EPC CONTRACTOR :IOT INFRASTRUCTURE & ENERGY SERVICES LTD EPC CONTRACTOR'S CONSULTANT :DEVELOPMENT CONSULTANTS PVT LTD,

MUMBAI PROJECT :ACC FOR 1X300MW COAL BASED THERMAL POWER PLANT, VILL. BANDAKHAR, TEHSIL : PALI, DIST : KORBA, C.G ACC OPERATION PHILOSOPHY
IOTIES DOCUMENT NO :- MCCPL-PCTL-ACC-DOC-M-0001_REV. P3
PCTL DOCUMENT NO :- 12-7-0002/ ACC OPERATION PHILOSOPHY/01

OWNER :- MARUTI CLEAN COAL & POWER LIMITED

OWNER'S CONSULTANT :- FICHTNER CONSULTING ENGINEERS INDIA (PVT) LTD

DOCUMENT CONTROL SHEET

PROJECT

:-

ACC FOR 1X300MW COAL BASED THERMAL POWER PLANT, VILL. BANDAKHAR, TEHSIL : PALI, DIST : KORBA, C.G

CLIENT DOCUMENT TITLE

::-

IOT INFRASTRUCTURE & ENERGY SERVICES LTD ACC OPERATION PHILOSOPHY MCCPL-PCTL-ACC-DOC-M-0001_REV.P3
12-7-0002/ACC OPERATION PHILOSOPHY/01

IOTIES DOCUMENT NO PCTL DOCUMENT NO REV NO PCTL JOB NO

::::-

P3 12-7-0002

P3 P2 P1 P0 REV NO

02.11.12 16.10.12 11.09.12 31.05.12 DATE

Comments incorporated Comments incorporated Comments incorporated First release DESCRIPTION

SK SK SK SK PREP BY

DD DD DD DD MECH ELECT INST REVIEWED BY CIVIL

PKG PKG PKG PKG APPRVD BY

PROJECT

IOTIES DOC NO : MCCPL-PCTL-ACC-DOC-M0001_REV.P3(PCTL DOC NO-12-7-0002/ACC OPERATION ACC FOR 1X300MW COAL BASED THERMAL PHILOSOPHY/01)

POWER PLANT, CHATTISGARH, INDIA DATE 26.10.12 PAGE 2 OF 23

PAHARPUR COOLING TOWERS LIMITED

Paharpur House, 8/1/B, Diamond Harbour Road, Kolkata - 700 027, INDIA. : (033) 4013 3000 Fax: +91 - 33 -2 479 - 2188 E - Mail: pctccu@paharpur.com

AN ISO 9001 COMPANY

ACC OPERATION PHILOSOPHY

(DOC No. MCCPL-PCTL-ACC-DOC-M-0001_REV P3)

START-UP
1) Fill TEB hot-well with feed water quality water up to half full level. Ensure that drain valve is closed before filling with water. 2) Check DM/DMCW inlet water-line valves (Tag nos. 01-MAG-41-AA-002, 01-MAG-40-AA-006, 01MAG-47-AA-020, 01-MAG-47-AA-018, 01-MAG-57-AA-069 & 01-MAG-57-AA-037) are open 3) Fill separator drum to appropriate level with DM/DMCW water. 4) Check vacuum pump system is initialised. The system inlet valves 01-MAG-38-AA-022, 01-MAG-36AA-027, 01-MAG-37-AA-043 & 01-MAG-35-AA-044 are to be closed, separator water-level has to be above low level (120 mm), the motor and bearing temperature is not high & all motors are to be in STOPPED condition. 5) Motors of both hogging vacuum pumps (Tag nos. 01-MAG-00-AP-01, 01-MAG-00-AP-02), holding vacuum pumps(Tag nos. 01-MAG-00-AP-03, 01-MAG-00-AP-04) and motors of seal water recirculation pumps connected to holding vacuum pumps(Tag nos. 01-MAG-00-AP-03, 01-MAG-00AP-04) can be started (GROUP-start with the sequential time delay, one after another). 6) Check and confirm that all valves (Tag nos. 01-MAG-47-AA-020, 01-MAG-57-AA-069, 01-MAG-43AA-024, 01-MAG-56-AA-028, 01-MAG-41-AA-002 & 01-MAG-40-AA-006) in the DM/DMCW water lines are open. 7) Open valve (01-MAG-33-AA-59) in the quick hogger line. The unit is now ready for evacuation of air. Note: Check to ensure turbine gland steam condenser is in operation. In approximately 30 minutes, the liquid ring vacuum pumps will be able to achieve a design pressure of 34 KPA (a). 8) Check all four vacuum pumps are in operation. 9) Start the condensate extraction pump. Open the valve depending on the pump used. 10) Ensure that the condensate tank level is maintained at half full level to avoid cavitations of pump, by opening the valve on the minimum recirculation line. 11) Now all vacuum pumps are in parallel operation. 12) Two hogging vacuum pumps (Tag nos. 01-MAG-00-AP-01 & 01-MAG-00-AP-02) are to be stopped manually as soon as the vacuum reaches to 30 KPA (a). Vacuum pump system as supplied by M/s G.D.Nash is for manual switching-off of both hogger pumps. However, if automatic switching-off of the hogger pumps is required, pumps are to be switched-off thru PLC at back-pressure of 30 KPA (a) based on back-pressure signal coming from PTs (01-MAG01-CP-001/01-MAG-01-CP-002) to PLC. When the hogging vacuum pump motors are switched-off, the pneumatic valves (Tag nos. 01-MAG37-AA-043 & 01-MAG-35-AA-044) will be closed by energizing solenoid valves (Tag nos. 01-MAG-53AA-055 & 01-MAG-52-AA-056).

PAHARPUR COOLING TOWERS LIMITED

Paharpur House, 8/1/B, Diamond Harbour Road, Kolkata - 700 027, INDIA. : (033) 4013 3000 Fax: +91 - 33 -2 479 - 2188 E - Mail: pctccu@paharpur.com

AN ISO 9001 COMPANY

13) Close quick hogger line valve (01-MAG-33-AA-59). 14) Both holding pumps (Tag no. 01-MAG-00-AP-03 & 01-MAG-00-AP-04) will run till the pressure reaches to 15 KPA (a). 15) Second holding pump (Tag no. 01-MAG-00-AP-04), which is a stand-by pump considering operation, will stop automatically when the pressure reaches to 15 KPA (a). Now only first holding vacuum pump (Tag no. 01-MAG-00-AP-03) is in operation in holding mode. 16) Stand-by holding pump (Tag no. 01-MAG-00-AP-04) will again come into operation if pressure reaches to 20 KPA (a). The unit is ready to accept turbine exhaust steam. All fans are in OFF position. As the steam flow increases, the turbine exhaust pressure also increases. Note that the condensate tank level also rises. The recirculation valve (TEB system) is regulated to control the liquid level When the absolute pressure at TEB reaches 20 KPA (a), depending on the back-pressure input coming from PTs (01-MAG-01-CP-001/01-MAG-01-CP-002) to PLC, the fan switching-on sequence will be initiated depending on the back pressure rise. A time delay is built-in to avoid excessive in rush of current.

NORMAL OPERATION
All fans are at full speed. There are two possible modes of operation. a) As the ambient temperature decreases, the B.P can be kept at design point and fan can be switched to OFF position progressively. Or b) The B.P can be reduced to lowest possible operating pressure by keeping all fans at full speed. Once the minimum B.P is reached, the fans can be switched off

PAHARPUR COOLING TOWERS LIMITED

Paharpur House, 8/1/B, Diamond Harbour Road, Kolkata - 700 027, INDIA. : (033) 4013 3000 Fax: +91 - 33 -2 479 - 2188 E - Mail: pctccu@paharpur.com

AN ISO 9001 COMPANY

If the ambient temperature increases, the back pressure will also increase. See performance curve for expected back pressure values. If the B.P rises beyond the turbine alarm pressure, the alarm will be sounded in the control room. The steam load has to be reduced to lower the BP down to below alarm B.P.

SHUT DOWN PROCEDURE.

As the steam flow decreases, the B.P also decreases. When the B.P. reaches the minimum set point, the fans are sequentially switched off. When any vacuum pump is switched off, the corresponding pneumatic butterfly valve(s) in the NCG line(s) will be closed by energizing respective 5-way solenoid valve(s) in the same line. Follow condensate extraction pump manufacturers procedure for shut off sequence.

OPERATION & CONTROL FOR LIQUID RING VACUUM PUMP

Controls for vacuum pump include the following activities; 1. Control of motors(To start or stop): The system is to be initialized before starting the motors. The system inlet valves 01-MAG-38-AA022, 01-MAG-36-AA-027, 01-MAG-37-AA-043 & 01-MAG-35-AA-044 are to be closed, separator level has to be above low level (120 mm), the motor and bearing temperature is not high & all motors are to be in STOPPED condition. All vacuum pump motors and recirculation pump motors can be started (GROUP-start with the sequential time delay, one after another). 2. Control of separator level: The level switches 01-MAG-103-CL-001/01-MAG-102-CL-002 at separator is set at low level (120 mm) and the normal level (165 mm). When the separator level falls below low level the respective make-up water valve 01-MAG-47-AA-019/01-MAG-57-AA-036 will open for make-up water. On the other hand when level rises above 165 mm, the respective make-up water valve will close.

3. Over-temperature control for process liquid: When the temperature of process liquid TE (01-MAG-58-CT-322/01-MAG-59-CT-323) rises above 45 deg C, there is an alarm in PLC.

PAHARPUR COOLING TOWERS LIMITED

Paharpur House, 8/1/B, Diamond Harbour Road, Kolkata - 700 027, INDIA. : (033) 4013 3000 Fax: +91 - 33 -2 479 - 2188 E - Mail: pctccu@paharpur.com

AN ISO 9001 COMPANY

4. Control of Stand-by pump: While one vacuum pump is running, if pressure (vacuum) increases to 20 KPA(a), the solenoid valve 01-MAG-54-AA-054 turns on the respective system pressure switch 01-MAG-36-CP-103 will open system inlet valve and the stand-by pump will start. This control will be through PLC. Again, while two vacuum pumps are running, if pressure (vacuum) falls below 15 KPA(a), the solenoid valve 01-MAG-55-AA-053 turns on the respective system pressure switch 01-MAG- 38-CP101 will close system inlet valve and the stand-by pump will stop. This control will be through PLC.

FAN SWITCHING-ON SEQUENCE

ACC FAN SERIAL NUMBERING: 8 7 6 5 4 3 2 1 16 15 14 13 12 24 23 22 21 20 32 31 30 29 28

Secondary Modules 11 19 27 10 9 18 17 26 25

TG BUILDING SIDE

PAHARPUR COOLING TOWERS LIMITED

Paharpur House, 8/1/B, Diamond Harbour Road, Kolkata - 700 027, INDIA. : (033) 4013 3000 Fax: +91 - 33 -2 479 - 2188 E - Mail: pctccu@paharpur.com

AN ISO 9001 COMPANY

Fan should be switched-on as per the following sequence;

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Fan Sl. No.4 Fan Sl. No.12 Fan Sl. No.20 Fan Sl. No.28 Fan Sl. No. 8,16, 24 & 32, one by one Fan Sl. No. 7, 15, 23 & 31, one by one Fan Sl. No. 6, 14, 22 & 30, one by one Fan Sl. No. 5, 13, 21 & 29, one by one Fan Sl. No. 3, 11, 19 & 27, one by one Fan Sl. No. 2, 10, 18 & 26, one by one Fan Sl. No. 1, 9, 17 & 25, one by one

FAN SWITCHING-OFF SEQUENCE

Fan should be switched-off as per the following sequence; 1. 2. 3. 4. 5. 6. 7. 8. Fan Sl. No 1, 9, 17 & 25, one by one Fan Sl. No 2, 10, 18 & 26, one by one Fan Sl. No 3, 11, 19 & 27, one by one Fan Sl. No 5, 13, 21 & 29, one by one Fan Sl. No 6, 14, 22 & 30, one by one Fan Sl. No 7, 15, 23 & 31, one by one Fan Sl. No 8, 16, 24 & 32, one by one Fan Sl. No 4, 12, 20 & 28, one by one

The fan switching-off at partial load may be done manually or through PLC depending on the back pressure as per signals received from PTs (01-MAG-01-CP-001/01-MAG-01-CP-002) to PLC. The fan switching-off sequence may be initiated when the absolute pressure at TEB reaches 16 KPA (a), depending on the fall in back pressure. The same logic may also be followed for change in effective load due to drop in ambient temperature at site.

PAHARPUR COOLING TOWERS LIMITED

Paharpur House, 8/1/B, Diamond Harbour Road, Kolkata - 700 027, INDIA. : (033) 4013 3000 Fax: +91 - 33 -2 479 - 2188 E - Mail: pctccu@paharpur.com

AN ISO 9001 COMPANY

OPERATING PRINCIPLE
As air is the cooling medium, the ACC is located outdoors. As the ACC is located away from the turbine exhaust, steam has to be delivered to the ACC. 5800 MM OD large duct is used for this purpose. The cooling air flows outside the multitude of tubes required to condense the steam. The steam flows through the inside of the tubes. The condensate is drained to the Turbine Exhaust Box. The steam from the turbine exhaust is under vacuum. From the flange connections, gland seals and chemicals used to scavenge oxygen from the boiler, non condensibles (mainly air) leak into the steam. The non condensibles have to be removed continuously to achieve effective operation of the ACC. Non condensibles removal equipment, liquid ring vacuum pumps, are used to remove the non condensibles. To ensure effective removal of non condensibles as the steam is condensed in the tubes, the tubes are separated into two sections. Most of the steam is condensed in the main or primary condenser section and the remaining steam in the after cooling or secondary condenser section. The main and the after-cooling sections are connected in series. The series connection assists in accumulating the non condensibles at the end of the after cooler section. The end of the after cooling section is connected to the non condensibles removal equipment to be vented to the atmosphere. The cooling air flow is delivered by axial fans driven by electric motors via gearboxes. For the air to flow through the fans, the ACC has to be elevated above grade level. Concrete structure is used to elevate the ACC.

MAIN CONDENSER & AFTER-COOLING SECTION

As the ACC is located outdoors, it must be capable of operating under the range of ambient temperature it is subjected to. The goal is to achieve positive steam flow from the main condenser at all ambient temperature conditions. The main and after cooler section consist of single row of tubes. The tubes are clustered together to form a tube bundle. The length of the tube and the width are decided by the design requirement and transport limitation. A number of these bundles are located over the fan to form a section, often known as cell or module. A number of these sections make up the main condenser and after cooler. To make the unit compact, the sections are arranged to form an A-Frame. Steam enters at the top of the A-Frame and the condensate flows out from the bottom.

PAHARPUR COOLING TOWERS LIMITED

Paharpur House, 8/1/B, Diamond Harbour Road, Kolkata - 700 027, INDIA. : (033) 4013 3000 Fax: +91 - 33 -2 479 - 2188 E - Mail: pctccu@paharpur.com

AN ISO 9001 COMPANY

Each module consists of one fan to deliver the air flow. The fan is located at the bottom of the A-frame. The fan delivers the air flow in forced draft mode (the fan forces the air through the bundles). There are six (6) tube bundles located on either side of the A-frame. The ends of the A-Frame are closed by panels to provide a chamber for each fan to deliver all the cooling air to the bundles. To operate the ACC over the range of ambient temperature at site, the ratio of the main condensing section to the after cooler section is set at 87.5: 12.5. A number of main condensing and after cooling sections are located adjacent to each other to form an AFrame street. Each street has eight (8) modules (seven main condensing modules and one after-cooler module).The after cooler module is located in the middle in between the main condenser modules.

CAUSES AND EFFECTS

(1).VIBRATION:If the vibration set limit (6.3 mm/sec) is exceeded, an alarm signal is sent to PLC and the respective motor is switched off. The turbine exhaust pressure rises due to motor being switched-off. The motor is locked out to investigate the cause of vibration. The fan & gearbox are required to be checked.

(2).VACUUM PUMPS:In case, the operating vacuum pump stops, an alarm signal is sent to PLC and the standby pump comes into operation. No visible change in turbine exhaust pressure will occur as the stand-by pump comes into operation within a very short time.

PAHARPUR COOLING TOWERS LIMITED

Paharpur House, 8/1/B, Diamond Harbour Road, Kolkata - 700 027, INDIA. : (033) 4013 3000 Fax: +91 - 33 -2 479 - 2188 E - Mail: pctccu@paharpur.com

AN ISO 9001 COMPANY

(3).RECIRCULATING SEAL WATER PUMP:The pump stops operating. An alarm signal is sent to PLC. The operating vacuum pump is stopped and the stand-by vacuum pump is started.

(4).COOLING WATER TO VACUUM PUMP:If water flow is stopped, sealing water temperature rises and pressure will increase. When the water temperature exceeds 45 deg C, the alarm is sent to PLC.

REFERENCE ACC P & ID Drg. No is MCCPL-PCTL-ACC-DWG-I-0001

REFERENCE ACC P & ID (FOR VACUUM PUMP SECTION) is Drg. No isMCCPL-PCTL-ACC-DWG-I-0003

PLEASE REFER TO THE ATTACHED ANNEXURE-1 FOR ON-OFF LOGIC & ANNEXURE-II FOR CONTROL DESCRIPTION (AS RECEIVED FROM M/s G D NASH) APPLICABLE FOR VACUUM PUMPS

20 KPA(a) 20 KPA(a)

PLC

PLC

PLC INDICATION

PLC ALARM

15 KPA(a) 15 KPA(a)

20 KPA(a) 20 KPA(a)

TITLEControl description for condenser vacuum pump DOC NO.: MARUT-VAC-022 C B A REV NO. Oct.10,2012 Sep.24,2012 Jul. 06, 2012 DATE Third Second issue Initial issue REVISION SUMMARY Keguo.Li Keguo.Li Keguo.Li PREPARED Gang.Hou Gang.Hou Gang.Hou REVIEWED

NOTE: 2BE4 400 should be operated manually. In this description, auto control description are only for TC-11E unless special noted. 1. DISCRIPTION AND FUNCTION

The vacuum pump unit consists of the liquid ring vacuum pump, directly coupled main drive motor, separator, plate type heat exchanger, common base, recirculation pump(except for 2BE4 400), interconnecting piping, junction box with interconnecting wiring on the common base plate. 2. 2.1 OVERALL UNIT OPERATIONS OPERATIONS FOR TC-11E

The seal water in the Condenser Exhaust Unit is circulated through a closed loop that consists of a two-stage vacuum pump, a separator, a centrifugal pump and a heat exchanger. Seal water is pumped by the centrifugal pump from the separator through the heat exchanger to the vacuum pump. As the seal water flows through the heat exchanger, it is cooled to a temperature approximately 2 to 4 (1 to 2) above the inlet temperature of the cooling water that flows through the heat exchanger. Seal water from the heat exchanger outlet flows to the vacuum pump where it is fed to the head of the vacuum pump.

Seal water entering the head is applied through open spray nozzle that is threaded into the head. The spray nozzle form the seal water into a spray pattern through which the system air-water vapor mixture entering the vacuum pump must pass. As the system air-water vapor mixture contacts the seal water spray, most of the water vapor in the mixture is condensed. The condensed water vapor, the balance of the air-water vapor mixture and seal water spray flow through inlet passages in the first stage head into the vacuum pump.

At the same time, the seal water fed directly to the vacuum pump from the heat exchanger flows through the passages in the first stage head into the pump to seal clearances in the vacuum pump. Within the pump, the seal water contacts the mixture flowing from the head. Water vapor in this mixture is thereby condensed, reducing the volume of air that has to be removed by the two-stage vacuum pump.

PROJECT: PAHARPUR 300MW ACC 1/5

The inlet air is partially compressed in the first stage of the vacuum pump and is discharged with the seal water to the inlet of the second stage of the vacuum pump. The second stage compresses the air to atmospheric pressure and discharges all of the seal water and compressed air into the separator.

Within the separator,the seal water drops from the air stream to the bottom of the separator. Two automatic switched and make-up solenoid valve and an over-flow loop maintain the proper level of seal water. The discharge air, from which the seal water has been separated, passes through the separator outlet and through the air leakage test valve to the atmosphere.

The low level switch senses the level of water in the separator. If the level low, the low switch opens the make-up solenoid valve, permitting make-up water to flow into the vacuum pump. When the water level in the separator is high enough to provide the proper reservoir of seal water. For the vacuum pump, the normal level switch closes the make-up solenoid valve. An overflow loop automatically controls the maximum water level in the separator. Level switch sent level signal of separator to DCS/PLC for indication. Thermo-resistance detects temperature of process liquid of sealing water line(if rises above 45 DCS/PLC alarm). 2.2 OPERATIONS FOR 2BE4 400 The seal water in the Condenser Exhaust Unit is circulated through a closed loop that consists of a one-stage vacuum pump, a separator. 2BE4 400 should be operated manually.

3.

Detail control description

3.1 DISTINCTION SHOULD BE MADE BETWEEN THE FOLLOWING MODES FOR OPERATING 3.1.1 Hogging operation (all vacuum pumps operate parallel to reduce evacuation time) In hogging operation the air is extracted from the condenser into suction connection of all the vacuum pumps via suction line and inlet butterfly valve (FV). Holding standby pump (TC-11E) ends automatically when a suction pressures reached by 15kpa .A (PSHH). Hogger pump(2BE4 400) needs to stop manually when a suction pressures reached by 30 kpa.A or other setpoint (PSHH). 3.1.2 Holding operation (one vacuum pump is in operation, the other is stand-by) The vacuum pump unit is set to the holding operation by shutdown of the stand-by vacuum pumps controlled by pressure switch at vacuum level 15kpa.A. 3.2 Function description of the parts (only for TC-11E)
PROJECT: PAHARPUR 300MW ACC 2/5

The suction line is equipped with a pneumatically operated butterfly valve (FV), pressure gauge to have the suction pressure indicated locally and the pressure switch to control the system inlet valve (FV) and the pressure switch to control the stand-by pump on/off. The pneumatic operated butterfly valve (FV) has operating actions such as below. When the pump is operated at hogging condition (Ambient condition in condenser), Pneumatic valve is opened by solenoid valve. When the turbine is stopped long time, vacuum pump will be stopped and inlet valve will be closed by 5-way solenoid valve Inlet valve should be opened at hogging and holding condition. Inlet valve should be closed by stop signal of vacuum pump motor. When the pump starts by switching on vacuum pump motor, Pneumatic valve will be opened by energizing 5-way solenoid valve at the same time. When the pump stops by switching off vacuum pump motor, Pneumatic valve will be closed by energizing 5-way solenoid valve at the same time. When the stand-by pump starts by switching on vacuum pump motor, if pressure after system butterfly is lower than 20kpa.A, delay, pneumatic valve will be opened by energizing 5-way solenoid valve at the same time. When the stand-by pump stops by switching off vacuum pump motor, Pneumatic valve will be closed by energizing 5-way solenoid valve at the same time. The leakage air is indicated by flow meter . Release the hand lever after max. 20 seconds and the valve will open self-acting. Air leakage measurements can only be taken during holding operation with steady condenser operation condition.

The separator is provided with a liquid level gauge(LI), two level switches (LSL/LSN)with solenoid valve (SV) to make up seal water, drain ball valve and overflow loop. The water level in the separator is shown by the level gauge (LI). The level switch signal opens the solenoid valve (SV) when the water level is dropped below at predetermined point and the level switch (LSL/LSH) signal closes the solenoid valve when the water level is raised at predetermined point of level as set guild line of sheet 2.

SHEET 1 Item NO. Tug number NORMAL Solenoid valve off SEPARATOR A SEPARATOR B 165mm Not applicable LOW Solenoid valve on 120mm Not applicable TC-11E 2BE4 400 ALARM SET POINT LOW LOW REMARKS

The fresh water is supplied via the solenoid valve to feed seal water into the separator until the desired
PROJECT: PAHARPUR 300MW ACC 3/5

liquid level is attained. The operating water is required to perform the liquid ring in the vacuum pump. It is drawn out of the separator by recirculation pump, then fed via pipe to the heat exchanger and after cooling returned to the vacuum pump through pipe. The heat due to compression and also the heat resulting from condensing of the vapor drawn in with the air are thereby drawn off from the operating water and dissipated.

The Heat exchanger connection is provided with temperature gauge (TI) to indicate the operating water and cooling water temperature locally. The overflow loop drains off excess water through the drain pipe. All electric instruments except main drive motor and motor for recirculation pump are wired up to the junction box separately as analog, switch, etc.

4.

Vacuum Pump Motor and Recirculation Pump Motor control (TC-11E)

When vacuum pump motor is running , then start the recirculation Pump Motor . When vacuum pump motor is running and recirculation Pump Motor is not running, Vacuum pump motor should be shut down if the case continues for 20 seconds.

5.

CONTROL & TRIP CONDITIONS (TC-11E)

5.1 HEAT EXCHANGER 1) Cooling water to supply to heat exchanger *If vacuum pump trip conditions are not released, pump should not be started by auto mode. 5.2 VACUUM PUMP-VACUUM PUMP START CONDITION 1) Separator level not low 2) Vacuum pump motor ready to run -Vacuum pump trip condition 1) Vacuum pump motor trip on overload relay 2) Vacuum pump trip on Emergency trip from Field 3) Recirculation pump motor trip on Motor overload relay operates or emergency trip from field. 4) Pneumatic butterfly valve do not open within 30 seconds after vacuum pump start up. 5.3 RECIRCULATION PUMP-Recirculation pump start conditions 1) Separator level not low (Refer to the sheet 1 for Set points.) 2) Recirculation pump motor is ready to run. -Recirculation pump trip conditions 1) Recirculation pump motor trip on overload relay or emergency trip from field. 2) Separator level trip condition (Refer to the sheet 1 for Set points of low level.) 5.4 SYSTEM INLET VALVE (Auto open/close condition)
PROJECT: PAHARPUR 300MW ACC 4/5

-Inlet valve open The system inlet valve initialization is closed While the motor is "running", if the pressure switch< 20kpa.A PSHL ,DCS/PLC give signal to solenoid valve, then open inlet valve(FV).When the motor stopped, then inlet valve keep position 5.5. MAKE-UP LINE SOLENOID VALVE ON-OFF CONDITION -Refer to the sheet 1 for separator set points The level switch set the low level (120mm) and the normal level (165mm).When the level falls b elow 120mmDCS/PLC control make-up water valve(SV) to open to make up water, and when

the level rises above 165mm, DCS/PLC control make-up water valve to close. If the level low remains 5 seconds, DCS/PLC alarm; If the level low remains 5 minites, DCS/PLC interlock. 5.6.Control of the standby pump -The main and standby pump operation is recommended for hogging condenser to operate vacuum At the operating vacuum, set one pump to "standby", When the pressure falls below 15kpa.A,DC S/PLC give signal to stop the stand-by pump; and when the pressure rises above 20 kpa.A, DCS/P LC give signal to start stand-by pump.

-When the main pump stopped because of fault or repairmentthe standby pump will start. The control logic will be realized in DCS/PLC system. The logics for other pumps are the same.

6.ALARMS - All trip conditions - The system inlet valve is not operated successfully for more than 30 seconds. -When seal water temperature is 45,the TE will give signal to DCS/PLC system , then DCS/PLC give alarm signal - Level alarm when liquid level in separator is less the set point.(Refer to the sheet 1 for Set points.)

PROJECT: PAHARPUR 300MW ACC 5/5


Gardner Denver Nash Machinery Ltd
C B EDIT. CFC CFC STATUS LKG DESIGNED HG CHECKED ZZX
APPROVALED

Control description for condenser vacuum pump

Doc..No:MARUT-VAC-022

PROJECT SUBPROJECT SPECIALITY STAGE

PAHARPUR 300MW ACC CONDENSER VACUUM PUMP AUTOMATIZATION Shop drawing :1 3 Pages:Sheet 1 of 3

Control description for condenser vacuum pump (TC11E)

Controls for the pump include: control of the motors to stop or startcontrol of the separator level; control of the system inlet valve to open or close; motor stators and bearing temperature measuring; control of the standby pump. Please refer to the logic drawing to read the description. The system initialization: systme inlet valve (FV) "closed"; the separator level correct; the motor "stopped". The motor to start or stop While the system start command exists, if system inlet valve (FV) "closed"; the separator level "not low"; the motor stators and bearing temperature "not high", Start the vacuum pump motor(M01) and recirculating pump motor(M02). While the system stop command exists, stop the vacuum pump motor (M01) and recirculating pump motor(M02). If the vacuum pump motor (M01) is "stopped", the system inlet valve (FV) will be closed. The system inlet valve to open or close The system inlet valve initialization is closed While the vacuum pump motor (M01) is "running", if the vacuum degree > 20kpa.A, pressure switchPSHactionsolenoid valve741-2-Y1turn on to open inlet valve (FV). When the vacuum pump motor (M01) stoppedsolenoid valve741-2-Y2turn on to close inlet valve (FV). 741-2-Y1 and 741-2-Y2 can not turn on at same time, and only impulse is enough. 741-2-Y1 and 741-2-Y2 all turn off, system inlet valve (FV) remains as before

45999# TC-11E 2012.10.10


Gardner Denver Nash Machinery Ltd
C B EDIT. CFC CFC STATUS LKG DESIGNED HG CHECKED ZZX
APPROVALED

Control description for condenser vacuum pump

Doc..No:MARUT-VAC-022

PROJECT SUBPROJECT SPECIALITY STAGE

PAHARPUR 300MW ACC CONDENSER VACUUM PUMP AUTOMATIZATION Shop drawing :2 3 Pages:Sheet 2 of 3

III. Separator level monitor and control The level swiches set the low level (120mm) and the normal level (165mm). When the level falls below 120mmDCS/PLC control make-up water valve (SV) to open to makeup water, and when the level rises above 165mm, DCS/PLC control make-up water valve (SV) to close. If the low level remains 5 seconds, DCS/PLC alarm. If the low level remains 5 minites , DCS/PLC interlock to stop the motor. Level transmitter sent level signal of separator to DCS/PLC for indication. VTemperature of process liquid monitor and control Temperature of process liquid TE rises above 45DCS/PLC alarm VI Control of the standby pump The main and standby pump operation is recommended for hogging condenser to operate vacuum At the operating vacuum, set one pump to "standby" , When the vacuum degree rises above 15kpa.A, the pressure switch (PSHH) act to stop the stand-by pump; When the vacuum degree falls below 20 kpa.A, the pressure switch (PSHL) reset to restart stand-by pump. When the main pump stopped because of fault or repairment the standby pump will be started. The logic for other pump system is the same. The logic for control should be realized in customer's DCS/PLC system.

45999# TC-11E 2012.10.10


Gardner Denver Nash Machinery Ltd
C B EDIT. CFC CFC STATUS LKG DESIGNED HG CHECKED ZZX
APPROVALED

Control description for condenser vacuum pump

Doc..No:MARUT-VAC-022

PROJECT SUBPROJECT SPECIALITY STAGE

PAHARPUR 300MW ACC CONDENSER VACUUM PUMP AUTOMATIZATION Shop drawing :3 3 Pages:Sheet 3 of 3

Control description for vacuum pump 2BE4 400

Controls for the pump include: control of the motors to stop or start; control of the system inlet valve to open or clos; control of the standby pump. Please refer to the logic drawing to read the description. The system initialization: systme inlet valve (FV) "closed"; make-up water open; the motor "stopped". The motor to start or stop While the system start command exists, if system inlet valve (FV) "closed"; start the vacuum pump motor(M1) . While the system stop command exists, stop the vacuum pump motor (M01) . If the vacuum pump motor (M01) is "stopped", the system inlet valve (FV) will be closed. The system inlet valve to open or close The system inlet valve initialization is closed While the vacuum pump motor (M01) is "running", solenoid valve741-2-Y1turn on to open inlet valve (FV). When the vacuum pump motor (M01) stoppedsolenoid valve741-2-Y2turn on to close inlet valve (FV). 741-2-Y1 and 741-2-Y2 can not turn on at same time, and only impulse is enough. 741-2-Y1 and 741-2-Y2 all turn off, system inlet valve (FV) remains as before III. Control of the standby pump The main and standby pump operation is recommended for hogging condenser to operate vacuum When the main pump stopped because of fault or repairment the standby pump will be started. The logic for other pump system is the same. The logic for control should be realized in customer's DCS/PLC system.

45999# 2BE4 400 2012.10.10