WI/OPS/ HRSG-01 STANDARD OPERATING PROCEDURE
1. SYST SYSTE EM NA NAME: ME: HEAT RECOVERY STEAM GENERATOR. 2. OBJ OBJECT ECTIVE: IVE: The Heat Recovery Steam Generators (HRSG) ut!"e# n the Com$ne# Cyc!e %!ants& carres out the 'uncton to ro#uce steam to su!y the Steam Tur$nes (ST)& ut!"n the therma! enery o' the Gas*Tur$nes (GT) e+haust as& $e'ore #scharn t to atmoshere $y means o' the $o!er stac,.
3. SYST SYSTEM EM DES DESCR CRIP IPTI TION ON:: To carry out ths 'uncton& the HRSG are !ocate# #o-nstream the GT an# are contane# n casns to 'ormn an e+tenson o' the GT ases e+haust #ucts. The steam enera enerator tors s are o' mu!tt mu!ttu$u u$u!ar !ar tye tye an# steam steam #rum& #rum& natura natura!! or actvate# -ater crcu!aton& -th econom"er an# suer heater. The e+haus e+haustt ases ases comn comn 'rom 'rom the GT cross crosses& es& n seue seuence nce&& the #stn #stnct ct comonents o' steam enerators to trans'er to them the heat 'or convecton mo#e. The 'ee# -ater re*heate# n the econom"er& '!o-s n the evaorator an# the saturate# steam ro#uce# s co!!ecte# n the steam #rum& !ocate# n the uer "one o' the steam enerator. The steam crosses then the suer heater an# s #e!vere# to the ST. To contro! the $o!er out!et steam temerature& the suer heater s rov#e# -th #esuerheater& #esuerheater& -hch may $e o' -ater sray tye or sur'ace tye. /n the com$ne# cyc!e unt o' !are caacty& caacty& 'or technue an# economc reasons& the the stea steam m ene enera rato tors rs are are su$# su$#v v# #e# e# n t-o t-o or thre three e sect secto ons ns&& o' hh hh&& nterme#ate an# !o- ressure& an# the re!evant heat e+chaner e!ements are conv conven ene ent nt!y !y #st #str r$u $ute te# # a!on a!on the the cour course se o' the the GT e+ha e+haus ustt as. as. The suerheate# steam ro#uce# $y the #''erent sectons o' the steam enerators& s conveye#& resectve!y& resectve!y& to the hh& nterme#ate an# !o- sectons o' ST. /n some cases the HRSG are rov#e# -th su!ementary su!ementary 'rn& !ocate# !ocate# n the e+hau e+haust st as #uct #uct ustre ustream am o' the suerh suerheat eate# e# to ncrea ncrease se the suer suerhea heate# te# steam temerature. The Heat Recovery Steam Generator s a #ua! steam ressure tye& natura! crcu!aton& -thout su!ementary 'rn. The suerheate# steam ro#uce# at #''erent ressure s ut!"e# to 'ee# the hh an# !o- ressure o' Steam Tur$ne sectons. A 0#verter #amer1. 2ocate# at the entrance o' the GT e+haust as o' the HRSG& ermts to e+c!u#e the $o!er #scharn the e+haust as #rect!y to atmoshere& -henever t s necessary. /nta! /s /ssue 3a 3ate: 45 45.56.6447
Current Re Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3a 3ate: 45 45.56.6447
%ae 5
WI/OPS/ HRSG-01 The HRSG heatn sur'aces are #v#e# n the 'o!!o-n sectons& n the #recton o' the e+haust as '!o-:
- H% suer heater 6 H% suer heater 5
- H% evaorator * H% econom"er 6
- 2% suer heater - 2% evaorator - H% econom"er 5 n ara!!e! -th 2% econom"er The heatn sur'aces are assem$!e# n mo#u!es& searate# $y cavtes. /n the n!et #uct a ressure transmtter& a ressure n#cator an# t-o ressure tan ont are rov#e#. S+ temer temeratu ature re tan tan ont& ont& one occu occue# e# $y a thermo thermocou cou!e !e&& are rov rov#e# #e# ustream H% suer heater 6. /n each cavty s+ temerature tan ont are rov#e#& three each s#e& one occue# $y a thermocou!e 'tte# 'or suervson o' the as temerature ro'!e a!on the heatn sur'aces. 3o-nstream the $an,s& at the n!et o' the stac,& s+ temerature tan ont& one occue# $y a thermocou!e& are rov#e#. 8our ressure*tan onts are a!so rov rov# #e# e#&& one one occu occu e# e# $y a !oca !oca!! res ressu sure re n# n#ca cato torr an# an# one one $y a res ressu sure re transmtter to contro! room. A!! the nstruments rov#e# 'or the e+haust e+haust as system have have the on!y urose o' !oca! or remote suervson. HRSG HIGH PRESSURE LEVEL The HRSG hh*ressure !eve! has the urose to enerate H% steam at the correct ressure& temerature& an# ua!ty n accor#ance -th the heat ava!a$!e 'rom the GT e+haust as an# reurements o' the ST. 8or ths urose& t -!! $e su!e# -th the #ue amount o' 'ee# -ater at any tme #urn ts oeraton: stea#y !oa#& start*u or !oa# chanes. /nta! /s /ssue 3a 3ate: 45 45.56.6447
Current Re Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3a 3ate: 45 45.56.6447
%ae 6
WI/OPS/ HRSG-01 The H% suerheate# steam -!! $e su!e# to the ST throuh the H% man steam n system. The H% system s eue# -th nterme#ate #esuerheater to contro! the man steam out!et temerature at the #esre# va!ue n any oeratn con#ton. The H% #rum !eve! contro! staton s !ocate# #o-nstream the H% econom"er to revent 'rom steamn n the econom"er tse!'& 'or 'ee# -ater !o- '!o- #urn the start*u.
HP SECTION STEAM GENERATOR The hh ressure secton o' steam enerator s !ocate# #o-nstream the e+haust as n!et to the HRSG an# ts heatn sur'ace s ma#e o' 'nne# tu$es& crosse# $y he hot as n the 'o!!o-n or#er:
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H% Suer heater 6
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H% Suer heater 5
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H% Evaorator
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H% Econom"er 6
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H% Econom"er 5.
9ater 'rom the H% 'ee# -ater !ne enters the H% econom"er 5 an# 6& n counter '!o- -th resect to the e+haust as& -here t s heate# u to the arorate econom"er out!et temerature an# s then #e!vere# to the H% #rum. The H% econom"ers 5 an# 6 are eue# -th manua! #rans an# vents. A #rum !eve! contro! staton s !ocate# #o-nstream the H% econom"er an# conssts o' t-o man 'ee# -ater contro! va!ves suta$!e to contro! the H% #rum !eve! n the rane 4*544; MCR (one n stan#*$y) an# a !o- !oa# 'ee# -ater contro! va!ve suta$!e 'or !oa#s $e!o- 4; MCR. Each !eve! contro! va!ve s rov#e# -th one ntercetn motor"e# on*o'' va!ve ustream an# one ntercetn manua! on*o'' va!ve #o-nstream. Suta$!e manua! #rans are a!so rov#e# $et-een the ntercetn va!ves an# the contro! va!ves to emty the !nes n case o' contro! va!ves mantenance. <stream the contro! staton a sa'ety va!ve s rov#e#. Once -ater has entere# the H% #rum& t 'a!!s #o-n throuh the #o-n comers an# reaches the n!et hea#er o' the H% evaorator. The H% evaorator $an, /nta! /ssue 3ate: 45.56.6447
Current Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3ate: 45.56.6447
%ae
WI/OPS/ HRSG-01 enerates steam heatn the -ater -th the hot as& -hch asses throuh the $an, n cross*'!o-. The resu!tn -ater an# steam m+ture can o u throuh a natura! crcu!aton !oo to the evaorator out!et hea#ers an# then aan to the H% #rum throuh some connectn es (ca!!e# rsers)& un'orm!y #str$ute# a!on the #rum !enth. The $o!er #rum has the am to:
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Ensure a oo# m+n $et-een n!et 'ee# -ater an# $o!er -ater
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Consttute a -ater reserve reure# 'or the crcu!aton system
- A!!o- -ater e+anson #urn start*u -
Ensure oo# -ater an# steam searaton.
The #rum caacty s se!ecte# to ensure a sta$!e an# sa'e oeraton un#er a!! the nomna! oeratve con#tons. The steam an# -ater searaton s acheve# $y means o' arorate rmary (cyc!one tye) an# secon#ary scru$$ers (corruate# !ates tye). /n the cyc!ones a mechanca! centr'ua! searaton occurs n the m+ture o' saturate# -ater an# steam comn 'rom the rsers. Searate# -ater 'a!!s #o-n n the cyc!ones to the #rum -h!e saturate# Steam s conveye# to the secon#ary scru$$ers -here a tortuous ath ma,es t vrtua!!y #ry. A chemca! #osn !ne 'or hoshates are 'oreseen n the H% #rum n or#er to contro! $o!er -ater H to a suta$!e va!ue. A $!o-*#o-n !ne& eue# -th a motor"e# on*o'' va!ve (-th #ou$!e manua! $y*ass va!ve) an# a manua! contro! va!ve& s 'oreseen to contro! $o!er -ater con#uctvty. A $!o-*o'' !ne& eue# -th a manua! on*o'' va!ve an# a motor"e# nchn tye va!ve& s a!so 'tte# to contro! #rum s-e!!n #urn the start*u. A #e#cate# !ne a!so ensures sam!n o' the $!o-*#o-n -ater. The H% #rum s eue# -th t-o sa'ety va!ves -th s!encers& three !eve! transmtters ressure comensate# 'or contro!& a!arm an# tr uroses& an# s+ s,n meta! temerature thermocou!es& 'or suervson an# a!arm. T-o hy#ra ste tye !eve! n#cators to contro! room an# t-o !eve! aues (!oca! #rum !eve! n#cators) are rov#e# 'or remote an# !oca! suervson.
/nta! /ssue 3ate: 45.56.6447
Current Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3ate: 45.56.6447
%ae =
WI/OPS/ HRSG-01 Saturate# steam '!o-s 'rom the H% #rum to H% suer heater 5 n!et throuh connectn n. 8or the con#uctvty montorn o' the saturate# steam s 'oreseen a sam!n !ne& -h!e a motor"e# on*o'' vent va!ve s rov#e# n the connectn n& to $e c!ose# #urn the $ennn o' the ressursaton. 8rom the H% suer heater 5 the steam& '!o-n n counter '!o- -th resect to the e+haust as& enters the nterme#ate #esuerheater& use# to !mt the man steam temerature (#o-nstream H% suer heater 6) at the #esre# va!ue n any oeratn con#ton an# then reaches the H% suer heater 6. Seven s,n meta! thermocou!es are 'tte# at the out!et o' ths $an, to montor an# a!arm the re!evant meta! temerature. >oth H% suer heater 5 an# 6 are eue# -th motor"e# #ran va!ves& to $e use# #urn start*u or !oa# varatons to ensure no con#ensate reman ns#e the suer heater tu$es.
HP MAIN STEAM PIPING Man steam n s rov#e# -th:
- A sa'ety va!ve -th s!encer? - A '!o- meter& eue# -th #ou$!e transmtters& #ou$!e temerature an# ressure transmtters 'or '!o- measurements comensaton.
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2oca! temerature an# ressure n#cators.
The t-o temerature transmtters are a!so use# 'or man steam temerature contro! uroses. A sam!n !ne s rov#e# 'or the suerheate# steam ua!ty montorn. A start*u motor"e# nchn tye vent& com!ete -th re!evant s!encer& s 'oreseen to !mt the H% #rum ressure ra#ent #urn HRSG start*u. An e!ectrometrc va!ve& com!ete -th an ntercetn manua! on*o'' va!ve an# s!encer& s rov#e# to revent 'rom H% suer heater sa'ety va!ve oenn. A motor"e# on*o'' va!ve& ate tye& s !ocate# n HRSG area to ntercet man steam n an# $o!er so!aton. Ths va!ve s eue# -th a motor oerate# $y*ass va!ve 'or the steam !ne -armn.
/nta! /ssue 3ate: 45.56.6447
Current Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3ate: 45.56.6447
%ae 7
WI/OPS/ HRSG-01 3o-nstream o' the HRSG so!atn va!ve& the $ranch 'or the tur$ne $y*ass s rov#e#. Chemca! c!eann connecton n the man steam e s a!so rov#e#.
HRSG LOW PRESSURE LEVEL
The HRSG !o-*ressure !eve! has the urose to enerate 2% steam at a correct ressure& temerature an# ua!ty to the !o-*ressure stae o' the ST. 8or ths urose& t -!! $e su!e# -th the #ue amount o' 'ee# -ater at any tme #urn ts oeraton: stea#y !oa#& start*u or !oa# chanes. The 2% suerheate# steam -!! $e su!e# to the ST throuh the 2% man steam n system. The 2% #rum !eve! contro! staton s !ocate# #o-nstream the 2% econom"er to revent 'rom steamn n the econom"er tse!'.
LP SECTION STEAM GENERATOR
The !o- ressure secton o' steam enerator s !ocate# #o-nstream the e+haust as n!et to the HRSG $ehn# the H% !eve! an# ts heatn sur'ace s ma#e o' 'nne# tu$es& crosse# $y he hot as n the 'o!!o-n or#er:
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2% Suer heater
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2% evaorator
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2% Econom"er
9ater 'rom the 2% 'ee# -ater !ne enters the 2% econom"er& n counter '!o- -th resect to the e+haust as& -here t s heate# u to the arorate econom"er out!et temerature an# s then #e!vere# to the 2% #rum. The 2% econom"er s eue# -th manua! #rans an# vents. A #rum !eve! contro! staton s !ocate# #o-nstream the 2% econom"er an# conssts o' t-o man 'ee# -ater contro! va!ves suta$!e to contro! the 2% #rum /nta! /ssue 3ate: 45.56.6447
Current Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3ate: 45.56.6447
%ae @
WI/OPS/ HRSG-01 !eve! n the rane 4*544; MCR (one n stan#*$y). Each !eve! contro! va!ve s rov#e# -th one ntercetn motor"e# on*o'' va!ve ustream an# one ntercetn manua! on*o'' va!ve #o-nstream. <stream the contro! staton a sa'ety va!ve s rov#e#. Once -ater has entere# the 2% #rum& t 'a!!s #o-n throuh the #o-n comers an# reaches the n!et hea#er o' the 2% evaorator. The 2% evaorator $an, enerates steam heatn u the -ater -th the hot as -hch ass throuh the $an, n cross*'!o-. The resu!tn -ater an#
Steam m+ture can o u throuh a natura! crcu!aton !oo to the evaorator out!et hea#ers an# then aan to the 2% #rum throuh some connectn es (ca!!e# rsers) un'orm!y #str$ute# a!on the #rum !enth. The $o!er #rum has the am to:
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Ensure a oo# m+n $et-een n!et 'ee# -ater an# $o!er -ater
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Consttute a -ater reserve reure# 'or the crcu!aton system
- A!!o- -ater e+anson #urn start*u -
Ensure oo# -ater an# steam searaton.
The #rum caacty s se!ecte# to ensure a sta$!e an# sa'e oeraton un#er a!! the nomna! oeratve con#tons. The steam an# -ater searaton s acheve# $y means o' arorate rmary (cyc!one tye) an# secon#ary scru$$ers (corruate# !ates tye). /n the cyc!ones a mechanca! centr'ua! searaton occurs n the m+ture o' saturate# -ater an# steam comn 'rom the rsers. Searate# -ater 'a!!s #o-n n the cyc!ones to the #rum -h!e saturate# steam s conveye# to the secon#ary scru$$ers -here a tortuous ath ma,es t vrtua!!y #ry. A chemca! #osn !ne 'or hoshates s 'oreseen n the 2% #rum n or#er to contro! $o!er -ater H to a suta$!e va!ue. A $!o-*#o-n !ne& eue# -th a motor"e# on*o'' va!ve (-th manua! $y*ass va!ve) an# a manua! contro! va!ve& s 'oreseen to contro! $o!er -ater con#uctvty. A $!o-*o'' !ne& eue# -th a manua! on*o'' va!ve an# a motor"e# nchn tye va!ve& s a!so 'tte# to contro! #rum s-e!!n #urn the start*u. A #e#cate# !ne a!so ensures sam!n o' the $!o-*#o-n -ater.
The 2% #rum s eue# -th t-o sa'ety va!ves -th s!encers& three !eve! transmtters ressure comensate# 'or contro!& a!arm an# tr uroses& an# a /nta! /ssue 3ate: 45.56.6447
Current Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3ate: 45.56.6447
%ae
WI/OPS/ HRSG-01 s,n meta! temerature thermocou!e ('or suervson an# a!arm). T-o hy#ra ste tye !eve! n#cators to contro! room an# t-o !eve! aues (!oca! #rum !eve! n#cators) are rov#e# 'or remote an# !oca! suervson. Saturate# steam '!o-s 'rom the 2% #rum to 2% suer heater n!et throuh connectn n. 8or the con#uctvty montorn o' the saturate# steam s 'oreseen a sam!n !ne& -h!e a motor"e# on*o'' vent va!ve& s rov#e# n the connectn n& to $e c!ose# #urn the $ennn o' the ressursaton. 8rom the 2% suer heater out!et the steam s conveye# to the 2% man steam n. The 2% suer heater s eue# -th a motor"e# #ran va!ve& to $e use# #urn start*u or !oa# varatons to ensure no con#ensate reman ns#e the suer heater tu$es. No temerature contro! s necessary on the 2% suer heater as the 2% man steam temerature s very !o- an# remans sta$!e n the norma! $o!er oeratve rane.
LP STEAM PIPING The am o' ths e s to !ea# the !o- ressure steam to the !o- ressure stae o' the ST. Steam n s rov#e# -th:
- A sa'ety va!ve -th s!encer? - A '!o- meter& eue# -th #ou$!e transmtters& #ou$!e temerature an# ressure transmtters 'or '!o- measurement comensaton?
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2oca! temerature an# ressure n#cators.
A sam!n !ne s rov#e# 'or the suerheate# steam ua!ty montorn. A start*u motor"e# nchn tye vent& com!ete o' s!encer& s 'oreseen to !mt the 2% #rum ressure ra#ent #urn HRSG start*u. A motor"e# on*o'' va!ve& com!ete -th re!evant motor"e# $y*ass& s !ocate# n HRSG area to ntercet man steam n.
HRSG DRAINS AND VENTS SYSTEM
/nta! /ssue 3ate: 45.56.6447
Current Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3ate: 45.56.6447
%ae B
WI/OPS/ HRSG-01 The system 'u!'!s the 'o!!o-n reurements:
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Co!!ects an# #schares $!o-*o'' -ater 'rom the #rums #urn start*u to the
atmosherc '!ash tan,
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Co!!ects -ater 'rom the suer heater #rans to the atmosherc '!ash tan,
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Co!!ects -ater 'rom the econom"er an# evaorator #rans to the atmosherc
'!ash tan,& -hen ths oeraton s necessary to emty the $o!er
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Co!!ects an# #schares $!o-*#o-n -ater 'rom the #rums #urn norma!
oeraton to the atmosherc '!ash tan,
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Co!!ects #rum an# econom"er vents an# sa'ety an# e!ectrometrc va!ve
#rans to the atmosherc '!ash tan,
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3e!vers co!!ecte# -ater n the '!ash tan, to the !ant #ranae system.
FUNCTIONAL DESCRIPTION The -ater co!!ecte# ns#e the atmosherc tan, '!ashes an# s s!tte# n t-o arts: steam s conveye# to a s!ence# vent an# then s #schare# to the atmoshere? the remann -ater s co!!ecte# to the !ant #ranae system.
HRSG NITROGEN FILLING SYSTEM
The system 'u!'!s the reurement to carry out HRSG -et conservaton (!ay*u) n case o' !on shut#o-n.
FUNCTIONAL DESCRIPTION
The system conssts o' a ntroen tan, connecte# to 2% an# H% saturate# steam es (the hhest HRSG onts) an# 'e# $y a ntroen e connecte# to a ntroen $ott!es set com!ete o' a sa'ety va!ve an# a ressure re#ucn va!ve. 3emnera!se# -ater s use# to '!! the HRSG u to the m##!e o' the ntroen tan,? ntroen s then ntro#uce# n the tan, at a very !o- ressure ( 6 $ar). %ressure an# -ater !eve! n the tan, can $e eas!y montore# $y means o' #e#cate# !oca! nstruments. /nta! /ssue 3ate: 45.56.6447
Current Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3ate: 45.56.6447
%ae D
WI/OPS/ HRSG-01 Once -ater !eve! or ressure #ecrease& -ater or ntroen have to $e 'urther ntro#uce#.
RATING The uantty o' suerheate# steam enerate# ($oth 2% H%)
No %T9 en#n 'or HRSG (H%2% system) an# mantenance actvty&
-hch cou!# mact the start*u oeratons& s over.
Ensure that the nee#e# nsectons 'o!!o-n to a !on ero# o' nactvty
a'ter shut#o-n have $een carre# out.
A!! MOVs meer va!ues shou!# $e O.. A!! euments roer!y earthe#. A!! contro! va!ves 'unctona! chec,e# com!ete#. A!! the nstruments are !ne# u an# suervson system an# the recor#ers are n servce. Ensure HRSG sum um s auto ava!a$!e. 3M -ater storae tan, !eve! s norma! 'or startu. Ensure 3M -ater #str$uton um& CE%& 2%>8%& H%>8% s ava!a$!e 'or oeraton. Ensure that the e!ectrca! automaton system an# the re!evant trans#ucers are n servce.
Ensure that the sa'ety ru!es are correct!y met.
Ensure that a!! the man manua! va!ves are n ther correct oston.
Chec, that the 're rotecton system s ava!a$!e.
Chec, that e!ectrca! su!es are ava!a$!e.
Ensure that a!! the nstrument mu!se !ne*so!atn va!ves are oen an# the eua!"n va!ves are c!ose#.
Chec, that the Natura! as or NahthaHS3 'ue! systems are ava!a$!e.
/nta! /ssue 3ate: 45.56.6447
Current Revson: 4
Reliance Energy Limited, Samalkot Power Station
Revson 3ate: 45.56.6447
%ae 54
WI/OPS/ HRSG-01
Ensure that the 9aste 9ater Treatment System an# the HVAC System are norma!!y oeratn.
%er'orm a!! the #eta!e# re*chec,s sec'e# $y the manu'actures an# ut the re!evant #rves n A
Ensure that a!! the va!ves& nc!u#n coc, va!ves& are not un#er mantenance an# n the correct oston.
Ensure
that a!! the sa'ety va!ves are #senae# an# ther re!evant srn
acton s e''cent.
Ensure that the HRSG #rums !eve! s at !east at start*u !eve! an# '!! them& ' necessary.
Chec, that the Chemca! 3osn System s rea#y.
Chec, that the HRSG #ran an# vent va!ves are n automatc mo#e
SAFETY CHECS: 5.8re #etecton an# 8re a!arm system 'or a!! areas shou!# $e ava!a$!e. 6.8re hoses shou!# !ace a!! hose $o+es. .A!! the va!ves shou!# $e 'ree 'or oeraton.
HYDRO TEST OF HP SYSTEM:
Oen the econom"er 56 vent va!ve. Oen #rum vent va!ve -th so!aton va!ve. Oen evaorator vent va!ve. Oen suer heater 5 6 vent va!ve. C!ose the $!o- #o-n an# $!o- o'' so!aton va!ve. 2oc, the h econom"er& h #rum ($oth)& an# h suer heater sa'ety va!ve 'or reventn the ou. ee the ERV n manua! mo#e. C!ose the H%MS shuto'' va!ve an# ts $yass va!ve. Oen the h eco n!et va!ve. Oen the nta! '!!n va!ve 'rom 3M -ater #str$uton um. ee the 'ee# contro! va!ves (6I544; J5I4;)n manua! oeraton mo#e. Start the one 3M -ater #str$uton um an# oen the #schare va!ve o' the um.
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%ae 55
WI/OPS/ HRSG-01
/' contnuous -ater s comn 'rom the eco vent& c!ose the eco vent. Sto the 3M -ater #str$uton um an# c!ose the #schare va!ve o' the um. C!ose the nta! '!!n va!ve 'rom 3M -ater #str$uton um. Start one H%>8% -th chemca! nKecton as er chemca! reurement. Oen the manua! so!aton va!ve an# MOV o' 4; contro! va!ve. S!o-!y oen the 4; contro! va!ve manua!!y ma+mum u to 4;. O$serve the H%>8% #schare ressure. Oen or c!ose the 4; contro! va!ve $y ,een the H%>8% #schare ressure more than 564 $ar. /' contnuous -ater s comn 'rom the suer heater 56 vents& c!ose the resectve vent. /' h #rum !eve! reache# hh* hh va!ue (74 mm) an# contnuous -ater s comn 'rom the H% #rum vent& c!ose the vent. O$serve the #rum ressure ' t s more than 54 $ar& c!ose the 4; contro! va!ve an# ts MOV. Sto the H%>8% an# c!ose the #schare an# ts $yass va!ve. O$serve the #rum ressure 'or 4 mnutes. /' #rum ressure s ho!#n 54 $ars u to 4mnutes than t s conc!u#e# that hy#ro test s com!ete# success'u!!y an# system s !ea, roo'.
HYDRO TEST OF LP SYSTEM:
Oen the econom"er vent va!ve. Oen #rum vent va!ve -th so!aton va!ve. Oen evaorator vent va!ve. Oen suer heater vent va!ve. C!ose the $!o- #o-n an# $!o- o'' so!aton va!ve. 2oc, the 2% econom"er& 2% #rum ($oth)& an# 2% suer heater sa'ety va!ve 'or reventn the ou. ee the ERV n manua! mo#e. C!ose the 2%MS shuto'' va!ve an# ts $yass va!ve. Oen the 2%ECO n!et va!ve. Oen the nta! '!!n va!ve 'rom 3M -ater #str$uton um. ee the 'ee# contro! va!ves (6I544;)n manua! oeraton mo#e. Start the one 3M -ater #str$uton um an# oen the #schare va!ve o' the um. /' contnuous -ater s comn 'rom the eco vent& c!ose the eco vent. Sto the 3M -ater #str$uton um an# c!ose the #schare va!ve o' the um. C!ose the nta! '!!n va!ve 'rom 3M -ater #str$uton um. Start one 2%>8% -th chemca! nKecton as er chemca! reurement.
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WI/OPS/ HRSG-01
Oen the manua! so!aton va!ve an# MOV o' one contro! va!ve. S!o-!y oen the contro! va!ve manua!!y ma+mum u to 57;. O$serve the 2%>8% #schare ressure. Oen or c!ose the contro! va!ve $y ,een the 2%>8% #schare ressure more than 64 $ar. /' contnuous -ater s comn 'rom the suer heater vents& c!ose the resectve vent. /' h #rum !eve! reache# hh* hh va!ue (644 mm) an# contnuous -ater s comn 'rom the H% #rum vent& c!ose the vent. O$serve the #rum ressure ' t s more than 56 $ars? c!ose the contro! va!ve an# ts MOV. Sto the 2%>8% an# c!ose the #schare an# ts $yass va!ve. O$serve the #rum ressure 'or 4 mnutes. /' #rum ressure s ho!#n 56 $ars u to 4mnutes than t s conc!u#e# that hy#ro test s com!ete# success'u!!y an# system s !ea, roo'.
HYDRO TEST OF CPH SYSTEM:
Oen the C%H vent va!ve. C!ose the #eaerator 'ee# -ater n!et manua! va!ve& MOV an# ts $yass va!ve. Oen the nta! '!!n va!ve 'rom 3M -ater #str$uton um. Start the one 3M -ater #str$uton um an# oen the #schare va!ve o' the um. Chare the GSC 'rom -aters#e a'ter #on roer ventn. Chare the 2% heater 'rom -aters#e a'ter #on roer ventn. C!ose the $oth C%H um sucton an# #schare va!ve. Oen the manua! so!aton va!ve an# MOV o' the C%H co! an# c!ose manua! so!aton va!ve an# MOV o' the C%H co! $yass !ne. /' contnuous -ater s comn 'rom the C%H vent& c!ose the vent. Sto the 3M -ater #str$uton um an# c!ose the #schare va!ve o' the um. C!ose the nta! '!!n va!ve 'rom 3M -ater #str$uton um. Start one CE% -th chemca! nKecton as er chemca! reurement. Ensure CE% #schare va!ve oen n auto. O$serve the CE% #schare ressure. O$serve the C%H co! out!et ressure ' t s more than 5@ $ars? Sto the CE% an# c!ose the #schare an# ts $yass va!ve. O$serve the C%H co! ressure 'or 4 mnutes. /' ressure s ho!#n 5@ $ars u to 4mnutes than t s conc!u#e# that hy#ro test s com!ete# success'u!!y an# system s !ea, roo'.
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%ae 5
WI/OPS/ HRSG-01 STARTUP PROCEDURE COLD START- UP PROCEDURE (ST meta! temerature L 574C? H% #rum at atmosherc ressure)
PRE-REQUISITES:
No %T9 en#n 'or HRSG (H%2% system) an# mantenance actvty&
-hch cou!# mact the start*u oeratons& s over.
Ensure that the nee#e# nsectons 'o!!o-n to a !on ero# o' nactvty a'ter shut#o-n have $een carre# out.. A!! the nstruments are !ne# u an# suervson system an# the recor#ers are n servce. Ensure HRSG sum um s auto ava!a$!e. Ensure AC9 um s n servce. 3M -ater storae tan, !eve! s norma! 'or startu. Ensure at !east one CE%& H%>8%& 2%>8% are n*servce an# other s auto ava!a$!e. Ensure con#enser an# #eaerator !eve! s norma!. Ensure chemca! #osn ums are runnn as er chemca! reurement. Ensure that the e!ectrca! automaton system an# the re!evant trans#ucers are n servce. Ensure that a!! sa'ety va!ves are n servce .e. a!! sa'ety va!ves are n un!oc,e# oston. Ensure that the sa'ety ru!es are correct!y met.
Ensure that a!! the man manua! va!ves are n ther correct oston.
Chec, that the 're rotecton system s ava!a$!e.
Chec, that e!ectrca! su!es are ava!a$!e.
Ensure that a!! the nstrument mu!se !ne*so!atn va!ves are oen an# the eua!"n va!ves are c!ose#.
Ensure GT s synchron"e# -th r#.
Ensure that the 9aste 9ater Treatment System an# the HVAC System are norma!!y oeratn.
%er'orm a!! the #eta!e# re*chec,s sec'e# $y the manu'actures an# ut the re!evant #rves n A
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WI/OPS/ HRSG-01
Ensure that a!! the va!ves& nc!u#n coc, va!ves& are not un#er mantenance an# n the correct oston.
Ensure
that a!! the sa'ety va!ves are #senae# an# ther re!evant srn
acton s e''cent.
Ensure that the HRSG #rums !eve! s at !east at start*u !eve!(*544mm) an# '!! them& ' necessary.
Ensure the H% an# 2% 'ee# contro! staton a!! contro! va!ves are n auto an# H% 4; va!ve s n servce.
Chec, that the HRSG #ran an# vent va!ves are n automatc mo#e.
Ensure H% an# 2% $!o- #o-n an# $!o- o'' so!aton va!ves are n oen con#ton.
Ensure H% an# 2% #rum vents are n oen con#ton an# ,et n auto.
Ensure H% an# 2% suer heater vents are n oen con#ton an# ,et n auto.
Ensure H%SH ray so!aton va!ve s oen an# contro! va!ve s n auto.
P!"#$%&!$
Set the GT !oa# set ont 57M9.
Reset the HRSG tr 'rom $ac, u ane!.
%arta!!y oen the H% an# 2% MS #ran va!ve.
Oen the H% an# 2% man steam shuto'' va!ve.
Oen the #verter #amer manua!!y $y vn the as '!o- taret va!ue 54;.
Mantan the #rum !eve! F544mm& ' reure# essenta!!y than ve the $!o#o-n or $!o- o''.
Oen the HRSG sum -ater*coo!n va!ve.
8or mantann the #rum !eve! F544mm ' reure# chane the !eve! $asn.
Oen the #verter #amer $y ta,n care o' 'o!!o-n arameters.
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WI/OPS/ HRSG-01 a) Mantan the #rum meta! tem rse !ess than @4 C Mn. $) Mantan the H% steam tem rse !ess than 564 C Mn. c) 3rum to an# $ottom meta! tem #''erence !ess than 544oC
O$serve the H% #rum ressure ' t s more than .7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.
O$serve the H%SH ressure ' t s more than .7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.
O$serve the 2% #rum ressure ' t s more than 6.7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.
O$serve the 2%SH ressure ' t s more than 6.7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.
Start at !east one C9 um as er um startn roce#ure.
/' H%MS ressure come u to 54 $ar start the man steam #eaerator en !ne heatn $y crac, oenn o' the 'rst ressure contro! va!ve an# ts so!aton va!ve.
Oen the man steam #eaerator en #e suer heatn !ne so!aton va!ve an# ,ee the #e suer heatn contro! va!ve n auto at 674 4 C set va!ue.
O$serve the man steam #eaerator en !ne temerature ' t come u to 6444 an# H% #rum ressure come u to 5 $ar start the #eaerator en charn $y manua! oenn o' 5 st an# 6n# ressure contro! va!ve an# mantan the !ne ressure a'ter the 5st contro! va!ve at @.4 $ar.
Oen the GSC #ran va!ve.
/' #eaerator ressure s mantann 5.4 $ar ,ee the $oth ressure contro! va!ve n auto.
Start one GSC $!o-er as er chec,!st.
/' H% #rum ressure comes u to 64 $ars oen the 'rst ressure contro! va!ve an# ts so!aton va!ve manua!!y.
Oen the secon# ressure contro! va!ve s!o-!y an# oen the 'r st ressure contro! va!ve n manua! mo#e 'or mantann the ressure57 $ar.
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WI/OPS/ HRSG-01
ee the sea! steam tem contro! va!ve n auto at 5B4 oC set va!ue.
/' sea! ressure comes u to 67m$ar than ,ee the $oth ressure contro! va!ve n auto.
C!ose the vacuum $rea,er va!ve.
Start $oth vacuum ums as er startu roce#ure.
/' con#enser ressure comes u to 644 m$ar oen the H% an# 2% $yass contro! va!ve arta!!y n manua! mo#e.
Ensure the oenn o' the H% an# 2% $yass coo!n !ne so!aton va!ve.
Set the H% an# 2% $yass ressure contro! va!ve s!ht!y !ess than the u actua! u stream!ne ressure an# ,ee the H% an# 2% $yass ressure contro! va!ve n auto.
Mantan the u stream!ne ressure $y s!o-!y chann the ressure set ont an# ta,n care o' H% an# 2% #rum !eve! as er steam tur$ne ro!!n con#ton.
ee the #verter #amer n auto.
WARM START- UP PROCEDURE (ST meta! temerature L 74C? H% #rum r. = $ar)
%ermssve con#tons:
/nstruments an# servce ar ava!a$!e?
3em -ater ava!a$!e (tan, !eve! not !o-)?
Crcu!atn -ater an# c!ose# coo!n system n servce?
Con#enser !eve! an# #eaerator !eve! not !o-?
HRSG tr reset?
>y*ass system hy#rau!c su!y n servce.
P!"#$%&!$
Set the GT !oa# set ont 57M9.
Reset the HRSG tr 'rom $ac, u ane!.
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WI/OPS/ HRSG-01
%arta!!y oen the H% an# 2% MS #ran va!ve.
Oen the H% an# 2% man steam shuto'' va!ve.
Oen the #verter #amer manua!!y $y vn the as '!o- taret va!ue 54;.
/ncrease the GT !oa# u to 7M9 n 67 mn.
Mantan the #rum !eve! F544mm& ' reure# essenta!!y than ve the $!o#o-n or $!o- o''.
Oen the HRSG sum -ater coo!n va!ve.
8or mantann the #rum !eve! F544mm ' reure# chane the !eve! $asn.
Oen the #verter #amer $y ta,n care o' 'o!!o-n arameters. #) Mantan the #rum meta! tem rse !ess than @4 C Mn. e) Mantan the H% steam tem rse !ess than 564 C Mn. ') 3rum to an# $ottom meta! tem #''erence !ess than 544oC
O$serve the 2% #rum ressure ' t s more than 6.7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.
O$serve the 2%SH ressure ' t s more than 6.7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.
/' H%MS ressure come u to 54 $ar start the man steam #eaerator en !ne heatn $y crac, oenn o' the 'rst ressure contro! va!ve an# ts so!aton va!ve.
Oen the man steam #eaerator en #e suer heatn !ne so!aton va!ve an# ,ee the #e suer heatn contro! va!ve n auto at 674 4 C set va!ue.
O$serve the man steam #eaerator en !ne temerature ' t come u to 6444 an# H% #rum ressure come u to 5 $ar start the #eaerator en charn $y manua! oenn o' 5 st an# 6n# ressure contro! va!ve an# mantan the !ne ressure a'ter the 5st contro! va!ve at @.4 $ar.
Oen the GSC #ran va!ve.
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%ae 5B
WI/OPS/ HRSG-01
/' #eaerator ressure s mantann 5.4 $ar ,ee the $oth ressure contro! va!ve n auto.
Start one GSC $!o-er as er chec,!st.
/' H% #rum ressure comes u to 64 $ars oen the 'rst ressure contro! va!ve an# ts so!aton va!ve manua!!y.
Oen the secon# ressure contro! va!ve s!o-!y an# oen the 'r st ressure contro! va!ve n manua! mo#e 'or mantann the ressure57 $ar.
ee the sea! steam tem contro! va!ve n auto at 5B4 oC set va!ue.
/' sea! ressure comes u to 67m$ar than ,ee the $oth ressure contro! va!ve n auto.
C!ose the vacuum $rea,er va!ve.
Start $oth vacuum ums as er startu roce#ure.
/' con#enser ressure comes u to 644 m$ar oen the H% an# 2% $yass contro! va!ve arta!!y n manua! mo#e.
Ensure the oenn o' the H% an# 2% $yass coo!n !ne so!aton va!ve.
Set the H% an# 2% $yass ressure contro! va!ve s!ht!y !ess than the u actua! u stream!ne ressure an# ,ee the H% an# 2% $yass ressure contro! va!ve n auto.
Mantan the u stream!ne ressure $y s!o-!y chann the ressure set ont an# ta,n care o' H% an# 2% #rum !eve! as er steam tur$ne ro!!n con#ton.
ee the #verter #amer n auto.
HOT START- UP PROCEDURE (ST meta! temerature 74C? H% #rum r. 7 $ar)
%ermssve con#tons:
/nstruments an# servce ar ava!a$!e?
3em -ater ava!a$!e (tan, !eve! not !o-)?
Crcu!atn -ater an# c!ose# coo!n system n servce?
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%ae 5D
WI/OPS/ HRSG-01
Con#enser !eve! an# #eaerator !eve! not !o-?
HRSG tr reset?
>y*ass system hy#rau!c su!y n servce.
P!"#$%&!$
Set the GT !oa# set ont 57M9.
Reset the HRSG tr 'rom $ac, u ane!.
%arta!!y oen the H% an# 2% MS #ran va!ve.
Oen the H% an# 2% man steam shuto'' va!ve.
Oen the #verter #amer manua!!y $y vn the as '!o- taret va!ue 4;.
/ncrease the GT !oa# u to @4M9 P55M9mn.
Mantan the #rum !eve! F544mm& ' reure# essenta!!y than ve the $!o#o-n or $!o- o''.
Oen the HRSG sum -ater*coo!n va!ve.
8or mantann the #rum !eve! F544mm ' reure# chane the !eve! $asn.
%ut the #verter #amer n auto.
Start $oth vacuum ums (' reure#) as er startu roce#ure.
/' con#enser ressure comes u to 644 m$ar oen the H% an# 2% $yass contro! va!ve arta!!y n manua! mo#e.
Ensure the oenn o' the H% an# 2% $yass coo!n !ne so!aton va!ve.
Set the H% an# 2% $yass ressure contro! va!ve s!ht!y !ess than the u actua! u stream!ne ressure an# ,ee the H% an# 2% $yass ressure contro! va!ve n auto.
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%ae 64
WI/OPS/ HRSG-01
Mantan the u stream!ne ressure $y s!o-!y chann the ressure set ont an# ta,n care o' H% an# 2% #rum !eve! as er steam tur$ne ro!!n con#ton.
SHUTDOWN PROCEDURE
%ermssve con#tons:
A!! necessary !ant #rves ava!a$!e an# n Auto mo#e?
GT n servce?
3verter #amer HRSG 'u!!y oen?
HRSG H% 2% steam $y*ass n Auto.
S'(!' ") *!"#$%&!$
S-tch H% ressure set*ont to Manua! mo#e (H% steam $y*ass o' HRSG an# ST contro! va!ves -!! mantan the ressure at the actua! va!ue)?
/' the steam '!o- 'rom HRSG s reater than 7; o' nomna! va!ue (#een#n on the actua! GT
!oa#)& arta! c!osure reuest (4; oenn) to #verter
#amer
C!ose the #verter #amer S!o-!y $y ta,n care o': ) Mantan the #rum meta! tem #ecreasn rate not !ess than =.4 C Mn. h) Mantan the H% steam tem #ecreasn rate not !ess than D.@4 C Mn.
/8 ST H% CV oston comes #o-n u to 64; tr the steam tur$ne manua!!y.
C!ose the #verter #amer 'u!!y.
CHEMICAL PARAMETERS AND OPERATING LIMITATIONS
CHEMICAL PARAMETERS
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%ae 65
WI/OPS/ HRSG-01 /n or#er to ermt the set o' the montorn 'e!# nstrument an# to er'orm the man chemca! ana!yss& -e su!y the recommen#e# man chemca! arameters on the 'o!!o-n $ass: The steam O6 an# H va!ues correctons& -!! $e chec,e# throuh a!,a!ne scavener& su!e# $y means o' the chemca! !ant. 8ee# -ater har#ness !ea,ae& -!! $e chec,e# usn hoshate nKecton !ant nto $o!er #rum& ' reure#. Ma+mum H an# con#uctvty va!ues& n the $o!er -ater& -!! $e mantane# $y means o' the use o' the $!o-*#o-n system. /n the anne+ #aram n 56& s sho-n the $o!er s!ca reartton ressure rate curve. The $!o-*#o-n '!o- a#Kustment -!! mantan the SO6 ma+mum va!ue.
Sam!n ont
Measure
Rane
8ee# -ater con#uctvty I QScm ma+ 4&6 8ee# -ater H * D&4 >!o-*#o-n con#uctvty I QScm H%? 7 2% Steam SO6 m ma+ 4&46 Steam con#uctvty I QScm 4&6 ( 4&7II) O+en O6 at #eaerator out m ma+ 4&4= Hy#ra"ne N6H= 'ee# -ater m 4&46 /ron (8e) n 'ee# -ater m ma+ 4&46 I The con#uctvty va!ue ta,es n cons#eraton the sam!e a'ter catonc e+chane (ac# con#uctvty) S()$'+ ,(,$ $''0: Actua! settn at the s#e s as 'o!!o-s: HRSG SA8ETY VV SET RESET VA2AR >AR 5 ERV D6.D BB.6 6 H% S<%ER HEATER D@.= D.D5 H%*3R
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%ae 66
WI/OPS/ HRSG-01 @ B
2% S<%ER HEATER 2% 3R
.D= 54 54
. D.77 D.77
%reare# $y
Reve-e# $y
3Y manaer. * Oeraton
Hea# (Oeraton)
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%ae 6