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Projects and Customer’s Information: Fujairah 2 Project Company Additional Project Information Project name: Fujairah II Country
Projects and Customer’s Information:
Fujairah 2 Project Company
Additional Project Information
Project name:
Fujairah II
Country
UAE
Revision History
Rev.
Revision/Date
Created by
Checked by
Approved by
Description
B
18/07/2008
Varatharaj
N.Gobi
MAXY
Initial Issue
C
23/10/2008
Varatharaj
N.Gobi
N.Gobi
Burner operating proce-
dure generally revised
D
20/02/2009
Varatharaj
N.Gobi
N.Gobi
Generally Revised
Scale
Project Document Coding
FUJ/00/M/H------A30/OI/006 Rev.D
Responsible dept.
Created by
Checked by
Approved by
Format
EHG
Varatharaj
N.Gobi
AJR
Word
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Document Type
Document Status
Selection Sheet
Electronically Released
abcd
Title, Subtitle
Originator Identification number
FUJ/00/M/H------A30/OI/006 Rev.D
Power Turbo-Systems
OPERATING PROCEDURE
Rev.
Date
Lang.
Sheet
D
20-02-2009
EN
1 of 49
abcd
ALSTOM Project India Limited
EHG
Document Number
PB0048-19.02
© THIS DOCUMENT IS THE
PROPERTY OF
ALSTOM PROJECTS INDIA LIMITED AND IS ONLY ALLOWED TO BE USED BY
EXPRESS PERMISSION & LICENCE FROM ALSTOM PROJECTS INDIA LIMITED

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ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

OPERATING PROCEDURE

TABLE OF CONTENTS

TITLE

PAGE NO.

INTRODUCTION COMPLETION OF MAINTENANCE PRIOR TO OPERATION

..........................................................................................................................

....................................................

4

4

INITIAL FILLING HP FILLING

..........................................................................................................................

.................................................................................................................................. PRE-OPERATIONAL EQUIPMENT CHECKS START-UP FROM A COLD CONDITION

.............................................................................

....................................................................................

4

5

6

6

START-UP FROM A WARM / HOT CONDITION

........................................................................

8

SUPPLEMENTARY FIRING SYSTEM

.......................................................................................

10

SECURING TO A WARM LAY-UP CONDITION SECURING TO DRAIN (WITHOUT NITROGEN BLANKETING)

.......................................................................

..............................................

11

11

CONTROLS AND INSTRUMENTATION

...................................................................................

12

Controls

..................................................................................................................................... Instrumentation ........................................................................................................................ SAFETY VALVES

......................................................................................................................

12

12

12

EMERGENCY PROCEDURES High Water Level ...................................................................................................................... Low Water Level Tube Failure

..................................................................................................

.......................................................................................................................

.............................................................................................................................. Loss of Feedwater Supply

.......................................................................................................

14

14

15

15

15

SUPPLEMENTARY FIRING SYSTEM OPERATING PRINCIPLES……………………….……22

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ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

OPERATING PROCEDURE

TABLES:

Table 1 - Valve Alignment: High Pressure Section Table 2 - HP Drum Level Setpoints

ENGINEERING DRAWINGS:

Piping & Instrumentation Diagram Legend Sheet………………………………………………

 
B
B

..

...

FUJ/00/M/H ………A30/FD/001

HP System

FUJ/00/M/H ………A30/FD/002

......................................................................

FUJ/00/M/H ………A30/FD/003

Gas Side

.................................................................................. Burner Head Valve Train and Burner Head

FUJ/00/M/H ………A30/FD/004 FUJ/00/M/H ………A30/FD/005

Diesel Oil Pumping set

FUJ/00/M/H ………A30/FD/006 FUJ/00/M/H ………A30/FD/007

Instrument , service air & Nitrogen system …………………FUJ/00/M/H ………A30/FD/041

D
D

REFERENCE DOCUMENTS:

FUJ/00/M/H ……

..

A30/LV/001

- Valve List

B
B

FUJ/00/M/H ………A30/LI/001 - Instrument List FUJ/00/M/H ………A30/OI/006 - Operating Procedures

FUJ/01/B/H………

..

A30/EI/004

– Input Data for Functional and Logic Diagrams

FUJ/00/M/H ………A30/OI/001 – Start-Up and Shut down curves

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ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

OPERATING PROCEDURE

INTRODUCTION

These procedures are intended to serve as a guide during the initial operating stages of a Heat Recovery Steam Generator (HRSG). They include the proper operating sequences for the steam generator and auxiliary equipment furnished by ALSTOM Projects India Ltd. Refer to the Piping and Instrumentation Dia- grams. The sequential procedures do not include detailed reference to equip- ment not furnished by ALSTOM Projects India Ltd, such as the feed pumps, or the gas turbine.

Because the steam generator is only one part of the power plant, and all equip- ment must operate in unison, specific procedures and detailed values cannot be included in this manual. As operating experience is gained and the controls are fine-tuned, the characteristics and operating requirements of the unit will become apparent.

Refer to manufacturer's instructions for further operating details for specific equipment supplied by ALSTOM Projects India Ltd.

COMPLETION OF MAINTENANCE PRIOR TO OPERATION

Check the HRSG to make sure that all maintenance work has been completed, all tools and debris have been removed, the hand hole plates and manhole cov- ers have been installed and secured, and all access doors have been installed and secured.

Check the safety valves to see that the gags have been removed, the lifting lev- ers have been replaced, and the valves are not fouled or hung up. In addition, check to ensure that the steam and feed water isolation valves are operational ready to open according to procedures, drain and vent valves are all operational ready to be preset according to procedures and as listed in the appropriate valve alignment list.

Ensure all the components were installed after acid cleaning

The operator should understand the start up and shut down curves (PB0048- 01.04) prior to operating the HRSG.

D
D

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ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

OPERATING PROCEDURE

INITIAL FILLING

This section describes the recommended procedure for fiIIing an empty HRSG

with water.

If the unit is hot, filling of a pressure level system with cold water should not be initiated until the drum metal temperature for that pressure level has cooled to within 56°C (100°F) of the incoming feedwater temperature. Filling should be done slowly, with the feedwater 30% control valve at 10% open, to avoid severe temperature strains. Otherwise, damage may result due to relatively cool water coming into contact with heated pressure parts.

B
B

Also, since deposits of solids in a superheater can cause corrosion or inhibit heat transfer, introduction of solids by carryover of boiler water from the drum during filling, hydrostatic testing or chemical cleaning must be avoided.

Proceed as follows:

  • 1. Prepare HP Feed water Pumps and plant feed piping for start-up.

  • 2. Align all HRSG valves as shown under the column labeled “START FROM COLD” on Tables 1.

3. Make sure all drain valves are closed.

  • 4. Before starting the HP Feed water Pumps used in initial filling operation, feed system control valve station should be positioned to allow for filling of the boiler, including the following (Refer to Piping and Instrumentation Diagrams):

a.

Close HP Feedwater Stop Valve (LAB96 AA051).

b.

Open the HP Feedwater Bypass Fill Valve (LAB96 AA061) to allow for

filling.

c.

Open the HP Feedwater Control Valve (30%) (HAC58 AA024) to allow

for filling

HP FILLING

5.

D
D

Start the HP Feedwater Pump used for initial filling operations and open (approximately 1/4 turns) the HP Drum Outlet Vent Valves (HAD52 AA201, HAD52 AA202), the HP Economizer Vent Valves (HAC53 AA201, HAC53 AA202, HAC53 AA211, HAC53 AA212, HAC53 AA221, HAC53 AA222 HAC53 AA231, HAC53 AA232, HAC53 AA261, HAC53 AA262, HAC54 AA211, HAC54 AA212, HAC54 AA221, HAC54 AA222, HAC54 AA231, HAC54 AA232, HAC54 AA201, HAC54 AA202, HAC55 AA211, HAC55 AA212, HAC55 AA221, HAC55 AA222, HAC55 AA231, HAC55 AA232, HAC55 AA201, HAC55 AA202, HAC56 AA211, HAC56 AA212, HAC56 AA221, HAC56 AA222, HAC56 AA231, HAC56 AA232, HAC56 AA201, HAC56 AA202, HAC57 AA211, HAC57 AA212, HAC57 AA221, HAC57 AA222, HAC57 AA231, HAC57 AA232, HAC57 AA201, HAC57 AA202, HAC58 AA201, HAC58 AA202, HAC58 AA211, HAC58 AA212)

and Feed Water Heater Vent valves ( HAC10 AA201,

AA202,

AA203, AA204,AA208,AA209,AA210,AA211,AA212,AA213,AA214,AA215).

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ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

OPERATING PROCEDURE

  • 6. Fill the HP Economizer and HP Evaporator until the Cold Start-up NWL has been cleared in the HP Drum (see Table 2 for Drum Levels). DO NOT OVERFILL THE DRUMS. Close the HP Economizer Vent Valves for each section when all air has been displaced from that section. Close the HP Drum Outlet Vent Valves when the HP Drum fill is complete.

  • 7. After the drum fill is complete close HP Feedwater Control Valve (HAC58 AA024). Place all feed system control valve stations including associated drum level controls in AUTO MODE.

All condensate / feed water pumps can be temporarily off-line while waiting for pre-operation equipment checks and valve alignments prior to start-up. The HRSG is now ready to be started using the procedure for “START-UP FROM A COLD CONDITION”.

PRE-OPERATIONAL EQUIPMENT CHECKS

Have all HRSG auxiliary equipment lined up for operation prior to allowing flow of

the gas turbine exhaust to the HRSG. Prior to initial operation:

  • 1. Make sure that:

    • a. All instrument valves should be lined up for service.

    • b. All drum level transmitter reference legs are filled.

    • c. All sample line valves should be closed.

    • d. All chemical and nitrogen feed valves should be closed.

    • e. All drain valves should be closed.

  • 2. Open and close the following valves to ensure that water level gauges are reading correctly:

    • a. HP Drum Level Indicator Drains (HAD50 AA243, HAD50 AA244).

    • b. HP Drum Level Control Unit Drains (HAD50 AA251, HAD50 AA252).

  • START-UP FROM A COLD CONDITION

    This section describes the recommended procedure for starting the HRSG from a cold condition with no pressure in the HP boiler section. Proceed as follows:

    • 1. Purge the HRSG in accordance with NFPA 85 dated 2004, Chapter 8.9.2 (Combustion Turbine Exhaust Systems) guidelines.

    It is understood that purging is accomplished by using air at ambient tem- peratures. The ambient air temperatures during a normal purge cycle will not have any damaging effect on any of the HRSG components.

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    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

    OPERATING PROCEDURE

    • 2. Align all HRSG valves as shown under the column labeled “START FROM COLD” on Table 1.

    NOTE: Some of the following procedures are redundant to what is shown on Table 1. This is done to emphasize the importance of performing these procedures.

    • 3. Place the HP Desuperheater Spray Water Control Valve (LAE50 AA005, LAE50 AA002) in ‘AUTO’. Place the HP Desuperheater Spraywater Power Block Valve (LAE50 AA024, LAE50 AA001) in ‘AUTO’.

    B
    B

    NOTE: Although desuperheating is not required except at peak turbine load, it is good practice to have the con- trol station available whenever the unit is operating.

    • 4. Open and place the following Drain Valves in AUTO:

      • a. HP Superheater 1/2 Drain Isolation Valve (HAH52 AA202),

      • b. HP Superheater 3 Drain Isolation Valve (HAH51 AA202),

    Allow any condensate in these sections to drain.

    • 5. Prior to start up, reset the water level set points in the feedwater control sys- tem to ensure that the water levels in the HP Drum is just above the Cold Start-up NWL (see Table 2 for Drum Levels). Use the HP Evaporator (HAD50 AA209) Intermittent Blow-off Isolation Valves as necessary to reduce water levels.

    • 6. Close HP Feedwater Stop Valve (LAB96 AA051). Open the HP Feedwater Stop Fill Valve (LAB96 AA061) and open the HP Feedwater 30% Control Valve (HAC58 AA024) to allow for filling of the drum.

    7.

    Open

    the

    HP

    Main

    Steam

    Outlet

    Stop

    Valve

    (LBA51

    AA001,

    LBA51

    AA002 # )[Manual Valve] in order to warm up the piping downstream of ALSTOM Projects India Ltd scope.

    D
    D
    D B
    D
    B
    • 8. Open the HP Steam Startup Vent Isolation Valve (LBA51 AA211) and HP

    steam Startup vent MOV (LBA51 AA212). ‘AUTO’.

    This

    vent

    should

    be

    placed in

    • 9. If needed, restart condensate / feedwater pumps and ensure that pumps are running.

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    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

    OPERATING PROCEDURE

    • 10. Allow heated gas turbine exhaust flow to enter the HRSG by starting the gas turbine (Flame On).

    • 11. While the steam generator is being brought up to pressure, all cold steam piping should be gradually heated and drained of condensate. The HP Steam Startup Vent Valve (LBA51 AA211, LBA51 AA212) must stay opened to in- sure a positive flow of steam which will reduce thermal expansion.

    D
    D

    To warm the piping downstream of ALSTOM Projects India Ltd’s scope, open a drain or vent downstream of ALSTOM Projects India Ltd’s scope to allow the steam from the bypass valve to warm the piping. Ensure that all steam piping downstream of the boiler piping is drained prior to admitting steam.

    • 12. When a measurable HP steam flow is established (approximately 10% of full flow), the HP steam section is “on line” and the HP Main Steam Outlet Stop Valve (LBA51 AA001, LBA51 AA002 # )[Manual Valve] may be opened and the HP Startup Vent Valve (LBA51 AA211, LBA51 AA212) may be closed.

    D
    D

    NOTE: During startup or steam startup vent operation

    the HP system’s steam flow can be obtained from the

    HP Feedwater Flow HAC58 CF002).

    Transmitters (HAC58 CF001 and

    B
    B
    • 13. The water level set points in the feedwater control system for the HP Drum will return to the normal operating water level settings automatically when the respective system steam flow > 10%.

    Flowrates by Pressure Section (kg/s)

     

    Normal unfired Op. Setpoints (Case 6)

    Startup Setpoints

    Section

    100%

    < 10 %

    HP

    110.66

    11.066

    • 14. Open the following continuous blowdown isolation valves:

      • a. HP Drum Continuous Blowdown Isolation Valve (LCQ61 AA001).

    Blow down flow should be controlled with the following valves:

    • a. HP Drum Continuous Blowdown Metering Valve (LCQ61 AA002).

    START-UP FROM A WARM / HOT CONDITION

    This section describes the recommended procedure for starting the HRSG from a Warm / Hot condition, which is when the HP Drum Pressure (HAD50 CP003) > 1.72 barg (2.74 bara). Proceed as follows:

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    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

    OPERATING PROCEDURE

    • 1. Purge the HRSG in accordance with NFPA 85 dated 2004, Chapter 8.9.2 (Combus- tion Turbine Exhaust Systems) guidelines. It is understood that purging is accomplished by using air at ambient tempera- tures. The ambient air temperatures during a normal purge cycle will not have any damaging effect on any of the HRSG components.

    • 2. Align all HRSG valves as shown under the column labeled “START FROM WARM” on Table 1.

    NOTE: Some of the following procedures are redundant to what is shown on Table 1. This is done to emphasize the importance of performing these procedures.

    • 3. Place the HP Desuperheater Spray Water Control Valve (LAE50 AA005, LAE50 AA002) in ‘AUTO’. Place the HP Desuperheater Spray water Power Block Valve (LAE50 AA024, LAE50 AA001) in ‘AUTO’.

    NOTE: Although desuperheating is not required except at peak turbine load, it is good practice to have the con- trol station available whenever the unit is operating.

    • 4. Open and place the following Drain Valves in AUTO:

      • a. HP Superheater 1/2 Drain Isolation Valve (HAH52 AA202),

      • b. HP Superheater 3 Drain Isolation Valve (HAH51 AA202),

    Allow any condensate in these sections to drain.

    • 5. Prior to start up, reset the water level set points in the feedwater control sys- tem to ensure that the water levels in the HP Drum is just above the Cold Start-up NWL (see Table 2). Use the HP Evaporator (HAD50 AA209) Intermit- tent Blow-off Isolation Valves as necessary to reduce water levels.

    • 6. Open the HP Feedwater Stop Valve (LAB96 AA051).

    7.

    Open

    the

    HP

    Main

    Steam

    Outlet

    Stop

    Valve

    (LBA51

    AA001,

    LBA51

    AA002 # )[Manual Valve] in order to warm up the piping downstream of ALSTOM Projects India Ltd’s scope.

    • 8. Open the HP Steam Startup Vent Isolation Valve (LBA51 AA211) and the HP steam Startup vent MOV (LBA51 AA212). This vent should be placed in ‘AUTO’.

    • 9. If needed, restart condensate / feedwater pumps and ensure that pumps are running.

    10. Allow heated gas turbine exhaust flow to enter the HRSG by starting the gas turbine (Flame On).

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    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

    OPERATING PROCEDURE

    • 11. While the steam generator is being brought up to pressure, all colsteam piping should be gradually heated and drained of condensate. The HP Steam Startup Vent Valves (LBA51 AA211, LBA51 AA212) must stay opened to insure a positive flow of steam, which will reduce thermal expansion.

    To warm the piping downstream of ALSTOM Projects India Ltd’s scope, open a drain or vent downstream of ALSTOM Projects India Ltd’s scope to allow the steam from the bypass valve to warm the piping. Ensure that all steam piping downstream of the boiler piping is drained prior to admitting steam.

    D
    D
    • 12. When a measurable HP steam flow is established (approximately 10% of full flow), the HP steam section is “on line” and the HP Main Steam Outlet Stop Valve (LBA51 AA001, LBA51 AA002*)[Manual Valve] may be opened and the HP Startup Vent Valves (LBA51 AA211, LBA51 AA212) may be closed.

    NOTE: During startup or steam startup vent operation the HP system’s steam flow can be obtained from the HP Feedwater Flow Transmitters (HAC58 CF001, HAC58 CF002).

    D
    D
    • 13. The water level set points in the feedwater control system for the HP Drum will return to the normal operating water level settings automatically when the respective system steam flow > 10%.

    Flowrates by Pressure Section (kg/s)

     

    Normal Unfired Op. Setpoints (Case 6)

    Startup Setpoints

    Section

    100%

    > 10 %

    HP

    110.66

    11.066

    14. Open the following continuous blowdown isolation valves:

    • a. HP Drum Continuous Blowdown Isolation Valve (LCQ61 AA001).

    Blowdown flow should be controlled with the following valves:

    • b. HP Drum Continuous Blowdown Metering Valve (LCQ61 AA002).

    SUPPLEMENTARY FIRING SYSTEM

    This section describes the recommended procedure for start up and shut down of the Supplementary Firing system and its auxiliaries. Please refer An- nexure(08.0.0.1436.00, Part 8 – Operating Principles) to this document for operating principles of supplementary firing system.

    B
    B

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    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

    OPERATING PROCEDURE

    SECURING TO A WARM LAY-UP CONDITION

    SECURING

    TO

    WARM

    LAY-UP

    CONDITION

    WITHIN

    24

    HOURS

    IMMEDIATELY FOLLOWING THE GAS TURBINE SHUT DOWN.

    This section describes the recommended procedure for securing the HRSG to a warm lay-up condition. Proceed as follows:

    • 1. Prevent the gas turbine exhaust flow to the HRSG by shutting down the Gas Turbine to the HRSG.

    • 2. Align all HRSG valves as shown under the column labeled “SECURE TO

    WARM” on Table 1. closed:

    In particular, ensure that the

    following valves are

    a. HP Feed water Stop Valve (LAB96 AA051) and HP Feedwater Fill Valve (LAB96 AA061).

    b.

    HP

    Main Steam Outlet Stop Valve (LBA50 AA001, LBA50

    AA002 # )[Manual Valve].

    c. HP Drum Continuous Blowdown Isolation Valve (LCQ61 AA001).

    d.

    HP

    Feed

    Water

    AA002)[Manual Valve].

    Preheater Valves (LAA96 AA001,

    • 3. When the HP Drum Pressure (HAD50 CP003) falls below 1.72 barg (2.74 bara), the drum pressure may be allowed to decrease to atmospheric pressure by opening the HP Steam Startup Vent Valve (LBA51 AA212) or a nitrogen blanket may be maintained by opening the HP Nitrogen Stop Valve (HAD50 AA702).

    SECURING TO DRAIN (WITHOUT NITROGEN BLANKETING)

    This section describes the recommended procedure for securing the HRSG with- out nitrogen blanketing in order to drain the unit prior to performing maintenance. Proceed as follows:

    • 1. Prevent any gas turbine exhaust flow to the HRSG by shutting down the gas turbine.

    • 2. Align all HRSG valves as shown under the column labeled “SECURE TO

    DRAIN” on Tables 1. a. HP Feedwater Stop Valve (LAB96 AA051).

    b.

    HP Main Steam Outlet Stop Valve (LBA51AA001, LBA51

    AA002 # )[Manual Valve].

     

    c.

    HP

    Drum

    Continuous

    Blowdown

    Isolation

    Valve

    (LCQ61

    AA001).

     

    d.

    HP

    Feed

    Water

    Preheater Valves (LAA96 AA001,

    AA002)[Manual Valve].

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    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

    OPERATING PROCEDURE

    • 3. When the HP Drum Pressure (HAD50 CP003) falls to 1.72 barg (2.73 bara), open the HP Steam Startup Vent Valve (LBA50 AA212). These main steam vent valves must be opened before the associated drum pressure falls any lower to prevent a vacuum from developing that may cause leakage of the drum man way gaskets.

    • 4. When the HP Drum Pressure (HAD50 CP003) falls to 1.03 barg (2.04 bara), open the HP Superheater 1/2 and HP Superheater 3 Drain Isolation Valves (HAH52 AA201, HAH52 AA202, HAH51 AA201, HAH51 AA202). The drum pressure may be allowed to decrease to atmospheric pressure.

    • 5. The HRSG can be drained when it is completely cooled (when vapor no longer escapes from the vents).

    • 6. Open the vent valves and drain valves one heat exchanger section at a time to avoid overloading the drain discharge system downstream of the HRSG. Open the Blowdown Stop Valves if the blowdown lines are to be drained.

    CONTROLS AND INSTRUMENTATION

    Controls

    It is beyond the scope of this manual to discuss the design parameters and se- lection criteria of control systems. Instead, we will review the steam generator dynamics involved in tuning these systems and note problems we have found on actual operating units. When we discuss steam generator control, we are actually referring to the drum level controls; all other controls are supplied by others.

    The drum level controls will regulate the rate of feedwater flow to maintain a proper drum level throughout the operating range of the steam generator.

    To get maximum benefit from a three-element system, feedwater flow should be proportional to steam flow with reset action on drum level. This means that pounds of feedwater entering should always equal pounds of steam leaving, with periodic small corrections made to correct deviations from level set points. The best drum level control is achieved through mass flow balance.

    Instrumentation

    Even the most sophisticated and well-tuned control systems do not take the place of the judgment of an alert, motivated and trained operator. The only means that an operator has to make his judgments is through adequate and cali- brated instrumentation.

    SAFETY VALVES

    Safety valves serve to protect pressure vessels from overpressure. On superhea- ter outlets they serve the additional purpose of protecting the superheater from overheating in the event of a sudden interruption in steam consumption.

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    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

    OPERATING PROCEDURE

    The total relieving capacity of the safety valves on a boiler cannot be less than the de- sign steaming capacity. It is a Code requirement that one or more safety valves on the steam drum be set at or below the design pressure of the unit. Any economizer which can be isolated from the boiler must have its own safety valve. The discharge ca- pacity of any superheater safety valve or valves can be included in the total relieving ca- pacity of the boiler, provided there is no way to isolate the superheater. Valves are to be designed to operate without chattering and to obtain full lift at no more than 3% above their set pressure. Valves are to close within 4% of set pressure, but no less than 2% of set pressure.

    The popping point tolerance shall not exceed:

    • 0.14 barg (2 psig) for pressures up to 4.83 barg (70 psig).

    3% for pressures up to 20.68 barg (300 psig).

    • 0.69 barg (10 psig) for pressures up to 68.95 barg (1000 psig).

    1% for pressures over 68.95 barg (1000 psig).

    ALSTOM Projects India Ltd recommends that all safety valves be lifted to check popping pressure and blow down prior to annual maintenance outages. During these outages, valves that leaked or had a tendency to simmer or chatter should be disassembled and repaired. During valve testing, it is important to maintain drum level at or below normal water level to prevent water damage to drum valve seats and to prevent high solids boiler water from being drawn into superheaters.

    Any time a valve is disassembled, its seat should be touched up with a lap and 1000 grit-lapping compound. If the seat is in poor shape, use a carborundum disc first, then progressively finer grits.

    The following are safety tips and helpful hints:

    • 1. Never set safety valves by holding set pressure and lowering the popping pressure setting with a wrench. This is extremely hazardous. Valve setting changes should be made with the boiler pressure considerably lower than set point. After the wrench adjustment is made the lifting gear should be replaced and boiler pressure should be raised to the new popping point.

    • 2. Ring locking pins can vibrate loose when a valve is relieving. The pins should always be wired to each other except when one pin is removed to make a ring adjustment.

    • 3. Entrained water will cause excessive blowdown on drum valves. Set drum

    valves with the drum water level a few inches below normal water level, if possible.

    • 4. A rule of thumb: Vent pipes should be 50 mm (2 inches) larger in diameter

    than the valve discharge pipe.

    • 5. The discharge pipe should extend no more than 350 mm (14 inches) into

    the vent pipe from the bottom of the drip pan.

    • 6. A safety valve seat can be damaged by debris and water, which enters the valve

    body through the vent pipe. This debris is blown around when the valve lifts. Cover-

    ing the vent pipe with a plastic bag can eliminate the problem.

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    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048

    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

    OPERATING PROCEDURE

    • 7. It is occasionally necessary to mount a vent pipe rigidly to the discharge elbow. This should be done only when there is no alternative. Care should be taken that the vent pipe is cut off square, not on the bias.

    • 8. Do not exceed five pops on a valve. If more pops are required, allow valve to cool before proceeding.

    • 9. Do not make adjustments on first pop. Always evaluate the necessary ad- justment from two pops.

    • 10. When popping a valve, always have the cap and drop lever assembly in place with a rope affixed. If the valve begins to chatter, it can be manually popped before the seating surfaces are damaged.

    • 11. Observe the popping pressure on a suitable gauge mounted in the prox- imity of the valve being tested. A second gauge, preferably a dead weight gauge, should be used to validate the calibration of the observed gauge.

    EMERGENCY

    PROCEDURES

    High Water Level

    Abnormally high water levels should be avoided, as it may lead to carry-over and even priming.

    In the event of a high water level, there will be a high drum level alarm. Pro- ceed as follows:

    • 1. Isolate the feedwater supply for the appropriate drum using the HP Fe- edwater Control Valves (HAC58 AA004, HAC58 AA014 and HAC58 AA024) and HP Feedwater Stop Valve (LAB96 AA051) as required.

    B
    B
    • 2. Blowdown the appropriate drum until the water level is at the normal level. Use the HP Intermittent Blow-off Isolation Valve (HAD50 AA209) as re- quired. The Intermittent Blow-off Valves may be used when the HRSG is operating at any pressure in order to reduce the drum water level.

    • 3. Isolate the steam outlet for the appropriate drum using the HP Main

    Steam Outlet Stop Valve (LBA51 AA001, LBA50 AA002#)[Manual Valve] as required. Open Superheater Drain Valves for appropriate drum using HP Su- perheater Drain Isolation Valves (HAH52 AA202, HAH51 AA202) as appro- priate.

    • 4. If the HIGH HIGH HIGH alarm has not cleared within 2 minutes, initiate

    trip of gas turbine.

    • 5. Investigate the water conditions (alkalinity and solids).

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    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

    OPERATING PROCEDURE

    Low Water Level

    If the water level falls out of sight in the water gauge, due to failure of the fe- edwater supply or neglect of the operator, appropriate action should be taken at once. The only exception is in the case of momentary fluctuations that might occur with extraordinary changes in load. Any decision to continue to operate, even if only for a short time at a reduced rating, would have to be made by someone in authority who is thoroughly familiar with the circum- stances that led to the emergency and positively certain that the water level can be restored immediately without damaging the boiler. In the absence of such a decision:

    • 1. Isolate the steam outlet for the appropriate drum using the HP Main Steam Outlet Stop Valve (LBA51 AA001, LBA50 AA002 # )[Manual Valve] as required.

    • 2. If the condition has not been stabilized and gas turbine trip has been initi- ated, allow HRSG to cool so that it may be inspected for damage if re- quired. After correcting the cause, the unit may be restarted.

    ALSTOM Projects India Ltd. Contract Name: Fujairah II Contract No.: PB0048 Item No.: 19.02 Rev.

    CAUTION: Do not attempt to add water until the steam generator has cooled down sufficiently to where the drum metal temperatures are within 56°C (100°F) of the feedwater temperature; otherwise, damage may result due to relatively cool water coming in contact with heated pressure parts.

    Tube Failure

    • 1. Immediately secure the gas turbine exhaust flow.

    • 2. Secure unaffected sections of HRSG according to “Securing to Warm

    Lay-up Condition” instructions.

    • 3. Isolate and drain affected sections of HRSG according to “Securing to

    Drain” instructions.

    Loss of Feedwater Supply

    The loss of feedwater supply is a rare occurrence in a properly maintained steam plant. However, loss of the feedwater supply can happen and it is to be treated as an extreme emergency.

    A steady persistent drop in the steam drum level indicates problems with the feed pump, feed pump recirculation control, steam generator feedwater valve control or a tube leak. By quickly comparing system pressures and flows with data taken at comparable loads during normal operation, the operators should be able to identify the problem area.

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    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

    OPERATING PROCEDURE

    If feedwater flow is increasing relative to steam flow and the drum water level is still falling, a tube leak can be assumed. Secure the gas turbine ex- haust flow and proceed with tube failure emergency procedures (see Emer- gency Procedures – Tube Failure section for details).

    For the HP Drum, an alarm will sound when the drum water goes to the low

    level.

    At the low low HP Drum level the gas turbine exhaust flow should be

    secured.

    If the problem is with the feed pump or controls, restrict steam generator steam flow to balance the ability of the crippled feedwater system to maintain drum level.

    If it is not possible to stabilize drum levels by reducing load, secure the gas turbine exhaust flow and bottle up the steam generator, keeping all vents closed. When the feedwater system is repaired, restart the unit as detailed under the procedure titled “Start-Up From A Warm Condition”.

    In any case, the first consideration must be the protection of the steam gen- erator pressure parts from operation with low water.

    As is true of any emergency situation with a steam plant, events do not al- ways follow an orderly pattern. The procedures above may or may not fit the pattern for every circumstance. The intent is to emphasize what should be done in order to protect the steam generator and bring the plant back in op- eration as soon as possible.

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    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

    OPERATING PROCEDURE

    Table 1 – Valve Alignment: High Pressure Section

       

    START

    START

    NORMAL

    SECURE

    SECURE

    VALVE TAG

    FROM

    FROM

    OPERATION

    TO

    TO

    DESIGNATION

    VALVE DESCRIPTION

    COLD

    WARM

    WARM

    DRAIN

    11LAA96 AA001

    HP Feed Water Preheater inlet

    Closed

    Closed

    Open

    Closed

    Closed

    11LAA96 AA002

    HP Feed Water Preheater Outlet

    Closed

    Closed

    Open

    Closed

    Closed

    11LAA96 AA251

    HP Feed Water Preheater inlet

    Closed

    Closed

    Closed

    Closed

    Closed /

    11LAA96 AA252

    Line Drain Valves

    Open*

    11HAC10 AA201

    HP Feed Water Preheater Vent

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC10 AA202

    Valves

    Open*

    11HAC10 AA203

    11HAC10 AA204

    11HAC10 AA208

    11HAC10 AA209

    11HAC10 AA210

    11HAC10 AA211

    11HAC10 AA212

    11HAC10 AA213

    11HAC10 AA214

    11HAC10 AA215

    11HAC10 AA205

    HP Feed Water Preheater Drain

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC10 AA206

    Valves

    Open*

    11HAC10 AA207

    11LAA96 AA253

    HP Feed Water Preheater Outlet

    Closed

    Closed

    Closed

    Closed

    Closed /

    11LAA96 AA254

    Line Drain Valves

    Open*

    11LAB96AA051

    HP Feedwater Stop Valve

    Closed /

    Closed /

    Open / Auto

    Closed /

    Closed /

    Auto

    Auto

    Auto

    Auto

    11LAB96AA061

    HP Feedwater Stop BYPASS MOV Valve

    Open

    Open

    Open

    Open

    Open

    11LAB96AA251

    HP Feedwater Inlet Drain Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11LAB96AA252

    Open*

    11LAB96AA253

    11LAB96AA254

    11HAC53 AA241,

    HP Economizer 6 Drain Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC53 AA242,

    Open*

    11HAC53 AA251

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    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

    OPERATING PROCEDURE

    11HAC53 AA201,

    HP Economizer 6 Vent Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC53 AA202,

    Open*

    11HAC53 AA211,

    11HAC53 AA212,

    11HAC53 AA221,

    11HAC53 AA222,

    11HAC53 AA231,

    11HAC53 AA232,

    11HAC53 AA261,

    11HAC53 AA262

    11HAC54 AA241,

    HP Economizer 5 Drain Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC54 AA242,

    Open*

    11HAC54 AA251

    11HAC54 AA211,

    HP Economizer 5 Vent Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC54 AA212, 11HAC54 AA221, 11HAC54 AA222, 11HAC54 AA231, 11HAC54 AA232, 11HAC54 AA201, 11HAC54 AA202

    Open*

    11HAC55 AA241,

    HP Economizer 4 Drain Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC55 AA242,

    Open*

    11HAC55 AA251

    11HAC55 AA211,

    HP Economizer 4 Vent Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC55 AA212,

    Open*

    11HAC55 AA221,

    11HAC55 AA222,

    11HAC55 AA231,

    11HAC55 AA232,

    11HAC55 AA201,

    11HAC55 AA202

    11HAC56 AA241,

    HP Economizer 3A/3B Drain

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC56 AA242,

    Valves

    Open*

    11HAC56 AA251

    11HAC56 AA211,

    HP Economizer 3A/B Vent Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC56 AA212,

    Open*

    11HAC56 AA221,

    11HAC56 AA222,

    11HAC56 AA231,

    11HAC56 AA232,

    11HAC56 AA201,

    11HAC56 AA202

    11HAC57 AA241,

    HP Economizer 2 Drain Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC57 AA242, 11HAC57 AA251

    Open*

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    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

    OPERATING PROCEDURE

    11HAC57 AA211,

    HP Economizer 2 Vent Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC57 AA212,

    Open*

    11HAC57 AA221,

    11HAC57 AA222,

    11HAC57 AA231,

    11HAC57 AA232,

    11HAC57 AA201,

    11HAC57 AA202

    11HAC58 AA241,

    HP Economizer 1 Drain Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC58 AA242,

    Open*

    11HAC58 AA251

    11HAC58 AA201,

    HP Economizer 1 Vent Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAC58 AA202,

    Open*

    11HAC58 AA211,

    11HAC58 AA212

    11HAC58 AA001,

    HP Feedwater CV Isolation Valves

    Open

    Open

    Open

    Open

    Open

    11HAC58 AA011,

    11HAC58 AA021,

    11HAC58 AA005,

    11HAC58 AA015,

    11HAC58 AA025,

    11HAC58 AA007

    11HAC58 AA261,

    HP Feedwater CV Drain Valves

    Closed

    Closed

    Closed

    Closed

    Closed

    11HAC58 AA262,

    11HAC58 AA263,

    11HAC58 AA264

    11HAC58 AA265,

    11HAC58 AA266,

    11HAC58 AA267,

    11HAC58 AA268

    11HAC58AA004,

    HP Feedwater Control Valve

    Closed /

    Closed /

    Auto

    Closed /

    Closed /

    11HAC58AA014,

    Auto

    Auto

    Auto

    Auto

    11HAC58AA024

    11HAC58AA003

    HP Feedwater CV Stop Valve

    Open

    Open

    Open

    Open

    Open

    11LCQ61AA001

    HP Drum Continuous Blowdown

    Closed /

    Closed /

    Open / Auto

    Closed /

    Closed /

    Isolation MOV Valve

    Auto

    Auto

    Auto

    Auto

    11LCQ61AA002

    HP Drum Continuous Blowdown Metering Valve

    Open

    Open

    Open

    Open

    Open

    11HAD50AA201

    HP Evaporator Drain Isolation Valve

    Closed

    Closed

    Closed

    Closed

    Open

    11HAD50AA202

    HP Evaporator Drain Isolation

    Closed

    Closed

    Closed

    Closed

    Closed /

    Valve

    Open*

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    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 DocumentType: E

    OPERATING PROCEDURE

    11HAD50AA208

    HP Evaporator Intermittent Blowoff Valve

    Open

    Open

    Open

    Open

    Open

    11HAD50AA209

    HP Evaporator Intermittent Blowoff

    Closed /

    Closed /

    Closed / Auto

    Closed /

    Closed /

    Isolation Valve

    Auto

    Auto

    Auto

    Auto

    11HAD52AA201,

    HP Drum Outlet Vent Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAD52AA202

    Open*

    11HAD50AA702

    HP Nitrogen Feed Stop Valve

    Closed

    Closed

    Closed

    Closed

    Closed

    11HAH51AA201

    HP Superheater 3 Drain Isolation Valve

    Open

    Open

    Open

    Open

    Open

    11HAH51AA202

    HP Superheater 3 Drain Isolation

    Closed /

    Closed /

    Closed / Auto

    Closed

    Closed /

    Valve

    Auto

    Auto

    Open*

    11HAH52AA201

    HP Superheater 1/2 Drain Isolation Valve

    Open

    Open

    Open

    Open

    Open

    11HAH52AA202

    HP Superheater 1/2 Drain Isolation

    Closed /

    Closed /

    Closed / Auto

    Closed

    Closed /

    Valve

    Auto

    Auto

    Open*

    11HAH51AA250,

    HP Superheater 2/3 Vent Valves

    Closed

    Closed

    Closed

    Closed

    Closed /

    11HAH51AA251

    Open*

    11LBA51AA211

    HP Steam Startup Vent Isolation

    Closed

    Closed

    Closed / Auto

    Closed /

    Closed /

    Valve (M)

    Open**

    Open**

    11LBA51AA212

    HP Steam Startup Vent MOV

    Closed /

    Closed /

    Closed / Auto

    Closed /

    Closed /

    Valve

    Auto

    Auto

    Open**

    Open**

    11LAE50AA001,

    HP Desuperheater Spraywater

    Closed /

    Closed /

    Auto

    Closed

    Closed

    11LAE50AA024

    Power Block Valve

    Auto

    Auto

    11LAE50 AA201,

    HP Desuperheater Spraywater

    Closed

    Closed

    Closed

    Closed

    Closed

    11LAE50 AA202,

    Drain Valves

    11LAE50 AA203,

    11LAE50 AA204

    11LAE50 AA003,

    HP Desuperheater Spraywater CV

    Open

    Open

    Open

    Open

    Open

    11LAE50 AA006

    Isolation Valves

    11LAE50AA002,

    HP Desuperheater Spraywater

    Closed /

    Closed /

    Auto

    Closed /

    Closed /

    11LAE50AA005

    Control Valve

    Auto

    Auto

    Auto

    Auto

    11LBA51AA001,

    HP Steam Outlet Stop Valve

    Closed

    Closed

    Open

    Closed

    Closed

    11LBA51AA002

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    Item No.: 19.02 Rev. No.: D Date: 20 Feb 09 Document Type: E

    OPERATING PROCEDURE

    11LBA51AA222

    HP DSH Outlet Drain ISV MOV

    Closed /

    Closed /

    Closed / Auto

    Closed

    Closed /

    Auto

    Auto

    Open*

    11LBA51 AA221

    HP Steam Outlet Drain

    Closed

    Closed

    Closed

    Closed

    Closed

    #

    *

    **

    Open applies to after the drum pressu re falls below 0.5 barg (1.51 bara) and HRSG is completely cooled (when vapor no longer escapes from the vents.).

    Open applies to after the drum pressure falls below 1.72 barg (2.74 bara).

    Not Applicable to HRSG-21

    Table 2 – HP Drum Level Setpoints

    D
    D
     

    Drum Level Setpoints for 1981 mm (78 inch) ID HP Drum

    Cold Start-up Setpoints [P drum < 1.72 barg (2.73 bara)]

    Normal Operating Setpoints

    Level

    Value

    Level

    [P drum > 55.4 barg (56.4bara)] Value

    HHH[MAX3]

    +330 mm (+13 in)

    HHH[MAX3]

    +330 mm (+13 in)

    HH[MAX2]

    +279 mm (+11 in)

    HH[MAX2]

     

    H[MAX1]

    +228mm (+9 in)

    H[MAX1]

    +279 mm (+11 in) +228mm (+9 in)

    NWL

    -711 mm (-28 in)

    NWL

     

    L[MIN1]

    -762 mm (-30 in)

    L[MIN1]

    +102 mm (+4 in) -102 mm (-4 in)

    LL[MIN2]

     

    LL[MIN2]

     

    LLL[MIN3]

    -813 mm (-32 in) -864 mm (-34 in)

    LLL[MIN3]

    -787 mm (-31 in) -864 mm (-34 in)

    Levels are referenced to drum centerline.

    Dimensions are in inches and millimeters.

    Drum level setpoints will be determined based on drum pressure. An HP Drum

    Pressure (HAD50 CP003) < 1.72 barg (2.73 bara) will utilize Cold Startup Set- points. An HP Drum Pressure between 1.72 barg (2.73 bara) and 55.4 barg (56.4 bara) will utilize a linear function of determining the set points. An HP drum pressure> 55.4 barg (56.4 bara) will utilize Normal Operating setpoints. Field tuning of startup setpoints is permissible.

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    OPERATING PROCEDURE

    ANNEXURE

    SUPPLEMENTARY FIRING SYSTEM OPERATING PRINCIPLES

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    FUJAIRAH II – O & M MANUAL

     

    08.0.0.1436.00

    Date: 2009/01/12

    PART 8 - OPERATING PRINCIPLES

    Rev. 5 - 2/21

     
       

    PART 8 OPERATING PRINCIPLES

       

    GRC DUAL FUEL FIRED INDUCT BURNER

    (Refer to the P&I Diagrams N° FUJ/00/M/H----A30/FD/005 &

     

    FUJ/00/M/H----A30/FD/007)

    C O N T E N T S

     
    • 1. SUBJECT

     

    3

    • 2. SAFETY DEVICES AND OPERATION SEQUENCES

     

    3

    • 2.1. Safety devices

     

    3

    • 2.1.1. GT/HRSG main safety devices

     

    3

    • 2.1.2. Measurement main safety devices

    4

    • 2.1.3. Burner safety devices

     

    4

    • 2.2. purge

     

    7

    • 2.2.1. HRSG (turbine) PURGE

     

    7

    • 2.2.2. Duct burner purge

     

    7

    • 2.3. Operator Interface

    8

    • 2.4. Cooling air fan sequences (switch-over logic)

     

    9

    • 2.5. AUGMENTING AIR FAN

     

    9

    • 2.6. DIESEL OIL BOOSTER PUMPS sequences (switch-over logic)

    10

    • 2.7. Diesel oil sequence

     

    10

    • 2.7.1. Prior to ignition:

    10

    • 2.7.2. Burner ignition sequence

     

    11

    • 2.7.3. Burner shut-down sequences

    13

    • 2.7.4. Diesel oil gun cleaning sequence

    15

    • 2.8. Natural gas sequence

     

    16

    • 2.8.1. Burner ignition sequence

     

    16

    • 2.8.2. Shut-Down NG burner head

    19

    • 2.9. Automatic change-over sequence

    20

    • 2.9.1. Change-over from natural gas to diesel oil

    20

    • 2.9.2. Change-over from diesel oil to natural gas

    21

    2.10.

    Interface between BMS and DCS (hardwired signals)

     

    21

    • 3. BURNER LOAD CONTROL

     

    21

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    FUJAIRAH II – O & M MANUAL

    08.0.0.1436.00

    PART 8 - OPERATING PRINCIPLES

     

    Date: 2009/01/12

    Rev. 5 - 3/21

    1.

    SUBJECT

    This technical instruction specifies the general operating conditions for a dual fuel fired GRC LOW NOx Induct Burner installed in an exhaust gas duct, upstream to a Heat Recovery Steam Generator (HRSG). The dual fuel fired GRC LOW NOx Induct Burner consists of twelve (12) "GR" type Burner heads, mounted and firing horizontally with natural gas (NG) or diesel oil (DO). The operating mode is the post-combustion mode only.

    The design code is NFPA 85, 2004 edition. Additional client requirement:

     

    The client has requested a remote burner start-up or shut-off from the DCS or from the BMS.

     

    The igniters operate intermittently with each fuel; each igniter flame is detected by its own built-in flame detection system. Each "GR" type burner head flame is detected by 2 (UV) flame scanners both for NG and DO operation.

    This document focuses on defining the control and operating principles of the heating equipment, and should therefore be considered as an explanatory basic description for the purposes of design and manufacture of automation equipment. It is not an operating manual, and should not be considered as a substitute for the operating guide of the generator assembly, nor as instructions for commissioning of the generator assembly.

    OPERATING PRINCIPLE

     

    Post-combustion mode

    The gas turbine and duct burner are in operation. The duct burner increases the temperature of the gas turbine exhaust gas Except during the light off, the burner is normally in operation with the 12 heads.

     

    2.

    SAFETY DEVICES AND OPERATION SEQUENCES

    2.1.

    SAFETY DEVICES

    Burner ignition and shut-down sequences, and burner protection logic are ensured by a "fail-safe" programmable logic controller (PLC).

    To increase availability, the PLC is fitted with redundant CPU, redundant communication cards, redundancy of discrete safety I/O cards (except for lamps) , redundant 24VDC power supplies, and each pressure safety device (for DO, NG, cooling air and atomizing steam) is treated by the BMS in a 2 out of 3 voting logic system.

    A manual fault reset on the BMS cabinet front façade is needed to allow a new burner ignition sequence after a burner trip.

    In the following safety devices description, a "valve position discrepancy" means that the limit switch(es) fitted to the valve does not indicate the position -digital status- required regarding to the ON/OFF valve control signal.

     

    2.1.1. GT/HRSG main safety devices

    The protection logic system is to be made by DCS. These safety devices shut-down the burner or prevent it from igniting; they are gathered via three logic information (in a 2 out of 3 voting logic system):

     

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    08.0.0.1436.00 FUJAIRAH II – O & M MANUAL PART 8 - OPERATING PRINCIPLES Rev. 5 -
    08.0.0.1436.00
    FUJAIRAH II – O & M MANUAL
    PART 8 - OPERATING PRINCIPLES
    Rev. 5 - 4/21
    Date: 2009/01/12
    o
    Burner trip
    This information must include the following safety devices:
    Turbine running with sufficient load
    Emergency stop
    2.1.2. Measurement main safety devices
    The protection logic system is to be made by CCS
    The burner trip from the CCS must include the following devices:
    DO flow (11HJF10 CF001) or pressure (11HJF10 CP001) transmitters bad signal (only when burners are
    lightening with DO)
    Atomizing steam pressure (11HJM10 CP001 and CP002) transmitters bad signal (only when burners are
    lightening with DO)
    NG flow (11HJG10 CF001), pressure (11HJG10 CP001) or temperature (11HJG10 CT001) transmitters
    bad signal (only when burners are lightening with NG)
    Augmenting air flow (11HJL10 CF001) transmitter bad signal
    Cooling air pressure (11HJQ10 CP001) transmitter bad signal
    2.1.3. Burner safety devices
    The burner protection logic is ensured by the BMS supplied by Fives Pillard.
    The burner safety devices consist of the following:
    2.1.3.1. Ignition main safety devices
    (refer to the P&I Diagram FUJ/00/M/H----A30/FD/007)
    -
    Ignition gas shut-off valves position discrepancy of the main ignition gas line (11HJA10 CG081 & CG84),
    -
    Ignition gas vent valve position discrepancy (11HJA10 CG082/CG083),
    -
    Ignition gas purge valve position discrepancy (11HJA10 CG085),
    -
    Loss of ignition gas pressure (11HJA10 CP801) checked after the opening of the ignition gas shut-off valves
    (with 2 seconds time delay),
    -
    Excess of ignition gas pressure (11HJA10 CP802) checked after the opening of the ignition gas shut-off
    valves (with 2 seconds time delay).
    These safety devices prevent all igniters and burner heads from igniting (with NG or DO) and generate:
    A shut-down of burner heads igniting sequences,
    A shut-down of do burner heads cleaning sequences,
    An alarm signal if burner heads were firing with GN or DO,
    A safety signal if burner heads were on light off sequence.
    2.1.3.2. Ignition safety devices for each igniter
    (refer to the P&I Diagram FUJ/00/M/H----A30/FD/005)
    -
    Ignition gas individual shut-off valve position discrepancy of each igniter (CG081, lines HJA11 to HJA62),
    -
    Igniter flame detected before ignition (ionization) (CR001, lines HJA11 to HJA62),
    -
    Igniter flame not detected during ignition (ionization): (CR001, lines HJA11 to HJA62),
    These safety devices prevent each igniter and associated burner head from igniting and generate:
    An igniter shut-down,
    A shut-down of DO burner head cleaning sequence,
    An alarm signal if burner head was firing with NG or DO.
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    08.0.0.1436.00

    PART 8 - OPERATING PRINCIPLES

     

    Date: 2009/01/12

    Rev. 5 - 5/21

    2.1.3.3. Diesel oil main safety devices (refer to the P&I Diagram FUJ/00/M/H----A30/FD/007)

     
    • - Loss of DO pressure at the inlet of main DO valve train (with 2 seconds time delay) obtained with a 2 out of 3 voting system between 11HJF10 CP801, CP802 and CP803 pressure switches (PSL)

    • - Loss of atomizing steam pressure of the main atomizing line, obtained with a 2 out of 3 voting system between 11HJM10 CP801, CP802 and CP803 pressure switches (PSL),

    • - Loss of DO pressure downstream to the flow control valve, checked after the opening of the main shut-off valve (with time delay to be adjusted during commissioning) obtained with a 2 out of 3 voting system between 11HJF10 CP804, CP805 and CP806 pressure switches (PSL),

    • - Excess of DO pressure downstream to the flow control valve, checked after the opening of the main shut-off valve (with time delay to be adjusted during commissioning) obtained with a 2 out of 3 voting system between 11HJF10 CP807, CP808 and CP809 pressure switches (PSH)

    • - DO flow control valve (11HJF10 AA101)ignition position discrepancy (i.e. the valve is not positioned at its ignition position prior to and during ignition of the first two burner heads) 11HJF10 CG082 ,

    • - DO accumulator isolating valve (11HJF10 AA152) position discrepancy (i.e. the valve is not closed before ignition of the 1 st burner head couple (11HJF10 CG083) NOTE: an alarm signal is generated in case of closure of the valve after ignition of the 1 st burner head couple.

    • - DO main shut-off valve (11HJF10 AA151) position discrepancy, 11HJF10 CG081,

     
    • - DO flow or DO pressure transmitters bad signal 11HJF10 CF001 or 11HJF10 CP001, safety device generated in the CCS,

    • - Loss or excess of DO pressure during start-up under pressure control loop (threshold on the pressure transmitter 11HJF10 CP001, safety device generated in the CCS),

    • - Loss of CCS watchdog,

    • - DO individual burner head shut-off valve closing position discrepancy

     

    Concerning loss of NG safety devices when burner heads are firing with DO:

     
    • - NG vent valve (11HJG10 AA152) position discrepancy (.i.e. the limit switches fitted to this valve do not indicate the opening position required when the burner is operated with DO) 11HJG10 CG083 & CG084,

    • - One NG main shut-off valve (11HJG10 AA151 or AA153) discrepancy (i.e. the limit switches fitted to this valve do not indicate the closure position required) 11HJG10 CG082 or CG085.

    These safety devices causes a burner shut-down (of the 12 burner heads) if DO was fired, or prevent it from igniting with DO.

    Note 1:

    These safety devices are not active if the NG manual isolating valve (11HJG10 AA001) is closed (11HJG10 CG080)

    Note 2:

    Upon condition there is no position discrepancy for NG main shut-off valves (11HJG10 AA151 or AA153) and vent valve (11HJG10 AA152), one or more NG individual burner head shut-off valve closing position discrepancy (closure position required) only generates an alarm.

    2.1.3.4. Diesel oil safety devices for each burner head

     

    There are 2 groups of safeties:

    Group 1:

    • - DO individual burner head shut-off valve (AA151, lines HJF11 to HJF62) opening position discrepancy (CG081, lines HHF11 to HHF62).

    • - Flame detected before ignition (CR001 or CR002 lines HJQ11 to HJQ62).

     
    • - Flame not detected after ignition (CR001 and CR002 lines HJQ11 to HJQ62). Group 2 :

    • - Atomizing steam individual burner head manual valve (AA001 line HJM11 to HJM62) position discrepancy (CG081, lines HJM11 to HJM62).

    • - Atomizing steam individual burner head automatic shut-off valve (AA151 line HJM11 to HJM62) position discrepancy (CG082, lines HJM11 to HJM62).

    • - Cleaning individual burner head shut-off valve (AA152 line HJM11 to HJM62) position discrepancy (CG083, lines HJM11 to HJM62).

     

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    These 2 groups of safeties devices cause a shutdown of each considered head during DO firing, or prevent it from igniting with DO. Group 1 prevents to start the 1 st couple heads and reset purge if problems occurred when purging or after purging.

     
    • 2.1.3.5. Natural gas main safety devices

    -

    Loss of NG pressure at the inlet of main NG valve train (with 2 seconds time delay) obtained with a 2 out of 3 voting system between HJG10 CP801, CP802 and CP803 pressure switches (PSLL),

    -

    Loss of NG pressure downstream to the flow control valve, checked after the opening of the main shut-off valves (with time delay to be adjusted during commissioning) obtained with a 2 out of 3 voting system between HJG10 CP804, CP805 and CP806 pressure switches (PSL),

    -

    Excess of NG pressure downstream to the flow control valve checked after the opening of the main shut-off valves (with time delay to be adjusted during commissioning) obtained with a 2 out of 3 voting system between HJG10 CP807, CP808 and CP809 pressure switches (PSH),

    -

    NG main shut-off valves (HJG10 AA151 & 153) position discrepancy for the upstream or downstream shut- off valves (HJG10 CG082 & CG085) limit switches (ZSC),

    -

    NG main vent valve (HJG10 AA152) position discrepancy (HJG10 CG083 & CG084) limit switches (ZSC & ZSO),

    -

    NG manual vent valve(HJG10 AA501) position discrepancy (HJG10 CG081) limit switch (ZSC),

     

    -

    NG purge valve (HJG10 AA154) position discrepancy (HJG10 CG087) limit switch (ZSC),

    -

    NG flow control valve (HJG10 AA101) position discrepancy (i.e. the valve is not positioned at its ignition position prior to and during ignition of the first two heads) HJG10 CG086 limit switch (ZSC),

    -

    NG flow transmitter HJG10 CF001 bad signal (safety device generated in the CCS),

     

    -

    Loss or excess of NG pressure during start-up under pressure control (threshold on the pressure transmitter HJG10 CP002, safety device generated in the CCS).

    -

    NG individual burner head shut-off valve (AA151, line HJG11 to HJG62) closing position discrepancy (CG081, line HJG11 to HJG62) limit switches (ZSC).

    Concerning loss of DO safety devices when burner heads are firing with NG:

     

    -

    A DO main shut-off valve closing position discrepancies (CG081 line HHF10) causes a burner shut-down (of all burner heads in operation).

    -

    The closing position discrepancy of one or more DO individual shut-off valve prevents the burner from igniting with NG, generates an alarm signal and causes a burner shut-down (of all burner heads in operation) after a time delay (5 minutes) if the burner was in operation with NG.

    These safety devices cause a burner shut-down (of the 12 burner heads) during NG firing, or prevent it from igniting with NG.

    Note :

     

    These safety devices are not active if the two DO booster pumps (HJF01 AP001 & AP002) are not

    running.

    • 2.1.3.6. Natural gas safety devices for each burner head

     

    -

    NG individual burner head shut-off valve (AA151 line HJG11 to HJG62) opening position discrepancy (CG081, line HJG11 to HJG62) limit switches (ZSC),

    -

    Flame detected before ignition: CR001 or CR002 line HJQ11 to HJQ62,

    -

    Flame not detected after ignition: CR001 and CR002 line HJQ11 to HJQ62,

     

    These safety devices cause a shut-down of each considered burner head during NG firing, or prevent it from

     

    igniting with NG.

    • 2.1.3.7. Main safety devices

    -

    Conditions see § 2.1.1,

    -

    Conditions see § 2.1.2,

    -

    Emergency shut-down,

     

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    • - Loss of instrument air pressure obtained with a 2 out of 3 voting system between HNX10 CP801, CP802 and CP803 (see P&I Diagram No FUJ/00/M/H----A30/FD/007) pressure switches (PSLL),

    • - Loss of cooling air pressure, obtained with a 2 out of 3 voting system between HJQ10 CP801, CP802 and CP803, line HJQ10 (with time delay to be adjusted during commissioning of the installation) (see P&I Diagram No FUJ/00/M/H----A30/FD/007) pressure switches (PSL).

    • - Loss of augmenting air pressure, obtained with a 2 out of 3 voting system between HJL10 CP801, CP802 and CP803, line HJL10 (with time delay to be adjusted during commissioning of the installation) (see P&I Diagram No FUJ/00/M/H----A30/FD/007) pressure switches (PSL).

    These safety devices generate a burner shut-down (12 heads) or prevent it from igniting (with NG or DO).

    AFTER EACH SHUT DOWN CAUSED BY A SAFETY, THE BURNERS NEED TO BE ACKNOWLEDGED (ON BMS PANEL OR BURNER LOCAL CONTROL BOX) AND RESTART LOCALLY. IT IS IMPOSSIBLE TO START A TRIPPED BURNER FROM THE DCS.

    2.2.

    PURGE

    2.2.1. HRSG (turbine) PURGE

    The HRSG purge sequence makes sure that the exhaust gas path of the process is free from gaseous or suspended flammable matter prior to turbine ignition.

    Purge conditions of the HRSG are performed by the DCS. The turbine purge is made to ensure at least five (5) volume changes of the HRSG enclosure (total volume of the physical boundary of ductwork from the inlet of turbine to portion of the HRSG where the combustion turbine exhaust gas temperature is reduce to at least 56°C below the lowest auto ignition temperature of the gas. The augmenting air plenum and associated ductwork shall also be purge into the HRSG enclosure. Prior to make the turbine purge, the operator must manually start the cooling air fan system. As the cooling air flow through the augmenting air plenum is up to 25% of the full flow of the augmenting air, the BMS end to the DCS "GT purge permissive". At this moment, the DCS can start the turbine purge. A burner purge shall be accomplished before each 1 st burner head couple ignition.

    The burner purge control is made by the BMS. Information “HRSG purge completed” is send from the BMS to the DCS to confirm that the burner purge has been realized according to NFPA 85 2004 requirements and to allow a burner start.

     

    2.2.2. Duct burner purge

    The burner purge sequence makes sure that the exhaust gas path of the process is free from gaseous or suspended flammable matter prior to burner ignition.

    Purge may be performed once the safety devices and checks listed in §. 2.1 have been carried out. The purge conditions of the duct burner are performed by the GT. The gas turbine must therefore be operating at insufficient load to ensure that the TEG rate is sufficient for adequate purging (combustion turbine exhaust gas at not less then 25% of full load mass flow rate). The burner purge is made to ensure at least eight (8) volume changes of the HRSG enclosure (total volume of the physical boundary of ductwork downstream of burner + all steam generator pressure parts + flue gas path downstream of HRSG to stack inlet). The augmenting air plenum and associated ductwork shall also be purge into the HRSG enclosure. As the cooling air flow through the augmenting air plenum is up to 25% of the full flow of the augmenting air, the BMS send to the DCS "GT purge permissive". At this moment, the DCS can start the turbine purge. A burner purge shall be accomplished before each 1 st burner head couple ignition.

     

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    The burner purge control is made by the BMS. Information “HRSG purge completed” is send from the BMS to the DCS to confirm that the burner purge has been realized according to NFPA 85 2004 requirements and to allow a burner start.

    2.3.

    OPERATOR INTERFACE

    The operator has, on the front door of the BMS cubicle (located into the air conditioned container) the following items to start the sequences:

    1 Emergency shut-down push button

    1 push button "Failure reset"

    1 push button "Lamp test"

    1 push button "Horn reset"

    1 illuminated push button "DO selection"

    1 illuminated push button "NG selection"

    1 three positions switch (with key) "BMS/Local/DCS"

    1 Human Machine Interface (H.M.I.)

    1 lamp "400 VAC power on"

    1 lamp "230 VAC UPS 1 power on"

    1 lamp "230 VAC UPS 2 power on"

    1 lamp "110 VDC UPS power on"

    1 lamp "24 VDC UPS power on – Emergency stop"

    1 lamp "24 VDC UPS power on – BMS"

    1 lamp "24 VDC UPS power on – CCS"

    1 lamp "Igniter fault"

    1 lamp "Alarm"

    1 lamp "Main flame fault"

    1 lamp "Main failure"

    1 lamp "Ignition gas valves discrepancy"

    1 lamp "Ignition gas pressure fault"

    1 lamp "cooling air system fault"

    1 lamp "augmenting air fault"

    1 alarm and safety horn

    For DO sequences:

    • - 1 illuminated push button "Diesel oil burner stop "

    • - 1 illuminated push button "Diesel oil burner start-up"

    • - 1 lamp "Atomizing, cleaning, DO shut-off valves discrepancy"

     
    • - 1 lamp "DO pressure fault"

    For the NG sequences:

    • - 1 illuminated push button "Natural gas burner stop "

    • - 1 illuminated push button " Natural gas burner start-up"

    • - 1 lamp "NG shut-off valves discrepancy"

    • - 1 lamp "NG pressure fault"

    For CCS :

    • - 1 10" touch panel

    Note 2:

    Twelve local control boxes are also provided to allow local start, stop, cleaning sequences of each burner head.

    Each local control box is fitted with:

     

    1 push button "priority stop"

    1 push button "Burner head start-up"

    1 push button "Burner head stop"

    1 push button "Burner head start-up cleaning sequence"

     

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    1 push button "Lamp test"

    1 lamp "Burner head in operation with NG"

    1 lamp "Burner head in operation with DO"

    1 lamp "Ready to start"

    1 lamp "Burner head cleaning sequence in progress"

    1 lamp "Igniter in operation"

    Note 1: the fuel is selected with the two illuminated push buttons "Diesel oil selection" or "Natural gas selection" on the BMS cubicle.

    Note 2:

    Lamps and push buttons on the BMS cubicle are provided to allow the burner start-up in case of a H.M.I. failure.

    • 2.4. COOLING AIR FAN SEQUENCES (SWITCH-OVER LOGIC)

     

    The operator has, on the HMI dedicated to the BMS , the following items to start the cooling air fan sequences:

    1 two position switch "Maintenance/Backup"

    And for each fan:

    1 Push button "Start fan"

    1 Push button "Stop fan"

    1 Lamp "Fan ON"

    1 Lamp "Fan Fault"

    Before transfer of TEG through the duct, the operator must check that all manual isolating valves on cooling air lines are open and must start-up one cooling air fan to protect burner heads, burner igniters, and flame scanners.

    When "Backup" mode is selected (which corresponds to the normal operation mode), one fan can be started manually by the operator with the "Start fan" push button (if "BMS" or "LOCAL" is selected with the three position switch on the BMS cubicle) or the fan no1 automatically from the BMS (when information "GT running" is received from the DCS with "DCS" selected on the BMS cubicle). In case of fan deficiency (electrical motor fault, loss of start response, loss of cooling air pressure, excess of wrapping temperature, excess of bearing temperature) an alarm signal is generated and the second fan is automatically started by the sequence.

    When "Maintenance" mode is selected (on the BMS cubicle) regardless the choice "BMS" or "DCS", each fan can be started and stopped manually by the operator and not automatically by the sequence.

    • 2.5. AUGMENTING AIR FAN

     

    The operator has, on the HMI dedicated to the BMS, the following items to start the augmenting air fan:

    1 two position switch "Maintenance/Backup"

    1 Push button "Start fan"

    1 Push button "Stop fan"

    1 Lamp "Fan ON"

    1 Lamp "Fan Fault"

    Before the burner light of, the operator must check that all manual isolating valves on augmenting air lines are open and must start-up augmenting air fan.

    When "Backup" mode is selected (which corresponds to the normal operation mode) the augmenting fan is automatically start from the BMS when information "Burner start" is received from the DCS with "DCS" selected on the BMS cubicle or when the operator start the burner from local panel with "Local" selected.

     

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    When "Maintenance" mode is selected, regardless the choice "BMS" or "DCS", the fan is started and stopped manually by the operator and not automatically by the sequence.

    • 2.6. DIESEL OIL BOOSTER PUMPS SEQUENCES (SWITCH-OVER LOGIC)

     

    The operator has, on the HMI dedicated to the BMS, the following items to start the cooling air fan sequences:

     

    1 two position switch "Maintenance/Backup"

    1 two position switch "pump selection"

     

    And for each pump:

     

    1 Push button "Start pump"

    1 Push button "Stop pump"

    1 Lamp "pump ON"

    1 Lamp "pump Fault"

    Before the burner light of with DO, the operator must check that all manual isolating valves on fuel oil lines are open and must start-up one booster pump

    When "Backup" mode is selected (which corresponds to the normal operation mode), the selected pump is automatically started from the BMS when information "Burner start" is received from the DCS with "DCS" selected on the BMS cubicle or when the operator start the burner from local panel with "Local" selected. In case of pump deficiency (electrical motor fault, loss of start response, loss of DO feeder pump low pressure, loss of DO downstream low pressure ) an alarm signal is generated and the second pump is automatically started by the sequence.

    When "Maintenance" mode is selected (on the BMS cubicle) regardless the choice "BMS" or "DCS", each pump can be started and stopped manually by the operator and not automatically by the sequence.

    • 2.7. DIESEL OIL SEQUENCE

     

    When the GT is running and a burner head is not in operation, to prevent oil gun atomizing sets overheating that would cause their damage, the burner gun is cooled with steam through the DO automatic cleaning valve (valve AA152 line HJM11 to HJM62).

     

    2.7.1. Prior to ignition:

    • - the operator must first check that:

     
     

    All manual isolating valves on diesel oil, instrument air, steam line and cooling air lines are open,

    All flexible hoses are correctly connected.

    All DO guns are installed

    All atomizing sets are installed

    • - "Diesel oil" operation must be selected with the associated illuminated push button, on the BMS cubicle.

    Note:

     

    If the dummy atomizing tips are not installed in the burner heads before boiler start-up: all burner heads

    should be started-up in a reasonable time. If the dummy atomizing tips are installed in the burner heads before boiler start-up: each atomizing set should be installed in lieu of the dummy atomizing tip just before starting-up the burner heads.

    After a burner head shut-down (voluntary or by fault) the burner should be re-started quickly or the atomizing set replaced by a dummy atomizing tip.

     

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    2.7.2. Burner ignition sequence

     

    DO valves train particularity (see P&I Diagrams No FUJ/00/M/H----A30/FD/005 & FUJ/00/M/H----A30/FD/007):

    The main DO valves train is supplied with 1 flow control valve (HJF10 AA101), 1 ignition pressure transmitter (HJF10 CP001) and 1 flow transmitter (HJF10 CF001), line HJF10. Each burner head piping is fitted with 1 DO shut-off valve (XSV AA151, lines HJF11 to HJF62), 1 atomizing shut- off valve (XSV AA151, lines HJM11 to HJM62) and 1 cleaning shut-off valve (XSV AA152, lines HJM11 to HJM62), allowing independent operation of each burner head. The atomizing/purging piping is fitted with 2 pressure transmitter (HJM10 CP001 & CP002) and 1 pressure control valve (HJM10 AA101).

    Local start-up:

    According to NFPA 85, 2004, "The start-up of the burner as a first-time function shall be accomplished by the operator at the burner location who has a direct view of the burner”.

    So FIVES-PILLARD recommends that after a complete burner shut-down, first start-up for each couple of burner head (not only the first couple of heads) should be done from the local control box by pressing the "Burner head start-up" push button of one of the two local boxes associated to burner heads.

    This recommendation is given for the following reasons:

     
    • - To make sure that each oil gun is installed in the head,

    • - To verify that there is no leak, in particular between the oil gun and the shut-off valve.

     

    Remote start-up:

    According to CLIENT request, it is possible to initiate the burner start-up from the BMS or from the DCS by pressing the "DO burner start-up" push button. In such a case, all the couples of burner heads are automatically started-up the one after the other.

    The three position switch "BMS/Local/DCS" on the BMS cubicle, enables choice of the operating mode. In local mode, each burner head couple ignition is locally started by the operator from the local boxes. There is no order to manually start each burner heads couple but it is recommended to respect the requested order used in automatic sequence. The requested start-up order of the burner heads couples (in automatic sequence from the BMS or from the DCS) is the following:

    • - Burner heads couple no XB31/XB32,

     
    • - Burner heads couple no XB41/XB42,

    • - Burner heads couple no XB21/XB22,

    • - Burner heads couple no XB51/XB52,

    • - Burner heads couple no XB11/XB22.

    • - Burner heads couple no XB61/XB62.

    If the TEG characteristics are in accordance with the specified technical parameters for duct burner (mass flow rate, no CO, sufficient O2 content…, control is made by the DCS and information "Burner trip" sent to the BMS is ON) the automation proceeds with starting ignition, under control of the safety devices, of burner heads n° XB31 and XB32. The lamp "Ready to start" of each burner head local panel is ON when safety devices and checks listed in §. 2.1 and 2.2 have been carried out.

    The "Burner head in operation with DO" lamp of the associated local boxes flashes during ignition and the burner heads status is indicated on the H.M.I. in front of the BMS cabinet. During ignition of the two first burner heads, the DO flow control valve HJF10-AA101 and the atomizing pressure control valve HJM10-AA101 are forced on their ignition position.

    T0

    - Opening of upstream + downstream ignition gas shut-off valves HJA10- AA151 and AA153

    • - Closure of ignition gas vent valve HJA10-AA152

     
    • - Opening of ignition gas purge valve HJA10-AA154

     

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    T0 + 4''

    - Energizing of ignition transformers HJA31-CE001 and HJA32-CE001

     
    • - Maintaining open the upstream + downstream ignition gas shut-off valves HJA10-AA151 and AA153

    • - Maintaining close the ignition gas vent valve HJA10-AA152

     
    • - Closure of ignition gas purge valve HJA10-AA154

    • - Opening of the two burner heads ignition gas shut-off valves HAJ31-AA151 and HJA32 –AA151

     

    T0 + 10''

    - De-energizing of ignition transformers HJA31-CE001 and HJA32-CE001

     
    • - Maintaining open upstream + downstream + burner heads ignition gas shut-off valves HJA10-AA151, HJA10-AA153, HJA31-AA151 and HJA32 –

    AA151

    • - Maintaining closed ignition gas vent and purge valves HJA10-AA152 and

    HJA10-AA154

    • - Checking igniter flames by the 2 individual igniter flame ionization detection HJA31-CR001 and HJA32- CR001

     

    T0 + 16" + vidt

    - Maintaining open upstream + downstream + burner head ignition gas shut-off valves HJA10-AA151, HJA10-AA153, HJA31-AA151 and HJA32 –

     

    AA151

    • - Maintaining closed the ignition gas vent and purge valves HJA10-AA152 and

    HJA10-AA154

    • - Opening of the DO main shut-off valve HJF10-AA151

     
    • - Opening of the two DO burner head shut-off valves HHF31-AA151 and HHF32-AA151

    • - Opening of the two burner head atomizing shut-off valves HJM31-AA151 and HJM32- AA151

    • - Information "Taking into account of DO flow rate " is sent from BMS to CCS

     

    T0 + 21" + vidt + FuT

    - Closure of upstream + downstream + burner head ignition gas shut-off valves HJA10-AA151, HJA10-AA153, HJA31-AA151 and HJA32 –AA151

     
    • - Opening of ignition gas vent valve HJA10-AA152

     
    • - Maintaining closed ignition gas purge valve HJA10-AA154

    • - Maintaining open the DO main shut-off valve HJF10-AA151 + DO burner head shut-off valves HJF31-AA151 and HJF32-AA151

    • - Maintaining open the burner heads atomizing shut-off valves HJM31-AA151 and HJM32- AA151

    • - Checking main flames by individual flame detection HJQ31-CR001 or HJQ31-CR002 and HJQ32-CR001 or HJQ32-CR002

    • - Maintaining information "Taking into account of DO flow rate" from BMS to CCS

     

    T0 + 27" + vidt + FuT

    - Ignition of burner heads XB31 and XB32 is completed

     
     
    • - Maintaining information "Taking into account of DO flow rate" from BMS to DCS - DO ignition pressure loop is released in the CCS.

    Note 1:

     

    FuT = DO line filling-up time

     

    FuT = 6 second for burner heads re-ignition without cleaning,

     

    FuT = 20 seconds for burner heads re-ignition with cleaning.

    During the first commissioning of the installation, FuT will be adjusted at the shortest time possible

     

    vidt = steam line purging time

     

    vidT = 0 second after the 1 st DO couple ignited,

     

    vidt = 60 seconds for 1 st DO couple ignition.

    During the first commissioning of the installation, vidt will be adjusted at the shortest time possible

     

    The "Burner head in operation with DO" lamp of the associated local panels flashes during the burner light of and switches to a permanently lit status when the burner is ignited. The burner head status is indicated on the H.M.I.

     

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    Rev. 5 - 13/21
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    Once ignition of burner heads XB31 and XB32 is completed, the operator (from the local box) or the automatic
    sequence (initiated from BMS or DCS) proceeds with ignition start-up (under control of the safety devices) of the
    other burner head couples, respecting the requested order (n°XB41/XB42, XB21/XB22,
    equivalent actions on the associated local panels, valves and igniters.
    Time between 2 burner heads couples ignition is at least 10 seconds.
    ,
    XB61/XB62) with
    Note 2:
    During ignition:
    If a fault appears during ignition (but main DO shut-off valves remained closed) of at least one burner
    head of the first burner heads couple, the couple is tripped; the fault should be determined and
    corrected. The burner light off is not allowed until the lamp "Ready to start" is off. The operator should
    restart ignition sequence of the burner heads couple, with "Local" mode selected, by pressing the
    "Burner head start-up" push button on the local panel,
    If a fault appears during ignition (but main NG shut-off valves remained closed) of one or two head(s)
    of a burner heads couple, with at least another head already in operation, only the head(s) faulty is
    (are) stopped, the fault should be determined and corrected. The operator should restart ignition
    sequence of the head(s), with "Local" mode selected, by pressing the "Burner head start-up" push
    button on the local panel, after the end of the automatic burner light off sequence.
    After ignition:
    If a fault appears after ignition (after opening of the main ng shut-off valves) of a burner head, with at
    least 2 other head already in operation in pressure control or with at least 8 other head already in
    operation in flow control, only the faulty head is stopped, the failure should be determined and
    corrected the burner ignition is not allowed until the lamp "ready to start" is off. The operator should
    restart ignition sequence of the head(s), with "local" mode selected, by pressing the "burner head start-
    up" push button on the local panel, if the automatic burner light off sequence is ended.
    The normal burner operation is obtained with 12 burner heads firing simultaneously with DO or NG.
    After ignition of the 12 burner heads is complete or after ignition of 8 burners head and the validation of
    the ”flow control validation” on the CCS HMI, NG flow control can modulate, but with n burner heads in
    operation, the maximum load shall be limited to n x 8.33 %.
    When 8 burner heads are in operation with the NG flow control loop released, loss of one head initiates
    a shut-down sequence of the complete burner.
    After ignition of the requested burner heads (8 to12 heads) when NG flow control loop is operational, if one or
    two burner heads stop because of a safety device or of a voluntary shut-down (for maintenance), the DCS shall
    automatically reduce the load according to the number of burner heads remaining in service.
    The NG flow control loop will automatically distribute the load on the heads remaining in service.
    After determination and correction of the fault, the operator should locally start up the remaining heads.
    2.7.3. Burner shut-down sequences
    Voluntary shut-down of one burner head:
    The operator can shut-down each burner head (for maintenance) by pressing the associated "Burner head stop"
    push-button on the local box. This action has priority regardless the choice "BMS/Local/DCS" given by the three
    positions switch on the BMS cubicle.
    After each voluntary shut-down of one head, excepted for the last one, the operator should start a cleaning
    sequence of the associated DO gun (see §. 2.7.4) by pressing the "Burner head start-up cleaning sequence"
    push-button on the local panel.
    The lamp "Burner cleaning sequence in progress" flashes slowly to inform the operator that the cleaning
    sequence must be made.
    For each head, the shut-off sequence is as follows:
    -
    The associated DO and atomizing shut-off valves XSV AA151 lines HJF11 to HJF62 and HJM11 to HJM62
    close
    -
    The associated local "Burner head in operation with DO" lamp switches off.
    For the complete burner:
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    The complete voluntary shut-down of the burner can be realized by the operator by pressing the "DO burner stop" push-button on the BMS panel or from the DCS.

    The requested shut-down order of the burner heads couples (in automatic sequence from the BMS or from the DCS, or to be respected by the operator in manual mode) is the following:

    • - Burner heads couple no XB61/XB62,

    • - Burner heads couple no XB11/XB12,

    • - Burner heads couple no XB51/XB52,

    • - Burner heads couple no XB21/XB22

    • - Burner heads couple no XB41/XB42,

    • - Burner heads couple no XB31/XB32.

    After a complete voluntary shut-down of the burner, the BMS automatically proceeds with a cleaning sequence of all burner heads (see §. 2.7.4) excepted of the last one. The time delay between each couple shut-down will be adjusted during the first commissioning in order to allow complete cleaning sequence of each burner heads couple before shut-down of the last couple.

    The complete shut-off sequence is as follows:

    • - Each DO burner head (XSV AA151 lines HJF11 to HJF62) and atomizing (XSV AA151 lines HJM11 to

    HJM62) shut-off valves close,

    • - The DO main shut-off valve (HJF10- AA151) close,

    • - The DO accumulator isolating valve (HJF10- AA152) close,

    • - The DO flow control valve (HJF10- AA101) forced to its ignition position,

    • - All the local "Burner head in operation with DO" lamps switch off.

    Note:

    • - If a general burner start-up occurs (from the BMS or from the DCS) during a complete voluntary shut-down sequence, the shut-down sequence is automatically stopped and an ignition sequence restarts,

    Safety shut-down:

    After a safety shut-down of the complete burner, the cleaning sequence is forbidden. In order to clean the DO guns, the operator should determine and correct the fault then should restart ignition of at least one burner heads couple (after a boiler purge) before starting a cleaning sequence of each head. A safety shut-down produces the same actions as the voluntary shut down. The burner head fault is indicated on the H.M.I.

     

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    2.7.4. Diesel oil gun cleaning sequence

     

    After a voluntary shut-down of the complete burner, a cleaning sequence of each head (excepted of the last one) is made by the BMS, except in the case of:

    -

    DO burner head individual shut-off valve discrepancy stops or prevents the cleaning sequence of the considered head,

    -

    Atomizing pressure very low obtained with the 2 out of 3 voting system between PSL CP801, PSL CP802 and PSL CP803, line HJM10 (stops or prevents the cleaning sequence of the heads),

    -

    Main safety devices (see §. 2.1.3.7, stops or prevents the cleaning sequence of the heads),

     

    -

    Individual igniter safeties (see §. 2.1.3.5 and 2.1.3.6) stop or prevent the cleaning sequence of the considered head.

    The "Burner head cleaning sequence in progress" lamp(s) of the associated local panel(s) flash(es) rapidly during cleaning sequence and the burner head status is indicated on the H.M.I.

    T0

    - Opening of upstream + downstream ignition gas shut-off valves HJA10-AA151 and

    HJA10-AA153

    • - Closure of ignition gas vent valve HJA10-AA152

    • - Opening of ignition gas purge valve HJA10-AA154

    T0 + 4''

    - Energizing of burner head ignition transformer HJAxx-CE001

     
    • - Maintaining open upstream + downstream ignition gas shut off valves HJA10-AA151 and

    HJA10-AA153

    • - Maintaining closed ignition gas vent valve HJA10-AA152

     
    • - Closure of ignition gas purge valve HJA10-AA154

    • - Opening of the burner head ignition gas shut-off valve HJAxx-AA151

     

    T0 + 10''

    - De-energizing of burner heads ignition transformer HJAxx-CE001

    • - Maintaining open upstream + downstream ignition gas shut-off valves HJA10-AA151 and

    HJA10-AA153

    • - Maintaining open the burner head(s) ignition gas shut-off valves HJAxx-AA151

     
    • - Maintaining closed ignition gas vent valve HJA10-AA152

    • - Maintaining closed the ignition gas purge valve HJA10-AA154

    • - Checking igniter flames by the 2 individual igniter flame ionization detection HJAxx-CR001

    T0 + 16''

    - De-energizing of burner heads ignition transformer HJAxx-CE001

     
    • - Maintaining open upstream + downstream ignition gas shut-off valves HJA10-AA151 and

    HJA10-AA153

    • - Maintaining open the burner head(s) ignition gas shut-off valves HJAxx-AA151

     
    • - Maintaining closed ignition gas vent valve HJA10-AA152

    • - Maintaining closed the ignition gas purge valve HJA10-AA154

    • - Checking igniter flames by the individual igniter flame ionization detection

    HJAxx-CR001

    • - Opening of individual burner head atomizing shut-off valve HJMxx-AA151

     
    • - Opening of individual burner head cleaning shut-off valve HJMxx-AA152

    T0 + 21'' + CT

    - Closure of upstream + downstream ignition gas shut-off valves HJA10-AA151 and HJA10-

    AA153

    • - Closure of the burner head(s) ignition gas shut-off valve HJAxx-AA151

     
    • - Opening of ignition gas vent valve HJA10-AA152

    • - Maintaining closed the ignition gas purge valve HJA10-AA154

     
    • - Closure of individual burner head atomizing shut-off valve HJMxx-AA151

    • - Closure of individual burner head cleaning shut-off valve HJMxx-AA152

     

    Note:

    -

    CT = DO gun cleaning time; CT will be adjusted on site during the first commissioning of the installation. CT will be as short as possible though at the same time making sure of an efficient purging.

    -

    During the cleaning sequence, a starting command from the local panel is priority. In this case, the BMS makes the present sequence shorter and proceeds with burner head restarting.

     

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    2.8.

    NATURAL GAS SEQUENCE

    Prior to ignition :

     
    • - The operator must first check that all manual isolating valves on NG, instrument air and cooling air lines are open,

    • - "Natural gas" operation must be selected with the associated illuminated push button, on the BMS cubicle.

    When a burner head is not in operation with DO, to prevent oil gun atomizing sets overheating that would cause their damage, a dummy atomizing tip should be installed in lieu of each DO gun atomizing set or the atomizing shut of valve should be open in order to cooling the atomizing sets.

     

    2.8.1. Burner ignition sequence

    NG valves train particularity (see P&I Diagrams No FUJ/00/M/H----A30/FD/005 and FUJ/00/M/H----A30/FD/007):

    The main NG valves train is supplied with 1 gas flow transmitter (HJG10-CF001), 1 gas pressure transmitter (HJG10-CP001) and 1 gas temperature transmitter (HJG10-CT001) for gas flow correction, 1 upstream shut-off valve (HJG10-AA151), 1 vent valve (HJG10-AA152), 1 downstream shut-off valve (HJG10-AA153), 1 gas flow control valve (HJG10-AA101), 1 ignition gas pressure transmitter (HJG10-CP001). Each burner head piping is fitted with 1 NG shut-off valve AA151, lines HJG11 to HJG62.

     

    Local start-up:

    According to NFPA 85, 2004 edition: "The start-up of the burner as a first-time function shall be accomplished by the operator at the burner location who has a direct view of the burner”.

    So FIVES-PILLARD recommends that after a complete burner shut-down, first start-up for each couple of burner head (not only the first couple of heads) should be done from the local control box by pressing the "Burner head start-up" push button of one of the two local boxes associated to burner heads. This recommendation is given for the following reasons:

    To make sure that there is no problem on each burner head,

    To verify that there is no leak.

    Remote start-up:

     

    According to CLIENT request, it is possible to initiate the burner start-up from the BMS or from the DCS by pressing the "DO burner start-up" push button. In such a case, all the couples of burner heads are automatically started-up the one after the other.

    Even if ignition of the first couple of burner heads is done from the local control box, it remains possible to initiate start-up of the other burner heads from the BMS or from the DCS. In such a case, start-up of the other heads is done automatically as explained here after.

    The three position switch "BMS/Local/DCS" on the BMS cubicle, enables choice of the operating mode. In local mode, each burner head couple ignition is locally started by the operator from the local box. There is no order to manually start each burner heads couple but it is recommended to respect the requested order used in automatic sequence.

    The requested start-up order of the burner heads couples (in automatic sequence from the BMS or from the DCS, or to be respected by the operator in manual mode) is the following:

    • - Burner heads couple no XB31/XB32,

     
    • - Burner heads couple no XB41/XB42,

    • - Burner heads couple no XB21/XB22,

    • - Burner heads couple no XB51/XB52,

    • - Burner heads couple no XB11/XB22.

    • - Burner heads couple no XB61/XB62.

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    In all cases, the start-up sequence is initiated by the operator by pressing a push button.

     

    If the TEG characteristics are in accordance with the specified in the technical parameters for Duct burner (mass

    flow rate, no CO, sufficient O2 content,

    ,

    control is made by the DCS and information "Burner trip" sent to the

    The "Burner head in operation with NG" lamp of the associated local panels flashes during ignition and the burner heads status is indicated on the H.M.I. in front of the BMS cabinet.

    During ignition of the two first burner heads, the NG flow control valve HJG10-AA101 is forced on its ignition position.

    T0

    - Opening of upstream + downstream ignition gas shut-off valves HJA10-AA151 and

    HJA10-AA153

    • - Closure of ignition gas vent valve HJA10-AA152

     
    • - Opening of ignition gas purge valve HJA10-AA154

     

    T0 + 4''

    - Energizing of ignition transformers HJA31-CE001 and HJA32-CE001

    • - Maintaining open the upstream + downstream ignition gas shut-off valves HJA10- AA151 and HJA10-AA153

    • - Maintaining close the ignition gas vent valve HJA10-AA152

     
    • - Closure of ignition gas purge valve HJA10-AA154

    • - Opening of the two burner heads ignition gas shut-off valves HJA31-AA151 and

    HJA32-AA151

    T0 + 9"

    - De-energizing of ignition transformers HJA31-CE001 and HJA32-CE001

     
    • - Maintaining open the upstream + downstream ignition gas shut-off valves HJA10- AA151 and HJA10-AA153

    • - Maintaining close the ignition gas vent valve HJA10-AA152

     
    • - Maintaining close ignition gas purge valve HJA10-AA154

    • - Maintaining close the two burner heads ignition gas shut-off valves HJA31-AA151 and

    HJA32-AA151

    • - Checking igniter flames by the 2 individual igniter flame ionization detections HJA31-CR001 and HJA32-CR001.

    T0 + 13"

    - Maintaining open the upstream + downstream ignition gas shut-off valves HJA10- AA151 and HJA10-AA153

    • - Maintaining close the ignition gas vent valve HJA10-AA152

     
    • - Maintaining close ignition gas purge valve HJA10-AA154

    • - Maintaining open the two burner's heads ignition gas shut-off valves HJA31-AA151 and HJA32-AA151

    • - Checking igniter flames by the 2 individual igniter flame ionization detections HJA31-CR001 and HJA32-CR001.

    • - Opening of the main upstream shut-off valve HJG10-AA151

     
    • - Opening of the main downstream shut-off valve HJG10-AA153

    • - Closure of the main gas vent valve HJG10-AA152

    • - Opening of the purge valve HJG10-AA154

     

    T0 + 17"

    - Maintaining open the upstream + downstream ignition gas shut-off valves HJA10- AA151 and HJA10-AA153

    • - Maintaining close the ignition gas vent valve HJA10-AA152

     
    • - Maintaining close ignition gas purge valve HJA10-AA154

    • - Maintaining open the two burner's heads ignition gas shut-off valves HJA31-AA151 and HJA32-AA151

    • - Checking igniter flames by the 2 individual igniter flame ionization detections HJA31-CR001 and HJA32-CR001.

    • - Maintaining open the main upstream shut-off valve HJG10-AA151

     
    • - Maintaining open the main downstream shut-off valve HJG10-AA153

    • - Maintaining closed the main gas vent valve HJG10-AA152

     

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    • - Closure of the purge valve HJG10-AA154

    • - Opening of the NG burner head shut off valves HJA31-AA151 and HJA32-AA151

    • - Information "Taking into account of NG flow