747MW (Gross) Combined Cycle Power Plant Project At GUDDU

HRSG MANUAL

1 Power Plant Overview

Pakistan Guddu power plant adopts S209FA two plus one combined cycle unit (two sets of PG9351FA
Gas Turbine two sets of HRSG, one set of steam turbine generator set. A total installed capacity of
747 MW).
Two HRSG for this project is produced by Hangzhou HRSG group co., LTD., NG - S209FA - R type
HRSG. The HRSG chose to high, medium and low pressure distribution design, three classes of each
distribution system are independent cycle steam supply. The whole HRSG for tight closed, open,
horizontal layout, adopts reheat itself, does not burn, bringing oxygen and natural circulation form.
Its ontology using N/E standard design module structure of heating surface, the vertical arrangement
of paramagnetic column and staggered spiral fin tube and the import and export container. Flue
combustion engine exhaust through the transition period of export into the HRSG and then in turn
flows through the convection heating surface composed of six modules after outlet flue chimney (65
m) high into the atmosphere. In the import of waste heat HRSG flue also equipped with flue gas
damper (hydraulic) and the bypass chimney (40 m), can achieve the single combustion engine and
the combination of the steam engine startup.

HRSG Protection and Logic

1) HRSG alarm
Under any circumstances, request control system alarm to attract the attention of the operators and
timely take measures to control：
HP steam drum water level is higher than the alarm value
HP steam drum water level is lower than the alarm value
IP steam drum water level is higher than the alarm value
IP steam drum water level is lower than the alarm value
LP steam drum water level is higher than the alarm value
LP steam drum water level is lower than the alarm value
HP main steam temperature H
RH temperature H
HP/IP feed water pump inlet filter DP high
HP/IP feed water pump outlet pressure low, HP drum water level lower than normal value

2) HRSG running judging conditions

HRSG stack damper open
HRSG (inlet) bypass smoke damper full open
HRSG to ST HP main steam valve full open
HRSG main steam on-line motorized valve full open
HRSG to ST IP main steam valve full open
HRSG IP steam on-line motorized valve full open
Cold reheated steam to corresponding HRSG motorized valve
HRSG to ST LP main steam valve full open
HRSG LP steam on-line motorized valve full open

3) HRSG trip conditions

Unit trip
In order to achieve combined cycle unit normal running and protecting unit devices safety running.
When any of circumstances below happens, unit needs trip protection:
HP drum water level HHH, delayed 3s
HP drum water level LL, delayed 3s
IP drum water level HHH, delayed 3s
IP drum water level LL, delayed 3s
LP drum water level HHH, delayed 3s
LP drum water level LL, delayed 3s
HP feed water pump all stopped, delayed 120s
IP feed water pump all stopped, delayed 120s
Condensate water pump all stopped, delayed 120s
ST bypass quick open order is sent, but it is not open

GT trip
HRSG fuel gas inlet smoke pressure high
HRSG fuel gas outlet smoke pressure high

4) Equipments action after HRSG tripping：

HRSG bypass flue gas damper fast pass failure, the corresponding combustion engine trip
Turbine trip under one plus one mode
Close the HRSG bypass flue gas damper
Close the corresponding HRSG to the turbine HP main steam MV
Close the corresponding HRSG to the turbine HP main steam bypass MV
Close the corresponding HRSG to the turbine IP main steam MV
Close the corresponding HRSG to the turbine IP main steam bypass MV
Close the corresponding HRSG to the turbine LP main steam MV
Close HRSG SH spray water MV
Close HRSG RH spray water MV

5) Equipments action after turbine tripping：

HP/IP/LP bypass quick opening
Close two HRSG to turbine HP main steam paralleling steam MV
Close two HRSG to turbine IP main steam paralleling steam MV
Close two HRSG to turbine LP main steam paralleling steam MV
Close two HRSG SH spray water MV
Close two HRSG RH spray water MV
Close the high exhaust non-return valve
Open turbine exhaust ventilation valve
Close two HRSG reheat inlet MV
Open turbine all drain valves

6) Interlock
A One plus one HRSG trip - if HRSG bypass flue gas damper to quickly shut down, the corresponding
combustion engine trip, turbine trip - turbine generator tripping
B One plus one the combustion engine trip - HRSG trip, turbine trip - turbine generator trip (one to
one correspondence)
C Two plus one ，one combustion engine trip and corresponding HRSG trip
D Two plus one ，Turbine trip→ turbine generator trip
E Two plus one Turbine generator trip - turbine trip - if the bypass quick opening failure (# 1HRSG
corresponding # 1 bypass flue gas damper), fast close beside the two HRSGs and flue gas damper - if
HRSG bypass flue gas damper to quickly shut down, the corresponding combustion engine trip

7) GT RB\FCB function: (only suit for two plus one)

A Manual put into service (soft button)
B Trigger condition: When corresponding GT power >50%, one of items below happens
(1) Two condensate water pump stop and two boilers’ HP & IP steam capacity>X
(2) Two HP feed water pumps stop
(3) Two IP feed water pumps stop
(4) Two CW pumps stop
C GT load <50%, then reset automatically

4 HRSG Protections and Interlock Checkout

In case one of the following circumstances, the steam turbine and gas turbine outage protection
action, and the door shut down HRSG reduce warm water.
HRSG HP drum with full water (H/HH/HHH at the same time meet the values) 102,153,203.
HRSG IP drum with full water (H/HH/HHH at the same time meet the values). 102,153,203.
HRSG LP drum with full water (H/HH/HHH at the same time meet the values). 102,153,203.
HRSG HP drum water depletion (L/LL/LLL at the same time meet the values). -102,-153,-670.
HRSG IP drum water depletion (L/LL/LLL at the same time meet the values). -102,-153,-407.
HRSG LP drum water depletion (L/LL/LLL at the same time meet the values). -102,-153,-1614.
HRSG flue gas inlet pressure is greater than 65 bar, HRSG trip.
HRSG flue gas outlet pressure is greater than 12.5 bar, HRSG trip.
HRSG flue gas damper close, HRSG trip.

Drum water level protection interlock

HP/IP emergency discharge valves: when HP/IP drum water level more than HH(+102mm),
interlocking open the emergency discharge valve, HP/IP drum water level is lower than H value (-
102mm) interlock close the emergency discharge valve. Spray water main valve: when turbine
trip, interlocking close spray water valve. LP drum emergency discharge valve: when LP drum
water level HH (+102mm) and LP heater vent valve not open, interlocking, open LP emergency
discharge valve, LP drum water level is lower than the H (-102mm), interlocking close LP
emergency discharge valve.

Feed water pump interlock

Feed water pump one is running, another is standby, when HP header pressure lower than 139BAR,
or the running pump trip, and the standby pump will be interlock start.
Feed water pump one running and one standby, when IP feed water main pressure is lower than
50bar or running feed water trip, interlock start standby pump.
LP drum water level lower than-1664mm, feed water pump trip.
Stop turbine and combustion engine protection checkout
HP drum full water tripping steam turbine and combustion engine protection check
put the combustion engine into test position, supply the power to DEH, open turbine automatic main
steam valve.
Feed water pump on power supply.
Start BFP and feed water to HP drum, open spray water MV.
When the HP drum water level up to HHH alarm and drum H/HH both alarm, protection action,
turbine auto main steam valve closed, spray water MV closed.
Low pressure drum with full water trip turbine and combustion engine protection
Test method with high pressure drum water conservation calibration method.
High pressure steam drum water steam turbine and combustion engine protection
put test position, the combustion engine switch to DEH sending, open the door main steam turbine
automatic.
Feed water pump on power supply.
Start the feed water pump of high pressure steam drum water and water to steam drum water level,
normal electric door opens and will reduce the warm water.
With HP drum water emergency discharge valve and HP CBD valve discharge water, When the HP
drum water level up to HHH alarm and drum H/HH both alarm, protection action, turbine auto main
steam valve closed, spray water MV closed.
IP/LP drum water shortage trip turbine and combustion engine protection calibration method the
same with HP drum water shortage protection method.
 The protection’s above is seen at attached logic protection list

HRSG Control Introductions

1. HP drum water level control

Drum water level is mainly through the opening of feed water regulator to control the water level,
when normal running, steam flow, drum water level and water flow system is composed of three
impulse adjust system, drum water level of starting and low load only single pulse control system.
Feed water bypass valve set at 30% of the HRSG load, mainly for HRSG water starts. Within the
scope of the entire operation, including the single pulse and switch between three impulse control
system, the system should be stable, specific control is described below：
Measuring drum water level transmitter for redundancy configuration, and pressure compensation,
comparison and choice;
The temperature compensation of feed water flow total feed water flow are obtained
Adopt the temperature and pressure compensation of the main steam flow is used as the steam flow
measurement;
Starting and low load, the drum water level by single pulse adjustment, stable in steam parameters,
feed water flow allows, under the condition of control system can automatically or manually without
three impulse disturbance switch to adjust;
The characteristics of the control system to ensure water flow and a linear relationship with load
instruction;
⑥Drum water level (pressure compensation transducer signal, signal can be comprehensive
considering electric contact water table)HH, interlocking open drum emergency drain electric valve
until the water level normal, drum water level is high, low, have alarm signal output;
2. IP drum water level control
IP drum water level is mainly through the feed water regulating valve opening change into the water
to control the water level, in the normal run by steam flow, drum water level and water flow system
is composed of three impulse, drum water level of starting and low load only single pulse control
system.
Within the scope of the entire operation, including the single pulse and switch between three impulse
control system, the system should be stable.
Measuring drum water level transmitter for redundancy configuration, and pressure compensation,
comparison and choice;
The temperature compensation of feed water flow rate as the total feed water flow;
Adopt the temperature and pressure compensation of superheated steam flow is used as the steam
flow;
Starting and low load, the drum water level by single pulse adjustment, stable in steam parameters,
feed water flow allows, under the condition of control system can automatically or manually without
three impulse disturbance switch to adjust;
The characteristics of the control system to ensure water flow and a linear relationship with load
instruction;
⑥Drum water level (pressure compensation of transducer signal, signal can be comprehensive
considering electric contact water table)H, interlocking open drum emergency drain electric valve
until the normal water level, drum water level is high, low, have alarm signal output.

3. LP drum water level control

Low pressure drum feed water control valve is located in the low pressure economizer outlet, the
control and the related description is as follows:
When LP drum starting and low load, the water level by single pulse (water level control). When
normal load, the control for the three impulse control, maintain the main feed flow rate and low main
steam flow and steam drum water level balance, and carry on the switch control of single, three
impulse.
Before starting the HRSG, the drum water level can be set a little high, after filling water the water
level set point back to normal.

Main steam header vent valve (HP/IP/LP)

HP:
When HRSG feed water open, close the valve when it is started. System startup high pressure steam
bypass into the cold and hot reheat, the temperature rise rate of high pressure system through the
bypass cannot control, through high pressure air exhaust valve to control.
IP:
When HRSG feed water open, can through IP air exhaust valve to adjust IP system temperature rise
rate, when IP superheat steam meet paralleling steam conditions, shut down the air exhaust valve.
LP:
When HRSG feed water open, close the valve when it is started. Go low pressure steam by-pass
system startup, the temperature rise rate of low pressure system through the bypass can't control,
can be adjusted by the lower pressure of air exhaust valve
Feed water heater recirculation control
Is the function of feed water heater recycling in order to improve feed water heater inlet water
temperature, to prevent condensation of tube fin surface and Settings. HRSG startup can be put into
recycle control, the design of the recirculation system in rated running under the steady condition,
the variable load and low load condition, should be controlled recirculation flow to protect the safe
operation of pump.
Adopt one set in a case of circulating pump, recirculation control valve according to feed water
heater 1 entry to automatically adjust the water temperature, the opening shall be limited to, the
lower limit on, the purpose is to protect the safe operation of the pump.
Feed water heater bypass control
Feed water heater bypass control system is the HRSG feed water to the water heater and/or feed
water heater around the line, the main work can be: (1) to make all of the HRSG give water to the
water heater, (2) all of the HRSG water flows through the feed water heater bypass, and (3) any part
of the flow to the water heater or bypass around the water heater. The three-way valve position can
be made of DCS root according to automatically adjust the HRSG operation form.
In the normal operation of HRSG, recirculation flow, the largest cannot meet the inlet water
temperature of feed water heater, the feed water heater import and export of differential pressure is
greater than the set value, can be part of the bypass feed water heater.