HRSG OPERATION AND MAINTENANCE

signal that is then sent to the level controller (LC). The total error is compared with the setpoint
to provide the error signal that positions the feedwater control valve.

In a swell condition (water level is increasing), the water level signal alone will call for less
water. However, this would starve the boiler because the swell condition is caused by an
increased steam flow (decreased steam pressure), which means more water is needed. By
comparing the water level error with the steam flow, the amount of increased water flow
called for by the steam and water flow error is balanced against the decrease in flow called
for by the rising drum level. This action will continue to occur until steam pressure is
restored to normal by stabilizing load demand at a new level. As the water level decreases
to normal, more water is allowed to enter the boiler until feedwater flow equals steam flow.

The drum level signal is density compensated to generate a corrected drum level signal to
the drum level controller.

To control swell during start-up, drum levels are maintained at a lower control level, just
above its low water alarm setpoint, until steam flow reaches 10% of full flow for that system.

NOTE:
The following process control statements are generic for a typical 3 drum HRSG with reheater,
fed by a GT and coupled to an HP/IP/LP steam turbine set. Please review final operating
recommendation for your actual unit operating process logic:

4.3 DEAERATOR STORAGE TANK LEVEL (Set Points for 3658 mm (144) OD DA
STORAGE TANK)

Level Comments or Control actions Start-up Normal

Set Operating
Points Set
Points
High High Sound the alarm
+1372mm +1372mm
After time delay, close the feedwater stop valve (+54) (+54)
Feedwater control valve should be closed.
High Sound the alarm, permit opening of the feedwater +1219mm +1219mm
valve (+48) (+48)
Normal The DA storage tank level controls will regulate the
rate of feedwater flow to maintain a proper drum +566 mm +566 mm
level throughout the operation range of the steam (+22.3) (+22.3 )
generator.
Low Sound the alarm -1524 mm -1524 mm
(-60) (-60)
Open the feedwater stop valve (automatic).
Low Low Alarm
-1676 mm -1676 mm
Feedwater Control Valve should be open (-66) (-66)
Initiate GT normal runback

Stop and hold runback if low level alarm is cleared.

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Project: NUBARIA POWER STATION I & II
HRSG OPERATION AND MAINTENANCE

LP DRUM LEVEL (Gage Visibility = XX) Set Points for 1524 mm (60) ID LP Drum

Level Comments or Control actions Start-up Normal

Set Operating
Points Set
Points
High High Sound the alarm
+229 mm +229 mm
After time delay, close the feedwater stop valve (+9) (+9)
Feedwater control valve should be closed.
High Sound the alarm, permit opening of the feedwater +178 mm +178 mm
valve (+7) (+7)
Normal The drum level controls will regulate the rate of
feedwater flow to maintain a proper drum level -533 mm 0 mm
throughout the operation range of the steam (-21) (0 )
generator.
Low Sound the alarm -584 mm -102 mm
(-23) (-4 )
Open the feedwater stop valve (automatic).
Low Low Alarm
-635 mm -635 mm
Feedwater Control Valve should be open (-25) (-25)
Initiate GT normal runback

Stop and hold runback if low level alarm is cleared.

Figure 4-3: Table of LP Drum Level Control Settings

4.4 LP STEAM VENT VALVE CONTROL

Open if drum pressure is less than 25 psig.

Closed if drum pressure is greater than 25 psig.

Provide manual override for nitrogen blanketing.

Note: For lay-up with nitrogen blanket, valve shall remain closed independent of pressure.

ALSTOM Power Revision: 0 4-9

Copyright 2005 04/02/05
Project: NUBARIA POWER STATION I & II
HRSG OPERATION AND MAINTENANCE

4.5 IP DRUM LEVEL (Gage visibility = XX) Set Points for 1372 mm (54) ID IP
Drum

The drum level controls will regulate the rate of feedwater flow to maintain a proper drum level
throughout he operation range of the steam generator.

Level Comments or Control action Start-up Normal Operating

Set Set Points
Points
High High Sound the alarm
After time delay, close the feedwater +229 mm +229 mm
stop valve (+9) (+9)
Feedwater control valve should be
closed
High Sound the alarm, permit opening of +178 mm +178 mm
feedwater stop valve (+7) (+7)
Normal The drum level controls will regulate the
rate of feedwater flow to maintain a -457 mm 0 mm
proper drum level throughout the (-18) (0)
operation range of the steam generator.
Low Sound the alarm
Open the feedwater stop valve. -508 mm -102 mm
Close the IP drum continuous (-20) (-4)
blowdown motor operated stop valve.
Low Low Alarm
Feed control valve should be open -559 mm -559 mm
Initiate GT normal runback. (-22) (-22)
Stop and hold runback until low level
alarm is cleared and reset by operator.

Figure 4-4: Table of IP Drum Level Control Settings

To get the maximum benefit from a three-element system, feedwater flow should be
proportional to steam flow with reset action on drum level. This means that the mass of
feedwater entering should always equal the mass of steam leaving, with periodic small
corrections made to correct deviations from level set points. The best drum level control is
achieved through the mass flow balance.

4.6 IP DRUM CONTINUOUS BLOWDOWN ISOLATION VALVE

Open if level is > than low AND superheated steam flow is > than 30%.

Close if level is < than low OR superheated steam flow is < than 30%.

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Copyright 2005 04/02/05
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HRSG OPERATION AND MAINTENANCE

4.7 HRSG IP MAIN STEAM VENT VALVE

Open if drum pressure is less than 25 psig.

Closed if superheated steam flow is great than 10%

Provide manual override for nitrogen blanketing.

Note: For lay-up with nitrogen blanket, valve shall remain closed independent of pressure.

4.8 IP TO LP PEGGING STEAM CONTROL

Where provided, a pegging steam control valve will regulate the flow of IP Superheated steam
to the LP drum to maintain minimum LP drum pressure based on operator decision. The
pegging steam control valve may be left in active mode during natural gas firing at operators
option.

4.9 HP DRUM CONTINUOUS BLOWDOWN ISOLATION VALVE

Open if level is > than low AND superheated steam flow is > than 30%.

Close if level is > OR superheated steam flow is < than 30%.

4.10 HP DRUM LEVEL (Gage visibility = XX) Set Points for 1829 mm (72) ID HP Drum

Level Comments or Control Action Start-up Normal

Set Operating
Points Set Points
High High Sound the alarm
After time delay, close the feedwater stop valve. +292 mm +292 mm
Feed water control valve should be closed (+11.5) (+11.5)
High Sound the alarm +241 mm +241 mm
(+9.5) (+9.5)
Normal The drum level controls will regulate the rate of
feedwater flow to maintain a proper drum level -686 mm +64 mm
throughout the operation range of the steam (-27) (+2.5)
generator.
To get the maximum benefit from a three-element
system, feedwater flow should be proportional to
steam flow with reset action on drum level
Low Sound the alarm -737 mm -38 mm
Open the feedwater stop valve (-29) (-1.5)
Close the HP drum cascade blowdown motor
operated stop valve.
Low Low Alarm -787 mm -787 mm
Feed control valve should be open (-31) (-31)
Initiate GT normal runback.
Stop and hold runback if low level alarm is cleared.

Figure 4-5: Table of HP Drum Level Control Settings

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Copyright 2005 04/02/05
Project: NUBARIA POWER STATION I & II
HRSG OPERATION AND MAINTENANCE

4.11 HP STEAM TEMPERATURE CONTROL

Startup Operation
Required actions:
Open the following valves if HP Steam Temperature (TE-1114A & TE-1114B) >568C (1055F):
HP Desup Spraywater Control Valve (TV-301)
HP Desup Spraywater Power Block Valve (HV-300)
Close when HP Steam Temperature (TE-1114A & TE-1114B) 568 C (1055 F):
Close when HP Steam Flow < min

Alarm steam temperature high 576.67 C (1070 F)

Alarm steam temperature low 537.78 C (1000 F) for Natural Gas
Alarm steam temperature low 530.56 C (987 F) for Distillate Oil
Trip Duct Burner when temp. alarm = 586.7C (1080 F)
GT protective load shedding (*) when temp. alarm 586.7C (1080 F)
GT trip (after 2 min. of total elapsed time) if alarm not cleared.

Ramp setpoint of HP Spraywater Controller based on commissioning test and on CTG signal
of 10% load. Set ramp rate according to overall design.

The HP spray water block valve to open when the demand on the control valves is greater
than 3%.

The HP spray water block valve to close when the demand on the control valves is less than
3% for 5 minutes.

Alarm steam temperature high equal to or greater than design plus a safe margin.

Alarm steam temperature low less than or equal or design.

Initiate GT normal runback when temperature high high is equal to or greater than plus 10
degrees. Stop and hold runback if alarm is cleared.

Close the HP Spraywater Control Valves on CTG trip.

4.12 HP OVERPRESSURE
Required actions:
Trip Duct Burner (If supplied) when HP steam pressure (PT-342) = 148.237 bar (2150 psig )
GT protective load shedding (*) when HP steam pressure (PT-342) 148.237 bar (2150 psig ),
GT trip after 2 minutes of PLS, if HP steam pressure (PT-342) > 126.519 bar (1835 psig ).

Set the GT normal load runback slightly below the safety valve set pressure to avoid lifting
the safety valve.
NOTE:
No safety valve should be permitted to blow for more than a 15 minute period. If safety valve
open continues beyond 15 minutes, the operator shall take corrective action.
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HRSG OPERATION AND MAINTENANCE

4.13 HP MAIN STEAM OUTLET VENT VALVE

Open if drum pressure is less than 1.724 bar (25 psig).

Close if superheated steam flow is greater than 10%.

NOTE:

Provide manual override for nitrogen blanketing. For lay-up with nitrogen blanket, valve shall
remain closed independent of pressure.

4.14 RH STEAM TEMPERATURE CONTROL

Startup Operation

Required actions:

Open the following valves if RH Desup. Outlet Steam Temp. (TE-781A & TE-781B) > 1053 F:
RH Desup Spraywater Control Valve (TV-701)
RH Desup Spraywater Power Block Valve (HV-700)
Close when RH Desuperheater Outlet Steam Temperature (TE-781A & TE-781B) 1053 F

Alarm steam temperature high 570 C (1058 F)

Alarm steam temperature low 541 C (1006 F) for Natural Gas
Alarm steam temperature low 532 C ( 990 F) for Distillate Oil

Trip Duct Burner (If supplied) when temp. alarm = 572.78 C (1063 F)
GT protective load shedding (*) when temp. alarm 572.78 C (1063 F)
GT trip (after 2 min. of total elapsed time) if alarm not cleared

Ramp setpoint of Reheat Spraywater Controller based on commissioning test and on CTG
signal of 10% load. Set ramp rate according to overall design.

Ramp setpoint of Reheat Spraywater Controller based on commissioning test and on

release from Turbine control. Set ramp according to overall design.

At all times, maintain design minimum Superheat.

Normal Operation

Set RH spray water control valves at design plus a safe margin.

The RH spray water block valve to open when the demand on the control valves is greater
than 3%.

The RH spray block valve to close when the demand on the control valves is less than 3%
for 5 minutes.

Alarm steam temperature high equal to or greater than design plus a safe margin plus 10
degrees.
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HRSG OPERATION AND MAINTENANCE

Alarm steam temperature low less than or equal to design.

Initiate GT normal runback when temperature high high is equal to or greater than 1067 F or
575 C . Stop and hold runback if alarm is cleared.

Close the RH spraywater Control valves on CTG trip.

At all times maintain a safe minimum of Superheat.

4.15 FEEDWATER HEATER RECIRCULATION CONTROL:

The condensate recirculation pump will be activated (manually) when condensate temperature
(TE-005A & B) is less than the temperature set point of 135 F.

Control valve (TV-040) will start to open when pump is switched on and modulate to keep up the
corresponding condensate temperature set point.

4.16 BOILER PROTECTION

The water is kept constant in both drums. For HP and IP, during normal operation the signal
setting for the feed water control valve is derived from the feedwater flow minus boiler water
extraction, the steam flow and the drum water level (three-element control).

4.16.1 Drum Level

Low Low Level Initiate GT normal runback. Stop and hold runback if low level alarm is
cleared.

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Copyright 2005 04/02/05
Project: NUBARIA POWER STATION I & II