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1

ISSUED FOR INFORMATION

JAP

JSI

CGP

07.02.13

ISSUED FOR INFORMATION

JAP

JSI

CGP

27.09.12

REV

DESCRIPTION

PREP

CHKD

APPD

DATE

PROJECT:

PP10 CCGT POWER STATION


CONTRACT NO: 31121111/00
CLIENT

CONSULTANT:

CONTRACTOR:

DOCUMENT TITLE:

CLOSED COOLING WATER SYSTEM FUNCTIONAL DESCRIPTION


COMPANY/ORIGINATOR:

PROJECT DOCUMENT NUMBER:

ARABIAN BEMCO
CONTRACTING COMPANY
DISTRIBUTION CODE:

PP10CC-00-6PGB-YR-ABC-001

SHEET NO.

I&C

1 OF 19

SIZE

REV.

SCALE:

A4

N.T.S

FILE NAME:

PP10CC-00-6PGB-YR-ABC-001-REV 1 CLOSED COOLING WATER FUNCTIONAL


DESCRIPTION

PP10CC-T13T-2563

PP10CC Combined Cycle

Document Code

Date

PP10CC-00-6PGB-YR-ABC-001

07/02/13

CLOSED COOLING WATER SYSTEM FUNCTIONAL DESCRIPTION

Page 2

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Rev.: 1

INDEX OF CONTENTS

1. INTRODUCTION............................................................................................................... 3
1.1.OBJECTIVE OF THE DOCUMENT .................................................................................. 3
1.2.SCOPE OF THE DOCUMENT.......................................................................................... 3
1.3.REFERENCE DOCUMENTATION ................................................................................... 3
2. SYSTEM DESCRIPTION .................................................................................................. 5
2.1.MAIN EQUIPMENT, PERMISSIVES AND INTERLOCKS ................................................ 5
2.2.MECHANICAL BATTERY LIMITS .................................................................................... 6
2.3.FUNCTIONALITY.............................................................................................................. 7
2.4.CONTROL INTERFACES WITH OTHER SYSTEMS ....................................................... 7
2.5.SIGNALS MONITORING .................................................................................................. 7
2.5.1. Measuring instrument....................................................................................... 7
2.5.2. Selection logic architecture ............................................................................. 8
2.5.3. Bad quality concept .......................................................................................... 9
2.6.PROCESS DRIVES/ACTUATORS ................................................................................... 9
2.6.1. Process drives/actuators ................................................................................. 9
2.6.2. Drives/Actuators Fault Tolerance .................................................................. 10
2.7.FUNCTIONAL GROUPS................................................................................................. 11
2.7.1. Number of Functional Groups ....................................................................... 11
2.7.2. Functional Groups Operation Modes ............................................................ 11
2.8.SYSTEM CONTROL LOCATION ................................................................................... 12
3. SYSTEM OPERATION MODES ..................................................................................... 13
3.1.POSITION IN THE PLANT GENERAL START-UP SEQUENCE ................................... 13
3.2.CRITERION FOR SYSTEM START-UP ......................................................................... 13
3.3.START-UP SEQUENCE ................................................................................................. 13
3.4.NORMAL OPERATION................................................................................................... 14
3.5.POSITION IN THE PLANT GENERAL SHUTDOWN SEQUENCE ................................ 14
3.6.CRITERION FOR SHUTDOWN...................................................................................... 15
3.7.SHUTDOWN SEQUENCE .............................................................................................. 15
3.8.EMERGENCY SHUTDOWN SEQUENCE ...................................................................... 15
4. LOGIC LOOPS/CONTROL DESCRIPTION ................................................................... 16
4.1.LOGIC LOOPS................................................................................................................ 16
4.2.CONTROL DESCRIPTION ............................................................................................. 18

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CLOSED COOLING WATER SYSTEM FUNCTIONAL DESCRIPTION

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1.

INTRODUCTION

1.1. OBJECTIVE OF THE DOCUMENT


The objective of the document is to provide the functional description of the CLOSED
COOLING WATER SYSTEM of the project.

For design information on the system, as well as details and functions of each item, refer to
PP10CC-0009-3PGB-MR-ABC-001 CLOSED COOLING WATER SYSTEM DESCRIPTION

1.2. SCOPE OF THE DOCUMENT


The scope of the document is to describe the followings topics:
System description
System operation
Control loops

1.3. REFERENCE DOCUMENTATION


PP10CC-0009-3PGB-MDD-ABC-001 P&ID CLOSED COOLING WATER SYSTEM
PP10CC-0009-3PGB-MR-ABC-001

CLOSED

COOLING

WATER

SYSTEM

DESCRIPTION
PP10CC-00-6PGB-YDY-ABC-001 CLOSED COOLING WATER SYSTEM LOGIC
DIAGRAMS
PP10CC-00-6Y-YR-ABC-001 CCPP OPERATION PHILOSOPHY
PP10CC-0009-6Y-YDZ-ABC-001 CONTROL TYPICAL DEVICES
PP10CC-0009-6Y-YLI-ABC-002 DEVICE DEFINITION CONCEPT
PP10CC-0009-6Y-YDY-ABC-001 MASTER LOGIC DIAGRAMS
PP10CC-0009-6Y-YDY-ABC-004

PERMANENT

STANDBY

PREPARATION

SEQUENCE
1

PP10CC-0009-6Y-YDY-ABC-002 CC SIMULTANEOUS START UP SEQUENCE


PP10CC-0009-6Y-YDY-ABC-005 CC SEQUENTIAL START UP SEQUENCE

PP10CC Combined Cycle

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Date

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PP10CC-0009-6Y-YDY-ABC-003 NORMAL SHUT DOWN SEQUENCE


1

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Date

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2.

SYSTEM DESCRIPTION

2.1. MAIN EQUIPMENT, PERMISSIVES AND INTERLOCKS


The main equipments which belong to this system are 2 x 100% centrifugal pumps, one
1

atmospheric expansion tank and six fin fan coolers. The TAGs of these equipments are the
followings:
Centrifugal pumps: A119-PGB11-AP001 and A119-PGB12-AP001.
Fin fan coolers: A119-PGB10-AK001
Atmospheric expansion tank: A119-PGB50-BB001
CCW header pressure control valve: A119-PGB40-AA101
CCW filling line on-off motorized valve: A119-GHC15-AA051

For further information see system description PP10CC-0009-3PGB-MDD-ABC-001 P&ID


CLOSED COOLING WATER SYSTEM

The CCW system has the following permissive (start condition) and interlocks:

Instrument
A119-GHC15CF001

Service

Setting

Level

Consequences/Actions

Demin water flow

L > 60%

HHH

L > 55%

HH

Alarm

Override close A119-GHC15-AA051

A119-PGB50-

Atmospheric expansion

L > 50%

Close valve A119-GHC15-AA051

CL001

tank level

L < 20%

Open valve A119-GHC15-AA051

L < 15%

LL

Alarm

L < 8%

LLL

Trip pumps A119-PGB11/12-AP001

L > 60%

HHH

L > 55%

HH

Alarm

Override close A119-GHC15-AA051

A119-PGB50-

Atmospheric expansion

L > 50%

Close valve A119-GHC15-AA051

CL002

tank level

L < 20%

Open valve A119-GHC15-AA051

L < 15%

LL

Alarm

L < 8%

LLL

Trip pumps A119-PGB11/12-AP001

A119-PGB11-

CCW pump 1 Suction

P < 0,8 bara

LL

Alarm

CP001

Pressure

P < 0,4 bara

LLL

Trip A119-PGB11-AP001

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Instrument

Service

Setting

Level

Consequences/Actions

A119-PGB12-

CCW pump 2 Suction

P < 0,8 bara

LL

Alarm

CP001

Pressure

P < 0,4 bara

LLL

Trip A119-PGB12-AP001

CCW pumps

P > 7,5 barg

HH

Alarm

A119-PGB13-

Discharge Pressure

P > 6,8 barg

SP

Control SP A119-PGB40-AA101

CP001

P > 4,8 barg

LL

P > 7,5 barg

HH

Alarm

P > 6,8 barg

SP

Control SP A119-PGB40-AA101

P > 4,8 barg

LL

A > 50 ppm

HH

Alarm

T > 55C

HH

Alarm

A119-PGB13-

CCW pumps

CP002

Discharge Pressure

A119-PGB35-

CCW hot header oil

CQ001

detector

A119-PGB35-

CW hot header

CT001

temperature

A119-PGB35-

CW hot header

CP001

pressure

Alarm (pump change over


requirement)

Alarm (pump change over


requirement)

A119-PGB10-

CCW fin fan cooler outlet

T > 53C

Start additional fan

CT001

temperature

T < 47C

Stop one fan

T < 45C

LL

Alarm

T > 55C

HH

Alarm

A119-PGB10-

CCW fin fan cooler outlet

T > 53C

Start additional fan

CT002

temperature

T < 47C

Stop one fan

T < 45C

LL

Alarm

Note: (1) = All pressure trips will have a time delay

2.2. MECHANICAL BATTERY LIMITS

Terminal

Service

System From / To

Demin water supply

From demin water system

Corrosion inhibitor

pH correction

Ref. Document.

Point
PP10CC-0009-8GHC-MDDABC-001

From Chemical dosing

PP10CC-0009-3QC-MDD-

System

ABC-001

From Chemical dosing

PP10CC-0009-3QC-MDD-

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Terminal

Service

System From / To

Ref. Document.

System

ABC-001

To Steam Turbine Lube Oil

PP10CC-0009-3MAV-MDD-

System

ABC-001

To ST HYDRAULIC FLUID

PP10CC-0009-3MAX-MDD-

SYSTEM

ABC-001

Point
-

Cooling water

Cooling water

Cooling water

To ST GENERATOR

321310700

COOLERS

Cooling water

To Sampling System

Cooling water

To Feed water System

Cooling water

To HRSG Recirculation
pumps

PP10CC-0009-1QU-MDDABC-001
PP10CC-00-4LAC-DD-TMP001
PP10CC-00-H-MDD-NEM-006

2.3. FUNCTIONALITY
The Closed Cooling Water system functionality is described in the system description. See:
PP10CC-0009-3PGB-MR-ABC-001

CLOSED

COOLING

WATER

DESCRIPTION

2.4. CONTROL INTERFACES WITH OTHER SYSTEMS


There arent control interfaces with other systems.

2.5. SIGNALS MONITORING

2.5.1.

Measuring instrument

The measuring instruments which belong to this system are the followings:

SYSTEM

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Equipment/Line
A119-GHC15-BR001-253C1-NI

A119-PGB50-BB001

Service

Demin water flow

Atmospheric expansion
tank level

Instrument
FIT
A119-GHC15-CF001
LIT
A119-PGB50-CL001
A119-PGB50-CL002

A119-PGB11-BR001-300-

CCW pump 1 Suction

PIT

1A1-NI

Pressure

A119-PGB11-CP001

A119-PGB12-BR001-300-

CCW pump 2 Suction

PIT

1A1-NI

Pressure

A119-PGB12-CP001

A119-PGB13-BR001-300-

CCW pumps

1A1-NI

Discharge Pressure

A119-PGB35-BR003-3001A1-PP

CCW oil in water

PIT
A119-PGB13-CP001
A119-PGB13-CP002
AIT
A119-PGB35-CQ001

A119-PGB35-BR003-300-

CCW fin fan cooler inlet

TIT

1A1-PP

temperature

A119-PGB35-CT001

PP10CC-A119-PGB35-

CCW fin fan cooler inlet

PIT

BR003-300-1A1-PP

pressure

A119-PGB35-CP001

PP10CC-A119-PGB10-

CCW fin fan cooler

BR001-300-1A1-NI

outlet temperature

2.5.2.

TIT
A119-PGB10-CT001
A119-PGB10-CT002

Selection
Logic

Notes

DUAL
SELECT

DUAL
SELECT

DUAL
SELECT

Selection logic architecture

As a general rule, if a signal is out of configured range, an alarm shall be generated in the
control system.

When two or more measurements are available for the same process value, the value used
for interlocking will depend on the selected logic architecture.

In a DUAL SELECT logic architecture, two measures are available, if both are healthy the
average of the two measurements is used. In case of bad quality of one of the

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measurements, automatic change-over to the healthy measurement takes place and an


alarm is generated.

In a MEDIAN SELECT logic architecture, three measures are available if all of them are
healthy the average of the three measurements is used. In case of bad quality of one of the
measurements, automatic change-over to the other healthy measurements takes place and
an alarm is generated.

The selected logic architecture of each instrument has been identified in the previous table
(see section 2.5.1).

2.5.3.

Bad quality concept

In case of bad quality of one of the redundant measurements, automatic change-over to


the healthy measurement will take place and an alarm will be generated. Bad quality
means that the signal is out of range < 4 or > 20 mA.

2.6. PROCESS DRIVES/ACTUATORS

2.6.1.

Process drives/actuators

The process drives/actuators which belong to this system are the followings:

Line/Equipment

Service

Drive/Actuator

Fail Safe

Notes

Position
A119-GHC15-BR001-253C1-NI
A119-PGB10-AK001

A119-PGB10-AK001

A119-PGB10-AK001

Demin water supply


CCW fin fan cooler
fan 1
CCW fin fan cooler
fan 2
CCW fin fan cooler
fan 3

A119-GHC15-AA051

FS

A119-PGB10-AN001

2, 3

A119-PGB10-AN002

2, 3

A119-PGB10-AN003

2, 3

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Line/Equipment

Service

Drive/Actuator

Fail Safe

Notes

Position
A119-PGB10-AK001

A119-PGB10-AK001

A119-PGB10-AK001

A119-PGB40-BR001-2001A1-NI

CCW fin fan cooler


fan 4
CCW fin fan cooler
fan 5
CCW fin fan cooler
fan 6

A119-PGB10-AN004

2, 3

A119-PGB10-AN005

2, 3

A119-PGB10-AN006

2, 3

A119-PGB40-AA101

FC

CCW recirculation
line for pressure
control

Notes:
1.- Valve electrically actuated. Not fail safe position. Fail Steady (in position).
2.- Electrically actuated. Not fail safe position.
3.- The Fin Fan cooler skid A119-PGB10-AK001 will have six individual fans.

2.6.2.

Drives/Actuators Fault Tolerance

When redundant drives/actuators are available, at least one of the followings strategies
shall be configured:

Automatic pump selection


If there is a fault in one of the selected pumps which are in operation, the control system
will start automatically another pump in order to keep the required demand of pumps.

Maximum waiting time


When it is required to start a drive/actuator or to change its position, the control system
shall monitor the maximum admitted time to finish its maneuver. If this time is exceeded,
the control system will generate an alarm.

- CCW pumps expected starting time is 20 seconds

PP10CC Combined Cycle

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Date

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- Motorized Valve open/close expected time is 30 seconds


- Fin fan coolers expected starting time is 20 seconds

Fail safe position


It will be considered the Fail Safe Position the one that the device will go to in case of
control signal, air supply or power supply failure.

The fail safe position of each actuator has been identified in the previous table (see 2.6.1).

2.7. FUNCTIONAL GROUPS

2.7.1.

Number of Functional Groups

There will be the following functional groups:


Closed Cooling Water System: CCWS / 9PGB10GF001

2.7.2.

Functional Groups Operation Modes

As a general rule, the system will operate in automatic mode, following not only required
sequences and settings, also taking into account required protections over the operation in
the control system. All functional groups could operate in one of the following modes:

Automatic mode
In auto mode the functional group will follow the control strategies configured in the control
system.

Manual mode
In manual mode the functional group will check required sequences, settings and
protections for system operation depending on control strategy, but in this case some
process actuators could be selected to be operated according to operators decision.

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2.8. SYSTEM CONTROL LOCATION


The DCS controller location for this system is the STG Control Compartment.

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3.

SYSTEM OPERATION MODES


The system operation modes are the followings:
Cold start-up: cover the initial filling and the initial preparation (system ready to start).
Hot start-up: cover all required sequences up to the moment the system is in operation.
Normal operation.
Shutdown: cover all required sequences up to the moment the system has been
stopped.
Emergency shutdown.

3.1. POSITION IN THE PLANT GENERAL START-UP SEQUENCE


This system belongs to preparation systems and it will be set in operation following the
steps described in this sequence:
1

PP10CC-0009-6Y-YDY-ABC-004

PERMANENT

STANDBY

PREPARATION

SEQUENCE

3.2. CRITERION FOR SYSTEM START-UP


From the plant general start-up sequence it will be required to start-up this system under
the following requirements:
Not Low Low Level in Atmospheric Expansion Tank (A119-PGB50-BB001 > LLL)

3.3. START-UP SEQUENCE


The start-up sequence of the system will follow the following steps:
Step 01: CCW pumps (A119-PGB11-AP001 & A119-PGB12-AP001), Demin water
supply MOV (A119-GHC15-AA051), CCW header pressure control valve (A119-PGB40AA101) and Fin Fan Coolers (A119-PGB10-AK001) to AUTO MODE.
Step 02: START selected CCW pump (A119-PGB11-AP001 or A119-PGB12-AP001).

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3.4. NORMAL OPERATION

This system operates as a closed circuit and in a normal operation one CCW pump will be
running to supply required cool water flow at the required pressure. There is a recirculation
line with a pressure control valve to maintain constant CCW pressure (6,8 barg) to coolers
when one of them has its cooling water shut off.

At the same time, the fin fan cooler installed upstream the pumps will release the heat of
the hot closed cooling water to the atmosphere, starting the required number of fans. So
the cold outlet water will be ready to be pumped again to the equipments in order to
evacuate the produced heat during normal operation.

On the other hand, demin water supply on-off valve (A119-GHC15-AA051) will make up for
the leakages produced in the closed cooling water system. During normal operation is not
expected to have leakages in the system so the filling of the system will be sporadic.

Interlock
For process interlocks see section 2.1.

Alarms
For process alarms see section 2.1.

3.5. POSITION IN THE PLANT GENERAL SHUTDOWN SEQUENCE


This system belongs to operation systems and it will be set out of operation following the
1

steps described in the normal shut down sequence PP10CC-0009-6Y-YDY-ABC-003

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3.6. CRITERION FOR SHUTDOWN


From the plant general shutdown sequence it will be required to stop this system under the
following requirements:

- The Combined Cycle has been shut-down.

3.7. SHUTDOWN SEQUENCE

The shutdown sequence of the system will follow the following steps:
Step 01: STOP selected CCW pump (A119-PGB11-AP001 & A119-PGB12-AP001).
Step 02: STOP Fin Fan Coolers (A119-PGB10-AK001).
1

3.8. EMERGENCY SHUTDOWN SEQUENCE

There is not emergency shutdown of CCW system.

In case of an emergency shutdown (blackout), CCW pumps and fin fan coolers have to be
feed from the essential system in order to continue in operation and to continue cooling
required systems.

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4.

LOGIC LOOPS/CONTROL DESCRIPTION

4.1. LOGIC LOOPS


In this system there are the following logic loops:

Loop

Atmospheric Expansion Tank


Level Control

Instrument TAG:

PV

Level

A119-PGB50-CL001
A119-PGB50-CL002

SP
Permissives

Open if L < 20%


Close if L > 50%
-

Instrument TAG:

Override

Force to Close if HHH

A119-PGB50-CL001
A119-PGB50-CL002

Actuator

Loop

Motorized valve

Fin Fan Cooler (A119-PGB10-AK001)


Temperature Control

A119-GHC15-AA051

Instrument TAG:

PV

Temperature

A119-PGB10-CT001
A119-PGB10-CT002

SP

Start one fan if T > 53C


(if after 2 min T > 53C, other fan will be started)
Stop if T < 47C

(if after 2 min T < 47C, other fan will be stopped)

Permissives

Interlock

A119-PGB10-AN001

Actuator

Fin Fan Cooler

A119-PGB10-AN002
A119-PGB10-AN003
A119-PGB10-AN004

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Loop

Fin Fan Cooler (A119-PGB10-AK001)


Temperature Control

A119-PGB10-AN005
A119-PGB10-AN006

Loop

Closed Cooling Water pumps


CCW water supply

PV

SP

Selected pump always running.

Permissives

For both pumps

Atmospheric expansion tank level Low Low (LLL)

Interlock

For A119-PGB12-AP001
Suction pressure Low Low (LLL)

Loop

A119-PGB50-CL001
A119-PGB50-CL002

For A119-PGB11-AP001
Suction pressure Low Low (LLL)

Actuator

Instrument TAG:

Electric Pumps

CCW header
Pressure Control

A119-PGB11-CP001

A119-PGB12-CP001
A119-PGB11-AP001
A119-PGB12-AP001

Instrument TAG:

PV

Pressure

A119-PGB13-CP001
A119-PGB13-CP002

SP

SP = 6,8 barg

Override

Force to Close if valve position demand 6%

Actuator

Pneumatic control valve

Permissives

A119-PGB40-AA101

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4.2. CONTROL DESCRIPTION

Once the Demin Water System is in operation, the Master Sequence Following Controller
(M.S.F.C) will send an automatic command to Closed Cooling Water System Functional
Group (CCWS GROUP) to set in AUTO MODE this system. The CCWS GROUP will
send an automatic command to each CCW Pump, motorized valve, control valve and fin
fan cooler. After being in AUTO MODE, the M.S.F.C will start the system sending a start
command to the Functional Group (CCWS GROUP) which will start the auto change over
block. The auto change over bloc will start selected CCW Pump.

In operation one pump will be running and if a fault happens the system will automatically
change over the standby pump. CCW header pressure control valve will maintain constant
CCW header pressure (6,8 barg) to coolers.

To control the closed cooling water system temperature the system will start/stop the
required number of fans. When the temperature increases above 53C the system will start
1

an additional fan. If after 2 minutes the temperature is still higher than 53C an additional
fan will be started, and soon after the temperature is lower than 53C.
On the contrary when the temperature decreases below 47C the system will stop one fan.

If after 2 minutes the temperature is still lower than 47C an additional fan will be stopped,
and soon after the temperature is higher than 47C.

In order to equilibrate fans working hours, the DCS will start the fan with less working hours
when is required to start a fan according to process conditions. On the contrary, The DCS
will stop the fan with more working hours when is required to stop a fan according to
process conditions.

The Atmospheric Expansion Tank level will be controlled through a MOV which will open
when the level decreases below 20% and will close when the level increases above 50%.

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On the contrary, during the shutdown sequence, the M.S.F.C will stop the system sending
a stop command to the Functional Group (CCWS GROUP) which will stop the fin fan
1

cooler and the auto change over block which will stop selected CCW Pump.

See attached sketch for better understanding of above explanation.

HHH

MV-01
FT

AUTO / MANUAL
HI_LO_MON

GROUP
CCWS
9PGB10GF001

AUTO / MANUAL
START / STOP

M.S.F.C

AUTO / MANUAL
START / STOP

DEMIN WATER
DISTRIBUTION

AUTO
CHANGE OVER

LT

ATMOSPHERIC
EXPANSION TANK

LLL

DUALSEL

HI_LO_MON

START / STOP

LT
HI_LO_MON

HI_LO_MON

LL

LLL

LVMP-09

HI_LO_MON

PT

START / STOP

DUALSEL

DUALSEL
FILTER

TT

PT

TT

PT

COLD HEADER
HI_LO_MON

LLL

LVMP-09

PT

LVMF-03

LVMF-03

LVMF-03

LVMF-03

LVMF-03

FILTER

CV-01

LVMF-03

OIL

FIN FAN COOLER

PT

TT

AT

HOT HEADER

CLOSED COOLING WATER SYSTEM

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