O&M Training 1

For Training Only

Heat Recovery Steam Generator
Control Philosophy And Instrumentation
O&M Training 2
For Training Only
Permit the HRSG to followthe Gas Turbine Load AND lead the operation of the
steam turbine.
Achieved by carefully considering economizer steaming impacts, and drum level
control. Specifically, in the HRSG evaporator, steam flow varies depending upon
heat energy extracted from the gas turbine exhaust gas stream.
The operator must bear in mind that at all times the gas turbine loading dictates
the power output of the steam cycle.
The HRSG is designed for sliding pressure and constant pressure operation.
Maximum operating efficiency is obtained during sliding pressure operation.
In the sliding pressure configuration the steam turbine throttle valves remain in
the wide open position. This minimizes the pressure drop losses associated with
constant pressure operation.
CONTROL PHILOSOPHY
O&M Training 3
For Training Only
Drum water level control uses three element feedwater control.
Provides a continuous drum water mass balance, since every pound of steam
or water removed from the evaporator must be replaced.
Three elements
Steam flow from the HRSG, (pressure and temperature compensated)
Feed water flow into the HRSG,
Drum level (pressure and temperature compensated)
Drum level is used for trimming the mass balance of steam flow and feedwater
flow signals.
Mass balance measurements are pressure corrected to compensate for
temperature/pressure fluctuations.
Steam flow signal reacts to changes in steam demand, causing a corresponding
change in feed flow. Once the steam demand has stabilized, the drum level
controller will maintain the desired level.
To accommodate sliding pressure operation, the drum level pressure decreases
in response to lower steam turbine throttle pressure. The lower pressure
changes the steam specific volume through out the steam cycle components.
DRUM LEVEL CONTROL
O&M Training 4
For Training Only
"Shrink" and "Swell" are two terms associated with drum water level and steam
and water specific volume characteristics.
Shrink = The decline in drum water level that occurs when boiling decreases.
When boiling decreases, the steam/water volume and the drum level
decrease, because steam bubbles start collapsing.
Swell = The increase in drum level due to increased boiling resulting from an
increase in heat absorption.
Essentially, swell occurs because steam bubbles formed increase the
steam/water volume and, as a follow up, the drum level.
Swell is a boiler start-up characteristic. Most boilers are started with a lower
drum level. This allows the drum water to reach NWL after the increase in
drum water level due to swell. If NWL is exceeded during start-up, the
intermittent blowdown drain systems, or a decrease in the CT loading ramp
rate should be used to manage the water level swell of the drum.
SHRINK AND SWELL
O&M Training 5
For Training Only
Attemperation
Why?
Control Steam Temperature to within the limits.
Where?
Before and after last Superheater.
Attemperator
Attemperators inject low solids water from the feed pumps.
Attemperation control is a feed forward control loop. The primary control is
achieved by measuring the final steam temperature and comparing it to a setpoint.
The feed forward portion is measuring the attemperator outlet temperature and
steam turbine load changes. The feed forward components assure attemperator
system has adequate time to react to a change in operating conditions.
To assure that wet steam is not admitted to the heating surface, the attemperator
outlet setpoint prevents final stage steam temperature from falling within a certain
degree of saturation temperature at anytime.
ATTEMPERATION
O&M Training 6
For Training Only
The HRSG drain and blowdown system provides a means to:
Continuously and Intermittently blowdown various sections of the HRSG for chemistry
and sediment control,
Drain the HRSG superheater and reheater sections during startup
Drain the HRSG water sections for maintenance during shutdowns.
All blowdown and drains except the water section drains are directed to a blowdown tank. The
blowdown tank automatically drains to a blowdown sump.
Water section drains go directly to the blowdown sumps.
Continuous Blowdown
A portion of the evaporator drum water is continuously removed by skimming the water
and entrained solids from the surface of the water in the steam drum. Maintain the
required total dissolved solids in the drum water to maintain proper steam purity.
Intermittent Blowdown
The intermittent blowoff line is designed for rapid removal of drum water either at start-
up (swell control) or for rapid changes in TDS control of the steam drum.
During cold HRSG start-up, rapid load swings which result in rapid pressure decay of
the steam system, the intermittent blowdown system is available to remove excessive
amounts of feed water to control drum level and water solids for steam purity
considerations. Intermittent blowdown is not normally needed after the unit is stabilized.
Drain and Blowdown System
O&M Training 7
For Training Only
Various instruments required by the Code. Many instruments aid in reliable and safe operation.
Instruments are shown on the P&ID Drawings.
Instrumentation Used on the HRSG include:
Pressure Indicators - required by the Boiler Code to provide a local indication of drum
pressure.
Pressure Transmitters - supplied to collect operating pressures for the control system.
Temperature Indicators - give a local indication of temperature.
Thermocouples - located in the piping system and HRSG ductwork to monitor critical
temperatures. The thermocouples in the HP superheater and reheater attemperator are used
by the attemperator systems to control final steam temperatures.
INSTRUMENTS
O&M Training 8
For Training Only
Instrumentation Used on the HRSG include:
Drum Water Level Indicators - required by the Boiler Code.
Direct line of sight indicators or gauge glasses - Gauge glass observations must be
unobstructed. The gauges can be viewed easily by direct line-of-sight at the HRSG operating
platform.
Level transmitters - provided on each of HP, IP and LP drum to monitor drum operating water
level. The signal levels are monitored and alarms are generated to alert the operator of levels
beyond those required for safe operation of the HRSG pressure levels and feed pump
operation.
WARNING: NO BOILER SHOULD BE IN OPERATION WITHOUT AT LEAST TWO
ACCEPTABLE, DEPENDABLE MEANS OF WATER LEVEL DETECTION IN SERVICE. DRUM
LEVEL MUST BE CONTROLLED NEAR NORMAL WATER LEVEL AT ALL TIMES.
INSTRUMENTS
O&M Training 9
For Training Only
HRSG Operation
Prior to starting the GT
HRSG must be prepared to Start,
HRSG Auxiliaries must be prepared to Start
HRSG prepared to receive water, steam and gas flows.
The following Major Systems must be verified In Service prior to HRSG Startup.
Condensate System,
Feedwater System,
Plant Instrument Air System,
Blowdown System,
Steam Turbine on turning gear.
Preparing for HRSG Operation
O&M Training 10
For Training Only
Low Pressure Steam System
Start Up From A Cold Piping State
LP drum is filled to start-up level (MIN4) with the Feedwater control valve.
Intermittent blowdown valve level opens and closes to control level at Start-Up Level (MIN4)
Start-up =Warm-up of piping to avoid entrainment of condensate droplets into the steam turbine. Steam
turbine is isolated - insufficient steam pressure, temperature and steam quality.
When LP Steam is produced the LP drum level and overflow level is switched to the normal water level (NWL).
As steam forms, drum water level increases. If water level >(MAX2), intermittent blowdown valve opens.
Increasing thermal input more steam is generated LP Bypass Station begins to open.
When the variable fixed set point has been reached Pressure in the low pressure system increases in
accordance with the variable pressure characteristic of the bypass station.
Steam turbine control valve is opened when all conditions have been satisfied for loading of the steam turbine;
Steam flow rate,
Purity and
Temperature.
LP pressure bypass valve, which is set to pressure control, starts to close slowly in proportion to the steam
quantity flowing to the turbine but still performing its pressure controlling task.
Drain stations will open as long as the steam is NOT sufficiently superheated.
Warm / Hot Start
The sequences for cold start also apply for a warm/hot start.
O&M Training 11
For Training Only
Low Pressure Steam System
2.
3.
4.
5.
6.
1.
O&M Training 12
For Training Only
Low Pressure Steam System
#1 LP Drum Level Control
2.
3.
4.
5.
6.
1.
Level maintained by an automatic level control valve.
Operator must verify that the level control valve is in automatic on the OM
screen.
Two level setpoints fed into the level control valve controller
S/U LVL
NORM LVL.
Initial startup S/U LVL SLC is Automatically Selected by the control system.
Ensures drum level is NOT exceeded as the water swells.
S/U LVL mode
Level control valve compares actual drum level to the S/U LVL setpoint
only and adjusts to maintain level.
As LP drum water is heated, water level will rise and pressure will build in the
system. Steam will begin to flow to the LP superheater and out of the startup
vent. Water level will drop and condensate will be fed through the level control
valve to maintain the S/U LVL setpoint.
LP steam flow >15% of rated flow
3-element control logic will become active. (LP steam flow, LP drum
condensate flow and LP drum water level).
After 3 minutes of sustained 3 element control logic operation or when LP
drum pressure >3 bars,
Level control valve setpoint changes from S/U LVL to NORM LVL (0cm).
Level control valve will raise the LP drum to the normal operating level.
In 3-element control, if either steam flow or feedwater flow transmitters fail, the
SLC NO 3 ELE will activate and remove the affected instrument from the
calculation for controlling drum level.
O&M Training 13
For Training Only
Low Pressure Steam System
#2 LP Drum Continuous Blowdown Valve
2.
3.
4.
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6.
1.
Motor Operated Continuous Blowdown Valve
Allows blowdown of LP drum water to control chemistry in the drum during
operation.
The rate of blowdown is controlled by a precision manual throttle valve
downstream of the motor operated valve.
Operator must open and close the motor operated valve from the OM screen.
Must OPEN the continuous blowdown valve within 30 minutes of gas
turbine startup.
If the operator fails to open the valve within 30 minutes, a CLOSED
WARNINGwill display on the alarm screen. The alarm will continue to
re-display every 30 minutes until the valve is opened.
Must CLOSE the continuous blowdown valve within 20 minutes of gas
turbine shutdown.
If the operator fails to close the valve within 20 minutes, an OPEN
WARNINGwill display on the alarm screen. The alarm will continue to
re-display every 20 minutes until the valve is closed.
O&M Training 14
For Training Only
Low Pressure Steam System
#3 LP Feedwater Block Valve
2.
3.
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1.
Motor Operated Block Valve Upstream of the Level Control valve
Ensures positive isolation of water into the LP Drum.
With Controller in AUTOMATIC,
Block valve will open and stay open when LP drum level is in its
normal operating range.
Valve will close If LP drum level increases to Imminent Trip HI-
HIsetpoint.
As level decreases below the reset level value, block valve will
reopen.
O&M Training 15
For Training Only
Low Pressure Steam System
#4 LP Startup Vent BlockValve
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Motor Operated Vent Valve Downstream of the Superheater
Provides a flow path of steam during startup of the LP section of the
HRSG.
Prevents potential overheating of the superheater
With Controller in AUTOMATIC,
Vent valve will open when the gas turbine is in operation and the
LP Drum indicates a rise in pressure of 0.5 bar from its initial
pressure when the gas turbine is started.
Vent valve will close when:
LP Steam Block valve is open,
Condenser is ready for steam,
LP Bypass Pressure Controller is in AUTO and
LP Bypass valve is 10% open.
O&M Training 16
For Training Only
Low Pressure Steam System
#5 LP Steam BlockValve
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Motor Operated Block Valve Downstream of the Startup Vent
Isolates LP Section of the HRSG from the LP steam header.
Must be opened and closed by the operator from the OM screen.

Has a protective close feature for future application when a second

HRSG is provided. When installed, if the second HRSG is in service
and the first HRSG LP Steam Block Valve is closed for more than 3
minutes, a protective feature will not allow the operator to open the
valve from the OM screen. It will have to be open locally once
pressure across the valve is locally equalized.
O&M Training 17
For Training Only
Low Pressure Steam System
#6 LP Drum Intermittent BlowdownBlockValve
2.
3.
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1.
Motor Operated Block Valve
Provides a means to isolate the LP Intermittent Blowdown Control
valve which controls excessive drum level during startup and
transients during normal operations.
Automatically opened when blowdown control valve demanded
position is greater than 10% and the position demand is greater than
5% of the valves actual position.
Automatically closed when blowdown control valve position demand
is less than 5% of actual position or the valve position demand is less
than 10%.
O&M Training 18
For Training Only
Intermediate And Reheater Pressure Steam System
Start Up From A Cold Piping State
If the economizer is partly or fully drained - Vents are manually opened during filling.
System is filled via the feedwater bypass valve, when the feedwater isolating valve is closed.
Vent valves are manually closed when filling of the economizer is complete (visual check).
If the current drum level is below the start-up level
Open the feedwater isolating valve.
Close the feedwater bypass valve.
Open the feedwater control valve and fill the IP Drum to the start-up level.
If the current drum level is above the start-up level
The intermittent blowdown valve level is switched over to start-up level (MIN5).
Some water maybe blown down to the HRSG blowdown system LBH.
IP steam isolating valve is opened after filling and prior to the start-up.
When the condenser and other necessary systems are ready for service, the steam generator is started
up.
Intermittent blowdown valve is switched over to normal water level.
IP Economizer is fed with a minimum flow rate of ~5 kg/s to protect the evaporator from flashing during
GT start up.
After steam production has been established,
IP feedwater control station is switched over to 3 element control.
Intermittent blowdown valve of the IP drum is switched over to blowdown level.
For start-up, the GT exhaust gas temperature is controlled to maintain main steam temperature within the
range required by the steam turbine. If the temperature cannot be controlled in GT premix operation the steam
temperatures can be controlled by activating the spray attemperators.
O&M Training 19
For Training Only
Intermediate And Reheater Pressure Steam System
Start Up From A Cold Piping State
Start-up of the reheat steam piping system mainly consists of piping warm-up to avoid entrainment of
condensate droplets into the steam turbine. Initially during start up, the steam turbine is isolated from the
reheater main steam system due to insufficient steam pressure, temperature and steam quality.
The drains are closed once the steam is sufficiently superheated.
Increasing thermal input more steam is generated IP Bypass Station begins to open.
When the fixed set point has been reached Pressure in the IP system increases in accordance with the
variable pressure characteristic of the bypass station.
Steam turbine control valve is opened when all conditions have been satisfied for loading of the steam turbine;
Steam flow rate,
Purity and
Temperature.
IP bypass valve, which is set to pressure control, starts to close slowly in proportion to the steam quantity
flowing to the turbine.
After the IP bypass station has been closed, the load is increased in accordance with the allowable load
change gradients of the steam turbine. The pressure set point of the IP station is increased 45 psig above the
steam pressure set point resulting from the actual steam mass flow. The IP bypass station opens upon a
sudden rise in pressure. The IP bypass station prevents exceeding of the design pressure prior to the safety
valve.
O&M Training 20
For Training Only
Intermediate And Reheater Pressure Steam System
Start Up From A Cold Piping State
Warm / Hot Start
The same sequences for the cold start apply for preparation for a warm/hot start.
The drain valves may be opened only after the HRSG is heated and a pressure increase has been initiated.
The drains are closed in accordance with the same criteria as a cold start.
The IP bypass valve opens when a pressure increase is detected. It maintains the correct pressure until the
variable pressure characteristic has been reached.
The combustion turbine is then loaded according to the steam conditions required by the steam turbine with
the allowable gradients for the heat recovery steam generator and the steam turbine.
O&M Training 21
For Training Only
Intermediate And Reheater Pressure Steam System
1.
2.
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O&M Training 22
For Training Only
Intermediate And Reheater Pressure Steam System
#1 IP Feedwater Block Valve
1.
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7.
Motor Operated Block Valve Upstream of the Level Control valve
Ensures positive isolation of water into the IP Drum.
With Controller in AUTOMATIC,
Block valve will open and stay open when:
A boiler feedwater pump is running,
IP Feedwater Startup Block Valve is open and
Differential pressure across feedwater block valve is <3.5
bars.
If the pressure instruments before or after the block valve fail, the
valve will open when a boiler feedwater pump has been running
for >5 minutes
Valve will close when:
The boiler feedwater pump is off, or
IP drum level reaches the HI-HI trip level with the CT
shutdown, or
IP boiler feedwater pump pressure drops below 28.5 bars.
O&M Training 23
For Training Only
Intermediate And Reheater Pressure Steam System
#2 IP Feedwater Startup Block Valve
1.
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3.
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4.
7.
Solenoid Operated Block Valve
Provides a means to equalize pressure across the IP Feedwater
Block Valve prior to opening.
With Controller in AUTOMATIC,
Startup Block valve will open when:
A boiler feedwater pump is running, and
IP Discharge Pressure from pump is >32 bar.
If the pressure transmitter for the IP discharge pressure fails, the
valve opens within a short time period on indication that a boiler
feedwater pump is in service
O&M Training 24
For Training Only
Intermediate And Reheater Pressure Steam System
#3 HRH Intermediate and Final Desuperheater Block Valve
1.
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7.
Solenoid Operated Block Valves
Provide positive isolation of IP feedwater to their
corresponding control valves.
HRH Final Desuperheater Block Valve
With Controller in AUTOMATIC,
Block valve will OPEN when:
A boiler feedwater pump is in service,
Final HRH steam has >25 superheat,
Final HRH temperature is >305C,
HRH temperature before desuperheater is >305C,
Total HRH steam flow >35%, and
Final desuperheater control valve is demanded open.
Block valve will CLOSE IF any of the previous conditions
are not met.
HRH Intermediate Desuperheater Block Valve
With Controller in AUTOMATIC,
Block valve will OPEN when:
A boiler feedwater pump is in service,
Final HRH steam has >25 superheat,
Intermediate HRH temperature is >305C,
HRH temperature before desuperheater is >
305C,
Total HRH steam flow >35%,
Intermediate desuperheater outlet temperature
has >5 superheat, and
Intermediate desuperheater control valve is
demanded open.
Block valve will CLOSE IF any of the previous
conditions are not met.
O&M Training 25
For Training Only
Intermediate And Reheater Pressure Steam System
#4 IP Drum Level Control
1.
2.
3.
9.
8.
6.
5.
4.
7.
Level maintained by an automatic level control valve.
Operator must verify that the level control valve is in automatic on the OM
screen.
Two level setpoints fed into the level control valve controller
S/U LVL
NORM LVL.
Initial startup S/U LVL SLC is Automatically Selected by the control system.
Ensures drum level is NOT exceeded as the water swells.
S/U LVL mode
Level control valve compares actual drum level to the S/U LVL setpoint
only and adjusts to maintain level.
As IP drum water is heated, water level will rise and pressure will build in the
system. Steam will begin to flow to the IP superheater and out of the startup
vent. Water level will drop and feedwater will be fed through the level control
valve to maintain the S/U LVL setpoint.
IP steam flow >15% of rated flow
3-element control logic will become active. (IP steam flow, IP drum
feedwater flow and IP drum water level).
After 3 element control logic operation with CT in Service or when IP drum
pressure >5 bars, and IP drum pressure indicates a 3.5 bar rise from initial
drum pressure with the CT in service
Level control valve setpoint changes from S/U LVL to NORM LVL (0cm).
Level control valve will raise the IP drum to the normal operating level.
In 3-element control, if either steam flow or feedwater flow transmitters fail, the
SLC NO 3 ELE will activate and remove the affected instrument from the
calculation for controlling drum level.
O&M Training 26
For Training Only
Intermediate And Reheater Pressure Steam System
#5 IP Drum Continuous Blowdown Valve
1.
2.
3.
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5.
4.
7.
Motor Operated Continuous Blowdown Valve
Allows blowdown of IP drum water to control chemistry in the drum during
operation.
The rate of blowdown is controlled by a precision manual throttle valve
downstream of the motor operated valve.
Operator must open and close the motor operated valve from the OM screen.
Must OPEN the continuous blowdown valve within 30 minutes of gas
turbine startup.
If the operator fails to open the valve within 30 minutes, a CLOSED
WARNINGwill display on the alarm screen. The alarm will continue to
re-display every 30 minutes until the valve is opened.
Must CLOSE the continuous blowdown valve within 20 minutes of gas
turbine shutdown.
If the operator fails to close the valve within 20 minutes, an OPEN
WARNINGwill display on the alarm screen. The alarm will continue to
re-display every 20 minutes until the valve is closed.
O&M Training 27
For Training Only
Intermediate And Reheater Pressure Steam System
#6 IP Economizer Vent Valve
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Motor Operated Vent Valve
Buildup of non condensable gases in the economizer tubes can reduce heat
transfer. The vent valve ensures adequate cooling by keeping the economizer
tubes full of water.
With Controller in AUTOMATIC, Economizer Vent valve will open when:
IP drum pressure drops below a preset value (~1.72 bar),
A boiler feedwater pump is in service and
The IP feedwater block valve is open.
With Controller in AUTOMATIC, Economizer Vent valve will close when:
As pressure builds in the IP drum above the minimum preset
pressure setpoint (~1.72 bar),
The IP feedwater block valve is closed, or
The boiler feedwater pump is shutdown.
O&M Training 28
For Training Only
Intermediate And Reheater Pressure Steam System
#7 IP Drum Intermittent Blowdown Block Valve
1.
2.
3.
9.
8.
6.
5.
4.
7.
Motor Operated Block Valve
Provides a means to isolate the IP Intermittent Blowdown Control
valve which controls excessive drum level during startup and
transients during normal operations.
Automatically opened when blowdown control valve demanded
position is >3%.
Automatically closed when blowdown control valve position demand
is <3%.
O&M Training 29
For Training Only
Intermediate And Reheater Pressure Steam System
#8 IP Steam Vent Valve
1.
2.
3.
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8.
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5.
4.
7.
Motor Operated Vent Valve Downstream of the Superheater
Provides a flow path of steam during startup of the IP section of the
HRSG.
Prevents potential overheating of the superheater
With Controller in AUTOMATIC,
Vent valve will open when the gas turbine is in operation and the
IP Steam Control Valve closed and the IP Drum pressure less
than 2 bar.
Vent valve will close when any one of these conditions are not
met.
O&M Training 30
For Training Only
Intermediate And Reheater Pressure Steam System
#9 CRH Equalization Control Valve
1.
2.
3.
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7.
Motor Operated Valve
Provides to balance out CRH steam flow during two HRSG
operations.
Ensures that the exact amount of steam flow is returned to each
HRSG that is taken from them.
Under the current design, no balancing is required with one HRSG.
Therefore the current purpose of the CRH Equalization Control Valve
is to isolate the CRH to the HRSG when the control valve position
demand drops below 5%. When Valve demand is greater than 5%,
the CRH Equalization Control Valve will open.
O&M Training 31
For Training Only
High Pressure Steam System
Start Up From A Cold Piping State
Drains and Vents of the HP system are opened.
HP drum is filled to start-up level.
Intermittent blowdown valve level is switched over to start-up level.
When the condenser and other necessary systems are ready for service, the steam generator is started up.
Intermittent blowdown valve is switched over to normal water level.
HP Economizer is fed with a minimum flow rate of ~10% of normal flow to protect the evaporator from flashing
during GT start up.
If HP drum water level rises above normal water level, the HP intermittent blowdown valve opens.
After steam production has been established,
HP feedwater control station is switched over to 3 element control.
Intermittent blowdown valve of the HP drum is switched over to blowdown level.
Initially during start up, the steam turbine is isolated from the main steam system due to insufficient steam
pressure, temperature and steam quality.
The drains are closed once the steam is sufficiently superheated.
With increasing thermal input, the HP bypass station will begin to open when a certain pressure level is
achieved (typically 90 to 120 psig). Once the position set point is reached, the pressure in the high pressure
system rises in accordance with the variable pressure characteristic of the bypass station.
Steam turbine control valve is opened when all conditions have been satisfied for loading of the steam turbine;
Steam flow rate,
Purity and
Temperature.
HP bypass valve, which is set to pressure control, starts to close slowly in proportion to the steam quantity
flowing to the turbine.
After the HP bypass station is closed, the load will be increased in accordance with the allowable load change
gradients of the steam turbine, the steam generator and the pipes.
O&M Training 32
For Training Only
High Pressure Steam System
Warm / Hot Start
The same sequences for the cold start apply for a warm/hot start. The drain valves may be opened after the
HRSG is in operation. The drains are closed in accordance with the same criteria as in the cold start.
The HP bypass valve opens when a pressure rise is detected. It maintains the previous setpoint until the
variable pressure characteristic has been reached.
The combustion turbine is then run up corresponding to the steamconditions required by the steam turbine in
accordance with the allowable gradients for the heat recovery steam generator and the steam turbine.
O&M Training 33
For Training Only
High Pressure Steam System
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O&M Training 34
For Training Only
High Pressure Steam System
#1 Press Hold SLC
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1.
Sub Loop Controller
Operator Activated
Should be Turned ONprior to Start up.
When Turned ON:
Limit pressure setpoint for HP bypass valve,
Limit pressure setpoint for HP vent valve, and
Limit CT load control to prevent exceeding a pressure and
temperature limit on the HP section.
If NOT Turned ON:
Operator is responsible for ensuring pressure and thermal limits
are not exceeded during startup and operation.
O&M Training 35
For Training Only
High Pressure Steam System
#2 HP Feedwater Block Valve
2.
3.
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11.
10.
1.
Motor Operated Block Valve Upstream of the HP Level Control valve
Ensures positive isolation of water into the HP Drum.
With Controller in AUTOMATIC,
Block valve will open and stay open when:
A boiler feedwater pump is running,
HP Feedwater Startup Block Valve is open and
Differential pressure across feedwater block valve is <3.5
bars.
If the pressure instruments before or after the block valve fail, the
valve will open when a boiler feedwater pump has been running
for >5 minutes
Block Valve will close when:
The boiler feedwater pump is off, or
HP drum level reaches the HI-HI trip level with the CT
shutdown, or
HP boiler feedwater pump pressure drops below 118.5 bars.
O&M Training 36
For Training Only
High Pressure Steam System
#3 HP Startup Block Valve
2.
3.
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5.
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11.
10.
1.
Solenoid Operated Block Valve
Provides a means to equalize pressure across the HP Feedwater
Block Valve prior to opening.
With Controller in AUTOMATIC,
Startup Block valve will open when:
A boiler feedwater pump is running, and
HP Discharge Pressure from pump is >122 bar.
If the pressure transmitter for the IP discharge pressure fails, the
valve opens within a short time period on indication that a boiler
feedwater pump is in service
O&M Training 37
For Training Only
High Pressure Steam System
#4 HP Bypass Desuperheater Block Valve
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3.
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10.
1.
Solenoid Operated Block Valve
Isolates feedwater to the HP Bypass valve when not required for
operation.
With Controller in AUTOMATIC,
Block valve will open when:
HP Bypass valve position demand reaches 5% increasing.
Block valve will close when:
HP Bypass valve position demand reaches 3% decreasing.
O&M Training 38
For Training Only
High Pressure Steam System
#5 HP Interstage and Final Desuperheater Block Valves
2.
3.
4.
6.
5.
7.
8.
9.
11.
10.
1.
Solenoid Operated Block Valves
Provide positive isolation of HP feedwater to their
corresponding control valves.
Final Desuperheater Block Valve
With Controller in AUTOMATIC,
Block valve will OPEN when:
A boiler feedwater pump is in service,
Final HP steam has >25 superheat,
Final HP temperature is >325C,
HP temperature before desuperheater is >305C,
Total HP steam flow >25%, and
Final desuperheater control valve is demanded open.
Block valve will CLOSE IF any of the previous conditions
are not met.
HP Interstage Desuperheater Block Valve
With Controller in AUTOMATIC,
Block valve will OPEN when:
A boiler feedwater pump is in service,
Final HP steam has >25 superheat,
HP temperature before desuperheater is >
305C,
Total HP steam flow >25%,
Interstage desuperheater outlet temperature
has >5 superheat, and
Interstage desuperheater control valve is
demanded open.
Block valve will CLOSE IF any of the previous
conditions are not met.
O&M Training 39
For Training Only
High Pressure Steam System
#6 HP Drum Level Control
2.
3.
4.
6.
5.
7.
8.
9.
11.
10.
1.
Level maintained by an automatic level control valve.
Operator must verify that the level control valve is in automatic on the OM
screen.
Two level setpoints fed into the level control valve controller
S/U LVL
NORM LVL.
Initial startup S/U LVL SLC is Automatically Selected by the control system.
Ensures drum level is NOT exceeded as the water swells.
S/U LVL mode
Level control valve compares actual drum level to the S/U LVL setpoint
only and adjusts to maintain level.
As HP drum water is heated, water level will rise and pressure will build in the
system. Steam will begin to flow to the HP superheater and out of the startup
vent. Water level will drop and feedwater will be fed through the level control
valve to maintain the S/U LVL setpoint.
HP steam flow >15% of rated flow
3-element control logic will become active. (HP steam flow, HP drum
feedwater flow and HP drum water level).
After 3 element control logic operation with CT in Service or when HP drum
pressure >10 bars, and HP drum pressure indicates a 7 bar rise from initial
drum pressure with the CT in service
Level control valve setpoint changes from S/U LVL to NORM LVL (0cm).
Level control valve will raise the HP drum to the normal operating level.
In 3-element control, if either steam flow or feedwater flow transmitters fail, the
SLC NO 3 ELE will activate and remove the affected instrument from the
calculation for controlling drum level.
O&M Training 40
For Training Only
High Pressure Steam System
#7 HP Economizer Vent Valve
2.
3.
4.
6.
5.
7.
8.
9.
11.
10.
1.
Motor Operated Vent Valve
Buildup of non condensable gases in the economizer tubes can reduce heat
transfer. The vent valve ensures adequate cooling by keeping the economizer
tubes full of water.
With Controller in AUTOMATIC, Economizer Vent valve will open when:
HP drum pressure drops below a preset value near saturation
temperature,
A boiler feedwater pump is in service
The HP feedwater block valve and Startup Block Valves are open
and
HP drum level control valve is greater than 1.5% open.
With Controller in AUTOMATIC, Economizer Vent valve will close when:
As pressure builds in the HP drum above the minimum preset
temperature setpoint ,
The HP feedwater block valve or Startup Block Valve is closed, or
The boiler feedwater pump is shutdown.
O&M Training 41
For Training Only
High Pressure Steam System
#8 HP Drum Continuous BlowdownValve
2.
3.
4.
6.
5.
7.
8.
9.
11.
10.
1.
Motor Operated Continuous Blowdown Valve
Allows blowdown of HP drum water to control chemistry in the drum during
operation.
The rate of blowdown is controlled by a precision manual throttle valve
downstream of the motor operated valve.
Operator must open and close the motor operated valve from the OM screen.
Must OPEN the continuous blowdown valve within 30 minutes of gas
turbine startup.
If the operator fails to open the valve within 30 minutes, a CLOSED
WARNINGwill display on the alarm screen. The alarm will continue to
re-display every 30 minutes until the valve is opened.
Must CLOSE the continuous blowdown valve within 20 minutes of gas
turbine shutdown.
If the operator fails to close the valve within 20 minutes, an OPEN
WARNINGwill display on the alarm screen. The alarm will continue to
re-display every 20 minutes until the valve is closed.
O&M Training 42
For Training Only
High Pressure Steam System
#9 HP Drum Intermittent BlowdownValve
2.
3.
4.
6.
5.
7.
8.
9.
11.
10.
1.
Motor Operated Block Valve
Provides a means to isolate the HP Intermittent Blowdown Control
valve which controls excessive drum level during startup and
transients during normal operations.
Automatically opened when blowdown control valve demanded
position is >5%.
Automatically closed when blowdown control valve position demand
is <3%.
O&M Training 43
For Training Only
High Pressure Steam System
#10 HP Superheater Steam Block Bypass Valve
2.
3.
4.
6.
5.
7.
8.
9.
11.
10.
1.
Motor Operated Block Valve
Provides a means to equalization of pressure across the HP
Superheat Steam Block Valve to prevent damage due to high
differential pressure.
Automatically opened when the SLC HRSG SETUP FOR IN
SERVICE is activated from the Water/Steam Overview OM screen.
Automatically closed when the HP Superheat Steam Block Valve
indicates it is open.
O&M Training 44
For Training Only
High Pressure Steam System
#11 HP Superheater Steam Block Valve
2.
3.
4.
6.
5.
7.
8.
9.
11.
10.
1.
Motor Operated Block Valve
Provides a means to isolate the HRSG HP section from the plants
HP steam system during periods of shutdown.
Automatically opened when differential pressure across the valve
reaches <7 bar.
Automatically closed when the gas turbine is shutdown.
O&M Training 45
For Training Only
Duct Burner System
1.
2.
3.
5.
4.
O&M Training 46
For Training Only
1.
2.
3.
5.
4.
Duct Burner System
#1 Duct Burner Start SLC
Allows the duct burner to be placed into service once the gas turbine
is online and is on outlet temperature control (OTC).
Duct Burner will Start When:
SLC is activated,
Duct burner PLC is OK,
Duct burner fan is in service and
HRSG is in service (GT OTC is active).
SLC will command the Duct Burner PLC to activate the duct burner
startup sequence.
O&M Training 47
For Training Only
1.
2.
3.
5.
4.
Duct Burner System
#2 Duct Burner Stop SLC
Commands the Duct Burner PLC to shutdown the duct burner
system.
SLC can be activated by:
The operator,
The PLC Burner Management Master Fuel Trip or
Abnormal conditions with the steam plant.
Gas turbine trip,
High HP steam pressure, 118 bar
HI-HI HP steam temperature, 557 >60 s, 560 >3 s
Steam turbine trip or
Low HP drum level. -15.24
O&M Training 48
For Training Only
1.
2.
3.
5.
4.
Duct Burner System
#3 Duct Burner MFT Reset SLC
Provides the operator a means to reset the duct burner system PLC
remotely after any trip of the duct burner.
Prior to starting the duct burner, the operator should reset the system
with this SLC.
O&M Training 49
For Training Only
1.
2.
3.
5.
4.
Duct Burner System
#4 & 5 Duct Burner Fans SLC/ASO
#4 Duct Burner Fans SLC
Turns on the selected fan to provide cooling to the flame scanners.
SLC can be activated by:
The operator,
Automatically when gas turbine exhaust temperature increases
to 60C.
Selected fan will continue to run until gas turbine exhaust
temperature drops to 55C for 5 minutes
#5 Duct Burner Fans ASO
Allows the operator to select which fan should be the primary and
starts that fan when the SLC Duct Burner Fans is active.
If primary fan fails to indicate proper operation, the ASO will
automatically start the backup fan and provide an alarm.
O&M Training 50
For Training Only
Shutdown and Part-Load Behavior
On a load reduction of the gas turbine, the gas turbine exhaust gas flow rate is reduced to
approximately 70% at nearly constant exhaust gas temperature in the first phase.
The exhaust gas flow rate is then held constant and the exhaust gas temperature is reduced
as a function of combustion inlet temperature. The main steam temperature starts to rise
slightly. The interstage spray attemperators limit the main steam temperature. The main
steam temperature drops proportionally to the gas turbine exhaust gas temperature only
when additional load is reduced on the gas turbine.
The heat recovery steam generator adapts to the characteristics of the gas turbine.
The low pressure system is operated in the variable fixed pressure mode over the load
range. For the shutdown of the steam turbine, the turbine inlet valves are closed. Additional
steam produced in the heat recovery steam generator is routed to the condenser via the
bypass stations.