SYSTEM DESCRIPTION

EKT - FUEL GAS PREHEATER

Owner:
TRUenergy Tallawarra Pty Ltd

Contractor:
ALSTOM Power Limited

TALLAWARRA Combined Cycle Power Plant

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ALSTOM Document Code

TWA/00/M/EKT-------/OI/001
Responsible dept.

Created by

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Format

PEE

Pfeifer B.

Zaengerlein F.

Zaengerlein F.

A4

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Description

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Title, Subtitle

Identification number

Power Turbo-Systems /
Power Environment

SYSTEM DESCRIPTION
EKT - FUEL GAS PREHEATER

1AHA052263
Rev.

Date

Lang.

Sheet

19.12.2006

en

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Template No.: GGG/00/-/EQA---/FT/302E (released with Work Instruction GGG/00/-/EQA---/WI/306)

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Rev. A

Copyright
All rights reserved
Copyright 2006 ALSTOM Power Turbo-Systems (comprised of ALSTOM (Switzerland) Ltd. and/or affiliates
CH-5401 Baden, Brown Boveri Strasse 7
Printed in Switzerland
We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure
to third parties without express authority is strictly forbidden.
This work, including all parts thereof, is protected by copyright. Any use of it beyond the narrow restrictions of
the copyright law without prior approval of ALSTOM (Switzerland) Ltd., CH-5401 Baden is prohibited and
subject to punishment under the applicable law.

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Contents
1

2.

3.

Introduction ................................................................................................................................................. 9
1.1.

Purpose ............................................................................................................................................................. 9

1.2.

System Overview.............................................................................................................................................. 9

1.2.1.

Main Components ...................................................................................................................... 9

1.2.2.

Interface to other Systems ......................................................................................................... 9

Safety Instructions ..............................................................................................................................10

2.1.

General Safety Instructions ............................................................................................................................10

2.2.

System-specific Safety Instructions ...............................................................................................................10

System Description ............................................................................................................................12

3.1.

4.

Operation .....................................................................................................................................................13
4.1.

5.

6.

Overview .........................................................................................................................................................12

Overview .........................................................................................................................................................13

4.1.1.

Specific Safety Instructions...................................................................................................... 13

4.1.2.

Component Operating Instructions .......................................................................................... 14

4.1.3.

Automatic Control Logic........................................................................................................... 14

4.2.

Initial System Filling ........................................................................................................................................14

4.3.

Normal Start-up...............................................................................................................................................14

4.4.

Normal Operation............................................................................................................................................15

4.5.

Normal Shut-down..........................................................................................................................................15

4.6.

Abnormal Operation........................................................................................................................................15

Maintenance ..............................................................................................................................................16
5.1.

Specific Safety Precautions............................................................................................................................16

5.2.

System-related Maintenance .........................................................................................................................16

Appendices ................................................................................................................................................17
6.1.

Manual Preparation Check List prior to Start-up ...........................................................................................17

6.2.

Alarm List.........................................................................................................................................................17

6.3.

Externals Documents and Diagrams.............................................................................................................18

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List of Tables
Table 1

Brief Description of Manual Contents ........................................................................................ 5

Table 2

Abbreviations and Acronyms ..................................................................................................... 8

Table 3

Manual Preparation Check List prior to Start-up...................................................................... 17

Table 4

Alarm List ................................................................................................................................. 17

Table 5

External Documents and Diagrams ......................................................................................... 18

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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 components. 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
Chapter

Title

Contents

Introduction

Provides an overview of the system and its components.

Safety Instructions

Describes the safety rules and general residual risks.

System Description

Describes the system and its components on a functional

level.

Operation

Describes the operation sequences required for routine

operational tasks and the standard operational phases.

Maintenance

Contains basic maintenance schedules and describes

various maintenance procedures.

Appendices

Contains miscellaneous additional information.

Table 1

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:
1.
Table of Contents at the beginning of the book
2.
Lists of tables at the beginning of the book
3.
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

Explanation

DCS

Distributed Control System

FWT

Feed Water Tank

GT

Gas Turbine

HRSG

Heat Recovery Steam Generator

IP

Intermediate Pressure

PFUP

Process Function Plans

PHR

Preheater

P & ID

Piping and Instrumentation Diagram

ST

Steam Turbine

Table 2

Abbreviations and Acronyms

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INTRODUCTION

1.1.

Purpose

Rev. A

The system fulfils the following tasks:

4.
Preheating of the fuel gas in order to achieve a higher thermal efficiency of the gas
turbine

1.2.

System Overview
Note
For an overview of the system, refer to P & ID 1AHA049449 and P & ID
1AHA050087

1.2.1.

Main Components
The system consists of the following main components:
5.
Fuel gas preheater 11EKC10AC001 equipped with gas detection device 11EKC10CL001
and safety valve 11EKC10AA001.
6.
Fuel gas separator 11EKC10AT001 downstream of the fuel gas preheater equipped with
gas detection device 11EKC10CL002
7.
Straightway shut-off valve 11HAC24AA002 downstream of HRSG extraction point
8.
Straightway shut-off valve 11EKT10AA001 downstream of fuel gas separator
9.
Electric motor-actuated gas preheater water shut-off gate valve 11EKT10AA002
10.
Gas preheater angle control valve 11EKT10AA003
11.
Feed water extraction line 11EKT10BR010 from HRSG to fuel gas preheater
12.
Connection line 11EKT10BR001 between fuel gas preheater and fuel gas separator
13.
Return lines 11EKT10BR002/3 from fuel gas separator to FWT

1.2.2.

Interface to other Systems

14.
Fuel gas enters from the fuel gas fine filter
15.
Fuel gas exits to the GT
16.
Feed water enters from extraction point downstream of the IP economizer of HRSG

17.

Feed water exits to the FWT

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2.

SAFETY INSTRUCTIONS

2.1.

General Safety Instructions

All personnel working with or at the systems and components 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
High pressure system
Inappropriate handling can cause serious injuries

Before start-up
18. ensure the components, valves, and instrumentations are ready
for operation. Refer to Manual Preparation Check List prior to
Start-up on page 17.
19. ensure the instrument root valves for all permanent instruments
are open. Refer to Manual Preparation Check List prior to Startup on page 17.
20. ensure the instrument root valves for all temporary instruments
are closed. These temporary instruments are shown in the
P & ID with a P, PP, T, or TP and are used only for the
performance test or commissioning. Refer to Manual Preparation
Check List prior to Start-up on page 17.

Before maintenance

21. ensure the system is depressurized, cooled down and drained.

22. secure the drives and valves against unintentional starting and
moving.
The instructions of the component suppliers must be adhered to.

WARNING
Hot medium
The feed water 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.

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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.

Read the component safety instructions before operation!

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3.

SYSTEM DESCRIPTION

3.1.

Overview
The fuel gas preheating system preheats the fuel gas to a constant temperature with feed water
taken from an extraction point downstream of the IP economizer of HRSG. Finally the water
returns to the feed water tank via gas preheating control valve. The gas preheating control valve
is located right upstream of the feed water tank inlet to prevent evaporation of gas preheater
water. The preheater and the water line downstream of the gas preheater is equipped with a gas
detection device in order to protect the water /steam cycle from gas ingress.

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4.

OPERATION

4.1.

Overview

4.1.1.

Specific Safety Instructions

WARNING
High pressure system
Inappropriate handling can cause serious injuries

Before start-up
23. ensure the components, valves, and instrumentations are ready
for operation. Refer to Manual Preparation Check List prior to
Start-up on page 17.
24. ensure the instrument root valves for all permanent instruments
are open. Refer to Manual Preparation Check List prior to Startup on page 17.
25. ensure the instrument root valves for all temporary instruments
are closed. These temporary instruments are shown in the
P & ID with a P, PP, T, or TP and are used only for the
performance test or commissioning. Refer to Manual Preparation
Check List prior to Start-up on page 17.

During operation

26. Follow the operating instructions and the component operating

instructions
27. Shut down the system / section in case of leakages
The instructions of the component suppliers must be adhered to.

WARNING
Hot medium
The feed water 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.

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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.

Read the component safety instructions before operation!

4.1.2.

Component Operating Instructions

To ensure operational reliability of the individual system components, the relevant operation
instructions must be observed.

Read the component operating instructions before operation!

4.1.3.

Automatic Control Logic

For details of the automatic control logic refer to the PFUP and the Set Point List of the system.

4.2.

Initial System Filling

The feed water extraction lines shall be filled during the boiler filling procedure.
Refer also to the O&M instructions of the fuel gas preheater.

4.3.

Normal Start-up
Note
The normal start-up is performed in automatic mode by starting of the related
function group GT Gas preheater control by the relevant sequencer in the
DCS.
For automatic start-up, no operator actions are required.
When exhaust gas temperature at stack exceeds a certain value, the feed water shut-off valve
21EKT10AA002 is opened. After opening of the feed water shut-off valve, the feed water control
valve is released. The gas temperature will be ramped up to the required set point with a limited
temperature gradient by controlling the feed water extraction supply with the water control valve.

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4.4.

Rev. A

Normal Operation
The fuel gas preheating system is taken into service when exhaust gas temperature at stack
exceeds a certain value and fuel gas is selected. The flow of the feed water depends on the fuel
gas flow and its target temperature. The feed water control valve is controlled by the measured
temperature in the fuel gas line downstream the fuel gas preheater. The purpose is to maintain a
constant fuel gas preheater outlet temperature, independent of the actual fuel gas flow and inlet
temperature.

4.5.

Normal Shut-down
Note
The normal shut-down is performed in automatic mode by stopping of the
related function group GT Gas preheater control by the relevant sequencer in
the DCS.
For automatic shut-down, no operator actions are required.
Here are no special requirements for the shut-down procedure. The system can be shut-down at
any time or automatically as soon as GT flame is off or command off is given.

CAUTION
Standstill of the system during sub-zero ambient temperature condition may
following in icing and consequently in serious damages of the system or
components.
Switch the heat tracing system into operation during standstill at sub-zero
ambient condition.
Follow the component operating instructions.

4.6.

Abnormal Operation
The water extraction shut-off valve 11EKT10AA002 is closed in following cases
The fuel gas temperature exceeds a certain limit (MAX2).
When fuel gas is detected downstream of the gas preheater and if the gas preheater shut-off
valve is already closed, the following actions have to be taken:

Check the gas detection device on top of the gas preheater

If gas is detected on the gas preheater shell side, the manual shut-off valve
11HAC24AA002 (in HRSG scope) of the extraction line must be closed in order to prevent
gas increase in the boiler system.

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5.

MAINTENANCE

5.1.

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 components is to be maintained by adhering to the relevant
operation & maintenance documentation supplied by the supplier, and must be consulted before
operation or maintenance begins.

5.2.

System-related Maintenance

Carry out a visual inspection of the entire system every day.

Component specific maintenance instructions must be observed.

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6.

APPENDICES

6.1.

Manual Preparation Check List prior to Start-up

Before start-up, prepare the systems, all components, valves, and

instrumentations to be ready for operation according to Table 3.

System/Component

Status

KKS number

Gas preheater

Ready for operation

11EKC10AC001

Remote controlled valves

Ready for operation

various

Instrumentations

Ready for operation

various

Valve

Position

KKS number

Instrument root valve for all permanent

instruments

open

various

maintenance drains

closed

various

Instrument root valves for all temporary

instruments

closed

various

Manual isolation valve

open

11HAC24AA002

Manual isolation valve

open

11EKT10AA001

Extraction shut-off valve

closed

11EKT10AA002

Control valve

closed

11EKT10AA003

Table 3

6.2.

Manual Preparation Check List prior to Start-up

Alarm List
KKS

Code

Description

Remarks

11EKC10CL001

LA

GAS DETECTION PHR

Check PHR (tube break)

Close isolation valve
11HAC24AA002

11EKC10CL002

11EKG90CT001

LA

<MIN1

GAS DETECTION AFT

PHR

Check PHR (tube break)

T FUEL GAS AFT PHR

Check isolation valves

Close shut-off valve

11EKT10AA002
Check shut-off valve
Check functionality of control
valve

11EKG90CT001

>MAX1

T FUEL GAS AFT PHR

Check functionality of control

valve

11EKG90CT001

>MAX2

T FUEL GAS AFT PHR

Check functionality of control

valve

Table 4

Alarm List

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6.3.

Rev. A

Externals Documents and Diagrams

The following external documents and diagrams are referenced throughout this manual.
Document No.

Title

1AHA049449

P & ID Fuel Gas Preheating System

1AHA049450

Legend to P & ID Fuel Gas Preheating System

1AHA050087

P & ID Fuel Gas System

Legend to P & ID Fuel Gas System
Process Function Plan Fuel Gas Preheating System
Set Point List Fuel Gas Preheating System

Table 5

External Documents and Diagrams

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Index
A

abbreviations and acronyms, 10

alarm list, 23

main components, 11
MANDATORY ACTION
explanation, 9
manual preparation check list prior to start-up, 23

C
CAUTION
explanation, 8
compulsory reading, 7
copyright, 2

O
Operational readiness, 21
S

system tasks, 11

DAMAGE
explanation, 9
DANGER
explanation, 8

T
target audience, 7
TN04/0297, 13

external documents and diagrams, 24

user audience, 7

general note
explanation, 9

visual inspection, 21
W

WARNING
explanation, 8

interface to other systems, 11

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