ProSimulator

PROSIMULATOR
COGENERATION BOILER
PS5014

Version 2.0
Aug 2017

Sim Infosystems Private Limited,

Chennai

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1.OBJECTIVE ........................................................................................................................................ 3

2.PROCESS DESCRIPTION ................................................................................................................. 3

HEAT RECOVERY STEAM GENERATOR ..................................................................................... 8

3. NORMAL OPERATING CONDITION ............................................................................................. 9

4. START-UP PROCEDURE ................................................................................................................ 15

5.LIST OF FAILURES ......................................................................................................................... 21

6. LIST OF PROCESS DISTURBANCES........................................................................................... 21

7.INTERLOCKS ................................................................................................................................... 22

8. PROCESS CONTROL LOOPS…………………………………………………………………………………………………23

9. ESD PAGES...................................................................................................................................... 24

10. COGENERATION BOILER - P&ID ............................................................................................. 25

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CO-GENERATION BOILER – PS5014

1.OBJECTIVE
The primary objective of PS5014- COGENERATION BOILER UNIT program is to
teach trainees the operating fundamentals of a cogeneration boiler system using
dynamic simulation.
ProSimulator provides opportunities to identify the main equipments associated with
this systems, to describe the operation of Cogeneration boiler unit, how to startup and
shutdown the process using documented procedures, how to respond safely and efficiently to
disturbances and malfunctions in the process, understand how temperature and pressure affect
the operation of a Gas Turbine Unit.

2.PROCESS DESCRIPTION

The simulated Gas Turbine and Heat Recovery Steam Generation unit is divided into
following sections:
1. Air Systems

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2. Combustion Section

3. Turbine and Generation Section

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Gas Turbine section, in which compressed air and fuel oil or fuel gas are ignited, driving the
turbine, which in turn drives the electric generator. In the Generator section, which produces
75 MW electrical power at 3000 RPM, with a voltage of 15.75 KV at 50 Hz.

4.Waste heat recovery unit and Turbine-Generation section

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5.Condensate System

6.Plant Utilities

The purpose of this system is to generate a low power auxiliary electrical output.The
gas turbine engine is composed of a single axial flow air compressor, combustion chamber
(combustor), and a single axial flow turbine housed in one unit and rotating on a common
shaft. Its shaft rotation speed is geared down via a gear box to drive the electrical generator,
which is connected to the compressor end of the shaft.

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The gas turbine is started initially by the diesel starter, which is on a common shaft
with the torque converter. A gear box on the same shaft shaft is connected to the turbine shaft,
and converts the lower diesel shaft speed to the higher speed required for the compressor and
turbine operation. The compressor and turbine are mounted on a common shaft. When the
turbine reaches 900 RPM, fuel and air can be mixed and fired in the combustor.
Air flows into the compressor through the air intake port, and is compressed to 25.5
kg/cm2. It is then delivered to the combustor through guide vanes which diffuse the air
equally to the combustor burners. Fuel oil or fuel gas are delivered under governor pressure
control through the fuel nozzles into the burner cans, where it is mixed with the compressed
air and ignited.
Once the fuel is ignited, the compressor turbine rotation becomes self-sustaining. As
the air-fuel mixture burns, the gas of combustion expands and flows across the turbine
blading, providing rotation to the shaft to drive the compressor and generator.
The gases exhausted from the turbine section flow through the gas flue and either out the
stack or into the HRSG to produce steam for other plant operations.
The generator is an air-cooled 75 megawatt (MW), 15.75 kilovolt (KV) machine
whose shaft is driven by the compressor-turbine shaft through a gear box.

A motor-driven exciter establishes the field voltage to the generator. The terminal
voltage of the generator is controlled by either a rheostatic manual voltage regulator or an
automatic voltage regulator.
The generator 15.75 KV terminal voltage is boosted to 230 KV across the transformer.
The voltage regulator maintains the deviation between the generator high-side voltage and the
grid voltage at zero volts by adjusting the excitation field to the generator. That is, the
transformer voltage is matched with the grid voltage at the main bus.
The governor system regulates the power generated which is set by the load controller
by adjusting the flow of fuel to the turbine combustor.
The generator core is cooled by a filtered air system.
Turbine - Generator Lube Oil System
The lube oil system is a major auxiliary to the turbine generator. It provides
lubrication and heat dissipation for the turbine, compressor, and generator shaft bearings and
seals, including: Generator shaft bearings, the turbine-compressor thrust bearing, the turbine-
compressor shaft bearings, the generator gear box, the turbine auxiliary gear box, and the
diesel shaft torque converter.
The lube oil is taken from the lube oil tank by one of three available lube oil pumps
and is delivered to the bearings, gears, and oil seals of the components mounted on the shafts.
Besides providing lubrication to the bearings and gears, the lube oil picks up heat generated
there and keeps the bearing and gear temperatures within a safe operating range. From the
bearings, gears, and seals, the hot lube oil drains back to the lube oil reservoir.
The main lube oil pump is driven by the turbine shaft. Normally, this pump delivers
the oil to the bearings and gears. During startup, or when the main pump is out of service, a
motor-driven pump is used. The lube oil discharged from either of these pumps flows through
the air-cooled lube oil cooler. The cooler fans reduce the temperature of the hot lube oil to a
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temperature suitable for cooling the shaft bearings. The lube oil then passes through two lube
oil filter strainers in the lube oil manifold line, which remove particles and debris from the oil
before it is delivered to the shaft-mounted components.

HEAT RECOVERY STEAM GENERATOR

The heat recovery steam generator (HRSG) provides superheated, medium-pressure
steam for plant heating and various other plant processes. The HRSG produces steam from
feed water.
The HRSG system consists of a furnace section, three feed water and steam heating
coil sections (with one steam desuperheater, a steam drum, and two boiler water circulating
pumps BWCP's).
The HRSG can be operated as a steam plant alone, fired by either fuel oil of fuel gas,
when the gas turbine is not in operation. Or, the feed water in the boiler can be converted to
steam from the heat of the gas turbine exhaust, without use of fuel oil or gas.
When the gas turbine is in operation, the flue gas (exhaust) flow is controlled by the
positioning of dampers in the flue. Normally, when the steam generator is not in operation,
the flue gas inlet damper to the boiler is closed, and the flue damper leading to the stack is
open. The gas turbine exhaust thus goes out to the atmosphere through the stack.

Generating Steam Via Turbine Gases

When the steam generator is to be placed in operation using the gas turbine exhaust
heat, the turbine flue gases are routed through the damper into the furnace heating chamber.
The gases rise up through the furnace, passing across the superheater coils first, then the
evaporator coils, and finally the economizer coils. The gas then exits the furnace through a
damper into the exhaust flue, and then flowing out the stack.
As the hot gas flows over the various heating coils, the heat in the gases is transferred
to the cooler water and steam in the coils. The greatest amount of heat is picked up by the
steam in the superheater, somewhat less by the steam-water mixture in the evaporator, and
some by the feed water in the economizer.
The feed water to the HRSG first enters the economizer tubes. The flow of feed water
is regulated by the steam drum level controller, which balances the water flow in against the
steam drum level.From the economizer, the heated feed water flows to the steam drum. From
the drum the water is circulated through the HRSG coils by one of the two motor-driven
boiler water circulating pumps (BWCP's).From the discharge header of the BWCP's, the
boiler water flows through a filter screen and into the evaporator tubes. Here, the water is
heated to a point where steam bubbles form. The steam-water mixture flows back to the
steam drum. The steam bubbles are released from the mixture and rise into the steam
chambers of the drum, while the water is recirculated through the BWCP's.
As mentioned above, the level of boiler water in the drum is controlled by automatic
regulation of the flow of feed water into the HRSG. During startup, because of the shrink and
swell effects created when the drum is filling and being heated, a valved blowdown line is
provided, which is used by the operator to help control the level manually. A vent valve is
provided to relieve excess steam pressure from the steam drum, and to vent it during
shutdown.

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The steam released into the upper part of the steam drum flows to the superheater
section of the HRSG. Here the greatest amount of heat from the gas turbine exhaust is
delivered to the steam. The steam becomes superheated and passes through a desuperheater.
The steam temperature controller regulates the flow of attemperating spray water, diverted off
the feed water line, into the desuperheater. To keep the steam temperature from rising above
setpoint, the spray is injected into the superheated steam, where it absorbs the excess heat,
thus reducing the steam temperature. The steam then exits the HRSG and is directed to the
facilities or processes for which it is intended.
A motor-driven forced draft (FD) fan provides additional combustion air for the fuel
gas or fuel oil.The combustion of the air-fuel mixture, along with the recovered heat from the
GT, produces the heat needed to turn the boiler water into superheated steam.The fuel to be
used, either oil, gas, or a mixture of both, is selected by a manual control. The fuel flow,
which is based on the steam flow generated, is regulated by flow controller FC02. Feed water
temperature, pressure, and steam supply back pressure are variables selected by the instructor,
and affect the operating conditions of the HRSG.

3. NORMAL OPERATING CONDITION

Tag Scale Scale Design

Type TagDesc Engg-Unit
Name Low High Val
CTL LIC101 COND LVL CONTROL mm 0.00 1400.00 700.00
CTL PIC101 CEP PR CONTROL Kg/cm2 0.00 50.00 20.00
CTL LIC102 DEA LVL CONTROL mm 0.00 4000.00 2000.00
CTL PIC102 BFP PR CONTROL Kg/cm2 0.00 180.00 90.00
CTL LIC103 DRUM LVL CONTROL mm -400.00 400.00 0.00
CTL PIC103 FUEL GAS PR CONTROL Mpa 0.00 7.00 3.00
CTL PIC104 FD AIR PR CONTROL Kpa 0.00 3.00 1.50
-
CTL PIC105 FUR PR CONTROL Pa 4000.00 -50.00
4000.00
CTL PIC106 SH PR CONTROL Kg/cm2 0.00 180.00 87.20
CTL TIC101 SH TEMP CONTROL Deg C 0.00 800.00 535.00
CTL PIC107 MP HDR PR CONTROL Kg/cm2 0.00 70.00 35.00
CTL TIC102 MP HDR TEMP CONTROL Deg C 0.00 600.00 350.00
CTL PIC108 LP HDR PR CONTROL Kg/cm2 0.00 20.00 7.15
CTL TIC103 LP HDR TEMP CONTROL Deg C 0.00 400.00 200.00
CTL PIC001 FUEL GAS PR CTRL Kg/cm2 0.00 10.00 3.00
CTL PIC002 FUEL OIL PR CTRL Kg/cm2 0.00 10.00 3.50
CTL FIC001 COMP I/L FLOW CTRL T/hr 0.00 200.00 100.00
CTL PIC003 LUBE OIL PR CTRL Kg/cm2 0.00 5.00 1.50
CTL TIC001 AIR TEMP CTRL Deg C 0.00 100.00 45.00
IND LI101 CST LEVEL mm 0.00 8000.00 4500.00
IND FI101 MAKE-UP FLOW T/hr 0.00 500.00 20.00
IND FI102 AIR FLOW T/hr 0.00 200.00 52.13

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IND LI102 COND LEVEL mm 0.00 1500.00 700.00

IND TI101 COND TEMP Deg C 0.00 100.00 42.00
IND FI103 CEP DIS FLOW T/hr 0.00 1000.00 518.00
IND PI101 CEP DIS PRES Kg/cm2 0.00 50.00 20.00
IND TI102 CEP DES TEMP Deg C 0.00 100.00 45.00
IND FI104 RE-CIR FLOW T/hr 0.00 150.00 80.00
IND TI103 EXT 4 TEMP Deg C 0.00 300.00 150.00
IND TI104 LPH 4 O/L TEMP Deg C 0.00 200.00 80.00
IND TI105 EXT 3 TEMP Deg C 0.00 500.00 270.00
IND TI106 LPH 3 O/L TEMP Deg C 0.00 300.00 150.00
IND FI105 DEA I/L FLOW T/hr 0.00 1000.00 518.00
IND LI103 DEA LEVEL mm 0.00 4000.00 2000.00
IND TI107 DEA TEMP Deg C 0.00 500.00 170.00
IND TI108 EXT 2 TEMP Deg C 0.00 600.00 300.00
IND FI106 BFP RE-CIR FLOW T/hr 0.00 200.00 100.00
IND PI102 BFP DIS PR Kg/cm2 0.00 200.00 90.00
IND FI107 BFP DIS FLOW T/hr 0.00 1000.00 660.00
IND TI109 EXT 1 TEMP Deg C 0.00 600.00 340.00
IND PI103 FRS PRES Kg/cm2 0.00 200.00 89.80
IND FI108 FRS FLOW T/hr 0.00 1000.00 660.00
IND TI110 FRS TEMP Deg C 0.00 600.00 247.00
IND PI104 FUEL GAS PRES Mpa 0.00 10.00 3.00
IND FI109 FUEL GAS FLOW T/hr 0.00 20.00 10.00
IND TI111 FUEL GAS TEMP Deg C 0.00 100.00 35.00
IND FI110 FD AIR FLOW T/hr 0.00 1000.00 400.00
IND TI112 FD AIR TEMP Deg C 0.00 100.00 30.00
IND PI105 FD AIR PRES Kpa 0.00 5.00 1.50
IND TI113 APH O/L FD TEMP Deg C 0.00 600.00 300.00
IND PI106 ID INLET PRES Kpa -4.00 4.00 -0.20
IND TI114 ID INLET TEMP Deg C 0.00 500.00 134.74
IND FI111 ID INLET FLOW T/hr 0.00 1000.00 525.00
IND PI107 ID FAN O/L PRES Kpa -4.00 4.00 -0.05
IND PI108 CHIMNEY I/L PR Kpa -4.00 4.00 -0.02
-
IND PI109 FURNACE PRES Pa 4000.00 -50.00
4000.00
IND TI115 FURNACE TEMP Deg C 0.00 1700.00 1370.00
IND TI116 FLUE GAS TEMP Deg C 0.00 1700.00 1350.00
IND TI117 DIV SH TEMP Deg C 0.00 600.00 440.00
IND TI118 FIN SH TEMP Deg C 0.00 600.00 540.00
IND TI119 HSH I/L FG TEMP Deg C 0.00 1700.00 873.54
IND TI120 ECO I/L FG TEMP Deg C 0.00 1700.00 704.73
IND TI121 APH I/L FG TEMP Deg C 0.00 600.00 395.39

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IND TI122 DRUM I/L TEMP Deg C 0.00 600.00 343.00

IND LI104 DRUM LEVEL mm -400.00 400.00 0.00
IND FI112 ECO RE-CIR FLOW T/hr 0.00 200.00 100.00
IND FI113 FSH DSH FLOW T/hr 0.00 20.00 10.00
IND PI110 FSH PRES Kg/cm2 0.00 200.00 87.20
IND TI123 FSH TEMP Deg C 0.00 600.00 534.96
IND FI114 FSH FLOW T/hr 0.00 1000.00 660.00
IND FI115 HP HDR FLOW T/hr 0.00 600.00 470.00
IND PI111 HP HDR PRES Kg/cm2 0.00 200.00 87.20
IND TI124 HP HDR TEMP Deg C 0.00 600.00 534.96
IND FI116 UTILITY 1 FLOW T/hr 0.00 300.00 150.00
IND FI117 UTILITY 2 FLOW T/hr 0.00 300.00 120.00
IND PI112 HP DSH PRES Kg/cm2 0.00 200.00 90.00
IND TI125 HP DSH TEMP Deg C 0.00 500.00 170.00
IND FI118 HP DSH FLOW T/hr 0.00 20.00 7.00
IND FI119 MP HDR FLOW T/hr 0.00 600.00 317.00
IND PI113 MP HDR PRES Kg/cm2 0.00 100.00 35.00
IND TI126 MP HDR TEMP Deg C 0.00 600.00 346.37
IND FI120 UTILITY 1 FLOW T/hr 0.00 200.00 90.00
IND FI121 UTILITY 2 FLOW T/hr 0.00 200.00 100.00
IND PI114 MP DSH PRES Kg/cm2 0.00 200.00 90.00
IND TI127 MP DSH TEMP Deg C 0.00 500.00 170.00
IND FI122 MP DSH FLOW T/hr 0.00 10.00 3.00
IND FI123 LP HDR FLOW T/hr 0.00 200.00 123.00
IND PI115 LP HDR PRES Kg/cm2 0.00 20.00 7.15
IND TI128 LP HDR TEMP Deg C 0.00 300.00 199.31
IND FI124 UTILITY 1 FLOW T/hr 0.00 100.00 65.00
IND FI125 UTILITY 2 FLOW T/hr 0.00 100.00 55.00
IND PI116 FLASH TANK PRES Kg/cm2 0.00 5.00 1.50
IND TI129 FLASH TANK TEMP Deg C 0.00 300.00 210.00
IND FI126 FLASH TANK FLOW T/hr 0.00 500.00 61.73
IND TI130 DEA TEMP Deg C 0.00 300.00 170.00
IND TI131 DRUM TEMP Deg C 0.00 600.00 350.00
IND PI117 COND PRES Kpa -200.00 200.00 -90.00
IND PI118 DRUM PRES Kg/cm2 0.00 200.00 88.00
IND SI101 TURBINE SPEED rpm 0.00 6000.00 3000.00
IND EI01 GEN POWER MW 0.00 100.00 50.00
IND FI127 FLASH TANK FLOW T/hr 0.00 500.00 200.00
IND FI128 CBD FLOW T/hr 0.00 20.00 10.00
IND PI001 FUEL GAS PR Kg/cm2 0.00 10.00 3.50
IND PI002 FUEL GAS FILTER DP Kg/cm2 0.00 1.00 0.50

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IND FI001 FUEL GAS FLOW T/hr 0.00 20.00 10.00

IND TI001 FUEL GAS TEMP Deg C 0.00 100.00 35.00
IND FI002 FUEL OIL TANK FLOW T/hr 0.00 30.00 15.00
IND LI001 FUEL OIL TANK LEVEL T/hr 0.00 10000.00 4500.00
IND TI002 FUEL OIL TANK TEMP Deg C 0.00 100.00 30.00
IND FI003 PUMP DIS FLOW T/hr 0.00 30.00 15.00
IND PI003 PUMP DIS PR Kg/cm2 0.00 10.00 3.50
IND TI003 EXT STEAM I/L TEMP Deg C 0.00 200.00 130.00
IND TI004 EXT STEAM O/L TEMP Deg C 0.00 200.00 105.00
IND TI005 FUEL OIL TEMP Deg C 0.00 200.00 100.00
IND FI004 FUEL OIL FLOW T/hr 0.00 30.00 15.00
IND TI006 SUPPLY AIR TEMP Deg C 0.00 100.00 30.00
IND PI004 AIR FILTER DP Kg/cm2 0.00 1.00 0.02
IND FI005 SUPPLY AIR FLOW Deg C 0.00 200.00 100.00
IND TI007 EXT STEAM I/L TEMP T/hr 0.00 200.00 130.00
IND TI008 EXT STEAM O/L TEMP Deg C 0.00 200.00 105.36
IND PI005 COMP I/L PR Kg/cm2 0.00 2.00 0.98
IND FI006 COMP I/L FLOW T/hr 0.00 200.00 100.00
IND TI009 COMP I/L TEMP Deg C 0.00 100.00 45.00
IND PI006 COMP O/L PR Kg/cm2 0.00 30.00 25.49
IND FI007 COMP O/L FLOW T/hr 0.00 200.00 100.00
IND TI010 COMP O/L TEMP Deg C 0.00 500.00 359.70
IND TI011 FURNACE TEMP Deg C 0.00 1700.00 1370.00
IND TI012 FUEL GAS TEMP Deg C 0.00 1000.00 534.73
IND PI007 EXT STEAM I/L PR Kg/cm2 0.00 5.00 1.50
IND FI008 EXT STEAM I/L FLOW T/hr 0.00 100.00 30.00
IND PI008 SUPPLY AIR PR Kg/cm2 0.00 2.00 0.98
IND FI009 LUBE OIL TANK FLOW T/hr 0.00 100.00 40.00
IND LI002 LUBE OIL TANK LEVEL mm 0.00 10000.00 3000.00
IND TI013 LUBE OIL TANK TEMP Deg C 0.00 100.00 70.00
IND FI010 PUMP DIS FLOW T/hr 0.00 50.00 40.00
IND PI009 PUMP DIS PR Kg/cm2 0.00 5.00 1.70
IND TI014 WATER I/L TEMP Deg C 0.00 100.00 30.00
IND TI015 WATER O/L TEMP Deg C 0.00 100.00 45.00
IND TI016 LUBE OIL TEMP Deg C 0.00 100.00 35.00
IND FI011 LUBE OIL FLOW T/hr 0.00 50.00 40.00
IND SI001 TURBINE SPEED rpm 0.00 4000.00 3000.00
IND SI002 SPEED % % 0.00 120.00 100.00
IND VI001 TURBINE VIBRATION micron 0.00 100.00 43.54
IND EI001 GEN POWER MW 0.00 100.00 75.00
IND EI002 REACTIVE POWER MVAR 0.00 100.00 25.39

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IND EI003 SYSTEM VOLT V 0.00 500.00 343.00

IND EI004 GEN VOLT KV 0.00 30.00 15.75
IND EI005 GEN CURRENT A 0.00 4000.00 3234.36
IND EI006 POWER FACTOR PF 0.00 1.00 0.85
IND EI007 FREQUENCY Hz 0.00 100.00 50.00
IND BEI001 BOILER EFFICIENCY % 0.00 100.00 87.41
IND HRI001 HEAT RATE KJ/KWHR 0.00 50.00 8624.18
DIFFERENTIAL HEAT
IND DHRI001 KJ/KWHR -50.00 50.00 0.00
RATE
IND FCI01 FUEL CONSUMPTION TON/HR 0.00 50.00 35.00
OVERALL PLANT
IND OPEI01 % 0.00 100.00 49.83
EFFICIENCY
SWT FOD001 CEP A SUC V/V 0.00 1.00 0.00
SWT SW001 CEP PUMP A 0.00 1.00 1.00
SWT FOD002 CEP A DIS V/V 0.00 1.00 1.00
SWT FOD003 CEP B SUC V/V 0.00 1.00 1.00
SWT SW002 CEP PUMP B 0.00 1.00 0.00
SWT FOD004 CEP B DIS V/V 0.00 1.00 0.00
SWT FOD005 EXT 4 VALVE 0.00 1.00 1.00
SWT FOD006 EXT 3 VALVE 0.00 1.00 1.00
SWT FOD007 EXT 2 VALVE 0.00 1.00 1.00
SWT FOD008 EXT 1 VALVE 0.00 1.00 1.00
SWT FOD009 BFP A SUC V/V 0.00 1.00 1.00
SWT SW003 BFP A 0.00 1.00 1.00
SWT FOD010 BFP A DIS V/V 0.00 1.00 1.00
SWT FOD011 BFP B SUC V/V 0.00 1.00 1.00
SWT SW004 BFP B 0.00 1.00 0.00
SWT FOD012 BFP B DIS V/V 0.00 1.00 0.00
SWT FOD013 SUPPLY GAS V/V 0.00 1.00 1.00
SWT SW005 FD FAN 0.00 1.00 1.00
SWT SW006 ID FAN 0.00 1.00 1.00
SWT FOD014 CST INLET V/V 0.00 1.00 0.00
SWT SW007 APH AC MOTOR 0.00 1.00 1.00
SWT SW008 APH DC MOTOR 0.00 1.00 1.00
SWT SW009 FLAME 0.00 1.00 0.00
SWT FOD015 TURBINE I/L V/V 0.00 1.00 1.00
SWT FOD016 AIR EJACTOR 0.00 1.00 1.00
SWT A/M AUTO/MANUAL 0.00 1.00 1.00
SWT FOD017 ECO RE-CIR V/V 0.00 1.00 0.00
SWT SYNC SYNCRONISER 0.00 1.00 0.00
SWT FOD018 DRUM VENT 0.00 1.00 0.00
SWT FOD101 FOP A SUC V/V 0.00 1.00 1.00

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SWT SW101 FO PUMP A 0.00 1.00 1.00

SWT FOD102 FOP A DIS V/V 0.00 1.00 1.00
SWT FOD103 FOP B SUC V/V 0.00 1.00 1.00
SWT SW102 FO PUMP B 0.00 1.00 0.00
SWT FOD104 FOP B DIS V/V 0.00 1.00 0.00
SWT FOD105 FUEL GAS V/V 0.00 1.00 0.00
SWT FOD106 FUEL OIL V/V 0.00 1.00 1.00
SWT FOD107 AIR SUPPLY V/V 0.00 1.00 1.00
SWT FOD108 EXT STEAM VALVE 0.00 1.00 1.00
SWT FOD109 AIR FILTER CMPR 0.00 1.00 1.00
SWT FOD110 AIR SHUT OFF V/V 0.00 1.00 1.00
SWT FOD111 CMPR BLEED OFF 1 0.00 1.00 0.00
SWT FOD112 CMPR BLEED OFF 2 0.00 1.00 0.00
SWT SW103 EXCITER 0.00 1.00 1.00
SWT FOD113 LUBE OIL V/V 0.00 1.00 0.00
SWT FOD114 LOP A SUC V/V 0.00 1.00 0.00
SWT SW104 LO PUMP A 0.00 1.00 1.00
SWT FOD115 LOP A DIS V/V 0.00 1.00 1.00
SWT FOD116 LOP B SUC V/V 0.00 1.00 1.00
SWT SW105 LO PUMP B 0.00 1.00 0.00
SWT FOD117 LOP B DIS V/V 0.00 1.00 0.00
SWT A/M1 AUTO/MANUAL 0.00 1.00 1.00
SWT SW106 IGNITOR 0.00 1.00 0.00
SWT SW107 FLAME 0.00 1.00 1.00
SWT SW108 COMPRESSOR 0.00 1.00 1.00
SWT LATCH1 TURBINE LATCH 0.00 1.00 1.00
SWT SYNC1 SYNCHRONIZER 0.00 1.00 1.00
MLS HIC001 CEP RE-CIR FLOW % 0.00 100.00 0.00
MLS HIC002 BFP RE-CIR FLOW % 0.00 100.00 0.00
MLS HIC003 CBD FLOW % 0.00 100.00 0.00
MLS HIC004 CST INLET VALVE % 0.00 100.00 50.00
MLS HIC005 CBD FLOW % 0.00 100.00 50.00
MLS HIC006 FUEL OIL I/L % 0.00 100.00 50.00
ALM ALM01 LUBE OIL I/L 0.00 0.00 0.00
ALM ALM02 COMPRESSOR TRIP 0.00 0.00 0.00
ALM ALM03 SHUT OFF VALVE CLOSE 0.00 0.00 0.00
ALM ALM04 GUIDE VANE CLOSE 0.00 0.00 0.00
ALM ALM05 BLEED OFF VALVE OPEN 0.00 0.00 0.00
ALM ALM06 TURBINE SPEED LO 0.00 0.00 0.00
ALM ALM07 LUBE OIL PMP TRIP 0.00 0.00 0.00
ALM ALM08 GAS TURBINE TRIP 0.00 0.00 0.00

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ALM ALM09 LOW LVL IN CONDENSER 0.00 0.00 0.00

ALM ALM10 DEAERATOR LOW LVL 0.00 0.00 0.00
ALM ALM11 AC & DC MOTOR TRIP 0.00 0.00 0.00
ALM ALM12 MASTER FUEL TRIP 0.00 0.00 0.00
ALM ALM13 ID & FD FAN TRIP 0.00 0.00 0.00
ALM ALM14 GENERATOR TRIP 0.00 0.00 0.00
LIT LIT01 GEN VOLTAGE LESS 0.00 0.00 0.00
LIT LIT02 EXCITER STOP 0.00 0.00 0.00
LIT LIT03 LUBE OIL PR. LOW 0.00 0.00 0.00
LIT LIT04 FUEL OIL PR. LOW 0.00 0.00 0.00
LIT LIT05 COMPR I/L FLOW LOW 0.00 0.00 0.00
LIT LIT06 TURBINE VIBRATION HI. 0.00 0.00 0.00
LIT LIT07 FURNACE PR. 0.00 0.00 0.00
LOW FD AIR & FUEL
LIT LIT08 0.00 0.00 0.00
FLOW
LIT LIT09 DRUM LVL HI / LO 0.00 0.00 0.00
ALL STEAM VALVES
LIT LIT10 0.00 0.00 0.00
CLOSE

4. START-UP PROCEDURE

 Ensure that all maintenance of unit is complete & work permits are cancelled
 Ensure that instrument air compressors are working & instrument air pressure is
normal
 Ensure healthiness of DCS & DEH systems
 Open all the drain and vent valves in furnace & Turbine area
 Ensure that all safety valves are in normal position

INDUCED DRAFT FAN

 Start APH AC motor (SW007) [Gr Pg - 6]

 Check the furnace pressure is in normal range[Gr Pg - 6]
 Start the ID Fan A (SW006), Now open PIC105 to 5% to maintain furnace pressure in
negative value [Gr Pg - 6]
 Now switch PIC105 in AUTO with a set point of -50 pa.

AIR COMPRESSOR

 Start the Air Filter Compressor (FOD109) which supplies compressed air to pulse
filter [Gr Pg - 3]
 Open the Supply air Shut-off Valve (FOD110), observe the supply air flow and
pressure [Gr Pg - 3]

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 Open the Auxiliary steam Shut-off Valve (FOD108) and open the control valve
(TIC001) manually to 10% and switch it to AUTO with a set point of 45 degC [Gr Pg
- 3]
 Wait till the outlet air temperature at Anti-icing air heater stabilizes at 45 degC
 Now ensure the compressor Bleed off Valve at 4th and 8th stage (FOD111 & FOD112)
are in closed condition [Gr Pg - 3]
 Start the Compressor (SW108) observe the outlet temperature and pressure will
increase [Gr Pg - 3]
 Now Switch the Compressor inlet air flow controller (FIC001) in AUTO mode with a
set point of 100 t/hr [Gr Pg - 3]
 Wait till the compressor discharge flow rises to 100 T/hr, pressure to 25 Kg/cm2 and
temperature above 350 DegC [Gr Pg - 3]

TURBINE LUBE OIL SYSTEM

 Open lube oil inlet valve to storage tank (FOD113&HIC006) wait till the level
reaches 2500mm [Gr Pg - 5]
 Open the suction valve of both the lube oil pump (FOD114 & FOD116) [Gr Pg - 5]
 Start lube oil pump A (MS103) and open its discharge valve (FOD115) [Gr Pg - 5]
 Now Switch the lube oil pressure controller (PIC003) in AUTO mode with a set point
of 1.5 Kg/cm2 [Gr Pg - 5]

CONDENSATE WATER SYSTEM

 Open the make-up valve (HIC004) from DM plant to Condensate storage tank allow
the tank to fill up to 3000mm [Gr Pg - 7]
 Open the condenser make-up MCV (LIC101) manually to 50%, observe the water
level in condenser will start to increase, fill the condenser till 900mm [Gr Pg - 7]
 Now Start Air ejector (FOD016) and create Vacuum inside condenser around -90 Kpa
 Now before starting any CEP open both CEP suction valves (FOD001 & FOD003)
[Gr Pg - 7]
 Start either one CEP (SW001 or SW002) and open its corresponding discharge valve
(FOD002, FOD004) now open PIC101 to 10% Manually the discharge pressure and
flow will increase gradually
 Open CEP Re-circulation Valve HIC001 to 20% to maintain Hot-well level and adjust
accordingly
 Now switch PIC101 to AUTO mode with a set point of 20 Kg/cm2
 Now open deaerator make-up MCV (LIC102) manually to 7% in steps of 2%, observe
the deaerator flow will increase at 80 t/hr, fill the deaerator till 1000mm [Gr Pg - 7]
 Now Switch LIC102 to AUTO with a set point of 2000mm [Gr Pg - 7]

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BOILER FEED PUMP

 Now line-up the Motor driven BFP.

 Check the deaerator level have to be above 1000mm[Gr Pg - 7]
 Open the MD-BFP suction valve (FOD009 & FOD011), open the recirculation valve
(HIC002) to 30% and check the discharge valve (PIC102) is in closed condition [Gr
Pg - 7]
 Now start the MD-BFP (SW003 or SW004) and open its discharge valve (FOD010,
FOD012), now open PIC102 to 10% Manually the discharge pressure and flow will
increase gradually [Gr Pg - 7]
 Open the BFP scoop control (LIC103) gradually to 10% [Gr Pg - 7]
 Fill the drum up to -24mm [Gr Pg - 6]
 Maintain the drum level at -24mm and switch FRS control valve LIC103 to AUTO
with a set point of -24mm [Gr Pg - 6]
 Close the vents of different zones after checking the water start to come out in
pressure (Not Simulated) [Gr Pg - 6]

FORCED DRAFT FAN

 Ensure APH AC motor and ID FAN A (SW006 & SW007) is in running condition [Gr
Pg - 6]
 Check the furnace pressure is in normal range[Gr Pg - 6]
 Start the FD Fan A (SW005), Now open PIC104 to 5% and maintain furnace pressure
in negative value [Gr Pg - 6]
 Now switch PIC104 in AUTO with a set point of 1.5 Kpa.

HEATERS

 Now charge all the heaters from low pressure to high pressure zones
 Open the Extraction Steam supply valve (FOD005) observe the LPH4 Outlet
temperature will increase[Gr Pg - 7]
 Open the Extraction Steam supply valve (FOD006) observe the LPH3 Outlet
temperature will increase[Gr Pg - 7]
 Open the Extraction Steam supply valve (FOD007) observe the DEA Outlet
temperature will increase[Gr Pg - 7]
 Open the Extraction Steam supply valve (FOD008) observe the HPH1 Outlet
temperature will increase[Gr Pg - 7]
 Note the temperature at FRS station is around 247 DegC

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COMBUSTION CHAMBER
1. Combustion can be done with either Fuel gas or Fuel oil
Fuel Gas
 Open Fuel gas shut off valve (FOD105) [Gr Pg - 4]
 Now Switch the fuel gas pressure controller (PC101) in AUTO mode with a set
point of 1 Kg/cm2 [Gr Pg - 4]
Fuel Oil
 Open fuel oil inlet valve to storage tank (FOD106&HIC005) wait till the level
reaches 2500mm [Gr Pg - 4]
 Open the suction valve of both the fuel oil pump (FOD101 & FOD103) [Gr Pg
- 4]
 Start Fuel oil pump A (SW101) and open its discharge valve (FOD102) [Gr Pg
- 4]
 Now Switch the fuel oil pressure controller (PIC002) in AUTO mode with a
set point of 1 Kg/cm2 [Gr Pg - 4]

2. Now SPARK the igniter (SW106) inside furnace, flame will induce inside furnace and
its temperature will increase [Gr Pg - 4]

GAS TURBINE

 Check the vibration of the gas turbine, it must be in normal condition [Gr Pg - 5]
 Now latch the turbine using (LATCH1) switch and admit flue gas in the turbine [Gr
Pg - 5]
 Observe the turbine speed and bearing vibration will increase gradually [Gr Pg - 5]
 When the turbine speed is above 2990 rpm, start the EXCITER using (SW103), Now
observe the generator terminal voltage will start to increase [Gr Pg - 5]
 After the generator voltage reaches above 15.5 KV and turbine speed is near
3000rpm, synchronize the generator using (SYNC1) switch [Gr Pg - 5]
 Observe the power will start to increase in generator [Gr Pg - 5]
 Now gradually rise either fuel oil or fuel gas to its design value, simultaneously
observe the generator power will rise to its full load [Gr Pg - 5]
 Check for abnormalities in all the page and continue with WHRU & steam turbine [Gr
Pg - 5]

BOILER LIGHT-UP

 Open the Fuel Gas supply trip valve (FOD013) [Gr Pg - 6]

 Open the Fuel Gas supply control valve and gradually increase it to 20% in steps of
5%

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 Now observe that the Furnace temperature will start to increase gradually maintain
the rate of rise of furnace temperature.
 The firing rate should be controlled slowly enough and the drum wall temperature
increasing rate is recommended less than 1.5DegC/min.
 At 2 Kg/cm2 pressure flush the local drum level gauge glass (Not simulated)
 Maintain drum level and gradually increase fuel gas [Gr Pg - 6]
 Now observe that the temp at all the Super heater zones will increase gradually reach
the rated temperature and pressure at super heater outlet
 Maintain the Super Heater Pressure by gradually opening PIC106, and temperature
with TIC101 and maintain at 535 DegC

TURBINE ROLLING

 Open turbine stop valve (FOD015) Observe the turbine speed will increase and
gradually it’ll reach 3000 rpm[Gr Pg - 6]

SYNCHRONISING

 Ensure Turbine speed is above 2990 rpm [Gr Pg - 6]

 Now synchronize the generator using SYNC switch, observe the power will start to
increase [Gr Pg - 6]
 Gradually increase and maintain the Super heater pressure and temperature at rated
valve, then the generator can produce its rated power of 50MW

PLANT UTILITIES

 Now Maintain the HP Header Supply steam pressure with PIC106 at 87.2 kg/cm2 [Gr
Pg - 8]
 Now the steam have to be admitted to MP steam header via PIC107 and maintain the
pressure at 35 kg/cm2 and maintain the temperature with the help of TIC102 at 346
DegC [Gr Pg - 8]
 From MP steam header steam goes to LP steam header via PIC108 and maintain the
pressure at 7.15 kg/cm2 and maintain the temperature with the help of TIC103 at 200
DegC [Gr Pg - 8]
 observe that all the drains will be collected at flash tank and after reducing the
pressure steam will be let into condenser [Gr Pg - 8]
 Gradually increase all the valves to 50%, to reach design parameters
 now switch the whole plant to AUTO mode using (A/M) switch

GAS TURBINE DESIGN PARAMETERS

a. Gen Power - 75 MW
b. Reactive power - 25.39 MVAR
c. Gen Voltage - 15.75 KV
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d. Gen Current - 3234.36 A

e. Fuel gas pressure - 3 KSC
f. Fuel gas temperature - 35 DegC
g. Fuel gas flow - 10 T/hr
h. Fuel Oil pressure - 3.5 KSC
i. Fuel Oil temperature - 100 DegC
j. Fuel Oil flow - 15 T/hr
k. Comp I/L pressure - 0.98 KSC
l. Comp I/L Temp - 45 DegC
m. Comp I/L flow - 100 T/hr
n. Comp O/L pressure - 25.49 KSC
o. Comp O/L Temp - 359.7 DegC
p. Comp O/L flow - 100 T/hr
q. MS flow - 1872 T/hr
r. Coal flow - 230 T/hr
s. Furnace Temp - 1370 Deg
t. GT Exhaust Temp - 1152.74 Deg
u. Turbine Lube oil pr - 1.5 KSC

STEAM TURBINE & FURNACE DESIGN PARAMETERS

a. Power - 50 MW
b. SH pressure - 87.2 kg/cm2
c. SH temperature - 535 DegC
d. FW flow - 660 T/hr
e. FW temp - 247 DegC
f. Fuel gas flow - 10 T/hr
g. Drum Level - -24mm
h. Total Air flow - 400 T/hr
i. Furnace Pr - -50 Kpa
j. Vacuum - -90 Kpa
k. Condenser level - 700 mm
l. Deaerator level - 2000 mm
m. Furnace temp - 1370 DegC
n. HP Header pressure - 87.2 kg/cm2
o. HP Header Temp - 535 DegC
p. HP Header Flow - 470 T/hr
q. MP Header pressure - 35 kg/cm2
r. MP Header Temp - 346 DegC
s. MP Header Flow - 317 T/hr
t. LP Header pressure - 7.15 kg/cm2
u. HP Header Temp - 200 DegC
v. HP Header Flow - 123 T/hr

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5. LIST OF FAILURES
 PUMP FAILURE
a.Feed Oil Pump Failure
b.Lube Oil Pump Failure
c.Condensate Extraction Pump Failure
d.Boiler Feed Pump Failure
 FAN FAILURE
a.FD fan failure
b.ID fan failure
c.APH AC failure
d.Air Ejector failure

6. LIST OF PROCESS DISTURBANCES

The instructor can change variables and inject faults into the system to demonstrate the
effects on the process operation and to train operators on accurate response procedures. These
values will always return to design when the program is initialized in the Design Start IC.

S.No DESCRIPTION UNIT RANGE DESIGN

VALUE

1 FUEL GAS PRESSURE kg/cm2 1-5 kg/cm2 3.5

2 COMP INLET AIR PR Kpa 0.5-2 0.98

3 MOLE WT OF AIR 30-50 40

4 HEATING VALUE OF FG 3000-10000 8461

5 OIL HTR FOULING % 0-100 0

6 AIR HEATER FOULING % 0-100 0

7 LO COOLER FOULING % 0-100 0

8 TURBINE BRG CLOGING % 0-100 0

9 TURBINE EFFECIENCY % 0-90 58

10 GEN EFFECIENCY % 0-100 98

11 BOILER LOSSES % 0-5 0.02

12 TURBINE GAS LEAKAGE % 0-100 0

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S.No DESCRIPTION UNIT RANGE DESIGN

VALUE

13 BOILER DRUM FOULING % 0-100 0

14 DIV SH FOULING % 0-100 0

15 FINAL SH FOULING % 0-100 0

16 ECONOMISER FOULING % 0-100 0

17 APH FOULING % 0-100 0

18 FUEL OIL HTR FOULIN % 0-100 0

19 AIR HEATER FOULING % 0-100 0

20 LUBE OIL HTR FOULING % 0-100 0

21 TURBINE BRG CLOGING % 0-100 0

7. INTERLOCKS
 When Fuel oil Storage tank level drops below 300mm both Fuel oil pumps will trip in
interlock and can be started again only when the level is above 300mm.

 If air compressor (SW108) trips then its shut-off damper (FOD110) and Inlet Guide
Vane (FIC001) will close and its bleed-off valves (FOD111 & FOD112) will open in
interlock to release air pressure.

 Turbine LATCH can be done only above 2990 rpm

 Generator can be SYNCHRONIZED only when the gen voltage is above 15.5 KV,
Turbine Speed is near 3000rpm and exciter (FOD114) is running.

 Gas turbine trips in following conditions

1. Turbine LATCH is turned to TRIP position
2. Turbine speed decreases below 2950 rpm
3. Turbine lube oil pressure drops below 0.5 Ksc
4. Compressor air flow drops below 30 T/hr
5. Fuel pressure drops below 0.5 Ksc
6. Vibration is above 75 microns
 Gas turbine trip will cause
1. Compressor will trip
2. Compressor bleed-off valve will open
3. Fuel oil pumps will trip
4. Exciter will trip
5. Generator will trip

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 Both Condensate extraction pumps (SW001 & SW002) will trip when condenser level
is below 200mm and can be started again only when the level is above 200mm.
 Both Boiler feed pumps (SW003 & SW004) will trip when condenser level is below
500mm and can be started again only when the level is above 500mm.
 When AC APH motor (SW007) trips then DC APH Motor (SW008) will start in
AUTO
 If both AC & DC APH Motor (SW007 & SW008) trips then ID fan (SW006) & FD
fan (SW005) will trip in interlock to prevent damages to the furnace.
 Furnace Master Fuel Trip will occur in following conditions
1. FD fan trip
2. ID fan trip
3. Both APH AC & DC motors trip
4. Both Boiler feed pump trip
5. Furnace pressure is above 2000 pa or below -2000 pa
6. FD air flow below 100 t/hr and fuel flow below 1 t/hr
7. Drum level above 350mm or below -350mm
 Master Fuel trip will cause
1. Both FD and ID fans will trip
2. Fuel gas shut-off valve will close
3. All steam extraction valves will close
4. Turbine will trip
5. Generator Sync will trip

8. PROCESS CONTROL LOOPS

Steam Drum Level Control: LIC103
The Steam Drum Level controller(LIC103) maintain the drum level for continuous
production of steam in boiler. When any of these controllers is in MANUAL mode, the output
signal is set by the operator.

Furnace pressure control: PIC105

The Furnace Pressure Master controller (PIC105) maintains a constant negative pressure
(-50.0 Pa) in the furnace over the entire range of operating conditions.

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As boiler load demand increases, the Combustion Control system increases the demand for
air. Air flow to the boiler increases, raising the furnace pressure. The induced draft fan speeds
will increase as the steam flow increases. The furnace pressure is adjusted to match the
setpoint by changing the induced draft fan inlet vane positions. This control scheme will
maintain the pressure design point over the full range of operating conditions.

9. ESD PAGES

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