Reference LAC50 DM

7/30/2019 Reference LAC50 DM

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Consortium Partner

ALSTOM (SWITZERLAND) LTD.,Brown Boveri Strasse 7, CH 5401-BadenReplaces Consortium Document Code

MTV/58/M/LAC50-----/DM/001

Responsible dept.

GSAEM-MYCreated by

Loi T.-S.Checked by

Janarthanan H.Approved by

Sharma R.-K.Format

A4Document Type

Design ManualDocument Status

Electronically releasedIdentification number

1AHA071015

Originator

Title, Subtitle

SYSTEM MANUALLAC50 - HP FEEDWATER PUMPSYST

Rev.

CDate

25.11.2011Lang.

enSheet

1/41 ALSTOM 2009. All rights reserved. Please consider the environment before printing this document.

SYSTEM MANUAL

LAC50 - HP FEEDWATER PUMP SYSTEM

Owner :

PT. PLN (PERSERO)PROYEK INDUK PEMBANGKIT DAN JARINGAN JAWA, BALI & NUSA TENGGARAJL. SLAMET NO. 1 CANDI BARUSEMARANG - INDONESIA

MUARA TAWAR GAS FIRED POWER PLANTEXTENSION PROJECT, BLOCK 5, INDONESIA

Contract No: 261.PJ/041/DIR/07

Drawing No:Owners Engineer :

The Consortium ofTOKYO ELECTRIC POWER SERVICES CO.LTD

AndFICHTNER GmbH & Co.KG

A Reviewed

B Reviewed with Comments

Status

C As BuiltAction

Date Recorded Date ReturnedIssued Reviewed Checked

Project Manager Lead Engineer in Charge Engineer

Consortium :

Alstom (Switzerland) LtdPT Alstom Power Energy Systems Indonesia

Revision HistoryRev. Rev. Date Created by Checked by Approved by Description


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Electronically released Rev.

OriginatorALSTOM POWER SYSTEMS Identification number1AHA071015 Rev.C Date25.11.2011 Lang.en Sheet2/41 ALSTOM 2009. All rights reserved.

Copyright

All rights reserved

Copyright 2011 ALSTOM (Switzerland) Ltd.

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 disclosureto 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 ofthe copyright law without prior approval of ALSTOM (Switzerland) Ltd., CH-5401 Baden is prohibited andsubject to punishment under the applicable law.


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Contents

1 Introduction.........................................................................................................................................................11

1.1. Purpose...........................................................................................................................................................11

1.2. System Overview............................................................................................................................................11

1.2.1. Main Equipments.......................................................................................................................11

1.2.2. Interface to other Systems.........................................................................................................12

2. Safety Instructions ............................................................................................................................................13

2.1. General Safety Instructions............................................................................................................................13

2.2. System-specific Safety Instructions ............................................................................................................... 13

3. System Description ...........................................................................................................................................17

3.1. Overview .........................................................................................................................................................17

3.2. HP Feedwater Pump......................................................................................................................................17

3.3. Pump Suction Strainer ...................................................................................................................................18

3.4. Automatic Recirculation Check Valve ...........................................................................................................18

3.5. The Lube Oil System...................................................................................................................................... 18

3.6. Electric Motor..................................................................................................................................................18

3.7. Noise Hood.....................................................................................................................................................19

4. Operation.............................................................................................................................................................21

4.1. Overview .........................................................................................................................................................21

4.1.1. Specific Safety Instructions .......................................................................................................21

4.1.2. Equipment Operating Instruction...............................................................................................23

4.1.3. Automatic Control Logic ............................................................................................................23

4.2. Conditions Prior to Start-up............................................................................................................................24

4.3. Normal Start-up............................................................................................................................................... 24

4.4. Initial Filling of the System..............................................................................................................................25

4.4.1. Pre-conditions to fill the system.................................................................................................25

4.4.2. Procedure to fill the system .......................................................................................................26

4.5. Normal Operation ...........................................................................................................................................27

4.5.1. Normal operation .......................................................................................................................27

4.5.2. Pump change-over ....................................................................................................................27

4.6. Normal Shut-down..........................................................................................................................................27

4.7. Abnormal Operation .......................................................................................................................................28

4.8. Inadmissible Operation................................................................................................................................... 28

4.9. Other Operation Modes.................................................................................................................................. 29

4.9.1. Failure of Equipment .................................................................................................................29


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4.9.2. Standby......................................................................................................................................29

4.9.3. Measures during outages..........................................................................................................29

4.9.4. Shutdown for maintenance or long-term outage.......................................................................29

4.9.5. System preservation..................................................................................................................295. Maintenance........................................................................................................................................................31

5.1. Specific Safety Precautions ...........................................................................................................................31

5.2. System-related Maintenance.........................................................................................................................31

5.2.1. Daily Checks..............................................................................................................................31

5.3. Depressurization Prior to Maintenance.........................................................................................................32

6. Appendices.........................................................................................................................................................35

6.1. Manual Preparation Check List prior to Start-up...........................................................................................35

6.2. Alarm List ........................................................................................................................................................37

6.3. External documents and diagrams................................................................................................................ 39


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List of Tables

Table 1 Brief Description of Manual Contents......................................................................................7

Table 2 Abbreviations and Acronyms.................................................................................................10

Table 3 Manual Preparation Check List prior to Start-up ...................................................................36

Table 4 Alarm List...............................................................................................................................38

Table 5 External Documents and Diagrams.......................................................................................39


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About this Manual

Purpose

This manual contains the essential information needed for safe and efficient handling andmaintenance of the described systems.

The information in this manual is compulsory reading matter for anyoneworking with or at the systems and equipments. This means that every onemust understand what safety means. ALSTOM Power declines allresponsibility for personal injuries or material damages occurring as a result ofnon-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

Chap Title Contents

1 Introduction Provides an overview of the system and its equipments

2 Safety Instructions Describes the safety rules and general residual risks

3 System Description Describes the system and its equipments on a functionallevel

4 Operation Describes the operation sequences required for routineoperational tasks and the standard operational phases

5 Maintenance Contains basic maintenance schedules and describes

various maintenance procedures.6 Appendices Contains miscellaneous additional documents, e.g.

piping and instrumentation diagrams (P & ID)

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 coursesdelivered by ALSTOM.

There are several features that will help you find specific information quickly:

Table of Contents at the beginning of the book

Lists of figures and tables at the beginning of the book

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.


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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

Steps to avoid the hazard.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death orserious injury.

WARNING

Type/Source of Hazard

Hazard consequences


CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor ormoderate injury. It may also be used to alert against unsafe practices.

CAUTION

Type/Source of hazard

Hazard consequences



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DAMAGE information not relevant for the safety of personnel but pointing out possible damage to themachine 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 thismanual or in external reference documents.

Read instructions!

MANDATORY ACTION symbols are used to point out instructions and information that must be strictlyfollowed to prevent any risk for personal safety or to avoid machine damage.

General requirement sign


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Abbreviations and Acronyms

Item Explanation

CCWS Closed Cooling Water System

DCS Distributed Control System

FG Function Group

GT Gas Turbine

HP High Pressure

HRSG Heat Recovery Steam Generator

P & ID Piping and Instrumentation Diagram

WSC Water Steam Cycle

Table 2 Abbreviations and Acronyms


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1 INTRODUCTION

1.1. Purpose

The system fulfils the following tasks:

Feeding the HP drum of the HRSG with feedwater from feedwater storage tank

Providing the HP live steam attemperator of the HRSG with feedwater for water injection

1.2. System Overview

Note

For an overview of the system, refer to P & ID MTV/58/M/LAC50-----/FD/001.

1.2.1. Main EquipmentsThe system is made up of two redundant pump systems (2 x 100%) feeding the feedwater consumersvia a common piping. It consist of the following main equipments:

HP feedwater pump

58LAC50AP001

58LAC60AP001

HP feedwater pump suction shut-off valve

58LAB51AA001

58LAB61AA001

HP feedwater pump suction line strainer

58LAC50AT001

58LAC60AT001

HP feedwater pump discharge shut-off valve

58LAB52AA002

58LAB62AA002

HP feedwater pump minimum flow recirculation shut-off valve

58LAB53AA001

58LAB63AA001

HP feedwater pump filling bypass shut-off valve

58LAB54AA002

58LAB64AA002

The common HP feed water discharge line consists mainly of:

Common HP feed water discharge line 58LAB95BR001

Sampling probe extraction line 58LAB95BR401

Common discharge line pressure measurements 58LAB95CP001, 58LAB95CP002 and58LAB95CP003


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HP feedwater pump 58LAC50AP001 is equipped with the following equipments:

Auxiliary lube oil pump (2 X 100% per HP feedwater pump)

58LAC51AP001 (electrically driven standby lube oil pump)

58LAC51AP002 (shaft driven main lube oil pump)

Noise hood light

58LAC56AH052

Motor space heater

58LAC50AH001

Noise hood fan

58LAC56AH050

58LAC56AH060

The equipments for pump 58LAC60AP001 are similar with exception of the KKS function number codefirst digit, which changes from 5 (e.g 58LAC50AP020) to 6 (e.g 58LAC60AP020).

1.2.2. Interface to other Systems

Feedwater enters from the feedwater storage and deaeration system (LAA) and exit at theHP economizers of the HRSG.

The minimum recirculation flow returns back to the feedwater tank (LAA).

A part of the feedwater leaves to the sampling system (QUL).

Cooling water from closed cooling water system (PG) to cool pump mechanical seal, lube oilcooler and motor cooler system.


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2. SAFETY INSTRUCTIONS

2.1. General Safety Instructions

All personnel working with or at the systems and equipments must have readand understood the safety instructions in ALSTOM technical manualTN04/0297, which is part of the overall customer documentation set.

2.2. System-specific Safety Instructions

WARNING

Water steam cycle under high pressure and high temperature

Inappropriate handling can cause serious injuries or death.

Prior start-up

Ensure that the equipments and instruments are ready foroperation. Refer to section 6.1 Manual Preparation CheckList prior to Start-up on page 35.

Follow the Water Chemistry WSC Technical Specification toensure the required water and steam quality.

Ensure that the instrument root valves for all permanentinstruments are open. Refer to section 6.1 ManualPreparation Check List prior to Start-up on page 35.

Ensure that the instrument root valves for all temporaryinstruments are closed. These temporary instruments are

shown in the P & ID with a P, PP, T or TP and are used onlyfor the performance test or commissioning. Refer to section6.1 Manual Preparation Check List prior to Start-up on page35.

Prior maintenance

Ensure that the system is depressurized, cooled down anddrained.

Secure the drives and valves against unintentional startingand moving.

Do not modify systems or equipments.

The instructions of the equipment suppliers must be adhered to.

WARNING

Hot surface

Inappropriate handling can cause serious burns

Do not touch piping- or component-surface, if there is no heatinsulation and the plant is not cooled down.


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WARNING

High voltage/Electrical shock

Electric motors and actuators powered with high voltage, inappropriatehandling can cause serious injuries or death.

Keep away from live parts.

Do not remove guards.

Avoid wet surfaces.

Prior to maintenance:

Isolate equipment from power supply.

Take effective measures to prevent reconnection.

Ensure no residual voltage remains.

Do not modify systems or equipment.


WARNING

Rotating or moving parts


Keep away from rotating or moving parts.


Prior to maintenance, take effective measures to prevent rotating ormoving.



WARNING

Flammable lubrication oil

Inappropriate handling can cause fire and serious burns

Shutdown the pumps system in case of major oil leakages

Remove oil before maintenance activities in e.g. welding


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WARNING

Hot medium

The feedwater temperature can be up to 150C. Inappropriate handling

can cause serious burnsDo not open vent valves during operation or during standstill unless

the system is depressurized and cooled down

Wait for system cool down before maintenance activities

DANGER

Danger of suffocation

Nitrogen in high concentration can cause unconsciousness and lead tosuffocation.

Avoid inhaling of leaking gas.

Ensure sufficient ventilation.

Close drains / vents when gas is leaking.

Close sampling isolation valves.

For safety reasons it is strongly recommended not to enter thehazardous area alone (team of minimum two people).

The HP feedwater pump system and its equipment must be operated andmaintained by trained and authorized personnel only!

All applicable safety rules and regulations are strictly to be followed. Forequipment relevant instructions refer to the separate operation andmaintenance manuals for the individual subsystems and equipment.

For maintenance work it is mandatory to have all required work permits.

All applicable local rules and regulations as well as national andinternational directives must be strictly followed.

Read the equipment safety instructions before operation!


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3. SYSTEM DESCRIPTION

3.1. Overview

Feedwater enters the HP feedwater pump suction lines from the feedwater storage tank . Each pumphas its own suction line, which can be individually isolated from the feedwater storage tank by meansof manually operated suction line shut-off valves.

Downstream of the suction line shut-off valves there are strainers installed in order to prevent dirt fromentering the pumps. Differential pressure transmitters are installed for monitoring of the strainers.

The filtered feedwater is fed to the suction nozzle of the HP feedwater pump. The HP feedwater pumpincreases the fluid pressure depending on the feedwater flow demand.

The minimum required flow rate through each operating HP feedwater pump is ensured by theautomatic recirculation check valve that is installed downstream of the HP feedwater pump dischargenozzle. The HP recirculation flows are fed back into the feedwater storage tank. Throttling orifices areprovided in the recirculation line near to the feedwater tank in order to prevent steaming out.

Before starting the first pump, the common feedwater line might be empty or not pressurised. To

ensure the minimum required back pressure at the pump discharge, the motorised discharge shut-offvalves remain closed during start-up and the feedwater lines are filled and pressurised via the fillingbypass line. The bypass flow is limited by the filling bypass line of the 4 way automatic recirculationcheck valve. When the pressure in the common feedwater line has exceeded a minimum value, theHP feedwater pump discharge shut-off valve opens.

The four way automatic recirculation check valve limits the filling bypass flow and also preventsreverse rotation of the standby pump by back-feed through the main line. Back-feed through the fillingline is prevented by means of the check valve actions of ARC valve.

The HP pump lines downstream of the discharge shut-off valves are connected to the common HPfeedwater line. The common HP feedwater line is connected to the economizer of the HRSG.

Analogous to the feedwater lines, the HRSG feedwater pipes and economizers need to be filled andpressurized via the filling bypass lines (flow limited by orifice) before the main HRSG gate valves canbe opened. As soon as the HRSG economizer and the HP feedwater line to the HRSG arepressurized and the pressure difference between these two systems is within the allowed limits the

main HRSG gate valves are opened.

3.2. HP Feedwater Pump

The HP feedwater pump is a horizontal, centrifugal multistage ring section type. The pump radial andthrust bearings are connected to the lubrication oil system.

For preventing inadmissible heating of the pump during low flow operation, minimum feed water flowthrough the pump is ensured by the automatic recirculation check valve.

The mechanical seals are cooled by means of the closed cooling water system (CCW).

Each pump is equipped with bearing temperature measurements for supervision and protectionpurposes. In case of high temperature (>MAX1), alarms are generated in the DCS and at furtherincrease (>MAX2) the feed water pump will be tripped.

Each radial bearing is equipped with vibration measurements to monitor pump shaft vibration. In case

of high vibration level (>MAX1) alarms are generated in the DCS and if the vibration level increasefurther (>MAX2) the feed water pump will be tripped.

Additionally, a reverse rotation detector is supplied, which will also generate an alarm in the DCS.

For more detailed information of this equipment, consult the Operation & Maintenance Manual of thesupplier.


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3.3. Pump Suction Strainer

Each pump is equipped with duplex type suction strainers, which allow easy maintenance during pumpstandstill and when the system section is depressurised.

The strainer prevents dirt particles bigger than permitted by the pump to enter the feed water pump.

The strainer is equipped with a differential pressure measurement. In case the differential pressureincreases (due to strainer clogging) an alarm (>MAX1) will be generated in the DCS. At furtherincrease (>MAX2) the feed water pump will be tripped.


3.4. Automatic Recirculation Check Valve

The automatic recirculation check valve ensures the minimum required flow rate through the feedwaterpump, allows a pump start-up through the filling bypass line, prevents back flow to the feedwater pumpand protects the feedwater pump against overheating. The automatic recirculation check valve ismechanically controlled type and therefore requires no auxiliary power or separate control system.

At flows lower than the required minimum flow, the check valve is activated, by means of a lever and avortex plug. When lifted of its seat, the vortex plug allows a flow through the pressure reduction

section to the feedwater storage tank.The internal check valve is spring loaded and prevents back flow to the pump. The check valvedampens pulsations because of its throttling effect on the main flow and stabilizes the pumpcharacteristics in part load operation.

For filling of the feedwater system, the fourth gate of the automatic recirculation check valve isconnected to the filling bypass line. The throttling device of the recirculation check valve realizes therequired pressure reduction.


3.5. The Lube Oil System

The lube oil circuit provides the lubrication oil for the bearings of feed water pump and electrical motor.

A shaft driven main lube oil pump is provided to supply the feed water pump with lube oil. An alarm willbe sent when the lube oil pressure in the lube oil supply line drops below MIN1. Further reduction oflube oil pressure (


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The motor bearings are fed and cooled by the forced lubrication oil system.

The electric motor is equipped with winding and bearing temperature supervision. In case of hightemperature (>MAX1), alarms are generated in the DCS and at further increase (>MAX2) the motorwill be tripped. An electric heater prevents condensing during stand still of the motor.

For more detailed information of this equipment, consult the Operation & Maintenance Manual of the

supplier.

3.7. Noise Hood

Each feedwater pump is provided with a noise hood to reduce the noise level generated by the pump.Each noise hood is equipped with two numbers of cooling fans to avoid overheating of air under thehood. One fan is always in operation when the pump is running. If the temperature under the hoodrises (>MAX1), the stand-by fan is automatically switched on.



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4. OPERATION

4.1. Overview

4.1.1. Specific Safety Instructions

WARNING

Water steam cycle under high pressure and high temperature


Prior start-up

Ensure that the equipments and instruments are ready foroperation. Refer to section 6.1 Manual Preparation CheckList prior to Start-up on page 35.

Follow the Water Chemistry WSC Technical Specification toensure the required water and steam quality.

Ensure that the instrument root valves for all permanentinstruments are open. Refer to section 6.1 ManualPreparation Check List prior to Start-up on page 35.

Ensure that the instrument root valves for all temporaryinstruments are closed. These temporary instruments areshown in the P & ID with a P, PP, T or TP and are used onlyfor the performance test or commissioning. Refer to section6.1 Manual Preparation Check List prior to Start-up on page35.

Do not modify systems or equipments.


WARNING

Hot surface

Inappropriate handling can cause serious burns.

Do not touch piping- or equipment-surface, if there is no heatinsulation and the plant is not cooled down.


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WARNING

High voltage/Electrical shock

Electric motors and actuators powered with high voltage, inappropriate

handling can cause serious injuries or death. Keep away from live parts.


Avoid wet surfaces.

Prior to maintenance:

Isolate equipment from power supply.

Take effective measures to prevent reconnection.

Ensure no residual voltage remains.



WARNING

Rotating or moving parts


Keep away from rotating or moving parts.


Prior to maintenance, take effective measures to prevent rotating ormoving.



WARNING

Flammable lubrication oil

Inappropriate handling can cause fire and serious burns

Shutdown the pumps system in case of major oil leakages

Remove oil before maintenance activities in e.g. welding

WARNING

Hot medium

The feedwater temperature can be up to 150C. Inappropriate handlingcan cause serious burns

Do not open vent valves during operation or during standstill unlessthe system is depressurized and cooled down

Wait for system cool down before maintenance activities


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The HP feedwater pump system and its equipments must be operatedand maintained by trained and authorized personnel only!

All applicable safety rules and regulations are to be followed strictly.For equipment-relevant instructions, refer to the separate operationand maintenance manuals for the individual subsystems and

equipment.

For maintenance work it is mandatory to have all required workpermits.

All applicable local rules and regulations as well as national andinternational directives must be strictly followed.


4.1.2. Equipment Operating Instruction

To ensure operational reliability of the individual system equipments, the relevant operationinstructions must be observed.


4.1.3. Automatic Control Logic

Note

Remote operated actuators, pumps or similar equipment are represented witha dedicated DRIVE element in the control system.

A SELECTOR controls the Drives of redundant equipment like pumps.

Equipments which have to operate together to maintain a specific function of asub-process are combined into a FUNCTION GROUP (FG).

Refer to the Plant Operation and Control Concept for more information aboutthe general automation structure.

The HP feedwater pumps 58LAC50AP001, 58LAC60AP001, the HP feedwater pump discharge shut-off valves 58LAB52AA002, 58LAB62AA002, the lube oil pumps 58LAC51AP001, 58LAC61AP001 andthe pump hood fans 58LAC56AH050/60, 58LAC66AH050/60 are combined into function group FG HPFDW PMPS 58LAC50EA100.

For details of the automatic control logic refer to the Process Function Plan and the Set Point List ofthe system.


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4.2. Conditions Prior to Start-up

After maintenance activities, major repair, or initial installation, the system shall be cleaned before thesystem is started and taken in operation.

Before Start-up, ensure the systems, equipment, valves, andinstrumentations are ready for operation. Refer to 6.1 ManualPreparation Check List prior to Start-up on page 35.

4.3. Normal Start-up

Note

The normal start-up is performed in automatic mode by starting the relatedfunction groups by the relevant sequencer in the DCS.

Following function group is started:

FG HP FDW PMPS

For automatic start-up, no operator actions are required.

CAUTION

Starting against an empty or partially drained system or HRSG might damageequipment.

Follow initial filling procedure if the system or HRSG was partially orcompletely drained. Refer to section 4.4 Initial Filling of the System on page

CAUTION

Prior to start-up of any feedwater pump, the closed cooling water system hasto be in operation for cooling of the pump unit.

CAUTION

In order to prevent major damage to the pump motor windings, the number ofsequential starts is limited to two successive starts per hour if the motor isstarted from the hot condition. The number of sequential starts is limited tothree successive starts per hour if the motor is started from the cold condition(initial motor temperature at maximum ambient temperature). It isrecommended not to shut down the pump before it has run for at least half an

hour.

Note

The duty and the stand-by pump can be pre-selected by the operator, todefine the starting order of the pumps.


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Note

The duty and the stand-by pump are started and stopped automatically by a2-unit-selector based on demand. The demand is created by superior controllogic.

For details of the automatic control logic refer to the Process Function Plan (PFUP) and the Set-pointList of the system. The two HP feed water pumps 58LAC50AP001/58LAC60AP001 are started andstopped automatically by a 2-unit-selector. During normal system operation, one pump is alwaysrunning, while the second pump remains in stand-by. The starting order of the pumps can be pre-selected by the operator.

The lube oil pumps (two per feed water pump) ensure the required minimum lube oil pressure for thefeed water pump and motor, especially during run-up and coast-down of the feed water pump.

To enable the stand-by feed water pump to start without time delay, the electric motor driven lube oilpumps in operation during the stand-by phase.

In automatic mode the normal start-up doesnt require any operator action and is effectuated byactivating the related functional group in the DCS.

NoteThe lubrication system is required for the lubrication of feedwater pump andelectrical motor. Therefore it is recommended to verify the lube oil pressureafter the auxiliary lube oil pump prior to feedwater pump start.

Before start-up, the HP feedwater pump discharge shut-off valves 58LAB52AA002 and58LAB62AA002 are closed. The first pump (selected one) starts, fills and pressurizes the common HPfeedwater line via the filling bypass line.

When the pressure in the common feedwater line measured at 58LAB95CP001/002/003 is above theminimum value MIN1, both discharge valves 58LAB52AA002 and 58LAB62AA002 are opened.

4.4. Initial Filling of the System

The initial filling procedure must be executed only if the system or the HRSG was partially orcompletely drained. If this initial filling procedure was completed and no partial or complete drainingwas done, the system can be started according to section 4.3 Normal Start-up on page 24.

The geodetic liquid pressure of the feedwater storage tank will fill the pump suction lines and a part ofthe discharge line. The water system downstream of the pumps will finally be filled by means of thepump.

CAUTION

Initial filling of the system downstream of the feedwater pump with opendischarge shut-off valve 58LAB52AA002/58LAB62AA002 may create waterhammer and consequential damage of the piping and interfacing systems.Further serious pump damages can not be excluded.

4.4.1. Pre-conditions to fill the system

The entire HP feedwater system is visually checked and ready for filling.

The mesh of the pump suction strainers should be cleaned and has to be inserted correctly;the strainer casings must be closed.

The conditions according to the pump and motor operating manuals have to be fulfilled.


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Root valves for the two sensing lines (+ and ) of the differential pressure measurement atsuction strainer 58LAB51CP001/58LAB61CP001 are open. The + and the valves at thedifferential pressure transmitter are open. The bypass valve between + and - at differentialpressure transmitter is open. The venting valves at differential pressure transmitter for + and- are closed.

Root valves 58LAB95AA301/311/312/302/312/322 of common HP discharge pressuremeasurements 58LAB95CP001/2/3 are open. The valves at the pressure transmitters areopen. The venting valves of the pressure transmitters are closed.

Feedwater storage tank is filled at least above minimum level MIN3, one condensate pump ispreferable in operation to maintain the feedwater storage tank level.

Closed cooling water system is in operation.

The discharge valves 58LAB52AA002/58LAB62AA002 downstream of the pumps are closed.

The drain valves 58LAB52AA201/58LAB62AA201 and 58LAB52AA202/58LAB62AA202 areclosed.

The vent valve 58LAB51AA201/58LAB61AA201 is closed.

All system- and component vent valves are closed.

4.4.2. Procedure to fill the system1. Start the electric motor driven lube oil pump 58LAC51AP001 (58LAC61AP001).

2. Open the HP feedwater pump suction shut-off valve 58LAB51AA001 (58LAB61AA001).

3. Open the venting valve on the + and - side of the differential pressure transmitters58LAB51CP001 (58LAB61CP001) and close when feedwater leaks. Close the equalizing valve atthe differential pressure transmitter.

4. Vent the feedwater pump 58LAC50 (58LAC60) according to the component operatinginstructions.

5. Open the HP feedwater pump filling line bypass shut-off valve 58LAB54AA002 (58LAB64AA002).Wait for a few minutes to fill the HP feedwater system section by gravity.

6. Open the vent valves at the pressure transmitter for the HP feedwater discharge pressuremeasurement 58LAB95CP001/002/003 and close when feedwater leaks.

7. Start the HP feedwater pump units according to the component operating instructions.

8. Check that minimum HP feedwater discharge pressure 58LAB95CP001/002/003 (MIN1) isestablished.

9. Fill the complete system, HRSG economizers and HRSG drums via the HRSG filling bypassvalves. Supervise the system pressure 58LAB95CP001/002/003.


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4.5. Normal Operation

4.5.1. Normal operation

One of the 2 x 100% HP feedwater pumps is required for the supply of the feedwater consumers. Theother pump is on stand-by. Both discharge valves 58LAB52AA002 and 58LAB62AA002 remain open.

The HP feedwater control valves of the HRSG open according to the HP drum level control logic.

4.5.2. Pump change-over

Change-over of the pump on duty can be executed during system operation.

For the automatic change-over the operator has to change and confirm the pump selection in theDCS. No further operator action is required.

Note

Change-over to a disturbed pump line can cause reduced feedwater flows forcertain periods unless the first pump is restarted automatically. This can causeunit trips or unplanned system outages.

Check prior to manual change-over that the standby pump line is available,the electric motor driven lube oil pump is on and the pump is ready foroperation.

In order to ensure a high availability of the standby pump line it is recommended to change over thepump on duty at least once a week. The regular change-over should preferable be conducted duringstable plant load operation.

Read the component instructions regarding permissible / recommended stand-by durations.

4.6. Normal Shut-down

Note

The normal shut-down is performed in automatic mode by stopping the relatedfunction groups by the relevant sequencer in the DCS.

Following function group is stopped:

FG HP FDW PMPS

For automatic shut-down, no operator actions are required.

NoteThe HP feedwater pump system can be normally switched off after shutdownof the GT. However due to the residual heat of the various consumers,feedwater supply may still be required.

Read the component instructions regarding shutdown times prior to manualshutdown of the feedwater pump system.

When using the unit sequencer for the shutdown of the feedwater pumpsystem, the required waiting times are already considered in the automaticfunction.

The normal shut-down will be realized in automatic mode by deactivation of the related functionalgroup in the DCS. For this automatic shut-down no operator action is required.


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When both pumps are stopped, both discharge line shut-off valves 58LAB52AA002 and58LAB62AA002 closed.

4.7. Abnormal Operation

Following conditions lead to an emergency shut-down of a feedwater pump by the control system:

Water level in the feedwater tank falls below minimum level MIN4

Pressure in the common HP feedwater line drops below minimum pressure MIN2

The suction valve is not fully open (limit switch not in open position)

Pressure difference across the suction strainer exceeds maximum value MAX2

Motor winding temperature exceeds maximum temperature MAX2

Motor bearing temperature exceeds maximum temperature MAX2

Pump bearing temperature exceeds maximum temperature MAX2

Lube oil pressure drops below minimum pressure MIN2

Pump or motor vibrations exceed the maximum value MAX2

Lube oil level in lube oil tank drops below MIN1.

In case of a power supply failure (electrical protection), the relevant pump is switched off.

Note

In automatic mode, after emergency shut-down of one pump, a back-up pumpswitches on automatically (if no common emergency shut-down is active). Forthe back-up pump no warm-up procedure is necessary.

For the standby pump/motor no warm-up procedure is necessary.

Note

To avoid run-out protection trip (low pressure at high feed water flow) ofthe pump, the HRSG HP drum level control valves will be throttled at lowfeed water discharge pressures.

For details please refer to the HRSG system description.

4.8. Inadmissible Operation

The following operation modes are not permitted:

Continuous normal operation of two HP feedwater pumps

Any pump operation against not open HP feedwater pump suction shut-off valves

Any pump operation against not open shut-off valves in the discharge line

Any pump operation against not open shut-off valves in the minimum flow line

Starting the feedwater pump against not closed HP feedwater pump discharge shut-off valve Stopping the electric motor lube oil pump of the not running HP feedwater pump during plant

operation

Starting against an empty or partially drained system or HRSG without completing the initialfilling procedure

Any pump operation without the closed cooling water system in operation

Operating the equipment outside defined limits as per equipment Operation & MaintenanceDocumentation


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CAUTION

Operating the system in an inadmissible operation mode will cause damage ofthe system and equipment.

4.9. Other Operation Modes

The operation modes described in section 4.3 Normal Start-up, 4.5 NormalOperation and 4.6 NormalShut-down are the normal operation modes. Apart from normal operation mode, there are otheroperation modes, which are considered as acceptable, short term, time limited operation modes. Thefollowing operation modes are admissible.

4.9.1. Failure of Equipment

Failure and alarms of equipment controlled by DCS will be indicated in the MCR via DCS. Forequipment failures and trouble shooting, refer to the relevant sections of the suppliers instructions.Local checks, repairs, resetting, etc. are required within time frame according to the relevant sectionsof the suppliers instructions.

4.9.2. Standby

The standby of individual equipment is defined in the referenced subsystem and equipment operatinginstructions. This is an essential condition for operational standby of the system.

4.9.3. Measures during outages

In order to prevent malfunction and damage of the subsystem and the individual equipment, themeasures during outages must be observed. Refer to the relevant sections of the suppliersinstructions.

4.9.4. Shutdown for maintenance or long-term outage

The shut down procedures for long-term outages and for normal shutdown are exactly the same. Forlong-term outages the instructions and the measures for long-term shutdowns of the subsystem andthe individual equipment must be observed. Refer to the relevant sections of the suppliersinstructions. In case of a planned long-term outage, an increase of the ammonia dosing into the watersystem is recommended prior to plant shutdown. This will improve the water chemistry for wetpreservation. For details please refer to the applicable water chemistry guideline and to the section4.9.5 System preservation. Dry preservation is to be used for the steam systems.

4.9.5. System preservation

The HP feed water system preservation method to be applied depends on several factors:

The purpose and length of the standstill period.

The preservation methods of the interfacing systems.

The equipment preservation requirements.

Read the equipment operating instructions regarding long-term standstill& preservation!

In general the available options are wet and dry preservation. Special attention is required in casenitrogen capping is used for equipment / system preservation.


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DANGER

Danger of suffocation

Nitrogen in high concentration can cause unconsciousness and lead to

suffocation. Avoid inhaling of leaking gas.

Ensure sufficient ventilation.

Close drains / vents when gas is leaking.

Close sampling isolation valves.

For safety reasons it is strongly recommended not to enter thehazardous area alone (team of minimum two people).


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5. MAINTENANCE

5.1. Specific Safety Precautions

Operation as well as maintenance and repair work of the system has tobe done by qualified personnel and under observation of general rulesand regulation and the special safety rules and regulations for pressureequipment.

Prior to executing any maintenance work you must have read andunderstood the safety instructions in chapter 2 of this manual.

Operational readiness of the system equipments is to be maintained by adhering to the relevantoperation & maintenance documentation supplied by the supplier, and must be consulted before

operation begins.

5.2. System-related Maintenance

If any maintenance work at the feed water pumps system as e.g. thepump suction line strainer has to be done, the applicable depressurizingprocedure is mandatory!

Read the respective equipment maintenance instructions. Theres one

for every major equipment: e.g. feed water pumps, suction strainers,etc.

5.2.1. Daily Checks

Carry out a visual inspection of the entire system every day.

Check all potential sources of water and oil leakages (flanges, joints) daily.

If any major water- or oil leakage is detected, the system must berepaired in accordance with the relevant codes and standards (e.g.welding procedure).

Check the pressure difference across the strainer daily.

Check that the standby pump does not rotate.


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5.3. Depressurization Prior to Maintenance

If the feedwater pump system or sections of it must be decommissioned for maintenance or repairwork, the whole system must be depressurized.

Depressurizing the system

1. Shut-down the HP feedwater pump system according to chapter 4.6.

2. Disconnect the pumps from the power supply.

3. Close feedwater shut-off valve to HRSG.

4. Open low point drain valves 58LAB52AA201/202 (58LAB62AA201/202) until the system isdepressurized. Supervise the system pressure measurements 58LAB95CP001/002/003.

NoteIf no maintenance works on the common discharge lines are required, these

lines dont need to be fully emptied. In that case the low point drain valves58LAB52AA201/202 (58LAB62AA201/202) can be closed when the pressuredrops below approx. 5 bar.

5. Close the HP feedwater pump discharge shut-off valves 58LAB52AA002 (58LAB62AA002) andthe HP feedwater pump fi lling bypass shut-off valves 58LAB54AA002 (58LAB64AA002).

6. Close the HP feedwater pump minimum flow recirculation shutoff valves 58LAB53AA001(58LAB63AA001).

7. Close the HP feedwater pump suction shut-off valves 58LAB51AA001 (58LAB61AA001).

8. Open the HP feedwater pump suction line vent valve 58LAB51AA201 (58LAB61AA201).

9. Open the drain valves at the suction strainers 58LAC50AT001 (58LAC60AT001) and the pumpsinternal drains.

10. If access to the common discharge lines is required, open the low point drain valves58LAB52AA201/202 (58LAB62AA201/202) again and wait until the water ceases to flow.

De-pressurizing of the pump / strainer :

CAUTION

Procedure must be followed strictly to prevent serious damage

In order to prevent pressurization of the closed pump suction line by leakingdischarge valve the discharge valve 58LAB52AA002 (58LAB62AA002) & thefilling bypass line shut-off valve 58LAB54AA002 (58LAB64AA002)depressurized pump has to be closed first

1. Shutdown the corresponding feed water pump 58LAB50AP001/58LAB60AP0012. Disconnect the pump from power supply

3. Close the feed water discharge valve 58LAB52AA002/58LAB62AA002

4. Close the filling bypass line shutoff valve 58LAB54AA002/58LAB64AA002

5. Close the minimum flow recirculation shutoff valves 58LAB53AA001/58LAB63AA001

6. Close the suction line shut-off valves 58LAB51AA001/58LAB61AA001

7. Open the depressurised pump suction line vent valve 58LAB51AA201/ 58LAB61AA201


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8. Open the drain valves of the depressurized pump suction strainers58LAC50AT001/58LAC60AT001 and the pump internal drain 58LAC50AA401/58LAC60AA401 and wait until the water ceases to flow.


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6. APPENDICES

6.1. Manual Preparation Check List prior to Start-up

Before Start-up, ensure the systems, equipment, valves, andinstrumentations are ready for operation. Refer to 6.1 ManualPreparation Check List prior to Start-up on page 35.

System/Equipment Status KKS number

Closed cooling water system Command On PG

Feedwater storage tank level control Command On LAA

Main condensate system Command On LC

Feed water pumps (min one pump) Ready for operation 58LAC50AP00158LAC60AP001

HRSG Ready for operation H

Instrumentation Ready for operation Various

Remote Controlled Valves Ready for operation Various

Feed water sampling system Ready for operation QUL40


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Valve Position KKS number

Instrumentation bypass valves Closed *1) 58LAB51CP00158LAB61CP001

HP suction line vent valves Closed 58LAB51AA20158LAB61AA201

Suction valves HP feedwater pump Open 58LAB51AA00158LAB61AA001

Filling bypass line shut-off valves Open 58LAB54AA00258LAB64AA002

Minimum flow recirculation shut-offvalves

Open 58LAB53AA00158LAB63AA001

HP drain valves Closed 58LAB52AA20158LAB52AA20258LAB62AA20158LAB62AA202

HP feedwater sampling valve Open 58LAB95AA401HP Feedwater pump check list See Pump doc.

HRSG HP feedwater shut-off valves Closed *2) See HRSG doc.

Root valves for permanent instruments Open 58LAB95AA30158LAB95AA31158LAB95AA32158LAB51AA30158LAB51AA30258LAB61AA30159LAB61AA302

*1) differential pressure transmitter only

*2) refer also to HRSG instruction manual

Table 3 Manual Preparation Check List prior to Start-up


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6.2. Alarm List

KKS Code Description Action

58LAA10CL00258LAA10CL003

58LAA10CL005

MAX1 T MOT WDG HPFWP

Motor winding temperature toohigh. Change over to back-uppump and check lubrication andCCW system.

58LAC50CT004

58LAC50CT005

58LAC60CT004

58LAC60CT005

>MAX1 T HP FWP MONDE BRG

T HP FWP MO DEBRG

Motor bearing temperature toohigh. Change over to back-uppump and check lubrication andCCW system.

58LAC50CT007

58LAC50CT008

58LAC60CT007

58LAC60CT008

>MAX1 T HP FWP RD DEBRG

T HP FWP RDNDE BRG

Pump bearing temperature toohigh. Change over to back-uppump and check lubrication andCCW system.

58LAC50CT010

58LAC50CT012

58LAC60CT010

58LAC60CT012

>MAX1 T HP FWP THR

BRG

Pump bearing temperature too

high. Change over to back-uppump and check lubrication andCCW system.

58LAC51CP004

58LAC61CP004

>MAX1 DP HP FWP LOILSTR

Pressure across oil filter too high.Change over to back-up strainerat next possibility and cleanclogged strainer.

58LAC50CY001-9

58LAC60CY001-9

>MAX1 VIB-X/Y/Z NDE/DEHP FWP

Pump vibration too high. Changeover to back-up pump and check.

58LAC51CL001

58LAC61CL001


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KKS Code Description Action

58LAB51CG001

58LAB61CG001

NOTOPEN

POS SUCT V HPFWP

Pump suction valve not open.Check the valve and limit switch.

58LAB95CP001

58LAB95CP002

58LAB95CP003

DIST P HP FWL Disturbance of measurement.

Check measurement.Note: Disturbance of secondmeasurement will trip system.

58LAB95CP001

58LAB95CP002

58LAB95CP003


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6.3. External documents and diagrams

The following documents and diagrams are referenced throughout this manual.

Doc No. Title

MTV/58/M/LAC50-----/FD/001 P & ID HP Feedwater Pump

MTV/58/M/LAC50-----/FD/002 Legend to P & ID HP Feedwater Pump

MTV/58/M/LAC50-----/LO/001 Process Function Plans HP Feedwater Pump

MTV/58/M/LAC50-----/SL/001 Set Point List HP Feedwater Pump

MTV/58/M/LAC50B30/MM/002 HP Pump Motor Operation and Maintenance Manual

MTV/51/B/H------A30/TP/001 HRSG Operation and Maintenance Procedure

MTV/00/M/01-----005/PF/001 Plant Operation and Control Concept

MTV/00/M/03-----010/GS/001 Water Chemistry WSC Technical Specification

Table 5 External Documents and Diagrams


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IndexA

abbreviations and acronyms, 10

Alarms, 17, 18, 19

automatic control logic, 23

automatic recirculation check valve, 18

B

Back-feed, 17

C

CAUTION

explanation, 8

cleaning, 24Closed cooling water system, 18, 19

compulsory reading, 7

Conservation, 30

copyright, 2

D

DAMAGE

explanation, 9

DANGER

explanation, 8

De-pressurizing, 32

E

Electric motor, 19

emergency shut-down pump, 28

equipment failures, 29

F

feed water pump, 17

feedwater pump system

abnormal operation, 28

inadmissible operation, 29

Feedwater storage tank, 17

Filling bypass, 17

G

general note

explanation, 9

I

inadmissible operation, 29

initial filling procedure, 25

Interface to other systems, 12

L

Lubrication oil, 18

M

main equipments, 11

MANDATORY ACTION

explanation, 9

Manual Preparation Check List prior to Start-up, 35

Minimum flow, 17

O

Operational readiness, 31outages, 30

P

piping and instrumentation diagrams, 38

R

Reverse rotation, 17

S

standby of equipment, 30

Suction strainer, 18

system tasks, 11

T

target audience, 7

TN04/0297, 13

U

user audience, 7

V

visual inspection, 31

W

WARNING

explanation, 8

Reference LAC50 DM

Documents

Transcript of Reference LAC50 DM