3 20/02/08 Malek / Ravelli Degen As Built

2 03/23/07 Degen Degen Revision according Functional Diagrams

1 01/16/06 JII/DRI JPM PRJ Initial Issue

0 11/15/05 JII/DRI JPM PRJ Preliminary Issue

Rev. Date: Originator Mech I&C Details of Revision

SUPPLIER
2675 Morgantown Road
Reading, Pennsylvania 19607
Telephone: +1 610 855 2000
Internet: www.worleyparsons.com

DSD-Project No.:
5705/102242-M01 Termozulia – Expansion to Combined Cycle

Status
REVISION 3
SYSTEM DESCRIPTION
DATE NAME FOR
CIRCULATING WATER SYSTEM
BY 11-15-05 J.I. Inglis

MECH 11-15-05 JP Mitton

SHEET No.:
E&C 11-15-05 D.R. Iserman ALL RIGHTS RESERVED DIN 34
1 of 27
DRWG No..:
SIZE Letter (8.5“ x 11“) SUPPLIER -
REV.
SCALE NA
3
DRWG.-
No.:
DSD
TZ03-CD-PA-PAR0001
FILENAME TZ03-CD-PA-PAR0001-R3
SYSTEM DESCRIPTION TERMOZULIA CCPP
CIRCULATING WATER SYSTEM
TABLE OF CONTENTS

SECTION TITLE PAGE

1.0 PURPOSE 3

2.0 DESIGN CRITERIA 3

2.1 Codes and Standards 3

2.2 System Design Basis 4

3.0 DESCRIPTION OF SYSTEM AND EQUIPMENT 4

3.1 Description of System 4

3.2 Description of Equipment 8
3.3 Description of Control 14

4.0 SAFETY PRECAUTIONS 20

4.1 Hazards 20
4.2 Precautions 20

5.0 SYSTEM OPERATION 20

5.1 Commissioning 20
5.2 Start-up 20
5.3 Normal Operation 21
5.4 Filling of the System 22
5.5 Special or Infrequent Operation 22

6.0 EVENT LIST 23

7.0 E_STOP/EMERGENCY 25

8.0 INTERFACE SYSTEMS 25

9.0 REFERENCES 26

9.1 Instrument and Control Drawings and Diagrams 26

9.2 Electrical Drawings and Diagrams 26
9.3 Piping and Instrumentation Diagrams 26
9.4 Specifications 27
9.5 Piping Materials 27

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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1. PURPOSE

The Circulating Water (CW) System serves to remove the heat from the Steam Turbine
Condenser. The purpose of the Circulating Water System is to provide cooling water to
the surface condenser for condensing the steam turbine exhaust, steam dumps and other
steam drains, and to cool various water steam cycle plant liquid drains which are routed
to the condenser. The CW System supplies the required cooling water flow to cool the
condenser halves.

The objective of the Service Cooling Water System is to remove the heat from the Closed
Cooling Water (CCW) Heat Exchangers. The Service Cooling Water System takes the
water from the CW System upstream of the condenser and discharges it downstream of
the condenser.

1.1 Abbreviations:

ANSI – American National Standards Institute

ARC – Automatic Recirculation Check valves
B & PVC - Boiler & Pressure Vessel Code
BEP – Boiler External Piping
BOP – Balance Of Plant
ASME – American Society of Mechanical Engineers
DN – Diameter Nominal
GT – Gas Turbine
HP – High Pressure
HRSG – Heat Recovery Steam Generator
IP – Intermediate Pressure
LP – Low Pressure
NBEP – Non-Boiler External Piping
TG-VWO – Turbine Generator - Valves Wide Open
CW - Circulating Water
GRP – Glass-Reinforced Plastic
AWWA – American Water Works Association

2. DESIGN CRITERIA

2.1. Codes and Standards

Circulating Water System piping is designed in accordance with ASTM 3517, ASTM
3754 and AWWA C-950 (applicable for large bore Glass Reinforced Plastic (GRP)
piping) and ASME B31.1 "Power Piping" for small bore piping.

The pumps are designed in accordance with the standards of the Hydraulic Institute.

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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2.2. System Design Basis

The Circulating Water System valves and equipment are designated with the KKS code
PA. The Service Cooling Water System valves and equipment are designated with the
KKS code PC.

The design pressure range for the Circulating Water System is 5.0 barg (72.5 psig) and
full vacuum.

The design temperature is 50°C.

The large bore circulating water system piping is Glass Reinforcement Plastics (GRP)
conforming to ASTM 3517, ASTM 3754 and AWWA C-950 specifications. Drilling of
flanges for large bore fittings conform to AWWA C207 specifications.

The Circulating Water System is designed for a flow of 55 000 m3/h (15 277 kg/s) at a
normal operating differential pressure of 1.37 barg (19.87 psig). The condenser uses most
of this cooling water with a cooling water flow of 14 338 kg/s (51 617m³/h). Flow is
provided by two 50% vertical, mixed flow pull out type circulating water pumps. Each
pump is rated for 27 750 m3/h (7 708.33 kg/s) at 14.0 m TDH.

3. DESCRIPTION OF SYSTEM AND EQUIPMENT

3.1. Description of System

Refer to Piping and Instrument Diagrams TZ03-XN-PA-DSD0071 and

TZ03-XN-PC-DSD0072.

The Circulating Water System performs the following duties:

• supplies the condenser with cooling water;

• supplies cooling water to the service cooling water system which cools the CCW
heat exchangers;

• discharges the warm water from the condenser and service cooling water system
to Lake Maracaibo at appropriate points;

• facilitates the injection and removal of tube cleaning balls in and out of the
Circulating Water and Service Cooling Water Systems;

• facilitates the inspection and maintenance of one half of the condenser during
plant operation and

• maintains required cooling water temperature across the condenser and CCW
System.

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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Circulating Water System:

The cooling water flows from the Lake Maracaibo through the intake channel to the sump
pit of the Circulating Water Pump structure, passing through the intake bar screens (trash
rakes) (10PAA01 AT001 / 10PAA02 AT001 / 10PAA03 AT001 / 10PAA04 AT001) and
traveling band screen (10PAA01 AT002 / 10PAA02 AT002 / 10PAA03 AT002 /
10PAA04 AT002) cleaning systems for removal of leaves, driftwood, grass-weed,
jellyfish, fibrous materials, course debris, marine life, and other debris. To avoid
biological growth in the sump pit, intake chambers and the CW system including the
condenser tubes, the upstream section of the CW system is chlorinated by shock and
continuous chemicals dosing from the Sodium Hypochlorite system (TZ03-CD-PUN-
DSD0001).

There are four sets (4x33%) of intake bar screen and traveling band screen cleaning
systems installed for 2 x 50% Circulating Water Pumps (10PAC11 AP001 / 10PAC12
AP001). Each suction channel can be isolated from the pumps by means of inlet
floodgate (stoplog) (10PAA01 AB001 / 10PAA02 AB001 / 10PAA03 AB001 / 10PAA04
AB001) and outlet floodgate (stoplog) (10PAA01 AB002 / 10PAA02 AB002 / 10PAA03
AB002 / 10PAA04 AB002). The discharge of each CW pump flows into individual
DN1800 pipe lines. Each separate pipeline is provided with local pressure indication
(10PAB11 CP501 / 10PAB12 CP501) and remote pressure indication (10PAB11 CP001 /
10PAB12 CP001) used to monitor CW pump operation. The flow then passes through the
CW pump discharge valves (Hydraulic operated quick closing butterfly valve) (10PAB11
AA002 / 10PAB12 AA002) with various position indicators.

The discharge then flows into a common DN2400 pipeline before being split back into
two DN1800 pipelines leading to each half of the condenser. This common pipe allows
either CW Pump to circulate to either half of the condenser.

In the condenser the heat of the steam condensation is transferred to the circulating water
flowing on the tube side. Before entering the condenser, the circulating water passes
through a first motor operated isolating butterfly valve (10PAB21 AA001 / 10PAB22
AA001) before entering the self-cleaning Debris Filter System, installed prior to the
condenser to ensure no coarse impurities, fibrous materials, and marine life etc. that could
cause damage to the condenser passes through. The Debris Filter system (provided by
Koller) contains a debris filter (10PBB21 AT001 / 10PBB22 AT001) with a funnel
screen that is scrapped by a motor actuated backwash rotor to carry large debris into a
hole at the end of the backwash pipe. The filter backwash system is activated by the
screen monitoring system comprised of a differential pressure transmitter (10PBB21
CP001 / 10PBB22 CP001) which opens and closes the motor operated backwash valve
(10PBB21 AA001 / 10PBB22 AA001) which leads the trapped debris into the circulating
water discharge line downstream of the condenser leading back to the lake discharge
diffuser piping. Refer to Koller Operation and Maintenance Manual for a detailed
description of the Debris Filter System operation (TZ03-CQ-PBB00-KOL0041).

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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Downstream of the debris filters, the circulating water piping continues to each condenser
inlet water box. The balls from the tube cleaning system (described below) are injected
into this section of pipe via two ball injectors (provided by Koller).

Compensators (rubber expansion joints) are provided at each inlet and outlet condenser
water box connection (10PAB21 AA002 / 10PAB22 AA002 / 10PAB31 AA001 /
10PAB32 AA001) to accommodate thermal movement.

Inlet and outlet circulating water temperature indication (10PAB21 CT001 / 10PAB22
CT001 / 10PAB31 CT001 / 10PAB32 CT001) is provided at the outlet of each water box
connection for remote monitoring. A differential pressure transmitter (10PAB21 CP001 /
10PAB22 CP001) is also installed across each condenser half for monitoring and alarm
purposes.

Downstream of each outlet condenser water box connection, the circulating water system
piping flows through ball filters (part of the Condenser Tube Cleaning System described
below) where the balls are collected and returned to the circulating water inlet piping
through ball circulation pumps. Thereafter, butterfly isolating valves (10PAB31 AA002 /
10 PAB AA002) are provided to isolate the circulating water piping to each condenser
half in the case maintenance is required. Downstream of these last isolating valves, the
Service Water return and debris filter backwash piping are connected and the entire
circulating water return system is drained back to the Maracaibo Lake through the
discharge diffuser piping.

Service Cooling Water System:

The Service Cooling Water System is fed by the Circulating Water system through
DN500 branch pipelines located downstream of the Debris Filter System of each
condenser half. These lines provide cooling water to the 2x100% CCW heat exchangers
(10 PGB21 AC001 / 10PGB22 AC001). Butterfly isolating valves (10PCB11 AA001 /
10PCB12 AA001) are provided each branch line to allow one condenser half to be shut
down. The branch lines are then combined into one common pipeline which feeds the
CCW heat exchangers. Temperature indication (10PCB20 CT501, 10PCB31 CT501,
10PCB32 CT501, 10PCB40 CT001) is provided and used for monitoring the circulating
water system temperature at the inlet and outlet of the CCW heat exchangers.

In the CCW Heat Exchanger area, the Service Cooling water common pipe is split back
into two DN500 pipes leading to each CCW Heat Exchanger. Isolating butterfly valves
are provided at the inlet (10PCB32 AA001 / 10PCB31 AA001) and outlet (10PCB32
AA002 / 10PCB31 AA002) of each heat exchanger. A differential pressure transmitter
(10PCB31 CP001 / 10PCB32 CP001) is installed across each heat exchanger to monitor
and alarm on high differential pressure. A temperature transmitter 10PAB31 CT001 /
10PAB32 CT001) is installed at the outlet lines of the condenser, providing temperature
indication of the service water return and allow for remote monitoring. Relief valves
(10PCB31 AA191 / 10PCB32 AA191), installed between each heat exchanger and outlet

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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isolating valve, provide over-pressure protection in case thermal expansion with closed
inlet and outlet isolating valves.

Downstream of the CCW heat Exchangers, the piping flows back into a common DN500
pipe, through the ball filter (part of the ball cleaning system described below) and back
into the circulating water system piping downstream of the condenser leading back to the
lake discharge diffuser piping.

The pressure loss in the Service Cooling Water System is the same (or less) as the
pressure loss in the Circulating Water System between the service cooling water supply
and return points. Therefore, there is no need to provide any pumps for the Service
Cooling Water System.

Tube Cleaning Systems:

To remove any deposits or scaling and micro fouling in the Condenser and Closed
Cooling Water heat exchanger tubes, a ball type online automatic tube clean system is
provided for each Condenser half and for the Service Cooling water System. These
systems are provided by Koller and are all designed in similar fashion. The principal
components are the ball strainers (10PAH31 AT001 / 10PAH32 AT001 / 10PCH10
AT001), the ball collectors (10PAH21 AT001 / 10PAH22 AT001 / 10PCH10 AT002)
and the ball circulation pumps (10PAH21 AP001 / 10PAH22 AP001 / 10PCH10 AP005).
Tube cleaning balls are injected into the inlet lines of each half of the condenser and at
each heat exchanger via ball injectors (provided by Koller). The balls, which are slightly
larger than the tube ID, are dispersed throughout the circulating and service water flow
stream and forced through the tubes to scrub and clean the circulating water (cold) side of
the tubes. At the outlet of each half of the condenser and at each heat exchanger, the balls
are withdrawn from the circulating water and service flow streams by the ball strainers.
The balls are drawn out of the strainers by the ball circulation pumps which circulate a
fixed amount of water and balls back into the inlet ball injectors. The ball collectors are
provided in this circulation side stream to provide a means to add, remove or collected
the tube cleaning balls to and from the system. Refer to Koller Operation and
Maintenance Manual for a detailed description of the tube cleaning system operation
(TZ03-CQ-PAH00-KOL0039).

Evacuation for Circulating Cooling Water System:

The Evacuation System for the Circulating Water and Service Cooling Water Systems
removes any air or vapor that is formed and/or accumulated in the condenser water boxes
and the service cooling water system at the vicinity of the CCW heat exchangers during
normal operation. During filling and start-up of the Circulating Water and Service
Cooling Water systems, the Evacuation system is put in operation to prime the water
boxes and piping related to the Service Cooling Water System.

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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The Evacuation for Circulating Cooling Water System is provided by Holtec/NASH and
is common to both the Circulating Water and Service Cooling Water Systems. The
system consists of 2 x 100% capacity liquid ring vacuum pumps (10PUE10 AP001 /
10PUE20 AP001) which draw air/vapor from one common Air Accumulation or Priming
Tank (10PUE10 BB001).

Air and vapor lines are connected to the high spots on condenser water boxes and in the
Service Cooling Water System piping outlet to each CCW heat exchanger. The DN50
pipe lines are routed into one common DN50 line that is routed into the Air
Accumulation Tank. Double isolation valves are provided at each condenser water box
and CCW heat exchanger in the event that maintenance is required.

Each liquid ring vacuum pumps discharges into its own water trap separating and
silencing tank (10PUE10 BS001 / 10PUE20 BS001). This tank receives the water/vapor
discharge from each tank, separates out the seal water from the vapor and discharges the
vapor through a silencer to limit noise emissions. The separated seal water is drawn
through the seal water heat exchangers (10PUE10 AC001 / 10PUE20 AC001) and back
into the suction side of liquid ring vacuum pumps (seal water circulating pumps are not
required). The seal water is cooled by the Closed Cooling Water System. Seal water
make-up is provided from the Service Water System (TZ03-XN-GHE-DSD0007) via seal
water make-up valves (10PUE10 AA003 / 10PUE20 AA003).

The pressure at Condenser outlet is almost 0.43 bara (6.24 psia). The setpoint of the
evacuation system should be 0.3-0.4 bara (4.35-5.8 psia) for the case of two operating
CW pumps. When the system started-up with one CW pump or any other time that one
CW pump is in operation, the pressure at Condenser outlet is almost 0.16 bara (2.32
psia). The setpoint of the evacuation system should be 0.15 bara (2.18 psia) for the case
of one operating CW pump.

Refer to the Holtec/NASH Operation and Maintenance Manual for a detailed description
of the Evacuation System operation (TZ03-CQ-PUE-HOL0001).

3.2.Description of Equipment

The design specifications of the major components of the Circulating Water System are
as follows:

Circulating Water Pumps (2): (10PAC11/12AP001)

Vendor: Kirloskar Brothers, INDIA

Design Flow: 27 750 m3/h
Design Head: 14 meters TDH
Pump Efficiency: 86.1 %
Rated Speed (nominal speed): 395 RPM
Motor Manufacturer: WEG

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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Motor RPM: 395
Motor kW: 1700
Voltage / Frequency / Phase: 4160 V/ 60 Hz/ 3 Phase

Condenser:

Vendor: Holtec
Design Cooling Water Flow: 14,338 kg/s
Heat Load:
Tube O.D.- BWG:
Tube Material: Titanium
Tube Length:
Temperature Rise:

CW Pump Discharge Valves (2): (10PAB11 AA002 / 10PAB12 AA002)

Specification: TZ03-DC-PAB-DSD0001
Manufacturer: Tyco Valves & Controls
Model number: RMI Dubex
Normal Operating Pressure: 1.37 barg (approximate)
Design Pressure: 5.0 barg & full vacuum
Water temperature (Rated): 35°C
Design Temperature: 50°C
Valve size: DN 1800
Flange connection: PN6
Dimension and drilling ass per: AWWA C207 class D, FF

Materials:
Valve body Material: GGG40 rubberlined
Valve disc Material: GGG40 rubberlined
Retaining ring: SS EN-1.4404
Shaft: SS EN-1.4462
Bushing: CuSn12
O ring: EPDM

Hydraulic unit:
Operating medium Hydaulic oil
Operating pressure 185 barg
Capacity of hydraulic pump 10 lit/min
Maximum operating temperature 70°C
Tubing material Stainless Steel
Sealing material NBR
Voltage / Frequency / Phase 480 V / 60Hz / 3 Phase (4 wires)
Control voltage 24 V DC

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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Condenser Inlet and Outlet Isolation Valves (4):
(10PAB21 AA001 / 10PAB22 AA001 / 10PAB31 AA002 / 10PAB32 AA002)

Specification: TZ03-DC-PAB-DSD0002
Manufacturer: Tyco Valves & Controls
Model number: RMI Dubex - Double eccentric butterfly valve
Normal Operating Pressure: 1.37 barg (approximate)
Max allowable working Pressure: 3.5 barg
Design Pressure: 5.0 barg & full vacuum
Water temperature (Rated): 35°C
Design Temperature: 50°C
Valve size: DN 1800
Flange connection: PN10 - Double Flanged
Dimension and drilling ass per: AWWA C207 class D, FF
Materials:
Valve body Material: GGG40 rubberlined
Valve disc Material: GGG40 rubberlined
Retaining ring: SS EN-1.4404
Shaft: SS EN-1.4462
Bushing: PTFE – coated Steel
O ring: EPDM

Electric Actuator:
Type Drehmo- DIM 249
Duty For inching duty
Manufacturer Drehmo – i-matic
Voltage / Frequency / Phase 480 V / 60Hz / 3 Phase
Full Opening / Full Closing time sec Approximate 180 sec / 180 sec
Limit switches / Torque switches 2 SPDT each direction / 2 SPDT each direction
Position transmitter 4- 20 mA

Intake Structure Bar Screen (4): (10PAA01/A02/A03/A04AT001)

Vendor: Geiger
Design Flow Rate: 18 500 m3/hr
Bar Spacing: 30 mm
Max Head Loss: 139 mm WC @30% blocked

Intake Structure Grab Rake (4): (10PAA01/A02/A03/A04AZ001)

Vendor: Geiger
Type: Welded Construction
Lifting / Lowering speed: 7 / 14 m/min
Maximum Debris Load: 800 kgs
Power rating of Lifting Motor : 2.5 / 5 kW

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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Power rating of Pivoting Motor : 2.2 kW
Voltage / Frequency / Phase: 480 V/ 60 Hz/ 3 Phase

Floodgates (Stoplogs) (4) with guideways (8): (10PAA01/A02/A03/A04AB001)

Vendor: Geiger
Type: Welded Construction
Width: 4.0 meters
Height: 3.0 meters
Lifting Beam Capacity: 3.6 tons

Intake Structure Traveling Band Screens (4): (10PAA01/A02/A03/A04AT002)

Vendor: Geiger
Type: Center Flow – Flow inside to outside
Design Flow Rate: 18,500 m3/hr
Mesh Opening Size: 6 mm
Maximum Head Loss: 48 mmWC @30% blocked
Screen Speed (two spped): 5.4 / 10.8 m/min
Power rating of Motor : 0.8 / 1.6 kW
Voltage / Frequency / Phase: 480 V/ 60 Hz/ 3 Phase

Screen Wash Pumps (2): (10PAA10/20AP001)

Vendor: Geiger
Type: Centrifugal, Submersible
Design Flow: 150 m3/h
Design Head: 55 m TDH
Nominal Pump Speed 3500
Motor Power: 30 kW
Motor Rating: 480 V/ 60 Hz/ 3 Phase

Debris Filters (2): (10PBB21/22AT001)

Vendor: Koller
Design Flow: 27 750 m3/h
Maximum Pressure Drop: 90 mbar
Mesh Size: 5.0 mm
Rotor Drive Motor Rating: 0.18 kW
Backwash Flow (maximum): 800 m3/h

The design specifications of the major components of the Condenser Tube Cleaning
System are as follows:

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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Ball Strainers (2): (10PAH31/32AT001)

Rated Flow: 27 750 m3/hr

Number of Tubes per Pass: 8500
Tube Length: 9474 mm
Tube ID: 30.14 mm
Maximum allowable Pressure Drop: 50 mbar
Mesh Size: 6 mm
Inclination: 20 degrees
Motor Rating: 0.18 kW
Voltage / Frequency / Phase: 480 V/ 60 Hz/ 3 Phase

Ball Circulation Pumps (2): (10PAH21/22AP001)

Type: Non-clogging Centrifugal

Pump Capacity: 50 m3/h
Differential Head: 12 meters TDH
Pump Efficiency: 60%
Motor Rating: 4.0
Voltage / Frequency / Phase: 480 V/ 60 Hz/ 3 Phase

The design specifications of the major components of the Closed Cooling Water Tube
Cleaning System are as follows:

Ball Strainer: (10PCH10AT001)

Rated Flow: 1080 m3/h
Number of Tubes per Pass: 690
Tube Length: 7500 mm
Tube ID: 17.05 mm
Maximum allowable Pressure Drop: 50 mbar
Mesh Size: 6 mm
Inclination: 30 degrees

Ball Circulation Pump: (10PCH10AP001)

Type: Non-clogging Centrifugal

Pump Capacity: 20 m3/h
Differential Head: 12 meters TDH
Motor Rating: 2.2
Pump Efficiency: 55%
Voltage / Frequency / Phase: 480 V/ 60 Hz/ 3 Phase

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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The design specifications of the major components of the Evacuation for Circulating
Water System are as follows:

Liquid Ring Vacuum Pumps (2): (10PUE10/20AP001)

Type: EC90M Dupex Priming

Pump Capacity: 1 SCFM
Motor Rating: 3.7 kW
Voltage / Frequency / Phase: 480 V/ 60 Hz/ 3 Phase

Air Accumulation or Priming Tank: (10PUE10BB001)

Design Pressure: 1.034 barg

Design Temperature: 93 °C
Capacity: 11.5 lit

Discharge Seperators and Silencing Tank (2): (10PUE11/21AT001)

Design Pressure: 1.034 barg & Full vacuum

Design Temperature: 93 °C
Capacity: 961 lit

Heat Exchanger (2): (10PUE10/20AC001)

Design Temperature: 149 °C

Design Pressure: 10.34 barg
Inlet/Outlet Temperature (Tube Side): 41/45 °C
Tube side Pressure Drop: 0.2 bar
Cooling water requirement: 30.3 lit/min

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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3.3. Description of Control

Circulating Water Pumps (2): (10PAC11/12AP001)

The circulating water is forwarded by two 50% capacity Circulating Water Pumps
(10PAC11/12AP001).
There is no standby pump. Under the normal operating conditions, both pumps are
operating in parallel mode.
The pumps are selected by the operation staff in the Central Control Room (CCR)
The isolation valves 10PAB 21/22 AA001 upstream of the Condenser and 10PAB31/32
AA002 downstream of the Condenser must be open.
The pumps are started and shutdown in sequence to prevent dynamic waterhammer in the
piping system or level interference in the cooling water intake pump chamber/intake
channel.
The hydraulic operated quick closing butterfly valves installed on discharge of the
Circulating Water Pumps are actuated by its own Black Box controlled electro-hydraulic
pump system.
Each hydraulic operated quick closing butterfly valve is fitted with 1 analog position
indicator 10PAB11/12 CG001and 5 binary limit switches 10PAB11/12
CG101/102/103/104/105.
Start-up of Circulating Water Pumps.
Protection of Circulating Water Pumps (Process Trip):

Any of the following conditions can trip a Circulating Water Pump on Process Trip:

• If the water level in the pump chamber / sump drops below the minimum
allowable level, the associated Circulating Water Pump are switched off.

• If the pressure at the Circulating Water Pump discharge drops below minimum
set point or goes above the maximum allowable pressure setpoint, the
associated Circulating Water Pump is switched off.

• If hydraulic system of discharge butterfly valve fails and the butterfly valve can
not be kept opened, the associated Circulating Water Pump is switched off.

• If the thrust bearing temperature of a Circulating Water Pump increases above

the maximum allowable temperature, the associated Circulating Water Pump is
switched off.

• If Field Emergency Stop is actuated.

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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• If the bearing oil bath temperature of a Circulating Water Pump increases
above the maximum allowable temperature, the associated Circulating Water
Pump is switched off.

• If the Motor bearing temperature increases above the maximum allowable

temperature, the associated Circulating Water Pump is switched off.

• If the Motor winding temperature increases above the maximum allowable

temperature, the associated Circulating Water Pump is switched off.

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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The Circulating Water Pumps are controlled from the DCS using a 4160V Motor with
Auto/Manual Control and Auto Discharge Valve Control (MVMTRA-1) macro and faceplate.
The following macro logic definition table outlines the DCS control functions:

Process Trip: ● Circulating Water Pump Thrust Bearing Temperature

High High (10PAC11 CT001, 10PAC11 CT002, 10PAC12
CT001, 10PAC12 CT002 > 110ºC), OR
● Circulating Water Pump Oil Bath Temperature High
High (10PAC11 CT003, 10PAC12 CT003 > 100ºC), OR
● Circulating Water Pump Motor Bearing Temperature
High High (10PAC11 CT004, 10PAC11 CT005, 10PAC12
CT004, 10PAC12 CT005 > 110ºC), OR
● Circulating Water Pump Motor Winding Temperature
High High (10PAC11 CT006, 10PAC11 CT007, 10PAC11
CT008, 10PAC11 CT009 10PAC11 CT010 10PAC11
CT011, 10PAC12 CT006, 10PAC12 CT007, 10PAC12
CT008, 10PAC12 CT009 10PAC12 CT010 10PAC12
CT011 > 155ºC) OR
● Water Level in Pump Sump Low Low (10PAB11 CL001,
10PAB11 CL002, 10PAB11 CL003, 10PAB12 CL001,
10PAB12 CL002, 10PAB12 CL003 < 4.7m), OR
● Circulating Water Pump Discharge Pressure High High
(10PAC11 CP001, 10PAC12 CP001 > 2.25 barg (32,7
psig), if signal present for 60 sec), OR
● Circulating Water Pump Discharge Pressure Low Low
(10PAC11 CP001, 10PAC12 CP001 < 0.13 barg (1.9 psig),
if signal present for 60 sec)
● Field Emergency Stop actuated 10PAC11/12CH001
Bus Undervoltage: Trip CW Pump
Auto Start: None
Auto Stop: None
Start Permit: ● Water Level in Pump Sump (10PAB11 CL001, 10PAB11
CL002, 10PAB11 CL003, 10PAB12 CL001, 10PAB12
CL002, 10PAB12 CL003) > 4.8m, AND
● Discharge butterfly valves CLOSED- (Hydraulic
operated quick closing butterfly valve
10PAB11/12 CG105) = TRUE, AND
● Condenser Isolation Valves (10PAB21/22AA001 OPEN
and 10PAB31/32AA002 > 30%) = TRUE
Events:
Running: None
Tripped: None
Stopped: None
Auto: None

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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Start Permissive: None
Alarm: Macro: Spring Charger Fault, Ground Switch Closed, Ground
Fault, Control Voltage Tripped, Protection Trip, Not In
Operate Position
Specific: ●. Circulating Water Pump Thrust Bearing Temperature
High (10PAC11 CT001, 10PAC11 CT002, 10PAC12
CT001, 10PAC12 CT002 > 90ºC), OR
●. Circulating Water Pump Oil Bath Temperature High
(10PAC11 CT003, 10PAC12 CT003 > 80ºC), OR
●. Circulating Water Pump Motor Bearing Temperature
High (10PAC11 CT004, 10PAC11 CT005, 10PAC12
CT004, 10PAC12 CT005 > 90ºC), OR
●. Circulating Water Pump Motor Winding Temperature
High High (10PAC11 CT006, 10PAC11 CT007, 10PAC11
CT008, 10PAC11 CT009, 10PAC11 CT010, 10PAC11
CT011, 10PAC12 CT006, 10PAC12 CT007, 10PAC12
CT008, 10PAC12 CT009, 10PAC12 CT010, 10PAC12
CT011> 130ºC), OR
●. Water Level in Pump Sump Low (10PAB11 CL001,
10PAB11 CL002, 10PAB11 CL003, 10PAB12 CL001,
10PAB12 CL002, 10PAB12 CL003 < 5.3m), OR
●. Circulating Water Pump Discharge Pressure High
(10PAB11 CP001, 10PAB12 CP001 > 2.0 barg (29 psig), if
signal present for 240 sec)
●. Field Emergency Stop actuated 10PAC11/12CH001

Circulating Water Pump Discharge Valve- (Hydraulic operated quick closing butterfly
valves)-10PAB11/12 AA002

These hydraulic operated quick closing butterfly valves are actuated by its own Black
Box (Local Control Panel) controlled electro-hydraulic pump system. The Local Control
Panel is equipped with selector switch “LOCAL/REMOTE”. During the normal
operation of the CW System these valves are kept in REMOTE mode and are operated
from the DCS. At first Black Box (Local Control Panel) START command (Hydraulic
pump ON) is initiated from DCS and sufficient oil pressure is developed by the electro-
hydraulic pump system. CW pump starts running and the command “OPEN” from DCS
is given to Black Box (Local Control Panel). The Solenoid valves of the control valves
are energized to open the hydraulic operated quick closing butterfly valve. CW pump
stops running (or trip) and the command “CLOSE” from DCS is given to Black Box
(Local Control Panel). The Solenoid valves of the control valves are de-energized to
close the hydraulic operated quick closing butterfly valve.

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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These valves can also be operated locally with the push buttons (VALVE OPEN,
VALVE CLOSE) provided in the Black Box (Local Control Panel). While opening and
closing from the Local Control Panel, each valve can also be stopped in an intermediate
position by pressing the push button “VALVE STOP” provided in the Local Control
Panel.

Each hydraulic operated quick closing butterfly valve is fitted with 1 analog position
indicator and 5 binary limit switches.

Normal Operation

During the normal operation, sufficient pressure is developed by the electro-hydraulic

pump system of the valve actuator to bring the discharge butterfly valve to 100% open
position.

As the butterfly valve will remain a long time in this position and as small leakage in
hydraulic system is possible, the counterweight will very slowly move down, however,
the Circulating Water mass flow through the butterfly valve remain unchanged. If the
pressure in the hydraulic system is equal to the setting of the low pressure switch in the
manifold block, the electric motor operated hydraulic pump is turned-on. The pressurized
oil brings the cylinder to full open position, the high pressure switch in the manifold
block is actuated to stop the hydraulic pump.

Shutdown/Trip of Circulating Water Pumps

When one of the Circulating Water Pump is stopped (due to shutdown or power failure),
the associated discharge butterfly valve is closed automatically in quick closing mode
action. The piston of hydraulic actuator is pressure-relieved by opening a discharge line
as a result of de-energizing the solenoid valve in the hydraulic system. The valve is
closed by means of counterweight.

In order to avoid the waterhammer in the Circulating Water Piping System, the closing
velocity is controlled in two steps:

1. first in a quick closing range 100 % to 10 %, controlled by designated speed

control valve located at the hydraulic control block – 10 sec

2. then in a smooth closing 10 % to 0 %, controlled by designated throttle valve at

the hydraulic cylinder – 20 sec

The closing characteristics and closing time is pre-adjusted by the supplier and may be
re-adjusted at Site in accordance with the result of waterhammer calculation.

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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An alarm is actuated if 20 sec after shutdown command, the valve is still more than 10 %
opened.

Signal Exchange

KKS SET POINT TASK

10PAB11/12CG001 0% - 100% Position indication – Analog 4-20mA

Feedback to DCS
10PAB11/12CG105 Valve CLOSED
Release for start-up of CW Pump
Protection shut off (trip) if signal is
10PAB11/12CG104 Valve opened < 10 % still present 10 sec after CW Pump
start.
Protection shut off (trip) if signal is
10PAB11/12CG103 Valve opened > 50 %, or
not present for 20 sec after CW Pump
10PAB11/12GH001 Valve opened < 50 %
runs for 60 sec.
Protection shut off (trip) if signal is
10PAB11/12CG102 Valve opened > 90 %, or
not present for 20 sec after CW Pump
10PAB11/12GH001 Valve opened < 90 %
runs for 240 sec.

10PAB11/12CG101 Valve OPENED 100% Feedback to DCS

Mechanical CW Cleaning System

(i.e. Traveling bar Screens, Bar Rakes and Screen Wash Pumps )

The Traveling bar Screens, bar rakes and screen wash pumps are provided as a black box
system by Geiger with PLC controls. The PLC will exchange signals over a datalink to
the DCS. Refer to the Signal Exchange List, Geiger Document Number
TZ03-YY-PAA-GGR0001 for the available signals from the PLC.

Debris Filter System and Tube Cleaning System

The Debris Filter System and Tube Cleaning System are provided as a black box system
by Koller. A PLC will supply the controls based upon the Logic Diagrams provided in
Koller document number TZ03-YD-PAH-KOL0301. The PLC will exchange signals
over a datalink to the DCS. Refer to the Signal Exchange List, Koller Document Number

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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TZ03-YC-PAH-PCH-PBB-KOL0007 for the available signals from the PLC.
While starting of any CW pump after an outage and /or maintenance, it is important that
Debris Filter must be in operation in MANUAL MODE. Under this MANUAL MODE of
operation, the Debris Filter will be backwashed immediately when debris will flow in
concentrated nature and in big quantity. In case of AUTOMATIC MODE, the Debris
Filter needs some time to open the waste water valve until the start of back wash flow
and this could lead to blockage of filter in case of large amount of debris flow in
suddenly during start of CW pump. After few hours of operation, the filter can be
switched to AUTOMATIC MODE.

4.0 SAFETY PRECAUTIONS

4.1. Hazards

No special personnel hazards are considered to exist in the Circulating Water System
beyond those normally observed around moving parts and high temperature piping.

4.2. Precautions

There are no special precautions for safe operation of the Circulating Water System.
Startup, normal operation, and shutdown must be in accordance with the Plant Operating
Manual and the Plant Startup and Shutdown Procedures for this system.

5.0 SYSTEM OPERATION

5.1. Commissioning

The Circulating Water System, subsystems and components will be commissioned as

described in the Startup Plan for the Termozulia Combined Cycle Power Plant.

5.2. Start-up

The operation of the Circulating Water System is a prerequisite for start-up of the
steam/water cycle. Subsequently the operation of the Circulating Water System is
required until all connected components or systems are switched off.

When one CW pump is started and two condenser halves are used, the condenser outlet
valves must be throttled to keep the pump water flow in the maximum limit 33 920 m3/h
(9 422 kg/s). The condenser outlet butterfly valve (10PAB31/32 AA002) is required to be
throttled to provide an angle of approximately 60º and butterfly valve outlet to CCW heat
exchanger is required to be throttled to provide an angle of approximately 55º. When one
CW pump is in operation as described above, the condenser gets a mass flow
approximately 61% of the design data. While one CW pump is in operation, the pressure
at condenser outlet is almost 0.16 bar abs (2.32 psia) and the setpoint for the pressure of
the evacuation system is 0.15 bar abs (2.175 psia).

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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After first the CW pump operation stabilizes, the second CW pump can be started. The
condenser outlet butterfly valve (10PAB31/32 AA002) is required to be fully opened.
The Butterfly valve outlet to the CCW heat exchanger is required to be throttled to
provide an angle of approximately 55º or it can be fully opened depending on the thermal
load and the actual site conditions. While two CW pumps are in operation, the pressure at
the condenser outlet is almost 0.43 bar abs (6.24 psia) and the setpoint for the pressure of
the evacuation system is 0.3-0.4 bar abs (4.35-5.8 psia).

5.3. Normal Operation

Under normal operating conditions, the cooling water is pumped by two 50% capacity
Circulating Water Pumps, which are designed to deliver cooling water through piping to
the tube side of the steam turbine condenser and Service Cooling Water System. The
cooling water is taken from the intake of Lake Maracaibo through the intake
channel/structure. The cooling water to each pump is supplied by a dedicated suction
intake channel.

Each of the circulating water pumps is equipped with a hydraulically operated butterfly
valve, which has a counter weight arrangement for quick closing up to the defined limits
of the configurable closing characteristic.

The condenser is divided into two parts. Each half is designed to be isolated by motor
operated butterfly valves in case of repair or maintenance.

The isolation valves 10PAB21/22AA001 upstream of the condenser and

10PAB31/32AA002 downstream of the condenser must be fully open when both
circulating water pumps are in operation. In case of a process requirement, the opening
position of the valve 10PAB31/32AA002 can be adjusted from the DCS room. If both
halves of the condenser are operating and only one CW pump is operational, the pump
flow can be adjusted by throttling of the valves 10PAB31/32AA002. The throttling is
recommended to avoid the excessive vacuum rise associated with the operation of two
condenser halves with only one CW pump.

The system is designed to be available during start-up, normal operation and shutdown of
the Steam Turbine Plant. During normal operation of the plant the PAH, PCH, PBB,
PUE, and PUN Systems are in operation.

5.4. Filling of the System

The Circulating Water piping, Service Cooling Water System and the Condenser (tube
side) are filled by cooling water taken from Lake Maracaibo through the intake channel
via a Mechanical CW Cleaning System by means of two Screen washing Pumps
(10PAB10/20AP001). Also, the system can be filled by one CW pump with opening of
the hydraulic operated quick closing butterfly valve on the discharge side of the pump to
definite percentage in accordance with the continuous minimum flow required for pump

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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operation by monitoring the discharge pressure between 1.7 - 1.9 barg
(24.66 - 27.56 psig). The opening position of the valve is to be adjusted from the Black
Box (Local Control Panel).

During the filling operation, the PUE system should be turned on and kept in operation
as described herein above in order to remove the air trapped inside the condenser water
boxes and the CW piping. Once the filling is satisfactorily completed, the pump
discharge valve should be gradually opened to its fully open position.

5.5. Special or Infrequent Operation

If the circulating water temperature increases, the condenser vacuum would deteriorate
and the power output of the steam turbine should be reduced. In case leakage occurs in
the CW system, the entire PAB system and consequently the water/steam cycle have to
be shut down.

6.0 SETPOINT/EVENT LIST

TAG NUMBER EVENT SETTING CONSEQUENCES/ACTIONS

Circulating Water Pumps

10PAC11 CT001, Circulating Water > 90ºC Alarm (H)

10PAC11 CT002, Pump Thrust
Bearing
> 110ºC Alarm (HH)
10PAC12 CT001, Temperature
10PAC12 CT002 Trip CW Pump

10PAC11 CT003, Circulating Water > 80ºC Alarm (H)

Pump Oil Bath
10PAC12 CT003 Temperature > 100ºC Alarm (HH)

Trip CW Pump

10PAC11 CT004, Circulating Water > 90ºC Alarm (H)

10PAC11 CT005, Pump Motor
Bearing > 110ºC Alarm (HH)
10PAC12 CT004, Temperature
10PAC12 CT005 Trip Pump

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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TAG NUMBER EVENT SETTING CONSEQUENCES/ACTIONS

10PAC11 CT006, Circulating Water > 130ºC Alarm (H)

10PAC11 CT007, Pump Motor
10PAC11 CT008 Winding
10PAC11 CT009 Temperature
10PAC11 CT010,
10PAC11 CT011,
> 155ºC Alarm (HH)
10PAC12 CT006,
10PAC12 CT007, Trip CW Pump
10PAC12 CT008
10PAC12 CT009
10PAC12 CT010
10PAC12 CT011

10PAB11 CL001, Water Level in < 5.3 m Alarm (L)

10PAB11 CL002, Pump Sump
10PAB11 CL003, > 4.8 m Sends signal to Circulating
Water Startup Sequencer
10PAB12 CL001,
10PAB12 CL002, CW Pumps Start Permit
10PAB12 CL003 < 4.7 m Alarm (LL)

Trip CW Pump

10PAC11/12CH001 Field Emergency actuated Alarm

Stop
Trip CW Pump

10PAB11 CP001, Circulating Water > 2.25 barg Alarm (HH)

10PAB12 CP001 Pump Discharge (32,7 psig), if
Pressure signal present for Trip CW Pump
60 sec

> 2.0 barg Alarm (H)

(29 psig), if signal
present for 240 sec

< 2.0 barg Sends signal to Circulating

(29 psig) Water Startup Sequencer

> 0.74 barg Sends signal to Circulating

(10.7 psig) Water Startup Sequencer

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SYSTEM DESCRIPTION TERMOZULIA CCPP
CIRCULATING WATER SYSTEM
TAG NUMBER EVENT SETTING CONSEQUENCES/ACTIONS

< 0.74 barg Alarm (L)

(10.7 psig), if
signal present for
240 sec

< 0.13 barg Alarm (LL)

(1.9 psig), if signal
present for 60 sec Trip CW Pump

Discharge Valve Hydraulic Pumps

Valve opened Alarm

10PAB11/12 < 10 %
CG104 10 sec after CW Trip CW Pump
Pump start.
Valve opened Alarm
10PAB11/12CG103
> 50 % AND
signal is not Trip CW Pump
[or
present for 20 sec
10PAB11/12GH001
after CW Pump
< 50 %]
runs for 60 sec
Valve opened Alarm
10PAB11/12CG102 > 90 % AND
signal is not Trip CW Pump
[or present for 20 sec
10PAB11/12GH001 after CW Pump
< 90 %] runs for 240 sec.
10PAB11/12 Valve opened Alarm
CG104 > 10 %
20 sec after close
command
Condenser and Closed Cooling Water Heat Exchanger

10PAB21 CP001, Condenser > 0.83 bar Alarm (H)

10PAB22 CP001 (12 psi)
Inlet/Outlet
Differential Sends signal to Circulating
> 0.7 bar (10 psi) Water Startup Sequencer
Pressure
10PCB31 CP001, Closed Cooling > 0.083 bar Alarm (H)
10PCB32 CP001 Water Heat (1.2 psi)
Exchanger Sends signal to Circulating
> 0.07 bar (1 psi)
Differential

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SYSTEM DESCRIPTION TERMOZULIA CCPP
CIRCULATING WATER SYSTEM
TAG NUMBER EVENT SETTING CONSEQUENCES/ACTIONS

Pressure Water Startup Sequencer

7.0 E_STOP/EMERGENCY

For each Circulating Water Pump (10PAC11AP001, 10PAC12AP001) a local

Emergency-Off Push Button (10PAC11CH001, 10PAC12CH001) is provided. These
buttons are connected to the pumps motor control switchgears (00BBA03, 00BBB06) to
switch off directly the corresponding pump in case of danger. The actuation of a button
and sequentially shut-off of a circulating water pump will be reported to the operator
(CCR).

8.0 INTERFACE SYSTEMS

System Description

PC Service Cooling Water System

PAH Condenser Tube Cleaning System
PUE Evacuation for CW System
PUN Dosing System for Sodium Hypochlorite
PGB Closed Cooling Water System
MAG Condensing System
PAA Mechanical CW Cleaning System
PBB Debris Filter

9.0 REFERENCES

9.1 Instrument and Control Drawings and Diagrams

Dwg. No. Dwg. Title

TZ03-XC-PAB11/12-TYC0301/0351 Hydraulik Unit 10PAB11/12AA002

TZ03-YA-PAA-GGR0002 Mechanical CW Cleaning System
TZ03-YD-PAH-KOL0301 Debris Filter and Tube Cleaning System
TZ03-YD-10MAJ00-HOL0301 Vacuum Pumps PLC-Panel
TZ03-YD-10MAJ10/20-HOL0301 Condenser Vacuum Pumps
TZ03-YD-10PUE10-HOL0301 Circulating Water Vacuum Pump
160000588_10PUN01AW001 Technical_Documentation (included)
TZ03-YL-700-DSD0020 BOP Functional Control Diagrams

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SYSTEM DESCRIPTION TERMOZULIA CCPP
CIRCULATING WATER SYSTEM
9.2 Electrical Drawings and Diagrams

Dwg. No. Dwg. Title

TZ03-YD-BBA-SIV0313 10PAC11AP001 Circulating Water Pump Motor

Control 00BBA03
TZ03-YD-BBA-SIV0316 10PAC12AP001 Circulating Water Pump Motor
Control 00BBA06
TZ03-YD-BHA-SIN-0300 Low Voltage Switchgear 00BHA_00BHB

9.3 Piping and Instrumentation Diagrams

Dwg. No. Dwg. Title

TZ03-XN-PA-DSD0071 Circulating Water System

TZ03-XN-PC-DSD0072 Service Cooling Water System
TZ03-XN-PAA-GGR0001 Mechanical Circulating Water Cleaning System
TZ03-XN-PCH-KOL0018 CCW Heat Exchanger Tube Cleaning System
TZ03-XN-PAH-DSD0073 Condenser Tube Cleaning System
TZ03-XN-PAH-KOL0016/0017 Tube Cleaning System CCW C - PAH 31/32
TZ03-XN-PAB-TYC0004 Butterfly Valves 10PAB11/12AA002
TZ03-XN-PBB-KOL0019 Debris Filter
TZ03-XN-PUE-HOL0700 Circulating Water Evacuation System
TZ03-XN-PUN-DSD0088 Chemical Dosing of Biocide

9.4 Specifications

Number Title

TZ03-DC-PAC-DSD0001 Technical Specification - CW Pumps

TZ03-DC-PAB-DSD0001 Technical Specification - Hydraulic operated
quick closing butterfly valves
TZ03-DC-PAB-DSD0002 Technical Specification - Electric motor
operated butterfly valves
TZ03-DC-PAA-DSD0001 Technical Specification - Mechanical CW,
Cleaning System
TZ03-DC-PBB-PAH-PCH-DSD0001 Technical Specification - Debris Filter System,
Automatic Tube Cleaning Systems for
Condenser and CCW Heat Exchanger
TZ03-CD-PUE-DSD0185 Technical Specification - Evacuation for
Circulating Water + Service Cooling Water
System
TZ03-DC-MAG-DSD0001 Technical Specification - Water Cooled Steam
Surface Condenser

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SYSTEM DESCRIPTION TERMOZULIA CCPP
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9.5 Piping Materials

Number Title

TZ03-XW-U-TEC-0201 Design Criteria of Piping Systems

TZ03-XW-U-TEC-0205 Glass Reinforced Polyester Piping
TZ03-XU-U-TEC0000 1-2 Geotube and Geotextil
TZ03-XU-U-TEC0000 2-2 Multiple Permanent Barrier System
TZ03-XR-PAB-DSD0001 Piping Material Specification 0150 PAB 300
TZ03-XR-PAH-DSD0001 Piping Material Specification 0150 PAH 300
TZ03-XR-PUE-DSD0001 Piping Material Specification 0150 PUE 300

TZ03-CD-PA-PAR0001-R3_CIRCULATING WATER SYSTEM_description.doc 27 of 27

 3 24/11/07 Ravelli Degen As Built
2 03/23/07 Degen Degen Revision according Functional Diagrams
1 01/09/06 DRI/JPM JPM DRI Initial Issue
0 12/13/05 DRI/JPM JPM DRI Preliminary Issue
Rev. Date Originator Mech I&C Details of Revision

SUPPLIER
2675 Morgantown Road
Reading, Pennsylvania 19607
Telephone: +1 610 855 2000
Internet: www.worleyparsons.com

DSD-Project No.:
5705/102242-M01 Termozulia – Expansion to Combined Cycle
Status CIRCULATING WATER SYSTEM
REVISION 3 SUB GROUP CONTROL SEQUENCER
DATE NAME
10PAC00EC001
MECH 12/13/05 JP MITTON

I&C 12/13/05 D.R. ISERMAN ALL RIGHTS RESERVED DIN 34

SHEET No.:
1 of 8
SIZE Letter (8.5“ x 11“)
DRWG No..: REV.
SUPPLIER
SCALE NA DRWG.-

FILENAME TZ03-CQ-PA-PAR0001-R3
No.:
DSD
TZ03-CQ-PA-PAR0001 3
 TERMOZULIA EXPANSION TO CCPP
CIRCULATING WATER SYSTEM
SUB GROUP CONTROL SEQUENCER
10PAC00EC001

Table of Contents

1.0 PURPOSE.................................................................................................................................................................................... 3

2.0 PREREQUISITES........................................................................................................................................................................ 4

3.0 PROCEDURE .............................................................................................................................................................................. 5

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 TERMOZULIA EXPANSION TO CCPP
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SUB GROUP CONTROL SEQUENCER
10PAC00EC001

1.0 PURPOSE

The intent of this procedure is to instruct the operator how to start the Circulating Water system using the Subgroup
Controller (Sequencer). This procedure assumes all equipment is operational and the system is filled.
At the conclusion of the sequence the Circulating Water System is in operation.

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 TERMOZULIA EXPANSION TO CCPP
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SUB GROUP CONTROL SEQUENCER
10PAC00EC001

2.0 PREREQUISITES

STEP COMPONENT/SYSTEM DESCRIPTION REQUIREMENT COMPLETE

1 Circulating Water System Verify the setpoints are set to the values indicated in the Events COMPLETED
List (Section 6.0 of System Description TZ03-CD-PA-PAR0001).
2 Circulating Water System Valves pre-aligned and system prerequisites complete COMPLETED
3 Chemical Dosing of Biocide – Chemical Dosing System ready for use COMPLETED
PUN
4 Circulating Water Cleaning – Mechanical Circulating Water Cleaning System ready for use COMPLETED
PAA
5 Debris Filter System - PBB Debris Filter System ready for use COMPLETED
6 Condenser Tube Cleaning Condenser Tube Cleaning Systems ready for use COMPLETED
Systems – PAH
7 Closed Cooling Water Heat Closed Cooling Water Heat Exchanger Tube Cleaning System COMPLETED
Exchanger Tube Cleaning ready for use
Systems – PCH
8 Evacuation for Circulating Water Evacuation for Circulating Water System ready for use COMPLETED
System – PUE
9 Evacuation for Condenser – MAJ Evacuation for Condenser ready for use COMPLETED
10 Circulating Water System Circulating Water Pumps Ready to Start (no disturbances) COMPLETED
11 Circulating Water System Circulating Water Pumps in Remote Control Mode SELECTED
12 Circulating Water System Circulating Water Pumps in Automatic Control Mode SELECTED
13 Circulating Water System Lead Circulating Water Pump selected to Start SELECTED
14 Circulating Water System Circulating Water System Butterfly Valves Ready to Start
COMPLETED
Butterfly Valves PAB (Panel on / no disturbances)
15 Circulating Water System
Circulating Water System Butterfly Valves in Remote Control Mode SELECTED
Butterfly Valves PAB
16 Circulating Water System
Circulating Water System Butterfly Valves CLOSED
Butterfly Valves PAB
17 Condenser Inlet/Outlet Isolation Set Condenser Inlet/Outlet Isolation Valves to Automatic Control
SELECTED
Valves Mode
18 10PAB11/12CL901 Circulating Water Pumps Sump Levels > 4800 mm
Allowable
19 Closed Cooling Water System CCW Heat Exchanger SELECTED

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 TERMOZULIA EXPANSION TO CCPP
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SUB GROUP CONTROL SEQUENCER
10PAC00EC001

3.0 PROCEDURE
NOTE: 1. The various sequences and pre-selection cause certain setpoint values to automatically be selected. This is NORMAL. Minor
transients and over/undershooting is to be expected during startup, shutdown and transients. The process should be given time to
return to its setpoint. The operator should only assume manual operation if the deviation is exceeding design limits and the logic is
not correcting it quickly enough.
2. All secondary systems, such as Raw Water Cleaning, Chemical Dosing, Debris Filter, Tube Cleaning Systems and Evacuation
systems have to be started and stopped by Operators Action.

This Procedure is intended to provide the operator with instruction on how to start using the sub-group sequences.

Column Legend: STEP = Sequence Step,

ACTION = Automatically by Control Sequencer or Operator Action in Manual Operation,
CRT DISPLAY = DCS Screen Display,
STATUS/RESULT = Equipment Status as a Result of Action,
COMPLETE = Used by Operator as check sheet during start-up in Manual Operation.

It is important to note that some of the steps have checkbacks from other sequences or process conditions that require the sequence step to be held until
certain the checkbacks are satisfied.

PROCEDURE – CIRCULATING WATER START USING SUB GROUP SEQUENCE

STEP ACTION CRT DISPLAY STATUS/RESULT COMPLETE

1 TURN ON Circulating Water Startup Sequencer SEQUENCE STARTUP ON
10PAC00EC001 STARTED
1A Condenser Inlet Isolation Valves STEP XS01
10PAB21/22AA001 OPEN
1B Step complete Condenser Inlet Isolation Valves
advance to next step 10PAB21/22AA001 OPEN
2A Set Condenser Outlet Isolation Valves STEP XS02
10PAB31/32AA002 THROTTLE
2B Step complete Condenser Outlet Isolation Valves
advance to next step 10PAB31/32AA002 30% OPEN

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 TERMOZULIA EXPANSION TO CCPP
CIRCULATING WATER SYSTEM
SUB GROUP CONTROL SEQUENCER
10PAC00EC001

PROCEDURE – CIRCULATING WATER START USING SUB GROUP SEQUENCE

STEP ACTION CRT DISPLAY STATUS/RESULT COMPLETE

3A First CW Pump start 10PAC11/12AP001 (10PAC10EE001) STEP XS03
3B 1. CW Pump
10PAC11AP001 RUNNING and
Butterfly Valve
10PAB11CG101 OPEN or
2. CW Pump
10PAC12AP001 RUNNING and
Butterfly Valve
10PAB12CG101 OPEN
3C Filling Condenser water box and first CW pump comes to Step complete Step Waits for 5 minutes
stable operation advance to next step
4A 1. Second CW Pump start 10PAB11/12AP001 STEP XS04
(10PAC10EE001)
(Adjust both discharge valves 10PAB31/32AA002 just to
have discharge pressure on the running pump of 18 psig in
10 minutes. Open both valves till the pressure goes to
10 psig)
4B 1. CW Pump
10PAB11AP001 RUNNING and
Butterfly Valve
10PAB11CG101 OPEN and
2. CW Pump
10PAB12AP001 RUNNING and
Butterfly Valve
10PAB12CG101 OPEN
4C CW pumps come to stable operation Step complete Step Waits for 12 minutes
advance to next step
5A 1. Set Condenser Outlet Isolation Valves STEP XS05
10PAB31/32AA002 OPEN
(Only one CCW Heat Exchanger is required at a time)
5B 1. Condenser Outlet Isolation Valves
10PAB31/32AA002 100% OPEN
2. Condenser Water Box Differential
Pressure > 0.7 bar (10 psi)
(10PAB21/22CP001) and
TZ03-CQ-PA-PAR0001-R3_CIRCULATING WATER SYSTEM_sequence.doc Page 6 of 8
 TERMOZULIA EXPANSION TO CCPP
CIRCULATING WATER SYSTEM
SUB GROUP CONTROL SEQUENCER
10PAC00EC001

PROCEDURE – CIRCULATING WATER START USING SUB GROUP SEQUENCE

STEP ACTION CRT DISPLAY STATUS/RESULT COMPLETE

3. CCW Heat Exchanger Differential
Pressure > 0.07 bar (1 psi)
Step complete (10PCB31CP001 or
advance to next step 10PCB32CP001)
6A Evacuation for Circulating Cooling Water System STEP XS06
6B Evacuation for Circulating Cooling
Step complete Water System RUNNING (Nash)
advance to next step 10PUE10AP001 ON or
10PUE10AP002 ON
7A fill/remove air from the water box and CCW Heat Exchanger STEP XS07
7B CW Pump Discharge Pressures
> 0.74 bar (10.7 psi) and
< 2 bar (29 psi)
(10PAB11CP001 and
10PAB12CP001)
7C Step complete Step Waits for 10 minutes
advance to next step
8 10PAC00EC001 start
sequence complete
51 TURN ON Circulating Water System Shutdown Sequencer SEQUENCE SHUTDOWN ON
10PAC00EC001 STARTED
51A First CW Pump stop 10PAC11/12AP001 STEP XS51
(10PAC10EE001)
51B 1. CW Pump
10PAC11AP001 OFF and
Butterfly Valve
10PAB11CG101 CLOSED or
2. CW Pump
10PAC12AP001 OFF and
Butterfly Valve
10PAB12CG101 CLOSED
51C Step complete Step Waits for 45 Seconds
advance to next step

TZ03-CQ-PA-PAR0001-R3_CIRCULATING WATER SYSTEM_sequence.doc Page 7 of 8

 TERMOZULIA EXPANSION TO CCPP
CIRCULATING WATER SYSTEM
SUB GROUP CONTROL SEQUENCER
10PAC00EC001

PROCEDURE – CIRCULATING WATER START USING SUB GROUP SEQUENCE

STEP ACTION CRT DISPLAY STATUS/RESULT COMPLETE

52A Second CW Pump stop 10PAC11/12AP001 STEP XS52
(10PAC10EE001)
52B 1. CW Pump
10PAC11AP001 OFF and
Butterfly Valve
10PAB11CG101 CLOSED and
2. CW Pump
10PAC12AP001 OFF and
Butterfly Valve
10PAB12CG101 CLOSED
52C Step complete Step Waits for 45 Seconds
advance to next step
53A 1. Set Condenser Outlet Isolation Valves STEP XS53
10PAB31/32AA002 THROTTLE
2. Condenser Inlet Isolation Valves
10PAB21/22AA001 CLOSE
53B 1. Condenser Outlet Isolation Valves
10PAB31/32AA002 30% OPEN
Step complete and
advance to next step 2. Condenser Inlet Isolation Valves
10PAB21/22AA001 CLOSED
54 10PAC00EC001
shutdown sequence
complete

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