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TRUenergy Tallawarra Pty Ltd
Contractor:
ALSTOM Power Limited
Revision History
Rev.
Revision Date
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Description
Replaces
TWA/00/M/-------LCM/DM/001
Responsible dept.
Created by
Checked by
Approved by
Format
PEE
Pfeifer B.
Zaengerlein F.
Zaengerlein F.
A4
Originator
Document Type
Document Status
abcd
Description
Electronically released
Title, Subtitle
Identification number
Power Turbo-Systems /
Power Environment
SYSTEM DESCRIPTION
LCM - CLEAN DRAINS SYSTEM
1AHA052256
Rev.
Date
Lang.
Sheet
19.12.2006
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Rev. A
Copyright
All rights reserved
Copyright 2006 ALSTOM Power Turbo-Systems (comprised of ALSTOM (Switzerland) Ltd. and/or affiliates
CH-5401 Baden, Brown Boveri Strasse 7
Printed in Switzerland
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to
third parties without express authority is strictly forbidden.
This work, including all parts thereof, is protected by copyright. Any use of it beyond the narrow restrictions of the
copyright law without prior approval of ALSTOM (Switzerland) Ltd., CH-5401 Baden is prohibited and subject to
punishment under the applicable law.
Revision History
Revision
Date
2006-08-09
Document Pages
total :
Content of Revision
Initial Draft
24
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Contents
1
2.
3.
4.
Introduction ............................................................................................................................................... 11
1.1.
Purpose........................................................................................................................................................... 11
1.2.
1.2.1.
Main Components.....................................................................................................................11
1.2.2.
2.2.
Overview......................................................................................................................................................... 14
3.2.
3.3.
3.4.
ADV................................................................................................................................................................. 14
3.5.
ADV Pump...................................................................................................................................................... 14
Operation ..................................................................................................................................................... 15
4.1.
5.
6.
Overview......................................................................................................................................................... 15
4.1.1.
4.1.2.
4.1.3.
4.2.
4.3.
4.4.
4.5.
Maintenance.............................................................................................................................................. 20
5.1.
5.2.
System-related Maintenance......................................................................................................................... 20
Appendices................................................................................................................................................ 21
6.1.
6.2.
6.3.
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Rev. A
List of Tables
Table 1
Table 2
Table 3
Table 4
Table 5
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List of Figures
Figure 1
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Rev. A
Additional Documents
Doc No.
Title
1AHA049437
1AHA049438
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Rev. A
Title
Contents
Introduction
Safety Instructions
System Description
Operation
Maintenance
Appendices
Table 1
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DANGER
Type/Source of Hazard
Hazard consequences
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
WARNING
Type/Source of Hazard
Hazard consequences
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices.
CAUTION
Type/Source of hazard
Hazard consequences
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DAMAGE information not relevant for the safety of personnel but pointing out possible damage to the
machine is depicted as shown below.
CAUTION
Information pointing out possible damages to the Machine.
A General Note contains supplementary information of general interest for the reader.
Note
This is supplementary information for the reader.
READ INSTRUCTIONS means that it is mandatory to read the specific instructions contained in this
manual or in external reference documents.
Read instructions!
MANDATORY ACTION symbols are used to point out instructions and information that must be
strictly followed to prevent any risk for personal safety or to avoid machine damage.
General requirement sign
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Explanation
ADV
DCS
HP
High Pressure
HRSG
IP
Intermediate Pressure
LP
Low Pressure
OTC
PFUP
P & ID
Table 2
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INTRODUCTION
1.1.
Purpose
Rev. A
1.2.
Draining of condensate out of the steam lines and the steam turbine
Collecting the condensate and forwarding to the blow down system (external drains) respectively
returning to the process (internal drains)
System Overview
Note
For an overview of the system, refer to P & ID 1AHA049437.
1.2.1.
Main Components
The system consists of the following main components:
Drain lines including drain shut-off valves, steam traps and orifices
19LCM20BR001
19LCM30BR001
Drain lines, steam traps, orifices and drain valves of various steam lines are indicated by a 2 following
the letters BR/BP/AA (for example: 18LBA50BR201).
Warm-up lines, orifices and warm-up valves of various steam lines are indicated by a 6 following the
letters BR/BP/AA (for example: 18LBA45BR601).
Steam turbine drains to the flash box are not part of this system, refer to the relevant steam turbine
documentation.
Steam line drains from the HRSG enter into the blow down- / flash-tank, but are not part of this
system, refer to relevant HRSG documentation.
1.2.2.
Steam and condensate enters though the various drain lines and warm-up lines from the Main
Steam System (LBA), the Air Removal System (MAJ), the IP Bypass (MAN40), the LP Bypass
(MAN10), the GT Air cooling system (MBH), the feedwater deaeration steam piping (LAA), and the
steam turbine.
Steam exits trough the vent lines of the atmospheric drain vessel to atmosphere.
Condensate collected in the flash box returns to the process via the condenser hotwell (LC).
Condensate collected in the atmospheric drain vessel is further directed to the hot waste water
collecting pit 90GMP20BB001 of the Waste Water System (GMA).
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2.
SAFETY INSTRUCTIONS
2.1.
2.2.
Before start-up
ensure the instrument root valves for all permanent instruments are
open. Refer to Table 3 Manual Preparation Check List prior to
Start-up on page 21.
ensure the instrument root valves for all temporary instruments are
closed. These temporary instruments are shown in the P & ID with a
P, PP, T or TP and are used only for the performance test or
commissioning. Refer to Table 3 Manual Preparation Check List
prior to Start-up on page 21.
Before maintenance
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WARNING
WARNING
Hot surface
Inappropriate handling can cause serious burns
The clean drain system and its components must be operated and
maintained by trained and authorized personnel only!
All applicable safety rules and regulations are strictly to be followed. For
component-relevant instructions refer to the separate operation and
maintenance manuals for the individual subsystems and equipment.
For maintenance work it is mandatory to have all required work permits.
All applicable local rules and regulations as well as national and
international directives must be strictly followed.
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3.
SYSTEM DESCRIPTION
3.1.
Overview
The clean drain system mainly acts during start-up of the water steam cycle. During these periods,
large amounts of steam condense in the piping of the water steam cycle. The condensate is collected
either in the ADV or in the blow down tank.
During normal operation of the plant, the clean drain system acts with little amounts of condensate.
There are two different groups of drains: external drains and internal drains.
3.2.
External Drains
External drains are the drains of all lines where steam can flow while the steam turbine is not in
operation and the condenser is not evacuated. The external drains are guided to the relevant
collectors on the ADV respectively to the blow down tank.
The steam drains of the HRSG and the intermittent and continuous blow down drains are routed to the
blow down tank.
The connection of some drains of the main steam system and GT air cooling system to the blow down
tank of the HRSG is done due to arrangement reasons.
The condensate/steam mixture expands and is separated in the ADV respectively in the blow down- /
flash-tank. The flashed-out steam in the ADV is discharged via the exhaust lines to the atmosphere
outside of the main hall building. The flashed out steam of the flash tank is recovered in the feed water
tank and the steam from the blow down is routed to safe location in HRSG area.The condensate is
transferred by the ADV pump respectively the blow down tank pumps to the waste water system.
3.3.
Internal Drains
Internal drains are all drains where steam can flow only if the steam turbine is in operation. Generally,
these are all steam turbine internal drain lines downstream of the steam turbine control valves.
These drain lines are connected to the flash box of the condenser system.
The condensate/steam mixture is cooled down by water injection in the flash box. The flashed-out
steam is discharged to the condenser neck.
The condensate is returned to the process via the main condensate system.
3.4.
ADV
The ADV is a vertical cylinder vessel. The instruments for monitoring and controlling of the level are
mounted on the outside of the vessel. For more detailed information of this component, consult the
Operation & Maintenance Manual of the supplier.
3.5.
ADV Pump
The ADV pump is a single stage pump. It is connected by a coupling to the electric motor. The electric
motor is a three-phase induction type and is powered by the plant low voltage board. Motor cooling is
ensured by the motor internal ventilation device. For more detailed information of this component,
consult the Operation & Maintenance Manual of the supplier.
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4.
OPERATION
4.1.
Overview
4.1.1.
Before start-up
ensure the instrument root valves for all permanent instruments are
open. Refer to Table 3 Manual Preparation Check List prior to
Start-up on page 21.
ensure the instrument root valves for all temporary instruments are
closed. These temporary instruments are shown in the P & ID with a
P, PP, T or TP and are used only for the performance test or
commissioning. Refer to Table 3 Manual Preparation Check List
prior to Start-up on page 21.
The instructions of the component suppliers must be adhered to.
WARNING
WARNING
Hot surface
Inappropriate handling can cause serious burns
The clean drain system and its components must be operated and
maintained by trained and authorized personnel only!
All applicable safety rules and regulations are strictly to be followed. For
component-relevant instructions refer to the separate operation and
maintenance manuals for the individual subsystems and equipment.
For maintenance work it is mandatory to have all required work permits.
All applicable local rules and regulations as well as national and
international directives must be strictly followed.
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4.1.2.
Rev. A
4.1.3.
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4.2.
Rev. A
Normal Start-up
Note
The normal start-up is performed in automatic mode by starting of the related
function groups by the relevant sequencer in the DCS.
Following function groups are started:
During start-up, the drain shut-off valves and the warm-up shut-off valves open automatically
according to the process requirements in order to drain the condensate. The drain shut-off valves and
the warm-up shut-off valves open if the specific process conditions for each individual valve are
fulfilled.
The ADV pump 19LCM10AP001 is set to automatic operation and is switched on when the level in the
ADV measured with 19LCM10CL002 reaches maximum level MAX1. When the level in the ADV
measured with 19LCM10CL002 drops below minimum level MIN1, the ADV pump is switched off.
Refer to Figure 1 Atmospheric Drain Vessel Levels and Actions on page 23.
4.3.
Normal Operation
During normal operation, all drain shut-off valves and the warm-up shut-off valves close. During this
period, the small accumulated amount of condensate is drained with the steam traps.
When the level in the ADV reaches a maximum level MAX1, the ADV pump 19LCM10AP001 is
switched on. When the level in the ADV drops below a minimum level MIN1, the ADV pump
19LCM10AP001 is switched off. Refer to Figure 1 Atmospheric Drain Vessel Levels and Actions on
page 23.
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4.4.
Rev. A
Normal Shut-down
Note
For automatic shut-down, no operator actions are required.
All bypass stations, drain shut-off valves and the warm-up shut-off valves remain closed after shutdown of the steam turbine. The related steam piping remains pressurized. The accumulated
condensate is drained with the steam traps.
The ADV pump 19LCM10AP001 remains in automatic operation and is switched on when the level in
the ADV reaches maximum level MAX1, respectively is switched off when the level in the ADV drops
below minimum level MIN1. Refer to Figure 1 Atmospheric Drain Vessel Levels and Actions on page
23.
Note
There is no automatic shut-down for the function groups of the clean drain
system.
In automatic mode, following function groups remain started:
Note
Manual stopping of the function group HP steam drains forces the related
drain shut-off valves to fail safe position open.
Manual stopping of the function group IP steam drains forces the related drain
shut-off valves to fail safe position open.
Manual stopping of the function group LP steam drains forces the related
drain shut-off valves to fail safe position open.
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4.5.
Rev. A
Abnormal Operation
All drain shut-off valves have fail safe position open, except the drain shut-off valves in the OTC
feedwater lines and the drain shut-off valves on the OTC air side with fail safe position closed.
All warm-up shut-off valves have fail safe position closed.
When the level in the ADV exceeds maximum level MAX1 and the ADV pump 19LCM10AP001 fails to
lower the level, the accumulated condensate is drained with the ADV overflow line 19LCM10BR011
located between level MAX1 and MAX2.
When the level in the ADV exceeds maximum level MAX2, an alarm is issued. The proper functioning
of the ADV pump 19LCM10AP001 must be checked. In this situation also the drain siphon of the ADV
overflow line 19LCM10BR011 must be checked for clogging.
When the level in the ADV drops below minimum level MIN2, an emergency shut-down will switch off
the ADV pump 19LCM10AP001 to protect the pump from cavitation. Refer to Figure 1 Atmospheric
Drain Vessel Levels and Actions on page 23.
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5.
MAINTENANCE
5.1.
Prior to executing any maintenance work you must have read and
understood the safety instructions in chapter 2 of this manual.
Operational readiness of the system components is to be maintained by adhering to the relevant
operation & maintenance documentation supplied by the supplier, and must be consulted before
operation begins.
5.2.
System-related Maintenance
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6.
APPENDICES
6.1.
Status
KKS number
ADV pump
19LCM10AP001
ADV
Manhole closed
Ready for operation
19LCM10AC001
Level ADV
19LCM10CL002
Steam traps
various
various
Flash box
18MAG04AC001
11LCQ80BB001
11LCQ81AP001
11LCQ82AP001
Valve
Position
KKS number
open
19LCM10AA001
open
19LCM10AA003
open
various
open
various
open
various
closed
various
closed
various
Table 3
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6.2.
Alarm List
KKS
Code
Description
Remarks
18LBC10CL001
>MAX1
18LBH10CL001
>MAX1
18LBS10CL001
>MAX1
19LCM10CL002
>MAX2
L ADV
19LCM10CL002
<MIN2
L ADV
Table 4
6.3.
Rev. A
Alarm List
Title
1AHA049437
Table 5
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19LCM10AC001
MAX2
MAX1
LISZA
LI
MIN1
MIN2
Reference level
19LCM10AP001
Figure 1
Measuring Instrument
Differential pressure transmitter 19LCM10CL002
Level
MAX2
MAX1
MIN1
MIN2
Control action
At rising level: level ALARM
At rising level: switch on ADV pump
At falling level: switch off ADV pump
At falling level: emergency shut-down ADV pump, level ALARM
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explanation, 12
Index
A
abbreviations and acronyms, 13
alarm list, 29
atmospheric drain vessel, 19
atmospheric drain vessel pump, 19
C
CAUTION
explanation, 12
compulsory reading, 11
copyright, 2
D
DAMAGE
explanation, 13
DANGER
explanation, 12
E
external drains, 19
G
general note
explanation, 13
I
interface to other systems, 16
internal drains, 19
M
main components, 15
MANDATORY ACTION
explanation, 13
manual preparation check list prior to start-up, 28
O
Operational readiness, 26
P
piping and instrumentation diagrams, 29
S
system tasks, 15
T
target audience, 11
TN04/0297, 17
U
user audience, 11
V
visual inspection, 26
W
WARNING
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