cm2 per minute.
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• During Boiler island operation / house load operation, deaerator pressure is
maintained through Boiler Input Demand (BID) with a minimum temperature set
value of 160°C (corresponding to 5.29 kg/cm2 (g)).
6.25 AUX TO DA PEG STM CV
(1LBG70AA081)
Purpose:
This valve controls Aux steam to Deaerator.
Functional Description:
Deaerator pressure will be controlled through this valve when CRH steam AND IP
extraction steam is not available. Deaerator is provided with three pressure
transmitters for interlock, alarm, control and monitoring. The controller will compare
the pressure with setpoint & modulate the valve accordingly. The set point of this
valve in normal operation & cleanup will be 0.5 kg/cm2(a)*. This valve will be force
closed when CRH valve open position is greater than 2%.
*Set point will be finalized during Commissioning stage.
6.26 CRH to Deaerator CV Isolation MOV & Integral bypass MOV
(1LBC01AA025 & 1LBC01AA025A)
Purpose:
This valve will isolate CRH pegging steam from deaerator.
Functional Description:
This valve will be open during deaerator heating condition when CRH pressure is
higher than 13kg/cm2(g) AND integral bypass of this MOV is open.
This valve will be closed when LP heater & deaerator inlet steam MOVs are closed
AND LP heaters are isolated from water side AND vacuum breaker valve open &
ALL CEP stop for 5 seconds.
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The operating sequence for integral bypass MOV is as follows:
When main MOV open command is generated, first the integral bypass MOVs open
automatically.
• Auto open command for main MOV is generated 10 seconds after the integral
bypass MOVs fully open.
• Integral bypass MOVs close 10 seconds after main MOV is open.
• When main MOV is fully opened & integral bypass MOV is closed, the main
MOV open sequence in service is reset
Protective command:
Valve receives override close command from DCS when Deaerator level is
emergency high (3100 mm).
6.27 AUX steam to Deaerator CV isolation MOV
(1LBG70AA007)
Purpose:
This valve will isolate aux pegging steam from deaerator.
Functional Description:
This valve will be closed from DCS when IP extraction steam is available AND
turbine is not tripped.
This valve will be opened from DCS during LP cleanup recirculation when aux steam
pressure is higher than 15kg/cm2(g) OR during Deaerator steam admission when
CRH AND IP extraction steams are not ready.
Protective command:
Valve receives override close command from DCS when Deaerator level is
emergency high (3100 mm).
LTSL-M0-00951 REV 0 Page 426 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
6.28 AUX steam to Deaerator CV bypass MOV
(1LBG70AA005)
Purpose:
This valve will provide aux pegging steam to deaerator when Control valve fails.
Functional Description:
This MOV will be operated manually by the operator through DCS. This MOV is
provided for controlling deaerator pressure if aux steam to deaerator control valve
fails.
MOV will be in closed condition during the normal operation when control valve is
functioning properly.
Protective command:
Valve receives override close command from DCS when Deaerator level is
emergency high (3100 mm).
6.29 Deaerator steam balance MOV
(1LBC01AA030)
Purpose:
This valve will balance steam in H-rack & Y-rack of deaerator.
Functional Description:
This MOV will be closed during normal operation & this MOV will be opened during
turbine trip allowing the steam flow to pass through both the rakes of deaerator.
LTSL-M0-00951 REV 0 Page 427 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
7.0 VALVE LINE-UP LIST
LTSL-M0-00951 REV 0 Page 428 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
Chapter 7
Valve Line-Up List
7.1 List
CAUTION
Do not operate valves without proper authorization such as work
permit, as unauthorized operation may lead to serious injury and
damage to the equipment.
Valve line-up list tabulated below provides recommended position of manual valves
of the extraction steam system for starting the system.
System Pre Start
Valve Tag no. Description
Position
Outlet Isolating valve of AUX steam to
1LBG70AA105 OPEN
Deaerator Control Valve
Inlet Isolating valve of Steam Trap
1LBG70AA405 downstream of isolating MOV of AUX OPEN
steam to Deaerator Control Valve
Outlet Isolating valve of Steam Trap
1LBG70AA407 downstream of isolating MOV of AUX OPEN
steam to Deaerator Control Valve
Bypass valve of Steam Trap
1LBG70AA408 downstream of isolating MOV of AUX CLOSE
steam to Deaerator Control Valve
Inlet Isolating valve of Steam Trap
1LBG70AA410 upstream of isolating MOV of AUX OPEN
steam to Deaerator Control Valve
Outlet Isolating valve of Steam Trap
1LBG70AA411 upstream of isolating MOV of AUX OPEN
steam to Deaerator Control Valve
Bypass valve of Steam Trap upstream
1LBG70AA412 of isolating MOV of AUX steam to CLOSE
Deaerator Control Valve
Inlet Isolating valve of Steam Trap in
1LBC01AA450 the common line after AUX steam and OPEN
CRH to Deaerator Control Valve
LTSL-M0-00951 REV 0 Page 429 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
System Pre Start
Valve Tag no. Description
Position
Outlet Isolating valve of Steam Trap in
1LBC01AA451 the common line after AUX steam and OPEN
CRH to Deaerator Control Valve
Bypass valve of Steam Trap in the
1LBC01AA452 common line after AUX steam and CLOSE
CRH to Deaerator Control Valve
Isolation Valve on Steam Trap line
1LBC01AA405 upstream of CRH to Deaerator control OPEN
valve isolation MOV
Inlet Isolating Valve of Steam Trap
1LBC01AA408 upstream of CRH to Deaerator control OPEN
valve isolation MOV
Outlet Isolating Valve of Steam Trap
1LBC01AA409 upstream of CRH to Deaerator control OPEN
valve isolation MOV
Bypass Valve of Steam Trap upstream
1LBC01AA420 of CRH to Deaerator control valve CLOSE
isolation MOV
Isolation Valve of HP heater 8A/8B
1LBQ10AA401 Extraction Steam Check valve OPEN
Downstream drain SOV
Isolation Valve of HP heater 8A/8B
1LBQ10AA402 Extraction Steam Check valve OPEN
upstream drain valve
Isolation Valve of HP heater 8A/8B
1LBQ10AA403 &
Extraction Steam Check valve CLOSE
1LBQ10AA404
upstream Drain pipe
1LBQ10AA501 & Vent Valves of HP heater 8A/8B
CLOSE
1LBQ10AA502 Extraction Steam line
Isolation Valve of HP heater 7A/7B
1LBQ20AA401 Extraction Steam Check valve OPEN
downstream drain valve
Isolation Valve of HP heater 7A/7B
1LBQ20AA402 Extraction Steam Check valve OPEN
upstream drain valve
Isolation Valve of HP heater 7A/7B
1LBQ20AA403 &
Extraction Steam Check valve CLOSE
1LBQ20AA404
upstream Drain pipe
Isolation Valve of HP heater 7A/7B
1LBQ20AA405 &
Extraction Steam Check valve CLOSE
1LBQ20AA406
downstream Drain pipe
1LBQ20AA501 & Vent Valves of HP heater 7A/7B
CLOSE
1LBQ20AA502 Extraction Steam line
Isolation Valve of HP heater 6A/6B
1LBQ30AA401 Extraction Steam Check valve OPEN
Downstream drain SOV
LTSL-M0-00951 REV 0 Page 430 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
System Pre Start
Valve Tag no. Description
Position
Isolation Valve of HP heater 6A/6B
1LBQ30AA402 Extraction Steam Check valve OPEN
upstream drain valve
Isolation Valve of HP heater 6A/6B
1LBQ30AA403 Extraction Steam Check valve CLOSE
upstream drain pipe
Vent Valve of HP heater 6A/6B
1LBQ30AA501 CLOSE
Extraction Steam line
Isolation Valve of BFPT & Deaerator
1LBD40AA401 Extraction Steam Check valve OPEN
Downstream drain SOV
Isolation Valve of BFPT & Deaerator
1LBD40AA402 Extraction Steam Check valve OPEN
upstream drain SOV
Isolation Valve of Deaerator Extraction
1LBD50AA402 Steam Check valve upstream drain OPEN
valve
Isolation Valve of Deaerator Extraction
1LBD50AA403 Steam Check valve upstream drain CLOSE
pipe
Isolation Valve of downstream drain
1LBD61AA401 valve of BFPT-A inlet steam inching OPEN
MOV
Isolation Valve of downstream drain
1LBD61AA402 pipe of BFPT-A inlet steam inching CLOSE
MOV
Isolation Valve of upstream drain valve
1LBD61AA403 OPEN
of BFPT-A inlet steam inching MOV
Isolation Valve of upstream drain pipe
1LBD61AA404 CLOSE
of BFPT-A inlet steam inching MOV
Isolation valve of BFPT- A gland steam
1LBD61AA405 OPEN
control valve I/L drain MOV
Inlet isolation valve of steam trap
1LBD61AA406 downstream of BFPT- A gland steam OPEN
control valve I/L drain MOV
Outlet isolation valve of steam trap
1LBD61AA407 downstream of BFPT- A gland steam OPEN
control valve I/L drain MOV
Isolation Valve of BFPT-A MSV I/L air
1LBD61AA502 OPEN
vent valve
Upstream isolation valve of CRH to
1LBC20AA101 OPEN
BFPT-A control valve
LTSL-M0-00951 REV 0 Page 431 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
System Pre Start
Valve Tag no. Description
Position
Isolation Valve of downstream drain
1LBC20AA401 OPEN
valve of CRH to BFPT-A control valve
Isolation Valve of downstream drain
1LBC20AA402 CLOSE
pipe of CRH to BFPT-A control valve
Inlet isolation valve of upstream orifice
1LBC20AA407 OPEN
of CRH to BFPT-A control valve
Outlet isolation valve of upstream
1LBC20AA408 OPEN
orifice of CRH to BFPT-A control valve
Isolation Valve of downstream drain
1LBG55AA401 OPEN
valve of Aux steam to BFPT-A MOV
Isolation Valve of downstream drain
1LBG55AA402 CLOSE
pipe of Aux steam to BFPT-A MOV
Isolation Valve of downstream drain
1LBD62AA401 valve of BFPT-B inlet steam inching OPEN
MOV
Isolation Valve of downstream drain
1LBD62AA402 pipe of BFPT-B inlet steam inching CLOSE
MOV
Isolation Valve of upstream drain valve
1LBD62AA403 OPEN
of BFPT-B inlet steam inching MOV
Isolation Valve of upstream drain pipe
1LBD62AA404 CLOSE
of BFPT-B inlet steam inching MOV
Isolation valve of BFPT- B gland steam
1LBD62AA405 OPEN
control valve I/L drain MOV
Inlet isolation valve of steam trap
1LBD62AA406 downstream of BFPT- B gland steam OPEN
control valve I/L drain MOV
Outlet isolation valve of steam trap
1LBD62AA407 downstream of BFPT- B gland steam OPEN
control valve I/L drain MOV
Isolation Valve of BFPT-B MSV I/L air
1LBD62AA502 OPEN
vent valve
Upstream isolation valve of CRH to
1LBC20AA102 OPEN
BFPT-B control valve
Isolation Valve of downstream drain
1LBC20AA403 OPEN
valve of CRH to BFPT-B control valve
Isolation Valve of downstream drain
1LBC20AA404 CLOSE
pipe of CRH to BFPT-B control valve
LTSL-M0-00951 REV 0 Page 432 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
System Pre Start
Valve Tag no. Description
Position
Inlet isolation valve of upstream orifice
1LBC20AA411 OPEN
of CRH to BFPT-B control valve
Outlet isolation valve of upstream
1LBC20AA412 OPEN
orifice of CRH to BFPT-B control valve
Isolation Valve of downstream drain
1LBG55AA403 OPEN
valve of Aux steam to BFPT-B MOV
Isolation Valve of downstream drain
1LBG55AA404 CLOSE
pipe of Aux steam to BFPT-B MOV
Isolation Valve of LP heater -4
1LBS70AA401 Extraction Steam Check valve OPEN
Downstream drain SOV
Isolation Valve of LP heater -4
1LBS70AA402 Extraction Steam Check valve OPEN
Upstream drain valve
Isolation Valve of LP heater -4
1LBS70AA403 Extraction Steam Check valve CLOSE
Upstream drain pipe
Vent Valve of LP heater-4 Extraction
1LBS70AA501 CLOSE
Steam line
Isolation Valve of LP heater -3
1LBS80AA401 Extraction Steam Check valve OPEN
Downstream drain SOV
Inlet isolation Valve of steam trap
parallel to LP heater -3 Extraction
1LBS80AA403 OPEN
Steam Check valve Downstream drain
SOV
Outlet isolation Valve of steam trap
parallel to LP heater -3 Extraction
1LBS80AA404 OPEN
Steam Check valve Downstream drain
SOV
Isolation Valve of LP heater -3
1LBS80AA402 Extraction Steam Check valve OPEN
Upstream drain valve
Inlet isolation Valve of steam trap
parallel to LP heater -3 Extraction
1LBS80AA405 OPEN
Steam Check valve Upstream drain
valve
Outlet isolation Valve of steam trap
parallel to LP heater -3 Extraction
1LBS80AA406 OPEN
Steam Check valve Upstream drain
valve
Isolation Valve of LP heater -3
1LBS80AA407 Extraction Steam Check valve CLOSE
Upstream drain pipe
LTSL-M0-00951 REV 0 Page 433 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
System Pre Start
Valve Tag no. Description
Position
Vent Valve of LP heater-3 Extraction
1LBS80AA501 CLOSE
Steam line
LTSL-M0-00951 REV 0 Page 434 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
ABBREVIATIONS
LTSL-M0-00951 REV 0 Page 435 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
Abbreviations:
Abbreviation Meaning
ASME American Society of Mechanical Engineers
ANSI American National Standard Institute
ASTM American Society for Testing and Materials International
BFP Boiler Feed water Pump
BFPT Boiler Feed Pump-drive Turbine
BID Boiler Input Demand
CV Control Valve
CRH Cold Reheat
DC Direct Contact
DA Deaerator
DCS Distributed Control System
FCB Fast Cut Back
HP High Pressure
HPH High Pressure Heater
IP Intermediate Pressure
I/L Inlet
LMTG L&T MHI Turbine Generators Private Limited
LP Low Pressure
LPH Low Pressure Heater
MOV Motor Operated Valve
MW Mega Watt
NRV Non Return Valve
O&M Operation & Maintenance
O/L Outlet
P&IDs Piping & Instrumentation Diagram
PID Proportional Integral Differential
RPM Revolution Per Minute
SOV Solenoid Operated Valve
TDBFP Turbine Driven Boiler Feed Pump
TWIP Turbine Water Induction Prevention
QCNRV Quick Closing Non Return Valve
LTSL-M0-00951 REV 0 Page 436 of 860
JAYPEE O&M MANUAL – VOLUME 1 EXTRACTION STEAM SYSTEM
EXHIBITS
LTSL-M0-00951 REV 0 Page 437 of 860
l
16 I IS 14 13 12 1U 9 8 6 5 4 2
coc:oo·II'I-1S.L1 "ON ·~•a I
IP TURBINE HP TURBIN£ ,,
K N~ TP-0141!f ~
K
300X250 I~I ~
LBO I REFERENCE DRAWINGS
I-0~81J---o81J---l CP001
DRAWING TITLE DRAWING NUNBER
I--O!~'JI---o~81J---l ~ri1 J
..)~~~ ~ ~ ~--~
J 1-TE-RMIN-ALPO-INT_
L.II-STF_ORST-EAW-
TURBII--j.INE_ _L_MTG-110--0-1110-112----4
zso9LB~•OV.':,~Bo•ozsc r~ll t_,_~_J
AASOZ
AA501
CG080 (ID CG081 ~
,.~~~~;;'JL___j-~------------~~=IG==1=86:2:90:::~:i----------------~:;~~J.jT;P:-1;1;0~-----r_J~
1515-0N300
"'
~ IIOO"LTMCR.O"Mlj 1
TP-109 ~TP-108
r--------------+--------~1
NOTES
1. FOR INDEX. LEGEHOS AND SYMBOLS REFER OWG NO. LTSL-M0-00200.
300X200 300X200 2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
SINGLE ISOLATION VALVE IS PROVIDED & 25 NB WHEREVER DOUBLE
1515-0N200
~~~~~~~ONV~~~~S S~~~lP:V~~~o~;-~C~~,~~~~T~=~V~~~:
H INC,NC..r--:;;;:::---...
~ 1LBO~~AGOI) .~ HAVING
PRESSURE LESS THAN 40 KG/CWZ AND FOR SERVICES HAVING PRESSURE
MORE THAN 40KG/CM2 RESPECTIVELY AS PER IS-554.THIS HAS BEEN
H
13.09.2011
::~~~--',l 3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST Of -
r1Uill1lt---
1LB01TE 1LB01 TW
t:.C.:~~!
CTD01 CT001
DN25 UNLESS OTHERWISE SPECIFIED.
4. ------- IN JPYL SCOPE
Tl TW - - - IN L&T STCI SCOPE
1L801 1LB01 S. ~~~~~:z~c 1 gP~::r~~~~KC~~;.:~LL BE LOCATED AS CLOSE AS G
G CTS01 CT501"J------I~•-••-•<"•
I, ,,
6. MOTAR OPERATED ISDI.ATION VALVES SHALL BE LOCATED AS CLOSE AS
(;r~~~d POSSIBLE TO THE FEEDWATER HEATER CONNECTION.
7. • DENOTES ITEM SUPPLIED BY TGV.
~~~:~JTE
NOTE 18
~~l &.ALL OCS FUNCTION SHOWN AS DOTTED. ARE TO BE IMPLEMENTED IN
PLANT DCS BY JPVL. .... -
F NOTE 18
1LADI PI 9. END PREPARATION AT TURBINE NOZZLE WILL BE DONE BY TGV TO SUIT
CP5D1 CT001
LV '- Vi
)-1
THE CONNECTING EXTRACTION PIPING.
10.ENO PREPARATION AT HEATER NOZZLE WILL BE DONE BY FWHV TO SUIT
THE CONNECTING EXTRACTION PIPING.
~l
1 LB01 0AA452
1LAD1 11.ALL PIPING WILL BE SLOPED IN THE DIRECTION Of FLOW.HAVING
CD CT00 1 TW MINIMUM SLOPE OF 1:100.
NOTE~
T""JSr;-l
10 ___, "--
I<I<CI
~
12.SPECIAL INSTRUMENTS FOR PG TEST SHALL BE SUPPLIED BY TGV.
THE SAW£ SHALL BE TAKEN BACK Af!'TER COMPLETION OF PG TEST.
PG TEST THERI<OWELLS SHALL BE SUPPL lED BY L&T.
N
3.POC- PIPING DESIGN CODE
~~
0
HP HEATER 8A ?"' POT-PIPE DESIGN TABLE
~~
~
1LA01 UC001 4.ALL DCS FUNCTION SHOWN AS FIRM ARE TO BE IMPLEMENTED IN STCS
BY L&T STGI.
15. JPVLL___j DENOTES INSTRUMENT ARE IN JPVL SCOPE.
TO TUR61NE
FLASH TANK-1
TO T~INE
FlASH TANK -1
REST OF THE INSTRUMENTS WILL BE SUPPLIED BY L&T.
6.ALL HIGH POINT HYDRO TEST VENTS SHALL BE CAPPED
AFTER HYDRO TEST.
!E
7. TEMPERATURE MEASUREMENT CABLES FOR HEATER MOUNTED AND HEATER
UPSTREAM TEMPERATURE ELEMENTS WILL BE SUPPLIED BY JPVL.
&.PNEUMATIC OPEF{ATEO DRAIN VALVE SHALL BE PROVIDfD NEAR TO
SOURCE PIP£. -
r~"'~
IN-H!Nu ~
ID PI
D
-
?~~·~,1 -~~ ~-JI9t-~
t~~~~~r-~ ::;~-~~,. I PDC
NUMBER
OESIG~~
PRESSIJPE
DESIGN
TEMP.
MAX OPER.
PRESSURE
I MAX OPE.R., PIPE
TEMP.
£0EG. C I
CLASS
I PDT !FIELD TEST
PRESSURE
I REMARKS
I
T ~1LB01 ~~~WT f',-~~1~-1
kQ/Cm2 I g) IOEG.C J kg/cm2ICJl kg/cnQI g J DATE I PROJECT:
tLBOt TW
CT501 CT501 1LB01 f,}TOOJ-~ J ES-8 1 11o.91 1 457.0 I 100.10 I 431.2 I D I JPN IS15 I 166 •• 55 I I f--r:-:-.,..-,----f----j JAYPEE NIGRIE SUPER THERMAL POWER PROJECT. 2 X 660 IIW C
AX201 ·-~,---· !PRELIMINARY STEAII TURBINE GENERATOR AND AUXILIARIES PACKAGE
1fpA~d1 P·~tl:Ot
!FOR INFORMATION
TE IFOR APPROVAL !OWNER:
CT001 UIPRAKASH POWER VENTURES LIIIITED
X IFDR CONSTRUCT ION FS.OI.ZOI:
~'f
; 1LAD1 TW lAS-BUILT oWNER"S
!:B
1
CT001
SIGN DATE DEVELOPIIENT CONSULTANTS PRIVATE LIIIITED
B
NO~~~ ~h _lSlli...,l,...,--l fo~;e;J~~~~~~::::~:::~N'fi~Tffif~~:_
DRAWN BY ______LA_RS__E_N_'__T_O_U_BR_O__L-111-IT_E_D-------iiB
: ~~~ HP HEATER 88 ~ 1~cH.
1LAD12AC001 ;, I CIVIL. L&T"S
L---------~~~~==~==~----~------------~~~~----------~--------------_J§IELECT. ~
Lt.T - SARGENT ' LUNDY LIIIITEO
i~liiiiiliiiil~~~~~~il~~~ii~liiiiiiiii~~~~~~~~~~~~~~~~ii~~~~~~~i!~A~WIN~G~RELL~EA~i~REC~~~~~~~~REv~"ISIONS~~~~~~~~TH:I~S;O~R~A~W~IN~GifA~NO~O;E~SI~GN~~IS~T~HE~P~ROP~E~R:TY~O~FJ~~~~~~~~~~::~~~"~·M·~~~~SCA~LI~NT~S~~T~I~TL~E;:~~~~~~~~~~~~~~J
DRAWING RELEASE REClO!D
DATE REVISIONS REV, DATE
lA REV.
W HNP., LI!.T-SARGENT & LUNDY LIMITED APPD. BY YOM PIPING AND INSTRUMENTATION DIAGRAW lA
I IAYA
lAY•
IHNP
IHNP
IYDM
IYDM
FOR~TRUCTIOH
FOR
FOR APPROVAL AS PER 101 DATED 20.04.2012 ·~ I
AND MUST NOT BE COPIED OR LENT WITHOUT
THEIR PERMISSION IN WRITING 1
PROJ_E£_T NO. ~:~:·;•"
L&T-S&L JOB NO.:Lsnooo
Sl
;.~~~~~.
EXTRACTION STEAII
owe. NO.:LTSL-111-00203
SYSTEW
SHT IDFOT fT
16 I 15 I 14 I 1J I 12 11 10 I 9 .&. 8 I 7 I 6 I 5 I 4 3 I REVISE THIS OWG. USING CAD2YSTEM ONLY
I
LTSL-M0-00951 REV 0 Page 438 of 860
-----------------·-·----····-····-----------------------··-------
13 12 11 10 9
l
16 15 8 I 7 6 5 3 2
t "ON"A3HI £0ZOO-IK-1SJ.1 "ON "9100 I
l
~=175526
K
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./ ST-016
100'1JMCR.O'IMJ
k0/h1
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:~
-
0907-DN450
BR405
-R
0907-DN100 TO TUBUlE FlASH TAJ«-1
~A502 Ul
TSt -tit -oo215-02' REFERENCE DRAWINGS
AA501
0'.101-DNZSO
TO BFPT
TSL -M1 -&203-04 .1 O!!lll-<:l\'<5QU401 ( LV
1LB020AA451
'A~ NOTE 19
vF
19
DRAWING TITLE
~~A ~~RH~~ 1 :'~SSURE CLOSED FEED WATER
DRAWING
l T_.,-o:5062
J
.....
~ TERMINAL POINT LIST FOR STEAM TURBINE liiTG-MG-01012
~M~A~IN~S~T~EA~M~&~R~E~H~EA~T~S~TE~A~M~SY~S~T~EM~P~&~!D~------9~7~0Mh==~2~1~1~1-~1~--~
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- ~~a~~~-~~r..~Fo.cc-
TP-106
IIIITE-·1-@.:-4
~--------------------~~---------------1'
BR402
'--- M~/2 0907-DN100 TO TUBINE FLASH TANK-1
zso B0<03 lO
ogo7-9N50 AA<II02 NOTE 19 F~ / LV )
TSL-MI-oD215-G2
10 NOTES -
w ~ V5 \ 1LB020AA452 1. FOR INDEX. LEGENDS AND SYMBOLS REFER DWC NO. lTSL-t0-00200.
2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL 8£ 15 N8 ~WHEREVER
SINGLE ISOLATION VALVE IS PROVIDED & 25 NB -REVER OOUBI.E
H ~ ISOLATION VALVES ARE PROVIDED. All TENPERATURE STUB
CONNECTION SIZE SHALL BE RC1 AND RC1''2 FOR S£RVIC£S HAVIHC
H
v PRESSURE LESS THAN 40 KG/CW2 AND fOR SERVICES KAYrNG PR!SSURE
MORE THAN 40KG/CM2 RESPECT! VEL Y AS PER IS-5:54. THtS AAS SEEN
AA502
FOLLOWED BASED ON OCPLIJPVL RECOI6tE.NOATl(JIJ VliJE IIAH. OAT£0
13.09.2011.
AA501
D 3. DRAINS AND VENTS CONNECTION ON PlPEL INES SHAlt BE ATLEAST OF"
BR501
0907-DN25 ON25 UNLESS OTHERWISE SPEC IF lEO.
4. ------- IN JPVL SCOPE
- - - IN L&T STGI SCOPE
G
5. PNEUMATIC OPERATED CHECK VALVES SHALL BE LOCATED AS CLOSE AS G
POSSIBLE TO THE TURBINE CONNECTION.
6. MOTAR OPERATED ISOLATION VALVES SHALL BE LOCATED AS CLOSE AS
POSSIBLE TO THE FEEOWATER HEATER CONNECTION.
7 • • DENOTES ITEM SUPPLIED BY TGV.
8. ALL OCS FUNCTION SHOWN AS DOTTED• ARE TO BE INPLEM£.NTEO IN
PLANT OCS BY JPVL.
,jjSQJ:350 9. END PREPARATION AT TURBINE NOZZLE WILL BE OONE BY TCV TO SUI
THE CONNECTING EXTRACTION PIPINC.
~HlNG
0907-DN350 450X'350 AA201 0907-QN350 10.END PREPARATION AT HEATER NOZZLE WILL BE DONE BY Fwt'f TO SUi
1L80-::;.AOOI THE CONNECTING EXTRACTION PIPING. F
11.ALL PIPING WILL BE SLOPED IN THE DIRECTION OF FLOW.H4VING
MINIMUM SLOPE OF 1:100.
12.SPECIAL INSTRUMENTS FOR PC TEST SHALL BE SuPPliED 8Y TGV.
THE SAME SHALL BE TAkEN BACK AFTER COIFLETION OF PC TEST.
PG TEST THERMOWELLS SHALL BE SUPPLIED BY L&T. r-
13.POC- PIPING DESIGN CODE
POT-PIPE DESIGN TABLE
14.ALL OCS FUNCTION SHOWN AS FIRM ARE TO BE IMPLEMENTED IN STCS
BY L&T STGI.
14. JPVL~ DENOTES INSTRUMENT ARE IN JPVL SCOPE.
REST OF THE INSTRUMENTS Will BE S~PPL lEO BY L&T. [
15.ALL HIGH POINT HYDRO TEST VENTS SHALl BE CAPPED
AFTER HYDRO TEST.
16. TEWERATURE MEASUREMENT CABLES FOR HEATER MOUNTED AND HEATER
UPSTREAM TEMPERATURE ELEMENTS WILL BE SUPPLIED BY JPVl.
11.REOUCER TO BE INSTALLED ATLEAST 10 DIAMETERS UPSTR(..AY or -
FEEOWATER HEATER NOZZLES AS PEA H[ 1.
18.PNEUMATIC OPERATED DRAIN VALVE SHALL BE PROVIDED NEAR TO
SOURCE P I PE •
19.THE DOCUMENT NO. LTSL-M1-00216--Q1 IS AN INTERNAl DOCUI.I£NT Of"
L&T & PREPARED BASED ON LMTG GLAND STEAM & DRAtN PIPIIIiG
D DIAGRAM fDOCUMENT NO. UfTG-MO--Q1005). 0
!")L&T BT-D17 0907-0N150 3'i0x25~. 350x250 ·
,.....__. TO CiLAIC) STEA.IIt HUOCR
NOTE 18 ~ NOTE 18 ~
ti
"''
o~
00
0
"''
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<00
"'"'
<00
~I
HP HEATER 78
~I
1LAD22AC001
HP HEATER 7A
RELEASE STATUS DATE PROJECT'
c 1LAD21 AC001 JAYPEE NIGRIE SUPER THERMAL POWER PROJECT. 2 X 660 IIW C
i"REL I MiliARY STEAII TURBINE GENERATOR AND AUXILIARIES PACKAGE
'----
JAIPRAKASH POWER VENTURES LIKITED
X irDR CONSTRUCIION rs.01.zo1
I POC
NUMBER I DESIGN
PRESSURE
kQ/Cm2(Q)
I DE SIC..
TEW.
IIJEC.t l
I MAX OP'ER.
P'R£SSURE
kotcm?tg)
WAX QPER.
TEIIF.
40EG. Cl
I I PIPE
CLASS
POT IF' PRESSURE
IELD TEST I
kQ/Cm2(g)
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DRAWING TITLE DRAWING NUioi!ER
GA OF HIGH PRESSURE CLOSED FEED WATER LT.....a-o306G
HEATER HPH6A/8
TERMINAL POINT LIST FOR STEAM TURBINE UffC-J«l-Q1 012
GLAND STEAM & DRAIN PIPING DIAGRAM LMTG-Iol0-o1 ODS
NOTES
1. FOR INDEX. LEGENDS AND SY..:!OLS REFER OWC NO. L TSL1t0-Q0200.
2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
SINGLE ISOLATION VALVE IS PROVIDED & 25 NB WHEREVER DOUBLE
BR403 TO TURBINE ISOLATION VALVES ARE PROVIDED. ALL TUI'£RATURE STUB
0625-DNSO FLASH TANK-1
H
N CONNECTION SIZE SHALL BE RC1 AND RC1 1"z FOR SERVIC£5 HAVING
0
PRESSURE LESS THAN "10 KC/CM2 AND FOR SERVICES HAVING PRESSURE
: LO
MORE THAN o40KG/CM2 RESPECTIVELY AS PER IS-55-1. TH l S HAS BEEN
FOLLOWED BASED ON OCPL/JPYL RECOUMENOATTON VIDE VAtL DATED
13.09.2011.
3. DRAINS AND VENTS CONNECTION ON PIPELINES SHAll BE. ATlEAST Of
ON2S UNLESS OTHERWISE SPEC IF lED.
-4. - .. ----- IN JPVL SCOPE
- - - IN L&T STGI SCOPE
S. PNEUMATIC OPERATED CHECK VALVES SHALL BE LOCATED AS CLOSE AS G
POSSIBLE TO THE TURBINE CONNECTION.
6. MOlAR OPERATED ISOLATION VALVES SHALL BE LOCATED AS CLOSE AS
POSSIBLE TO THE FEEOWATER HEATER CONNECTION.
1. • CENOTES ITEM SUPPLIED BY TGV.
8. ALL DCS FUNCTION SHOWN AS OOTTEO. ARE TO BE IMPLEMENTED IN
PLANT OCS BY JPVL.
9. END PREPARATION AT TURBINE NOZZLE WILL BE CONE BY TGV TO SUIT
THE CONNECTING EXTRACTION PIPING.
10.ENO PREPARATION AT HEATER NOZZLE WILL BE DONE BY FWHV TO SUIT
THE CONNECTING EXTRACTION PIPING.
11.ALL PIPING WILL BE SLOPED IN THE DIRECTION OF FLOW.HAVING
MINIWUM SLOPE OF 1:100.
12.SPECIAL INSTRUMENTS FOR PC TEST SHALL BE SUPPLIED BY TCV.
THE SAME SHALL BE TAKEN BACK AFTER COMPLETION OF PC TEST.
PG TEST THERMOWELLS SHALL BE SUPPL lED BY L&T.
13.PQC- PIPING DESIGN CODE
PDT-PIPE DESIGN TABLE
14.ALL OCS FUNCTION SHOWN AS FIRM ARE TO BE IMPLEMENTED IN
STCS BY l&T STG 1.
15. JPVLL____j DENOTES INSTRUUENT ARE IN JPVL SCOPE.
REST OF THE INSTRUhE.NTS WILL BE SUPPLIED BY l&T.
E 16.ALL HIGH POINT HYDRO TEST VENTS SHALL BE CAPPED E
AFTER HYDRO TEST.
17. TEMPERATURE MEASUREMENT CABLES FOR HEATER MOUNTED AND HEATER
UPSTREAM TEMPERATURE ELEMENTS WILL BE SUPPLIED BY JPVL.
B.PNEUNATIC OPERATED DRAIN VALVE SliALL BE PROVIOED NEAR TO
SOURCE P JPE •
8R402
TO TURBINE
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X FOR CONSTRUCT ION J.07.l01
AS-BUILT
POC DESIGN DESIGN MAX OPER. NAX OP£R. PIPE POT FIELD TEST REMARKS
TO OEAERATOR NUMBER PRESSURE TEMP. PRESSURE TEMP. CLASS PRESSURE
ko/cm21 ol IDEG.C I kotcm2<ol IOEG. Cl tc.olcm2<oJ
L TSL-N1-00202-D
L15 ES-5 13.97 391.0 12.60 37-4.3 JPN 0305 20.96
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LTSL-M0-00951 REV 0 Page 440 of 860
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1. FOR INDEX. lEGENDS AND SY6o60LS R£F£R DWG NO. l TSL--M0-00200.
2. INSTRUMENT PRESSURE CONNECTJON SIZE SHALL BE 15 NB :wHEREVER
SINGLE ISOlAT10H VA.LYE IS PROVIOEU .& 25 NB WHEREVER DOUBLE
ISOLATION VALV£.5 ARE PADVIOEO. ALL TEUPERATURE STUB H
H
CONNECTION Sllf. SHALL Sf RC1 AND RC1 1"z FOR SERVICES HAVING
PRESSURE lESS THAN -40 KC/J;WC A.NO f(.lm SERVICES HAVING PRESSURE
MORE THAN <40KG/Ol2 R'£SPECllVEL Y AS PER IS-554. THIS HAS BEEN
FOLLOWED BASED ON DCPl/JPVL RECOMMENDATION VIDE MAIL DATED
I- 13.09.2011.
1--
3. DRAINS AND VENTS CONNE-CTION ON PiPELINES SHALL BE ATLEAST Of
ON25 UNLESS OTH(R!f.IS( SP€.CtfJ(O.
4. ------- IN JPVl SCOP£
- - - IN L&.T STGI SCOP£
G 5. PNEUWATIC OPERATED CHECK VALVES SHA.LL BE LOCATED AS CLOSE AS G
POSSIBLE TO TH£ TURBINE CONNECTION.
6. MOlAR OPERATED lst.'li.HON VALVES SHALL BE LOCATED AS CLOSE AS
POSSIBLE TO "THE F£.£0WAT£R HEATH! CONNECTION.
7, • DENOTES ITEW SIJPPll£0 BY TCV.
8. All OCS FUNCTION SHO!Mttl AS OOTU.O~ ARE TO BE JMPLENENT£0 IN
PLANT DCS BY JPVL.
9. END PREPARATION AT TURBiN£ NOlllf. WILL BE DONE BY TCV TO SUIT
THE CONNECTING £XT'H:ACTlON PtPtN:G.
lO.ENO PREPARATION AT H£HfR NOZZ:l£ WILL 8£ DONE 8'1' FWHV TO SUIT
THE CONNECTING EXTRACTION PIPING.
F 11.A.Ll P!PINC WILL BE SLOPED IN THE DIRE.CTJON OF FLOW.!oiAYING
MINIWW SLOPE Of 1: 1'00.
12. DELETED
13 . . . DENOTES THE VALUES TO BE CONf IRM£0 AFTER RECIEVJNG DATA
FROM SUPPLIER.
1o4.SPEClAL INSTRUMENTS FOR PG TEST SHAll 8£ SUPPLIED 8'1' TGV.
THE SAME SHALL B£ TAKEN BACK AFTER COMPLETION OF PG TEST.
PG TEST THERMOWELLS SHALL BE SUPPliED BY l&T.
15.POC- PIPING DESIGN CODE
PDT-PIPE OE.S!GN TA8Lt
16. JPVLL__j OEN:JTES INSTRUMENT AR£ IN JPVL SCOP£,
REST Of THE INSTfiU"-'£NT$ Will BE SCPPLlED 8'1' L&T.
11.ALL HIGH POINT HYOHO T(ST V[NT$ SHALL BE CAPPED
AFTER HYDRO TEST.
18.TEW'ERA.TUA£ MEASiJ'<fMENT CASL£5 fOR 1-lEATEA I.!OUNT£0 TEMPE.RATURE
t-- ELEWENTS WILL BE Sli'-'Pl lEO 8Y JPVL. t--
19.• INDICATES BFPT SUPPLIER'S SCoPE.
20.PNEUtJATIC CPERATEG CRAP.: V~LV( SHALL BE PROVIDED NCAR TO
SOI.iRC£ PIP£.
21.VENT SHOULD BE AS NEAR AS PO'SSH!Lt: TO BFPT STOP VA:.._I/E
22.SPOOL Of 0N100 TO 6( PROVIDED FUR INSTALLING THERVOYt"Ell. D
D
l&T OTV 23.VALVE SHALL BE !NSH.LLEO IN REVERS£ OIRECT!ON OF THE FLOW.
24. INSTRUMENTS SHALL SE ON THE BFPT EXHAUST.
25.JNFOOMATION GIVEN IN Bf"P ORliiE TUR'3!NE VENDOR P~ID
lSIEC-M0-03t.OOJ. IS FOR REFERENC£ ONLY. FOR ACTUAL
t-- INSTRUMENTS .!. PlfllNC LAYOUT. THIS P&.ID SHALL BE REFERR;;:O. 1--
RELEASE STATUS DATE PROJECTo
c ~~------~-~ JAYPEE NIGRIE SUPER T!!ERMAL POYIER PROJECT. 2 X 660 MW C
PRELIMINARY STEAM TURBINE GENERATOR AND AUXILIARIES PACKAGE
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OW NERo
FOR APPROVAL
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LTSL-M0-00951 REV 0
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REFERENCE DRAWINGS
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:
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CG092 GA OF LOW PRESSURE CLOSED FEED WATER
HEATER LPH4
L T-M0-03071
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GA OF DUPLEX LP FEED WATER HEATER L T-M0-03080
LP TURBINE -1 I LP1 +LP2)
P~-s--}--- i! TERMINAL POINT LIST FOR STEA• TURBINE LMTG-M0-01 012
•\ /e:-~
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GLAND STEAM & DRAIN PIPING DIAGRAM LMTG-M0-01 005
~n
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TP-076 TP-077
0
~ TP-080 TP-082~ ~------------------~~------------~~
~ TP-081 TP-083~
~-----------------NO-T-ES--~------------~~
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1. FOR INDEX. LEGENDS AND SYMBOLS REFER OWG NO. L TSL-MO-D0200.
l{ I '~
: ',, ,/": 2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
250X150 BROOS
!~,;~;',i SINGLE ISOLATION VALVE IS PROVIDED & 25 NB WHEREVER DOUBLE
H
-+---+, ISOLATION VALVES ARE PROVIDED. ALL TEt.PERATURE STUB H
~
CONNECTION SIZE SHALL BE RC1 AND RC1 1'2 FOR SERVICES HAVING
1
250X200N
zs;o~'•-~T~~·Jsc A LBS7
1 PRESSURE LESS THAN 4D KG/CM2 AND FOR SERVICES HAVING PRESSURE
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CG081 FOLLOWED BASED ON DCPL/JPVL RECOMMENDATION VIDE MAIL DATED
TO TURBINE 13.09.2011.
0105-DN750 FLASH TANK-1
~~BRn4~0~1QN!~~LO~~==~~~~~~=;~~~----~T~S~L~-1~~~lS~02~1~5~02~
3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST OF
TO LP FEEOWATER 0N25 UNLESS OTHERWISE SPEC IF lEO.
G
HEATER -1 B
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4. ------- IN JPYL SCOPE
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5. PNEUMATIC OPERATED CHECK VALVES SHALL BE LOCATED AS CLOSE AS
G
00 I I
"':;; TP~97 }P-095 ( LV )
POSSIBLE TO THE TURBINE CONNECTION.
6. MOlAR OPERATED ISOLATION VALVES SHALL BE LOCATED AS CLOSE AS
~ - I§) • •FC 1LBS70AA055 POSSIBLE TO THE F'EEDWATER HEATER CONNECTION.
•• • TP-096 7. • DENOTES ITEM SUPPLIED BY TGV.
8. ALL DCS FUNCTION SHOWN AS DOTTED. ARE TO BE IMPLENTEO IN
NOTE 14 L -@,:-BS7 ,J PLANT OCS BY JPVL.
--- CG083 \ AA201 9. EXTRACTION STEAM PIPE CONNECTION TO DUPLEX HEATERS AND
EXTRACTION-3 & 4 TO OUTLET NOZZLE OF CONDENSER ARE IN
zso CEV SCOPE.
v 10.T~;oC~=~:t~:~~O~X~~Az~~g~N~I~i!~~E WILL BE DONE BY TGV TO SUI F
11.END PREPARATION AT HEATER NOZZLE WILL BE DONE BY FWHV TO SUfT
AA501 THE CONNECTING EXTRACTION PIPING.
I rsnh
~105 ON50 AA<02 NOTE 19 ~'A J15
12.ALL PIPING WILL BE SLOPED IN THE DIRECTION OF FLOW.HAVING
~
MINIKJM SLOPE OF 1:100.
BR501
13.POC- PIPING DESIGN CODE
LP FEEDWATER HEATER -2A 01 05-DN25
1LCC10AC001
Z N POT-PIPE DESIGN TABLE
rsn'n rsnAl
:---~
0 "' 14.ALL OCS FUNCTION SHOWN AS FIRM ARE TO BE IMPLEMENTED IN
~·
0 "' ~
~~~~~~~~~~~~~----------+-------------------------------------------~l/
~~0 >~ STCS BY L&T STGJ.
LP FEEOWATER HEATER -1A ... ~~ 15. JPVLL__j DENOTES INSTRUMENT ARE IN JPVL SCOPE.
E 1LCC 10AC002 AA-403 ~ REST OF THE INSTRUMENTS WILL BE SUPPL lED BY L&T. E
16.ALL HIGH POINT HYDRO TEST VENTS SHALL BE CAPPED
I --@f-sc
LBS7 AFTER HYDRO TEST.
LOCATED IN CONDENSER -1 I ,-- CG087
CLOW PRESSURE SHELL I
________ j_J___ , 7. TEMPERATURE MEASUREMENT CABLES FOR HEATER MOUNTED AND HEATER
1 LCAOt AC001
1 ,/" ',,J,.. DCS .... , I
;r( 1LBS~~A001) UPSTREAM TEMPERATURE ELEMENTS WILL BE SUPPL lED BY JPVL.
S.REDUCER TO BE INSTALLED ATLEAST 10 DIAMETERS UPSTREAM OF
K I t------}- o J---j-'--)( INCH ING FEEDWATER HEATER NOZZLES AS PER HE!.
TW
[_'~~~~~J~:::-r.~J ~ 9.PNEUMATIC OPERATED DRAIN VALVE SHALL BE PROVIDED NEAR TO
SOURCE PIPE.
1LCC1 1LCC1 O. THE DOCUMENT NO. L TSL-M1-00216-01 IS AN INTERNAL DOCUMENT OF
CT002 CT002 [email protected]
CG086 L&T & PREPARED BASED ON LMTG GLAND STEAM & DRAIN PIPING
D
D DIAGRAM IOOCUMENT NO. UHG-M0-01 005 I.
zso
~I --
RELEASE STATUS DATE PROJECT'
c JAYPEE NIGRIE SUPER THERMAL POWER PROJECT. 2 X 660 MW C
PRELl M INARY STEAM TURBINE GENERATOR AND AUXILIARIES PACKAGE
FOR INFORMATION
FOR APPROVAL OWNER'
JAIPRAKASH POWER VENTURES LIMITED -
X FOR CONSTRUCT ION 2l.07.20t
DESIGN DESIGN MAX OPER. MAX OPER. FIELD TEST AS-BUILT OWNER'S CONSULTANT'
POC PRESSURE TEMP. PRESSURE TEMP. PIPE POT PRESSURE REMARKS f--..L...---,-S-1-GN-t-0-A_T_E-l !]~ DEVELOPMENT CONSULTANTS PRIVATE LIMITED
NUMBER o/sqcm{ Q WEG. C I Q/SQCm( Q I ( OEG. C I CLASS KQ/sQcmc 91
B ES-4 5. 97 320 5. 2 279.6 JPN 0105 8.96 ~D:R~A~WN~B~Y~-.~,=~~,.=,-t~,.=M~-~=,j,~C~O~N~T~R~A~C~T~O;R:,===-------------------------~B
GS-1 3.5 383 o. 3 383 JPN 0105 5.25
~ LP FEEDWATER HEATER -4
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1 LCC60AC001 ~"C;I~V~I~L~.-t-----j--~,L~~T"'"~S-C~O~N~S~U~L;,T;A;N~T"-,------------------------------i
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DRAWING RELEASE RECORD DRAWING RELEASE RECORD
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16 1 15 14 1 13 1 12 11 10 I 9 8 I I 6 I 5 I I REVISE THIS OWG. USING CAD SYSTEM ONLY
I
LTSL-M0-00951•REV 0 • Page 442 of 860
•
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16 I 15 I 14 I 13 12 11 10 9 8 6 5 3 2 I
t ·oN·A3ij £0200-tlt-'ISJ.'l ·oN ·~•oJ
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REFERENCE DRAWINGS
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~"
f9 "~" ~. ~i~ j ~----------------------r----------------;1
~f;~lT:E~
NOTES
1. FOR INDEX. LEGENDS AND SYMBOLS REFER OWG NO. L TSL-MO-D0200.
1 2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
: f??g1 T 1LBS8'
·lr
......
H ><C
oo
.. LBSB
CT00 1
TW
1LBS8 TW
CT501
AX201
WT
SINGLE ISOLATION VALVE IS PROVIDED & 25 NB WHEREVER DOUBLE
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CONNECTION SIZE SHALL BE OF RC 1 AND RC 11'z FOR SERGICES
H
"':l:
~ ~~ ic=8S111 kgttvj~
~OO"lTMCR.o7.MUI ~
HAYING PRESSURE LESS THAN 40KC/CM2 AND FOR SERVICES HAVING
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~:~E~E~~-~~~~~~0 BASED ON OCPL/JPVL RECOMMENDATION VIDE MAIL r
~. 3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST OF
~ vs ON25 MM UNLESS OTHERWISE SPEC IF lEO.
4. ------- IN JPVL SCOPE
~ - - - IN L&T STGI SCOPE
S. PNEUMATIC OPERATED CHECK VALVES SHALL BE LOCATED AS CLOSE AS
POSSIBLE TO THE TURBINE CONNECTION.
G
6. MOTAR OPERATED ISOLATION VALVES SHALL BE LOCATED AS CLOSE AS
POSSIBLE TO THE FEEOWATER HEATER CONNECT I ON,
7. • DENOTES ITEM SUPPL I EO BY TGV.
8. ALL DCS FUNCTION SHOWN AS DOTTED. ARE TO BE JY'LENTEO IN
PLANT OCS BY JPVL.
9. EXTRACTION STEAM PIPE CONNECTION TO DUPLEX HEATERS AND
EXTRACTION-3 & 4 TO OUTLET NOZZLE OF CONDENSER ARE IN
CEV SCOPE.
TO TURBINE 10.ENO PREPARATION AT TURBINE NOZZLE WILL BE DONE BY TGV TO SUIT
FLASH TANK-1 THE CONNECTING EXTRACTION PIPING. F
11-ENO PREPARATION AT HEATER NOZZLE WILL BE DONE BY FWHV TO SUIT
TSL-M1 110f215-02) THE CONNECTING EXTRACTION PIPING.
rsrn rsr1n AA~02 0105-DNSO F~ NOTE 19 12.ALL PIPING WILL BE SLOPED IN THE DIRECTION OF FLOW.HAVING
~ AU~~ vs MINIMUM SLOPE OF 1:100.
LP FEEDWATER HEATER -28
1LCC39AC002 . "' vs
BR404 AT2
v 13-PDC- PIPING DESIGN CODE
POT-PIPE DESIGN TABLE
14. ALL OCS FUNCTION SHOWN AS FIRM ARE TO BE IMPLENTED IN
"'i5 0105-0N50 T f - - - - - . J STCS BY L&T STCI.
LP FEEOWATER HEATER -1B ) "''
con 15. JPVL~ DENOTES INSTRUI.ENT ARE IN JPVL SCOPE.
..-o
E
'-------'
!!!LJTm"1'l"TIIL>I..!!'J--m-m-rn..!.i'-',---------+-------------j-"'
hmm-L>I
LOCATED IN CONDENSER -2
1LCC30AC001 o:-
0>0 vs ..
~ REST OF THE INSTRUI.ENTS WILL BE SUPPLIED BY L&T.
16.ALL HIGH POINT HYDRO TEST VENTS SHALL BE CAPPED
AFTER HYDRO TEST.
E
CHI GH PRESSURE SHELL J BR501 17. TEMPERATURE MEASUREMENT CABLES FOR HEATER MOUNTED AND HEATER
1LCA02AC001 0105-DNZS UPSTREAM TEMPERATURE ELEMENTS WILL BE SUPPLIED BY JPVL.
18.REOUCER TO BE INSTALLED ATLEAST 10 DIAMETERS UPSTREAM OF
FEEDWATER HEATER NOZZLES AS PER HE I.
19.PNEUr.tATIC OPERATED DRAIN VALVE SHALL BE PROVIDED NEAR TO
SOURCE PIPE.
D D
TW
vs 1LCC30 1LCC3
CT512 CT512
RELEASE STATUS DATE PROJECT'
c 1-,--:-::--::-:--::---f----i JAYPEE NIGRIE SUPER THERIIAL POWER PROJECT, 2 X 660 IIW C
PRELIMINARY STEAIL TURBINE GENERATOR AND AUXILIARIES PACKAGE
FOR INFORMATION
OWNER'
FOR APPROVAL
JAIPRAKASH POWER VENTURES LIILITED
X FOR CONSTRUCTION J,01.2Cl1
PDC DESIGN DESIGN MAX OPER. MAX OPER. PIPE PDT FIELD TEST REMARKS
NUMBER PRESSURE TEMP. PRESSURE TEMP. CLASS PRESSURE
kg/cm2<oJ COEG.C I kg/cm2CQI CDEG. CJ kg/cm2CgJ
ES-3 3.50 185-0 1.10 179.0 JPN 0105 5.25
B GS-1 3.50 383.0 0.30 383.0 JPN 0105 5.25
~ LARSEN a. TOUBRD LIILITED
~ LP FEEDWATER HEATER - 3
1LCCSOAC001
LI.T • SARGENT a. LUNDY LIIIITED
3 23.05.2012 SWIJBS MV YA NP ON OR APPROVAL AS PER""" DATED 20.04.2012 _,.. THEIR PERMISSION IN WRITING L&T-S&L JOB NO.:L543000 LTSI.-<IH)020l-D6 DWG. NO.:LTSL-Ioll-00203 SHT060F07 4
16 1 15 1 14 1 13 1 12 11 10 1 9 .&. 8 1 1 1 6 1 5 4 3 I REVISE THIS OWG. USING CAO SYSTEM ONLY
I
LTSL-M0-00951 REV 0 • • 4
Page 443 of 860
• •
16 15 13 12 11 10 9 8 7 6 5 3 2
t' "ON"A311 COC!OO-II'I-1S~1 "ON "9110
POC DESIGN lWU GPER. PIPE POT F IELO TEST
NUMBER PRESSURE 1E.MF~ CLASS PRESSURE
L kg/cm2{ .gl 1&'f.G. C) kg/cm2CgJ
\A$-1 JPN 0305 30.6
FRCIII IP
EXTRACT ION
K K
REFERENCE DRAWINGS
l
DRAWING TITLE DRAWING - R
~~~ 0 DRtV£ TURBINE STEAU &. DRAINAGE SIEC-N0-03600
AUX IUARY STEAN P&IO 97000-211'2-U
J J
~--------------------~~--------------~
BR401
030'i-I)N150
NOTES
1, FOR INO£X, L£G£NOS AND SYMBOLS REFER OWG NO. LTSL~-oo200.
2. INSTRUlE.NT PR£SSUAE CONNECTION SIZE SHALL BE 15 N8 WHEREVER
SINGLE ISOLATJON VALVE IS PROVIDED &. 25 NB WHEREV£R DOUBLE
ISOLATION VAtVES ARE PROVfOEO. ALL TEMPERATURE STUB H
H
CCWNECTION S1ZE SHALL BE OF AC 1 AND AC 1''2 FOR SERVlCES
BR403 HAVING PR£SSURE LESS THAN 40KG/CM2 AND FOR SERVICES t!AV1NG
0305-0N25 PRESSURE MlR£ THAN 40KG/CM2 RESPECTIVELY AS PER IS-554. THJS
HAS SEEN FOLLOWED BASED ON DCPL/JPVL RECOMUENOUH)N IJIOE MA~L
~
DATED 13.09.2011.
LO 3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE AfltAST 0~
0N25 UNLESS OTHERWISE SPECIFIED.
4. ------- JN JPVL SCOPE
- - - IN L&T STGI SCOPE
G BR404
5. PNEUMATIC OPERATED CHECK VALVES SHALL BE LOCATED AS CLOSE AS
0305-QN150
20 N POSSIBLE TO THE TURBINE CONNECTION.
6. 'IJTAR OPERATED ISOLATION VALVES SHALL BE LOCATED AS CLOS£ AS
~ POSSIBLE TO THE FEEDWATER HEATER CONNECT JON.
"' 1 • • DENOTES ITEM SUPPLIED BY TCV.
8. All DCS fUNCTION SHOWN AS DOTTEO. ARE TO BE JMPLOENTED IN
PLANT OCS BY JPVL.
'L END PREPARATION AT TURBINE NOZZLE WILL BE DONE 8Y TCV TO SUIT
THE CONNECTINC EXTRACTION PIPING.
1Q.£ND PREPARATION AT HEATER NOZZLE WILL BE DONE BY FW!-(V TO SUlT
THE CONNECTING EXTRACTION PIPING.
11.ALL PIPING Will BE SLOPED IN THE DIRECTION OF FLOW.HAVING f
MINIMUM SLOPE Of 1 :100.
12.DHET£D.
13.** DENOTES THE VALUES TO BE CONF lAMED AFTER RECIEYlNG DATA
FROM SUPPLIER.
~<!.SPECIAL INSTRUK:NTS FOR PG TEST SHALL BE SUPPLIED B't TGV.
THE SAM( SHALL BE TAKEN BACK AFTER COMPLETION OF PG TE5T.
PG TEST TH£Rio«JW£LLS SHALL BE SUPPLIED BY L&T.
~S.PDC- PIPING DESIGN CODE
POT-PIPE DESIGN TABLE
~ 6. JPVLL____j DENOTES INSTRUMENT ARE l N JPVL SCOPE.
REST OF THE INSTRUMENTS WILL BE SUPPLIED BY l&T.
17.ALL HIGH POTN1 t1YORO TEST VENTS SHALL BE CAPPED
AFT£R HYDRO TEST.
; B. TEUPERATUR£ I£ASUR£MENT CABLES FOR HEATER MOUNTED TE!tlPERATVRE
EL[J4ENTS WILL BE SUPPL !ED BY JPVL.
19.• INO!CAT£S BFPT SUPPLIER'S SCOP£.
20.PNEUMATIC OPERATED DRA.Ir--< VALV[
SHALL BE: PROV!DfD NEAA TO
S01JR:E PIPE.
AA501 21.VENT SHOULD 8£ AS NEAR AS POSSIBLE TO BFPT STOP VALVE
22.SP00L OF ONTOO TO BE PROVIDED FOR INSTALLING THERMO:WELL.
D 23.VALV£ SHALL BE INSTALLED IN R£VERSE DIRECTION Of TH( FLOW.
D
BR501 L-&1 ,m_v_ 24. INSTRUMENTS SHALL 8£ ON THE BFPT EXHAUST.
0305-0N25
25. !NFQR1.4ATION GIVEN IN SFP DRIVE TURBINE VENDOR PtlD
BR004 ($JEG-MO-(l-3600J, IS FOR REFERENC£ ONLY. FOR ACTUAL
S IE G-M0-03600
INSTRUMENTS A. PIPING LAYOUT. THIS P&!O SHALL BE REFERR£0,
SEALING
RELEASE STATISS DATE PROJECT'
c f-=-:-:-::---'f---j JAYPEE NIGRIE SUPER THERMAL POWER PROJECT. 2 X 660 MW
PRELIII!NARY STEAM TURBINE GENERATOR AND AUXILIARIES PACKAGE
FOR I NFORIIA Tl ON
TC AT!r.IOSPHERIC OWNER'
FOR APPROVAl
fLASH TANK LnPEE
·---,-·;·:;·-,-- JAIPRAKASH POWER VENTURES LIMITED
'TSL-M1-Q0215-04 X fOR CONSTRUCT ION J.or.lOl
F6
AS-BUILT 01fNER"S CONSULTANT'
10 BFP DRIVE
TURBINE-S FT
S!Qi DATE rn DEVELOPMENT CONSULTANTS PRIVAT£ LIMITE
B S ! E G-M0-03600
K8
LARSEN & TOUBRO LIMITED
LTSL-M0-00951 REV 0 Page 444 of 860
1 2 3 4
TAG-No.: 1LBD60-AA055
2LBD60-AA055
A
B
Schutzvermerk ISO 16016 beachten / Refer to protection notice ISO 16016
E
Gewicht/Weight:
Maßstab / Scale:
001 Title corrected 11.01.2012 ks/og n.t.s.
000 Erstmalige Erstellung 27.09.2011 ks/og Ersatz für / Replacement for:
Rev. Änderung / Modification Datum/Date Name
Ersetzt durch / Replaced by:
Allgemeintoleranzen nach / General tolerances acc. to KR 00A-5000
Typ Dokumentenart / Document type Dokumentenstatus / Document status
F <400°C
Partlist Einzelteil / Component Part Freigegeben / Release
Erstellt durch / Created by Titel / Title Zeichnungs-Nr. / DWG No.
ks SCV DN 650 Class 300 204926-01-30B01
Freigabe durch/ Released by Rev. Ausgabedat./Date of issue Format Blatt /Sheet
LTSL-M0-00951 REV 0
og 001 27.09.2011 A4
Page 445 of 860
1/2
1 2 3 4
Pos Benennung Designation Material DIN Mat.No. ASTM (or similar)
A 1000 Gehäuse Valve body G17CrMo5-5+QT 1.7357+QT A 217 WC6
1002 Sitzbeschichtung Seat facing E 17 B 22 1.4015 E 430-15
2010 Klappe Disc 10CrMo9-10+NT 1.7380 A 387 Gr 22
2050 Hebel Lever G17CrMo5-5+QT 1.7357+QT A 217 WC6
2060 Bolzen Stud A 564 TP 630 H1150D
2065 Lochmutter (4 Löcher) Round nut (4 holes) A 564 TP 630 H1150D
3000 Klappenwelle Disc Shaft X17CrNi16-2+QT800 1.4057+QT800 A 276 Gr 431
3010 Antriebswelle Drive shaft X17CrNi16-2+QT800 1.4057+QT800 A 276 Gr 431
3060 Paßfeder Parallel key A4-70 A 240 TP 316 (Ti)
3090 Zylinder Stift Parallel pin A4-70 A 276 TP 316 (Ti)
3120 Lagerbuchse Bearing EN-GJSA-XNiCr20-2 EN-JS3011 A 439 TP D2
B 3220 Lagerbuchse Bearing EN-GJSA-XNiCr20-2 EN-JS3011 A 439 TP D2
3300 Distanzbuchse Spacer X5CrNi18-10+AT 1.4301+AT A 276 Gr 304
3320 Distanzbuchse Spacer X5CrNi18-10+AT 1.4301+AT A 276 Gr 304
3410 Deckel Cap G17CrMo5-5+QT 1.7357+QT A 217 WC6
3420 Deckeldichtung Gasket Graphit Graphite
3430 Sechskantschraube Hexagon screw A4-70 F 738M Cl A4-70
3470 Geteilter Ring Thrust bearing EN-GJSA-XNiCr20-2 EN-JS3011 A 439 TP D2
3910 Domdeckel Bonnet 16Mo3+N 1.5415
3916 Verschlußschraube Plug A4-70 F 738M Cl A4-70
3917 Dichtung Gasket Weicheisen Soft iron
Schutzvermerk ISO 16016 beachten / Refer to protection notice ISO 16016
3920 Deckeldichtung Gasket X6CrNiTi18-10+AT/Graphit 1.4541 / Graphit A 240 Gr 321 / Graphite
C 3930 Sechskantschraube Hexagon screw 21CrMoV 5-7+QT 1.7709+QT
4100 Stopfbuchspackung Packing Graphit Graphite
4150 Stiftschraube Stud C3-80 F 738 Cl C3
4190 Lagerbuchse Bearing EN-GJSA-XNiCr20-2 EN-JS3011 A 439 TP D2
4210 Brillenbuchse Gland bushing X5CrNi18-10+AT 1.4301+AT A 276 Gr 304
4220 Brillenflansch Gland flange X5CrNi18-10+AT 1.4301+AT A 240 Gr 304
4230 Sechskantmutter Hexagon nut A4-70 A 194 Gr B8 (F 836 Cl A4-70)
6010 Deckel Cap P265GH+N / P250GH+N 1.0425 / 1.0460 A 516 Gr 60 / A 696 Gr B
6020 Geteilter Ring Thrust bearing EN-GJSA-XNiCr20-2 EN-JS3011 A 439 TP D2
6030 Lagerbuchse Bearing EN-GJSA-XNiCr20-2 EN-JS3011 A 439 TP D2
6050 Zwischenstück Bracket EN-GJS-400-15 EN-JS1030 A 536 Gr.60-40-18
6110 Zylinderschraube Screw A4-70 F 738M Cl A4-70
D 6120 Zylinderschraube Screw 8.8 F 568 Cl.8.8 galv.
7000 Antrieb Actuator divers divers various
7290 Zylinderschraube Screw 8.8 F 568 Cl.8.8 galv.
8010 Typenschild Type plate X6CrNiMoTi17-12-2+AT 1.4571+AT A 240 TP316L
8110 Richtungspfeil Arrow X5CrNi18-10+AT 1.4301+AT A 240 Gr 304
8130 Schild 'Strömungsrichtung' Tag 'Flow Direction' X5CrNi18-10+AT 1.4301+AT A 240 Gr 304
Verschleißteile wearing parts
E
Gewicht/Weight:
Maßstab / Scale:
001 Title corrected 11.01.2012 ks/og n.t.s.
000 Erstmalige Erstellung 27.09.2011 ks/og Ersatz für / Replacement for:
Rev. Änderung / Modification Datum/Date Name
Ersetzt durch / Replaced by:
Allgemeintoleranzen nach / General tolerances acc. to KR 00A-5000
Typ Dokumentenart / Document type Dokumentenstatus / Document status
F <400°C
Partlist Einzelteil / Component Part Freigegeben / Release
Erstellt durch / Created by Titel / Title Zeichnungs-Nr. / DWG No.
ks SCV DN 650 Class 300 204926-01-30B01
Freigabe durch/ Released by Rev. Ausgabedat./Date of issue Format Blatt /Sheet
LTSL-M0-00951 REV 0
og 001 27.09.2011 A4
Page 446 of 860
2/2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A A
B B
C C
D D
E E
F F
G G
TAG-No.: 1LBD60-AA055
2LBD60-AA055
H H
Schutzvermerk ISO 16016 beachten / Refer to protection notice ISO 16016
J J
3010
3000 C-C
K K
Kupplung von Antriebs- und Klappenwelle
in geschlossener Stellung dargestellt.
Clutches of drive shaft & disc shaft
L are shown in closed position. Stömungsrichtung L
Gewicht/Weight:
Fehler: Keine Referenz
flow direction Maßstab / Scale:
001 Title corrected 11.01.2012 ks/og d.n.s
000 Erstmalige Erstellung 27.09.2011 ks/og Ersatz für / Replacement for:
Rev. Änderung / Modification Datum/Date Name
Ersetzt durch / Replaced by:
Allgemeintoleranzen nach / General tolerances acc. to KR 00A-5000
Typ Dokumentenart / Document type Dokumentenstatus / Document status
l=1346 ZusZng Einzelteil / Component Part Freigegeben / Release
M Erstellt durch / Created by Titel / Title Zeichnungs-Nr. / DWG No. M
ks SCV DN 650, Class 300 204926-01-30A01
Freigabe durch/ Released by Rev. Ausgabedat./Date of issue Format Blatt /Sheet
og <400°C 001 27.09.2011 A1 1/1
1
LTSL-M0-00951 REV 0 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 447 of 860
Page
1 2 3 4 5 6 7 8
MM *** M A B H G
A A
R1
D
E
E1
ED Ø
C
B Z
B
75
J
Y
Drainport closed (not machined) Ø70*
TAG-No.: 1LBD60-AA055
* : Body Mat. L
*** : Ausbaumaß / Space of Disassembly 2LBD60-AA055
Strömungsrichtung
Flow Direction
Schutzvermerk ISO 16016 beachten / Refer to protection notice ISO 16016
Z
C C
ø DE
1,6
se
,5°
Strömungsrichtung
Dep ipe
sep ipe
37
Flow Direction
le
D D
DN in mm / inch DN in mm / inch
Alle anderen Abmessungen in mm All other dimensions in mm
L = Baulänge L = Face to Face
W = Gewicht in kg W = Weight in kg
Antriebssteuerdruck min. 4,08 kg/cm²(a) Actuator working pressure min. 4,08 kg/cm²(a)
Weitere Ausführungen auf Anfrage Further Design on Request
E E
Pressure drop = 0,006 kg/cm² (a) Gewicht/Weight:
Valve closing time < 1 sec. at 12.07 kg/cm²(a); 358,8°C
(122741 kg/hr at TMCR 100% 0%MU) Maßstab / Scale:
Title and pressure indicate changed, Drainport text added n.t.s.
Desig n pressure= 13,28 kg/cm²(g)
000 Erstmalige Erstellung 27.09.2011 ks/og Ersatz für / Replacement for:
Desig n temperature= 391°C
Rev. Änderung / Modification Datum/Date Name
Ersetzt durch / Replaced by:
Allgemeintoleranzen nach / General tolerances acc. to KR 00A-5000
DE se Typ Dokumentenart / Document type Dokumentenstatus / Document status
660,0 9,50
<400°C Dimens. Draw Einzelteil / Component Part Freigegeben / Release
F DN Class A B C D E E1 R1 G H J L M MM DE se dy sy le
W W
Body Mat.
Erstellt durch / Created by Titel / Title Zeichnungs-Nr. / DWG No. F
valve actuator ks SCV DN 650 Class 300 204926-01-30O01
650/26 300 670 460 495 758 415 110 110 510 510 460 1346 368 85 670,0 14,5 48,3 3,2 50 1818 68 A217WC6 Freigabe durch/ Released by Rev. Ausgabedat./Date of issue Format Blatt /Sheet
og 001 27.09.2011 A3 1/1
1
LTSL-M0-00951 REV 0 2 3 4 5 6 7 8 of 860
Page 448
LTSL-M0-00951 REV 0 Page 449 of 860
LTSL-M0-00951 REV 0 Page 450 of 860
8 7 6 5 4 3 2 1
01 I CONTENTS 34 70
02 II LEGEND
35 T2-01 TURBINE TURNING SYSTEM SIMPLIFIED P&I DIAGRAM 71 T5-01 LP HEATER & EXTRACTION SYSTEM SIMPLIFIED P&I DIAGRAM
03 III OPS OPERATION SELECTION CONCEPT LOGIC FOR GROUP
36 T2-02 TURBINE TURNING GROUP STRUCTURE 72 T5-02 LP HEATER & EXTRACTION GROUP STRUCTURE
04 IV OPS OPERATION SELECTION CONCEPT LOGIC FOR DRIVE
37 T2-G1 TURBINE TURNING START-UP 1/3 73 T5-D1 No. 3 EXTRACTION STEAM NON-RETURN VALVE
05 V TURBINE START UP PREPARATION FLOW DIAGRAM
38 T2-G2 TURBINE TURNING START-UP 2/3 74 T5-D2 No. 4 EXTRACTION STEAM NON-RETURN VALVE
G 06 VI TURBINE SHUTDOWN PREPARATION FLOW DIAGRAM
39 T2-G3 TURBINE TURNING START-UP 3/3 75 T5-D3 No. 5 EXTRACTION STEAM NON-RETURN VALVE (A)
07 40 T2-D1-1 TURNING GEAR MOTOR (1/2) 76 T5-D4 No. 5 EXTRACTION STEAM NON-RETURN VALVE (B)
08 T1-01 TURBINE OIL SUPPLY SIMPLIFIED P&I DIAGRAM 41 T2-D1-2 TURNING GEAR MOTOR (2/2) 77 T5-D5 No. 5 EXTRACTION STEAM NON-RETURN VALVE (C) (TO BFPT)
09 T1-02 TURBINE OIL SUPPLY GROUP STRUCTURE (1/2) 42 T2-D2 TURNING GEAR ENGAGE / DISENGAGE 78
10 T1-03 TURBINE OIL SUPPLY GROUP STRUCTURE (2/2) 43 T2-D3 TURNING GEAR OIL SUPPLY SOLENOID VALVE
79 T6-01 HP HEATER & EXTRACTION SYSTEM SIMPLIFIED P&I DIAGRAM
11 T1-G1 TURBINE OIL SUPPLY START-UP 1/3 44 80 T6-02 HP HEATER & EXTRACTION GROUP STRUCTURE
F 12 T1-G2 TURBINE OIL SUPPLY START-UP 2/3
45 T3-01 CONDENSER VACUUM SYSTEM SIMPLIFIED P&I DIAGRAM 81 T6-D1 COLD REHEAT NON-RETURN VALVE (L.H.)
13 T1-G3 TURBINE OIL SUPPLY START-UP 3/3
46 T2-02 CONDENSER VACUUM GROUP STRUCTURE 82 T6-D2 COLD REHEAT NON-RETURN VALVE (R.H.)
14 T1-G10 TURBINE SPEED
47 T3-G1 CONDENSER VACUUM GROUP ALL AUTO 83 T6-D3 No. 6 EXTRACTION STEAM NON-RETURN VALVE
15 T1-S1 MAIN OIL TANK VAPOR EXTRACTOR FAN SELECTOR
48 T3-S1 GLAND STEAM CONDENSER EXHAUSTER FAN SELECTOR 84 T6-D4 No. 7 EXTRACTION STEAM NON-RETURN VALVE
16 T1-S3 EH OIL PUMP SELECTOR
49 T3-D1A GLAND STEAM CONDENSER EXHAUST FAN (A) 85 T6-D5 No. 8 EXTRACTION STEAM NON-RETURN VALVE
17 T1-D1 AUXILIARY OIL PUMP (AOP)
50 T3-D1B GLAND STEAM CONDENSER EXHAUST FAN (B) 86
18 T1-D2 TURNING OIL PUMP (TOP)
51 T3-D2 LP-1 VACUUM BREAKER VALVE
E 19 T1-D3 EMERGENCY OIL PUMP (EOP) 87 GA-01 TYPICAL LOGIC FOR GENERATOR AUXILIARIES 1/2
52 T3-D3 LP-2 VACUUM BREAKER VALVE
33
20 T1-4A MAIN OIL TANK VAPOR EXTRACTOR FAN (A) 88 GA-02 TYPICAL LOGIC FOR GENERATOR AUXILIARIES 2/2
53 T3-D4 GLAND STEAM DESUPERHEATER SPRAY CV BYPASS MOTOR VALVE
21 T1-4A
T1-4B MAIN OIL TANK VAPOR EXTRACTOR FAN (A)
(B)
22 T1-D5A JACKING OIL PUMP (A) 54
23 T1-D5B JACKING OIL PUMP (B) 55 T4-01 TURBINE STEAM & DRAIN SYSTEM SIMPLIFIED P&I DIAGRAM
24 T1-D6A EH OIL PUMP (A) 56 T4-02 TURBINE STEAM & DRAIN GROUP STRUCTURE
25 T1-D6B EH OIL PUMP (B) 57 T4-G1 TURBINE STEAM & DRAIN GROUP START-UP 1/3
D 26 T1-D7 EH POLISHING PUMP 58 T4-G2 TURBINE STEAM & DRAIN GROUP START-UP 2/3
27 T1-D8 OIL PURIFIER (A) INLET PUMP 59 T4-G3 TURBINE STEAM & DRAIN GROUP START-UP 3/3
28 T1-D9 OIL PURIFIER COALESCER FILTER (A) DRAIN VALVE 60 T4-D1 MAIN STEAM LEAD PIPE DRAIN MOTOR VALVE
29 T1-D10 OIL PURIFIER (B) INLET PUMP 61 T4-D2 HP TURBINE INNER CASING DRAIN MOTOR VALVE
30 T1-D11 OIL PURIFIER COALESCER FILTER (B) DRAIN VALVE 62 T4-D3 HP TURBINE OUTER CASING DRAIN MOTOR VALVE
31 T1-D12 MAIN OIL TANK HEATER 63 T4-D4 REHEAT STEAM INLET PIPE DRAIN MOTOR VALVE
32 T1-D13 STORAGE TANK OIL TRANSFER PUMP 64 T4-D5 HP STEM LEAK RECOVERY MOTOR VALVE
C 33 T1-D14 MAIN OIL TANK OIL TRANSFER PUMP 65 T4-D6 HP STEM LEAK BLOW OFF MOTOR VALVE
66 T4-D7 REHEAT STOP VALVE (A) EQUALIZING VALVE
67 T4-D8 REHEAT STOP VALVE (B) EQUALIZING VALVE
68 T4-D9 TURBINE EXHAUST HOOD SPRAY WATER ON-OFF VALVE
69 T4-D10 VENTILATOR VALVE
TITLE:
CONTENTS
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 I F
04100-61000-1010 -1
LTSL-M0-00951 REV 0 Page 451 of 860
8 7 6 5 4 3 2 1
H
LEGEND:
AND (Logic Conjuction) AAA Input Signal Side of connection within sheets.
OR (Logic Sum)
AAA Output Signal Side of connection within sheets.
NOT (Logic Negation)
G
T1D1
H/L HIGH-LOW MONITOR Input Signal Side of connection from other sheets.
1
H/ HIGH MONITOR
T1D1
Output Signal Side of connection to other Sheet
1
/L LOW MONITOR
F
H/L DEVIATION MONITOR ANALOG SIGNAL
TIME DELAY WIPE OUT
DIGITAL SIGNAL
ON DELAY TIMER
T=xxx
COMMUNICATION
E
OFF DELAY TIMER
T=xxx
LAMP INDICATOR
A ALARM
E EVENT
D
S
SET/RESET (Set Signals are Prioritized)
R
S
SET/RESET (Reset Signals are Prioritized)
R
TITLE:
LEGEND
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 II F
04100-61000-1010 -2
LTSL-M0-00951 REV 0 Page 452 of 860
8 7 6 5 4 3 2 1
OPS (TCS) TCS OPS (DCS)
OPERATION
SELECTION DISPLAY
H
DCS
DCS S SELECT
R DCS OPERATION SELECTED
1 TO This sheet, Sheet-IV TCS
TCS OPC SELECT
TCS OPERATION SELECTED
2 TO This sheet, Sheet-IV
ETHERNET OPS (TCS) DISPLAY
OPS (DCS) DCS
SELECT
TCS
ETHERNET
G OPERATION SELECT
SELECTION
TYPICAL GROUP LOGIC
DCS TCS OPS (DCS) DISPLAY
TCS ONMD ON
OPC OFMD OFF
AUTO
TYPICAL SELECTION LOGIC APM
PERMIT
F OPS (DCS) TCS AUTO
ABP
FROM BYPASS
VDU OPERATION This Sheet 1
PRE-OPE
POPM
ON P.B. ONP PERMIT
ON
ON
RPM
PERMIT
OFF OFF P.B. OFP ONP ON PERMIT RPM OFF
SPM
PERMIT
OPC
OPS (TCS)
AUTO BYPASS P.B. ABP OFP OFF PERMIT DLA ABNORMAL
FROM SPM
E VDU OPERATION This Sheet 2
ON APM AUTO PERMIT APM
OPC
OFF OPS (TCS) DISPLAY
AUTO BYPASS ABP
OPS (DCS) ETHERNET
ONMD ON
FROM
MACRO
VDU OPERATION This Sheet 1 LOGIC POPM PRE-OPE PERMIT POPM OFMD OFF
AUTO BYP IF REQUIRED AUTO
D APM
PERMIT
OPC
AUTO
OPS (TCS) AUTO START FROM
GROUP SEQUENCE
ACO ABP
BYPASS
FROM ONMD ON MODE ONMD
VDU OPERATION This Sheet 2 POPM
PRE-OPE
AUTO STOP FROM ACF PERMIT
GROUP SEQUENCE
AUTO BYP RPM
ON
ABP
OFMD OFF MODE OFMD PERMIT
ETHERNET OFF
SPM
PERMIT
C DLA ABNORMAL
START PERMIT PMO RSA RESET AVAILABLE RSA ETHERNET
INTERLOCK
STOP PERMIT PMF
INTERLOCK DLA ABNORMAL DLA
TITLE:
OPS OPERATION SELECTION CONCEPT
B LOGIC FOR GROUP
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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TYPICAL SELECTION LOGIC TYPICAL DRIVE LOGIC
H OPS (DCS) TCS TCS
FROM
VDU OPERATION 1 OPS (DCS)
Sheet-III DISPLAY
START P.B. PBO
START RUN START
STOP STOP P.B. PBF
STOP STOP
OPC
OPS (TCS) AUTO AUTO
RESET P.B. PBR
FROM
G VDU OPERATION Sheet-III 2 MAN MAN
START AUTO P.B. PBA REM REMOTE
STOP LOC LOCAL
MANUAL P.B. PBM
RUN
OPS (DCS) ETHERNET ONP RUN PERMIT RPM RPM
PERMIT
FROM
VDU OPERATION Sheet-III 1 TAGGING P.B. TAG STOP
SPM
PERMIT
OFP STOP PERMIT SPM
RESET
F TRIP TRIP
OPC ATM AUTO MODE AUTO
RSA RESET
OPS (TCS)
FROM
VDU OPERATION Sheet-III 2 DLA ABNORMAL
MAN MANUAL MODE MAN
RESET MACRO TGP TAGGING
LOGIC REM REMOTE MODE REM
ETHERNET
OPC
OPS (DCS) OPS (TCS)
E LOM LOCAL MODE DISPLAY
FROM
VDU OPERATION Sheet-III 1 LOC
RUN START
AUTO ON RUN RUN STOP STOP
AUTO START INTERLOCK ACO
MANUAL AUTO AUTO
ACF OFF STOP STOP
AUTO STOP INTERLOCK
OPS (TCS) OPC
MAN MAN
FROM
VDU OPERATION Sheet-III 2 PROTECTION START PCO TRP TRIP TRIP
INTERLOCK REM REMOTE
D AUTO PROTECTION STOP PCF LOC LOCAL
INTERLOCK RSA RESET AVAILABLE RSA
MANUAL RUN
START PERMIT PMO RPM
PERMIT
INTERLOCK
OPS (DCS) ETHERNET DLA ABNORMAL DLA
SPM
STOP
FROM STOP PERMIT PMF PERMIT
VDU OPERATION Sheet-III
1 INTERLOCK
TGP TAGGING PROHIBIT DLA TRIP TRIP
TAGGING
RSA RESET
OPC
C
OPS (TCS) DLA ABNORMAL
FROM
VDU OPERATION Sheet-III
2
TGP TAGGING
TAGGING
ETHERNET
ETHERNET
TITLE:
OPS OPERATION SELECTION CONCEPT
B LOGIC FOR DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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SYMBOLS
H TURBINE OIL SUPPLY
Refer to Sheet T1-G1 GROUP ON
: HARDWIRED SIGNAL INTERFACE
Refer to Sheet T1-D1, TURBINE OIL SUPPLY
D2, D4A, D4B, D5A, DRIVES ALL AUTO
D5B, D6A, D6B TURBINE OIL &
TURNING
PREPARATION
TURBINE TURNING ESTABLISH : BREAK POINT PUSH BUTTON
Refer to Sheet T2-G1 GROUP ON WITH INDICATOR
Refer to Sheet T2-D1, TURBINE TURNING
G D2, D3 DRIVES ALL AUTO
: COMMAND
: STATUS
VACUUM
BREAKER VALVE
F CLOSE
DCS
Maintain
Momentary
CONDENSATE GLAND STEAM GLAND STEAM
PUMP START UP IN SERVICE CONDENSER DCS
SEQUENCE COMMAND EXHAUST FAN START
OTHER
Maintain CONDITION
ESTABLISHED Maintain
(DCS SIDE) GLAND CONDENSER
E Momentary VACUUM VACUUM UP
< kg/cm2 START UP
SEQUENCE
08MAW01CP102/105
( VACUUM BREAKER VALVE
CLOSE COMMAND ) CONDENSER VACUUM ST START
ESTABLISHED PREPARATION
COMPLETED
GLAND STEAM
HEADER PRESS
> kg/cm2
VACUUM GROUP COND. VAC
DRIVES ALL AUTO Maintain < LATER
01MAW01CP101/103/104
Refer to Sheet T3-G1 08MAG10CP101A/B/C
08MAG10CP104A/B/C
D
TITLE:
TURBINE START UP PREPARATION FLOW DIAGRAM
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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SYMBOLS
H
: HARDWIRED SIGNAL INTERFACE
: BREAK POINT PUSH BUTTON
WITH INDICATOR
: COMMAND
TURBINE SPEED
< 400 rpm
VACUUM
BREAKER VALVE : STATUS
OPEN
Maintain
Momentary
F
DCS
SHUTDOWN VACUUM PUMP
CONDITION SHUTDOWN Momentary
ESTABLISHED SEQUENCE
(DCS SIDE)
COND. VAC GLAND SEAL
> LATER SHUTDOWN
E SEQUENCE
GLAND STEAM PRESS. DCS
OTHER CV (FROM AUX.
CONDITION STEAM) CLOSED
ESTABLISHED
(DCS SIDE) 01MAW01AA001
GLAND STEAM
CONDENSER
EXHAUST FAN STOP
GLAND STEAM PRESS.
CV (FROM CRH CONDENSER VACUUM
STEAM) CLOSED SHUTDOWN
COMPLETED
01MAW01AA002
OTHER CONDITION
Maintain ESTABLISHED
D (DCS SIDE)
VACUUM GROUP Maintain
DRIVES ALL AUTO
Refer to Sheet T3-G1
TITLE:
TURBINE SHUTDOWN PREPARATION FLOW DIAGRAM
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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T1 – TURBINE OIL SUPPLY
D
TITLE:
TURBINE OIL SUPPLY
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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D1 AUXILIARY OIL PUMP (AOP) 01MAV03AP101
H D2 TURNING OIL PUMP (TOP) 01MAV04AP101
D3 EMERGENCY OIL PUMP (EOP) 01MAV05AP101
D4A MAIN OIL TANK VAPOR EXTRACTOR FAN (A) 01MAV07AN101
D4B MAIN OIL TANK VAPOR EXTRACTOR FAN (B) 01MAV07AN102
D5A JACKING OIL PUMP (A) 01MAV06AP101
D5B JACKING OIL PUMP (B) 01MAV06AP102
AIR IN D6A EH OIL PUMP (A) 01MAY02AP101
G TRIP LEVER D6B EH OIL PUMP (B) 01MAY02AP102
ATMOSPHERE
D7 EH POLISHING PUMP 01MAY05AP101
S D8 OIL PURIFIER (A) INLET PUMP 01MAV21AP101
RESET
OVER SPEED LEVER
TRIP PIN
D9 OIL PURIFIER COALESCER FILTER (A) DRAIN SOLENOID VALVE 01MAV21AA902
D10 OIL PURIFIER (B) INLET PUMP 00MAV21AP102
TEST S TO
DRAIN
LEVER D11 OIL PURIFIER COALESCER FILTER (B) DRAIN SOLENOID VALVE 00MAV21AA902
D12 MAIN OIL TANK HEATER 01MAV01AH101
F D13 STORAGE TANK OIL TRANSFER PUMP 00MAV22AP201
TO
D14 MAIN OIL TANK OIL TRANSFER PUMP 01MAV22AP301
DRAIN
TO
DRAIN
AUTO STOP OIL LINE TURNING
GEAR
M
D7
F
E HP/IP
LP-1 & 2 TURBINE GEN.
TURBINE
EH POLISHING PUMP
S
EH OIL TANK
No. 7-8 BRG.
D
HP OIL LINE
D6B
TURNING EMERGENCY AUXILIARY
D4B D4A OIL PUMP OIL PUMP OIL PUMP
T1-5A T1-5B
RETURN F
VAPOR OIL
EXTRACTOR D2 D3 D1
FANS AC DC AC
EH FLUID EH OIL PUMP
JACKING
OIL PUMP
F
D6A
C OIL
COOLER
D8
TITLE:
D12 TURBINE OIL SUPPLY
HEATER
B OIL PURIFIER (A) SIMPLIFIED P&I DIAGRAM
S D9 JAYPEE NIGRIE/ 2 x 700MW
D13 POWER PLANT/ Steam Turbine
D14
OIL OIL D10 TURBINE AUXILIARY MACHINE
STORAGE STORAGE
TANK TANK CONTROL LOGIC DIAGRAM
(Clean) (Dirty)
A
OIL PURIFIER (B)
04100 61000 61000-1010 T1 01 F
S D11
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T1
H
TURBINE OIL SUPPLY
Tag no.
Sht. No.
GROUP T1G1, T1G2, T1G3
LEVEL
(G)
G
SELECTOR SELECTOR
Tag no. Tag no.
Sht. No. Sht. No.
T1S1 T1S3
SUB GROUP
E LEVEL
(SG)
C DRIVE
LEVEL
(D) 01MAV03AP101 01MAV04AP101 01MAV05AP101 01MAV07AN101 01MAV07AN102 01MAV06AP101 01MAV06AP102 01MAY02AP101 01MAY02AP102 01MAY05AP101 01MAV21AP101 01MAV21AA902
D1 D2 D3 D4A D4B D5A D5B D6A D6B D7 D8 D9
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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GROUP
LEVEL
(G)
SUB GROUP
E LEVEL
(SG)
C DRIVE
LEVEL
(D) 00MAV21AP102 00MAV21AA902 01MAV01AH101 00MAV22AP201 01MAV22AP301
D10 D11 D12 D13 D14
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 03 F
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OPS (TCS/DCS) Refer to Sheet-III
for OPS operation OPS (TCS/DCS) DISPLAY
OPERATION selection logic
ON
ONM
PERMIT
ON P.B. PBO ONP ON PERMIT
H ON ONM
OFF
OFM
PERMIT
OFF P.B. PBF OFP OFF PERMIT
OFF OFM
AUTO
APM
PERMIT
PBR ATP AUTO PERMIT
OFF APM
AUTO
ABP
BYPASS
AUTO BYPASS P.B. PBAB ABP AUTO BYPASS
AUTO BYP ABP
G POPM
PRE-OPE
PERMIT
PBPO
OFF
E
ON
POP PRE-OPE PERMIT POP ONMD
MODE
PBA M
OFF
OFF
OFMD
MODE
PBT PBP
ON D
DLA ABNORMAL
F
AUTOMATIC COMMAND
AUT
AOC
D
OFF
AUTOMATIC CONDITION
AFC
AUX. OIL PUMP AUTO MODE OFF
T1D1
1 OUT
D
T1D2 TURNING OIL PUMP AUTO MODE
E 1 TURBINE OIL SUPPLY START-UP ON MODE T1G1 TO T1G2, T1G3
1
T1D4A MAIN OIL TANK VAPOR EXTRACTOR (A) AUTO MODE ONM GL ON MODE ONM
1 D
EVNT
T1D4B MAIN OIL TANK VAPOR EXTRACTOR (B) AUTO MODE
1
E
OFM GL OFF MODE OFM
D
T1D5A JACKING OIL PUMP (A) AUTO MODE
1 PAT
D
E
T1D6A EH OIL PUMP (A) AUTO MODE
1
A
ABN ABNORMAL
EH OIL PUMP (B) AUTO MODE DLA
T1D6B
1
T1S1 MAIN OIL TANK VAPOR EXTRACTOR ASL IN MODE
1 ONM EON
C D RESET
AVAILABLE
RSA
T1S3 EH OIL PUMP ASL IN MODE
1
TAGNAME:
PPO
ON
TITLE:
PERMISSIVE CONDITION
B T1D6A EH OIL TANK LEVEL LOW
8
PPM
JAYPEE NIGRIE/ 2 x 700MW
T1D2 MAIN OIL TANK LEVEL LOW POWER PLANT/ Steam Turbine
5
SLF
TURBINE AUXILIARY MACHINE
MAIN OIL TANK VAPOR EXTRACTOR ASL ABNORMAL
T1S1
6
CONTROL LOGIC DIAGRAM
A T1S3 EH OIL PUMP ASL ABNORMAL
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8 7 6 5 4 3 2 1
H T1G1 TURBINE OIL SUPPLY START-UP ON MODE
1
5 sec
MFT
From TPS AUXILIARY OIL PUMP AUTO START COMMAND T1G2 TO T1D1
1
> 30 kg/cm2
MAIN STEAM PRESS
H/
From Plant-DCS via DEH (61140-1001)
G
5 sec
T1G10 TURBINE SPEED > 2800rpm
2
AI < -0.8 kg/cm2
AOP INITIAL START T1G2
CONDENSER VACUUM /L 8
TO T1G3
01MAG10CP101/102/103
01MAG10CP104/105/106 < -0.863 kg/cm2
CONDENSER VACUUM < -0.863 kg/cm2 T1G2
/L TO T4D10, T3D4
6
F > -0.107 kg/cm2
CONDENSER VACUUM > -0.107 kg/cm2 T1G2
H/ TO T3D1A, T3D1B
7
AUXILIARY OIL PUMP AUTO STOP COMMAND T1G2 TO T1D1
2
T1G10 TURBINE SPEED > 2950rpm
1 5 sec
E AI > 20 kg/cm2 3 sec
MOP DISCHARGE PRESS.
01MAV02CP101
H/ →
TURNING OIL PUMP AUTO START COMMAND T1G2 TO T1D2, T1D3
3
TURBINE TRIP
D from TPS
TURNING OIL PUMP AUTO STOP COMMAND T1G2 TO T1D2
4
AI < 0.75 kg/cm2
TOP/EOP AUTO START /L
C
01MAV10CP102
TOP/EOP AUTO START CONDITION T1G2 TO T1D3, T1D2
5
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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T1G1 TURBINE OIL SUPPLY START-UP ON MODE
1
MAIN OIL TANK VAPOR EXTRACTOR ASL AUTO ON COMMAND T1G3 TO T1S1
1
T1D1 AUX. OIL PUMP STOPPED
3
T1D3 EMERGENCY OIL PUMP STOPPED
2 1800 sec
MAIN OIL TANK VAPOR EXTRACTOR ASL AUTO OFF COMMAND T1G3 TO T1S1
G TURNING OIL PUMP STOPPED
2
T1D2
3
TURBINE TRIP
from TPS
TOP/EOP RUNNING T1G3 TO T1D4A, D4B, D5A, D5B
6
F
T1D2 TURNING OIL PUMP RUNNING
2
JACKING OIL PUMP (A) AUTO START COMMAND T1G3 TO T1D5A
3
T1D3 EMERGENCY OIL PUMP RUNNING
1
T1G10 TURBINE SPEED < 900rpm
3
3sec
T2G2 TURNING GEAR ENGAGED JACKING OIL PUMP (A) AUTO STOP COMMAND T1G3 TO T1D5A
7 4
5 sec
T2D1-1 TURNING GEAR MOTOR RUNNING
2
T2G2 TURBINE SPEED < 1 rpm
D 6
EH OIL PUMP ASL AUTO ON COMMAND T1G3 TO T1S3
5
T1G2 AOP INITIAL START
8
30sec
EH OIL PUMP ASL AUTO OFF COMMAND T1G3 TO T1S3
C 7
TURBINE TRIP
from TPS
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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8 7 6 5 4 3 2 1
> 2950 rpm
TURBINE SPEED TURBINE SPEED > 2950 rpm
H/L T1G10 TO T1G2, T1D1
from DEHC 1
> 2800 rpm
TURBINE SPEED > 2800 rpm
H/L T1G10 TO T1G2
2
G
< 900 rpm
TURBINE SPEED < 900 rpm
T1G10 TO T1G3, T1D5A, T1D5B,
H/L T2D1-2
3
> 600 rpm
TURBINE SPEED > 600 rpm
H/L T1G10 TO T1D5A, T1D5B
4
< 400 rpm
F TURBINE SPEED < 400 rpm
H/L T1G10 TO T3D2
5
< 50 rpm
TURBINE SPEED < 50 rpm
H/L T1G10 TO T2G3, T2D2
6
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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OPS (TCS/DCS) Refer to sh. no.27
for OPS operation MAIN OIL TANK VAPOR EXTRACTOR ASL IN MODE T1S1 OPS (TCS/DCS) DISPLAY
OPERATION selection logic. 1
TO T1G1
IN ASL IN MODE IN
H PBA E
A SELECT OUT ASL OUT MODE OUT IN ASL IN ON ASL ON
PBB E
B SELECT OFM ASL OFF MODE OFF OUT ASL OUT OFF ASL OFF
PBR E
RESET ONM ASL ON MODE ON ASEL A SEL ABN ASL ABN
PBO E
ASL ON ASEL A SEL MODE
ASEL BSEL B SEL AABN A ABN
G
PBF
ASL OFF
RSA RESET BABN B ABN
PBI BSEL
E B SEL MODE
ASL IN BSEL
PBT
ASL OUT
E
F ABN ASL ABNORMAL ABN
OTC MAIN OIL TANK VAPOR EXTRACTOR ASL ABNORMAL
OFF T1S1 TO T1G1
6
A ASL ABN
T1G3 MAIN OIL TANK VAPOR EXTRACTOR ASL AUTO ON COMMAND AOC
1 MAIN OIL TANK VAPOR EXTRACTOR FAN (A)
AONC START COMMAND T1S1 TO T1D4A
2
T1G3 MAIN OIL TANK VAPOR EXTRACTOR ASL AUTO OFF COMMAND AFC
E 2
MAIN OIL TANK VAPOR EXTRACTOR FAN (A)
AOFC STOP COMMAND T1S1 TO T1D4A
OFF ADO 3
ASL2
OFF ADF
MAIN OIL TANK VAPOR EXTRACTOR FAN (B)
BONC START COMMAND T1S1 TO T1D4B
4
T1D4A MAIN OIL TANK VAPOR EXTRACTOR (A) RUNNING AEON
2
MAIN OIL TANK VAPOR EXTRACTOR (A) STOPPED MAIN OIL TANK VAPOR EXTRACTOR FAN (B)
D T1D4A AEOF BOFC STOP COMMAND T1S1 TO T1D4B
3 5
T1D4A MAIN OIL TANK VAPOR EXTRACTOR (A) RUN TIME OVER AEOT
5
T1D4A MAIN OIL TANK VAPOR EXTRACTOR (A) TRIPPED AEAB
4
T1D4A MAIN OIL TANK VAPOR EXTRACTOR (A) AUTO MODE AEAT AABN AABN
1 AABN
C T1D4A MAIN OIL TANK VAPOR EXTRACTOR (A) RUN COMMAND AEOM
A ASL A ABNORMAL
6 BABN BABN
BABN
T1D4B MAIN OIL TANK VAPOR EXTRACTOR (B) RUNNING BEON A ASL B ABNORMAL
2
MAIN OIL TANK VAPOR EXTRACTOR (B) STOPPED BEOF RSA RESET AVAIL
T1D4B RSA
3
T1D4B MAIN OIL TANK VAPOR EXTRACTOR (B) RUN TIME OVER BEOT TITLE:
5 MAIN OIL TANK
EXO EXCESSIVE OPERATION
B A VAPOR EXTRACTOR FAN SELECTOR
T1D4B MAIN OIL TANK VAPOR EXTRACTOR (B) TRIPPED BEAB
4
JAYPEE NIGRIE/ 2 x 700MW
T1D4B MAIN OIL TANK VAPOR EXTRACTOR (B) AUTO MODE BEAT POWER PLANT/ Steam Turbine
1
T1D4B MAIN OIL TANK VAPOR EXTRACTOR (B) RUN COMMAND BEOM
6 TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
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OPS (TCS/DCS) Refer to sh. no.27
for OPS operation EH OIL PUMP ASL IN MODE T1S3 OPS (TCS/DCS) DISPLAY
OPERATION selection logic. 1
TO T1G1
IN ASL IN MODE IN
H PBA E
A SELECT OUT ASL OUT MODE OUT IN ASL IN ON ASL ON
PBB E
B SELECT OFM ASL OFF MODE OFF OUT ASL OUT OFF ASL OFF
PBR E
RESET ONM ASL ON MODE ON ASEL A SEL ABN ASL ABN
PBO E
ASL ON ASEL A SEL MODE BSEL B SEL AABN A ABN
ASEL
G
PBF
ASL OFF RSA RESET BABN B ABN
PBI BSEL
E B SEL MODE
ASL IN BSEL
PBT
ASL OUT
E
F ABN ASL ABNORMAL ABN
OTC EH OIL PUMP ASL ABNORMAL
OFF T1S3 TO T1G1
6
A ASL ABN
T1G3 EH OIL PUMP ASL AUTO ON COMMAND AOC
5
AONC EH OIL PUMP (A) START COMMAND T1S3
EH OIL PUMP (A) RUNNING TO T1D6A
T1D6A 2
2 15 sec
E
EH OIL PUMP (B) RUNNING
→ T1G3
7
EH OIL PUMP ASL AUTO OFF COMMAND AFC
T1D6B
2 AOFC EH OIL PUMP (A) STOP COMMAND T1S3
ADO TO T1D6A
3
AI < 93 kg/cm2 3 sec ASL2
EH OIL PRESS. /L → OFF ADF
EH OIL PUMP (B) START COMMAND
01MAY02CP101 BONC T1S3 TO T1D6B
4
> 137 kg/cm2 EH OIL PUMP (A) RUNNING
T1D6A AEON
HIGH
H/ A ALARM
2
EH OIL PUMP (A) STOPPED AEOF
D < 98 kg/cm2
T1D6A BOFC EH OIL PUMP (B) STOP COMMAND T1S3
3 TO T1D6B
LOW 5
/L A ALARM
T1D6A EH OIL PUMP (A) RUN TIME OVER AEOT
5
AI > 2.9 kg/cm2 EH OIL PUMP (A) TRIPPED
T1D6A AEAB
HIGH
E/H OIL DRAIN PRESS. H/ A ALARM
4
01MAY04CP101 EH OIL PUMP (A) AUTO MODE
T1D6A AEAT AABN AABN
1 AABN
C T1D6A EH OIL PUMP (A) RUN COMMAND AEOM
A ASL A ABNORMAL
6 BABN BABN
BABN
T1D6B EH OIL PUMP (B) RUNNING BEON A ASL B ABNORMAL
2
EH OIL PUMP (B) STOPPED BEOF RSA RESET AVAIL
T1D6B RSA
3
T1D6B EH OIL PUMP (B) RUN TIME OVER BEOT TITLE:
5
EXO
A EXCESSIVE OPERATION EH OIL PUMP SELECTOR
B EH OIL PUMP (B) TRIPPED
T1D6B BEAB
4
JAYPEE NIGRIE/ 2 x 700MW
T1D6B EH OIL PUMP (B) AUTO MODE BEAT POWER PLANT/ Steam Turbine
1
T1D6B EH OIL PUMP (B) RUN COMMAND BEOM
6 TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 S3 F
04100-61000-1010 -16
LTSL-M0-00951 REV 0 Page 466 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
START P.B. PBO DO
START ONC
H ON COMMAND
COMMAND-1
DO
STOP P.B. PBF
STOP ON COMMAND-2
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
COMMAND-1
DO
OFF COMMAND-2
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E AUX. OIL PUMP AUTO MODE T1D1 TO T1G1
TAGGING P.B. TAG 1
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
AUXILIARY OIL PUMP ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
AUXILIARY OIL PUMP OFF
REM REMOTE MODE REM
AUXILIARY OIL PUMP MOTOR TRIP RUN START TRIP TRIP
DI A
ETR
AUXILIARY OIL PUMP MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI AUX. OIL PUMP RUNNING T1D1 TO T1D4A, T1D4B
EAV 2
AUXILIARY OIL PUMP CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E AUXILIARY OIL PUMP REMOTE ENR E
MODE AUX. OIL PUMP STOPPED T1D1 TO T1G3 STOP
3 MAN MAN SPM
AI < 7.64 kg/cm2 PERMIT
OFE STOP
AOP AUTO START PRESS /L STOP
01MAV13CP102 PF TAGGING
AUTOMATIC COMMAND RSA RESET TGP
PROHIBIT
TURBINE TRIP A
from TPS
MCC
ETR REM REMOTE AVL
TRIP AVAILABLE
TRIP
T1G10 TURBINE SPEED > 2950rpm TRP
1
AOC
D
T1G2 AUXILIARY OIL PUMP AUTO START COMMAND
1
TGP TAGGING PROHIBIT TGP
T1G2 AUXILIARY OIL PUMP AUTO STOP COMMAND AFC
2 AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
CONTROL POWER (AC/DC)
PROTECTION COMMAND
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
OFF POC
SUPERVISORY CURRENT VIBRATION
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
OFF PFC
PUMP / FAN /MISCELLANEOUS
DLA DRIVE ABNORMAL DLA
OFF IFC TAG No. 01MAV03AP101
NAME OF DRIVE
OND
A RUN DISCREPANCY
B PERMISSIVE CONDITION
PMO OFT
ON A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
PMF OFD
ON A STOP DISCREPANCY
TURBINE AUXILIARY MACHINE
DI
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
HP OIL STRAINER DIFF. PRESS.
A HIGH ALARM
HIGH
A
01MAV13CP601
AI < 7.64 kg/cm2 04100 61000 61000-1010 T1 D1 F
HP OIL PRESS. /L A LOW ALARM
01MAV13CP101
04100-61000-1010 -17
LTSL-M0-00951 REV 0 Page 467 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
START P.B. PBO DO
START ONC
H ON COMMAND
COMMAND-1
DO
STOP P.B. PBF
STOP ON COMMAND-2
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
COMMAND-1
DO
OFF COMMAND-2
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E TURNING OIL PUMP AUTO MODE T1D2 TO T1G1
TAGGING P.B. TAG 1
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
TURNING OIL PUMP ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
TURNING OIL PUMP OFF
REM REMOTE MODE REM
TOP ELECTRICAL TRIP RUN START TRIP TRIP
DI A
ETR
TURNING OIL PUMP MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI TURNING OIL PUMP RUNNING T1D2 TO T1G3
EAV 2
TURNING OIL PUMP CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E TURNING OIL PUMP REMOTE ENR E
MODE TURNING OIL PUMP STOPPED T1D2 TO T1G3, D3 STOP
3 MAN MAN SPM
AI PERMIT
TURNING OIL PUMP MOTOR OFE STOP
CURRENT CUR MOTOR CURRENT STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
A
MCC
AUTOMATIC COMMAND ETR
TRIP
REM REMOTE AVL
AVAILABLE
TRIP
TRP
T1G2 TOP/EOP AUTO START CONDITION
D 5 CUR XXX A
AOC TURNING OIL PUMP TRIPPED T1D2 TO T1D3
4
T1G2 TURNING OIL PUMP AUTO START COMMAND
3 TGP TAGGING PROHIBIT TGP
T1G2 TURNING OIL PUMP AUTO STOP COMMAND AFC AVL AVAILABLE AVL
4 MOTOR POWER (AC/DC)
CONTROL POWER (AC/DC)
PROTECTION COMMAND
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
OFF POC
SUPERVISORY CURRENT VIBRATION
PFC RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
OFF
PUMP / FAN /MISCELLANEOUS
OFF IFC
DLA DRIVE ABNORMAL DLA
TAG No. 01MAV04AP101
AI < 0.764 kg/cm2
BEARING OIL (NO.1 BEARING) NAME OF DRIVE
PRESS.
/L A LOW ALARM
OND
PERMISSIVE CONDITION A RUN DISCREPANCY
01MAV10CP101
B
DI PMO
LUB. OIL STRAINER DIFF. PRESS. ON
HIGH ALARM OFT
HIGH A A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
01MAV10CP601 PMF POWER PLANT/ Steam Turbine
ON
DI OFD
A STOP DISCREPANCY
MAIN OIL TANK LEVEL HIGH A HIGH ALARM
01MAV01CL201
TURBINE AUXILIARY MACHINE
DI
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
MAIN OIL TANK LEVEL LOW A LOW ALARM
A 01MAV01CL201
MAIN OIL TANK LEVEL LOW T1D2
DI 5
TO T1G1 04100 61000 61000-1010-30 T1 D2 F
MAIN OIL TANK LEVEL LOW LOW A LOW LOW ALARM
01MAV01CL201
04100-61000-1010 -18
LTSL-M0-00951 REV 0 Page 468 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation DC STARTER
OPERATION selection logic.
(HARDWIRED LOGIC)
START P.B. PBO DO
START ONC
H ON COMMAND
COMMAND-1
DO
STOP P.B. PBF
STOP ON COMMAND-2
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
COMMAND-1
DO
OFF COMMAND-2
AUTO P.B. PBA ONP RUN PERMIT
TEST
AUTOIN S TEST OFF RPM
R
G
MANUAL P.B. PBM OFP STOP PERMIT > 0.65 kg/cm2
TEST
MANUAL
OUT A EOP AUTO START TEST MODE ON SPM
EMERGENCY OIL PUMP
AUTO START (NOT)
E
01MAV10CP205
TAGGING P.B. TAG
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
EMERGENCY OIL PUMP ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
EMERGENCY OIL PUMP OFF
REM REMOTE MODE REM
EOP ELECTRICAL TRIP RUN START TRIP TRIP
DI A
EMERGENCY OIL PUMP MOTOR ETR
TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI EMERGENCY OIL PUMP RUNNING T1D3 TO T1G3
EMERGENCY OIL PUMP MOTOR EAV 1
CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E ON
ENR E
EMERGENCY OIL PUMP STOPPED T1D3
2 TO T1G3 STOP
MAN MAN SPM
AI PERMIT
EMERGENCY OIL PUMP MOTOR OFE STOP
CURRENT CUR MOTOR CURRENT STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
A
CONTROL
MCC
AUTOMATIC COMMAND ETR
TRIP
REM REMOTE AVL
AVAILABLE
TRIP
TRP
OFF AOC
D CUR XXX A
OFF AFC
TGP TAGGING PROHIBIT
PROTECTION COMMAND TGP
T1D2 TURNING OIL PUMP TRIPPED
4 AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
T1G2 TURNING OIL PUMP AUTO START COMMAND
3 CONTROL POWER (AC/DC)
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
SUPERVISORY CURRENT VIBRATION
2 sec RSA RESET AVAILABLE INSTRUMENTS TEMP
RSA
T1G2
5
TOP/EOP AUTO START CONDITION
→ POC
PUMP / FAN /MISCELLANEOUS
DLA DRIVE ABNORMAL DLA
T1D2 TURNING OIL PUMP STOPPED
OFF PFC TAG No. 01MAV05AP101
3
NAME OF DRIVE
OND
IFC A RUN DISCREPANCY
TEST OFF
B
OFT
A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
LOCAL TO MCC POWER PLANT/ Steam Turbine
PERMISSIVE CONDITION
DI > 0.65 kg/cm2 OFD
EMERGENCY OIL PUMP PMO A STOP DISCREPANCY
AUTO START (NOT) ON
01MAV10CP205
TURBINE AUXILIARY MACHINE
PMF
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
ON
A
04100 61000 61000-1010 T1 D3 F
04100-61000-1010 -19
LTSL-M0-00951 REV 0 Page 469 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
MAIN OIL TANK VAPOR EXTRACTOR (A) RUN COMMAND T1D4A TO T1S1
START P.B. PBO 6 DO
START ONC
H ON COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E MAIN OIL TANK VAPOR EXTRACTOR (A) AUTO MODE T1D4A TO T1G1, S1
TAGGING P.B. TAG 1
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
VAPOR EXTRACTOR FAN (A) ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
VAPOR EXTRACTOR FAN (A) OFF
REM REMOTE MODE REM
MAIN OILT TANK VAPOR EXTRACTOR (A) RUN START TRIP TRIP
DI A MOTOR TRIP
VAPOR EXTRACTOR FAN (A) ETR
MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI MAIN OIL TANK VAPOR EXTRACTOR (A) RUNNING T1D4A TO T1S1, D4B
VAPOR EXTRACTOR FAN (A) CTRL EAV 2
AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E VAPOR EXTRACTOR FAN (A) ENR E
REMOTE MODE MAIN OIL TANK VAPOR EXTRACTOR (A) STOPPED T1D4A TO T1S1 STOP
3 MAN MAN SPM
PERMIT
OFE STOP
AUTOMATIC COMMAND STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
MAIN OIL TANK VAPOR EXTRACTOR FAN (A) START COMMAND
T1S1 AOC A
2
MCC
ETR REM REMOTE AVL
TRIP AVAILABLE
TRIP
TRP
D T1S1 MAIN OIL TANK VAPOR EXTRACTOR FAN (A) STOP COMMAND AFC
3 MAIN OIL TANK VAPOR EXTRACTOR (A) TRIPPED T1D4A TO T1S1
4
TGP TAGGING PROHIBIT TGP
AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
PROTECTION COMMAND
MAIN OIL TANK VAPOR EXTRACTOR (A) RUN TIME OVER T1D4A CONTROL POWER (AC/DC)
POC TO T1S1
OFF 5
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
OFF PFC
SUPERVISORY CURRENT VIBRATION
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
OFF IFC
PUMP / FAN /MISCELLANEOUS
DLA DRIVE ABNORMAL DLA
TAG No. 01MAV07AN101
PERMISSIVE CONDITION
NAME OF DRIVE
OND
A RUN DISCREPANCY
B TURBINE TRIP
from TPS
OFT
AUX. OIL PUMP RUNNING A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
T1D1
2
POWER PLANT/ Steam Turbine
PMO
ON
OFD
A STOP DISCREPANCY
TURBINE AUXILIARY MACHINE
TOP/EOP RUNNING
T1G3
6 PMF
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
A MAIN OIL TANK VAPOR EXTRACTOR (B) RUNNING
T1D4B
2 04100 61000 61000-1010 T1 D4A F
04100-61000-1010 -20
LTSL-M0-00951 REV 0 Page 470 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
MAIN OIL TANK VAPOR EXTRACTOR (B) RUN COMMAND T1D4B TO T1S1
6
START P.B. PBO DO
START ONC
H ON COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E MAIN OIL TANK VAPOR EXTRACTOR (B) AUTO MODE T1D4B TO T1G1, S1
TAGGING P.B. TAG 1
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
VAPOR EXTRACTOR FAN (B) ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
VAPOR EXTRACTOR FAN (B) OFF
REM REMOTE MODE REM
MAIN OIL TANK VAPOR EXTRACTOR (B) RUN START TRIP TRIP
DI A MOTOR TRIP
VAPOR EXTRACTOR FAN (B) ETR
MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI MAIN OIL TANK VAPOR EXTRACTOR (B) RUNNING T1D4B TO T1S1, D4A
VAPOR EXTRACTOR FAN (B) CTRL EAV 2
AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E VAPOR EXTRACTOR FAN (B) ENR E
REMOTE MODE MAIN OIL TANK VAPOR EXTRACTOR (B) STOPPED T1D4B TO T1S1 STOP
3 MAN MAN SPM
PERMIT
OFE STOP
AUTOMATIC COMMAND STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
MAIN OIL TANK VAPOR EXTRACTOR FAN (B) START COMMAND
T1S1 AOC A
4
MCC
ETR REM REMOTE AVL
TRIP AVAILABLE
TRIP
TRP
D T1S1 MAIN OIL TANK VAPOR EXTRACTOR FAN (B) STOP COMMAND AFC
5 MAIN OIL TANK VAPOR EXTRACTOR (B) TRIPPED T1D4B TO T1S1
4
TGP TAGGING PROHIBIT TGP
AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
PROTECTION COMMAND
MAIN OIL TANK VAPOR EXTRACTOR (B) RUN TIME OVER T1D4B CONTROL POWER (AC/DC)
POC TO T1S1
OFF 5
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
OFF PFC
SUPERVISORY CURRENT VIBRATION
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
OFF IFC
PUMP / FAN /MISCELLANEOUS
DLA DRIVE ABNORMAL DLA
TAG No. 01MAV07AN102
PERMISSIVE CONDITION NAME OF DRIVE
OND
A RUN DISCREPANCY
B TURBINE TRIP
from TPS
OFT
AUX. OIL PUMP RUNNING A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
T1D1
2
POWER PLANT/ Steam Turbine
PMO
ON
OFD
A STOP DISCREPANCY
TURBINE AUXILIARY MACHINE
TOP/EOP RUNNING
T1G3
6 PMF
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
A MAIN OIL TANK VAPOR EXTRACTOR (A) RUNNING
T1D4A
2 04100 61000 61000-1010 T1 D4B F
04100-61000-1010 -21
LTSL-M0-00951 REV 0 Page 471 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
START P.B. PBO DO
START ONC
H ON COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E JACKING OIL PUMP (A) AUTO MODE T1D5A TO T1G1
TAGGING P.B. TAG 1
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
JACKING OIL PUMP (A) ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
JACKING OIL PUMP (A) OFF
REM REMOTE MODE REM
JACKING OIL PUMP (A) MOTOR TRIP RUN START TRIP TRIP
DI A
JACKING OIL PUMP (A) ETR
MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI JACKING OIL PUMP (A) RUNNING T1D5A TO T1D5B
JACKING OIL PUMP (A) EAV 2
CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E JACKING OIL PUMP (A) ENR E
REMOTE MODE
STOP
MAN MAN SPM
PERMIT
OFE STOP STOP
AUTOMATIC COMMAND
PF RSA RESET TGP
TAGGING
T1G3 JACKING OIL PUMP (A) AUTO START COMMAND AOC PROHIBIT
3 A
MCC
ETR REM REMOTE AVL
T1G3 JACKING OIL PUMP (A) AUTO STOP COMMAND AFC TRIP AVAILABLE
TRIP
4 TRP
D
PROTECTION COMMAND JACKING OIL PUMP (A) TRIPPED T1D5A TO T1D5B
4
TGP TAGGING PROHIBIT TGP
OFF POC
3 sec
PFC AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
IFC
OFF CONTROL POWER (AC/DC)
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
PERMISSIVE CONDITION
SUPERVISORY CURRENT VIBRATION
T1G10 TURBINE SPEED < 900 rpm RSA RESET AVAILABLE INSTRUMENTS TEMP
RSA
3
PUMP / FAN /MISCELLANEOUS
T1G3 TOP/EOP RUNNING PMO DLA DRIVE ABNORMAL DLA
6 TAG No. 01MAV06AP101
AI < 1 kg/cm2 3 sec NAME OF DRIVE
OND
JOP (A) SUCTION PRESS /L A RUN DISCREPANCY
B 01MAV06CP101/104
A JOP (A) SUCTION PRESS. LOW
T2G2 TURNING GEAR ENGAGED OFT
7 A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
T2D1-1 TURNING GEAR MOTOR RUNNING OFD
2 A STOP DISCREPANCY
TURBINE AUXILIARY MACHINE
TURBINE SPEED < 1 rpm
T2G2
6 PMF
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
A T1G10 TURBINE SPEED > 600 rpm
4
DI
04100 61000 61000-1010 T1 D5A F
T1D5B JACKING OIL PUMP (B) RUNNING JACKING OIL PUMP (A) INLET
FILTER DIFF. PRESS. HIGH A HIGH ALARM
2
01MAV06CP601
04100-61000-1010 -22
LTSL-M0-00951 REV 0 Page 472 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation DC STARTER
OPERATION selection logic.
START P.B. PBO DO
START ONC
H ON COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO OFF RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL ON SPM
E
TAGGING P.B. TAG
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
JACKING OIL PUMP (B) ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
JACKING OIL PUMP (B) OFF
REM REMOTE MODE REM
JACKING OIL PUMP (B) MOTOR TRIP RUN START TRIP TRIP
DI A
JACKING OIL PUMP (B) MOTOR ETR
TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI JACKING OIL PUMP (B) RUNNING T1D5B TO D5A
JACKING OIL PUMP (B) CTRL EAV 2
AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E JACKING OIL PUMP (B) REMOTE
ON
ENR E
MODE
STOP
MAN MAN SPM
PERMIT
OFE STOP STOP
AUTOMATIC COMMAND
PF RSA RESET TGP
TAGGING
AOC PROHIBIT
OFF
A
AFC MCC
OFF ETR REM REMOTE AVL
TRIP AVAILABLE
TRIP
TRP
PROTECTION COMMAND
1
D
T1D5A JACKING OIL PUMP (A) TRIPPED
4 10 sec
T1D5A JACKING OIL PUMP (A) RUNNING
2 TGP TAGGING PROHIBIT TGP
POC
AI < 60 kg/cm2
JACKING OIL PUMP OUTLET
PRESS. /L 2 AVL AVAILABLE AVL
01MAV06CP103 TO 3 sec MOTOR POWER (AC/DC)
T1D5B T2D1-1, 3 sec PFC
8 T2D1-2
CONTROL POWER (AC/DC)
LOW ALARM 3
A IFC
OTHERS
OFF
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
PERMISSIVE CONDITION 1 SUPERVISORY CURRENT VIBRATION
T1G10 TURBINE SPEED < 900 rpm RSA RESET AVAILABLE INSTRUMENTS TEMP
RSA
3
PUMP / FAN /MISCELLANEOUS
T1G3 TOP/EOP RUNNING PMO DLA DRIVE ABNORMAL DLA
6 TAG No. 01MAV06AP102
AI < 1 kg/cm2 3 sec NAME OF DRIVE
JOP (B) SUCTION PRESS /L OND
A RUN DISCREPANCY
B 01MAV06CP102/105
JOP (B) SUCTION
T2G2 TURNING GEAR ENGAGED A PRESS. LOW OFT
7 A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
T2D1-1 TURNING GEAR MOTOR RUNNING 2 OFD
2 A STOP DISCREPANCY
TURBINE AUXILIARY MACHINE
TURBINE SPEED < 1 rpm
T2G2
6 PMF
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
3
A T1G10 TURBINE SPEED > 600 rpm
4
DI
04100 61000 61000-1010 T1 D5B F
T1D5A JACKING OIL PUMP (A) RUNNING JACKING OIL PUMP (B) INLET
FILTER DIFF. PRESS. HIGH A HIGH ALARM
2
01MAV06CP602
04100-61000-1010 -23
LTSL-M0-00951 REV 0 Page 473 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
EH OIL PUMP (A) RUN COMMAND T1D6A TO T1S3
START P.B. PBO 6 DO
START ONC
H ON COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E EH OIL PUMP (A) AUTO MODE T1D6A TO T1G1, S3
TAGGING P.B. TAG 1
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
EH OIL PUMP (A) ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
EH OIL PUMP (A) OFF
REM REMOTE MODE REM
EH OIL PUMP (A) MOTOR TRIP RUN START TRIP TRIP
DI A
ETR
EH OIL PUMP (A) MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI EH OIL PUMP (A) RUNNING T1D6A TO T1S3
EAV 2
EH OIL PUMP (A) CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E EH OIL PUMP (A) REMOTE MODE
ENR E EH OIL PUMP (A) STOPPED T1D6A TO T1S3 STOP
3 MAN MAN SPM
AI PERMIT
EH OIL PUMP (A) MOTOR OFE STOP
CURRENT CUR MOTOR CURRENT STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
AUTOMATIC COMMAND A
MCC
ETR REM REMOTE AVL
TRIP AVAILABLE
EH OIL PUMP (A) START COMMAND TRIP
T1S3 AOC TRP
2
D CUR XXX A
EH OIL PUMP (A) TRIPPED T1D6A TO T1S3
4
T1S3 EH OIL PUMP (A) STOP COMMAND AFC
3 TGP TAGGING PROHIBIT TGP
> NOL+90 mm AVL AVAILABLE
PROTECTION COMMAND AVL
MOTOR POWER (AC/DC)
H/ A EH OIL TANK LEVEL HIGH
POC
OFF
EH OIL TANK LEVEL LOW LOW EH OIL PUMP (A) RUN TIME OVER T1D6A CONTROL POWER (AC/DC)
AI < NOL-340 mm A TO T1S3
5
OTHERS
C EH OIL TANK LEVEL /L PFC ONT
A RUN TIME OVER LOCAL OPERATION YES NO
01MAY01CL101/102 SUPERVISORY CURRENT VIBRATION
OFF IFC
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
EH OIL TANK LEVEL LOW LOW T1D6A TO T1D6B, D7
7 PUMP / FAN /MISCELLANEOUS
DLA DRIVE ABNORMAL
PERMISSIVE CONDITION DLA
TAG No. 01MAY02AP101
A EH OIL TANK LEVEL LOW
< NOL-220 mm NAME OF DRIVE
PMO OND
/L A RUN DISCREPANCY
B
PMF OFT
ON
EH OIL TANK LEVEL LOW T1D6A A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
TO T1G1, D6B, D7
8 POWER PLANT/ Steam Turbine
AI > 7.03 kg/cm2 OFD
E/H FILTER DIFF. PRESS. (A) HIGH A STOP DISCREPANCY
(FOR HIGH ALARM) H/ A HIGH ALARM
01MAY02CP502
TURBINE AUXILIARY MACHINE
DI
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
E/H OIL COOLER (A) INLET FILTER
A HIGH ALARM
DIFF. PRESS. HIGH
A 01MAY04CP602
DI
04100 61000 61000-1010 T1 D6A F
E/H OIL COOLER (B) INLET FILTER
A HIGH ALARM
DIFF. PRESS. HIGH
01MAY04CP603
04100-61000-1010 -24
LTSL-M0-00951 REV 0 Page 474 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
EH OIL PUMP (B) RUN COMMAND T1D6B TO T1S3
START P.B. PBO 6 DO
START ONC
H ON COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E EH OIL PUMP (B) AUTO MODE T1D6B TO T1G1, S3
TAGGING P.B. TAG 1
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
EH OIL PUMP (B) ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
EH OIL PUMP (B) OFF
REM REMOTE MODE REM
EH OIL PUMP (B) MOTOR TRIP RUN START TRIP TRIP
DI A
ETR
EH OIL PUMP (B) MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI EH OIL PUMP (B) RUNNING T1D6B TO T1S3
EAV 2
EH OIL PUMP (B) CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E EH OIL PUMP (B) REMOTE MODE
ENR E EH OIL PUMP (B) STOPPED T1D6B TO T1S3 STOP
3 MAN MAN SPM
AI PERMIT
EH OIL PUMP (B) MOTOR OFE STOP
CURRENT CUR MOTOR CURRENT STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
AUTOMATIC COMMAND A
MCC
ETR REM REMOTE AVL
TRIP AVAILABLE
EH OIL PUMP (B) START COMMAND TRIP
T1S3 AOC TRP
4
D CUR XXX A
EH OIL PUMP (B) TRIPPED T1D6B TO T1S3
4
T1S3 EH OIL PUMP (B) STOP COMMAND AFC
5 TGP TAGGING PROHIBIT TGP
AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
PROTECTION COMMAND
POC EH OIL PUMP (B) RUN TIME OVER T1D6B CONTROL POWER (AC/DC)
OFF TO T1S3
5
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
T1D6A EH OIL TANK LEVEL LOW LOW PFC
7 SUPERVISORY CURRENT VIBRATION
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
OFF IFC PUMP / FAN /MISCELLANEOUS
DLA DRIVE ABNORMAL DLA
TAG No. 01MAY02AP102
PERMISSIVE CONDITION
NAME OF DRIVE
OND
A RUN DISCREPANCY
B T1D6A EH OIL TANK LEVEL LOW PMO
8
OFT
A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
PMF
ON
OFD
A STOP DISCREPANCY
AI > 7.03 kg/cm2 TURBINE AUXILIARY MACHINE
E/H FILTER DIFF. PRESS. (B) HIGH
(FOR HIGH ALARM)
H/ A HIGH ALARM STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
01MAY02CP503
A AI > 2.4 kg/cm2
BACK-UP FILTER DIFF. PRESS.
HIGH (FOR HIGH ALARM)
H/ A HIGH ALARM 04100 61000 61000-1010 T1 D6B F
01MAY04CP502
04100-61000-1010 -25
LTSL-M0-00951 REV 0 Page 475 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
START P.B. PBO DO
START ONC
H ON COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO OFF RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL ON SPM
E
TAGGING P.B. TAG
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
EH POLISHING PUMP ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
EH POLISHING PUMP OFF
REM REMOTE MODE REM
EH POLISHING PUMP ELECTRICAL TRIP RUN START TRIP TRIP
DI A
ETR
EH POLISHING PUMP MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI
EAV
EH POLISHING PUMP CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E EH POLISHING PUMP REMOTE ENR E
MODE
STOP
MAN MAN SPM
PERMIT
OFE STOP STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
AUTOMATIC COMMAND A
MCC
ETR REM REMOTE AVL
TRIP AVAILABLE
TRIP
TRP
OFF AOC
D
OFF AFC
TGP TAGGING PROHIBIT TGP
AVL AVAILABLE
PROTECTION COMMAND AVL
MOTOR POWER (AC/DC)
POC
OFF CONTROL POWER (AC/DC)
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
T1D6A EH OIL TANK LEVEL LOW LOW PFC
7
SUPERVISORY CURRENT VIBRATION
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
PUMP / FAN /MISCELLANEOUS
OFF IFC
DLA DRIVE ABNORMAL DLA
TAG No. 01MAY05AP101
NAME OF DRIVE
OND
PERMISSIVE CONDITION A RUN DISCREPANCY
B
T1D6A EH OIL TANK LEVEL LOW PMO OFT
8 A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
OFD
PMF A STOP DISCREPANCY
ON
TURBINE AUXILIARY MACHINE
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
A DI
POLISHING FILTER DIFF. PRESS.
HIGH A HIGH ALARM 04100 61000 61000-1010 T1 D7 F
01MAY05CP601
04100-61000-1010 -26
LTSL-M0-00951 REV 0 Page 476 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) OIL PURIFIER (A) LOCAL
OPERATION CONTROL PANEL
RUN COMMAND
H
OIL PURIFIER (A) LOCAL
CONTROL PANEL
F START S
R
STOP
OPS (TCS/DCS) DISPLAY
DI
OIL PURIFIER (A) INLET PUMP
START
RUNNING
E STOP
E
MOTOR POWER (AC/DC)
CONTROL POWER (AC/DC)
OTHERS
C LOCAL OPERATION YES NO
SUPERVISORY CURRENT VIBRATION
INSTRUMENTS TEMP
PUMP / FAN /MISCELLANEOUS
TAG No. 01MAV21AP101
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 D8 F
04100-61000-1010 -27
LTSL-M0-00951 REV 0 Page 477 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) LOCAL
OPERATION
01MAV21AA902
H
ENERGIZED OPEN
DE-ENERGIZED CLOSE
OIL PURIFIER (A) LOCAL
CONTROL PANEL
OPS (TCS/DCS) DISPLAY
F FILTER DRAIN VALVE OPEN
COMMAND
POWER FOR
(AC/DC)
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO OPEN CLOSE
TAG No. 01MAV21AA902
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 D9 F
04100-61000-1010 -28
LTSL-M0-00951 REV 0 Page 478 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) OIL PURIFIER (B) LOCAL
OPERATION CONTROL PANEL
RUN COMMAND
H
OIL PURIFIER (B) LOCAL
CONTROL PANEL
F START S
R
STOP
OPS (TCS/DCS) DISPLAY
DI
OIL PURIFIER (B) INLET PUMP
START
RUNNING
E STOP
E
MOTOR POWER (AC/DC)
CONTROL POWER (AC/DC)
OTHERS
C LOCAL OPERATION YES NO
SUPERVISORY CURRENT VIBRATION
INSTRUMENTS TEMP
PUMP / FAN /MISCELLANEOUS
TAG No. 00MAV21AP102
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 D10 F
04100-61000-1010 -29
LTSL-M0-00951 REV 0 Page 479 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) LOCAL
OPERATION
00MAV21AA902
H
ENERGIZED OPEN
DE-ENERGIZED CLOSE
OIL PURIFIER (B) LOCAL
CONTROL PANEL
FILTER DRAIN VALVE OPEN
OPS (TCS/DCS) DISPLAY
F COMMAND
POWER FOR
(AC/DC)
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO OPEN CLOSE
TAG No. 00MAV21AA902
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 D11 F
04100-61000-1010 -30
LTSL-M0-00951 REV 0 Page 480 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation
OPERATION selection logic.
START P.B. PBO DO
START ONC
H ON COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET OFF COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E
TAGGING P.B. TAG
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
MAIN OIL TANK HEATER ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
MAIN OIL TANK HEATER OFF
REM REMOTE MODE REM
RUN START TRIP TRIP
DI A
ETR
MAIN OIL TANK HEATER TRIP
ETR MOTOR
TRIP TRIP E STOP STOP DLA ABNORMAL
DI
MAIN OIL TANK HEATER CTRL EAV
AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E MAIN OIL TANK HEATER REMOTE ENR E
MODE
STOP
MAN MAN SPM
PERMIT
OFE STOP STOP
PF TAGGING
AUTOMATIC COMMAND RSA RESET TGP
PROHIBIT
A
AI < 15 ℃ CONTROL
MCC
ETR REM REMOTE AVL
ACO TRIP AVAILABLE
AVAILABLE
MAIN OIL TANK TEMP /L TRP
TRIP
01MAV01CT001
D
> 33 ℃
ACF
H/ TGP TAGGING PROHIBIT TGP
AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
CONTROL POWER (AC/DC)
PROTECTION COMMAND
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
OFF PCO
SUPERVISORY CURRENT VIBRATION
AI > 80 ℃ RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
PCF
MAIN OIL TANK HEATER TEMP H/
PUMP / FAN /MISCELLANEOUS
01MAV01CT003
DLA DRIVE ABNORMAL DLA
OFF ICF TAG No. 01MAV01AH101
NAME OF DRIVE
OND
A RUN DISCREPANCY
B PERMISSIVE CONDITION
PMO OFT
A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
PMF OFD
ON A STOP DISCREPANCY
TURBINE AUXILIARY MACHINE
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 D12 F
04100-61000-1010 -31
LTSL-M0-00951 REV 0 Page 481 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) MCC
OPERATION
RUN COMMAND
H
STOP COMMAND
OFF RETURN
G
ON RETURN
PUMP LOCAL PANEL
PUMP LOCAL PANEL
START
START
F STOP
STOP
MOTOR POWER (AC/DC)
CONTROL POWER (AC/DC)
OTHERS
C LOCAL OPERATION YES NO
SUPERVISORY CURRENT VIBRATION
INSTRUMENTS TEMP
PUMP / FAN /MISCELLANEOUS
TAG No. 00MAV22AP201
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 D13 F
04100-61000-1010 -32
LTSL-M0-00951 REV 0 Page 482 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) MCC
OPERATION
RUN COMMAND
H
STOP COMMAND
OFF RETURN
G
ON RETURN
PUMP LOCAL PANEL
PUMP LOCAL PANEL
START
START
F STOP
STOP
MOTOR POWER (AC/DC)
CONTROL POWER (AC/DC)
OTHERS
C LOCAL OPERATION YES NO
SUPERVISORY CURRENT VIBRATION
INSTRUMENTS TEMP
PUMP / FAN /MISCELLANEOUS
TAG No. 01MAV22AP301
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T1 D14 F
04100-61000-1010 -33
LTSL-M0-00951 REV 0 Page 483 of 860
8 7 6 5 4 3 2 1
T2 – TURBINE TURNING
D
TITLE:
TURBINE TURNING
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T2 F
04100-61000-1010 -34
LTSL-M0-00951 REV 0 Page 484 of 860
8 7 6 5 4 3 2 1
H D1 TURNING GEAR MOTOR 01MAK11AE101
D2 TURNING GEAR ENGAGE / DISENGAGE 01MAK11AA721/722
D3 TURNING GEAR OIL SUPPLY SOLENOID VALVE 01MAV10AA721
AIR IN DISENGAGE S D2
G TRIP LEVER
AIR IN
ATMOSPHERE ENGAGE S
S D2
RESET
OVER SPEED LEVER ENGAGE
TRIP PIN
DISENGAGE
TEST S TO
DRAIN
LEVER
F
TURNING GEAR ENGAGEMENT
TO
DRAIN
TO
DRAIN
AUTO STOP OIL LINE TURNING
GEAR
D1 M
F
E HP/IP
TURBINE
LP-1 & 2 TURBINE GEN.
EH OIL POLISHING PUMP
S D3
EH OIL TANK
No. 7-8 BRG.
D
HP OIL LINE
TURNING EMERGENCY AUXILIARY
OIL PUMP OIL PUMP OIL PUMP
RETURN F
VAPOR OIL
EXTRACTOR
FANS AC DC AC
EH FLUID EH OIL PUMP
JACKING
OIL PUMP
F
C OIL
COOLER
TITLE:
TURBINE TURNING SYSTEM
OIL HEATER
B OIL PURIFIER (A) SIMPLIFIED P&I DIAGRAM
S JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
OIL OIL TURBINE AUXILIARY MACHINE
STORAGE STORAGE
TANK TANK CONTROL LOGIC DIAGRAM
(Clean) (Dirty)
A
OIL PURIFIER (B)
04100 61000 61000-1010 T2 01 F
S
04100-61000-1010 -35
LTSL-M0-00951 REV 0 Page 485 of 860
8 7 6 5 4 3 2 1
T2
H
TURBINE TURNING
Tag no.
Sht. No.
GROUP T2G1, T2G2, T2G3
LEVEL
(G)
SUB GROUP
E LEVEL
(SG)
C DRIVE
LEVEL 01MAK11AA721 /
(D) 01MAK11AE101
01MAK11AA722
01MAV10AA721
D1 D2 D3
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T2 02 F
04100-61000-1010 -36
LTSL-M0-00951 REV 0 Page 486 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-III
for OPS operation OPS (TCS/DCS) DISPLAY
OPERATION selection logic
ON
ONM
PERMIT
ON P.B. PBO ONP ON PERMIT
H ON ONM
OFF
OFM
PERMIT
OFF P.B. PBF OFP OFF PERMIT
OFF OFM
AUTO
APM
PERMIT
PBR ATP AUTO PERMIT
OFF APM
AUTO
ABP
BYPASS
AUTO BYPASS P.B. PBAB ABP AUTO BYPASS
AUTO BYP ABP
G POPM
PRE-OPE
PERMIT
PBPO
OFF
E
ON
POP PRE-OPE PERMIT POP ONMD
MODE
PBA M
OFF
OFF
OFMD
MODE
PBT PBP
ON D
DLA ABNORMAL
F AUTOMATIC COMMAND
AUT
D
AOC
OFF
AFC
OFF
OUT
D
E AUTOMATIC CONDITION
ONM GL ON MODE ONM
D
T2D1-1 TURNING GEAR MOTOR AUTO MODE EVNT
1 TURBINE TURNING GROUP ON MODE T2G1 TO T2G2,
1 T2G3,
T2D2 TURNING GEAR ENGAGE/DISENGAGE SV AUTO MODE PAT E
1 OFM GL OFF MODE OFM
D
T2D3 TURNING GEAR OIL SUPPLY SV AUTO MODE
D 1
E
A
ABN ABNORMAL
DLA
ONM EON
C D RESET
AVAILABLE
RSA
PPO
ON
TAGNAME:
PERMISSIVE CONDITION TITLE:
B
T2D1-1 GENERATOR SEAL OIL DIFF PRESS. LOW PPM
5 JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
SLF
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
OFF
A
04100 61000 61000-1010 T2 G1 F
04100-61000-1010 -37
LTSL-M0-00951 REV 0 Page 487 of 860
8 7 6 5 4 3 2 1
T2G1 TURBINE TURNING GROUP ON MODE
1
H
T2D1-2 JOG MODE
1
TURNING GEAR AUTO START COMMAND T2G2 TO T2D1-1
DI 1
TURNING GEAR TOOTH CONTACT
01MAK11CG203
DI
TURNING GEAR ENGAGED
01MAK11CG201
G
TURNING GEAR AUTO STOP COMMAND T2G2 TO T2D1-1
2
DI 3 sec
TURNING GEAR DISENGAGED
01MAK11CG202
F 5 sec
TURNING GEAR ENGAGE/DISENGAGE SV AUTO ENGAGE COMMAND T2G2 TO T2D2
3
DI 10 sec
TURBINE SPEED < 1rpm
From TSI
E 5 sec
TURNING GEAR ENGAGE/DISENGAGE SV AUTO DISENGAGE COMMAND T2G2 TO T2D2
4
T2D1-1 TURNING GEAR MOTOR STOPPED
3
TURBINE SPEED < 1 rpm T2G2 TO T2D1-1, T2D1-2, T1G3,
6 T1D5A, T1D5B
TURNING GEAR ENGAGED T2G2 TO T1G3, T1D5A, T1D5B,
D 7 T2D2
TURNING GEAR DISENGAGED T2G2 TO T2D2, T2D1-1
8
TURNING GEAR TOOTH CONTACT T2G2 TO T2D1-1
9
3 sec
TURNING GEAR PROTECTION INTERLOCK STOP COMMAND T2G2 TO T2D1-1
C 5
T2D2 TURNING GEAR ENGAGE/DISENGAGE SV ENGAGE COMMAND
2
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T2 G2 F
04100-61000-1010 -38
LTSL-M0-00951 REV 0 Page 488 of 860
8 7 6 5 4 3 2 1
H T2G1 TURBINE TURNING GROUP ON MODE
1
TURNING GEAR OIL SUPPLY SV AUTO OPEN COMMAND T2G3 TO T2D3
1
T1G2 TURBINE SPEED < 50 rpm
6
TURNING GEAR OIL SUPPLY SV AUTO CLOSE COMMAND T2G3 TO T2D3
2
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T2 G3 F
04100-61000-1010 -39
LTSL-M0-00951 REV 0 Page 489 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
T2D1-2 TURNING GEAR JOG “ON”
2
START P.B. PBO
START DO
H T2D1-2 TURNING GEAR JOG “OFF” ONC RUN COMMAND
3
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET STOP COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
T2D1-2 TURNING GEAR JOG MODE
G 1
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E TURNING GEAR MOTOR AUTO MODE T2D1-1
TO T2G1 TURNING GEAR PANEL
TAGGING P.B. TAG 1
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
EON
TURNING GEAR MOTOR ON
MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
EOF A
TURNING GEAR MOTOR OFF
REM REMOTE MODE REM
OPS (TCS/DCS) DISPLAY
TURNING GEAR MOTOR TRIP RUN START TRIP TRIP
DI A
ETR
TURNING GEAR MOTOR TRIP
ETR MOTOR TRIP E STOP
RUN START
STOP TRIP
DLA ABNORMAL
TRIP
DI TURNING GEAR MOTOR RUNNING T2D1-1 TO T1G3, T1D5A,
TURNING GEAR MOTOR CTRL EAV 2 T1D5B
AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO
STOP AUTO
STOP RPM
DLA ABNORMAL
DI PERMIT
E TURNING GEAR MOTOR ENR E
REMOTE MODE TURNING GEAR MOTOR STOPPED T2D1-1
TO T2G2, D1-2 START
STOP
3 AUTO
MAN AUTO
MAN RPM
SPM
PERMIT
OFE STOP STOP
PF TAGGING
STOP
AUTOMATIC COMMAND MAN
RSA RESET
MAN SPM
TGP
PROHIBIT
PERMIT
A
T2G2 TURNING GEAR AUTO START COMMAND AOC TAGGING
MCC
ETR REM
RSA REMOTE
RESET TGP
AVL
1 TRIP AVAILABLE
PROHIBIT
TRIP
TRP
D T2G2 TURNING GEAR AUTO STOP COMMAND AFC MCC
REM REMOTE AVL
2 AVAILABLE
TOOTH DIS-
TGP TAGGING PROHIBIT TGP 1 CONTACT 2 ENGAGED
PROTECTION COMMAND
OFF POC AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
T1D5B JACKING OIL PUMP OUTLET PRESS. LOW CONTROL POWER (AC/DC)
8
OTHERS
C PFC ONT
A RUN TIME OVER LOCAL OPERATION YES NO
AI < 0.3 kg/cm2
SUPERVISORY CURRENT VIBRATION
TURNING GEAR INTERLOCK PRESS /L
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
01MAV10CP103
TURNING GEAR
INTERLOCK T2D1-1 PUMP / FAN /MISCELLANEOUS
TO T2D1-2
4
DLA DRIVE ABNORMAL DLA
TAG No. 01MAK11AE101
T2G2 TURNING GEAR PROTECTION INTERLOCK STOP COMMAND IFC NAME OF DRIVE
5 OND
A RUN DISCREPANCY
B
PERMISSIVE CONDITION OFT
A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
DI POWER PLANT/ Steam Turbine
GENERATOR SEAL OIL DIFF. PMO
PRESS. LOW OFD
From SCP GENERATOR SEAL OIL A STOP DISCREPANCY
DIFF PRESS. LOW T2D1-1
5
TO T2G1, D1-2 TURBINE AUXILIARY MACHINE
TURBINE SPEED < 1 rpm
T2G2
6
ON PMF STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
A T1S2 JACKING OIL PUMP OUTLET PRESS. LOW T2G2 TURNING GEAR TOOTH CONTACT
8 9
1
04100 61000 61000-1010 T2 D1-1 F
T2G2 TURNING GEAR DISENGAGED
8
2
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
H 1
JOG MODE P.B.
JOG TURNING GEAR JOG MODE T2D1-2
S TO T2G2, T2D1-1
1
R 2
NORMAL MODE P.B.
NORMAL
TURNING GEAR PANEL
F TURNING GEAR JOG “ON” T2D1-2
TO T2D1-1
JOG P.B. 2
JOG
OPS (TCS/DCS) DISPLAY
TURNING GEAR JOG “OFF” T2D1-2
TO T2D1-1
3
E
1 JOG
2 NORMAL
T1D5 JACKING OIL PUMP OUTLET PRESS. LOW
8
JOG
3
PERMIT
T2D1-1 TURNING GEAR INTERLOCK
4
D
T2D1-1 TURNING GEAR MOTOR STOPPED
3
3
T2G2 TURBINE SPEED < 1 rpm
6
T2D1-1 GENERATOR SEAL OIL DIFF PRESS. LOW
5
C
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T2 D1-2 F
04100-61000-1010 -41
LTSL-M0-00951 REV 0 Page 491 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
TURNING GEAR ENGAGE/DISENGAGE SV
ENGAGE COMMAND T2D2 TO T2G2
2 DO 01MAK11AA721
OPEN COMMAND
OPEN COMMAND ENERGIZED ENGAGE
PBO (ENGAGE COMMAND)
H ENGAGE
DO DE-ENERGIZED FREE
CLOSE COMMAND
CLOSE COMMAND
PBC (DISENGAGE COMMAND)
DISENGAGE
01MAK11AA722
OPC OPC OPL ENERGIZED DISENGAGE
OPL
PBR
RESET DE-ENERGIZED FREE
CLC CLC CLL CLL
PBA
AUTO
G E
PBM OPE OPE
MANUAL
DM
E
TAG CLE CLE
TAGGING
DLA DRIVE LEVEL ABNL
DLA DLA
T2G2 TURNING GEAR ENGAGED EOP
7 RSA RESET AVAIL
OPS (TCS/DCS) DISPLAY
F RSA RSA
T2G2 TURNING GEAR DISENGAGED ECL
8
OPL ENGAGE DLA ABNORMAL
AUTOMATIC COMMAND
ENGAGE
OPP OPEN PERMIT OPM CLL DISENGAGE OPM
PERMIT
T2G2 TURNING GEAR ENGAGE/DISENGAGE SV AUTO ENGAGE COMMAND AOC
3
DISENGAGE
E AUTO AUTO CPM
PERMIT
T2G2 TURNING GEAR ENGAGE/DISENGAGE SV AUTO DISENGAGE COMMAND ACC CLP CLOSE PERMIT CPM
4
DSV MAN MAN TGP TAGGING
AUT AUTO MODE AUTO RSA RESET
TURNING GEAR ENGAGE/DISENGAGE SV AUTO MODE T2D2 TO T2G1
1
D MAN MANUAL MODE MAN
PROTECTION COMMAND
TGP TAGGING PROHIBIT TGP
OFF POC POWER FOR
(AC/DC)
SOLENOID VALVE
T2G2 TURNING GEAR DISENGAGED
8 POWER FAILURE LOCK YES NO
PCC
OTHERS
C SOLENOID SINGLE DUAL
T1G10 TURBINE SPEED < 50 rpm ON-OFF
6
VALVES
AIR TO OPEN CLOSE
TAG No. 01MAK11AA721/722
OPT OPEN TIME OVER
A
PERMISSIVE CONDITION OPD NAME OF DRIVE
3 sec A OPEN DISCREPANCY
B 3 sec
T2G2 TURBINE SPEED < 1 rpm PMO CLT
A CLOSE TIME OVER
6
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
T2D1-1 TURNING GEAR MOTOR STOPPED CLD
A CLOSE DISCREPANCY
3
PMC
ON
STA
TURBINE AUXILIARY MACHINE
A STATUS ABNORMAL
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T2 D2 F
04100-61000-1010 -42
LTSL-M0-00951 REV 0 Page 492 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
PBO
H OFF
DO 01MAV10AA721
OPEN COMMAND ENERGIZED OPEN
PBC
OFF DE-ENERGIZED CLOSE
OPC OPL OPL
PBR
OFF
OPC CLC CLL CLL
PBA
ON
E
G
OPE OPE
PBM
OFF
E DM
CLE CLE
TAG
OFF
DRIVE ABNORMAL
DLA
DLA
LOCAL RESET AVAILABLE
RSA
RSA OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
EOP OPP OPEN PERMIT
OPL OPM
E ECL
CLP CLOSE PERMIT
CPM
SSVO AUT AUTO MODE TURNING GEAR OIL SUPPLY SV AUTO MODE
AUTO T2D3 TO T2G1
1
AUTOMATIC COMMAND MANUAL MODE
MAN MAN
D
T2G3 TURNING GEAR OIL SUPPLY SV AUTO OPEN COMMAND AOC TGP TAGGING PROHIBIT
TGP
1
T2G3 TURNING GEAR OIL SUPPLY SV AUTO CLOSE COMMAND ACC
2 POWER FOR
(AC/DC)
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO OPEN CLOSE
PROTECTION COMMAND TAG No. 01MAV10AA721
POC
OFF
OPT OPEN TIME OVER
A
NAME OF DRIVE
PCC
OFF
OPD OPEN DISCREPANCY
B A
CLT JAYPEE NIGRIE/ 2 x 700MW
PERMISSIVE CONDITION A CLOSE TIME OVER
POWER PLANT/ Steam Turbine
PMO
ON
CLD CLOSE DISCREPANCY
A
TURBINE AUXILIARY MACHINE
PMC
ON STA
CONTROL LOGIC DIAGRAM
A STATUS ABNORMAL
A
04100 61000 61000-1010 T2 D3 F
04100-61000-1010 -43
LTSL-M0-00951 REV 0 Page 493 of 860
8 7 6 5 4 3 2 1
T3 – CONDENSER VACUUM
D
TITLE:
CONDENSER VACUUM
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T3 F
04100-61000-1010 -44
LTSL-M0-00951 REV 0 Page 494 of 860
8 7 6 5 4 3 2 1
H
D1A GLAND STEAM CONDENSER EXHAUST FAN (A) 01MAW01AN101
D1B GLAND STEAM CONDENSER EXHAUST FAN (B) 01MAW01AN102
D2 LP-1 VACUUM BREAKER VALVE 01MAC11AA701
D3 LP-2 VACUUM BREAKER VALVE 01MAC21AA701
D4 GLAND STEAM DESUPERHEATER SPRAY CV BYPASS MOTOR VALVE 01MAW11AA702
GLAND STEAM HEADER
G
DESUPER HEATER
FROM
CONDENSATE PUMP
D4 M
F
TO ATMOSPHERE
D1B D1A
E
FROM
CONDENSATE PUMP
GLAND CONDENSER TO LP No.1 HEATER
LP-1 TURBINE LP-2 TURBINE
HP/IP TURBINE
D2 D3
M M
CONDENSER - 1 CONDENSER - 2
TITLE:
CONDENSER VACUUM SYSTEM
B SIMPLIFIED P&I DIAGRAM
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T3 01 F
04100-61000-1010 -45
LTSL-M0-00951 REV 0 Page 495 of 860
8 7 6 5 4 3 2 1
COMMAND FROM COMMAND FROM COMMAND FROM
GROUP PLANT-DCS PLANT-DCS PLANT-DCS
LEVEL
(G)
G
SELECTOR
Tag no.
Sht. No.
T3S1
SUB GROUP
E LEVEL
(SG)
C DRIVE
LEVEL
(D) 01MAW01AN101 01MAW01AN102 01MAC11AA701 01MAC21AA701 01MAW11AA702
D1A D1B D2 D3 D4
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T3 02 F
04100-61000-1010 -46
LTSL-M0-00951 REV 0 Page 496 of 860
8 7 6 5 4 3 2 1
T3D1A GLAND STEAM COND. EXH. FAN (A) AUTO MODE
1
T3D1B GLAND STEAM COND. EXH. FAN (B) AUTO MODE
1
T3S1 GLAND STEAM COND. EXH. FAN ASL IN MODE
G 1
T3D2 LP-1 VACUUM BREAKER VALVE AUTO MODE
1
DO
CONDENSER VACUUM GROUP ALL
AUTO
T3D3 LP-2 VACUUM BREAKER VALVE AUTO MODE To Plant-DCS
1
GLAND STEAM PCV (FROM AUX. STEAM) AUTO OR STANDBY MODE
F From TCS
GLAND STEAM PCV (FROM CRH STEAM) AUTO OR STANDBY MODE
From TCS
GLAND STEAM SPILL OVER CV AUTO OR STANDBY MODE
From TCS
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T3 G1 F
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation GLAND STEAM COND. EXH. FAN ASL IN MODE T3S1
TO T3G1
OPS (TCS/DCS) DISPLAY
OPERATION selection logic. 1
TO Plant-DCS
(via OPC)
IN ASL IN MODE IN
H PBA E
A SELECT OUT ASL OUT MODE OUT IN ASL IN ON ASL ON
PBB E
B SELECT OFM ASL OFF MODE OFF OUT ASL OUT OFF ASL OFF
PBR E
RESET ONM ASL ON MODE ON ASEL A SEL ABN ASL ABN
GLAND STEAM COND. EXH. FAN ASL ON MODE T3S1 TO Plant-DCS
PBO
ASL ON E
6 (via OPC)
ASEL A SEL MODE
ASEL
BSEL B SEL AABN A ABN
G
PBF
ASL OFF RSA RESET BABN B ABN
E
PBI BSEL B SEL MODE
ASL IN BSEL
PBT
ASL OUT
E
F OTC ABN ASL ABNORMAL ABN
OFF
DI A ASL ABN
GLAND STEAM IN SERVICE AOC
COMMAND
From Plant-DCS
DI AONC GLAND STEAM COND. EXH. FAN (A) START COMMAND T3S1
GLAND STEAM SHUT DOWN AFC TO T3D1A
2
COMMAND
From Plant-DCS
E
GLAND STEAM PCV (FROM AUX. STEAM) FULL CLOSED
From TCS AOFC GLAND STEAM COND. EXH. FAN (A) STOP COMMAND T3S1
ADO TO T3D1A
3
GLAND STEAM PCV (FROM CRH STEAM) FULL CLOSED
From TCS ASL2
ADF
OFF GLAND STEAM COND. EXH. FAN (B) START COMMAND
BONC T3S1 TO T3D1B
4
GLAND STEAM COND. EXH. FAN (A) RUNNING 15 sec
T3D1A
2
→ T3D1A GLAND STEAM COND. EXH. FAN (A) RUNNING AEON
D 2 BOFC GLAND STEAM COND. EXH. FAN (B) STOP COMMAND T3S1 TO T3D1B
T3D1B GLAND STEAM COND. EXH. FAN (B) RUNNING
5
2
T3D1A GLAND STEAM COND. EXH. FAN (A) STOPPED AEOF
AI > -0.01 kg/cm2 3 sec
3
GLAND CONDENSER (VACUUM)
01MAW01CP102/105
H/ ← T3D1A GLAND STEAM COND. EXH. FAN (A) RUN TIME OVER AEOT
5
T3D1A GLAND STEAM COND. EXH. FAN (A) TRIPPED AEAB
4 AABN AABN
AABN
C T3D1A GLAND STEAM COND. EXH. FAN (A) AUTO MODE AEAT A ASL A ABNORMAL
1 BABN BABN
BABN
T3D1A GLAND STEAM COND. EXH. FAN (A) RUN COMMAND AEOM A ASL B ABNORMAL
6
T3D1B GLAND STEAM COND. EXH. FAN (B) RUNNING BEON RSA RESET AVAIL
RSA
2
T3D1B GLAND STEAM COND. EXH. FAN (B) STOPPED BEOF
3 TITLE:
EXO
A EXCESSIVE OPERATION GLAND STEAM CONDENSER EXHAUST FAN SELECTOR
B T3D1B GLAND STEAM COND. EXH. FAN (B) RUN TIME OVER BEOT
5
JAYPEE NIGRIE/ 2 x 700MW
T3D1B GLAND STEAM COND. EXH. FAN (B) TRIPPED BEAB POWER PLANT/ Steam Turbine
4
T3D1B GLAND STEAM COND. EXH. FAN (B) AUTO MODE BEAT
1 TURBINE AUXILIARY MACHINE
T3D1B GLAND STEAM COND. EXH. FAN (B) RUN COMMAND BEOM
CONTROL LOGIC DIAGRAM
6
A
04100 61000 61000-1010 T3 S1 F
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
GLAND STEAM COND. EXH. FAN (A) RUN COMMAND T3D1A TO T3S1
START P.B. PBO 6
START DO
H ONC RUN COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET STOP COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E GLAND STEAM COND. EXH. FAN (A) AUTO MODE T3D1A TO T3G1, S1
TAGGING P.B. TAG 1 TO Plant-DCS (via OPC)
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
GLAND STEAM CNSR EXHAUST EON
FAN (A) ON MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
GLAND STEAM CNSR EXHAUST EOF A
FAN (A) OFF REM REMOTE MODE REM
GLAND STEAM COND. EXHAUST FAN (A) MOTOR TRIP RUN START TRIP TRIP
DI A
GLAND STEAM CNSR EXHAUST ETR
FAN (A) MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI GLAND STEAM COND. EXH. FAN (A) RUNNING T3D1A TO T3S1, D1B
GLAND STEAM CNSR EXHAUST EAV 2 TO Plant-DCS (via OPC)
FAN (A) CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E GLAND STEAM CNSR EXHAUST ENR E
FAN (A) REMOTE MODE GLAND STEAM COND. EXH. FAN (A) STOPPED T3D1A TO T3S1
3 TO Plant-DCS (via OPC) STOP
MAN MAN SPM
PERMIT
OFE STOP STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
AUTOMATIC COMMAND A
MCC
ETR REM REMOTE AVL
TRIP AVAILABLE
TRIP
TRP
T3S1 GLAND STEAM COND. EXH. FAN (A) START COMMAND AOC
D 2
GLAND STEAM COND. EXH. FAN (A) TRIPPED T3D1A TO T3S1
4
TGP TAGGING PROHIBIT TGP
T3S1 GLAND STEAM COND. EXH. FAN (A) STOP COMMAND AFC
3
AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
GLAND STEAM COND. EXH. FAN (A) RUN TIME OVER T3D1A CONTROL POWER (AC/DC)
PROTECTION COMMAND 5
TO T3S1
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
OFF POC
SUPERVISORY CURRENT VIBRATION
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
OFF PFC
PUMP / FAN /MISCELLANEOUS
DLA DRIVE ABNORMAL DLA
OFF IFC TAG No. 01MAW01AN101
NAME OF DRIVE
OND
PERMISSIVE CONDITION A RUN DISCREPANCY
B
OFT
T1G2 CONDENSER VACUUM > -0.107 kg/cm2 PMO A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
ON
７ POWER PLANT/ Steam Turbine
OFD
T3D2 LP-1 VACUUM BREAKER VALVE OPENED A STOP DISCREPANCY
1
PMF
TURBINE AUXILIARY MACHINE
T3D3 LP-2 VACUUM BREAKER VALVE OPENED
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
1
A
T3D1B GLAND STEAM COND. EXH. FAN (B) RUNNING
2
04100 61000 61000-1010 T3 D1A F
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation MCC
OPERATION selection logic.
GLAND STEAM COND. EXH. FAN (B) RUN COMMAND T3D1B TO T3S1
START P.B. PBO 6
START DO
H ONC RUN COMMAND
STOP P.B. PBF
STOP
DO
RESET P.B. PBR OFC
RESET STOP COMMAND
AUTO P.B. PBA ONP RUN PERMIT
AUTO RPM
G
MANUAL P.B. PBM OFP STOP PERMIT
MANUAL SPM
E GLAND STEAM COND. EXH. FAN (B) AUTO MODE T3D1B TO T3G1, S1
TAGGING P.B. TAG 1 TO Plant-DCS (via OPC)
TAGGING
AUT AUTO MODE AUTO
MCC E
DI
GLAND STEAM CNSR EXHAUST EON
FAN (B) ON MAN MANUAL MODE MAN
OPS (TCS/DCS) DISPLAY
F
DI NOT REMOTE
GLAND STEAM CNSR EXHAUST EOF A
FAN (B) OFF REM REMOTE MODE REM
GLAND STEAM COND. EXHAUST FAN (B) MOTOR TRIP RUN START TRIP TRIP
DI A
GLAND STEAM CNSR EXHAUST ETR
FAN (B) MOTOR TRIP
ETR MOTOR TRIP E STOP STOP DLA ABNORMAL
DI GLAND STEAM COND. EXH. FAN (B) RUNNING T3D1B TO T3S1, D1A
GLAND STEAM CNSR EXHAUST EAV 2 TO Plant-DCS (via OPC)
FAN (B) CTRL AVAIL
ONE RUN START
AVL CONTROL AVAILABLE RUN AUTO AUTO RPM
DI PERMIT
E GLAND STEAM CNSR EXHAUST ENR E
FAN (B) REMOTE MODE GLAND STEAM COND. EXH. FAN (B) STOPPED T3D1B TO T3S1
3 TO Plant-DCS (via OPC) STOP
MAN MAN SPM
PERMIT
OFE STOP STOP
PF RSA RESET TGP
TAGGING
PROHIBIT
AUTOMATIC COMMAND A
MCC
ETR REM REMOTE AVL
TRIP AVAILABLE
TRIP
TRP
T3S1 GLAND STEAM COND. EXH. FAN (B) START COMMAND AOC
D 4
GLAND STEAM COND. EXH. FAN (B) TRIPPED T3D1B TO T3S1
4
TGP TAGGING PROHIBIT TGP
T3S1 GLAND STEAM COND. EXH. FAN (B) STOP COMMAND AFC
5
AVL AVAILABLE AVL
MOTOR POWER (AC/DC)
GLAND STEAM COND. EXH. FAN (B) RUN TIME OVER T3D1B CONTROL POWER (AC/DC)
PROTECTION COMMAND 5
TO T3S1
OTHERS
C ONT
A RUN TIME OVER LOCAL OPERATION YES NO
OFF POC
SUPERVISORY CURRENT VIBRATION
RSA RESET AVAILABLE RSA
INSTRUMENTS TEMP
OFF PFC
PUMP / FAN /MISCELLANEOUS
DLA DRIVE ABNORMAL DLA
OFF IFC TAG No. 01MAW01AN102
NAME OF DRIVE
OND
PERMISSIVE CONDITION A RUN DISCREPANCY
B
OFT
T1G2 CONDENSER VACUUM > -0.107 kg/cm2 PMO A STOP TIME OVER JAYPEE NIGRIE/ 2 x 700MW
ON
7 POWER PLANT/ Steam Turbine
OFD
T3D2 LP-1 VACUUM BREAKER VALVE OPENED A STOP DISCREPANCY
1
PMF
TURBINE AUXILIARY MACHINE
T3D3 LP-2 VACUUM BREAKER VALVE OPENED
STA
A STATUS ABNORMAL CONTROL LOGIC DIAGRAM
1
A
T3D1A GLAND STEAM COND. EXH. FAN (A) RUNNING
2
04100 61000 61000-1010 T3 D1B F
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LTSL-M0-00951 REV 0 Page 500 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
LP-1 VACUUM BREAKER MOV EOP
OPEN OPS (TCS/DCS) DISPLAY
F
DI
LP-1 VACUUM BREAKER MOV ECL
CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
LP-1 VACUUM BREAKER MOV CLC CLC CLL
CLL
OPEN TRQ OVER LP-1 VACUUM BREAKER OPEN
CLL CLOSE OPM
ETQ VALVE OPENED T3D2 TO T3D1A, D1B PERMIT
DI 2 TO Plant-DCS (via OPC)
LP-1 VACUUM BREAKER MOV OPE OPE
CLOSE TRQ OVER LP-1 VACUUM BREAKER CLOSE
TO AUTO AUTO CPM
VALVE CLOSED T3D2 PERMIT
DI 3
Plant-DCS E DM
(via OPC)
E LP-1 VACUUM BREAKER MOV EMT CLE CLE
ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
LP-1 VACUUM BREAKER MOV ELC DLA DLA
REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
AUTOMATIC COMMAND
TGP TAGGING PROHIBIT
TGP
DI
D LP-1 VACUUM BREAKER VALVE
OPEN COMMAND
From Plant-DCS AOC
LP-1 VACUUM BREAKER VALVE AUTO MODE T3D2 TO T3G1
AUTO
T1G10 TURBINE SPEED < 400 rpm 1 TO Plant-DCS (via OPC)
5
MOTOR POWER (AC/DC)
DI MVT
A TROUBLE
LP-1 VACUUM BREAKER VALVE ACC CONTROL POWER (AC/DC) V
CLOSE COMMAND
From Plant-DCS
LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
ASC
OFF
C SEATING TORQUE GEARED
OPT
PROTECTION COMMAND A OPEN TIME OVER
INCHING YES NO
OPD
OPEN DISCREPANCY POSITION TRANS YES NO
POC A
OFF
TAG No. 01MAC11AA701
CLQ
A CLOSE TORQUE OVER
OFF PCC NAME OF DRIVE
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
TURBINE TRIP PMO
from TPS
STA
PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
ON
CONTROL LOGIC DIAGRAM
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
LP-2 VACUUM BREAKER MOV EOP
OPEN OPS (TCS/DCS) DISPLAY
F
DI
LP-2 VACUUM BREAKER MOV ECL
CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
LP-2 VACUUM BREAKER MOV CLC CLC CLL
CLL
OPEN TRQ OVER OPEN
LP-2 VACUUM BREAKER VALVE OPENED TO T3D1A, D1B CLL CLOSE OPM
ETQ T3D3 PERMIT
TO Plant-DCS
DI 2 (via OPC)
LP-2 VACUUM BREAKER MOV OPE OPE
CLOSE TRQ OVER LP-2 VACUUM BREAKER CLOSE
TO AUTO AUTO CPM
VALVE CLOSED T3D2 PERMIT
DI 3
Plant-DCS E DM
(via OPC)
E LP-2 VACUUM BREAKER MOV EMT CLE CLE
ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
LP-2 VACUUM BREAKER MOV ELC DLA DLA
REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
AUTOMATIC COMMAND
TGP TAGGING PROHIBIT
TGP
DI
D LP-2 VACUUM BREAKER VALVE
OPEN COMMAND
From Plant-DCS AOC
LP-2 VACUUM BREAKER VALVE AUTO MODE T3D2 TO T3G1
AUTO
T1G10 TURBINE SPEED < 400 rpm 1 TO Plant-DCS (via OPC)
5
MOTOR POWER (AC/DC)
DI MVT
A TROUBLE
LP-2 VACUUM BREAKER VALVE ACC CONTROL POWER (AC/DC) V
CLOSE COMMAND
From Plant-DCS
LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
ASC
OFF
C SEATING TORQUE GEARED
OPT
PROTECTION COMMAND A OPEN TIME OVER
INCHING YES NO
OPD
OPEN DISCREPANCY POSITION TRANS YES NO
POC A
OFF
TAG No. 01MAC21AA701
CLQ
A CLOSE TORQUE OVER
OFF PCC NAME OF DRIVE
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
TURBINE TRIP PMO
from TPS
STA
PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
ON
CONTROL LOGIC DIAGRAM
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO OFF E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL ON
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
DSPRHTR SPRAY CV BYPASS EOP
MOV OPEN OPS (TCS/DCS) DISPLAY
F
DI
DSPRHTR SPRAY CV BYPASS ECL
MOV CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
DSPRHTR SPRAY CV BYPASSMOV CLC CLC CLL
CLL
OPEN TRQ OVER OPEN
CLL CLOSE OPM
ETQ PERMIT
DI
DSPRHTR SPRAY CV BYPASS OPE OPE
MOV CLOSE TRQ OVER CLOSE
AUTO AUTO CPM
PERMIT
DI E DM
E DSPRHTR SPRAY CV BYPASS EMT CLE CLE
MOV ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
DSPRHTR SPRAY CV BYPASS ELC DLA DLA
MOV REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
AUTOMATIC COMMAND
TGP TAGGING PROHIBIT
TGP
AOC
OFF
D
ACC
OFF
MOTOR POWER (AC/DC)
ASC
OFF
MVT
A TROUBLE
CONTROL POWER (AC/DC) V
PROTECTION COMMAND
LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
T1G2 CONDENSER VACUUM < -0.863 kg/cm2
C 6
SEATING TORQUE GEARED
POC
OFF
DI OPT
GLAND STEAM ISOL MOV (CRH) A OPEN TIME OVER
INCHING YES NO
CLOSED
From Plant-DCS
DI PCC OPD
OPEN DISCREPANCY POSITION TRANS YES NO
GLAND STEAM ISOL MOV (AUX A
STM) CLOSED
From Plant-DCS TAG No. 01MAW11AA702
DI CLQ
A CLOSE TORQUE OVER
ALL CP STOPPED NAME OF DRIVE
From Plant-DCS
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
PMO
ON
STA
PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
ON
CONTROL LOGIC DIAGRAM
A
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8 7 6 5 4 3 2 1
T4 – TURBINE STEAM & DRAIN
D
TITLE:
TURBINE STEAM & DRAIN
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T4 F
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8 7 6 5 4 3 2 1
D1 MAIN STEAM LEAD PIPE DRAIN MOTOR VALVE 01MAL02AA902
D2 HP TURBINE INNER CASING DRAIN MOTOR VALVE 01MAL03AA902
H
D3 HP TURBINE OUTER CASING DRAIN MOTOR VALVE 01MAL03AA904
D4 REHEAT STEAM INLET PIPE DRAIN MOTOR VALVE 01MAL06AA902
D5 HP STEM LEAK RECOVERY MOTOR VALVE 01MAM30AA701
D6 HP STEM LEAK BLOW OFF MOTOR VALVE 01MAM30AA901
D7 RSV (A) EQUALIZING ON-OFF VALVE 01MAB02AA751
D8 RSV (B) EQUALIZING ON-OFF VALVE 01MAB02AA752
D9 TURBINE EXHAUST HOOD SPRAY WATER ON-OFF VALVE 01LCE01AA751
G
D10 VENTILATOR VALVE 01LBC01AA710
LP
(1) TURBINE (2)
HP/IP TURBINE
D2
M
TO D9
F CONDENSER
FROM
CONDENSATE PUMP
D3
M ICV (#1)
TO
CONDENSER
RSV (A)
ICV (#2) D7
E
S
CONDENSER-1 CONDENSER-2 D4
M ICV (#3)
FROM REHEAT STEAM
TO HP MANIFOLD
TO REHEATER
RSV (B)
D ICV (#4) D8
D10
M S
TO HP MANIFOLD
D5
MSV & GV (A) MSV & GV (B)
FROM
CONDENSATE M
PUMP OUTLET
TO NO.6 ECT
C
FROM MAIN STEAM
D1 M
M
D6
TO HP MANIFOLD
TO BLOWDOWN TITLE:
TANK TURBINE STEAM & DRAIN SYSTEM
B SIMPLIFIED P&I DIAGRAM
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T4 01 F
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8 7 6 5 4 3 2 1
T4
H TURBINE STEAM &
DRAIN
Tag no.
Sht. No.
GROUP T4G1, T4G2, T4G3
LEVEL
(G)
BY PLANT-DCS
G
SUB GROUP
E LEVEL
(SG)
C DRIVE
LEVEL
(D) 01MAL02AA902 01MAL03AA902 01MAL03AA904 01MAL06AA902 01MAM30AA701 01MAM30AA901 01MAB02AA751 01MAB02AA752 01LCE01AA751 01LBC01AA710 01LBC01AA908 01LBC01AA904 01LBC01AA910 01LCA25AA081
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T4 02 F
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-III
for OPS operation OPS (TCS/DCS) DISPLAY
OPERATION selection logic
ON
ONM
PERMIT
ON P.B. PBO ONP ON PERMIT
H ON ONM
OFF
OFM
PERMIT
OFF P.B. PBF OFP OFF PERMIT
OFF OFM
AUTO
APM
PERMIT
PBR ATP AUTO PERMIT
OFF APM
AUTO
ABP
BYPASS
AUTO BYPASS P.B. PBAB ABP AUTO BYPASS
AUTO BYP ABP
G POPM
PRE-OPE
PERMIT
PBPO
OFF
E
ON
POP PRE-OPE PERMIT POP ONMD
MODE
PBA M
OFF
OFF
OFMD
MODE
PBT PBP
ON D
DLA ABNORMAL
F AUTOMATIC COMMAND
AOC AUT
OFF D
AFC
OFF
OUT
AUTOMATIC CONDITION D
E TURBINE STEAM & DRAIN GROUP ON MODE T4G1
MAIN STEAM LEAD PIPE DRAIN MOTOR VALVE AUTO TO T4G2, T4G3
T4D1 1
1
ONM GL ON MODE ONM
D
T4D2 HP TURBINE INNER CASING DRAIN MOTOR VALVE AUTO EVNT
1
T4D3 HP TURBINE OUTER CASING DRAIN MOTOR VALVE AUTO E
1 OFM GL OFF MODE OFM
D
T4D4 REHEAT STEAM INLET PIPE DRAIN MOTOR VALVE AUTO
D 1
E
T4D5 HP STEM LEAK RECOVERY MOTOR VALVE AUTO
1
PAT
A
T4D6 HP STEM LEAK BLOW OFF MOTOR VALVE AUTO ABN ABNORMAL
DLA
1
T4D7 RSV (A) EQUALIZING VALVE AUTO
C 14 RESET
ONM EON AVAILABLE
RSA
D
T4D8 RSV (B) EQUALIZING VALVE AUTO
1
PPO
ON
TAGNAME:
T4D9 TURBINE EXHAUST HOOD SPRAY WATER ON-OFF VALVE AUTO
1
TITLE:
T4D10 VENTILATOR VALVE AUTO
1
PERMISSIVE CONDITION
B DI
HP TURBINE EXHAUST LH DRAIN PPM
VALVE AUTO MODE
ON
From Plant-DCS JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
DI
HP TURBINE EXHAUST RH DRAIN
VALVE AUTO MODE
From Plant-DCS SLF
OFF TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 T4 G1 F
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8 7 6 5 4 3 2 1
H T4G1 TURBINE STEAM & DRAIN GROUP ON MODE
1
MAIN STEAM LEAD PIPE DRAIN MOTOR VALVE AUTO OPEN COMMAND T4G2 TO T4D1
1
< 15 % 3 sec
GENERATOR MW
From TCS (61140-1001 sh.2) L HP TURBINE INNER CASING DRAIN MOTOR VALVE AUTO OPEN COMMAND T4G2 TO T4D2
2
G HP TURBINE OUTER CASING DRAIN MOTOR VALVE AUTO OPEN COMMAND T4G2 TO T4D3
3
REHEAT STEAM INLET PIPE DRAIN MOTOR VALVE AUTO OPEN COMMAND T4G2 TO T4D4
4
HP STEM LEAK RECOVERY MOTOR VALVE AUTO CLOSE COMMAND T4G2 TO T4D5
9
F
HP STEM LEAK BLOW OFF MOTOR VALVE AUTO OPEN COMMAND T4G2 TO T4D6
12
MAIN STEAM LEAD PIPE DRAIN MOTOR VALVE AUTO CLOSE COMMAND T4G2 TO T4D1
5
> 20 % 3 sec
E H HP TURBINE INNER CASING DRAIN MOTOR VALVE AUTO CLOSE COMMAND T4G2 TO T4D2
6
HP TURBINE OUTER CASING DRAIN MOTOR VALVE AUTO CLOSE COMMAND T4G2 TO T4D3
7
REHEAT STEAM INLET PIPE DRAIN MOTOR VALVE AUTO CLOSE COMMAND T4G2 TO T4D4
8
D
HP STEM LEAK RECOVERY MOTOR VALVE AUTO OPEN COMMAND T4G2 TO T4D5
10
HP STEM LEAK BLOW OFF MOTOR VALVE AUTO CLOSE COMMAND T4G2 TO T4D6
11
TURBINE STEAM & DRAIN GROUP ON MODE T4G2 TO Plant-DCS
14 (via OPC)
C
> 10 %
GENERATOR LOAD > 10% T4G2
H 13
TO T4D10
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 T4 G2 F
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8 7 6 5 4 3 2 1
H T4G1 TURBINE STEAM & DRAIN GROUP ON MODE
1
RSV (A) EQUALIZING VALVE AUTO OPEN COMMAND T4G3 TO T4D7
5 sec 3
TURBINE RESET COMMAND
From TCS
DI
RSV (LH) FULL OPENED
01MAB02CG201
G RSV (B) EQUALIZING VALVE AUTO OPEN COMMAND T4G3 TO T4D8
4
DI
RSV (RH) FULL OPENED
01MAB02CG251
RSV (A) EQUALIZING VALVE AUTO CLOSE COMMAND T4G3 TO T4D7
5
F
TURBINE TRIP
from TPS
> 80 ℃
RSV (B) EQUALIZING VALVE AUTO CLOSE COMMAND T4G3
H/ TO T4D8
6
A HIGH ALARM
> 80 ℃
H/
E
AI > 70 ℃
LP-1 TURBINE EXHAUST STEAM TURBINE EXHAUST HOOD SPRAY WATER ON-OFF VALVE AUTO OPEN COMMAND T4G3
TEMP. H/ TO T4D9
7
01MAC11CT001/002/051
AI > 70 ℃
LP-2 TURBINE EXHAUST STEAM
TEMP. H/
01MAC21CT001/002/051
60 sec
D TURBINE EXHAUST HOOD SPRAY WATER ON-OFF VALVE AUTO CLOSE COMMAND T4G3 TO T4D9
8
60 sec
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 T4 G3 F
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
MAIN STEAM LEAD PIPE DRAIN EOP
MOV OPEN OPS (TCS/DCS) DISPLAY
F
DI
MAIN STEAM LEAD PIPE DRAIN ECL
MOV CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
MAIN STEAM LEAD PIPE DRAIN CLC CLC CLL
CLL
MOV OPEN TRQ OVER OPEN
CLL CLOSE OPM
ETQ PERMIT
DI
MAIN STEAM LEAD PIPE DRAIN OPE OPE
MOV CLOSE TRQ OVER CLOSE
TO AUTO AUTO CPM
CLOSED T4D1 PERMIT
Plant-DCS E
DI 2 (via OPC)
DM
E MAIN STEAM LEAD PIPE DRAIN EMT CLE CLE
MOV ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
MAIN STEAM LEAD PIPE DRAIN ELC DLA DLA
MOV REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
TGP TAGGING PROHIBIT
AUTOMATIC COMMAND TGP
D
T4G2 MAIN STEAM LEAD PIPE DRAIN MOTOR VALVE AUTO OPEN COMMAND AOC MAIN STEAM LEAD PIPE DRAIN MOTOR VALVE AUTO T4D1
AUTO TO T4G1
1 1
MOTOR POWER (AC/DC)
T4G2 MAIN STEAM LEAD PIPE DRAIN MOTOR VALVE AUTO CLOSE COMMAND ACC
5 MVT
A TROUBLE
CONTROL POWER (AC/DC) V
ASC
OFF LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
C PROTECTION COMMAND SEATING TORQUE GEARED
OPT
A OPEN TIME OVER
INCHING YES NO
TURBINE TRIP POC
OPD
OPEN DISCREPANCY POSITION TRANS YES NO
from TPS A
OFF PCC TAG No. 01MAL02AA902
CLQ
A CLOSE TORQUE OVER
NAME OF DRIVE
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
PMO A CLOSE DISCREPANCY
ON
STA
PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
ON
CONTROL LOGIC DIAGRAM
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
HP TURBINE INNER CASING DRAIN EOP
MOV OPEN OPS (TCS/DCS) DISPLAY
F
DI
HP TURBINE INNER CASING DRAIN ECL
MOV CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
HP TURBINE INNER CASING DRAIN CLC CLC CLL
CLL
MOV OPEN TRQ OVER OPEN
CLL CLOSE OPM
ETQ PERMIT
DI
HP TURBINE INNER CASING DRAIN OPE OPE
MOV CLOSE TRQ OVER CLOSE
TO AUTO AUTO CPM
CLOSED T4D2 PERMIT
Plant-DCS E
DI 2 (via OPC)
DM
E HP TURBINE INNER CASING DRAIN EMT CLE CLE
MOV ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
HP TURBINE INNER CASING DRAIN ELC DLA DLA
MOV REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
TGP TAGGING PROHIBIT
AUTOMATIC COMMAND TGP
D
T4G2 HP TURBINE INNER CASING DRAIN MOTOR VALVE AUTO OPEN COMMAND AOC HP TURBINE INNER CASING DRAIN MOTOR VALVE AUTO T4D2
AUTO TO T4G1
2 1
MOTOR POWER (AC/DC)
T4G2 HP TURBINE INNER CASING DRAIN MOTOR VALVE AUTO CLOSE COMMAND ACC
6 MVT
A TROUBLE
CONTROL POWER (AC/DC) V
ASC
OFF LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
C PROTECTION COMMAND SEATING TORQUE GEARED
OPT
A OPEN TIME OVER
INCHING YES NO
TURBINE TRIP POC
OPD
OPEN DISCREPANCY POSITION TRANS YES NO
from TPS A
OFF
PCC TAG No. 01MAL03AA902
CLQ
A CLOSE TORQUE OVER
NAME OF DRIVE
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
PMO
ON
STA
PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
ON
CONTROL LOGIC DIAGRAM
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
HP TURBINE OUTER CASING EOP
DRAIN MOV OPEN OPS (TCS/DCS) DISPLAY
F
DI
HP TURBINE OUTER CASING ECL
DRAIN MOV CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
HP TURBINE OUTER CASING CLC CLC CLL
CLL
DRAIN MOV OPEN TRQ OVER OPEN
CLL CLOSE OPM
ETQ PERMIT
DI
HP TURBINE OUTER CASING OPE OPE
DRAIN MOV CLOSE TRQ OVER CLOSE
TO AUTO AUTO CPM
CLOSED T4D3 PERMIT
Plant-DCS E
DI 2 (via OPC)
DM
E HP TURBINE OUTER CASING EMT CLE CLE
DRAIN MOV ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
HP TURBINE OUTER CASING ELC DLA DLA
DRAIN MOV REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
TGP TAGGING PROHIBIT
AUTOMATIC COMMAND TGP
D
T4G2 HP TURBINE OUTER CASING DRAIN MOTOR VALVE AUTO OPEN COMMAND AOC HP TURBINE OUTER CASING DRAIN MOTOR VALVE AUTO T4D3
AUTO TO T4G1
3 1
MOTOR POWER (AC/DC)
T4G2 HP TURBINE OUTER CASING DRAIN MOTOR VALVE AUTO CLOSE COMMAND ACC
7 MVT
A TROUBLE
CONTROL POWER (AC/DC) V
ASC
OFF LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
C PROTECTION COMMAND SEATING TORQUE GEARED
OPT
A OPEN TIME OVER
INCHING YES NO
TURBINE TRIP POC
OPD
OPEN DISCREPANCY POSITION TRANS YES NO
from TPS A
OFF
PCC TAG No. 01MAL03AA904
CLQ
A CLOSE TORQUE OVER
NAME OF DRIVE
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
PMO
ON
STA
PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
ON
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T4 D3 F
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LTSL-M0-00951 REV 0 Page 512 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
REHEAT STEAM PIPE DRAIN MOV EOP
OPEN OPS (TCS/DCS) DISPLAY
F
DI
REHEAT STEAM PIPE DRAIN MOV ECL
CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
REHEAT STEAM PIPE DRAIN MOV CLC CLC CLL
CLL
OPEN TRQ OVER OPEN
CLL CLOSE OPM
ETQ PERMIT
DI
REHEAT STEAM PIPE DRAIN MOV OPE OPE
CLOSE TRQ OVER CLOSE
TO AUTO AUTO CPM
CLOSED T4D4 PERMIT
Plant-DCS E
DI 2 (via OPC)
DM
E REHEAT STEAM PIPE DRAIN MOV EMT CLE CLE
ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
REHEAT STEAM PIPE DRAIN MOV ELC DLA DLA
REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
TGP TAGGING PROHIBIT
AUTOMATIC COMMAND TGP
D
T4G2 REHEAT STEAM INLET PIPE DRAIN MOTOR VALVE AUTO OPEN COMMAND AOC REHEAT STEAM INLET PIPE DRAIN MOTOR VALVE AUTO T4D4
AUTO TO T4G1
4 1
MOTOR POWER (AC/DC)
T4G2 REHEAT STEAM INLET PIPE DRAIN MOTOR VALVE AUTO CLOSE COMMAND ACC
8 MVT
A TROUBLE
CONTROL POWER (AC/DC) V
ASC
OFF LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
C PROTECTION COMMAND SEATING TORQUE GEARED
OPT
A OPEN TIME OVER
INCHING YES NO
TURBINE TRIP POC
OPD
OPEN DISCREPANCY POSITION TRANS YES NO
from TPS A
OFF
PCC TAG No. 01MAL06AA902
CLQ
A CLOSE TORQUE OVER
NAME OF DRIVE
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
PMO
ON
STA
PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
ON
CONTROL LOGIC DIAGRAM
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
HP STEM LEAK RECOVERY MOV EOP
OPEN OPS (TCS/DCS) DISPLAY
F
DI
HP STEM LEAK RECOVERY MOV ECL
CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
HP STEM LEAK RECOVERY MOV CLC CLC CLL
CLL
OPEN TRQ OVER OPEN
CLL CLOSE OPM
ETQ HP STEM LEAK RECOVERY T4D5 PERMIT
TO T4D6
DI MOTOR VALVE OPENED 2
HP STEM LEAK RECOVERY MOV OPE OPE
CLOSE TRQ OVER CLOSE
AUTO AUTO CPM
PERMIT
DI E DM
E HP STEM LEAK RECOVERY MOV EMT CLE CLE
ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
HP STEM LEAK RECOVERY MOV ELC DLA DLA
REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
TGP TAGGING PROHIBIT
AUTOMATIC COMMAND TGP
D
T4G2 HP STEM LEAK RECOVERY MOTOR VALVE AUTO OPEN COMMAND AOC HP STEM LEAK RECOVERY MOTOR VALVE AUTO T4D5
AUTO TO T4G1
10 1
MOTOR POWER (AC/DC)
T4G2 HP STEM LEAK RECOVERY MOTOR VALVE AUTO CLOSE COMMAND ACC
9 MVT
A TROUBLE
CONTROL POWER (AC/DC) V
ASC
OFF LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
C PROTECTION COMMAND SEATING TORQUE GEARED
OPT
A OPEN TIME OVER
INCHING YES NO
POC
OFF
OPD
OPEN DISCREPANCY POSITION TRANS YES NO
A
OFF
PCC TAG No. 01MAM30AA701
CLQ
A CLOSE TORQUE OVER
NAME OF DRIVE
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
PMO
ON
STA
T4D6 HP STEM LEAK BLOW OFF MOTOR VALVE OPENED PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
2 CONTROL LOGIC DIAGRAM
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
HP STEM LEAK BLOW OFF MOV EOP
OPEN OPS (TCS/DCS) DISPLAY
F
DI
HP STEM LEAK BLOW OFF MOV ECL
CLOSE OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
HP STEM LEAK BLOW OFF MOV CLC CLC CLL
CLL
OPEN TRQ OVER OPEN
CLL CLOSE OPM
ETQ HP STEM LEAK BLOW OFF MOTOR T4D6 PERMIT
TO T4D5
DI VALVE OPENED 2
HP STEM LEAK BLOW OFF MOV OPE OPE
CLOSE TRQ OVER CLOSE
AUTO AUTO CPM
PERMIT
DI E DM
E HP STEM LEAK BLOW OFF MOV EMT CLE CLE
ACTUATOR TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
HP STEM LEAK BLOW OFF MOV ELC DLA DLA
REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
TGP TAGGING PROHIBIT
AUTOMATIC COMMAND TGP
D
T4G2 HP STEM LEAK BLOW OFF MOTOR VALVE AUTO OPEN COMMAND AOC HP STEM LEAK BLOW OFF MOTOR VALVE AUTO T4D6
AUTO TO T4G1
12 1
MOTOR POWER (AC/DC)
T4G2 HP STEM LEAK BLOW OFF MOTOR VALVE AUTO CLOSE COMMAND ACC
11 MVT
A TROUBLE
CONTROL POWER (AC/DC) V
ASC
OFF LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
C PROTECTION COMMAND SEATING TORQUE GEARED
OPT
A OPEN TIME OVER
INCHING YES NO
POC
OFF
OPD
OPEN DISCREPANCY POSITION TRANS YES NO
A
OFF
PCC TAG No. 01MAM30AA901
CLQ
A CLOSE TORQUE OVER
NAME OF DRIVE
B CLT
CLOSE TIME OVER
A
PERMISSIVE CONDITION JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
PMO
ON
STA
T4D5 HP STEM LEAK RECOVERY MOTOR VALVE OPENED PMC A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
2 CONTROL LOGIC DIAGRAM
A
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LTSL-M0-00951 REV 0 Page 515 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H DO 01MAB02AA751-Y01
OPEN COMMAND ENERGIZED OPEN
CLOSE P.B. PBC
CLOSE
DE-ENERGIZED CLOSE
RESET P.B. PBR OPC OPL
RESET OPL
AUTO P.B. PBA OPC CLC CLL
AUTO CLL
E
G
MANUAL P.B. PBM OPE OPE
MANUAL
E DM
TAGGING P.B. TAG CLE CLE
TAGGING
DRIVE ABNORMAL
DLA
LOCAL DLA
RESET AVAILABLE
RSA
DI
RSV (A) EQUALIZING VALVE OPEN
EOP RSA OPS (TCS/DCS) DISPLAY
F
01MAB02CG203
OPL OPEN DLA ABNORMAL
DI
RSV (A) EQUALIZING VALVE ECL
CLOSE
01MAB02CG203 OPEN
CLL CLOSE OPM
PERMIT
OPP OPEN PERMIT
OPM
CLOSE
AUTO AUTO CPM
PERMIT
E
CLP CLOSE PERMIT
CPM MAN MAN TGP TAGGING
SSVO AUT AUTO MODE
AUTO
RSA RESET
AUTOMATIC COMMAND RSV (A) EQUALIZING VALVE AUTO T4D7 TO T4G1
1
MAN MANUAL MODE
MAN
T4G3 RSV (A) EQUALIZING VALVE AUTO OPEN COMMAND AOC
D 3
TGP TAGGING PROHIBIT
TGP
T4G3 RSV (A) EQUALIZING VALVE AUTO CLOSE COMMAND ACC
5
POWER FOR
(AC/DC)
SOLENOID VALVE
PROTECTION COMMAND
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
POC ON-OFF
OFF
VALVES
AIR TO OPEN CLOSE
TAG No. 01MAB02AA751
PCC
OFF
OPT OPEN TIME OVER
A
NAME OF DRIVE
PERMISSIVE CONDITION OPD
A OPEN DISCREPANCY
B
PMO CLT JAYPEE NIGRIE/ 2 x 700MW
ON A CLOSE TIME OVER
POWER PLANT/ Steam Turbine
CLD CLOSE DISCREPANCY
A
PMC
TURBINE AUXILIARY MACHINE
ON
STA
CONTROL LOGIC DIAGRAM
A STATUS ABNORMAL
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H DO 01MAB02AA752-Y01
OPEN COMMAND ENERGIZED OPEN
CLOSE P.B. PBC
CLOSE
DE-ENERGIZED CLOSE
RESET P.B. PBR OPC OPL
RESET OPL
AUTO P.B. PBA OPC CLC CLL
AUTO CLL
E
G
MANUAL P.B. PBM OPE OPE
MANUAL
E DM
TAGGING P.B. TAG CLE CLE
TAGGING
DRIVE ABNORMAL
DLA
LOCAL DLA
RESET AVAILABLE
RSA
DI
RSV (B) EQUALIZING VALVE OPEN
EOP RSA OPS (TCS/DCS) DISPLAY
F
01MAB02CG204
OPL OPEN DLA ABNORMAL
DI
RSV (B) EQUALIZING VALVE ECL
CLOSE
01MAB02CG204 OPEN
CLL CLOSE OPM
PERMIT
OPP OPEN PERMIT
OPM
CLOSE
AUTO AUTO CPM
PERMIT
E
CLP CLOSE PERMIT
CPM MAN MAN TGP TAGGING
SSVO AUT AUTO MODE
AUTO
RSA RESET
AUTOMATIC COMMAND RSV (B) EQUALIZING VALVE AUTO T4D8 TO T4G1
1
MAN MANUAL MODE
MAN
T4G3 RSV (B) EQUALIZING VALVE AUTO OPEN COMMAND AOC
D 4
TGP TAGGING PROHIBIT
TGP
T4G3 RSV (B) EQUALIZING VALVE AUTO CLOSE COMMAND ACC
6
POWER FOR
(AC/DC)
SOLENOID VALVE
PROTECTION COMMAND
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
POC ON-OFF
OFF
VALVES
AIR TO OPEN CLOSE
TAG No. 01MAB02AA752
PCC
OFF
OPT OPEN TIME OVER
A
NAME OF DRIVE
PERMISSIVE CONDITION OPD
A OPEN DISCREPANCY
B
PMO CLT JAYPEE NIGRIE/ 2 x 700MW
ON A CLOSE TIME OVER
POWER PLANT/ Steam Turbine
CLD CLOSE DISCREPANCY
A
PMC
TURBINE AUXILIARY MACHINE
ON
STA
CONTROL LOGIC DIAGRAM
A STATUS ABNORMAL
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H DO 01LCE01AA751-Y01
CLOSE COMMAND DE-ENERGIZED OPEN
CLOSE P.B. PBC
CLOSE
ENERGIZED CLOSE
RESET P.B. PBR OPC OPL
RESET OPL
AUTO P.B. PBA CLC CLC CLL
AUTO CLL
E
G
MANUAL P.B. PBM OPE OPE
MANUAL
E DM
TAGGING P.B. TAG CLE CLE
TAGGING
DRIVE ABNORMAL
DLA
LOCAL DLA DLA
RESET AVAILABLE
RSA
DI
EXHAUST HOOD SPRAY EOP RSA RSA OPS (TCS/DCS) DISPLAY
F ON-OFF VALVE OPEN
01LCE01CG201
DRIVE
OPL OPEN DLA
DI ABN.
EXHAUST HOOD SPRAY ECL
ON-OFF VALVE CLOSE
01LCE01CG201 OPEN
CLL CLOSE OPM
PERMIT
OPP OPEN PERMIT
OPM
CLOSE
AUTO AUTO CPM
PERMIT
E
CLP CLOSE PERMIT
CPM MAN MAN TGP TAGGING
SSVC AUT AUTO MODE
AUTO
RSA RESET
AUTOMATIC COMMAND TURBINE EXHAUST HOOD SPRAY WATER ON-OFF VALVE AUTO T4D9 TO T4G1
1
MAN MANUAL MODE
MAN
T4G3 TURBINE EXHAUST HOOD SPRAY WATER ON-OFF VALVE AUTO OPEN COMMAND AOC
D 7
TGP TAGGING PROHIBIT
TGP
T4G3 TURBINE EXHAUST HOOD SPRAY WATER ON-OFF VALVE AUTO CLOSE COMMAND ACC
8
POWER FOR
(AC/DC)
SOLENOID VALVE
PROTECTION COMMAND
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
POC ON-OFF
OFF
VALVES
AIR TO OPEN CLOSE
TAG No. 01LCE01AA751
PCC
OFF
OPT OPEN TIME OVER
A
NAME OF DRIVE
PERMISSIVE CONDITION OPD
A OPEN DISCREPANCY
B
PMO CLT JAYPEE NIGRIE/ 2 x 700MW
ON A CLOSE TIME OVER
POWER PLANT/ Steam Turbine
CLD CLOSE DISCREPANCY
A
PMC
TURBINE AUXILIARY MACHINE
ON
STA
CONTROL LOGIC DIAGRAM
A STATUS ABNORMAL
A
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8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation LOCAL
OPERATION selection logic.
OPEN P.B. PBO
OPEN
H OPP OPEN PERMIT
OPM
PBS
OFF DO
OPEN COMMAND
CLOSE P.B. PBC CLP CLOSE PERMIT
CLOSE CPM
RESET P.B. PBR
RESET STP
AUTO P.B. PBA DO
AUTO OFF E
CLOSE COMMAND
AUT AUTO MODE
AUTO
G MANUAL P.B. PBM
MANUAL ON
E
TAGGING P.B. TAG MAN MANUAL MODE
TAGGING MAN
REM REMOTE MODE
REM
LOCAL
DI LOC LOCAL MODE
LOC
EOP
VENTILATOR MOV OPEN
OPS (TCS/DCS) DISPLAY
F
DI
ECL
VENTILATOR MOV CLOSE
OPC OPC OPL
OPL OPL OPEN DLA ABNORMAL
DI
VENTILATOR MOV OPEN TRQ CLC CLC CLL
CLL
OVER OPEN
CLL CLOSE OPM
ETQ PERMIT
DI
VENTILATOR MOV CLOSE TRQ OPE OPE
OVER CLOSE
AUTO AUTO CPM
PERMIT
DI E DM
E VENTILATOR MOV ACTUATOR EMT CLE CLE
TRBL
MAN MAN REM REMOTE
DRIVE ABNORMAL
FLT DLA E
DI
ELC DLA DLA
VENTILATOR MOV REMOTE MODE
MOV RESET AVAILABLE
RSA
RSA RESET LOC LOCAL
RSA RSA
TAGGING
TGP
PROHIBIT
AUTOMATIC COMMAND
AOC TGP TAGGING PROHIBIT
GENERATOR LOAD > 10% OFF TGP
T4G2
D 13
ACC
TURBINE TRIP VENTILATOR VALVE AUTO T4D10
LOW AUTO TO T4G1
from TPS ASC 1
OFF
475 degC
H/ MOTOR POWER (AC/DC)
MVT
PROTECTION COMMAND 475 degC A HIGH ALARM A TROUBLE
CONTROL POWER (AC/DC) V
H/
LOCAL OPE. YES NO
OTHERS
OPQ
A OPEN TORQUE OVER
AI 460 degC
C HP TURBINE EXHAUST STEAM
H/ SEATING TORQUE GEARED
TEMP (LH)
01LBC01CT003 OPT
AI 460 degC
S 5 sec A OPEN TIME OVER
INCHING YES NO
HP TURBINE EXHAUST STEAM POC
TEMP (RH)
H/ R
01LBC01CT051 OPD
OPEN DISCREPANCY POSITION TRANS YES NO
420 degC A
/L TAG No. 01LBC01AA710
CLQ
LOW A CLOSE TORQUE OVER
420 degC NAME OF DRIVE
/L A LOW ALARM
B CLT
CLOSE TIME OVER
T1G2 CONDENSER VACUUM < -0.863 kg/cm2 PCC A
6
JAYPEE NIGRIE/ 2 x 700MW
CLD POWER PLANT/ Steam Turbine
A CLOSE DISCREPANCY
DI 5 sec 300 sec
VENTILATOR VALVE OUTLET PERMISSIVE CONDITION
SPRAY CV FULL CLOSED STA
From Plant-DCS PMO A STATUS ABNORMAL TURBINE AUXILIARY MACHINE
ON
CONTROL LOGIC DIAGRAM
CLL
PMC
ON
A
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LTSL-M0-00951 REV 0 Page 519 of 860
8 7 6 5 4 3 2 1
T5 – LP HEATER & EXTRACTION
D
TITLE:
LP HEATER & EXTRACTION
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T5 F
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LTSL-M0-00951 REV 0 Page 520 of 860
8 7 6 5 4 3 2 1
D1 No. 3 EXTRACTION STEAM NON-RETURN VALVE 01LBS03AA501
H D2 No. 4 EXTRACTION STEAM NON-RETURN VALVE 01LBS04AA501
D3 No. 5 EXTRACTION STEAM NON-RETURN VALVE (A) 01LBQ01AA501
D4 No. 5 EXTRACTION STEAM NON-RETURN VALVE (B) 01LBQ01AA502
D5 No. 5 EXTRACTION STEAM NON-RETURN VALVE (C) (TO BFPT) 01LBD60AA055
F
HP-IP TURBINE LP-1 TURBINE LP-2 TURBINE
E
D2
TO
NO.4 HEATER
D D1
D4 D3 TO
NO.3 HEATER
TO
NO.5 HEATER
(DEAERATOR)
D5
C
TO BFPT
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T5 01 F
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LTSL-M0-00951 REV 0 Page 521 of 860
8 7 6 5 4 3 2 1
(LP HEATER &
H
EXTRACTION GROUP
BY PLANT-DCS)
GROUP
LEVEL
(G)
SUB GROUP
E LEVEL
(SG)
C DRIVE
LEVEL
(D) 01LBS03AA501 01LBS04AA501 01LBQ01AA501 01LBQ01AA502 LATER
D1 D2 D3 D4 D5
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T5 02 F
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LTSL-M0-00951 REV 0 Page 522 of 860
8 7 6 5 4 3 2 1
LOCAL
DI
H No.3 FEED WATER HEATER LEVEL
HIGH HIGH
From Plant-DCS
01LBS03AA501-Y01
No.3 EXTR. STEAM NON-RETURN AC240V
ENERGIZED FREE
VALVE ENERGIZE COMMAND
TURBINE TRIP
DE-ENERGIZED CLOSE
From TPS
DI
PARALLEL OPERATION (S/S CB
CLOSE)
From TCS (61140-1001 sh.4) E
G LP NRV CLOSE COMMAND T5D1 LATER
TO T5D2, T5D3, T5D4
1 No.3 EXTRACTION STEAM NON-
< 12 % 3 sec OPL
RETURN VALVE OPENED
GENERATOR MW
From TCS (61140-1001 sh.2) L LATER
No.3 EXTRACTION STEAM NON-
CLL
RETURN VALVE CLOSED
HP NRV CLOSE COMMAND T5D1
2
TO T6D3, T6D4, T6D5
OPS (TCS/DCS) DISPLAY
F
< 16 % 3 sec
L OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBS03AA501
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T5 D1 F
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8 7 6 5 4 3 2 1
LOCAL
DI
H No.4 FEED WATER HEATER LEVEL
HIGH
DCSHIGH
(SIC)
From Plant-DCS
01LBS04AA501-Y01
No.4 EXTR STEAM NON-RETURN AC240V
ENERGIZED FREE
VALVE ENERGIZE COMMAND
DE-ENERGIZED CLOSE
T5D1 LP NRV CLOSE COMMAND
1
E
G LATER
No.4 EXTRACTION STEAM NON-
OPL
RETURN VALVE OPENED
LATER
No.4 EXTRACTION STEAM NON-
CLL
RETURN VALVE CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBS04AA501
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T5 D2 F
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8 7 6 5 4 3 2 1
LOCAL
DI
DEAERATOR
No.5 EXTRACTIONLEVEL HIGH
STEAM HIGH
NRV (A)
H CLOSE COMMAND
From Plant-DCS
01LBQ01AA501-Y01
No.5 EXTR. STEAM NON-RETURN AC240V
ENERGIZED FREE
VALVE (A) ENERGIZE COM
DE-ENERGIZED CLOSE
T5D1 LP NRV CLOSE COMMAND
1
E
G LATER
No.5 EXTRACTION STEAM NON-
OPL
RETURN VALVE (A) OPENED
LATER
No.5 EXTRACTION STEAM NON-
CLL
RETURN VALVE (A) CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBQ01AA501
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T5 D3 F
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8 7 6 5 4 3 2 1
LOCAL
DI
DEAERATOR LEVEL HIGH HIGH
H DEAERATOR LEVEL HIGH HIGH
From Plant-DCS
01LBQ01AA502-Y01
No.5 EXTR. STEAM NON-RETURN AC240V
ENERGIZED FREE
VALVE (B) ENERGIZE COM
DE-ENERGIZED CLOSE
T5D1 LP NRV CLOSE COMMAND
1
E
G LATER
No.5 EXTRACTION STEAM NON-
OPL
RETURN VALVE (B) OPENED
LATER
No.5 EXTRACTION STEAM NON-
CLL
RETURN VALVE (B) CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBQ01AA502
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T5 D4 F
04100-61000-1010 -76
LTSL-M0-00951 REV 0 Page 526 of 860
8 7 6 5 4 3 2 1
LOCAL
H
TURBINE TRIP
From TPS 01LBD60AA055-Y01
No.5 EXTR. STEAM NON-RETURN AC240V
ENERGIZED FREE
DI VALVE (C) ENERGIZE COM
BOTH BFPT INLET STM ISOL MV
DE-ENERGIZED CLOSE
CLOSE
From Plant-DCS
< 20 % 3 sec
GENERATOR MW
From TCS (61140-1001 sh.2) L E
G LATER
No.5 EXTRACTION STEAM NON-
OPL
RETURN VALVE (C) OPENED
LATER
No.5 EXTRACTION STEAM NON-
CLL
RETURN VALVE (C) CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBD60AA055
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T5 D5 F
04100-61000-1010 -77
LTSL-M0-00951 REV 0 Page 527 of 860
8 7 6 5 4 3 2 1
T6 – HP HEATER & EXTRACTION
D
TITLE:
HP HEATER & EXTRACTION
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T6 F
04100-61000-1010 -78
LTSL-M0-00951 REV 0 Page 528 of 860
8 7 6 5 4 3 2 1
D1 COLD REHEAT NON-RETURN VALVE (L.H.) 01LBC01AA501
H D2 COLD REHEAT NON-RETURN VALVE (R.H.) 01LBC01AA502
D3 No. 6 EXTRACTION STEAM NON-RETURN VALVE 01LBQ02AA501
D4 No. 7 EXTRACTION STEAM NON-RETURN VALVE 01LBQ03AA501
D5 No. 8 EXTRACTION STEAM NON-RETURN VALVE 01LBQ04AA501
G
HP-IP TURBINE
D5
TO
E NO.8 HEATER
D3
D
TO
NO.6 HEATER
C
D2 D1
TO
REHEATER TITLE:
D4 JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TO
NO.7 HEATER TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T6 01 F
04100-61000-1010 -79
LTSL-M0-00951 REV 0 Page 529 of 860
8 7 6 5 4 3 2 1
(HP HEATER &
H
EXTRACTION GROUP
BY PLANT-DCS)
GROUP
LEVEL
(G)
SUB GROUP
E LEVEL
(SG)
C DRIVE
LEVEL
(D) 01LBC01AA501 01LBC01AA502 01LBQ02AA501 01LBQ03AA501 01LBQ04AA501
D1 D2 D3 D4 D5
TITLE:
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T6 02 F
04100-61000-1010 -80
LTSL-M0-00951 REV 0 Page 530 of 860
8 7 6 5 4 3 2 1
LOCAL
H
ICV-RH FULL CLOSED
From TCS 01LBC01AA501-Y01
COLD REHEAT NON-RETURN AC240V
ENERGIZED FREE
VALVE (L.H.) ENERGIZE COMMAND
ICV-LH FULL CLOSED
DE-ENERGIZED CLOSE
From TCS
E
G LATER
COLD REHEAT NON-RETURN
OPL
VALVE (L.H.) OPENED
LATER
COLD REHEAT NON-RETURN
CLL
VALVE (L.H.) CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBC01AA501
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T6 D1 F
04100-61000-1010 -81
LTSL-M0-00951 REV 0 Page 531 of 860
8 7 6 5 4 3 2 1
LOCAL
H
ICV-RH FULL CLOSED
From TCS 01LBC01AA502-Y01
COLD REHEAT NON-RETURN AC240V
ENERGIZED FREE
VALVE (R.H.) ENERGIZE COMMAND
ICV-LH FULL CLOSED
DE-ENERGIZED CLOSE
From TCS
E
G LATER
COLD REHEAT NON-RETURN
OPL
VALVE (R.H.) OPENED
LATER
COLD REHEAT NON-RETURN
CLL
VALVE (R.H.) CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBC01AA502
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T6 D2 F
04100-61000-1010 -82
LTSL-M0-00951 REV 0 Page 532 of 860
8 7 6 5 4 3 2 1
LOCAL
DI
No.6 FEED WATER HEATER LEVEL
HIGH HIGH
H From Plant-DCS
01LBQ02AA501-Y01
No.6 EXTR. STEAM NON-RETURN AC240V
ENERGIZED FREE
VALVE ENERGIZE COMMAND
DE-ENERGIZED CLOSE
T5D1 HP NRV CLOSE COMMAND
2
E
G LATER
No.6 EXTRACTION STEAM NON-
OPL
RETURN VALVE OPENED
LATER
No.6 EXTRACTION STEAM NON-
CLL
RETURN VALVE CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBQ02AA501
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T6 D3 F
04100-61000-1010 -83
LTSL-M0-00951 REV 0 Page 533 of 860
8 7 6 5 4 3 2 1
LOCAL
DI
No.7 FEED WATER HEATER LEVEL
HIGH HIGH
H From Plant-DCS
01LBQ03AA501-Y01
No.7 EXTR. STEAM NON-RETURN AC240V
ENERGIZED FREE
VALVE ENERGIZE COMMAND
DE-ENERGIZED CLOSE
T5D1 HP NRV CLOSE COMMAND
2
E
G LATER
No.7 EXTRACTION STEAM NON-
OPL
RETURN VALVE OPENED
LATER
No.7 EXTRACTION STEAM NON-
CLL
RETURN VALVE CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBQ03AA501
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T6 D4 F
04100-61000-1010 -84
LTSL-M0-00951 REV 0 Page 534 of 860
8 7 6 5 4 3 2 1
LOCAL
DI
No.8 FEED WATER HEATER LEVEL
HIGH HIGH
H From Plant-DCS
01LBQ04AA501-Y01
No.8 EXTR. STEAM NON-RETURN AC240V
ENERGIZED FREE
VALVE ENERGIZE COMMAND
DE-ENERGIZED CLOSE
T5D1 HP NRV CLOSE COMMAND
2
E
G LATER
No.8 EXTRACTION STEAM NON-
OPL
RETURN VALVE OPENED
LATER
No.8 EXTRACTION STEAM NON-
CLL
RETURN VALVE CLOSED
OPS (TCS/DCS) DISPLAY
F
OPL OPEN
CLL CLOSE
POWER FOR
(AC/DC) 240 V
SOLENOID VALVE
POWER FAILURE LOCK YES NO
OTHERS
C SOLENOID SINGLE DUAL
ON-OFF
VALVES
AIR TO FREE CLOSE
TAG No. 01LBQ04AA501
NAME OF DRIVE
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 T6 D5 F
04100-61000-1010 -85
LTSL-M0-00951 REV 0 Page 535 of 860
8 7 6 5 4 3 2 1
TYPICAL LOGIC FOR GENERATOR AUXILIARIES
D
TITLE:
TYPICAL LOGIC FOR GENERATOR AUXILIARIES
B
JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
TURBINE AUXILIARY MACHINE
CONTROL LOGIC DIAGRAM
A
04100 61000 61000-1010 GA F
04100-61000-1010 -86
LTSL-M0-00951 REV 0 Page 536 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation PUMP LOCAL PANEL
OPERATION selection logic.
START P.B.
START DO
H
RUN COMMAND
AVL
DO
STOP P.B.
STOP STOP COMMAND
REMOTE
REM
PUMP LOCAL PANEL
DI
REMOTE SELECTED
OPS (TCS/DCS) DISPLAY
F
DI
ON RETURN RUN RUN
RUN START
E
1 sec STOP STOP
A STATUS ABNORMAL
MCC TRIP TRIP
E
E
DI MCC
STOP STOP AVL
OFF RETURN AVAILABLE
MOTOR TRIP
DI A REM REMOTE
MOTOR TRIP TRIP TRIP
DI
CONTROL AVAILABLE AVAILABLE AVL
D
TITLE:
TYPICAL LOGIC FOR GENERATOR AUXILIARIES 1/2
B
NOTES: JAYPEE NIGRIE/ 2 x 700MW
POWER PLANT/ Steam Turbine
1. THIS TYPICAL LOGIC IS APPLICABLE TO FOLLOWING PUMPS:
a. GENERATOR VAPOR EXTRACTOR
b. H2 SIDE SEAL OIL PUMP
c. GENERATOR GLAND SEAL FLOAT PUMP TURBINE AUXILIARY MACHINE
2. REFERENCE DRAWING: CONTROL LOGIC DIAGRAM
MELCO DWG. NO. 04100-EEJEZ2V683 (LOGIC DIAGRAM OF
A GENERATOR AUXILIARIES)
04100 61000 61000-1010 GA 01 F
04100-61000-1010 -87
LTSL-M0-00951 REV 0 Page 537 of 860
8 7 6 5 4 3 2 1
OPS (TCS/DCS) Refer to Sheet-IV
for OPS operation PUMP LOCAL PANEL
OPERATION selection logic.
START P.B.
START
H DO
RUN COMMAND
AVL
STOP P.B. DO
STOP
STOP COMMAND
REMOTE
REM
PUMP LOCAL PANEL
DI
LOCKED
OPS (TCS/DCS) DISPLAY
F
DI
REMOTE SELECTED
RUN START
DI E
ON RETURN RUN RUN
STOP STOP
DI
AUTO AUTO AUTO
SEE NOTE-2 TRIP TRIP
E
1 sec
MCC
MCC A STATUS ABNORMAL AVL
AVAILABLE
DI E
STOP STOP REM REMOTE
OFF RETURN
A MOTOR TRIP AUTO AUTO SEE NOTE-2
DI
MOTOR TRIP TRIP TRIP
D CUR XXX A
DI SEE NOTE-4
CONTROL AVAILABLE AVAILABLE AVL
AI
MOTOR CURRENT MOTOR CURRENT CUR
SEE NOTE-4
TITLE:
NOTES: TYPICAL LOGIC FOR GENERATOR AUXILIARIES 2/2
B
1. THIS TYPICAL LOGIC IS APPLICABLE TO FOLLOWING PUMPS:
a. AIR SIDE SEAL OIL PUMP-A JAYPEE NIGRIE/ 2 x 700MW
b. AIR SIDE SEAL OIL PUMP-B POWER PLANT/ Steam Turbine
c. EMERGENCY SEAL OIL PUMP
d. STATOR COIL COOLING WATER PUMP-A
e. STATOR COIL COOLING WATER PUMP-B
TURBINE AUXILIARY MACHINE
2. APPLICABLE ONLY FOR EMERGENCY SEAL OIL PUMP CONTROL LOGIC DIAGRAM
3. REFERENCE DRAWING:
A MELCO DWG. NO. 04100-EEJEZ2V683 (LOGIC DIAGRAM OF
GENERATOR AUXILIARIES) 04100 61000 61000-1010 GA 02 F
4. APPLICABLE ONLY FOR STATOR COIL COOLING WATER PUMP-A & B
04100-61000-1010 -88
LTSL-M0-00951 REV 0 Page 538 of 860
JAYPEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 MW
STEAM TURBINE GENERATOR & AUXILIARIES PACKAGE
OWNER:
JAIPRAKASH POWER VENTURES LIMITED
OWNER’S CONSULTANT:
DEVELOPMENT CONSULTANTS PRIVATE LIMITED
CONTRACTOR:
LARSEN & TOUBRO LIMITED
L&T’S CONSULTANT:
L&T-SARGENT & LUNDY LIMITED
SUPPLIER:
SIEMENS AG
L&T-S&L JOB NO.: L543000 PROJECT NO.: T209001
TITLE:
Control Concept FOR BFP DRIVE TURBINE
TOTAL NO. OF PAGES. : 5
DOC/DRG NO. : SIEG-I0-03661 REV: - 0
TOTAL NO. OF DRAWINGS. :
FOR INFORMATION
REVISION CERTIFICATION
REVISION
PREPARED REVIEWED APPROVED
NO.
NAME SIGN DATE NAME SIGN DATE NAME SIGN DATE
0 Standke 26.05.2011 Pflügl 26.05.2011 Pflügl 26.05.2011
LTSL-M0-00951 REV 0 Page 539 of 860
JAIPRAKASH POWER VENTURES LIMITED
JAYPEE NIGRIE SUPER THERMAL POWER
PROJECT, 2 x 660 MW L&T - S&L LIMITED
LARSEN & TOUBRO LIMITED
STEAM TURBINE GENERATOR Rev: 0
Control Concept FOR BFP DRIVE TURBINE
AND AUXILIARIES PACKAGE Date: 25.05.2011
Page: 2 of 5
SUPPLIER: Siemens
Revision Summary Sheet
Rev. Details / Description Date
LTSL-M0-00951 REV 0 Page 540 of 860
Control Concept for Jaypee Nigrie (48005-48008)
Boiler Feedwater Pump Drive Turbine (BFWP)
1. Basic control task:
Steam is supplied from three sources:
- Main steam (max 12,25 kg/cm2)
- Alternate steam -CRH steam (max 58 kg/cm2 )
- Auxiliary steam (max 15,2 kg/cm2)
Four control valves are used for speed control:
- CRH control valve
- Turbine control valve
- Startup control valve
- Bypass control valve
2. Description of actuation of the control valves by the W505 Enhanced speed governor
Two W505 controllers are utilized in master-slave / hot backup function.
There are three controller manipulated variables which are coupled in split-range mode in the Woodward governor.
- 1st controller manipulated variable is acting upon the startup control valve and the turbine control valve via
an IP converter and a staggered hydraulic characteristic of the two valves
- 2nd controller manipulated variable (open-loop analog output, free, 600 Ohm): Actuation of the bypass control
valve via an I/P converter
the bypass valve must be opened/closed via a ramp as a function of controller output 1 (position CRH
control valve > 2%; relay in the W505, level switch actuator 2, % value is freely adjustable) or as a function
of differential pressure across the drum (XAA15CP910 – XAA25CP910)
- 3rd controller manipulated variable (closed-loop controller output 2 [Actuator2]: 4 - 20 mA): Actuation of the
CRH control valve via an I/P converter
3. STARTUP PROCEDURE
3.1 Startup via auxiliary steam
- warm up of auxiliary steam line up to the motor-operated isolation valve
- open motor-operated isolation valve and warm up main steam header up to BFWP drive turbine
ESV(emergency stop valve)
- If the X1 criterion(release turbine ESV for opening) is fulfilled enable open turbine ESV.
Index Blatt Plan-q Datum bearbeitet geprüft Änderungsbeschreibung / Description of Change
Rev Sheet Coordin Date Coordinated Checked
TuG-Benennung /TuG Title Werkstoff / Typ Material Type
Control Concept
Sach-Nr. / Unterlagen-Nr. Item Number Document Number Blatt /Sheet Index / Revision
Siemens AG SIEG-I0-03661
Energy Sector Abteilung/Department Datum / Date bearbeitet /Coordinated geprüft / checked
Oil & Gas Division
26.05.2011 Standtke Pflügl
Verteiler 0 8 H I Q X Y
Distrib
LTSL-M0-00951 REV 0 Page 541 of 860
- If the X5 criterion(release control valves for opening) is fulfilled enable open control valves (“Start
Permissive” signal to the W505, enable controller)
- Since the X1 and X5 criteria have the same value, the enable for the control valves will be delayed by 5
minutes; integration into “Activation trip system” (step program)
- Speed control up to 30% pump output is accomplished via startup control valve and turbine control valve
1st controller manipulated variable active .
2nd controller manipulated variable is enabled but is not used here.
4. OPERATING POINTS AND CONDITIONS
NOTE: For all transfer actions from one steam source to another the temperature difference shall
be less then 60K.
4.1 Auxiliary steam CRH steam
- Steam line up to the CRH control valve have to be prewarmed properly.
- A signal is generated in the DCS when the CRH valve is released for operation.
o The enable signal for the 3rd manipulated variable is blocked up to this point via a relay (interrupting
the signal flow between the W505 output and the I/P converter)
- The motor-operated isolation valve in the auxiliary steam line will be closed. To counteract the speed
reduction the controller will now open the startup control valve, turbine control valve and bypass control
valve (split range in W505) fully.
- Only at this point the CRH control valve will start to open (because of split range in the W505) and
counteract the speed undershoot. The bypass valve closes simultaneously via a ramp as a function of the
CRH valve position (> 2 %) or as a function of differential pressure across the drum
- Speed control is now accomplished fully via the CRH control valve (3rd controller manipulated variable
active, 1st controller manipulated variable at 100%, 2nd controller manipulated variable blocked [however,
controller thinks it is at 100%])
4.2 Auxiliary steam Main steam(manual)
- If steam at approx. 2.5 bar is already available in the extraction line during startup via the auxiliary steam
line, steam would be supplied directly from the extraction line as soon as the motor-operated isolation valve
in the auxiliary steam line is closed .
Speed control is via startup control valve, turbine control valve and bypass control valve (1st and 2nd
controller manipulated variables active)
4.3 Extraction steam CRH steam(automatic)
Note: CRH valve has to be in standby function!
- If demand on pump output is higher then the available corresponding extraction steam flow the controller
will attempt to open the CRH valve.
- The startup control valve, turbine control valve and bypass control valve are all fully open in this case.
- the bypass valve closes simultaneously via a ramp as a function of the CRH valve position (> 2 %) or as a
function of differential pressure across the drum
Index Blatt Plan-q Datum bearbeitet geprüft Änderungsbeschreibung / Description of Change
Rev Sheet Coordin Date Coordinated Checked
TuG-Benennung /TuG Title Werkstoff / Typ Material Type
Control Concept
Sach-Nr. / Unterlagen-Nr. Item Number Document Number Blatt /Sheet Index / Revision
Siemens AG SIEG-I0-03661
Energy Sector Abteilung/Department Datum / Date bearbeitet /Coordinated geprüft / checked
Oil & Gas Division
26.05.2011 Standtke Pflügl
Verteiler 0 8 H I Q X Y
Distrib
LTSL-M0-00951 REV 0 Page 542 of 860
- Speed control is now implemented fully via the CRH control valve (3rd controller manipulated variable
active, 1st controller manipulated variable at 100%, 2nd controller manipulated variable blocked [however,
controller thinks it is at 100%])
4.4 CRH steam Main steam (manual)
This can be done by closing the isolation valve in the CRH steam line. After closing of CRH valve, a signal
will be provided which will be used to open the isolation valve again and set the CRH valve in standby
position.
4.5 CRH steam Main steam (automatic)
- This happens under the following conditions:
The output from the BFWP drive turbine is in a load point at which the CRH valve is controlling the
pressure in the main steam header at < 11 bar.
The rising extraction steam pushes the non-return valve in the extraction line to open which results in a
“mixed” steam flow.
- since the steam from the extraction point has a greater enthalpy (more energy), the BFWP turbine attempts
to increase speed, the controller counteracts this and slowly closes the CRH control valve .
- at CRH valve position<2% the bypass valve will be enabled and its opening controlled so that the desired
speed will be attained.
- Speed control is via the startup control valve, the turbine control valve and the bypass control valve (1st and
2nd controller manipulated variables are active, 3rd controller manipulated variable should always be
enabled [customer] but is at 0%)
5. Shutdown
By reducing the set point to the Woodward the controller output signal will be lowered and
the valves will close in the contrary sequence of its opening i.e. first CRH valve then
bypass valve and finally turbine control and start up valve.
Index Blatt Plan-q Datum bearbeitet geprüft Änderungsbeschreibung / Description of Change
Rev Sheet Coordin Date Coordinated Checked
TuG-Benennung /TuG Title Werkstoff / Typ Material Type
Control Concept
Sach-Nr. / Unterlagen-Nr. Item Number Document Number Blatt /Sheet Index / Revision
Siemens AG SIEG-I0-03661
Energy Sector Abteilung/Department Datum / Date bearbeitet /Coordinated geprüft / checked
Oil & Gas Division
26.05.2011 Standtke Pflügl
Verteiler 0 8 H I Q X Y
Distrib
LTSL-M0-00951 REV 0 Page 543 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Operation & Section E.
Maintenace Volume 1 Heater Drain
Manual & Vent System
Table of Contents 545
1. Overview of Heater Drain & Vent System 547
2. System Description 570
3. Normal Operation, Start-up / Shutdown 581
4. Emergency Operations & Alarms 585
5. Instrumentation & Process Control 593
6. Interlock & Protection 597
7. Valve Line-up List 605
Abbreviations 609
Exhibits 611
LTSL-M0-00951 REV 0 Page 544 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Table of Contents
1.0 OVERVIEW OF HEATER DRAIN AND VENT SYSTEM
1.1 Purpose
1.2 Specifications
1.2.1 Design Data of Major Equipment
1.2.2 Operation Limit
1.3 References
1.3.1 P & ID
1.3.2 System documents
1.3.3 Heat Balance Diagram
1.3.4 Vendor Drawings / Documents
2.0 SYSTEM DESCRIPTION
2.1 Overview
2.1.1 Drain System
2.1.2 Vent system
2.2 Major Component
2.2.1 System Piping
2.2.2 Pneumatically Operated Control Valves
2.2.3 Motor Operated valves
2.2.4 Relief Valves and Blow off Stand Pipe
3.0 NORMAL OPERATION, START-UP AND SHUTDOWN
3.1 Description of Operation
3.1.1 Normal Start-up
3.1.2 Normal Operation
3.1.3 Normal Plant Shut Down
3.2 Checklist
4.0 EMERGENCY OPERATION AND ALARMS
4.1 Emergency Operation
4.1.1 Insufficient/Diminished Normal Drain Capacity
4.1.2 Turbine Water Induction Prevention (TWIP) Events
4.1.3 Loss of Instrument Air/Power
4.1.4 Feedwater Heater Out of Service
4.1.5 Part Load Operation
4.1.6 Flash Tanks
4.2 Alarms
4.3 Cause & Effect Table
5.0 INSTRUMENTATION AND PROCESS CONTROL
5.1 Instrument and Process Control
5.1.1 Heater Drain Level Control – Normal & Emergency drain control valves
6.0 INTERLOCKS AND PROTECTION
6.1 HP Heater Normal Drain CV inlet MOVs
LTSL-M0-00951 REV 0 Page 545 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
6.2 HP Heater 6 Normal Drain CV outlet MOVs
6.3 LP Heater 4 Normal Drain CV inlet MOVs
6.4 LP Heater 3 & HP heater 6 Normal Drain CV inlet MOVs
6.5 LP Heater 3 Normal Drain CV outlet MOVs
6.6 LP Heater 1 & 2 Normal Drain CV inlet MOVs
6.7 HP Heaters start-up vent MOVs
6.8 LP Heaters & Deaerator Start-up Vent MOVs
6.9 Deaerator vent (orifice outlet) MOV
6.10 LPH normal drain to vacuum drain tank MOV
6.11 HP heater 6A/B to Atmospheric flash tank MOV
6.12 Turbine flash tank quenching valves
6.13 Atmospheric flash tank quenching valves
6.14 Vacuum tank drain pump Discharge control valve
6.15 Vacuum tank drain pump
7.0 VALVE LINE-UP LIST
7.1 List
ABBREVIATIONS
EXHIBITS
LTSL-M0-00951 REV 0 Page 546 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
1.0 OVERVIEW OF HEATER DRAIN AND
VENT SYSTEM
LTSL-M0-00951 REV 0 Page 547 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Chapter 1
Overview of Heater Drain and Vent System
1.1 Purpose
The purpose of heater drain and vent system O&M manual document is to provide
the operating personnel with necessary information to safely operate and maintain
the condensate and feed water heater drain and vent system & associated
equipment.
The scope of the manual covers an overview of the Heater Drain and Vent System,
description of its major components with associated equipment & devices and
details of the startup, shutdown and normal operation and process control.
The Heater Drain System removes condensed extraction steam from the shell side
of Heater & Cascade it to next lower pressure feed water heater. During plant
normal operation, the Heater drains are cascaded from higher to lower pressure
feed water heaters to conserve thermal energy by transferring the residual heat to
feed water passing through heaters tube side and hence improving overall plant
efficiency. However if abnormal conditions result in high water levels within the
heater shells, the emergency level controls will automatically divert the drains
directly to the condenser (For HP heaters, through HP flash tank and for LP heaters,
direct to condenser) through the emergency drain valves. Deaerator overflow to the
condenser is provided with a control valve to protect the feed water storage tank
against high water level.
Heater Vent System removes maximum possible non condensable gases/ trapped
air from the stagnant areas of feed water heater both during startup and continuous
operation.
The start-up vent from each high pressure feed water heater shell side is separately
connected to the Deaerator and low pressure feed water heater shell side vents to
the surface condenser. Also start-up vent is provided at each feed water heater tube
and routed to the atmosphere. The start-up vents are provided at the highest point of
any closed section where air may be trapped during start-up.
The continuous vent from each high pressure feed water heater and low pressure
feed water heater is separately connected to the Deaerator and surface condenser
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respectively. The continuous vent from Deaerator will be connected to surface
condenser.
Notes:
1. It is advisable to read this manual carefully to achieve the performance objective.
2. The scope of the document covers the overall system description for the heater
drain and vent system, description of its major components and associated
auxiliaries & system startup, shutdown, operation & process control.
3. If the heater drain and vent system equipment and components are operated
under conditions different than its design, it is possible that the system may not
achieve its performance objectives and is likely to result in serious trouble.
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1.2 Specifications
1.2.1 Design Data of Major Equipment
A. Control Valve
Valve description
1LCH10AA081, 1LCH15AA081
Valve Tag
“Heater 8A/8B Cascade Drain Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class IV
Normal size 6"
Body connection Butt Weld
Weight without Actuator 250 kg
Normal Operating Data (Typical)
Temperature 278.2 °C
Pressure 92.43 kg/cm2 (g)
Flow 93145 kg/hr
Design Data
Temperature 320 °C
Pressure 111.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Close
Valve description
1LCH10AA082, 1LCH15AA082
Valve Tag
“Heater 8A/8B Emergency Drain Control
Valve”
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Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class V
Normal size 6"
Body connection Butt Weld
Weight without Actuator 550 kg
Special Accessory Low Noise Plate (Catridge) of 10” size
Normal Operating Data (Typical)
Temperature 304.8°C
Pressure 93.79 kg/cm2 (g)
Flow 93145 kg/hr
Design Data
Temperature 320°C
Pressure 112.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Double Acting Piston
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Open
Valve description
1LCH20AA081, 1LCH25AA081
Valve Tag
“Heater 7A/7B Cascade Drain Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class IV
Normal size 6"
Body connection Butt Weld
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Weight without Actuator 460 kg
Normal Operating Data (Typical)
Temperature 238.8 °C
Pressure 57.66 kg/cm2 (g)
Flow 180908 kg/hr
Design Data
Temperature 290 °C
Pressure 74.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Close
Valve description
1LCH20AA082, 1LCH25AA082
Valve Tag “Heater 7A/7B Emergency Drain Control
Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class V
Normal size 10"
Body connection Butt Weld
Weight without Actuator 675 kg
Normal Operating Data (Typical)
Temperature 272.5 °C
Pressure 58.79 kg/cm2 (g)
Flow 180908 kg/hr
Design Data
Temperature 290 °C
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Pressure 75.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Double Acting Piston
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Open
Valve description
1LCH30AA081, 1LCH35AA081
Valve Tag
“Heater 6A/6B Cascade Drain Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class IV
Normal size 8"
Body connection Butt Weld
Weight without Actuator 600 kg
Normal Operating Data (Typical)
Temperature 196.6 °C
Pressure 26.59 kg/cm2 (g)
Flow 243710 kg/hr
Design Data
Temperature 245 °C
Pressure 37.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Close
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Valve description
1LCH30AA082, 1LCH35AA082
Valve Tag “Heater 6A/6B Emergency Drain Control
Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class V
Normal size 12"
Body connection Butt Weld
Weight without Actuator 1200 kg
Normal Operating Data (Typical)
Temperature 231.5 °C
Pressure 29.26 kg/cm2 (g)
Flow 243710 kg/hr
Design Data
Temperature 245 °C
Pressure 37.97 kg/cm2 (g)
ACTUATOR
Type Double Acting Piston Cylinder
Control Modulating
Stroke Time Open / Close < 10 Sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Open
Valve description
1LCJ40AA081
Valve Tag
“Heater 4 Cascade Drain Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class IV
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Normal size 6"
Body connection Butt Weld
Weight without Actuator 270 kg
Normal Operating Data (Typical)
Temperature 123.7 °C
Pressure 4.18 kg/cm2 (g)
Flow 89583 kg/hr
Design Data
Temperature 165 °C
Pressure 6.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Close
Valve description
1LCJ40AA082
Valve Tag
“Heater 4 Emergency Drain Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class V
Normal size 10"
Body connection Butt Weld
Weight without Actuator 560 kg
Normal Operating Data (Typical)
Temperature 153.9 °C
Pressure 5.47 kg/cm2 (g)
Flow 89583 kg/hr
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Design Data
Temperature 165 °C
Pressure 7.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Open
Valve description
1LCJ50AA081, 1LCJ50AA082
Valve Tag “Heater 3 to Heater 2A/2B Cascade Drain
Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class IV
Normal size 6"
Body connection Butt Weld
Weight without Actuator 420 kg
Normal Operating Data (Typical)
Temperature 90.7 °C
Pressure 1.62 kg/cm2 (g)
Flow 87347 kg/hr
Design Data
Temperature 150 °C
Pressure 4.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
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Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Close
Valve description
1LCJ50AA083
Valve Tag
“Heater 3 to Emergency Drain Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class V
Normal size 10"
Body connection Butt Weld
Weight without Actuator 580 kg
Normal Operating Data (Typical)
Temperature 120.9 °C
Pressure 2.16 kg/cm2 (g)
Flow 174694 kg/hr
Design Data
Temperature 150 °C
Pressure 4.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Open
Valve description
1LCJ60AA081, 1LCJ65AA081
Valve Tag “Heater 2A/2B to Heater 1A/1B Cascade
Drain Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
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Medium Steam + water
Leakage Class IV
Normal size 8"
Body connection Butt Weld
Weight without Actuator 540 Kg
Normal Operating Data (Typical)
Temperature 72.7 °C
Pressure -0.49 kg/cm2 (g)
Flow 110224 kg/hr
Design Data
Temperature 150 °C
Pressure 3.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Close
Valve description
1LCJ60AA082, 1LCJ65AA082
Valve Tag
“Heater 2A Emergency Drain Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class V
Normal size 8"
Body connection Butt Weld
Weight without Actuator 580 kg
Normal Operating Data (Typical)
Temperature 87.9 °C
Pressure 0.488 kg/cm2 (g)
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Flow 110224 kg/hr
Design Data
Temperature 150 °C
Pressure 3.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Open
Valve description
1LCJ70AA081, 1LCJ75AA081
Valve Tag “Heater 1A/1B to Condenser Cascade Drain
Control Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class IV
Normal size 8"
Body connection Butt Weld
Weight without Actuator 590 kg
Normal Operating Data (Typical)
Temperature 49.9 °C
Pressure 0.048 kg/cm2 (g)
Flow 137950.5 kg/hr
Design Data
Temperature 150 °C
Pressure 3.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
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Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Open
Valve description
1LCJ70AA082, 1LCJ75AA082
Valve Tag “Heater 1A/1B Emergency Drain Control
Valve”
Valve Make MIL
Valve type Globe
Operation Modulating
Medium Steam + water
Leakage Class IV
Normal size 10"
Body connection Butt Weld
Weight without Actuator 880 kg
Normal Operating Data (Typical)
Temperature 69.9 °C
Pressure 0.166 kg/cm2 (g)
Flow 137950.5 kg/hr
Design Data
Temperature 150 °C
Pressure 3.97 kg/cm2 (g)
ACTUATOR
Type Pneumatic Diaphragm
Control Modulating
Stroke Time Open / Close < 10 sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Open
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B. Motorized Operated Valve
Valve description
Valve Tag 1LCH10AA001, 1LCH15AA001
Valve Make L&T VALVE
Valve type Parallel Slide Gate Valve
Operation On-Off
Medium Steam + water
Design ASME B16.34
Normal size 8"
Body connection Buttweld End
Total Weight 570 kg
Design Data
Temperature 320 °C
Pressure 111.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 2.2 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 51 sec
Weight 72 kg
Valve description
Valve Tag 1LCH20AA001, 1LCH25AA001
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation On-Off
Medium Steam + water
Fluid group --
Design ASME B16.34
Normal size 10"
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Body connection Buttweld End
Total Weight 760 kg
Design Data
Temperature 290 °C
Pressure 74.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 2.2 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 14 sec
Weight 87 kg
Valve description
Valve Tag 1LCH30AA001, 1LCH35AA001
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation On-Off
Medium Steam + water
Design ASME B16.34
Normal size 12"
Body connection Buttweld End
Total Weight 435 kg
Design Data
Temperature 245 °C
Pressure 37.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 2.2 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
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Operating Time 69 sec
Weight 75 kg
Valve description
Valve Tag 1LCH30AA002, 1LCH35AA002
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation On-Off
Medium Steam + Water
Design ASME B16.34
Normal size 14"
Body connection Buttweld End
Total Weight 595 kg
Design Data
Temperature 245 °C
Pressure 37.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 2.2 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 180
Operating Time 76 sec
Weight 72 kg
Valve description
Valve Tag 1LCH30AA003, 1LCH35AA003
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation On-Off
Medium Steam + Water
Design ASME B16.34
Normal size 6"
Body connection Buttweld End
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Total Weight 192 kg
Design Data
Temperature 245 °C
Pressure 37.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 1.1 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 36 sec
Weight 87 kg
Valve description
Valve Tag 1LCJ40AA001
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation On-Off
Medium Steam + water
Design ASME B16.34
Normal size 8"
Body connection Buttweld End
Total Weight 160 kg
Design Data
Temperature 165 °C
Pressure 6.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 0.55 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 46 sec
Weight 39 kg
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Valve description
Valve Tag 1LCJ50AA001, 1LCJ50AA002
Valve Make L&T VALVES
Valve type Pressure Seal Bonnet Globe Valve
Operation On-Off
Medium Steam + water
Design ASME B16.34
Normal size 8"
Body connection Buttweld End
Total Weight 160 kg
Design Data
Temperature 150°C
Pressure 4.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 0.55 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 46 sec
Weight 39 kg
Valve description
Valve Tag 1LCJ50AA003, 1LCJ50AA004
Valve Make L&T VALVES
OS & Y , Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation On-Off Duty
Medium Steam + water
Design ASME B16.34
Normal size 10"
Body connection Buttweld End
Total Weight 225 kg
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Design Data
Temperature 150°C
Pressure 4.97 kg/cm2 (g)
Actuator Details
Service On-Off duty
Power Rating 0.55 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 58 sec
Weight 39 kg
Valve description
Valve Tag 1LCJ50AA005, 1LCJ50AA006
Valve Make L&T VALVES
OS & Y, Bolted Bonnet, Flexible
Valve type
Wedge Gate Valve
Operation On-Off Duty
Medium Steam + water
Design ASME B16.34
Normal size 10"
Body connection Buttweld End
Total Weight 225 kg
Design Data
Temperature 150 °C
Pressure 4.97 kg/cm2 (g)
Actuator Details
Service On-Off duty
Power Rating 0.55 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 58 sec
Weight 39 kg
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Valve description
Valve Tag 1LCJ60AA001, 1LCJ65AA001
Valve Make L&T VALVES
Valve type Pressure Seal Bonnet Globe Valve
Operation On-Off
Medium Steam + water
Design ASME B16.34
Normal size 8"
Body connection Buttweld End
Total Weight 160 kg
Design Data
Temperature 150°C
Pressure 3.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 0.55 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 46 sec
Weight 39 kg
Valve description
Valve Tag 1LCJ70AA001, 1LCJ75AA001
Valve Make L&T VALVES
Valve type Pressure Seal Bonnet Globe Valve
Operation On-Off
Medium Steam + water
Design ASME B16.34
Normal size 8"
Body connection Buttweld End
Total Weight 160 kg
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Design Data
Temperature 150°C
Pressure 3.97 kg/cm2 (g)
Actuator Details
Service On-Off Duty
Power Rating 0.55 kW
Power Supply 415 V, 50 Hz, 3 Phase
RPM 45
Operating Time 46 sec
Weight 39 kg
1.2.2 Operation Limit
Sr. Value
Parameter Unit
No (from ID of the Heater)
Lo – 161
1 LP Heater 1A / 2A Level mm Hi – 200
Hi Hi – 225
Lo – 161
2 LP Heater 1B / 2B Level mm Hi – 200
Hi Hi – 225
Lo – 143
3 LP Heater 3 Level mm Hi – 195
Hi Hi – 220
Lo – 113
4 LP Heater 4 Level mm Hi – 160
Hi Hi – 185
Lo – 155
5 HPH 6A / 6B Level mm Hi – 215
Hi Hi – 240
Lo – 140
6 HPH 7A / 7B Level mm Hi – 200
Hi Hi – 225
Lo – 110
7 HPH 8A / 8B Level mm Hi – 170
Hi Hi – 195
Lo Lo – 870
Lo – 2400
8 Deaerator mm Hi – 3000
Hi Hi – 3050
Hi Hi Hi- 3100
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1.3 References
1.3.1 P & ID
a) Heater Drain and Vent System P&ID Dwg. No. LTSL-M1-00204 (Sheet 1 to 11)
b) Drain and Vent Collection System P&ID Dwg. No. LTSL-M1-00215 (Sheet 1 to 5)
Note: All above drawings are attached as Exhibits.
1.3.2 System documents
a) System Description, Operation & Control Dwg. No. LTSL-M1-00154
b) Logic Drawings Dwg. No. LTSL-I1-00200
c) Process Control Function Dwg. No. LTSL-I1-00202
d) PDT & VDT Dwg. No. LTSL-M0-00712
1.3.3 Heat Balance Diagram
a) Dwg. No. T3101AAAB110
1.3.4 Vendor Drawings / Documents
a) Data Sheet – Normal and Emergency drain control Valve Dwg. No. MIL-10-
03501
b) GA Drawings – MOV Dwg. No. LTV-M0-04912, LTV-M0-04930, LTV-M0-04931,
LTV-M0-04949, LTV-M0-04969, LTV-M0-04970, LTV-M0-04971, LTV-M0-04995,
LTV-M0-04996
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2.0 SYSTEM DESCRIPTION
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Chapter 2
System Description
2.1 Overview
2.1.1 Drain System
The Heater Drain System removes condensed extraction steam from the High
Pressure (HP) and Low Pressure (LP) feed water Heaters.
Under normal operating condition, the feed water heater drains are cascaded to the
next lower pressure feed water heater to recover thermal energy and improve overall
plant efficiency. Function of cascading drains from high pressure heaters to
preceding heaters is to recover residual heat to heat the feed water, which is
passing through feed water heater tube side.
During plant start-up or operating modes where the normal cascade drain path is not
available or its flow capability is diminished due to low system operating pressure,
an alternate drain path is furnished for each feed water heater drain to the
condenser (For HP heaters, through HP flash tank and for LP heaters, direct to
condenser).
In case of abnormal conditions, a pneumatically operated drain control valve is
provided for each feedwater heater to allow condensed extraction steam to
discharge to the condenser (For HP heaters, through HP flash tank and for LP
heaters, direct to condenser) when the normal cascade drain path is not available or
its flow capability is diminished due to low system operating pressure or the
feedwater heater water level reaching high level.
Each feed water heater (including HP and LP heaters) is provided with three
numbers of level transmitters for interlock, alarm, control and monitoring.
At any HP feed water Heater High level, respective heater emergency drain valve
will start controlling heater level by directing the excess amount of water to the
condenser via HP flash tank. Necessary alarms/annunciations will also be generated
to make operator aware for the same.
In case of any HP feed water heater High-High level, respective HP Heater train (6A-
7A-8A / 6B-7B-8B) will be fully isolated by opening respective Heater train Bypass
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valves and closing the normal drain valve(s) from the upstream feed water heater(s)
and respective extraction steam block valve.
For the LP feed water heaters 3&4, in case of high heater level, respective heater
emergency drain valve will start controlling heater level by directing the excess
amount of water to the condenser. Necessary alarms/annunciations will also be
generated to make operator aware for the same.
In case of LP feed water heater (3 or 4) High-High level, respective LP feed water
heater (3 or 4) will be isolated by closing normal drain valve(s) from upstream of the
feed water heaters, extraction steam check valve and extraction steam block valve.
For the duplex LP feed water heaters (1A-2A & 1B-2B) installed in the condenser
neck high-high level, respective LP feed water heaters 1A-2A / 1B-2B will be isolated
by opening the feed water heater bypass valve and closing feedwater heater tube
side isolation valves & normal drain valve(s) from upstream of the feed water
heaters.
Both normal and emergency drains from LP feedwater heater 1A / 1B are directly
routed to the condenser.
A pneumatically operated emergency overflow drain valve is provided for Deaerator
to allow condensed extraction steam to discharge to the condenser via HP flash
tank.
Deaerator is provided with three level transmitters for interlock, alarm, control and
monitoring. High-High level will fully open the deaerator emergency overflow drain
valve, which directs the drain to the condenser via HP flash tank. Deaerator
emergency high-high level will close the pneumatic operated steam check valve and
motor operated steam block valve located in extraction steam line to deaerator.
Flushing line has been provided from normal drain line of HP feedwater heater 6A/B
to deaerator and LP feed water heater 3 to heater 2A & 2B. Flushing line from HP
feedwater heater 6A/B is connected to Atmospheric flash tank. Flushing line from LP
feedwater heater 3 is connected to Vacuum drain tank. From Vacuum drain tank the
drain will be transferred to Atmospheric flash tank through Vacuum drain pump.
Cleanup/Flushing line from deaerator to Atmospheric flash tank / Condenser is also
provided.
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The feedwater heater drain piping is provided with sample taps to enable collection
of grab samples from HP feedwater heater 6A/B drain line and vacuum drain tank
pump discharge line that can be used to monitor corrosion product transport.
The drains routed to flash tank is fed inside the flash tank through distributors to
avoid direct impingement on the flash tank shell.
Condensate separates from the steam and drops to the water in the lower portion of
the flash tanks. Steam is vented to condenser through a vent pipe attached to the
top of the HP flash tank and drain is connected to the condenser hotwell.
2.1.2 Vent system
Heater Vent System removes maximum possible non condensable gases/ trapped
air from the stagnant areas of feedwater heater both during startup and continuous
operation.
The continuous vent from each high pressure feedwater heater and low pressure
feedwater heater is separately connected with an orifice to the deaerator and
surface condenser respectively. The continuous vent from Deaerator is connected to
surface condenser.
The startup vents from each high pressure feedwater heater shell side are
separately connected to the deaerator and low pressure feedwater heater shell side
vents are separately connected to the surface condenser. Also start up vents are
provided at each feedwater heater tube and routed to the atmosphere. The start-up
vents are provided at the highest point of any closed section where air may be
trapped during start-up. The start-up vent from deaerator is connected to condenser.
The flow diagram for heater drain and vent system is as shown in the schematic on
next page.
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Note: DCS Graphics is common for both Heater Drain & Vent System and Extraction Steam System.
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Note: DCS Graphics is common for both Heater Drain & Vent System and Extraction Steam System.
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2.2 Major Component
Extraction steam system will have the following major components:
• System Piping
• Pneumatically operated control valves
• Motor operated valves
• Safety Relief Valves and Blow off Stand Pipe
2.2.1 System Piping
Heater drain piping is of carbon steel material. Normal drain control valve
downstream piping material is ASTM A335 Gr. P11. However, Emergency drain
control valve downstream piping is of Carbon Steel with minimum schedule 80. The
heater drain system piping is designed in accordance with ANSI/ASME B31.1 Power
Piping Code. Piping and piping components are insulated with Mineral Wool for heat
retention and/or personnel protection.
2.2.2 Pneumatically Operated Control Valves
2.2.2.1 Cascade Drain Control Valves
A pneumatically operated drain control valve is provided for each feed water heater
to allow condensed extraction steam to cascade to the next lower pressure feed
water heater during normal operation.
Following is a list of Cascade Drain Control Valves:
Tag Number Description
1LCH10AA081 Heater 8A Cascade Drain Control Valve
1LCH15AA081 Heater 8B Cascade Drain Control Valve
1LCH20AA081 Heater 7A Cascade Drain Control Valve
1LCH25AA081 Heater 7B Cascade Drain Control Valve
1LCH30AA081 Heater 6A Cascade Drain Control Valve
1LCH35AA081 Heater 6B Cascade Drain Control Valve
1LCJ40AA081 Heater 4 Cascade Drain Control Valve
1LCJ50AA081 Heater 3 to Heater 2A Cascade Drain Control Valve
1LCJ50AA082 Heater 3 to Heater 2B Cascade Drain Control Valve
1LCJ60AA081 Heater 2A to Heater 1A Cascade Drain Control Valve
1LCJ65AA081 Heater 2B to Heater 1B Cascade Drain Control Valve
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1LCJ70AA081 Heater 1A to Condenser Cascade Drain Control Valve
1LCJ75AA081 Heater 1B to Condenser Cascade Drain Control Valve
2.2.2.2 Emergency Drain Control Valves
A pneumatically operated drain control valve is provided for each feedwater heater
to allow condensed extraction steam to discharge into condenser (For HP heaters,
through HP flash tank and for LP heaters, direct to condenser) when normal cascade
drain path is not available or its flow capacity is diminished due to low system
operating pressure or the feedwater heater water level reaching high level.
Following is a list of Emergency Drain Control Valves:
Tag Number Description
1LCH10AA082 Heater 8A Emergency Drain Control Valve
1LCH15AA082 Heater 8B Emergency Drain Control Valve
1LCH20AA082 Heater 7A Emergency Drain Control Valve
1LCH25AA082 Heater 7B Emergency Drain Control Valve
1LCH30AA082 Heater 6A Emergency Drain Control Valve
1LCH35AA082 Heater 6B Emergency Drain Control Valve
1LCJ40AA082 Heater 4 Emergency Drain Control Valve
1LCJ50AA083 Heater 3 to Emergency Drain Control Valve
1LCJ60AA082 Heater 2A Emergency Drain Control Valve
1LCJ65AA082 Heater 2B Emergency Drain Control Valve
1LCJ70AA082 Heater 1A Emergency Drain Control Valve
1LCJ75AA082 Heater 1B Emergency Drain Control Valve
2.2.2.3 Deaerator Overflow Valve
A pneumatically operated Deaerator overflow control valve (1LAR05AA081) is
provided in the deaerator overflow line to allow excess condensate to discharge to
the condenser when the Deaerator water level reaches high-high level.
2.2.3 Motor Operated valves
All the Heaters (HP and LP) are provided with startup vent lines having motor
operated valves. Motor operated valves are also used in Deaerator startup and
normal vent lines. In addition two motor operated valves are provided in HP heater
drain cleaning / flushing line. Both lines are taken from HP heater- 6A/6B normal
drain line and connected to Atmospheric flash tank.
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Tag Number Description
Inlet isolating valve of Heater- 8A Normal Drain Control
1LCH10AA001
Valve
Inlet isolating valve of Heater- 8B Normal Drain Control
1LCH15AA001
Valve
Inlet isolating valve of Heater- 7A Normal Drain Control
1LCH20AA001
Valve
Inlet isolating valve of Heater- 7B Normal Drain Control
1LCH25AA001
Valve
Inlet isolating valve of Heater- 6A Normal Drain Control
1LCH30AA001
Valve
Outlet isolating valve of Heater- 6A Normal Drain Control
1LCH30AA002
Valve
Isolating valve of HP heater-A train drain line Cleaning /
1LCH30AA003
Flushing line
Inlet isolating valve of Heater- 6B Normal Drain Control
1LCH35AA001
Valve
Outlet isolating valve of Heater- 6B Normal Drain Control
1LCH35AA002
Valve
Isolating valve of HP heater-B train drain line Cleaning /
1LCH35AA003
Flushing line
1LCJ40AA001 Inlet isolating valve of Heater- 4 Normal Drain Control Valve
Inlet isolating valve of Heater- 3 Normal Drain Control Valve
1LCJ50AA001
to LP Heater-2A
Inlet isolating valve of Heater- 3 Normal Drain Control Valve
1LCJ50AA002
to LP Heater-2B
Outlet isolating valve of Heater- 3 Normal Drain Control
1LCJ50AA003
Valve to LP Heater-2A
Outlet isolating valve of Heater- 3 Normal Drain Control
1LCJ50AA004
Valve to LP Heater-2B
1LCJ50AA005 &
Isolating valve of LP heaters drain Cleaning / Flushing line
1LCJ50AA006
Inlet isolating valve of Heater- 2A Normal Drain Control
1LCJ60AA001
Valve to LP Heater-1A
Inlet isolating valve of Heater- 1A Normal Drain Control
1LCJ70AA001
Valve to Condenser Shell-1
Inlet isolating valve of Heater- 2B Normal Drain Control
1LCJ65AA001
Valve to LP Heater-1B
Inlet isolating valve of Heater- 1B Normal Drain Control
1LCJ70AA001
Valve to Condenser Shell-2
1LAD11AA001 Start up vent Isolating valve of HP Heater-8A
1LAD12AA001 Start up vent Isolating valve of HP Heater-8B
1LAD21AA001 Start up vent Isolating valve of HP Heater-7A
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Tag Number Description
1LAD22AA001 Start up vent Isolating valve of HP Heater-7B
1LAD31AA001 Start up vent Isolating valve of HP Heater-6A
1LAD32AA001 Start up vent Isolating valve of HP Heater-6B
1LCC55AA001 Start up vent Isolating valve of LP Heater-3
1LCC65AA001 Start up vent Isolating valve of LP Heater-4
1LCC15AA001 Start up vent Isolating valve of LP Heater-1A
1LCC25AA001 Start up vent Isolating valve of LP Heater-2A
1LCC35AA001 Start up vent Isolating valve of LP Heater-1B
1LCC45AA001 Start up vent Isolating valve of LP Heater-2B
1LAA10AA002 Normal vent Isolating valve of Deaerator
1LAA10AA002 Start up vent Isolating valve of Deaerator
2.2.4 Relief Valves and Blow off Stand Pipe
A tube side thermal relief valve is provided on each feedwater heater to protect the
tube side against over pressure from water expansion when the water inlet and
outlet valves are closed.
A shell side safety relief valve is provided on each feedwater heater except for LP
heater 1A/B and 2A/B to protect the shell from over pressure in case of tube or tube
sheet failure.
The Pressure Relief Valve piping is connected to Blow off stand pipe where it vents
the steam to atmosphere and condensate to Atmospheric Flash Tank.
Deaerator is provided with five (5) relief valves either to protect the pressure vessel
against over pressurization or to act as sentinel relief.
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3.0 NORMAL OPERATION, START-UP AND
SHUTDOWN
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Chapter 3
Mode of Operation
3.1 Description of Operation
3.1.1 Normal Start-up
HP & LP heaters normal drain control valve’s inlet motor operated isolation valves
and HP heater 6A/B and LP heater 3 normal drain control valve’s outlet motor
operated isolation valves will be opened when heater drain cleanup blow startup is
initiated. During start-up, the emergency drain control valve should be manually
opened to remove cold condensate prior to steam admission then put it in auto at
that time normal drain valve is in manual. Drain flows during warm-up of extraction
steam piping and heater are handled by the emergency valve based on heater water
level. Heaters are put into service sequentially (lowest pressure to highest pressure).
Once the individual feedwater heater has established a stable operating condition
(and the downstream heater is available to accept drain flow) the normal valve is put
in auto. The emergency valve closes as the normal picks up the duty and maintains
level. If the operating pressure of the heater is insufficient to sustain normal drain
operation (which is typical during initial start-up period), the emergency remains
open to maintain level until the level is controllable by the normal valve only.
Also during start-up motor operated vent valves for all heaters will be opened in
order to discharge air during filling of the heaters by extraction steam and cascade
drains. LP heaters and deaerator startup vent valves are opened, when deaerator
pressure is less than 0.08 kg/cm2(g) during LP extraction group is on. As soon as
turbine is synchronized, LP heater 1A/B & 2A/B startup vents will be closed. LP
heater 3 & 4 startup vent valves will be closed when extraction steam motor
operated isolation valves are fully opened. Deaerator vent valve will be closed when
deaerator pressure is higher than 0.1 kg/cm2(g). Motorized start-up vent valve of
deaerator will open the vent line to condenser. HP heaters startup vent valves will
open when all LP heaters startup vent valves are opened and will be closed when
load is higher than 10% and respective HP heater steam side motor operated
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isolation valve is opened. However during normal operation these startup vent
valves will be in close position. Deaerator vent (orifice outlet) will be opened when
any condensate extraction pump startup is completed. During Nitrogen purging of
Deaerator, Start-up vent MOV should be opened/ closed by the operator
intervention.
Refer to Feedwater Heater Vendor Installation and Operation Manual (LT-M0-03053
& LT-M0-03054) in Volume 2 for further details.
3.1.2 Normal Operation
During normal plant operation, all feed water heaters are in service operating on the
normal (cascaded) drain lines for removal of condensate. The normal drain control
valves as well as the emergency drain control valves for each heater are in
automatic mode regulating water level in each heater.
Deaerator over flow control valve should be in auto mode with upstream isolation
valve in locked open condition.
The normal drain control valve modulates while the emergency drain and overflow
drain control valve remains closed. The emergency drain control valve is set to start
opening once the respective heater level reaches high water level. However, during
high level control, the normal drain cascade control valve will remain functioning
unless it is closed by interlocks from low pressure heater high-high level status.
The start-up vent valves should be closed and the heater shell continuous vent valve
should be locked open during normal operation.
Valve (1LAA10AA001) in the common line of the Deaerator continuous vent line to
condenser remains open during normal operation.
3.1.3 Normal Plant Shut Down
During normal plant shutdown, heater cascade drains become unavailable due to
the reduced operating pressure. This results in rising of heater level. When the
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heater reaches high level the emergency drain will open discharging the condensate
to the condenser (For HP heaters, through HP flash tank and for LP heaters, direct
to condenser).
3.2 Checklist
DANGER
Strictly follow the work permit system to avoid unacceptable troubles
or danger.
• Ensure cancellation of any work permit issued for control valve, MOV or heater
• Ensure that the power supply for MOV is available from the feeder.
• Make sure all interlocks and protections test of MOV are qualified.
• All related instruments are mounted and properly fitted.
• Ensure availability of instrument air supply.
• Ensure all valves are on auto.
• Manual isolating valves of Heater drains and continuous vent valve are open.
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4.0 EMERGENCY OPERATION AND
ALARMS
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Chapter 4
Emergency Operation and Alarms
4.1 Emergency Operation
4.1.1 Insufficient/Diminished Normal Drain Capacity
When the water level in a feed water heater continues to rise and the normal drain
control valve is fully opened, the emergency drain control valve automatically opens
in conjunction with the normal drain control valve to provide sufficient drain capacity.
The normal drain capacity may be diminished or insufficient under the following
circumstances:
• During start-up/shutdown where low extraction steam operating pressures are
common
• Normal drain control valve malfunction or damage
• Tube leakage or breakage
• Load transitions resulting in water level transients exceeding the capacity of the
normal drain control valves
If the water level continues to rise to high-high conditions, the necessary precautions
for turbine water induction prevention must be taken.
4.1.2 Turbine Water Induction Prevention (TWIP) Events
Due to excessive tube leaks or improper drain operation, the feedwater heaters may
flood with operating water levels exceeding the high-high alarm limit. To prevent
water from entering the turbine through the extraction piping, the appropriate
feedwater heater or train of heaters is automatically isolated and bypassed. The
emergency drain from the respective feedwater heater is opened fully. All inlet
sources are isolated (condensate/feedwater, extraction steam, and cascaded heater
drains) in case of feedwater heaters. In case of deaerator emergency high-high (H-
H-H) level, only extraction steam source is isolated and cascade heater drain from
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upstream HP heater 6A/B is kept open. Refer to the Sections A & D (Condensate,
and Extraction steam systems) in this Volume 1 for details regarding TWIP events.
4.1.3 Loss of Instrument Air/Power
Upon loss of control air, signal, or power, the heater normal drain valves will close
and emergency drain valve will open. Motorized isolation valve will maintain status
quo.
NOTE: If Heater 6A/B Emergency drain control valve fail opened, Operator should
isolate the Emergency drain control valve before bypassing the HP heater 6A/B from
shell side to avoid vacuum condition in HP Heater 6A/B.
4.1.4 Feedwater Heater Out of Service
When a feedwater heater is removed from service due to TWIP events or for routine
maintenance, the normal drain control valve is automatically closed while the
emergency drain control valve is automatically opened to remove condensate from
the heater shell. The normal drains of the next higher pressure feedwater are also
automatically closed requiring condensate removal through the emergency drain
system.
4.1.5 Part Load Operation
The normal drains and associated equipment are designed for stable operation from
low load to full load including heater bypass operation. The emergency drains and
associated equipment are designed to operate in conjunction with the normal drains
for stable operation from startup to full load including heater bypass operation and
abnormal load transients.
4.1.6 Flash Tanks
For turbine flash tank-1 & turbine flash tank-2, quenching water is provided from
condensate system and quenching water for Atmospheric flash tank is provided from
service water (APH wash pump discharge). The ON/OFF valves (1LCA25AA051
/1LCA25AA055 / 1GHD30AA081) in the quenching water line will operate based on
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operating temperature inside the tank. When respective turbine flash tank
temperature reaches 70ºC, valve on the respective flash tank quenching water line
will open. These valves will close only when temperature in the flash tank reaches
50ºC. When atmospheric flash tank temperature reaches 70ºC, valve on the
atmospheric flash tank quenching water line will open. These valves will close only
when temperature in the flash tank reaches 60ºC.
Vacuum tank drain pump recirculation control valve will maintain the normal level in
the vacuum drain tank. Motor Operated valve (1LCM50AA010) has to be operated
manually by operator.
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4.2 Alarms
The Heater drain & vent System alarms can be monitored from the DCS operator
interface console alarm graphic display.
CAUTION
Operator should take appropriate corrective action, if any alarms
mentioned below appear. Specifically, on any heater level hi hi
ensure that heater is bypassed properly and check the turbo-visory
parameters.
The following alarms related to Heater Drain & vent system are generated in the
DCS:
HP Heater 8A Level Hi
HP Heater 8A Level Transmitter Hi Hi
HP Heater 8A Level Low
HP Heater 8A Level Switch Hi Hi
HP Heater 8Blevel Hi
HP Heater 8B Level Hi Hi
HP Heater 8B Level Low
HP Heater 8B Level Switch Hi Hi
HP Heater 7A Level Hi
HP Heater 7A Level Hi Hi
HP Heater 7A Level Low
HP Heater 7A Level Switch Hi Hi
HP Heater 7Blevel Hi
HP Heater 7B Level Hi Hi
HP Heater 7B Level Low
HP Heater 7B Level Switch Hi Hi
HP Heater 6A Level Hi
HP Heater 6A Level Hi Hi
HP Heater 6A Level Low
HP Heater 6A Level Switch Hi Hi
HP Heater 6Blevel Hi
HP Heater 6B Level Hi Hi
HP Heater 6B Level Low
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HP Heater 6B Level Switch Hi Hi
LP Heater 4 Level Hi
LP Heater 4 Level Hi Hi
LP Heater 4 Level Low
LP Heater 4 Level Switch Hi Hi
LP Heater 3 Level Hi
LP Heater 3 Level Hi Hi
LP Heater 3 Level Low
LP Heater 3 Level Switch Hi Hi
LP Heater 2A Level Hi
LP Heater 2A Level Hi Hi
LP Heater 2A Level Low
LP Heater 2A Level Switch Hi Hi
LP Heater 2B Level Hi
LP Heater 2B Level Hi Hi
LP Heater 2B Level Low
LP Heater 2B Level Switch Hi Hi
LP Heater 1A Level Hi
LP Heater 1A Level Hi Hi
LP Heater 1A Level Low
LP Heater 1A Level Switch Hi Hi
LP Heater 1B Level Hi
LP Heater 1B Level Hi Hi
LP Heater 1B Level Low
LP Heater 1B Level Switch Hi Hi
The following information will be provided on the control room display on the CRT as
a function of the DCS.
Heater Level (mm) & Temperature (ºC)
Heater Emergency Drain Valve Opening (%)
Heater Cascading Drain Valve Opening (%)
Heater Cascading Drain Temperature (ºC)
Deaerator Level (mm), Temperature (ºC) & Pressure (kg/cm2)
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4.3 Cause & Effect Table
Cause Effect Action
1 HP heater level high-high
1. Full opening of
corresponding
heater emergency 1. Check the status of the feed
drain valve water I/L and O/L valve of the
respective train which should
2. Closing of be close and bypass valve
cascaded drain should be open.
1. Tube leakage in
valve of next
any Heater
higher pressure 2. Check the status of I/L isolating
heater MOV of normal drain control
2. Mal operation of
valve of upstream heater which
respective heater
should be closed.
drain control
3. Respective train
valve
gets bypassed
from water side if
3. Check the Turbo Supervisory
level high-high
parameters and ensure no
persist for more
undue variations.
than 1 min.
4. Decrease in feed
water I/L
temperature to
Economiser.
2 LP heater level high-high
1. Tube leakage in 1. Full opening of 1. Check the status of the feed
any Heater corresponding water I/L and O/L valve of the
heater emergency respective heater which should
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Cause Effect Action
drain valve be close and bypass valve
should be open.
2. Mal operation of 2. Closing of 2. Check the status of I/L isolating
respective heater cascaded drain MOV of normal drain control
drain control valve of next valve of upstream heater which
valve higher pressure should be closed.
heater
3. Respective heater 3. Check the Turbo Supervisory
(LP 1A/2A or parameters and ensure no
1B/2B will bypass undue variations.
on group basis)
gets bypassed
from water side if
level high-high
persist for more
than 1 min.
4. Decrease in
condensate I/L
temp to Deaerator
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5.0 INSTRUMENTATION AND PROCESS
CONTROL
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Chapter 5
Instrumentation & Process Control
5.1 Instrument and Process Control
5.1.1 Heater Drain Level Control – Normal & Emergency drain control valves
Purpose:
Heater level is to be maintained at a fixed point to avoid flooding of heaters by
modulating normal & emergency drain control valves.
Functional Description:
Heater level will be controlled by the DCS through modulating normal and
emergency drain control valves. Each feedwater heater is provided with three level
transmitters for interlock, alarm, control and monitoring. Two different controllers with
different set points each for normal and emergency drain control valve are provided.
The controller compares set points with process variable and acts upon the deviation
to modulate control valves. During normal condition, Heater level will be controlled
by normal drain control valve. If heater level still not controlled & heater level
becomes “High”, then respective Emergency drain valve will open, which direct the
drains to the condenser (For HP heaters, through HP flash tank and for LP heaters,
direct to condenser). At heater level High-high condition, respective feedwater
heater tube side isolation valves, the extraction steam isolation valve and the non-
return valve(s) in accordance with the turbine water induction prevention logic
requirements will be closed and bypass valve will be opened & Normal drain valve of
upstream feedwater heater(s) will be force closed by setting controller output zero
(0%) & close command will be given to quick close SOV and full open command will
be given to emergency drain valves.
For the feedwater heaters installed in the condenser neck, at high-high level
condition normal drain valve(s) of upstream of the feedwater heaters and respective
feedwater heater tube side isolation valves will be closed and respective feedwater
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heater bypass valve will be opened and full open command will be given to
emergency drain valves.
During heater drain clean up blow when water quality check-1 is completed (as
described in Section I – Cl. No. 4.3 in this Volume 1), HP heater 6A/6B Normal drain
valve will be force closed & HP heater 6A/6B Emergency drain valve will be
modulate based on NWL set point. Emergency drain valve will be closed when load
is higher than 30% and water quality check-2 is completed (as described in Section I
– Cl. No. 4.3 in this Volume 1) & normal drain valve will start modulate based on
NWL setpoint.
The Deaerator is provided with three level transmitters for interlock, alarm, control
and monitoring. Deaerator blow down/overflow drain valve will fully open at (Hi-Hi)
3050 mm level, which directs the drain to the condenser (HP shell) via HP flash tank.
Extraction steam block valve will close at 3100mm emergency high-high level and
cascade drain from HP heater 6A & 6B will remain open which is in accordance with
the turbine water induction prevention logic requirements.
This control description covers the process control functional logic requirement for
following equipment:
Valve tag no. Description
1LCH10AA081 HP HTR-8A NORM DRN CV
1LCH10AA082 HP HTR-8A EMRG DRN CV
1LCH15AA081 HP HTR-8B NORM DRN CV
1LCH15AA082 HP HTR-8B EMRG DRN CV
1LCH20AA081 HP HTR-7A NORM DRN CV
1LCH20AA082 HP HTR-7A EMRG DRN CV
1LCH25AA081 HP HTR-7B NORM DRN CV
1LCH25AA082 HP HTR-7B EMRG DRN CV
1LCH30AA081 HP HTR-6A NORM DRN CV
1LCH30AA082 HP HTR-6A EMRG DRN CV
1LCH35AA081 HP HTR-6B NORM DRN CV
1LCH35AA082 HP HTR-6B EMRG DRN CV
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Valve tag no. Description
1LCJ50AA081 LP HTR-3 TO HTR-2A NORM DRN CV
1LCJ50AA082 LP HTR-3 TO HTR-2B NORM DRN CV
1LCJ50AA083 LP HTR-3 EMRG DRN CV
1LCJ40AA081 LP HTR-4 NORM DRN CV
1LCJ40AA082 LP HTR-4 EMRG DRN CV
1LCJ60AA081 LP HTR-2A NORM DRN CV
1LCJ60AA082 LP HTR-2A EMRG DRN CV
1LCJ70AA081 LP HTR-1A NORM DRN CV
1LCJ70AA082 LP HTR-1A EMRG DRN CV
1LCJ65AA081 LP HTR-2B NORM DRN CV
1LCJ65AA082 LP HTR-2B EMRG DRN CV
1LCJ75AA081 LP HTR-1B NORM DRN CV
1LCJ75AA082 LP HTR-1B EMRG DRN CV
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6.0 INTERLOCKS AND PROTECTION
LTSL-M0-00951 REV 0 Page 597 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Chapter 6
Interlock and Protection
6.1 HP Heater Normal Drain CV inlet MOVs
(1LCH10AA001, 1LCH15AA001, 1LCH20AA001, 1LCH25AA001)
Purpose:
Valve will isolate respective HP heater normal drain control valve.
Functional Description:
MOV will be opened from DCS during HP heater drain cleanup blow start up OR
respective downstream heater recovery* command given by operator.
Protective Command:
MOV receives Override close command from DCS when respective downstream
heater level high high is observed.
6.2 HP Heater 6 Normal Drain CV outlet MOVs
(1LCH30AA002, 1LCH35AA002)
Purpose:
Valve will isolate respective HP heater 6A/6B normal drain control valve.
Functional Description:
MOV will be initially closed during start-up of HP heater drain cleanup blow & will be
opened from DCS during HP heater drain cleanup blow when water quality check-2
is completed OR Deaerator extraction steam recovery* command given by operator.
LTSL-M0-00951 REV 0 Page 598 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Close permissive:
Respective HP heater 6A/6B normal drain to atmospheric flash tank MOV open OR
Respective HP heater 6A/6B drain CV inlet MOV close.
6.3 LP Heater 4 Normal Drain CV inlet MOVs
(1LCJ40AA001)
Purpose:
Valve will isolate LP heater 4 normal drain control valve.
Functional Description:
MOV will be opened from DCS during LP heater drain cleanup blow start up OR LP
heater 3 recovery* command given by operator.
Protective Command:
MOV receives Override close command from DCS when LP heater 3 level high high
is observed.
6.4 LP Heater 3 & HP heater 6 Normal Drain CV inlet MOVs
(1LCJ50AA001, 1LCJ50AA002, 1LCH30AA001, 1LCH35AA001)
Purpose:
Valve will isolate respective normal drain control valve.
Functional Description:
LP heater 3 MOV will be opened from DCS during LP heater drain cleanup blow &
HP heater 6 MOV will be opened from DCS during HP heater drain cleanup blow.
6.5 LP Heater 3 Normal Drain CV outlet MOVs
(1LCJ50AA003, 1LCJ50AA004)
Purpose:
Valve will isolate respective normal drain control valve.
LTSL-M0-00951 REV 0 Page 599 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Functional Description:
This valve will be closed initially during LP heater drain cleanup blow & will be
opened from DCS during LP heater drain cleanup blow when drain water quality
check is completed OR respective downstream heater recovery* command given by
operator.
Protective Command:
MOV receives Override close command from DCS when respective downstream
heater level high high is observed.
6.6 LP Heater 1 & 2 Normal Drain CV inlet MOVs
(1LCJ60AA001, 1LCJ70AA001, 1LCJ65AA001, 1LCJ75AA001)
Purpose:
Valve will isolate respective normal drain control valve.
Functional Description:
MOV will be opened from DCS when turbine is not tripped.
6.7 HP Heaters start-up vent MOVs
(1LAD11AA001, 1LAD12AA001, 1LAD21AA001, 1LAD22AA001, 1LAD31AA001,
1LAD32AA001)
Purpose:
Start-up vent MOV removes non condensable gases from heater while shell is being
occupied by extraction steam during start-up.
Functional Description:
All HP heaters vent MOVs will be opened from DCS when
All LP heaters vent MOV are opened
AND
Turbine is tripped
AND
LTSL-M0-00951 REV 0 Page 600 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Generator breaker (52G) not on
All HP heaters vent MOV will be closed when
Generator load is higher than 10%
AND
Respective heater isolation MOV is opened
6.8 LP Heaters & Deaerator Start-up Vent MOVs
(1LCC15AA001, 1LCC25AA001, 1LCC35AA001, 1LCC45AA001, 1LCC55AA001,
1LCC65AA001, 1LAA10AA002)
Purpose:
Start-up vent MOV removes non condensable gases from heater/deaerator while
shell is being occupied by extraction steam during start-up.
Functional Description:
All LP heaters vent MOVs & Deaerator vent MOV will be opened from DCS when
Deaerator pressure is less than 0.08kg/cm2.
LP heater 1 & 2 vent MOV will be closed when 52G ON.
LP heater 3 & 4 vent MOV will be closed when respective heater isolation MOV fully
opened.
Deaerator vent MOV will be closed when deaerator pressure is higher than
0.1kg/cm2.
6.9 Deaerator vent (orifice outlet) MOV
(1LAA10AA001)
Purpose:
This vent MOV removes non condensable gases & steam from Deaerator.
Functional Description:
LTSL-M0-00951 REV 0 Page 601 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
MOV will be opened from DCS when Any CEP start-up is completed & Condenser
vacuum group start-up is completed.
6.10 LPH normal drain to vacuum drain tank MOV
(1LCJ50AA005 & 1LCJ50AA006)
Purpose:
This MOV blows drain water from LP heaters (except LP heater 1 & 2) during LP
heater Drain Clean-up Blow.
Functional Description:
MOV will be opened from DCS during LP heaters Drain Clean-up Blow start-up.
These MOVs will be closed when drain water quality check is completed & LP
Heater 3 Drain CV outlet MOVs are open.
Close permissive
LP Heater 3 Drain CV outlet MOVs are open.
6.11 HP heater 6A/B to Atmospheric flash tank MOV
(1LCH30AA003 & 1LCH35AA003)
Purpose:
This MOV blows drain water from HP heaters during HP heater Drain Clean-up
Blow.
Functional Description:
MOV will be opened from DCS during HP heaters Drain Clean-up Blow start-up.
These MOV will be closed when drain water quality check-1 is completed & HP
heater-6A/6B emergency drain valve is modulating based on normal level set point
during cleanup cycle.
Close permissive
HP Heater 6 Drain CV outlet MOVs are open.
LTSL-M0-00951 REV 0 Page 602 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
6.12 Turbine flash tank quenching valves
Valve tag numbers – 1LCA25AA051 & 1LCA25AA055
Purpose:
This MOV will spray water in turbine flash tanks.
Functional Description:
MOV will be opened from DCS when respective turbine flash tank temperature is
higher than 70 °C AND Any CEP is running. MOV will be closed when Turbine flash
tank temperature is lower than 50°C.
6.13 Atmospheric flash tank quenching valves
Valve tag number – 1GHD30AA081
Purpose:
This MOV will spray water in Atmospheric flash tank.
Functional Description:
MOV will be opened from DCS when Atmospheric flash tank temperature is higher
than 70°C. MOV will be closed when Atmospheric flash tank temperature is lower
than 60°C.
6.14 Vacuum tank drain pump Discharge control valve
Valve tag numbers – 1LCM55AA081
Purpose:
This valve will maintain level in vacuum drain tank
Functional Description:
This valve will modulate based on vacuum drain tank level. This valve will be force
closed by setting controller output zero (0%) when vacuum drain pump is not started
OR load is 15%.
LTSL-M0-00951 REV 0 Page 603 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
6.15 Vacuum tank drain pump
Pump tag number – 1LCM55AP001
Purpose:
This pump will maintain level in vacuum drain tank.
Functional Description:
This pump will start when vacuum drain tank level is normal water level & it will stop
when drain tank level is lower than low level.
Start Permissive:
• Vacuum drain tank level is higher than low low level
• Vacuum drain pump suction MOV open
• Vacuum drain pump discharge valve close
Override close:
Vacuum drain tank level low low for 5 seconds
Note: * - For Heater Recovery Operation, refer Section D – Clause No. 4.1.4 of
Extraction Steam System in this Volume 1.
LTSL-M0-00951 REV 0 Page 604 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
7.0 VALVE LINE-UP LIST
LTSL-M0-00951 REV 0 Page 605 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Chapter 7
Valve Line-Up List
7.1 List
CAUTION
Do not operate valves without proper authorization such as work
permit, as unauthorized operation may lead to serious injury and
damage to the equipment.
Valve line-up list tabulated below provides recommended position of manual valves
of the heater drain and vent system for starting the system.
System Pre Start
Valve Tag no. Description
Position
Outlet Isolating valve of HP heater -
1LCH10AA102 OPEN
8A Normal Drain Control Valve
Inlet Isolating valve of HP heater -8A
1LCH10AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of HP heater -
1LCH10AA104 OPEN
8A Emergency Drain Control Valve
Outlet Isolating valve of HP heater -
1LCH15AA102 OPEN
8B Normal Drain Control Valve
Inlet Isolating valve of HP heater -8B
1LCH15AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of HP heater -
1LCH15AA104 OPEN
8B Emergency Drain Control Valve
Outlet Isolating valve of HP heater -
1LCH20AA102 OPEN
7A Normal Drain Control Valve
Inlet Isolating valve of HP heater -7A
1LCH20AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of HP heater -
1LCH20AA104 OPEN
7A Emergency Drain Control Valve
LTSL-M0-00951 REV 0 Page 606 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
System Pre Start
Valve Tag no. Description
Position
Outlet Isolating valve of HP heater -
1LCH25AA102 OPEN
7B Normal Drain Control Valve
Inlet Isolating valve of HP heater -7B
1LCH25AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of HP heater -
1LCH25AA104 OPEN
7B Emergency Drain Control Valve
Inlet Isolating valve of HP heater -6A
1LCH30AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of HP heater -
1LCH30AA104 OPEN
6A Emergency Drain Control Valve
Inlet Isolating valve of HP heater -6B
1LCH35AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of HP heater -
1LCH35AA104 OPEN
6B Emergency Drain Control Valve
Inlet Isolating valve of LP heater -3
1LCJ50AA105 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -3
1LCJ50AA105 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -4
1LCJ40AA102 OPEN
Normal Drain Control Valve
Inlet Isolating valve of LP heater -4
1LCJ40AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -4
1LCJ40AA104 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -2A
1LCJ60AA102 OPEN
Normal Drain Control Valve
Inlet Isolating valve of LP heater -2A
1LCJ60AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -2A
1LCJ60AA104 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -1A
1LCJ70AA102 OPEN
Normal Drain Control Valve
Inlet Isolating valve of LP heater -1A
1LCJ70AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -1A
1LCJ70AA104 OPEN
Emergency Drain Control Valve
LTSL-M0-00951 REV 0 Page 607 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
System Pre Start
Valve Tag no. Description
Position
Outlet Isolating valve of LP heater -2B
1LCJ65AA102 OPEN
Normal Drain Control Valve
Inlet Isolating valve of LP heater -2B
1LCJ65AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -2B
1LCJ65AA104 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -1B
1LCJ75AA102 OPEN
Normal Drain Control Valve
Inlet Isolating valve of LP heater -1B
1LCJ75AA103 OPEN
Emergency Drain Control Valve
Outlet Isolating valve of LP heater -1B
1LCJ75AA104 OPEN
Emergency Drain Control Valve
Vacuum Tank Drain Pump Suction
1LCM50AA105 OPEN
Valve
LTSL-M0-00951 REV 0 Page 608 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
ABBREVIATIONS
LTSL-M0-00951 REV 0 Page 609 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
Abbreviations:
Abbreviation Meaning
ASME American Society of Mechanical Engineers
ANSI American National Standard Institute
ASTM American Society for Testing and Materials International
CV Control Valve
CRT Cathode Ray Tube
DA Deaerator
DCS Distributed Control System
HP High Pressure
HPH High Pressure Heater
ID Inner Diameter
IP Intermediate Pressure
I/L Inlet
kV Kilo Volt
LP Low Pressure
LPH Low Pressure Heater
MOV Motor Operated Valve
O&M Operation & Maintenance
O/L Outlet
P&IDs Piping & Instrumentation Diagram
RPM Revolution Per Minute
TWIP Turbine Water Induction Prevention
LTSL-M0-00951 REV 0 Page 610 of 860
JAYPEE O&M MANUAL – VOLUME 1 HEATER DRAIN & VENT SYSTEM
EXHIBITS
LTSL-M0-00951 REV 0 Page 611 of 860
l
16 1 15 14 13 12 11 10 6 I
1>0200-II'I-1SJ.1 'ON 'DMO I
L
I
r::~~;~i
CTOO?-'. VENT
·-'T~--
1
AA501
I
NOTE 14 .-L. TE
/iLCH10.1 AA50~
~ CT002 I REFERENCE DRAWINGS
\ ....,_r_."/ DRAWING TITLE DRAWING NUMBER
~
EMERGENCY ORA IN
TO HP FLASH TANK AA104 GA OF HIGH PRESSURE CLOSED FEED WATER l T-M0-03058
vs : lA HEATER HPH8A/B
w: rL...,~fl~ ~
(LTSL t.t1 1 ~0215 0 TSL-M1 -00204-02
0905 DN250 LO 0915 DN250 12
JPVL w
AA103 ~ NORMAL DRAIN TO
NOTE 151~----~--~--~~~~~~~~~~~--~-----{~~~~~~~ HP FEEDWATER HEATER # 7A
250X150_;?fvol 200X150 ~ LO 0905-0N200 "'
0
/ HD-~IHD-1 ~ 9 1LCH1 1LCH1
rL... 0"'
CT501 CT501
AA<O~
~~ Tl TW
H N
H
0
~
~-----------------------+----------------l
"'"'
AA-10
NOTES
1. FOR INDEX. LEGENDS AND SYMBOLS REFER DWG NO. l TSL-M0-00200.
2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
SINGLE ISOLATION VALVE IS PROVIDED & 25 NB WHEREVER DOUBLE
G ISOLATION VALVES ARE PROVIDED. All TEMPERATURE STUB G
CONNECTION SIZE SHALL BE RC1 AND RC1 1'2 FOR SERVICES HAVING
PRESSURE LESS THAN 40 KG/CM2 AND SERVICES HAVING PRESSURE
MORE THAN 40 KG/CM2 AS PER IS-554. THIS HAS BEEN FOLLOWED
BASED ON OCPL/JPVL RECOMMENDATION VIDE MAIL DATED 13.09.2011 ..... ! -
J. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST OF
N825 NN UNLESS OTHERWISE SPECIFIED.
4. ------- IN JPVL SCOPE
- - - IN L&T STGI SCOPE
F 5. FOR HEATER VENTS SEE SHEET NO 07-11.
G. FOR EMERGENCY HEATER DRAINS. FIRST HORIZONTAL PIPING RUN
DOWNSTREAM OF HEATER SHALL HAVE ATLEAST SLOPE OF 1:100.
1. HEATER DRAIN CONTROL VALVES SHALL BE LOCATED AS CLOSE
TO THE RECEIVING VESSEL AS POSSIBLE. ALSO DRAIN CONTROL 1-
VALVES tBOTH NORMAL & EMERGENCY! IS LOCATED UNDER THE WATER
LEVEL OF UPSTREM HEATER.
8. STAND PIPE WITH ISOLATION VALVE. ROOT VALVES FOR
INSTRUMENTS AND ISOLATION VALVES FOR VENTS AND DRAIN
SHALL BE SUPPLIED BY FWHV.
E VENT 9. All OCS FUNCTION SHOWN AS DOTTED ARE TO BE IMPLENTED IN E
~AA501 PLANT OCS BY JPVL.
10.SPECIAL INSTRUMENTS FOR PC TEST SHALL BE SUPPLIED BY TGV.
NOTE AASO~~ THE SAME SHALL BE TAKEN BACK AFTER COMPLETION OF PC TEST.
PG TEST THERMOWELLS SHALL BE SUPPLIED BY L&T.
1-
N"' 11.ENO PREPARATION AT FEEDWATER HEATER NOZZLE WILL BE DONE BY
_,z0 FWHV TO SUIT THE CONNECTING DRAIN PIPING.
.,.,_
0"'
12.All HIGH POINT HYDRO TEST VENTS SHALL BE CAPPED AFTER
HYDRO TEST.
<rm
<DO TSL M1 00204 02 13.PDC- PIPING DESIGN CODE
0915 ON250 G12 POT-PIPE DESIGN TABLE
D NORMAL DRAIN TO 14.SK IN TYPE THERt.fOCOUPLE SHALL BE PROVIDED FOR TEMPERATURE D
MEASUREMENT. SUPPLIED BY JPVL.
HP FEEDWATER HEATER # 7B
15.RENEWABLE IMPINGEMENT PLATE TO BE PROVIDED AT THE FIRST
CHANGE IN DIRECTION DOWNSTREAM OF DRAIN CONTROL VALVES IF
CHANGE IN DIRECTION REQUIRED DUE TO PHYSICAL ARRANGEMENT.
16. JPVLL___j DENOTES INSTRUMENT ARE IN JPVL SCOPE. -
REST OF THE INSTRUMENTS WILL BE SUPPLIED BY L&T.
N?
c i§ RELEASE STATUS DATE PROJECT'
JAY PEE NIGRIE SUPER THERMAL POWER PROJECT. 2 X 660 IIW C
AA•o~~ PRELl MI NARY
STEAII TURBINE GENERATOR AND AUXILIARIES PACKAGE
FOR INFORMATION
~••o• OWNER'
FOR APPROVAL -
PDC DESIGN DESIGN MAX OPER. MAX OPER. PIPE PDT F IELO TEST REMARKS I X FOR CONSTRUCTION ].07.201
JAIPRAKASH POWER VENTURES LIMITED
NUMBER PRESSURE TEMP. PRESSURE TEMP. CLASS PRESSURE
kg/cm2 c Q 1 COEG.C l kQ/cm21Ql IDE G. C l kg/cm2 c Q J AS-BUILT OWNER'S CONSULTANT'
H0-01 111.97 320.0 97.10 281.0 JPN 0905 167.96 1--'----.-S-1-GN-+--0-A_T_E-l !Jtf
DEVELOPIIENT CONSULTANTS PRIVATE LIIIITED
B
H0-02 111 .97 320-0 97.10 281.0 JPN 0915 167.96
~D~R~A~W:N~B~Y~-.:,:~~Ja:s-t:,.~~->:O,j_C~O~N~T~R~A~C~TnO~R~=,===-------------------~6
HD-1 112.97 320.0 97.10 281.0 JPN 0905 169.46
1-.-NE_C_H-.-+--..,.--+--,_,.-_,.-,,-l '1:J LARSEN & TOUBRO LIIIITED
HD-2 112.97 97.10 281.0 JPN 0905 169.46
~r,C;I~V~I~L~--~---r---t~~~~N7;;~..-------------------i
320.0
~ 1-E-L_E_C_T-.+ - - - f - - - 1 L&T'S CONSULTANT' 1-
L--------------------~~~~-----------------,-----------------~~~~~~~~-----------------.--------------------~~
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g, AYA 1.05.201 ~ L&T - SARGENT & LUNDY LIIIITED
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TITLE :
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~ ~~:::~~~~ :~=~~~~ :~lAC :~: :: ~= : ~~~~:~~~:: 4 23.07.20 A:-J~ N~ :tj L&T-SARGENT & LUNDY LIMITED
~ YOM ~·~~~~0 AS PER LATEST VENDeR INPUT AND PIPING AND MUST NOT BE COPIED OR LENT WITHOUT 1-PR_O_J_E_C_T_N_O.L.--:-T-20.._9_0_0_1--iSIZE : HEATER DRAIN AND VENT SYSTEM
~ ;;:~:::g;; :~=~~:~ :~ :~: : ~~ g: ~~~6~~r!~PER ..vw DATED 20 • 04 • 2012 1~ THEIR PERMISSION IN WRITING L&T-s&.L JOB NO.:LS43ooo Er'i~ 1:-oo2o4 - 1 OWG. NO. :LTSL- Ml-00:204 I SHT 01 OF 11 I~
4
16 1 15 1 14 1 13 1 12 11 10 9 .&. s 1 1 6 1 5 1 4 3 I REVISE THIS OWG. USING CAD SYSTEM ONLY
I
LTSL-M0-00951 REV 0 Page 612 of 860
• •
LTSL-M0-00951 REV 0 Page 613 of 860
LTSL-M0-00951 REV 0 Page 614 of 860
16 15 14 12 11 10 9 8 6 5 2
t 'ON'A3H t0200·lK·1SJ.1 'ON ·~MO
,--------
L 1 L
K K
REFERENCE DRAWINGS
ORAWING TITLE DRAWING NUioi!ER
GA OF LOW PRESSURE CLOSED FEED WATER l T-MO-D3071
HEATER LPH4
GA OF LOW PRESSURE CLOSED FEED WATER L T-MO-D3075
HEATER LPH3
TSL -M1 -00204-05
AA~05 VS K14
NORMAL ORA IN TO
H LP FEEOWATER
HEATER # 2A
~-----------------------+----------------~H
NOTES
1. FOR INDEX, LEGENDS AND SYMBOLS REFER OWG NO. l TSL-MJ-D0200.
2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
SINGLE ISOLATION VALVE IS PROVIDED & 25 NB WHEREVER DOUBLE
G ISOLATION VALVES ARE PROVIDED. All TEMPERATURE STUB G
CONNECTION SHALL BE WELDED TYPE RC1 AND RC1''2 FOR SERVICES
HAVING PRESSURE LESS THAN 40KG/CM2 AND FOR SERIVCES HAVING
PRESSURE MORE THAN 40 KG/CM2 AS PER IS-554. THIS HAS BEEN
.-------- FOLLOWED BASED ON OCPL/JPVL RECOIOENOATION VIDE MAIL DATED
1
I 13.09.2011.
I 3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST OF
I VENT· NB2S MM UNLESS OTHERWISE SPECIFIED.
I 4. ------- IN JPVL SCOPE
I - - - - - IN L&T STGI SCOPE
F I ._"' 5. FOR HEATER VENTS SEE SHEET NO. D7-11 F
I ._ 6. FOR EMERGENCY HEATER DRAINS. FIRST HORIZONTAL PIPING RUN
I 0
DOWNSTREAM OF HEATER SHALL HAVE ATLEAST SLOPE OF 1 :1DO.
I
~ AA501 1. HEATER DRAIN CONTROL VALVES SHALL BE LOCATED AS CLOSE
,~.--,1--~--, Ir-------J
V DCS' , / ' ..,:
TO THE RECEIVING VESSEL AS POSSIBLE. ALSO DRAIN CONTROL
VALVES I BOTH NORMAL & EMERGENCY I IS LOCATED UNDER THE WATER
r.------ ' I "~ LEVEL Of UPSTREM HEATER.
•->: --"--- :
r--; ... --,-•
,', ./ ', / : I '' LSL '}' 8. STAND PIPE WITH ISOLATION VALVE. ROOT VALVES FOR
f-~ctf~. -- INSTRUMENTS AND ISOLATION VALVES FOR VENTS AND DRAIN
E 1 LY I ---~-- SHALL BE SUPPLIED BY F WHY.
9. ALL OCS FUNCTION SHOWN AS OOTTEO.ARE TO BE IMPLENTED IN E
NOTE
PLANT OCS BY JPVL.
10.SPECIAL INSTRUMENTS FOR PG TEST SHALL BE SUPPLIED BY TGV.
THE SAME SHALL BE TAKEN BACK AFTER COMPLETION OF PG TEST.
L:.J
PC TEST THERMOWELLS SHALL BE SUPPLIED BY l&T.
11.ENO PREPARATION AT FEEDWATER HEATER NOZZLE WILL BE DONE BY
FWHV TO SUIT THE CONNECTING DRAIN PIPING.
N 12.ALL HIGH POINT HYDRO TEST VENTS SHALL BE CAPPED AFTER
D
(j.fp SHELL I
vs ~
.. HYDRO TEST.
13.PDC- PIPING DESIGN CODE
POT-PIPE DESIGN TABLE
D
14.SKIN TYPE THERMOCOUPLE SHALL BE PROVIDED FOR TEMPERATURE
MEASUREMENT. SUPPLIED BY JPVL.
15.RENEWA8LE IMPINGEMENT PLATE TO BE PROVIDED AT THE FIRST
CHANGE IN DIRECTION DOWNSTREAM OF DRAIN CONTROL VALVES IF
CHANGE IN DIRECTION REOUIRED DUE TO PHYSICAL ARRANGEl.ENT.
16. JPVL~ DENOTES INSTRUMENT ARE IN JPVL SCOPE.
REST OF THE INSTRUMENTS WILL BE SUPPLIED BY L&T.
RELEASE STATUS DATE PROJECT'
c POC DESIGN DESIGN MAX OPER.
PRESSURE
MAX OPER. PIPE POT F IELO TEST REMARKS "'
N
JA YPEE NIGRIE SUPER THERIIAL POWER PROJECT, 2 X 660 IIW C
NUMBER PRESSURE
kg/cm21gJ
TEMP.
CDEG.C J kQ/cm21QJ
TEMP.
IDEG. C l
CLASS PRESSURE
kg/cm2CgJ
i'i
NO PRELIMINARY
STEAII TURBINE GENERATOR AND AUXILIARIES PACKAGE
~~
HO-Q16 6.97 165.0 5.DO 127.4 0 JPN 0105 10.46 «- FOR INFORMATION
coo
H0-017 6.97 16S:o 5.00 127.4 JPN 0115 10.46 AA-401 FOR APPROVAL
SAIPRAKASH POWER VENTURES LIIIITED
HD-020 4.97 150.0 1.3D 93.9 JPN 0105 7.46 X FOR CONSTRUCTION 3.01.201
H0-021 4.97 150.0 1.3D 93.9 0 JPN 0115 7.46 AS-BUILT OWNER'S CONSULTANT'
H0-16 7.97 165.0 5.00 127.4 0 JPN 0105 11.96 SIGN DATE rn DEVELOPIIENT CONSULTANTS PRIVATE LIIIITED
B HD-17 7.97 165.0 5.00 127.4 0 JPN 0106 11.96 r:O:R:A:WN~B:Y~~A=sw~I:JB:s-t,~.~::.m:j~c=o~N~T~R~A~CT;O;R;~====------------------------------------~8
H0-20 4.97 150.0 1.30 93.9 0 JPN 0105 7.46
MECH. ..,. •·~·'"' '1:) LARSEN lo TOUBRO LIIIITED
~~C~I~V~I~L~.-t------t---~,L~IoT~'~S~COnNuS~U~LT;A;NuT~,~----------------------------------~
HD-21 4.97 15D.O 1.30 93.9 JPN 0106 7.46
~ ELECT. ~ LloT -SARGENT 1o LUNDY LIIIITED
1---------------------------------~~~~~~~~---------------------------------,--------------------------------~~~-=~~~~~--------------------------------r----------------------------------------i~u-~~&~l====t=~~=E~~~~~~~~~~~r-~~~-===:=~~~~~-=~~:_----i
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~ ~~:~;·.~~~~A~:~~:~ NV A~: : y~: ~:~~=~~T:~ : 23.07.20 A~~~D AS PER ATEST VENDOR INPUT AND PIPI~ AND MUST NOT BE COPIED DR LENT WITHOUT 2.1.09- 0-0- 1-!SIZE :
I--PR_O_J_E_C_T_N_O.L.----,-T- HEATER DRAIN AND
:~: :: ~~: ·: ~~~:~~~T!~PER ..... OATEO 20.04.2012 THEIR PERMISSION IN WRITING L&T-So!l. JOB NO.:L543000 UJi.':..,'~2~~ owe. NO. :LTSL-Ill-00204
15 REVISE THIS DWG •
•
LTSL-M0-00951 REV 0 • • Page 615 of 860
•
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16 I 15 I 14 I 13 I 12 I 11 I 10 9 8 6 5 3 2
t "ON"A3ij tozoo-IK-1SJ.1 'ON ·~•o I
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0115-DN250
NORMAL DRAIN FROM
LP FEEOWATER HEATER# 3
r--------------------------------, 'I
K K
J J
REFERENCE DRAWINGS
DRAWING TITLE DRAWING NUMBER
GA OF LOW PRESSURE CLOSED FEED WATER LT-loiQ-03080
HEATER LPH1 A/B-2A/B
NOTES
I. FOR INDEX. LEGENDS AND SYMBOLS REFER OWG NO. LTSL-Ioi0-00200.
2. INSTRU~NT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
SINGLE ISOLATION VALVE IS PROVIDED & 25 NB WHEREVER DOUBLE
G ISOLATION VALVES ARE PROVIDED. All TEMPERATURE STUB G
CONNECTION SHALL BE WELDED TYPE RC1 AND RC1 1'2 FOR SERVICES
HAVING PRESSURE LESS THAN 40KG/CM2 AND FOR SERIVCES HAVING
PRESSURE MORE THAN 40 KG/CM2 AS PER IS-554. THIS HAS BEEN
FOLLOWED BASED ON OCPL/JPVL RECOWENOATION VIDE MAIL DATED
13.09.2011.
3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST OF
NB25 MM UNLESS OTHERWISE SPECIFIED.
4. ------- IN JPVL SCOPE
- - - IN L&T STGI SCOPE
F 5. FOR HEATER VENTS SEE SHEET NO. 07-11 F
6. FOR EMERGENCY HEATER DRAINS. FIRST HORIZONTAL PIPING RUN
DOWNSTREAM OF HEATER SHALL HAVE ATLEAST SLOPE OF 1:100.
EMERGENCY DRAIN 7. HEATER DRAIN CONTROL VALVES SHALL BE LOCATED AS CLOSE
TO CONDENSER I TO THE RECEIVING VESSEL AS POSSIBLE. ALSO DRAIN CONTROL
~HEll) VALVES <BOTH NORMAL & EMERGENCY1 IS LOCATED UNDER THE WATER
LEVEL OF UPSTREM HEATER.
0106-DN250~ 8. STAND PIPE WITH ISOLATfON VALVE. ROOT VALVES FOR:
INSTRUMENTS AND ISOLATION VALVES FOR VENTS AND DRAIN
E SHALL BE SUPPLIED BY FWHV. E
9. ALL OCS FUNCTION SHOWN AS DOTTEO.ARE TO"BE INPLENTED IN
PLANT OCS BY JPVL.
IO.SPECIAL INSTRUMENTS F~ PG TEST SHALL BE SUPPLIED BY TGV.
THE SAME SHALL BE TAKEN BACK AFTER COMPLETION OF PG TEST.
PG TEST THERioiOWELLS SHALL BE SUPPLIED BY L&T.
11.ENO PREPARATION AT FEEOWATER HEATER NOZZLE WILL BE DONE BY
FWHV TO SUIT THE CONNECTING DRAIN PIPING.
12.All HIGH POINT HYDRO TEST VENTS SHALL BE CAPPED AFTER
HYDRO TEST.
13.PDC- PIPING DESIGN CODE
0 PDT-PIPE DESIGN TABLE 0
14.RENEWABLE IMPINGEMENT PLATE TO BE PROVIDED AT THE FIRST
CHANGE IN DIRECTION DOWNSTREAM OF DRAIN CONTROL VALVES IF
CHANGE IN DIRECTION REOUIREO DUE TO PHYSICAL ARRANGEMENT.
15.SKIN TYPE THERioiOCOUPLE SHALL BE PROVIDED FOR TEMPERATURE
MEASfEMENT •• SUPPL I EO BY JPVL.
16. JPVL DENOTES INSTRUMENT ARE IN JPVL SCOPE. -
REST OF THE INSTRUMENTS WILL BE SUPPLIED BY L&T.
17.ClEANING/FlUSHING CONNECTION DURING COWNISIONING AND
START P.
RELEASE STATUS PROJECT'DATE
c POC DESIGN DESIGN r.tAX OPER. r.tAX OPER. PIPE POT FIElD TEST REMARKS
1-=-:----:---t---i JAY PEE NIGRIE SUPER THERMAL POWER PROJECT, 2 X 660 llW C
NUMBER PRESSURE TEMP. PRESSURE TEMP. ClASS PRESSURE PRELIMINARY STEAil TURBINE GENERATOR AND AUXILIARIES PACKAGE
kg/cm2<gl CDEG.CI kg/cm2(Ql lDEG. Cl kg/cm21QI
FOR INFORMATION
H0-021 4.97 150.0 1.30 93.9 0 JPN 0115 7.46
FOR APPROVAL
HD-o26 3.97 150.0 -0.30 75.4 0 JPN 0105 5.55 IAIPRAKASH POWER VENTURES LllliTED
X FOR CONSTRUCTION l.07.20t
HD-Q27 3.97 150.0 -0.30 75.4 0 JPN 0115 5.55
AS-BUILT OWNER"S CONSULTANT'
H0-028 3.97 150.0 -0.70 55.9 0 JPN 0105 5.55
SIGN DATE ~ DEVELOPMENT CONSULTANTS PRIVATE LllliTED
B HD-029 3.97 150.0 -0.70 55.9 0 JPN 0115 5.55 t-;~::;;--;;-;;t-:::;;-t-:-::::1-;;;;==-;;;;;;U;;:=~=--------------------~
H0-26 3.97 15o.o -o.3o 75.4 o JPN o•os 5.55 1-DR..-A_WN_s_Y-+-·-··_,_
...
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H0-27 3.97 150.0 -0.30 75.4 0 JPN 0106 5.55 IIECH. sov t.05.20t '1/ LARSEN lo TOUBRO LllliTED
H0-28 3.97 150.0 -0.70 55.9 0 JPN 0105 5.55 i:irCOI;-;V;;I;-L-:-.-t---~-~7L"a.T"'";;;S:r:co=Ns"'U.;LT;A;N""T",:------------------~
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REV. DATE REPARE REVIEWED C'l SES APPROVED REVISIONS REV. DATE REPAR£0 . . CH. CIVILREEVLEIECIET.D C'l SES APPRO!ED REVISIONS SES NNP 1.05.20! SCALE: NTS
A ,..cH. CIVIL ELECT. o o Jl. LAT-SARGENT A LUNDY LIMITED APPO. BY ..., ,. 05•201 PIPING AND INSTRUMENTATION DIAGRAil A
~ ;~-.~~·.;~11~ .~:~~:~ ::/AC .~~ H:: y~:. ~ ~:::~:=~~:~::: 4 23.07.20 3 AS J8 " I~A HNP YON ,._ ~~~~0 AS PER LATEST VEND~ INPUT AND PIP INC
DRAWING AND DESIGN IS THE PROPERTY OF
AND MUST NOT BE COPIED OR LENT WITHOUT I-PR-O_J_E-CT_N_O'-.--,-T-20L9-0_0_I-ISIZE :
TITLE:
HEATER DRAIN AND VENT SYSTEil
2 12.12.2011 ASW/JSS NV AU HNP YON OR CONSTRUCTION THEIR PERMISSION IN WRITING ~~==-~~-_:~~~-{FLFiiiiSLL:iE-II;-;I,-Cl0-2-.-.-5--jr._-:-::---:-:--:-:::::---:-~===----r
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3 23.05.2012 ASW/JBS MY AVA NP OM OR APPROVAL AS PER WOM DATED 20 •. 04.2012 L&T-S&L JOB NO.: L543000 y, OWG. NO. :L TSL·}(l-00204 11
SHT OS OF 1 4
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DRAWING TITLE
CA OF HIGH PRESSURE CLOSED FEED WATER
HEATER HPHSA/8
DRAWING NUMBER
L T-M0-03058
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F 0"'
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HAVING PRESSURE LESS THAN 40KG/CM2 AND FOR SERIVCES HAVING
PRESSURE MORE THAN 40 KG/CM2 AS PER IS-554. THIS HAS BEEN
FOLLOWED BASED ON DCPL/JPVL RECO"*'AENDATION VIDE MAIL DATED
--
F
! o I !_ ________________ 1 ~ 4 /)... ~ !• i,. I E;~ i L"':,· 0306-0N150 13.09.2011.
~~ i r-i
I
0 i I o 3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST OF
1 o I ! >llRso2 i ffisR502 ' . ,---------------..! LO i r ~ ~ ~ i i NB25 WM UNLESS OTHERWISE SPECIFIED.
! ~~ zs ,~-t8~, I 1 LO i 0105~ 0105~ i il ~~ i i 4. ------- IN JPVL SCOPE
E
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j
j
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[_·_"]ITEMS WITHIN THIS BOUNDARY ARE TO BE SUPPLIED BY FWHV. E
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T 38 T 3A T
~ 31
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j_ _________ TsT g-,------------rh- ~------------,
6. POC- PIPING DESIGN CODE
PDT-PIPE DESIGN TABLE
z 7. **DENOTES THAT OPERATING PARAMETERS WILL BE FINALIZED
v'0
~g HIGH PRESSURE HEATER 88
ij ~~
~ ~
ij AFTER RECE IV lNG INPUT FROM U-48. -
a>O
1LA012AC001 j m 0 j HIGH PRESSURE HEATER 76
1LAD22A.C001
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RELEASE STATUS OATE PROJECT'
c f - , - - - - - - - - - - t - - - - - 1 JAYPEE NIGRIE SUPER THERIIAL POWER PROJECT, 2 X 660 MW C
PDC DESIGN DESIGN MAX OPER. MAX DPER. PIPE PDT FIELD TEST REMARKS I ...., L-----------------------T-----------------------J5 PRELIMINARY
NUMBER
:;;,s,:ku,~El ctif~~Cl :;Jz.:k"c"J, <D~~~P.CI CLASS :;Jz.:k"c"J, t I "; FOR INFORMATION
STEAII TURBINE GENERATOR AND AUXILIARIES PACKAGE
;--, __H_DV_-_7_+__
1r
6_8_.9_7_+-_2_8_5_._o_!-_5_9_.6_0_+__
27_6_._o_t-_o_-t_J_P_N_06_0_S--f--10_3_._4_6_!-------i I TO. FLOOR ORA IN fI TO FLOOR DRAIN
FOR APPROVAL
JAIPRAKASH POWER VENTURES LIIIITED -
HDV-70 68.97 285.0 11.90 192.6 D JPN 0605 103.46 1_ _ _!>~~--~-=--=--=--=--=--=-> I DNSO ,--------...... X FOR CONSTRUCTION 3.07-201
HOV-71 38.00 247.0 0.20 155.2 D JPN 0306 57 ------;;::'>_______ )' AS-BUILT OWNER'S CONSULTANT'
HOV-72 3.50 150.0 0.20 104.8 0 JPN 0105 5-25 f-.L..:_:_::.:.:'-r-5-IG-N-t-D-A-TE----j !Jilt DEVELOPIIENT CONSULTANTS PRIVATE LIIIITED
Blr~H~D~V-~8~-t-1~1~0--9~7~+-~32~0_.~o-t-_9_6_.~80~+--3-08_._o_t-~0-t-J_P~N~09~0~5---j--1~66~--4~6-t---------j r:D:R~A=WN~B~Y~~•=sw~/~JB:s-t,~.~~.m=r~C~O"N~TnR7AnCT~O;R;~::::____________________________________~8
HDV-80 110.97 320.0 11.90 190.4 0 JPN 0905 166.46 MECH. SIN ,_.,_,., \;IJ LARSEN ~ TOUBRO LIIIITED
HOV-81 36.00 244.0 0.20 129.9 D JPN 0306 54 ~ ~C~I~V:;-IL:-.:-r------r---tL'"'&'"T"''""S-,C"'O"'N"'S""'U"'L~T~A~N""T"',---------------------l
HOV-82 3.50 150.0 0.20 104.8 0 JPN 0105 5.25 0 -
NT-1 1.02 55.0 0.02 35.0 D JPN 0105 1.52 ~ ELECT. ~ LU - SARGENT L LUNDY LIIIITED
~========~======~========:b====OO~AW~I~NdGbR=EL=E=A=SE~RE~C=O~RO====:b========d=========~=======,==~----------------------------~OO~A~W~IN~G~R=E~L~EA~S~E~R~E7Co=R~O---------------------------------r-T-H_I_S__
O_R_AW--IN_G__A_N_0__0_E_S_I_G_N__
IS__T_H_E__P_R_O_P_E_R_T_Y__
OF-it CS&ESI •.: I.~.~~ TITLE :
SCALE: NTS
REV. DATE PREPARE REVIEWED APPROVED REVISIONS REV. DATE REPAR£0 H. CIVIL REEVLEIECWET.O C&l SES APPlWVtO REVISIONS ...,... 1•05 · 201
A~~~~~~~~iji~~~C~H~-~CI~V~IL~E~L~EC~T~.~c~&~I~~SE~s~~~~~ii~~~lt~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~a~A-~~~~~~~~~~~~~~~~~~ r-A~P;P;D~.~B~Y~--:,~=--t~,.=~~-Z<l:,j---------~
PIPING AND INSTRUMENTATION DIAGRAM A
0 21.05.2010 SW/JBS NV AYA NP ON OR CONSTRUCTION 4f 23.07-~3 A /J AYA NP n YON-~ EVISED AS PER lATEST VENDOR INPUT AND PIPING f--.c__:__L_ _ _.L..----jSIZ£ : HEATER DRAIN AND VENT SYSTEil
1 2<4.05.2011 SW/JBS NV/AC AYA NP OM OR CONSTRUCTION l.A\, tH'l.»r- LAYOJT L&T-SARGENT COPIED
AND MUST NOT BE & LUNDY LIMITED
OR LENT WITHOUT PROJECT NO. :T209001
~ ~~:~~:~6:; ~=~~:~ :~ :~~ ~~ Yg: g~ ;~~~~~~r!~FER KJN DATED 20 • 04 • 2012 ~ THEIR PERMISSION IN WRlTING L&T-S&. JOB NO.:L543ooo [r1s'L~,-oo 2o~-7 OWG. NO.:LTSL-Ml-00204 I SHT070F 11 II
16 I 15 I 14 1 13 1 12 11 10 1 9 £ 8 1 1 1 6 1 5 1 4 3 I REVISE THIS owe. USING CAD SYSTEM ONLY
I
LTSL-M0-00951 REV 0 Page 618 of 860
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16 15 14 13 12 I 11 I 10 I 6 5 2
t "0N"A3~ t0200·11'1·1SJ.1 "ON "9•0 I POC DESIGN DESIGN MAX OPER. MAX OPEA. PIPE POT FIELD TEST REMARKS
NUMBER PRESSURE TEMP. PRESSURE TEW. CLASS PRESSURE
TO CONDENSER kg/cm21g 1 <DE G. C l kgtcrrelgl IDE G. C I kg/cm21 g 1
L TSL-M1 -00204 1 0 HDV-5 13.97 205.0 8. 20 176.0 JPN 0305 20.95
I-14
0305-0NZOO
HOV-50 13.97 205.D 2.10 156.0 JPN 0305 20.95
HDV-6 34.97 245.0 28.30 232.0 JPN 0306 52.45
v
HDV-60 34.97 245.0 11.90 197.7 JPN 0306 52.45 -
HOV-61 18.00 207 .o 0.20 163. B JPN 0306 27
~
0
HOV-62 3. 50 150.0 D. 20 104.8 JPN 0105 5.25
0 LAA1 Jl 285-0
'x HOV-70 68.97 11.90 JPN 0605
r
CG082 -- 192.6 103.46
K ZSO ~ HDV-80 110.97 320.0 11.90 190.4 JPN 0905 166.46 K
OPERATING VENTS HEADER NT-1 1.02 55.0 0.02 35.0 JPN 0105 ,, 52
~
VENT TO VENT TO
0305-0N200
REFERENCE DRAWINGS
DRAWING TITLE DRAWING NUMBER
GA OF HIGH PRESSURE CLOSED FEED WATER L T -M0-03066
HEATER HPH6A/8
H GA OF DEAERATOR L T -M0-031 00 H
G • G
~------------------------~------------~
NOTES
HOV-6 NT -1 1. FOR INDEX, LEGENDS AND SYMBOLS REFER DWG NO. L TSL-M0-00200.
FROM NITROGEN
SUPPLY SYSTEM 2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
F 0306-DN25 AA201 0105-0N25
L TSL Mix 00220 < LTSL-M1-00220 <,~
SINGLE ISOLATION VALVE IS PROVIDED &. 25 NB WHEREVER DOUBLE
ISOLATION VALVES ARE PROVIDED. ALL TEMPERATURE STUB F
D306-0N25 I 01 05 ON25 XX 1 LA032
CONNECTION SHALL BE WELDED TYPE RC1 AND RC1 1"2 FOR SERVICES
HAVING PRESSURE LESS THAN 40KG/CM2 AND FOR SERIVCES HAVING
HOV-61NT -1 BR501
PRESSURE MORE THAN 40 KG/CM2 AS PER IS-554. THIS HAS BEEN
TO BLOW OFF
STANO PIPE TO BLOW OFF r~e·~~~!:::~{-------------------~~~~~A
0306-DN25 0306 0N40
114 FOLLOWED BASED ON OCPL/JPVL RECOMMENDATION VIDE MAIL DATED ;....._
BR505 STAND PIPE 13.09.2011.
. .
~
l,~~~~~~,:
t,------h
0306-0N25 0306 ON40
(~~- 3. DRAINS AND VENTS CONNECTION ON PIPELINES SHAll BE ATLEAST OF
~
Dv '"'R'""I ,{~~~~~~~'• I I N825 MM UNLESS OTHERWISE SPECIFIED.
E BR504
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1. FOR INDEX. LEGENDS AND SYMBOLS REFER OWG NO. L TSL-M0-00200.
2. INSTRUMENT PRESSURE CONNECTION SIZE SHALL BE 15 NB WHEREVER
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PDC OES I GN DESIGN MAX OPER. MAX OPER. PIPE PDT FIELD TEST REMARKS 13.D9.2011.
NUMBER PRESSURE TEMP. PRESSURE TEMP. CLASS PRESSURE 3. DRAINS AND VENTS CONNECTION ON PIPELINES SHALL BE ATLEAST OF
kg/cm21 g 1 IOEG.Cl kg/cm21QI WEG. Cl kQ/cm21gl
N825 UM UNLESS OTHERWISE SPECIFIED.
HOV-3 3.50 150.0 1.30 125.0 0 JPN 0105 5.25 4. ------- IN JPVL SCOPE
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HDV-31 3.50 139.0 0.20 119.1 D JPN 0105 5.25
6. PDC- PIPING DESIGN CODE
HOV-32 3.50 150.0 0.20 104.8 0 JPN 0105 5.25 POT-PIPE DESIGN TABLE
7. **DENOTES THAT OPERATING PARAMETERS Will BE F JNALIZED
HOV-4 5.97 165.0 4.40 155.0 0 JPN 0105 8.95
AFTER RECEIVING INPUT FROM U.48.
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PIPING AND INSTRUMENTATION DIAGRAM A
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L---------~~--------------------------------------~----------------------------------------~----------------------------------------~--------------------------------------~·
LTSL-M0-00951 REV 0 Page 620 of 860
• •
LTSL-M0-00951 REV 0 Page 621 of 860
LTSL-M0-00951 REV 0 Page 622 of 860
LTSL-M0-00951 REV 0 Page 623 of 860
LTSL-M0-00951 REV 0 Page 624 of 860
LTSL-M0-00951 REV 0 Page 625 of 860
LTSL-M0-00951 REV 0 Page 626 of 860
LTSL-M0-00951 REV 0 Page 627 of 860
JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Operation & Section F.
Maintenace Volume 1 LP Bypass
Manual System
Table of Contents 629
1. Overview of LP Bypass System 631
2. System Description 649
3. Normal Operation, Start-up / Shutdown 664
4. Emergency Operations & Alarms 668
5. Instrumentation & Process Control 671
6. Interlock & Protection 677
7. Instrument & Drive List 680
Abbreviations 686
Exhibits 688
LTSL-M0-00951 REV 0 Page 628 of 860
JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Table of Contents
1.0 SYSTEM OVERVIEW
1.1 Purpose
1.2 Specifications
1.2.1 Design Data of Major Equipment
1.3 References
1.3.1 P & ID
1.3.2 System documents
1.3.3 Heat Balance Diagram
1.3.4 Vendor Drawings / Documents
2.0 SYSTEM DESCRIPTION
2.1 Overview
2.2 Major Components
2.3 System Piping
2.3.1 LP Bypass System Piping
2.3.2 LP Bypass Spray water control System
2.3.3 LP Bypass system Piping Drains
2.4 Hydraulic Power Unit
2.4.1 Application
2.4.2 Signals
2.4.3 Functions
2.4.4 Supplies
2.4.5 Junction boxes
3.0 NORMAL OPERATION, START-UP AND SHUTDOWN
3.1 Description of Operation
3.1.1 Normal Start-up
3.1.2 Normal Operation
3.1.3 Normal Shut Down
3.2 Checklist
LTSL-M0-00951 REV 0 Page 629 of 860
JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
4.0 EMERGENCY OPERATION AND ALARMS
4.1 Emergency Operation
5.0 INSTRUMENTATION AND PROCESS CONTROL
5.1 Process Control
5.1.1 LP Bypass Pressure Control Valves (1LBH01AA081 & 1LBH01AA082)
5.1.2 LP Bypass Temperature Control Valve (1LCE45AA081 & 1LCE45AA082)
6.0 INTERLOCKS AND PROTECTION
6.1 LP Bypass Steam Isolation Valves (1LBH01AA051 & 1LBH01AA052)
6.2 Spray Water Isolation MOV (1LCE45AA001 & 1LCE45AA002)
6.3 LP Bypass Drain MOV (1LBH01AA001 & 1LBH01AA002)
6.4 LP BYPS DRIPLEG MOV (1LBH01AA451, 1LBH01AA452, & 1LBH01AA453)
7.0 INSTRUMENT & DRIVES LIST
7.1 Instrument List
7.2 Drives List
ABBREVIATIONS
EXHIBITS
LTSL-M0-00951 REV 0 Page 630 of 860
JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
1.0 OVERVIEW OF LP BYPASS
SYSTEM
LTSL-M0-00951 REV 0 Page 631 of 860
JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Chapter 1
Overview of LP Bypass System
1.1 Purpose
The purpose of LP Bypass system O&M manual document is to provide the
operating personnel with necessary information to safely operate and maintain the
LP Bypass system & associated equipment.
The scope of the manual covers an overview of the LP Bypass System, description
of its major components with associated equipment & devices and details of the
startup, shutdown and normal operation and process control.
LP bypass line is tapped off from equalizing line of hot reheat line. The line is then
bifurcated into two lines near LP Bypass valve. Hydraulic-actuated LP bypass steam
isolation valves are provided to isolate HRH steam system from LP bypass steam.
Hydraulic-actuated 2 X 50% LP bypass pressure control valves bypasses IP/LP
turbine to maintain HRH steam pressure at a set point during start-up, shutdown,
load rejection or turbine trip condition.
LP Bypass spray water line is tapped off from condensate extraction pump discharge
header. The line is then bifurcated into two lines near LP Bypass spray water valves.
Condensate will be sprayed in de-superheaters of LP Bypass system to control the
temperature of Bypassed steam. LP Bypass spray water supply system consists of a
hydraulically operated spray control valve along with spray water isolation MOV.
This isolation MOV will remain open during normal operation.
All LP Bypass control valve consists of individual valve drain lines. Each LP Bypass
valve drain line connected to Turbine flash tank consists of a power actuated
ON/OFF valve.
LTSL-M0-00951 REV 0 Page 632 of 860
JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Notes:
1. It is advisable to read this manual carefully to achieve the performance objective.
2. The scope of the document covers the overall system description for the LP
Bypass system, description of its major components and associated auxiliaries &
system startup, shutdown, operation & process control.
3. If the LP Bypass system equipment and components are operated under
conditions different than its design, it is possible that the system may not achieve
its performance objectives and is likely to result in serious trouble.
LTSL-M0-00951 REV 0 Page 633 of 860
JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
1.2 Specifications
1.2.1 Design Data of Major Equipment
A. LP Bypass Steam Isolation Valve
Valve description
Unit#1: 1LBH01AA051, 1LBH01AA052
Valve Tag
Unit#2: 2LBH01AA051, 2LBH01AA052
T/A Drawing 202835-1CH
Valve Type NA80-700
Valve Make CCI Switzerland
Quantity 4 (2/Unit)
Valve Sizing ISA 75.01
Design Code DIN EN 12516-2
Hydrotest Pressure 2 X Design Pressure
Body Type Angle
Body Material A182-F91
Nozzle Material In A182-F91
Connection In BWE acc. to ANSI B16.25
Nozzle Material Out A182-F91
Connection Out BWE
Units
Design Pressure in kg/cm²a 72.4
Design Pressure Out kg/cm²a 72.4
Design Temp. In °C 604
Design Temp. Out °C 604
Hydrotest Press. In kg/cm²a 143.8 (140 barg)
Hydrotest Press. Out kg/cm²a 143.8 (140 barg)
Valve trim
Type Pressurized
Characteristic Modified linear
Flow Direction Flow to close
LTSL-M0-00951 REV 0 Page 634 of 860
JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Leakage Class MSS-SP61
Rated Cv 5592
XT 0.79
Rated Travel (mm) 211
Plug / Seat / Piston guide A182-F91
Service conditions
Fluid Steam
Case 1 Case 2 Case 3 Case 4 Case 5
60% BMCR
30% BMCR
Units 60% BMCR heat 30% BMCR
with
Just after with input with with
Boiler Island
FCB Houseload Boiler Houseload
Operation
Island
operation
Flow
kg/h 778407.60 523467.03 501893.90 230099.70 311122.50
Rate
Inlet
kg/cm²a 61.50 24.00 24.00 24.00 13.00
Pressure
Outlet
kg/cm²a 59.74 21.91 22.17 23.64 11.68
Pressure
Diff.
kg/cm²g 1.76 2.09 1.83 0.36 1.32
Pressure
Inlet
Tempera °C 596.0 560.0 530.0 520.0 520.0
ture
Outlet
Tempera °C 595.4 559.18 529.2 519.84 519.4
ture
Required
5592 5592 5592 5592 5592
Cv
Travel % 100% 100% 100% 100% 100%
Noise
Level,
dBA 62 79 76 46 79
un-
insulated
Line description
Pipe Dimension In ID572.4xTHK44
Pipe Dimension Out ID480xTHK45
Pipe Material In SA335-P91
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Pipe Material Out A182-F91
Valve Actuator
Type Hydraulic
Model / Size GHZ 100/30-330
Actuator Orientation vertical up
Stem Orientation vertical
Fail Mode Fail close
Supply Pressure 164.2 kg/cm²a (16MPag)
Valve Positioner
Positioner Type Electro-Hydraulic
Model N/A
I/P Transducer N/A
Input Signal ON/OFF
Pos. Transmitter N/A
Limit Switch R +4K
Solenoid Valve
Trip Mode Device SSB
Function open
Quantity 1
Trip Mode Device SSB
Function close
Quantity 1
Sep. Accumulator yes
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B. LP Bypass Steam Control Valve
Valve description
Unit#1: 1LBH01AA081,
1LBH01AA082
Valve Tag
Unit#2: 2LBH01AA081,
2LBH01AA082
T/A Drawing 202835-1CH
Valve Type NBSE80-700-3
Valve Make CCI Switzerland
Quantity 4 (2/Unit)
ISA 75.01/ IBR Form - III C qualified
Valve Sizing
No. of stages: 3
Design Code DIN EN 12516-2
Hydrotest Pressure 2 X Design Pressure
Body Type Angle
Body Material A182-F91
Nozzle Material In A182-F91
Connection In BWE
Nozzle Material Out A387-Gr.22Cl.2
Connection Out BWE acc. to ANSI B16.25
Units
Design Pressure In kg/cm²a 72.4
Design Pressure Out kg/cm²a 9
Design Temp. In °C 604
Design Temp. Out °C 585
Hydrotest Press. In kg/cm²a 143.8 (140 barg)
Hydrotest Press. Out kg/cm²a 17 (15.5 barg)
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Valve trim
Type Pressurized
Characteristic Modified linear
Flow Direction Flow to close
Leakage Class MSS-SP61
Rated Cv 3758
XT 0.84
Rated Travel (mm) 310
Plug / Seat / Piston guide A182-F91
Service conditions
Fluid Steam
Case 1 Case 2 Case 3 Case 4 Case 5
60% BMCR
60% 30% BMCR
Units heat 30% BMCR
BMCR with
Just after input with With
with Boiler Island
FCB Boiler Houseload
Houseload Operation
Island
operation
Flow 778407. 523467.0 230099.7 311122.5
kg/h 501893.90
Rate 60 3 0 0
Inlet kg/cm²
59.74 21.91 22.17 23.64 11.68
Pressure a
Outlet kg/cm²
6.94 4.58 4.31 1.97 2.66
Pressure a
Diff. kg/cm²
52.80 17.33 17.86 21.67 9.02
Pressure g
Inlet
Tempera °C 595.4 559.18 529.2 519.84 519.4
ture
Outlet
Tempera °C 171.8 164.3 163.4 155.3 157.8
ture
Required
1649 2983 2769 1182 3249
Cv
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Travel % 46% 77% 72% 35% 84%
Trim Exit
Kinetic kPa 1295 346 372 481 170
Energy
Sound
Level,
dBA 104 98 98 97 94
un-
insulate
Velocity
m/s 110.9 110.9 110.7 110.0 110.5
at outlet
Line description
Pipe Dimension In ID480xTHK45
Pipe Dimension Out OD1016xTHK22
Pipe Material In A182-F91
Pipe Material Out A691 2-1/4Cr Cl.22
Valve Actuator
Type Hydraulic
Model / Size GHZ 80/30-330
Actuator Orientation horizontal
Stem Orientation horizontal
Fail Mode Fail close
Supply Pressure 164.2 kg/cm²a (16MPag)
Open Time (s) modulating < 8s trip < 3s
Close Time (s) modulating < 8s trip < 3s
Valve Positioner
Positioner Type Electro-Hydraulic
Model PVR12-2
I/P Transducer N/A
Input Signal 4-20 mA
Increasing Signal Valve open
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Pos. Transmitter RSG 16+4K
Limit Switch Incl. in Position Transmitter
Solenoid Valve
Trip Mode Device SSB
Function open
Quantity 1
Trip Mode Device SSB
Function close
Quantity 1
Sep. Accumulator yes
C. LP Bypass Spray Water Control Valve
Valve description
Temperature control valve with hydraulic
actuator:
Valve Tag
Unit#1: 1LCE45-AA081, 1LCE45-AA082
Unit#2: 2LCE45-AA081, 2LCE45-AA082
Dwg. No. B92101
Application Spray water control valve
Model 840H
Design ASME B16.34, latest edition
Valve Make CCI Switzerland
Quantity 4 (2/Unit)
Valve trim
Trim type ANTI_CAVITATION
Trim Size 5in
Rated Cv 200
Trim Char. EQ - %
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Number of Pressure Reducing
1 - Stage
Stages
Plug Type Balanced
Stem Material 410SS + HT
Plug Material 410SS + HT
Seat Material 410SS + HT
Guide Material 410SS + HT
Line description
Pipe Dimension In 6” Sch 40
Pipe Dimension Out 6” Sch 40
Pipe Material In A106 Gr. B
Pipe Material Out A106 Gr. B
Misc.
Seat Leakage ANSI Class V
Open Time (s) <8 sec (Trip < 3 sec)
Close Time (s) <8 sec (Trip < 3 sec)
Weight 250 kg
Service conditions
Fluid Liquid
Critical Pressure 225 kg/cm²a
Case 1 Case 2 Case 3 Case 4 Case 5
60% BMCR
Plant 30% BMCR
Units 60% BMCR heat 30% BMCR
conditions with
Just after with input with With
Boiler Island
FCB Houseload Boiler Houseload
Operation
Island
operation
Flow rate kg/h 264462.43 165345.40 145367.93 64029.41 88003.82
Inlet
kg/cm²a 15.96 24.87 27.83 31.78 31.44
Pressure
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Inlet
Temperat °C 54.2 45.92 45.09 38.84 39.53
ure
Outlet
kg/cm2 a 12.16 8.82 8.37 5.42 6.28
Pressure
Diff.
kg/cm² 3.8 16.05 19.46 26.36 25.16
Pressure
Specific
SG 0.9867 0.9909 0.9913 0.9940 0.9937
Gravity
Vapor
kg/cm2 a 0.1540 0.1021 0.09786 0.07046 0.07311
Pressure
Viscosity cP 0.5109 0.5870 0.5957 0.6679 0.6593
Required
159.45 48.4 38.64 14.6 20.54
Cv
Travel % 82.7 48.1 44.3 26.8 33.6
Predicted
< 85 68.15 75.49 76.18 74.59 75.67
SPL
D/S
Valve 4.080 2.540 2.230 0.980 1.340
Velocity
U/S
Valve 3.340 2.080 1.830 0.804 1.100
Velocity
Cavitatio
n/Flashin None None None None None
g
Noise
dBA < 70 75.49 76.18 74.59 75.67
level
Valve Body/ Bonnet
Type GLOBE
Size 6" (150A)
In 42 kg/cm² g
Design Pressure
Out 42 kg/cm² g
In 55 °C
Design Temperature
Out 55°C
In ASME 300#
Rating(s)
Out ASME 300#
Material A216 WCB
Connect In ASME 300# BW (Same as Body)
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Connect Out ASME 300# BW (Same as Body)
Flow Dir. Over Flow
Bonnet Type Standard
Bonnet Seal Standard
Packing Type Standard
Packing Material V – PTFE (25% G.F)
Valve Actuator
Actuator Type Electro Hydraulic
Mfr / Model CHZ 50/20-100
Failure Mode Valve Open
Supply Type Hydraulic
Avail. Supply (Min) 165 kg/cm²g
Avail. Supply (Max) 165 kg/cm2g
Stem Orientation Vertical Up
Valve Positioner
Positioner Type Electro-Hydraulic
Mfr / Model CCI Standard
Input Signal 4 ~ 20 mA DC
Increasing Signal To close valve
Cam Characteristic LINEAR
Valve Accessories
Filter (Filter Reg) N/A
Limit/Torque Switch Integral to Position transmitter
Position Feedback RSG16+4K
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I-P Transducer N/A
Solenoid Valve(s) Yes, for close
Elect Housing STD Per Specification
D. Hydraulic Power Unit
Valves description
Valves connected Actuators Quantity
NBSE 80-700 GHZ 80/30-330-V 2
NA 80-700 GHZ 100/30-330-V 2
840 H 5” GHZ 50/20-65-V 2
System data
Hydraulic system diagram 103.236.653
Electrical connection diagram YB101 / YB102
Hydraulic Power Unit
Type HV200AH
Dimensional Drawing 103.226.757
Functional Diagram 103.237.469
Extra drip tray Yes
Syst. pressure P1 160 kg/cm²
Syst. pressure P2 N/A
Syst. pressure P3 N/A
Pr. relief valve P1 170 kg/cm²(g)
Pr. relief valve P3 N/A
Accumulator charging on 216 kg/cm²(g)
Accumulator charging off 240 kg/cm²(g)
Standby pump on 201 kg/cm²(g)
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Standby pump off 216 kg/cm²(g)
Pressure too low P << 120 kg/cm²(g)
Pres. too high P > 250 kg/cm²(g)
Level low L < 200 mm
Level too low L << 170 mm
Fan on 55 °C
Fan off 50 °C
Heater on 30 °C
Heater off 35 °C
Temperature too high T >> 70 °C
Technical Details
Hydraulic fluid/ISO VG Mineral Oil / VG 46
Tank capacity 310 l
Usable capacity 190 l
Pump discharge rate 8.4 l/min
Motor protect. Class/isolation IP55 / F
Phase/volt/frequency 3/415/50
Power redundancy No
Signal voltage 24 VDC
Signal Redundancy No
Pump mot. type/qty. E5AZAE 112M-4; IMB5
Power/speed 4 kW / 1445 rpm
Fan motor 5.5AZE 63B-4; IMB5
Power/speed 0.18 kW / 1350 rpm
Filter motor type 5.5AZAE 71B-4; IMB5
Power/speed 0.37 kW / 1390 rpm
Heating/wattage N/A
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Phase/volt/frequency N/A
Local Control SHV200AS
Main pump motor 000.101.008.841
Filter pump motor 000.101.008.772
Cooler motor 000.101.009.375
Heater 000.101.009.151
Accumulator
Fluid connection M50x1.5
Nitrogen connection Ø22
Nominal capacity / Quantity 50 l / 1
Gas filling pr. at room temp. 120 kg/cm²
Admissible operating press. 330 kg/cm²
Conformity CE (97/23/EG)
Spec. material bladder NBR
Spec. material seals NBR
Standby accumulator
Fluid connection M50x1.5
Nitrogen connection Ø22
Nominal capacity / Quantity 20 l / 4
Gas filling pr. at room temp. 80 kg/cm²
Admissible operating press. 330 kg/cm²
Conformity CE (97/23/EG)
Spec. material bladder NBR
Spec. material seals NBR
Pressure gauges (whole
MPa/Bar
system)
Additional pressure switch No
Switching point "pressure low" --- kg/cm²
Accumulator filling device Yes
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Hydraulic Piping
Pipe supplier CCI
Pipe material Stainless steel
Pipe connection Screwed
Connector manufacturer Ermeto
1.3 References
1.3.1 P & ID
a) LP Bypass Steam System P&ID Dwg. No. LTSL-M1-00205 (Sheet 1/1)
b) PID Index, Legends and Symbols Dwg. No. LTSL-M0-00200 (Sheet1 to 4)
c) Main Steam & Reheat Steam System P&ID Dwg. No. 97000-2111-1
d) Legend for P&ID Dwg. No. 97000-21101
e) Condensate System P&ID’s Dwg. No. LTSL-M1-00201 (Sheet 1 to 6)
1.3.2 System documents
a) System Description, Operation & Control for LP Bypass Steam System Doc. No.
LTSL-M1-00155
b) Logic Drawings Dwg. No. LTSL- I1-00200
c) Process Control Function Dwg. No. LTSL-I1-0202
1.3.3 Heat Balance Diagram
a) HMBD’s for Bypass Operation Dwg. No. JPN-SK-M-042
1.3.4 Vendor Drawings / Documents
a) CVDS & Valve Sizing Calculation – NA-80-700+NBSE-80-700-3 Doc./ Dwg. No.
CCI-M0-05511
b) CVDS & Valve Sizing Calculation – Spray Water CV Doc./ Dwg. No. CCI-M0-
05514
c) Spray Water Isolation MOV Doc./ Dwg. No. LTV-M0-04928
d) Drain Line MOV’s Doc./ Dwg. No. LTV-M0-05016/17
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e) LP Isolation & CV TA Drawing (NA-80-700+NBSE-80-700-3) Doc./ Dwg. No.
CCI-M0-05510_ Rev: 4/ Dwg. No. 202835-1 CH
f) Spray Water CV TA Drawing -840-H Doc./ Dwg. No. CCI-M0-05513_ Rev: 3 /
Dwg. No. B92101
g) Hydraulic Power Supply Unit Data sheet Doc./ Dwg. No. CCI-I0-05528_ Rev: 2
h) Hydraulic Power Supply Unit Recommended System Logics & Write-up Doc./
Dwg. No. 202835_HV200-350AH_ Rev: 0
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2.0 SYSTEM DESCRIPTION
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Chapter 2
System Description
2.1 Overview
The LP Bypass steam system consists of following:
• LP bypass line is tapped off from equalizing line of hot reheat line. The line is
then bifurcated into two lines near LP Bypass valve.
• LP Bypass spray water line is tapped off from condensate extraction pump
discharge header. The line is then bifurcated into two lines near LP Bypass spray
water control valve.
2.2 Major Components
LP Bypass steam system will have the following major components:
• LP Bypass System Piping
• LP Bypass Spray Water Control System
• LP Bypass System Piping Drains
• LP Bypass Isolation and Control Valve
• Hydraulic Power Pack
2.3 System Piping
2.3.1 LP Bypass System Piping
During startup and shutdown operation, the IP/LP Turbine bypass system routes Hot
Reheat Steam to condenser through the LP bypass valves and desuperheaters. 2 x
50% LP Bypass valves will be provided to bypass IP/LP turbine. Each LP Bypass
system consists of a hydraulically operated shut off valve (1LBH01AA051 /
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1LBH01AA052) and a hydraulically operated pressure control valve (1LBH01AA081
/ 1LBH01AA082).
Spray water will be provided by the Condensate system for the LP bypass
desuperheater. The LP bypass system will be used to facilitate start-up, turbine
trip/stop and overpressure relief during abnormal increasing of Hot Reheat Steam
pressure.
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Flow Diagram: LP Bypass Steam System
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DCS Graphics: LP Bypass Steam System
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2.3.2 LP Bypass Spray water control System
Condensate will be sprayed in desuperheaters of LP Bypass system to control the
temperature of Bypass steam. The spray water is provided from the CEP Discharge
header. Each spray water supply system consists of a motor operated shut off valve
(1LCE45AA001 / 1LCE45AA002) and a hydraulically operated spray control valve
(1LCE45AA081 / 1LCE45AA082). A drain connection is provided in the pipe
between Shut off valve and spray control valve.
2.3.3 LP Bypass System Piping Drains
A low point drain connection with drip leg will be provided in common LP Bypass line
and each LP Bypass valve upstream piping. The drain lines consist of an isolation
valve and a motor operated drain valve (1LBH01AA451 / 1LBH01AA452 /
1LBH01AA453). All LP Bypass control valve consists of individual valve drain lines.
Each LP Bypass valve drain line connected to Turbine flash tank consists of a power
actuated ON/OFF valve (1LBH01AA001 / 1LBH01AA002). The steam trap (AA801 /
802) is provided in the bypass line of this drain On/OFF valve with manual isolation
valves.
2.4 Hydraulic Power Unit
2.4.1 Application
The hydraulic power unit HV200-350AH provides pressurized oil for the
operation of hydraulic actuators. The hydraulic power unit is equipped with two
main oil pumps, one pump for the filter circuit and one cooling fan. The controller is
installed on the DCS.
The controller monitors the hydraulic power unit by 2 level transmitters, a
temperature transmitter and pressure transmitters. The controller activates the
control devices such as accumulator charging valves, main pump motors, filter pump
motor, cooling fan motor. The operation signals, display signals and alarming signals
in the DCS are used for the operation, maintenance and trouble shooting.
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The Junction boxes on HV200-350AH are fully wired to the control devices and
transmitters.
2.4.2 Signals
2.4.2.1 Operating, display and alarming signals
Operation modes and fault messages are displayed on the DCS. Fault messages
are always stored. When the fault is cleared, the hydraulic power unit will start
operation automatically again. The fault message will be kept stored until the
operator has checked locally the hydraulic power unit and reset the fault message
with the “Alarm reset”.
Signal Type
HPU auto/manual Operation
Alarm reset Operation
Oil pump 1 ON/OFF Operation
Oil pump 2 ON/OFF Operation
Filter pump ON/OFF Operation
Fan ON/OFF Operation
HPU auto Display
Pump 1 on Display
Pump 2 on Display
Filter pump on Display
Fan on Display
Pressure too low, more than 2 minutes P<< 120 kg/cm² Alarm
Pressure too high P> 250 kg/cm² Alarm
Level low L< 200 mm Alarm
Level too low L<< 170 mm Alarm
Temperature too high T>> 70 °C Alarm
Accumulator Nitrogen pressure low Alarm
MCC fault Alarm
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Pump change after fault Alarm
Transmitter fault Alarm
2.4.2.2 I/O Signals
The following command signals must be available at the DCS output terminals:
Signal Target Switching element (localisation)
Oil pump 1 on MCC Power Relay (MCC)
Oil pump 2 on MCC Power Relay (MCC)
Filter pump on MCC Power Relay (MCC)
Fan on MCC Power Relay (MCC)
Accumulator charging valve 1 on HPU Intermediate Relay (DCS)
Accumulator charging valve 2 on HPU Intermediate Relay (DCS)
HPU Pressure not too low PVR Intermediate Relay (DCS)
HPU Pressure not too low PVR Intermediate Relay (DCS)
HPU Pressure not too low PVR Intermediate Relay (DCS)
HPU Pressure not too low PVR Intermediate Relay (DCS)
The signal “HPU Pressure not too low” is used for unlock the positioner PVR.
2.4.3 Functions
2.4.3.1 Controller
By operation input “HPU auto/manual” the controller is switched to auto mode. In
“HPU auto” mode the controller monitors and controls the hydraulic power unit.
2.4.3.2 Main pumps
The main pumps supply the hydraulic oil from the tank to the accumulator. Running
of the main pumps are displayed “Oil pump 1 on”, “Oil pump 2 on”.
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As soon as the controller is switched to automatic mode “HPU auto” both pumps
are started, in order to reach the operating pressure as quickly as possible. The
start-up of the standby pump is delayed by 3 seconds. Pressure is built up in
accumulator. After crossing pressure “Standby pump off”, the standby pump is
switched off. The selected pump remains running continuous.
If the pressure falls below “Standby pump on”, the standby pump will be switched
on again, to increase the pressure as quick as possible. The standby pump is
switched off when pressure exceed “Standby pump off”.
To check, if both pumps are ready for operation, the pumps are switched over
automatically each 3 days.
Also automatic pump switch-over takes place at the following fault conditions:
• Pressure below “Standby pump on” three times in a row without attending
pressure “Accumulator charging valve off”
• “Pressure too high”
• MCC fault on selected pump
If the pressure drops below “Pressure too low” with 2 pumps running and does not
recover within 2 minutes, both pumps will be switched off and the fault message
“Pressure too low, more than 2 minutes” is displayed.
A similar sequence takes place when starting from the zero pressure condition. If
the “Pressure too low” is not crossed within two minutes, both pumps will be
switched off and the fault message “Pressure too low, more than 2 minutes “ is
displayed.
For safety and protection reasons the main pumps are switched OFF at
following fault conditions:
• “Level too low”
• “Temperature too high”
• “Pressure too high”
When above fault conditions are cleared the pumps are switched on again.
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2.4.3.3 Accumulator charging valves
The accumulator charging valves control the accumulator pressure of hydraulic
power unit.
As soon as the main pump is started, the corresponding accumulator charging valve
is activated with 2 seconds delay. When the pressure reach “Accumulator charging
valve off” the accumulator charging valve is de-energized and the oil from the main
pump flows back to the tank. If the pressure in the accumulator falls below
“Accumulator charging valve on”, the accumulator charging valve is energized again
and the oil from the main pump is charging the accumulator.
Normal charging time for the accumulator is 15 seconds. If accumulator charging is
shorter than 8 second three times in a row the fault message “Accumulator Nitrogen
pressure low” is displayed. Remark: The nitrogen must be filled in at depressurized
accumulator. Please refer vendor’s O&M manual (CCI-P0-05536 in Volume 2) for
further details.
2.4.3.4 Filter pump
In automatic mode the filter pump is continuous in operation. Running of the filter
pump is displayed “Filter pump on”. The filter pump is switched off at “Level too low “
In manual mode it is possible to start the filter pump at “Level too low” for first oil
filling.
2.4.3.5 Cooling fan
In automatic mode the cooling fan is switched on when the oil temperature exceed
“Fan on”. As soon the temperature falls below “Fan off” the cooling fan is switched
off again. Running of the cooling fan is displayed “Fan on”.
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2.4.3.6 HV auto/manual (only used for commissioning)
For commissioning the controller can be switched to manual operation by the
operator. The message “HV auto” is turned off.
By switching to manual operation, all the control devices (main pumps, filter pump,
cooling fan) will first be switched off before they can be switched on and off
manually by the operator.
By switching back to automatic mode “HV auto”, all the control devices (main
pumps, filter pump, cooling fan) will first be switched off. Then the controller starts to
monitor and control the individual pumps and fan corresponding to the actual
operating conditions.
For safety and protection reasons the following interlocks are also active in manual
operation! Main pumps are switched OFF for:
• “Level too low”
• “Temperature too high”
• “Pressure too high”
2.4.3.7 Measurement (Transmitters)
The monitoring criteria for operation are built from the following transmitters installed
on the hydraulic power unit.
Transmitters Signal Range
Level transmitter 1 4 - 20 mA 0 - 390 mm
Level transmitter 2 4 - 20 mA 0 - 390 mm
Temperature transmitter 4 - 20 mA -20 - 120 °C
Pressure transmitter 1 4 - 20 mA 0 - 25 MPa
Pressure transmitter 2 4 - 20 mA 0 - 25 MPa
Pressure transmitter 3 4 - 20 mA 0 - 25 MPa
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The pressure signal is 2 out of 3 logic
For safety and protection reasons the main pumps are switched OFF at pressure
signal fault.
2.4.3.8 Measurement (Transmitters)
These signals are derived from the analog signal of the transmitters.
Monitor / Alarm Set-point
Accumulator charging valve on 216 kg/cm²
Accumulator charging valve off 240 kg/cm²
Standby pump on 201 kg/cm²
Standby pump off 216 kg/cm²
Pressure too low P<< 120 kg/cm²
Pressure not too low 120 kg/cm²
Pressure too high P> 250 kg/cm²
Level low L< 200 mm
Level too low L<< 170 mm
Fan on 55 °C
Fan off 50 °C
Temperature too high T>> 70 °C
2.4.4 Supplies
2.4.4.1 Motor power supply
The Motors requires three-phase electrical supply 3x415VAC/50Hz.The fusing and
switching elements are fitted in the MCC.
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2.4.4.2 Accumulator charging valves supply
The accumulator charging valves ACV requires a 24VDC/1A electrical supply. The
fusing and switching elements are fitted in the DCS.
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2.4.4.3 Transmitters supply
The Transmitters requires a 24VDC/20mA electrical supply. The fusing elements
are fitted in the DCS.
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2.4.5 Junction boxes
For easy connection there are 2 junction boxes fitted on the HV200-350AH Hydraulic
Power Unit. The junction box 24V includes connection to DCS for the accumulator
charging valves ACV and transmitters. The junction box 415VAC includes
connection to MCC for the motor power supplies.
Cable screw fittings to MCC Motor power supplies M25x1.5
Cable screw fittings to DCS ACV / Transmitters M16x1.5
Standard connection terminals Motor power supplies max.10 mm 2
ACV / Transmitters max.6 mm 2
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
3.0 NORMAL OPERATION, START-
UP AND SHUTDOWN
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Chapter 3
Mode of Operation
3.1 Description of Operation
3.1.1 Normal Start-up
Normally from plant startup to rolling of turbine there will be no flow through the HP
turbine. Main steam will be allowed to flow through HP/LP bypass steam system to
condenser until the Steam Turbine start-up steam parameters will be attained. When
the steam parameters match the steam turbine start-up parameters then rolling of
the Steam Turbine will be started.
During start-up operation, the hydraulically operated steam isolation valves will open
when respective LP steam bypass control valve starts opening.
LP Bypass steam control valves will operate as per the following steps:
Minimum position mode:
Once Boiler is light off for 60 sec and HRH steam pressure above 0.05 kg/cm2, LP
bypass is operated in minimum position mode. In this mode, LP Bypass valve is kept
at minimum position of 5%. HRH pressure is gradually increased to floor pressure
(13 kg/cm2(a)).
Minimum position mode is deactivated once 52G (Generator Circuit Breaker) on and
pressure set point is received from coordinated control mode.
LP bypass steam isolation & control valve will close automatically when vacuum
unloader is operated and condenser protection signal (from TCS, derived based on
condenser vacuum) is received.
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The LP bypass drip leg MOV will open automatically when CRH pressure is below
predefined pressure and LP bypass control valve is closed and will be closed 1 min.
after opening of respective LP bypass pressure control valve. This valve is used to
drain condensate from the LP Bypass steam piping and warm the system piping as
steam will be admitted.
The spray water control valve will be in controlling action when respective LP bypass
control valve starts opening. The operation of spray water valve will be based on the
enthalpy control as described under 5.1.2. The LP bypass spray water control valve
closes immediately when vacuum unloader is operated and condenser protection
signal (from TCS, derived based on condenser vacuum) is received.
3.1.2 Normal Operation
During normal plant operation, LP bypass steam isolation valve will be closed to
isolate IP steam system from LP bypass steam system. Small amount of hot reheat
steam will pass through the LP Bypass steam piping to LP bypass valve body with
LP bypass steam stop valve (1LBH01AA051 / 1LBH01AA052) normally open for
warming this isolation cum steam control valve. The same steam will flows from
each LP bypass steam stop cum control valve to hot reheat leads again.
The LP bypass pressure control valve will operate in follow mode (MW Control
Mode). In follow mode, control valve will be tracking the IP pressure with additional
predefined Bias (to be decided at the time of commissioning); hence the pressure
control valve will remain closed. The bypass spray water control valve will remain in
closed condition same as LP bypass pressure control valve during normal operation.
LP bypass drip leg MOV and LP bypass valve drain MOV will remain closed during
normal operation. LP bypass valve body drain MOV will open for few seconds after
respective LP bypass pressure control valve is closed.
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3.1.3 Normal Shut Down
During a unit shutdown, LP bypass steam control valve will be in follow mode and
spray water control valve will be in closed condition same as during normal
operation.
The LP bypass valve drain MOV (1LBH01AA001 & 1LBH01AA002) will open for 40
sec after respective LP bypass spray water CV is closed. The LP bypass drip leg
MOV (1LBH01AA451, 1LBH01AA452 & 1LBH01AA453) will open when CRH
pressure is below setpoint (as decided during commissioning) & LP bypass pressure
control valve is closed. Drip leg MOV will close 60 sec after opening of respective LP
bypass PCV.
3.2 Checklist
DANGER
Strictly follow the work permit system to avoid unacceptable troubles
or danger.
• Ensure cancellation of any work permit issued for steam lines, condensate
lines, and hydraulic valves, MOV or Hydraulic Supply Unit.
• Ensure the proper working of Hydraulic Supply Unit.
• Ensure that the power supply for MOV is available from the feeder.
• Make sure all interlocks and protections test of Hydraulic Supply Unit, hydraulic
valves & MOV are qualified.
• All related instruments are mounted and properly fitted.
• Ensure all valves are on auto.
• Manual isolating valves are open.
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4.0 EMERGENCY OPERATION AND
ALARMS
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Chapter 4
Emergency Operation
4.1 Emergency Operation
LP Bypass pressure control valves will be in controlling action from follow mode in
case of Turbine trips or Boiler MFT or FCB. However in case of turbine trip, LP
bypass control valve will act from predefined minimum position. During these
abnormal operations, LP bypass control valves are modulated with respect to
upstream HRH pressure & set point corresponding to MW demand. Spray water
control valves will open as the LP bypass control valves open and limits the LP
bypass downstream enthalpy (2780 kJ/kg) values as per HEI guidelines for surface
condenser.
CAUTION
During boiler island operation following FCB, HRH pressure should
be reduced to13 kg/cm2(a) with Boiler load of 30% BMCR for
resynchronizing the turbine.
4.2 Alarms
CAUTION
Operator must take appropriate corrective action, if any of the alarms
mentioned below appears. Continuous operation without corrective
action may lead to the tripping of equipment and may lead to the
possible damage to the equipment.
• Hydraulic Oil Tank Level Low
• Hydraulic Oil Tank Level Low-Low
• Hydraulic Lube Oil Line Discharge Line Pressure Low-Low
• Hydraulic Lube Oil Line Discharge Line Pressure High-High
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
• Hydraulic Oil Tank Temperature Low
• Hydraulic Oil Tank Temperature High
• Hydraulic Oil Tank Temperature High-High
• Hydraulic Pump Motor of LP Bypass System Trip
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5.0 INSTRUMENTATION AND
PROCESS CONTROL
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Chapter 5
Process Control
5.1 Process Control
5.1.1 LP Bypass Pressure Control Valves (1LBH01AA081 & 1LBH01AA082)
Purpose:
Two number LP bypass pressure control valves are provided to maintain HRH
steam pressure during start-up, shutdown, load rejection or turbine trip condition.
Functional Description:
Hydraulic-actuated LP bypass pressure control valves are provided for HRH steam
pressure control. Triple redundant pressure transmitters (1LBH01CP001,
1LBH01CP002, 1LBH01CP003) are provided for HRH steam pressure
measurement. The controller compares set point with HRH steam pressure and acts
upon the deviation to modulate pressure control valve. The valve will be modulated
towards open position to reduce the HRH steam pressure. The valve will operate in
following modes:
Minimum position mode:
In this mode, LP Bypass valve is kept at minimum position of 5%.
This mode is activated by following conditions:
a. HRH steam pressure above 0.05 kg/cm2 &
b. HP Bypass CV in auto &
c. Boiler is light off for 60 sec &
d. LP Bypass CV in auto.
This mode is de-activated by following conditions:
a. PT backup pressure control mode (Pressure from coordinated control mode)
operated
OR
b. 52G (Generator Circuit Breaker) on
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
OR
c. Boiler is not light off
OR
d. LP Bypass CV in manual.
MW control mode:
During normal operation, HRH pressure setpoint corresponding to MW demand is
fed to a pressure controller (PID) to modulate the valve by comparing setpoint to
actual HRH pressure.
PT backup pressure control mode is selected in case all of the following conditions
are satisfied:
i. Turbine is synchronized and BID signal is normal
ii. Boiler is in dry mode OR load demand is >30% OR (load demand >20% & HP
bypass valve is closed)
If PT backup pressure mode is selected from station DCS then a bias is added to the
setpoint to keep LP bypass CV in tracking mode.
Turbine trip mode:
During Turbine trip, LP bypass CV is kept at minimum position of 10%.
Boiler MFT mode:
During boiler MFT, LP bypass CV is modulated with respect to upstream pressure &
setpoint corresponding to MW demand.
FCB mode:
During FCB, LP bypass CV is modulated with respect to upstream pressure &
setpoint corresponding to MW demand.
Permissive
LP Bypass valves will be allowed to open if condenser vacuum is healthy (vacuum
unloader not operated), and condenser protection signal (from TCS, derived based
on condenser vacuum) is not activated.
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Controller is shifted to manual control if either of the following conditions occurs:
1. HPSU pressure too low OR
2. Corresponding valve positioner not healthy.
Protective Override Commands
LP Bypass valves will be quick closed if condenser vacuum is unhealthy (vacuum
unloader operated), or condenser protection signal is activated.
5.1.2 LP Bypass Temperature Control Valve (1LCE45AA081 & 1LCE45AA082)
Purpose:
Condensate will be sprayed in de-superheaters of LP Bypass system to control the
temperature of Bypass steam. The spray water will be provided from the CEP
Discharge header. LP Bypass spray water supply system consists of a hydraulically
operated spray control valve (1LCE45AA081 & 1LCE45AA082). The purpose of this
loop is to maintain the LP steam bypass outlet temperature/enthalpy below the
design limit of condenser specified in HEI.
Functional Description:
Enthalpy control is provided in the control loop. Each LP bypass attemperator control
provides feed forward control for the calculation of spray water flow demand (QATT).
This allows the system to react before an event, thus avoiding injection of the
incorrect amount of spray water and increases accuracy. The result will be used as
the set-point for the flow rate controller which provides the output to the spray water
control valve (1LCE45AA081 & 1LCE45AA082). The attemperation water flow
(QSPRAY) measured by the flow transmitter (1LCE45CF001, 1LCE45CF002,
1LCE45CF003, 1LCE45CF004) will be used to maintain the calculated attemperator
water flow demand (QATT) set-point. The calculated enthalpy (HOUT) at the
downstream of the LP bypass is achieved from the energy balance equation as
below:
HOUT = (QSTEAM * HSTEAM + QSPRAY * HSPRAY) / (QSTEAM + QSPRAY)
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Where,
QSTEAM − Total LP bypass steam flow rate
QSPRAY − Attemperation water flow rate
HSTEAM − HRH bypass steam enthalpy
HSPRAY − Attemperation water enthalpy
Dynamic spray water flow rate demand (QATT) setpoint is calculated from the
energy balance equation as under:
QATT = QSTEAM * [(HSTEAM – 2780) / (2780 – HSPRAY)] (2780 indicates required
enthalpy setpoint)
LP steam bypass flow will be calculated by a function generator with inputs of each
LP bypass pressure control valve “standard valve size coefficient (Cv)” and HRH
steam pressure. The valve Cv value will be interpolated from each LP bypass
pressure control valve position. Temperature elements 1LBH01CT001,
1LBH01CT002, 1LBH01CT003 measure the HRH steam (re-heater outlet steam)
header temperature. Pressure transmitters 1LBH01CP001, 1LBH01CP002,
1LBH01CP003 measure the HRH steam header pressure. The inlet HRH steam
enthalpy (HSTEAM) will be derived as a function of the pressure and temperature
before the desuperheater. The spray water enthalpy (HSPRAY) will be derived by the
function generator from the condensate pressure (measured by 1LCE45CP001,
1LCE45CP002, 1LCE45CP003) and condensate temperature (measured by
1LCE45CT001, 1LCE45CT002, 1LCE45CT003). Flow transmitter 1LCE45CF001,
1LCE45CF002, 1LCE45CF003, 1LCE45CF004 measures attemperation flow to the
desuperheater.
Permissive:
These control valves will be allowed to open and control action will be enabled when
respective LP steam Bypass pressure control valve starts opening.
Controller is shifted to manual control if either of the following conditions occurs:
1. HPSU pressure too low OR
2. Corresponding valve positioner not healthy.
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Protective Override Commands:
The LP Bypass station temperature control valves closes immediately (Quick Close)
if condenser vacuum is unhealthy (vacuum unloader operated), or condenser
protection signal is activated.
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6.0 INTERLOCKS AND
PROTECTION
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Chapter 6
Interlock and Protection
6.1 LP Bypass Steam Isolation Valves (1LBH01AA051 & 1LBH01AA052)
Purpose:
LP bypass steam isolation valves are provided to isolate HRH steam system from
LP bypass system.
Functional Description:
Hydraulic-actuated LP bypass steam isolation valves are provided to isolate HRH
steam system from LP bypass system.
Permissive:
LP Bypass steam isolation valves will be opened if condenser vacuum is healthy and
condenser protection signal is not activated.
Protective Override Commands:
LP Bypass steam isolation valves will be force closed if condenser vacuum is
unhealthy (vacuum unloader operated), or condenser protection signal is activated.
6.2 LP Bypass Drain MOV (1LBH01AA001 & 1LBH01AA002)
Functional Description:
The LP bypass valve drain MOV will open for 40 sec after respective LP bypass
spray water CV is closed.
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
6.3 LP BYPS DRIPLEG MOV (1LBH01AA451, 1LBH01AA452, &
1LBH01AA453)
Functional Description:
The LP bypass drip leg MOV will open when CRH pressure is below setpoint & LP
bypass pressure control valve is closed. Drip leg MOV will close 60 sec after
opening of respective LP bypass PCV.
6.4 Spray Water Isolation MOV (1LCE45AA001 & 1LCE45AA002)
Functional Description:
Spray water isolation MOV will open when any of the CEP is running.
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7.0 INSTRUMENT & DRIVES LIST
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Chapter 7
Instrument & Drives List
7.1 Instrument List
Inst.
S.No. Description Parent Tag KKS Tag Remarks
type
1 CEP DSCH PR PT 1LCE45BR001 1LCE45CP001
2 CEP DSCH PR PT 1LCE45BR001 1LCE45CP002
3 CEP DSCH PR PT 1LCE45BR001 1LCE45CP003
CEP DSCH
4 TE 1LCE45BR001 1LCE45CT001
TEMP
CEP DSCH Non-
5 TW 1LCE45BR001 1LCE45CT001
TEMP Intelligent
CEP DSCH
6 TE 1LCE45BR001 1LCE45CT002
TEMP
CEP DSCH Non-
7 TW 1LCE45BR001 1LCE45CT002
TEMP Intelligent
SPRAY WATER
8 DPIS 1LCE45BR002 1LCE45CP080
LINE 2 DP
SPRAY WATER
9 FE 1LCE45BR002 1LCE45CF251
LINE 2 FLOW
SPRAY WATER
10 FT 1LCE45BR002 1LCE45CF001
LINE 2 FLOW
SPRAY WATER
11 FT 1LCE45BR002 1LCE45CF002
LINE 2 FLOW
SPRAY WATER
12 ZT 1LCE45AA081 1LCE45CG001
LINE 2 CV POS
SPRAY WATER Non-
13 TY 1LCE45AA081 1LCE45AA001
LINE 2 CV CMD Intelligent
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Inst.
S.No. Description Parent Tag KKS Tag Remarks
type
LP BYPS LN 2
14 ZT 1LCE45AA051 1LCE45CG002
CV POS
LP BYPS LN 2 Non-
15 PY 1LCE45AA051 1LCE45AA002
CV CMD Intelligent
LP BYPS LN 2
16 ZSO 1LCE45AA051 1LCE45CG080
CV OPN
LP BYPS LN 2
17 ZSC 1LCE45AA051 1LCE45CG081
CV CL
LP BYPS LN 2
18 PT 1LBU45BR009 1LBU45CP001
PR
SPRAY WATER
19 DPIS 1LCE45BR003 1LCE45CP081
LINE 1 DP
SPRAY WATER
20 FE 1LCE45BR003 1LCE45CF252
LINE 1 FLOW
SPRAY WATER
21 FT 1LCE45BR003 1LCE45CF003
LINE 1 FLOW
SPRAY WATER
22 FT 1LCE45BR003 1LCE45CF004
LINE 1 FLOW
SPRAY WATER
23 ZT 1LCE45AA082 1LCE45CG003
LINE 1 CV POS
SPRAY WATER Non-
24 TY 1LCE45AA082 1LCE45AA003
LINE 1 CV CMD Intelligent
LP BYPS LN 1
25 ZT 1LCE45AA052 1LCE45CG004
CV POS
LP BYPS LN 1 Non-
26 PY 1LCE45AA052 1LCE45AA004
CV CMD Intelligent
LP BYPS LN 1
27 ZSO 1LCE45AA052 1LCE45CG082
CV OPN
LP BYPS LN 1
28 ZSC 1LCE45AA052 1LCE45CG083
CV CL
LP BYPS LN 1
29 PT 1LBU45BR005 1LBU45CP002
PR
30 HR LN PR PT 1LBB45BR001 1LBB45CP001
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Inst.
S.No. Description Parent Tag KKS Tag Remarks
type
31 HR LN PR PT 1LBB45BR001 1LBB45CP002
32 HR LN PR PT 1LBB45BR001 1LBB45CP003
33 HR LN TEMP TE 1LBB45BR001 1LBB45CT001
Non-
34 HR LN TEMP TW 1LBB45BR001 1LBB45CT001
Intelligent
35 HR LN TEMP TE 1LBB45BR001 1LBB45CT002
Non-
36 HR LN TEMP TW 1LBB45BR001 1LBB45CT002
Intelligent
Ref.: P&ID No. : M1-00205-01
7.2 Drives List
Final Actuating Control Feedback
S.No. Description Remarks
Actuator Equipment Signal Signal
1 HPU Oil Pump 1 Electric Motor 3x415VAC
2 HPU Oil Pump 2 Electric Motor 3x415VAC
3 HPU Filter pump Electric Motor 3x415VAC
4 HPU Fan Electric Motor 3x415VAC
HPU
Solenoid
5 Accumulator Hydraulic 24VDC
valve ACV
charging valve1
HPU
Solenoid
6 Accumulator Hydraulic 24VDC
valve ACV
charging valve2
LP Bypass valve Prop. valve
7 Hydraulic 24VDC 4-20mA
LBP1 PVA
LP Bypass valve Prop. valve
8 Hydraulic 24VDC
LBP1 PVB
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Final Actuating Control Feedback
S.No. Description Remarks
Actuator Equipment Signal Signal
LP Bypass valve Blocking
9 Hydraulic 24VDC
LBP1 unit BL
Solenoid energize
LP Bypass valve
10 Hydraulic valve SSB- 24VDC to fast
LBP1
OP open
de-
Solenoid energize
LP Bypass valve
11 Hydraulic valve SSB- 24VDC to
LBP1
CL emergen
cy close
Solenoid energize
LP Bypass block
12 Hydraulic valve SSB- 24VDC to trip
valve LBPI1
OP open
de-
Solenoid energize
LP Bypass block
13 Hydraulic valve SSB- 24VDC to
valve LBPI1
CL emergen
cy close
LP Bypass
Prop. valve
14 spray valve Hydraulic 24VDC 4-20mA
PVA
LBPE1
LP Bypass
Prop. valve
15 spray valve Hydraulic 24VDC
PVB
LBPE1
de-
LP Bypass
Solenoid energize
16 spray valve Hydraulic 24VDC
valve FC to fail
LBPE1
close
LP Bypass valve Prop. valve
17 Hydraulic 24VDC 4-20mA
LBP2 PVA
LP Bypass valve Prop. valve
18 Hydraulic 24VDC
LBP2 PVB
LP Bypass valve Blocking
19 Hydraulic 24VDC
LBP2 unit BL
Solenoid energize
LP Bypass valve
20 Hydraulic valve SSB- 24VDC to fast
LBP2
OP open
de-
Solenoid energize
LP Bypass valve
21 Hydraulic valve SSB- 24VDC to
LBP2
CL emergen
cy close
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Final Actuating Control Feedback
S.No. Description Remarks
Actuator Equipment Signal Signal
Solenoid energize
LP Bypass block
22 Hydraulic valve SSB- 24VDC to trip
valve LBPI2
OP open
de-
Solenoid energize
LP Bypass block
23 Hydraulic valve SSB- 24VDC to
valve LBPI2
CL emergen
cy close
LP Bypass
Prop. valve
24 spray valve Hydraulic 24VDC 4-20mA
PVA
LBPE2
LP Bypass
Prop. valve
25 spray valve Hydraulic 24VDC
PVB
LBPE2
de-
LP Bypass
Solenoid energize
26 spray valve Hydraulic 24VDC
valve FC to fail
LBPE2
close
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
ABBREVIATIONS
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
Abbreviation:
Abbreviation Meaning
BMCR Boiler Maximum Continuous Rating
CEP Condensate Extraction Pump
CMC Central Machine Complex
CV Control Valve
CVDS Control Valve Data Sheet
DCS Distributed Control System
GCB Generator Circuit Breaker
HBD Heat Balance Diagram
HEI Heat Exchanger Institute
HP High Pressure
HRH Hot Re-Heat
IP Intermediate Pressure
kV Kilo-Volt
LP Low Pressure
MOV Motor Operated Valve
MW Mega Watt
PCV Pressure Control Valve
PDT Piping Design Table
TA Top Assembly
VDT Valve Design Table
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JAYPEE O&M MANUAL – VOLUME 1 LP BYPASS SYSTEM
EXHIBITS
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LTSL-M0-00951 REV 0 Page 690 of 860
JAYPEE NIGRIE SUPER THERMAL POWER PROJECT
[2 X 660 MW ]
STEAM TURBINE GENERATOR & AUXILIARIES PACKAGE
OWNER:
JAI PRAKASH POWER VENTURES
LIMITED
OWNER’S CONSULTANT:
DEVELOPMENT CONSULTANTS PRIVATE
LIMITED, KOLKATA
CONTRACTOR:
LARSEN & TOUBRO LIMITED
L&T’S CONSULTANT:
L&T-SARGENT & LUNDY LIMITED
VENDOR:
CCI VALVE TECHNOLOGY GmbH
L&T-S&L JOB NO.: L543000 PROJECT NO: T209001
TITLE:
TA DRAWING
(NA-80-700 + NBSE-80-700-3)
TOTAL NO. OF PAGES. : 2
DOC/DRG NO. : CCI-M0-05510 REV: 4
TOTAL NO. OF DRAWINGS. : 1
LTSL DCPL/JPVL
FOR APPROVAL
FOR INFO
REVISION CERTIFICATION
PREPARED REVIEWED APPROVED
REV. No. NAME DATE NAME DATE NAME DATE
0 B. Phan 27.07.11 1st Issue H. Beth 27.07.11 U. Kaegi 27.07.11
1 B. Phan 19.08.11 Revised as per customer comment H. Beth 19.08.11 U. Kaegi 19.08.11
2 B. Phan 28-11.11 Revised as per customer comment H. Beth 28-11.11 U. Kaegi 28-11.11
3 B. Phan 01.12.11 Revised as per customer comment H. Beth 01.12.11 U. Kaegi 01.12.11
4 B. Phan 19.12.11 Revised as per customer comment H. Beth 19.12.11 U. Kaegi 19.12.11
LTSL-M0-00951 REV 0 Page 691 of 860
LTSL-M0-00951 REV 0 Page 692 of 860
JAYPEE NIGRIE SUPER THERMAL POWER PROJECT
[2 X 660 MW ]
STEAM TURBINE GENERATOR & AUXILIARIES PACKAGE
OWNER:
JAI PRAKASH POWER VENTURES
LIMITED
OWNER’S CONSULTANT:
DEVELOPMENT CONSULTANTS PRIVATE
LIMITED, KOLKATA
CONTRACTOR:
LARSEN & TOUBRO LIMITED
L&T’S CONSULTANT:
L&T-SARGENT & LUNDY LIMITED
VENDOR:
CCI VALVE TECHNOLOGY GmbH
L&T-S&L JOB NO.: L543000 PROJECT NO: T209001
TITLE:
TA Drawing - 840-H
TOTAL NO. OF PAGES. : 2
DOC/DRG NO. : CCI-M0-05513 REV: 3
TOTAL NO. OF DRAWINGS. : 1
LTSL DCPL/JPVL
FOR APPROVAL
FOR INFO
REVISION CERTIFICATION
PREPARED REVIEWED APPROVED
REV. No. NAME DATE NAME DATE NAME DATE
0 K.J.A. 16.08.11 1st Issue C.H.P 16.08.11
1 K.J.A. 29.09.11 Revised as per customer comment C.H.P 29.09.11
2 K.J.A. 25.10.11 Revised as per customer comment C.H.P 25.10.11
3 K.J.A. 13-01.12 Revised internally C.H.P 13-01.12
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Operation & Section G.
Maintenace Volume 1 Condenser Air
Manual Removal System
Table of Contents 696
1. Overview of Condenser Air Removal System 698
2. System Description 709
3. Normal Operation, Start-up / Shutdown 718
4. Emergency Operations & Alarms 723
5. Instrumentation & Process Control 730
6. Interlock & Protection 734
7. Valve Line-up List 738
Abbreviations 742
Exhibits 744
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Table of Contents
1.0 OVERVIEW OF CONDENSER AIR REMOVAL SYSTEM
1.1 Purpose
1.2 Specifications
1.3 References
1.3.1 P & ID
1.3.2 System documents
1.3.3 Heat Balance Diagram
1.3.4 Vendor Drawings / Documents
2.0 SYSTEM DESCRIPTION
2.1 Overview
2.2 Major Component
2.2.1 Vacuum Pumps
2.2.2 Separator
2.2.3 Plate Type Heat Exchanger
2.2.4 Recirculation Pump
2.2.5 System Piping
3.0 NORMAL OPERATION, START-UP AND SHUTDOWN
3.1 Description of Operation
3.2 Checklist
4.0 EMERGENCY OPERATION AND ALARMS
4.1 Emergency Operation
4.1.1 Loss of a Vacuum Pump
4.1.2 Deterioration of Condenser Vacuum
4.1.3 Loss of Seal water Pump
4.1.4 Abnormal Separator Tank water level
4.1.5 Loss of Instrument Air
4.2 Alarms
4.3 Cause & Effect Table
5.0 INSTRUMENTATION AND PROCESS CONTROL
5.1 Instrument and Process Control
5.1.1 Condenser HP shell vacuum level control
5.1.2 Condenser LP shell vacuum level control
5.1.3 Separator tank water level control of HP shell vacuum unit
5.1.4 Separator tank water level control of LP shell vacuum unit
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6.0 INTERLOCKS AND PROTECTION
6.1 Vacuum Pumps
6.2 Recirculation Pump
6.3 Separator tank make-up line solenoid valve
6.4 Pneumatically operated suction butterfly valve
6.5 Solenoid operated Spray Valve
7.0 VALVE LINE-UP LIST
7.1 List
ABBREVIATIONS
EXHIBITS
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1.0 OVERVIEW OF CONDENSER AIR
REMOVAL SYSTEM
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Chapter 1
Overview of Condenser Air Removal System
1.1 Purpose
The purpose of condenser air removal system O&M manual document is to provide
the operating personnel with necessary information to safely operate and maintain
the condenser air removal system & associated equipment.
The scope of the manual covers an overview of the Condenser air removal System,
description of its major components with associated equipment & devices and
details of the startup, shutdown and normal operation and process control.
The condenser operates under vacuum and air leaks in to the system from outside
atmosphere. This must be continuously removed to maintain the design vacuum.
The function of condenser air evacuation system is as follows:
a) During start-up mode, to evacuate the main condenser steam space
volume and ancillary piping and equipment by reducing pressure to
require starting levels.
b) During normal operating condition, to remove non-condensable gases
from condenser steam space.
The system is suitable for operation in conjunction with turbine and condenser
offered.
The evacuation system comprises of vacuum pumps for each condenser shell (HP
shell and LP shell) along with all accessories. The pumps are located indoor near
condenser.
Notes:
1. It is advisable to read this manual carefully to achieve the performance objective.
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2. The scope of the document covers the overall system description for the
condenser air removal system, description of its major components and
associated auxiliaries & system startup, shutdown, operation & process control.
3. If the condenser air removal system equipment and components are operated
under conditions different than its design, it is possible that the system may not
achieve its performance objectives and is likely to result in serious trouble.
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1.2 Specifications
Design Data of Major Equipment
A. Drive LT motor for liquid ring vacuum pump
Motor description
1MAJ32AP003, 1MAJ32AP004
Tag
1MAJ33AP001, 1MAJ33AP002
Make HHI (HYUNDAI)
Frame Size 280M
Type Squirrel Cage
Duty Cycle Continuous
Rated voltage and variation 415 V± 10%
Rated frequency and variation 50V± 5%
Rated Speed 1485 RPM
Rated continuous output 90 kW at 500C ambient
No load current 27.48 Amp
Full load current 153.7 Amp
Efficiency 94.2 %
Degree of Protection of Enclosure IP55
Method of Cooling IC411(FC)
Insulation F class for Stator
Temperature rise over 500C ambient 70 0C
DE: 6318C3, NDE: 6316C3
Make: Schaeffler Korea
Bearing
Type: Ball (Anti-Friction)
Lubricant: Alvania RL2 NLG1
Overall dimension (LxDxH) 1102 x 879 x 699 mm
Weight 740 kg
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B. Drive LT motor for Recirculation pump
Motor description
1MAJ32AP007, 1MAJ32AP008
Tag
1MAJ33AP005, 1MAJ33AP006
Make HHI (HYUNDAI)
Frame Size 100L
Type Squirrel Cage
Duty Cycle Continuous
Rated voltage and variation 415 V± 10%
Rated frequency and variation 50V± 5%
Rated Speed 1450 RPM
Rated continuous output 2.2 kW at 500C ambient
No load current 0.78 Amp
Full load current 4.4 Amp
Efficiency 84.3 %
Degree of Protection of Enclosure IP55
Method of Cooling IC411(FC)
Insulation F class for Stator
Temperature rise over 500C ambient 700C
DE: 6206ZZC3, NDE: 6206ZZC3
Make: SKF or KBC
Bearing
Type: Ball (Anti-Friction)
Lubricant: NA
Overall dimension (LxDxH) 368 x 329 x 214 mm
Weight 42 Kg
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C. Vacuum pump
Pump description
Unit HP Shell LP Shell
1MAJ33AP001 1MAJ32AP003
Tag
1MAJ33AP002 1MAJ32AP004
Make Gardner Denver Korea
Type Liquid Ring
No of Stages Two
Performance Data of Vacuum Pump at @VWO, 3%MU condition
Minimum Pump capacity
SCFM 28 20.1
each
Aux. power consumed
kW 52.74 51.29
by each pump
Hogging capacity of
SCFM 498 498
vacuum pump
Hogging time Min 22 23
mm Hg
Suction pressure 75.24 58.32
abs.
Suction Temperature Deg. C 41.72 36.79
Discharge pressure kg/cm2 (a) 1.033
Pump rotating speed RPM 450
Brake Power required
kW 72.54
(max.)
Pump body material 2% Ni cast iron
Pump shaft material AISI 1045
Pump rotor material Ductile iron
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D. Recirculation Pump
Pump description
Unit HP Shell LP Shell
1MAJ33AP005 1MAJ32AP007
Tag
1MAJ33AP006 1MAJ32AP008
Make Hyosung
Type Centrifugal
No of Stage One
Pump capacity each m3 / hr 13.68
NPSH required m 1.9
Max. Temperature of liquid Deg. C 90
Net developed head m 20
Pump rotating speed RPM 1450
Brake Power required (max.) kW 72.54
Casing material SS304
Pump shaft material AISI 1045
Impeller material SS304
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E. Vacuum pump Heat Exchanger
Heat Exchanger description
HP Shell LP Shell
1MAJ33AC001 1MAJ32AC003
Tag
1MAJ33AC002 1MAJ32AC004
Type Plate
Make Taebong Industries Inc.
40/H- 30/H-
Plate arrange / Configuration
Plate: 59 Plate: 101
Plate material SS316L
Plate Area m3 9.69 16.83
Seal water temperature at I/L of
Deg. C 46.28 41.38
Heat Exchanger
Seal water temperature at O/L of
Deg. C 37 34.05
Heat Exchanger
Design TTD Deg. C 4 1.05
Maximum seal water
kg/ sq.
cooler differential pressure 0.165 0.172
cm
(cooling water side)
F. Pneumatically operated suction valve for LP shell
Valve description
Valve Tag 1MAJ32AA071, 1MAJ32AA081
Valve Make SIRCA INTL
Valve type Butterfly valve, Wafer
Operation On-Off
Medium Steam + water
Normal size 8"
Body connection Flange #150 ANSI
Weight without Actuator 11 kg
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Operating Data
Temperature 36.58 °C
Pressure 0.0783 kg/cm2 (g)
Flow 141.6 kg/hr
Design Data
Temperature 90°C
Pressure 22.1 kg/cm2 (g)
ACTUATOR
Type Pneumatic, Rotary(piston/diaphragm)
Control On-Off
Stroke Time Open / Close < 2 Sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Stay-Put
G. Pneumatically operated suction valve for HP shell
Valve description
Valve Tag 1MAJ33AA051, 1MAJ33AA061
Valve Make SIRCA INTL
Valve type Butterfly valve, Wafer
Operation On-Off
Medium Steam + water
Normal size 8"
Body connection Flange #150 ANSI
Weight without Actuator 11 kg
Operating Data
Temperature 41.31 °C
Pressure 0.1002 kg/cm2 (g)
Flow 196.5 kg/hr
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Design Data
Temperature 90 °C
Pressure 22.1 kg/cm2 (g)
ACTUATOR
Type Pneumatic, Rotary (piston/diaphragm)
Control On-Off
Stroke Time Open / Close < 2 Sec
Available air Supply Pressure (Min) 4.5 kg/cm2 (g)
Air Failure condition for Valve Stay-Put
1.3 References
1.3.1 P & ID
a) Condenser Air Removal System P&ID Dwg. No. LTSL-M1-00208_Rev 1 (Sheet 1
and 2)
b) HP Shell Vacuum Pump P&ID Dwg. No. GDKL-M0-04202_Rev G (Sheet 1/2)
c) LP Shell Vacuum Pump P&ID Dwg. No. GDKL-M0-04202_Rev G (Sheet 2/2)
Note: All above drawings are attached as Exhibits.
1.3.2 System documents
a) Design Criteria Document for Air removal system Dwg. No. LTSL-M0-00108_Rev
B
b) Logic Drawings Dwg. No. LTSL-I1-00200_Rev 0
c) Calculation for Air removal System Sizing Dwg. No. LTSL-M0-00308_Rev C
d) PDT & VDT Dwg. No. LTSL-M0-00712_Rev B
1.3.3 Heat Balance Diagram
a) Dwg. No. T3101AAAB110
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1.3.4 Vendor Drawings / Documents
a) System operation functional description
Dwg. No. GDKL-P0-04210_Rev C
b) Instructions for the Start-up procedure
Dwg. No. GDKL-P0-04236_Rev C
c) Final O&M manuals including installation manual
Dwg. No. GDKL-P0-04228_Rev A
d) Valve list
Dwg. No. GDKL-P0-04211_Rev E
e) Condenser Vacuum pump motor data
Dwg. No. GDKL-P0-04218_Rev F
f) Technical data sheet for Condenser Vacuum pump
Dwg. No. GDKL-P0-04240_Rev D
g) Equipment List
Dwg. No. GDKL-P0-04216_Rev C
h) DCS input and output list along with alarm and set point
Dwg. No. GDKL-I0-04234_Rev C
i) Pneumatic operated valve data sheet
Dwg. No. GDKL-P0-04212_Rev D
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2.0 SYSTEM DESCRIPTION
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Chapter 2
System Description
2.1 Overview
The main function of the condenser air evacuation system is to evacuate the main
condenser steam space volume and ancillary piping and equipment by reducing
pressure to required levels during start-up and to remove non-condensable gases
from condenser steam space during normal operating condition.
The air and gases are withdrawn from the condenser through an individual air
removal manifold for each shell (HP & LP) by vacuum pump units. Each manifold is
connected with condenser shell through two manual isolating valves. The vacuum
pump unit consists of the liquid ring vacuum pump, directly coupled main drive motor
with gear reducer, pneumatic inlet valve, separator, plate type heat exchanger,
recirculation pump and interconnecting piping. Each pump is furnished with
automatic air inlet valves to isolate each pump, when idle, from the common air inlet
header (HP & LP), without leakage from the idle pump into the header.
There are two 100% capacity vacuum pump units for each shell thus providing 100%
standby air removal capacity. To provide the large air removal capacity required to
rapidly evacuate all the air from the condenser (HP & LP shell) during start-ups all
four vacuum pump units will operate in Hogging mode. All four vacuum pump units
will run in Hogging mode till HP and LP shell pressure achieves a pre-defined value
of 0.345 kg/cm2 (a). Stand-by pumps for HP and LP shell will stop when condenser
pressure achieves a predefined value (0.1002 kg/cm2(a) for HP shell and 0.0783
kg/cm2(a) for LP Shell) respectively but lead pumps for HP and LP shell should be
operated in Holding mode to maintain the condenser vacuum level.
The working parts of the liquid ring vacuum pump consist of a multi-bladed impeller
mounted eccentrically in a round casing which is partly filled with the seal liquid,
water. As the impeller rotates, the liquid is thrown by centrifugal force to form a liquid
ring which is eccentric with the periphery of the casing. Due to eccentric position of
the impeller relative to the casing and liquid ring, the spaces between the impeller
blades fill with liquid during rotation and any air or gas trapped in the impeller space
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or cell is compressed and discharged from the casing through the outlet port to
separator. This leaves the cell available to receive air or gas as it is presented to the
inlet port on the next revolution. A small portion of the seal water is discharged with
the vapor to the separator, and a constant supply of fresh water seal must be
maintained. The Separator is used to separate non-condensable gases from the
liquid and finally discharge to atmosphere through a vent pipe. There is a provision
to vent this mixture to atmosphere through an air flow meter. This facility is used
when there is a necessity to monitor the condenser air in-leakage flow. Seal water
make-up is supplied to the separator from the condensate extraction pump
discharge during normal operation and condensate transfer pump / DM service
water pump during start-up when CEP is not running.
In addition to being the compressing medium, the liquid ring absorbs the heat
generated by compression and friction, absorbs any liquid slugs or vapor entering
with the gas stream, and condenses water vapor entering with the gas. For
condenser exhaust service, a closed loop seal system is used. The seal water
temperature will be slightly warmer than the cooling water from auxiliary cooling
water supply to the pump heat exchanger.
The flow diagram for condenser air removal system is as shown in the schematic on
next page.
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Process Flow Diagram for Condenser Air Removal System
2x660 MW Jaypee Thermal Power Station
Heat Exchanger Heat Exchanger Make-Up Line
Instrument Air Cooling Water Cooling Water To Separator
IN OUT From CEP
Discharge
System Outlet
To Atmosphere
Vacuum Pump
Unit - A
Condenser System Drain
LP - Shell
System Outlet
To Atmosphere
Vacuum Pump
Unit - B
System Drain
System Outlet
To Atmosphere
Vacuum Pump
Unit - A
Condenser System Drain
HP - Shell
System Outlet
To Atmosphere
Vacuum Pump
Unit - B
System Drain
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To atm.
Instrument Air
S
Make Up
Separator
From
Condenser
Butterfly Valve
with Pneumatic Vacuum
Overflow
Actuator Pump
S
Recirculation
Pump
Heat Exchanger
CW In CW Out
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DCS Graphics: Vacuum Pump
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2.2 Major Component
Followings are the major equipment for Condenser Air Evacuation System:
a) Four (2 x 100% for HP shell capacity and 2 x 100% for LP shell capacity)
constant speed, liquid ring type vacuum pump skids each containing vacuum
pumps, separator (1 x100%), Plate type Heat Exchanger (1x100%), Seal
Water Pump (1x100%) & I/L solenoid v/v
b) System Piping
2.2.1 Vacuum Pumps
The vacuum pumps are double stage, liquid ring, directly coupled main drive motor
with gear reducer, skid mounted, located indoors. Pump sizing are in accordance
with HEI standards for steam condensers, latest edition, for both hogging and
holding functions.
Each pump is furnished with automatic air inlet valves to isolate each pump, when
idle, from the common air inlet header, without leakage from the idle pump into the
header.
Following is a list of Vacuum Pumps for each unit:
Tag Number Description
1MAJ32AP003 Vacuum pump-A for LP shell
1MAJ32AP004 Vacuum pump-B for LP shell
1MAJ33AP001 Vacuum pump-A for HP shell
1MAJ33AP002 Vacuum pump-A for HP shell
2.2.2 Separator
The Separator is used to separate non-condensable gases from the liquid. Seal
water make-up is supplied to the separator from the condensate extraction pump
discharge during normal operation and condensate transfer pump / DM service
water pump during start-up when CEP is not running. Air and non-condensable
gases leaves the separator at atmospheric pressure via check valve. The separator
is provided with a liquid level gauge, two level transmitters, solenoid valve to make
up seal water, ball valve for the drain line and overflow vent line with check valve.
Following is a list of Separator for each unit:
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Tag Number Description
1MAJ32BB003 Separator of Vacuum pump-A for LP shell
1MAJ32BB004 Separator of Vacuum pump-B for LP shell
1MAJ33BB001 Separator of Vacuum pump-A for HP shell
1MAJ33BB002 Separator of Vacuum pump-A for HP shell
2.2.3 Plate Type Heat Exchanger
The Heat Exchanger cools the Vacuum Pump seal water. Cooling water for seal
water heat exchangers is tapped from Auxiliary cooling water system.
Following is a list of Heat Exchanger for each unit:
Tag Number Description
1MAJ32AC003 Heat Exchanger of Vacuum pump-A for LP shell
1MAJ32AC004 Heat Exchanger of Vacuum pump-B for LP shell
1MAJ33AC001 Heat Exchanger of Vacuum pump-A for HP shell
1MAJ33AC002 Heat Exchanger of Vacuum pump-A for HP shell
2.2.4 Recirculation Pump
Each vacuum pump skid is equipped with 1x100% motor-driven recirculation pumps.
These pumps take suction from the separator and discharge to the liquid ring
vacuum pump through heat exchangers. Following is a list of Seal Water Pump for
each unit:
Tag Number Description
1MAJ32AP007 Seal water Pump of Vacuum pump-A for LP shell
1MAJ32AP008 Seal water Pump of Vacuum pump-B for LP shell
1MAJ33AP005 Seal water Pump of Vacuum pump-A for HP shell
1MAJ33AP006 Seal water Pump of Vacuum pump-A for HP shell
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2.2.5 System Piping
The piping of air removal manifold for each condenser shell will be carbon steel
material (ASTM A 106 GR. B (S)). Piping for make-up water to separator from CEP
discharge is also made up with carbon steel.
The following table represents the design parameters for the various piping :-
Design
Sr. Design
SERVICE Material Pressure
No. Temp. 0C
kg/cm2 (g)
Condenser shell to Vacuum ASTM A 106
1 3.5 120
pump suction GR. B (S)
Make-up line to Separator from ASTM A 106
2 41.97 55
CEP discharge GR. B (S)
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3.0 NORMAL OPERATION, START-UP AND
SHUTDOWN
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Chapter 3
Mode of Operation
3.1 Description of Operation
3.1.1 Normal Start-up
Prior to start-up of the condenser air removal system, all manual isolation valves
corresponding to the vacuum pump skid should be in the open position. Water from
CEP discharge (during normal operation and water from condensate transfer pump /
DM service water pump during start-up when CEP is not running) will provide the
initial fill for the separator of all four vacuum pump units. The water level in the
separator is shown by the level gauge (1MAJ33CL 501/502, 1MAJ32CL 503/504).
The level transmitters (1MAJ33CL0 11 /12/21/22, 1MAJ32CL 31/32/41/42) signal
opens the solenoid valve (1MAJ33AA0 53 /63,1MAJ32AA 73/83) when the water
level is dropped below at predetermined point (for HP shell 575 mm and LP shell
624 mm) and the level transmitters signal closes the solenoid valve when the water
level is raised at predetermined point of level (for HP shell 607 mm and LP shell 656
mm). The fresh water is supplied via the solenoid valve to feed seal water into the
separator until the desired liquid level is attained.
Condenser air removal system can be placed in service by operator after ensuring
the following conditions:
• Turbine on Turning Gear
• Auxiliary steam header pressure is greater than 14 kg/cm2.
• Turbine gland steam system is in service and header pressure is greater than
0.1 kg/cm2.
• Auxiliary cooling water is available and plate heat exchanger is charged.
• Instrument air is available
Ensuring all above conditions and proper seal water level at all separator start
command of all four units should be given to exhaust the dry air from condenser.
Vacuum pump and seal water pump of all units should start simultaneously.
Pneumatically operated suction butterfly valve of each unit will open and all the
pumps will operate in Hogging mode till the condenser vacuum level (Both for HP
and LP shell) is reached to 0.345 kg/cm2 (a). All four units will be operated after this
value but mode of operation will change from Hogging to Holding.
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As soon as HP shell vacuum level will reach 0.1002 kg/cm2(a), standby pump of HP
shell will stop and lead pump will continue its operation in Holding mode. For LP
shell standby pump will stop at set value of 0.0783 kg/cm2(a) and lead pump will
continue its operation in Holding mode.
Hogging operation
In hogging operation the air is extracted from the condenser into suction connection
of all the vacuum pumps via suction line and inlet butterfly valve (1MAJ33AA051/61,
1MAJ32AA71/81). Hogging operation is up to 0.345 kg/cm2 (a) (10"hgA), but stand-
by pump will be operated to the set point with lead pump.
Holding operation
The vacuum pump unit is set to the holding operation by pressure transmitter
(1MAJ33CP012/13, 1MAJ32CP45/46) at vacuum level. The function of the
difference pressure transmitter (1MAJ33CP011/021,1MAJ32CP031/041) is to open
the solenoid valve (1MAJ33AA052/62, 1MAJ32AA72/82) at a predefined difference
pressure “0.0345 kg/cm2 (a)”. At operation, the solenoid valve (1MAJ33AA052/62,
1MAJ32AA072/82) will open the pneumatically operated butterfly valve
(1MAJ33AA051/61, 1MAJ32AA071/81) in the suction line. When vacuum level
reaches 0.17 kg/cm2 (a) (10"hgA), the two stage of vacuum pump starts operating for
higher vacuum with spray nozzle in function. The solenoid valve (1MAJ33AA054/64,
1MAJ32AA074/84) is provided for the spray on/off operation.
3.1.2 Normal Operation
During normal plant operation, lead vacuum pump unit for HP & LP shell are in
service and standby vacuum pump unit of both shell of condenser are in stop
condition with pneumatically operated butterfly valve in close position. Water level in
the separator of all vacuum pump units will be maintained through the solenoid valve
(1MAJ33AA0 53 /63,1MAJ32AA 73/83). Cooling water line I/L and O/L valve of all
vacuum units plate heat exchanger remain in open condition.
The discharge check valve (1MAJ33AA211/21, 1MAJ32AA31/41) of lead pumps is
normally open. To check air leakages of the condenser system, occasionally open
the flow meter shut-off valve (1MAJ33AA115/125,1MAJ32AA135/145). The check
valve (1MAJ33AA211/21, 1MAJ32AA31/41) is equipped with a hand lever to keep
the valve disk manually closed during the leakage measurement. The leakage air is
indicated by flow meter (1MAJ33CF501/502, 1MAJ32CF503/504). Release the hand
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lever after max. 20 seconds and the valve (1MAJ33AA211/21, 1MAJ32AA31/41) will
open self-acting. Air leakage measurements can only be taken during holding
operation with steady condenser operation condition. During start-up and hogging
operation it is important that the discharge check valve (1MAJ33AA211/21,
1MAJ32AA31/41) is normally open.
3.1.3 Normal Shut Down
During normal plant shutdown when turbine is tripped, bypass not in operation and
turbine speed is less than 400 RPM stop all vacuum pump units, kill gland steam
and open vacuum breaker valves of both shell.
3.2 Checklist
Vacuum unit in service
DANGER
Strictly follow the work permit system to avoid unacceptable troubles
or danger.
• Ensure cancellation of any work permit issued for vacuum unit and condenser.
• Ensure that the power supply for motor is available from the feeder.
• Make sure all interlocks and protections test of vacuum unit is qualified.
• All related instruments are mounted and properly fitted.
• Ensure availability of instrument air supply.
• Ensure all valves are on auto.
• Manual isolating valves line up as per chapter-7.
• Normal water level in condenser hotwell.
• Normal water level in separator tank
• Ensure that the sealing steam to turbine glands made available.
• Confirm that bearings for pump with motors are filled with grease.
• Ensure that cooling water for heat exchanger is available .
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• Confirm that pump casing & heat exchanger are filled with seal water.
• Rotate the shaft by hand to check Pump and motor freeness.
Vacuum unit in operation
• Heat exchanger cooling water inlet/outlet temperature.
CAUTION
Ensure control parameters (pressure, temperature, level etc.) are
controlled as specified
• Heat exchanger cooling water inlet/outlet temperature.
• Pump bearing temperature.
• Motor bearing temperature.
• Pump vibration amplitude on the bearing housing.
• Motor vibration amplitude on the bearing housing.
• Abnormal noise.
• Motor running current.
• Separator level.
• Condenser pressure.
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
4.0 EMERGENCY OPERATION AND
ALARMS
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Chapter 4
Emergency Operation and Alarms
4.1 Emergency Operation
4.1.1 Loss of a Vacuum Pump
If vacuum pump of lead Vacuum unit of any shell is tripped, pneumatically operated
butterfly valve of the respective unit will close and standby vacuum unit of respective
shell will cut-in and maintain the predetermined vacuum level.
4.1.2 Deterioration of Condenser Vacuum
In case the condenser vacuum level deteriorates below 0.17 kg/cm2(a), the standby
pump of respective shell will cut-in to maintain the predetermined value. The
condenser vacuum level (HP or LP) is detected through two pressure transmitters
(For HP shell: 1MAJ33CP012/013, For LP shell 1MAJ32CP045/046).
Standby pump will stop and pneumatically operated butterfly valve will close when
condenser shell vacuum level achieve the preset value (HP shell - 0.1002 kg/cm2(a)
and LP shell - 0.0783 kg/cm2(a)).
4.1.3 Loss of Seal water Pump
Running vacuum pump will trip due to tripping of seal water pump of respective
vacuum unit. Stand-by vacuum unit of respective shell will cut-in and maintain
vacuum level.
4.1.4 Abnormal Separator Tank water level
The water level in the separator of individual vacuum unit is controlled by individual
solenoid valve. Due to abnormal operation of individual solenoid valve respective
separator tank water level may increase or decrease. Isolate defective solenoid
valve by closing manual valves and maintain separator tank water level by operating
bypass manual valve of solenoid valve.
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
4.1.5 Loss of Instrument Air
Upon loss of instrument air pneumatically operated butterfly valve of all vacuum
units will close.
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
4.2 Alarms
CAUTION
Operator must take appropriate corrective action, if any of the
alarms mentioned below appears. Continuous operation without
corrective action may lead to the tripping of equipment and may
lead to the possible damage to the equipment.
The Condenser air removal system alarms can be monitored from the DCS operator
interface console alarm graphic display.
The following alarms related to Condenser air removal system are generated in the
DCS:
Condenser HP shell Vacuum unit - A Seal water flow low
Condenser HP shell Vacuum unit - B Seal water flow low
Condenser HP shell Vacuum Pump - A DE Brg temp high
Condenser HP shell Vacuum Pump - A DE Brg temp high High
Condenser HP shell Vacuum Pump - A IE Brg temp high
Condenser HP shell Vacuum Pump - A IE Brg temp high high
Condenser HP shell Vacuum Pump - B DE Brg temp high
Condenser HP shell Vacuum Pump - B DE Brg temp high high
Condenser HP shell Vacuum Pump - B IE Brg temp high
Condenser HP shell Vacuum Pump - B IE Brg temp high high
Condenser HP shell Vacuum Unit - A Seal water temp high
Condenser HP shell Vacuum Unit - A Seal water temp high high
Condenser HP shell Vacuum Unit - B Seal water temp high
Condenser HP shell Vacuum Unit - B Seal water temp high high
Condenser HP shell Vacuum Pump Motor - A DE Brg temp high
Condenser HP shell Vacuum Pump Motor - A DE Brg temp high high
Condenser HP shell Vacuum Pump Motor - A IE Brg temp high
Condenser HP shell Vacuum Pump Motor - A IE Brg temp high high
Condenser HP shell Vacuum Pump Motor - B DE Brg temp high
Condenser HP shell Vacuum Pump Motor - B DE Brg temp high high
Condenser HP shell Vacuum Pump Motor - B IE Brg temp high
Condenser HP shell Vacuum Pump Motor - B IE Brg temp high high
Condenser HP shell Vacuum Pump Motor – A winding temp high
Condenser HP shell Vacuum Pump Motor – A winding temp high high
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Condenser HP shell Vacuum Pump Motor – B winding temp high
Condenser HP shell Vacuum Pump Motor – B winding temp high high
Condenser LP shell Vacuum unit- A Seal water flow low
Condenser LP shell Vacuum unit- B Seal water flow low
Condenser LP shell Vacuum Pump - A DE Brg temp high
Condenser LP shell Vacuum Pump - A DE Brg temp high High
Condenser LP shell Vacuum Pump - A IE Brg temp high
Condenser LP shell Vacuum Pump - A IE Brg temp high high
Condenser LP shell Vacuum Pump - B DE Brg temp high
Condenser LP shell Vacuum Pump - B DE Brg temp high high
Condenser LP shell Vacuum Pump - B IE Brg temp high
Condenser LP shell Vacuum Pump - B IE Brg temp high high
Condenser LP shell Vacuum Unit - A Seal water temp high
Condenser LP shell Vacuum Unit - A Seal water temp high high
Condenser LP shell Vacuum Unit - B Seal water temp high
Condenser LP shell Vacuum Unit - B Seal water temp high high
Condenser LP shell Vacuum Pump Motor - A DE Brg temp high
Condenser LP shell Vacuum Pump Motor - A DE Brg temp high high
Condenser LP shell Vacuum Pump Motor - A IE Brg temp high
Condenser LP shell Vacuum Pump Motor - A IE Brg temp high high
Condenser LP shell Vacuum Pump Motor - B DE Brg temp high
Condenser LP shell Vacuum Pump Motor - B DE Brg temp high high
Condenser LP shell Vacuum Pump Motor - B IE Brg temp high
Condenser LP shell Vacuum Pump Motor - B IE Brg temp high high
Condenser LP shell Vacuum Pump Motor – A winding temp high
Condenser LP shell Vacuum Pump Motor – A winding temp high high
Condenser LP shell Vacuum Pump Motor – B winding temp high
Condenser LP shell Vacuum Pump Motor – B winding temp high high
The following information will be provided on the control room display on the CRT as
a function of the DCS.
HP shell Vacuum unit- A Seal water flow low
HP shell Vacuum unit- B Seal water flow low
HP shell Vacuum Unit-A system I/L DP
HP shell Vacuum Unit-B system I/L DP
HP shell system I/L pressure
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HP shell Vacuum Unit-A seal water pressure
HP shell Vacuum Unit-B seal water pressure
HP shell Vacuum Unit-A separator tank water level
HP shell Vacuum Unit-B separator tank water level
HP shell Vacuum Unit-A system I/L valve Open/Close
HP shell Vacuum Unit-B system I/L valve Open/Close
LP shell Vacuum unit- A Seal water flow low
LP shell Vacuum unit- B Seal water flow low
LP shell Vacuum Unit-A system I/L DP
LP shell Vacuum Unit-B system I/L DP
LP shell system I/L pressure
LP shell Vacuum Unit-A seal water pressure
LP shell Vacuum Unit-B seal water pressure
LP shell Vacuum Unit-A separator tank water level
LP shell Vacuum Unit-B separator tank water level
LP shell Vacuum Unit-A system I/L valve Open/Close
LP shell Vacuum Unit-B system I/L valve Open/Close
4.3 Cause & Effect Table
Cause Effect Action
1 Condenser Vacuum Level Low
1. Check the status of the
1. Stand-by vacuum unit of pneumatically operated
respective shell will cut butterfly valve of all
in if condenser vacuum running vacuum units
level (HP or LP) low which should be open.
1. Sudden opening alarm (0.172 kg/cm2(a))
of HP-LP bypass rings. 2. Check the status of seal
water flow volume for all
2. Disturbance in 2. Both stage of the lead running vacuum pump
Cooling Water vacuum pump will come unit.
Flow into action and spray
nozzle solenoid valve of
respective lead pump 3. Identify and try to
will open if condenser eliminate the cause of
vacuum level (HP or disturbance in cooling
LP) low alarm (0.172 Water Flow.
kg/cm2(a)) rings.
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Cause Effect Action
2 Trip of Vacuum Pump of lead vacuum unit
1. Check the status of
pneumatically operated
Any Condition as Stand-by vacuum unit of
I/L butterfly valve of
listed in Chapter 6 respective shell will cut
tripped unit, should be
for Vacuum pump in
close.
trip
2. Identify and eliminate the
cause of the tripping. Put
the tripped pump on Auto
after ensuring availability
of all start permissive.
3 Abnormal Separator tank water level
A Separator tank level low
1. Due to low separator 1. Isolate solenoid valve by
tank level seal water closing manual I/L and
pump will trip and O/L valve.
respective vacuum
Mal operation of
pump will trip. 2. Identify and eliminate the
Inlet solenoid
cause of mal operation of
valve
2. Stand-by vacuum unit of solenoid valve and check
respective shell will cut its auto operation. Put
in. the vacuum unit in stand-
by mode.
B Separator tank level high
1. Isolate solenoid valve by
closing manual I/L and
O/L valve.
Water will come out
Mal operation of
through separator tank 2. Identify and eliminate the
Inlet solenoid
overflow line to surface cause of mal operation of
valve
drain. solenoid valve and check
its auto operation. Put
the vacuum unit in stand-
by mode.
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5.0 INSTRUMENTATION AND PROCESS
CONTROL
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Chapter 5
Instrumentation & Process Control
5.1 Instrument and Process Control
5.1.1 Condenser HP shell vacuum level control
Purpose:
Condenser HP shell vacuum level will be maintained around a fixed point to maintain
turbine efficiency and power generation.
Functional Description:
Condenser HP shell vacuum level will be maintained by the vacuum units. There are
two 100% capacity vacuum pump units (1MAJ33AP001, 1MAJ33AP002) for HP
shell. Under normal operating condition, lead vacuum pump unit will be in
operational and stand-by unit will be in stop condition. The suction line is equipped
with two pressure transmitters (1MAJ33CP012/13) to control the lead pump, stand-
by pump on/off and also control the spray nozzle solenoid valve (1MAJ33AA054/64).
Due to any disturbance if vacuum level measured by transmitters
(1MAJ33CP012/13) reached to 0.17 kg/cm2 (a) standby vacuum unit will start and
pneumatically operated suction line butterfly valve will also open if differential
pressure (Sensed by DPT 1MAJ33CP011/021) between condenser side and
vacuum pump side is lower than 0.034 kg/cm2 (a). Also two stage of lead vacuum
pump will be in operational and spray nozzle (1MAJ33AA054/64) will open. Standby
vacuum unit will stop when condenser vacuum level will reach 0.1002 kg/cm2 (a).
5.1.2 Condenser LP shell vacuum level control
Purpose:
Condenser LP shell vacuum level will be maintained around a fixed point to maintain
turbine efficiency and power generation.
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Functional Description:
Condenser LP shell vacuum level will be maintained by the vacuum units. There are
two 100% capacity vacuum pump units (1MAJ32AP003, 1MAJ32AP004) for LP
shell. Under normal operating condition, lead vacuum pump unit will be in
operational and stand-by unit will be in stop condition. The suction line is equipped
with two pressure transmitters (1MAJ32CP45/46) to control the lead pump, stand-by
pump on/off and also control the spray nozzle solenoid valve (1MAJ32AA74/84).
Due to any disturbance if vacuum level measured by transmitters (1MAJ32CP45/46)
reached to 0.17 kg/cm2 (a) standby vacuum unit will start and pneumatically
operated suction line butterfly valve will also open if differential pressure (Sensed by
DPT 1MAJ32CP031/041) between condenser side and vacuum pump side is lower
than 0.034 kg/cm2 (a). Also two stage of lead vacuum pump will be in operational
and spray nozzle (1MAJ32AA74/84) will open. Standby vacuum unit will stop when
condenser vacuum level will reach 0.0783 kg/cm2 (a).
5.1.3 Separator tank water level control of HP shell vacuum unit
Purpose:
Separator tank water level will be maintained within a range to prevent tripping of
seal water pump and overflow of condensate.
Functional Description:
Water from CEP discharge is provided to maintain water level in vacuum unit
separator. The water level in the separator is shown by the level gauge
(1MAJ33CL501/502,). The level transmitters (1MAJ33CL011/12/21/22,) signal
opens the solenoid valve (1MAJ33AA053/63) when the water level is dropped below
575 mm and the level transmitters signal closes the solenoid valve when the water
level attained a value of 607 mm . The fresh water is supplied via the solenoid valve
to feed seal water into the separator until the desired liquid level is attained.
5.1.4 Separator tank water level control of LP shell vacuum unit
Purpose:
Separator tank water level will be maintained within a range to prevent tripping of
seal water pump and overflow of condensate.
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Functional Description:
Water from CEP discharge is provided to maintain water level in vacuum unit
separator. The water level in the separator is shown by the level gauge
(1MAJ32CL503/504).The level transmitters (1MAJ32CL31/32/41/42) signal opens
the solenoid valve (1MAJ32AA73/83) when the water level is dropped below 624
mm and the level transmitters signal closes the solenoid valve when the water level
attained a value of 656 mm. The fresh water is supplied via the solenoid valve to
feed seal water into the separator until the desired liquid level is attained.
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6.0 INTERLOCKS AND PROTECTION
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Chapter 6
Interlock and Protection
6.1 Vacuum Pumps
(1MAJ33AP001, 1MAJ33AP002, 1MAJ32AP003, 1MAJ32AP004)
Purpose:
To evacuate the main condenser steam space volume and ancillary piping and
equipment by reducing pressure to require starting levels and to remove non-
condensable gases from condenser steam space during normal operating condition.
Functional Description:
The vacuum pumps will be normally started and stopped manually from the DCS.
For each condenser shell one of the pumps will be in standby and will start
automatically upon loss of the lead pump or vacuum level low.
The vacuum pumps are controlled manually by the operator from the DCS operator
interface console. Start / Stop / Auto soft manual controls are provided through the
DCS.
Permissive:
• Recirculation pump is running
• Pump bearing temp not high (<85 0C)
• Motor bearing temp not high (<55 0C)
• Motor winding temp not high (<55 0C)
• Separator water level not low
Protective Command:
• Recirculation pump trip
• Pneumatic butterfly valve does not open within 30 seconds after vacuum pump
start up.
• Pump bearing temp high high (>95 0C)
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
6.2 Recirculation Pump
(1MAJ32AP007, 1MAJ32AP008, 1MAJ33AP005, 1MAJ33AP006)
Purpose:
Supply water from separator tank to vacuum pump to form liquid ring inside vacuum
pump and absorbs the heat generated by compression and friction
Functional Description:
Pump will start as soon as start command is given to respective vacuum unit. It
recirculate water from separator to vacuum pump.
Permissive:
• Separator water level not low ( for HP> 575 mm and LP >624 mm)
Protective Command:
• Separator water level low low ( for HP< 511 mm and LP < 560 mm)
• Vacuum pump motor trip
6.3 Separator tank make-up line solenoid valve
(1MAJ33AA053, 1MAJ33AA0653, 1MAJ32AA73, 1MAJ32AA83)
Purpose:
Valve will control the respective separator tank water level.
Functional Description:
Water from CEP discharge (during normal operation and water from condensate
transfer pump / DM service water pump during start-up when CEP is not running)
will provide the initial fill and make-up for the separator of all four vacuum pump
units. The level transmitters (1MAJ33CL0 11 /12/21/22,1MAJ32CL 31/32/41/42)
signal opens the solenoid valve (1MAJ33AA0 53 /63,1MAJ32AA 73/83) when the
water level is dropped below at predetermined point (for HP shell 575 mm and LP
shell 624 mm) and the level transmitters signal closes the solenoid valve when the
water level is raised at predetermined point of level (for HP shell 607 mm and LP
shell 656 mm).
6.4 Pneumatically operated suction butterfly valve
(1MAJ33AA051, 1MAJ33AA061, 1MAJ32AA71, 1MAJ32AA81)
Purpose:
Valve will isolate vacuum unit from suction manifold.
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Functional Description:
Valve will open at the same time base on the vacuum pump running, when the pump
is operated at hogging condition. For lead pump, Inlet valve should be opened at
hogging and holding condition. Inlet valve should be closed by stop signal of vacuum
pump motor.
When the stand-by pump starts by switching on vacuum pump motor, if differential
pressure between condenser side and vacuum pump side is lower than 0.034
kg/cm2 (a). Pneumatic valve will be opened by energizing 4-way solenoid valve at
the same time. When the stand-by pump stops by switching off vacuum pump motor,
Pneumatic valve will be closed by energizing 4-way solenoid valve at the same time.
6.5 Solenoid operated Spray Valve
(1MAJ33AA054, 1MAJ33AA064, 1MAJ32AA74, 1MAJ32AA84)
Purpose:
Valve will on/off the spray at the suction of the vacuum pump.
Functional Description:
When vacuum level reaches 0.17 kg/cm2 (a) (10"hgA), then two stage of vacuum
pump starts operating for higher vacuum with the solenoid valve (1MAJ33AA054/64,
1MAJ32AA074/84) opens to provide the spray at the suction of the vacuum pump.
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7.0 VALVE LINE-UP LIST
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Chapter 7
Valve Line-Up List
7.1 List
CAUTION
Do not operate valves without proper authorization such as work
permit, as unauthorized operation may lead to serious injury and
damage to the equipment.
Valve line-up list tabulated below provides recommended position of manual valves
of the condenser air removal system for starting the system.
System Pre Start
Valve Tag no. Description
Position
1MAJ50AA101 & Isolating valve of HP shell air removal
OPEN
1MAJ501AA02 manifold near to condenser
1MAJ50AA103 & Isolating valve of HP shell air removal
OPEN
1MAJ50AA104 manifold near to Vacuum Unit- A & B
Isolating valve of Instrument air line
1MAJ33AA158 &
connected to Vacuum Unit- A & B for OPEN
1MAJ33AA168
HP shell
Isolating valve of Make-up water line
1MAJ33AA111 &
connected to Separator of Vacuum OPEN
1MAJ33AA121
Unit- A & B for HP shell
Inlet and Outlet isolating valve of
1MAJ33AA165 &
make up seal water line solenoid valve OPEN
1MAJ33AA166
of HP shell Vacuum Unit-A
Bypass valve of make up seal water
1MAJ33AA112 line solenoid valve of HP shell Vacuum CLOSE
Unit-A
Flow meter isolating valve of HP shell
1MAJ33AA115 CLOSE
Vacuum Unit-A
Separator tank drain valve of HP shell
1MAJ33AA117 CLOSE
Vacuum Unit-A
Vacuum pump casing drain valve of
1MAJ33AA159 CLOSE
HP shell Vacuum Unit-A
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
System Pre Start
Valve Tag no. Description
Position
I/L and O/L isolating valve of plate
1MAJ33AA055 &
heat exchanger cooling water line of OPEN
1MAJ33AA056
HP shell Vacuum Unit-A
Inlet and Outlet isolating valve of
1MAJ33AA175 &
make up seal water line solenoid valve OPEN
1MAJ33AA176
of HP shell Vacuum Unit-B
Bypass valve of make up seal water
1MAJ33AA122 line solenoid valve of HP shell Vacuum CLOSE
Unit-B
Flow meter isolating valve of HP shell
1MAJ33AA125 CLOSE
Vacuum Unit-B
Separator tank drain valve of HP shell
1MAJ33AA127 CLOSE
Vacuum Unit-B
Vacuum pump casing drain valve of
1MAJ33AA169 CLOSE
HP shell Vacuum Unit-B
I/L and O/L isolating valve of plate
1MAJ33AA065 &
heat exchanger cooling water line of OPEN
1MAJ33AA066
HP shell Vacuum Unit-B
1MAJ10AA101 & Isolating valve of LP shell air removal
OPEN
1MAJ101AA02 manifold near to condenser
1MAJ10AA103 & Isolating valve of LP shell air removal
OPEN
1MAJ10AA104 manifold near to Vacuum Unit- A & B
Isolating valve of Instrument air line
1MAJ33AA178 &
connected to Vacuum Unit- A & B for OPEN
1MAJ33AA188
LP shell
Isolating valve of Make-up water line
1MAJ33AA131 &
connected to Separator of Vacuum OPEN
1MAJ33AA141
Unit- A & B for LP shell
Inlet and Outlet isolating valve of
1MAJ33AA185 &
make up seal water line solenoid valve OPEN
1MAJ33AA186
of LP shell Vacuum Unit-A
Bypass valve of make up seal water
1MAJ33AA132 line solenoid valve of LP shell Vacuum CLOSE
Unit-A
Flow meter isolating valve of LP shell
1MAJ33AA135 CLOSE
Vacuum Unit-A
Separator tank drain valve of LP shell
1MAJ33AA137 CLOSE
Vacuum Unit-A
Vacuum pump casing drain valve of LP
1MAJ33AA179 CLOSE
shell Vacuum Unit-A
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
System Pre Start
Valve Tag no. Description
Position
I/L and O/L isolating valve of plate
1MAJ33AA075 &
heat exchanger cooling water line of OPEN
1MAJ33AA076
LP shell Vacuum Unit-A
Inlet and Outlet isolating valve of
1MAJ33AA195 &
make up seal water line solenoid valve OPEN
1MAJ33AA196
of LP shell Vacuum Unit-B
Bypass valve of make up seal water
1MAJ33AA142 line solenoid valve of LP shell Vacuum CLOSE
Unit-B
Flow meter isolating valve of LP shell
1MAJ33AA145 CLOSE
Vacuum Unit-B
Separator tank drain valve of LP shell
1MAJ33AA147 CLOSE
Vacuum Unit-B
Vacuum pump casing drain valve of LP
1MAJ33AA189 CLOSE
shell Vacuum Unit-B
I/L and O/L isolating valve of plate
1MAJ33AA085 &
heat exchanger cooling water line of OPEN
1MAJ33AA086
LP shell Vacuum Unit-B
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
ABBREVIATIONS
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JAYPEE O&M MANUAL – VOLUME 1 CONDENSER AIR REMOVAL SYSTEM
Abbreviations:
Abbreviation Meaning
Amp Ampere
ASTM American Society for Testing and Materials International
BFPT Boiler Feed Pump-drive Turbine
CEP Condensate Extraction Pump
DE Driving End
DCS Distributed Control System
DP Differential Pressure
DPT Differential Pressure Transmitter
FC Forced Cooling
HP High Pressure
HEI Heat Exchange Institute
IE Idle End
I/L Inlet
kV Kilo Volt
Kg Kilogram
LP Low Pressure
LxDxH Length x Depth X Height
MW Mega Watt
NDE Non Driving End
O&M Operation & Maintenance
O/L Outlet
P&IDs Piping & Instrumentation Diagram
PID Proportional Integral Differential
RPM Revolution Per Minute
SCFM Standard Cubic Feet per Minute
Sec Second
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EXHIBITS
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JAYPEE O&M MANUAL – VOLUME 1 WATER, AIR & NITROGEN DITRIBUTION SYSTEM
Section H. Water,
Operation &
Air & Nitrogen
Maintenace Volume 1
Distribution
Manual
System
Table of Contents 752
1. Overview of Water, Air & Nitrogen Dist. Sys. 753
2. System Description 756
Abbreviations 764
Exhibits 766
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JAYPEE O&M MANUAL – VOLUME 1 WATER, AIR & NITROGEN DITRIBUTION SYSTEM
Table of Contents
1.0 OVERVIEW OF WATER, AIR & NITROGEN DISTRIBUTION SYSTEM
1.1 PURPOSE
1.2 REFERENCES
1.2.1 P & ID
2.0 SYSTEM DESCRIPTION
2.1 OVERVIEW
2.1.1 CIRCULATING WATER (CW) SYSTEM
2.1.2 DM WATER DISTRIBUTION SYSTEM
2.1.3 SERVICE WATER SYSTEM
2.1.4 INSTRUMENT AIR / SERVICE AIR SYSTEM
2.1.5 NITROGEN DISTRIBUTION SYSTEM
2.2 FLOW PATH
2.2.1 CIRCULATING WATER (CW) SYSTEM
2.2.2 DM WATER DISTRIBUTION SYSTEM
2.2.3 SERVICE WATER SYSTEM
2.2.4 INSTRUMENT AIR/SERVICE AIR SYSTEM
2.3 MAJOR EQUIPMENT
2.3.1 CIRCULATING WATER (CW) SYSTEM
2.3.2 DM WATER DISTRIBUTION SYSTEM
2.3.3 SERVICE WATER SYSTEM
2.3.4 INSTRUMENT AND SERVICE AIR SYSTEM
ABBREVIATIONS
EXHIBITS
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JAYPEE O&M MANUAL – VOLUME 1 WATER, AIR & NITROGEN DITRIBUTION SYSTEM
1.0 OVERVIEW OF WATER, AIR &
NITROGEN DISTRIBUTION SYSTEM
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JAYPEE O&M MANUAL – VOLUME 1 WATER, AIR & NITROGEN DITRIBUTION SYSTEM
Chapter 1
Overview of Water, Air & Nitrogen Distribution System
1.1 Purpose
The purpose of water, air & nitrogen distribution system O&M manual document is
to provide the operating personnel with necessary information to safely operate
and maintain the various water & air distribution & associated equipment.
The scope of the manual covers an overview of the System, description of its
distribution with associated equipment & devices, if any.
Various Water systems covered in this section are:
1. Circulating Water (CW) System
2. DM Water Distribution System
3. Service Water System
Air system is further categorized as following:
1. Instrument Air System
2. Service Air System
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1.2 References
1.2.1 P & ID
a) Circulating Water System P&ID _ Dwg. No. LTSL-M1-00209 Rev 3
b) DM Water Distribution System P&ID _ Dwg. No. LTSL-M1-00211 Rev 1
c) Service Water System P&ID _ Dwg. No. LTSL-M1-00213 Rev 1
d) Instrument Air & Service Air System P&ID _ LTSL-M1-00212 Rev 1
e) Nitrogen Distribution System P&ID _ LTSL-M1-00220 Rev A
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2.0 SYSTEM DESCRIPTION
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Chapter 2
System Description
2.1 Overview
2.1.1 Circulating Water (CW) System
The function of the Circulating Water (CW) system is to dissipate the latent
thermal load of main turbine exhaust steam, boiler feed pump turbine exhaust
steam, and sensible heat of condensate from gland steam condenser and drain
from Low Pressure Heater-1 by providing a continuous supply of cooling water to
the main condenser thereby effecting condensation.
2.1.2 DM Water Distribution System
The DM water distribution system is designed to distribute DM water for the
following purposes:
• Normal make-up water to condenser hotwell
• Quick fill line or emergency make-up water to condenser hotwell
• For CEP initial sealing
• For generator stator coil coolers
• To CCW overhead Tank
• To deaerator filling
• Initial sealing for vacuum breaker line & sealing water makeup for vacuum
pump
• Vacuum drain tank for initial filling
2.1.3 Service Water System
The service water system is designed to distribute water for the following
purposes:
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• CPU regeneration area for floor washing & eye wash/ safety shower
• To different consumptive points inside TG building for floor washing
• To Atmospheric Flash Tank, Drain and vent collecting system. Reference
drawing no: LTSL-M1-00215-04 (From APH wash water pump discharge -TP
with LMB).
• CO2 Gas vaporizer for CO2 Gas System. Reference drawing no: A11K934
(Turbine Generator H2 & CO2 Gas Diagram)
2.1.4 Instrument Air / Service Air System
The Instrument Air (IA) / Service Air (SA) distribution system receives Instrument
and Service Air from owner’s terminal point to provide the following functions:
• Provides oil free, clean, dry compressed (instrument) air for operation and
maintenance of all pneumatic instruments, control equipment and air
operated valves within the scope of Steam Turbine Generator & Auxiliaries
Package
• Provides compressed (service) air for start-up, normal operation and
maintenance within the scope of Steam Turbine Generator & Auxiliaries
Package.
2.1.5 Nitrogen Distribution System
The Nitrogen distribution system is designed for following:
• LP Heater 1A/1B, 2A/2B, 3, 4 Shell Side Preservation
• LP Heater 1A/1B, 2A/2B, 3, 4 Tube Side Preservation
• HP Heater 6A/6B, 7A/7B, 8A/8B Shell Side Preservation
• HP Heater Stream A/B Tube Side Preservation
• De-aerator Preservation
• Vacuum Drain Tank Preservation
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2.2 Flow Path
2.2.1 Circulating Water (CW) System
The CW supply lines (2 nos.) are connected to LP shell of Condenser. CW outlet
lines from LP shell are connected to inlet of HP shell. CW return lines from HP
shell are going back to Cooling Tower.
2.2.2 DM Water Distribution System
The system consists of Distribution system, complete with piping, valves, fittings,
instruments & with all necessary vents, drains etc. to supply water.
DM Water is supplied from Condensate storage tank placed at ground floor. There
are three terminal points from JPVL at 50 meters east of “C” row to the turbine
building for various usages.
2.2.3 Service Water System
The system consists of Distribution system, complete with piping, valves &fittings
with all necessary vents, drains etc.
JPVL has provided two (2) service water connections (one for each TG unit) from
overhead service water booster pump discharge near ‘C’ row about 4 m from local
grade level with isolation valve at a pressure of 6.05 kg/cm2 (g) minimum as
calculated. A separate connection is also provided to CPU regeneration area from
Service Water distribution header.
2.2.4 Instrument Air/Service Air System
Instrument Air / Service Air distribution system have Instrument & Service air
distribution piping from the JPVL’s terminal point to user points within the scope of
Steam Turbine Generator & Auxiliaries Package.
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DCS Graphics: Circulating Water System
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2.3 Major Equipment
2.3.1 Circulating Water (CW) System
Condenser
Rectangular type, Two shell, dual pressure, shell and tube type, water cooled,
single pass, divided water box design condenser are provided for each unit.
Detailed description is covered in Section A - Condensate system. For condenser
details, please refer vendor’s O&M manual LT-M0-03036 provided in Volume 2.
Online Tube Cleaning System (OLTCS)
Online tube cleaning system is provided for condenser tubes cleaning. The
sponge ball shaped cleaning elements which are collected in the ball separator
are extracted and recirculated into cooling water through ball vessels by non-
clogging type centrifugal pumps. Taps are provided in main CW inlet pipelines for
the installation of ball injection ports as well as a catch strainer downstream of the
condenser.
• CW line expansion joints & fittings, isolating motor operated butterfly valves
with matching flanges
• CW Piping to condenser inlet & outlet up to CW Pit near TG building ‘A’ row
SALIENT FEATURES:
1. The Control logic is set out to cater to the operational requirements of Tube
Cleaning System under all conditions.
2. Tube Cleaning System functions in two operational modes.
• LOCAL AUTOMATIC MODE – Operation in LOCAL AUTO can be
selected by turning the function selector switch in the Control Panel to
LOCAL AUTO.
• MANUAL MODE – Operation in MANUAL can be selected by turning
the function selector switch in the Control panel to MANUAL.
• REMOTE MODE – Operation in REMOTE can be selected by turning
the function selector switch in the Control panel to REMOTE.
3. Electric Actuators for the Ball Separator Screens (T11/1PAH20AT001-M03 &
T12/1PAH20AT001-M04) and the Ball Valves (T01/1PAH20AA051-M01 &
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T02/1PAH20AA052-M01) are provided with end travel limit and torque
switches.
4. Provision for operating the individual drives for ON/OFF, CLOSE/OPEN,
AUTO STOP/AUTO START, FAULT ACCEPT, FAULT RESET and
SEQUENCE HALT & RESET is provided as push buttons in the MIMIC on the
Local PLC panel.
5. Indication lamps and audible alarm are provided in the Mimic for all failure
signals.
6. 4-20 mA Analog Signal from the Differential Pressure Transmitter (D01 /
1PAH20CP001) is used for DP measurement across Ball Separator. DP
Transmitter (D02 / 1PAH20CP002) is used as redundant for the DP
Transmitter (D01 / 1PAH20CP001).
7. Ready to start lamp will glow only when all the electrical drives are in
"HEALTHY" condition. The "HEALTHY" condition is defined as a condition
when all "FAIL", "Normal Backwash" and "Emergency Backwash" indicating
lamps on the MIMIC are in "OFF" condition. These conditions and the
availability of the "MAIN CW PUMP ON" signal from the Main Control Room
will lead to switch “ON" the "READY TO START" indicating lamp by the PLC.
The Ready to start lamp will switch on only when the system is selected in
AUTO MODE.
8. The illuminated pushbutton will blink when the electric actuator operated
valves / screens move from one status to another status. The corresponding
illuminated push button will glow steadily when end travel limit switch is
reached.
9. Summary failure indication is provided for failures in the power circuitry of
individual drives. Sequence failure indication is provided for run time failure of
actuators during the operation of the system.
10. When the system is in "AUTOMATIC" mode, it will not respond for any manual
pressing of individual illuminated pushbutton and turning of selector switches
in the mimic will respond only after the system is stopped.
11. If Power fails, in any stage of the logic sequence - all equipment will come to
initial position when power is restored, and manual interference is required for
restarting the system as per the sequence explained in 10.11.
For further details on COLTCS, please refer GEA-I0-04321 provided in Volume 2.
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2.3.2 DM Water Distribution System
DM water distribution system will have following major components:
• Associated piping, valves and instruments required to distribute the DM water
inside TG building.
• System & distribution piping with associated valves & instruments.
2.3.3 Service Water System
The major system components as covered under this system are as follows:
• Associated piping, valves required to distribute the service water inside TG
building
• Provision has been made for connecting hose for cleaning of floors at various
consumer points within TG building.
• System & distribution piping with associated valves.
2.3.4 Instrument and Service Air System
Instrument and Service Air piping are the major components of this system. Also,
it includes instrument air supply impulse tubing, fittings & valves on impulse tubing
to all users which is of stainless steel (SS) material.
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ABBREVIATIONS
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Abbreviations:
Abbreviation Meaning
CW Circulating Water
CCW Closed Cooling Water
DM Demineralized
DCPL Development Consultant Private Limited
JPVL Jaypee Power Venture Limited
OLTCS On -Line Tube Cleaning System
CPU Condensate Polishing Unit
IA Instrument Air
SA Service Air
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EXHIBITS
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JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Section I.
Operation &
Maintenace Volume 1 Start-up and
Manual Shutdown
Procedure
Subsection 1. Start-up and Shutdown Procedure 776
Subsection 2. Start-up Cleanup Procedure 801
Subsection 3. Attachments 836
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SUBSECTION 1. START-UP AND
SHUTDOWN PROCEDURE
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SUBSECTION 1. START-UP AND SHUTDOWN PROCEDURE
CHAPTER 1: INTRODUCTION
CHAPTER 2: START-UP PREPARATION
A. Condensate Storage and Transfer System
B. ACW System
C. CCW system
D. Turbine Oil system
E. Main Turbine Turning Gear Start
F. Hotwell/ Deaerator Initial Fill
G. Startup Cleanup Operation
LP System Cleanup
H. Condensate System Startup
I. Turbine Gland sealing & Vacuum Pulling
J. Condensate Polishing Unit in Service
K. Deaerator vent valve operation
L. LP Heater In line
M. Gland Steam Spill Over line
N. Deaerator Initial Heating
O. HP System Cleanup
P. MDBFP Startup
Q. HP Heaters in line
R. Boiler Light off and Loading
S. LP Bypass Valve Operation
T. DA pegging steam source changeover – Aux Steam to CRH
U. Auxiliary Oil Pump
V. Turbine Drain Valve Operation
W. High Pressure Fluid System
X. Generator Auxiliary System
CHAPTER 3: STEAM TURBINE STARTUP
A. Automatic Turbine Startup System (ATS)
B. Turbine Metal - MS temperature matching
C. Steam Purity Recommendation
D. Main activities during automatic turbine startup (ATS)
E. ST loading
F. Feedwater Heater Cut-in
G. BFPT Start-up
H. MDBFP to TDBFP Changeover
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I. Second CEP Startup
J. 2nd TDBFP Startup
CHAPTER 4: SHUTDOWN PROCEDURE
A. Steam Turbine Shutdown
B. One CEP Shutdown
C. TDBFP to MDBFP Changeover
D. Turbine Drain Valve Operation
E. Feedwater Heater Cut-off
F. Feedwater System Shutdown
G. Checks for Hot Shutdown
H. Condensate System Shutdown
I. Vacuum System Shutdown
J. Preservation for Long Shutdowns
SUBSECTION 2. START-UP CLEANUP PROCEDURE
CHAPTER 1: INTRODUCTION
CHAPTER 2: REFERENCE DRAWING AND DOCUMENTS
CHAPTER 3: SYSTEM DESCRIPTION
3.1. Overview
3.2. Details of each step
TABLE1: Standard Clean up Schedule
3.3. Clean up Flow Rate
3.4. Major Equipment
CHAPTER 4: OPERATION
4.1. Pre-Boiler Cleanup
4.1.1. Condensate Bottom Blow
4.1.2. Condensate Blow Cleanup
4.1.3. CPU Bypass Cleanup Blow
4.1.4. Condensate Recirculation Cleanup
4.1.5. LP Line Cleanup Blow
4.1.6. LP Line Cleanup Circulation
4.1.7. HP Line Cleanup Blow
4.1.8. HP Line Cleanup Circulation
4.2. Boiler Cleanup
4.3. Heater Drain Cleanup
4.3.1. LP Heater Drain Cleanup (at 13% load)
4.3.2. HP Heater Drain Cleanup Blow (at 18% load)
4.3.3. HP Heater Drain Cleanup Recirculation
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EXHIBIT 1: CLEANUP FLOW PATH
SUBSECTION 3. ATTACHMENTS
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CHAPTER 1: INTRODUCTION
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Chapter 1
Introduction
The document is intended to provide the assistance to plant personnel
understanding the concept and steps followed for start-up and shutdown. This
document mainly describes methodology for the start-up of STGI and
auxiliaries. However, other auxiliaries which are required for the startup of
STG Island are also explained in brief. System description for respective
systems should be referred for the detailed start-up and shutdown procedure
for these systems.
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CHAPTER 2: START-UP PREPARATION
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Chapter 2
Startup Preparation
Following checks are recommended, prior to initiating plant start-up.
• Startup power required for STGI auxiliaries is available from Station
Transformer.
• All relevant work permits have been cancelled and Unit can be taken in
to operation.
• Clearance has been received for dispatch of power to the grid.
• Following balance of plant systems shall be ensured to be operational:
1. Raw Water System
2. Clarified Water System
3. Service Water System
4. Fire Water System
5. DM Water System
6. Plant Drain System
7. Circulating Water System
8. Compressed Air System
Following systems are to be started manually by operator as per requirement.
A. Condensate Storage and Transfer System
Ensure that Condensate transfer pump (by others) is in operation and make
up water is available for hotwell at terminal point.
Ensure that compressed air system (by others) is in operation and instrument
air and service air is available at terminal point.
B. ACW System
Ensure that ACW system (by others) is operational and cooling water is
available to the terminal point.
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C. CCW system
Initial filling of CCW expansion tank will be done by DM water through the DM
make-up line. MOV (1PGB10-AA001) in the makeup line is opened to fill the
tank. Two CCW pumps will be started and the 3rd pump will be in auto mode.
Two PHE will be taken in to line by opening respective inlet and outlet
isolation valve and third PHE can remain isolated for any maintenance
activity.
Once cooling water is available,
• Corrosion inhibitor chemicals will be kept ready for dosage, if required.
• Subsequent to loading the system, individual coolers will be taken in to
service as per operational requirements.
Refer Volume 1 – Section C: CCW System for detailed start-up procedure.
D. Turbine Oil system
Turbine oil system will be started as per manufacturer recommendation.
Please refer Volume 2 – LMTG-P0-01033: Steam Turbine O&M Manual.
E. Main Turbine Turning Gear Start
• Engage the turning gear if not already in service.
• Observe eccentricity meter and note indication of rotor truth reading.
In the event that continuous rolling during shut-down is not practical, the
turning gear should be started again at least an hour before rolling the turbine
with steam. Seal oil pressure needs to be established prior to putting turning
gear in to operation.
It should remain in operation for a sufficient length of time before admitting
steam to the turbine to allow the rotor to become straight within the limits.
Please refer Volume 2 – LMTG-P0-01033: Steam Turbine O&M Manual.
F. Hotwell/ Deaerator Initial Fill
The condensate storage tank will provide the initial fill for the condensate
system. The normal make-up control valves will be used to fill the condenser
hotwell. Alternatively, higher capacity Quick fill MOV (1GHC15AA001) will be
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used for initial filling of hotwell. CEP suction isolation valve will be opened to
fill the condensate up to the CEP discharge valve.
Initial system fill of condensate system will be performed by use of one
condensate pump. A motor operated bypass valve of main condensate
pump’s discharge valve is provided to allow a controlled start of a condensate
pump. The pump will run with motor operated bypass valve open to complete
system fill the condensate system piping. During initial fill all the high point
vent valves shall be kept open to vent any trapped air into atmosphere.
A separate initial fill line is provided from condensate transfer pump (By
others) for deaerator initial filling. System high point vent valves are operated
during initial filling. Once filling is completed, vent valves are closed.
Refer Volume 1 – Section A: Condensate System.
G. Startup Cleanup Operation
Startup clean up procedure includes LP system cleanup and HP system clean
up and feedwater heater shell side cleanup.
Each section cleanup is performed in two steps.
• Blowout
• Recirculation
However, requirement of performing any cleanup step depends upon mode of
startup as well as vacuum condition of condenser. Refer to Volume 1- Section
I- Subsection 2: Startup Cleanup Procedure”.
LP System Cleanup
LP system cleanup is divided in to following steps which will be performed
sequentially:
• Condenser Bottom Blow (This step is required to be performed only during
commissioning and after a long shutdown. This step will be performed
manually by operator. )
• Condensate Clean up Blow
• Condensate CPU Bypass Cleanup Blow
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• Condensate Clean up Recirculation
• LP Line Clean up Blow
• LP line Clean up Recirculation
Completion of each step shall be confirmed by operator after checking
necessary completion criteria. Once Operator confirms a step completion, the
sequence will move further to the next step.
H. Condensate System Startup
During Condensate cleanup blow operation, CEP subgroup is started. Once
following start permissive for CEP are satisfied, start respective CEP and
open its discharge MOV.
• Corresponding CEP suction valve open.
• CEP recirculation CV in AUTO.
• CEP discharge valve closed or any other CEP started with corresponding
discharge valve open.
• Hotwell level not low low
• Corresponding CEP motor bearing temperature not high.
• Corresponding motor winding temperature not high.
Refer Volume 1 – Section A: Condensate System for detailed startup
procedure.
I. Turbine Gland sealing & Vacuum Pulling
During LP cleanup operation, condenser vacuum is built up during
Condensate Recirculation Cleanup.
However, for condenser vacuum building, gland seal steam is to be
established first. Gland Seal steam source during this period will be steam
supply from operating unit aux. steam header (fed from aux boiler/ unit inter
connection).
Vacuum group startup shall be carried out as per following sequence:
• Vacuum breaker FG auto open command
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• Gland steam startup command
• BFPT gland steam startup command
• Vacuum pump on command
• BFPT exhaust MOV open command
• Vacuum breaker FG auto close command
The gland system is arranged so that sealing steam is furnished on start-up
from the auxiliary steam and finally from the cold reheat and the HP-IP glands
when the cold reheat pressure is adequate. Please refer Volume 2 – LMTG-
P0-01033: Steam Turbine O&M Manual.
During start-up both vacuum pumps will be running. Once condenser vacuum
is established to 0.93 kg/cm2(a), one vacuum pump will be stopped and there
after only one vacuum pump will be running. Refer Volume 1 – Section G:
Condenser Air Removal System for detailed startup procedure.
J. Condensate Polishing Unit in Service
During Condensate Cleanup Recirculation, once vacuum group startup is
completed and water quality is acceptable as per CPU manufacturer’s
recommendation, any Condensate Polishing Unit start command will be
initiated. Once any one CPU is started, CPU bypass line MOV is closed.
As load increases, 2nd stream of CPU will be taken in to service by operator.
Refer Volume 2 – SWTL-P0-00106: CPU O&M Manual for detailed startup
procedure.
K. Deaerator vent valve operation
Deaerator normal vent MOV (1LAA10AA001) will be opened from DCS when
any CEP start-up is completed. Once vacuum group startup is completed and
deaerator pressure reduces below 0.08 kg/cm2 deaerator startup vent MOV
(1LAA10AA001) shall be opened and it will remain open until deaerator
pressure increase above 0.1 kg/cm2.
L. LP Heater In line
Initially during LP system blow out, LP heater will be kept in bypass mode.
Then LP heater will be taken in to service from water side.
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• Open command to all LP heater outlet isolation MOV
• Open command to all LP heater inlet isolation MOV
• Close command to all LP heater bypass isolation MOV
M. Gland Steam Spill Over line
Once LP heater 1& 2 are in line from water side, gland steam spill over line
MOV (1LBS70AA442) to LP heater 1A & 1B is opened and subsequently
gland steam spill over line MOV (1LBS70AA442) to condenser is closed.
N. Deaerator Initial Heating
During LP cleanup recirculation, auxiliary steam will be supplied to deaerator
for heating condensate by opening deaerator auxiliary steam control valve
(1LBG70AA081), deaerator vents are connected to condenser & deaeration is
carried out. Isolation MOV in the aux steam line to deaerator (1LBG70AA007)
will be opened when aux steam pressure is higher than 15 kg/cm2. PCV
provided in aux steam line to deaerator (1LBG70AA081) will maintain
deaerator pressure to 0.5 kg/cm2a.
O. HP System Cleanup
HP system cleanup is divided in to following steps which will be performed
sequentially:
• HP Line Cleanup Blow
• HP Line Cleanup Recirculation
Completion of each step shall be confirmed by operator after checking
necessary completion criteria. Once Operator confirms a step completion,
operator will initiate the next step. Refer to Volume 1- Section I- Subsection 2:
Startup Cleanup Procedure” for detailed description.
P. MDBFP Startup
It is prudent to prime the HP Heaters through deaerator static head prior to
start-up of MDBFP.
Once following permissive are available feedwater system function group will
be started.
• CCW system startup complete
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• Deaerator storage tank level > 2900 mm
MDBFP sub group startup will be initiated automatically as a part of feedwater
group startup once following permissive are available:
• CCW system startup complete
• Deaerator storage tank level > 2900 mm
• MDBFP warm up complete.
MDBFP sub group startup will be as per following sequence:
• MDBFP Auxiliary lube oil pump will be started first.
• MDBFP inlet cooler valve open command
• MDBFP outlet cooler valve open command
• MDBFP discharge MOV close command
• MDBFP hydraulic coupling 0% position command
• MDBFP start command
• Discharge MOV open command
Q. HP Heaters in line
During HP system blowout HP heaters will be taken in line from water side.
• Open command to all HP heater outlet isolation MOV (1LAB41/44AA001)
• Open command to all HP heater inlet isolation MOV (1LAB40/43AA001)
• Close command to all HP heater bypass isolation MOV
(1LAB40/43AA002)
R. Boiler Light off and Loading
Once pre boiler cold cleanup operation is completed, boiler startup activities
will be initiated. First boiler cold clean-up will be performed. Then after boiler
light off, boiler hot cleanup will be performed. Subsequently, boiler loading will
be done with the help of HP-LP bypass valve which will increase MS/RH
pressure and temperature towards turbine steam admission requirement.
Refer to boiler OEM guidelines for detailed boiler start-up procedure.
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S. LP Bypass Valve Operation
LP bypass valves will be operated for reheat steam pressure control until
steam admission parameters are achieved. LP bypass valve isolation valve
(1LBH01AA051/52) will remain open once condenser vacuum is established.
Once following conditions are fulfilled, LP bypass PCV (1LBH01AA081/82)
will be opened to minimum opening position (5%).
• HRH steam pressure above 0.05 kg/cm2
• HP Bypass CV in auto
• Boiler is light off for 60 sec
• LP Bypass CV in auto
Reheat pressure will increase gradually towards the pressure required for
steam admission to turbine. Minimum position mode will continue until
generator is synchronized.
Once generator is synchronized, mode of LP bypass operation will be
changed over to follow mode. LP bypass PCV controller set-point will be
following the LP bypass pressure additional bias, hence the PCV will remain
closed in follow mode.
Spray water for LP bypass valve will be provided from the CEP Discharge
header through hydraulically operated spray control valve (1LCE45AA081 &
1LCE45AA082).
Refer to Volume 1- Section F: LP Bypass System for detailed operation of LP
bypass system.
T. DA pegging steam source changeover – Aux Steam to CRH
Once feedwater flow increase beyond 20% and CRH parameter is suitable for
supply to Deaerator (pressure > 13 kg/cm2), DA pegging CRH steam integral
MOV (1LBC01AA025A) from CRH steam will be opened first and then main
MOV (1LBC01AA025) will be opened. Hereafter, DA pegging steam will be
supplied from CRH steam. PCV (1LBC01AA090) will maintain deaerator
pressure.
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U. Auxiliary Oil Pump
AOP shall be started before turbine reset, and it will be stopped automatically
corresponds to turbine rotating speed during start up.
Please refer Volume 2 – LMTG-P0-01033: Steam Turbine O&M Manual.
V. Turbine Drain Valve Operation
Prior to admitting steam in turbine, various drain valves will be operated for
pre-warming of piping and valves. Refer Volume 2 – LMTG-P0-01033: Steam
Turbine O&M Manual for detailed operation of drain valves.
W. High Pressure Fluid System
Start the High Pressure Fluid System as per OEM guidelines. Please refer
Volume 2 – LMTG-P0-01033: Steam Turbine O&M Manual
X. Generator Auxiliary System
Generator auxiliary systems will be started and kept in operation as per the
operational requirements. Also, following checks need to be performed:
• Generator Hydrogen pressure ok
• Generator stator cooling water pump is in service
Refer Volume 2 - LMTG-E0-02386: Steam Turbine Generator Auxiliaries
O&M manual.
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CHAPTER 3: STEAM TURBINE STARTUP
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Chapter 3
Steam Turbine Startup
A. Automatic Turbine Startup System (ATS)
Turbine startup will be performed through Automatic Turbine Startup System.
Steam turbine startup mode is defined based on 1st stage temperature as per
the table given below:
Sr No HP Inlet Casing Metal Mode of Startup
Temperature (T ⁰C)
1 T < 121 Cold Startup
2 121 < T < 450 Warm Startup
3 T > 450 Hot Startup
Please refer Volume 2 – LMTG-P0-01033: Steam Turbine O&M Manual.
B. Turbine Metal - MS temperature matching
During startup, once main steam temperature comes within the permissible
range turbine steam admission can be initiated.
To facilitate matching of turbine metal and steam temperature on start-up,
start-up steam conditions at the main stop valves should be selected on the
following basis:
• COLD STARTS use steam at a temperature of 430°C. Starting conditions
for a cold turbine should be selected so that there is at least 56°C of
superheat in the steam to the main stop valves.
• HOT STARTS use steam at high temperature to minimize the temperature
loss from throttling the steam through the turbine inlet valve.
Following table shows the limits of operation for main steam temperature
during startup:
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Application Limit Remark
Main steam superheat above 56°C
degree
Cold start (curtis metal Below 430°C Superheat Degree:
temperature < 250°C) above 56°C
Hot start Differential temperature between curtis exit steam
temperature and initial curtis metal temperature is
within +110°C- -56°C.
C. Steam Purity Recommendation
Steam purity requirements for steam turbine as mentioned in Attachment 3 will be
ensured depending upon AVT/ CWT mode of operation:
D. Main activities during automatic turbine startup (ATS)
Major activities during by ATS during cold startup are as listed below:
• ST reset
• ST speed reaches 500 rpm, rub check
• ST speed reaches 2000 rpm, warming up
• ST speed reaches 3000 rpm
• Valve transfer from MSV to GV
• ST Synchronization via Automatic Synchronization System
• Generator Initial Loading
E. ST loading
From Initial load condition, further load increase will be done manually by
operator. Load ramp rate will also be decided based on mode of startup:
Mode of Startup Ramp Rate Ramp Rate
Cold 0.5 %/min (5%-30%) 1.0 %/min (30%-100%)
Warm 0.5 %/min (5%-30%) 1.0 %/min (30%-100%)
Hot 1.0 %/min (5%-37%) 2.0 %/min (37%-100%)
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F. Feedwater Heater Cut-in
LP Heater Cut-in
Once steam turbine generator is synchronized, vent MOV (1LCC15AA001/
1LCC25AA001/ 1LCC35AA001/ 1LCC45AA001) of LP heater 1 & 2 will be
closed. As generator load increases more than 13%, LP heater extraction
group will be started and LP heater drain side cleanup will be initiated first.
Once cleanup is completed, LP heaters 3 & 4 will be in service. Once heater
steam side inching MOV (1LBS80AA055/ 1LBS70AA001) is opened, startup
vent valves and drain valves for LP Heater 3 & 4 will be closed.
Please refer Volume 1 – Section D: Extraction Steam System for detailed
procedure.
Refer to Volume 1- Section I- Subsection 2: “Startup Cleanup Procedure” for
detailed cleanup procedure.
HP Heater Cut-in
Once generator load increases beyond 18%, HP heater extraction group will
be started and HP heater drain side cleanup will be initiated first. Once
cleanup is completed, HP heaters will be in service. Once heater steam side
inching MOV (1LBQ11/12AA001, 1LBQ21/22AA001, and 1LBQ31/32AA001)
is opened, respective startup vent valves and drain valves will be closed.
Please refer Volume 1 – Section D: Extraction Steam System for detailed
procedure.
Refer to Volume 1- Section I- Subsection 2: “Startup Cleanup Procedure” for
detailed cleanup procedure.
G. BFPT Start-up
First BFPT should be started and kept ready for TDBFP operation.
Steam source for BFPT startup will be taken from auxiliary steam. Once
steam from CRH is available, changeover from aux steam to CRH will be
done. There after once extraction steam is available from IP extraction, BFPT
steam source will be changed over to IP steam.
Major activities involved in BFPT group startup are as listed below:
• BFPT Gland sealing on
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• BFPT Warm-up Start
• BFPT Drain valve open
• BFPT Protection System Activation
• Warm-up Completed
• BFPT Controller Start Enabled
• Run to BFPT Controller
• BFPT Drain Valve Close
• BFPT Remote Set point Enabled
Refer to Volume 2- Section B- Subsection 2 – 7.8.27 SFC Turbine Control
Start Sequence for BFP Drive Turbine (0-06430-48005-98) for stepwise
startup sequence for BFPT.
Refer to Attachment 5: BFPT Startup Curve for details of mode of startup and
speed ramp rate during startup.
Second BFPT will also be started and kept ready for operation before 50%
load.
H. MDBFP to TDBFP Changeover
1st TDBFP will come in service at 20% TMCR (approx.) and gradually
MDBFP out of service taken place. At 35% TMCR (approx.), BID requirement
will switch over to TDBFP speed control and feed control valve
(1LAB29AA081) will hold its position. At the same point of time bypass MOV
(1LAB21AA001) of feed control valve will start opening. Feed control valve
will close when bypass MOV is fully open.
I. Second CEP Startup
Once load reaches near to 50%, operator will manually start second CEP.
During normal operation two CEPs will run and the third CEP will remain in
standby mode.
J. 2nd TDBFP Startup
Second TDBFP will be taken in to service at approx. 50% load. There after
both TDBFP will respond simultaneously to meet the feed-water demand
variations.
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CHAPTER 4: SHUTDOWN PROCEDURE
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Chapter 4
Shutdown Procedure
When turbine island shutdown is to be performed by operator, first generator
load is reduced to minimum load condition.
If shutdown is envisaged for a shorter duration, boiler will be boxed up &
condenser vacuum will be maintained and turbine will be kept on turning gear.
Under this condition steps A to G mentioned in subsequent sections will be
performed. However, if shutdown is planned for a longer duration then
condenser vacuum will be broken and condensate system will be shutdown.
Under this condition steps A to J mentioned in the subsequent sections will be
performed.
A. Steam Turbine Shutdown
Major activities involved in turbine shutdown are listed below:
• Decrease load
o Load Ramp Down Rate: -1.5%/min (from 100% - 50% load)
-1.0%/min (from 50%- 5% load)
• Generator load reaches min load condition (5%)
• Turbine trip and generator circuit breaker off
• Turbine speed decreases to zero speed
• Turbine turning gear starts automatically once turbine speed reaches to
zero.
All other auxiliaries which are not required as load reduces will be taken out of
service by operator.
B. One CEP Shutdown
As load reduces during shutdown, one CEP can be taken out of service by
operator once load is below 50%.
C. TDBFP to MDBFP Changeover
During shutdown BFPs are operated based on feedwater flow requirement
dictated by unit load.
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While decreasing the load, both BFPTs are kept in running up to
approximately 50% - 60% of TMCR load. At about 50 % load, One TDBFP
can be taken out of service and other TDBFP will take care of the load
demand.
As load reduces further, MDBFP will be started once load reduces below
30%. Once MDBFP is running, feed control will be changeover from TDBFP
to MDBFP and thereafter TDBFP will be taken out of service. Post
changeover, feed water demand will be fulfilled by MDBFP.
However, in case sufficient auxiliary steam is available, one BFPT can be
kept in operation and MDBFP need not be started.
The BFPT turning gear engages once zero speed of drive turbine is detected.
D. Turbine Drain Valve Operation
Drains valves from the turbine unit will be opened as steam turbine load
reduces. Refer Volume 2 – LMTG-P0-01033: Steam Turbine O&M Manual for
detailed operation of drain valves.
E. Feedwater Heater Cut-off
As steam turbine load reduces below 17%, HP Heater extraction will be cut-
off by closing respective extraction NRV and isolation MOV. Once load
reduces below 12% load, extraction steam to LP heater 3& 4 will be cut off by
closing respective extraction NRV and isolation MOV.
F. Feedwater System Shutdown
Once boiler shutdown is done and there is no further requirement for
feedwater MDBFP shutdown sequence to be initiated manually.
G. Checks for Hot Shutdown
When shutdown is envisaged for a shorter duration ensure following condition
(Vacuum Keep):
1. Turbine is on turning gear
2. Gland steam system is running with a steam from CRH
3. One CEP continues to run to provide LP gland desuperheating water
4. Condenser vacuum pump is running
5. Condenser Cooling Water system remains in operation
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6. Deaerator is under vacuum
H. Condensate System Shutdown
After Feedwater system shutdown, if there is no requirement for condensate
and after ensuring adequate cooling of system, second CEP can also be
shutdown. CPU may be shutdown as per operational requirements.
I. Vacuum System Shutdown
If shutdown is planned for a longer duration, condenser vacuum system will
be shutdown.
Vacuum can be killed after the turbine coasts down to below 400 rpm. Open
vacuum breaker valves and stop seal steam supply to glands.
Once vacuum pump system shutdown command is issued from console
following drives will be stopped:
• Vacuum pump A/B HP shell stop
• Recirculation pump A/B for HP shell stop
• Vacuum pump A/B LP shell stop
• Recirculation pump A/B for LP shell stop
J. Preservation for Long Shutdowns
If shutdown is planned for a longer duration, refer Attachment -4 for Typical
Recommendations on Layup and Preservation Procedure for different
components of Supercritical Units.
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SUBSECTION 2. START-UP CLEANUP
PROCEDURE
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CHAPTER 1: INTRODUCTION
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ABBREVIATION
BFP: Boiler Feed Pump
CEP: Condensate Extraction Pump
CPU: Condensate Polishing Unit
DCS: Distributed Control System
FW: Feed water
HP: High Pressure
LP: Low Pressure
LCV: Level Control Valve
LPH: Low Pressure Heater
MOV: Motor Operated Valve
MDBFP: Motor Driven Boiler Feed Pump
ST: Station Transformer
STG: Steam Turbine Generator
TMCR: Turbine Maximum Continuous Rating
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JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Chapter 1
Introduction
This document covers System Description, Operation & Control for Startup
Cleaning of pre-boiler system and feed water heater drain clean up for 2 x
660 MW Jaypee Nigrie Super Thermal Power Project. It is intended to provide
a general guideline for the normal pre-boiler cleanup required to be carried
out for super-critical Plant.
Jaypee Nigrie Super Thermal Power Project consists of two units of 660 MW
designed to operate at supercritical parameters. These supercritical units
have once through boilers without the drum and therefore blowing out of
impurities (silica, iron etc.) is not possible. Stringent feedwater quality
requirements are to be met to prevent possibilities of concentration and
deposition of impurities on boiler tubes inner surface impeding heat transfer
which ultimately results into tube failures. To meet the feed water quality
requirements pre-boiler and boiler system undergoes the clean up operation
during start up.
The pre-boiler system and feed water heater drain clean up consists of the
condenser, condensate pump, GSC, CPU, condensate water system, LP / HP
feed water heaters, deaerator, MDBFP, Feed water system and LP/HP heater
drain lines.
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CHAPTER 2: REFERENCE DRAWINGS AND
DOCUMENTS
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JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Chapter 2
Reference Drawing and Documents
AUTHORING
DOCUMENT NO. DESCRIPTION
ORGANIZATION
L&T – SARGENT Extraction Steam System
LTSL – M1- 00203
& LUNDY P&IDS
L&T – SARGENT Feedwater Steam System
LTSL – M1- 00202
& LUNDY P&IDS
L&T – SARGENT Condensate Steam System
LTSL – M1- 00201
& LUNDY P&IDS
L&T – SARGENT Drain & Vent Collection
LTSL – M1- 00215
& LUNDY System P&IDS
L&T – SARGENT DM Water Distribution
LTSL – M1- 00211
& LUNDY System P&ID
L&T – SARGENT
LTSL- I1- 00201 Control Loop Drawings
& LUNDY
L&T – SARGENT
LTSL- I1- 00200 Control Logic Drawings
& LUNDY
L&T – SARGENT Process Control Function
LTSL- I1- 00202
& LUNDY Description
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CHAPTER 3: SYSTEM DESCRIPTION
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Chapter 3
System Description
3.1. Overview
In order to achieve a high purity feedwater requirement, supercritical power
plants impose a requirement for Startup Cleanup. Overall clean up procedure
includes Pre boiler cleanup (LP system cleanup & HP system cleanup), Boiler
Cleanup and feedwater heater shell side cleanup.
Each system cleanup is performed in following two steps.
• Blowout
• Circulation
However, requirement of any step depends upon mode of startup (i.e. cold,
warm or hot startup) and vacuum condition during shutdown (i.e. vacuum
keep or vacuum break).
This document covers LP system cleanup, HP system cleanup and heater
drain cleanup. Refer to manufacturer guidelines for Boiler Cleanup
Procedure.
Pre-Boiler cleanup is divided to 8 steps.
Step 1: Condenser Bottom Blow
Step 2: Condensate Cleanup Blow
Step 3: Condensate CPU Bypass Cleanup Blow
Step 4: Condensate Cleanup Recirculation
Step 5: LP Line Blow Cleanup
Step 6: LP Line Recirculation Cleanup
Step 7: HP Heater Line Blow Cleanup
Step 8: HP Heater Line Recirculation Cleanup
Heater Drain cleanup is divided to 3 steps.
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Step 1: LP Heater Drain Cleanup
Step 2: HP Heater Drain Cleanup Blow
Step 3: HP Heater Drain Cleanup Recirculation
3.2. Details of each step
Depending on startup condition, cleanup schedule will be decided. Standard
clean up schedule is shown in below TABLE1.
TABLE1: Standard Clean up Schedule
STEP Condenser Condensate Clean LP line HP line LP HP
Bottom up Heater Heater
Clean up Clean up
Blow Drain Drain
Clean Clean
up up
(steam (steam
side) side)
START
COND. CPU
Blow Blow Bypass Recir Blow Recir Blow Recir Blow Blow
blow
HOT V.K × × × × × ○ × × ○ ○
V.K × × × × × ○ × × ○ ○
WARM
V.B ○ ○ ○ ○ ○ × × ○ ○
COLD V.B ○ ○ ○ ○ ○ ○ ○ ○ ○
Remarks:
V.K …… Condenser Vacuum Keep
○ …… Required
V.B …… Condenser Vacuum Broken
× …… Not Required
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…… Carry out when the water out of Condenser and
Condenser water quality exceed the value (Turbidity > 3
NTU)
3.3. Clean up Flow Rate
Flow rate for cleanup shall be the maximum flow rate which will not affect or
damage or cause any troubles on equipment, piping, etc. during clean up.
Approximately 25% of BMCR feedwater flow will be applied for cleanup.
3.4. Major Equipment
Sr. No. Description Tag No.
1 Condenser Quick Fill MOV 1GHC15AA001
2 Condensate pump 1LCA13/14/15AP001
3 Atmospheric flash tank inching MOV 1LCA35AA001
4 MOV located in cleanup line going to
1LAB44AA006
condenser
5 LP cleanup isolation MOV 1LAA20AA003
6 MOV located in cleanup line going to
1LAB44AA005
Atmospheric flash tank
7 Upstream isolation MOV of DA LCV 1LCA50AA001/002
MOVs provided at cleanup line of each
8 1LAB41/44AA002
HP heater train outlet
9 HPH 6A,7A,8A bypass MOV 1LAB40AA002
10 HPH 6B,7B,8B bypass MOV 1LAB43AA002
11 HPH 8A outlet MOV 1LAB41AA001
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JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Sr. No. Description Tag No.
12 HPH 8B outlet MOV 1LAB44AA001
13 HPH 6A inlet MOV 1LAB40AA001
14 HPH 6B inlet MOV 1LAB43AA001
15 MDBFP A 1LAC10AP001
16 MDBFP B 1LAC15AP001
17 MDBFP A discharge MOV 1LAB24AA001
18 MDBFP B discharge MOV 1LAB26AA002
19 LPH normal drain to vacuum flash tank
1LCJ50AA005
MOV
20 LPH normal drain to vacuum flash tank
1LCJ50AA006
MOV
21 LP heater 3 to 2A normal drain CV
1LCJ50AA003
outlet MOV
22 LP heater 3 to 2B normal drain CV
1LCJ50AA004
outlet MOV
23 HP Heater 6A Cleanup Blow Isolation
1LCH30AA003
MOV
24 HP Heater 6B Cleanup Blow Isolation
1LCH35AA003
MOV
25 HP heater 6A normal drain to deaerator
1LCH30AA002
line isolation MOV
26 HP heater 6B normal drain to deaerator
1LCH35AA002
line isolation MOV
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CHAPTER 4: OPERATION
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Chapter 4
Operation
Pre-boiler cleanup operation will be initiated as a group startup except for
“Condenser Bottom Blow”. Condenser bottom blow is to be performed only
after a long shutdown when any maintenance work has been carried out in
condenser. This step is performed manually by operator. Also, completion of
each cleanup step shall be confirmed by operator. Once operator confirms
“water quality ok”, sequence will move to the next step of cleanup.
Detailed stepwise procedure for each step is explained in the following
section. Cleanup flow path for each step is shown in Exhibit I: Cleanup Flow
Path.
4.1. Pre-Boiler Cleanup
4.1.1. Condensate Bottom Blow
• Procedure
1. Purpose of this step is to clean the inner surface of Condenser hotwell.
Especially, deposits such as mud at the bottom of the hotwell shall be well
removed.
2. Check condensate storage tank level not low.
3. DM water is filled in the condenser up to normal water level (765mm) (*)
through Condenser Quick Fill Control Valve (1GHC15AA081) / normal
make up control valve (1GHC10AA081). Hotwell Overflow to CST Control
Valve (1LCA48AA081) shall remain closed.
4. Open Condenser Blow Valves manually to drain the stored water.
5. Repeat fill & blow (step 4 & 5) sequentially, until blow water quality satisfy
the below condition.
6. Re-fill demineralized water to Condenser.
• Completion Criteria
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Turbidity at grab sample line from hotwell (S1, S2) ≦ 3 NTU
Note: (*) Operator may choose to fill the condenser to high level (940 mm)
for better cleaning.
4.1.2. Condensate Blow Cleanup
• Procedure
Condensate Cleanup Blow can be initiated either by operator from DCS or
as a part of group startup sequence.
Following sequential operation will be performed under condensate
cleanup blow operation:
1. CPU out of service and CPU bypass valve is closed.
2. Start command to condensate water group
a. CEP discharge MOV close command
b. Primary CEP will be started
c. Respective discharge MOV shall be opened
3. Open command will be issued to condensate to atmospheric flash tank
inching MOV (1LCA35AA001) located downstream of GSC
4. Continue condensate blow cleanup until water quality mentioned in the
completion criteria is achieved.
• Completion Criteria
Fe content at GSC outlet (S3) ≦300 μg/l (Analyzed by membrane filter)
4.1.3. CPU Bypass Cleanup Blow
• Procedure
CPU Bypass Cleanup Blow can be initiated either by operator from DCS
or as a part of group startup.
Following sequential operation will be performed under CPU bypass
cleanup blow operation:
1. Close command to DA LCV inlet isolation valve (1LCA50AA001/002)
2. Close command to DA LCV bypass MOV (1LCA50AA003)
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3. Open command will be issued to condensate to atmospheric flash tank
inching MOV (1LCA35AA001) located downstream of GSC
4. Start command to 2nd CEP
5. Stop command to 1st CEP (Discharge valve closes and thereafter CEP
stops)
6. Start command to 3rd CEP (after pump 2 has been running for 300 sec)
7. Stop command to 2nd CEP (Discharge valve closes and thereafter CEP
stops)
8. Bypass command to CPU
a. Open command to CPU (bypass modulating butterfly valve)
b. CEP recirculation valve closed, there after CEP minimum
recirculation flow will be maintained via GSC recirculation valve
(1LCA47AA081).
9. Continue condensate recirculation cleanup until water quality
mentioned in the completion criteria is achieved.
• Completion Criteria
Fe content at CPU outlet (S4) ≤ 300 (μg/l)
4.1.4. Condensate Recirculation Cleanup
Condensate Circulation Cleanup can be initiated either by operator from DCS
or as a part of group startup.
Following sequential operation will be performed under condensate circulation
cleanup operation:
1. Close command will be issued to condensate to atmospheric flash tank
inching MOV
2. Start command to Chemical Injection group
5. Start command to vacuum group
a. LP turbine 1 & 2 vacuum breaker valve open
b. Gland steam system startup
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JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
• Anyone gland steam condenser fan on & in auto mode
• Gland steam condenser vacuum ok
• Gland steam header pressure normal
• Aux steam to gland steam and CRH to gland steam line MOV
open
• Both BFPT gland steam in service
c. BFPT exhaust MOV open
d. HP shell vacuum pump group on
e. LP shell vacuum pump group on
f. Vacuum breaker valve close
3. Continue condensate recirculation through CPU bypass line until
influent water quality is acceptable for taking CPU in to service.
4. In Service command to 1st CPU
5. Close command to CPU bypass MOV
6. Continue condensate recirculation cleanup until water quality
mentioned in the completion criteria is achieved.
• Completion Criteria
CC at GSC outlet (S3) ≤0.1 (mS/m)
Fe content at GSC outlet (S3) ≤ 300 (μg/l) (Analyzed by membrane
filter)
Fe content at CPU outlet (S4) ≤ 50 (μg/l)
4.1.5. LP Line Cleanup Blow
LP line blow cleanup is performed in two steps. Initially LP heaters are kept in
bypass mode and blow cleanup is done. Afterwards, LP heaters are taken in
to service and blow cleanup is done until the water quality is achieved. It is
assumed that deaerator has been thoroughly cleaned manually before
initialing this step.
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• Procedure
LP Line Blow Cleanup can be initiated either by operator from DCS or as a
part of APS sequence.
Following sequential operation will be performed under LP line blow
cleanup operation:
1. Close command to MOV located in cleanup line going to condenser
(1LAB44AA006)
2. Close command to LP cleanup isolation MOV (1LAA20AA003)
3. Close command to MOV located in cleanup line going to Atmospheric
flash tank (1LAB44AA005)
4. Open command to upstream isolation MOV (1LCA50AA001/002) of DA
LCV.
5. Shutdown command LP Heater group
6. Open command to LP cleanup isolation MOV (1LAA20AA003)
7. Open command to MOV located in cleanup line going to Atmospheric
flash tank (1LAB44AA005)
8. Start command to LP Heater group
9. Continue LP line blow cleanup until water quality mentioned in the
completion criteria is achieved.
• Completion Criteria
Fe content at LP heater line cleanup line (S5) ≤ 300 (μg/l) (Analyzed by
membrane filter)
4.1.6. LP Line Cleanup Circulation
• Procedure
1. Open command to aux steam supply to deaerator line MOV
(1LBG70AA007)
2. Close command to MOV located in cleanup line going to Atmospheric
flash tank (1LAB44AA005)
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JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
3. Open command to MOV located in HP cleanup line going to condenser
(1LAB44AA006)
4. Continue LP line circulation cleanup until water quality mentioned in
the completion criteria is achieved.
5. Close command to MOV located in cleanup line going to condenser
(1LAB44AA006)
• Completion Criteria
CC at CPU outlet (S4) ≤0.1 (mS/m)
DO at deaerator storage tank (S10) ≤10 (μg/l)
Fe content at LP heater line cleanup line (S5) ≤ 50 (μg/l)
4.1.7. HP Line Cleanup Blow
• Procedure
1. Close command to MOV located in HP cleanup line going to
condenser (1LAB44AA006)
2. Close command to HP Heater 8A/ 8B outlet MOV (1LAB41AA001 /
1LAB44AA001)
3. Close command to HP Heater stream A/B bypass MOV
(1LAB40AA002 / 1LAB43AA002)
4. Open command to MOV located in HP cleanup line going to
Atmospheric flash tank (1LAB44AA005)
5. Open command to HP Heater stream A cleanup MOV (1LAB41AA002)
6. Open command to HP Heater stream B cleanup MOV(1LAB44AA002)
7. Open command to HP Heater 6A/6B inlet MOV (1LAB40AA001 /
1LAB43AA001)
8. MDBFP start command
10. Continue HP line blow cleanup until water quality mentioned in the
completion criteria is achieved.
LTSL-M0-00951 REV 0 Page 818 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
• Completion Criteria
Fe content at HP heater line cleanup line (S6) ≤ 300 (μg/l) (Analyzed by
membrane filter)
Note: During this process HP heater stream A/B shall be switched at
intervals.
4.1.8. HP Line Cleanup Circulation
• Procedure
1. Open command to MOV located in HP cleanup line going to condenser
(1LAB44AA006)
2. Close command to MOV located in HP cleanup line going to
Atmospheric flash tank (1LAB44AA005)
3. Continue HP line circulation cleanup until water quality mentioned in
the completion criteria is achieved.
4. Close command to MOV located in HP cleanup line going to
condenser (1LAB44AA006)
5. Close command to HP Heater Stream A/B cleanup MOV
(1LAB41AA002/1LAB44AA002)
• Completion Criteria
CC at GSC outlet (S3) ≤0.1 (mS/m)
Fe content at HP heater line cleanup line (S6) ≤ 50 (μg/l)
SiO2 content at HP heater line cleanup line (S6) ≤ 30 (μg/l)
4.2. Boiler Cleanup
Once preboiler cleanup is completed, boiler cleanup will be initiated as per
boiler OEM recommendation.
Once boiler cleanup is completed, boiler startup- loading and turbine startup
is performed.
LTSL-M0-00951 REV 0 Page 819 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
4.3. Heater Drain Cleanup
Once turbine is synchronized and initial load break point is completed, first LP
heater extraction will be available and then HP heater extraction will be
available. Here, before taking heaters in to service, heater drain side cleanup
is to be performed.
4.3.1. LP Heater Drain Cleanup (at 13% load)
Once LP extraction is ready LP heater drain operation will be initiated.
However, as LP heater drain cleanup is in progress, turbine start-up will follow
the normal start-up curve, load hold is not required.
• Procedure
1. Close command to LP heater 3 to 2A/2B normal drain CV outlet MOV
(1LCJ50AA003 / 004)
2. Open command to LPH normal drain to vacuum flash tank MOVs
(1LCJ50AA005 / 006)
3. Open command to LP Heater 3 to 2A/2B normal drain CV upstream
MOV (1LCJ50AA001 / 002)
4. Close command to LP Heater Cleanup Recirculation Heater 2A MOV
(LPH 3 normal drain LCV outlet MOV) (1LCJ50AA003)
5. Close command to LP Heater Cleanup Recirculation Heater 2B MOV
(LPH 3 normal drain LCV outlet MOV) (1LCJ50AA004)
6. In service command to LP heater extraction
7. Continue LP Heater drain cleanup until water quality mentioned in the
completion criteria is achieved.
8. LP Heater drain normal in service command
• Completion Criteria
Fe content at LP heater drain blow line (S6) ≤300 (μg/l)
LTSL-M0-00951 REV 0 Page 820 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
4.3.2. HP Heater Drain Cleanup Blow (at 18% load)
As steam turbine is loaded further and HP heater extraction is available, HP
Heater drain cleanup blow operation is initiated. However, as HP heater drain
cleanup is in progress, turbine start-up will follow the normal start-up curve,
load hold is not required.
• Procedure
1. Close command to HP Heater 6A/6B normal LCV outlet MOV
(1LCH30AA002 / 1LCH35AA002)
2. Open command to HP Heater 6A/6B drain blow MOV
(1LCH30AA003/1LCH35AA003))
3. Open command to HP Heater 6A/6B LCV inlet
MOV(1LCH30AA001/1LCH35AA001)
4. Open command to HP Heater 7A/7B LCV inlet MOV (1LCH20AA001 /
1LCH25AA001)
5. Open command to HP Heater 8A/8B LCV inlet MOV (1LCH10AA001 /
1LCH15AA001)
6. HP Heater Extraction “in service” command
7. Continue HP Heater drain cleanup blow until water quality mentioned
in the completion criteria is achieved.
• Completion Criteria
Fe content at HP heater normal drain line (S7) ≤300 (μg/l)
4.3.3. HP Heater Drain Cleanup Recirculation
Once HP Heater drain cleanup blow is completed, water will be circulated
back to condenser via emergency drain line of heater 6A/B. during this period
emergency drain valve will maintain heater level to normal. Heater 6A/B
normal drain control valve along with outlet isolation MOV will be closed.
• Procedure
1. Close command to HP Heater 6A/6B drain blow isolation MOV
(1LCH30AA003/1LCH35AA003)
LTSL-M0-00951 REV 0 Page 821 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
2. Continue HP Heater drain cleanup blow until water quality mentioned
in the completion criteria is achieved.
• Completion Criteria
Fe content at HP Heater 6A/B Emergency drain line ≤ 50 µg/l
Once water quality is achieved and load is more than 30%, HP heater 6A/6B
normal drain CV outlet MOV will be opened. There after HP heater 6A/B
normal drain control valve (1LCH30/35AA081) will start to modulate to normal
level and HP Heater 6A/B Emergency drain control valve (1LCH30/35AA082)
will be closed.
LTSL-M0-00951 REV 0 Page 822 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
EXHIBIT 1: CLEANUP FLOW PATH
LTSL-M0-00951 REV 0 Page 823 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
OVERALL CLEANUP DIAGRAM
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION VACUUM
FROM LPT
EXTRACTION
FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT
HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
FROM IPT HP SHELL MAKEUP
EXTRACTION VALVE
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV FROM CST
S9
FCS
S5
OVERFLOW CV EMERGENCY
MIN RECIRC
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
LTSL-M0-00951 REV 0 Page 824 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
STEP:1 CONDENSATE BOTTOM BLOW
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION
VACUUM
FROM LPT
EXTRACTION FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT
HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
FROM IPT HP SHELL MAKEUP
EXTRACTION VALVE
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV FROM CST
S9
FCS
S5
OVERFLOW CV EMERGENCY
MIN RECIRC
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
Hotwell – Drain valve – Drain System
LTSL-M0-00951 REV 0 Page 825 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
TO BOILER STEP:2 CONDENSATE CLEANUP BLOW
FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION VACUUM
FROM LPT
FT
EXTRACTION
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT
HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
FROM IPT HP SHELL MAKEUP
EXTRACTION VALVE
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV
FROM CST
S9
FCS
S5
OVERFLOW CV EMERGENCY
MIN RECIRC
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
Condenser - CEP – GSC Bypass – Condensate to Atmospheric tank MOV - Atmospheric Flash Tank – Drain Pit
LTSL-M0-00951 REV 0 Page 826 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
STEP:3 CONDENSATE CPU BYPASS CLEANUP BLOW
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION
VACUUM
FROM LPT
EXTRACTION FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
TO EXTRACTION AUX LPH1A LPH1B
HP STEAM
FT
HPH7
HPH7A HPH7B
DEAERATOR LP SHELL NORMAL
FROM IPT MAKEUP
HP SHELL
EXTRACTION VALVE
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV
FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
Condenser - CEP - GSC – (CPU Bypass – GSC recirculation Valve – Condenser) - Condensate to Atmospheric tank MOV - Atmospheric Flash Tank – Drain Pit
LTSL-M0-00951 REV 0 Page 827 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
STEP:4 CONDENSATE CLEANUP RECIRCULATION
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION
VACUUM
FROM LPT
EXTRACTION FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
FROM IPT HP SHELL MAKEUP
EXTRACTION VALVE
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV
FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
Condenser - CEP - GSC – CPU – GSC Recirculation Valve – Condenser
LTSL-M0-00951 REV 0 Page 828 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
TO BOILER STEP:5 LP LINE CLEANUP BLOW
FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION
VACUUM
FROM LPT
EXTRACTION FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
FROM IPT
HP SHELL MAKEUP
EXTRACTION
VALVE
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
Condenser - CEP - GSC - CPU - DA LCV - LPHs - Deaerator – LP Cleanup Isolation Valve – HP cleanup to flash tank MOV - Atmospheric Flash Tank – Drain Pit
LTSL-M0-00951 REV 0 Page 829 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
TO BOILER STEP:6 LP LINE CLEANUP RECIRCULATION FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION VACUUM
FROM LPT FT
EXTRACTION
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
HPH7A
HPH7 HPH7B
FT DEAERATOR NORMAL
LP SHELL
HP SHELL MAKEUP
FROM IPT
VALVE
EXTRACTION
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
Condenser - CEP - GSC - CPU - DA LCV - LPHs - Deaerator – LP Cleanup Isolation Valve – HP cleanup to condenser MOV -– Condenser
LTSL-M0-00951 REV 0 Page 830 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
STEP:7 HP LINE CLEANUP BLOW
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION VACUUM
FROM LPT
EXTRACTION
FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
HPH7A
HPH7 HPH7B
FT DEAERATOR NORMAL
LP SHELL
HP SHELL MAKEUP
FROM IPT VALVE
EXTRACTION
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV
FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
Condenser - CEP - GSC - CPU - DA LCV - LPH – Deaerator – MDBFP – FCV – HP Heaters - MOVs provided at cleanup line of each HP heater train outlet - MOV located
in cleanup line going to Atmospheric flash tank – Atmospheric Flash Tank – Drain Pit
LTSL-M0-00951 REV 0 Page 831 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
STEP:8 HP LINE CLEANUP RECIRCULATION
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION
VACUUM
FROM LPT
EXTRACTION FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
FROM IPT HP SHELL MAKEUP
EXTRACTION VALVE
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV
FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
Condenser - CEP - GSC - CPU - DA LCV - LPH – Deaerator – MDBFP – FCV – HP Heaters - MOVs provided at cleanup line of each HP heater train outlet -
MOV located in cleanup line going to condenser – Condenser
LTSL-M0-00951 REV 0 Page 832 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
STEP:1 LP HEATER DRAIN CLEANUP BLOW
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION
VACUUM
FROM LPT
EXTRACTION FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
FROM IPT MAKEUP
HP SHELL
EXTRACTION VALVE
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
FLOW PATH: TO DRAIN PIT
LP Heater 4 – LP Heater 3 – LP Heater Cleanup Blow MOV –Vacuum Flash Tank –Vacuum Flash Tank Blow pump - – Atmospheric Flash Tank – Drain Pit
LTSL-M0-00951 REV 0 Page 833 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
STEP:2 HP HEATER DRAIN CLEANUP BLOW
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION VACUUM
FROM LPT FT
EXTRACTION
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
HP SHELL MAKEUP
FROM IPT VALVE
EXTRACTION
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
HP Heater 8 - HP Heater 7 – HP Heater 6 - HP Heater Cleanup Blow Isolation Valve (from HPH 6 Normal Drain Line) – Atmospheric Flash Tank – Drain Pit
LTSL-M0-00951 REV 0 Page 834 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
STEP:3 HP HEATER DRAIN CLEANUP CIRCULATION
TO BOILER FROM LP TURBINE
FROM HPT FROM LPT
EXTRACTION EXTRACTION
VACUUM
FROM LPT
EXTRACTION FT
LPH4
HPH8B LPH2A LPH2B
HPH8A LPH3
S7
FROM CRH
EXTRACTION AUX LPH1A LPH1B
STEAM
TO
HP
FT HPH7A
HPH7 HPH7B
DEAERATOR LP SHELL NORMAL
HP SHELL MAKEUP
FROM IPT VALVE
EXTRACTION
S10
BFP
HPH6A HPH6B
S2 S1
DRAIN
S8
DRAIN
DA LCV
FROM CST
S9
FCS
S5
OVERFLOW CV
MIN RECIRC EMERGENCY
S4 S3 MAKEUP
VALVE
FROM
CST
TO CST
GSC CEP
S6
CPU
ATM.
FT
TO
CONDENSER
HP SHELL
TO DRAIN PIT
FLOW PATH:
HP Heater 8 - HP Heater 7 – HP Heater 7 – HP Heater 6 - HP Heater 6 Emergency Drain LCV - HP Flash Tank – Condenser
LTSL-M0-00951 REV 0 Page 835 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
SUBSECTION 3. ATTACHMENTS
LTSL-M0-00951 REV 0 Page 836 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Attachment 1: Start-up and Shutdown Curve –
STG Island
LTSL-M0-00951 REV 0 Page 837 of 860
STG Island Start-up Curve (Cold Mode) More Than 50 Hours Shutdown
593 ˚C
300 600
565 ˚C
Main/HRH Steam Temperature (ºC)
HRH Steam Temperature
275 550
Main Steam Temperature 247 kg/cm2 (a)
250 500
225 450
408 ˚C
Main Steam Pressure (kg/cm2abs)
200 400 380 ˚C
Load (%)
175 350
100 %
150 300 100
125 250 90
100 200 80 86 kg/cm2 (a) Main Steam Pressure 1.0 % / min
75 70
Speed 3000 rpm
60 3000 60 55.4 kg/cm2(a)
HRH Steam Pressure (kg/cm2(a)
2000 50 2500 50
1758 TPH
HRH Steam Flow (TPH)
2000 rpm
1600 40 2000 40
Speed (RPM)
Load
1200 30 1500 30
150 rpm / min
800 20 1000 20
13 kg/cm2 (a) HRH Steam Pressure 0.5 % / min
400 10 500 10 5 %
HRH Steam Flow
0 0
120
150
180
210
240
270
300
330
360
300
420
‐30
30
60
90
0
Turbine Rolling Time (Minutes) Turbine Synchronization Full Load
TURBINE RESET 1ST BFPT STARTUP @ 5% LOAD 2ND CEP STARTUP
LOAD AUXILIARY OIL PUMP STOP AT 2950 RPM 2ND TDBFP IN SERVICE
MS PRESSURE RUB CHECK @ 500RPM TURNING OIL PUMP STOP AT 2950 RPM
HRH STEAM PRESSURE JACKING OIL PUMP STOP AT 900 RPM SPEED REACHES 3000 RPM BFPT STEAM SOURCE-AUX STEAM TO CRH
SPEED TURBINE SPEED HOLD @ 2000 RPM VALVE TRANSFER FROM MSV TO GV BFPT STEAM SOURCE-CRH TO IP EXT
MAIN/ HRH STEAM TEMPERATURE SPEED HOLD FOR HEAT SOAKING LP HEATER 3,4 IN LINE @13% LOAD
HRH STEAM FLOW HP HEATER IN LINE @ 18% LOAD
DA PEGGING STEAM FROM IP EXTRACTION
2ND BFPT STARTUP @ 20% LOAD
This startup curve is provided for reference only. 1ST TDBFP IN SERVICE
Startup Curve and Sequence point can be changed as per site condition and operating procedure.
M-T TRANSFER
MDBFP SHUTDOWN
LTSL-M0-00951 REV 0 Page 838 of 860
STG Island Start‐up Curve (Warm Mode) 10 to 50 Hours Shutdown
593 ºC
300 600 565 ºC
275 550
247 kg/cm2 abs
Reheat Steam Temperature
250 500
Main Steam Temperature (ºC)
225 450 428 ºC
Main Steam Temperature
Main Steam Pressure
200 400
Load (%)
400 ºC
175 350
100 %
150 300 100
125 250 90
100 200 80 Main Steam Pressure
75 70
86 kg/cm2 abs 1.0 % / min
Speed 3000 rpm
3000 60
60 55.4 kg/cm2 abs
HRH Steam Pressure (kg/cm2(a)
2500 50
2000 50 1758 TPH
HRH Steam Flow (TPH)
2000 40 300 rpm / min
Speed (RPM)
1600 40
1500 30
1200 30
1000 20
800 20 0.5 % / min
13 kg/cm2 abs
500 10 5 %
400 10
120
150
180
‐30
30
60
90
0
Turbine Rolling
Full Load
Turbine Synchronization
Time (Minutes)
2ND CEP STARTUP
TURBINE RESET LP HEATER 3,4 IN LINE @13% LOAD
LOAD HP HEATER IN LINE @ 18% LOAD
MS PRESSURE RUB CHECK @ 500RPM DA PEGGING STEAM FROM IP EXTRACTION
HRH STEAM PRESSURE BFPT STEAM SOURCE-AUX STEAM TO CRH
SPEED JACKING OIL PUMP STOP AT 900 RPM BFPT STEAM SOURCE-CRH TO IP EXT
ST
MAIN/ HRH STEAM TEMPERATURE AUXILIARY OIL PUMP STOP AT 2950 RPM 1 TDBFP IN SERVICE
HRH STEAM FLOW TURNING OIL PUMP STOP AT 2950 RPM M-T TRANSFER
SPEED REACHES 3000 RPM MDBFP SHUTDOWN
VALVE TRANSFER FROM MSV TO GV 2ND TDBFP IN SERVICE
This startup curve is provided for reference only. 1ST BFPT STARTUP @ 5% LOAD
Startup Curve and Sequence point can be changed as per site
2ND BFPT STARTUP @ 20% LOAD
condition and operating procedure.
LTSL-M0-00951 REV 0 Page 839 of 860
STG Island Start‐up Curve (Hot Mode) 10 Hours Shutdown
593 ºC
300 600
565 ºC
Reheat Steam Temperature
Main Steam Temperature (ºC)
275 550 528 ºC
247 kg/cm2 abs
Main Steam Temperature
250 500
500 ºC
Main Steam Pressure
225 450
200 400
Load (%)
175 350
100 %
150 300 100
125 250 90
100 200 80 Main Steam Pressure 2.0 % / min
75 70
86 kg/cm2 abs
Speed 3000 rpm
3000 60
60
55.4 kg/cm2 abs
300 rpm / min
HRH Steam Pressure (kg/cm2(a)
2500 50
2000 50 1758 TPH
HRH Steam Flow (TPH)
2000 40
1600 40
Speed (RPM)
1500 30
1200 30
1000 20 1.0 % / min
800 20
13 kg/cm2 abs
500 10 5 %
400 10
120
‐30
30
60
90
0
Turbine Rolling Full Load
Turbine Synchronization Time (Minutes)
1ST TDBFP IN SERVICE
TURBINE RESET M-T TRANSFER
LOAD JACKING OIL PUMP STOP AT 900 RPM MDBFP SHUTDOWN
MS PRESSURE AUXILIARY OIL PUMP STOP AT 2950 RPM BFPT STEAM SOURCE-AUX STEAM TO CRH
HRH STEAM PRESSURE TURNING OIL PUMP STOP AT 2950 RPM BFPT STEAM SOURCE-CRH TO IP EXT
SPEED SPEED REACHES 3000 RPM 2ND CEP STARTUP
MAIN/ HRH STEAM TEMPERATURE VALVE TRANSFER FROM MSV TO GV 2ND TDBFP IN SERVICE
HRH STEAM FLOW 1ST BFPT STARTUP @ 5% LOAD
2ND BFPT STARTUP @ 20% LOAD
This startup curve is provided for reference only. LP HEATER 3,4 IN LINE @13% LOAD
Startup Curve and Sequence point can be changed as per site DA PEGGING STEAM FROM IP EXTRACTION
condition and operating procedure. HP HEATER IN LINE @ 18% LOAD
LTSL-M0-00951 REV 0 Page 840 of 860
STG Island Shutdown Curve
593 ˚C HRH Steam Temperature
300 600
Main Steam Temperature (ºC)
565 ˚C Main Steam Temperature
275 550
247 kg/cm2 (a)
250 500
225 450
200 400
Load (%)
Main Steam Pressure
175 350
(kg/cm2abs)
100 %
150 300 100
125 250 90
Main Steam Pressure
‐1.5 % / min
100 200 80 86 kg/cm2 (a)
75 70
60 3000 60 55.4 kg/cm2(a)
HRH Steam Pressure (kg/cm2(a)
Load
2000 50 2500 50
HRH Steam Flow (TPH)
1758 TPH
1600 40 2000 40
‐1.0 % / min
Speed (RPM)
1200 30 1500 30
HRH Steam Flow
800 20 1000 20
HRH Steam Pressure 13 kg/cm2(a)
400 10 500 10
100
‐30
20
40
60
80
0
Turbine Desynchronization
LOAD T‐M TRANSFER
MS PRESSURE ONE TDBFP OUT OF SERVICE HPH CUT OFF
HRH STEAM PRESSURE ONE CEP STOP LPH CUT OFF
SPEED
MAIN/ HRH STEAM TEMPERATURE
HRH STEAM FLOW
This startup curve is provided for reference only.
Startup Curve and Sequence point can be changed as per site condition and operating
procedure.
LTSL-M0-00951 REV 0 Page 841 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Attachment 2: Steam Turbine Start-up Curve
LTSL-M0-00951 REV 0 Page 842 of 860
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JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Attachment 3: Steam Purity Recommendation
LTSL-M0-00951 REV 0 Page 849 of 860
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JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Attachment 4: STGI Lay-up Recommendation
LTSL-M0-00951 REV 0 Page 854 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Layup and Preservation Procedure – AVT operation
Duration 1-3 Days 4-7 8-30
Months
Classification 32 hours 72 Hours Days Days
Preservation under condition
Condenser Dry out
at stop of the unit
Preservation Preservation -Layup -Layup -Layup with
under under with N2H4 with N2H4 N2H4 water
condition at condition at water water (N2H4 - 500
Water stop of the stop of the (N2H4 - (N2H4 - mg/l) & N2
Side unit unit & N2 50 mg/l) 50 mg/l x sealing
sealing & N2 weeks) &
LP
sealing N2
Heater
sealing
Shell Same as N2 sealing -Layup with
Side water side N2H4 water
(N2H4 - 500
mg/l) & N2
sealing
Water
Same as LP Heater water side
HP Side
Heater Shell
Same as LP Heater shell side
Side
Deaerator Same as LP Heater water side
LTSL-M0-00951 REV 0 Page 855 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Layup and Preservation Procedure – CWT operation
Duration 1-3 Days 4-7 8-30
Months
Classification 32 hours 72 Hours Days Days
Preservation under
Condenser Dry out
condition at stop of the unit
Preservation Preservation -Layup -Dry out -Dry out
under under with AVT -N2 sealing -N2 sealing
Water condition at condition at water &
LP Side stop of the stop of the N2
Heater unit unit & N2 sealing *2
sealing*1
Shell Same as
N2 sealing
Side water side
Water
Same as LP Heater water side
HP Side
Heater Shell
Same as LP Heater shell side
Side
Deaerator Same as LP Heater water side
Note:
*1: Nitrogen gas pressure must be recorded every day during Nitrogen preservation (N2
pressure- 0.3-0.6 Kg/sq.cm)
*2: The unit shall be changed over to AVT operation before 2 hours of shutdown
(without N2H4 injection)
LTSL-M0-00951 REV 0 Page 856 of 860
JAYPEE O&M MANUAL – VOLUME 1 START-UP AND SHUTDOWN PROCEDURE
Attachment 5: BFPT Start-up Curve
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