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SYSTEM DESCRIPTION EKT - FUEL GAS PREHEATER
Owner: TRUenergy Tallawarra Pty Ltd
Contractor: ALSTOM Power Limited
TALLAWARRA Combined Cycle Power Plant
Revision History Rev.
Revision Date
Created by
Checked by
Approved by
Description
Description latest Revision: Replaces
ALSTOM Document Code
TWA/00/M/EKT-------/OI/001 Responsible dept.
Created by
Checked by
Approved by
Format
PEE
Pfeifer B.
Zaengerlein F.
Zaengerlein F.
A4
Originator
Document Type
Document Status
abcd
Description
Electronically released
Title, Subtitle
Identification number
Power Turbo-Systems / Power Environment
SYSTEM DESCRIPTION EKT - FUEL GAS PREHEATER
1AHA052263 Rev.
Date
Lang.
Sheet
A
19.12.2006
en
1/19
Template No.: GGG/00/-/EQA---/FT/302E (released with Work Instruction GGG/00/-/EQA---/WI/306) © ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
Copyright All rights reserved © Copyright 2006 ALSTOM Power Turbo-Systems (comprised of ALSTOM (Switzerland) Ltd. and/or affiliates CH-5401 Baden, Brown Boveri Strasse 7 Printed in Switzerland We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. This work, including all parts thereof, is protected by copyright. Any use of it beyond the narrow restrictions of the copyright law without prior approval of ALSTOM (Switzerland) Ltd., CH-5401 Baden is prohibited and subject to punishment under the applicable law.
Originator
Identification number
Rev.
Date
Lang.
Sheet
ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
2/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
Contents 1
2.
3.
Introduction ................................................................................................................................................. 9 1.1.
Purpose ............................................................................................................................................................. 9
1.2.
System Overview.............................................................................................................................................. 9
1.2.1.
Main Components ...................................................................................................................... 9
1.2.2.
Interface to other Systems ......................................................................................................... 9
Safety Instructions ..............................................................................................................................10 2.1.
General Safety Instructions ............................................................................................................................10
2.2.
System-specific Safety Instructions ...............................................................................................................10
System Description ............................................................................................................................12 3.1.
4.
Operation .....................................................................................................................................................13 4.1.
5.
6.
Overview .........................................................................................................................................................12
Overview .........................................................................................................................................................13
4.1.1.
Specific Safety Instructions...................................................................................................... 13
4.1.2.
Component Operating Instructions .......................................................................................... 14
4.1.3.
Automatic Control Logic........................................................................................................... 14
4.2.
Initial System Filling ........................................................................................................................................14
4.3.
Normal Start-up...............................................................................................................................................14
4.4.
Normal Operation............................................................................................................................................15
4.5.
Normal Shut-down..........................................................................................................................................15
4.6.
Abnormal Operation........................................................................................................................................15
Maintenance ..............................................................................................................................................16 5.1.
Specific Safety Precautions............................................................................................................................16
5.2.
System-related Maintenance .........................................................................................................................16
Appendices ................................................................................................................................................17 6.1.
Manual Preparation Check List prior to Start-up ...........................................................................................17
6.2.
Alarm List.........................................................................................................................................................17
6.3.
Externals Documents and Diagrams.............................................................................................................18
Originator
Identification number
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ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
3/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
List of Tables Table 1
Brief Description of Manual Contents ........................................................................................ 5
Table 2
Abbreviations and Acronyms ..................................................................................................... 8
Table 3
Manual Preparation Check List prior to Start-up...................................................................... 17
Table 4
Alarm List ................................................................................................................................. 17
Table 5
External Documents and Diagrams ......................................................................................... 18
Originator
Identification number
Rev.
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Lang.
Sheet
ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
4/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
About this Manual Purpose This manual contains the essential information needed for safe and efficient handling and maintenance of the described systems. The information in this manual is compulsory reading matter for anyone working with or at the systems and components. This means that every one must understand what safety means. ALSTOM Power declines all responsibility for personal injuries or material damages occurring as a result of non-observance of the instructions and warnings in this manual!
Target Audience This manual is written for everyone working on or with the described systems. It conveys information for different user audiences to understand and fulfill their work and duties. Manual Contents Chapter
Title
Contents
1
Introduction
Provides an overview of the system and its components.
2
Safety Instructions
Describes the safety rules and general residual risks.
3
System Description
Describes the system and its components on a functional level.
4
Operation
Describes the operation sequences required for routine operational tasks and the standard operational phases.
5
Maintenance
Contains basic maintenance schedules and describes various maintenance procedures.
6
Appendices
Contains miscellaneous additional information.
Table 1
Brief Description of Manual Contents
How to Use this Manual This manual is a reference book. It requires application knowledge acquired in training courses delivered by ALSTOM. There are several features that will help you find specific information quickly: 1. Table of Contents at the beginning of the book 2. Lists of tables at the beginning of the book 3. Alphabetical Index at the end of the book A manual is also a notebook, feel free to write your own notes, ideas, questions, indices, glossary items, etc. into this manual.
Originator
Identification number
Rev.
Date
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Sheet
ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
5/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
Symbols used in this Manual DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.
DANGER Type/Source of Hazard Hazard consequences Æ
Steps to avoid the hazard.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
WARNING Type/Source of Hazard Hazard consequences Æ
Steps to avoid the hazard.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
CAUTION Type/Source of Hazard Hazard consequences Æ
Steps to avoid the hazard.
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© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
DAMAGE information not relevant for the safety of personnel but pointing out possible damage to the machine is depicted as shown below. CAUTION Information pointing out possible damages to the Machine.
A General Note contains supplementary information of general interest for the reader. Note This is supplementary information for the reader.
READ INSTRUCTIONS means that it is mandatory to read the specific instructions contained in this manual or in external reference documents. Read instructions!
MANDATORY ACTION symbols are used to point out instructions and information that must be strictly followed to prevent any risk for personal safety or to avoid machine damage. General requirement sign
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ALSTOM PT-PE
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Rev. A
Abbreviations and Acronyms Item
Explanation
DCS
Distributed Control System
FWT
Feed Water Tank
GT
Gas Turbine
HRSG
Heat Recovery Steam Generator
IP
Intermediate Pressure
PFUP
Process Function Plans
PHR
Preheater
P & ID
Piping and Instrumentation Diagram
ST
Steam Turbine
Table 2
Abbreviations and Acronyms
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ALSTOM PT-PE
1AHA052263
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19.12.2006
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1
INTRODUCTION
1.1.
Purpose
Rev. A
The system fulfils the following tasks: 4. Preheating of the fuel gas in order to achieve a higher thermal efficiency of the gas turbine
1.2.
System Overview Note For an overview of the system, refer to P & ID 1AHA049449 and P & ID 1AHA050087
1.2.1.
Main Components The system consists of the following main components: 5. Fuel gas preheater 11EKC10AC001 equipped with gas detection device 11EKC10CL001 and safety valve 11EKC10AA001. 6. Fuel gas separator 11EKC10AT001 downstream of the fuel gas preheater equipped with gas detection device 11EKC10CL002 7. Straightway shut-off valve 11HAC24AA002 downstream of HRSG extraction point 8. Straightway shut-off valve 11EKT10AA001 downstream of fuel gas separator 9. Electric motor-actuated gas preheater water shut-off gate valve 11EKT10AA002 10. Gas preheater angle control valve 11EKT10AA003 11. Feed water extraction line 11EKT10BR010 from HRSG to fuel gas preheater 12. Connection line 11EKT10BR001 between fuel gas preheater and fuel gas separator 13. Return lines 11EKT10BR002/3 from fuel gas separator to FWT
1.2.2.
Interface to other Systems 14. Fuel gas enters from the fuel gas fine filter 15. Fuel gas exits to the GT 16. Feed water enters from extraction point downstream of the IP economizer of HRSG
17.
Feed water exits to the FWT
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© ALSTOM 2006. All rights reserved.
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Rev. A
2.
SAFETY INSTRUCTIONS
2.1.
General Safety Instructions All personnel working with or at the systems and components must have read and understood the safety instructions in ALSTOM technical manual TN04/0297, which is part of the overall customer documentation set.
2.2.
System-specific Safety Instructions
WARNING High pressure system Inappropriate handling can cause serious injuries Æ
Before start-up 18. ensure the components, valves, and instrumentations are ready for operation. Refer to Manual Preparation Check List prior to Start-up on page 17. 19. ensure the instrument root valves for all permanent instruments are open. Refer to Manual Preparation Check List prior to Startup on page 17. 20. ensure the instrument root valves for all temporary instruments are closed. These temporary instruments are shown in the P & ID with a P, PP, T, or TP and are used only for the performance test or commissioning. Refer to Manual Preparation Check List prior to Start-up on page 17.
Æ
Before maintenance
Æ
21. ensure the system is depressurized, cooled down and drained. 22. secure the drives and valves against unintentional starting and moving. The instructions of the component suppliers must be adhered to.
WARNING Hot medium The feed water temperature can be up to 150°C. Inappropriate handling can cause serious burns Æ
Do not open vent valves during operation or during standstill unless the system is depressurized and cooled down.
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ALSTOM PT-PE
1AHA052263
A
19.12.2006
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© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
WARNING Hot surface Inappropriate handling can cause serious burns Æ
Do not touch piping- or component-surface, if there is no heat insulation and the plant is not cooled down.
Read the component safety instructions before operation!
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1AHA052263
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19.12.2006
en
11/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
3.
SYSTEM DESCRIPTION
3.1.
Overview The fuel gas preheating system preheats the fuel gas to a constant temperature with feed water taken from an extraction point downstream of the IP economizer of HRSG. Finally the water returns to the feed water tank via gas preheating control valve. The gas preheating control valve is located right upstream of the feed water tank inlet to prevent evaporation of gas preheater water. The preheater and the water line downstream of the gas preheater is equipped with a gas detection device in order to protect the water /steam cycle from gas ingress.
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© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
4.
OPERATION
4.1.
Overview
4.1.1.
Specific Safety Instructions
WARNING High pressure system Inappropriate handling can cause serious injuries Æ
Before start-up 23. ensure the components, valves, and instrumentations are ready for operation. Refer to Manual Preparation Check List prior to Start-up on page 17. 24. ensure the instrument root valves for all permanent instruments are open. Refer to Manual Preparation Check List prior to Startup on page 17. 25. ensure the instrument root valves for all temporary instruments are closed. These temporary instruments are shown in the P & ID with a P, PP, T, or TP and are used only for the performance test or commissioning. Refer to Manual Preparation Check List prior to Start-up on page 17.
Æ
During operation
Æ
26. Follow the operating instructions and the component operating instructions 27. Shut down the system / section in case of leakages The instructions of the component suppliers must be adhered to.
WARNING Hot medium The feed water temperature can be up to 150°C. Inappropriate handling can cause serious burns Æ
Do not open vent valves during operation or during standstill unless the system is depressurized and cooled down.
Originator
Identification number
Rev.
Date
Lang.
Sheet
ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
13/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
WARNING Hot surface Inappropriate handling can cause serious burns Æ
Do not touch piping- or component-surface, if there is no heat insulation and the plant is not cooled down.
Read the component safety instructions before operation!
4.1.2.
Component Operating Instructions To ensure operational reliability of the individual system components, the relevant operation instructions must be observed.
Read the component operating instructions before operation!
4.1.3.
Automatic Control Logic For details of the automatic control logic refer to the PFUP and the Set Point List of the system.
4.2.
Initial System Filling The feed water extraction lines shall be filled during the boiler filling procedure. Refer also to the O&M instructions of the fuel gas preheater.
4.3.
Normal Start-up Note The normal start-up is performed in automatic mode by starting of the related function group GT Gas preheater control by the relevant sequencer in the DCS. For automatic start-up, no operator actions are required. When exhaust gas temperature at stack exceeds a certain value, the feed water shut-off valve 21EKT10AA002 is opened. After opening of the feed water shut-off valve, the feed water control valve is released. The gas temperature will be ramped up to the required set point with a limited temperature gradient by controlling the feed water extraction supply with the water control valve.
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4.4.
Rev. A
Normal Operation The fuel gas preheating system is taken into service when exhaust gas temperature at stack exceeds a certain value and fuel gas is selected. The flow of the feed water depends on the fuel gas flow and its target temperature. The feed water control valve is controlled by the measured temperature in the fuel gas line downstream the fuel gas preheater. The purpose is to maintain a constant fuel gas preheater outlet temperature, independent of the actual fuel gas flow and inlet temperature.
4.5.
Normal Shut-down Note The normal shut-down is performed in automatic mode by stopping of the related function group GT Gas preheater control by the relevant sequencer in the DCS. For automatic shut-down, no operator actions are required. Here are no special requirements for the shut-down procedure. The system can be shut-down at any time or automatically as soon as GT flame is off or command off is given.
CAUTION Standstill of the system during sub-zero ambient temperature condition may following in icing and consequently in serious damages of the system or components. Switch the heat tracing system into operation during standstill at sub-zero ambient condition. Follow the component operating instructions.
4.6.
Abnormal Operation The water extraction shut-off valve 11EKT10AA002 is closed in following cases • The fuel gas temperature exceeds a certain limit (MAX2). When fuel gas is detected downstream of the gas preheater and if the gas preheater shut-off valve is already closed, the following actions have to be taken: • •
Check the gas detection device on top of the gas preheater If gas is detected on the gas preheater shell side, the manual shut-off valve 11HAC24AA002 (in HRSG scope) of the extraction line must be closed in order to prevent gas increase in the boiler system.
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1AHA052263
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19.12.2006
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© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
5.
MAINTENANCE
5.1.
Specific Safety Precautions Operation as well as maintenance and repair work of the system has to be done by qualified personnel and under observation of general rules and regulation and the special safety rules and regulations for pressure equipment.
Prior to executing any maintenance work you must have read and understood the safety instructions in chapter 2 of this manual. Operational readiness of the system components is to be maintained by adhering to the relevant operation & maintenance documentation supplied by the supplier, and must be consulted before operation or maintenance begins.
5.2.
System-related Maintenance •
Carry out a visual inspection of the entire system every day.
•
Component specific maintenance instructions must be observed.
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A
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© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
6.
APPENDICES
6.1.
Manual Preparation Check List prior to Start-up
Before start-up, prepare the systems, all components, valves, and instrumentations to be ready for operation according to Table 3.
System/Component
Status
KKS number
Gas preheater
Ready for operation
11EKC10AC001
Remote controlled valves
Ready for operation
various
Instrumentations
Ready for operation
various
Valve
Position
KKS number
Instrument root valve for all permanent instruments
open
various
maintenance drains
closed
various
Instrument root valves for all temporary instruments
closed
various
Manual isolation valve
open
11HAC24AA002
Manual isolation valve
open
11EKT10AA001
Extraction shut-off valve
closed
11EKT10AA002
Control valve
closed
11EKT10AA003
Table 3
6.2.
Manual Preparation Check List prior to Start-up
Alarm List KKS
Code
Description
Remarks
11EKC10CL001
LA
GAS DETECTION PHR
Check PHR (tube break) Close isolation valve 11HAC24AA002
11EKC10CL002
11EKG90CT001
LA
<MIN1
GAS DETECTION AFT PHR
Check PHR (tube break)
T FUEL GAS AFT PHR
Check isolation valves
Close shut-off valve 11EKT10AA002 Check shut-off valve Check functionality of control valve
11EKG90CT001
>MAX1
T FUEL GAS AFT PHR
Check functionality of control valve
11EKG90CT001
>MAX2
T FUEL GAS AFT PHR
Check functionality of control valve
Table 4
Alarm List
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6.3.
Rev. A
Externals Documents and Diagrams The following external documents and diagrams are referenced throughout this manual. Document No.
Title
1AHA049449
P & ID Fuel Gas Preheating System
1AHA049450
Legend to P & ID Fuel Gas Preheating System
1AHA050087
P & ID Fuel Gas System Legend to P & ID Fuel Gas System Process Function Plan Fuel Gas Preheating System Set Point List Fuel Gas Preheating System
Table 5
External Documents and Diagrams
Originator
Identification number
Rev.
Date
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A
19.12.2006
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© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
Index A
M
abbreviations and acronyms, 10 alarm list, 23
main components, 11 MANDATORY ACTION explanation, 9 manual preparation check list prior to start-up, 23
C CAUTION explanation, 8 compulsory reading, 7 copyright, 2
O Operational readiness, 21 S
D
system tasks, 11
DAMAGE explanation, 9 DANGER explanation, 8
T target audience, 7 TN04/0297, 13
E
U
external documents and diagrams, 24
user audience, 7
G
V
general note explanation, 9
visual inspection, 21 W
I
WARNING explanation, 8
interface to other systems, 11
Originator
Identification number
Rev.
Date
Lang.
Sheet
ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
19/19
© ALSTOM 2006. All rights reserved.
Owner: TRUenergy Tallawarra Pty Ltd
Contractor: ALSTOM Power Limited
TALLAWARRA Combined Cycle Power Plant
Revision History Rev.
Revision Date
Created by
Checked by
Approved by
Description
Description latest Revision: Replaces
ALSTOM Document Code
TWA/00/M/EKT-------/OI/001 Responsible dept.
Created by
Checked by
Approved by
Format
PEE
Pfeifer B.
Zaengerlein F.
Zaengerlein F.
A4
Originator
Document Type
Document Status
abcd
Description
Electronically released
Title, Subtitle
Identification number
Power Turbo-Systems / Power Environment
SYSTEM DESCRIPTION EKT - FUEL GAS PREHEATER
1AHA052263 Rev.
Date
Lang.
Sheet
A
19.12.2006
en
1/19
Template No.: GGG/00/-/EQA---/FT/302E (released with Work Instruction GGG/00/-/EQA---/WI/306) © ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
Copyright All rights reserved © Copyright 2006 ALSTOM Power Turbo-Systems (comprised of ALSTOM (Switzerland) Ltd. and/or affiliates CH-5401 Baden, Brown Boveri Strasse 7 Printed in Switzerland We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden. This work, including all parts thereof, is protected by copyright. Any use of it beyond the narrow restrictions of the copyright law without prior approval of ALSTOM (Switzerland) Ltd., CH-5401 Baden is prohibited and subject to punishment under the applicable law.
Originator
Identification number
Rev.
Date
Lang.
Sheet
ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
2/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
Contents 1
2.
3.
Introduction ................................................................................................................................................. 9 1.1.
Purpose ............................................................................................................................................................. 9
1.2.
System Overview.............................................................................................................................................. 9
1.2.1.
Main Components ...................................................................................................................... 9
1.2.2.
Interface to other Systems ......................................................................................................... 9
Safety Instructions ..............................................................................................................................10 2.1.
General Safety Instructions ............................................................................................................................10
2.2.
System-specific Safety Instructions ...............................................................................................................10
System Description ............................................................................................................................12 3.1.
4.
Operation .....................................................................................................................................................13 4.1.
5.
6.
Overview .........................................................................................................................................................12
Overview .........................................................................................................................................................13
4.1.1.
Specific Safety Instructions...................................................................................................... 13
4.1.2.
Component Operating Instructions .......................................................................................... 14
4.1.3.
Automatic Control Logic........................................................................................................... 14
4.2.
Initial System Filling ........................................................................................................................................14
4.3.
Normal Start-up...............................................................................................................................................14
4.4.
Normal Operation............................................................................................................................................15
4.5.
Normal Shut-down..........................................................................................................................................15
4.6.
Abnormal Operation........................................................................................................................................15
Maintenance ..............................................................................................................................................16 5.1.
Specific Safety Precautions............................................................................................................................16
5.2.
System-related Maintenance .........................................................................................................................16
Appendices ................................................................................................................................................17 6.1.
Manual Preparation Check List prior to Start-up ...........................................................................................17
6.2.
Alarm List.........................................................................................................................................................17
6.3.
Externals Documents and Diagrams.............................................................................................................18
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Electronically released
Rev. A
List of Tables Table 1
Brief Description of Manual Contents ........................................................................................ 5
Table 2
Abbreviations and Acronyms ..................................................................................................... 8
Table 3
Manual Preparation Check List prior to Start-up...................................................................... 17
Table 4
Alarm List ................................................................................................................................. 17
Table 5
External Documents and Diagrams ......................................................................................... 18
Originator
Identification number
Rev.
Date
Lang.
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ALSTOM PT-PE
1AHA052263
A
19.12.2006
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4/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
About this Manual Purpose This manual contains the essential information needed for safe and efficient handling and maintenance of the described systems. The information in this manual is compulsory reading matter for anyone working with or at the systems and components. This means that every one must understand what safety means. ALSTOM Power declines all responsibility for personal injuries or material damages occurring as a result of non-observance of the instructions and warnings in this manual!
Target Audience This manual is written for everyone working on or with the described systems. It conveys information for different user audiences to understand and fulfill their work and duties. Manual Contents Chapter
Title
Contents
1
Introduction
Provides an overview of the system and its components.
2
Safety Instructions
Describes the safety rules and general residual risks.
3
System Description
Describes the system and its components on a functional level.
4
Operation
Describes the operation sequences required for routine operational tasks and the standard operational phases.
5
Maintenance
Contains basic maintenance schedules and describes various maintenance procedures.
6
Appendices
Contains miscellaneous additional information.
Table 1
Brief Description of Manual Contents
How to Use this Manual This manual is a reference book. It requires application knowledge acquired in training courses delivered by ALSTOM. There are several features that will help you find specific information quickly: 1. Table of Contents at the beginning of the book 2. Lists of tables at the beginning of the book 3. Alphabetical Index at the end of the book A manual is also a notebook, feel free to write your own notes, ideas, questions, indices, glossary items, etc. into this manual.
Originator
Identification number
Rev.
Date
Lang.
Sheet
ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
5/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
Symbols used in this Manual DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.
DANGER Type/Source of Hazard Hazard consequences Æ
Steps to avoid the hazard.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
WARNING Type/Source of Hazard Hazard consequences Æ
Steps to avoid the hazard.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
CAUTION Type/Source of Hazard Hazard consequences Æ
Steps to avoid the hazard.
Originator
Identification number
Rev.
Date
Lang.
Sheet
ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
6/19
© ALSTOM 2006. All rights reserved.
Electronically released
Rev. A
DAMAGE information not relevant for the safety of personnel but pointing out possible damage to the machine is depicted as shown below. CAUTION Information pointing out possible damages to the Machine.
A General Note contains supplementary information of general interest for the reader. Note This is supplementary information for the reader.
READ INSTRUCTIONS means that it is mandatory to read the specific instructions contained in this manual or in external reference documents. Read instructions!
MANDATORY ACTION symbols are used to point out instructions and information that must be strictly followed to prevent any risk for personal safety or to avoid machine damage. General requirement sign
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ALSTOM PT-PE
1AHA052263
A
19.12.2006
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Rev. A
Abbreviations and Acronyms Item
Explanation
DCS
Distributed Control System
FWT
Feed Water Tank
GT
Gas Turbine
HRSG
Heat Recovery Steam Generator
IP
Intermediate Pressure
PFUP
Process Function Plans
PHR
Preheater
P & ID
Piping and Instrumentation Diagram
ST
Steam Turbine
Table 2
Abbreviations and Acronyms
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ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
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1
INTRODUCTION
1.1.
Purpose
Rev. A
The system fulfils the following tasks: 4. Preheating of the fuel gas in order to achieve a higher thermal efficiency of the gas turbine
1.2.
System Overview Note For an overview of the system, refer to P & ID 1AHA049449 and P & ID 1AHA050087
1.2.1.
Main Components The system consists of the following main components: 5. Fuel gas preheater 11EKC10AC001 equipped with gas detection device 11EKC10CL001 and safety valve 11EKC10AA001. 6. Fuel gas separator 11EKC10AT001 downstream of the fuel gas preheater equipped with gas detection device 11EKC10CL002 7. Straightway shut-off valve 11HAC24AA002 downstream of HRSG extraction point 8. Straightway shut-off valve 11EKT10AA001 downstream of fuel gas separator 9. Electric motor-actuated gas preheater water shut-off gate valve 11EKT10AA002 10. Gas preheater angle control valve 11EKT10AA003 11. Feed water extraction line 11EKT10BR010 from HRSG to fuel gas preheater 12. Connection line 11EKT10BR001 between fuel gas preheater and fuel gas separator 13. Return lines 11EKT10BR002/3 from fuel gas separator to FWT
1.2.2.
Interface to other Systems 14. Fuel gas enters from the fuel gas fine filter 15. Fuel gas exits to the GT 16. Feed water enters from extraction point downstream of the IP economizer of HRSG
17.
Feed water exits to the FWT
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1AHA052263
A
19.12.2006
en
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Rev. A
2.
SAFETY INSTRUCTIONS
2.1.
General Safety Instructions All personnel working with or at the systems and components must have read and understood the safety instructions in ALSTOM technical manual TN04/0297, which is part of the overall customer documentation set.
2.2.
System-specific Safety Instructions
WARNING High pressure system Inappropriate handling can cause serious injuries Æ
Before start-up 18. ensure the components, valves, and instrumentations are ready for operation. Refer to Manual Preparation Check List prior to Start-up on page 17. 19. ensure the instrument root valves for all permanent instruments are open. Refer to Manual Preparation Check List prior to Startup on page 17. 20. ensure the instrument root valves for all temporary instruments are closed. These temporary instruments are shown in the P & ID with a P, PP, T, or TP and are used only for the performance test or commissioning. Refer to Manual Preparation Check List prior to Start-up on page 17.
Æ
Before maintenance
Æ
21. ensure the system is depressurized, cooled down and drained. 22. secure the drives and valves against unintentional starting and moving. The instructions of the component suppliers must be adhered to.
WARNING Hot medium The feed water temperature can be up to 150°C. Inappropriate handling can cause serious burns Æ
Do not open vent valves during operation or during standstill unless the system is depressurized and cooled down.
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ALSTOM PT-PE
1AHA052263
A
19.12.2006
en
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Rev. A
WARNING Hot surface Inappropriate handling can cause serious burns Æ
Do not touch piping- or component-surface, if there is no heat insulation and the plant is not cooled down.
Read the component safety instructions before operation!
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1AHA052263
A
19.12.2006
en
11/19
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Rev. A
3.
SYSTEM DESCRIPTION
3.1.
Overview The fuel gas preheating system preheats the fuel gas to a constant temperature with feed water taken from an extraction point downstream of the IP economizer of HRSG. Finally the water returns to the feed water tank via gas preheating control valve. The gas preheating control valve is located right upstream of the feed water tank inlet to prevent evaporation of gas preheater water. The preheater and the water line downstream of the gas preheater is equipped with a gas detection device in order to protect the water /steam cycle from gas ingress.
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1AHA052263
A
19.12.2006
en
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Rev. A
4.
OPERATION
4.1.
Overview
4.1.1.
Specific Safety Instructions
WARNING High pressure system Inappropriate handling can cause serious injuries Æ
Before start-up 23. ensure the components, valves, and instrumentations are ready for operation. Refer to Manual Preparation Check List prior to Start-up on page 17. 24. ensure the instrument root valves for all permanent instruments are open. Refer to Manual Preparation Check List prior to Startup on page 17. 25. ensure the instrument root valves for all temporary instruments are closed. These temporary instruments are shown in the P & ID with a P, PP, T, or TP and are used only for the performance test or commissioning. Refer to Manual Preparation Check List prior to Start-up on page 17.
Æ
During operation
Æ
26. Follow the operating instructions and the component operating instructions 27. Shut down the system / section in case of leakages The instructions of the component suppliers must be adhered to.
WARNING Hot medium The feed water temperature can be up to 150°C. Inappropriate handling can cause serious burns Æ
Do not open vent valves during operation or during standstill unless the system is depressurized and cooled down.
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1AHA052263
A
19.12.2006
en
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Rev. A
WARNING Hot surface Inappropriate handling can cause serious burns Æ
Do not touch piping- or component-surface, if there is no heat insulation and the plant is not cooled down.
Read the component safety instructions before operation!
4.1.2.
Component Operating Instructions To ensure operational reliability of the individual system components, the relevant operation instructions must be observed.
Read the component operating instructions before operation!
4.1.3.
Automatic Control Logic For details of the automatic control logic refer to the PFUP and the Set Point List of the system.
4.2.
Initial System Filling The feed water extraction lines shall be filled during the boiler filling procedure. Refer also to the O&M instructions of the fuel gas preheater.
4.3.
Normal Start-up Note The normal start-up is performed in automatic mode by starting of the related function group GT Gas preheater control by the relevant sequencer in the DCS. For automatic start-up, no operator actions are required. When exhaust gas temperature at stack exceeds a certain value, the feed water shut-off valve 21EKT10AA002 is opened. After opening of the feed water shut-off valve, the feed water control valve is released. The gas temperature will be ramped up to the required set point with a limited temperature gradient by controlling the feed water extraction supply with the water control valve.
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1AHA052263
A
19.12.2006
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4.4.
Rev. A
Normal Operation The fuel gas preheating system is taken into service when exhaust gas temperature at stack exceeds a certain value and fuel gas is selected. The flow of the feed water depends on the fuel gas flow and its target temperature. The feed water control valve is controlled by the measured temperature in the fuel gas line downstream the fuel gas preheater. The purpose is to maintain a constant fuel gas preheater outlet temperature, independent of the actual fuel gas flow and inlet temperature.
4.5.
Normal Shut-down Note The normal shut-down is performed in automatic mode by stopping of the related function group GT Gas preheater control by the relevant sequencer in the DCS. For automatic shut-down, no operator actions are required. Here are no special requirements for the shut-down procedure. The system can be shut-down at any time or automatically as soon as GT flame is off or command off is given.
CAUTION Standstill of the system during sub-zero ambient temperature condition may following in icing and consequently in serious damages of the system or components. Switch the heat tracing system into operation during standstill at sub-zero ambient condition. Follow the component operating instructions.
4.6.
Abnormal Operation The water extraction shut-off valve 11EKT10AA002 is closed in following cases • The fuel gas temperature exceeds a certain limit (MAX2). When fuel gas is detected downstream of the gas preheater and if the gas preheater shut-off valve is already closed, the following actions have to be taken: • •
Check the gas detection device on top of the gas preheater If gas is detected on the gas preheater shell side, the manual shut-off valve 11HAC24AA002 (in HRSG scope) of the extraction line must be closed in order to prevent gas increase in the boiler system.
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1AHA052263
A
19.12.2006
en
15/19
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Rev. A
5.
MAINTENANCE
5.1.
Specific Safety Precautions Operation as well as maintenance and repair work of the system has to be done by qualified personnel and under observation of general rules and regulation and the special safety rules and regulations for pressure equipment.
Prior to executing any maintenance work you must have read and understood the safety instructions in chapter 2 of this manual. Operational readiness of the system components is to be maintained by adhering to the relevant operation & maintenance documentation supplied by the supplier, and must be consulted before operation or maintenance begins.
5.2.
System-related Maintenance •
Carry out a visual inspection of the entire system every day.
•
Component specific maintenance instructions must be observed.
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1AHA052263
A
19.12.2006
en
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Rev. A
6.
APPENDICES
6.1.
Manual Preparation Check List prior to Start-up
Before start-up, prepare the systems, all components, valves, and instrumentations to be ready for operation according to Table 3.
System/Component
Status
KKS number
Gas preheater
Ready for operation
11EKC10AC001
Remote controlled valves
Ready for operation
various
Instrumentations
Ready for operation
various
Valve
Position
KKS number
Instrument root valve for all permanent instruments
open
various
maintenance drains
closed
various
Instrument root valves for all temporary instruments
closed
various
Manual isolation valve
open
11HAC24AA002
Manual isolation valve
open
11EKT10AA001
Extraction shut-off valve
closed
11EKT10AA002
Control valve
closed
11EKT10AA003
Table 3
6.2.
Manual Preparation Check List prior to Start-up
Alarm List KKS
Code
Description
Remarks
11EKC10CL001
LA
GAS DETECTION PHR
Check PHR (tube break) Close isolation valve 11HAC24AA002
11EKC10CL002
11EKG90CT001
LA
<MIN1
GAS DETECTION AFT PHR
Check PHR (tube break)
T FUEL GAS AFT PHR
Check isolation valves
Close shut-off valve 11EKT10AA002 Check shut-off valve Check functionality of control valve
11EKG90CT001
>MAX1
T FUEL GAS AFT PHR
Check functionality of control valve
11EKG90CT001
>MAX2
T FUEL GAS AFT PHR
Check functionality of control valve
Table 4
Alarm List
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1AHA052263
A
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6.3.
Rev. A
Externals Documents and Diagrams The following external documents and diagrams are referenced throughout this manual. Document No.
Title
1AHA049449
P & ID Fuel Gas Preheating System
1AHA049450
Legend to P & ID Fuel Gas Preheating System
1AHA050087
P & ID Fuel Gas System Legend to P & ID Fuel Gas System Process Function Plan Fuel Gas Preheating System Set Point List Fuel Gas Preheating System
Table 5
External Documents and Diagrams
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1AHA052263
A
19.12.2006
en
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Rev. A
Index A
M
abbreviations and acronyms, 10 alarm list, 23
main components, 11 MANDATORY ACTION explanation, 9 manual preparation check list prior to start-up, 23
C CAUTION explanation, 8 compulsory reading, 7 copyright, 2
O Operational readiness, 21 S
D
system tasks, 11
DAMAGE explanation, 9 DANGER explanation, 8
T target audience, 7 TN04/0297, 13
E
U
external documents and diagrams, 24
user audience, 7
G
V
general note explanation, 9
visual inspection, 21 W
I
WARNING explanation, 8
interface to other systems, 11
Originator
Identification number
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Date
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1AHA052263
A
19.12.2006
en
19/19
© ALSTOM 2006. All rights reserved.
