13 DMCW For SG System Description

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 7.1.13
SYSTEM DISCRIPTION FOR
DMCW SYSTEM FOR SG AUXILIARIES
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.: B
MAIN PLANT PACKAGE CONTROL FOR DE-MINERALIZED COOLING Date: 20/07/2012
WATER SYSTEM (SG)
L&T Project No. : C10901 Page: 2 of 21
Document No.: L555-00M-00914
REVISION SUMMARY SHEET
REV. DETAILS / DESCRIPTION DATE

A FOR APPROVAL 03/04/2012
B FOR APPROVAL 20/07/2012
MAHARASHTRA
WATER SYSTEM (SG)
TABLE OF CONTENTS
1. GENERAL DESCRIPTION ................................................................................................................................. 5
1.1 INTRODUCTION .............................................................................................................................. 5
1.2 REFERENCE DRAWINGS & DOCUMENTS .......................................................................................... 5
I. MECHANICAL DRAWINGS & DOCUMENTS .......................................................................................... 5
II. ELECTRICAL DRAWINGS AND DOCUMENTS ...................................................................................... 6
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. DMCW PUMPS ............................................................................................................................. 9
2.2.3. NAOH DOSING SYSTEM .............................................................................................................. 10
2.2.4. PLATE TYPE HEAT EXCHANGER (PHE) ......................................................................................... 10
2.2.5. DMCW EXPANSION/ MAKE-UP TANK ............................................................................................ 10
3. DESIGN AND OPERATING PARAMETERS ................................................................................................ 10
4. MODE OF OPERATION .................................................................................................................................... 11

4.1 START UP ................................................................................................................................... 11
4.2 NORMAL OPERATION ................................................................................................................... 12
4.3 ABNORMAL OPERATION ............................................................................................................... 12
4.3.1. DEMINERALISED COOLING WATER PUMP TRIP .............................................................................. 13
4.3.2. DEMINERALISED COOLING WATER HEAT EXCHANGER OUTAGE ...................................................... 13
4.3.3. DMCW PUMP/ MOTOR BEARING TEMPERATURE HIGH ................................................................... 13
4.3.4. DMCW PUMP MOTOR WINDING TEMPERATURE HIGH .................................................................... 13
4.3.5. DMCW PUMP MOTOR CURRENT HIGH ......................................................................................... 13
4.4 NORMAL SHUTDOWN ................................................................................................................... 13
5. INSTRUMENTATION & CONTROL................................................................................................................ 14

5.1 OPEN LOOP CONTROL ................................................................................................................. 14
5.1.1 DMCW (SG) PUMP DISCHARGE MOV (08PGB19-AA001 / 002) ............................................. 14

MAHARASHTRA
WATER SYSTEM (SG)
5.1.2 DMCW PUMP SUCTION VALVE (08PGB19-AA171 / 172) ....................................................... 15
5.1.3 DMCW OVERHEAD TANK INLET SOV (08GHC27-AA0021) .......................................................... 15
5.1.4 DMCW(SG) RECIR CV BYPASS MOV ..................................................................................... 16
5.1.5 DMCW(SG) PMP#A & PMP#B ( 08PGB19-AP001, 08PGB19-AP002) ...................................... 16
5.2 CLOSE LOOP CONTROL ............................................................................................................... 19
5.2.1 TEMPERATURE CONTROL VALVES ...................................................................................... 19
5.2.2 DMCW (SG) PMP RECIRC CV(08PGB19AA052) ..................................................................... 19
5.3 ALARMS ..................................................................................................................................... 19
ANNEXURE I ............................................................................................................................................................... 21
MAHARASHTRA
WATER SYSTEM (SG)
1. GENERAL DESCRIPTION
1.1 Introduction
Purpose:
Purpose of this document is to detail out the description & functions of demineralized
cooling water (DMCW) system (SG and auxiliaries) 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:
DMCW system starts from DMCW pump discharge and supplies water to various SG and
its auxiliaries. Return line from various auxiliaries’ joins to form return header which goes
to the suction of pumps. Make up connection is provided from DMCW expansion cum
makeup tank.
1.2 Reference Drawings & Documents

i. Mechanical drawings & documents
AUTHORING DOCUMENT NO. SHT DESCRIPTION

ORGANIZATION NO.
L&T-S&L L555-08M-00212 1-2 P&IDs DMCW system
L&T-S&L l555-08M-00111 1-16 Design Criteria For DMCW system

MAHARASHTRA
WATER SYSTEM (SG)
ii. Electrical Drawings and Documents

ORGANIZATION NO.
WPIL LIMITED M-HH-50273-78- 1 MOTOR GAD FOR DMCW PUMP FOR

GAD SG AUXILIARIES
WPIL LIMITED M-HH-50273-78- 9 MOTOR DATASHEET FOR DMCW

DS PUMP FOR SG AUXILIARIES
iii. Vendor-Supplied Drawings and Documents

ORGANIZATION NO.
L&T-MHI BOILERS 97000-2612 1 CLOSED CYCLE COOLING WATER

PRIVATE LTD. CONSUMPTION LIST
L&T-MHI BOILERS 97000-2122 1 CLOSED COOLING WATER SYSTEM

PRIVATE LTD. P&I DIAGRAM
L&T-MHI BOILERS 97000-2115-1 1 BOILER CIRCULATING PUMP

PRIVATE LTD. SYSTEM P&I DIAGRAM
WPIL LIMITED P-HH-50273-78- 1 GA DRAWING OF DMCW PUMP FOR

GAD SG AUXILIARIES
WPIL LIMITED P-HH-50273-78- 1 CROSS SECTION DRAWING OF

CSD DMCW PUMP FOR SG AUXILIARIES
WPIL LIMITED P-HH-50273-78- 1 TECHNICAL DATASHEET DMCW

TDS PUMP FOR SG AUXILIARIES
MAHARASHTRA
WATER SYSTEM (SG)
2. SYSTEM DESCRIPTION
2.1 Flow Description

The DMCW system is a closed loop circuit that circulates passivated demineralized water
along to various coolers of Boiler auxiliaries within the scope of ‘steam turbine generator
& auxiliaries’ package. The heated DMCW is in turn cooled in Plate Heat Exchangers
(PHE) by the auxiliary cooling water system. Passivated demineralized quality water shall
be used in DMCW system for this purpose with provision for alternate supply from the
condensate system. The circulation of water in the closed circuit DMCW system will be
maintained by a set of horizontal centrifugal pumps (08PGB19AP001 / 002) & make-up to
the system will be catered from an overhead tank (08PGB19BB001) located on deaerator
roof. One (1) independent DMCW system, for SG auxiliaries shall be provided for each
unit. All DMCW pumps & PHE’s shall be located in the Ground Floor of Power House
Building of each 660 MW unit.
The DMCW system shall be designed to provide the necessary cooling water to the
following:
SG auxiliary coolers:
a) Forced Draft Fan and Motor

b) Forced Draft Fan
c) Primary Air Fan and Motor
d) Primary Air Fan
e) Induced Draft Fan and Motor
f) Induced Draft Fan
g) Air Preheater
h) Boiler Circulating Pump
i) Boiler Circulating Pump (Purge Water Cooling)
j) Pulverizer (32 R) – Lube Oil & Journal Cooling
k) Sampling Cooler
MAHARASHTRA
WATER SYSTEM (SG)
Consumption list of DMCW for TG auxiliaries’ coolers is given in Annexure I
2.2 Main Components

Cooling water system will have following components:
2.2.1 System Piping
2.2.2 DMCW Pumps
2.2.3 Plate Heat Exchangers
2.2.4 DMCW makeup Tank (Common for TG and SG System)
2.2.5 NaOH Dosing System (Common for TG and SG System)
2.2.6 Expansion tank inlet solenoid operated valve
2.2.1. System Piping

Two (3) individual pump discharge lines (08PGB19-BR320 / 315) of DN 250 mm join
together to form a common header (08PGB19-BR325) DN 250 mm which carries DMCW
water to PHEs.
Minimum recirculation line (08PGB19-BR355) is provided from the outlet of PHE common
discharge header to the pump suction header. From the outlet of PHEs cold water is sent
to various SG and auxiliaries coolers. Return line from all the coolers join to form return
header (08PGB19-BR300). Make-up water line (08PGB19-BR250) from make-up water
tank joins suction header to make up for the water losses in the circuit.
DMCW pipe will be manufactured from pipes confirming to IS 3589 /1239.
The piping 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 are provided to monitor water purity.
MAHARASHTRA
WATER SYSTEM (SG)
2.2.2. DMCW pumps

Technical details of the pump are as mentioned below. The pumps are capable of parallel
operation. The pumps are operated and controlled from the DCS. Each DMCW pump
discharge is provided with non-return valve (08PGB19-AA201/202) to prevent reverse
flow in stand-by pump and motor-operated butterfly valve (08PGB19AA001/002) for
isolation.
Technical details of DMCW pumps are as follows:
B SL. DESCRIPTION DMCW TG pumps

NO.
1.0 GENERAL
1.1. Total Number of
Two (1W+ 1S) per unit
pumps
1.2. No. of working
One (1)
pumps
1.3. No. of stand-by
One (1)
pumps
1.4. Liquid handled Passivated demineralized water
1.5. Type of pump Horizontal, centrifugal
1.6. Duty Continuous
1.7. Location Indoor
1.8. Design Temperature Deg.C 60
1.9. Design Code HIS
1.10. Performance Test
standard HIS
1.11. Rated capacity Per m3/hr

400
Pump
1.12. Total head developed mLC
45
at rated capacity
1.13. NPSHA mLC Flooded suction
1.14. Type of casing Axially Split casing
1.15. Impeller type Closed
1.16. Suction & Discharge
Class #150
connection and
ANSI B 16.5
Rating
2.0 Material of
Construction
2.1. Casing ASTM A 743 Gr CF 8M
2.2. Impeller ASTM A 743 Gr CF 8M
2.3. Wearing ring ASTM A 743 Gr CF 8M
2.4. Shaft SS 316
MAHARASHTRA
WATER SYSTEM (SG)
SL. DESCRIPTION DMCW TG pumps

NO.
2.5. Shaft Sleeves SS 316

2.6. Base Plate IS 2062
2.7. Common base plate for pump &
Mounting
motor
2.2.3. NaOH Dosing System

The pH of DM water in the circuit will be maintained around 9.5 by manually dosing
NaOH solution in the DMCW over head tank and DMCW pump suction header. For this
purpose one overhead sodium hydroxide solution dosing tank (08PGB19BB002) will be
provided at an elevation higher than DMCW tank, so that dosing solution is injected into
DM water by gravity flow.
2.2.4. Plate Type Heat Exchanger (PHE)

There will be Two (2 x 100%) Plate type Heat Exchangers (08PCD18AC001/002/) for SG
auxiliaries per unit i.e. total Six (6) PHE for three units. In PHEs, Passivated DM water will
B
be in primary side and plant Auxiliary Cooling Water (ACW) will be in secondary side.
DMCW system rejects heat to the plant ACW system, circulated through secondary side
of the heat exchangers. The heat exchangers are constructed of material suitable for the
auxiliary cooling water / DM water quality.
2.2.5. DMCW Expansion/ Make-up tank

The DMCW overhead tank (08PGB19BB001) will accommodate the expansion volume of
DMCW liquid due to temperature fluctuation in the system. Capacity of the tank will be 10
m3.
Level transmitters (08PGB19-CL101A/101B) will be connected to DCS and local level

B indicators (08PGB19-CL501) are also installed on each tank. Make-up to the tank is done
from either condensate system or from cycle make up pump.
3. DESIGN AND OPERATING PARAMETERS
Design parameters for the DMCW system

Design Pressure - 12 Kg/cm2 (g)
MAHARASHTRA
WATER SYSTEM (SG)
Design Temperature – 60 0C
Operating parameters for the DMCW system

Operating Pressure – 8.9 Kg/cm2 (g)
Operating Temperature – 36 0C
4. MODE OF OPERATION
4.1 Start up
 DM water will be pumped into system through the DM make-up line into the DMCW
expansion tank (08PGB19-BB001).
 During initial filling, high point vents in the piping system are to be kept open to
remove the entrapped air completely from the system.
 Check the suction (08PGB19-AA171/172) and discharge valves (08PGB19-

AA001/002) of the pumps (08PGB19-AP001/002) are fully open.
 Open the valves (08PGB19-AA165 & 08PGB19-AA110) downstream to tank to fill the
entire system by gravity.
 Once water starts overflowing from vent lines, close the vent lines.
 Once the level of cooling water in the expansion tank reaches high enough to satisfy
the pump start permissive, One (1) DMCW pump may be started and the 2nd pump
will be in auto mode. When the pump reaches the full speed, the discharge valve will
be fully opened and the discharge pressure will be checked with pressure transmitter
(08PGB19-CP106A/106B).
 Equipment cooled by this system is provided with valves in supply and return line at
suitable location in order to isolate the equipment from the system. It should be
ensured that the circulating cooling water must be flowing through the DMCW Heat
Exchanger before these valves are manually adjusted to regulate cooling water flow
through the equipment.
 Initial fill of the system will be stopped by closing the filling valve (08GHC27-AA170)
when the DMCW overhead tank level reaches high
 NaOH chemicals are to be added in the chemical tank during the end of the filling
process.
 The chemical tank is to be partially drained before adding the chemicals.

MAHARASHTRA
WATER SYSTEM (SG)
 Subsequent to loading the system, individual discharge throttling valves of plant

coolers are to be adjusted to control the outlet water temperature through the coolers.
 The auxiliary cooling water flow through the plate heat exchangers is to be adjusted
by manually operating the heat exchanger discharge (butterfly) valves, to bring the
DMCW supply temperature within specified limits.
 Once the temperatures have stabilized, the system is considered to be balanced.
4.2 Normal Operation
 The DMCW loop is in continuous service during plant operation and functions with
One (1) pump in operation. The second pump will remain in standby. The standby
DMCW pump is arranged for automatic start on an electrical trip of running pump or
low discharge header pressure after main pump running for a preset time.
 During normal operation, the solenoid operated valve (08GHC27-AA021) at the inlet
of the tank will get open or close signal through DCS for tank level make-up. If the
tank level is at low level the tank inlet valve will be opened and make-up water is
supplied from CEP discharge or cycle make up pump discharge. Valve will be closed
after the tank level high is reached. The level is controlled through the level
transmitter (LT-08PGB19CL101A & 08PGB19CL101B).
 Pumps have manually operated isolation (butterfly) valves (08PGB19AA-171/172) in

their suction and motor operated isolation (butterfly) valves (08PGB19-AA001/002)
with check valves (08PGB19AA201/202) provided in the pump discharge lines.
 During system operation, DMCW cooling water is cooled by two plate heat
exchangers (2 x 100%, 08PCD18-AC001, and 08PCD18-AC002) to a temperature
equal to 36 degC by plant auxiliary cooling water available at 33 degC.
 Temperature indicators are provided on inlet suction header and outlet of across each
PHE along with DPT (08PGB19CP155, 08PGB19CP156) across each PHE.
 Periodically, a grab sample should be taken for water chemistry analysis from the
head tank and PHE outlet.
 Corrosion inhibitor should be added as required into the chemical addition tank. The
drain point connection provided on any nearby cooler may be used to take a grab
sample for evaluating the distribution of corrosion inhibitor in the loop.
4.3 Abnormal Operation

The anticipated abnormal operation modes are as follows:
MAHARASHTRA
WATER SYSTEM (SG)
4.3.1. DeMineralised Cooling Water Pump Trip
 If the DeMineralised cooling water pump trips due to electrical failure, an alarm is
initiated in the DCS (common trouble alarm). With the tripping of one DMCW pump,
standby pump will come into the service. Operator needs to investigate and rectify the
cause of malfunction. If cause for the tripping identified in the short time, operator
needs to reset pump status from the DCS & pump will be kept on the stand-by.
However, if the cause is not identified in short time, operator needs to isolate the
pump.
4.3.2. DeMineralised Cooling Water Heat Exchanger Outage
 If more than one DMCW heat exchanger is out of service, plant load will have to be
reduced to the point that the DMCW outlet temperature does not exceed 36 degC.
4.3.3. DMCW Pump/ Motor Bearing Temperature High
 If the temperature of any DMCW 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.
4.3.4. DMCW Pump Motor Winding Temperature High
 If the temperature of any DMCW 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.
4.3.5. DMCW Pump Motor Current High
 If the current drawn by any of the DMCW 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 drawn continues to rise to a
predetermined high-high value, the motor protection relay will trip the pump.
4.4 Normal Shutdown
 If the DeMineralised cooling water system is to be shut down, stop the closed cooling
water pumps. During a prolonged outage, the water chemistry of the DMCW system
should be monitored periodically and corrosion inhibitor should be added as required.
Operation & Maintenance Manuals of DMCW pumps and plate heat exchangers
should be consulted for shutdown maintenance of this equipment.
MAHARASHTRA
WATER SYSTEM (SG)
5. INSTRUMENTATION & CONTROL
5.1 Open Loop Control
5.1.1 DMCW (SG) PUMP DISCHARGE MOV (08PGB19-AA001 / 002)
Purpose:
These valves are On/off type motor operated valve with open-close limit switch at the
discharge of DMCW Pumps which are provided for proper operation of the DMCW
system
Functional description:
It can be controlled manually or in Auto via the DCS. DMCW pump discharge MOVs will
be in closed conditions when no DMCW Pump is running. Respective MOV at each pump
discharge will open automatically within a preset time after the starting of any DMCW
pump. When selected in auto mode, if the selected pump (main pump) is running, then
discharge valve at the discharge of the non-running DMCW Pump (stand-by) will also
open in order to bring standby pump online quickly.
5.1.1.1 Controls and Monitoring
i. Permissive
Open Permissive
 Any DMCW(SG) running
Close Permissive
 Corresponding DMCW(SG) Pump is not running
ii. Auto Interlock
Auto Open Interlock

 Open command from group level
 These motorized valves open fully under automatic control when any pump is running
Auto Close Interlock

 Close command from group level
 These motorized valves close fully under automatic control when no pump is running
MAHARASHTRA
WATER SYSTEM (SG)
iii. Protective Override Commands
Override Open
 None
Override Close
 Corresponding Pump trips.
iv. References
This control description covers the process control functional logic requirement for
following equipment
 08PGB19AA001 DMCW(SG) PMP#A DSCH MOV
 08PGB19AA002 DMCW(SG) PMP#B DSCH MOV
Logic Diagram reference:

Equipment Tag Description Drawing Number Sheet Number
08PGB19AA001 DMCW (SG) PUMP#A L555-00I-00206 484A
DISCHARGE VALVE
08PGB19AA002 DMCW (SG) PUMP#B L555-00I-00206 485A
DISCHARGE VALVE
5.1.2 DMCW PUMP SUCTION VALVE (08PGB19-AA171 / 172)
Purpose:
These are manually operated butterfly valves for isolation purpose.
These valves are opened manually at the time of start-up and they remain locked open
during normal operation of the system. These valves are provided with open position limit
switches and the switches are wired into the DCS for monitoring and pump start
permissive interlock.
5.1.3 DMCW Overhead Tank Inlet SOV (08GHC27-AA0021)
Purpose:
MAHARASHTRA
WATER SYSTEM (SG)
This valve is provided for DMCW Tank make up in case of low level in DMCW tank.
Covered in DMCW (TG)
5.1.4 DMCW(SG) RECIR CV BYPASS MOV
Purpose:
To provide alternate path for the DMCW(SG) Pumps recirculation in case of failure of
recirculation control valve to maintain minimum flow through GSC.
This valve will operate in manual mode only.
References
following equipment
08PGB19AA007 DMCW(SG) Pumps recirculation CV bypass MOV

08PGB19AA007 DMCW(SG) Pumps recirculation L555-00I-00206 486
CV bypass MOV
5.1.5 DMCW(SG) PMP#A & PMP#B ( 08PGB19-AP001, 08PGB19-AP002)
Purpose:
Refer cl. No. 2.1.

The DMCW will be normally started and stopped manually from the DCS. One of the
pumps will be in standby and will start automatically upon loss of the running pump or
discharge header pressure low.
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.
MAHARASHTRA
WATER SYSTEM (SG)
Two pressure switches are provided at individual pump discharge to protect (trip) the
pump when pressure on pump discharge is high due to accidental closure of valve.
Under Normal operating condition the operator can select pumps in manual mode or Auto
mode. In Auto mode, start and stop command for the Pump will be given from Group
level based on the set sequence and permissive as defined in the group.
The DMCW pumps are also controlled manually by the operator from the DCS operator
interface console. 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.
5.1.5.1 Controls and Monitoring
i. Permissive
Start Permissive
 DMCW Overhead tank level not low

 Pump discharge valve closed (For first Pump)
 Pump and motor bearing temperature is not high
 Motor winding temperature is not high
 Pump suction Valve open
 DMCW system recirculation Valve in Auto or open (>5%)
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
MAHARASHTRA
WATER SYSTEM (SG)
Main Pump 1 Auto Standby
 running pump trips OR

 Header pressure low
At drive level auto operation of Stand-by pump is also possible.

Auto stop Interlock
 Stop command from group level.
iii.Protective Override Commands
Override Stop
 DMCW Overhead tank level low low.
 Pump discharge valve not fully open within a preset time after pump starting.
 Bearing temperature (either pump or motor) high high.
 Motor winding temperature high high.
 Vibration of the bearing of either pump or motor high high.
 Pump discharge pressure high due to accidental closure of valve (This can be
achieved through two pressure switches located at discharge of each DMCW pump ) .
iv.References
following equipment
 08PGB19AP001 DMCW(SG) PMP-A
 08PGB19AP002 DMCW(SG) PMP-B

08PGB19AP001 DMCW(SG) PMP-A L555-00I-00206 426A
08PGB19AP002 DMCW(SG) PMP-B L555-00I-00206 427A

MAHARASHTRA
WATER SYSTEM (SG)
5.2 Close Loop Control
5.2.1 TEMPERATURE CONTROL VALVES
5.2.2 DMCW (SG) PMP RECIRC CV(08PGB19AA052)
To protect the pump and piping system from high pressure during low flow conditions and
to meet the minimum flow requirement of the pump during startup and when header flow
is less than two pumps minimum recirculation flow.
All three DMCW pumps series is provided with common modulating type minimum flow
recirculation pressure control valve (08PGB19AA052). This recirculation control valve is
controlled via the DCS based on Differential Pressure across the supply and return
header downstream of Plate Heat exchangers. Differential Pressure Transmitter
(08PGB19CP157) senses the differential pressure and the controller generates a control
signal to modulate the recirculation pressure control valve (08PGB19AA052). The valve
normally controlled from DCS in auto mode, and provision is also made for opening
recirculation valves manually from the DCS.
References
following equipment
 08PGB19AP152 DMCW (SG) PMP RECIRC CV
08PGB19AP152 DMCW (TG) PMP RECIRC CV L555-00I-00253 488
5.3 Alarms
 DMCW Overhead tank level low.

 DMCW Overhead tank level low low.
 DMCW Overhead tank level high.
 DMCW Overhead tank level high high.
 Running pump trip.
MAHARASHTRA
WATER SYSTEM (SG)
 Bearing temperature (either pump or motor) high.

 Motor winding temperature high, high high
 Vibration of the bearing of either pump or motor high.
 DMCW temperature at PHE Outlet header high.
 DMCW temperature at PHE Inlet header high.
 Pump discharge Header pressure high high
 Pump discharge Header pressure low.
 Pump discharge Header pressure low low
 DP across PHE 08PCD18-AC003 high
 DP across PHE 08PCD18-AC004 high
 Pump suction Header Pressure low
 Pump suction Header Pressure low low
MAHARASHTRA
WATER SYSTEM (SG)
ANNEXURE I
Quantity/unit Total
Sl. Flow
Description of cooler
No. Working Stand-by
m3/hr
Equipment requiring Aux cooling water
1. FD fan and motor - lube oil cooler 2 2 4
2. FD fan - hydraulic oil cooler 2 2 2.88
3. PA fan and motor - lube oil cooler 2 2 5
4. PA fan - hydraulic oil cooler 2 2 2.88
5. ID fan and motor - lube oil cooler 2 2 8.08
6. ID fan - hydraulic oil cooler 2 2 4.8
Air preheater - lube oil cooler 2 2 0.8
7. Boiler circulating pump motor cooler 1 1 17.5
8. Boiler circulating pump purge water cooler 1 1 11
Pulverizer (32 R) - lube oil cooler 4 2 140
9. Pulverizer (32 R) journal oil cooler 4 2 10
10. Sampling cooler 4 0 17.8

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

LARSEN & TOUBRO LIMITED

REVISION SUMMARY SHEET

REV. DETAILS / DESCRIPTION DATE

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

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

II. ELECTRICAL DRAWINGS AND DOCUMENTS ...................................................................................... 6

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

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

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

2.2.2. DMCW PUMPS ............................................................................................................................. 9

2.2.3. NAOH DOSING SYSTEM .............................................................................................................. 10

2.2.4. PLATE TYPE HEAT EXCHANGER (PHE) ......................................................................................... 10

2.2.5. DMCW EXPANSION/ MAKE-UP TANK ............................................................................................ 10

3. DESIGN AND OPERATING PARAMETERS ................................................................................................ 10

4. MODE OF OPERATION .................................................................................................................................... 11

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

4.3 ABNORMAL OPERATION ............................................................................................................... 12

4.3.1. DEMINERALISED COOLING WATER PUMP TRIP .............................................................................. 13

4.3.2. DEMINERALISED COOLING WATER HEAT EXCHANGER OUTAGE ...................................................... 13

4.3.3. DMCW PUMP/ MOTOR BEARING TEMPERATURE HIGH ................................................................... 13

4.3.4. DMCW PUMP MOTOR WINDING TEMPERATURE HIGH .................................................................... 13

4.3.5. DMCW PUMP MOTOR CURRENT HIGH ......................................................................................... 13

4.4 NORMAL SHUTDOWN ................................................................................................................... 13

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

5.1.1 DMCW (SG) PUMP DISCHARGE MOV (08PGB19-AA001 / 002) ............................................. 14

5.1.2 DMCW PUMP SUCTION VALVE (08PGB19-AA171 / 172) ....................................................... 15

5.1.3 DMCW OVERHEAD TANK INLET SOV (08GHC27-AA0021) .......................................................... 15

5.1.4 DMCW(SG) RECIR CV BYPASS MOV ..................................................................................... 16

5.1.5 DMCW(SG) PMP#A & PMP#B ( 08PGB19-AP001, 08PGB19-AP002) ...................................... 16

5.2 CLOSE LOOP CONTROL ............................................................................................................... 19

5.2.1 TEMPERATURE CONTROL VALVES ...................................................................................... 19

5.2.2 DMCW (SG) PMP RECIRC CV(08PGB19AA052) ..................................................................... 19

5.3 ALARMS ..................................................................................................................................... 19

1.2 Reference Drawings & Documents

AUTHORING DOCUMENT NO. SHT DESCRIPTION

L&T-S&L L555-08M-00212 1-2 P&IDs DMCW system

L&T-S&L l555-08M-00111 1-16 Design Criteria For DMCW system

ii. Electrical Drawings and Documents

AUTHORING DOCUMENT NO. SHT DESCRIPTION

WPIL LIMITED M-HH-50273-78- 1 MOTOR GAD FOR DMCW PUMP FOR

WPIL LIMITED M-HH-50273-78- 9 MOTOR DATASHEET FOR DMCW

iii. Vendor-Supplied Drawings and Documents

AUTHORING DOCUMENT NO. SHT DESCRIPTION

L&T-MHI BOILERS 97000-2612 1 CLOSED CYCLE COOLING WATER

L&T-MHI BOILERS 97000-2122 1 CLOSED COOLING WATER SYSTEM

L&T-MHI BOILERS 97000-2115-1 1 BOILER CIRCULATING PUMP

WPIL LIMITED P-HH-50273-78- 1 GA DRAWING OF DMCW PUMP FOR

WPIL LIMITED P-HH-50273-78- 1 CROSS SECTION DRAWING OF

WPIL LIMITED P-HH-50273-78- 1 TECHNICAL DATASHEET DMCW

2.1 Flow Description

a) Forced Draft Fan and Motor

Consumption list of DMCW for TG auxiliaries’ coolers is given in Annexure I

2.2 Main Components

2.2.1 System Piping

2.2.2 DMCW Pumps

2.2.3 Plate Heat Exchangers

2.2.4 DMCW makeup Tank (Common for TG and SG System)

2.2.5 NaOH Dosing System (Common for TG and SG System)

2.2.6 Expansion tank inlet solenoid operated valve

2.2.1. System Piping

DMCW pipe will be manufactured from pipes confirming to IS 3589 /1239.

2.2.2. DMCW pumps