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Electronically released Rev.

Plant Operation and Control Concept

Employer

ESB Power Generation


Employer’s Representative

ESB International
Project Title

Aghada CCGT
Consortium

ALSTOM (Switzerland) Ltd.


ALSTOM Ireland Ltd.
Revision History
Rev. Revision Date Created by Checked by Approved by Description

A Description latest Revision: First Issue

Replaces ALSTOM Document Code


AGH/00/M/01-----005/DO/001
Responsible dept. Created by Checked by Approved by Format
PEE M. Blum Gysel B. Sturzenegger R. A4
Originator Document Type Document Status

abcd Title, Subtitle


Plant Operation and Control
Electronically released
Identification number
1AHA066247
Power Turbo-Systems / Rev. Date Lang. Sheet
Power Environment Concept
A Nov 1, 2007 en 1/34
Template No.: GGG/00/-/EQA---/FT/302E (released with Work Instruction GGG/00/-/EQA---/WI/306)
© ALSTOM 2006. All rights reserved.
Electronically released Rev.

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

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3.4. Automation Structure......................................................................................................................................20


3.5. Unit Automation Level ....................................................................................................................................21
3.6. Gas Turbine Automation ................................................................................................................................21
3.6.1. General .................................................................................................................................... 21
3.6.2. Open loop control..................................................................................................................... 22
3.6.3. Closed loop control .................................................................................................................. 22
3.7. Steam Turbine Automation ............................................................................................................................23
3.7.1. General .................................................................................................................................... 23
3.7.2. Open Loop Control................................................................................................................... 23
3.7.3. Closed Loop Control ................................................................................................................ 23
3.8. WSC Automation ............................................................................................................................................24
3.8.1. General .................................................................................................................................... 24
3.8.2. Open Loop Control................................................................................................................... 24
3.8.3. Closed Loop Control ................................................................................................................ 24
3.9. HRSG Automation ..........................................................................................................................................25
3.9.1. General .................................................................................................................................... 25
3.9.2. Open Loop Control................................................................................................................... 26
3.9.3. Closed Loop Control ................................................................................................................ 26
3.10. BOP Automation .............................................................................................................................................26
3.10.1. General .................................................................................................................................... 26
3.10.2. Open loop control..................................................................................................................... 26
3.10.3. Closed Loop Control ................................................................................................................ 27
4. OPERATION PROCEDURES............................................................................................................................28
4.1. General............................................................................................................................................................28
4.2. Preparations prior to Start-up .........................................................................................................................29
4.3. Normal Start-up Procedure ............................................................................................................................29
4.4. Normal Shut-down Procedure........................................................................................................................29
4.5. Steam Turbine Bypass Operation..................................................................................................................30
4.6. Plant House Load Operation..........................................................................................................................30
4.7. Idle Operation..................................................................................................................................................30
4.8. Turning Gear Operation (GT rotor barring / ST turning gear).......................................................................30
4.9. GT Compressor on-line Cleaning ..................................................................................................................31
4.10. GT Rotor Turning Operation (Forced Cooling) .............................................................................................31
4.11. Shut down from Plant House Load Operation ..............................................................................................31
5. SAFETY PROCEDURES ...................................................................................................................................31
5.1. General............................................................................................................................................................31
5.2. Safety Procedure Definitions..........................................................................................................................32

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5.2.1. Gas Turbine ............................................................................................................................. 32


5.2.2. Steam Turbine ......................................................................................................................... 32
5.2.3. Bypass system ......................................................................................................................... 32
5.2.4. Electrical protection.................................................................................................................. 33
5.3. External Protection Criteria.............................................................................................................................33
5.3.1. Actions on Gas Turbine ........................................................................................................... 33
5.3.2. Actions on Steam Turbine........................................................................................................ 34
5.3.3. Actions on IP/LP Bypass.......................................................................................................... 34
6. REFERENCE DOCUMENTS .............................................................................................................................34
7. Enclosures ..........................................................................................................................................................34

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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.

Abbreviations used in this document are explained in Enclosure 2.

1.2. Purpose of the Combined Cycle Power 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.

Design ambient conditions are:

9 °C ambient temperature
1013 mbar ambient pressure
82 % relative humidity
12 °C cooling water temperature (Sea water)

For start-up power supply from the HV grid has to be available.


If the HV grid breaks down, house load operation is maintained.

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.

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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.

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1.3. Overview of Major Components and Systems

Picture 1.3-1 illustrates the different systems of the plant and shows the associated inter-system
signal transfer.

COMBINED CYCLE POWER PLANT OVERVIEW

Arrangement and Civil


18 14
Civil Piping Building Facilities Fire
(HVAC, Lighting)
Protection

Electrical
Power Electrical Systems I&C
16 15 17
Electrical Main Step-up Control
Distribution Transformer System

Gasturbine/Generator WSC with Steam Turbine


1 2 3 4
Air Gas Generator SSS Steam
Turbine Clutch Turbine

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

Picture 1.3-1: Combined Cycle Power Plant System Overview

The numbers represents the last letters of the paragraphs in this chapter 1.3.

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Power Train

The power train consists of the gas turbine, the generator, the self shifting and synchronising
clutch and the steam turbine set.

Gas Turbine Generator Clutch Steam


Turbine

Picture 1.3-1: Single shaft power train arrangement

1.3.1. Gas Turbine

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.

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1.3.3. Self Shifting and Synchronising Clutch

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.

1.3.4. Steam Turbine

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.

1.3.5. Heat Recovery Steam Generator and Once Through Coolers

Heat Recovery Steam Generator


One Heat Recovery Steam Generator (HRSG), triple pressure reheat, operates in natural
circulation mode for LP-, IP- and HP system and is of the horizontal design.
The hot exhaust gas, discharged from the GT, serves as a heat source to produce superheated
HP-, IP-, LP- and reheat steam and at last feedwater preheating.

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.

Saturated steam is generated at the HP, IP and LP evaporator.


The saturated HP steam is led to the multi-stage HP superheater, the saturated IP steam to the
IP superheater and subsequently to the reheater. The LP steam is superheated as well. At the
outlet of the HRSG, the HP and reheat steam are attemperated with feedwater extracted from the
feedwater line HP at the economiser outlet and IP economiser respectively. The LP-steam is
directly led to the LP steam turbine.
A water extraction from within the HP economiser feeds the OTCs , controlling their outlet stem
temperature. In order to adjust the feedwater temperature upstream the OTCs in a certain range,
there is the possibility to attemperate with an extraction upstream of the first HP economiser, if
necessary (manual control valve adjusted during commissioning).

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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.

Once Through Coolers


One HP and one LP Once Through Cooler (OTC) are required for GT air cooling. The OTCs are
of the helicon heat exchanger type, designed as once through steam generators. The steam from
the OTCs is supplied into the main HRSG HP steam system.

1.3.6. Water Steam Cycle

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.

Condenser Evacuation System (Steam Side)


The evacuation system consists of one (1 x 100 %) single stage steam jet start-up ejector and
two (2 x 100 %) two stage steam jet service ejectors with inter- and after condenser. During
normal operation, one service ejector is in service. The other serves as standby unit.
The ejectors evacuate the steam side of the condenser during start-up and extract non-
condensable gases during operation from the air coolers of the condenser.
The motive steam for the ejectors is taken from the cold reheat line and the extracted non-
condensable gases are discharged to the atmosphere. The condensed steam of the service
ejector is returned to the flash box. A pressure-reducing valve controls the steam pressure at the
inlet of the start-up ejector and a second pressure control valve reduces the motive steam
pressure at the inlet of the service ejectors.

Feedwater storage tank / Deaerator


One feedwater storage tank (FWST)/deaerator provides feedwater storage for the HRSG and
preheats and deaerates the main condensate.
During normal operation, feedwater preheating is ensured by feedwater recirculation (see
Feedwater Preheater Pumps). At low load or at full load and very low cooling water temperature,
failure of both feedwater preheater pumps, preheating is done with pegging steam extracted from
the cold reheat steam line. The condensate is physically mixed in the direct contact deaerator.
The separated gas is collected at the top of the deaerator and vented to the inlet side of the
condenser.

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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.

Steam Turbine Bypasses


For any conditions at which the full amount of HP steam can not be admitted to the steam turbine,
the HP bypass system guides the HP steam via the attemperation station and through the cold
reheat line back to the HRSG. This ensures cooling of the HRSG reheater. The feedwater used
for attemperation is extracted downstream the HP feedwater pumps
The IP and LP bypasses lead the IP and LP steam flows into the main condenser via respective
desuperheating / pressure reducing stations. For IP and LP bypasses, the condensate used for
attemperation is extracted downstream the main condensate pumps.
Each steam bypass is designed for 100 % HRSG live steam mass flow at 100 % live steam
pressure.

Gland Steam System of Steam Turbine


The gland steam system of the steam turbine prevents air from being sucked into the part of the
turbine, which is under vacuum, and steam from the steam turbine glands leaking into the
machine house. The pressure side as well as the suction side of the gland steam system is
connected for all three turbine sections.
During start-up of the steam turbine, the gland steam is provided from the cold reheat pipe, during
normal operation, the turbine is producing internal gland steam from within the HP casing.

Gland Steam Condenser (GSC)


The 2 x 100 % fans downstream of the gland steam condenser creates a slight vacuum on the
suction side of all glands and the sucked off gland steam is condensed in the 1 x 100 %
condenser, which is cooled by main condensate. The condensed steam is returned to the flash
box.

Atmospheric Drain Vessel


The atmospheric drain vessel (ADV) collects steam turbine external drains from the steam
system. After separation in the ADV steam is discharged to atmosphere and condensate is
discharged to the waste water system.

1.3.7. Cooling System

Main cooling water system (MCWS)


The waste heat of the WSC & CCW is transposed by direct cooling with extracted water from the
sea. Two (2 x 100 %) main cooling water pumps supply the cold water from the cooling water
intake to the main condenser and in parallel to the intercoolers of the CCW-system. One pump is
in operation from start-up until full load. The second pump serves as standby unit and is
automatically switched on in case of failure of the operating pump.

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.

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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.

Electro Chlorination System


A chlorination dosing to various points of the sea water intake serves to counter biological growth.
The chlorine is produced locally by the electro-chlorination system. The operation foresees aside
the continuous dosing also periodic shock dosing to reduce more drastically eventual faster
growth.

Condenser Tube Cleaning System


The main condenser is equipped with a sponge ball cleaning system to reduce bio fouling and
scaling of the condenser tubes.

Closed Cooling Water System


A separate modularised closed cooling water (CCW) system ensures the cooling of the
generator, lube oil, feedwater pumps, main condensate pumps, condenser waterbox evacuation
pumps, sampling coolers etc.. Two 100 % capacity circulating pumps are provided for the CCW
system. The heat picked up in the CCW is dissipated to the main cooling water system via two
100 % capacity water/water heat exchangers.
Constant pressure is maintained via a head tank and water losses are replaced via a make- up
water line to the pump suction pipe.

1.3.8. Water Supply System

Raw Water Supply


One raw water source is available: The raw water is fed into the raw/fire fighting water tank
serving the water treatment plant and the fire fighting system.

Demineralised Water Supply


A 2 x 100 % demineralised water plant, ensures the supply of demineralised water for the facility.
Its main components are raw water pumps, ultra filtration units, activated carbon filters,
cation/anion exchangers, mixed bed units, regeneration,degasser and neutralizing equipment.
The treated water is stored in a demineralised water tank.
From the demineralised water tank, 2 x 100 % demin water pumps forward the demineralised
water to the consumers.
The main parts of the demineralised water consumption are water losses mainly due to blow
downs in the water steam cycle. In case of oil firing 2x100% NOx water pumps feed the demin
water to the GT.

1.3.9. Chemical System

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.

Dosing of the HRSG and Water/Steam Cycle


The boiler is equipped with a Trisodium Phosphate Dosing System including pumps for injecting
the chemicals into the HRSG drums.
The water/steam cycle is provided with Ammonia/Hydrazine Dosing System including pumps
injecting it into the feedwater storage tank or condensate pump discharge line.

Dosing of Closed Cooling Water system


The CCW- system is provided with separate dosing line from Ammonia/Hydrazine dosing
equipment for injecting oxygen scavenger (Hydrazine) chemicals into the closed cooling water
system.

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1.3.10. Continuous Emission Monitoring System

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.

1.3.11. Fuel Supply System

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.

The system consists of the following main components:


- main inlet isolation valve
- 2x100% fuel gas scrubbing device
- 2x100% fuel gas metering station
- 2x100% fuel gas pressure unit, incl. pressure control unit
- 2x100% fuel gas fine filter
- 1x100% fuel gas efficiency preheater
- 2x100% dew point heater to preheat gas prior to pressure reducing station. The dew point
heater keeps the gas temperature above the dew point downstream the pressure reducing
station and heats the gas up to the level required by the gas turbine in case the gas efficiency
heater is not in operation.

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

1.3.12. Waste Water System

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.

1.3.13. Compressed Air System

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.

1.3.14. Fire Protection System

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

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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.

1.3.15. Step-up Transformer

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.

1.3.16. Electrical Distribution

Station Service Transformer and Auxiliary Transformer


One three winding station service transformer provides power to the 6.6 kV medium voltage
switch gear and to the static starting device (SSD).
The station medium voltage switch gear board supplies power to the feedwater pumps, main
cooling water pumps, attemperation pumps and to the auxiliary transformers.
The auxiliary transformers supply power to the low voltage boards.

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Static Starting Device


The GT is equipped with a static frequency converter for starting the GT from zero speed until
approximately 90 % of nominal speed and for the possibility of forced (maintenance) cooling after
shutdown.

Static Excitation
A static excitation system and an automatic voltage controller (AVR) control the generator
voltage.

Emergency and standby power system


A battery powered DC/UPS system in combination with the standby diesel provides a safe
emergency source for a shutdown in case of loss of AC power supply. In this case, the standby
diesel generator starts automatically and feeds all loads essential for a safe shut down.

1.3.17. Control System

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.

1.3.18. Building Facilities

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.

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2. OPERATION AND OPERATION MODE

2.1. Load Operation

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”).

2.1.2. Base Load Operation

The GT base load (100 % GT load) is defined as follows:


• The turbine inlet temperatures are at the pre-set base load values
• The GT-compressor variable inlet guide vanes (VIGV) are at base load position fully open
This definition applies to ambient temperatures between –1 °C and 40 °C.

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

2.1.3. Part Load Operation

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.

2.2. Plant operating modes


The combined cycle power plant is designed for the production of electricity according to the
National Electricity Market and local grid requirements, base load operation or cycling operation.

2.2.1. Frequency Support

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.

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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”.

2.2.2. Anti Icing

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.

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3. CONTROL SYSTEM

3.1. General Description


The facility is equipped with an overall plant process control system, based on DCS technology.

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 DCS provides functions such as:


• Signal conditioning, annunciation, recording
• Operation, monitoring and supervision
• Open and closed loop control, sequence logic, protection
• Data communication, plant management applications, sequence of events
• Interfacing of GT and ST control systems

Closed loop control:


Control structure where the set point of control variable is compared with its actual value. The
controller changes the manipulated variable to achieve zero deviation between set point and
actual value. (Examples: feedwater tank temperature control, steam turbine bypass pressure
control, ...)

Open loop control:


Sequence control without comparison of the actual control variable value with the set point of it.
Controller changes the manipulated variable according to a set point (demand) without attempting
to reach the control variable set point. (Examples: condensate extraction pump control, feedwater
tank level control, ...)

3.2. Control System Overview


The operator interface (HMI) is video based, driven by Windows applications. It allows process
operation, monitoring and supervision. The Control System provides plant management facilities,
such as trending, recording and calculations.

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:

UNITMASTER Sequencer and UNIT LOAD COORDINATOR


• Co-ordinates GT operation with HRSG, Water steam cycle, BOP and steam turbine and
activates the appropriate GT holding points according to the activated way of start-up.

Gas Turbine Controller (EGATROL®)


• Includes start-up and shut-down sequence, open and closed loop control and the GT
protection system.

Steam Turbine Controller (TURBOTROL®)


• Includes open and closed loop control of all the ST auxiliaries and including ST control with
thermal stress calculator, ST protection and WSC/ST sequencer.

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Water/Steam Cycle & HRSG Controller


• Includes open loop control, closed loop control, protection and HRSG sequencer.

BOP Control Module


• Includes open loop control, closed loop control, protection, interfaces to the autonomous
systems and sequencer.

Electrical Controller (SAE Module)


• Includes open loop control, closed loop control, protection, interfaces to the plant electrical
systems.

Common BOP Controller


• Includes open loop control, closed loop control, protection, interfaces to the plant common
systems (e.g. Fuel Gas)

An Overview of the control system is shown in Enclosure 3.

3.3. Control Locations

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.

List of Autonomous Systems:

Autonomous System Remote Remote Remarks


Control from Monitoring in
DCS DCS
Fuel Gas Compressor Yes Yes
Fuel Oil Unloading No No
Fuel Oil Treatment Plant Yes Yes
**)
Water Treatment Plant Yes Yes serial link
Waste Water System No Yes
**)
Miscellaneous Chemical Dosing Systems Yes Yes
Emission Monitoring System No Yes serial link
***)
Compressed Air Supply System Yes Yes serial link
Miscellaneous Sampling Systems No Yes
Fire Protection System No No Main fire control
board is in CCR
**)
Tube Cleaning System Yes Yes serial link
Debris Filter of main cooling water No No
Debris Filter of auxiliary cooling water No Yes
Cooling Water Screening Plant No Yes
Evaporative Cooler No No
Emergency Diesel Generator Yes Yes serial link
*) Except trip for main gas SOV
**) ON/OFF only

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***) 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.

3.4. Automation Structure

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.

Single Drive Level


This level consists of all drives/control drives/selectors. On this level each drive such as remote
operated actuators, pumps or similar equipment, each control drive and each selector can be
operated individually by the operator from the central control room. The respective protective
functions are active to initiate trips or interlocks if necessary.

Function Group Level


Several aggregates and drives/control drives/selectors are functionally combined to maintain the
specific function of a sub-process. Such combinations are grouped together to so called function
groups (FGs).
The order ON to a FG will be forwarded by the FG to all subordinated systems, supervises the
execution of the command and control the designated drives/control drives/selectors
automatically.
The order OFF to a FG will be processed accordingly and will change over the designated
process into the defined OFF condition.
The order STOP to a FG however, will reset all outgoing orders from the FG and omit supervision
of the subordinated systems. This way, manual operation of those subordinated systems (i.e.
single drives) is possible without interference through automatic order from the FGs

Main component Level and Unit Level (sequencer)


Superior automation levels are outlined more detailed in the following chapters.

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3.5. Unit Automation Level

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.

Unit Load Coordinator


The Unit Load Coordinator is always part of the single shaft power train control and co-ordinates
the activation of the holding points of the GT load depending on the activated way of start-up
(cold, warm, hot start) and co-ordinates the GT load with the ST load. The Unit Load Coordinator
exchanges signals between:
- ST control
- GT control
- Unit Master

Automatic Generation Control (AGC)


The AGC can control the power output of the respective unit automatically from a local or remote
setpoint. For one single shaft Unit it coordinates the power output of the gas turbine connection
with the unit power output.

3.6. Gas Turbine Automation

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

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3.6.2. Open loop control

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).

3.6.3. Closed loop control

The closed loop control of the GT consists mainly of following functions:

Start-up / Speed Control


The Start-up Speed Controller controls:
• the start-up of the gas turbine until nominal speed
The Static Frequency Converter (SFC) uses the generator as speed variable motor to bring
the GT to ignition speed. The start-up controller ensures that the fuel/air ratio is such that the
outlet gas temperature does not exceed permissible limits.
• the adjustment of the parameters of frequency, phase angle and voltage to suit the grid during
synchronising.
• the speed control during Idling by controlling the GT rotating speed to nominal speed.

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.

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3.7. Steam Turbine Automation

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.

3.7.2. Open Loop Control

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”.

3.7.3. Closed Loop Control

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.

FG Gland Steam Control


During start-up phase or lower steam turbine load, gland steam is supplied from cold reheat line.
The gland steam pressure is then controlled by a pneumatic control valve to a pressure value
slightly above atmospheric pressure in order to ensure an air tight sealing between atmosphere
and the turbine at the turbine shaft.

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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. WSC Automation

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.

3.8.2. Open Loop Control

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

For details please refer to the respective P-FUPs.

3.8.3. Closed Loop Control

The closed loop control of the WSC, which is processed in the WSC sequencer, consists mainly
of following function groups (FG):

FG Hotwell Level Control (also called Condenser Level Control)


The condensate level in the hotwell is kept constant by controlling the main condensate control
valve and the main condensate recirculation control valve downstream of the condensate
extraction pumps.
If the flow rate through the condensate extraction pump falls below the required minimum (as
determined by the position of the main condensate discharge control valve), the main condensate
recirculation control valve opens. The condensate is then recirculated back to the condenser
hotwell via the flash box.

FG Feedwater Tank Temperature Control


The condensate enters the feedwater tank through the Spray head of the deaerator. During
normal operation, it is heated up by hot feedwater from the preheater coil recirculated by the 2 x
100 % feedwater preheater pumps. The recirculated feedwater flow is controlled in such a way
that the FWT pressure is kept fixed during normal operation. For the operation with natural gas
the pressure setpoint is set to 0.2 bara (corresponds to 60°C feedwater temperature), for No.2
fuel oil the setpoint is 2.7 bara (corresponds to 130°C).
In cases the FWT pressure respectively temperature reaches a min. set point value additional
pegging steam from cold reheat line is used.

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FG Start-up and Service Ejector Motive Steam Pressure Control


The motive steam pressure reducing valves control the pressure before the ejectors to a constant
value as required by the ejectors. As soon as the motive steam pressure after the control valve
reaches the necessary value, the ejector evacuation air shut-off valve opens and the ejector is in
operation.

FG HP/IP/LP Steam Turbine Bypass Station


The steam bypasses are used in connection with starting, loading and unloading of the ST and
for dumping the steam into the condenser (IP /LP bypass) resp. into the cold reheat line (HP
bypass) in case of a steam turbine trip. The bypass station expands and desuperheats the steam
to protect the condenser resp. the cold reheat line.
The set points of the bypass pressure control are kept constantly slightly above the pressure set
point of the ST according to the ST load diagram (see Enclosure 5).
Consequently, the set point of the bypass pressure control is kept at low ST loads constant until
the inlet control valves of the ST are fully open. Once the ST inlet valves are fully open, the
bypass setpoint is allowed to slide. During sliding pressure operation the pressure set points of
the HP, IP and LP bypasses are adjusted according to the ST load diagram with a maximum
gradient.
During the start-up of the boiler, the HP-bypass opens to a minimum opening as soon as the HP
pressure attains a minimum value. The HP bypass limits the HP steam pressure according to the
allowable pressure gradient. If the HP bypass back pressure rises over a certain value, the HP
bypass opening is controlled by limiting the back pressure.
After the steam temperature has exceeded a certain value, the bypass temperature control unit
will keep the steam outlet temperature at a fixed value.
The stand-by condensate pump will be switched on, by a high bypass injection water demand.
On a ST trip and GT on high load the stand-by condensate pump is switched ON automatically.
Under normal operating conditions, the bypass control valves are closed and the IP bypass shut-
off valve is open.

FG HP/LP OTC GT Air Temp Control


The temperatures of the GT cooling air at the outlet of the HP and the LP OTC are to be
controlled at a constant value TGT,CA. This is performed by controlling the feedwater flow through
the OTCs only.
To get defined start-up conditions, the OTCs will be filled to the start-up level and kept within a
defined range by controlling the OTC feedwater control valves and the OTC water-side drain
valves. As soon as the GT flame is ON, the OTC level controller is inactive.

FG Fuel Gas Preheater Control


Warm water extracted downstream of the HRSG IP economiser preheats the fuel gas in a heat
exchanger. The cooled water is led to the feedwater storage tank.
The GT fuel gas inlet temperature is to be controlled at a constant value. This is performed by
controlling the water flow through the fuel gas preheater only. The automatic water control valve
is located downstream of the gas preheater close to the feedwater tank.

3.9. HRSG Automation

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.

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3.9.2. Open Loop Control

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

For details please refer to the respective PFUPs.

3.9.3. Closed Loop Control

The closed loop control of the HRSG consists mainly of following function groups (FG) that are
processed in the HRSG sequencer:

FG HP/IP/LP Drum Level


The drum level is controlled by means of the feedwater control valve situated at the inlet of the
drum. Two operation modes for drum level control are foreseen:
• Start-up control (single element control)
• Normal operation control (three elements control)
The control mode is switched automatically to ‘three element control’ (drum level, feedwater –
and steam flow operation) as soon as stable operation is obtained and steam flow has exceeded
a minimum value.

FG HP and IP (Reheat) Steam Temperature Control


The temperature of the HP and IP steam from the HRSG is limited by means of a desuperheater.
The injection water is extracted from the corresponding economiser line. During start up the
HP/IP temperatures are set at a lower set point than at normal operation to allow an optimised
start-up of the steam turbine. The ST controller will give these set points automatically.

3.10. BOP Automation

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.

3.10.2. Open loop control

The open loop control of the BOP consists mainly of following function groups (FG):

FG Main Cooling Water Pumps/combined function valves


The 2 x 100 % main cooling water pumps supply the cooling water to the condenser and to the
CCW water/water intercooler.
The function group “Main Cooling Water” will coordinate start-up and shut down of the pumps and
combined function valves, their pump protection, etc. for smooth operation.

FG Tube Cleaning System


The tube cleaning system is controlled by a local PLC and can be switched ON and OFF by the
corresponding function group in the DCS.

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FG Closed Cooling Water Pump


One of the 2 x 100 % closed cooling water pumps supplies the heated closed cooling water to
the 2 x 100 % water/water intercooler and supplies the cooling water to the components of the
CCW system.
The function group “Closed Cooling Water” will co-ordinate start-up and shut down of the pumps,
pump protection, etc. to ensure smooth operation.
During normal operation one closed cooling water pump is working. If this pump fails, the
selection logic will automatically start the standby pump.
The 2 x 100 % debris filter on the main cooling water side in front of each of the CCW intercoolers
are controlled by a local control panel.

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.

FG Dew Point Heater


The dew point heater preheats the gas upstream of to the pressure reducing station. This keeps
the gas temperature above the dew point.

FG Closed Cooling Water Head Tank


The closed cooling water head tank is initially filled manually. During normal operation water level
in the head tank / CCW system is maintained automatically. The level is supervised by a function
group and will be controlled with the filling valve. Make up water is supplied from the
demineralised water distribution system.

3.10.3. Closed Loop Control

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

For details please refer to the respective PFUPs.

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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.

Electrical Power Supply


The plant will be started with power supplied from the HV grid. In case of an HV grid failure the
start of the plant is not possible.

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.

Rotor Turning Gear / Rotor Barring


Start-up of the turbines from standstill to rotor barring (GT) or turning gear (ST) is described in the
GT and ST operating instructions. Depending on the shaft standstill periods, holding times on
turning gear are required for smooth speed up (see turbine instructions).

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ALSTOM Power Systems 1AHA066247 A Nov 1, 2007 en 28/34
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Electronically released Rev.

4.2. Preparations prior to Start-up

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.

Electrical and Control System


• Electrical power supply and distribution from the grid to medium and low voltage bus bars and
motor control centres must be in accordance with the electrical operation concept.
• The control and monitoring system must be available and disturbances cleared.
• All sub systems, which are necessary for the initial speed-up, must be energised during stand
still.

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.

4.3. Normal Start-up Procedure

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.

4.4. Normal Shut-down Procedure

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.

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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.

4.5. Steam Turbine Bypass Operation

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.

4.6. Plant House Load Operation

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).

4.7. Idle Operation

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.

4.8. Turning Gear Operation (GT rotor barring / ST turning gear)

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.

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4.9. GT Compressor on-line Cleaning

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).

4.10. GT Rotor Turning Operation (Forced Cooling)

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.

4.11. Shut down from Plant House Load Operation


(Synchronization via HV CB not possible)
If it is not allowed or possible to close the HV CB, the Operator can decide to shut down the GT
Train manually. The manual shut down can be carried out as described below:

Shut Down by Standby Diesel Generator

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),

Operator opens manually BMA00GS101 or BMA00GS102 ( so BMA00GS101 and BMA00GS102


are open) from DCS.

SDG is connected automatically from SDG Control Panel to BMA Bus, since Interlocks are now
not active (BMA00GS101 and BMA00GS102 are open),

Manual GT Shut Down is initiated via DCS.

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.

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5.2. Safety Procedure Definitions

5.2.1. Gas Turbine

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.

GT Protective Load Shedding Trip (PLST)


A PLST means a protective load shedding followed by a trip. The GT load is reduced with a
defined load gradient and by reaching idle mode, all the GT fuel shut-off valves will be closed
immediately.
The purpose of a PLST is to bring the process parameter causing the malfunction back within
safe limits by reducing the GT load as fast as possible.
This occurs, when it is evident, that the responsible actuating protection signal does not
disappear during unloading. Therefore a quick closing of the fuel shut-off valves is executed
immediately after reaching the idle mode.
If the PLST signal can be reset during the deloading procedure, the load set point will remain at
the momentary value. The GT can be loaded again by the operator by acknowledging the PLST
command.
A PLST can either be initiated by GT internal criteria or from external systems.

GT Protective Load Shedding (PLS)


A PLS means a protective load shedding. The GT load is reduced with the same gradient as for
PLST, but the GT will remain at idle mode for several minutes followed by quick closing of all the
GT fuel shut-off valves.
The purpose of a PLS is on one side to achieve steady state temperature conditions and on the
other side to bring the process parameters causing the malfunction back within safe limits by
reducing the GT load as fast as possible and additionally by remaining the GT at idle mode for
several minutes.
If the PLS signal can be reset during the deloading or idling procedure, the load set point will
remain at the momentary value. The operator can load the GT again by acknowledging the PLS
command.
A PLS can either be initiated by GT internal criteria or from external systems.

SEV Emergency Switch Off


This GT type has the possibility of an internal separated trip of the SEV burners by shutting off of
the SEV burner fuel valves. The GT will consequently be deloaded to single operation of the EV
burner.

5.2.2. Steam Turbine

Steam Turbine Trip


A steam turbine trip means the shutting-off of all the steam turbine stop valves and control valves.
Instantaneously the bypass valves will be opened and the steam is dumped into cold reheat
system, respectively into the condenser. The operator has to decide if the gas turbine continues
at default operation condition or reducing load. No other system is affected by a steam turbine
trip.
A ST trip can be initiated by ST internal criteria or from ST external systems.
An LP admission ST trip (LP trip) means the shutting off of the LP admission control and stop
valve only. The ST remains in operation with HP and IP steam.

5.2.3. Bypass system

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.

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5.2.4. Electrical protection

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.

5.3. External Protection Criteria

5.3.1. Actions on Gas Turbine

Malfunction Emergency Initiation


Procedure Delay
HRSG HP drum level <MIN 3 PLST No
HRSG IP drum level <MIN 3 PLST No
HRSG LP drum level <MIN 3 PLST No
HRSG HP drum level >MAX 3 PLS No
HRSG IP drum level >MAX 3 PLS No
HRSG LP drum level >MAX 3 PLS No
HP/LP OTC tripped PLS No
HRSG HP steam pressure > MAX2 PLS 30 sec
IP bypass tripped AND steam turbine tripped PLS No
LP bypass tripped AND LP steam turbine tripped PLS No
HP/IP live steam temperature >MAX 2 PLST 120 sec
Temperature after HP Bypass >MAX 2 PLST 15 sec
ST trip and SSS engaged PLS 40 sec
HV circuit breaker open GT island mode No
Generator breaker open GT idle mode No
HP live steam pressure > PRMTR PLS No

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5.3.2. Actions on Steam Turbine

Malfunction Emergency Initiation


Procedure Delay
Condenser pressure >Max 3 (ST- internal process) Trip No
GT Trip Trip No
HV circuit breaker open Trip No
HRSG HP drum level >MAX 3 Trip No
HRSG IP drum level >MAX 3 Trip No
HRSG LP drum level >MAX 3 LP Trip No
Hotwell level >MAX 3 Trip 5 sec
Loss of Cooling Water Pumps Trip 5 sec
Generator breaker open Trip No

5.3.3. Actions on IP/LP Bypass

Malfunction Emergency Initiation


Procedure Delay
Loss of Cooling Water Pumps IP/LP bypass Trip 5 sec
Condenser pressure>Max (Function of ST speed) IP/LP bypass Trip 5 sec
Temp. after IP/LP Bypass >Max 2 IP/LP bypass Trip 5 sec
Temp. after CV IP/LP Bypass >Max 1 IP/LP bypass Trip 5 sec
Hotwell level >MAX3 IP/LP bypass Trip 5 sec

6. REFERENCE DOCUMENTS

For specific information, please refer to the documents listed in Enclosure 1.

7. ENCLOSURES

Enclosure 1: Reference Documents


Enclosure 2: Abbreviation List
Enclosure 3: Automation Structure
Enclosure 4: Closed Control Loop of W/S Cycle
Enclosure 5: Steam Turbine Load Diagram
Enclosure 6: Start-up and Shut-down Curves
Enclosure 7: Start-up and Shut-down Sequences

Enclosure 8: Plant Load Limitations for Thermo Shock Operation

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STRUCTURE OF PLANT OPERATION AND CONTROL DOCUMENTS / REFERENCE DOCUMENTS

PLANT OPERATION AND CONTROL CONCEPT OF THE COMBINED CYCLE

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 -

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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 -

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ABBREVIATION LIST

AGC : Automatic Generation Control


BMA : Low Voltage Essential Board
CB : Circuit Breaker
CCR : Central Control Room
CCW : Closed Cooling Water
CM : Control Module
CO2 : Carbon Dioxide
DCS : Distributed Control System
EV : Environmental Burner
FG : Function Group
FWST : Feed Water Storage Tank
GT : Gas Turbine
H2 : Hydrogen
HP : High Pressure
HRSG : Heat Recovery Steam Generation
HV : High Voltage
IP : Intermediate Pressure
kV : kilo Volt
LP : Low Pressure
LV : Low Voltage
MCW Main Cooling Water
HMI : Human Machine Interface
MV : Medium Voltage
MW : Mega Watt
NOx : Nitrogen Oxides
ODAF Oil Directed Air Forced
OTC : Once Through Cooler
PCC Point of Common Connection
PFUP : Process Function Plan (process logic function plan)
PLC : Program Logic Controller
PLS : Protection Load Shedding
PLST : Protection Load Shedding Trip
POS : Process Operator Station
SDG : Standby Diesel Generator
SEV : Sequential Environmental Burner
SOV Shut Off Valve
SS Selector Switch
SSD or SFC : Static Starting Device or Static Frequency Converter
ST : Steam turbine
TAT : Turbine Outlet Temperature
TIT : Turbine Inlet Temperature
UPS : Un- interruptible Power supply
VIGV : Variable Inlet Guide Vanes
WSC : Water/Steam Cycle

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Nov. 1,2007
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Automation structure
Automation
Level

UNIT MASTER UNIT


Part II

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

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Closed Control Loop Diagram of Steam Water Cycle

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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 [%]

HP steam pressure HP bypass setpoint

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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 [%]

IP steam pressure IP bypass setpoint

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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 [%]

LP steam pressure LP bypass setpoint

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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)

Cold start-up conditions: - Start-up begins with GT ignition


-average IP ST rotor temperature < 100.0 ºC - Start-up considered finished when GT VIGV end position reached and ST bypass closed and ST control valves remain fully open
- HRSG pressure > 1 bar - Possible waiting time to reach adequate steam quality for ST operation not included in start-up time
- Preconditions for the Start-up fulfilled - ISO ambient conditions

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
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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)

Warm start-up conditions: - Start-up begins with GT ignition


- average IP ST rotor temperature > 130.0 ºC - Start-up considered finished when GT VIGV end position reached and ST bypass closed and ST control valves remain fully open
- HRSG pressure > 1 bar - Possible waiting time to reach adequate steam quality for ST operation not included in start-up time
- Preconditions for the Start-up fulfilled - ISO ambient conditions

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.

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Nov. 1,2007
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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)

Hot start-up conditions: - Start-up begins with GT ignition


-average IP ST rotor temperature > 350.0 ºC - Start-up considered finished when GT VIGV end position reached and ST bypass closed and ST control valves remain fully open
- HRSG pressure > 22 bar - Possible waiting time to reach adequate steam quality for ST operation not included in start-up time
- Preconditions for the Start-up fulfilled - ISO ambient conditions

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.

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START- UP SEQUENCES

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SHUT- DOWN SEQUENCES

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