Ps5014 - Combined Cycle Power Plant Manual.pdf

ProSimulator

PROSIMULATOR COGENERATION BOILER PS5014

Version 2.0 Aug 2017

Sim Infosystems Private Limited, Chennai

COGENERATION BOILER

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1.OBJECTIVE ........................................................................................................................................ 3 2.PROCESS DESCRIPTION ................................................................................................................. 3 HEAT RECOVERY STEAM GENERATOR ..................................................................................... 8 3. NORMAL OPERATING CONDITION ............................................................................................. 9 4. START-UP PROCEDURE ................................................................................................................ 15 5.LIST OF FAILURES ......................................................................................................................... 21 6. LIST OF PROCESS DISTURBANCES........................................................................................... 21 7.INTERLOCKS ................................................................................................................................... 22 8. PROCESS CONTROL LOOPS…………………………………………………………………………………………………23 9. ESD PAGES...................................................................................................................................... 24 10. COGENERATION BOILER - P&ID ............................................................................................. 25

COGENERATION BOILER

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CO-GENERATION BOILER – PS5014

1.OBJECTIVE The primary objective of PS5014- COGENERATION BOILER UNIT program is to teach trainees the operating fundamentals of a cogeneration boiler system using dynamic simulation. ProSimulator provides opportunities to identify the main equipments associated with this systems, to describe the operation of Cogeneration boiler unit, how to startup and shutdown the process using documented procedures, how to respond safely and efficiently to disturbances and malfunctions in the process, understand how temperature and pressure affect the operation of a Gas Turbine Unit. 2.PROCESS DESCRIPTION The simulated Gas Turbine and Heat Recovery Steam Generation unit is divided into following sections: 1. Air Systems

COGENERATION BOILER

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2. Combustion Section

3.

Turbine and Generation Section

COGENERATION BOILER

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Gas Turbine section, in which compressed air and fuel oil or fuel gas are ignited, driving the turbine, which in turn drives the electric generator. In the Generator section, which produces 75 MW electrical power at 3000 RPM, with a voltage of 15.75 KV at 50 Hz. 4.Waste heat recovery unit and Turbine-Generation section

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5.Condensate System

6.Plant Utilities

The purpose of this system is to generate a low power auxiliary electrical output.The gas turbine engine is composed of a single axial flow air compressor, combustion chamber (combustor), and a single axial flow turbine housed in one unit and rotating on a common shaft. Its shaft rotation speed is geared down via a gear box to drive the electrical generator, which is connected to the compressor end of the shaft. COGENERATION BOILER

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The gas turbine is started initially by the diesel starter, which is on a common shaft with the torque converter. A gear box on the same shaft shaft is connected to the turbine shaft, and converts the lower diesel shaft speed to the higher speed required for the compressor and turbine operation. The compressor and turbine are mounted on a common shaft. When the turbine reaches 900 RPM, fuel and air can be mixed and fired in the combustor. Air flows into the compressor through the air intake port, and is compressed to 25.5 kg/cm2. It is then delivered to the combustor through guide vanes which diffuse the air equally to the combustor burners. Fuel oil or fuel gas are delivered under governor pressure control through the fuel nozzles into the burner cans, where it is mixed with the compressed air and ignited. Once the fuel is ignited, the compressor turbine rotation becomes self-sustaining. As the air-fuel mixture burns, the gas of combustion expands and flows across the turbine blading, providing rotation to the shaft to drive the compressor and generator. The gases exhausted from the turbine section flow through the gas flue and either out the stack or into the HRSG to produce steam for other plant operations. The generator is an air-cooled 75 megawatt (MW), 15.75 kilovolt (KV) machine whose shaft is driven by the compressor-turbine shaft through a gear box. A motor-driven exciter establishes the field voltage to the generator. The terminal voltage of the generator is controlled by either a rheostatic manual voltage regulator or an automatic voltage regulator. The generator 15.75 KV terminal voltage is boosted to 230 KV across the transformer. The voltage regulator maintains the deviation between the generator high-side voltage and the grid voltage at zero volts by adjusting the excitation field to the generator. That is, the transformer voltage is matched with the grid voltage at the main bus. The governor system regulates the power generated which is set by the load controller by adjusting the flow of fuel to the turbine combustor. The generator core is cooled by a filtered air system. Turbine - Generator Lube Oil System The lube oil system is a major auxiliary to the turbine generator. It provides lubrication and heat dissipation for the turbine, compressor, and generator shaft bearings and seals, including: Generator shaft bearings, the turbine-compressor thrust bearing, the turbinecompressor shaft bearings, the generator gear box, the turbine auxiliary gear box, and the diesel shaft torque converter. The lube oil is taken from the lube oil tank by one of three available lube oil pumps and is delivered to the bearings, gears, and oil seals of the components mounted on the shafts. Besides providing lubrication to the bearings and gears, the lube oil picks up heat generated there and keeps the bearing and gear temperatures within a safe operating range. From the bearings, gears, and seals, the hot lube oil drains back to the lube oil reservoir. The main lube oil pump is driven by the turbine shaft. Normally, this pump delivers the oil to the bearings and gears. During startup, or when the main pump is out of service, a motor-driven pump is used. The lube oil discharged from either of these pumps flows through the air-cooled lube oil cooler. The cooler fans reduce the temperature of the hot lube oil to a COGENERATION BOILER

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temperature suitable for cooling the shaft bearings. The lube oil then passes through two lube oil filter strainers in the lube oil manifold line, which remove particles and debris from the oil before it is delivered to the shaft-mounted components. HEAT RECOVERY STEAM GENERATOR The heat recovery steam generator (HRSG) provides superheated, medium-pressure steam for plant heating and various other plant processes. The HRSG produces steam from feed water. The HRSG system consists of a furnace section, three feed water and steam heating coil sections (with one steam desuperheater, a steam drum, and two boiler water circulating pumps BWCP's). The HRSG can be operated as a steam plant alone, fired by either fuel oil of fuel gas, when the gas turbine is not in operation. Or, the feed water in the boiler can be converted to steam from the heat of the gas turbine exhaust, without use of fuel oil or gas. When the gas turbine is in operation, the flue gas (exhaust) flow is controlled by the positioning of dampers in the flue. Normally, when the steam generator is not in operation, the flue gas inlet damper to the boiler is closed, and the flue damper leading to the stack is open. The gas turbine exhaust thus goes out to the atmosphere through the stack.

Generating Steam Via Turbine Gases When the steam generator is to be placed in operation using the gas turbine exhaust heat, the turbine flue gases are routed through the damper into the furnace heating chamber. The gases rise up through the furnace, passing across the superheater coils first, then the evaporator coils, and finally the economizer coils. The gas then exits the furnace through a damper into the exhaust flue, and then flowing out the stack. As the hot gas flows over the various heating coils, the heat in the gases is transferred to the cooler water and steam in the coils. The greatest amount of heat is picked up by the steam in the superheater, somewhat less by the steam-water mixture in the evaporator, and some by the feed water in the economizer. The feed water to the HRSG first enters the economizer tubes. The flow of feed water is regulated by the steam drum level controller, which balances the water flow in against the steam drum level.From the economizer, the heated feed water flows to the steam drum. From the drum the water is circulated through the HRSG coils by one of the two motor-driven boiler water circulating pumps (BWCP's).From the discharge header of the BWCP's, the boiler water flows through a filter screen and into the evaporator tubes. Here, the water is heated to a point where steam bubbles form. The steam-water mixture flows back to the steam drum. The steam bubbles are released from the mixture and rise into the steam chambers of the drum, while the water is recirculated through the BWCP's. As mentioned above, the level of boiler water in the drum is controlled by automatic regulation of the flow of feed water into the HRSG. During startup, because of the shrink and swell effects created when the drum is filling and being heated, a valved blowdown line is provided, which is used by the operator to help control the level manually. A vent valve is provided to relieve excess steam pressure from the steam drum, and to vent it during shutdown. COGENERATION BOILER

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The steam released into the upper part of the steam drum flows to the superheater section of the HRSG. Here the greatest amount of heat from the gas turbine exhaust is delivered to the steam. The steam becomes superheated and passes through a desuperheater. The steam temperature controller regulates the flow of attemperating spray water, diverted off the feed water line, into the desuperheater. To keep the steam temperature from rising above setpoint, the spray is injected into the superheated steam, where it absorbs the excess heat, thus reducing the steam temperature. The steam then exits the HRSG and is directed to the facilities or processes for which it is intended. A motor-driven forced draft (FD) fan provides additional combustion air for the fuel gas or fuel oil.The combustion of the air-fuel mixture, along with the recovered heat from the GT, produces the heat needed to turn the boiler water into superheated steam.The fuel to be used, either oil, gas, or a mixture of both, is selected by a manual control. The fuel flow, which is based on the steam flow generated, is regulated by flow controller FC02. Feed water temperature, pressure, and steam supply back pressure are variables selected by the instructor, and affect the operating conditions of the HRSG.

3. NORMAL OPERATING CONDITION

CTL CTL CTL CTL CTL CTL CTL

Tag Name LIC101 PIC101 LIC102 PIC102 LIC103 PIC103 PIC104

CTL

PIC105

FUR PR CONTROL

CTL CTL CTL CTL CTL CTL CTL CTL CTL CTL CTL IND IND IND

PIC106 TIC101 PIC107 TIC102 PIC108 TIC103 PIC001 PIC002 FIC001 PIC003 TIC001 LI101 FI101 FI102

SH PR CONTROL SH TEMP CONTROL MP HDR PR CONTROL MP HDR TEMP CONTROL LP HDR PR CONTROL LP HDR TEMP CONTROL FUEL GAS PR CTRL FUEL OIL PR CTRL COMP I/L FLOW CTRL LUBE OIL PR CTRL AIR TEMP CTRL CST LEVEL MAKE-UP FLOW AIR FLOW

Type

COGENERATION BOILER

TagDesc COND LVL CONTROL CEP PR CONTROL DEA LVL CONTROL BFP PR CONTROL DRUM LVL CONTROL FUEL GAS PR CONTROL FD AIR PR CONTROL

Engg-Unit mm Kg/cm2 mm Kg/cm2 mm Mpa Kpa Pa Kg/cm2 Deg C Kg/cm2 Deg C Kg/cm2 Deg C Kg/cm2 Kg/cm2 T/hr Kg/cm2 Deg C mm T/hr T/hr

Scale Low 0.00 0.00 0.00 0.00 -400.00 0.00 0.00 4000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

Scale High 1400.00 50.00 4000.00 180.00 400.00 7.00 3.00

Design Val 700.00 20.00 2000.00 90.00 0.00 3.00 1.50

4000.00

-50.00

180.00 800.00 70.00 600.00 20.00 400.00 10.00 10.00 200.00 5.00 100.00 8000.00 500.00 200.00

87.20 535.00 35.00 350.00 7.15 200.00 3.00 3.50 100.00 1.50 45.00 4500.00 20.00 52.13

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IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND

LI102 TI101 FI103 PI101 TI102 FI104 TI103 TI104 TI105 TI106 FI105 LI103 TI107 TI108 FI106 PI102 FI107 TI109 PI103 FI108 TI110 PI104 FI109 TI111 FI110 TI112 PI105 TI113 PI106 TI114 FI111 PI107 PI108

COND LEVEL COND TEMP CEP DIS FLOW CEP DIS PRES CEP DES TEMP RE-CIR FLOW EXT 4 TEMP LPH 4 O/L TEMP EXT 3 TEMP LPH 3 O/L TEMP DEA I/L FLOW DEA LEVEL DEA TEMP EXT 2 TEMP BFP RE-CIR FLOW BFP DIS PR BFP DIS FLOW EXT 1 TEMP FRS PRES FRS FLOW FRS TEMP FUEL GAS PRES FUEL GAS FLOW FUEL GAS TEMP FD AIR FLOW FD AIR TEMP FD AIR PRES APH O/L FD TEMP ID INLET PRES ID INLET TEMP ID INLET FLOW ID FAN O/L PRES CHIMNEY I/L PR

IND

PI109

FURNACE PRES

Pa

IND IND IND IND IND IND IND

TI115 TI116 TI117 TI118 TI119 TI120 TI121

FURNACE TEMP FLUE GAS TEMP DIV SH TEMP FIN SH TEMP HSH I/L FG TEMP ECO I/L FG TEMP APH I/L FG TEMP

Deg C Deg C Deg C Deg C Deg C Deg C Deg C

COGENERATION BOILER

mm Deg C T/hr Kg/cm2 Deg C T/hr Deg C Deg C Deg C Deg C T/hr mm Deg C Deg C T/hr Kg/cm2 T/hr Deg C Kg/cm2 T/hr Deg C Mpa T/hr Deg C T/hr Deg C Kpa Deg C Kpa Deg C T/hr Kpa Kpa

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -4.00 0.00 0.00 -4.00 -4.00 4000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

1500.00 100.00 1000.00 50.00 100.00 150.00 300.00 200.00 500.00 300.00 1000.00 4000.00 500.00 600.00 200.00 200.00 1000.00 600.00 200.00 1000.00 600.00 10.00 20.00 100.00 1000.00 100.00 5.00 600.00 4.00 500.00 1000.00 4.00 4.00

700.00 42.00 518.00 20.00 45.00 80.00 150.00 80.00 270.00 150.00 518.00 2000.00 170.00 300.00 100.00 90.00 660.00 340.00 89.80 660.00 247.00 3.00 10.00 35.00 400.00 30.00 1.50 300.00 -0.20 134.74 525.00 -0.05 -0.02

4000.00

-50.00

1700.00 1700.00 600.00 600.00 1700.00 1700.00 600.00

1370.00 1350.00 440.00 540.00 873.54 704.73 395.39

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IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND

TI122 LI104 FI112 FI113 PI110 TI123 FI114 FI115 PI111 TI124 FI116 FI117 PI112 TI125 FI118 FI119 PI113 TI126 FI120 FI121 PI114 TI127 FI122 FI123 PI115 TI128 FI124 FI125 PI116 TI129 FI126 TI130 TI131 PI117 PI118 SI101 EI01 FI127 FI128 PI001 PI002

COGENERATION BOILER

DRUM I/L TEMP DRUM LEVEL ECO RE-CIR FLOW FSH DSH FLOW FSH PRES FSH TEMP FSH FLOW HP HDR FLOW HP HDR PRES HP HDR TEMP UTILITY 1 FLOW UTILITY 2 FLOW HP DSH PRES HP DSH TEMP HP DSH FLOW MP HDR FLOW MP HDR PRES MP HDR TEMP UTILITY 1 FLOW UTILITY 2 FLOW MP DSH PRES MP DSH TEMP MP DSH FLOW LP HDR FLOW LP HDR PRES LP HDR TEMP UTILITY 1 FLOW UTILITY 2 FLOW FLASH TANK PRES FLASH TANK TEMP FLASH TANK FLOW DEA TEMP DRUM TEMP COND PRES DRUM PRES TURBINE SPEED GEN POWER FLASH TANK FLOW CBD FLOW FUEL GAS PR FUEL GAS FILTER DP

Deg C mm T/hr T/hr Kg/cm2 Deg C T/hr T/hr Kg/cm2 Deg C T/hr T/hr Kg/cm2 Deg C T/hr T/hr Kg/cm2 Deg C T/hr T/hr Kg/cm2 Deg C T/hr T/hr Kg/cm2 Deg C T/hr T/hr Kg/cm2 Deg C T/hr Deg C Deg C Kpa Kg/cm2 rpm MW T/hr T/hr Kg/cm2 Kg/cm2

0.00 -400.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -200.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

600.00 400.00 200.00 20.00 200.00 600.00 1000.00 600.00 200.00 600.00 300.00 300.00 200.00 500.00 20.00 600.00 100.00 600.00 200.00 200.00 200.00 500.00 10.00 200.00 20.00 300.00 100.00 100.00 5.00 300.00 500.00 300.00 600.00 200.00 200.00 6000.00 100.00 500.00 20.00 10.00 1.00 11

343.00 0.00 100.00 10.00 87.20 534.96 660.00 470.00 87.20 534.96 150.00 120.00 90.00 170.00 7.00 317.00 35.00 346.37 90.00 100.00 90.00 170.00 3.00 123.00 7.15 199.31 65.00 55.00 1.50 210.00 61.73 170.00 350.00 -90.00 88.00 3000.00 50.00 200.00 10.00 3.50 0.50

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IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND IND

FI001 TI001 FI002 LI001 TI002 FI003 PI003 TI003 TI004 TI005 FI004 TI006 PI004 FI005 TI007 TI008 PI005 FI006 TI009 PI006 FI007 TI010 TI011 TI012 PI007 FI008 PI008 FI009 LI002 TI013 FI010 PI009 TI014 TI015 TI016 FI011 SI001 SI002 VI001 EI001 EI002

COGENERATION BOILER

FUEL GAS FLOW FUEL GAS TEMP FUEL OIL TANK FLOW FUEL OIL TANK LEVEL FUEL OIL TANK TEMP PUMP DIS FLOW PUMP DIS PR EXT STEAM I/L TEMP EXT STEAM O/L TEMP FUEL OIL TEMP FUEL OIL FLOW SUPPLY AIR TEMP AIR FILTER DP SUPPLY AIR FLOW EXT STEAM I/L TEMP EXT STEAM O/L TEMP COMP I/L PR COMP I/L FLOW COMP I/L TEMP COMP O/L PR COMP O/L FLOW COMP O/L TEMP FURNACE TEMP FUEL GAS TEMP EXT STEAM I/L PR EXT STEAM I/L FLOW SUPPLY AIR PR LUBE OIL TANK FLOW LUBE OIL TANK LEVEL LUBE OIL TANK TEMP PUMP DIS FLOW PUMP DIS PR WATER I/L TEMP WATER O/L TEMP LUBE OIL TEMP LUBE OIL FLOW TURBINE SPEED SPEED % TURBINE VIBRATION GEN POWER REACTIVE POWER

T/hr Deg C T/hr T/hr Deg C T/hr Kg/cm2 Deg C Deg C Deg C T/hr Deg C Kg/cm2 Deg C T/hr Deg C Kg/cm2 T/hr Deg C Kg/cm2 T/hr Deg C Deg C Deg C Kg/cm2 T/hr Kg/cm2 T/hr mm Deg C T/hr Kg/cm2 Deg C Deg C Deg C T/hr rpm % micron MW MVAR

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

20.00 100.00 30.00 10000.00 100.00 30.00 10.00 200.00 200.00 200.00 30.00 100.00 1.00 200.00 200.00 200.00 2.00 200.00 100.00 30.00 200.00 500.00 1700.00 1000.00 5.00 100.00 2.00 100.00 10000.00 100.00 50.00 5.00 100.00 100.00 100.00 50.00 4000.00 120.00 100.00 100.00 100.00 12

10.00 35.00 15.00 4500.00 30.00 15.00 3.50 130.00 105.00 100.00 15.00 30.00 0.02 100.00 130.00 105.36 0.98 100.00 45.00 25.49 100.00 359.70 1370.00 534.73 1.50 30.00 0.98 40.00 3000.00 70.00 40.00 1.70 30.00 45.00 35.00 40.00 3000.00 100.00 43.54 75.00 25.39

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IND IND IND IND IND IND IND IND IND IND SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT

EI003 EI004 EI005 EI006 EI007 BEI001 HRI001

SYSTEM VOLT GEN VOLT GEN CURRENT POWER FACTOR FREQUENCY BOILER EFFICIENCY HEAT RATE DIFFERENTIAL HEAT DHRI001 RATE FCI01 FUEL CONSUMPTION OVERALL PLANT OPEI01 EFFICIENCY FOD001 CEP A SUC V/V SW001 CEP PUMP A FOD002 CEP A DIS V/V FOD003 CEP B SUC V/V SW002 CEP PUMP B FOD004 CEP B DIS V/V FOD005 EXT 4 VALVE FOD006 EXT 3 VALVE FOD007 EXT 2 VALVE FOD008 EXT 1 VALVE FOD009 BFP A SUC V/V SW003 BFP A FOD010 BFP A DIS V/V FOD011 BFP B SUC V/V SW004 BFP B FOD012 BFP B DIS V/V FOD013 SUPPLY GAS V/V SW005 FD FAN SW006 ID FAN FOD014 CST INLET V/V SW007 APH AC MOTOR SW008 APH DC MOTOR SW009 FLAME FOD015 TURBINE I/L V/V FOD016 AIR EJACTOR A/M AUTO/MANUAL FOD017 ECO RE-CIR V/V SYNC SYNCRONISER FOD018 DRUM VENT FOD101 FOP A SUC V/V

COGENERATION BOILER

V KV A PF Hz % KJ/KWHR

0.00 0.00 0.00 0.00 0.00 0.00 0.00

500.00 30.00 4000.00 1.00 100.00 100.00 50.00

343.00 15.75 3234.36 0.85 50.00 87.41 8624.18

KJ/KWHR

-50.00

50.00

0.00

TON/HR

0.00

50.00

35.00

%

0.00

100.00

49.83

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00

0.00 1.00 1.00 1.00 0.00 0.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.00 0.00 1.00 1.00 1.00 0.00 1.00 1.00 0.00 1.00 1.00 1.00 0.00 0.00 0.00 1.00

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SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT SWT MLS MLS MLS MLS MLS MLS ALM ALM ALM ALM ALM ALM ALM ALM

SW101 FOD102 FOD103 SW102 FOD104 FOD105 FOD106 FOD107 FOD108 FOD109 FOD110 FOD111 FOD112 SW103 FOD113 FOD114 SW104 FOD115 FOD116 SW105 FOD117 A/M1 SW106 SW107 SW108 LATCH1 SYNC1 HIC001 HIC002 HIC003 HIC004 HIC005 HIC006 ALM01 ALM02 ALM03 ALM04 ALM05 ALM06 ALM07 ALM08

COGENERATION BOILER

FO PUMP A FOP A DIS V/V FOP B SUC V/V FO PUMP B FOP B DIS V/V FUEL GAS V/V FUEL OIL V/V AIR SUPPLY V/V EXT STEAM VALVE AIR FILTER CMPR AIR SHUT OFF V/V CMPR BLEED OFF 1 CMPR BLEED OFF 2 EXCITER LUBE OIL V/V LOP A SUC V/V LO PUMP A LOP A DIS V/V LOP B SUC V/V LO PUMP B LOP B DIS V/V AUTO/MANUAL IGNITOR FLAME COMPRESSOR TURBINE LATCH SYNCHRONIZER CEP RE-CIR FLOW BFP RE-CIR FLOW CBD FLOW CST INLET VALVE CBD FLOW FUEL OIL I/L LUBE OIL I/L COMPRESSOR TRIP SHUT OFF VALVE CLOSE GUIDE VANE CLOSE BLEED OFF VALVE OPEN TURBINE SPEED LO LUBE OIL PMP TRIP GAS TURBINE TRIP

% % % % % %

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 100.00 100.00 100.00 100.00 100.00 100.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 14

1.00 1.00 1.00 0.00 0.00 0.00 1.00 1.00 1.00 1.00 1.00 0.00 0.00 1.00 0.00 0.00 1.00 1.00 1.00 0.00 0.00 1.00 0.00 1.00 1.00 1.00 1.00 0.00 0.00 0.00 50.00 50.00 50.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

ProSimulator

ALM ALM ALM ALM ALM ALM LIT LIT LIT LIT LIT LIT LIT

ALM09 ALM10 ALM11 ALM12 ALM13 ALM14 LIT01 LIT02 LIT03 LIT04 LIT05 LIT06 LIT07

LIT

LIT08

LIT

LIT09

LIT

LIT10

LOW LVL IN CONDENSER DEAERATOR LOW LVL AC & DC MOTOR TRIP MASTER FUEL TRIP ID & FD FAN TRIP GENERATOR TRIP GEN VOLTAGE LESS EXCITER STOP LUBE OIL PR. LOW FUEL OIL PR. LOW COMPR I/L FLOW LOW TURBINE VIBRATION HI. FURNACE PR. LOW FD AIR & FUEL FLOW DRUM LVL HI / LO ALL STEAM VALVES CLOSE

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

4. START-UP PROCEDURE     

Ensure that all maintenance of unit is complete & work permits are cancelled Ensure that instrument air compressors are working & instrument air pressure is normal Ensure healthiness of DCS & DEH systems Open all the drain and vent valves in furnace & Turbine area Ensure that all safety valves are in normal position

INDUCED DRAFT FAN    

Start APH AC motor (SW007) [Gr Pg - 6] Check the furnace pressure is in normal range[Gr Pg - 6] Start the ID Fan A (SW006), Now open PIC105 to 5% to maintain furnace pressure in negative value [Gr Pg - 6] Now switch PIC105 in AUTO with a set point of -50 pa.

AIR COMPRESSOR  

Start the Air Filter Compressor (FOD109) which supplies compressed air to pulse filter [Gr Pg - 3] Open the Supply air Shut-off Valve (FOD110), observe the supply air flow and pressure [Gr Pg - 3]

COGENERATION BOILER

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

    

Open the Auxiliary steam Shut-off Valve (FOD108) and open the control valve (TIC001) manually to 10% and switch it to AUTO with a set point of 45 degC [Gr Pg - 3] Wait till the outlet air temperature at Anti-icing air heater stabilizes at 45 degC Now ensure the compressor Bleed off Valve at 4th and 8th stage (FOD111 & FOD112) are in closed condition [Gr Pg - 3] Start the Compressor (SW108) observe the outlet temperature and pressure will increase [Gr Pg - 3] Now Switch the Compressor inlet air flow controller (FIC001) in AUTO mode with a set point of 100 t/hr [Gr Pg - 3] Wait till the compressor discharge flow rises to 100 T/hr, pressure to 25 Kg/cm2 and temperature above 350 DegC [Gr Pg - 3]

TURBINE LUBE OIL SYSTEM  Open lube oil inlet valve to storage tank (FOD113&HIC006) wait till the level reaches 2500mm [Gr Pg - 5]  Open the suction valve of both the lube oil pump (FOD114 & FOD116) [Gr Pg - 5]  Start lube oil pump A (MS103) and open its discharge valve (FOD115) [Gr Pg - 5]  Now Switch the lube oil pressure controller (PIC003) in AUTO mode with a set point of 1.5 Kg/cm2 [Gr Pg - 5] CONDENSATE WATER SYSTEM     

   

Open the make-up valve (HIC004) from DM plant to Condensate storage tank allow the tank to fill up to 3000mm [Gr Pg - 7] Open the condenser make-up MCV (LIC101) manually to 50%, observe the water level in condenser will start to increase, fill the condenser till 900mm [Gr Pg - 7] Now Start Air ejector (FOD016) and create Vacuum inside condenser around -90 Kpa Now before starting any CEP open both CEP suction valves (FOD001 & FOD003) [Gr Pg - 7] Start either one CEP (SW001 or SW002) and open its corresponding discharge valve (FOD002, FOD004) now open PIC101 to 10% Manually the discharge pressure and flow will increase gradually Open CEP Re-circulation Valve HIC001 to 20% to maintain Hot-well level and adjust accordingly Now switch PIC101 to AUTO mode with a set point of 20 Kg/cm2 Now open deaerator make-up MCV (LIC102) manually to 7% in steps of 2%, observe the deaerator flow will increase at 80 t/hr, fill the deaerator till 1000mm [Gr Pg - 7] Now Switch LIC102 to AUTO with a set point of 2000mm [Gr Pg - 7]

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BOILER FEED PUMP   



   

Now line-up the Motor driven BFP. Check the deaerator level have to be above 1000mm[Gr Pg - 7] Open the MD-BFP suction valve (FOD009 & FOD011), open the recirculation valve (HIC002) to 30% and check the discharge valve (PIC102) is in closed condition [Gr Pg - 7] Now start the MD-BFP (SW003 or SW004) and open its discharge valve (FOD010, FOD012), now open PIC102 to 10% Manually the discharge pressure and flow will increase gradually [Gr Pg - 7] Open the BFP scoop control (LIC103) gradually to 10% [Gr Pg - 7] Fill the drum up to -24mm [Gr Pg - 6] Maintain the drum level at -24mm and switch FRS control valve LIC103 to AUTO with a set point of -24mm [Gr Pg - 6] Close the vents of different zones after checking the water start to come out in pressure (Not Simulated) [Gr Pg - 6]

FORCED DRAFT FAN    

Ensure APH AC motor and ID FAN A (SW006 & SW007) is in running condition [Gr Pg - 6] Check the furnace pressure is in normal range[Gr Pg - 6] Start the FD Fan A (SW005), Now open PIC104 to 5% and maintain furnace pressure in negative value [Gr Pg - 6] Now switch PIC104 in AUTO with a set point of 1.5 Kpa.

HEATERS      

Now charge all the heaters from low pressure to high pressure zones Open the Extraction Steam supply valve (FOD005) observe the LPH4 temperature will increase[Gr Pg - 7] Open the Extraction Steam supply valve (FOD006) observe the LPH3 temperature will increase[Gr Pg - 7] Open the Extraction Steam supply valve (FOD007) observe the DEA temperature will increase[Gr Pg - 7] Open the Extraction Steam supply valve (FOD008) observe the HPH1 temperature will increase[Gr Pg - 7] Note the temperature at FRS station is around 247 DegC

COGENERATION BOILER

Outlet Outlet Outlet Outlet

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COMBUSTION CHAMBER 1. Combustion can be done with either Fuel gas or Fuel oil Fuel Gas  Open Fuel gas shut off valve (FOD105) [Gr Pg - 4]  Now Switch the fuel gas pressure controller (PC101) in AUTO mode with a set point of 1 Kg/cm2 [Gr Pg - 4] Fuel Oil    

Open fuel oil inlet valve to storage tank (FOD106&HIC005) wait till the level reaches 2500mm [Gr Pg - 4] Open the suction valve of both the fuel oil pump (FOD101 & FOD103) [Gr Pg - 4] Start Fuel oil pump A (SW101) and open its discharge valve (FOD102) [Gr Pg - 4] Now Switch the fuel oil pressure controller (PIC002) in AUTO mode with a set point of 1 Kg/cm2 [Gr Pg - 4]

2. Now SPARK the igniter (SW106) inside furnace, flame will induce inside furnace and its temperature will increase [Gr Pg - 4] GAS TURBINE        

Check the vibration of the gas turbine, it must be in normal condition [Gr Pg - 5] Now latch the turbine using (LATCH1) switch and admit flue gas in the turbine [Gr Pg - 5] Observe the turbine speed and bearing vibration will increase gradually [Gr Pg - 5] When the turbine speed is above 2990 rpm, start the EXCITER using (SW103), Now observe the generator terminal voltage will start to increase [Gr Pg - 5] After the generator voltage reaches above 15.5 KV and turbine speed is near 3000rpm, synchronize the generator using (SYNC1) switch [Gr Pg - 5] Observe the power will start to increase in generator [Gr Pg - 5] Now gradually rise either fuel oil or fuel gas to its design value, simultaneously observe the generator power will rise to its full load [Gr Pg - 5] Check for abnormalities in all the page and continue with WHRU & steam turbine [Gr Pg - 5]

BOILER LIGHT-UP  

Open the Fuel Gas supply trip valve (FOD013) [Gr Pg - 6] Open the Fuel Gas supply control valve and gradually increase it to 20% in steps of 5%

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     

Now observe that the Furnace temperature will start to increase gradually maintain the rate of rise of furnace temperature. The firing rate should be controlled slowly enough and the drum wall temperature increasing rate is recommended less than 1.5DegC/min. At 2 Kg/cm2 pressure flush the local drum level gauge glass (Not simulated) Maintain drum level and gradually increase fuel gas [Gr Pg - 6] Now observe that the temp at all the Super heater zones will increase gradually reach the rated temperature and pressure at super heater outlet Maintain the Super Heater Pressure by gradually opening PIC106, and temperature with TIC101 and maintain at 535 DegC

TURBINE ROLLING 

Open turbine stop valve (FOD015) Observe the turbine speed will increase and gradually it’ll reach 3000 rpm[Gr Pg - 6]

SYNCHRONISING   

Ensure Turbine speed is above 2990 rpm [Gr Pg - 6] Now synchronize the generator using SYNC switch, observe the power will start to increase [Gr Pg - 6] Gradually increase and maintain the Super heater pressure and temperature at rated valve, then the generator can produce its rated power of 50MW

PLANT UTILITIES  



  

Now Maintain the HP Header Supply steam pressure with PIC106 at 87.2 kg/cm2 [Gr Pg - 8] Now the steam have to be admitted to MP steam header via PIC107 and maintain the pressure at 35 kg/cm2 and maintain the temperature with the help of TIC102 at 346 DegC [Gr Pg - 8] From MP steam header steam goes to LP steam header via PIC108 and maintain the pressure at 7.15 kg/cm2 and maintain the temperature with the help of TIC103 at 200 DegC [Gr Pg - 8] observe that all the drains will be collected at flash tank and after reducing the pressure steam will be let into condenser [Gr Pg - 8] Gradually increase all the valves to 50%, to reach design parameters now switch the whole plant to AUTO mode using (A/M) switch

GAS TURBINE DESIGN PARAMETERS a. b. c.

Gen Power Reactive power Gen Voltage

COGENERATION BOILER

- 75 MW - 25.39 MVAR - 15.75 KV 19

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d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u.

Gen Current - 3234.36 A Fuel gas pressure - 3 KSC Fuel gas temperature - 35 DegC Fuel gas flow - 10 T/hr Fuel Oil pressure - 3.5 KSC Fuel Oil temperature - 100 DegC Fuel Oil flow - 15 T/hr Comp I/L pressure - 0.98 KSC Comp I/L Temp - 45 DegC Comp I/L flow - 100 T/hr Comp O/L pressure - 25.49 KSC Comp O/L Temp - 359.7 DegC Comp O/L flow - 100 T/hr MS flow - 1872 T/hr Coal flow - 230 T/hr Furnace Temp - 1370 Deg GT Exhaust Temp - 1152.74 Deg Turbine Lube oil pr - 1.5 KSC

STEAM TURBINE & FURNACE DESIGN PARAMETERS a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u. v.

Power SH pressure SH temperature FW flow FW temp Fuel gas flow Drum Level Total Air flow Furnace Pr Vacuum Condenser level Deaerator level Furnace temp HP Header pressure HP Header Temp HP Header Flow MP Header pressure MP Header Temp MP Header Flow LP Header pressure HP Header Temp HP Header Flow

COGENERATION BOILER

- 50 MW - 87.2 kg/cm2 - 535 DegC - 660 T/hr - 247 DegC - 10 T/hr - -24mm - 400 T/hr - -50 Kpa - -90 Kpa - 700 mm - 2000 mm - 1370 DegC - 87.2 kg/cm2 - 535 DegC - 470 T/hr - 35 kg/cm2 - 346 DegC - 317 T/hr - 7.15 kg/cm2 - 200 DegC - 123 T/hr 20

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5. LIST OF FAILURES  PUMP FAILURE a.Feed Oil Pump Failure b.Lube Oil Pump Failure c.Condensate Extraction Pump Failure d.Boiler Feed Pump Failure 

FAN FAILURE a.FD fan failure b.ID fan failure c.APH AC failure d.Air Ejector failure

6. LIST OF PROCESS DISTURBANCES The instructor can change variables and inject faults into the system to demonstrate the effects on the process operation and to train operators on accurate response procedures. These values will always return to design when the program is initialized in the Design Start IC.

S.No DESCRIPTION

UNIT

RANGE

DESIGN VALUE

1

FUEL GAS PRESSURE

kg/cm2

1-5 kg/cm2

3.5

2

COMP INLET AIR PR

Kpa

0.5-2

0.98

3

MOLE WT OF AIR

30-50

40

4

HEATING VALUE OF FG

3000-10000 8461

5

OIL HTR FOULING

%

0-100

0

6

AIR HEATER FOULING

%

0-100

0

7

LO COOLER FOULING

%

0-100

0

8

TURBINE BRG CLOGING

%

0-100

0

9

TURBINE EFFECIENCY

%

0-90

58

10

GEN EFFECIENCY

%

0-100

98

11

BOILER LOSSES

%

0-5

0.02

12

TURBINE GAS LEAKAGE

%

0-100

0

COGENERATION BOILER

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S.No DESCRIPTION

UNIT

RANGE

DESIGN VALUE

13

BOILER DRUM FOULING

%

0-100

0

14

DIV SH FOULING

%

0-100

0

15

FINAL SH FOULING

%

0-100

0

16

ECONOMISER FOULING

%

0-100

0

17

APH FOULING

%

0-100

0

18

FUEL OIL HTR FOULIN

%

0-100

0

19

AIR HEATER FOULING

%

0-100

0

20

LUBE OIL HTR FOULING

%

0-100

0

21

TURBINE BRG CLOGING

%

0-100

0

7. INTERLOCKS  When Fuel oil Storage tank level drops below 300mm both Fuel oil pumps will trip in interlock and can be started again only when the level is above 300mm. 

If air compressor (SW108) trips then its shut-off damper (FOD110) and Inlet Guide Vane (FIC001) will close and its bleed-off valves (FOD111 & FOD112) will open in interlock to release air pressure.

 

Turbine LATCH can be done only above 2990 rpm Generator can be SYNCHRONIZED only when the gen voltage is above 15.5 KV, Turbine Speed is near 3000rpm and exciter (FOD114) is running.



Gas turbine trips in following conditions 1. Turbine LATCH is turned to TRIP position 2. Turbine speed decreases below 2950 rpm 3. Turbine lube oil pressure drops below 0.5 Ksc 4. Compressor air flow drops below 30 T/hr 5. Fuel pressure drops below 0.5 Ksc 6. Vibration is above 75 microns Gas turbine trip will cause 1. Compressor will trip 2. Compressor bleed-off valve will open 3. Fuel oil pumps will trip 4. Exciter will trip 5. Generator will trip



COGENERATION BOILER

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    



Both Condensate extraction pumps (SW001 & SW002) will trip when condenser level is below 200mm and can be started again only when the level is above 200mm. Both Boiler feed pumps (SW003 & SW004) will trip when condenser level is below 500mm and can be started again only when the level is above 500mm. When AC APH motor (SW007) trips then DC APH Motor (SW008) will start in AUTO If both AC & DC APH Motor (SW007 & SW008) trips then ID fan (SW006) & FD fan (SW005) will trip in interlock to prevent damages to the furnace. Furnace Master Fuel Trip will occur in following conditions 1. FD fan trip 2. ID fan trip 3. Both APH AC & DC motors trip 4. Both Boiler feed pump trip 5. Furnace pressure is above 2000 pa or below -2000 pa 6. FD air flow below 100 t/hr and fuel flow below 1 t/hr 7. Drum level above 350mm or below -350mm Master Fuel trip will cause 1. Both FD and ID fans will trip 2. Fuel gas shut-off valve will close 3. All steam extraction valves will close 4. Turbine will trip 5. Generator Sync will trip

8. PROCESS CONTROL LOOPS Steam Drum Level Control: LIC103 The Steam Drum Level controller(LIC103) maintain the drum level for continuous production of steam in boiler. When any of these controllers is in MANUAL mode, the output signal is set by the operator.

Furnace pressure control: PIC105 The Furnace Pressure Master controller (PIC105) maintains a constant negative pressure (-50.0 Pa) in the furnace over the entire range of operating conditions. COGENERATION BOILER

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As boiler load demand increases, the Combustion Control system increases the demand for air. Air flow to the boiler increases, raising the furnace pressure. The induced draft fan speeds will increase as the steam flow increases. The furnace pressure is adjusted to match the setpoint by changing the induced draft fan inlet vane positions. This control scheme will maintain the pressure design point over the full range of operating conditions. 9. ESD PAGES

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10. COGENERATION BOILER - P&ID

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