12.1.

1 WATER STEAM CYCLE - OPTION

Main Condensate Supply System

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20).

The condensed turbine exhaust steam, the turbine drains and the demineralized water
accumulated in the ACC condensate storage tank are discharged by the condensate extraction
pumps to the condensate preheating system and several ST consumers.
Deaeration of the condensate during normal operation is mainly performed in the condenser
under vacuum. If necessary, the bypass deaerator will provide condensate deaeration by
removing non condensable gases in the water/steam cycle during filling of the HRSG, start-up
mode and when the condensate quality needs to be maintained during normal operation.
4x33% condensate extraction pumps (CEP) are arranged in parallel, which are common for all
three HRSGs. Under normal operating conditions, condensate is pumped by three of the four
pumps via the respective condensate preheating system to the HRSG LP drum and to the
feedwater system. The pumps are designed so that each pump covers all operating conditions
and code requirements but excluding bypass operation. During bypass operation, the other
pump in standby will cut in automatically. Also, in the event of failure of the operating pump, the
standby pump will cut in automatically.
A strainer is located at the suction side of each CEP to protect the pump.
Non-condensable gases or steam bubbles (which can cause damage due to cavitation)
accumulated in the suction line are removed continuously from each CEP via permanent vent
lines and routed back to the condenser.
An automatic recirculation check valve is installed at the discharge side of each CEP to ensure
the required pump minimum flow. In case that the condensate flow to the condensate
preheating system is low, the minimum flow from each CEP is returned to the condensate
storage tank by the automatic recirculation check valve (ARC). Every line is equipped with an
orifice.
Hand-operated shutoff valves are installed at the suction and discharge sides and in the
minimum flow line of each pump to permit isolating the pump from the running plant for
maintenance or repair. The discharge valves are equipped with internal pressure equalization
valves.
Safety valves are installed to protect each suction line against overpressure in case of small
leakage through the automatic recirculation check valve of the standby pump if the suction
shutoff valve of the standby pump is close while the discharge side is still open.
Two motor-actuated demineralized water supply valves are installed to keep the condensate
storage tank level between the defined limits. The valves deliver demineralized water via spray
devices into the condenser: The valve with the smaller capacity is used for make-up during
normal operation and the valve with the higher capacity is used during periods of higher
demineralized water demand (e.g., for first filling or during start-up). The valves are opened and
closed depending on the condenser level.
After passing the condensate polishing plant (mechanical filters), the cleaned condensate is
routed to the suction line of the running CEP. Every line is equipped with a motorized isolation
valve. A connection from the demineralized water distribution system GHC with a

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motorized valve is provided for filling and pressurizing the condensate polishing plant discharge
side up to the closed valves during condensate polishing plant standstill.
The CEP pump discharge lines are joined to a common header.
A condensate sampling line, branching off the common header, is provided.
The sealing and cooling drains system LCW branches off from the main condensate header.
After passing a water filtering station with two manually selectable strainers for online cleaning,
the pressure is reduced with a throttle valve and the sealing water is routed to several
consumers to avoid air ingress at the components under vacuum. A safety valve downstream of
the pressure reducing valve protects the sealing water against overpressure.
Seal water is also routed to the CEP shaft seal to seal against air ingress, to cool and lubricate
the shaft seal when the pump is in operation, to wet the shaft seal and to prevent drying out of
the seal when the pump is not in operation.
A connection from the demineralized water distribution system with a motorized valve is
provided for filling of the pump discharge side and pressurizing the condensate system during
standstill.
A condensate branch which can be isolated by a manual shutoff valve provides injection water
to the IP and LP steam bypass system MAN. A smaller line branches off from this line which
can be isolated by a motorized valve to avoid flooding of the condenser during pump standstill.
The condensate from this second line is used for cooling the LP turbine casing and blades, for
keeping filled the lines downstream of the bypass injection water valves and for permanent
injection to the condenser flash pipe.
Drains and vents are routed to the plant drainage system.

Condensate Preheating System

(Refer to process diagram IR1013-L-&MFB020-400744).

The condensate inlet temperature into the condensate preheater (CPH) of the HRSG is
controlled to avoid condensation of flue gas on the heat exchanger tubes. For this, a certain
amount of feedwater is extracted from the first stage of the feedwater pumps, recirculated to
the CPH inlet and mixed with the condensate flow coming from the condensate extraction
pumps. This raises the condensate inlet temperature into the CPH to inhibit dew point corrosion
on the cold preheater heating surfaces.
If sulphurous fuel gas is to be fired in the GT, the condensate inlet temperature into the CPH of
the HRSG may be further raised to an enhanced temperature level. This is accomplished by
feedwater recirculation, additional condensate recirculation via the condensate recirculation
pump, increased LP-pressure and the condensate preheater cold bypass. Thus more exhaust
heat is shifted to the CPH to ensure adequate condensate inlet temperature into the CPH and
also to ensure the required inlet temperature for the HP- and IP- economizers.
The main condensate line is equipped with a flow meter upstream of the cold bypass branch-
off. Downstream of this branch-off, a non-return valve is provided to avoid backflow. A safety

valve is installed in the CPH inlet line downstream of the condensate recirculation return to
prevent unallowable pressure increases.
Temperature measuring points are arranged at the inlet and outlet of the CPH for condensate
temperature monitoring and temperature control. If necessary, condensate can be routed to the

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cold bypass line of the CPH to control the condensate outlet temperature into the LP drum and
to avoid exceeding the maximum allowable temperature (e.g. < 160C). The cold bypass line is
equipped with a control valve and a non-return valve.
A sampling line is installed downstream the flowmeter.
The line to the bypass deaerator LAA20 branches off from the CPH outlet line downstream of
the cold bypass return line. Between the outlet line and inlet line to/from the bypass deaerator
there is a non return valve to prevent back flow.
An additional bypass line from the CPH cold bypass to the LP feedwater line is provided to
improve the efficiency in certain cases (e.g., some special part load cases or fuel gas preheater
out of service). The LP drum inlet temperature can be reduced by opening the isolation valve in
this line to an intermediate position. Therefore, the CPH outlet temperature after admixing of
the cold bypass is not limited to a value lower than the LP drum temperature to fulfil the
approach point requirement. In this way, it is possible to avoid steaming in the LP feedwater
control valve even with increased feedwater pump inlet temperature, resulting in higher thermal
performance due to higher LP steam production.
The minimum flow line of the feedwater pumps is routed to the main condensate line upstream
of the CPH and provides the minimum flow rate through the HP/IP part of the feedwater pump.
As discussed above, a portion of the feedwater flow is extracted from the first stage of the
feedwater pump, recirculated to the CPH inlet and mixed with the condensate flow. This
feedwater recirculation line is equipped with a control valve, a safety valve and a flow-
measuring device (including a temperature measurement for flow-correction). The extraction
flow can be increased up to the maximum rate permitted by the feedwater pump design.
The required CPH inlet temperature depends on the sulphur content in the fuel. The following
measures are available and would be used in the listed order to increase the CPH inlet
temperature:
Maximum feedwater recirculation
Control by condensate recirculation up to the maximum allowable mass flow (additional
component)
In case of very high sulphur content in the fuel gas, the exhaust heat input into the CPH is
increased by raising the LP pressure
If the maximum condensate recirculation is reached, the control for the CHP outlet
temperature is switched over to the cold CPH bypass.

The setpoint for the CPH inlet temperature must be determined as a function of the sulphur
content of the fuel on a project specific basis. If the CPH inlet temperature is 5K below this
setpoint, HRSG shutdown (if required) is initiated after a time delay. A warning level is also
established at 3k below the setpoint.
The condensate recirculation system is equipped with a non-return valve downstream of the
condensate recirculation pump(s) to avoid back flow. A condensate recirculation control valve is
located downstream of the recirculation pump(s).
The minimum flow through the condensate recirculation pump(s) is achieved by allowing the
recirculation control valve only to close down to a minimum position.
The design of the system is based on the applicable codes and standards.

Feedwater System

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(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20)
Feedwater is routed from the common header downstream of the condensate preheater in
separate suction lines to the feedwater pumps via a strainer located upstream of the pump. An
automatic recirculation check valve for the pump minimum flow requirement is located
downstream of each FW pump. If the HP pump discharge valve is closed or HP feedwater
mass flow is insufficient, the minimum flow is returned to the condensate preheating system
upstream of the condensate preheater by the automatic recirculation check valve via a common
header.
A safety valve is installed in the common header of the pumps min-flow line.
The HP pump discharge lines are connected to a common header which delivers feedwater to
the HP part of the HRSG. IP feedwater is tapped from a specific pump stage. The tapping lines
are connected to a common header which delivers the feedwater to the IP part of the HRSG.
Another tapping point of each feedwater pump is used to recirculate feedwater via a common
header to the condensate preheating system.
During full load operation, feedwater is pumped by three of the four feedwater pumps (common
for three HRSGs) via the HP and IP economizers of the HRSG into the HP drum

th
and IP drum. The other pump (4 pump) is in stand-by. In case of failure of the operating
feedwater pump, the stand-by pump will cut in automatically. Only one pump must be in
operation to cover all operation conditions including bypass operation and code requirements.
Each feedwater pump is equipped with a hydraulic coupling for speed control.
Hand-operated isolation valves are provided at the suction and discharge side and in the
minimum flow line of each pump for isolating the pump during maintenance or repair. The pump
HP discharge valves are equipped with bypass valves which are used for filling the line and
pressure equalization with the header pressure after pump maintenance or repair. The suction
valves are equipped with internal pressure equalizing valves.
A safety valve is provided on the suction side of each pump to protect this line against
overpressure. Such a pressure increase is possible in the event of small leakage through the
automatic recirculation check valve of the stand-by pump if the suction shutoff valve of the
stand-by pump is closed.
Venting and drain lines and valves used only for maintenance purposes or first filling of the
system are led to the plant drainage system GM.

HP Feedwater Supply

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20)

The HP feedwater line is equipped with flow meter and non-return valve to prevent back flow
from the HRSG. The line can be isolated by a motor operated valve. A bypass valve is provided
for filling and pressure equalizing purposes.
The injection water lines to the HP bypass reducing station and the HP desuperheating spray
system branch off from the HP feedwater line. The HP desuperheating spray system delivers
water to the HP attemperator located in the HP main steam piping system and to the interstage
attemperator. It limits the HP steam temperature to the design value during part load operation
at high ambient temperature and during start-up of the ST. To prevent cooling down of these
lines when the HP desuperheating system and the HP bypass reducing station are not

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operating with the corresponding hazard of thermal shock, recirculation lines for these injection
lines are included.
A filling line is provided to allow filling of evaporator II independently of evaporator I. This filling
line can be isolated by a motor operated valve.
A HP feedwater control station is located upstream of the HP economizer. A single HP
feedwater control valve suitable for operation over the whole load range of 0-100% MCR
(maximum continuous rating) will be supplied.
A split-range feedwater control station with the main feedwater control valve suitable for 25-
100% boiler MCR and the low load feedwater control valve suitable for up to 30% boiler MCR
will be supplied, if required, as per HRSG suppliers design.
A sampling connection is provided in the system for HP feedwater sampling during operation.
During operation with high-sulphur fuel, the HP economizer I can be partially bypassed so that
economizer II absorbs more heat due to lower inlet temperature and less IP steam is generated
due to the lower heat input into the IP evaporator. The reduced IP mass flow, together with the
increased LP pressure and thus decreased LP steam production increase the heat available to
the condensate preheater. This, in turn, allows the condensate inlet temperature to be
increased to the required value to inhibit dew point corrosion.

IP Feedwater Supply

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20).

The IP feedwater line is equipped with flowmeter and non-return valve to prevent back-
streaming from the HRSG. This line can be isolated by a motor operated valve. A bypass valve
is provided for filling and pressure equalizing purposes.
The IP desuperheating spray system LAF branches off from the IP feedwater line and delivers
water to the RH attemperators. It limits the RH steam temperature to the design value during
part load operation at high ambient temperature and during start-up of the ST. To prevent
cooling down of the injection water line when the IP desuperheating system is not operating
with the corresponding hazard of thermal shock, a recirculation line for this injection line is
included.
The IP feedwater control valve is located downstream of the IP economizer to prevent flashing
of feedwater in the economizer.
A safety valve is installed upstream of the IP economizer to prevent overpressure in the
economizer in case the IP feedwater control valve is closed with the HRSG in operation.

Fuel Gas Preheating System

Not applicable!

HP Main Steam Piping System

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20).

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The HP main steam piping system receives HP steam from the each of the three HRSGs in a
block and transfers the total HP steam to the ST.
The HRSG HP steam piping system is furnished with a flow meter for steam flow measurement
and with a spray attemperator to maintain HP steam temperature within the allowable ST
operating range during part load operation at high ambient temperature and ST start-up. Warm-
up drain stations are provided in the system to allow system drainage and warm-up during plant
start-up. The warm-up drain stations remain active during normal plant operation to maintain
superheated steam condition within the HP steam piping.
Sampling connections are provided in the system for HP steam sampling during operation.

Intermediate Pressure Main Steam System

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20).

The IP main steam piping system receives IP steam from the each of the three HRSGs in a
block and transfers the total IP steam to the ST.
The IP economizer recovers the heat from the exhaust gas at the IP drum outlet. The IP
evaporator generates steam through a natural circulation loop from and to the IP drum. The IP
superheater heats the saturated steam from IP drum temperature up to the required conditions.
A non return valve located in the connection line from the IP superheater to the reheater cold
line protects the IP system from impermissible pressure increases and the resulting level
decreases in the IP drum during pressure fluctuations in the RH system.
The IP system can be isolated from the RH system by means of a motorized valve.
The intermittent blow down line is routed from the IP drum to the HRSG blow down system
LBH. The continuous blow down line is routed to the LP steam system to separate the clean
steam and polluted condensate before further discharge of the polluted condensate to the
HRSG blow down system (LBH).
The intermittent blow down line from the IP drum to the HRSG blow down system LBH is
equipped with a motorized isolation and a control valve (intermittent blow down valve). The
continuous blow down line from the IP drum to the HRSG blow down system is equipped with
motorized shutoff valve (continuous blow down valve) and manual trim valve.

Hot/Cold Reheat System

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20).

The common cold reheat piping system LBC routes the exhaust steam from the HP ST to the
respective reheater of the HRSGs. The common cold reheat piping will branch-off into three
piping near exhaust of HP ST which divides and routes cold reheat to each HRSG.
The hot reheat piping system LBB feeds the IP part of the ST with superheated steam coming
from the reheater.
A stop-check valve in the cold reheat line prevents back flow to the ST, especially in case of a
ST trip.
Upstream of the reheater, the cold reheat steam joins the steam supplied from the
IP superheater. Whenever the HP bypass station is in operation, pressure-reduced HP steam is
led via the cold reheat piping system to the reheater.
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Each HRSG hot reheat piping supply IP steam to a common IP steam header which leads the
HRH steam to the emergency stop valve/control valve combination of the IP ST. A strainer,
integrated in the emergency stop valve/control valve combination, protects the ST.

Each HRSG is installed with IP bypass station. The line to the IP bypass station for dumping
steam to the condenser MAG taps off from the HRH line upstream of the IP steam common
header.
Directly at the IP bypass reducing valve, a line branches off to the hot reheat header for
keeping the bypass line warm during normal ST operation.
A warm-up line is routed from the HP main steam system to the hot reheat line upstream of the
IP ST emergency stop valve/control valve. This is used to warm-up the hot reheat-pipe
backwards from the ST up to the branch of the IP bypass station.
Drain lines from the reheat piping are led to the clean drains system LCM. They are equipped
with motor-operated shutoff valves.
Pressure and temperature measuring points are arranged on the steam lines.

Auxiliary Steam System

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20).

The auxiliary steam piping system receives saturated steam either from the LP drum or from
the auxiliary boiler (provided by EPC contractor). During start-up and shutdown of the HRSG,
the auxiliary steam is supplied by the auxiliary boiler. During normal combined cycle operation,
the auxiliary steam is delivered from the LP steam generating system HAD80.

The system is completely designed for saturated steam, except the branch to the ST seal
steam system downstream of and including the electrical superheater.
To avoid water drops entering the ST seal steam system, a drop separator is installed in that
branch. The electrical superheater is installed upstream of the seal steam control valve to heat
up the auxiliary steam per the requirements of the ST. A safety valve is installed at the electrical
superheater to prevent pressure increase above the design pressure.
A motorized drain valve is installed upstream of the seal system control valve to warm-up this
line during start-up and to keep the line warm during normal plant operation. This drain line is
routed to the clean drains system.
The drain line upstream of the separator which is routed to the clean drains system is equipped
with a motor-operated shutoff valve for removal of condensate and incorporates a sludge trap
for the reception of deposits. The valve is controlled via 2 binary level switches.
Warming lines are routed to the three pressure stages of the HRSG. A safety valve in the
common HRSG warming line protects the auxiliary steam system against overpressure caused
by back flow from the HP or IP evaporators (displayed on HAD80 P&ID).
Drain lines which are routed to the boiler start-up and shutdown system LBH are equipped with
manual shutoff valves and steam traps for removal of condensate during start-up and
shutdown. The drains in the auxiliary steam lines leading to the seal steam system are also
equipped with sludge traps for the reception of deposits.

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The auxiliary boiler can be isolated from the auxiliary steam system by a motorized shutoff
valve. A non return valve is installed downstream of the shutoff valve to prevent back flow to the
auxiliary boiler.
The LP steam system can be isolated from the auxiliary steam piping system by a hand-
operated valve (for maintenance). A non-return valve is installed upstream of the hand-operated
valve to prevent back flow into the LP main steam header in case the HRSG is out of operation.

Vacuum Drains System

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20).

The objectives of the vacuum drains system MAL are:
to collect steam and drains from the water/steam cycle, auxiliary steam system in the area
of the steam turbine building and the condensate from ST exhaust steam duct to Air cooled
condenser (ACC),
to expand steam and water in the vacuum drains flash tank to atmospheric pressure,
to vent flash steam to the atmosphere,
to discharge the collected drains from the vacuum drains tank to condensate storage tanks
by vacuum drain pumps.
Slightly superheated steam and high temperature water arising during the start-up, warm-up
sequence, normal plant operation and shutdown of the water/steam cycle are routed through
the lance pipes of the vacuum drains system MAL into the vacuum drains tank. Steam and
water above atmospheric pressure are expanded in the tank. The resulting vapor is released to
the atmosphere via an exhaust vent pipe and a silencer. The condensate is collected in the
lower part of the tank.
Since the vacuum drain system MAL operates only as the steam lines are heated slightly above
saturated condition, carbon steel is used for the lance pipes and for the vacuum drains tank.
The collected condensate is pumped by a self regulating pump into the condensate storage
tank.
The combined vacuum drains flash/collecting tank is designed as a vertical, free standing
cylindrical pressure vessel, equipped with vent pipe, silencer and two lances. One lance is for
the HP and hot reheat drains, the other one for cold reheat, LP and auxiliary steam drains.
All necessary drains, measuring devices and nozzles including a manhole are provided at the
vessel.

Bypass Deaeration LAA20

(Refer to process diagram IR1013-L-&MFB020-400744 in Section 20).

The objective of the system is:
to remove non condensable gases like carbon dioxide and oxygen from the condensate
during start-up and normal operation of the plant if required by the conductivity of the
condensate to meet the following criteria:
cation conductivity of the feedwater, low / intermediate and high pressure steam <0.2
S/cm

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 oxygen content of the condensate and feedwater < 100ppb
heat up the condensate during oil firing of the gas turbine
During filling of the heat recovery steam generator (HRSG) and during start-up of the plant the
bypass deaerator is put into operation to remove non condensable gases in the water/steam
cycle. With the bypass deaerator in operation the start-up time can be reduced because the
required steam quality for the steam turbine (ST) start-up is reached earlier. The bypass
deaerator is located downstream of the condensate preheaters.
During normal constant plant operation condensate deaeration is performed in the condenser. If
increased oxygen level in the condensate or feedwater occurs or if increased conductivity in the
condensate, feedwater or steam is detected additional deaeration can be performed in the
bypass deaerator, which is located downstream of the condensate preheaters.
With reference to full load up to 50% of the condensate can be deaerated. At higher
condensate flow through the condensate preheaters the surplus condensate is routed directly to
all low pressure (LP) drums and to the feedwater pumps. Deaeration is performed by delivering
condensate to the deaerator and heating it up to its saturation temperature with auxiliary steam
by direct contact. The deaerator temperature is controlled by a control valve in the auxiliary
steam supply line.
The condensate flow to the deaerator is controlled by the level control of the deaerator. The
deaerator is designed as a spray type / tray type deaerator. Inside the deaerator the steam is
routed as per the type of deaerator selection (spray / tray type) and heats up the incoming
condensate. The non condensable gases like oxygen and carbon dioxide are released to the
atmosphere via a vent pipe. The deaerated condensate is fed back to the outlet pipe of the
condensate preheaters by a 100% deaerator pump via a flow control valve and is routed to the
suction side of the feedwater pumps. A min flow line is provided to start the deaerator pump
with closed control valve.
The deaerator is designed as a vertical vessel with deaeration and storage section in one shell.
The unit consists of a cylindrical carbon steel shell and carbon steel dished ends. The deaerator
is equipped with a safety valve which avoids a rise in pressure over the maximum allowable
working pressure. For suitable maintenance access the deaerator has a manhole.
If deaeration is required during plant start-up or due to increased conductivity levels the
condensate temperature at the deaerator inlet is reduced to about 8K below the saturation
temperature in the bypass deaerator. The temperature difference of 8K ensures an ideal
deaeration process in the deaerator.
Carbon dioxide (CO 2 ) can only be removed from the condensate if the deaerator temperature is
kept above 135C because CO 2 will form to a salt (ammonium bicarbonate) when ammonia or
other caustic material is present. This salt is relatively stable below 135C and can only be
broken down at higher temperatures in order to set free the gaseous CO 2 which can be
eliminated afterwards by deaeration.
If one of the gas turbines (GTs) is operating in oil firing mode the bypass deaerator needs to be
started by the operator in case of too low high pressure/intermediate pressure (HP/IP)
economizer inlet temperature and is used as an external condensate preheater. The
condensate in the deaerator is heated up, so that the mixture of cold condensate coming from
the condensate preheaters and the heated up condensate coming from the bypass deaerator
reaches the required inlet temperature for the HP- and IP-economizers as well as the LP
drums.

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