KORADI TPS EXPANSION PROJECT – 3 x 660 MW L&T-S&L LIMITED

LARSEN & TOUBRO LIMITED

(UNIT #8, 9 & 10), KORADI, MAHARASHTRA
PART – I Rev.: 0
MAIN PLANT PACKAGE PLANT OPERATION AND CONTROL
PHILOSOPHY
L&T Project No. : C10901
Document No.: L555-00P-00101
L&T-S&L Job No.: L555000

ATTACHMENT 7.1.11
SYSTEM DISCRIPTION FOR
AUXLIARY COOLING WATER SYSTEM
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 2 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

REVISION SUMMARY SHEET

REV. DETAILS / DESCRIPTION DATE

A For Approval 03/03/2011
B For Approval 03/04/2012
C For Approval 11/09/2012
D For Approval 25/10/2013
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 3 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

TABLE OF CONTENTS
TABLE OF CONTENTS .............................................................................................................................................. 3

1. GENERL DESCRIPTION .................................................................................................................................... 5

1.1. INTRODUCTION .............................................................................................................................. 5

1.2. REFERENCE DRAWINGS & DOCUMENTS .......................................................................................... 5

I. MECHANICAL DRAWINGS & DOCUMENTS .......................................................................................... 5

II. ELECTRICAL DRAWINGS AND DOCUMENTS ...................................................................................... 5

III. VENDOR-SUPPLIED DRAWINGS AND DOCUMENTS ............................................................................ 6

2. SYSTEM DESCRIPTION..................................................................................................................................... 7
2.1. FLOW DESCRIPTION ...................................................................................................................... 7

2.2. MAIN COMPONENTS ...................................................................................................................... 8

2.2.1. SYSTEM PIPING............................................................................................................................. 8

2.2.2. ACW PUMPS ................................................................................................................................ 9

2.2.3. PLATE HEAT EXCHANGERS (PHE)................................................................................................ 10

2.2.4. CONDENSER VACUUM PUMP SEAL WATER COOLER ......................................................................... 11

2.2.5. BUTTERFLY VALVE ...................................................................................................................... 11

3. DESIGN AND OPERATING PARAMETERS ................................................................................................ 11

4. MODE OF OPERATION .................................................................................................................................... 12

4.1. START UP ................................................................................................................................... 12

4.2. NORMAL OPERATION ................................................................................................................... 12

4.3. ABNORMAL OPERATION ............................................................................................................... 13

4.3.1. ACW PUMP TRIP ........................................................................................................................ 13

4.3.2. ACW PUMP/ MOTOR BEARING TEMPERATURE HIGH ..................................................................... 13

4.3.3. ACW PUMP MOTOR WINDING TEMPERATURE HIGH ...................................................................... 13

4.3.4. ACW PUMP MOTOR CURRENT HIGH ............................................................................................ 13

4.3.5. FOREBAY LEVEL LOW ................................................................................................................. 14

4.3.6. FOREBAY LEVEL HIGH................................................................................................................. 14

4.3.7. NORMAL SHUTDOWN ................................................................................................................... 14

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 4 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

5. INSTRUMENTATION & CONTROL................................................................................................................ 14

5.1. OPEN LOOP CONTROL ................................................................................................................. 14

5.1.1. ACW PMP-A DSCH MOV & ACW PMP-B DSCH MOV ............................................................ 14

(08PCD18-AA001 & 08PCD18-AA002) ............................................................................................. 14

5.1.1.1. CONTROLS AND MONITORING................................................................................................ 15

5.1.2 ACW PMP- A & ACW PMP- B ( 08PCD18-AP001 & 08PCD18-AP002) ..................................... 16

5.2 ALARMS: .................................................................................................................................... 18

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 5 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

1. GENERAL DESCRIPTION

1.1. Introduction
Purpose:
Purpose of this document is to detail out the description & functions of auxiliary cooling
water (ACW) system along with controls envisaged to ensure intended function of the
system with regards to the overall plant operation. This document also outlines brief
operation philosophy of the system.

Scope:
Auxiliary cooling water system starts from auxiliary cooling water pump located in
foreway, goes to plate heat exchangers & other BoP auxiliaries and then return to cooling
tower.

1.2. Reference Drawings & Documents

i. Mechanical drawings & documents

AUTHORING DOCUMENT NO. SHT DESCRIPTION

ORGANIZATION NO.

L&T-S&L L555-08M-00212 N/A P&IDs CW & ACW system

L&T-S&L l555-08M-00112 N/A Design Criteria For CW & ACW system

ii. Electrical Drawings and Documents

AUTHORING DOCUMENT NO. SHT DESCRIPTION

ORGANIZATION NO.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 6 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

AUTHORING DOCUMENT NO. SHT DESCRIPTION

ORGANIZATION NO.

WPIL LIMITED LT/ACWP/M/GAD- GENERAL ARRANGEMENT

02 DRAWING OF ACW PUMP MOTOR

WPIL LIMITED LT/ACWP/M/AD- ACCESSORIES DRAWING FOR

04 MOTORS

iii. Vendor-Supplied Drawings and Documents

AUTHORING DOCUMENT NO. SHT DESCRIPTION

ORGANIZATION NO.

WPIL LIMITED SK-7492-B GA VT PUMP

WPIL LIMITED LT/ACWP/P/DS- PUMP DATASHEET

05

WPIL LIMITED LT/ACWP/P&ID- 2 P&ID FOR ACW PUMP

01

WPIL LIMITED LT/ACWP/OCP-01 4 OPERATION & CONTROL

PHILOSOPHY OF ACW PUMP

OTOKLIN OC- TECHNICAL DATASHEET OF SELF

GLOBAL 592/DS/SCF/01 CLEANING STRAINER
BUSINESS LTD.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 7 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

AUTHORING DOCUMENT NO. SHT DESCRIPTION

ORGANIZATION NO.

OTOKLIN L&T/GA/STR/2012 GA DRAWING OF SELF CLEANING

GLOBAL /775 STRAINER
BUSINESS LTD.

AUDCO VWE-39776-01 1 GAD OF BUTTERFLY VALVE OF 900

SIZE- MANUALLY OPERATED

AUDCO VWE-39776-02 1 GAD OF BUTTERFLY VALVE OF 900

SIZE- MOTOR OPERATED VALVES

TRACTEL TIRFOR 05-005-4117 1 GA DRAWING OF SINGLE GIRDER

INDIA PVT GANTRY CRANE
LIMITED

2. SYSTEM DESCRIPTION

2.1. Flow Description

ACW system removes the waste heat rejected in the various plant auxiliaries. Each pump
discharge (08PCD18BR001 & 08PCD18BR005) is connected to a common header for
each 660 MW unit which supplies ACW to DMCW (DeMineralised Cooling Water) heat
exchangers for SG & TG auxiliaries (secondary side) and vacuum pump coolers. Tapping
from each unit header (08PCD18BR025, 09PCD18BR025 and 10PCD18BR025) are
joined together to form a common header (00PCD18BR001) which supplies ACW to
common utilities as mentioned in c, d, e, f and g above. The hot water from the above
systems forms a common header (00PCD18BR045) and joins CW return header at two
(2) locations:

a. Near condenser – return header from PHEs and vacuum pump coolers
and

b. Near Switchyard – return header from common utilities as mentioned in c,

d, e, f, and g above.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 8 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

This water is then conveyed to the cooling tower where heat is dissipated from the hot
water to the atmosphere and cold water is returned from cold water basin of the cooling
tower to the sump of the ACW pump house by means of gravity flow through reinforce
concrete tunnels. This cold water is then recycled back by the ACW pumps.

For the above mentioned purpose two (2) Auxiliary cooling water pumps for each 660
MW Unit are provided. The pumps are located in ACW pump house structure. Provision
of indoor EOT crane is made for the maintenance of the pumps.

Periodic blow down shall be made to maintain the quality of cooling water. For this
purpose a tap-off from the condenser return header along with isolation valve is provided
at one point and further distribution is in Owner’s scope.

Required numbers of side stream filtration unit with adequate capacity are provided by
Owner to restrict the suspended solid impurities within a reasonable limit in CW & ACW
system.

Chemical dosing (by Owner) is provided for controlling biological growth and proprietary
chemical dosing (by Owner) is considered in ACW sump to control scaling or corrosion in
ACW system path.

2.2. Main Components

Cooling water system will have following components:

2.2.1 System Piping
2.2.2 Auxiliary Cooling Water Pumps
2.2.3 Self-Cleaning Strainers
2.2.4 Expansion Joint, isolating Butterfly valves
2.2.5 Air Release cum Vacuum breaker valves

2.2.1. System Piping

The two (2) individual pump discharge lines (08PCD18-BR001 / 005) of DN 900 mm join
together to form a common header (08PCD18-BR001) which carries ACW water to TG &
SG auxiliaries, MRHS compressors, AHP and plant air compressors. Near turbine
building this header bifurcates into two (2) pipelines (08PCD18-BR040 / 030) which
enters then goes to various coolers of each unit.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 9 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

A tapping from each unit header (08PCD18BR025) is joined together to form a common
header (00PCD18BR001) which supplies ACW to common utilities like Plant Air
Compressor and DG set house (owner’s scope), Mill reject system, Ash handling Plant
compressor house (owner’s scope). D

A common return header (00PCD18BR045) from these common utilities bifurcates into
individual unit pipeline (08PCD18BR105) to join unit CW return header near condenser.

ACW pipe will be manufactured from plates conforming to IS 2062 Gr. B.

The piping from the outlet of the ACW pumps to the inlet of the cooling tower is sized with
allowable pressure drops. Water velocity is maintained per velocity limits given in the
Design Criteria Document (DCD).

Pressure and temperature measurements are provided for monitoring the performance of
the cooling water system. Sample tapping is provided to monitor water purity.

2.2.2. ACW pumps

The function of the Auxiliary Cooling Water (ACW) pump is to provide a continuous
supply of cooling water to the following consumers:

a) Condenser vacuum pump coolers

b) DeMineralized cooling water (DMCW) plate heat exchangers (secondary side)
c) Plant air compressors (Owner’s scope)
d) DG Set (Owner’s scope)
e) Mill reject system
f) AHP compressors (Owner’s scope)
D

Two (2) (2 x 100%) ACW pumps [08PCD18-AP001/002] are vertical wet pit type, constant
speed, non pull out type with above floor discharge and motor driven. The pumps are
operated and controlled from the DCS. A reverse rotation switch is provided to sense the
reverse rotation of the pump, which will not allow the pump to start in that condition. Each
ACW pump discharge is provided with tied expansion joint (08PCD18AS001 &
08PCD18AS002) to limit the loads & moments and motor-operated butterfly valve
(08PCD18AA001 & 08PCD18AA002) for isolation.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 10 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

Technical details of ACW pumps are as follows:

Service: Auxiliary Cooling Water Pumps

Tag No: 08PCD18AP001 / 08PCD18AP002

Type: Vertical wet pit type, constant speed,

non pull out type with above floor
discharge and motor driven.

Rated flow: 4350 cum/hr

Total developed head at rated flow: 44 mWc

2.2.3. Plate Heat Exchangers (PHE)

Total five (5) PHE are provided; 3 x 50% capacity PHE (08PCD18AC003,
08PCD18AC004, 08PCD18AC005) for cooling DMCW of TG auxiliaries and 2 X 100%
capacity PHE (08PCD18AC001, 08PCD18AC002) for cooling DMCW of SG auxiliaries.
Closed cooling water system rejects heat to the plant auxiliary cooling water system,
circulating through the heat exchangers. The heat exchangers are constructed of material
suitable for the auxiliary cooling water quality. Manual operated butterfly valves
(08PCD18AA108, 08PCD18AA109, 08PCD18AA110) and (08PCD18AA113,
08PCD18AA114, 08PCD18AA115) are provided for isolation of each heat exchanger on
respective inlet and outlet of TG side PHEs. Similarly Manual operated butterfly valves
(08PCD18AA106, 08PCD18AA107) and (08PCD18AA111, 08PCD18AA112) are provided
for isolation of each heat exchanger on respective inlet and outlet of SG side PHEs.

Inlet and outlet lines of PHEs are connected through expansion joints (08PCD18AS003,
004, 005, 006, 007, 008, 009, 010, 011 and 012) to limit the load and moments on PHE
nozzles.

Technical details on the plate heat exchangers are as follows:

Tag No:
08PCD18AC003, 08PCD18AC004,
08PCD18AC005
Service: 3 X 50% for TG auxiliaries
Type: Plate
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 11 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

Rated ACW flow: 1200 m3/hr per PHE

D
Heat load: 8325475 Kcal/hr per PHE
ACW inlet temperature: 33 Deg C

Tag No:
08PCD18AC001, 08PCD18AC002
Service: 2 X 100% for SG auxiliaries
Type: Plate
Rated ACW flow: 311 m3/hr
D
Heat load: 1713480 Kcal/hr
ACW inlet temperature: 33 Deg C
2.2.4. Condenser vacuum pump seal water cooler

Auxiliary cooling water will act as cooling medium for condenser vacuum pump seal water
cooler. The coolers are constructed of material suitable for the auxiliary cooling water
quality.

2.2.5. Butterfly Valve

2% Ni Cast Iron body Motor operated Butterfly valves as per AWWA C504/ API/BS shall
be provided for ACW system. For further details on material of valves, refer Design
Criteria Document L555-00M-00112.

3. DESIGN AND OPERATING PARAMETERS

Design parameters for the ACW system

Design Pressure – 7.5 Kg/cm2 (g)
Design Temperature – 50 0C

Operating parameters for the ACW system

Operating Pressure – 4.4 Kg/cm2 (g)
Operating Temperature –
ACW supply header- 33 0C
ACW return header- 40 0C
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 12 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

4. MODE OF OPERATION

4.1. Start up
 For normal startup the ACW pump discharge isolation valves are closed. All other
system valves and vent valves are kept open. The associated MOV of the pump that
is started will be initially crack opened to establish the minimum flow required for initial
filing of the system once running feedback is received from the pump. If the valve fails
to leave its seat within 10 seconds (or within preset time as recommended by valve/
pump supplier), the pump will automatically trip.

 During this filling period the air is vented from the piping and equipment at the various
high point vent valves. After the system is filled and air is evacuated from the system
(sample checking that water starts coming out from the vent) the vent valves are
closed.

 Once the discharge header pressure stabilizes to rated pressure, the discharge MOV
should be opened completely.

 After the MOV at the ACW pump discharge is fully opened, the pumps are then put on
auto mode with discharge MOV of standby pump in completely closed condition.

4.2. Normal operation

 Start and stop commands for the ACW pumps are initiated from DCS. The
Auxiliary cooling water system is in continuous service during all modes of plant
operation.
Normal function at full plant load consists of one ACW pump in service.

 When an operating pump trips, its discharge valve starts closing uniformly and is fully
closed in 39 seconds.
D

 Stand by pump will start in the case of tripping of running pump or discharge header
pressure remain low while other pump in service for a preset time.

 Screens are regularly cleaned to ensure the minimum water submergence in the
pump sump (monitored through level switches mounted in pump sump) as required
for efficient pump operation.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 13 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

4.3. Abnormal Operation

4.3.1. ACW Pump Trip

 When operating ACW pump trips, its respective discharge valve will close
automatically to prevent reverse flow through the pump.

 If the discharge valve for the tripping pump is not fully closed within a predetermined
time then an alarm is initiated in DCS for operator intervention. The pump motor
bearings may be damaged if the pump is allowed to rotate in reverse direction for
longer than the manufacturer’s recommendation.

 Manual stop facility will be provided in DCS for each pump in the event the auto stop
interlocks fail.

4.3.2. ACW Pump/ Motor Bearing Temperature High

 If the temperature of any ACW pump motor bearing exceeds a predetermined high
value, the pump/ motor protection relay will alarm and a common trouble alarm will be
indicated in the DCS. If the temperature of the bearing continues to rise to a
predetermined high-high value, the pump/ motor protection relay will trip the pump.

4.3.3. ACW Pump Motor Winding Temperature High

 If the temperature of any ACW pump motor winding exceeds a predetermined high
value, the motor protection relay will alarm and a common trouble alarm will be
indicated in the DCS. If the temperature of the winding continues to rise to a
predetermined high-high value, the motor protection relay will trip the pump.

4.3.4. ACW Pump Motor Current High

 If the current drawn by any of the circulating water pump motors exceeds a
predetermined high value, the motor protection relay will alarm and a common
trouble alarm will be indicated in the DCS. If the current draw continues to rise to a
predetermined high-high value, the motor protection relay will trip the pump.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 14 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

4.3.5. Forebay Level Low

 If the forebay level falls below a predetermined low-low value, a trouble alarm will be
indicated in the DCS, the operator will trip the operating pump(s) if the low-low level is
continued for a predetermined time. The forebay level is measured through level
transmitter (00PCD18CL101) connected to DCS.
 The ACW pumps shall be tripped if the water level in sump is below a
predetermined low value. Sump water level is measured through three level switches
located at each pump sump

4.3.6. Forebay Level High

 If the forebay level is above a predetermined high level, then the operator should
investigate and take necessary action.

4.3.7. Normal Shutdown

 Manual stop signal is sent to pump and its discharge isolation valve (MOV) closes
subsequently. In shutdown condition, the circulating water system piping and
equipment should be maintained filled, for corrosion protection, unless maintenance
of the system piping is desired.

5. INSTRUMENTATION & CONTROL

5.1. Open Loop Control

5.1.1. ACW PMP-A DSCH MOV & ACW PMP-B DSCH MOV

(08PCD18-AA001 & 08PCD18-AA002)

Purpose:
These valves are Inching type motor operated valve at the discharge of ACW Pumps
which are provided for proper operation of the ACW system.

Functional description:
The control and monitoring of these valves will be from DCS. The valves shall always be
kept in auto mode.

These Inching type motorized valves have interlock with the ACW pumps and with
pressure transmitters located at discharge header of the pumps.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 15 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

They are cracked-open in ‘Auto’ (approx 10%) with the running feedback of their
corresponding pump to establish the minimum flow required for initial flow of the system.
Once the discharge header pressure stabilizes to rated pressure, the discharge MOV
should be opened completely.

These valves can also be opened and closed manually.

5.1.1.1. Controls and Monitoring

i. Permissive
Open Permissive
 Corresponding ACW pump running feedback

Close Permissive
 Corresponding ACW Pump is not running

ii. Auto Interlock

Auto Open Interlock
 Auto open command from group level
 Corresponding ACW pump is running

Auto Close Interlock

 Auto close command from group level
 corresponding ACW pump is tripped or stopped

iii. Protective Override Commands

Override Open
 None
Override Close
 These valves will receive override close command from DCS when corresponding
pump is tripped or stopped.
iv. References

This control description covers the process control functional logic requirement for
following equipment
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 16 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

Logic Diagram reference:

Equipment Tag Description Drawing Number Sheet Number
08PCD18AA001 ACWP A DISCH MOV L555-00I-00206 428A
08PCD18AA002 ACWP B DISCH MOV L555-00I-00206 429A

5.1.2 ACW PMP- A & ACW PMP- B ( 08PCD18-AP001 & 08PCD18-AP002)

Purpose:
Refer cl. No. 2.1.
Functional description:
The control and monitoring of ACW Pumps will be from CW/ACW pump house operator
workstation with repeat operation from central control room DCS. The system will be
connected to common DCS through Remote Processing Unit (RPU).

The DCS operator is provided with controls enabling him to select any individual pump to
Manual, Auto, Stand by or Lockout mode and to start and stop the pump under manual
control.

Selection of Lockout (offline) mode indicates that a pump operation is not available from
DCS Operator station. However, selection of Lockout (offline) mode is possible only if the
selected pump is not running.

The operator can select any one pump as main pump & other pump as a stand-by pump.
Stand-By means selected pump is available to run but it will start only when running
pump trip OR header pressure is low.

During normal operating condition any one ACW pump will be running continuously and
other will be in Auto stand-by mode.

Operator can select both the pumps in manual mode or Auto mode. In Auto mode, start
and stop command to the Pump will be given from Group level based on the set
sequence and permissive as defined in the group.

In manual mode, the operator can select any one pump (main pump) in manual mode
and give a start command to the pump. If start permissives are through for that pump
then, the pump will start. Other pump is put in auto stand-by mode which will start
automatically subject to availability of start permissive if any of the following condition
appears:

 Running pump tripped

 One pump running for a preset time and pump discharge header pressure low.

Both the pumps will be running until pump discharge header pressure reaches the set
value. Once the header pressure reaches the set value then the operator can stop any
one pump.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 17 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

In case the pump is not started after preset time, then an alarm of “Fail to Start” is
generated for the operator attention.

Controls for each pump (running or standby) also allow the operator to start or stop the
pump from the DCS by selecting the manual control mode.

5.1.5.1 Controls and Monitoring

i. Permissive
Start Permissive
 Level not low low from the level Switches located in each ACW pump sump pit
 Pump discharge valve closed or as recommended by the Pump manufacturer
 Pump bearing temperature is not high
 Motor winding and bearing temperature is not high
 Reverse rotation switch not activated
 ACW pump bearing cooling water flow not low

Stop Permissive
 None

ii. Auto Interlock

Auto start Interlock

Main Pump 1 Auto Standby

 Group Start command  Group Start command AND

 Start Permissive  Start Permissive available
available AND
 running pump trips OR
 Header pressure low

Auto stop Interlock

 Auto stop command from group level

iii.Protective Override Commands

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 18 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

Override Stop
 Level low low from the level Switches located in each CW sump

 Motor Bearing temperature high-high

 Motor winding temperature high-high

 Pump thrust bearing temperature high-high

 Vibration of the bearing of either pump or motor high-high

 Pump discharge valve fail to leave its seat within preset time (i.e. fail to reach 10%
open position within preset time of ACW pump running)

 Pump discharge pressure high due to accidental closure of valve (This can be
achieved through Pump running for considerable time and close feedback from
Discharge valve).

i. References

This control description covers the process control functional logic requirement for
following equipment

Logic Diagram reference:

Equipment Tag Description Drawing Number Sheet Number
08PCD18AP001M ACWP# A L555-00I-00206 426A
08PCD18AP002M ACWP# B L555-00I-00206 427A

5.2 Alarms:

Normal Alarm Trip

Description Initiating Device KKS Tag Number
Value Value Value
ACW Sump level 08PCD18CL201A/B/C
Level switches NA -2.625 m -2.775 m D
low low (2 out of 3)
ACW Forebay Level 00PCD18CL101A
NA -2.475 m NA
level low Transmitters (Average Value)
ACW Forebay Level 00PCD18CL101A
NA -2.525 m NA
level low low Transmitters (Average Value)
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: D
MAIN PLANT PACKAGE CONTROL FOR AUXILIARY COOLING Date: 25/10/2013
WATER SYSTEM
L&T Project No. : C10901 Page: 19 of 19
Document No.: L555-00M-00912
L&T-S&L Job No.: L555000

ACW Forebay Level 00PCD18CL101A

NA -0.775 m NA
level high Transmitters (Average Value)
ACW PMP
Pressure 4.0 5.1 5.2
discharge 08PCD18CP101
Transmitter Kg/Cm2 Kg/Cm2 Kg/Cm2
pressure
ACW PMP HDR
discharge Pressure 3.45
08PCD18CP103A/B/C NA NA
pressure (FOR Transmitter Kg/Cm2
STDBY PUMP)
Bearing
temperature RTDs 08PCD18CT051 NA 85 Deg C 90 Deg C
Pump Thrust
Bearing
temperature
RTDs 08PCD18CT053/54 NA 90 Deg C 95 Deg C
motor high(DE &
NDE)
Motor winding 08PCD18CT057/58/6 110 Deg 120 Deg
RTDs NA
temperature high 1/62/65/66 C C
Differential
pressure across
the self-cleaning DPT 08PCD18CP151 2.0 mwc 4.0 mwc NA
strainer high

Differential
pressure high 0.63 0.8
DPT 08PCD18CP152/53 NA
across PHE of kg/cm2 kg/cm2
Boiler Auxiliaries
Differential
pressure high
08PCD18CP154/55/5 0.65 0.8
across PHE of DPT NA
6 kg/cm2 kg/cm2
Turbine
Auxiliaries