Reference LAC50 DM

SYSTEM MANUAL
LAC50 - HP FEEDWATER PUMP SYSTEM

Owner :
PT. PLN (PERSERO) PROYEK INDUK PEMBANGKIT DAN JARINGAN JAWA, BALI & NUSA TENGGARA JL. SLAMET NO. 1 CANDI BARU SEMARANG - INDONESIA
MUARA TAWAR GAS FIRED POWER PLANT EXTENSION PROJECT, BLOCK 5, INDONESIA
Contract No: 261.PJ/041/DIR/07
Drawing No:
Owners Engineer :
The Consortium of TOKYO ELECTRIC POWER SERVICES CO.LTD And FICHTNER GmbH & Co.KG
Status A B C Reviewed Reviewed with Comments As Built
Action Date Recorded Issued Date Returned Reviewed Checked
Project Manager Consortium :
Lead Engineer in Charge
Engineer
Alstom (Switzerland) Ltd

PT Alstom Power Energy Systems Indonesia
Revision History
Rev. Rev. Date Created by Checked by Approved by Description
Consortium Partner
ALSTOM (SWITZERLAND) LTD., Brown Boveri Strasse 7, CH 5401-Baden

Replaces Responsible dept. Created by Checked by Consortium Document Code
MTV/58/M/LAC50-----/DM/001
Approved by Format
GSAEM-MY
Originator
Loi T.-S.
Title, Subtitle
Janarthanan H.
Document Type
Sharma R.-K.
Document Status
A4
Design Manual SYSTEM MANUAL LAC50 - HP FEEDWATER PUMP SYST

ALSTOM 2009. All rights reserved.
Electronically released
Identification number
1AHA071015
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Please consider the environment before printing this document.
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Copyright
All rights reserved Copyright 2011 ALSTOM (Switzerland) Ltd. 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.
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Contents
1 Introduction......................................................................................................................................................... 11 1.1. 1.2. Purpose........................................................................................................................................................... 11 System Overview............................................................................................................................................ 11 Main Equipments .......................................................................................................................11 Interface to other Systems.........................................................................................................12
1.2.1. 1.2.2. 2.
Safety Instructions ............................................................................................................................................ 13 2.1. 2.2. General Safety Instructions............................................................................................................................ 13 System-specific Safety Instructions ............................................................................................................... 13
3.
System Description ........................................................................................................................................... 17 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. Overview ......................................................................................................................................................... 17 HP Feedwater Pump...................................................................................................................................... 17 Pump Suction Strainer ................................................................................................................................... 18 Automatic Recirculation Check Valve ........................................................................................................... 18 The Lube Oil System...................................................................................................................................... 18 Electric Motor .................................................................................................................................................. 18 Noise Hood ..................................................................................................................................................... 19
4.
Operation............................................................................................................................................................. 21 4.1. Overview ......................................................................................................................................................... 21 Specific Safety Instructions .......................................................................................................21 Equipment Operating Instruction ...............................................................................................23 Automatic Control Logic ............................................................................................................23
4.1.1. 4.1.2. 4.1.3. 4.2. 4.3. 4.4.
Conditions Prior to Start-up............................................................................................................................ 24 Normal Start-up............................................................................................................................................... 24 Initial Filling of the System.............................................................................................................................. 25 Pre-conditions to fill the system.................................................................................................25 Procedure to fill the system .......................................................................................................26
4.4.1. 4.4.2. 4.5.
Normal Operation ........................................................................................................................................... 27 Normal operation .......................................................................................................................27 Pump change-over ....................................................................................................................27
4.5.1. 4.5.2. 4.6. 4.7. 4.8. 4.9.
Normal Shut-down.......................................................................................................................................... 27 Abnormal Operation ....................................................................................................................................... 28 Inadmissible Operation................................................................................................................................... 28 Other Operation Modes.................................................................................................................................. 29 Failure of Equipment .................................................................................................................29
Identification number Rev. Date Lang. Sheet
4.9.1.
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4.9.2. 4.9.3. 4.9.4. 4.9.5. 5.
Standby......................................................................................................................................29 Measures during outages ..........................................................................................................29 Shutdown for maintenance or long-term outage .......................................................................29 System preservation..................................................................................................................29
Maintenance........................................................................................................................................................ 31 5.1. 5.2. Specific Safety Precautions ........................................................................................................................... 31 System-related Maintenance ......................................................................................................................... 31 Daily Checks..............................................................................................................................31
5.2.1. 5.3. 6.
Depressurization Prior to Maintenance ......................................................................................................... 32
Appendices ......................................................................................................................................................... 35 6.1. 6.2. 6.3. Manual Preparation Check List prior to Start-up........................................................................................... 35 Alarm List ........................................................................................................................................................ 37 External documents and diagrams................................................................................................................ 39
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List of Tables
Table 1 Table 2 Table 3 Table 4 Table 5 Brief Description of Manual Contents ......................................................................................7 Abbreviations and Acronyms.................................................................................................10 Manual Preparation Check List prior to Start-up ...................................................................36 Alarm List...............................................................................................................................38 External Documents and Diagrams.......................................................................................39
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About this Manual

Purpose This manual contains the essential information needed for safe and efficient handling and maintenance of the described systems. The information in this manual is compulsory reading matter for anyone working with or at the systems and equipments. This means that every one must understand what safety means. ALSTOM Power declines all responsibility for personal injuries or material damages occurring as a result of non-observance of the instructions and warnings in this manual!
Target Audience This manual is written for everyone working on or with the described systems. It conveys information for different user audiences to understand and fulfill their work and duties. Manual Contents Chap 1 2 3 4 5 6 Table 1 Title Introduction Safety Instructions System Description Operation Maintenance Appendices Contents Provides an overview of the system and its equipments Describes the safety rules and general residual risks Describes the system and its equipments on a functional level Describes the operation sequences required for routine operational tasks and the standard operational phases Contains basic maintenance schedules and describes various maintenance procedures. Contains miscellaneous additional documents, e.g. piping and instrumentation diagrams (P & ID)
Brief Description of Manual Contents
How to Use this Manual This manual is a reference book. It requires application knowledge acquired in training courses delivered by ALSTOM. There are several features that will help you find specific information quickly: Table of Contents at the beginning of the book Lists of figures and tables at the beginning of the book Alphabetical Index at the end of the book A manual is also a notebook, feel free to write your own notes, ideas, questions, indices, glossary items, etc. into this manual.
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Symbols used in this Manual

DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.
DANGER
Type/Source of Hazard Hazard consequences Steps to avoid the hazard.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
WARNING
Type/Source of Hazard Hazard consequences Steps to avoid the hazard.
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 Steps to avoid the hazard.
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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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Abbreviations and Acronyms

Item CCWS DCS FG GT HP HRSG P & ID WSC Table 2 Explanation Closed Cooling Water System Distributed Control System Function Group Gas Turbine High Pressure Heat Recovery Steam Generator Piping and Instrumentation Diagram Water Steam Cycle Abbreviations and Acronyms
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1
1.1.
INTRODUCTION
Purpose
The system fulfils the following tasks: Feeding the HP drum of the HRSG with feedwater from feedwater storage tank Providing the HP live steam attemperator of the HRSG with feedwater for water injection
1.2.
System Overview
Note For an overview of the system, refer to P & ID MTV/58/M/LAC50-----/FD/001.
1.2.1.
Main Equipments The system is made up of two redundant pump systems (2 x 100%) feeding the feedwater consumers via a common piping. It consist of the following main equipments: HP feedwater pump
58LAC50AP001
58LAC60AP001 HP feedwater pump suction shut-off valve
58LAB51AA001 58LAB61AA001
HP feedwater pump suction line strainer
58LAC50AT001 58LAC60AT001
HP feedwater pump discharge shut-off valve 58LAB52AA002 58LAB62AA002 HP feedwater pump minimum flow recirculation shut-off valve
HP feedwater pump filling bypass shut-off valve
The common HP feed water discharge line consists mainly of: Common HP feed water discharge line 58LAB95BR001 Sampling probe extraction line 58LAB95BR401 Common discharge line pressure measurements 58LAB95CP001, 58LAB95CP002 and 58LAB95CP003
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HP feedwater pump 58LAC50AP001 is equipped with the following equipments: Auxiliary lube oil pump (2 X 100% per HP feedwater pump)
58LAC51AP001 (electrically driven standby lube oil pump) 58LAC51AP002 (shaft driven main lube oil pump)
Noise hood light
58LAC56AH052
Motor space heater
58LAC50AH001
Noise hood fan
58LAC56AH050 58LAC56AH060
The equipments for pump 58LAC60AP001 are similar with exception of the KKS function number code first digit, which changes from 5 (e.g 58LAC50AP020) to 6 (e.g 58LAC60AP020). 1.2.2. Interface to other Systems Feedwater enters from the feedwater storage and deaeration system (LAA) and exit at the HP economizers of the HRSG. The minimum recirculation flow returns back to the feedwater tank (LAA). A part of the feedwater leaves to the sampling system (QUL). Cooling water from closed cooling water system (PG) to cool pump mechanical seal, lube oil cooler and motor cooler system.
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2.
2.1.
SAFETY INSTRUCTIONS
General Safety Instructions
All personnel working with or at the systems and equipments must have read and understood the safety instructions in ALSTOM technical manual TN04/0297, which is part of the overall customer documentation set.
2.2.
System-specific Safety Instructions
WARNING
Water steam cycle under high pressure and high temperature Inappropriate handling can cause serious injuries or death. Prior start-up Ensure that the equipments and instruments are ready for operation. Refer to section 6.1 Manual Preparation Check List prior to Start-up on page 35. Follow the Water Chemistry WSC Technical Specification to ensure the required water and steam quality. Ensure that the instrument root valves for all permanent instruments are open. Refer to section 6.1 Manual Preparation Check List prior to Start-up on page 35.
Ensure that 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 section 6.1 Manual Preparation Check List prior to Start-up on page 35. Prior maintenance Ensure that the system is depressurized, cooled down and drained.
Secure the drives and valves against unintentional starting and moving. Do not modify systems or equipments. The instructions of the equipment suppliers must be adhered to.
WARNING
Hot surface Inappropriate handling can cause serious burns Do not touch piping- or component-surface, if there is no heat insulation and the plant is not cooled down.
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WARNING
High voltage/Electrical shock Electric motors and actuators powered with high voltage, inappropriate handling can cause serious injuries or death. Keep away from live parts. Do not remove guards. Avoid wet surfaces. Prior to maintenance: Isolate equipment from power supply. Take effective measures to prevent reconnection. Ensure no residual voltage remains. Do not modify systems or equipment. The instructions of the equipment suppliers must be adhered to.
WARNING
Rotating or moving parts Inappropriate handling can cause serious injuries or death. Keep away from rotating or moving parts. Do not remove guards. Prior to maintenance, take effective measures to prevent rotating or moving. Do not modify systems or equipment. The instructions of the equipment suppliers must be adhered to.
WARNING
Flammable lubrication oil Inappropriate handling can cause fire and serious burns Shutdown the pumps system in case of major oil leakages Remove oil before maintenance activities in e.g. welding
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WARNING
Hot medium The feedwater temperature can be up to 150C. Inappropriate handling can cause serious burns Do not open vent valves during operation or during standstill unless the system is depressurized and cooled down Wait for system cool down before maintenance activities
DANGER
Danger of suffocation Nitrogen in high concentration can cause unconsciousness and lead to suffocation. Avoid inhaling of leaking gas. Ensure sufficient ventilation. Close drains / vents when gas is leaking. Close sampling isolation valves. For safety reasons it is strongly recommended not to enter the hazardous area alone (team of minimum two people).
The HP feedwater pump system and its equipment must be operated and maintained by trained and authorized personnel only! All applicable safety rules and regulations are strictly to be followed. For equipment 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.
Read the equipment safety instructions before operation!
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3.
3.1.
SYSTEM DESCRIPTION
Overview
Feedwater enters the HP feedwater pump suction lines from the feedwater storage tank . Each pump has its own suction line, which can be individually isolated from the feedwater storage tank by means of manually operated suction line shut-off valves. Downstream of the suction line shut-off valves there are strainers installed in order to prevent dirt from entering the pumps. Differential pressure transmitters are installed for monitoring of the strainers. The filtered feedwater is fed to the suction nozzle of the HP feedwater pump. The HP feedwater pump increases the fluid pressure depending on the feedwater flow demand. The minimum required flow rate through each operating HP feedwater pump is ensured by the automatic recirculation check valve that is installed downstream of the HP feedwater pump discharge nozzle. The HP recirculation flows are fed back into the feedwater storage tank. Throttling orifices are provided in the recirculation line near to the feedwater tank in order to prevent steaming out. Before starting the first pump, the common feedwater line might be empty or not pressurised. To ensure the minimum required back pressure at the pump discharge, the motorised discharge shut-off valves remain closed during start-up and the feedwater lines are filled and pressurised via the filling bypass line. The bypass flow is limited by the filling bypass line of the 4 way automatic recirculation check valve. When the pressure in the common feedwater line has exceeded a minimum value, the HP feedwater pump discharge shut-off valve opens. The four way automatic recirculation check valve limits the filling bypass flow and also prevents reverse rotation of the standby pump by back-feed through the main line. Back-feed through the filling line is prevented by means of the check valve actions of ARC valve. The HP pump lines downstream of the discharge shut-off valves are connected to the common HP feedwater line. The common HP feedwater line is connected to the economizer of the HRSG. Analogous to the feedwater lines, the HRSG feedwater pipes and economizers need to be filled and pressurized via the filling bypass lines (flow limited by orifice) before the main HRSG gate valves can be opened. As soon as the HRSG economizer and the HP feedwater line to the HRSG are pressurized and the pressure difference between these two systems is within the allowed limits the main HRSG gate valves are opened.
3.2.
HP Feedwater Pump
The HP feedwater pump is a horizontal, centrifugal multistage ring section type. The pump radial and thrust bearings are connected to the lubrication oil system. For preventing inadmissible heating of the pump during low flow operation, minimum feed water flow through the pump is ensured by the automatic recirculation check valve. The mechanical seals are cooled by means of the closed cooling water system (CCW). Each pump is equipped with bearing temperature measurements for supervision and protection purposes. In case of high temperature (>MAX1), alarms are generated in the DCS and at further increase (>MAX2) the feed water pump will be tripped. Each radial bearing is equipped with vibration measurements to monitor pump shaft vibration. In case of high vibration level (>MAX1) alarms are generated in the DCS and if the vibration level increase further (>MAX2) the feed water pump will be tripped. Additionally, a reverse rotation detector is supplied, which will also generate an alarm in the DCS. For more detailed information of this equipment, consult the Operation & Maintenance Manual of the supplier.
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3.3.
Pump Suction Strainer

Each pump is equipped with duplex type suction strainers, which allow easy maintenance during pump standstill and when the system section is depressurised. The strainer prevents dirt particles bigger than permitted by the pump to enter the feed water pump. The strainer is equipped with a differential pressure measurement. In case the differential pressure increases (due to strainer clogging) an alarm (>MAX1) will be generated in the DCS. At further increase (>MAX2) the feed water pump will be tripped. For more detailed information of this equipment, consult the Operation & Maintenance Manual of the supplier.
3.4.
Automatic Recirculation Check Valve

The automatic recirculation check valve ensures the minimum required flow rate through the feedwater pump, allows a pump start-up through the filling bypass line, prevents back flow to the feedwater pump and protects the feedwater pump against overheating. The automatic recirculation check valve is mechanically controlled type and therefore requires no auxiliary power or separate control system. At flows lower than the required minimum flow, the check valve is activated, by means of a lever and a vortex plug. When lifted of its seat, the vortex plug allows a flow through the pressure reduction section to the feedwater storage tank. The internal check valve is spring loaded and prevents back flow to the pump. The check valve dampens pulsations because of its throttling effect on the main flow and stabilizes the pump characteristics in part load operation. For filling of the feedwater system, the fourth gate of the automatic recirculation check valve is connected to the filling bypass line. The throttling device of the recirculation check valve realizes the required pressure reduction. For more detailed information of this equipment, consult the Operation & Maintenance Manual of the supplier.
3.5.
The Lube Oil System

The lube oil circuit provides the lubrication oil for the bearings of feed water pump and electrical motor. A shaft driven main lube oil pump is provided to supply the feed water pump with lube oil. An alarm will be sent when the lube oil pressure in the lube oil supply line drops below MIN1. Further reduction of lube oil pressure (<MIN2) will cause the HP feedwater pump to be tripped. Another standby electric motor driven lube oil pump is available and is used during start up / shut down and when the HP feedwater pump is not in operation or in stand by mode. A duplex filter continuously cleans the lubrication oil. The pressure loss over the filter is measured and an alarm will be generated in the DCS when it exceeds the permissible limit. Filter change-over has to be done manually. The oil tank stores the lubrication oil. A lube oil level indicator is available to check the oil level in the tank. If the level drops too low (<MIN1), an alarm will be generated. During system operation, the lube oil will be cooled by the closed cooling water system by means of an oil/water heat exchanger in the lube oil discharge line. For supervision of the lube oil system the lube oil pressure and oil tank level instruments are installed. Related alarms will be generated in the DCS. For more detailed information of this equipment, consult the Operation & Maintenance Manual of the supplier
3.6.
Electric Motor
The electric motor is a three-phase squirrel cage motor type and is powered by the plant medium voltage board. The motor shaft is connected through a flexible coupling with spacer to the pump. The motor cooling is ensured by the closed cooling water system (CCW).
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The motor bearings are fed and cooled by the forced lubrication oil system. The electric motor is equipped with winding and bearing temperature supervision. In case of high temperature (>MAX1), alarms are generated in the DCS and at further increase (>MAX2) the motor will be tripped. An electric heater prevents condensing during stand still of the motor. For more detailed information of this equipment, consult the Operation & Maintenance Manual of the supplier.
3.7.
Noise Hood
Each feedwater pump is provided with a noise hood to reduce the noise level generated by the pump. Each noise hood is equipped with two numbers of cooling fans to avoid overheating of air under the hood. One fan is always in operation when the pump is running. If the temperature under the hood rises (>MAX1), the stand-by fan is automatically switched on. For more detailed information of this equipment, consult the Operation & Maintenance Manual of the supplier.
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4.
4.1.
4.1.1.
OPERATION
Overview
Specific Safety Instructions
WARNING
Water steam cycle under high pressure and high temperature Inappropriate handling can cause serious injuries or death. Prior start-up Ensure that the equipments and instruments are ready for operation. Refer to section 6.1 Manual Preparation Check List prior to Start-up on page 35. Follow the Water Chemistry WSC Technical Specification to ensure the required water and steam quality. Ensure that the instrument root valves for all permanent instruments are open. Refer to section 6.1 Manual Preparation Check List prior to Start-up on page 35.
Ensure that 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 section 6.1 Manual Preparation Check List prior to Start-up on page 35. Do not modify systems or equipments. The instructions of the equipment suppliers must be adhered to.
WARNING
Hot surface Inappropriate handling can cause serious burns. Do not touch piping- or equipment-surface, if there is no heat insulation and the plant is not cooled down.
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WARNING
High voltage/Electrical shock Electric motors and actuators powered with high voltage, inappropriate handling can cause serious injuries or death. Keep away from live parts. Do not remove guards. Avoid wet surfaces. Prior to maintenance: Isolate equipment from power supply. Take effective measures to prevent reconnection. Ensure no residual voltage remains. Do not modify systems or equipment. The instructions of the equipment suppliers must be adhered to.
WARNING
Rotating or moving parts Inappropriate handling can cause serious injuries or death. Keep away from rotating or moving parts. Do not remove guards. Prior to maintenance, take effective measures to prevent rotating or moving. Do not modify systems or equipment. The instructions of the equipment suppliers must be adhered to.
WARNING
Flammable lubrication oil Inappropriate handling can cause fire and serious burns Shutdown the pumps system in case of major oil leakages Remove oil before maintenance activities in e.g. welding
WARNING
Hot medium The feedwater temperature can be up to 150C. Inappropriate handling can cause serious burns Do not open vent valves during operation or during standstill unless the system is depressurized and cooled down Wait for system cool down before maintenance activities
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The HP feedwater pump system and its equipments must be operated and maintained by trained and authorized personnel only! All applicable safety rules and regulations are to be followed strictly. For equipment-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.
Read the equipment safety instructions before operation!
4.1.2.
Equipment Operating Instruction To ensure operational reliability of the individual system equipments, the relevant operation instructions must be observed.
Read the equipment safety instructions before operation! 4.1.3. Automatic Control Logic Note Remote operated actuators, pumps or similar equipment are represented with a dedicated DRIVE element in the control system. A SELECTOR controls the Drives of redundant equipment like pumps. Equipments which have to operate together to maintain a specific function of a sub-process are combined into a FUNCTION GROUP (FG). Refer to the Plant Operation and Control Concept for more information about the general automation structure. The HP feedwater pumps 58LAC50AP001, 58LAC60AP001, the HP feedwater pump discharge shutoff valves 58LAB52AA002, 58LAB62AA002, the lube oil pumps 58LAC51AP001, 58LAC61AP001 and the pump hood fans 58LAC56AH050/60, 58LAC66AH050/60 are combined into function group FG HP FDW PMPS 58LAC50EA100. For details of the automatic control logic refer to the Process Function Plan and the Set Point List of the system.
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4.2.
Conditions Prior to Start-up

After maintenance activities, major repair, or initial installation, the system shall be cleaned before the system is started and taken in operation. Before Start-up, ensure the systems, equipment, valves, and instrumentations are ready for operation. Refer to 6.1 Manual Preparation Check List prior to Start-up on page 35.
4.3.
Normal Start-up
Note The normal start-up is performed in automatic mode by starting the related function groups by the relevant sequencer in the DCS. Following function group is started: FG HP FDW PMPS
For automatic start-up, no operator actions are required.
CAUTION Starting against an empty or partially drained system or HRSG might damage equipment. Follow initial filling procedure if the system or HRSG was partially or completely drained. Refer to section 4.4 Initial Filling of the System on page 25. CAUTION Prior to start-up of any feedwater pump, the closed cooling water system has to be in operation for cooling of the pump unit.
CAUTION In order to prevent major damage to the pump motor windings, the number of sequential starts is limited to two successive starts per hour if the motor is started from the hot condition. The number of sequential starts is limited to three successive starts per hour if the motor is started from the cold condition (initial motor temperature at maximum ambient temperature). It is recommended not to shut down the pump before it has run for at least half an hour.
Note The duty and the stand-by pump can be pre-selected by the operator, to define the starting order of the pumps.
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Note The duty and the stand-by pump are started and stopped automatically by a 2-unit-selector based on demand. The demand is created by superior control logic. For details of the automatic control logic refer to the Process Function Plan (PFUP) and the Set-point List of the system. The two HP feed water pumps 58LAC50AP001/58LAC60AP001 are started and stopped automatically by a 2-unit-selector. During normal system operation, one pump is always running, while the second pump remains in stand-by. The starting order of the pumps can be preselected by the operator. The lube oil pumps (two per feed water pump) ensure the required minimum lube oil pressure for the feed water pump and motor, especially during run-up and coast-down of the feed water pump. To enable the stand-by feed water pump to start without time delay, the electric motor driven lube oil pumps in operation during the stand-by phase. In automatic mode the normal start-up doesnt require any operator action and is effectuated by activating the related functional group in the DCS. Note The lubrication system is required for the lubrication of feedwater pump and electrical motor. Therefore it is recommended to verify the lube oil pressure after the auxiliary lube oil pump prior to feedwater pump start. Before start-up, the HP feedwater pump discharge shut-off valves 58LAB52AA002 and 58LAB62AA002 are closed. The first pump (selected one) starts, fills and pressurizes the common HP feedwater line via the filling bypass line. When the pressure in the common feedwater line measured at 58LAB95CP001/002/003 is above the minimum value MIN1, both discharge valves 58LAB52AA002 and 58LAB62AA002 are opened.
4.4.
Initial Filling of the System

The initial filling procedure must be executed only if the system or the HRSG was partially or completely drained. If this initial filling procedure was completed and no partial or complete draining was done, the system can be started according to section 4.3 Normal Start-up on page 24. The geodetic liquid pressure of the feedwater storage tank will fill the pump suction lines and a part of the discharge line. The water system downstream of the pumps will finally be filled by means of the pump.
CAUTION Initial filling of the system downstream of the feedwater pump with open discharge shut-off valve 58LAB52AA002/58LAB62AA002 may create water hammer and consequential damage of the piping and interfacing systems. Further serious pump damages can not be excluded.
4.4.1.
Pre-conditions to fill the system The entire HP feedwater system is visually checked and ready for filling. The mesh of the pump suction strainers should be cleaned and has to be inserted correctly; the strainer casings must be closed. The conditions according to the pump and motor operating manuals have to be fulfilled.
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Root valves for the two sensing lines (+ and ) of the differential pressure measurement at suction strainer 58LAB51CP001/58LAB61CP001 are open. The + and the valves at the differential pressure transmitter are open. The bypass valve between + and - at differential pressure transmitter is open. The venting valves at differential pressure transmitter for + and - are closed. Root valves 58LAB95AA301/311/312/302/312/322 of common HP discharge pressure measurements 58LAB95CP001/2/3 are open. The valves at the pressure transmitters are open. The venting valves of the pressure transmitters are closed. Feedwater storage tank is filled at least above minimum level MIN3, one condensate pump is preferable in operation to maintain the feedwater storage tank level. Closed cooling water system is in operation. The discharge valves 58LAB52AA002/58LAB62AA002 downstream of the pumps are closed. The drain valves 58LAB52AA201/58LAB62AA201 and 58LAB52AA202/58LAB62AA202 are closed. The vent valve 58LAB51AA201/58LAB61AA201 is closed. All system- and component vent valves are closed.
4.4.2.
Procedure to fill the system 1. Start the electric motor driven lube oil pump 58LAC51AP001 (58LAC61AP001). 2. 3. Open the HP feedwater pump suction shut-off valve 58LAB51AA001 (58LAB61AA001). Open the venting valve on the + and - side of the differential pressure transmitters 58LAB51CP001 (58LAB61CP001) and close when feedwater leaks. Close the equalizing valve at the differential pressure transmitter. Vent the feedwater pump 58LAC50 (58LAC60) according to the component operating instructions. Open the HP feedwater pump filling line bypass shut-off valve 58LAB54AA002 (58LAB64AA002). Wait for a few minutes to fill the HP feedwater system section by gravity. Open the vent valves at the pressure transmitter for the HP feedwater discharge pressure measurement 58LAB95CP001/002/003 and close when feedwater leaks. Start the HP feedwater pump units according to the component operating instructions. Check that minimum HP feedwater discharge pressure 58LAB95CP001/002/003 (MIN1) is established. Fill the complete system, HRSG economizers and HRSG drums via the HRSG filling bypass valves. Supervise the system pressure 58LAB95CP001/002/003.
4. 5. 6. 7. 8. 9.
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4.5.
4.5.1.
Normal Operation
Normal operation One of the 2 x 100% HP feedwater pumps is required for the supply of the feedwater consumers. The other pump is on stand-by. Both discharge valves 58LAB52AA002 and 58LAB62AA002 remain open. The HP feedwater control valves of the HRSG open according to the HP drum level control logic. Pump change-over Change-over of the pump on duty can be executed during system operation. For the automatic change-over the operator has to change and confirm the pump selection in the DCS. No further operator action is required. Note Change-over to a disturbed pump line can cause reduced feedwater flows for certain periods unless the first pump is restarted automatically. This can cause unit trips or unplanned system outages. Check prior to manual change-over that the standby pump line is available, the electric motor driven lube oil pump is on and the pump is ready for operation. In order to ensure a high availability of the standby pump line it is recommended to change over the pump on duty at least once a week. The regular change-over should preferable be conducted during stable plant load operation. Read the component instructions regarding permissible / recommended standby durations.
4.5.2.
4.6.
Normal Shut-down
Note The normal shut-down is performed in automatic mode by stopping the related function groups by the relevant sequencer in the DCS. Following function group is stopped: FG HP FDW PMPS For automatic shut-down, no operator actions are required.
Note The HP feedwater pump system can be normally switched off after shutdown of the GT. However due to the residual heat of the various consumers, feedwater supply may still be required. Read the component instructions regarding shutdown times prior to manual shutdown of the feedwater pump system. When using the unit sequencer for the shutdown of the feedwater pump system, the required waiting times are already considered in the automatic function. The normal shut-down will be realized in automatic mode by deactivation of the related functional group in the DCS. For this automatic shut-down no operator action is required.
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When both pumps are stopped, both discharge line shut-off valves 58LAB52AA002 and 58LAB62AA002 closed.
4.7.
Abnormal Operation
Following conditions lead to an emergency shut-down of a feedwater pump by the control system: Water level in the feedwater tank falls below minimum level MIN4 Pressure in the common HP feedwater line drops below minimum pressure MIN2 The suction valve is not fully open (limit switch not in open position) Pressure difference across the suction strainer exceeds maximum value MAX2 Motor winding temperature exceeds maximum temperature MAX2 Motor bearing temperature exceeds maximum temperature MAX2 Pump bearing temperature exceeds maximum temperature MAX2 Lube oil pressure drops below minimum pressure MIN2 Pump or motor vibrations exceed the maximum value MAX2
Lube oil level in lube oil tank drops below MIN1. In case of a power supply failure (electrical protection), the relevant pump is switched off. Note In automatic mode, after emergency shut-down of one pump, a back-up pump switches on automatically (if no common emergency shut-down is active). For the back-up pump no warm-up procedure is necessary.
For the standby pump/motor no warm-up procedure is necessary. Note To avoid run-out protection trip (low pressure at high feed water flow) of the pump, the HRSG HP drum level control valves will be throttled at low feed water discharge pressures. For details please refer to the HRSG system description.
4.8.
Inadmissible Operation
The following operation modes are not permitted: Continuous normal operation of two HP feedwater pumps Any pump operation against not open HP feedwater pump suction shut-off valves Any pump operation against not open shut-off valves in the discharge line Any pump operation against not open shut-off valves in the minimum flow line Starting the feedwater pump against not closed HP feedwater pump discharge shut-off valve Stopping the electric motor lube oil pump of the not running HP feedwater pump during plant operation Starting against an empty or partially drained system or HRSG without completing the initial filling procedure Any pump operation without the closed cooling water system in operation Operating the equipment outside defined limits as per equipment Operation & Maintenance Documentation
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CAUTION Operating the system in an inadmissible operation mode will cause damage of the system and equipment.
4.9.
Other Operation Modes

The operation modes described in section 4.3 Normal Start-up, 4.5 Normal Operation and 4.6 Normal Shut-down are the normal operation modes. Apart from normal operation mode, there are other operation modes, which are considered as acceptable, short term, time limited operation modes. The following operation modes are admissible.
4.9.1.
Failure of Equipment Failure and alarms of equipment controlled by DCS will be indicated in the MCR via DCS. For equipment failures and trouble shooting, refer to the relevant sections of the suppliers instructions. Local checks, repairs, resetting, etc. are required within time frame according to the relevant sections of the suppliers instructions. Standby The standby of individual equipment is defined in the referenced subsystem and equipment operating instructions. This is an essential condition for operational standby of the system. Measures during outages In order to prevent malfunction and damage of the subsystem and the individual equipment, the measures during outages must be observed. Refer to the relevant sections of the suppliers instructions. Shutdown for maintenance or long-term outage The shut down procedures for long-term outages and for normal shutdown are exactly the same. For long-term outages the instructions and the measures for long-term shutdowns of the subsystem and the individual equipment must be observed. Refer to the relevant sections of the suppliers instructions. In case of a planned long-term outage, an increase of the ammonia dosing into the water system is recommended prior to plant shutdown. This will improve the water chemistry for wet preservation. For details please refer to the applicable water chemistry guideline and to the section 4.9.5 System preservation. Dry preservation is to be used for the steam systems. System preservation The HP feed water system preservation method to be applied depends on several factors: The purpose and length of the standstill period. The preservation methods of the interfacing systems. The equipment preservation requirements. Read the equipment operating instructions regarding long-term standstill & preservation! In general the available options are wet and dry preservation. Special attention is required in case nitrogen capping is used for equipment / system preservation.
4.9.2.
4.9.3.
4.9.4.
4.9.5.
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DANGER
Danger of suffocation Nitrogen in high concentration can cause unconsciousness and lead to suffocation. Avoid inhaling of leaking gas. Ensure sufficient ventilation. Close drains / vents when gas is leaking. Close sampling isolation valves. For safety reasons it is strongly recommended not to enter the hazardous area alone (team of minimum two people).
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5.
5.1.
MAINTENANCE
Specific Safety Precautions
Operation as well as maintenance and repair work of the system has to be done by qualified personnel and under observation of general rules and regulation and the special safety rules and regulations for pressure equipment.
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 equipments 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
If any maintenance work at the feed water pumps system as e.g. the pump suction line strainer has to be done, the applicable depressurizing procedure is mandatory!
Read the respective equipment maintenance instructions. Theres one for every major equipment: e.g. feed water pumps, suction strainers, etc.
5.2.1.
Daily Checks Carry out a visual inspection of the entire system every day. Check all potential sources of water and oil leakages (flanges, joints) daily. If any major water- or oil leakage is detected, the system must be repaired in accordance with the relevant codes and standards (e.g. welding procedure). Check the pressure difference across the strainer daily. Check that the standby pump does not rotate.
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5.3.
Depressurization Prior to Maintenance

If the feedwater pump system or sections of it must be decommissioned for maintenance or repair work, the whole system must be depressurized. Depressurizing the system 1. Shut-down the HP feedwater pump system according to chapter 4.6. 2. 3. 4. Disconnect the pumps from the power supply. Close feedwater shut-off valve to HRSG. Open low point drain valves 58LAB52AA201/202 (58LAB62AA201/202) until the system is depressurized. Supervise the system pressure measurements 58LAB95CP001/002/003.
Note If no maintenance works on the common discharge lines are required, these lines dont need to be fully emptied. In that case the low point drain valves 58LAB52AA201/202 (58LAB62AA201/202) can be closed when the pressure drops below approx. 5 bar. 5. 6. 7. 8. 9. Close the HP feedwater pump discharge shut-off valves 58LAB52AA002 (58LAB62AA002) and the HP feedwater pump filling bypass shut-off valves 58LAB54AA002 (58LAB64AA002). Close the HP feedwater pump minimum flow recirculation shutoff valves 58LAB53AA001 (58LAB63AA001). Close the HP feedwater pump suction shut-off valves 58LAB51AA001 (58LAB61AA001). Open the HP feedwater pump suction line vent valve 58LAB51AA201 (58LAB61AA201). Open the drain valves at the suction strainers 58LAC50AT001 (58LAC60AT001) and the pumps internal drains.
10. If access to the common discharge lines is required, open the low point drain valves 58LAB52AA201/202 (58LAB62AA201/202) again and wait until the water ceases to flow.
De-pressurizing of the pump / strainer : CAUTION Procedure must be followed strictly to prevent serious damage In order to prevent pressurization of the closed pump suction line by leaking discharge valve the discharge valve 58LAB52AA002 (58LAB62AA002) & the filling bypass line shut-off valve 58LAB54AA002 (58LAB64AA002) depressurized pump has to be closed first 1. 2. 3. 4. 5. 6. 7.
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Shutdown the corresponding feed water pump 58LAB50AP001/58LAB60AP001 Disconnect the pump from power supply Close the feed water discharge valve 58LAB52AA002/58LAB62AA002 Close the filling bypass line shutoff valve 58LAB54AA002/58LAB64AA002 Close the minimum flow recirculation shutoff valves 58LAB53AA001/58LAB63AA001 Close the suction line shut-off valves 58LAB51AA001/58LAB61AA001 Open the depressurised pump suction line vent valve 58LAB51AA201/ 58LAB61AA201

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8.
Open the drain valves of the depressurized pump suction strainers 58LAC50AT001/58LAC60AT001 and the pump internal drain 58LAC50AA401/ 58LAC60AA401 and wait until the water ceases to flow.
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6.
6.1.
APPENDICES
Manual Preparation Check List prior to Start-up
Before Start-up, ensure the systems, equipment, valves, and instrumentations are ready for operation. Refer to 6.1 Manual Preparation Check List prior to Start-up on page 35. System/Equipment Closed cooling water system Feedwater storage tank level control Main condensate system Feed water pumps (min one pump) HRSG Instrumentation Remote Controlled Valves Feed water sampling system Status Command On Command On Command On Ready for operation Ready for operation Ready for operation Ready for operation Ready for operation KKS number PG LAA LC 58LAC50AP001 58LAC60AP001 H Various Various QUL40
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Valve Instrumentation bypass valves HP suction line vent valves Suction valves HP feedwater pump Filling bypass line shut-off valves Minimum flow recirculation shut-off valves HP drain valves
Position Closed *1) Closed Open Open Open Closed
KKS number 58LAB51CP001 58LAB61CP001 58LAB51AA201 58LAB61AA201 58LAB51AA001 58LAB61AA001 58LAB54AA002 58LAB64AA002 58LAB53AA001 58LAB63AA001 58LAB52AA201 58LAB52AA202 58LAB62AA201 58LAB62AA202 58LAB95AA401 See Pump doc. See HRSG doc. 58LAB95AA301 58LAB95AA311 58LAB95AA321 58LAB51AA301 58LAB51AA302 58LAB61AA301 59LAB61AA302
HP feedwater sampling valve HP Feedwater pump check list HRSG HP feedwater shut-off valves Root valves for permanent instruments
Open Closed *2) Open
*1) differential pressure transmitter only *2) refer also to HRSG instruction manual Table 3 Manual Preparation Check List prior to Start-up
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6.2.
Alarm List
KKS 58LAA10CL002 58LAA10CL003 58LAA10CL005 58LAB51CP001 58LAB61CP001 >MAX1 DP HP FWP Pump strainer clogged. Change over to standby pump at next possibility and clean clogged strainer. Motor winding temperature too high. Change over to back-up pump and check lubrication and CCW system. Code <MIN2 <MIN3 Description L FWT Action Water level in feedwater tank low. Check condensate supply system.
58LAC50CT001 58LAC50CT002 58LAC50CT003 58LAC60CT001 58LAC60CT002 58LAC60CT003 58LAC50CT004 58LAC50CT005 58LAC60CT004 58LAC60CT005 58LAC50CT007 58LAC50CT008 58LAC60CT007 58LAC60CT008 58LAC50CT010 58LAC50CT012 58LAC60CT010 58LAC60CT012 58LAC51CP004 58LAC61CP004
>MAX1
T MOT WDG HP FWP
>MAX1
T HP FWP MO NDE BRG T HP FWP MO DE BRG
Motor bearing temperature too high. Change over to back-up pump and check lubrication and CCW system. Pump bearing temperature too high. Change over to back-up pump and check lubrication and CCW system. Pump bearing temperature too high. Change over to back-up pump and check lubrication and CCW system. Pressure across oil filter too high. Change over to back-up strainer at next possibility and clean clogged strainer. Pump vibration too high. Change over to back-up pump and check. Lube oil level too low. Change over to back-up pump at next possibility and refill oil. Reverse rotation detected in pump. Check ARC. Cooling water leakages into pump detected. Change over to back-up pump and check cooling water line.
>MAX1
T HP FWP RD DE BRG T HP FWP RD NDE BRG
>MAX1
T HP FWP THR BRG
>MAX1
DP HP FWP LOIL STR
58LAC50CY001-9 58LAC60CY001-9 58LAC51CL001 58LAC61CL001 58LAC50CS001 58LAC60CS001 58LAC50CM001 58LAC60CM001
>MAX1 <MIN1
VIB-X/Y/Z NDE/DE HP FWP LL LOIL BOX HP FWP RVS DETN HP FWP CW LKG DETN HP FWP
DETEC TED DETEC TED
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KKS 58LAB51CG001 58LAB61CG001 58LAB95CP001 58LAB95CP002 58LAB95CP003 58LAB95CP001 58LAB95CP002 58LAB95CP003 Table 4
Code NOT OPEN DIST
Description POS SUCT V HP FWP P HP FWL
Action Pump suction valve not open. Check the valve and limit switch. Disturbance of measurement. Check measurement. Note: Disturbance of second measurement will trip system.
<MIN1
P HP FWL
Pump discharge pressure to low. Change over to back-up pump and check previously running pump. Check also possible leakages on piping in HRSG.
Alarm List
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6.3.
External documents and diagrams

The following documents and diagrams are referenced throughout this manual. Doc No. MTV/58/M/LAC50-----/FD/001 MTV/58/M/LAC50-----/FD/002 MTV/58/M/LAC50-----/LO/001 MTV/58/M/LAC50-----/SL/001 MTV/58/M/LAC50B30/MM/002 MTV/51/B/H------A30/TP/001 MTV/00/M/01-----005/PF/001 MTV/00/M/03-----010/GS/001 Table 5 Title P & ID HP Feedwater Pump Legend to P & ID HP Feedwater Pump Process Function Plans HP Feedwater Pump Set Point List HP Feedwater Pump HP Pump Motor Operation and Maintenance Manual HRSG Operation and Maintenance Procedure Plant Operation and Control Concept Water Chemistry WSC Technical Specification
External Documents and Diagrams
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Index
Interface to other systems, 12 A abbreviations and acronyms, 10 Alarms, 17, 18, 19 automatic control logic, 23 automatic recirculation check valve, 18 B Back-feed, 17 C CAUTION explanation, 8 cleaning, 24 Closed cooling water system, 18, 19 compulsory reading, 7 Conservation, 30 copyright, 2 D DAMAGE explanation, 9 DANGER explanation, 8 De-pressurizing, 32 E Electric motor, 19 emergency shut-down pump, 28 equipment failures, 29 F feed water pump, 17 feedwater pump system abnormal operation, 28 inadmissible operation, 29 Feedwater storage tank, 17 Filling bypass, 17 G general note explanation, 9 I inadmissible operation, 29 initial filling procedure, 25 U user audience, 7 V visual inspection, 31 W WARNING explanation, 8 L Lubrication oil, 18 M main equipments, 11 MANDATORY ACTION explanation, 9 Manual Preparation Check List prior to Start-up, 35 Minimum flow, 17 O Operational readiness, 31 outages, 30 P piping and instrumentation diagrams, 38 R Reverse rotation, 17 S standby of equipment, 30 Suction strainer, 18 system tasks, 11 T target audience, 7 TN04/0297, 13
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SYSTEM MANUAL

LAC50 - HP FEEDWATER PUMP SYSTEM

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Lead Engineer in Charge

Alstom (Switzerland) Ltd

ALSTOM (SWITZERLAND) LTD., Brown Boveri Strasse 7, CH 5401-Baden

Design Manual SYSTEM MANUAL LAC50 - HP FEEDWATER PUMP SYST

Please consider the environment before printing this document.

ALSTOM POWER SYSTEMS

4.1.1. 4.1.2. 4.1.3. 4.2. 4.3. 4.4.

4.4.1. 4.4.2. 4.5.

4.5.1. 4.5.2. 4.6. 4.7. 4.8. 4.9.

ALSTOM POWER SYSTEMS

4.9.2. 4.9.3. 4.9.4. 4.9.5. 5.

Depressurization Prior to Maintenance ......................................................................................................... 32

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

About this Manual

Brief Description of Manual Contents

ALSTOM POWER SYSTEMS

Symbols used in this Manual

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

Abbreviations and Acronyms

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

System-specific Safety Instructions

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

Read the equipment safety instructions before operation!

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

Pump Suction Strainer

Automatic Recirculation Check Valve

The Lube Oil System

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

Read the equipment safety instructions before operation!

ALSTOM POWER SYSTEMS

Conditions Prior to Start-up

For automatic start-up, no operator actions are required.

ALSTOM POWER SYSTEMS

Initial Filling of the System

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ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

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Other Operation Modes

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ALSTOM POWER SYSTEMS

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Depressurization Prior to Maintenance

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

ALSTOM POWER SYSTEMS

Position Closed *1) Closed Open Open Open Closed