PRESSURE REDUCING & DE-SUPERHEATING STATION FOR CDQ 10 & 11 POWER PLANT

OPERATION & CONTROL PHILOSOPHY

Measuring Equipment List:

The list of equipment's at PRV-1(CDQ-10) are as under:

1) PG-8004-1160- For local Pressure measurement at PRS inlet.

2) TG-8004-1170- For local Temperature measurement at PRS inlet.

3) PRV-4008- Pressure Control Valve of PRS Stream-1.

4) GL-1307- Motorized Control Valve of PRS Stream-2.

5) PG-8004-1161- For local Pressure measurement at PRS outlet.

6) TG-8004-1171- For local Temperature measurement at PRS outlet.

The list of equipment's at Common Header Node-B (CDQ-10 & CDQ-5, 6,7) are as under:

1) PT-8004-1151A / 1151B / 1151C- Pressure Measurement at common header.

The list of equipment's at PRV-2(CDQ-5,6,7) are as under:

1) PG-8013-03- For local Pressure measurement at PRS inlet.

2) TG-8013-12- For local Temperature measurement at PRS inlet.

3) PRV-4008- Pressure Control Valve of PRS Stream-1.

4) GL-4009- Motorized Control Valve of PRS Stream-2.

5) PG-8013-04- For local Pressure measurement at PRS outlet.

6) TG-8013-13- For local Temperature measurement at PRS outlet.

The list of equipment's at FCS(CDQ-5,6,7) are as under:

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1) PG-8013-01- For local Pressure measurement at FCS inlet.

2) TG-8013-10- For local Temperature measurement at FCS inlet.

3) FCV-4001- Flow Control Valve of FCS Stream-1.

4) GL-4002- Motorized Control Valve of FCS Stream-2.

5) PG-8013-02- For local Pressure measurement at FCS outlet.

6) TG-8013-11- For local Temperature measurement at FCS outlet.

7) FT-8013-30A / 30B/ 30C- Flow Measurement at FCS outlet.

8) PT-8013-40A / 40B- Pressure Measurement at FCS outlet.

9) TT-8013-50A / 50B- Temperature Measurement at FCS outlet.

The list of equipment's at PRV-3(CDQ-11) are as under:

1) PG-8005-1301- For local Pressure measurement at PRS inlet.

2) TG-8005-1350- For local Temperature measurement at PRS inlet.

3) PRV-1506- Pressure Control Valve of PRS Stream-1.

4) GL-1507- Motorized Control Valve of PRS Stream-2.

5) PG-8005-1302- For local Pressure measurement at PRS outlet.

6) TG-8005-1351- For local Temperature measurement at PRS outlet.

The list of equipment's at Common Header Near Nod-A (CDQ-11) are as under:

1) PT-8005-1400A / 1400b / 1400C- Pressure Measurement at common header.

The list of equipment's at PRDS are as under:

1) GV-1602- Motorized Isolation Valve at PRDS inlet.

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2) MCV-3A- Bypass Motorized Isolation Valve across GV-1602.

3) FT-8006-1571- Flow measurement at PRDS inlet.

4) PG-8006-1522- For local Pressure measurement at PRDS inlet.

5) TG-8006-1500- For local Temperature measurement at PRDS inlet.

6) PT-8006-1501- Pressure Measurement at PRDS inlet.

7) TT-8006-1490- Temperature Measurement at PRDS inlet

8) PCV-1608- Pressure Control Valve of PRDS Stream-1.

9) GL-1607- Motorized Control Valve of PRDS Stream-2.

10) TT-8006-1492A / 1492B- Skin Temperature Measurement at PRDS outlet.

11) PT-8006-1502A / 1502B- Pressure Measurement at PRDS outlet.

12) TT-8006-1491A / 1491B- Temperature Measurement at PRDS outlet.

13) PG-8006-1523- For local Pressure measurement at PDRS outlet.

14) TG-8006-1571- For local Temperature measurement at PRDS outlet.

15) FT-8006-1572- Flow measurement at PRDS outlet LP header-1.

16) FT-8006-1573- Flow measurement at PRDS outlet LP header-2.

The list of equipment's at DM Water Station are as under:

1) LT-8006-1451- Level measurement of DMW Tank.

2) LG-8006-1461- Local level measurement of DMW Tank.

3) PG-8006-1522- For local Pressure measurement at DMW pump-1 suction.

4) PG-8006-1523- For local Pressure measurement at DMW pump-2 suction.

5) DPT-8006-1501- Differential Pressure measurement across Y-Strainer FY-1601.

6) DPT-8006-1502- Differential Pressure measurement across Y-Strainer FY-1602.

7) PT-8006-1500- Pressure Measurement at DMW Pump discharge header.

8) PG-8006-1520- Local Pressure Measurement at DMW Pump discharge header.

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9) PCV-1609- Pressure Control Valve of DMWS Stream-1.

10) GL-1610- Motorized Control Valve of DMWS Stream-2.

11) FT-8006-1570- Flow measurement at DMWS outlet.

12) PG-8006-1521- For local Pressure measurement at DMWS outlet.

13) PT-8006-1501- Pressure Measurement at DMWS outlet.

14) TT-8006-1491A / 1491B- Temperature Measurement at PRDS outlet

15) PG-8006-1523- For local Pressure measurement at PDRS outlet.

16) TG-8006-1571- For local Temperature measurement at PRDS outlet.

17) FT-8006-1572- Flow measurement at PRDS outlet LP header-1.

18) FT-8006-1573- Flow measurement at PRDS outlet LP header-2.

Alarms, Feedback and display envisaged in HMI Screen:

As per IO List ( refer document no BSL-TSL-PRDS-CDQ-DE-050)

CONTROLS & INTERLOCKS OF PRDS FROM HP STEAM LINE TO PLANT LP STEAM HEADER (Refer Dwg. No. BSL-TSL-
PRDS-CDQ-DE-005/006/076):

The monitoring, control and interlocks of PRDS shall be realized in STG DCS. The operation of PRDS shall be from
OWS (Operator Work Station) of DCS and essential indications/alarms shall also be provided on the OWS(DCS
integration is in scope of other contractor).

All pressure reducing stations are have pneumatic control valves and motorized control valves (with integral
starter), which is also connected to STG DCS. The normal operation of PRDS shall be with manual intervention of
DCS operator as the frequency of operation is very rare.

PRDS START UP

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1) Kindly ensure that the heating line from LP circuit to PRDS outlet common header after PCV(PCV-1608)/ MCV
(GL-1607) is in line and the isolation valves(GV-1603, GV-1604, GV-1605, GV-1606, GV-1602 & MCV-3A) are in
open condition. This will help in maintaining the PRDS temperature and protect the pipeline from undue
damage due to sudden temperature variation. The PRDS Streams shall be heated and maintained at a
temperature of 220 to 350 Deg C depending upon the available temperature of the existing LP Steam at LP
Header.

2) To take the PRDS into service depending upon the status of the STG, HP steam header pressure and the
requirement of steam at the process LP headers, the operator increases the PRDS pressure controller set
point manually above the LP steam header pressure and required steam flow is established (FT -8006-1571
and FT-8006-1572 or 1573) by necessary flow compensation.

3) Ensure the DM Water Spray Control Station along with DM Water Pump is healthy and all instruments are in
proper working condition.

4) Now close GV-1602 & MCV-3A from DCS through manual intervention from DCS prior to HP Steam charging.

5) Now charge HP Steam. Before opening GV-1602, open MCV-3A through DCS. This will act as pressure
balancing at both inlet and outlet. Once MCV-3A is full open and the open feed back is reflected in DCS, start
opening GV-1602 through auto logic. Once GV-1602 is completely open MCV-3A will close automatically
(through logic).

6) Now HP Steam is available till PCV(PCV-1608)/ MCV (GL-1607) inlet.

7) Skin temperature of downstream of de-superheater should be > 250 Deg C, downstream de-superheater
pressure is more than 12.5 Kg/Cm2 and the upstream pressure of control valve is above 20 Kg/cm2.

8) This action will give permissive for control valve “PCV(PCV-1608)/ MCV (GL-1607)” to open. The pressure
controller set point is kept at a higher pressure than the LP header pressure as per the required flow and put
in AUTO.

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9) Steam pressure is sensed by pressure transmitters PT-8006-1502A & PT-8006-1502B “1 out of 2 scheme” and
PCV(PCV-1608) or MCV (GL-1607)(depending upon the valve selected for operation) is modulated to maintain
downstream pressure of 12.5-15.2 Kg/ Cm2 at the PRDS outlet with Low Low alarm at 12.5 Kg/Cm2, Low alarm
at 12.8 Kg/Cm2, High alarm at 15.3 Kg/Cm2 & High High alarm at 15.5 Kg/Cm2. PCV shall trip at High High
alarm.

10) Start the DM Water Pump P1/P2 (as per selection).

11) When PCV-1608/ GL-1607 opens greater than 2 %, the steam temperature control system shall be 'on auto
mode' and spray water control valves PCV-1609)/GL-1610 shall be put under operation immediately.

12) Once the pressure reduction steam is charged put PCV-1609/GL-1610 in AUTO mode. PCV-1609/GL1610 shall
start throttling by taking the temperature feedback. Steam temperature shall be sensed by temperature
elements TE-8006-1491A & TE-8006-1491B in “1 out of 2 scheme” & spray water temperature control valve
PCV (PCV-1609) or MCV(GL-1610) is modulated to maintain 220 to 350 Deg C at the PRDS outlet through the
de-superheater. The PID Controller is realized in DCS. Low Low alarm at 220 Deg C, Low alarm at 230 Deg C,
High alarm at 320 Deg C & High High alarm at 350 Deg C. PCV-1608 shall trip at High High alarm.

13) When the PRDS downstream temperature is well above 350 deg C a high high temperature alarm is
annunciated in the control room & pressure reducing valve in operation PCV-1608/ GL-1607 will close
automatically, on priority after a time delay of 0-120 secs (adjustable). This overrides auto & remote manual
operation. When PCV-1608) / GL-1607) is fully closed (valve opening less than 2%) after a time delay of 0-300
secs (adjustable), the control valves PCV-1609/GL-1610 in spray water line will close subsequently after
normalizing the LP Steam header temperature within a operational range of 220 to 350 Deg C.

14) If down steam pressure is more than 15.5 kg/cm2 (a), there will be no steam flow & PRDS shall be closed.

Note:

a. All pneumatically operated valves shall remain in Stay Put condition on event of Air Supply failure. Upon
power failure, all pneumatically operated valves shall go close position.

b. All Electrically Operated Valve(Motorized Valves) shall remain in last position/stay put on event of power
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failure.

All Low-Low, Low, High, High-High alarms shall be annunciated in DCS HMI page designed for PRDS & PRV Stations.

CONTROLS & INTERLOCKS OF PRS-1, PRS-2 & PRS-3 STATIONS : (Refer dwg. no. BSL-TSL-PRDS-CDQ-DE-
001/002/003/004): The basic intent of the control is to ensure a steam mixing from different steam generators at
different steam parameters and supply to the STG Turbine at all probable operating conditions of the process and
to get 40MW power from the power plant.

To achieve the same it is required to maintain variable dynamic pressure at the following nodes at various process
conditions to ensure uninterrupted operation of the Turbine. The control and monitoring of pressure reducing
stations are to be done from STG DCS. The nodes are:

 Node A: Junction point of HP Steam lines from CDQ 11 with the header from CDQ 10 & CDQ 5, 6 & 7.

 Node B: Junction point of HP Steam lines from CDQ-10, CDQ-5, 6 & 7 and outlet steam pipe towards Node A.

Steam pressure in the header at the specified nodes shall be maintained by Pressure Reducing Valves (PRV) placed
at HP Steam lines from CDQ-11, CDQ-5, 6 & 7 and CDQ-10. The control loop for this had been envisaged as below.

Set point for pressure at Node A will be determined from the inlet pressure to the Turbine. Pressure will be
measured at Node A and compared with the set pressure and will modulate the PRV- 3 at CDQ-11 steam header to
maintain the desired pressure at Node A.

To maintain Node A pressure, a set point for Node B pressure is also dynamically generated by the controller in
cascade mode and fed as set point to the secondary controller which modulates PRV-2 & PRV-1 in the HP Steam
line from CDQ-5, 6 & 7 and CDQ-10 HP steam line respectively.

Further to ensure 25 TPH steam from the HP Steam network of CDQ-5, 6 & 7 boiler, a control valve FCV-4001 is
placed which will be modulated by a flow controller. The FCV-4001 and PRV-4008 opening will together ensure 25
TPH flow through the header.
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It may be noted that LP steam is being generated from HP Steam produced by CDQ-5, 6 & 7. Since 25 TPH steam
had been taken out from the source, the balance HP Steam will be converted to LP Steam through the existing
PRDS station.

Measurement Scheme:

Pressure is measured at Node A & B. At each point three pressure transmitters are envisaged for 2 out of 3 logic
(PT-8004-1151A, B & C / PT-8005-1400A, B & C) in STG DCS before sending the measured value to the controller.

Flow is measured at the HP Steam line from CDQ 5, 6 & 7 by a flow nozzle and redundant Flow Transmitters in 2
out of 3 voting (FT-8013-30A/30B/30C). The measured flow is compensated for Pressure & Temperature (by
measuring pressure & temperature by redundant Pressure transmitters (PT-8013-40A/40B) & Temperature
transmitters(TT-8013-50A/50B). The compensated steam flow is fed to controller as feedback signal.

Integration with STG DCS:

Measurement of steam network and automation of the pressure reducing stations (PRVs) will be implemented in
the STG DCS .

To account for long distance between the STG building and the field instruments and control valve, three numbers
of remote I/O units (RI/O-1, RI/O-2 & RI/O-3) are placed at strategic locations as follows:

RI/O-1 at CDQ-10 ECR

RI/O-2 at CDQ 5,6,7 ECR

RI/O-3 at CDQ-11 ECR

The grouping of instruments in the RI/O shall be as per approved instrument cable cum wiring diagram.

Additional Recommendation:

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Although the PRDS System is designed as per tender specification and approved drawing and documents, some
additional recommendation have been envisaged for smooth operation PRDS jointly by Tata Steel & Blue Star.

1) Implementation of additional Pressure Transmitter (PT-1503) after PCV(PCV-1608)or MCV (GL-1607). This will
be in PID Loop with the PCV(PCV-1608)or MCV (GL-1607) for controlling the downstream pressure of PRDS.

2) Implementation of additional Pneumatic On Off Valves (ISV-1623) at the inlet line of DM Water before
entering the DM Water Tank. This will help in remote monitoring of DM Water supply line thereby avoiding
unnecessary wastage of DM Water.

The above points were discussed and agreed upon vide discussion and MOM dated 26.10.2018 held at Tata Steel,
Jamshedpur.

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