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1 HRSG OPERATION DESCRIPTION
This section describes operating procedures of the Heat Recovery Steam Generator (HRSG) for Qurayyah Combined Power Plant. They include the proper operating sequences for the HRSG and auxiliary equipment furnished. Refer to the relevant Piping and Instrumentation Diagram.
Because the steam generator is only one part of the power plant, and all equipment must operate in unison, specific procedures and detailed values for the equipment not furnished 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.
1.1 Completion of maintenance prior to operation
Check the HRSG to make sure that all maintenance work has been completed, all tools and debris have been removed, the handhole plates and manhole covers have been installed and secured, and all access doors have been installed and secured.
Check all relevant clearance certificates to be obtained and all work permits cancelled and signed out.
Check the safety valves to see if the gags have been removed, the lifting levers have been replaced, and the valves are not fouled or hung up.
1.2 Initial filling
This section describes the recommended procedure for filling an empty HRSG with water. If the unit is hot, the unit has to be cooled first to avoid severe temperature strains (Max. allowable temperature difference is approximately 50 deg.C). Also, since deposits of solids in a
superheater can cause corrosion or inhibit heat transfer, introduction of solids by carryover of boiler water from the drum during filling should be avoided.
Reference P&ID ;
P&I Diagram – HRSG H.P Superheater Section [Dwg No. EA-685640]
P&I Diagram – HRSG Reheater Section [Dwg No. EA-685641]
P&I Diagram – HRSG H.P Econ. & Evap. Section [Dwg No. EA-685642]
P&I Diagram – HRSG I.P Section [Dwg No. EA-685643]
P&I Diagram – HRSG L.P Section [Dwg No. EA-685644]
P&I Diagram – HRSG Condensate Preheater Section [Dwg No. EA-685645]
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Description Section Action
1. Precautions All 1. All instruments should be lined up for service.
2. All power-operated valves should be lined up.
3. All equipment should be lined up.
4. Align position of all manual valves as shown in HRSG P&IDs.
5. Align HP/IP/LP section Auto. Valves as shown on the column labeled “START UP” listed in the table 1, 2 and 3.
Note; The activity of initial filling require manual action from local or control room.
2. Ready for LP drum filling
LP Open and prepare the following valves for filling.
1. Confirm closed condensate stop MOV (LCA-90-AA-001).
2. Place the position of CPH 3-way valve (LCA-90-AA-081), full open to CPH direction.
3. Open CPH Recirculation line TCV (LCA-94-AA-081).
4. Open CPH inlet and outlet line vent valves (LCA-90-AA-501/502, LCA-91-AA-501/502).
5. Open CPH Recirculation pumps outlet line vent valves (LCA-92-AA-501/502, LCA-93-AA-501/502).
6. Open Deaerator vent MOV (HAD-97-AA-001) 7. Open LP drum vent valves (HAH-97-AA-501/502).
3. Ready for IP drum filling
IP Open and prepare the following valves for filling.
1. Open IP feedwater small stop MOV (LAB-94-AA-002) and Close main stop MOV (LAB-94-AA-001).
2. Open IP Econ. Inlet and outlet line vent valves (LAB-94-AA-501/502, HAC-94-AA-501/502).
3. Open IP drum vent valves (HAH-94-AA-501/502).
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4. Ready for HP drum filling
HP Open and prepare the following valves for filling.
1. Open HP feedwater small stop MOV (LAB-90-AA-002) and Close main stop MOV (LAB-90-AA-001).
2. Open HP Econ. Inlet and outlet line vent valves (LAB-90-AA-501/502, HAC-90-AA-501/502).
3. Open HP drum Low load LCV isolation MOV (HAC-90-AA-002).
4. Open HP drum vent valves (HAH-90-AA-501/502).
5. LP drum filling
LP 1. Initial water filling is done by separate filling line from the demineralized transfer pump. The filling line is prepared in the condensate line. The filling from the demi. Water pump is only used for initial filling (System is in empty case). In case of normal start up, which mean the system is already filled by water, the demi. water pump will not be used.
Open the initial filling line isolation valves (LCA-95-AA-101/102)
♠ Close it after water fill completed.
2. Adjust the water flow about 10% of MCR flow by LP drum LCV (LCA-91-AA-081).
3. Close following valves when water overflow through vent line - CPH inlet and outlet line vent valves (90-AA-501/502, LCA-91-AA-501/502).
- CPH Recirculation pumps outlet line vent valves (LCA-92-AA-501/502, LCA-93-AA-501/502).
4. Fill LP drum until Low Start up water level (-100 mm from Drum Center Line) has been reached.
♠ Do not overfill the drum
5. Close LP drum vent valves (HAH-97-AA-501/502) after water fill completed.
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Description Section Action 6. IP drum
filling
IP 1. Initial water filling is done by separate filling line from the demineralized transfer pump. The filling line is prepared in the feedwater pump IP discharge line (Refer to BOP P&ID-Feedwater System dwg.no. EA-682805-003). The filling from the demi. Water pump is only used for initial filling (System is in empty case). In case of normal start up, which mean the system is already filled by water, the demi. water pump will not be used.
Open the initial filling line isolation valves (LAB-45-AA-136/137)
♠ Close it after water fill completed.
2. Adjust the water flow about 10% of MCR flow by IP drum LCV (HAC-94-AA-081).
3. Close IP Econ. Inlet and outlet line vent valves (LAB-94-AA-501/502, HAC-94-AA-501/502) when water overflow through vent line.
4 Fill IP drum until Low Start up water level (-450 mm from Drum Center Line) has been reached.
♠ Do not overfill the drum
5. Close IP drum vent valves (HAH-94-AA-501/502) after water fill completed.
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7. HP drum filling
HP 1. Initial water filling is done by separate filling line from the demineralized transfer pump. The filling line is prepared in the feedwater pump HP discharge line (Refer to BOP P&ID-Feedwater System dwg.no. EA-682805-002). The filling from the demi. Water pump is only used for initial filling (System is in empty case). In case of normal start up, which mean the system is already filled by water, the demi. water pump will not be used.
Open the initial filling line isolation valves (LAB-45-AA-134/135)
♠ Close it after water fill completed.
2. Adjust the water flow about 10% of MCR flow by Low load HP drum LCV (HAC-90-AA-082).
3. Close HP Econ. Inlet and outlet line vent valves (LAB-90-AA-501/502, HAC-90-AA-501/502) when water overflow through vent line.
4. Fill HP drum until Low Start up water level (-550 mm from Drum Center Line) has been reached.
♠ Do not overfill the drum
5. Close HP drum vent valves (HAH-90-AA-501/502) after water fill completed.
Table 1 – Auto. Valve Alignment; High Pressure Section
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Ref. HRSG
P&ID Valve Number Valve Description Start Up Normal Operation
LAB-90-AA-001 HP Feedwater main stop MOV Auto(Open) Auto(Open) Auto(Close)
“ LAB-90-AA-002 HP Feedwater small stop MOV Auto(Close) Auto(Close) Auto(Close)
“ HAC-90-AA-002
HP Drum low load LCV isolation MOV
Auto(Close) Auto(Open) Auto(Close)
“ HAC-90-AA-082 HP Drum low load LCV Auto(Close) Auto Auto(Close)
“ HAC-90-AA-001
HP Drum Full load LCV isolation MOV
Auto(Close) Auto(Open) Auto(Close)
“ HAC-90-AA-081 HP Drum Full load LCV Auto(Close) Auto Auto(Close)
“ HAD-91-AA-002 HP Drum C.B.D MOV Auto(Close) Auto(Open) Auto(Close)
“ HAD-91-AA-001 HP Drum I.B.D MOV Auto(Close) Auto(Close) Auto(Close) H.P
Superheater.
Section [EA-685640]
HAH-91-AA-001 HP SH 1 inlet drain MOV Auto(Close) Auto(Close) Auto(Close)
“ HAH-90-AA-001 HP SH 2 drain MOV Auto(Close) Auto(Close) Auto(Close)
“ LBA-90-AA-001 HP SH 3 drain MOV Auto(Close) Auto(Close) Auto(Close)
“ LBA-90-AA-005 HP steam line drain MOV Auto(Close) Auto(Close) Auto(Close)
“ LBA-90-AA-002 HP start up vent MOV Auto(Close) Auto(Close) Auto(Close)
“ LBA-90-AA-004 HP steam small stop MOV Auto(Close) Auto(Close) Auto(Close)
“ LBA-90-AA-003 HP steam Main stop MOV Auto(Close) Auto(Open) Auto(Close)
“ LAE-90-AA-001 HP DESH. Spray block MOV Auto(Close) Auto Auto(Close)
“ LAE-90-AA-081 HP DESH. Spray TCV Auto(Close) Auto Auto(Close)
“ LAE-90-AA-002 HP DESH. Spray Bypass MOV Auto(Close) Auto(Close) Auto(Close) -End-
Table 2 – Auto. Valve Alignment; Intermediate Pressure Section Note. ; All manual valves position to be aligned per P&IDs
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P&ID Operation To Warm
I.P Section [EA-685643]
LAB-94-AA-001 IP Feedwater main stop MOV Auto(Open) Auto(Open) Auto(Close)
“ LAB-94-AA-002 IP Feedwater small stop MOV Auto(Close) Auto(Close) Auto(Close)
“ HAC-94-AA-001 IP Drum LCV bypass MOV Auto(Close) Auto(Close) Auto(Close)
“ HAC-94-AA-081 IP Drum LCV Auto(Close) Auto Auto(Close)
“ HAD-95-AA-002 IP Drum C.B.D MOV Auto(Close) Auto(Open) Auto(Close)
“ HAD-95-AA-001 IP Drum I.B.D MOV Auto(Close) Auto(Close) Auto(Close)
“ LBA-95-AA-003 IP steam line drain MOV Auto(Close) Auto(Close) Auto(Close)
“ LBA-95-AA-001 IP start up vent MOV Auto(Close) Auto(Close) Auto(Close)
“ LBA-95-AA-081 IP steam PCV Auto(Close) Auto(Open) Auto(Close)
“ LBA-95-AA-002 IP steam stop MOV Auto(Open) Auto(Open) Auto(Close) Reheater
Section [EA-685641]
LBC-90-AA-001 CRH steam stop MOV Auto(Close) Auto(Open) Auto(Close)
“ LBC-90-AA-002 CRH steam line drain MOV Auto(Close) Auto(Close) Auto(Close)
“ HAJ-90-AA-001 Reheater drain MOV Auto(Close) Auto(Close) Auto(Close)
“ LBB-90-AA-002 HRH steam line drain MOV Auto(Close) Auto(Close) Auto(Close)
“ LBB-90-AA-001 HRH start up vent MOV Auto(Close) Auto(Close) Auto(Close)
“ LBB-90-AA-081 HRH start up vent PCV Auto(Close) Auto(Close) Auto(Close)
“ LAF-90-AA-001 RH DESH. Spray block MOV Auto(Close) Auto Auto(Close)
“ LAF-90-AA-081 RH DESH. Spray TCV Auto(Close) Auto Auto(Close)
“ LAF-90-AA-002 RH DESH. Spray Bypass MOV Auto(Close) Auto(Close) Auto(Close) -End-
Table 3 – Auto. Valve Alignment; Low Pressure Section Note. ; All manual valves position to be aligned per P&IDs
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P&ID Valve Number Valve Description Start Up
Operation Warm Condensate
Preheater Section [EA-685645]
LCA-90-AA-001 Condensate stop MOV Auto(Open)(*) Auto(Open) Auto(Close)
“ LCA-90-AA-081 CPH 3-way valve
[EA-685644] LCA-91-AA-001 LP Drum LCV bypass MOV Auto(Open) Auto(Close) Auto(Close)
“ LCA-91-AA-081 LP Drum LCV Auto(Close) Auto Auto(Close)
“ LBA-96-AA-001 LP Drum Pegging stop MOV Auto(Close) Auto Auto(Close)
“ LBA-96-AA-081 LP Drum Pegging PCV Auto(Close) Auto Auto(Close)
“ HAD-97-AA-001 Deaerator vent MOV Auto(Close) Auto(Open) Auto(Close)
“ HAD-98-AA-001 LP Drum I.B.D MOV Auto(Close) Auto(Close) Auto(Close)
“ LBD-90-AA-004 LP steam line drain MOV Auto(Close) Auto(Close) Auto(Close)
“ LBD-90-AA-001 LP start up vent MOV Auto(Close) Auto(Close) Auto(Close)
“ LBD-90-AA-081 LP start up vent PCV Auto(Close) Auto(Close) Auto(Close)
“ LBD-90-AA-003 LP steam small stop MOV Auto(Close) Auto(Close) Auto(Close)
“ LBD-90-AA-002 LP steam Main stop MOV Auto(Close) Auto(Open) Auto(Close) -End-
Note ;
* The condensate stop MOV (LCA-90-AA-001) shall be opened after HRSG LP section water filling completed, if the system was earlier filled using the demineralized transfer pumps.
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All system (GT, ST, BOP and Auxiliary system) required for proper operation of the Heat Recovery Steam Generator (HRSG) must be ready prior to initiation of unit start.
The HRSG outputs (steam evaporation rates, superheated temperatures, pressures, energy outputs at HP, IP and LP steam outlets, respectively) varies according to available exhaust heat from the gas turbines.
1.3.1 Overall HRSG Start up Operation Sequence
Most operations normally required to establish a HRSG ready to start condition after an overnight shutdown can be accomplished from the central control room. These operations are remote manual actions by the control room operator. Some activity, such as HRSG water filling and manual valve alignments for HRSG ready to start condition requires local operator actions.
1) HRSG start up preparation work for HRSG Ready to Start Condition 2) HRSG start Commend initiated by Operator
3) HRSG purge
4) GT start, load up and exhaust gas temperature matching with HRSG thermal status 5) Diverter Damper step by step opening
6) HRSG steam side drain valve operation 7) HRSG steam start up vent operation 8) Steam bypass system operation
9 HRSG steam pressure increasing within allowable range 10) HRSG steam introduction to steam header
11) GT load increase to desired load
1.3.2 HRSG Ready to Start Condition
Certain conditions must be satisfied prior to the initiations of the HRSG start. All system (Gas turbine, Steam turbine, Mechanical Auxiliary/BOP equipments and etc) required for the plant operation must be ready for operation. Followings are HRSG Ready to Start Condition.
z HRSG water path filling completed.
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z Align HP/IP/LP section valves as shown on the column labeled “Start Up” listed in the table 1,2 and 3.
z One of feedwater pump is running z One of condensate pump is running z Guillotine Blanking Plate full opened z Diverter Damper close to HRSG and ready z Stack Damper full opened
z One of CPH Recirculation pumps is running
1.3.3 HRSG Start up Sequence
The HRSG can be started up using either of the two following methods which can be selected by the operating personnel;