KORADI TPS EXPANSION PROJECT – 3 x 660 MW L&T-S&L LIMITED

LARSEN & TOUBRO LIMITED

(UNIT #8, 9 & 10), KORADI, MAHARASHTRA
PART – I Rev.: 0
MAIN PLANT PACKAGE PLANT OPERATION AND CONTROL
PHILOSOPHY
L&T Project No. : C10901
Document No.: L555-00P-00101
L&T-S&L Job No.: L555000

ATTACHMENT 7.1.6
SYSTEM DISCRIPTION FOR
CONDENSATE SYSTEM
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 2 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

REVISION SUMMARY SHEET

REV. DETAILS / DESCRIPTION DATE

A FOR APPROVAL 03.03.2011
DOCUMENT IS GENERALLY REVISED AND COMMENTS
B 12.06.2012
ARE INCORPORATED
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 3 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

TABLE OF CONTENTS

1. GENERAL DESCRIPTION ..........................................................................................................4

1.1 Introduction ........................................................................................................................................................4
1.2 Reference Drawings & Documents ...............................................................................................................4
2. system Description .....................................................................................................................5
2.1 Flow Path Description .....................................................................................................................................5
2.2 Main Components & Piping ............................................................................................................................7
3. technical particulars ...................................................................................................................9
3.1 Design & Operating Parameters ...................................................................................................................9
3.2 Technical Particulars .....................................................................................................................................10
4. MODE OF OPERATION ............................................................................................................10
4.1 NORMAL OPERATION.................................................................................................................................10
4.2 ABNORMAL OPERATION ...........................................................................................................................12
4.3 START-UP & SHUT DOWN OPERATION PHILOSOPHY ....................................................................13
4.4 Flushing & Cleaning Operation....................................................................................................................15
5. INSTRUMENTATION & CONTROL ........................................................................................17
5.1. OPEN LOOP CONTROL ..............................................................................................................................17
5.2. CLOSE LOOP CONTROL ............................................................................................................................29
5.3. ALARM AND INSTRUMENTATION: ..........................................................................................................34
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 4 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

1. GENERAL DESCRIPTION

1.1 Introduction
Purpose

Purpose of this document is to detail out the description & functions of Condensate system
along with controls envisaged to ensure intended function of the system. with regards to the
overall plant operation. This document also outlines brief operation philosophy of the system.

Scope

Condensate system starts from condenser terminal point and consists of inline equipments
(Condensate extraction pump, condensate polishing unit, gland steam condenser, Low
pressure feedwater heaters), piping and piping components up to the deaerator inlet.

1.2 Reference Drawings & Documents

i. Mechanical Drawings and Documents
ii.

AUTHORING DOCUMENT NO. SHT DESCRIPTION

ORGANIZATION NO.

L&T-S&L L555-00M-00106 N/A DESIGN CRITERIA FOR

CONDENSATE SYSTEM

L&T-S&L L555-08M-00206 7 P&IDS CONDENSATE SYSTEM

L&T-S&L L555-08M-00905 N/A FEEDWATER SYSTEM

DESCRIPTION

L&T-S&L L555-08M-00506 N/A CONDENSATE PIPING

ISOMETRIC DRAWINGS

iii. Vendor-Supplied Drawings and Documents

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 5 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

AUTHORING DOCUMENT SHT DESCRIPTION

ORGANIZATION NO. NO.

LMTG - N/A HEAT BALANCE DIAGRAMS

L&T HED LATER N/A CONDENSER O&M MANUAL

L&T HED LATER N/A FEEDWATER HEATER O&M

MANUAL

L&T HED LATER N/A DEAERATOR O&M MANUAL

LMB LATER N/A BOILER FEEDWATER

QUALITY

LATER LATER N/A CHEMICAL CLEANING

PROCEDURE

KBL LATER N/A PUMP DIMENSIONAL

OUTLINE

DRIPLEX LATER N/A P&ID FOR CONDENSATE

POLISHER

2. SYSTEM DESCRIPTION

2.1 Flow Path Description

Condensate from the condenser hotwell is transferred to Deaerator through the
condensate system. Condensate is passed through CEP, CPU, GSC LP feed water
heater to Deaerator.
The Condensate System performs the following functions:
 Pump the condensed steam (condensate) from the main condenser hotwells to
the Deaerator.
 Route condensate through a polishing unit for purification.
 Provide cooling water flow for turbine gland steam condenser by routing
condensate flow through GSC.
 Accept chemicals from the chemical feed system to protect piping, feedwater
heaters, and the boiler from corrosion and scale buildup.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 6 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 Increase the condensate temperature by routing it through the Low Pressure (LP)
Feedwater Heaters.
 Remove non condensable gases by deaeration.
 Provide cycle make-up through make-up control valves
 Provide make-up water through quick fill line control valve during cleanup
operation
 Remove excess water from the system through Condenser Hotwell dump control
valve to the condensate storage tank (CST)
 Provide sealing to condensate extraction pumps

In addition, the Condensate System will also supply condensate to the following
equipment:
 Vacuum pump seal water make-up and condenser vacuum breaker valve seal
water
 Main Turbine Gland steam desuperheater spray
 Closed Cooling Water (CCW) overhead tank makeup
 Low pressure turbine exhaust hood spray
 LP turbine bypass desuperheater spray
 Dilution water for chemical injection
 Condenser Water Curtain Spray
 Auxiliary Steam desuperheater spray
 Turbine Flash Tank (If Required)
 Boiler sealing water requirements
 BFP drive turbine drip pot Cooling (If required)
 To generator stator coil cooling
The Condensate System includes piping provisions for cycle make-up to allow automatic
transfer from the condensate storage to the condenser hotwell for hotwell level control.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 7 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

2.2 Main Components & Piping

Condensate system shall have the following major components for each 660MW unit:

 Condenser ( 2 Nos )
 Condensate Extraction Pumps ( 3 x 50% )
 Gland Steam Condenser (1 x 100% )
 Condensate Polishing Unit ( 3 x 50% )
 Low pressure feedwater heaters ( 4 Nos )
 Deaerator cum feedwater storage tank ( 1 x 100% )
 Deaerator level control valves (1 x 30% and 2 x 100%)
 Make-Up Control Station
 Condensate quick fill control valve (1 x 100%)
 Hotwell excess return control station
 Minimum Recirculation Control Station
 Various other valves, instruments, piping and Electrical items.

Condensate System flow path consists following piping:

2.3.1 Condensate Piping
2.3.2 Condensate Extraction Pump Minimum Flow Protection
2.3.3 GSC Minimum Flow Protection
2.3.4 Hotwell Overflow Protection
2.3.5 Chemical Feed
2.3.6 Sample Points

2.3.1 Condensate Piping

Condensate from the low pressure (08LCA13-AC002) and high pressure (08LCA13-
AC001) condenser is transported through three (3 x 50% capacity) Condensate
Extraction Pumps (08LCB13-AP006, 08LCB13-AP007 and 08LCB13-AP008). A Suction
isolation manual gate valve (08LCA13-AA101, 08LCA13-AA103 & 08LCA13-AA105), a
relief valve (08LCY13-AA191, 08LCY13-AA192, 08LCY13-AA193) at downstream of the
suction isolation valve and a suction strainer, are provided on each condensate pump
suction line. The relief valve is provided to protect piping section between the pump
suction nozzle and suction isolation valve from overpressure in the event of discharge
side check valve leakage of the standby pump. Suction strainer is provided to arrest the
foreign particles. An expansion joint is provided at each condensate pump suction.
Condensate pump canister vent is led back to condenser for vacuum balancing.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 8 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

Each condensate pump discharge line having a check valve(08LCA13-AA201, 08LCA13-

AA202, 08LCA13-AA203) and a motor operated gate valve (08LCA13-AA001, 08LCA13-
AA003, 08LCA13-AA005) and are connected to a common header The main condensate
header directs condensate through several inline components (condensate polisher and
gland steam condenser) upstream of the deaerator level control valves (08LCA13-AA091,
08LCA13-AA092). Condensate from the deaerator level control valves is transferred to
deaeartor after passing through Low pressure feedwater heaters 1B/2B, 1A/2A, 3 & 4.
Two nos of duplex heaters (1A/2A & 1B/2B) are installed in condenser neck. Condensate
flows through the channel (tube) side of the LP feedwater heaters where it is heated from
the condensing extraction steam on the shell side. Condensate is supplied to the
deaerator spray valve manifold where dissolved non-condensable gases are removed.
The deaerated condensate is collected in the deaerator (08LAA14-AC091).
Individual bypass lines are provided to separately remove each feedwater heater from
service by use of motor operated isolation and bypass valves.

2.3.2 Condensate Extraction Pump Minimum Flow Protection

An individual recirculation line is provided from each condensate pump discharge line
before pump discharge valve. The recirculated condensate is returned to the LP
Condenser Shell Hotwell. The flow in this line is controlled via the recirculation control
valve (08LCA13-AA090, 08LCA13-AA095, 08LCA13-AA096) to maintain the minimum
continuous stable flow requirements of the respective Condensate Extraction Pump

2.3.3 GSC Minimum Flow Protection

A recirculation line is provided from GSC outlet line immediately after GSC. The
recirculated condensate is returned to the LP Condenser Shell Hotwell. The flow in this
line is controlled via GSC recirculation control valve (08LCA13-AA084) to maintain the
minimum continuous stable flow requirements of GSC.

2.3.4 Hotwell overflow protection

A hotwell dump line is provided with excess water dump control valve (08LCA13-
AA085).which serves to remove excess condensate from the system to the Condensate
storage tanks.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 9 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

2.3.5 Chemical Feed

During operation with CWT (Combined Water Treatment), condensate is treated with the
following chemicals to maintain cycle water chemistry within desired limits:
 Ammonia
 Oxygen
During operation with AVT, (All Volatile Treatment) condensate is treated with the
following chemicals to maintain cycle water chemistry within desired limits:
 Ammonia (NH3)
 Hydrazine (N2H4)

Ammonia, oxygen and hydrazine dosing connections are provided at outlet piping of
Condensate polishing unit.
It is noted that ammonia dosages will be different in the two modes of operation as the pH
is typically maintained in the range of 8.5 to 9.3 with CWT and 9.3 to 9.6 with AVT
Refer to the Boiler feed water quality document issued from Boiler group for further
details on chemical treatment for the condensate system.

2.3.6 Sample Points

Condensate is sampled to monitor the cycle chemistry and provided feedback to the
chemical feed system. Sampling of the condensate occurs at the following points:

 Condensate Polishing Unit (CPU) Inlet

 Condensate Polishing Unit (CPU) discharge
 Deaerator inlet;
 Bottom of Deaerator storage tank;
 Deaerator Drain line; (Required for cleaning operation)
 Condensate storage tank outlet (Hotwell makeup line)

3. TECHNICAL PARTICULARS

3.1 Design & Operating Parameters

Particulars Units Design Operating

(100%TMCR;0%MU)
Condensate Flow Rate Kg/hr 1705040 1541211
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 10 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

Particulars Units Design Operating

(100%TMCR;0%MU)
Condensate Pressure Kg/cm2(g) 38 31.566
Condensate Temperature deg C 50-165 43.9-149.0
Condensate Extraction
m3/hr 905 780
Pump Flow
Condensate Extraction
m 287 318
Pump Head

3.2 Technical Particulars

Technical details of Condensate Extraction pumps are as follows:

Service: Condensate Water

Tag No: 08LCA13-AP006/007/008

Type: Vertical Canister Type Multistage

Pump

Rated flow: 905 cum/hr

Total developed head at rated flow: 287 mWc

4. MODE OF OPERATION

4.1 NORMAL OPERATION

During normal operation Steam exhausted from each of the low-pressure turbine( LP-1 &
LP-2) enters separately to dedicated condenser shells ( LP-1 to HP shell and LP-2 to LP
shell). Hotwells of the both shells are inter connected via equalizing line. Condensate
from the hotwells flows to a CEP Suction header, which allows the condensate to be
pumped out by any combination of the 3X50% condensate pumps. During normal
operation, two condensate pumps operate with one in active standby. If an operating
pump trips, the standby pump will start up automatically. If the condensate level drops
below the preset minimum hotwell level, it will trip all operating pumps. Additionally, if
Pump trips due to hotwell level low low it will override standby pump start. The minimum
flow requirement of each condensate pumps is maintained by its individual recirculation
flow control valve provided at upstream of discharge MOV.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 11 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

Condensate from CEP discharge passes through polishers for removal of dissolved and
suspended solids.
The gland steam condenser is the first heat exchanger in the condensate pumps
discharge line. The condensate absorbs heat as it flows through this heat exchanger
which condenses the turbine gland leak-off steam. A recirculation line with control valve
(08LCA13-AA084) is provided from downstream of GSC to ensure minimum flow through
GSC during low load operation of the unit.
During normal operation after GSC condensate flows through Redundant control valves
(08LCA13-AA091 & 08LCA13-AA092) regulate the flow of condensate to deaerator.
based on level in the Deaerator. One 1x100% bypass MOV is provided across the control
valves. 1 x 30% (08LCA13-AA093) control valve is also provided for the deaeerator level
control during low load operation. The Deaerator level control is accomplished using a
three-element control which utilized deaerator level, condensate flow and feedwater flow.
After that the condensate flows through the LP Feedwater Heaters 1A/2A ,1B/2B, 3 and
4. These feedwater heaters are shell and tube type, with condensate flowing through the
tubes. Steam is supplied to the feedwater heaters from the main turbine extraction points
to heat the condensate.
A bypass is provided across each Duplex Feedwater Heaters 1A/2A and 1B/2B. LP
Heaters 3 and 4 are also provided with individual bypass line with MOV, which will permit
taking out the respective feedwater heaters from the service.
Condensate leaving LP Feedwater Heater 4 is routed to the Deaerator.
Oxygen, ammonia and hydrazine are injected into the condensate piping between the
condensate polisher and the gland steam condenser. Ammonia and oxygen are also
injected at the Deaerator outlet based on requirements. (Please refer to Boiler Feedwater
quality).
Makeup water to the condenser is required to replenish water loss from the plant cycle.
Makeup line also maintains the condenser hotwell level within specified limits and
ensures the smooth operation of the condensate pumps. Makeup water from the
condensate storage tank enters the Condenser (high pressure shell) through the normal
makeup control valve (08GHC27-AA082) and emergency mak-up control valve
(08GHC27-AA081). This normal level control valve is positioned by the DCS based upon
the level sensed by redundant condenser hotwell level transmitters. The normal make-up
is sized for 1% TG VWO flow and emergency make-up is sized for 5% TG VWO flow.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 12 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

4.2 ABNORMAL OPERATION

4.2.1 Loss of one condensate Pump

If one pump out of two running condensate pump tripps, a standby pump will pick-up the
load in auto mode.

4.2.2 Abnormal Deaerator Water Levels

Upon high levels in the deaerator, condensate flow is cut off by deaerator level control
valve. At high-high levels the deaerator overflow control valve opens fully to drain the
condensate to the condenser.
At low condensate levels in the deaerator, condensate flow is increased through the
deaerator control valves. If only one pump is operating, a second should be started. If
water levels continue to drop to unsafe levels, the boiler feed pumps must be tripped to
avoid damage associated with dry running.

4.2.3 Abnormal Condenser Hotwell Water Levels

At low water levels in the condenser hotwell, the condensate make-up system provides
make-up water from two (2) condensate transfer pumps through the normal and
emergency make-up control valves. If water level continues to fall, condensate extraction
pump will be tripped at hotwell level low-low resulting in plant run-back or plant trip.
For high water levels in the hotwell, condensate make-up control valves will close. If
water level continues to rise, the condensate overflow control valve opens to dump water
from the system to condensate storage tank.

4.2.4 Turbine Water Induction Prevention (TWIP) Events

Due to excessive tube leaks or improper drain operation, the feedwater heaters may flood
with operating water levels exceeding the high-high alarm limit. To prevent water from
entering the turbine through the extraction piping, the feedwater heaters are automatically
isolated and bypassed. The extraction steam lines are also automatically isolated and
drained. This will be further elaborated in the extraction steam system description for
details regarding to TWIP events.

4.2.5 Removing Feedwater Heater from Operation

As per the operational requirements Duplex heaters 1A/2A & 1B/2B and LP Heates 3 and
4 can be individually bypassed by operating respective bypass and condensate
inlet/outlet MOVs.

4.2.6 Resuming Feedwater Heater to Operation

As per the operational requirements Duplex heaters 1A/2A & 1B/2B and LP Heates 3 and
4 can be taken in line by operating respective condensate inlet / outlet & bypass MOVs.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 13 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

Detailed procedure for feedwater heaters removal and resuming shall be as per
Feedwater Heater O&M Manual.

4.2.7 Loss of Power or Instrument Air

Upon loss of power or instrument air to any component, the component fails in place or to
its designed fail safe position.

4.3 START-UP & SHUT DOWN OPERATION PHILOSOPHY

4.3.1 INITIAL FILL

The condensate storage tank will provide the initial filling water for the condensate
system. The Quick fill control valve (08GHC27-AA085) will be used to fill the condenser
hotwells and condensate system piping upto deaerator level control valve will be filled by
a separate filling line provided with manual isolation valve (08GHC27AA111).
Boiler fill pump will be used for performing the initial fill of the condensate system.
Condensate system will be filled up by the intial fill line upstream of deaerator level
control station. Deaerator level control valve shall be kept in manually closed condition.
As per the requirements, the deaerator level control valves may be opened in manual
mode to allow condensate flow to the deaerator for condensate system fill
During this operation, the temperature of the condensate flowing through the condensate
polisher must not exceed the limits established by the polishing equipment supplier. If
higher temperatures are expected, the polisher must be maintained in bypass mode until
the condensate temperature drops to within the allowable temperature range.

4.3.2 NORMAL PLANT START-UP

4.3.2.1 Condensate System Preparation

Prior to start-up of the condensate system and condensate pumps, all condensate pump
manual suction isolation valves should be in the open position – all other pump
discharge motor operated valves should be in the closed position. The deaerator level
control valves should be placed in manual operation in the closed position. The
condensate polisher skid should be bypassed by opening the bypass valve and closing
the inlet and outlet isolation valves.
The feedwater heater bypass motor-operated valves should be in the open position so
that condensate flow can be established before placing the feedwater heaters in service.
The channel (tube) side vent valves should be open along with any high point vents in
the condensate piping.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 14 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

The condensate system minimum flow individual recirculation valves should be in auto
or full open to maintain minimum continuous stable flow for each pump in operation.
The condensate pumps should never be operated at shutoff conditions to avoid damage
as per the manufacturer’s recommendations.
GSC recirculation control valve should be in auto to maintain a minimum flow through
the condensate system which is adequate to serve as the cold temperature sink for the
gland steam condenser in accordance with manufacturer’s recommendations.
Upon start-up, seal water is provided from the condensate make-up system to prevent
air ingress through the condensate pump seals.
Once all valves have been placed in the correct position and all start permissives have

4.3.2.2 Condensate System Operation

After the pump has attained a stable flow condition through the CEP minimum flow
recirculation valve, discharge MOV shall be opened and maintain minimum flow through
GSC by GSC recirculation control valve.
During start-up, as per the operational requirements flow to deaerator is maintained by
30% deaerator level control valve keeping LP heaters in bypass condition.
After condensate flow to the deaerator has been established, the tube-side of the
feedwater heaters may be placed in service in sequential order.
Every heater should be charged keeping respective tubeside vent valves open and
thereafter opening of heater inlet/outlet integral bypass MOV. Once all air has been
evacuated from the heaters and piping, vent valves should be closed and heater
inlet/outlet MOVs shall be opened. Once the tube side of the feedwater heaters is
charged, as per the operational requirements extraction steam may be admitted to the
shell side.
Detailed procedure for feedwater heaters removal and resuming shall be as per
Feedwater Heater O&M Manual.
The deaerator water level is initially controlled manually by the operator. Based on
operator experience, the deaerator level control valves should be switched to auto once
sufficient condensate flow is established.
As soon as CEP common discharge pressure is established the discharge valves of the
remaining standby pump can be kept open. The second pump can be taken in service as
per operational requirements and third pump should be kept as auto standby.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 15 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

4.3.3 NORMAL PLANT SHUTDOWN

Normal condensate system shutdown occurs after the boiler feed pumps have been
stopped and feedwater demand has ceased. Condensate flow should be maintained
through the feedwater heaters and other condensate equipment until the equipment has
cooled sufficiently for safe shutdown without undue stress and damage As the required
condensate flow demand to maintain water level in the deaerator at safe levels
decreases, the condensate pumps shall be stopped in succession. Care should be taken
to ensure that CEP shutoff or run out conditions are not experienced during plant
shutdown. The condensate make-up system should be maintained in auto until all
demineralized water demands have ceased.

4.4 Flushing & Cleaning Operation

The flushing & cleaning process should be carried out prior to plant start-up i.e.Cold
Start-up & Warm Start-up (required only if water quality is not adequate).
The flushing & cleaning operation of Condensate system is divided into following process:
1. Condenser Bottom Blow
2. Condensate Clean up Blow
3. Condensate Clean up Bypass Blow
4. Condensate Clean up (Recirculation)
5. LP Heater Clean up Blow
6. LP Heater Clean up (Recirculation)

4.4.1 CONDENSER BOTTOM BLOW

During this process condenser will be filled through Quick fill line control valve
(08GHC27AA085) & water will be drained out through condenser drain valves
(08LCA13AA481/482/483) until desired water quality (i.e. Turbidity ≤ 3) shall be
achieved.

4.4.2 CONDENSATE CLEAN UP BLOW

The condensate flow of 25% BMCR flow will be required for this operation. During
this process one CEP will be running and CPU inlet/ outlet & bypass valve will be
closed. The contaminated condensate will be thrown out of the cycle to
atmospheric flash tank using MOV (08LCA13AA060). The operation will be
continued until the Fe content at GSC outlet will be achieved below 300 µg/l.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 16 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

4.4.3 CONDENSATE CLEAN UP BYPASS BLOW

The process of flushing out the condensate to atmospheric tank is continued &
changeover from one CEP to another is done. However in this process, the CPU
bypass valve () will be opened & the operation will be continued until the Fe
content at CPU outlet will be achieved below 300 µg/l
4.4.4 CONDENSATE CLEAN UP (RECIRCULATION)
In this process, instead of flushing out the condensate flow to atmospheric tank,
the condensate will be routed back to condenser through GSC recirculation valve
(08LCA13AA084). In this regard, the clean up line MOV (08LCA13AA060)
discharging condensate to atmospheric tank is closed & GSC recirculation control
valve (08LCA13AA084) is opened. The condensate will be allowed to pass
through CPU and GSC. The process will be completed after achieving the
following quality of condensate at CEP outlet header & CPU outlet:

a. CEP outlet Fe < 300 µg/l

CC < 0.1 mS/m (Cation Conductivity)

a. GSC Outlet Fe < 50 µg/l

4.4.5 LP HEATER CLEAN UP BLOW

In this process condensate is routed through LP heaters bypass line to
deaerator. Deaerator is filled upto NWL & than flushed out to atmospheric
tank using MOV (08LAB14-AA037). After few minutes all LP heaters inlet &
outlet valve are opened & bypass valves are closed. The process is
completed after achieving the Fe content in LP Heater clean up line below
300 µg/l.
4.4.6 LP HEATER CLEAN UP (RECIRCULATION)
In this process, auxiliary steam is supplied to deaerator for heating
condensate (20°C temperature rise) by opening deaerator auxiliary steam
control valve & deaeration is carried out. The clean up line MOV (08LAB14-
AA037) is closed & condensate is routed back to condenser using MOV
(08LAB14-AA081). The process will be completed after achieving the
following quality of condensate at CEP Outlet header, LP Heater outlet &
deaerator storage tank:
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 17 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

a. CEP Outlet CC < 0.1 mS/m (Cation Conductivity)

b. Deaerator Storage tank DO < 10 µg/l (Dissolved Oxygen)

c. LP heater clean up Line Fe < 50 µg/l

5. INSTRUMENTATION & CONTROL

5.1. OPEN LOOP CONTROL

5.1.1. CONDENSATE EXTRACTION PUMPS (3 X 50 %) 08LCB13AP006 (CEP A), 08LCA13AP007

(CEP B), 08LCA13AP008 (CEP C)
Purpose:
The Condensate Extraction Pumps (CEP) 08LCB13-AP006 (CEP A), 08LCA13-AP007
(CEP B), 08LCA13-AP008 (CEP C) are used to force circulation of condensate in the
condensate system. These pumps are operated in Auto/ Manual mode with two pumps
normally operational and third pump normally in Auto. Operator will start CEP as soon as
the power plant is started requiring condensate to be supplied by the CEP.

Functional Description:
The DCS operator is provided with controls enabling him to select any individual pump to
Manual, Auto, Stand-By or Lockout mode. The operator can select any two pumps as
main pumps & third pump as a stand-by pump. Stand-By means selected pump is
available to run but it will start only when running pump trip OR header pressure is low.
Controls for each pump (running or standby) also allow the operator to start or stop the
pump from the DCS by selecting the manual control mode.
Selection of Lockout (offline) mode indicates that a pump is not available to run.
However, selection of Lockout (offline) mode is possible only if the selected pump is not
running.

5.1.1.1. CONTROL & MONITORING

i. Permissive:
Start permissive

 SOV at inner vent to condenser is open i.e. command “ON”

 Corresponding CEP suction valve open.
 If CEP discharge valve is closed then CEP recirculation valve shall be in AUTO
mode or Open
 Corresponding pump thrust bearing temperature not high
 Corresponding pump reverse rotation not detected
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 18 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 Hotwell level not low low

 Corresponding CEP motor DE/NDE bearing temperature not high
 Corresponding motor winding temperature not high
 Switchgear disturbance not available
 Thrust bearing Cooling water flow is normal (to be confirmed from the vendor)

Stop permissive
When STOP command to CEP is issued from DCS,

 First discharge MOV will get CLOSE command

 STOP command will be issued for respective Motor, once respective discharge
MOV closed feedback received

ii. Auto interlock

Auto start interlock

Main Pump 1 Main Pump 2 Auto Standby

 Group Start command  Group Start command  Group Start command

 Start Permissive AND AND
available  Start Permissive  Start Permissive
available AND available AND
 Main Pump 1 running  Either running pump trips
feedback AND OR
 Either discharge header  Header pressure low
pressure LOW OR
 Generator Load between
30 to 35%

At drive level auto operation of Stand-by pump is also possible.

Auto stop interlock

 None

iii. Protective Commands

Pump Trip Conditions:
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 19 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 Hotwell level low low

 Pump is running and discharge flow is less than min flow (271 m3/hr) after XX
time delay (CEP vendor to confirm)
 Corresponding pump thrust bearing temperature high high
 Corresponding pump motor vibrations high high
 Corresponding CEP motor bearing temperatures high high
 Corresponding CEP motor winding temperature high high
 Corresponding CEP motor vibration high high
 Switchgear disturbance available
 Suction Valve closed.

5.1.2. CEP DISCHARGE MOVS (08LCA13AA001, 08LCA13AA003 & 08LCB13AA005)

Purpose:
CEP discharge MOVs are provided to isolate corresponding Condensate Extraction
Pumps from CEP discharge header & for starting of the CEP.
Functional Description:
CEP discharge MOVs (08LCA13AA001, 08LCA13AA003 & 08LCB13AA005) will be in
closed conditions when all CEP are not running. First condensate pump will be started
with discharge valve in closed condition and minimum recirculation in open. Discharge
MOV of the pump shall be placed in AUTO mode as soon as the minimum recirculation
flow is established if the pump is operating in manual mode otherwise same sequence
will be followed in group auto mode. However if one pump is running others non-running
pump discharge MOV will get opened in auto.

An integral bypass MOV (08LCA13AA002, 08LCA13AA004 & 08LCA13AA006 for CEP

discharge MOVs 08LCA13AA001, 08LCA13AA003 & 08LCB13AA005 respectively) is
provided for opening CEP discharge MOV, thus protecting the CEP discharge MOV from
pressure surge.

The opening sequence for CEP discharge MOV shall be as follows:

 On receiving the discharge MOV OPEN command, first integral bypass MOV will be
opened
 CEP discharge MOV will open on integral bypass MOV full open feedback
 Bypass MOV will close on CEP discharge MOV full open feedback
 When CEP discharge MOV is fully opened & bypass MOV is closed, the CEP
discharge MOV open sequence in service will reset
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 20 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

5.1.2.1. CONTROL & MONITORING

i. Permissive
Open Permissive
 Respective Integral bypass valve open feedback

Close Permissive
 Respective condensate pump recirculation control valve in AUTO or full open
for the running pump

ii. Auto interlock

Auto Open Interlock:

 Any CEP running

Auto Close Interlock:

 Corresponding pump trips

Valve Number Start-Up Shut Down Normal Unit Trip

Operation
08LCA13-AA001, AUTO/ CLOSE OPEN -
08LCA13-AA003, OPEN (For
08LCA13-AA005, standby Pump)

5.1.3. GSC INLET & OUTLET MOV WITH INTEGRAL BYPASS MOV (08LCA13AA075,
08LCA13AA076, 08LCA13AA077, 08LCA13AA078)

Purpose:
To isolate Gland Steam Condenser from Condensate side

Functional Description:
This valve will be over-ride open with CEP discharge MOV open command.

Isolation MOV GSC inlet/outlet is operated from the DCS as per the sequence mentioned
below:
 Isolation MOV open sequence is initiated: Respective Integral bypass MOV opens
automatically.
 Isolation MOV will open on respective integral bypass MOV full open feedback
 Bypass MOV will close on Isolation MOV full open feedback
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 21 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 When Isolation MOV is fully opened & respective integral bypass MOV is closed, the
Isolation MOV open sequence in service will reset

5.1.3.1. CONTROL & MONITORING

i. Protective open
 CEP discharge MOV Open command

Valve Number Start-Up Shut Down Normal Operation Unit Trip

08LCA13-AA075 AUTO - OPEN -
08LCA13-AA077

5.1.4. CONDENSER CURTAIN SPRAY SOV (08LCA13AA088)

Purpose:
To reduce temperature of steam that enters into condenser within condenser design limit.

Functional Description:
Condenser curtain spray SOV (08LCA13AA088) will be operated automatically from the
DCS. Valve will open whenever turbine trip exists or LP bypass valve position > 5% or
WDC valves open

5.1.4.1. CONTROL & MONITORING

i. Permissive:
Open Permissive
 None
Close Permissive
 LP bypass valve position < 5% AND
 WDC valve closed

ii. Auto interlock

Auto Open interlock
 None
Auto Close interlock
 None

iii. Protective Commands

Override Open
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 22 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 Condenser curtain spray SOV shall be override open whenever any turbine
trip exists OR LP bypass valve position > 5%.
 WDC valve not closed

Override Close
 LP bypass valve position < 5%
 WDC valve closed

Valve Number Start-Up Shut Down Normal Unit Trip Valve

Operation Fail
Position
08LCA13-AA088 AUTO CLOSE AUTO OPEN OPEN

5.1.5. DEAERATOR LEVEL CONTROL VALVE BYPASS MOV (08LCA13-AA013)

Purpose:
This MOV is provided for controlling deaerator level if the deaerator level control valves
fail.

Functional Description:
Deaerator level control MOV (08LCA13AA013) must be kept in Auto mode to enable the
CPU bypass Clean-up operation. However this MOV will be in closed position during the
normal operation. In case of operational requirements operator can operate this valve in
manual mode.

5.1.5.1. CONTROL & MONITORING

i. Permissive:
Open Permissive
 None
Close Permissive
 None

ii. Auto interlock

Auto Open interlock
 None
Auto Close interlock
 CPU bypass Clean-up operation selected
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 23 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

iii. Protective Commands

Override close for Deaerator level high-high (whether valve is in Auto/Manual
mode).

Valve Number Start-Up Shut Normal Unit Trip CPU

Down Operation Bypass
Clean-up
08LCA13-AA013 CLOSE CLOSE CLOSE CLOSE CLOSE

5.1.6. DEAERATOR LEVEL CONTROL VALVE INLET MOVS (08LCA13-AA009, 08LCA13-AA010,

08LCA13-AA011, 08LCA13-AA012, 08LCA13-AA034)
Purpose:
To isolate Dearerator level control valve.

Functional Description:
Isolation MOV for the Deaerator level CV is operated manually from the DCS as per the
sequence mentioned below:
 Isolation MOV open sequence is initiated: Respective Integral bypass MOV opens
automatically.
 Isolation MOV will open on respective integral bypass MOV full open feedback
 Bypass MOV will close on Isolation MOV full open feedback
 When Isolation MOV is fully opened & respective integral bypass MOV is closed, the
Isolation MOV open sequence in service will reset

5.1.6.1. CONTROL & MONITORING

i. Permissive:
Open Permissive
 None
Close Permissive
 None

ii. Auto interlock

Auto Open interlock
 Respective control valve open > 5%
 LP Clean-up Blow & recirculation

Auto Close interlock

 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 24 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 CPU bypass Clean-up operation selected

iii. Protective Commands

Override close for Deaerator level high-high.

Valve Number Start-Up Shut Normal Unit Trip Clean-Up

Down Operation
08LCA13-AA009 OPEN CLOSE OPEN OPEN AUTO
08LCA13-AA010 (Operator
08LCA13-AA034 selection)

5.1.7. HEATER INLET MOV & THEIR INTEGRAL BYPASS MOV (08LCA13AA015 & 08LCA13AA016
FOR HEATER 1A/2A, 08LCA13AA036 & 8LCA13AA037 FOR HEATER 1B/2B,
08LCA13AA021& 08LCA13AA022 FOR HEATER 3, 08LCA12AA027 & 08LCA13AA028 FOR
HEATER 4)
Purpose:
To isolate corresponding heater from condensate side (working in conjunction with heater
bypass & heater outlet MOV).

Functional Description:
Condensate Inlet MOVs for feed water heaters are operated manually from the DCS as
per the sequence mentioned below:
 Isolation MOV open sequence is initiated: Respective Integral bypass MOV opens
automatically
 Isolation MOV will open on respective integral bypass MOV full open feedback
 Integral Bypass MOV will close on Isolation MOV full open feedback for 10 seconds
 When Isolation MOV is fully opened & respective integral bypass MOV is closed, the
Isolation MOV open sequence in service will reset

5.1.7.1. CONTROL & MONITORING

i. Permissive:
Open Permissive
 Respective Heater outlet valve is open.
Close Permissive
 Respective Heater bypass MOV is open feedback
OR
 All CEP off for 5 seconds
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 25 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

ii. Auto interlock

Auto Open interlock
 LP Extraction water start up sub group
Auto Close interlock
 Heater level high-high
 LP Extraction water shut down sub group
 Condensate CPS bypass clean-up blow start up
 LP HTR line cleanup blow Start-up

iii. Protective Commands

Inlet condensate MOV shall be override closed when feed water heater level is
high-high.

Valve Number Start-Up Shut Down Normal Unit Trip

Operation
08LCA13AA015, CLOSE OPEN OPEN --
08LCA13AA021 (Operator
08LCA13AA027 descrietion)
08LCA13AA036

5.1.8. HEATER BYPASS MOV & INTEGRAL BYPASS MOV (08LCA13AA019 & 08LCA13AA020
FOR HEATER 1A/2A, 08LCA13AA038 & 8LCA13AA039 FOR HEATER 1B/2B, 08LCA13AA025
& 08LCA13AA026 FOR HEATER 3, 08LCA12AA031 & 08LCA13AA032 FOR HEATER 4)
Purpose:
To isolate corresponding heater (working in conjunction with heater inlet & heater outlet
MOV).

Functional Description:
Heater bypass MOV for feed water heaters are operated manually from the DCS as per
the sequence mentioned below:
 Isolation MOV open sequence is initiated: Respective Integral bypass MOV opens
automatically.
 Isolation MOV will open on respective integral bypass MOV full open feedback
 Integral Bypass MOV will close on Isolation MOV full open feedback for 10 seconds
 When Isolation MOV is fully opened & respective integral bypass MOV is closed, the
Isolation MOV open sequence in service will reset
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 26 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

5.1.8.1. CONTROL & MONITORING

i. Permissive:
Open Permissive
 None
Close Permissive
 Respective heater inlet condensate MOV is open & Respective heater outlet
condensate MOV is open.
OR
 Condensate CPS bypass clean-up blow start up in progress

ii. Auto interlock

Auto Open interlock
 LP Extraction water shut down sub group
Auto Close interlock
 Respective heater recovery operation
 LP heater drain clean up subgroup
 Condensate CPS bypass clean-up blow start up
iii. Protective Commands
Heater bypass MOV shall be override opened when feed water heater level is
high-high.

Valve Number Start-Up Shut Down Normal Unit Trip

Operation
08LCA13AA019, OPEN -- CLOSE --
08LCA13AA025 (Operator
08LCA13AA032 descrietion)
08LCA13AA038

5.1.9. HEATER OUTLET MOV (08LCA13AA015 & 08LCA13AA016 FOR HEATER 1A/2A,
08LCA13AA036 & 8LCA13AA037 FOR HEATER 1B/2B, 08LCA13AA021& 08LCA13AA022
FOR HEATER 3, 08LCA12AA027 & 08LCA13AA028 FOR HEATER 4)
Purpose:
To isolate corresponding heater (working in conjunction with heater bypass & heater inlet
MOV).

Functional Description:
Outlet condensate MOV for feed water heaters are operated manually from the DCS as
per the sequence mentioned below:
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 27 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 Isolation MOV open sequence is initiated: Respective Integral bypass MOV opens
automatically.
 Isolation MOV will open on respective integral bypass MOV full open feedback
 Bypass MOV will close on Isolation MOV full open feedback
 When Isolation MOV is fully opened & respective integral bypass MOV is closed, the
Isolation MOV open sequence in service will reset

5.1.9.1. CONTROL & MONITORING

i. Permissive:
Open Permissive
 None
Close Permissive
 Heater bypass MOV is opened.
OR
 All CEP off for 5 seconds

ii. Auto interlock

Auto Open interlock
 LP Extraction water start up sub group
Auto Close interlock
 Heater level high-high
 LP Extraction water shut down sub group
 LP HTR line cleanup blow Start-up

iii. Protective Commands

Outlet condensate MOV shall be override closed when feed water heater level is
high-high.

Valve Number Start-Up Shut Down Normal Unit Trip

Operation
08LCA13AA017 CLOSE -- OPEN --
08LCA13AA023 (Operator
08LCA13AA029 descrietion)
08LCA13AA040
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 28 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

5.1.10. Condensate Clean up Blow Out MOV (08LCA13AA060)

Purpose:
To blow out the condensate extraction pump discharge to atmospheric flash tank during
plant clean-up operation. (Condensate Clean up Blow step)

Functional Description:
This valve will be opened immediately after CEP is started plant clean-up operation for
blowing out the condensate to atmospheric flash tank. The valve will be closed after the
desired water quality is achieved.

5.1.10.1. CONTROL & MONITORING

iv. Permissive:
Open Permissive
 None
Close Permissive
 None

v. Auto interlock
Auto Open interlock
 Condensate clean up Blow
 Condensate CPS bypass blow
Auto Close interlock
 Valve opening position is higher than XX%
5.1.11. HOTWELL MAKE-UP CONTROL STATION BYPASS MOV (08GHC27AA004)
Purpose:
To provide alternate path for the make-up water to condenser in case of failure of Normal
and Emergency Make-up control valves
Functional Description:
This valve will be operated in manual mode only.

5.1.12. GSC RECIRCULATION CV BYPASS MOV (08LCA13AA053)

Purpose:
To provide alternate path for the condensate in case of failure of GSC control valves to
maintain minimum flow through GSC.
Functional Description:
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 29 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

This valve will be operated in manual mode only.

5.1.13. HOTWELL EXCESS DUMP CV BYPASS MOV (08LCA13AA054)

Purpose:
To provide alternate path for the condensate in case of failure of hotwell excess Dump
control valves to maintain minimum flow through GSC.
Functional Description:
This valve will be operated in manual mode only.

5.2. CLOSE LOOP CONTROL

5.2.1. HOTWELL LEVEL CONTROL - MAKEUP CONTROL VALVE, HOTWELL OVERFLOW

CONTROL VALVE
Purpose:
The condenser hotwell level will be maintained in predefined range for all load conditions
to maintain a suitable NPSH for the condensate extraction pumps by modulating the air-
operated makeup control valves (08GHC27AA082 for normal make-up or the higher flow
control valve 08GHC27AA081 for emergency make-up) & Hotwell overflow control valve
(08LCA13AA085).

Functional Description:
These control valves are normally controlled automatically from the DCS based on
Hotwell level. The level control valves are operated from DCS either in auto or manual.
During normal operation valve will remain in auto and modulate according to hotwell
level. The level signal (Median selection of level transmitters 08LCA02CL101A,
08LCA02CL101B & 08LCA02CL101C) shall be used as process variable (PV) for control
of Make up control valves while level signal (Median selection of level transmitters
08LCA02CL102A, 08LCA02CL102B & 08LCA02CL102C) shall be used for Hotwell
overflow control valve (08LCA13AA085). The PID controller generates a control signal to
modulate the hot well level Control Valves according to error generated by the difference
in the process variable (PV) and set point (SP), rate of change of condensate flow is also
taken as a parameter in the control loop to maintain hotwell level under sudden load
fluctuation.

Set point for normal make up CV will be NWL & Set point for Emergency make up CV will
be NWL1 (NWL >NWL1). During the normal operation, condenser normal make up CV
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 30 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

maintains the level of the hotwell at level NWL (normal level). In case of any disturbances
causing the hotwell level to fall to level NWL1, the normal make-up CV will open fully and
emergency make-up CV will start controlling the hotwell level at the set point.

In the event of any condition that results hot well levels in excess/overflow of the normal
level, Hotwell overflow control valve opens and condensate is directed to the condensate
storage tank.

In case of valve trouble/maintenance, MOV provided at the bypass of the corresponding

valve (08GHC27AA004 for normal make-up control valve & emergency make-up control
valve and 08LCA13AA054 for Hotwell overflow control valve) can be operated manually
from DCS to achieve above mentioned functions.

Valve Number Start-Up Shut Normal Unit Trip Valve Fail

Down Operation Position
08GHC27AA081 MODULATING CLOSE MODULATING MODULA CLOSE
TING
08GHC27AA082 MODULATING CLOSE MODULATING MODULA CLOSE
TING

5.2.2. CEP MINIMUM RECIRCULATION CONTROL VALVE (08LCA13AA090 / 08LCA13AA095 /

08LCA13AA096)
Purpose:
To meet the minimum flow requirement of the pump during startup and when CEP
discharge flow is less than minimum recirculation flow.

Functional Description:

 The minimum flow requirement of each condensate extraction pump will be

maintained by individual air-operated recirculation flow control valve (08LCA13AA090
/ 08LCA13AA095 / 08LCA13AA096 respectively for CEP#1, CEP#2 & CEP#3).
 The control valve can be placed in automatic or manual control via DCS. The valve
will be normally placed in auto and modulates as required based on average flow of
respective pump (average of 08LCA13CF102A & 08LCA13CF102B for CEP#1,
08LCA13CF103A & 08LCA13CF103B for CEP#2 and 08LCA13CF104A &
08LCA13CF104B for CEP#3) to maintain a minimum flow for respective condensate
extraction pump.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 31 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

Valve Number Start-Up Shut Normal Unit Trip Valve Fail

Down Operation Position
08GHC27AA090 MODULATING CLOSE CLOSE MODULATING OPEN
08GHC27AA095
08GHC27AA096

5.2.3. GSC MINIMUM RECIRCULATION VALVE (08LCA13AA084)

Purpose:
To meet the minimum flow requirement of the Gland Steam condenser, also ensuring
(manual quality checking & modulating the valve by operator) that required quality water
is fed to the Boiler.

Functional Description:

 The minimum flow requirement of gland steam condenser is maintained by an air-

operated recirculation flow control valve (08LCA13AA084). The control valve can be
placed in automatic or manual control via the DCS. The valve is normally placed in
automatic and modulates as required to maintain a minimum flow.
 When placed in manual control through the DCS, plant operator can manually
modulate the control valve based on minimum flow requirements; also operator can
modulate this valve to check the quality of condensate into the boiler, by re-circulating
the condensate back to condensate polishing plant (CPP) unless required quality of
water is maintained at CPP discharge header.
 The condensate flow signals (Average value) from the flow transmitters (FT-
08LCA13CF105A & 08LCA13CF105B) at the CEP discharge header modulate this
recirculation CV. When the flow in the condensate polishing plant is more than the
permissible minimum flow through the gland steam condenser, the GSC minimum
recirculation CV remains closed.
 Incase of valve trouble/maintenance, MOV provided at the bypass of the
corresponding valve (08LCA13AA053) can be operated manually from DCS to
achieve above mentioned functions.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 32 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

Valve Number Start-Up Shut Down Normal Unit Trip Valve

Operation Fail
Position
08GHC27AA084 MODULATING CLOSE CLOSE MODULATING OPEN

08LCA13AA053 CLOSE CLOSE CLOSE CLOSE/ -

OPEN

5.2.4. DEAERATOR LEVEL CONTROL VALVES (2 X 100% 08LCA13AA091, 08LCA13AA092 AND

1 X 30% 08LCA13AA094)
Purpose:
To maintain Dearerator level at a preset value.

Functional Description:

 During plant start-up, 30% LCV(08LCA13AA094) shall be modulated by the controller

based on the feed water level (median of 08LAA04CL001, 08LAA04CL002,
08LAA04CL003), i.e. single element level control, when feed water inlet flow to boiler
is less than 30 % of 100 % feedwater flow. Controller compares level set point and
modulates 30% level control valve.

 During Normal operation, operator selected primary 100 % LCV (i.e. either
08LCA13AA091 OR 08LCA13AA092) will be modulated by (means greater than 30%
load) three element control. It consist of
i) Deaerator level (median of 08LAA04CL001, 08LAA04CL002,
08LAA04CL003),
ii) Deaerator inlet flow consist of condensate flow to Deaerator (median of
08LCA13CF106A, 08LCA13CF106B, 08LCA13CF106C), IP Extraction
steam flow(08LCD11CF103), Heater-6A drain flow (08LCH15CF101) &
Heater-6B drain flow (08LCH15CF102)
iii) Deaerator outlet flow consists of Feed water flow at Economizer inlet flow
(median of 08LAB14CF110A, 08LAB14CF110B, 08LAB14CF110C) &
Reheater attemperation flow (addition of Reheater A & B spray flow i.e.
08LAF01CF111A, 08LAF01CF111B, 08LAF01CF112A &
08LAF01CF112B) are used for controlling deaerator level.
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 33 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

Controller compares level set point and modulates 100% level control valve using
deaerator inlet flow, outlet flow and deaerator level. The output of level controller shall
be added with Deaerator outlet flow, this will be the set point for the condensate inlet
flow controller which modulates deaerator 100% valve.
 During any trouble in Primary control valve, redundant control valve will control the
Deaerator level.
 During Transition from Start-up mode to normal operation mode opening of 30 % LCV
shall be kept constant and 100 % LCV shall be modulated as per feed water increase
in demand, then slowly 30 % LCV will be closed and 100 % LCV will take over the
complete loop control.

Protective Commands:
Override close for Deaerator level high-high.

Valve Number Start-Up Shut Down Normal Unit Trip Valve Fail
Operation Position
08GHC27AA092 CLOSE CLOSE AUTO/ MODULATING LOCK
MODULA
TING
08GHC27AA091 CLOSE CLOSE AUTO/ MODULATING LOCK
MODULA
TING
08GHC27AA094 MODULATING CLOSE OPEN MODULATING LOCK

5.2.5. QUICK FILL LINE CONTROL VALVE (08GHC27-AA085)

Purpose:
To fill hotwell during cleanup operation.

Functional Description:
This valve (08GHC27AA085) will be operated in manual during condenser hotwell bottom
clean-up blowout operation. After completion of this operation, the valve will be kept in
auto for further cleanup operation and this will modulate based on hotwell level. This
valve will be in closed conditions during the normal operation.
Protective Commands
Override Close for Boiler fill pump stop
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 34 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

Valve Number Start-Up Shut Down Normal Initial Clean-up Valve Fail
Operation Position
08GHC27AA092 CLOSE CLOSE CLOSE MODULATING LOCK

5.3. ALARM AND INSTRUMENTATION:

The Condensate System alarms can be monitored from the DCS operator interface
console alarm graphic display.

The following system conditions are alarmed through the DCS

 Condenser Hotwell Level High
 Condenser Hotwell Level High-High
 Condenser Hotwell Level Low
 Condenser Hotwell Level Low-Low
 Condenser Makeup Valve Trouble
 Condenser Emergency Makeup Valve Trouble
 Deaerator Level High
 Deaerator Level Hi-Hi
 Deaerator Level Low
 Deaerator Level Low-Low
 Condensate pump motor stator winding temperature high (any one of 3 signals,
one per phase)
 Condensate pump motor stator temperature high-high (any one phase) & pump
motor trip
 Condensate pump motor bearing temperature high (any of 2 signals)
 Condensate pump motor DE/NDE bearing temperature high-high & pump motor
trip
 Condensate pump suction strainer differential pressure high
 Condensate high conductivity (condenser leak)
 Condensate pump discharge pressure High
 Condensate pump discharge pressure Low
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 35 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 Condensate pump discharge pressure Low-Low and pump motor trip

 Condensate pumps common header pressure low
 Condensate Pump and Discharge Valve status, consisting of:
xvi. Undefined Trip
xvii. DCS Emergency Stop Requested
xviii. Close Power Failure
xix. Trip Power/Coil Failure
xx. Failure to Start / Stop
xxi. Pump/Valve Congruency Trouble
xxii. Pump Electrical Trip
xxiii. System Rejection to Manual if it encounters errors while in Auto mode
xxiv. Auto Requested in Manual
xxv. High Vibrations
xxvi. Local Control Enabled
xxvii. Valve Failure to Open and to Close
xxviii. Fail to Travel – Open/Closed
xxix. Closing Torque High
xxx. Valve Starter Fail/Trip
 Polisher System high differential pressure (signal from CPU PLC), system
bypassed
 Polisher, Condensate Pump Suction, and ALL LP FW Heater (inlet, outlet,
bypass) Valve Status, consisting of:
viii. Fail to Open / Close
ix. Congruency Alarm
x. Reject to Manual
xi. Auto Requested in Manual
xii. Starter Fail / Trip
xiii. Local Mode Enabled
xiv. Opening / Closing Torque High
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 36 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 Deaerator LCV Inlet Valve Status, consisting of:

viii. Fail to Open / Close
ix. Congruency Trouble
x. Reject to Manual
xi. Auto Requested in Manual
xii. Starter Fail / Trip
xiii. Local Mode Enabled
xiv. Opening / Closing Torque High
 Condenser Screen Spray Block Valve Status, consisting of:
vi. Fail to Open / Close
vii. Congruency Alarm
viii. Reject to Manual
ix. Auto Requested in Manual
x. Control Power Failure
The following information will be provided on the control room display on the CRT as a
function of the DCS.
 Make-up Control Valve Status (0-100%)
 Emergency Make-up Control Valve Status (0-100%)
 Condenser Hotwell Blow Valve Status (OPEN/CLOSE)
 Deaerator Level
 Condensate Pump Status
 Condenser Hotwell Level
 Condenser Hotwell Temperature
 Condenser Hotwell Conductivity
 Condensate Header Pressure
 Polisher System Inlet/Outlet Valve Status (OPEN/CLOSE)
 Polisher System Bypass Valve Status (OPEN/CLOSE)
 ALL MOV Status (OPEN/CLOSE)
 Condensate Pump Motor Bearing Temperature
 KORADI TPS EXPANSION PROJECT – 3 x 660
LARSEN & TOUBRO LIMITED MW (UNIT #8, 9 & 10), KORADI, L&T-S&L LIMITED
MAHARASHTRA
SYSTEM DESCRIPTION, OPERATION & Rev.: B
MAIN PLANT PACKAGE
CONTROL FOR CONDENSATE SYSTEM Date: 12/06/2012
L&T Project No. : C10901 Page: 37 of 37
Document No.: L555-00M-00906
L&T-S&L Job No.: L555000

 Condensate Pump Motor Amperes

 Condensate Pump Motor Winding Temperature
 Deaerator Pressure
 Deaerator Level Control Valve and Bypass Valve Position (0-100%)
 Condensate Temperature at Dearator outlet
 All Heaters Inlet and Outlet Temperature
 Condensate Recirculation Valve Position (0-100%)
 Turbine Exhaust Hood Spray Control Valve Status (OPEN/CLOSE) (to be
implemented in the Turbine Control System (TCS))
 Condensate Flow to the Deaerator Measured by calibrated orifice

 Condensate Flow