SOP HRSG

23 

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STANDARD OPERATING PROCEDURE STANDARD OPERATING PROCEDURE

1.

1. SYSYSTSTEEM NM NAAMEME: HEAT RECOVERY STEAM GENERATOR.: HEAT RECOVERY STEAM GENERATOR. 2.

2. OBOBJJECECTTIVIVE:E:

The Heat Recovery Steam Generators (HRSG) ut!"e# n the Com$ne# Cyc!e The Heat Recovery Steam Generators (HRSG) ut!"e# n the Com$ne# Cyc!e %!ants& carres out the 'uncton to ro#uce steam to su!y the Steam Tur$nes %!ants& carres out the 'uncton to ro#uce steam to su!y the Steam Tur$nes (ST)& ut!"n the therma! enery o' the Gas*Tur$nes (GT) e+haust as& $e'ore (ST)& ut!"n the therma! enery o' the Gas*Tur$nes (GT) e+haust as& $e'ore #scharn t to atmoshere $y means o' the $o!er stac,.

#scharn t to atmoshere $y means o' the $o!er stac,.

3.

3. SYSYSTSTEM DEM DESESCRCRIPIPTITIONON::

To carry out ths 'uncton& the HRSG are !ocate# #o-nstream the GT an# are To carry out ths 'uncton& the HRSG are !ocate# #o-nstream the GT an# are contane# n casns to 'ormn an e+tenson o'

contane# n casns to 'ormn an e+tenson o' the GT ases e+haust #ucts.the GT ases e+haust #ucts. The steam

The steam eneneraeratortors s are are o' o' mu!mu!ttttu$uu$u!ar !ar tytye e an# an# stesteam am #ru#rum& m& natnaturaura! ! or or  actvate# -ater crcu!aton& -th

actvate# -ater crcu!aton& -th econom"er an# suer heater.econom"er an# suer heater. The

The e+he+hausaust t asases es comcomn n 'ro'rom m the the GT GT crocrosssses& es& n n seseueuencence& & the the #s#stntnctct comonents o' steam enerators to trans'er to them the heat 'or convecton comonents o' steam enerators to trans'er to them the heat 'or convecton mo#e.

mo#e.

The 'ee# -ater re*heate# n the econom"er& '!o-s n the evaorator an# the The 'ee# -ater re*heate# n the econom"er& '!o-s n the evaorator an# the saturate# steam ro#uce# s co!!ecte# n the steam #rum& !ocate# n the uer  saturate# steam ro#uce# s co!!ecte# n the steam #rum& !ocate# n the uer  "one o' the steam enerator. The steam crosses then the suer heater an# s "one o' the steam enerator. The steam crosses then the suer heater an# s #e!vere# to the ST.

#e!vere# to the ST.

To contro! the $o!er out!et steam temerature& the suer heater s rov#e# -th To contro! the $o!er out!et steam temerature& the suer heater s rov#e# -th #esuerheater

#esuerheater& -hch may $e o' -ater & -hch may $e o' -ater sray tye or sur'ace tye.sray tye or sur'ace tye. /n the com$ne# cyc!e

/n the com$ne# cyc!e unt o' !are unt o' !are caactycaacty& 'or technue an# & 'or technue an# economc reasons&economc reasons& th

the e ststeaeam m eeneneraratotors rs arare e susu$#$#vv##e# e# n n t-t-o o or or ththreree e sesectctoonsns& & o' o' hhhh&& nterme#ate an# !o- ressure& an# the re!evant heat e+chaner e!ements are nterme#ate an# !o- ressure& an# the re!evant heat e+chaner e!ements are co

convnveneneentnt!y !y ##ststrr$u$utete# # a!a!onon  ththe e cocoururse se o' o' ththe e GT GT e+e+hahausust t aas. s. TThehe suerheate# steam ro#uce# $y the #''erent sectons o' the steam enerators& s suerheate# steam ro#uce# $y the #''erent sectons o' the steam enerators& s conveye#& resectve!y

conveye#& resectve!y& to the & to the hh& nterme#ate an# !o- hh& nterme#ate an# !o- sectons o' ST.sectons o' ST. /n

/n some cases the HRSG some cases the HRSG are rov#e# -th su!emeare rov#e# -th su!ementary 'rn& !ocatentary 'rn& !ocate# # n then the e+

e+hauhaust st as as #uc#uct t usustretream am o' o' the the susuerherheateate# e# to to ncncrearease se the the susuererheaheate#te# steam temerature.

steam temerature.

The Heat Recovery Steam Generator s a #ua! steam ressure tye& natura! The Heat Recovery Steam Generator s a #ua! steam ressure tye& natura! crcu!aton& -thout su!ementary 'rn. The suerheate# steam ro#uce# at crcu!aton& -thout su!ementary 'rn. The suerheate# steam ro#uce# at #''erent ressure s ut!"e# to 'ee# the hh an# !o- ressure o' Steam Tur$ne #''erent ressure s ut!"e# to 'ee# the hh an# !o- ressure o' Steam Tur$ne sectons. A 0#verter #amer1. 2ocate# at the entrance o' the GT e+haust as o'  sectons. A 0#verter #amer1. 2ocate# at the entrance o' the GT e+haust as o'  the HRSG& ermts to e+c!u#e the $o!er #scharn the e+haust as #rect!y to the HRSG& ermts to e+c!u#e the $o!er #scharn the e+haust as #rect!y to atmoshere& -henever t s necessary.

atmoshere& -henever t s necessary.

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The HRSG heatn sur'aces are #v#e# n the 'o!!o-n sectons& n the #recton The HRSG heatn sur'aces are #v#e# n the 'o!!o-n sectons& n the #recton o' the e+haust as '!o-:

o' the e+haust as '!o-:

-- H% suer heater 6H% suer heater 6

H%

H% suer suer heater heater 55

-- H% evaorator H% evaorator 

*

* H% H% econom"er econom"er 66

-- 2% suer heater2% suer heater

-- 2% evaorator 2% evaorator 

-- H% econom"er 5 n ara!!e! -th H% econom"er 5 n ara!!e! -th 2% econom"er 2% econom"er 

The heatn sur'aces are assem$!e# n mo#u!es& searate# $y cavtes. The heatn sur'aces are assem$!e# n mo#u!es& searate# $y cavtes.

/n the n!et #uct a ressure transmtter& a ressure n#cator an# t-o ressure tan /n the n!et #uct a ressure transmtter& a ressure n#cator an# t-o ressure tan ont are rov#e#.

ont are rov#e#. S+

S+ temtemereratuature re tatann  oont& nt& one one ococcucue# e# $y $y a a thethermormocoucou!e!e& & are are rorovv#e##e# ustream H% suer heater 6.

ustream H% suer heater 6.

/n each cavty s+ temerature tan ont are rov#e#& three each s#e& one /n each cavty s+ temerature tan ont are rov#e#& three each s#e& one occue# $y a thermocou!e 'tte# 'or suervson o' the as temerature ro'!e a!on occue# $y a thermocou!e 'tte# 'or suervson o' the as temerature ro'!e a!on the heatn

the heatn sur'aces.sur'aces.

3o-nstream the $an,s& at the n!et o' the stac,& s+ temerature tan ont& one 3o-nstream the $an,s& at the n!et o' the stac,& s+ temerature tan ont& one occue# $y a thermocou!e& are rov#e#. 8our ressure*tan onts are a!so occue# $y a thermocou!e& are rov#e#. 8our ressure*tan onts are a!so r

rovov##e#e#& & onone e ococcucue# e# $y $y a a !o!ocaca! ! rresessusure re nn##cacatotor r anan# # onone e $y $y a a rresessusurere transmtter to contro! room.

transmtter to contro! room.

 A!! the nstruments rov#e# 'or the e+

 A!! the nstruments rov#e# 'or the e+haust as system havhaust as system have the on!y urose o'e the on!y urose o' !oca! or remote suervson.

!oca! or remote suervson.

HRSG HIGH PRESSURE LEVEL HRSG HIGH PRESSURE LEVEL

The HRSG hh*ressure !eve! has the urose to enerate H% steam at the The HRSG hh*ressure !eve! has the urose to enerate H% steam at the correct ressure& temerature& an# ua!ty n accor#ance -th the heat ava!a$!e correct ressure& temerature& an# ua!ty n accor#ance -th the heat ava!a$!e 'rom the GT e+haust as an# reurements o' the ST.

'rom the GT e+haust as an# reurements o' the ST.

8or ths urose& t -!! $e su!e# -th the #ue amount o' 'ee# -ater at any tme 8or ths urose& t -!! $e su!e# -th the #ue amount o' 'ee# -ater at any tme #urn ts oeraton: stea#y !oa#& start*u

#urn ts oeraton: stea#y !oa#& start*u or !oa# chanes.or !oa# chanes.

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The H% suerheate# steam -!! $e su!e# to the ST throuh the H% man steam n system.

The H% system s eue# -th nterme#ate #esuerheater to contro! the man steam out!et temerature at the #esre# va!ue n any oeratn con#ton.

The H% #rum !eve! contro! staton s !ocate# #o-nstream the H% econom"er to revent 'rom steamn n the econom"er tse!'& 'or 'ee# -ater !o- '!o- #urn the start*u.

HP SECTION STEAM GENERATOR

The hh ressure secton o' steam enerator s !ocate# #o-nstream the e+haust as n!et to the HRSG an# ts heatn sur'ace s ma#e o' 'nne# tu$es& crosse# $y he hot as n the 'o!!o-n or#er:

- H% Suer heater 6 - H% Suer heater 5 - H% Evaorator - H% Econom"er 6 - H% Econom"er 5.

9ater 'rom the H% 'ee# -ater !ne enters the H% econom"er 5 an# 6& n counter  '!o- -th resect to the e+haust as& -here t s heate# u to the arorate econom"er out!et temerature an# s then #e!vere# to the H% #rum.

The H% econom"ers 5 an# 6 are eue# -th manua! #rans an# vents.

 A #rum !eve! contro! staton s !ocate# #o-nstream the H% econom"er an# conssts o' t-o man 'ee# -ater contro! va!ves suta$!e to contro! the H% #rum !eve! n the rane 4*544; MCR (one n stan#*$y) an# a !o- !oa# 'ee# -ater contro! va!ve suta$!e 'or !oa#s $e!o- 4; MCR.

Each !eve! contro! va!ve s rov#e# -th one ntercetn motor"e# on*o'' va!ve ustream an# one ntercetn manua! on*o'' va!ve #o-nstream. Suta$!e manua! #rans are a!so rov#e# $et-een the ntercetn va!ves an# the contro! va!ves to emty the !nes n case o' contro! va!ves mantenance.

<stream the contro! staton a sa'ety va!ve s rov#e#.

Once -ater has entere# the H% #rum& t 'a!!s #o-n throuh the #o-n comers an# reaches the n!et hea#er o' the H% evaorator. The H% evaorator $an,

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enerates steam heatn the -ater -th the hot as& -hch asses throuh the $an, n cross*'!o-. The resu!tn -ater an# steam m+ture can o u throuh a natura! crcu!aton !oo to the evaorator out!et hea#ers an# then aan to the H% #rum throuh some connectn es (ca!!e# rsers)& un'orm!y #str$ute# a!on the #rum !enth.

The $o!er #rum has the am to:

- Ensure a oo# m+n $et-een n!et 'ee# -ater an# $o!er -ater  - Consttute a -ater reserve reure# 'or the crcu!aton system -  A!!o- -ater e+anson #urn start*u

- Ensure oo# -ater an# steam searaton.

The #rum caacty s se!ecte# to ensure a sta$!e an# sa'e oeraton un#er a!! the nomna! oeratve con#tons. The steam an# -ater searaton s acheve# $y means o' arorate rmary (cyc!one tye) an# secon#ary scru$$ers (corruate# !ates tye). /n the cyc!ones a mechanca! centr'ua! searaton occurs n the m+ture o' saturate# -ater an# steam comn 'rom the rsers. Searate# -ater 'a!!s #o-n n the cyc!ones to the #rum -h!e saturate#

Steam s conveye# to the secon#ary scru$$ers -here a tortuous ath ma,es t vrtua!!y #ry.

 A chemca! #osn !ne 'or hoshates are 'oreseen n the H% #rum n or#er to contro! $o!er -ater H to a suta$!e va!ue. A $!o-*#o-n !ne& eue# -th a motor"e# on*o'' va!ve (-th #ou$!e manua! $y*ass va!ve) an# a manua! contro! va!ve& s 'oreseen to contro! $o!er -ater con#uctvty. A $!o-*o'' !ne& eue# -th a manua! on*o'' va!ve an# a motor"e# nchn tye va!ve& s a!so 'tte# to contro! #rum s-e!!n #urn the start*u.

 A #e#cate# !ne a!so ensures sam!n o' the $!o-*#o-n -ater.

The H% #rum s eue# -th t-o sa'ety va!ves -th s!encers& three !eve! transmtters ressure comensate# 'or contro!& a!arm an# tr uroses& an# s+ s,n meta! temerature thermocou!es& 'or suervson an# a!arm. T-o hy#ra ste tye !eve! n#cators to contro! room an# t-o !eve! aues (!oca! #rum !eve! n#cators) are rov#e# 'or remote an# !oca! suervson.

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Saturate# steam '!o-s 'rom the H% #rum to H% suer heater 5 n!et throuh connectn n. 8or the con#uctvty montorn o' the saturate# steam s 'oreseen a sam!n !ne& -h!e a motor"e# on*o'' vent va!ve s rov#e# n the connectn n& to $e c!ose# #urn the $ennn o' the ressursaton.

8rom the H% suer heater 5 the steam& '!o-n n counter '!o- -th resect to the e+haust as& enters the nterme#ate #esuerheater& use# to !mt the man steam temerature (#o-nstream H% suer heater 6) at the #esre# va!ue n any oeratn con#ton an# then reaches the H% suer heater 6.

Seven s,n meta! thermocou!es are 'tte# at the out!et o' ths $an, to montor  an# a!arm the re!evant meta! temerature.

>oth H% suer heater 5 an# 6 are eue# -th motor"e# #ran va!ves& to $e use# #urn start*u or !oa# varatons to ensure no con#ensate reman ns#e the suer heater tu$es.

HP MAIN STEAM PIPING

Man steam n s rov#e# -th:

-  A sa'ety va!ve -th s!encer?

-  A '!o- meter& eue# -th #ou$!e transmtters& #ou$!e temerature an#

ressure transmtters 'or '!o- measurements comensaton.

- 2oca! temerature an# ressure n#cators.

The t-o temerature transmtters are a!so use# 'or man steam temerature contro! uroses.

 A sam!n !ne s rov#e# 'or the suerheate# steam ua!ty montorn.

 A start*u motor"e# nchn tye vent& com!ete -th re!evant s!encer& s 'oreseen to !mt the H% #rum ressure ra#ent #urn HRSG start*u. An e!ectrometrc va!ve& com!ete -th an ntercetn manua! on*o'' va!ve an# s!encer& s rov#e# to revent 'rom H% suer heater sa'ety va!ve oenn.

 A motor"e# on*o'' va!ve& ate tye& s !ocate# n HRSG area to ntercet man steam n an# $o!er so!aton. Ths va!ve s eue# -th a motor oerate# $y*ass va!ve 'or the steam !ne -armn.

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3o-nstream o' the HRSG so!atn va!ve& the $ranch 'or the tur$ne $y*ass s rov#e#.

Chemca! c!eann connecton n the man steam e s a!so rov#e#.

HRSG LOW PRESSURE LEVEL

The HRSG !o-*ressure !eve! has the urose to enerate 2% steam at a correct ressure& temerature an# ua!ty to the !o-*ressure stae o' the ST.

8or ths urose& t -!! $e su!e# -th the #ue amount o' 'ee# -ater at any tme #urn ts oeraton: stea#y !oa#& start*u or !oa# chanes.

The 2% suerheate# steam -!! $e su!e# to the ST throuh the 2% man steam n system.

The 2% #rum !eve! contro! staton s !ocate# #o-nstream the 2% econom"er to revent 'rom steamn n the econom"er tse!'.

LP SECTION STEAM GENERATOR

The !o- ressure secton o' steam enerator s !ocate# #o-nstream the e+haust as n!et to the HRSG $ehn# the H% !eve! an# ts heatn sur'ace s ma#e o'  'nne# tu$es& crosse# $y he hot as n the 'o!!o-n or#er:

- 2% Suer heater - 2% evaorator - 2% Econom"er

9ater 'rom the 2% 'ee# -ater !ne enters the 2% econom"er& n counter '!o- -th resect to the e+haust as& -here t s heate# u to the arorate econom"er  out!et temerature an# s then #e!vere# to the 2% #rum.

The 2% econom"er s eue# -th manua! #rans an# vents.

 A #rum !eve! contro! staton s !ocate# #o-nstream the 2% econom"er an# conssts o' t-o man 'ee# -ater contro! va!ves suta$!e to contro! the 2% #rum

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!eve! n the rane 4*544; MCR (one n stan#*$y). Each !eve! contro! va!ve s rov#e# -th one ntercetn motor"e# on*o'' va!ve ustream an# one ntercetn manua! on*o'' va!ve #o-nstream.

<stream the contro! staton a sa'ety va!ve s rov#e#.

Once -ater has entere# the 2% #rum& t 'a!!s #o-n throuh the #o-n comers an# reaches the n!et hea#er o' the 2% evaorator. The 2% evaorator $an, enerates steam heatn u the -ater -th the hot as -hch ass throuh the $an, n cross*'!o-. The resu!tn -ater an#

Steam m+ture can o u throuh a natura! crcu!aton !oo to the evaorator  out!et hea#ers an# then aan to the 2% #rum throuh some connectn es (ca!!e# rsers) un'orm!y #str$ute# a!on the #rum !enth.

The $o!er #rum has the am to:

- Ensure a oo# m+n $et-een n!et 'ee# -ater an# $o!er -ater  - Consttute a -ater reserve reure# 'or the crcu!aton system -  A!!o- -ater e+anson #urn start*u

- Ensure oo# -ater an# steam searaton.

The #rum caacty s se!ecte# to ensure a sta$!e an# sa'e oeraton un#er a!! the nomna! oeratve con#tons. The steam an# -ater searaton s acheve# $y means o' arorate rmary (cyc!one tye) an# secon#ary scru$$ers (corruate# !ates tye). /n the cyc!ones a mechanca! centr'ua! searaton occurs n the m+ture o' saturate# -ater an# steam comn 'rom the rsers. Searate# -ater 'a!!s #o-n n the cyc!ones to the #rum -h!e saturate# steam s conveye# to the secon#ary scru$$ers -here a tortuous ath ma,es t vrtua!!y #ry. A chemca! #osn !ne 'or hoshates s 'oreseen n the 2% #rum n or#er to contro! $o!er -ater H to a suta$!e va!ue. A $!o-*#o-n !ne& eue# -th a motor"e# on*o'' va!ve (-th manua! $y*ass va!ve) an# a manua! contro! va!ve& s 'oreseen to contro! $o!er -ater con#uctvty. A $!o-*o'' !ne& eue# -th a manua! on*o'' va!ve an# a motor"e# nchn tye va!ve& s a!so 'tte# to contro! #rum s-e!!n #urn the start*u.

 A #e#cate# !ne a!so ensures sam!n o' the $!o-*#o-n -ater.

The 2% #rum s eue# -th t-o sa'ety va!ves -th s!encers& three !eve! transmtters ressure comensate# 'or contro!& a!arm an# tr uroses& an# a

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s,n meta! temerature thermocou!e ('or suervson an# a!arm). T-o hy#ra ste tye !eve! n#cators to contro! room an# t-o !eve! aues (!oca! #rum !eve! n#cators) are rov#e# 'or remote an# !oca! suervson.

Saturate# steam '!o-s 'rom the 2% #rum to 2% suer heater n!et throuh connectn n. 8or the con#uctvty montorn o' the saturate# steam s 'oreseen a sam!n !ne& -h!e a motor"e# on*o'' vent va!ve& s rov#e# n the connectn n& to $e c!ose# #urn the $ennn o' the ressursaton. 8rom the 2% suer heater out!et the steam s conveye# to the 2% man steam n.

The 2% suer heater s eue# -th a motor"e# #ran va!ve& to $e use# #urn start*u or !oa# varatons to ensure no con#ensate reman ns#e the suer heater tu$es.

No temerature contro! s necessary on the 2% suer heater as the 2% man steam temerature s very !o- an# remans sta$!e n the norma! $o!er oeratve rane.

LP STEAM PIPING

The am o' ths e s to !ea# the !o- ressure steam to the !o- ressure stae o' the ST.

Steam n s rov#e# -th:

-  A sa'ety va!ve -th s!encer?

-  A '!o- meter& eue# -th #ou$!e transmtters& #ou$!e temerature an#

ressure transmtters 'or '!o- measurement comensaton?

- 2oca! temerature an# ressure n#cators.

 A sam!n !ne s rov#e# 'or the suerheate# steam ua!ty montorn.

 A start*u motor"e# nchn tye vent& com!ete o' s!encer& s 'oreseen to !mt the 2% #rum ressure ra#ent #urn HRSG start*u.

 A motor"e# on*o'' va!ve& com!ete -th re!evant motor"e# $y*ass& s !ocate# n HRSG area to ntercet man steam n.

HRSG DRAINS AND VENTS SYSTEM

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The system 'u!'!s the 'o!!o-n reurements:

- Co!!ects an# #schares $!o-*o'' -ater 'rom the #rums #urn start*u to the

atmosherc '!ash tan,

- Co!!ects -ater 'rom the suer heater #rans to the atmosherc '!ash tan,

- Co!!ects -ater 'rom the econom"er an# evaorator #rans to the atmosherc

'!ash tan,& -hen ths oeraton s necessary to emty the $o!er 

- Co!!ects an# #schares $!o-*#o-n -ater 'rom the #rums #urn norma!

oeraton to the atmosherc '!ash tan,

- Co!!ects #rum an# econom"er vents an# sa'ety an# e!ectrometrc va!ve

#rans to the atmosherc '!ash tan,

- 3e!vers co!!ecte# -ater n the '!ash tan, to the !ant #ranae system.

FUNCTIONAL DESCRIPTION

The -ater co!!ecte# ns#e the atmosherc tan, '!ashes an# s s!tte# n t-o arts: steam s conveye# to a s!ence# vent an# then s #schare# to the atmoshere? the remann -ater s co!!ecte# to the !ant #ranae system.

HRSG NITROGEN FILLING SYSTEM

The system 'u!'!s the reurement to carry out HRSG -et conservaton (!ay*u) n case o' !on shut#o-n.

FUNCTIONAL DESCRIPTION

The system conssts o' a ntroen tan, connecte# to 2% an# H% saturate# steam es (the hhest HRSG onts) an# 'e# $y a ntroen e connecte# to a ntroen $ott!es set com!ete o' a sa'ety va!ve an# a ressure re#ucn va!ve. 3emnera!se# -ater s use# to '!! the HRSG u to the m##!e o' the ntroen tan,? ntroen s then ntro#uce# n the tan, at a very !o- ressure ( 6 $ar).

%ressure an# -ater !eve! n the tan, can $e eas!y montore# $y means o'  #e#cate# !oca! nstruments.

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Once -ater !eve! or ressure #ecrease& -ater or ntroen have to $e 'urther  ntro#uce#.

RATING

The uantty o' suerheate# steam enerate# ($oth 2%  H%) <n#er GT !oa# o' 544; an# 6DoC am$ent are as 'o!!o-s:

a. H% steam F @6.7 sec at B=.5 Gcm6 an# 76BoC $. 2% steam F 57.7 sec at 7.B Gcm6 an# 64BoC PRE-REQUISITES:

 No %T9 en#n 'or HRSG (H%2% system) an# mantenance actvty& -hch cou!# mact the start*u oeratons& s over.

 Ensure that the nee#e# nsectons 'o!!o-n to a !on ero# o' nactvty a'ter shut#o-n have $een carre# out.

  A!! MOVs meer va!ues shou!# $e O..   A!! euments roer!y earthe#.

  A!! contro! va!ves 'unctona! chec,e# com!ete#.

  A!! the nstruments are !ne# u an# suervson system an# the recor#ers are n servce.

 Ensure HRSG sum um s auto ava!a$!e.

 3M -ater storae tan, !eve! s norma! 'or startu.

 Ensure 3M -ater #str$uton um& CE%& 2%>8%& H%>8% s ava!a$!e 'or  oeraton.

 Ensure that the e!ectrca! automaton system an# the re!evant trans#ucers are n servce.

 Ensure that the sa'ety ru!es are correct!y met.

 Ensure that a!! the man manua! va!ves are n ther correct oston.  Chec, that the 're rotecton system s ava!a$!e.

 Chec, that e!ectrca! su!es are ava!a$!e.

 Ensure that a!! the nstrument mu!se !ne*so!atn va!ves are oen an# the eua!"n va!ves are c!ose#.

 Chec, that the Natura! as or NahthaHS3 'ue! systems are ava!a$!e.

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 Ensure that the 9aste 9ater Treatment System an# the HVAC System are norma!!y oeratn.

 %er'orm a!! the #eta!e# re*chec,s sec'e# $y the manu'actures an# ut the re!evant #rves n A<TO mo#e.

 Ensure that a!! the va!ves& nc!u#n coc, va!ves& are not un#er  mantenance an# n the correct oston.

Ensure that a!! the sa'ety va!ves are #senae# an# ther re!evant srn acton s e''cent.

 Ensure that the HRSG #rums !eve! s at !east at start*u !eve! an# '!! them& ' necessary.

 Chec, that the Chemca! 3osn System s rea#y.

 Chec, that the HRSG #ran an# vent va!ves are n automatc mo#e

SAFETY CHECS:

5.8re #etecton an# 8re a!arm system 'or a!! areas shou!# $e ava!a$!e. 6.8re hoses shou!# !ace a!! hose $o+es.

.A!! the va!ves shou!# $e 'ree 'or oeraton.

HYDRO TEST OF HP SYSTEM:

 Oen the econom"er 56 vent va!ve.  Oen #rum vent va!ve -th so!aton va!ve.  Oen evaorator vent va!ve.

 Oen suer heater 5 6 vent va!ve.

  C!ose the $!o- #o-n an# $!o- o'' so!aton va!ve.

 2oc, the h econom"er& h #rum ($oth)& an# h suer heater sa'ety va!ve 'or reventn the ou.

 ee the ERV n manua! mo#e.

  C!ose the H%MS shuto'' va!ve an# ts $yass va!ve.  Oen the h eco n!et va!ve.

 Oen the nta! '!!n va!ve 'rom 3M -ater #str$uton um.

 ee the 'ee# contro! va!ves (6I544; J5I4;)n manua! oeraton mo#e.

 Start the one 3M -ater #str$uton um an# oen the #schare va!ve o' the um.

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 /' contnuous -ater s comn 'rom the eco vent& c!ose the eco vent.

 Sto the 3M -ater #str$uton um an# c!ose the #schare va!ve o'  the um.

 C!ose the nta! '!!n va!ve 'rom 3M -ater #str$uton um.

 Start one H%>8% -th chemca! nKecton as er chemca! reurement.  Oen the manua! so!aton va!ve an# MOV o' 4; contro! va!ve.

  S!o-!y oen the 4; contro! va!ve manua!!y ma+mum u to 4;.  O$serve the H%>8% #schare ressure.

 Oen or c!ose the 4; contro! va!ve $y ,een the H%>8% #schare ressure more than 564 $ar.

 /' contnuous -ater s comn 'rom the suer heater 56 vents& c!ose the resectve vent.

 /' h #rum !eve! reache# hh* hh va!ue (74 mm) an# contnuous -ater s comn 'rom the H% #rum vent& c!ose the vent.

 O$serve the #rum ressure ' t s more than 54 $ar& c!ose the 4; contro! va!ve an# ts MOV.

 Sto the H%>8% an# c!ose the #schare an# ts $yass va!ve.  O$serve the #rum ressure 'or 4 mnutes.

 /' #rum ressure s ho!#n 54 $ars u to 4mnutes than t s conc!u#e# that hy#ro test s com!ete# success'u!!y an# system s !ea, roo'.

HYDRO TEST OF LP SYSTEM:

 Oen the econom"er vent va!ve.

 Oen #rum vent va!ve -th so!aton va!ve.  Oen evaorator vent va!ve.

 Oen suer heater vent va!ve.

  C!ose the $!o- #o-n an# $!o- o'' so!aton va!ve.

 2oc, the 2% econom"er& 2% #rum ($oth)& an# 2% suer heater sa'ety va!ve 'or reventn the ou.

 ee the ERV n manua! mo#e.

  C!ose the 2%MS shuto'' va!ve an# ts $yass va!ve.  Oen the 2%ECO n!et va!ve.

 Oen the nta! '!!n va!ve 'rom 3M -ater #str$uton um.

  ee the 'ee# contro! va!ves (6I544;)n manua! oeraton mo#e.

 Start the one 3M -ater #str$uton um an# oen the #schare va!ve o' the um.

 /' contnuous -ater s comn 'rom the eco vent& c!ose the eco vent.

 Sto the 3M -ater #str$uton um an# c!ose the #schare va!ve o'  the um.

 C!ose the nta! '!!n va!ve 'rom 3M -ater #str$uton um.

 Start one 2%>8% -th chemca! nKecton as er chemca! reurement.

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 Oen the manua! so!aton va!ve an# MOV o' one contro! va!ve.   S!o-!y oen the contro! va!ve manua!!y ma+mum u to 57;.  O$serve the 2%>8% #schare ressure.

 Oen or c!ose the contro! va!ve $y ,een the 2%>8% #schare ressure more than 64 $ar.

 /' contnuous -ater s comn 'rom the suer heater vents& c!ose the resectve vent.

 /' h #rum !eve! reache# hh* hh va!ue (644 mm) an# contnuous -ater s comn 'rom the H% #rum vent& c!ose the vent.

 O$serve the #rum ressure ' t s more than 56 $ars? c!ose the contro! va!ve an# ts MOV.

 Sto the 2%>8% an# c!ose the #schare an# ts $yass va!ve.  O$serve the #rum ressure 'or 4 mnutes.

 /' #rum ressure s ho!#n 56 $ars u to 4mnutes than t s conc!u#e# that hy#ro test s com!ete# success'u!!y an# system s !ea, roo'.

HYDRO TEST OF CPH SYSTEM:  Oen the C%H vent va!ve.

  C!ose the #eaerator 'ee# -ater n!et manua! va!ve& MOV an# ts $yass va!ve.

 Oen the nta! '!!n va!ve 'rom 3M -ater #str$uton um.

 Start the one 3M -ater #str$uton um an# oen the #schare va!ve o' the um.

 Chare the GSC 'rom -aters#e a'ter #on roer ventn.

  Chare the 2% heater 'rom -aters#e a'ter #on roer ventn.  C!ose the $oth C%H um sucton an# #schare va!ve.

 Oen the manua! so!aton va!ve an# MOV o' the C%H co! an# c!ose manua! so!aton va!ve an# MOV o' the C%H co! $yass !ne.

 /' contnuous -ater s comn 'rom the C%H vent& c!ose the vent.

 Sto the 3M -ater #str$uton um an# c!ose the #schare va!ve o'  the um.

 C!ose the nta! '!!n va!ve 'rom 3M -ater #str$uton um.

 Start one CE% -th chemca! nKecton as er chemca! reurement.  Ensure CE% #schare va!ve oen n auto.

 O$serve the CE% #schare ressure.

 O$serve the C%H co! out!et ressure ' t s more than 5@ $ars? Sto the CE% an# c!ose the #schare an# ts $yass va!ve.

 O$serve the C%H co! ressure 'or 4 mnutes.

 /' ressure s ho!#n 5@ $ars u to 4mnutes than t s conc!u#e# that hy#ro test s com!ete# success'u!!y an# system s !ea, roo'.

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STARTUP PROCEDURE

COLD START- UP PROCEDURE (ST meta! temerature L 574C? H% #rum at atmosherc ressure)

PRE-REQUISITES:

 No %T9 en#n 'or HRSG (H%2% system) an# mantenance actvty& -hch cou!# mact the start*u oeratons& s over.

 Ensure that the nee#e# nsectons 'o!!o-n to a !on ero# o' nactvty a'ter shut#o-n have $een carre# out..

  A!! the nstruments are !ne# u an# suervson system an# the recor#ers are n servce.

 Ensure HRSG sum um s auto ava!a$!e.  Ensure AC9 um s n servce.

 3M -ater storae tan, !eve! s norma! 'or startu.

 Ensure at !east one CE%& H%>8%& 2%>8% are n*servce an# other s auto ava!a$!e.

 Ensure con#enser an# #eaerator !eve! s norma!.

 Ensure chemca! #osn ums are runnn as er chemca! reurement.  Ensure that the e!ectrca! automaton system an# the re!evant

trans#ucers are n servce.

 Ensure that a!! sa'ety va!ves are n servce .e. a!! sa'ety va!ves are n un!oc,e# oston.

 Ensure that the sa'ety ru!es are correct!y met.

 Ensure that a!! the man manua! va!ves are n ther correct oston.  Chec, that the 're rotecton system s ava!a$!e.

 Chec, that e!ectrca! su!es are ava!a$!e.

 Ensure that a!! the nstrument mu!se !ne*so!atn va!ves are oen an# the eua!"n va!ves are c!ose#.

 Ensure GT s synchron"e# -th r#.

 Ensure that the 9aste 9ater Treatment System an# the HVAC System are norma!!y oeratn.

 %er'orm a!! the #eta!e# re*chec,s sec'e# $y the manu'actures an# ut the re!evant #rves n A<TO mo#e.

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 Ensure that a!! the va!ves& nc!u#n coc, va!ves& are not un#er  mantenance an# n the correct oston.

Ensure that a!! the sa'ety va!ves are #senae# an# ther re!evant srn acton s e''cent.

 Ensure that the HRSG #rums !eve! s at !east at start*u !eve!(*544mm) an# '!! them& ' necessary.

 Ensure the H% an# 2% 'ee# contro! staton a!! contro! va!ves are n auto an# H% 4; va!ve s n servce.

 Chec, that the HRSG #ran an# vent va!ves are n automatc mo#e.  Ensure H% an# 2% $!o- #o-n an# $!o- o'' so!aton va!ves are n oen

con#ton.

 Ensure H% an# 2% #rum vents are n oen con#ton an# ,et n auto.  Ensure H% an# 2% suer heater vents are n oen con#ton an# ,et n

auto.

 Ensure H%SH ray so!aton va!ve s oen an# contro! va!ve s n auto.

P!"#$%&!$

 Set the GT !oa# set ont 57M9.

 Reset the HRSG tr 'rom $ac, u ane!.  %arta!!y oen the H% an# 2% MS #ran va!ve.  Oen the H% an# 2% man steam shuto'' va!ve.

 Oen the #verter #amer manua!!y $y vn the as '!o- taret va!ue 54;.

 Mantan the #rum !eve! F544mm& ' reure# essenta!!y than ve the $!o-#o-n or $!o- o''.

 Oen the HRSG sum -ater*coo!n va!ve.

 8or mantann the #rum !eve! F544mm ' reure# chane the !eve! $asn.

 Oen the #verter #amer $y ta,n care o' 'o!!o-n arameters.

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a) Mantan the #rum meta! tem rse !ess than @4C Mn. $) Mantan the H% steam tem rse !ess than 564C Mn.

c) 3rum to an# $ottom meta! tem #''erence !ess than 544oC

 O$serve the H% #rum ressure ' t s more than .7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.

 O$serve the H%SH ressure ' t s more than .7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.

 O$serve the 2% #rum ressure ' t s more than 6.7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.

 O$serve the 2%SH ressure ' t s more than 6.7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.

 Start at !east one C9 um as er um startn roce#ure.

 /' H%MS ressure come u to 54 $ar start the man steam #eaerator en !ne heatn $y crac, oenn o' the 'rst ressure contro! va!ve an# ts so!aton va!ve.

 Oen the man steam #eaerator en #e suer heatn !ne so!aton va!ve an# ,ee the #e suer heatn contro! va!ve  n auto at 6744C set va!ue.

 O$serve the man steam #eaerator en !ne temerature ' t come u to 6444 an# H% #rum ressure come u to 5 $ar start the #eaerator en charn $y manua! oenn o' 5st an# 6n# ressure contro! va!ve an# mantan the !ne ressure a'ter the 5st contro! va!ve at @.4 $ar.

 Oen the GSC #ran va!ve.

 /' #eaerator ressure s mantann 5.4 $ar ,ee the $oth ressure contro! va!ve n auto.

 Start one GSC $!o-er as er chec,!st.

 /' H% #rum ressure comes u to 64 $ars oen the 'rst ressure contro! va!ve an# ts so!aton va!ve manua!!y.

 Oen the secon# ressure contro! va!ve s!o-!y an# oen the 'r st ressure contro! va!ve n manua! mo#e 'or mantann the ressure57 $ar.

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 ee the sea! steam tem contro! va!ve n auto at 5B4oC set va!ue.

 /' sea! ressure comes u to 67m$ar than ,ee the $oth ressure contro! va!ve n auto.

 C!ose the vacuum $rea,er va!ve.

 Start $oth vacuum ums as er startu roce#ure.

 /' con#enser ressure comes u to 644 m$ar oen the H% an# 2% $yass contro! va!ve arta!!y n manua! mo#e.

 Ensure the oenn o' the H% an# 2% $yass coo!n !ne so!aton va!ve.  Set the H% an# 2% $yass ressure contro! va!ve s!ht!y !ess than the u

actua! u stream!ne ressure an# ,ee the H% an# 2% $yass ressure contro! va!ve n auto.

 Mantan the u stream!ne ressure $y s!o-!y chann the ressure set ont an# ta,n care o' H% an# 2% #rum !eve! as er steam tur$ne ro!!n con#ton.

 ee the #verter #amer n auto.

WARM START- UP PROCEDURE (ST meta! temerature L 74C? H% #rum r.  = $ar)

%ermssve con#tons:

 /nstruments an# servce ar ava!a$!e?  3em -ater ava!a$!e (tan, !eve! not !o-)?

 Crcu!atn -ater an# c!ose# coo!n system n servce?  Con#enser !eve! an# #eaerator !eve! not !o-?

 HRSG tr reset?

 >y*ass system hy#rau!c su!y n servce.

P!"#$%&!$

 Set the GT !oa# set ont 57M9.

 Reset the HRSG tr 'rom $ac, u ane!.

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 %arta!!y oen the H% an# 2% MS #ran va!ve.  Oen the H% an# 2% man steam shuto'' va!ve.

 Oen the #verter #amer manua!!y $y vn the as '!o- taret va!ue 54;.

 /ncrease the GT !oa# u to 7M9 n 67 mn.

 Mantan the #rum !eve! F544mm& ' reure# essenta!!y than ve the $!o-#o-n or $!o- o''.

 Oen the HRSG sum -ater coo!n va!ve.

 8or mantann the #rum !eve! F544mm ' reure# chane the !eve! $asn.

 Oen the #verter #amer $y ta,n care o' 'o!!o-n arameters. #) Mantan the #rum meta! tem rse !ess than @4C Mn.

e) Mantan the H% steam tem rse !ess than 564C Mn.

') 3rum to an# $ottom meta! tem #''erence !ess than 544oC

 O$serve the 2% #rum ressure ' t s more than 6.7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.

 O$serve the 2%SH ressure ' t s more than 6.7 $ar #rum vent c!ose# n auto& ' not c!ose# manua!!y.

 /' H%MS ressure come u to 54 $ar start the man steam #eaerator en !ne heatn $y crac, oenn o' the 'rst ressure contro! va!ve an# ts so!aton va!ve.

 Oen the man steam #eaerator en #e suer heatn !ne so!aton va!ve an# ,ee the #e suer heatn contro! va!ve  n auto at 6744C set va!ue.

 O$serve the man steam #eaerator en !ne temerature ' t come u to 6444 an# H% #rum ressure come u to 5 $ar start the #eaerator en charn $y manua! oenn o' 5st an# 6n# ressure contro! va!ve an# mantan the !ne ressure a'ter the 5st contro! va!ve at @.4 $ar.

 Oen the GSC #ran va!ve.

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 /' #eaerator ressure s mantann 5.4 $ar ,ee the $oth ressure contro! va!ve n auto.

 Start one GSC $!o-er as er chec,!st.

 /' H% #rum ressure comes u to 64 $ars oen the 'rst ressure contro! va!ve an# ts so!aton va!ve manua!!y.

 Oen the secon# ressure contro! va!ve s!o-!y an# oen the 'r st ressure contro! va!ve n manua! mo#e 'or mantann the ressure57 $ar.

 ee the sea! steam tem contro! va!ve n auto at 5B4oC set va!ue.

 /' sea! ressure comes u to 67m$ar than ,ee the $oth ressure contro! va!ve n auto.

 C!ose the vacuum $rea,er va!ve.

 Start $oth vacuum ums as er startu roce#ure.

 /' con#enser ressure comes u to 644 m$ar oen the H% an# 2% $yass contro! va!ve arta!!y n manua! mo#e.

 Ensure the oenn o' the H% an# 2% $yass coo!n !ne so!aton va!ve.  Set the H% an# 2% $yass ressure contro! va!ve s!ht!y !ess than the u

actua! u stream!ne ressure an# ,ee the H% an# 2% $yass ressure contro! va!ve n auto.

 Mantan the u stream!ne ressure $y s!o-!y chann the ressure set ont an# ta,n care o' H% an# 2% #rum !eve! as er steam tur$ne ro!!n con#ton.

 ee the #verter #amer n auto.

HOT START- UP PROCEDURE (ST meta! temerature  74C? H% #rum r.  7 $ar)

%ermssve con#tons:

 /nstruments an# servce ar ava!a$!e?  3em -ater ava!a$!e (tan, !eve! not !o-)?

 Crcu!atn -ater an# c!ose# coo!n system n servce?

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 Con#enser !eve! an# #eaerator !eve! not !o-?  HRSG tr reset?

 >y*ass system hy#rau!c su!y n servce.

P!"#$%&!$

 Set the GT !oa# set ont 57M9.

 Reset the HRSG tr 'rom $ac, u ane!.  %arta!!y oen the H% an# 2% MS #ran va!ve.  Oen the H% an# 2% man steam shuto'' va!ve.

 Oen the #verter #amer manua!!y $y vn the as '!o- taret va!ue 4;.

 /ncrease the GT !oa# u to @4M9 P55M9mn.

 Mantan the #rum !eve! F544mm& ' reure# essenta!!y than ve the $!o-#o-n or $!o- o''.

 Oen the HRSG sum -ater*coo!n va!ve.

 8or mantann the #rum !eve! F544mm ' reure# chane the !eve! $asn.

 %ut the #verter #amer n auto.

 Start $oth vacuum ums (' reure#) as er startu roce#ure.

 /' con#enser ressure comes u to 644 m$ar oen the H% an# 2% $yass contro! va!ve arta!!y n manua! mo#e.

 Ensure the oenn o' the H% an# 2% $yass coo!n !ne so!aton va!ve.  Set the H% an# 2% $yass ressure contro! va!ve s!ht!y !ess than the u

actua! u stream!ne ressure an# ,ee the H% an# 2% $yass ressure contro! va!ve n auto.

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 Mantan the u stream!ne ressure $y s!o-!y chann the ressure set ont an# ta,n care o' H% an# 2% #rum !eve! as er steam tur$ne ro!!n con#ton.

SHUTDOWN PROCEDURE

%ermssve con#tons:

  A!! necessary !ant #rves ava!a$!e an# n Auto mo#e?  GT n servce?

 3verter #amer HRSG 'u!!y oen?  HRSG H%  2% steam $y*ass n Auto.

S'(!' ") *!"#$%&!$

 S-tch H% ressure set*ont to Manua! mo#e (H% steam $y*ass o' HRSG an# ST contro! va!ves -!! mantan the ressure at the actua! va!ue)?

 /' the steam '!o- 'rom HRSG s reater than 7; o' nomna! va!ue (#een#n on the actua! GT !oa#)& arta! c!osure reuest (4; oenn) to #verter  #amer

 C!ose the #verter #amer S!o-!y $y ta,n care o':

) Mantan the #rum meta! tem #ecreasn rate not !ess than =.4C Mn.

h) Mantan the H% steam tem #ecreasn rate not !ess than D.@4C Mn.

 /8 ST H% CV oston comes #o-n u to 64; tr the steam tur$ne manua!!y.  C!ose the #verter #amer 'u!!y.

CHEMICAL PARAMETERS AND OPERATING LIMITATIONS

CHEMICAL PARAMETERS

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/n or#er to ermt the set o' the montorn 'e!# nstrument an# to er'orm the man chemca! ana!yss& -e su!y the recommen#e# man chemca! arameters on the 'o!!o-n $ass:

The steam O6 an# H va!ues correctons& -!! $e chec,e# throuh a!,a!ne scavener& su!e# $y means o' the chemca! !ant.

8ee# -ater har#ness !ea,ae& -!! $e chec,e# usn hoshate nKecton !ant nto $o!er #rum& ' reure#.

Ma+mum H an# con#uctvty va!ues& n the $o!er -ater& -!! $e mantane# $y means o' the use o' the $!o-*#o-n system.

/n the anne+ #aram n 56& s sho-n the $o!er s!ca reartton ressure rate curve.

The $!o-*#o-n '!o- a#Kustment -!! mantan the SO6ma+mum va!ue.

Sam!n ont Measure Rane

8ee# -ater con#uctvty I QScm ma+ 4&6

8ee#-ater H * D&4

>!o-*#o-n con#uctvty I QScm  H%? 7 2%

Steam SO6 m ma+ 4&46

Steam con#uctvty I QScm  4&6 ( 4&7II)

O+en O6 at #eaerator out m ma+ 4&4=

Hy#ra"ne N6H= 'ee# -ater m  4&46

/ron (8e) n 'ee# -ater m ma+ 4&46

I The con#uctvty va!ue ta,es n cons#eraton the sam!e a'ter catonc e+chane (ac# con#uctvty)

S()$'+ ,(,$ $''0:

 Actua! settn at the s#e s as 'o!!o-s:

HRSG SA8ETY VV SET  RESET VA2<E SR. NO. SA8ETY VV 3ESCR/%T/ONS SET VA2<ES /N >AR RESET VA2<E /N >AR 5 ERV D6.D BB.6 6 H% S<%ER HEATER D@.= D.D5  H%*3R<M*/ 54.BB 546.56 = H%*3R<M*// 54.5 DB.5 7 H% ECO // N.A. 5@B.7

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@ 2% S<%ER HEATER .D= .

 2% 3R<M 54 D.77

B 2% 3R<M 54 D.77

%reare# $y Reve-e# $y

3Y manaer. * Oeraton Hea# (Oeraton)

Figure

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References

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