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GENERAL COMMENT 1: Please update KKS as per latest information supplied.

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DESIGNER

PROJECT

AL DUR II IWPP

A 29/05/2019 FOR INFORMATION C.K.KIM S.H.KANG J.Y.PARK

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DOCUMENT NUMBER DOCUMENT NAME

AD2-C1-00-H-M-CR-BHI-03005 SYSTEM DESCRIPTION

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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 2 / 25

CONTENTS

1. GENERAL

2. COMPONENT DESCRIPTION

3. DESCRIPTION OF OPERATION
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1. GENERAL

This document describes operating procedures and control philosophy of the Heat Recovery Steam
Generator (HRSG) for AL DUR II IWP Project as a guide, which is mainly intended to be used during
engineering stage and initial stage of the operation. They include the proper operating sequences
for the HRSG and auxiliary equipment furnished. Please refer to the relevant Piping and
Instrumentation Diagram. (Drawing number : AD2-C1-00-H-P-DW-BHI-00510).

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

2. COMPONENT DESCRIPTION

2.1 INTRODUCTION

Total Two (2) Block of plant is supplied. Each block is Two (2) HRSGs which consist of triple
pressures supply steam to one (1) Steam turbine. The HRSG is natural circulation type with
horizontal gas turbine exhaust gas flow through vertical tube heat transfer sections. The heat
transfer sections are configured in the direction of exhaust gas flow to obtain optimum exhaust gas
energy utilization based on thermo-economic considerations. The basic heat transfer section
configuration is shown on the HRSG P&ID (Drawing number : AD2-C1-00-H-P-DW-BHI-00510).
The heat transfer in the HRSG is accomplished through convection in the banks of externally
finned tubes. Spiral finning is attached to the tubes by continuous welding. All tubes are seamless.

Feedwater flow through each economizer is counter to the exhaust gas flow, from the inlet to the
outlet header through the multi-pass arrangement of finned tubes. The economizers are designed to
heat the feedwater from supply temperature to a temperature slightly less than the saturation
temperature corresponding to the steam drum pressure. The sub-cooled economizer outlet
temperature reduces the possibility that the economizer steaming limit is exceeded during low load
and start-up operation. The economizer outlet flow is discharged directly to the steam drum. The
condensate water flow is supplied from the condensate extraction pump to condensate preheater.
Then, the feed water is supplied to the HP and IP economizer through the 2 x 100% boiler feed
water pumps.

Feedwater enters the steam drum from the economizer and is distributed along the length of the
steam drum by a distribution pipe. The water flows from the bottom of the steam drum to the
evaporator section through downcomer piping via the natural circulation process which is by static
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head and the difference of density between water and steam. The saturated water enters the
evaporator bottom header and flows upward through evaporator tubes where evaporation occurs.
The evaporator section operates essentially at constant temperature absorbing heat from the
exhaust gas in the amount equal to the latent heat of vaporization for the steam drum operation
pressure. The steam/water mixture leaves the evaporator top header through short pipe connections
to the steam drum and is directed to a primary separator where the first stage of steam/water
separation occurs. The primary separator of HP and IP drum is applied as cyclone type. However,
the primary separator of LP drum is applied as channel type instead of cyclone. The water
discharges downward while the steam rises to a secondary moisture separator (Chevron Dryer)
where final steam purity is reached before leaving the drum.

The steam drum is designed to provide high purity steam to the superheater and to accommodate
evaporator surge during start-up and operating transients.

Saturated steam is piped from the steam drum to the superheater inlet header and then flows
through a single-pass (IP and LP Superheater) or multi-pass (HP Superheater) arrangement of
finned tubes to the outlet header. The flow of steam is countered to the exhaust gas flow. The
superheater section raises the steam temperature from saturation to a superheated temperature
consistent with the gas turbine exhaust conditions and requirement of the steam turbine. An inter-
stage and final-stage attemperator utilizing feedwater is provided for the temperature control of the
high pressure superheater and reheater outlet steam.

The Condensate Preheater(CPH) is integrated in the HRSG and located upstream of the LP
evaporator section. The heating surfaces are also fabricated from finned tubes. This arrangement
enables higher efficiencies of the combined cycle power plant, by using the exhaust gas energy to
preheat the condensate water. A recirculation system is furnished for the condensate preheater to
protect the HRSG from cold end corrosion. The recirculation system consists of three(3) x 50%
motor driven recirculation pump(11LCA21/22/23AP001) which discharge through a modulating
recirculation flow control valve to control the Condensate preheater water inlet temperature to a
preset value (123℃or 119℃ for NG, 57℃ for RLNG), to maintain above the dew point of the exiting
flue gas. The pump is protected by a minimum flow limit on the control valve (11LCA30AA201). Also,
the condensate preheater is equipped with a bypass system. Flow control valve (11LAB75AA201)
send condensate water flow to the condensate preheater outlet for bypass to maintain approach
temperature (min. 1℃) at base load only. Approach temperature may modified by operator to reduce
dissolved oxygen. However, 1℃ approach temperature shall be maintained during performance test
to consider heat absorption.
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2.2 FEEDWATER SUPPLY

Feedwater is supplied from condensate pump to the condensate preheater. HP and IP Feedwater
are supplied through boiler feedwater pumps from LP drum. Minimum recirculation lines for the
boiler feedwater pump are applied on LP drum.

2.3 HIGH PRESSURE WATER/STEAM FLOW PATH

The HP system flow path is as below:
HP feedwater flow element (11LAB15CF601)
→ HP Drum level control valve(11LBA20AA201/202/203) → Check valve (11LBA20AA051)
→ HP inlet motorized stop valve (11LBA20AA101) → HP economizer 1 → HP economizer 2
→ HP economizer 3 → HP economizer 4 → HP economizer 5 → HP steam drum
→ HP evaporator → HP superheater 1 → HP superheater 2 → HP superheater 3
→ Inter-stage Attemperator → HP superheater 4 → Final-stage Attemperator
→ Check valve (11LBA10AA051) → HP main steam stop valve(11LBA10AA101/102)
→ HP main steam flow element (11LBA15CF601)

Generated HP steam is delivered to the HP steam turbine during normal operation. HP steam
temperature is maintained within the allowable steam turbine limits during part load at high ambient
temperature and steam turbine start-up. Before steam admission to steam turbine and during the
steam turbine bypass operation, HP steam is discharged directly to the Cold Reheater section by
HP steam bypass system.

2.4 INTERMEDIATE PRESSURE WATER/STEAM FLOW PATH

The IP system flow path is as below:
IP Feed water line flow element (11LAB45CF601 → Check valve (11LAB56AA051)
→ IP inlet motorized stop valve (11LAB56AA101) → IP economizer 1 → IP economizer 2
→ IP Drum level control valve(11LAB54AA201) → IP steam drum →IP evaporator
→ IP superheater → IP main steam flow element (11LBA40CF601)
→ IP main steam pressure control valve (11LBA40AA201)
→ IP main steam stop valve (11LBA40AA101)
→ IP main steam stop check valve (11LBA40AA501) → Cold reheater 1 → Cold reheater 2
→ Inter-stage Attemperator → Hot reheater → Final-stage Attemperator

Generated IP steam goes to the Reheater system. Reheater steam is delivered to the IP steam
turbine during normal operation. Reheater steam temperature is maintained within the allowable
steam turbine limits during part load at high ambient temperature and steam turbine start-up.
Before steam admission to steam turbine and during the steam turbine bypass operation, Hot
reheater steam is discharged directly to the condenser by reheater steam bypass system.
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2.5 LOW PRESSURE WATER/STEAM FLOW PATH

The LP system flow path is as below:
Condensate Preheater outlet → LP Drum level control valve(11LAB74AA201) → LP steam drum
→ LP evaporator → LP superheater → LP main steam check valve (11LBA60AA051) →
LP main steam stop valve (11LBA60AA101) → Terminal point → LP main steam flow element
(11LBA65CF601)

Generated LP steam is delivered to the LP Steam turbine during normal operation. Before steam
admission to the steam turbine and during steam turbine bypass operation, LP steam is discharged
directly to the condenser by LP steam bypass system.

2.6 CONDENSATE PREHEATER FLOW PATH

The Condensate preheater system flow path is as below:
Condensate water flow element (11LCA76CF601)
→ Condensate Preheater inlet motorized stop valve (11LCA76AA801)
→ Check valve (11LCA76AA841) → Condensate preheater → To LP drum

CPH recirculation system flow path is as below:

Condensate preheater outlet → Manual valve (11LCA21/22/23AA002) →
Strainer(11LCA21/22/23AT001) → CPH Recirculation Pump (11LCA21/22/23AP001)
→ Check valve (11LCA21/22/23AA051) → Manual valve (11LCA21/22/23AA001)
→ Flow element (11LCA30CF601) → Manual valve (11LCA30AA002)
→ Temperature control valve (11LCA30AA201) → Manual valve (11LCA30AA001)
→ Condensate preheater inlet

CPH bypass system flow path is as below:

CPH inlet motorized stop valve (11LCA76AA801) → Check valve (11LCA76AA841)
→ Flow control valve (11LAB75AA201) → Condensate preheater outlet

2.7 EXHAUST GAS PATH :

The exhaust gas that enters the HRSG will pass by the heat transfer sections of the HRSG,
heating the steam or water inside the tubes. The exhaust gas will pass across the pressure
sections in the following order:

Module #1 (HP Superheater 4 → Hot Reheater → HP Superheater 3 → Cold Reheaeter 2 →

HP Superheater 2 → Cold Reheaeter 1 → HP Superheater 1) → Module #2 (HP evaporator →
HP Economizer 5 → HP Economizer 4) → Module #3 (IP Superheater → HP Economizer 3 →
IP Evaporator → LP Superheater → HP Economizer 2/IP Economizer) → Module #4 (HP
Economizer 1 → LP Evaporator → Condensate preheater)
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2.8 HRSG INLET/OUTLET DUCT AND STACK

The HRSG inlet duct delivers the gas turbine exhaust gas from the outlet of Diverter damper to
the HRSG inlet and includes all supports, expansion joints and horizontal ducting. The duct is
designed to minimize pressure drop and to distribute the exhaust gas to the HRSG tube banks
uniformly.
The HRSG outlet duct, expansion joint and stack are provided to deliver the gas turbine exhaust
gas from the exit of the HRSG to the atmosphere. The outlet duct and COMMENT
stack is insulated
7.1:for
Please,
personnel protection at accessible area. It also is provided with platforms update
and test ports (CEMS).
this section.
2.9 HRSG BLOWDOWN TANK AND TRANSFER SYSTEM
One(1) Intermittent blowdown tank (11LBH10BB001) and
One(1) Continuous blowdown tank(11LAH10BB001) associated piping, valves and
instrumentations are provided with the HRSG to receive blowdown and water/steam drains.

(1) blowdown tank (24LBH10BB001) associated piping, valves and instrumentations are
provided with each HRSG to receive blowdown and water/steam drains.

The continuous blowdown is used to control the steam drum water chemistry during normal
operation in conjunction with the chemical feed system. During the continuous blowdown
operation, water is blown down directly into the blowdown tank. This is a water/steam flashing
mixture when it enters the blowdown tank.

The intermittent blowdown is used for two kinds of purpose. One is to assist in controlling water
level in the drums, if necessary. The other is to reduce the solids that are collected in the drums or
lower headers. It is operated intermittently, usually shortly after the HRSG is shut-down and still
pressurized. During the intermittent blowdown operation, water is also blown down directly into the
blowdown tank. This also is a water/steam flashing mixture when it enters the blowdown tank. The
flashed steam in the Blowdown tank is vented off via the blowdown tank silencer and the
discharged water flows out through the drain line and then it is sent to cooling water return line by
blowdown transfer pump. During start-up operation, all superheater drains are also blown down
through the drain manifolds into the blowdown tank.
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Blowdown transfer pumps (11LBH10AP001/002) will control the blowdown tank water level.
Blowdown transfer pump on :
If Intermittent blowdown tank level > 1300mm above lower tangent line
Blowdown transfer pump off :
If Intermittent blowdown tank level ≤ 500mm above lower tangent line

3. DESCRIPTIONS OF OPERATION

3.1 GENERAL
The operating sequence recommendation to ensure a safe and proper start-up is given below.
Modifications may be necessary as subsequent operating experience dictate. Follow the
manufacturer’s instructions for operating auxiliary equipment.

3.2 METHOD OF STARTING THE HRSG

Starting of the HRSG can be implemented in several ways as follows:
- Cold Start: Both GT and HRSG are initially in shut-down and in cold condition.
HP drum pressure ≤ 5 bar.a
- Warm Start: Both GT and HRSG are shut-down in warm condition.
5 bar.a < HP drum pressure ≤ 60 bar.a
- Hot Start: Both GT and HRSG are shut-down in hot condition.
HP Drum pressures > 60 bar.a

3.3 PREPARATION PRIOR TO START UP

Make sure that test gags are removed from all safety valves.
Check availability of utility service, power, and suitable treated feedwater
Check operation of chemical feed pumps and piping system
Close all access doors after it is ascertained that no one is inside the unit. New gaskets should be
used on all manways.
Check that all control valves have been stroked and tested by manual.
Check that all temperature indicating and/or recording equipment are functional.
Check that all the scaffolding, temporary brackets, lights, tools etc, have been removed.
Place the valves in the unit to the required open or closed position
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3.4 INITIAL FILLING (HOLD)

Fill the HP, IP and LP section by admitting water to the each economizer and CPH. Ensure that prior
to filling, the drum vent and all economizer vent valves are opened.
For HP, IP and LP section, feedwater flow may be regulated by HP level control valve 30%
(11LBA20AA203), IP level control valve (11LAB54AA201) and LP level control valve
(11LAB20AA201). Bring the water level in the each drum up to start-up level. The start-up level
shall be adjusted according to the each drum pressure.

3.5 HRSG PURGE

The HRSG will be purged prior to every GT start based on GT operating manual. The related
purging automatic is completely realized within the GT control. The purging of the HRSG has to be
done by spinning of the GT at purging speed and must be realized without active GT combustion.
The purging time starts when “purge speed is reached”. The purging time is reached if the purging
conditions had been maintained as long as the specified times above.
COMMENT 9.1: We cannot
find the information.
3.6 CONTROL OF DRUM LEVELS
Drum water level set points should be set to start-up set points to accept swelling of the water
contained in evaporators transferred to the drums as the steam generation in the evaporator starts.

3.6.1 DRUM START UP WATER LEVEL

The HP drum start-up level shall be decided as a linear function of initial HP drum pressure.
According to the HP drum pressure, the start-up level has two set points namely high start-up
level and low start-up level according to the drum pressure condition as below.
- If HP drum pressure ≤ 60 bar.a : Low start-up level (-500 mm from centerline)
- If HP drum pressure > 60 bar.a : High start-up level (-150 mm from centerline)
Note. HP drum Normal Water Level = HP drum center line +0 mm

IP and LP drums start-up levels also have two set points namely high start-up level and low start-
up level according to the drum pressure condition as below.
- If IP drum pressure ≤ 20 bar.a : Low start-up level (-250 mm from centerline)
- If IP drum pressure > 20 bar.a : High start-up level (-150 mm from centerline)
Note. IP drum Normal Water Level = IP drum center line + 0 mm
- If LP drum pressure ≤ 2.5 bar.a : Low start-up level (+250 mm from centerline)
- If LP drum pressure > 2.5 bar.a : High start-up level (+450 mm from centerline)
Note. LP drum Normal Water Level = LP drum center line +600 mm
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3.6.2 SINGLE ELEMENT CONTROL

Control drum level during HRSG start-up and the initiation of steaming, with attention to minimize
the effect of drum level swell resulting from changes of hot exhaust gas flow at lower steam
pressures. Single element control of level is utilized during this period since steam flow has not
materialized. It is selected for steam flow less than 30% of MCR. The measured level is compared
with the set value and the error is applied to the controller for positioning the HP, IP and LP level
control valve.

3.6.3 THREE ELEMENT CONTROL

This control is used for steam flow greater than 30% of MCR. It is based on three parameters
namely drum level, steam flow and feed water flow. The steam flow is applied as a feed forward
signal to the drum level controller and the output of the controller is given as the set point for the
feed water flow controller.

3.6.4 SINGLE ELEMENT / THREE ELEMENT TRANSFER

Changeover from single element to three element control and vice versa is carried out by an
automatic transfer circuit consisting of each HP, IP and LP steam flow.
Single element and three element transfer is as below :
- Transfer from single to three element :
When steam flow increase and reach 30% of MCR (base load), drum level control is
changed from single element to three element on operator selection of 3 element.
- Transfer from three element to single element :
1) When steam flow decrease and reach 10% of MCR (base load).
2) When feed water signal or steam flow signal is fault.

3.6.5 HP DRUM LEVEL

If HP Drum level was below Start-up level, the level should be topped-up from the Boiler Feed
Pump. The HP Level Control Valve 30% (11LBA20AA203) is capable of satisfactorily controlling
the low flow rate with high pressure differential from constant speed boiler feed pump.

Before any hot exhaust gas from GT is admitted to HRSG, the automated sequence of operation
should be followed as below:

 After BFP start, the HP FW Inlet Motorized Stop Valve (11LBA20AA101) and HP Level
Control Valve 30% (11LBA20AA203) will open to “top up” till the water up to the start-up water
level in the HP Drum.
 When there is a demand for FW to fill the drum, the HP Level Control Valve 30%
(11LBA20AA203) will be commanded open to preset set point (about 30%), and set time prior
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System Description of HRSG
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to the HP FW Inlet Motorized Stop Valve (11LBA20AA101) open command.

 When drum level reaches set point, the HP Level Control Valve 30% (11LBA20AA203) will
commanded open to minimum opening position 10% to keep minimum flow, and the FW Inlet
Motorized Stop valve (11LBA20AA101) will keep open during operation.
This kind of cyclical operation (open and close operation) will continue until steam flow
reaches set point (10%).
 When steam flow reaches set point (10%), two actions will be initiated.
1. HP drum level set point will switch from start-up level to Normal level.
2. HP level control valve 30% (11LBA20AA203) will switch from cyclical operation (open and
close operation) to modulating control.
 When steam flow reaches 30% of MCR, two actions will be initiated.
1. Switch from single element to three element controls.
2. Switch from HP Level Control Valve 30% (11LBA20AA203) to HP Level Control Valve
100%(11LBA20AA201).

The HP valves controlling the water feed to the HP drum are in a 2-valves arrangement consisting
of a 30% valve (11LBA20AA203) for low flow control and one 100% valve (11LBA20AA201). The
30% valve (11LBA20AA203) and 100% valve (11LBA20AA201) will respond to the level controller
output as per the graph below.

A controller output of 0 to 30% will be scaled to correspond 0 to 100% open of the 30% valve.
The 30% valve (11LBA20AA203) will be controlled up to 25% of the controller range having a flat
spot at this value as the 100% duty valve (11LBA20AA201) begins to open to allow for errors in
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System Description of HRSG
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setting up the valve positioner as the valve starts to operate together. Between 30 and 40% of the
controller output the 30% valve (11LBA20AA203) will close as the 100% valve (11LBA20AA201)
opens maintaining a linear controller characteristic between the two until the 100% valve
(11LBA20AA201) assumes full control at 40% controller output.

If the HP Drum was initially overfilled, water level may be adjusted to the Start-up Level by
manually opening a HP intermittent blowdown valve (11HAD22AA151). For manual operation this
valve is provided with open/stop/close control and position feedback.

When drum level set point starts to ramp from Start-up set point to NWL set point, intermittent
blowdown valve(11HAD22AA151) will open automatically (20% open for HP), if the actual drum
level is 100mm higher than the level set point. And then the actual drum level is lower than (the
level set point - 100mm) intermittent blowdown valve (11HAD22AA151) shall be closed.

3.6.6 IP DRUM LEVELS

If IP Drum level is below Start-up level, the levels will be topped up as similar procedure to those
outlined for the HP section.

Before any hot exhaust gas from GT is admitted to HRSG, the automated sequence of operation
should be followed as below:

 After BFP start, the IP FW Inlet Motorized Stop Valve (11LAB56AA101) and IP Level Control
Valve (11LAB54AA201) will open to “top up” till the water up to the start-up water level in the IP
Drum.
 When drum level reaches set point, the IP Level Control Valve (11LAB54AA201) will
commanded closed.
 When there is feed water demand to fill the drum, the IP level control valve (11LAB54AA201)
will be commanded open. This kind of cyclical operation (open and close operation) by the
level control valve will continue until steam flow reaches 10%.
 When steam flow reaches set point (10%), two actions will be initiated.
1. IP drum level set point will switch from start-up level to Normal level.
2. IP level control valve (11LAB54AA201) will switch from cyclical operation (open and close
operation) to modulating control.
 When steam flow reaches 30% of MCR, below actions will be initiated.
1. Switch from single element to three element controls.

If the IP Drum was initially overfilled, water level may be adjusted to the Start-up Level by
manually opening a IP intermittent blowdown valve (11HAD24AA151). For manual operation this
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valve is provided with open/stop/close control and position feedback.

When drum level set point starts to ramp from Start-up set point to NWL set point, intermittent
blowdown valve(11HAD24AA151) will open automatically, if the actual drum level is 100mm higher
than the level set point. And then the actual drum level is lower than (the level set point - 100mm)
intermittent blowdown valve (11HAD24AA151) shall be closed.

3.6.7 LP DRUM LEVELS

If LP Drum level is below Start-up level, the levels will be topped up as similar procedure to those
outlined for the IP section.

Before any hot exhaust gas from GT is admitted to HRSG, the automated sequence of operation
should be followed as below:

 After BFP start, the LP Level Control Valve (11LAB74AA201) will open to “top up” till the water
up to the start-up water level in the LP Drum.
 When drum level reaches set point, the LP Level Control Valve (11LAB74AA201) will
commanded closed.
 When there is feed water demand to fill the drum, the LP Level Control Valve
(11LAB74AA201) will be commanded open. This kind of cyclical operation (open and close
operation) by the level control valve will continue until steam flow reaches 10%.
 When steam flow reaches set point (10%), two actions will be initiated.
1. LP drum level set point will switch from start-up level to Normal level.
2. LP Level Control Valve (11LAB74AA201) will switch from cyclical operation
(open and close operation) to modulating control.
 When steam flow reaches 30% of MCR, below actions will be initiated.
1. Switch from single element to three element controls.

If the LP Drum was initially overfilled, water level may be adjusted to the Start-up Level by
manually opening a LP intermittent blowdown valve (11HAD72AA151). For manual operation this
valve is provided with open/stop/close control and position feedback.

When drum level set point starts to ramp from Start-up set point to NWL set point, intermittent
blowdown valve(11HAD72AA151) will open, if the actual drum level is 100mm higher than the
level set point. And then the actual drum level is lower than (the level set point - 100mm)
intermittent blowdown valve (11HAD72AA151) shall be closed.
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HP Drum Level Set point

Normal Level : ( Centerline )

The drum level controls will regulate the rate of feed water flow to maintain a proper drum level
throughout the operation range of the HRSG.
To get the maximum benefit from a three-element system, feed water flow should be proportional to
steam flow with reset action on drum level. This means that the mass of feed water entering should
always equal the mass of steam leaving, with continuous corrections made for deviations from level
set points. The best drum level control is achieved through the mass flow balance.

HHHLT (High High High level Trip) : (250mm above centerline)

Trip of HRSG.
Feedwater control valve (11LBA20AA201/202/203) and feedwater stop valve (11LBA20AA101)
remain closed.

HHLA (High High level Alarm) : (150mm above centerline)

Feedwater control valve (11LBA20AA201/202/203) and feedwater stop valve (11LBA20AA101)
closed

HLA (High level Alarm) : (100mm above centerline)

Sound the alarm.
Open the intermittent blowdown valve (11HAD22AA151).

LLA (Low level Alarm) : (150mm below centerline)

Sound the alarm.
Close continuous blowdown valve (11HAD21AA151)

LLLT (Low Low level Trip) : (650 mm below centerline)

Trip of HRSG.
Close HP main steam stop valve (11LBA10AA101/102).

IP Drum Level Set point

Normal Level : (Centerline)

The drum level controls will regulate the rate of feed water flow to maintain a proper drum level
throughout the operation range of the steam generator.
To get the maximum benefit from a three-element system, feed water flow should be proportional to
steam flow with reset action on drum level. This means that the mass of feed water entering should
always equal the mass of steam leaving, with continuous corrections made for deviations from level
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set points. The best drum level control is achieved through the mass flow balance.

HHHLT (High High High level Trip) : (200mm above centerline)

Trip of HRSG.
Feedwater control valve (11LAB54AA201/202) and feedwater stop valve (11LAB56AA101)
remain closed.

HHLA (High High level Alarm) : (150mm above centerline)

Feedwater control valve (11LAB54AA201/202) and feedwater stop valve (11LAB56AA101)
closed.

HLA (High level Alarm) : (100mm above centerline)

Sound the alarm.
Open the intermittent blowdown valve (11HAD24AA151).

LLA (Low level Alarm) : (150mm below centerline)

Sound the alarm.
Close continuous blowdown valve (11HAD23AA151)

LLLT (Low Low level Trip) : (400 mm below centerline)

Trip of HRSG.
Close IP main steam stop valve (11LBA40AA101/102).

LP Drum Level Set point

(Drum level will be corrected by the drum pressure).

Normal Level : (600mm above centerline)

The drum level controls will regulate the rate of feed water flow to maintain a proper drum level
throughout the operation range of the steam generator.
To get the maximum benefit from a three-element system, feed water flow should be proportional to
steam flow with reset action on drum level. This means that the mass of feed water entering should
always equal the mass of steam leaving, with continuous corrections made for deviations from level
set points. The best drum level control is achieved through the mass flow balance.

HHHLT (High High High level Trip) : (850mm above centerline)

Trip of HRSG.
Feedwater control valve (11LAB74AA201/202) and feedwater stop valve (11LCA76AA801)
remain closed.
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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 16 / 25

HHLA (High High level Alarm) : (750mm above centerline)

Feedwater control valve (11LAB74AA201/202) and feedwater stop valve (11LCA76AA801)
closed.

HLA (High level Alarm) : (700mm above centerline)

Sound the alarm.
Open the intermittent blowdown valve (11HAD72AA151).

LLA (Low level Alarm) : (Centerline)

Sound the alarm.

LLLT (Low Low level Trip) : (1350 mm below centerline)

Trip of HRSG.
Close LP main steam stop valve (11LBA60AA101/102).

3.6.8 DRUM HOLD UP TIME

The HP drum holding capacity is 1.5 minutes. The holding capacity volume is to be based upon the
maximum steam production between the normal water level (NWL) and the low-low-level trip (LLLT)

The IP drum holding capacity is 5 minutes. The holding capacity volume is to be based upon the
maximum steam production between the normal water level (NWL) and the low-low-level trip (LLLT)

The LP drum holding capacity is 10 minutes. The holding capacity volume is to be based upon the
maximum steam production between the normal water level (NWL) and the low-low-level trip (LLLT)

3.7 CONTROL OF SUPERHEATER AND STEAM LINE DRAINS

The purpose of the drain valves are to remove any accumulated condensate from the steam lines
and provide a flow path for steam to heat the piping during start up

HP Superheater 1, 2 Drain [MOV] 11HAH10AA101

HP Inter-stage desuperheater line Drain [MOV] 11HAH20AA101

HP Main steam line Drain [MOV] 11LBA10AA151

Cold Reheater Inlet Drain [MOV] 11LBC30AA151

Cold Reheater2 Drain [MOV] 11HAJ30AA151

RH inter-stage desuperheater line Drain [MOV] 11HAJ35AA151

IP Superheater Drain [MOV] 11HAC40AA151

LP Main steam line Drain [MOV] 11LBA60AA151

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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 17 / 25

These drain valves should be opened during purge before introducing hot GT exhaust gas to
HRSG and it is start up drain operation mode. After purge completion, start up drain operation
mode completion, then 11HAH10AA101, 11HAH20AA101, 11LBA10AA151, 11LBC30AA151,
11HAJ30AA151, 11HAJ35AA151, 11HAC40AA151, 11LBA60AA151 drain valves are closed and
placed into auto drain operation mode. During auto operation these drain valve will be activated as
follows.

3.7.1 HP SUPERHEATER SECTION DRAIN VALVES.

During the start-up drain operation (HRSG purge condition)
These valves (11HAH10AA101, 11HAH20AA101, 11LBA10AA151) are activated according to
requiring time for purge.
- Full open (100%)
If HP drum pressure (11HAD20CP001/002/003) ≤ 5 bar.a
- Intermediate open (20%)
If HP drum pressure (11HAD20CP001/002/003) > 5 bar.a

During the auto operation

As soon as purge completed, drain control placed into auto operation. These valves
(11HAH10AA101, 11HAH20AA101, 11LBA10AA151) are activated by monitoring the drain
pot temperature and comparing it with the saturated temperature at corresponding drum
pressure.
- Full Open :
2 bar.a < HP drum pressure (11HAD20CP001/002/003) ≤ 5 bar.a
- Intermediate open (20%)
HP drum pressure (11HAD20CP001/002/003) > 5 bar.a and
drain pot temperature (11LBA10CT041/042, 11LBC20CT001/002, 1HAH10CT001/002)
< Saturated temperature at HP drum pressure (11HAD20CP001/002/003) + 20℃
- Close:
HP drum pressure (11HAD20CP001/002/003) > 5 bar.a and
drain pot temperature (11LBA10CT041/042, 11LBC20CT001/002, 11HAH10CT001/002)
> Saturated temperature at HP drum pressure (11HAD20CP001/002/003) + 30℃
with time delay (3seconds).
In case of steady operation with GT load >50%, operator may close the steam drain valves
manually to avoid frequently open/close, if required.
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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 18 / 25

3.7.2 REHEATER SECTION DRAIN VLAVES.

During the start up drain operation (HRSG purge condition)

These valves (11LBC30AA151, 11HAJ30AA151, 11HAJ35AA151) are activated according to
requiring time for purge. The drain valve should be fully opened during purge condition.

During the auto operation

The valve (11LBC30AA151, 11HAJ30AA151, 11HAJ35AA151) are activated by monitoring the
drain pot temperature and comparing it with the saturated temperature at corresponding
drum pressure.
- Open :
2 bar.a < IP drum pressure (11HAD50CP001/002/003) ≤ 4 bar.a
IP drum pressure (11HAD50CP001/002/003) > 4 bar.a and
drain pot temperature (11HAJ35CT001/002, 11HAJ30CT001/002, LBC30CT001/002) >
Saturated temperature at IP drum pressure (11HAD50CP001/002/003) + 20℃ .
- Close :
IP drum pressure (11HAD50CP001/002/003) > 4 bar.a and
drain pot temperature (11HAJ35CT001/002, 11HAJ30CT001/002, LBC30CT001/002) <
Saturated temperature at IP drum pressure (11HAD50CP001/002/003) + 30℃
with time delay (3seconds).
In case of steady operation with GT load >50%, operator may close the steam drain valves
manually to avoid frequently open/close, if required.

3.7.3 IP SUPERHEATER SECTION DRAIN VALVES.

During the start up drain operation (HRSG purge condition)

This valve (11HAC40AA151) is activated according to requiring time for purge. The drain valve
should be fully opened during purge condition.

During the auto operation

The valve (11HAC40AA151) are activated by monitoring the drain pot temperature and
comparing it with the saturated temperature at corresponding drum pressure.
- Open :
2 bar.a < IP drum pressure (11HAD50CP001/002/003) ≤ 4 bar.a
IP drum pressure (11HAD50CP001/002/003) > 4 bar.a and
drain pot temperature (11HAC40CT001/002) > Saturated temperature
at IP drum pressure (11HAD50CP001/002/003) + 20℃ .
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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 19 / 25

- Close :
IP drum pressure (11HAD50CP001/002/003) > 4 bar.a and
drain pot temperature (11HAC40CT001/002) < Saturated temperature
at IP drum pressure (11HAD50CP001/002/003) + 30℃
with time delay (3seconds).
In case of steady operation with GT load >50%, operator may close the steam drain valves
manually to avoid frequently open/close, if required.

3.7.4 LP SUPERHEATER SECTION DRAIN VALVES.

During the start up drain operation (HRSG purge condition)

These valves (11LBA60AA151) are activated according to requiring time for purge. The drain
valve should be fully opened during purge condition.

During the auto operation

The valve (11LBA60AA151) are activated by monitoring the condensate level
(11LBA60CL301/302) at drain pot and drum pressure.
- Open :
1) 1.5 bar.a < LP drum pressure (11HAD70CP001/002/003) ≤ 2.5 bar.a
2) LP drum pressure (11HAD70CP001/002/003) > 2.5 bar.a and
drain pot level (11LBA60CL301/302) > High or High High.
- Close :
LP drum pressure (11HAD70CP001/002/003) > 2.5 bar.a and drain pot level
(11LBA60CL301/302) < High with time delay (3seconds).
In case of steady operation with GT load >50%, operator may close the steam drain valves
manually to avoid frequently open/close, if required.
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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 20 / 25

3.8 HP & RH STEAM TEMPERATURE CONTROL

The HP and RH inter-stage and final stage attemperator function to control HRSG HP main and
reheater steam outlet temperature by injection feedwater spray into the steam flow. The temperature
(11LBA10CT001/002 for Inter stage, 11LBA10CT011/012/013 for final stage) measured in the HP
main steam line is compared with fixed temperature set point 602.0 deg C. The temperature
(11LBB30CT001/002 for Inter stage, 11LBB30CT011/012/013 for final stage) measured in the RH
steam line is compared with fixed temperature set point 610.0 deg C. The difference is the input
signal for the controller of attemperator. During start-up, the steam temperature will be controlled
start-up temperature set point as requested by Steam turbine supplier.

The HP and RH steam temperature control will be controlled basically with inter stage attemperator
during base load operation. And final attemperator will operate after inter stage attemperator reach
to maximum operating capacity during start up.

Maximum capacity of Inter stage attemperator is defined as below :

HP inter stage attemperator : when steam temperature after attemperator reach the saturate
temperature of HP superheater operating pressure + 70 deg C or TCV 90% open, whichever comes
first.
RH inter stage attemperator : when steam temperature after attemperator reach the saturate
temperature of Reheater operating pressure + 110 deg C or TCV 90% open, whichever comes first.

As a feed forward signal, the temperature measurements (11LBA10CT001/002 for HP inter stage,
11LBB30CT001/002 for RH inter stage) downstream of the attemperator may be added with a
correction factor. Whereas final stage attemperator are does not apply the feed forward signal.
Motorized isolation valves (11LAE10AA101/102 and 11LAE20AA101/102 for HP and
11LAF10AA101/102 and 11LAF20AA101/102 for RH) are placed in the spray water line in series
with a spray control valves (11LAE10AA201/202 and 11LAE20AA201/202 for HP and
11LAF10AA201/202 and 11LAF20AA201/202 for RH). The isolation valves are automatically closed
whenever the attemperator control is not enable and is automatically opened when enable. It is
recommended that the minimum position of spray control valve will be not less than typically 5%, to
prevent excessive wear on the valve trim. Whereas the steam temperature at the discharge of the
inter stage attemperator should have a minimum of 28℃ above saturate temperature of HP
superheater and Reheater operating pressure at any cases.
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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 21 / 25

3.9 HP, RH AND LP MAIN STEAM START-UP VENTS

HP Main Steam Start up Vent [MOV] 11LBA17AA101

RH Steam Start up Vent [MOV] 11LBB31AA161

LP Main Steam Start up Vent [MOV] 11LBA60AA161

The functions of these valves is to provide release the generated HP, RH and LP main steam during
start-up before condenser vacuum completed and HP, RH and LP start-up vent valve starts opening
to min. position. After condenser vacuum is completed and steam turbine bypass valve opens with
min. position, these valve will start to close.
Another function of these valves is to release any non-condensable from superheaters at beginning
of start-up and to protect against vacuum if the pressure of steam drum is below 2.0 bar.a for HP
and 1.5bar.a for IP&LP.

HP non-condensable release and vacuum protection operation

- Open :
If HP Drum pressure ≤ 2.0 bar.a
- Close :
If HP Drum pressure > 3.0 bar.a
IP non-condensable release and vacuum protection operation
- Open :
If IP Drum pressure ≤ 1.5 bar.a
- Close :
If IP Drum pressure > 2.5 bar.a
LP non-condensable release and vacuum protection operation
- Open :
If LP Drum pressure ≤ 1.5 bar.a
- Close :
If LP Drum pressure > 2.0 bar.a

3.10 HP and IP DRUM CONTINUOUS BLOWDOWN

HP Drum Continuous Blowdown, Inching [MOV] 11HAD21AA151

IP Drum Continuous Blowdown, Inching [MOV] 11HAD23AA151

Continuous blowdown is to control the steam drum water chemistry (Conductivity) during normal
operation in conjunction with the chemical feed system. Blowdown flow will be controlled
automatically based on the feedback of drum and steam quality.
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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 22 / 25

Drum Continuous Blowdown Valves should be shut when associated Drum Levels fall below Low
Low Alarm level.

3.11 HP, IP AND LP EVAPORATOR INTERMITTENT BLOWDOWN

HP Evaporator Intermittent Blowdown MOV, Inching [MOV] 11HAD22AA151

IP Evaporator Intermittent Blowdown, MOV, Inching [MOV] 11HAD23AA151

LP Evaporator Intermittent Blowdown, MOV, Inching [MOV] 11HAD72AA151

The intermittent blowdown is used for two purposes. One is to assist in controlling water level in the
drums during start-up, if necessary. The other is to reduce the solids that collect in the drums or
lower headers.
- Opening set point
During start up: If each drum level > Ramp set point + 100mm
During Normal operation: If each drum level > High Level Alarm
Note. The term “ramp set point” is described as below.
- Closing set point
During start up: If each drum level = Ramp set point -100mm
During Normal operation: If each drum level = Normal Water Level
- Opening limit (for HP only):
Fully open : If HP Drum Pressure ≤ 5 bar.a
Intermediate open (20%) : If HP Drum Pressure > 5 bar.a

Figure 1. Drum Ramp set point

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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 23 / 25

3.12 CONDENSATE PREHEATER BYPASS CONTROL

CPH temp control valve in bypass line [Control] 11LAB75AA201

The Temperature Control valve (11LAB75AA201) on Condensate preheater system is used to

maintain the minimum approach temperature 1deg.C of deaerator at base load only. Approach
temperature may modified by operator to reduce dissolved oxygen. However, 1℃ approach
temperature shall be maintained during performance test to consider heat absorption.

3.13 CONDENSATE PREHEATER RECIRCULATION TEMPERATURE CONTROL

CPH recirculation temp control valve [Control] 11LCA30AA201

A temperature control valve, which is located in the recirculation pump discharge line, controls the
recirculation flow from condensate preheater outlet to maintain the condensate preheater inlet
temperature to preset value (123℃or 119℃ for NG, 57℃ for RLNG) which is above the acid/water
dew point of the exiting flue gas.The condensate preheater inlet water temperature shall be
monitored through the temperature measurement (11HAH75CT001/002) and the temperature
control valve shall be operated accordingly.
The CPH recirculation system consists of three (3) x 50% capacity for each HRSG motor driven
pump. Two (2) pumps are operated at normal operation and one (1) pump is back-up for NG fuel
operation, one (1) pumps is operated at normal operation and two (2) pumps are back-up for
RLNG operation. CPH recirculation Pump Designed Maximum flow : 45kg/s, 85m TDH per each
pump. The opening position of the temperature control valve shall be limited to maintain the
pump minimum flow (Approximately 10%). Also the opening position may be limited when
required to avoid pump run-out.

3.14 HP ECONOMIZER BYPASS CONTROL

HP Economizer partial bypass MOV, inching [MOV] 11HAC25AA121

To prevent steaming in HP economizer and downstream piping, HP Economizer bypass valve

(11HAC25AA121) can be used to maintain the entering temperature of each steam drum Min. 1.0
deg.C below saturate temperature of each steam drum operating pressure at base load operation only
(Not start up, part load or shut-down). And the valve will be closed again when the entering
temperature of each steam drum 3.0 deg.C (To be adjusted) below saturate temperature of each
steam drum operating pressure at base load operating only. Partial bypass is not used during
performance test to consider heat absorption.
This valve can be used to shift heat absorbed for LP evaporator to increase the heat duty for
feedwater heat exchanger by partial bypass operation when CPH inlet temperature does not meet set
temperature with CPH recirculation pump maximum flow operation as 45kg/s for each pump.
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System Description of HRSG
These pumps are
AD2-C1-00-H-M-CR-BHI-03005 A 24 / 25
not applicable
anymore.

3.15 BLOWDOWN TRANSFER PUMP

Blowdown Transfer pump [Pump] 11LBH10AP001/002

This blowdown transfer pump can be used to send blowdown water which is approx. 85 deg.C to
blowdown drain water heat exchanger.
According to the blowdown tank level which is measured by level transmitters (11LBH10CL001/002),
blowdown transfer pumps are operated at pump on level and stop at pump off level.
The transfer system consists of three (2) x 100% capacity for each HRSG motor driven transfer
pump. One (1) pump is operated at normal operation and one (1) pump is back-up.
Blowdown Transfer Pump Designed Maximum flow : 55 m3/hr, 30m TDH per each pump.

Blowdown Level Set point

High Water Level : (2200mm above Lower tangent line)

Sound the alarm.

Pump-On Level : (1300mm above Lower tangent line)

Primary transfer pump on.

Pump-Off-Level : (500mm below Lower tangent line)

Primary transfer pump off

Low Water Level : (200mm above Lower tangent line)

Sound the alarm.
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System Description of HRSG
AD2-C1-00-H-M-CR-BHI-03005 A 25 / 25

3.16 SHUT-DOWN OF HRSG

This description is to provide automatic shut-down sequences.
The shut-down operation is conducted to minimize life expenditure for the normal daily start-
up and shut-down cycle.

a. Gas Turbine load is decreased to the predetermined minimum load where HRSG can
easily be bottled up and shut-down.
b. Enable LP steam bypass line and close LP steam Shut-off Valve.
c. Enable IP steam bypass line and close RH & CRH steam Shut-off Valve.
d. Enable HP steam bypass line and close HP steam Shut-off Valve.
e. Shut down the Gas Turbine.
f. Close IP steam shut off valve.
g. After ensuring shut down of Gas Turbine, close all HP, IP and LP bypass valves in
sequence to bottle-up the pressure of each drum for pressure conservation, if required.
h. Close feed water control valve when drum level reach to proper condition.
i. Boiler feed water pump shall maintain minimum flow operation.
j. Stop the boiler feed water pump.
k. Open HP, RH and LP start-up vent valve to protect against vacuum if the pressure of
steam drum is below 2.0 bar.a for HP and 1.5bar.a for IP&LP.