Professional Documents
Culture Documents
Employer
ESB International
Project Title
Aghada CCGT
Consortium
Table of Contents:
1. GENERAL DESCRIPTION................................................................................................................................... 5
1.1. Introduction........................................................................................................................................................ 5
1.2. Purpose of the Combined Cycle Power Plant................................................................................................. 5
1.3. Overview of Major Components and Systems................................................................................................ 7
1.3.1. Gas Turbine ............................................................................................................................... 8
1.3.2. Generator ................................................................................................................................... 8
1.3.3. Self Shifting and Synchronising Clutch...................................................................................... 9
1.3.4. Steam Turbine ........................................................................................................................... 9
1.3.5. Heat Recovery Steam Generator and Once Through Coolers.................................................. 9
1.3.6. Water Steam Cycle .................................................................................................................. 10
1.3.7. Cooling System ........................................................................................................................ 11
1.3.8. Water Supply System .............................................................................................................. 12
1.3.9. Chemical System ..................................................................................................................... 12
1.3.10. Continuous Emission Monitoring System ................................................................................ 13
1.3.11. Fuel Supply System ................................................................................................................. 13
1.3.12. Waste Water System ............................................................................................................... 13
1.3.13. Compressed Air System .......................................................................................................... 13
1.3.14. Fire Protection System............................................................................................................. 13
1.3.15. Step-up Transformer................................................................................................................ 14
1.3.16. Electrical Distribution ............................................................................................................... 14
1.3.17. Control System ........................................................................................................................ 15
1.3.18. Building Facilities ..................................................................................................................... 15
2. OPERATION and OPERATION MODE............................................................................................................16
2.1. Load Operation ...............................................................................................................................................16
2.1.1. General .................................................................................................................................... 16
2.1.2. Base Load Operation ............................................................................................................... 16
2.1.3. Part Load Operation................................................................................................................. 16
2.2. Plant operating modes....................................................................................................................................16
2.2.1. Frequency Support .................................................................................................................. 16
2.2.2. Anti Icing .................................................................................................................................. 17
3. CONTROL SYSTEM ...........................................................................................................................................18
3.1. General Description ........................................................................................................................................18
3.2. Control System Overview...............................................................................................................................18
3.3. Control Locations ............................................................................................................................................19
1. GENERAL DESCRIPTION
1.1. Introduction
This document covers the overall plant operation and the corresponding inter-system functional
connections of the Combined Cycle Power Plant AGHADA. System internal functions are
described in the related system operation instructions.
In order to present the operation concept of the whole plant in a clear manner, the operation
documents are hierarchically structured as shown in Enclosure 1.
This overall operation and control concept includes brief descriptions of sub-systems to offer a
basic understanding of the operation of the whole plant.
The AGHADA Combined Cycle Power Plant is a floor mounted single shaft power train for the
generation of electrical energy. The power train consists of a gas turbine, a hydrogen cooled
generator and a three casing steam turbine and all auxiliaries to operate the plant.
The operation of the facility is dispatched according to National Electricity Market and local grid
requirements by the operator. The plant is designed to run at continuous base load or part load
operation with the possibility of daily start-up and shutdown. The level of automation fulfils the
requirement that shut down sequencing ensures restart in the shortest time. The stack damper
will close accordingly to maintain the heat in the boiler. Peak load operation of the gas turbine is
not possible. The plant can be operated in frequency response mode.
Base load is the maximum plant output at the given ambient conditions.
The facility will be capable of operating at base load without any restrictions in an ambient
temperature range of –8 °C to 28 °C.
9 °C ambient temperature
1013 mbar ambient pressure
82 % relative humidity
12 °C cooling water temperature (Sea water)
Power Generation
Under design ambient conditions and with natural gas fuel the facility generates 431.6 MW net
output with a Net Heat Rate of 6192 kJ/kWh (see HB 1AHV415841 Rev. A).
The electrical power supplied into the grid is three-phase 50 Hertz AC current, at a nominal
voltage of 220 kV at the HV side of the generator transformer (step up transformer). The power
factor is dispatched in the range between 0.85 lagging and 0.95 leading by the operator,
measured at the generator terminals. The reactive power capability must not be less than a
power factor of 0.93 lagging and 0.93 leading at the PCC and at nominal voltage.
The power plant output is adjusted by controlling the load of the gas turbine based on overall
plant output requirements.
Fuel
The facility is designed to operate with natural gas as main fuel according the Alstom fuel
specification. Diesel oil No. 2 is used as back-up fuel.
Picture 1.3-1 illustrates the different systems of the plant and shows the associated inter-system
signal transfer.
Electrical
Power Electrical Systems I&C
16 15 17
Electrical Main Step-up Control
Distribution Transformer System
10
CEMS
Flue 5 6
Gas HRSG and Once Water / Steam
Through Air Coolers Cycle
BOP Systems
9 8 7
Chemical Water Supply Cooling
Systems Systems Systems
11 12 13
Fuel Waste Water Air
Supply System Supply
Waste Cooling
Fuel Chemicals Water Water water Air
The numbers represents the last letters of the paragraphs in this chapter 1.3.
Power Train
The power train consists of the gas turbine, the generator, the self shifting and synchronising
clutch and the steam turbine set.
One ALSTOM GT26 type gas turbine (GT) consists of one common rotor for 1 HP turbine stage
and 4 LP turbine stages and 22 compressor stages. Heat input is performed by two annular
combustion chambers (EV+SEV burners), applying the sequential combustion principle. The HP
turbine is located downstream the EV burners and upstream the SEV burners for first expansion
of the exhaust gas. Combustion air (GT-inlet air) is filtered in the air intake block.
The rotor is rigidly coupled to the generator shaft.
The airflow through the gas turbine is controlled by the angular position of three variable inlet
guide vane (VIGV) rows, placed in front of the first three compressor blade rows. During part load
(above about 40 % of the GT load) the GT controller keeps the exhaust gas temperature constant
at its maximum - that ensures maximum CC efficiency. Therefore the turbine inlet temperature
(TIT) will be adjusted together by the fuel injection control and the VIGV.
For cooling and sealing purposes of the GT, air is drawn off from the compressor at several
stages (high pressure and low pressure). The drawn off air is cooled by two once through coolers
(OTC), one high pressure (HP OTC) and one low pressure cooler (LP OTC). The cooled air is
then re-directed back into the GT for the required cooling purposes.
1.3.2. Generator
One ALSTOM Generator type 50WT21H-120 is driven by both the GT and ST and generates
power at 21 kV. The generator is a 2-pole three phase synchronous generator, which is of H2
cooled design. The hot gas is recooled in heat exchangers located in the generator housing. The
heat is transferred into cooling water, which is recooled in a remote cooling system. A gas unit
supplies hydrogen at the correct condition from the bottle battery. A seal oil unit provides seal oil
to ensure the H2 is sealed against atmosphere. The rotor is rigidly coupled to the SSS clutch.
The generator is used as a synchronous starting motor fed by a static frequency converter.
During start-up up period the HV grid will provide the starting energy across the generator-step-
up transformer. Starting without power supply from HV grid is not possible.
The self shifting and synchronising clutch (SSS clutch) permits the ST to be accelerated and to
be connected to the generator already being driven by the GT.
• The SSS clutch engages automatically as soon as the torque from the ST shaft becomes
positive i.e. as soon as the speed of the ST tends to overtake that of the generator.
• The SSS clutch automatically disengages as soon as the ST torque becomes negative i.e. as
soon as the ST tends to decelerate with respect to the generator.
No control device is required for the SSS clutch.
The Alstom steam turbine type DKYZZ3-2N41 is a three casing triple pressure reheat condensing
steam turbine (ST). The first casing consists of the HP turbine, the second casing of the IP
turbine and the third casing of the two-flow LP turbine.
The three turbine shafts are coupled rigidly together and the HP turbine shaft is coupled rigidly to
the SSS clutch.
HP live steam enters the HP turbine through one stop and one control valve and is expanded to
reheat pressure. The cold reheat steam is mixed with the IP steam generated in the HRSG
reheated in the reheater section. The hot reheat steam is admitted to the IP turbine section via
two IP turbine admissions both equipped with one stop and one control valve. The LP steam
enters the LP turbine through one stop- and one control flap. The outlet steam of the LP turbine is
discharged to the condenser.
The steam turbine is operated in sliding pressure mode, limiting the minimal pressure at low load
(fixed pressure mode) to safeguard the boiler.
The HRSG is operated in sliding pressure mode with a minimum, fixed pressure mode at the
lower load range.
There are 2x100% HP/IP variable speed feedwater pumps feeding the HRSG with HP and IP and
LP feedwater. During normal operation, one pump is in service. The other serves as standby unit.
The IP/LP feedwater is extracted from the pump interstage bleed-off. The feedwater flows are
preheated in the respective economisers and admitted via control valves into the HP, IP and LP
drums. The drum level is controlled by the respective feedwater control valve and the hereto
required pump speed.
An extraction downstream of the IP economiser feeds water to a fuel gas preheater in order to
increase the GT fuel gas inlet temperature from about 15°C to 150°C, which improves the
combined cycle plant efficiency. The water leaving the gas preheater returns to the feedwater
tank.
The boiler blow down tank collects the boiler drains, the continuous blow down and the
intermittent blow-off from the three drums. After separation steam is discharged to atmosphere
and condensate is discharged to the waste water system by means of 2 x 100 % BD-Pumps.
Condenser
The condenser is designed as horizontally type. It is arranged laterally to the steam turbine. It is
built of two independent modules. Each module consists of two bundles, connected in series (2-
pass flow condenser with inlet- and reversing water boxes). The condenser tubes are cooled
directly with sea water from the bay. In order to be able to operate the condenser with one half (1
module) shut-down, separate water boxes and flaps are provided.
The non-condensable gases at the steam side are extracted at a defined point of every tube
bundle at the location of lowest pressure (the so-called “air coolers”). The condensed steam flows
into the common hotwell, which provides sufficient condensate storage capacity.
The flash box is connected to the condenser and collects the steam turbine internal drains. After
separation steam is discharged to the condenser inlet side and condensate is entering by gravity
the hotwell.
Condensate Pumps
The 2 x 100 % main condensate pumps are of the vertical design type. During normal operation,
one pump is in service. The other serves as standby unit. The standby pump is automatically
switched on either by failure of the operating pump, or for steam turbine bypass operation at high
load only.
Feedwater Pumps
The 2 x 100 % HP- feedwater pumps with extraction for IP/LP- feedwater supply are of horizontal
design with suction strainers and minimum flow check valves. One pump is in operation at full
load and during start-up. The second pump serves as standby unit and is automatically switched
on in case of failure of the operating pump.
Feedwater Preheater Pumps
The 2 x 100 % feedwater preheater pumps are of horizontal design with minimum flow check
valves. During normal operation, they work in parallel mode. Their purpose is to maintain the
feedwater at a constant temperature of about 60 °C. Therefore feedwater is pumped through the
last coil in the HRSG. The feedwater temperature of about 60 °C prevents corrosive sulphur
condensation at the IP/LP and HP economizers at the exhaust gas side of the HRSG. This
setpoint can be adjusted in case the sulphur content would require a higher feedwater
temperature.
Before entering the pump chambers in the pump station the cooling water is cleaned by
dedicated mechanical equipment like stop gate, storage rack, bar-screen, rotary drum screen,
wash water system and debris removal. Upstream to the condenser inlet there are on each side
debris collectors, outfitted with an automatic on-load cleaning system.
The hot water from the condenser and the auxiliary coolers is returned by the outfall installation
via seal weir to the outlet channel and back to the sea.
Sampling System of HRSG, Water/Steam Cycle, Main Cooling Water- and Waste Water system
Above systems are provided with a sampling system and instruments for chemical on-line
analysing and monitoring of steam and water quality of the process. Therefore, various sampling
points are installed.
The GT exhaust gas is connected to a continuous emission monitoring system for on line
analysing and monitoring of the exhaust gas composition. The exhaust gas components will be
measured according to the air permit and the local EPA requirements. Furthermore, exhaust gas
flow characteristic (T, p, flow) will be determined.
Fuel Gas
The fuel gas is delivered to the plant in pipelines. Due to the possible wide range of supply
pressure and quality conditions of the fuel gas, it has to be treated or conditioned before it can be
fed to the GT fuel gas blocks.
Fuel Oil
The fuel oil system acts as a back-up system to the fuel gas system and mainly consists of:
- 2 fuel oil tanks
- 2x100% fuel oil unloading equipment
- 2x100% fuel oil transfer equipment
- 1 fuel oil metering
- 1x100% fuel oil preheater
- 1 fuel oil treatment plant
Waste water from different sources are depending on their characteristics at the source
categorised and collected. The collected wastewater flows are then treated as required for the
regulatory limitations for discharge/disposal at the boundary. The composition of the water is
observed by different measurements.
The compressed air system generates/stores/treats and distributes general-purpose service air
and instrument air (oil free and dry) in separated pipe networks to various consumers throughout
the plant. The instrument air distribution system is served with higher priority.
Passive fire protection measures and fire protection systems (active features) as well as
explosion prevention features are provided as required by the local authorities and contractual
requirements to provide adequate protection of the plant. Main features of the active fire
protection are the fire detection and alarm systems, the gas detection system, the automatic fire
extinguishing systems & manual fire fighting equipment and an independent fire fighting water
supply system for the plant. A dedicated water supply is provided in the combined raw / fire
fighting water supply tank as required by the local applicable standards.
One 2 winding three phase step up transformer with on-load tap changer connects the 21 kV
generator with the 132 kV network. The step-up transformer is equipped with a specific number of
oil/air cooler units (ODAF cooling), each consisting of oil pump, fans and supervision equipment.
Static Excitation
A static excitation system and an automatic voltage controller (AVR) control the generator
voltage.
The DCS is hierarchically structured with a high automation degree, as shown in Enclosure 3.
The control system enables to start and stop the main components from the Central Control
Room (CCR), provides annunciation, open and closed loop control, interlock and protection of
each component.
Some independent balance of plant equipment might be provided with local control units. Status
indication for remote monitoring will be available in the CCR for such equipment/system.
HVAC
Heating, Ventilation and Air Conditioning Systems are provided in dedicated areas for
accommodation of staff and/or protection of systems.
Lighting
The indoor/outdoor Lighting System provides light for the entire plant. The battery powered
emergency light system provides light in the event of AC power loss.
2.1.1. General
The power output is controlled by means of the gas turbine alone. The steam turbine always
generates the power that is made available by the waste heat from the gas turbine. Therefore,
control simply involves varying the quantity of fuel supplied to the gas turbine and by changing
the gas turbine combustion air flow rate (“upper load range”).
Full load operation of the combined cycle power plant (100 % CC load) is defined as follows:
• GT running at VIGV base load position,
TIT EV combustor = TIT EV base load, TIT SEV combustor = TIT SEV base load and
• the whole steam production is lead through the ST
For high block efficiency at GT part load the VIGV and fuel flow controls keep the turbine exhaust
temperature at a maximum level of approx. 650 °C. At low part load operation, the exhaust
temperature starts to decrease followed by a decrease of the live steam temperature. The
increased emission values at GT part load have to comply with the authority regulations.
The plant output is defined by the pre-set load value given by the load dispatcher / operator.
According to this load set point, the plant output is controlled by means of gas turbine load
controlling.
The WSC incl. the steam turbine is designed for modified sliding pressure operation. During
steady-state operation in the upper load range, the ST inlet valves remain fully open and the live
steam pressure is allowed to slide. In the lower load range the live steam pressure is kept
constant by control of the ST inlet valves or the bypass valves (see enclosure 5).
In CC operation the min. GT load is at 40 % as long as the steam turbine is in operation. This is
performed in order to prevent excessive cooling of the ST rotor. In addition, the flue gas side
emission level has to be considered.
According to the National Electricity Market and local grid requirements, the plant can support the
grid frequency. In case of an electrical grid frequency outside the nominal frequency dead band,
the GT load will be increased or decreased with the frequency response gradient.
The Frequency Support can be switched ON / OFF by the operator and is limited by the plant
load operation range. Frequency Support cannot be activated during start-up, shut down, or any
GT emergency procedure.
For further information, please refer to the “GT operating instructions” and to the “ST operating
instructions”.
To avoid ice formation on the gas turbine compressor inlet, the system has to be switched on at
critical ambient conditions. The system is semi-automatic and needs human intervention. For
further information, please refer to the GT operating instructions (see reference in enclosure 1),
as well as to chapter 4.6 in this document.
3. CONTROL SYSTEM
The DCS system enables safe and reliable operation, control and supervision of the process with
a high degree of automation.
Start-up and shut-down of the unit are automated as well as load operation according to grid
requirements and mode changes.
The engineering station, which is physically a different computer, is used for control system
engineering, documentation, diagnostic and maintenance.
The overall process control system software consists mainly of the following control modules:
The plant will be operated from the integrated central control room (U1 + CCGT).
All information required for remote operation and supervision of the GT, ST and other remote
operable equipment is available in the integrated central control room.
Autonomous systems like some of the BOP systems (see table below) are equipped with their
own local control systems. These systems are provided with local control panels allowing for full
local operation, control and monitoring. The necessary information for remote monitoring and/or
control is transferred to the overall plant control system.
***) Compressed Air system will be active continiously. Switching on the system is possible from remote (but not switching off).
Systems that are not related to the plant process, such as air conditioning, communication and
lighting, are not integrated in the plant process control system.
The process control functions, realised within the DCS are hierarchically structured. This structure
reflects the process on a functional breakdown basis.
From bottom to top the levels of automation and operation are defined as follows:
• Single Drive Level
• Function Group Level
• Main component level (sequencer such as GT, ST & WSC, HRSG, BOP)
• Unit Automation Level
The operator normally has access to each operational level unless otherwise defined, e.g. by
safety requirements.
The ON and OFF command to single drives and Function Groups proceed only if the respective
release criteria is fulfilled. This is applicable for manual as well as for automatic order.
The plant is equipped with the “Unit Master Sequencer” (Unit Master) and the “Unit Load
Coordinator”.
Unit Master
Unit Master is the sequencer for the unit. It is superior to the following lower main system
automation level sequencer units:
− GT sequencer
− ST sequencer
− HRSG sequencer
− WSC sequencer
− BOP sequencer
The task of the unit sequencer is to co-ordinate GT operation with all the other associated
systems. The Unit Master has the following program selections, which are also called “unit
sections”:
1. Stand Still
2. Turning Gear
3. Ready to Start
4. GT load / Bypass
5. Unit Load
The connections between the sections of the main sequences are shown in Enclosure 7.
3.6.1. General
The operation of the gas turbine is a fully automated process with the gas turbine controller and
automated function groups for the various auxiliaries of the GT.
The functions groups and the controller are switched ON or OFF according to the start-up and
shut-down sequence. The GT sequencer normally performs this automatically.
The selected sequence proceeds only after the necessary permissive conditions for the step are
fulfilled. The various protective criteria are always active during the sequencing.
Operators’ intervention for the GT start-up is (after the GT is on Rotor Barring) only required for:
• Pre-selection of target plant load
• Command for start-up and shut down of the gas turbine
The open loop control of the GT consists mainly of following function groups (FG):
• FG Lube Oil
• FG Rotor Barring
• FG Seal Oil
• FG Power Oil
• FG Static Frequency Converter
• FG Ignition
• FG Excitation
• FG Synchronizing
• FG High Fogging
• FG Evaporation Cooling
For details, please refer to the “GT operating instructions” (See reference in Enclosure 1).
Temperature/Load Control
The Temperature/Load Controller is used to control the gas turbine output according to the load
operation.
The control is sequenced according to the GT load as follows:
• during low load (only EV burner in operation), the Controller controls the fuel flow to the EV
burner.
• At higher load, the Controller controls the fuel flow to the SEV burner.
• At even higher load, the Controller controls primarily the variable inlet guide vane angle by
opening the VIGV until they are fully open. Secondly, the fuel flow to the EV and SEV burner
are adjusted accordingly. The control of the VIGV-angle is therefore the primary load criteria in
the load range from app. 25 % to approx. 95 %.
• Above approx. 95 % GT load, when the VIGV are fully open, the fuel flows are increased up to
full load by controlling the TITHPT and TITLPT.
At full load, the fuel flow to the combustors are controlled to limit the turbine inlet temperatures
to the respective full load values TITHPT,BL and TITLPT,BL.
The turbine inlet temperatures are not measured but calculated values from TATHPT/TATLPT,
pressure ratio over the HP/LP turbine and the ambient temperature.
3.7.1. General
The operation of the steam turbine is a fully automated process within the steam turbine controller
and automated function groups for the various auxiliaries of the ST.
The functions groups and the controller are switched ON or OFF according to the start-up and
shut-down sequence. The ST sequencer normally performs this automatically.
The selected sequence proceeds only after the necessary permissive conditions for the step are
fulfilled. The various protective criteria are always active during the sequencing.
The open loop control of the ST consists mainly of following function groups (FG):
• FG Vacuum Breaking System
• FG LP-Hood Water Injection
• FG Turning Gear
• FG ST Sequencer
• FG WSC Sequencer
• FG Safety Device Test
• FG Valve Test
• FG Turbine Protection & Reset
• FG Measurement Conditioning
• FG VIB Measuring Conditioning
• FG Power Assisted Check Valves
• FG Steam Turbine Drains
• FG Gland Steam System
For details please refer to the “Starting and operation instructions for Steam Turbines”.
The closed loop control of the ST fulfils the following main tasks:
• Run up, speed, control and ST loading
• Rotor stress evaluation/limitation (TURBOMAX), loading gradient limiter
• HP steam pressure and gradient limiter
• RH steam pressure and gradient limiter
• LP steam pressure and gradient limiter
• Wheel chamber pressure limitation
• Exhaust steam temperature limitation
• Gland steam pressure and temperature control
The program device does the start-up and loading of the ST. The set point for the pre-pressure
controller is generated according to the ST load diagram (see Enclosure 5). The turbine
protection is provided and realised in the TURBOTROL system. The ST valve testing is realised
in the controller of the steam turbine.
During normal operation at higher steam turbine load, leakage steam from the HP and IP steam
turbine replaces the steam supply from cold reheat line. Excessive gland steam is discharged to
the LP turbine extraction steam line via the gland steam sealing dump valve.
To avoid thermal shocks on the LP gland sealing and at LP the rotor side, the gland steam is
conditioned before the ST LP part by a water injection control valve. The water is supplied from
condensate extracted from the condensate pump discharge line.
3.8.1. General
The operation of the WSC is done with automated function groups for the various components.
The function groups are switched on or off according to the start-up and shut-down sequence.
The WSC sequencer normally performs this automatically.
The open loop control of the WSC consists mainly of following function groups (FG):
• FG HP/IP- feedwater pumps
• FG main condensate extraction pumps
• FG ADV pump
• FG HP/IP/LP steam drains
• FG dosing
• FG OTC drain valves
• FG FWT level control
• FG Feedwater preheating pumps
The closed loop control of the WSC, which is processed in the WSC sequencer, consists mainly
of following function groups (FG):
3.9.1. General
The operation of the HRSG is done with automated function groups for the various components
of the HRSG. The function groups are switched on or off according to the described start-up and
shut-down sequence. This is normally performed automatically by the HRSG sequencer.
The selected sequence proceeds only after the necessary permissive conditions for the step are
fulfilled. The various protective criteria are always active during the sequencing.
The open loop control of the HRSG consists mainly of following function groups (FG):
• FG drums continuous blow down
• FG blow down tank pumps
• FG phosphate dosing
• FG stack damper
The closed loop control of the HRSG consists mainly of following function groups (FG) that are
processed in the HRSG sequencer:
3.10.1. General
The operation of the BOP is done with automated function groups for the various components.
The function groups are switched on or off according to the described start-up and shut-down
sequence. The BOP sequencer normally performs this automatically.
The selected sequence proceeds only after the necessary permissive conditions for the step are
fulfilled. The various protective criteria are always active during the sequencing.
The open loop control of the BOP consists mainly of following function groups (FG):
FG Demineralised Water
2 x 100 % make-up water supply pumps supplies demineralised water from the demineralised
water tank to the consumers. The pumps are supervised by the function group.
The closed loop control of the BOP consists mainly of following function groups (FG) that are
processed in the BOP sequencer:
• FG Hot Waste Water System
• FG Thermo Shock
4. OPERATION PROCEDURES
4.1. General
This chapter describes the overall plant start-up and shut-down procedures for fuel gas operation.
Inspection Walk
Prior to start-up of the combined cycle power plant or plant auxiliary systems a local inspection
has to be made by the plant operating staff. The manual checks are required for a safe and
trouble free automatic start. Afterwards the plant can be started and operated from the central
control room.
Start-up Definitions
As per steam turbine operation instructions cold, warm and hot starts are defined. The difference
between them is determined by the allowable start-up loading rates of the steam turbine.
Corresponding to the ST rotor temperature a different gradient for the acceleration of the steam
turbine is selected. After SSS clutch engagement the load up gradient is limited also
corresponding to the original ST rotor temperature.
Four GT holding points (H) for the GT load are defined:
GT-H1: approx. 3 % of max. GT load
GT-H2: approx. 8 % of max. GT load
GT-H3: approx. 12.5 % of max. GT load
GT-H4: approx. 75 % of max. GT load
Depending on the Steam Turbine Start-up conditions some of the GT holding points are activated
in order to fulfil the different start-up requirements (see start-up curves in enclosure 6).
Remark: The start-up curves attached as enclosure 6 are based on 3 holding points activated.
Purging
Before every ignition of a GT the associated exhaust gas system and the HRSG must be purged.
The purging is done automatically. The purging procedure is described in the GT operating
instructions.
The detailed preparation steps as described in the specific operating manuals of all sub-systems
and components must be carried out. The following points are a summary of general items that
have to be checked before an automatic start is initiated.
General
• Plant safety procedures, like maintenance tagging, must be completed as per plant safety
procedures and all systems must be released for operation.
• Lubrication of equipment available.
• Redundant components pre-selected according to system descriptions.
• Manual valves are in correct position according to system descriptions.
• Instrument root valves open and all instrumentation properly in service.
• Drain and vent valves in position as per process requirements.
• Tanks level above required minimum level.
• Local controls on “auto” and/or “remote”.
• All checks in accordance with the system or component instructions completed
• All non-autonomous systems are ready for operation / ready for start.
• All autonomous systems as per list in this document are in operation and ready for start-up of
the plant.
The start-up can be initiated by selecting the next higher unit section or directly by selecting “unit
load”.
Enclosures 6 shows curves for a cold, warm and hot start of the plant.
• The FGs are started in the sequence according to Enclosure 7.
• The GT sequencer will check if all the criteria for GT start-up are fulfilled and confirm by
inverting the signal “GT not ready”.
The GT will be started and will run through the GT start-up program including purging and
load up according to the activated GT holding points as per cold, warm and hot start
requirements.
In parallel to the GT start sequence, The ST-, HRSG- and BOP sequencer continue to start-
up the further function groups up to the unit section “GT load / bypass”.
• After finishing the GT start sequence, the unit coordinator controls the activation of the GT
holding points.
• The first steam produced in the HRSG and OTC will be used for gland steam and condenser
evacuation, until the condenser is ready for receiving steam and consequently the bypass
valves are released for opening.
• The GT is loaded to the next activated GT holding point and afterwards the ST starts.
• After the ST is loaded to minimum load, the unit can be loaded to the target load with holding
points according to the activated way of start-up.
Plant shut-down is initiated by the plant operator according to the dispatching requirement. This
may take place from base load or any part load condition.
In general, the shut down procedure is the reverse sequence of the start-up procedure. The shut
down can be initiated by selecting the next lower unit section or directly by selecting “stand still”.
In any shut-down way, the plant has to be operated during the required holding time on turning
gear.
1. Automatic shut-down sequence:
− de-load to 180 MW CC
− freeze GT, de-load ST → bypass operation
− de-load GT
2. maximum plant load before the ST can be de-loaded: 180 MW (ST HP exhaust ventilation)
For a longer shut down period nitrogen blanketing is applied to the HRSG.
If the ST is tripped or out of service, the SSS clutch disengages, the GT and the HRSG can
remain in operation. If the GT remains in operation, the ST will continue to rotate at low speed.
(See chapter 4.9)
The generated steam is dumped into the condenser via the ST bypass system. Therefore all
water/steam cycle systems, cooling and the ST turning gear must be in operation. Because of low
fuel efficiency, this operation mode will only be used as an exceptional mode.
If the plant is disconnected from the HV grid (e.g. grid failure), the ST will trip. The SSS clutch
disengages and the ST decelerates.
The GT perform a load rejection down to station auxiliary power. During this operation mode, the
GT is controlled by the “start-up / speed controller”.
The GT can be switched off or kept in operation for a quick reloading of the plant
The plant can be re-synchronised as soon as the grid is available (HV Synchronizing on HOLD).
If the generator is disconnected from the step-up transformer via generator breaker, the ST will
trip and the GT performs a load rejection down to idle operation. During this mode the GT is
controlled by the “start-up / speed controller”. The required station auxiliary power will be taken
from the grid.
When the unit is shut-down, the gas turbine and the steam turbine have to be turned slowly to
avoid bending of the rotor during the cool down period, thus keeping the instant re-starting
availability. Consequently, the GT operates on rotor barring and the ST on turning gear, called as
a unit section simply “turning gear”.
GT and ST operate independently on turning gear. The SSS clutch will not engage during this
mode.
Turning gear operation comes into operation automatically after a unit shut-down and can be
stopped manually, when the release from the relevant controllers is available.
After a certain operation period the power output and efficiency of the GT will decrease due to dirt
deposits on the compressor blades. The compressor can be automatically cleaned in the on-line
cleaning mode during operation.
For a thorough cleaning, the compressor can additionally be cleaned in the off-line cleaning,
when the plant is not in operation (according to the GT instructions).
If quick access to the GT is required, turning the GT rotor with the static starting device can
reduce the cool down time. Forced Cooling can only be initiated with a certain delay after shut-
down. Prior the stack damper has to be opened manually. Due to thermal stress in the
components, the application of this mode should be selected only if quick access to the engine is
required.
The SDG selector switch (SS) is set to “remote” (normal position). This has to be verified on SDG
Local Panel by the Operator.
SDG is started manually from DCS, Running Function of SDG must be checked,
SDG is not connected automatically from SDG Control Panel to BMA Bus, since Interlocks are
still active (BMA00GS101 or BMA00GS102 closed),
SDG is connected automatically from SDG Control Panel to BMA Bus, since Interlocks are now
not active (BMA00GS101 and BMA00GS102 are open),
5. SAFETY PROCEDURES
5.1. General
In this section the protection criteria between systems (GT, ST, HRSG, WSC, BOP and EL) and
main components are listed. For better understanding of the protection concept the safety
procedures of GT and ST are briefly explained. The complete description is to be found in the
specific operating procedures.
Each component also has its own protection logic and safety devices. System internal trip signals
or safety procedures are not listed here. They are dealt with in the corresponding documentation
of each system.
GT Trip
A Gas Turbine Trip means an immediate closing of all the GT fuel shut-off valves and of all
measures to ensure a safe shut down.
The bypass trip will be done by de-energising the corresponding solenoid valves.
The bypass stop valves and the bypass control valve will be closed fast.
The electrical protection is included in the operation and control concept of the electrical system.
Generator and Transformer protection is considered as to be an integral part of the turbine
protection and therefore not mentioned in this document.
6. REFERENCE DOCUMENTS
7. ENCLOSURES
Main-
Sub- system: P&ID: System description: Others:
system:
Operating
instructions:
GT - TWA/11/G/----------/FD/253 - HTCT6…………….
Set point list:
HTCT6…………
High fogging HTCT122380 - -
Operating
instructions:
Geno Gas cooling system TWA/01/A/MKG-------/FD/100 TWA/01/A/MKG-------/DM/100
AGH/01/A/MKG-------
/OI/100
Operating
instructions:
Seal oil system TWA/01/A/MKW-------/FD/100 TWA/01/A/MKW-------/DM/100
AGH/01/A/MKW-------
/OI/101
WSC Main condensate AGH/22/M/LC--------/FD/001 AGH/22/M/ -------- LC /DM/001 -
Air removal system AGH/22/M/MAJ-------/FD/001 AGH/22/M/ ------- MAJ /DM/001 -
Feedwater storage
AGH/22/M/LAA-------/FD/001 AGH/22/M/ ------- LAA /DM/001 -
tank
Operating manual:
HP/IP- feedwater
AGH/22/M/LAC50-----/FD/001 AGH/22/M/ ----- LAC50/DM/001 AGH/18/M/LAC50—
pump system B30/OI/001
Feedwater
AGH/22/M/LAA50-----/FD/001 AGH/22/M/-----LAC20/DM/001 -
preheater pump
Main steam system AGH/22/M/LBA-------/FD/001 AGH/22/M/-------LBA/DM/001 -
O&M Manual:
AGH/11/G/MBH30--
GT- air cooling
AGH/21/M/MBH30-----/FD/001 AGH/21/M/-------MBH/DM/001 A21/MM/001
system AGH/11/G/MBH40--
A21/MM/001
HP turbine bypass AGH/22/M/LBA-------/FD/001 AGH/22/M/-------LBF/DM/001 -
IP turbine bypass AGH/22/M/MAN40-----/FD/001 AGH/22/M/-----MAN40/DM/001 -
LP turbine bypass AGH/22/M/MAN10-----/FD/001 AGH/22/M/-----MAN10/DM/001 -
Clean drain system AGH/20/M/LCM-------/FD/001 AGH/22/M/-------LCM/DM/001 -
Fuel gas preheating AGH/21/M/EKT-------/FD/001 AGH/21/M/EKT-------/OI/001 -
Starting & operating
instructions:
AGH/22/S/MA--------
ST - AGH/22/S/M---------/FD/001 AGH/22/S/MA--------/DM/200 /OI/200
Set point list:
AGH/22/S/M---------
/SL/001
1. High Pressure AGH/21/B/H------A30/FD/002
2. Intermediate AGH/21/B/H------A30/FD/003
Pressure
HRSG AGH/21/B/H------A30/FD/004 - -
3. Low Pressure
4. Gas Side AGH/21/B/H------A30/FD/005
5. Blow Down Tank AGH/21/B/H------A30/FD/006
Closed cooling
BOP AGH/20/M/PG--------/FD/001 AGH/20/M/--------PG/DM/001 -
water
Main cooling water AGH/00/M/PA--------/FD/001 AGH/00/M/--------PA/FD/001 -
Fuel gas supply AGH/21/M/EK--------/FD/001 AGH/21/M/--------EK/FD/001 -
Main-
Sub- system: P&ID: System description: Others:
system:
Compressed air
AGH/00/M/QFB-------/FD/001 - -
supply
Raw water supply AGH/00/M/GA--------/FD/001 AGH/00/M/ --------- G/DM/001 -
Water pre-
treatment and AGH/00/M/GHC-------/FD/001 - -
demin water supply
Waste water
AGH/00/M/GMA-------/FD/001 - -
system
AGH/00/E/C----------/D0/001
Control - -
AGH/00/M/----------IT/GS/092
-
Single line diagram:
Electrical - AGH/00/E/----------EL/SD/001
AGH/00/E/----------EL/SD/001 -
ABBREVIATION LIST
Automation structure
Automation
Level
AUTOMATION
LEVEL
UNIT LOAD COORDINATOR
MAIN SYSTEM
GT ST & WCS HRSG BOP AUTOMATION
SEQUENCER SEQUENCER SEQUENCER SEQUENCER LEVEL
FUNCTION
GT FG etc. ST FG etc. FG etc. FG etc FG etc. GROUP
CONTROLLER CONTROLLER
LEVEL
Part I
SINGLE
SD SD SD SD SD etc. SD SD SD etc. SD etc. SD etc. DRIVE
LEVEL
Fuel ~ ~ ST
Control VGVs Control etc. etc. etc. etc. FIELD
Valve Valves
ST LOAD DIAGRAMS
• ST HP LOAD DIAGRAM
• ST IP LOAD DIAGRAM
• ST LP LOAD DIAGRAM
ST HP Load Diagram
HP steam pressure [%]
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
ST load [%]
ST IP Load Diagram
IP steam pressure [%]
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
ST load [%]
ST LP Load Diagram
LP steam pressure [%]
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
ST load [%]
KA 26-1 ICC
1AHA 032 998
Cold start, average IP ST rotor temp. < 100° C (after approx. 120 hrs shutdown)
Responsible department: Take over department: Revision: Doc. type: File Info: N:\kw\db\Archiv\1AHA\032998_I.xls
PIC I
Prepared Checked: Approved: Language: Page:
02-06, P. Schulle 02-06 F. Droux 02-06 F. Ruecker en 1 of 4
Valid for: Derived from: HTGD459854 Rev. 0 Replaces: Classify No.: Data Set:
KA 26-1 ICC
110
100
nGT nST
TGT
90
THP
80
70
PST
60
pHP
50
mGT
40
mHP
30
20
10 PGT
PCC
0
-5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150
Condenser evacuation Time (minutes)
ALSTOM POWER reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Originator Identification number Rev. Date Lang. Sheet
ALSTOM PT-PE Enclosure 6 to 1AHA066247 A 16.11.2007 en 1/4
Nov. 1,2007
© ALSTOM.
Electronically released Rev.
KA 26-1 ICC
1AHA 032 998
Warm start, average IP ST rotor temp. > 130° C (after approx. 60 hrs shutdown)
Responsible department: Take over department: Revision: Doc. type: File Info: N:\kw\db\Archiv\1AHA\032998_I.xls
PIC I
Prepared Checked: Approved: Language: Page:
02-06, P. Schulle 02-06 F. Droux 02-06 F. Ruecker en 2 of 4
Valid for: Derived from: HTGD459854 Rev. 0 Replaces: Classify No.: Data Set:
KA 26-1 ICC
110
TGT
100
nGT nST
90
THP
80
70
PCC
60
50 mGT
PST
40
mHP
30
pHP
20
PGT
10
0
-5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120
Condenser evacuation Time (minutes)
ALSTOM POWER reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
KA 26-1 ICC
1AHA 032 998
Hot start, average IP ST rotor temperature > 350° C (after approx. 8 hrs shutdown)
Responsible department: Take over department: Revision: Doc. type: File Info: N:\kw\db\Archiv\1AHA\032998_I.xls
PIC I
Prepared Checked: Approved: Language: Page:
02-06, P. Schulle 02-06 F. Droux 02-06 F. Ruecker en 3 of 4
Valid for: Derived from: HTGD459854 Rev. 0 Replaces: Classify No.: Data Set:
KA 26-1 ICC
110
100
TGT
nG
90
nST
80
THP
70
mGT mHP
60
P CC
50
40
pHP
30 P GT
P ST
20
10
0
-5 0 5 10 15 20 25 30 35 40 45 50
Condenser evacuation Time (minutes)
ALSTOM POWER reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
START- UP SEQUENCES