I&P For Regenerative System - R1 - CAT-E (Approved)

APPROVED CAT-E
NAME : SUNIL KUMAR
SIGN.: Dt. 07.03.2011
INDIABULLS POWER LIMITED.

DOCUMENT TITLE DOCUMENT PE-DC-352-100-N111
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INTERLOCK AND PROTECTION WRITE-
UP FOR REGENERATIVE SYSTEM REVISION 01 DATE 07/02/2011
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5 X 270 MW AMRAVATI TPP SHEET 2 OF 22
INDEX
S.No. Description Sheet No.
1.0 General 03
2.0 Level control of LP Heaters 04
3.0 Level control of HP Heaters 07
4.0 Condenser Hotwell level control 10
5.0 Deaerator level control 12
6.0 Deaerator pressure control 14
7.0 Condensate Extraction Pumps 16
8.0 Boiler Feed Pumps 17
9.0 Critical piping drains & CRH line drain pot control 18
10.0 Feed control station 20
11.0 Miscellaneous interlocks 22

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1.0 GENERAL
1.1 The thermal cycle for the plant has been designed in accordance with
the latest trends and concepts prevailing in the field of power plant
design. The cycle has been designed for the operation of turbine and
boiler on unit system.
1.2 The feed heating system for the unit consists of three low pressure
heaters, gland steam condenser, drain cooler, deaerator and two high
pressure heaters. The condensate extraction pump (2x100%) takes
suction from the condenser hot well and pumps the condensate to the
deaerator through the gland steam condenser, drain cooler and the low
pressure heaters (Refer drawing no. PE-DG-352-100-N104). The boiler
feed pump (3X50%) takes suction from the deaerator and pumps the
feed water to boiler through the high pressure heaters (Refer drawing
no. PE-DG-352-100-N105). The condensate/ feed water progressively
gets heated up by the bled steam from the turbine extractions and the
gland leak off steam (Refer drawing no. PE-DG-352-100-N102).
1.3 LP Heaters no. 1, 2 & 3 get the heating steam from the LP turbine.
Hydraulically operated non-return valves are provided in extraction lines
of LP heaters no. 2 & 3 to prevent the back flow of steam into the
turbine during a trip. These valves are controlled from ATRS. Motorized
block valves are also provided in extraction lines for LPH-2 & 3.
1.4 HP Heater no. 5 gets the heating steam from the IP turbine.
Hydraulically operated non-return valve is provided in extraction line to
HPH-5 controlled from ATRS. HP Heater no. 6 gets the heating steam
from the CRH line. Pneumatically operated non-return valve is provided
in extraction line to HPH-6. Motorized block valve are also provided in
extraction lines for HPH-5 & HPH-6.
1.5 The deaerator is designed to operate under variable pressure operation

in 55% to 100% range of turbine load. During this operation the steam is
drawn from the turbine extraction i.e. IP exhaust. During start-up of
turbine, the deaerator is supplied with steam from CRH line and also
from external source i.e. auxiliary steam header.
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2.0 LEVEL CONTROL OF LP HEATERS

Drawing No.
Refer PID of Heater Drain & Vents System: PE-DG-352-100-N103
R01
PID of Condensate System: PE-DG-352-100-N104
& PID Extraction Steam System: PE-DG-352-100-N102
2.1 INSTRUMENTATION
The following instrumentation has been provided for initiating alarms

and protective actions:
2.1.1 Three level transmitters (LCC30CL001, LCC30CL002 & LCC30CL003)

for LP Heater 3 for heater level control, alarm annunciation and
remote indication.
2.1.2 Three level transmitters (LCC20CL001, LCC20CL002 & LCC20CL003)

for LP Heater 2 for heater level control, alarm annunciation and
remote indication.
2.1.3 Two level transmitters (LCC10CL001 & LCC10CL002) for LP Heater 1

for heater level control, alarm annunciation and remote indication.
2.2 CONTROL FUNCTIONS
2.2.1 LP HEATER - 3
2.2.1.1 'LOW LEVEL' in LPH-3 is annunciated in the control room.
2.2.1.2 'NORMAL LEVEL' in LPH-3 is maintained by cascading the drain to

LPH-2 through control valve DR-19.
2.2.1.3 'HIGH LEVEL' in LPH-3 is annunciated in the control room and this level
is controlled by diverting the drain to LP Drain flash tank through control
valve DR-22.
2.2.1.4 When the high level control is in operation to open alternate drain to
condenser, the normal drain control valve DR-19 will also remain open
unless it has been closed from the interlocks of LPH-2.
2.2.1.5 HIGH HIGH LEVEL' in LPH-3 is annunciated in the control room and the
following interlock actions are initiated simultaneously:
i) Extraction steam line block valve EX-10 closes

ii) Motorized drain valves EX-125 & EX-126 on the extraction line
open
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iii) Repeat command given to alternate drain line control valve DR-
22 to open fully
iv) QCNRV in extraction line EX-3 is closed through ATRS
v) The heater is bypassed on condensate side automatically by
opening bypass valve CD-37 and closing the isolating valves
CD-35 & CD-36
2.2.1.6 The normal drain control valve DR-19 is released to auto control only
after the LPH-2 has been charged on steam side and there is no 'HIGH
HIGH LEVEL' in LPH-2. The control shall be put in auto mode by the
operator.
2.2.2 LP HEATER - 2
2.2.2.1 'LOW LEVEL' in LPH -2 is annunciated in the control room.
2.2.2.2 'NORMAL LEVEL' in LPH-2 is maintained by cascading the drains to

LPH-1through control valve DR-25.
2.2.2.3 'HIGH LEVEL' in LPH-2 is annunciated in the control room and this level
is controlled by diverting the drain to LP Drain flash tank through control
valve DR-28.
unless it has been closed from the interlocks of LPH-1.
2.2.2.5 HIGH HIGH LEVEL' in LPH-2 is annunciated in the control room and
the following interlock actions are initiated simultaneously:

ii) Motorized drain valves EX-127 & EX-128 on the extraction line
open
iii) Normal drain control valve DR-19 from LPH-3 to LPH-2 closes
iv) Repeat command given to alternate drain line control valve DR-
28 to open fully
v) QCNRV in extraction line EX-1 is closed through ATRS
vi) The heater is bypassed on condensate side automatically by
opening bypass valve CD-34 and closing the isolating valves CD-
32 & CD-33
2.2.2.6 The normal drain control valve DR-25 is released to auto control only
after the LPH-1 has been charged on steam side and there is no 'HIGH
HIGH LEVEL' in LPH-1. The control shall be put in auto mode by the
operator.
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2.2.3 LP HEATER 1
2.2.3.1 No level is maintained in the LPH-1. The LPH-1 drain is led to the drain
cooler through a siphon loop and finally to condenser through LP drain
flash tank.
2.2.3.2 'HIGH LEVEL' in LPH-1 is annunciated in the control room.
2.2.3.3 HIGH HIGH LEVEL' in LPH-1 is annunciated in the control room and
the following interlock actions are initiated simultaneously:
i) Normal drain control valve DR-25 from LPH-2 to LPH-1 closes

ii) The heater is bypassed on condensate side automatically by
opening bypass valve CD-31 and closing the isolating valves CD-
29 & CD-30
2.3 OPERATING REGIMES
3.3.1 LP heaters 1, 2 & 3 are brought into service on steam side immediately
R01
after synchronization of unit. LP heaters are properly charged from
water side before charging it from steam side by opening heater vent
and expelling the air out of the heater.
3.3.2 During the start up mode until the LP heaters are charged the motorized
drain valves on the extraction lines shall be kept open. These drain
valves shall be manually closed after the heaters are put in service.
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3.0 LEVEL CONTROL OF HP HEATERS

Drawing No.
R01
PID of Feed water System: PE-DG-352-100-N105
3.1 INSTRUMENTATION

3.1.1 Three level transmitters (LAD20CL001, LAD20CL002 & LAD20CL003)

for HP Heater 6 for heater level control, alarm annunciation and
remote indication.
3.1.2 Three level transmitters (LAD10CL001, LAD10CL002 & LAD10CL003)

for HP Heater 5 for heater level control, alarm annunciation and
remote indication.
3.2.1 HP HEATER - 6
3.2.1.1 'LOW LEVEL' in HPH-6 is annunciated in the control room.
3.2.1.2 'NORMAL LEVEL in HPH-6 is maintained by cascading the drain to

HPH-5 through control valve DR-2 and to deaerator through control
valve DR-6. The control valves DR-2 & DR-6 operate in split range
mode in such a way that in the initial phase of control range, DR-2
operates and in subsequent phase of control range, DR-6 operates.
3.2.1.3 'HIGH LEVEL' in HPH-6 is annunciated in the control room and this
level is controlled by diverting the drain to condenser via HP drain flash
tank through control valve DR-9.
unless it has been closed from the interlocks of HPH-5.
3.2.1.5 In case the extraction pressure at HPH-5 is below a preset value

(adjustable), the drain control valve DR-2 shall close automatically.
When the extraction pressure is above a preset value, the drain control
valve DR-2 shall modulate under automatic operation.
3.2.1.6 'HIGH HIGH LEVEL' in HPH-6 is annunciated in the control room and
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ii) Motorized drain valves EX-132 & EX-133 in the extraction line
opens.
iii) Repeat command given to alternate drain valve DR-9 and
normal drain valves DR-2/DR-6 to open fully.
iv) Heater is bypassed on the feed water side by opening bypass
valve FD-11 and closing isolating valves FD-10 & FD-12.
3.2.1.7 When deaerator level reaches HIGH HIGH LEVEL', the HPH-6 drain
control valve DR-6 to deaerator shall close automatically.
3.2.2 HP HEATER - 5
3.2.2.1 'LOW LEVEL' in HPH-5 is annunciated in the control room.
3.2.2.2 'NORMAL LEVEL' in HPH-5 is maintained by cascading the drain to

deaerator through control valve DR-13.
3.2.2.3 'HIGH LEVEL' in HPH-5 is annunciated in the control room and this
level is controlled by diverting the drain to condenser via HP Drain flash
tank through control valve DR-16.
3.2.2.4 When the high level control comes into operation to open alternate drain
to condenser, the normal drain control valve DR-13 will also remain
open.
3.2.2.5 'HIGH HIGH LEVEL' in HPH-5 is annunciated in the control room and

ii) Motorized drain valves EX-104 & EX-106 in the extraction line
open.
iii) Repeat command given to alternate drain control valve DR-16
and normal drain control valve DR-13 to open fully
iv) QCNRV in extraction line EX-7 is closed through ATRS
v) Normal drain control valve DR-2 from HPH-6 to HPH-5 closes
vi) Heater is bypassed on feed water side by opening bypass valve
FD-8 and closing isolating valves FD-7 & FD-9.
3.2.2.6 In case pressure in HPH-5 falls below a preset value, an over riding
command is given to close the control valve DR-2 in the drain from
HPH-6 to HPH-5.
3.2.2.7 When the deaerator level reaches HIGH HIGH LEVEL', the HPH-5
drain control valve DR-13 to deaerator shall close automatically.
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3.3 OPERATING REGIMES
3.3.1 HP heaters 5 & 6 are brought into service on steam side at approx. load
of 40% & 50% respectively. HP heaters are properly charged from water
R01 side before charging it from steam side by opening heater vent and
expelling the air out of the heater.
3.3.2 Whenever pressure in HPH-5 falls below a preset value, the control
valve DR-2 in drain line from HPH-6 to HPH-5 closes and HPH-6 drain
gets diverted to deaerator.
3.3.3 During the start up mode until the heaters are charged (opening of
motorized extraction line valves) the motorized drain valves on the
extraction lines shall be kept open. These drain valves shall be
manually closed after the heaters are put in service.
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4.0 CONDENSER HOTWELL LEVEL CONTROL
Drawing No.
Refer PID of Condensate system: PE-DG-352-100-N104
R01
PID of DM Make up system: PE-DG-352-100-N107
4.1 INSTRUMENTATION

4.1.1 Three level switches (MAG11CL101, MAG12CL101 & MAG12CL102) in

'2 out of 3' logic for 'LOW LOW LEVEL' annunciation and condensate
extraction pump trip interlock through ATRS.
4.1.2 Three level transmitters (MAG11CL001, MAG12CL002 &

MAG12CL001) for level control, alarm annunciation and remote
indication.
4.2.1 The make up to condenser is provided from Hot well make-up pumps
through low and high capacity make-up control valves DM-20 and DM-
15 respectively.
4.2.2 Normal level in the condenser is maintained by positioning the low

capacity control valve DM-20.
4.2.3 In the event of level not being maintained and going further low the
make-up control valve DM-15 shall be actuated through the level
transmitters provided on the hotwell.
4.2.4 'HIGH LEVEL' in the condenser is annunciated in the control room and
this level is maintained by diverting the condensate to the condensate
storage tank through control valve CD-21 on the excess condensate
return line.
4.2.5 'LOW LEVEL' in the condenser is annunciated in the control room.
4.2.6 NORMAL LEVEL in the condenser is used as CEP start permissive

for giving a permissive signal for starting of condensate extraction
pump.
4.2.7 'LOW LOW LEVEL' in the condenser is annunciated in the control room
and a signal to trip the running condensate extraction pump given.
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4.2.8 CEP minimum recirculation control valve CD-25 together with the main
condensate control valves CD-14 to deaerator shall maintain a minimum
flow. Two flow transmitters mounted across the flow orifice in the
condensate line will give signal to modulate valve CD-25.
Valve CD-25 is modulated such that when condensate flow exceeds the
set value, the valve is fully closed.
4.2.9 Following permissive conditions are required for starting any of the
R01 condensate pump :
i) Suction valves to be kept fully open (from limit switch contact on valves).
ii) Level Not low in the hotwell of both the condensers (from Level Transmitters
provided on the respective hotwell).
iii) Condensate pump discharge valve of the associated pump to be in closed

condition (for manual start only).
iv) Minimum recirculation valve is to be positioned initially at 40% (adjustable)

and then release it to auto with a time delay of 10 secs (adjustable at site).
v) The solenoid valve on the discharge vent pipe to the condenser is in open
condition. This valve shall close on auto after starting of the pump with a time
delay of 2 minutes.
vi) Open valve on equalising piping between pump canister and condenser.
vii) Check oil level in thrust bearing and open cooling water for the same.
viii) Any of the trip conditions do not exist.
ix) Electrical system should be ready.

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5.0 DEAERATOR LEVEL CONTROL

Drawing No.
R01
PID of Condensate System: PE-DG-352-100-N104
5.1 INSTRUMENTATION

5.1.1 Three level switches (LAA10CL101, LAA10CL102 & LAA10CL103) in '2

out of 3' logic for 'LOW LOW LEVEL' annunciation and boiler feed
pumps trip interlock through ATRS.
5.1.2 Three level transmitters (LAA10CL001, LAA10CL002 & LAA10CL003)

for level control, alarm annunciation, remote indication and boiler feed
pump start permissive.
5.2.1 The 'NORMAL LEVEL' in the deaerator is maintained with three element
control circuit by regulating control valve CD-14 on the main condensate
line to deaerator with valve selection facility from control room.
The three elements of the control system shall be -
- feed water flow

- condensate flow
- deaerator level
5.2.2 The feed water flow signal anticipates the change in the level of the
deaerator feed storage tank and positions the condensate flow control
valve CD-14 to the new position.
5.2.3 The condensate flow signal is a feedback signal in the control circuit
which shall confirm that the new demand is actually being supplied. This
level signal plays a minor role, and trims the control signal to maintain
required level.
5.2.4 'HIGH LEVEL' in the deaerator is annunciated in the control room.
5.2.5 As the deaerator level rises further to a preset value above HIGH
LEVEL, the overflow drain valve DR-38 opens and annunciation given in
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the control room. The overflow valve DR-38 closes when the deaerator
level falls to a preset valve above NORMAL LEVEL.
5.2.6 'HIGH HIGH LEVEL' in deaerator is annunciated in the control room and

ii)Repeat command given to overflow drain valve DR-38 to open
iii)Pegging steam control valves AS-2 & CRH-2 on steam supply lines
from auxiliary steam header & cold reheat line respectively close
iv) HPH-6 drain control valve DR-6 & HPH-5 drain control valve DR-
13 to deaerator close
5.2.7 ' LOW LEVEL' in the deaerator is annunciated in the control room.
5.2.8 'LOW LOW LEVEL' in the deaerator is annunciated in the control room
and a signal to trip the running boiler feed pumps given.
5.2.9 NORMAL LEVEL in the deaerator is used as BFP start permissive for
giving a permissive signal for starting of boiler feed pump.
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6.0 DEAERATOR PRESSURE CONTROL
Refer PID Extraction Steam System' diagram

(Drawing no. PE-DG-352-100-N102)
6.1 GENERAL
Variable pressure operation of deaerator is considered in the cycle.

Under normal conditions the heating steam is supplied from turbine
extraction with pressure around 6.4 ata at rated load condition. During
low load and turbine bypass operation, the pegging steam is taken from
cold reheat line through control valve. During start-up of unit, the
pegging steam is taken from the auxiliary steam header.
When the steam is not available from the turbine extraction during
conditions such as load rejection, the deaerator pressure could decay at
a steeper rate and cause severe flashing. In order to arrest such sharp
pressure decay, the deaerator provided with support steam from CRH
line through control valve.
6.2 CONTROL FUNCTION
6.2.1 START-UP
6.2.1.1 During cold start up, the deaerator pressure is maintained at 1.5 ata
with steam supplied from the auxiliary steam header through pressure
control valve AS-2.
6.2.1.2 During warm & hot start up and bypass operation, the deaerator is
pegged at 3.5 ata with steam supplied from the auxiliary steam header
through pressure control valve AS-2.
(Note: the set pressure is to be selected by the operator)
6.2.1.3 When the CRH line pressure reaches 8 ata and above, the deaerator
pegging is switched over to steam supplied from the CRH line through
pressure control valve CRH-2 and deaerator pressure is maintained at
3.5 ata. The change over from AS-2 to CRH-2 and vice versa is gradual
and only one valve is in operation at a time.
6.2.1.4 The change over from the CRH line to turbine extraction starts at
around 55% turbine load when the pressure in extraction line exceeds
the pegging pressure of 3.5 ata.
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6.2.2 NORMAL OPERATION
6.2.2.1 During normal operation, the deaerator pressure varies from around 6.4
ata at full load to the minimum pegging pressure of 3.5 ata.
6.2.2.2 The auto-loop of pegging valves AS-2/CRH-2 remain energized to

enable the valve to open when deaerator pressure falls below a preset
value.
6.2.4 LOAD REJECTION
6.2.4.1 In case of sudden load rejection, the deaerator pressure may decay at a
steeper rate. Under such conditions the pressure decay rate in the
deaerator is arrested to a preset rate of 0.5 ata/minute (adjustable) by
supplying steam from the CRH line through control valve CRH-2. Such
controlled decay is allowed till a minimum pre-selected pressure of 3.5
ata (adjustable) is achieved.
NOTE: The actual decay rate set point is set at site from the actual operating
experience of the decay rate during different load throw off.
6.2.4.2 In case the pressure decay rate exceeds the preset rate of 0.5 ata/
minute and simultaneously the pressure falls below 3.5 ata, the control
valve CRH-2 gets an over riding impulse to open fully. This impulse is
withdrawn when the pressure of 3.5 ata is achieved.
6.2.4.3 In case the CRH line pressure falls below 8 ata, the control valve AS-2
cuts in automatically and deaerator pegging is switched over to steam
supply from the auxiliary steam header. The CRH line pegging control
valve CRH-2 is given a force close command.
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7.0 CONDENSATE EXTRACTION PUMPS
Refer PID Condensate System' diagram

2x100% Condensate Extraction Pumps are provided, one working and

other standby.
One pump is in operation up to full load and the other pump is standby.
In case the discharge header pressure falls below a set value, the
standby pump shall cut in.
Once the system is stabilized (normal pressure for 10 minutes) the

running pump previously selected as standby is tripped through ATRS
or manually.
In case of high differential pressure alarm in the suction strainer, the

working pump is isolated and the standby pump is brought in service.
A 15 Nb vent line with solenoid operated valves VA-5/VA-6 and orifice

plate leading to the LP drain flash tank is provided at the discharge
elbow of each CEP.
Solenoid valves VA-5/VA-6 have the following interlocks:
i) For starting of any of the pump the respective solenoid valve will be
in open condition.
ii) After the pump has started, the respective solenoid valve shall be
closed on auto with a time delay of two minutes.
iii) The solenoid valve shall open on auto whenever the pump is tripped
or stopped.
The pump control forms part of ATRS and details are covered in ATRS
logic.
Facility is provided to select either of the pumps as stand-by pump for

automatic sequential starting.
The standby pump cuts into operation automatically when the running
pump trips and the standby pump permissives are satisfied.
For details refer sequential interlock write-up of BHEL HYD.

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8.0 BOILER FEED PUMPS
Refer PID Feed Water System' diagram

3x50% Boiler Feed Pumps are provided to meet the flow requirement of
one boiler.
Two pumps are in operation upto full load and the other pump is
standby. In case the header pressure falls below a set value, the
standby pump shall cut in.
Once the system is stabilized (normal pressure for 10 minutes) the

running standby pump is tripped.
In case of high differential pressure alarm in the suction strainer, the

working pump is isolated and standby pump is brought in service.
Facility is provided to select any of the pumps as a stand-by pump for

automatic sequential starting.
The standby pump cuts into operation automatically when the running
pump trips and the standby pump permissives are satisfied.
For details refer sequential interlock write-up of BHEL HYD drawing .

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9.0 CRITICAL PIPING DRAINS
Refer PID MS, HRH, CRH & HP/LP Bypass System' diagram
9.1 GENERAL
The critical piping drains comprise of the main steam, hot reheat and
cold reheat drains beyond the boiler limits. The main steam line drains
are connected to the atmospheric flash vessel and the HRH & CRH line
drains are connected to the condenser through the HP Drain Flash
Tank. Each path consists of an upstream locked open manual globe
valve and a downstream motor operated valve to be used for draining /
warming-up lines.
9.2 OPERATING MODES
The various operating regimes are explained below.
9.2.1 COLD START-UP
9.2.1.1 The drain lines from the MS strainers (with valves MS-105 & MS-106) to
atmospheric flash vessel and HRH strainer drains (with valves HRH-101
& HRH-102) & CRH line drains (with valves CRH-101) to condenser are
opened remote manually.
9.2.1.2 The LP bypass line drain valves to be kept open till LP bypass valves
are taken into service.
9.2.1.3 Close command for MS strainer drain valves & HRH strainer drain
valves shall be issued from ATRS.
9.2.2. HOT START-UP
9.2.2.1 Turbine tripped / Boiler tripped
Open and close drains as per 9.2.1.1 above.
9.2.2.2 Turbine tripped / boiler in service with HP/LP bypass
No drain to be opened if turbine is rolled immediately. In case there is

delay in turbine rolling, operate drains as per 9.2.1.1 above.
9.2.3 Before seat drain valves of HP & LP turbine stop valves are cascaded to
the respective steam strainer without any isolating valve by gravity, so
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that water does not accumulate in the space above the seat of the
closed stop valve.
9.2.4 Spray water from CEP discharge is taken to cool drains connected to
HP drain flash tank. When temperature in the HP drain flash tank rises
to 1200C (adjustable), an alarm is annunciated in the control room and
impulse is given to open ON/OFF duty control valve CD-82 in
condensate spray line on the HP drain flash tank shell.
9.2.5 Operation of turbine control valve seat drains, transfer pipe drains, and
CRH line drains before NRV is taken care of in ATRS. These drains are
all connected to condenser. For details refer turbine O&M Manual.
9.3 CRH LINE DRAIN POT CONTROL
A drain pot is provided at the lowest point in CRH line. Drains are led to
the HP drain flash tank through upstream locked open manual valve
CRH -102 and down stream motorized valve CRH-101.
9.3.1 INSTRUMENTATION
The following instruments are provided on the drain pot for initiating
alarms & protective actions:
9.3.1.1 One level switch at 'HIGH LEVEL' to open the motorized drain valve
CRH-101 fully and initiate an alarm in the control room.
9.3.1.2 One level switch at 'HIGH HIGH LEVEL' to give repeat command to
open the motorized drain valve CRH-101 and initiate alarm in the
control room.
9.3.2 CONTROL FUNCTIONS
The drain valve control shall provide the following features:
9.3.2.1 Drain valve shall open automatically on high water level in the drain
pot.
9.3.2.2 Facility to open or close the valve remote manually from the control
room is provided. However auto command (high level control) shall
overrides the manual closed position.
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10.0 FEED CONTROL STATION
Refer PID Feed Water System' diagram

10.1 Feed control station is provided to regulate the feed flow through boiler
depending upon system requirement and to maintain normal water level
in boiler drum at all loads.
1x30% low load Feed Control Stream (FCS) and 2x100% full load Feed
Control streams have been envisaged for each unit.
10.1.1 Low Load Feed Control Station
Low Load FCS comprises of 1x30% pneumatically operated feed

control vale FD-20 (LAB60AA103) , upstream motorized isolating valve
R01 FD-19(LAB60AA005) (with motor operated integral bypass valve), and
a downstream manual isolating valve FD-21 (with manual integral
bypass valve).
10.1.2 Full Load Feed Control Station
Full Load Feed Control Station consists of 2x100% streams.
Each stream comprises of pneumatically operated feed control valve

FD-14(LAB60AA101) / FD-17(LAB81AA101) , upstream motorized
isolating valve FD-13(LAB70AA312) / FD-16(LAB60AA102) (with
motor operated integral bypass valve), and a downstream manual
isolating valve FD-15 / FD-18.(with manual integral bypass valve)
10.2 OPERATION
10.2.1 During start up and upto 30% load single element feed control system is
adopted. During this operation the working BFP is run at minimum
stable speed. The drum level measured signal is compared with drum
level set point. The error signal from the single element controller
positions the low load feed control valve FD-20.
10.2.2 At loads higher than 30% the controls are automatically shifted from low
load FCS to Full load FCS.
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10.2.3 Any one of the 2x100% full load feed control streams can be selected for
operation by opening the upstream isolating valve remote manually. At
loads above 30% when full load FCV opens >2% low load FC valve
automatically gets a closing command. Their shall be smooth changeover
from 30% to 100% load. The operation of motorized valve upstream of
FCV shall be manual.
10.2.4 From 30% to 100% load three element feed water control is followed.
The three elements employed are:
i) Drum level
ii) Steam flow
iii) Feed water flow
10.2.5 The error signal produced between measured drum level and drum level
set point is added to the steam flow signal to form the feed water flow
demand signal i.e. set point for feed water flow. This is compared with
the feed water flow, in the feed water controller. Deviation, if any,
changes the feed water controller output, which modulates the feed
control valve and scoop tube of BFP. A constant differential pressure is
maintained across the feed control valve by regulating the speed of BFP
by scoop tube control. Variation in pump speed will contribute to change
the feed flow required by the three element control system.
NOTE:
i) Scoop tubes of the BFPs (whether running or tripped) shall

operate in synchronization.
ii) Scoop tube of both the BFPs (3X50%) shall be driven to the
R01 minimum position when
a) First BFP is to be started
b) The working BFP trips
b) For details refer sequential interlock write-up of BHEL HYD

drawing.
NUMBER
NUMBER
11.0 MISCELLANEOUS INTERLOCKS
11.1 Interlocks for valves with integral bypass.
11.1.1 The following valves are with motorized integral bypass valves.
Isolating valves before feed control

FD-13,FD-16 & FD-19 valves.
Isolating valves at inlet / outlet of HP

FD-7 and FD-9 Heater-5 in the feed water line.
Isolating valves at inlet / outlet of HP

FD-10 and FD-12 Heater-6 in the feed water line.
Isolating valves on bypass of feed

water of HP heater-5 & HP heater -6
FD-8 and FD-11
respectively.
Isolating valves in the boiler feed

FD-4 ,FD-5 & FD-6 pumps individual discharge line.
11.2 The above valves are provided with the following interlocks:
11.2.1 The main valve shall not open unless its motorized integral bypass valve
is in full open position. This interlock is not applicable for valve tag nos.
FD-8 and FD-11.
11.2.2
For valve tag nos. FD-8 and FD-11 the main as well as the integral
bypass valve shall open simultaneously at HIGH HIGH LEVEL in the
respective HP Heater.
11.2.3
When main valve is fully open its integral bypass valve shall be closed.
The motorized integral bypass valves shall close simultaneously when

its main valve is closed.
11.3 CD-71: This valve is envisaged in the condensate discharge line for
ensuring adequate water pressure to the valve gland seals. The pressure
downstream of CD-71 shall be maintained by modulating the valve.

I&P For Regenerative System - R1 - CAT-E (Approved)

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I&P For Regenerative System - R1 - CAT-E (Approved)

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APPROVED CAT-E

NAME : SUNIL KUMAR

SIGN.: Dt. 07.03.2011

INDIABULLS POWER LIMITED.

5 X 270 MW AMRAVATI TPP SHEET 2 OF 22

S.No. Description Sheet No.

2.0 Level control of LP Heaters 04

3.0 Level control of HP Heaters 07

4.0 Condenser Hotwell level control 10

5.0 Deaerator level control 12

6.0 Deaerator pressure control 14

7.0 Condensate Extraction Pumps 16

8.0 Boiler Feed Pumps 17

10.0 Feed control station 20

11.0 Miscellaneous interlocks 22

5 X 270 MW AMRAVATI TPP SHEET 3 OF 22

1.5 The deaerator is designed to operate under variable pressure operation

5 X 270 MW AMRAVATI TPP SHEET 4 OF 22

2.0 LEVEL CONTROL OF LP HEATERS

The following instrumentation has been provided for initiating alarms

2.1.1 Three level transmitters (LCC30CL001, LCC30CL002 & LCC30CL003)

2.1.2 Three level transmitters (LCC20CL001, LCC20CL002 & LCC20CL003)

2.1.3 Two level transmitters (LCC10CL001 & LCC10CL002) for LP Heater 1

2.2 CONTROL FUNCTIONS

2.2.1.1 'LOW LEVEL' in LPH-3 is annunciated in the control room.

2.2.1.2 'NORMAL LEVEL' in LPH-3 is maintained by cascading the drain to

i) Extraction steam line block valve EX-10 closes

5 X 270 MW AMRAVATI TPP SHEET 5 OF 22

2.2.2.1 'LOW LEVEL' in LPH -2 is annunciated in the control room.

2.2.2.2 'NORMAL LEVEL' in LPH-2 is maintained by cascading the drains to

i) Extraction steam line block valve EX-9 closes

5 X 270 MW AMRAVATI TPP SHEET 6 OF 22

2.2.3.2 'HIGH LEVEL' in LPH-1 is annunciated in the control room.

i) Normal drain control valve DR-25 from LPH-2 to LPH-1 closes

2.3 OPERATING REGIMES

5 X 270 MW AMRAVATI TPP SHEET 7 OF 22

3.0 LEVEL CONTROL OF HP HEATERS

The following instrumentation has been provided for initiating alarms

3.1.1 Three level transmitters (LAD20CL001, LAD20CL002 & LAD20CL003)

3.1.2 Three level transmitters (LAD10CL001, LAD10CL002 & LAD10CL003)

3.2 CONTROL FUNCTIONS

3.2.1.1 'LOW LEVEL' in HPH-6 is annunciated in the control room.

3.2.1.2 'NORMAL LEVEL in HPH-6 is maintained by cascading the drain to

3.2.1.5 In case the extraction pressure at HPH-5 is below a preset value

5 X 270 MW AMRAVATI TPP SHEET 8 OF 22

i) Extraction steam line block valve EX-13 closes

3.2.2.1 'LOW LEVEL' in HPH-5 is annunciated in the control room.

3.2.2.2 'NORMAL LEVEL' in HPH-5 is maintained by cascading the drain to

i) Extraction steam line block valve EX-12 closes

5 X 270 MW AMRAVATI TPP SHEET 9 OF 22

3.3 OPERATING REGIMES

5 X 270 MW AMRAVATI TPP SHEET 10 OF 22

4.0 CONDENSER HOTWELL LEVEL CONTROL

The following instrumentation has been provided for initiating alarms

4.1.1 Three level switches (MAG11CL101, MAG12CL101 & MAG12CL102) in

4.1.2 Three level transmitters (MAG11CL001, MAG12CL002 &

4.2 CONTROL FUNCTIONS

4.2.2 Normal level in the condenser is maintained by positioning the low

4.2.5 'LOW LEVEL' in the condenser is annunciated in the control room.

4.2.6 NORMAL LEVEL in the condenser is used as CEP start permissive

5 X 270 MW AMRAVATI TPP SHEET 11 OF 22

iii) Condensate pump discharge valve of the associated pump to be in closed

iv) Minimum recirculation valve is to be positioned initially at 40% (adjustable)