Simulator

DOE/NETL IGCC Dynamic Simulator
Research and Training Center

DOE/NETL-2008/1324
NETL Collaboratory for Process & Dynamic Systems Research
Volume 2: IGCC Process Descriptions
01 Aug 2008
Disclaimer
This report was prepared as an account of work sponsored by an agency of the United States
Government. Neither the United States Government nor any agency thereof, nor any of their
employees, makes any warranty, express or implied, or assumes any legal liability or
responsibility for the accuracy, completeness, or usefulness of any information, apparatus,
product, or process disclosed, or represents that its use would not infringe privately owned rights.
Reference therein to any specific commercial product, process, or service by trade name,
trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any agency thereof. The
views and opinions of authors expressed therein do not necessarily state or reflect those of the
United States Government or any agency thereof.
DOE/NETL IGCC Dynamic Simulator
Research and Training Center
DOE/NETL-2008/1324
NETL Collaboratory for Process & Dynamic Systems Research
Volume 2: IGCC Process Descriptions
01 Aug 2008
NETL Contact:
Stephen E. Zitney, Ph.D.
Director, Collaboratory for Process & Dynamic Systems Research
NETL Office of Research & Development
Prepared by:
Richard Turton, West Virginia University
Collaboratory for Process & Dynamic Systems Research
Michael R. Erbes, Enginomix, LLC

Herman P. Stone, Fossil Consulting Services, Inc.
Graham T. Provost, Fossil Consulting Services, Inc.
Michael McClintock, Fossil Consulting Services, Inc.
Jeffrey N. Phillips, EPRI
Merrill Quintrell, EPRI
Jose Marasigan, EPRI
National Energy Technology Laboratory

www.netl.doe.gov
DOE/NETL IGCC Dynamic Simulator Research and Training Center IGCC Process Descriptions
Revision 1: Summary of Revisions - List of Affected Pages
Section/
Change
Page No.
Section 4.2, Changed 5th bullet to reflect that the Gasifier output will also respond to
Page 53 changes in oxygen quality at the input of the Gasifier.
Section 4.2, Changed 3rd bullet to reflect that the model must be capable of cold,
Page 53 warm, and hot startups as stated in the spec.
Section 4.3,
Added Gasifier load control loop to the control scheme for the Gasifiers.
Page 54
Added Gasifier Condition control loop to the control scheme for the
Section 4.3,
Gasifiers to control gasifier temperature and steam output of the RSC
Page 54
Cooler.
Added the following malfunctions
o Lock hopper recycle flow reduced by fouling
Section 4.6, o Forming of slag lumps due to wrong gasifier conditions
Page 64 o Bad coal conversion due to wrong gasifier conditions
o By-as burners
o Blockage or overloading of slag crusher.
Gasifier Deleted steam connection from the ammonia stripper to the slag
System PFD’s lockhopper flush drum on the fourth pfd shown for the Gasifier System,
(4th PFD) GAS-FD-003
Section, 5.0 Added collection of chlorides as a function of the Syngas Scrubbing
Page 70 System through the collection of halogens.
Section 5.2, Added water pH as a parameter to be modeled and monitored to the first
Page 72 bullet of modeling expectations.
Added the following malfunctions:
Section 5.5, o Entrainment of water
Page 75 o Drifting pH of scrubber water
o Bad Scrubber function (excess Chlorides in scrubber gas outlet)
Sour Water
Deleted unnecessary stream from the Syngas scrubber KO drum.
Stripper PFD
Section 9.0, Added the following main components for the Mercury Removal System
Page 99 to reflect the inclusion of adsorbent regeneration
Rewrote Description of Mercury Removal Process to enhance the
Section 9.1,
information provided. Also added information on Regeneration of the
Page 99
Adsorbent in the last paragraph of the section.
Added the following modeling expectations to the Mercury Removal
System
Section 9.2,
o The operator will have the capability to start and stop each of the
Page 101
Gas Recycle Blowers.
o Liquid Mercury and water flow from the Mercury Drum need not be
ii
Section/
Change
Page No.
modeled.
o A constant level will be indicated for the Mercury Removal Drum.
o The operator will have the ability to bypass the Regeneration
Separator.
o When in use, the Regeneration Separator will provide liquid/gas
separation and a constant flow of product slipstream regeneration
gas to the main syngas supply line to the Acid Gas Removal
System.
Section 9.3, Added Syngas Temperature Control, Syngas Turndown, and Hg
Page 102 Removal Control to the Digital Control loops
Added Syngas Temperature Control, Syngas Turndown, and Hg
Section 9.4,
Concentration in Product Syngas to the HMI requirements for the
Page 102
Mercury Removal Process
Section 9.4, Amended amounts of Process Instrumentation to reflect the inclusion of
Page 102 an adsorbent regeneration system
Mercury
Amended PFD to reflect the inclusion of an adsorbent regeneration
Removal
system
System PFD
Section 12, Added wording to first function to state relationship between expander
Page 126 outlet temperature and gas dew point
Section 12.1, Added information to paragraph three to better describe relationships
Page 126 between gas dew point temperature and expander outlet temperature.
Inserted information (now paragraph four) to state that Pressure control
Section 12.1, of the Syngas entering the Expander will be based on the Syngas
Page 126 pressure upstream of the Fuel Gas Heater and pressure relief to flare.
Stated that the CT will control Expander backpressure.
Section 12.2,
Deleted “humidity” from modeling expectations.
Page 127
Section 12.3, Changed “Pressure Control of the Syngas exiting”, to “Pressure Control
Page 127 of the Syngas entering” in second bullet for train 1.
Added third bullet for train 1 to control scheme stating, “Pressure Control
Section 12.3,
of the Syngas exiting the Acid Gas Removal System (PV-003) with set
Page 127
pressure about 15 psi above PV-001”
Section 12.3, Changed “Pressure Control of the Syngas exiting”, to “Pressure Control
Page 127 of the Syngas entering” in second bullet for train 2.
Added third bullet for train 2 to control scheme stating, “Pressure Control
Section 12.3,
of the Syngas exiting the Acid Gas Removal System (PV-003) with set
Page 127
pressure about 15 psi above PV-001”
Section 12.4, Changed number of pressure and temperature indications for each train
Page 128 from “1” to “2” each to reflect inclusion of alarms.
Section 12.5, Changed malfunctions to the following items:
iii
Section/
Change
Page No.
Page 128 o Trip of Fuel Gas Expander – Syngas will be bypass the Fuel Gas
Expander and throttled to the appropriate pressure
o Slow reaction of transfer to bypass on expander trip –release of
gas to flare.
o Flare indication/alarm – open (or not closed) position of PV-003
and PV-103 can be used to signify this event
o Slow reaction of transfer to bypass on expander trip – drop of inlet
pressure to gas turbine.
o Loss of steam – Low temperature alarm on Expander exit.
Acknowledgments
The authors wish to acknowledge the contributions and support provided by the contractors who
reviewed this report and provided many useful remarks, corrections, and suggestions: Carlo
Wolters and Marco Kanaar from Gasification Solutions B.V., Jerry Henderson from Energy
Resources Consultancy International, LLC, and Dan Kubek from Gasification Processing
Solutions, LLC..
iv
Table of Contents
1. General IGCC Plant Description....................................................................... 11
1.1. Flowpath Description ............................................................................................. 12
1.1.1. Slurry Preparation ..................................................................................................... 13
1.1.2. Air Separation Unit .................................................................................................... 14
1.1.3. Gasifiers .................................................................................................................... 15
1.1.4. Syngas Scrubbers..................................................................................................... 16
1.1.5. Shift Reactors............................................................................................................ 16
1.1.6. Gas Cooling, MP and LP Steam Generation, and Knockout.................................... 17
1.1.7. Sour Water Stripper .................................................................................................. 17
1.1.8. Mercury Removal ...................................................................................................... 18
1.1.9. Selexol Acid Gas Removal ....................................................................................... 18
1.1.10. CO2 Compression ..................................................................................................... 20
1.1.11. Syngas Reheat and Expansion................................................................................. 21
1.1.12. Claus Plant................................................................................................................ 21
1.1.13. Hydrogenation Reactor and Gas Cooler................................................................... 22
1.1.14. Combustion Turbine-Generator Assemblies............................................................. 23
1.1.15. Heat Recovery Steam Generators and Steam Turbine-Generator .......................... 24
2. Slurry Preparation System ............................................................................... 27
2.1. Description of Slurry Preparation Process.............................................................. 28
2.2. Slurry Preparation System Modeling Expectations................................................. 29
2.3. Slurry Preparation System Controls ....................................................................... 30
2.4. Slurry Preparation System HMI Screens................................................................ 30
2.5. Slurry Preparation System Malfunctions ................................................................ 32
2.6. Slurry Preparation System Interconnections .......................................................... 33
2.7. Slurry Preparation System References .................................................................. 33
3. Air Separation Unit............................................................................................ 35
3.1. Description of Air Separation Unit Process............................................................. 36
3.2. Air Separation Unit Modeling Expectations ............................................................ 38
3.3. Air Separation Unit Controls................................................................................... 39
3.4. Air Separation Human-Machine Interface (HMI) Screens....................................... 40
3.5. Air Separation Unit System Malfunctions ............................................................... 43
3.6. Air Separation Unit Interconnections ...................................................................... 44
3.7. Air Separation Unit System References ................................................................. 44
4. Gasifier ............................................................................................................... 48
4.1. Description of Gasifier Process .............................................................................. 49
4.2. Gasifier Unit Modeling Expectations....................................................................... 55
4.3. Gasifier Controls .................................................................................................... 56
4.4. Gasifier Human-Machine Interface (HMI) Screens ................................................. 60
4.5. Gasifier Interconnections ....................................................................................... 65
4.6. Gasifier Malfunctions ............................................................................................. 66
4.7. Gasifier System References .................................................................................. 66
5. Syngas Scrubbers............................................................................................. 72
v
5.1. Description of Syngas Scrubber Process ............................................................... 72

5.2. Syngas Scrubber Modeling Expectations............................................................... 74
5.3. Syngas Scrubber Controls ..................................................................................... 75
5.4. Syngas Scrubber Human-Machine Interface (HMI) Screens .................................. 76
5.5. Syngas Scrubber System Malfunctions.................................................................. 77
5.6. Syngas Scrubber Interconnections ........................................................................ 77
5.7. Syngas Scrubber System References.................................................................... 78
6. Shift Reactors .................................................................................................... 80
6.1. Description of Process .......................................................................................... 80
6.2. Modeling Expectations........................................................................................... 83
6.3. Controls ................................................................................................................. 84
6.4. Human-Machine Interface (HMI) Screens .............................................................. 85
6.5. System Malfunctions.............................................................................................. 86
6.6. Interconnections .................................................................................................... 87
6.7. System Startup Considerations.............................................................................. 87
6.8. System References................................................................................................ 87
7. Gas Cooling, MP and LP Steam Generation and Knockout........................... 89
7.1. Description of Gas Cooling, MP and LP Steam Generation, and Knockout ............ 89
7.2. Gas Cooling, MP and LP Steam Generation and Knockout Modeling Expectations90
7.3. Gas Cooling, MP and LP Steam Generation and Knockout Controls ..................... 91
7.4. Gas Cooling, MP and LP Steam Generation and Knockout Human-Machine Interface
(HMI) Screens ................................................................................................................... 92
7.5. Gas Cooling, MP and LP Steam Generation and Knockout System Malfunctions .. 93
7.6. Gas Cooling, MP and LP Steam Generation and Knockout Interconnections......... 93
7.7. Gas Cooling, MP and LP Steam Generation and Knockout System References.... 94
8. Sour Water Strippers......................................................................................... 96
8.1. Description of Process .......................................................................................... 96
8.2. Modeling Expectations........................................................................................... 97
8.3. Controls ................................................................................................................. 98
8.4. Human-Machine Interface (HMI) Screens .............................................................. 98
8.5. System Malfunctions.............................................................................................. 99
8.6. Interconnections .................................................................................................... 99
8.7. System References................................................................................................ 99
9. Mercury Removal ............................................................................................ 101
9.1. Description of Mercury Removal Process ............................................................ 101
9.2. Mercury Removal Modeling Expectations ............................................................ 103
9.3. Mercury Removal Controls................................................................................... 104
9.4. Mercury Removal Human-Machine Interface (HMI) Screens ............................... 104
9.5. Mercury Removal Interconnections...................................................................... 105
9.6. Mercury Removal References.............................................................................. 105
vi
10. Selexol Acid Gas Removal with CO2 Capture ............................................... 108
10.1. Description of Selexol Acid Gas Removal Process .............................................. 109
10.2. Selexol Acid Gas Removal System Modeling Expectations ................................. 112
10.3. Selexol Acid Gas Removal System Controls........................................................ 113
10.4. Selexol Acid Gas Removal System HMI Screens................................................. 114
10.5. Selexol Acid Gas Removal System Malfunctions ................................................. 116
10.6. Selexol Acid Gas Removal System Interconnections ........................................... 117
10.7. Selexol Acid Gas Removal System References................................................... 118
11. CO2 Compression............................................................................................ 121
11.1. Description of CO2 Compression Process............................................................ 121
11.2. CO2 Compression Modeling Expectations............................................................ 122
11.3. CO2 Compression Controls .................................................................................. 123
11.4. CO2 Compression Human-Machine Interface (HMI) Screens............................... 124
11.5. CO2 Compression Malfunctions ........................................................................... 125
11.6. CO2 Compression Interconnections ..................................................................... 125
11.7. CO2 Compression System References ................................................................ 126
12. Syngas Reheat and Expansion ...................................................................... 128
12.1. Description of Process ........................................................................................ 128
12.2. Modeling Expectations......................................................................................... 129
12.3. Controls ............................................................................................................... 129
12.4. Human-Machine Interface (HMI) Screens ............................................................ 130
12.5. System Malfunctions............................................................................................ 130
12.6. Interconnections .................................................................................................. 131
12.7. System References.............................................................................................. 131
13. Claus Plant....................................................................................................... 133
13.3. Controls ............................................................................................................... 136
13.4. Human-Machine Interface (HMI) Screen.............................................................. 137
14. Hydrogenation Plant and Gas Cooler ............................................................ 140
14.3. Controls ............................................................................................................... 143
14.4. Human-Machine Interface (HMI) Screen.............................................................. 143
vii
15. Combustion Turbine Units ............................................................................. 147

15.1. Combustion Turbine Units Overview and Descriptions......................................... 147
15.1.1. Component Overview.............................................................................................. 147
15.1.2. Component Descriptions......................................................................................... 147
15.2. Combustion Turbine Units Modeling Expectations ............................................... 148
15.2.1. Simulation Model Architecture ................................................................................ 148
15.2.2. Description of Pressure and Flow Calculation Process .......................................... 149
15.2.3. Description of Combustion Process........................................................................ 150
15.2.4. Evaporative Cooler Model....................................................................................... 151
15.2.5. Turbine Temperatures, Speed and Power.............................................................. 152
15.2.6. Lubricating, Seal, and Trip Oil System Model......................................................... 154
15.2.7. Hydraulic and Lift Oil System Model ....................................................................... 156
15.2.8. Turning Gear and LCI Static Starter ....................................................................... 157
15.2.9. Turbine Supervisory Information............................................................................. 157
15.2.10. Compressor Inlet Vanes and Valves....................................................................... 158
15.3. Combustion Turbine Malfunctions........................................................................ 158
15.4. Combustion Turbine Remote Functions ............................................................... 159
15.5. Combustion Turbine External Parameters............................................................ 160
15.6. Combustion Turbine Fuel Systems ...................................................................... 161
15.6.1. Natural Gas Fuel System ........................................................................................ 161
15.6.2. Natural Gas System Malfunctions........................................................................... 162
15.6.3. Natural Gas System Remote Functions.................................................................. 162
15.6.4. Natural Gas System External Parameters .............................................................. 163
15.6.5. Syngas Fuel System ............................................................................................... 163
15.6.6. Syngas System Malfunctions.................................................................................. 164
15.6.7. Syngas System Remote Functions......................................................................... 165
15.6.8. Syngas System External Parameters ..................................................................... 165
15.7. Instrument / Service Air System ........................................................................... 166
15.7.1. Air Systems Model .................................................................................................. 166
15.7.2. BOP Service Air Compressors................................................................................ 166
15.7.3. BOP Instrument/Service Air Pressures................................................................... 166
15.7.4. IA Pressure ............................................................................................................. 166
15.8. Controls and Human-Machine Interface (HMI) Screens for Combustion Turbine and
Generator Assemblies ..................................................................................................... 166
15.8.1. Control Loops and Logic ......................................................................................... 167
15.8.2. Human-Machine Interface....................................................................................... 167
15.9. Alarms ................................................................................................................. 168
15.10. Generator Cooling................................................................................................ 169
15.10.1. Generator Temperatures Model.............................................................................. 169
15.10.2. Generator Stator and H2 Temperatures.................................................................. 169
15.10.3. Hydrogen Coolers ................................................................................................... 169
15.10.4. Generator Cooling Related Malfunctions ................................................................ 170
15.11. Electrical System ................................................................................................. 170
15.11.1. Switchyard............................................................................................................... 171
15.11.2. Electrical Generators............................................................................................... 172
15.11.3. Excitation System.................................................................................................... 173
15.11.4. Generator Main & Aux. Transformers ..................................................................... 173
15.11.5. Generator Output Breakers and Disconnects ......................................................... 173
15.11.6. Generator Protection............................................................................................... 174
15.11.7. Electrical Distribution............................................................................................... 174
15.11.8. Electrical Network Model Theory ............................................................................ 174
15.11.9. Station Service Transformers ................................................................................. 175
viii
15.11.10. 4160 V AC Distribution............................................................................................ 175

15.11.11. 4160 V / 480V Transformers................................................................................... 175
15.11.12. 480V AC Distribution............................................................................................... 176
15.11.13. 125V DC Distribution............................................................................................... 176
15.11.14. Battery and Battery Charger ................................................................................... 176
15.11.15. UPS ......................................................................................................................... 176
15.11.16. Electrical System Malfunctions ............................................................................... 176
15.11.17. Electrical System Remote Functions ...................................................................... 177
15.12. Combustion Turbine Units Modeling Details......................................................... 178
16. Heat Recovery Steam Generator (HRSG), Steam Turbine and BOP ........... 180
16.1. HRSG Overview................................................................................................... 180
16.1.1. Water and Steam Side Flow Paths ......................................................................... 181
16.1.2. Hot Gas Heat Transfer Flow Path........................................................................... 182
16.1.3. Combustion Turbine Exhaust Constituents ............................................................ 183
16.1.4. Component Descriptions......................................................................................... 184
16.1.5. HRSG Malfunctions................................................................................................. 190
16.1.6. HRSG Remote Functions ....................................................................................... 192
16.2. Condensate System............................................................................................. 192
16.2.1. Condensate System Description............................................................................. 192
16.2.2. Condensate System Control Methodology ............................................................. 193
16.2.3. Condensate thermo-hydraulic network solution...................................................... 194
16.2.4. Condensate System Malfunctions .......................................................................... 195
16.2.5. Condensate System Remote Functions ................................................................. 196
16.3. Feedwater System ............................................................................................... 196
16.3.1. Feedwater System Description ............................................................................... 196
16.3.2. Feedwater System Control Methodology................................................................ 197
16.3.3. Feedwater System Malfunctions............................................................................. 198
16.3.4. Feedwater System Remote Functions.................................................................... 199
16.4. Circulating Water System..................................................................................... 199
16.4.1. Circulating Water System Description .................................................................... 199
16.4.2. Circulating Water System Modeling Approach ....................................................... 199
16.4.3. Circulating Water System Malfunctions .................................................................. 200
16.4.4. Circulating Water System Remote Functions ......................................................... 200
16.5. Service Water System ......................................................................................... 200
16.5.1. Service Water System Description ......................................................................... 200
16.5.2. Service Water System Modeling Approach ............................................................ 201
16.5.3. Service Water System Malfunctions ....................................................................... 201
16.5.4. Service Water System Remote Functions .............................................................. 202
16.6. Controls and Human-Machine Interface (HMI) Screens for HRSG’s and Balance of
Plant 203
16.6.3. Alarms ..................................................................................................................... 204
16.7. Steam Turbine ..................................................................................................... 205
16.7.1. Description of Model ............................................................................................... 205
16.7.2. Turbine Supervisory Information............................................................................. 206
16.7.3. Modeling Approach for the Steam Turbine ............................................................. 206
16.7.4. Steam Turbine Malfunctions ................................................................................... 209
16.7.5. Steam Turbine Remote Functions .......................................................................... 209
16.8. Steam Turbine Generator .................................................................................... 209
16.8.1. Description of Model ............................................................................................... 209
16.8.2. Excitation System.................................................................................................... 209
ix
16.8.3. Modeling Approach for the Generator..................................................................... 210

16.8.4. Generator Malfunctions........................................................................................... 210
16.8.5. Generator Remote Functions.................................................................................. 211
16.9. Steam Turbine Generator Cooling ....................................................................... 211
16.9.1. Generator Temperatures Model.............................................................................. 211
16.9.2. Generator Stator and H2 Temperatures.................................................................. 211
16.9.3. Hydrogen Coolers ................................................................................................... 211
16.9.4. Generator Cooling Related Malfunctions ................................................................ 212
16.10. Controls and Human-Machine Interface (HMI) Screens for Steam Turbine and
Generator Assembly........................................................................................................ 212
16.11. Alarms ................................................................................................................. 213
16.12. HRSG, Steam Turbine and BOP Modeling Details............................................... 214
x
1. General IGCC Plant Description

The generic IGCC power plant produces 746 MW gross (556-megawatt net) electric
power and consists of dual-train gasifiers producing clean syngas for combustion in two
(2) F-class advanced combustion turbines with a combined net output of 464 MW. The
exhaust of each combustion turbine (CT) is sent through a heat recovery steam
generator (HRSG) and produces steam that is supplied to a steam turbine (ST) having a
net output of 275 MW. A syngas expander supplies an additional 6.3 MW of net output.
This document provides a conceptual design of the DOE/NETL IGCC Dynamic

Simulator reference plant. In this context, conceptual design means that all of the major
components and systems and the relevant control loops have been defined. The basis
of the simulator conceptual design is the engineering model of the IGCC Power Plant
included as Case 2 in the DOE / NETL’s report “Cost and Performance Comparison of
Fossil Energy Power Plants Volume 1, Bituminous Coal and Natural Gas to Electricity
Final Report (DOE/NETL-2007/1281), Rev. 1 August 2007.” A Process Flow Diagram
of Case 2 is presented below in Figure 1.
Figure 1– Case 2 Process Flow Diagram, GEE IGCC with CO2 Capture
11
1.1. Flowpath Description
The systems, and their associated subsystems listed in the associated Process
Description are:
Slurry Preparation
Air Separation Unit
Gasifiers
Syngas Scrubbers
Shift Reactors
Gas Cooling, MP and LP Steam Generation, and Knockout
Sour Water Stripper
Mercury Removal
Selexol™ Acid Gas Removal System
CO2 Compression
Syngas Reheat and Expansion
Claus Plant
Hydrogenation Reactor and Gas Cooler
Combustion Turbine-Generator Assemblies
Heat Recovery Steam Generators and Steam Turbine-Generator
12
1.1.1. Slurry Preparation
Fuel Conveying
There are four material storage silos which are maintained full of coal, coke, and a flux
(limestone or dolomite). Silos 1 and 2 hold coal, Silo 3 holds petroleum coke, and Silo 4
holds the flux. Each silo has a weighfeeder beneath it to measure and convey the
material from the silo to the Main Feed Conveyors for trains 1 and 2.
The Main Feed Conveyors collect the coal, coke, and flux from each of the silo material
weighfeeders and convey the material to Mill Feed Conveyors, of which there is one per
train that feed the Mill Inlet Chutes. “MODE” selection is available to permit the
following modes of operation and blending
Slurry Preparation
There are two Slurry Preparation trains which feed the two Slurry Run Tanks. The
combination of feed material from the conveying system, slag and fines water, viscosity
modifier, and grinding water from the Grinding Water Drum are fed into the rod mill
inlets. The Rod Mill grinds the fuel and water mixture into an acceptable slurry. The
trommel screen allows the acceptable slurry to go to the Mill Discharge tanks while
some of the larger particles are dumped in to the collection bins. A Variable speed Mill
Discharge Pump for each mill train controls the Discharge Tanks level and pumps the
slurry to the Slurry Run Tanks.
Diverters at the inlet of the Slurry Run Tanks permit the operator to select which Run
tank is being filled while the Slurry Preparation System is in service. Vibrating screens
are located at the inlet to the Slurry Run Tanks. These screens serve to remove
additional large particles that were not removed by the trommel screens. The rejects
from the vibrating screens are routed to another set of collection bins.
A Slurry Pump at the outlet of each Slurry Run Tank pumps the slurry to the inlet of
each of the Gasifiers. Prior to entering the Gasifier(s), the slurry is preheated in the
Slurry Preheater. This reduces the amount of fuel necessary for gasification of the coal
slurry. The Slurry Pumps can be cross connected to receive slurry from either of the
Slurry Run Tanks.
The grinding water drum also supplies water in its own process loop through the
Grinding Water Pump which supplies flushing water to the mill outlet strainers and
cooling water to both Mill Vapor Condensers. Grinding water which flows through the
Mill Vapor Condensers returns to the Grinding Water Drum in a closed loop. The
Grinding Water Control Valve uses the Mill Feed Conveyor Rate in tons per hour of
material being sent to each mill inlet chute.
13
1.1.2. Air Separation Unit
The air separation plant is designed to produce 95 mole percent O2 for use in the
gasifier and Claus Plants. The plant is designed with two production trains, one for
each gasifier. The air compressor is powered by an electric motor. Moderate purity
nitrogen (99% N2) is also recovered, compressed, and used as diluent in the gas
turbine combustor, adsorbent regeneration, system startup purge, and for emergency
shutdown in other units. Higher purity nitrogen (99.9 % N2) is used as an inerting agent
and purge gas in various plant sections.
The air feed to the ASU is supplied from a stand-alone main air compressor and
supplemented by pressurized air extracted from the gas turbine. Air to the stand-alone
compressor is first filtered in a suction filter upstream of the compressor. This air filter
removes particulate, which may cause compressor wheel erosion and foul intercoolers.
The filtered air is then compressed in the centrifugal compressor, with intercooling
between each stage.
Air from the stand-alone main air compressor is cooled and fed to an adsorbent-based
pre-purifier system (also known as a mole sieve). The adsorbent removes water,
carbon dioxide, and C4+ saturated hydrocarbons in the air. After passing through the
adsorption beds, the air is filtered with a dust filter to remove any adsorbent fines that
may be present.
Regeneration of the adsorbent in the pre-purifiers is accomplished by passing a hot

nitrogen stream through the off-stream bed(s) in a direction countercurrent to the normal
airflow. The nitrogen is heated against extraction steam (250 psia) in a shell and tube
heat exchanger. The regeneration nitrogen drives off the adsorbed contaminants.
Following regeneration, the heated bed is cooled to near normal operating temperature
by passing a cool nitrogen stream through the adsorbent beds. The bed is re-
pressurized with air and placed on stream so that the current on-stream bed(s) can be
regenerated.
The air from the pre-purifier is then split into three streams. (1) About 70 percent of the
air is fed directly to the cold box. (2) About 25 percent of the air is compressed in an air
booster compressor. This boosted air is then cooled in an aftercooler against cooling
water in the first stage and against chilled water in the second stage before it is fed to
the cold box. The chiller utilizes low pressure process steam at (50 psia). (3) The
remaining 5 percent of the air is fed to a turbine-driven, single-stage, centrifugal booster
compressor. This stream is cooled in a shell and tube aftercooler against cooling water
before it is fed to the cold box.
All three air feeds are cooled in the cold box to cryogenic temperatures against
returning product oxygen and nitrogen streams in plate-and-fin heat exchangers. The
large air stream is fed directly to the HP distillation column to begin the separation
process. The second largest air stream is liquefied against boiling liquid oxygen before
it is fed to the HP distillation column. The third, smallest air stream is fed to the
14
cryogenic expander to produce refrigeration to sustain the cryogenic separation process

and sent to the LP column.
Inside the distillation column the air is separated into oxygen and nitrogen products.
The oxygen product is withdrawn from the distillation column bottoms as a liquid and is
pressurized by a cryogenic pump. The pressurized liquid oxygen is then vaporized
against the high-pressure air feed before being warmed to ambient temperature. The
gaseous oxygen exits the cold box and is fed to the centrifugal compressor with
intercooling between each stage of compression. The compressed oxygen is then fed
to the gasification unit. Some low pressure oxygen is sent to the Claus units.
Nitrogen is produced from the cold box at two pressure levels. Low-pressure nitrogen is
split into two streams. The majority of the low-pressure nitrogen is compressed and fed
to the gas turbine as diluent nitrogen. A small portion of the nitrogen is used as the
regeneration gas for the pre-purifiers and recombined with the diluent nitrogen. A high-
pressure nitrogen stream is also produced from the cold box and is further compressed
before it is also supplied to the gas turbine.
1.1.3. Gasifiers
This plant utilizes two gasification trains to process a total of 5,448 tonnes per day of
coal at an operating pressure of 5.6 MPa (815 psia). Each of the 2 x 100 percent
Gasifiers operates at maximum capacity.
A Slurry Pump takes suction from the Slurry Run Tanks, and the slurry feed discharge is
sent to the feed injector of the Gasifier. Oxygen from the ASU is vented during
preparation for startup and is sent to the feed injector during normal operation. The air
separation plant supplies 4,635 tonnes per day of 95 mole percent oxygen to the
Gasifiers and Claus plant. The Oxygen that is sent to the Gasifier inlet first passes
through a preheater to preheat the oxygen coming from the air separation unit.
The Gasifier vessel is a refractory-lined, high-pressure reaction chamber. The coal

slurry feedstock and oxygen are fed through a fuel injector at the top of the Gasifier
vessel. The coal slurry and the oxygen react in the Gasifier at 5.6 MPa (815 psia) and
approximately 1,316°C (2,400°F) to produce syngas.
The gasification reactions take place in near adiabatic conditions. There is some heat
loss through the refractory-lined walls to the environment, but with a new refractory
lining the heat loss is only 0.2% of the slurry feed heating value.
15
1.1.4. Syngas Scrubbers
The purpose of the Syngas Scrubbers is to clean the syngas by separating the solids
and entrained liquids from the syngas. The Syngas Scrubber system also collects and
recycles the quench water used in the gasifier quench ring and dip tube. In addition, it
controls the level of chlorides and other contaminants in the scrubber water system by
bleeding some of the water off to the Vacuum Flash System.
The syngas exiting the RSC/Quench chamber is sent to the Syngas Scrubber. The
syngas also contains entrained solids (flyash and char) and water. Just before entering
the scrubber vessel the syngas passes through a venturi nozzle scrubber where
process condensate is mixed with the gas and wets the entrained solids. The mixture of
syngas, wetted solids and entrained liquid enters the scrubber vessel where the
entrained solids and liquid droplets are removed from the gas flow via centrifugal force.
The raw syngas exits the top of the Syngas Scrubber.
Quench Water System
The Quench Water System provides the Quench chamber with quench water that is
recirculated from the Syngas Scrubber.
The Syngas Scrubber (RSC/Quench Water) Pumps pump water and solids from the
bottom of the syngas scrubber vessel a takeoff line of the Syngas Scrubber to the
quench ring in the Quench chamber RSC. The solids from the scrubber settle in the
RSC sump along with the RSC course slag, both are flushed through the lockhopper
system. The solids are processed by the slag handling system where the course and
fine slag is separated and processed. Before flowing through the quench ring the water
passes through the Quench Water Strainers for removal of any entrained solids or pipe
scale. Both pumps and strainers operate simultaneously and the pumps have separate
suction lines and discharge lines (to strainer) to ensure maximum availability of quench
water.
1.1.5. Shift Reactors
The conversion of CO to CO2 for this plant is achieved by sour gas shift (SGS), where
the water-gas (CO-) shift reaction occurs prior to removal of the acid gas from the
synthesis gas. The shift reactors also serve to hydrolyze COS, which eliminates the
need for a separate COS hydrolysis reactor. They also decompose metal carbonyls,
formic acid, and hydrogen cyanide.
The SGS is placed after the Gasifier and subsequent syngas cooling, but before further
gas cooling in preparation for the de-Sulfurization step of the Acid Gas Removal Unit.
This flow scheme is depicted in the following general process flow diagram.
16
1.1.6. Gas Cooling, MP and LP Steam Generation, and Knockout
Gas Cooling and MP and LP Steam Generation
Syngas leaves the Water-Gas Shift (WGS) system and passes through a series of gas
coolers which also act to heat boiler feedwater and to produce steam at two pressures.
The syngas coming from the WGS system first enters the syngas / MP Boiler Feedwater
Heat Exchanger. The first stage of syngas cooling lowers the temperature
approximately 70° Fahrenheit as the Medium Pressure Boiler Feedwater passes
through the heat exchanger. The Boiler Feedwater is heated to Medium Pressure
Steam and enters a Medium Pressure steam header.
The syngas leaves the first stage of cooling and enters the second stage where it is
cooled by Low Pressure Boiler Feedwater passing through the heat exchanger. The LP
Boiler Feedwater heat exchanger lowers the temperature of the syngas by
approximately 115° Fahrenheit. The Low Pressure Boiler Feedwater is heated to LP
Steam and enters a Low Pressure steam header.
The third stage of syngas cooling takes place as the syngas enters the Final Syngas
Cooler to cool the syngas prior to entering the Mercury Removal System. The Final
Syngas Cooler uses process cooling water to lower the temperature of the syngas to
approximately 100° Fahrenheit on its way to the Knockout Drum and Mercury Removal
Beds.
Under normal operation, liquids should not condense out of the syngas until it reaches
the Final Syngas Cooler. However during start-up, shutdown, part-load and other
transients, condensate may form in the upstream heat exchangers.
Knockout
The syngas enters a Knockout Drum where any liquid in the syngas is collected. The
resulting Process Condensate liquid is pumped to the Syngas Scrubber system.
The level in the Knockout Drum is maintained by a split signal level controller.
1.1.7. Sour Water Stripper
The sour water stripper removes H2S, NH3, and other impurities from the syngas
scrubber and other waste streams.
The stripper system consists of a sour drum that accumulates sour water from the
syngas scrubber and condensate from syngas coolers. Sour water from the drum flows
to the sour water stripper, which consists of a packed column with a steam-heated
reboiler. As the sour water flows down the tower, sour gas is stripped from the liquid by
steam. The sour gas and steam rise to the tower cooling section.
17
The overhead sour gas flows through a top condenser air cooler and from there the
sour gas is sent to the sulfur recovery unit. The condensate is fed back to the stripper.
The stripped water is collected in the tower bottom and is either recycled back to the
process or sent to wastewater treatment. To maintain a minimum required flow through
the stripper, a recycle will be operational when the sour water feed flow to the stripper is
too low. The bottom flow is cooled to meet design specifications for the stripper
condensate.
1.1.8. Mercury Removal
Syngas leaving each of the Final Syngas Coolers in the Gas Cooling System is
superheated to approximately 5ºF above its water dewpoint in a Mercury Removal
Preheater using MP boiler feedwater. The purpose of the preheating is to prevent
condensation within the activated carbon beds. After leaving the preheater, the syngas
is passes to through a set of packed activated Carbon Beds that is designed to remove
mercury from the syngas. The syngas exiting the Carbon Bed is cooled in a Mercury
Removal Aftercooler prior to entering the Acid Gas Removal System.
Removal of mercury is necessary to prevent corrosion of heat exchangers, and to

remove it from the product gas stream and meet environmental regulations. After
passing through the activated carbon beds where mercury is removed from the syngas,
the syngas enters the Acid Gas Removal System.
1.1.9. Selexol Acid Gas Removal
The Selexol Acid Gas Removal Process (AGR) with CO2 Capture removes the
Hydrogen Sulfide (H2S) and Carbon Dioxide (CO2) gas from the shifted raw syngas
Stream, creating three product streams: clean syngas for the combustion turbine, H2S-
rich acid gas for use in the Claus Plant, and CO2 for sequestration. There are three
major vessels in the AGR process, the H2S Absorber, CO2 Absorber and the Stripper.
Both Absorber columns use Selexol for H2S and CO2 capture. Selexol is a physical
solvent which has an affinity to absorb both CO2 and H2S at high partial pressures and
low temperature and will release those gases when the solvent is depressurized and
heated. CO2 stripping is accomplished by flashing the gas off at various pressures.
H2S is stripped from the Selexol through reboiling and recirculation action.
Selexol H2S Absorber
Raw shifted Syngas from the gasification process is fed to the Selexol H2S Absorber.
Here, the cooled syngas is fed into the lower section of the Absorber below the
Absorber mixing trays. The syngas leaves the top of the H2S absorber. “Loaded”
solvent pumped from the bottom of the CO2 Absorber is cooled in the Loaded Solvent
Coolers and fed to the upper section of the H2S Absorber where it flows down across
18
the mixing trays. At this point, the solvent absorbs H2S in the syngas and becomes
“rich” solvent. This rich solvent flows out of the bottom of the Absorber through the Rich
Solvent Strainer which removes any solids that may be contained in the liquid. The rich
solvent then flows through a Lean/Rich Heat Exchanger where the rich solvent is
heated by lean solvent coming from the Stripper. After this preheating takes place, the
hot, rich solvent flows to the inlet of the H2S Concentrator where it partially flashed via
depressurization.
The stripped gases from the H2S Concentrator (predominantly CO2) are cooled, dried,
compressed and sent back to the raw syngas inlet of the H2S Absorber. The solvent
leaving the bottom of the H2S Concentrator is sent to the Stripper so that the remaining
gases in the rich solvent are liberated.
The clean or “sweet” fuel syngas flows out of the top to the H2S Absorber to the CO2
Absorber vessel.
Selexol Stripper
In the Stripper, rich solvent is heated in order to separate the H2S from the solvent.
Rich solvent from the H2S Concentrator enters the chimney portion of the Stripper at the
top, and the H2S that is easily separated vaporizes and goes off the top the unit,
together with the rest of the stripped steam and a small portion of the entrained Selexol.
This acid gas stream is cooled, so the condensed steam and the Selexol will enter the
stripper again as reflux. A small portion of the reflux will be blown off to keep the water
content of the Selexol constant. The solvent in the Selexol stripper is heated in the
Selexol Reboiler. The Reboiler uses low pressure steam (at approximately 50 psig) to
heat the solvent. The stripped steam rises in the column and aids in the separation of
the incoming rich solvent until the H2S exits at the top.
There are two major flows out of the Selexol Stripper, lean solvent that is recirculated
back to the CO2 Absorber from the Stripper bottom, and H2S-rich acid gas that flows out
of the top of the Stripper.
Lean solvent at the bottom of the Stripper is supplied to the inlet of the 2 x 100%
capacity Lean Solvent Pumps. The in-service pump discharges the lean solvent
through a strainer and pumps the lean solvent through the Lean/Rich Heat Exchangers
where the lean solvent is cooled as it preheats the rich solvent flowing to the H2S
Concentrator. The lean solvent then flows through the Lean Solvent Cooler where it is
cooler further prior to entering the chimney of the CO2 Absorber. In the CO2 Absorber,
the solvent cycle begins again by absorbing CO2 in the clean syngas coming from the
H2S Absorber.
The “sour” H2S-rich acid gas that is discharged from the top of the Stripper is routed
through an Acid Gas Cooler, where its temperature is lowered. Steam will condense
and any solvent remaining is removed from the sour gas. The Acid Gas Cooler is air
cooled by multiple speed fans. The exit temperature of the acid is controlled by
19
modulation of the Acid Gas Cooler Air Vanes. It is desirable to condense all the solvent
while keeping the temperature as high as possible so the H2S gas will not be absorbed
by the solvent. The condensed liquids removed from the acid gas stream are collected
in a Knock Out Drum and pumped back to the Stripper as reflux by either of the 2 x
100% capacity Reflux Pumps, while the acid gas exits from the Knock Out Drum and
leaves the Selexol Unit for processing in the Claus Plant to recover elemental Sulfur
from the H2S gas.
CO2 Absorber and CO2 Capture
The syngas leaving the H2S absorber is fed into the CO2 absorber. The CO2 Absorber
receives the lean solvent in the chimney portion of the structure near the top. The lean
solvent flows down over the upper tray and mixes with the semi-lean solvent from the
LP Flash Drum being fed at the top of the lower tray. This semi-lean solvent is the
resulting solvent flow after the CO2 Absorption and removal takes place. The gas outlet
of the CO2 absorber contains H2S and CO2.
A portion of the loaded solvent flow from the bottom of the CO2 Absorber is processed
for removal of captured H2 and CO2. The remainder flows to the Loaded Solvent
Pumps and eventually is used in the H2S Absorber.
The loaded solvent splits off for CO2 and H2 removal and is sent through a series of
three flash drums that operate at descending pressures (the first being the highest
pressure). The three drums involved in the CO2 removal process in order of flow are:
the H2 Recovery Drum operating at approximately 300 psia, the Medium Pressure (MP)
Flash Drum operating at approximately 150 psia and the Low Pressure (LP) Flash Drum
operating at approximately 75 psia.
H2 is recovered in the H2 Recovery Drum by flashing the loaded solvent, and then
compressing and cooling the resulting H2 and returning it to the CO2 Absorber syngas
inlet.
CO2 is recovered in the process as the solvent flashes in the MP and LP Flash Drums.
After the CO2 comes out of solution, it is sent to the CO2 Compression Unit.
1.1.10. CO2 Compression
Each CO2 Compression Train consists of a, five stage, intercooled, centrifugal CO2
Compressor connected to a Glycol dehydration system. Each compressor receives
CO2 at two different pressure levels from the CO2 capture portion of the Selexol Acid
Gas Removal System and raises the CO2 pressure from atmospheric, to about 2200 psi.
As a part of this process, the CO2 undergoes a phase shift from gas to supercritical fluid.
The CO2 from the LP Flash Drum of the Selexol system enters at the CO2 Compression
system at the 1st Stage Suction Drum. The CO2 from the MP Flash Drum of the Selexol
20
system enters the CO2 Compression system at the discharge of the 1st Stage
Aftercooler.
The pressure of the CO2 is raised as the gas passes from stage to stage. When the
CO2 reaches the end of the fourth stage, it passes to a Glycol Tower where the CO2 is
dried by mixing with Tri-ethylene Glycol, thereby minimizing the possibility of corrosion
in the transport piping due to moisture being present.
1.1.11. Syngas Reheat and Expansion
Clean syngas from the AGR system is combined with a small amount of clean gas from
the CO2 compression process and heated to 465°F using Cold Reheat steam before
passing through an expansion turbine.
The temperature of the syngas entering the Expander will be controlled by varying the
amount of steam entering the Fuel Gas Reheater. The condensed steam from the Fuel
Gas Reheater will be routed to the condenser.
The capability to bypass the Fuel Gas Expander will be included in the event of an
Expander trip or during startup. The bypass will include a pressure reducing station that
can accommodate startup conditions as well as a full load Expander trip. Isolation
valves for both the Expander and the pressure reducing station in the bypass line shall
be included.
1.1.12. Claus Plant
There is only one, oxygen-blown Claus Plant that receives acid gas from the AGR
system and sour gas from the sour water stripper. The Claus process converts H2S to
elemental sulfur.
The first reaction shown below is thermal and occurs in the reaction furnace. The
furnace temperature should be high enough to destroy any ammonia in the acid gas.
H2S + 3/2 O2 ↔ H2O + SO2
2H2S + SO2 ↔ 2H2O + 3S
One-third of the H2S is oxidized to SO2. The newly formed SO2 reacts with the
remaining H2S to form elemental sulfur. Since these reactions are highly exothermic, a
waste heat boiler, which recovers this heat to generate high-pressure steam while
cooling the process stream, usually follows the furnace. Sulfur is condensed in a
condenser that follows the high-pressure steam recovery section and is drained through
a seal leg to the sulfur pit. Low-pressure steam is raised in the condenser from further
cooling of the process gas.
21
The tail gas from the first condenser then goes to two catalytic conversion stages,
where the remaining sulfur is recovered via the Claus reaction:
3H2S + 3/2 O2 ↔ 3H2O + 3S
The Claus reaction is catalytic and equilibrium limited. The sulfur in the vapor phase
exists as S2, S6, and S8 molecular species, with the S2 predominant at higher
temperatures, and S8 predominant at lower temperatures.
Each catalytic stage consists of gas preheat (in the Converter Preheater), a catalytic
reactor (Sulfur Converter), and a Sulfur Condenser. Gas preheating is required prior to
entering the catalytic reactor to avoid sulfur condensing in the catalyst bed. In the
catalytic reactor, the Claus reaction takes place over a fixed bed of activated alumina
catalyst in which sulfur is formed. The reacted process gases then flow to the sulfur
condenser and are cooled while condensed sulfur drains to the sulfur pit. After the
second catalytic stage, the tail gas proceeds to the hydrogenation reactor for further
processing.
1.1.13. Hydrogenation Reactor and Gas Cooler
The tail gas from the Claus plant usually contains small but varying quantities of COS,
CS2, SO2, and elemental sulfur vapors. Sulfur recovery is increased by converting
these remaining sulfur compounds in the tail gas to H2S and then compressing the tail
gas and returning it to the Selexol AGR process.
The tail gas is first preheated in the Reactor Preheater with HP steam produced from
the Claus Waste Heat Boiler. The inlet temperature to the Hydrogenation Reactor is
controlled by adjusting the HP steam rate. An analyzer on the tail gas measures the H2
content of the stream and, if required, treated fuel gas from the Acid Gas Removal unit
is added to the reactor feed. The heated tail gas is hydrogenated where sulfur
compounds are reduced at elevated temperature. The following hydrogenation and
hydrolysis reactions occur in the hydrogenation reactor:
S + H2 → H2S
SO2 + 3H2 → H2S + 2H2O
CS2 + 2H2O → 2H2S + CO2
COS + H2O → H2S + CO2
The reactions are exothermic, and heat is removed from the gas in the Gas Cooler,
which produces LP steam.
22
The gas is further cooled in a Direct Contact Condenser (or Quench Tower). The gas
enters the condenser below the bottom trays and is contacted with caustic so that any
sulfur dioxide remaining in the gas is captured. The column bottoms is recycled in a
circulating loop and spent caustic is periodically removed from the loop and routed to
the effluent bio-treatment unit. Water from the Direct Contact Condenser is also
recycled with the following controls:
A pH indicator is included in the recycle.

When pH is too low, there is SO2 seep-through of the Hydrogenation reactor,
caused by too low inlet temperature of the reactor or too low H2 level in the feed of
the reactor. There is a risk that the Claus reaction takes place in the reactor and
gets solidified by sulfur.
When pH is too high, there is NH3 seep-through of the Claus reactor caused by too
low operating temperature of the thermal Claus. There is a risk then of corrosive salt
deposits in the DCC.
The scrubbed gas then flows up the condenser for direct quenching with water. The
water is removed from the chimney tray in the middle of the condenser and cooled in an
air cooler followed by a trim cooler with cooling water. If required, sour water is removed
from the system to maintain the water balance (flow rate is varied to control the liquid
level on the chimney tray). A portion of the water from the cooling loop may also be
diverted to the lower section of the condenser to maintain the liquid level in the bottom
of the column.
The contact condenser overhead gas is sent to the Tail Gas Knockout Drum to remove
entrained liquid before entering the Tail Gas Compressor. The compressed tail gas is
recycled back to the Acid Gas Removal unit.
1.1.14. Combustion Turbine-Generator Assemblies
The simulator shall model two independent combustion turbines (CT’s). Each CT shall
be directly coupled to a 3-phase AC generator driven at 3600 RPM by an extension of
the inlet compressor shaft. Each CT shall be capable of operating on either hydrogen-
rich syngas derived from coal gasification and various gas treatment processes or by
natural gas. CT’s shall be capable of transferring between fuels while maintaining
continuous operation at any load point. Furthermore, these CT’s shall be capable of
operating on any mixture between the two fuels.
Each combustion turbine shall be associated with a Heat Recovery Steam Generator
(HRSG) designed to recover the energy in the hot combustion turbine exhaust gas. The
combustion turbines are not able to operate in simple cycle mode. Under standard
conditions (59 degrees F., 29.92 in. hg.), each combustion turbine/generator assembly
shall be capable of delivering 232 MW on syngas fuel, and 185 MW on natural gas.
23
Purpose of the Combustion Turbine/Generator Assemblies are to:
Consume the flow of hydrogen-rich syngas supplied by the gasification island

Supply approximately 185 to 232 MWe depending on fuel
Supply a flow of hot exhaust gasses to their respective HRSG
1.1.15. Heat Recovery Steam Generators and Steam Turbine-Generator
HRSG’s
The simulator shall model two independent heat recovery steam generators, one for
each train. Each of these HRSG’s is a triple-pressure natural circulation water tube
steam generator that is designed to utilize exhaust energy available from its attached
CT. The HRSG design shall include high pressure, intermediate pressure, and low
pressure evaporator sections with superheater, drum, and economizer for each section.
The simulation shall model all of specified heat exchangers piping, tanks, valves, and
volumes specified. Each HRSG shall also be fitted with a selective catalytic reduction
grid with ammonia injection.
Exhaust gas from the CT is directed to the HRSG by the inlet transition duct. The
“setting” provides CT exhaust gas containment ductwork, encasement of various heat
recovery module units, and the exhaust stack. The HRSG setting includes ductwork
transitions for connection with CT outlet flange and HRSG module boxes.
Heat transfer is accomplished by a series of components arranged vertically and

perpendicular to the CT exhaust gas flow in a “double-wide” configuration. The heat
transfer surfaces are located in such a manner as to provide for maximum temperature
differential between the declining exhaust gas temperature and the temperature of the
steam and water inside the heat transfer surfaces.
In support of the coal gasification plant, the HRSG shall also be designed to supply an
adequate flow of heated feedwater to the syngas cooler equipment, and in return
receive a commensurate flow of high pressure steam which shall be used to augment
the HRSG’s production of high pressure steam. During times when the CT is operating
on natural gas, the syngas cooler feedwater supply and high pressure steam returns
shall be isolated.
The HRSG’s will have the following supporting systems, specified in the associated
Process Description in Appendix D:
Condensate System
Feedwater System
Circulating Water System
Service Water System
24
Steam Turbine
The function of turbine models is to convert the thermodynamic energy of main and
reheat steam into mechanical energy used to drive the generator rotor. LP, IP and HP
turbines are used. The reheat cycle takes HP exhaust steam and cycles it through the
HRSG. Reheat steam is returned to the IP turbine. The combined stop and control
valves regulate main steam flow to the turbine HP turbine. The combined reheat valves
control the admission of reheated steam into the IP turbine. The purpose of the stop,
control and intercept valves is to regulate the turbine speed, load, steam pressure and
to provide emergency protection. The positioning of these valves is performed by
Electro-hydraulic Control (EHC) System, where a combination of analog and digital
electrical signals is transformed by a high-pressure hydraulic fluid system. The Turbine
Supervisory Instrumentation (TSI) System, as implemented in the turbine control DCS,
monitors the following important turbine parameters:
Turbine eccentricity measured as the amount of bow in the turbine rotor at turning
gear speed.
Vibration of rotating shafts of the turbine and generator monitored at each bearing
for the purposes of recording and protective tripping.
Rotor-shell expansion due to differential temperature response of the turbine rotor
and shells.
Turbine temperatures monitored in order to minimize metal stress caused by thermal
gradients. Temperatures are measured at the stop valve, steam chest, HP turbine
first stage inner shell, and the IP turbine reheat bowl.
Water induction into the steam path of the turbine is monitored in order to prevent
serious damage to the high-pressure shells, rotors, buckets and bearings.
The turbine system also includes the turning gear, which rotates the turbine-generator
rotor train at slow speed (3-5 rpm) after the turbine shutdown to prevent the rotor
bowing and bearings overheating. Another use of the turning gear is to assist steam
flow in rolling off the turbine at startup.
The turbine lubricating oil supply provides cleaned and purified oil at regulated pressure
and temperature for lubrication and cooling of the rotor bearings of the turbine,
generator and exciter. Primary closed-loop cooling directly supplies oil to the turbine-
generator bearings.
The turbine hydraulic power supply provides a source of high-pressure fluid to convert
the electrical signals produced in the turbine’s analog and logic control circuits into
power for operating the turbine’s control and stop valves.
25
Generator
The electrical generator converts mechanical power from the prime mover (steam
turbine) into electrical energy for supply to the grid. The generator consists of a wire-
wound rotor that spins inside a wire-wound stator; the rotor windings are energized by a
separate excitation circuit, and creates a rotating magnetic and electrical field. This field
passes through the stationary windings of the stator to induce an electrical current and
terminal voltage. This voltage is stepped up to grid voltage by a transformer. Terminal
voltage strength and/or generator reactive power are determined by the field excitation,
transformer step-up ratios, and grid conditions.
The Generator shall have the following supporting system:

Steam Turbine Generator Cooling System
26
2. Slurry Preparation System

The simulator reference plant includes two Slurry Preparation trains. Each one feeds
an individual Gasifier train, but can be cross connected with the opposite Gasifier train if
necessary.
The purpose of the Slurry Preparation System is to:
Grind the raw fuel feed (coal, coke, flux) into slurry for use.
Transport, preheat and store the slurry for use as fuel in the Gasifier.
The Slurry Preparation System is shown in flow diagram SLURRY-FD-1 at the end of
this document. The system is comprised of the following main components:
Coal Silo 1
Coal Weighfeeder 1
Coal Silo 2
Coal Weighfeeder 2
Coke Silo 3
Coke Weighfeeder 1
Coke Weighfeeder 2
Flux Silo 4
Flux Weighfeeder 1
Flux Weighfeeder 2
Main Feed Conveyor 1
Main Feed Conveyor 2
Mill Feed Conveyor 1
Mill Feed Conveyor 2
Mill Inlet Chute (2)
Viscosity Modifier Injection System
Horizontal Rod Mills (2).
Mill Motor, Clutch and Control System (2)
Mill Discharge Tanks (2)
Mill Discharge Tank Agitators (2)
Mill Discharge Pumps (2)
Diverters
Slurry Run Tanks (2)
Slurry Run Tank Agitators (2)
Slurry Pumps (2)
Slurry Preheater
Mill Vapor Condensers (2)
Grinding Water Drum
Grinding Water Pump
Slurry Mill Ejector
Vibrating Screen
27
2.1. Description of Slurry Preparation Process
Referring to SLURRY-FD-1 at the end of this document:
Fuel Conveying
There are four material storage silos which are maintained full of coal, coke, and a flux
(limestone or dolomite). Silos 1 and 2 hold coal, Silo 3 holds petroleum coke, and Silo 4
holds the flux. Each silo has a weighfeeder beneath it to measure and convey the
material from the silo to the Main Feed Conveyors for trains 1 and 2.
The Main Feed Conveyors collect the coal, coke, and flux from each of the silo material
weighfeeders and convey the material to Mill Feed Conveyors, of which there is one per
train that feed the Mill Inlet Chutes. “MODE” selection is available to permit the
following modes of operation and blending. These modes are as follows:
o Coal only
o Coal + Coke
o Coke only
o Coal + Flux
o Coke + Flux
o Coal + Coke + Flux.
Conveyor systems are normally interlocked so that a conveyor failure results in the
tripping of all upstream conveyors.
Normal Conveyor interlocks include

o Broken belt
o Belt tracking
o Downstream conveyors must be started first (last to first)
Conveyor interlocks should be modified so that the interlocks are dependent on the
“Mode” selected
Weigh Feeders have similar interlocks and must be started in the last to first sequence
also.
Slurry Preparation
There are two Slurry Preparation trains which feed the two Slurry Run Tanks. The
combination of feed material from the conveying system, slag and fines water, viscosity
modifier, and grinding water from the Grinding Water Drum are fed into the rod mill
inlets. The Rod Mill grinds the fuel and water mixture into an acceptable slurry. The
trommel screen allows the acceptable slurry to go to the Mill Discharge tanks while
some of the larger particles are dumped in to the collection bins. A Variable speed Mill
Discharge Pump for each mill train controls the Discharge Tanks level and pumps the
slurry to the Slurry Run Tanks.
28
Diverters at the inlet of the Slurry Run Tanks permit the operator to select which Run
tank is being filled while the Slurry Preparation System is in service. Vibrating screens
are located at the inlet to the Slurry Run Tanks. These screens serve to remove
additional large particles that were not removed by the trommel screens. The rejects
from the vibrating screens are routed to another set of collection bins.
A Slurry Pump at the outlet of each Slurry Run Tank pumps the slurry to the inlet of
each of the Gasifiers. Prior to entering the Gasifier(s), the slurry is preheated in the
Slurry Preheater. This reduces the amount of fuel necessary for gasification of the coal
slurry. The Slurry Pumps can be cross connected to receive slurry from either of the
Slurry Run Tanks.
The grinding water drum also supplies water in its own process loop through the
Grinding Water Pump which supplies flushing water to the mill outlet strainers and
cooling water to both Mill Vapor Condensers. Grinding water which flows through the
Mill Vapor Condensers returns to the Grinding Water Drum in a closed loop. The
Grinding Water Control Valve uses the Mill Feed Conveyor Rate in tons per hour of
material being sent to each mill inlet chute.
2.2. Slurry Preparation System Modeling Expectations
It is anticipated that the Slurry Preparation System will be a functional model that allows
the operator to complete the startup, shutdown and normal monitoring of system
equipment.
There are a number of operational issues and considerations that control the
performance and reliability of the Slurry Preparation System. Each of these issues will
impact the training effectiveness of the simulator and shall be taken into account when
developing the model. In order to address these issues and achieve the fidelity of
simulation desired for research and operator training, the simulator model of the Slurry
Preparation System, the following parameters should be addressed in the model at a
minimum:
System pressures, flows, levels, and temperatures will respond to changes in

system operation.
Changes in the combustion properties of the slurry based upon varying the coal
/coke mixture as well as varying the heating capacity of the coal and coke.
Slurry viscosity will vary based upon the amount of coal, flux, grinding water and
viscosity modifier fed into the Rod Mills.
Slurry pH will vary based upon the amount of pH additive added to the mill, the
pH and flow rate of the water sent to the mill and the Coal and Coke constituents.
Variable feeder speeds for all coal, coke, and sand/crushed granite feeders.
Changes in individual mill loading are corollary to the amount of material being
fed to the feeder inlets. Rod Charge also has a pronounced affect on mill KW.
Slurry preheating should be accomplished by supplying a Low or Medium
pressure steam supply source.
29
2.3. Slurry Preparation System Controls
At a minimum, the following control schemes will be included as part of the simulator
model:
Train 1 Grinding Water Flow Control (FV-101)

LB/HR or GPM ratioed to amount of coal or coke being delivered to mill
Train 2 Grinding Water Flow Control (FV-102)
LB/HR or GPM ratioed to amount of coal or coke being delivered to mill
Train 1 Fines Water Flow Control (FV-103)
LB/HR or GPM ratioed to coal or coke being delivered to mill inlet
Train 2 Fines Water Flow Control (FV-104)
LB/HR or GPM ratioed to coal or coke being delivered to mill inlet
Coal Weighfeeder 1 Speed Control (tons per hour)
Coal Weighfeeder 2 Speed Control (tons per hour)
Coke Weighfeeder 1 Speed Control (tons per hour)
Coke Weighfeeder 2 Speed Control (tons per hour)
Flux Weighfeeder 1 Speed Control (tons per hour)
Flux Weighfeeder 2 Speed Control (tons per hour)
Main Feed Conveyor 1 Speed Control (tons per hour)
Main Feed Conveyor 2 Speed Control (tons per hour)
Mill Feed Conveyor 1 Speed Control (tons per hour)
Mill Feed Conveyor 2 Speed Control (tons per hour)
VM Flow Control to Inlet Chute 1 (lb/hr)
Ratioed to coal or coke flow
pH Additive Flow Control to Inlet Chute 1 (lb/hr)
VM Flow Control to Inlet Chute 2 (lb/hr)
pH Additive Flow Control to Inlet Chute 2 (lb/hr)
2.4. Slurry Preparation System HMI Screens
It is anticipated that there will need to be two Human-Machine Interface (HMI) Screens
associated with the Slurry Preparation System.
The HMI Screens shall be in a mimic diagram format with pop-up faceplates for the
controls. It is assumed that one HMI screen will contain the Fuel Conveying System
controls and instrumentation. The other will contain the Slurry Preparation Controls and
Instrumentation.
The two HMI Screens for the Slurry Preparation process will include the process mimic,
controls and instrumentation shown in SLURRY-FD-1and will include:
30
Fuel Conveying HMI

Analog Control Loops
o Coal Weighfeeder 1 Speed Control
o Coal Weighfeeder 2 Speed Control
o Coke Weighfeeder 1 Speed Control
o Coke Weighfeeder 2 Speed Control
o Flux Weighfeeder 1 Speed Control
o Flux Weighfeeder 2 Speed Control
o Grinding Water Control Valve Position
Digital Control Loops
o Coal Silo 1 Slide Gate Control
o Coal Silo 2 Slide Gate Control
o Coke Silo 3 Slide Gate A Control
o Coke Silo 3 Slide Gate B Control
o Flux Silo 4 Slide Gate A Control
o Flux Silo 4 Slide Gate B Control
o Main Feed Conveyor 1 Start/Stop Control
o Main Feed Conveyor 2 Start/Stop Control
o Mill Feed Conveyor 1 Start/StopControl
o Mill Feed Conveyor 2 Start/Stop Control
Process Instrumentation and Indication
o Coal Weighfeeder 1 Speed/weight
o Coal Weighfeeder 2 Speed/weight
o Coke Weighfeeder 1 Speed/weight
o Coke Weighfeeder 2 Speed/weight
o Sand/Granite Flux Weighfeeder 1 Speed/weight
o Sand/Granite Flux Weighfeeder 2 Speed/weight
o Coal Silo 1 Slide Gate Position
o Coal Silo 2 Slide Gate Position
o Coke Silo 3 Slide Gate A Position
o Coke Silo 3 Slide Gate B Position
o Sand/Granite Flux Silo 4 Slide Gate A Position
o Sand/Granite Flux Silo 4 Slide Gate B Position
o Alarm indications
Analog Control Loops and Indication
o Mill Discharge Tank 1 Level Control
o Mill Discharge Tank 2 Level Control
o Slurry Run Tank 1 Level Indication and HI/LO alarm only)
o Slurry Run Tank 2 Level Indication and HI/LO alarm only)
o Grinding Water Drum Level Control
o BM Pump Control Mill 1
o pH Additive Pump to Mill 1
o VM Pump Control to Mill 2
o pH Additive Pump Control to Mill 2
o Alarm indications
31
Digital Control Loops and indication

o Horizontal Rod Mill Train 1 Motor Control
o Horizontal Rod Mill Train 2 Motor Control
o Horizontal Rod Mill Train 1 Clutch Control
o Horizontal Rod Mill Train 2 Clutch Control
o Mill Discharge Pump 1 Start/stop Control
o Mill Discharge Pump 2 Start/Stop Control
o Mill 1 Lubricating Oil System Control
o Mill 2 Lubricating Oil System Control
o Slurry Pump 1 Control
o Slurry Pump 2 Control
o Grinding Water Pump Control
o Vibrating screen control
o Diverter control and position
o Slurry Mill Ejector Control?
Process Instrumentation
o Level Indications (5)
o Flow Indications
o Feeder Speeds for all Feeders and Conveyors
o Fuel Conveyance for each of the feeders (feeder output in tons per hour)
o Valve Position Indications for all operable valves and diverters
o Slurry Density on Slurry Pump Discharge
o Mill KW (2)
2.5. Slurry Preparation System Malfunctions
Failures or degradation in the operation of system equipment will be modeled to provide

realistic training, engineering modeling, and theory-to-practice data. At a minimum, the
following malfunctions will be modeled for the :
Weighfeeder Malfunctions (improper scaling, speed, broken belt, etc)

Plugged Silo Chutes
Loss of Mill Lube Oil System
High mill reject rates, low mill KW or combustion changes that indicate rod must
be added to mills
Failure of Slurry Feed Pump
Failure of Mill Discharge Tank Pump
32
2.6. Slurry Preparation System Interconnections
Slurry Supply to Gasifier 1

Slurry Supply to Gasifier 2
Slurry Discharge to the Slurry Area Sump
Closed Cooling Water supply and return to:
o Mill Vapor Condenser 1
o Mill Vapor Condenser 2
Condensate return from the Stripper Reboiler to the Grinding Water Drum
Condensate return from the AGR System Acid Gas Coolers
Caustic Supply to the Grinding Water Drum and Mill inlets
Slag and Fines Water to the Mills
Viscosity Modifier to the Mills
Slurry pH Additive to Mills
Mill Discharge pump to slag handling
Steam to slurry preheat
Steam from slurry preheat
2.7. Slurry Preparation System References
The following references served as a basis for the conceptual design of each of the
system described in this Process Description:
Higman, C, and Van der Burgt, M. (2008). Gasification. (2nd Edition). Oxford:
Elsevier.
Higman, C, and Van der Burgt, M. (2003). Gasification. Oxford: Elsevier
US Department of Energy, National Energy Technology Laboratory. (2007a).
DOE/NETL. (2007). Cost and Performance Comparison of Fossil Energy Power
Plants Study Volume 1: Bituminous Coal and Natural Gas to Electricity.
Available online at http://www.netl.doe.gov/energy-
analyses/pubs/Bituminous%20Baseline_Final%20Report.pdf.
33
1 2 3 4 5 6 7 8 9 10
A A
COAL COAL COKE FLUX

SILO #1 SILO #2 SILO #3 SILO #4
B CAUSTIC B
SUPPLY
SLAG & FINES WATER

SLURRY
WEIGH FEEDER WEIGH FEEDER WEIGH FEEDER WEIGH FEEDER TRAIN # 1 MILL EJECTOR
MAIN FEED CONVEYOR
COAL
WEIGH FEEDER WEIGH FEEDER MILL FEED CAUSTIC

CONVEYOR
MILL STARTUP
WARMUP
INLET
CHUTE WCCS STRIPPED CONDENSATE
MILL VAPOR
C MAIN FEED CONVEYOR WCCS COND. GRINDING C
FLASHED GAS
WATER
DRUM COND. COOLERS TO
AGITATOR
MILL DIVERTER SLAG
MILL FEED AGITATOR HANDLING
CONVEYOR AGITATOR
MILL LT
DISCHARGE
TANK
LT
SLURRY SLURRY
MILL VAPOR LT
CAUSTIC RUN RUN
SUPPLY
RECIRCULATION
VISCOSITY MODIFIER ADDITIVE
STARTUP LINE
SLAG & FINES WATER
MILL DISCHARGE
D PUMP D
TRAIN # 2
COAL
GRINDING WATER PUMP SLURRY SLURRY
PUMP 1 PUMP 2
RECIRCULATION
STARTUP LINE
MILL STARTUP
INLET TO GASIFIER 1
CHUTE WCCS
MILL VAPOR
WCCR COND. SLURRY
PREHEAT
TO GASIFIER 2
AGITATOR
MILL
E E
MILL LT
DISCHARGE DIVERTER
TANK DRAIN / FLUSH
STEAM TO SLURRY
PREHEAT
MILL DISCHARGE
FOSSIL CONSULTING SERVICES, INC.
PUMP COLUMBIA, MARYLAND, USA
DOE-NETL-IGCC
F SIMULATOR F
SLURRY PREPARATION
SYATEM
FLOW DIAGRAM
DATE DRAWING NO. REV.
05/28/2008 SLURRY-FD-1 B
1 2 3 4 5 6 7 8 9 10
34
3. Air Separation Unit

The purpose of the Air Separation Unit (ASU) is to:
Supply high pressure, high purity oxygen to the Gasifier Feed Injectors.
Supply Oxidant to the Claus Plant
Supply diluent nitrogen to the Combustion Turbines
Supply nitrogen to the AGR System for H2S Concentration
Supply purge nitrogen to the Gasifiers and Combustion Turbines
Produces liquid oxygen and nitrogen for storage
The IGCC includes two ASU trains, one for each gasifier. Each ASU train is comprised
of the following main components:
Air Inlet Filters

Main Air Compressor (MAC)
Main Air Compressor (MAC) Aftercooler
MAC Wash Water Tank
MAC Wash Water Pump
2 x 100% MAC Lubricating Oil Pumps
MAC Lubricating Oil Sump
Direct Contact Aftercooler
Evaporative Cooler
2 x 100% DCA Recirculation Pumps
Diluent Nitrogen Compressor
2 x 100% DNC Lubricating Oil Pumps
DNC Lubricating Oil Sump
2 x 100% Prepurifiers
Prepurifier Regenerative Heater and Cooler
Recycle Nitrogen Cooler
Primary Heat Exchanger
Lower Column Booster Expander
Lower Column Booster Compressor
2 x 100% LCT Lubricating Oil Pumps
LCT Lubricating Oil Sump
Main Condenser (integral to Cold Box)
Nitrogen Superheater
2 x 100% Liquid Oxygen Pumps
Buffer Vessel
35
3.1. Description of Air Separation Unit Process
Referring to figures ASU-FD-1, ASU-FD-2, and ASU-FD-3 at the end of this document:
The air separation plant is designed to produce 95 mole percent O2 for use in the
gasifier and Claus Plants. The plant is designed with two production trains, one for
each gasifier. The air compressor is powered by an electric motor. Moderate purity
nitrogen (99% N2) is also recovered, compressed, and used as diluent in the gas
turbine combustor, adsorbent regeneration, system startup purge, and for emergency
shutdown in other units. Higher purity nitrogen (99.9 % N2) is used as an inerting agent
and purge gas in various plant sections.
The air feed to the ASU is supplied from a stand-alone main air compressor and
supplemented by pressurized air extracted from the gas turbine. Air to the stand-alone
compressor is first filtered in a suction filter upstream of the compressor. This air filter
removes particulate, which may cause compressor wheel erosion and foul intercoolers.
The filtered air is then compressed in the centrifugal compressor, with intercooling
between each stage.
Air from the stand-alone main air compressor is cooled and fed to an adsorbent-based
pre-purifier system (also known as a mole sieve). The adsorbent removes water,
carbon dioxide, and C4+ saturated hydrocarbons in the air. After passing through the
adsorption beds, the air is filtered with a dust filter to remove any adsorbent fines that
may be present.
Regeneration of the adsorbent in the pre-purifiers is accomplished by passing a hot

nitrogen stream through the off-stream bed(s) in a direction countercurrent to the normal
airflow. The nitrogen is heated against extraction steam (250 psia) in a shell and tube
heat exchanger. The regeneration nitrogen drives off the adsorbed contaminants.
Following regeneration, the heated bed is cooled to near normal operating temperature
by passing a cool nitrogen stream through the adsorbent beds. The bed is re-
pressurized with air and placed on stream so that the current on-stream bed(s) can be
regenerated.
The air from the pre-purifier is then split into three streams. (1) About 70 percent of the
air is fed directly to the cold box. (2) About 25 percent of the air is compressed in an air
booster compressor. This boosted air is then cooled in an aftercooler against cooling
water in the first stage and against chilled water in the second stage before it is fed to
the cold box. The chiller utilizes low pressure process steam at (50 psia). (3) The
remaining 5 percent of the air is fed to a turbine-driven, single-stage, centrifugal booster
compressor. This stream is cooled in a shell and tube aftercooler against cooling water
before it is fed to the cold box.
All three air feeds are cooled in the cold box to cryogenic temperatures against
returning product oxygen and nitrogen streams in plate-and-fin heat exchangers. The
36
large air stream is fed directly to the HP distillation column to begin the separation
process. The second largest air stream is liquefied against boiling liquid oxygen before
it is fed to the HP distillation column. The third, smallest air stream is fed to the
cryogenic expander to produce refrigeration to sustain the cryogenic separation process
and sent to the LP column.
Inside the distillation column the air is separated into oxygen and nitrogen products.
The oxygen product is withdrawn from the distillation column bottoms as a liquid and is
pressurized by a cryogenic pump. The pressurized liquid oxygen is then vaporized
against the high-pressure air feed before being warmed to ambient temperature. The
gaseous oxygen exits the cold box and is fed to the centrifugal compressor with
intercooling between each stage of compression. The compressed oxygen is then fed
to the gasification unit. Some low pressure oxygen is sent to the Claus units.
Nitrogen is produced from the cold box at two pressure levels. Low-pressure nitrogen is
split into two streams. The majority of the low-pressure nitrogen is compressed and fed
to the gas turbine as diluent nitrogen. A small portion of the nitrogen is used as the
regeneration gas for the pre-purifiers and recombined with the diluent nitrogen. A high-
pressure nitrogen stream is also produced from the cold box and is further compressed
before it is also supplied to the gas turbine.
37
3.2. Air Separation Unit Modeling Expectations
It is anticipated that the Air Separation Unit System will be a first principle model that
allows the operator to complete the startup, shutdown and normal monitoring of system
equipment.
The ASU is a very tightly integrated unit. It is difficult to get stabilized and takes a long
time to reach steady-state with the right compositions so high fidelity modeling is
important.
performance and reliability of the Air Separation Unit System. Each of these issues will
simulation desired for research and operator training, the simulator model of the Air
Separation Unit System, the following parameters should be addressed in the model at
a minimum:
System composition, pressures, flows, levels, and temperatures will respond to

changes in system operation.
Diluent Nitrogen flowrate and oxygen concentration and its response to changes
in system operation and CT loading
Distillation columns will be modeled using a tray by tray approach with either
theoretical equilibrium trays or actual trays.
Air Separation Unit (cold box) operation is modeled with a rigorous cold box
model with second law heat transfer limitations.
The model changes in response to a leak in the main condenser.
Changes in system output (Diluent Nitrogen and Liquid Oxygen) due to changes
in MAC Loading and GT extraction air flow.
MAC Lubricating Oil, DNC Lubricating Oil, and LCT Lubricating Oil System
Operation will be simply modeled.
Breakthrough of hydrocarbons and CO2 from the mole sieves.
The simulation model must be shown to match a steady state heat and material
balance using a commercially available steady state simulator. If such a heat
and material balance is not provided, then one must be provided by the generic
IGCC vendor as validation of the dynamic model at normal operating conditions.
Ambient temperature and humidity.
ASU inlet flow control is driven by 02 demand for the gasifier and Claus Plant
DGAN control shall be modeled as part of GT control
The mol sieve sequence shall be modeled
38
3.3. Air Separation Unit Controls
model:
Air Separation Unit Train 1 Controls
Main Air Compressor Inlet Pressure Control (PV-050)

Diluent Nitrogen Pressure Supply Control (PV-051)
Prepurifier Line Temperature and Pressure Control (PV-052, 053)
LCT Booster Compressor Inlet Pressure Control (PV-054)
LCT Outlet Temperature Control (TCV-055)
DCA Level Control (LCV-056)
Evaporator Flow Control (PV-057, LCV-058, LV-059)
Kettle Feed Control (LV-060)
Kettle Reflux Flow Control (FV-061)
Lower Column Level Control (LV-062)
Primary Heat Exchanger Level Control (LV-063)
Liquid N2 Flow Control (FV-064)
LCT Expander Pressure Control (PV-068)
Prepurifier Recirculation Control (FV-076)
ASU inlet flow control (driven by O2 demand Gasifier and Claus)
Note: Valves and controls for Air Separation Unit Train 2 are the same as 1. The
difference in numbering is the leading numeral being a “1” vice a “0”. (e.g. PV-150 vice
PV-050)
Main Air Compressor Inlet Pressure Control (PV-150)

Diluent Nitrogen Pressure Supply Control (PV-151)
Prepurifier Line Temperature and Pressure Control (PV-152, 153)
LCT Booster Compressor Inlet Pressure Control (PV-154)
LCT Outlet Temperature Control (TCV-155)
DCA Level Control (LCV-156)
Evaporator Flow Control (PV-157, LCV-158, LV-159)
Kettle Feed Control (LV-160)
Kettle Reflux Flow Control (FV-161)
Lower Column Level Control (LV-162)
Primary Heat Exchanger Level Control (LV-163)
Liquid N2 Flow Control (FV-164)
LCT Expander Pressure Control (PV-168)
Prepurifier Recirculation Control (FV-176)
ASU inlet flow control (driven by O2 demand Gasifier and Claus)
39
3.4. Air Separation Human-Machine Interface (HMI) Screens
It is anticipated that there will need to be six (three per ASU train) Human-Machine
Interface (HMI) Screens associated with the Air Separation Unit System.
controls. It is assumed that one HMI screen will contain the Main Air Supply controls
and instrumentation, the second will contain the Nitrogen and Prepurifiers controls and
instrumentation, and the third will contain the Cryogenic Unit and Argon Refining
controls and instrumentation.
The six (three per ASU train) HMI Screens for the Air Separation process will include
the process mimic, controls and instrumentation shown in ASU-FD-1, ASU-FD-2, and
ASU-FD-3, and will include:
Main Air Supply A HMI:

Analog Control Loops:
o Main Air Compressor Inlet Pressure Control
o DCA Level Control
o Evaporator Flow Control
Digital Control Loops:
o Main Air Compressor Control
o Wash Water Pump Control
o Pressure Indications (5)
o Temperature Indications (5)
o Differential Pressure Indications (1)
o Flow Indications (2)
o Valve Position Indications for all operable valves
Nitrogen and Prepurifiers A HMI:

o Diluent Nitrogen Compressor Anti Surge Control
o Prepurifier Line Temperature and Pressure Control
o LCT Booster Compressor Warmup Flow Control
o LCT Booster Compressor Outlet Temperature Control
o Diluent Nitrogen Compressor Inlet Pressure Control
o LCT Expander Flow Control
o Nitrogen Recycle Blower Control
o Lower Column Turbine Booster Compressor Control
40
o CO2 analyzer (downstream of purifiers)
o Dewpoint analyzer (downstream of purifiers)
o Total hydrocarbon analyzer (downstream of purifiers)
Cryogenic Unit A HMI:

o LP Level Control
o Kettle Feed Control
o Liquid Nitrogen Flow Control
o Kettle Gas Flow Control
o O2 Quality Control
o O2 Flow Control (Gasification Demand)
o LIN Reflux Control

o None
o O2 concentration analyzers (2, one for O2 stream, and one for
purge N2)
Main Air Supply B HMI:

o Main Air Compressor Inlet Pressure Control
o DCA Level Control
o Evaporator Flow Control

o Main Air Compressor Control
o Wash Water Pump Control
41

Nitrogen and Prepurifiers B HMI:

o Diluent Nitrogen Compressor Anti Surge Control
o Prepurifier Line Temperature and Pressure Control
o LCT Booster Compressor Warmup Flow Control
o LCT Booster Compressor Outlet Temperature Control
o Diluent Nitrogen Compressor Inlet Pressure Control
o LCT Expander Flow Control
o Nitrogen Recycle Blower Control
o Lower Column Turbine Booster Compressor Control
o CO2 analyzer (downstream of purifiers)
o Dewpoint analyzer (downstream of purifiers)
o Total hydrocarbon analyzer (downstream of purifiers)
Cryogenic Unit B HMI:
o LP Level Control
o Kettle Feed Control
o Liquid Nitrogen Flow Control
o Kettle Gas Flow Control
o 02 Quality Control
o 02 Flow Control (Gasification Demand)
o LIN Reflux Control
o None
o O2 concentration analyzers (2, one for O2 stream, and one for
purge N2)
42
3.5. Air Separation Unit System Malfunctions

Oxygen Leakage
MAC motor driver trip
N2 Diluent compressor motor driver trip
Filter Plugging (MAC, DNC)
Heat Exchanger Tube Leakage
Gas Piping / Component Leakage
CO2 break through mol-sieve
Steam Valve failure in regeneration sequence causing to low temperature during
regeneration and consequently a bad regeneration.
Valve failures in mol sieve sequence.
Failure of direct contact cooler causing a higher H2O load to the mol-sieves
Malfunction of compander, causing less cooling capacity
Reduced Compressor capacity as a result of recycle valves of compressors
opening (or not closed)
Rising level in LP column
Reboiler valve fails closed or not allowing sufficient flow
Drifted analyzer(s) causing fault interpretation of presented value
43
3.6. Air Separation Unit Interconnections

o Main Air Compressor
o Main Air Compressor Aftercooler
o LCT Booster Compressor Aftercooler
o Diluent Nitrogen Compressor
o Diluent Compressor Aftercooler
o Recycle Nitrogen Cooler
Demineralized Water as makeup to the DCA / Evaporator
175 psia Steam to the Prepurifier Regenerative Heater and Cooler
Process Condensate Return from Prepurifier Regenerative Heater and Cooler
Liquid Oxygen System (includes oxygen storage and vaporizers)
Bleed Air from gas turbine
3.7. Air Separation Unit System References
Allam, R.J., Castle-Smith, H., Smith, A., Sorensen, J., Stein, V. (2000). Air
Separation Units, Design and Future Development. Paper presented at ECOS
2000 Gasification of Coal, Biomass and Oil. The Netherlands. Available online at
http://www.airproducts.com/NR/rdonlyres/6753032F-A8B8-4339-A12F-
BB1A8DB46735/0/ECOS.pdf.
Elsevier.
44
A B C D E F G H I J K L M N O P
TO
PREPURIFIERS
20 20
FE
PT TE
MAC INLET
PRESSURE DIRECT CONTACT TO PAGES
MAIN AIR CONTROL VENT AFTERCOOLER 2&3
PDI
18 COMPRESSOR SPARGER 18
PT
AIR FILTER
PV-050
INLET
4TH MAC
1ST 2ND 3RD
16 THRU TE PT AFTERCOOLER TE 16
6TH PT
LT
GUIDE
VANES SPARGER
INLET AIR
FLOW
HP NITROGEN FOR
14 14
WCCS WCCS PURGING
IN OUT
LEVEL
CONTROL
TE
12 LV-058
12
PT
WCCS WCCS NITROGEN TO
DILUENT
WCR WCR COMPRESSOR
10 LCV-056 10
LEVEL
CONTROL
LV-059
SPARGER
8 8
FLOW
PV-057
CONTROL
FT TE
LT
SPARGER
CHILLED 6
6
DCA N2
FROM PRIMARY
RECIRC HEAT EXCHANGER
PUMPS EVAPORATOR
WATER
HP NITROGEN FOR
DEMINERALIZED
PURGING
4 4
ASU
GASIFIER
2 DEMIN. WATER 2
1
45
FROM DIRECT CONTACT

AFTERCOOLER
2 2
0 0
PREPURIFIERS PREPURIFIER REGENERATIVE HEATER AND COOLER
AIR FLOW EXPANDER
PT TE
NO FLOW RECIRCULATION FROM FLOW
PAGE 1 CONTROL
FV-076
TE PT
VENT
TE VENT COLD NITROGEN
1 PREPURIFIER 1 175# 1
8 ALUMINA STEAM 8
SILICATE TO TE
PREPURIFIER
PURGE SYSTEM HOT NITROGEN
CONDENSATE FV-080
FT PT
1 1
6 FV-070 FV-072 6
FV-074 PREPURIFIER
PV-052
TO BLAC
LINE TEMP &
TEMP. ADJUST. AIR INLET PRESS FROM PRIMARY
PT TE PRESS HEAT
CONTROL LOWER COLUMN TURBINE
CONTROL EXCHANGER
PV-053 FT TE
BOOSTER COMPRESSOR
FV-075 SEAL 1
1 GAS
4 4
REGEN N2
FV-073 PREPURIFIER 2
FV-071
ALUMINA
TE
SILICATE PT
LCT LCT
WARMUP BOOSTER EXPANDER
FLOW
CONTROL PV-068
CO2 ANALYZER
1 1
2 PT 2
FT
FROM
H2O DEWPOINT FV-065
EVAPORATIVE
COOLER NITROGEN INSTRUMENT AIR
RECYCLE FV-067
BLOWER WCCS TOTAL PT
HYDROCARBONS
PV-054
1 1
KV-066
0 0
INLET OUTLET
VENT SURGE VENT
PV-710 WCCS AFTERCOOLER WCCS

DNC ANTI
SURGE PV-051
CONTROL
DILUENT N2 COMPRESSOR
8 8
TE
PT OUTLET
TEMP
1ST 3RD 4TH CONTROL
2ND TO PRIMARY
STAGE STAGE STAGE
STAGE HEAT
EXCHANGER
TCV-055
6 WCCS 6
DNC
AFTERCOOLER
FROM PRIMARY
INLET HEAT
PV-069 EXCHANGER
PRESSURE
FT
CONTROL TE
FROM AIR TO EVAPORATIVE

4 FLOW / PURGE TO 4
COOLER
FT COLUMN
PT
DILUENT N2
TO TURBINE
WCCS WCR
TO EVAPORATIVE COOLER
2 2
2
46
2 TO SUMP 2
0
HP NITROGEN FOR 0
WHEN PURGE
STORAGE
LIQUID N2 FROM LIQUID IS FULL
FLOW NITROGEN SEPARATOR
FT CONTROL
LIQUID N2 FEED LV-060 LIQUID O2 STORAGE 1

1
8 FC-064 8
NITROGEN SUPERHTR O2
ANALYZER
START-UP LINE 1
1
6 6
FT TE
REFLUX
LV-061
TE
FEED
LP
1 LV-062 1
TE
4 TO COLUMN 4
SHELF N2
C2
FT
O2 KETTLE
FEED LT
TE PRIMARY
1 CONTROL 1
2 HEAT BUFFER 2
LP COLUMN
VESSEL
EXCHANGER LEVEL
LT CONTROL
FC
TO LIQUID N2
TO LIQUID NITROGEN FT TE STORAGE
SEPARATOR
1 1
0 0
DURING
RAMP
O2
QUALITY C1 ANALYZER
CONTROL
8 LV-063 8
N2 ANALYZER
PRIMARY LT
FROM AIR FLOW HEAT NITROGEN TO H2S

PAGE 1 EXCHANGER CONCENTRATOR (AGR)
FT
LCT BOOTER 6
6
NITROGEN TO RECYCLE N2 COMPRESSOR
FT
AIR RETURN TO LCT LIQUID O2 RECIRC
FT TE
O2
REFLUX
LIQUID O2 TO OXYGEN TO PUMPS
THC ANALYZER 4
4
AIR FROM LCT FC
HIGH PRESS. N2 TO UPPER COLUMN FROM RECYCLE N2 COMPRESSOR

FLOW
O2 DEMAND CONTROL
CLASIFICATION
2 QUALITY 2
DGANO2
CONTROL
3
47
4. Gasifier
There are two, 50% capacity Gasifier trains.
The purpose of the Gasifier is to:
Produce syngas by reacting coal or coke slurry with oxygen in a high

temperature environment.
The purpose of the Radiant Syngas Cooler (RSC)/Quench Section is to:

Cool the syngas and molten slag exiting the gasifier to a temperature below the
melting point of the slag while recovering heat as HP steam
Provide a means to separate the syngas from the course slag and fines.
Each Gasifier Train is comprised of and supported by the following main components:
Gasifier Feed Injector

Slurry Charge Pump
Slurry Preheater
Gasifier Preheat Burner (Startup Injector fired with natural gas)
Injector CW Drum
Injector CW Cooler
Injector CW Pumps (2)
Oxygen Preheater
Gasifier
Radiant Syngas Cooler
Radiant Syngas Cooler Steam Drum
Radiant Syngas Cooler Recirculation Pumps (2)
Quench Chamber
Vacuum Tank
Vacuum Condenser
Caustic Tank
Caustic Pump
Flash Gas Scrubber
Recycle Condensate Pump
Slag Lockhopper
Slag Lockhopper Flush Drum
Slag Lockhopper Circulating Pump
Emergency Shutdown System: The emergency shutdown system is a separate
(independent of the main plant process control system) monitoring and control
system that mainly monitors the gasifier and RSC for unsafe conditions. When
the ESS determines that an unsafe condition exists the gasifier is automatically
and immediately shutdown. Triconex was the vendor selected by Bechtel for this
system
48
Nitrogen Purge System: Used to purge O2 lines between shutdown valves and
injector after gasifier shutdown
Steam Purge System: Used to purge slurry lines between shutoff valves and
feed injector
4.1. Description of Gasifier Process
Referring to figures GAS-FD-4, GAS-FD-5, GAS-FD-2, and GAS-FD-3 at the end of this
document:
This plant utilizes two gasification trains to process a total of 5,448 tonnes per day of
coal at an operating pressure of 5.6 MPa (815 psia). Each of the 2 x 100 percent
Gasifiers operates at maximum capacity.
A Slurry Pump takes suction from the Slurry Run Tanks, and the slurry feed discharge is
sent to the feed injector of the Gasifier. Oxygen from the ASU is vented during
preparation for startup and is sent to the feed injector during normal operation. The air
separation plant supplies 4,635 tonnes per day of 95 mole percent oxygen to the
Gasifiers and Claus plant. The Oxygen that is sent to the Gasifier inlet first passes
through a preheater to preheat the oxygen coming from the air separation unit.
The Gasifier vessel is a refractory-lined, high-pressure reaction chamber. The coal

slurry feedstock and oxygen are fed through a fuel injector at the top of the Gasifier
vessel. The coal slurry and the oxygen react in the Gasifier at 5.6 MPa (815 psia) and
approximately 1,316°C (2,400°F) to produce syngas.
The gasification reactions take place in near adiabatic conditions. There is some heat
loss through the refractory-lined walls to the environment, but with a new refractory
lining the heat loss is only 0.2% of the slurry feed heating value.
Slurry Charge Pump
The Slurry Charge Pump is a variable speed positive displacement diaphragm piston
pump. This pump is usually located in the slurry prep area and it takes suction from the
slurry run tanks. Slurry is fed to the Feed Injector under pressure sufficient to overcome
gasifier pressure. 30 minutes prior to gasifier light off the pump is started and adjusted
to provide the correct light off Slurry Flow. Slurry is re-circulated back to the slurry run
tanks until light off, at that time valves in the slurry lines operate to shutoff the recirc flow
and initiate flow to the feed injector. Timing of this operation must be precise and is
monitored by the Emergency Shutdown System (ESS). Additionally, the O2 valves
switch from venting the O2 flow to the atmosphere. The exact timing of both operations
is essential to proper light off. Other monitoring is accomplished by the ESS for this
pump and will shutdown the gasifier in the event of a problem that warrants it.
49
Feed Injector
The Feed Injector is inserted into the top of the gasifier. This device provides for the
proper mixing of the slurry mixture and oxygen as it is injected into the gasifier. The
passages and nozzle sections of the injector are such that the initial injection rate is
approximately equal to 80% of the gasifier’s full load throughput. Recycle CO2 from the
CO2 removal unit may also be injected into the gasifier through the Feed Injector
Preheat Burner
A natural gas or LP Gas pre-heat burner is provided to preheat the gasifier and RSC
prior to gasifier light off and to “cure” the refractory after replacement. The preheat
burner is attached to the gasifier in place of the Feed Injector for the preheat operation.
In both cases a formal preheat schedule must be followed. Curing refractory may take
several days of preheat burner operation. The preheat burner package consists of the
burner control system, Fuel control system and a combustion air fan that provides
combustion air to the burner. Additionally a positive draft down through the gasifier and
RSC is provided by LP steam powered Aspirators located between the RSC and
Syngas Scrubber. When the gasifier is properly preheated and “soaked” the preheat
burner is removed, and aspirators isolated. The Feed Injector is bolted into its place
and the injector feed piping is installed. Gasifier light off follows after all other
preparations are completed. Preheat other than refractory cure is usually determined
by the gasifier temperature at the time it is decided to light off. In the case of a gasifier
relight no preheat is necessary provided the gasifier temperature does not drop below
approximately 1800F. Steam for aspirators is obtained from the auxiliary boiler or from
the power block if a Gas Turbine is operating.
Injector Cooling Water
Fuel Injector Cooling Water is sent to the injector inlet tip at approximately 110°F. The
heated cooling water leaves the tip at approximately 120°F and returns to the Cooling
Water Drum where the Injector Cooling Water Pumps take suction. The cooling water
then flows through the Injector Cooling Water Cooler where the temperature of the
cooling water is lowered back down to 110°F.
The closed cooling water system pressure is maintained at slightly less than Gasifier
pressure so that operation can detect leaks in the cooling water system. Pressure on
the Cooling Water Drum is maintained using high-pressure nitrogen at approximately
210 psi. If a leak should occur, syngas will enter the cooling water and escape the
system in the cooling water drum. A CO analyzer on the vent of the Cooling Water
Drum is provided to detect the presence of syngas. If syngas is detected, the operator
must shut the unit down until repairs can be made.
50
Syngas Flowpath
The syngas consists primarily of hydrogen and carbon monoxide, with lesser amounts
of water vapor and carbon dioxide, and small amounts of hydrogen sulfide, carbonyl
sulfide, methane, argon, and nitrogen, and trace amounts of NH3, HCl and Hg. The
heat in the Gasifier liquefies coal ash. Hot syngas and molten solids from the reactor
flow downward into a radiant syngas cooler (RSC) where the syngas is cooled.
Steam is produced in the Radiant Syngas Cooler. At the exit of the syngas cooler the
syngas and entrained solids are “quenched” with water in the Quench Chamber.
Syngas leaves the Quench Chamber and flows to the Syngas Scrubber. The course
solids sink to the bottom of the Quench Chamber and exit through the Slag Lockhopper.
Slag Lockhopper and Slag Removal
The purpose of the Slag Lockhopper is the safe removal of the slag from the Gasifier
without disrupting the operation of the Gasifier.
During operation, the Gasifier not only produces synthesis gas (or syngas) it produces
molten slag and gasified coal constituents that condense back to entrained solids. The
ash from the coal, coke and flux are liquefied by the heat in the Gasifier and coat the
walls of the Gasifier. This molten slag flows down the side of the bricks to the gasifier
exit and falls through the Radiant Syngas Cooler to the Quench Chamber. The molten
slag solidifies on its way through the Radiant Syngas Cooler and shatters into smaller
pieces due to the thermal shock of the water quench.
A slag crusher is located at the bottom of the Quench Chamber. The slag crusher is in
continuous operation while the Gasifier is in service to break the slag into small pieces
to prevent any large pieces of slag from plugging the discharge piping of the Gasifier.
The Slag Lockhopper is a Lockhopper below the Quench Chamber and that allows the
slag from the Gasifier to be sent to the atmospheric pressure Slag Handling System
while maintaining Gasifier pressure. Solids that fall through the Quench Chamber go in
to the crusher at the bottom of the chamber and in to the Slag Lockhopper. A Slag
Lockhopper Circulation Pump aids this flow cycle. The pump moves about 120 gpm of
water through the cycle in collection mode and recirculates on itself in the dump mode
at 100 gpm. When the collection cycle is completed the Slag Lockhopper is isolated
from the Quench Chamber, the lower valves opened and put through a dump cycle,
which removes all the solids contained in the hopper and flushes the hopper with flush
water. The lockhopper lower valves are closed. It is then filled, repressurized, and the
upper valves between the RSC Sump/Quench sections are opened. The lockhopper is
then ready for another collection cycle.
51
RSC Steam Drum
The RSC contains numerous HP steam generating tubes. As the syngas exits the
gasifier it flows through and around the tubes generating steam and cooling the syngas.
Steam generated in the tubes is collected in the RSC Steam Drum. The steam drum
feeds saturated steam to the HRSG’s where it is combined with HRSG steam and both
streams flow through the HRSG superheaters. HP Feedwater from the power block is
used to replace water that is converted to steam maintaining the proper level in the RSC
steam drum. Prior to light off, the water in the steam drum and RSC tubes is preheated
by medium pressure sparging steam from the auxiliary boiler or power block.
RSC Circulation Pumps
The circulation pumps provide forced water circulation in the RSC steam generating
tubes. These pumps take suction on the steam drum and force flow through the RSC
tubes and back to the steam drum. The discharge of the pumps is fed to eductors that
have their suction ports connected to the steam drum. The eductors provide additional
flow capacity.
Vacuum Flash and Flash Gas Scrubber
The flow through this system changes from a relatively high pressure and high
temperature to a vacuum and contains a very large quantity of abrasive solids
accompanied by acidic liquids
The Vacuum Tank’s function is to act as a transitional vessel for separating the sour gas
from the waste water and deposing of the waste from the Gasifier. The Vacuum Tank is
maintained under approximately 5-10” of vacuum. Vacuum is provided by a steam
ejector system located downstream of the Vacuum Flash on the sour gas side of the
system. The Vacuum Tank and its associated inlet valve are designed for very rugged
service. The flow through this system changes from a relatively high pressure to a
vacuum and contains a very large quantity of abrasive solids accompanied by acidic
liquids. In the “Vacuum Tank” all of the acid gases are flashed off and exit the top of the
tank to the Vacuum Condenser. The water re-condenses and falls to the bottom of the
tank with the solids. This mixes with caustic and water that enters from the Slag
Lockhopper Depressurization line and the water and solids exit the bottom of the drum
to the Slag Handling System via gravity. (The Slag Handling System is external to this
model).
Emergency Shutdown System
The emergency shutdown System (ESS) is a separate independent system that

monitors gasifier and other essential gasifier processes and devices. It provides alarm
functions and in the event of an unsafe condition the gasifier is tripped (O2 and Slurry
valves to the Feed Injector are immediately shut.) The ESS operates completely
independent of the plant process control system. It consists of several cabinets of
52
processors and I/O cabinets. There are three independent channel monitoring various
gasifier, RSC and gasifier auxiliary parameters. For most processes parameters three
redundant pressures, levels, flows or valve positions, etc are monitored continuously
while the gasifier is in operation. Where gasifier tripping is preformed, three parameters
are normally monitored and a two out of three voting decision is accomplished. Loss of
two inputs or if the devices being monitored do not agree or are out of spec. the
decision to trip is made.
The ESS provides no control action (Control of the gasifier feeds and other process
flows is done by the plant process control system) other than shutting down the Gasifier
in the event it detects an unsafe condition. In most instances the ESS and plant
process control system receive information related to gasifier parameters from the same
field devices (transmitters)
PARTIAL list of Devices monitored by the ESS or Overridden by the ESS
SHUTDOWNS:

Slurry Charge Pump Speeds (3)
Slurry Charge Pump discharge pressure (3)
Slurry Flow to Feed Injector (3)
Steam Supply valve to Slurry Preheater
HP Nitrogen Purge Drum Pressure
Slurry shutoff valves
Feed Injector Cooling Water Drum Level
Feed Injector Cooling Water Pumps
Feed Injector Cooling water isolation valves (shut on cooling coil failure).
Cooling coil water temperature detectors (part of logic to detect gas leakage into
cooling circuit
O2 Supply valves to Feed Injector (4 valves with triple redundant position xmtrs
or position switches. 2 out of three must agree.
O2 flow to Feed Injector (3)
RSC Sump/Quench Level
RSC Steam Drum Level (3)
RSC Steam Circulation Flow (3)
RSC Steam Drum Back pressure Valve. (Maintain pressure in drum > gas
pressure)
RSC Gas Pressure
RSC/Quench Exit Gas Temperature
53
Lockhopper Valves
Additional Interlock to prevent all three valves from opening at the same time. (3
position transmitters per valve)
Flush Valve
Depressurization Valve
The Lockhopper is controlled by its own independent logic the ESS monitors and
prevents unsafe operation.
Nitrogen Purge Valves for O2 line and Feed Injector (multiple, operated on gasifier
shutdown/trip)
Steam Purge Valves (multiple, operated on gasifier shutdown/trip)
54
4.2. Gasifier Unit Modeling Expectations
It is anticipated that the Gasifier will be a first principle model that allows the operator to
complete the startup, shutdown and normal monitoring of system equipment.
performance and reliability of the Gasifier. Each of these issues will impact the training
effectiveness of the simulator and shall be taken into account when developing the
model. In order to address these issues and achieve the fidelity of simulation desired
for research and operator training, the simulator model of the Gasifier, the following
parameters should be addressed in the model at a minimum:

The model will track chemical components throughout the process. Rigorous
equation of state or other thermodynamic systems will be used to calculate vapor
liquid equilibrium.
The model must be capable of cold, warm, and hot startups. While starting, the
gasifier will initially send syngas to raw gas flare and the gasifier syngas piping
up to the LT GAS Cooling and AGR will be pressurized. After leak checks are
performed the gas will be brought into LT gas cooling and AGR and vented
through the Clean Flare Valve and header. The raw gas flare will be closed and
the entire system brought to normal pressure before routing to the Gas Turbine
and fuel switch.
The Gasifier temperature and syngas output composition responds to changes in
the composition of Gasifier slurry feed input.
The temperature and gas output of the Gasifier responds to changes in the
amount and quality of Oxygen being added for combustion.
Gasifier reaction modeling includes char partial combustion, shift, and
methanation.
Carbon conversion in the Gasifier is adjustable by the trainer and includes a fines
recycle stream. Equations for predicting carbon conversion can be supplied to
the simulator manufacturer on award if necessary.
Slagging and the thickness of the slag layer in the Gasifier, and on the refractory
lined walls of the Gasifier will be modeled.
Gasifier chamber temperature is detected by specially constructed
thermocouples inserted into passages in the gasifier refractory wall.
Temperatures are indicated, for use in analyzing gasifier operation and are inputs
into the ESS.
An integrated Gasifier startup feed injection and Gasifier lightoff system shall be
modeled. The startup fuel is sent to the same burner as the coal slurry and then
once the downstream plants are on line, the fuel feed is switched to coal slurry.
This is done to reduce emissions through the raw flare at startup.
55
The Injector Cooling Water Cooler will provide a set amount of cooling from the
Closed Cooling Water System to the Injector Cooling Water when the system is
in operation. This value will be set at 110°F and should not be variable.
The Raw Syngas outlet temperature to the Syngas Scrubber is based upon the
amount of process condensate spray flow provided, and the heat transfer within
the Radiant Syngas Cooler and Quench Section. The Radiant Syngas Cooler
shall be modeled as 11 perfectly mixed zones of approximately equal surface
area. Each zone will have its own fouling factor, which can be skewed by
engineer adjustable parameters to reflect higher fouling in the upper sections of
the cooler.
A constant volume of Makeup Water will be provided to the Injector Cooling
Water Drum to maintain level in the Cooling Water Drum if refilling or adding
makeup water is necessary.
The Vacuum Tank shall be maintained at approximately 7” of vacuum b y an
ejector downstream of the Flash Gas Scrubber.
Makeup water to the Slag Lockhopper Flush Drum shall be modeled with limited
fidelity, as they are not vital to the process.
The Slag Handling System will not be modeled, and will receive flow from the
Slag Lockhopper and Slag Lockhopper Flush Drum.
Nitrogen Sootblowing shall be modeled for the RSC section of the Gasifier.
Sootblowing the Gasifier while in operation will cause appropriate fluctuations in
syngas flow, pressure and composition.
Wind conditions around the Gasifier.
4.3. Gasifier Controls
At a minimum, the following control schemes will be included in the simulator model:
Gasifier Train 1 Controls
o Slurry Pre-heater steam flow control

o Slurry Charge Pump Speed / Flow Control
o Feed Injector Cooling Water Drum Level Control (FV-001)
o Feed Injector Cooling Water Drum Pressure Control (PV-015)
o Steam Purge Pressure control (FV-011)
o Primary and Secondary Injector O2 flow control valves (FV-003/ FV-
010)
o Nitrogen Purge differential pressure control to RSC Vessel
o Gasifier Load Control Loop: Oxygen and slurry flow are controlled by
either a Power Control loop or the CT load Control.
56
o Gasifier Pressure Control Loop: Controls the pressure to the gas

turbines. O2 and Slurry feed rate controllers receive pressure signal to
adjust their flow rates
O2 Flow Control
Coal / Oxygen Ratio Control
Slurry Flow Control
o Gasifier Condition Control Loop: Controls the steam output of the RSC
Cooler and the temperature of the gasifier
Gasifier Temperature Control
Gasifier RSC Steam Production
o Gasifier Level Control (controls RSC blowdown) (RSC
Blowdown Valve)
o RSC Steam Drum Level Control (controls HP Feedwater from power block
to RSC Drum) (FV-017)
o RSC level Blowdown valve (valve opens on high drum level to reduce
drum level and help prevent trip on high level excursions. (LV-012)
o RSC Sparging Steam Flow Control (used for preheating drum, drum water
prior to gasifier start.
o Flush Drum Level Control (Process condensate flow control to the
lockhopper flush drum)
o LP feed water flow control to the lockhopper flush drum (backup source)
o Vacuum Tank Level Control (LV-017)
o Flash Gas Scrubber Level Control (LV-018)
o Condensate Flow to Grinding Drum Control (FC-019)

o Slurry Charge Pump Control and Interlocks
o Feed Injector Cooling water Pumps (2)
o Feed Injector cooling water inlet and outlet valves
o Injector CW Pump A/B Control (backup pump auto starts on lead pump
failure.
o Slurry valves to injector
o O2 valves to injector
o Steam Purge Valves
o N2 Purge Valves
o RSC Circulation Pumps (backup pump starts on low flow or lead pump
failure (monitored by ESS).
o Slag Lockhopper Pump Control
o Lockhopper Sequence timer (controls following valves
Upper slag from RSC valves
Lower slag from lockhopper (1)
Flush water valve
o Recycle Condensate Pump A Control
o Warmup Condensate Flow to Grinding Water Drum A Control
o Interfaces to ESS
57
Gasifier B
Note: Valves and controls for Gasifier Train B are the same as A. The difference in
numbering is the leading numeral being a “1” vice a “0”. (e.g. LV-112 vice LV-012)

o Feed Injector Cooling Water Drum Level Control (FV-101)
o Feed Injector Cooling Water Drum Pressure Control (PV-115)
o Steam Purge Pressure control (FV-111)
o Primary and Secondary Injector O2 flow control valves (FV-103/ FV-
110)
O2 Flow Control
Slurry Flow Control
o Gasifier Level Control (controls RSC blowdown) (RSC
Blowdown Valve)
to RSC Drum) (FV-117)
drum level and help prevent trip on high level excursions. (LV-112)
o Vacuum Tank Level Control (LV-117)
o Flash Gas Scrubber Level Control (LV-118)
o Condensate Flow to Grinding Drum Control (FC-119)

failure.
o N2 Purge Valves
failure (monitored by ESS).
58

Flush water valve
o Recycle Condensate Pump B Control
o Warmup Condensate Flow to Grinding Water Drum B Control
o Interfaces to ESS
59
4.4. Gasifier Human-Machine Interface (HMI) Screens
It is anticipated that there will need to be eight Human-Machine Interface (HMI) Screens
associated with the Gasifiers, four HMI screens per train. This is in addition to any
control screen HMI’s identified in the specification.
controls. It is assumed that one HMI screen will contain the Gasifier Feed and Cooling
controls and instrumentation, the second will contain the Gasifier and RSC System
controls and instrumentation, the third will contain the Vacuum Flash System controls
and instrumentation, and the fourth will contain the Slag Lockhopper and Flush Drum
The four HMI Screens per Gasifier train will contain the process mimic, controls and
instrumentation shown in GAS-FD-4, GAS-FD-5, GAS-FD-2, and GAS-FD-3 and will
include:
Gasifier Feed and Cooling A HMI:

o Feed Injector Cooling Water Drum Level Control
o Feed Injector Cooling Water Drum Pressure Control
o Steam Purge Pressure control
o Primary and Secondary Injector O2 flow control valves
O2 Flow Control
Slurry Flow Control

o Interfaces to ESS
failure
o N2 Purge Valves
60
o Density Indication (1)
Gasifier and RSC System A HMI:

o Gasifier Level Control (controls RSC blowdown)
to RSC Drum)
drum level and help prevent trip on high level excursions. Helpful on
gasifier start and startup “feed and bleed” operations to the drum.

failure (monitored by ESS)
o Interfaces to ESS
Vacuum Flash System A HMI:

o Vacuum Tank A Level Control
o Flash Gas Scrubber Level Control

61
Slag Lockhopper and Flush Drum A HMI:


o Interfaces to ESS
Flush water valve
o Level indication (1)
Gasifier Feed and Cooling B HMI:

o Feed Injector Cooling Water Drum Level Control
o Feed Injector Cooling Water Drum Pressure Control
o Steam Purge Pressure control
o Primary and Secondary Injector O2 flow control valves
O2 Flow Control
Slurry Flow Control
62

o Interfaces to ESS
failure
o N2 Purge Valves
o Density Indication (1)
Gasifier and RSC System B HMI:

o Gasifier Level Control (controls RSC blowdown)
to RSC Drum)
drum level and help prevent trip on high level excursions. Helpful on
gasifier start and startup “feed and bleed” operations to the drum.

failure (monitored by ESS)
o Interfaces to ESS
63
Vacuum Flash System B HMI:

o Vacuum Tank B Level Control
o Flash Gas Scrubber Level Control

Slag Lockhopper and Flush Drum B HMI:


o Interfaces to ESS
Flush water valve
o Level indication (1)
64
4.5. Gasifier Interconnections

o Injector Cooling Water Cooler
o Recycle Condensate Pump
Utility Water to:
o Slag Lockhopper for flushing/cleaning
o Injector Cooling Water Drum as Makeup
High and Low Pressure Nitrogen to:
o Gasifiers
o Vacuum Tank
Process Condensate Spray water to the Gasifier Syngas outlet
Oxygen from the ASU to the Gasifier inlet
Slurry Feed from the Slurry Preparation System to the Gasifier inlet
Raw Syngas to the Syngas Scrubber Inlet
HP Steam from the Syngas Cooler Steam Drum for use in the plant
CO2 recovery to gasifier
Gasifier to Radiant Syngas Cooler
Make up water to injector CW pumps
High Pressure N2 to injector CW drum
Purged N2 to HP N2 Purge Drum
Injector CW Drum to Flare
Purged N2 to other Gasifier train
Recirculation line from run tanks
Reheated slurry from run tanks
RSC Steam Drum to Blowdown Tank
HP Feedwater from HRSG
RSC Steam Drum to HRSG HP Drum
Slag/Course Fines to Lockhopper
LH Circulation to Gasifier
LH Recirculation from Gasifier
Recycle Condensate from Flash Gas Scrubber
Quench water to Gasifier
Dirty water from Gasifier to the Syngas Scrubber
Recycle Condensate supply and return to the Syngas Scrubber
Caustic to the Grinding Water Drum
Condensate to the Grinding Water Drum
Recycle Condensate supply to the Steam Generator Knockout Tank
Deaerated Water to and from the Vacuum Condenser
Process Condensate from Trim Cooler Knockout Drum
Sour Gas from the Flash Gas Scrubber to the Sour Gas Ejector
Vacuum Tank Bottoms to the Slag Sump
HP Nitrogen to the Gasifier RSC Sootblowers
65
4.6. Gasifier Malfunctions

following malfunctions will be modeled for the s:
Ignition Failure
Ignition indication false positive
Gasifier feed control valve failures
Improper Coal / Air Ratio
Gasifier Emergency Shutdown
Slurry Charge Pump inlet or outlet valve
Hi/Lo RSC Drum Level problems including trips (ESS)
Loss or low RSC Steam Drum Circulation Flow Trip (loss of circ pumps)
Injector cooling coil leak and or trip
Lock hopper recycle flow reduced by fouling
Forming of slag lumps due to wrong gasifier conditions
Bad coal conversion due to wrong gasifier conditions
By-as burners
Blockage or overloading of slag crusher.
4.7. Gasifier System References
Allam, R.J., Castle-Smith, H., Smith, A., Sorensen, J., Stein, V. (2000). Air
Separation Units, Design and Future Development. Paper presented at ECOS
2000 Gasification of Coal, Biomass and Oil. The Netherlands. Available online at
http://www.airproducts.com/NR/rdonlyres/6753032F-A8B8-4339-A12F-
BB1A8DB46735/0/ECOS.pdf.
Hawley, Roger F. (2000). Delaware City Refinery Repowering Project Overview
and Project Status. Paper presented at 2000 Gasification Technologies
Conference. San Francisco, CA. Available Online at
http://www.gasification.org/Docs/2000_Papers/Gtc00170.pdf
Rao, A., Samuelson, G. (2006). Advanced Power Plant Development and
Analyses Methodologies. University of California, Irvine. Available online at
http://www.fischer-tropsch.org/DOE/DOE_reports/40845/40845.pdf
Elsevier.
66

67
1 2 3 4 5 6 7 8 9 10
O2
O2 FROM ASU
A A
FV-012 ESV004 ESV006
TT PT FT FC
ESV-007 PRIMARY SECONDARY
ESV-005
ATMOS ESV-008 FV-003 HIC FV-010
PRE-
HEATER FV-013
ESV-009 ESV-010
REHEATED
SLURRY SLURRY
FROM RUN ESV-001 ESV-002 ESV-003
TANKS CHARGE ESV-015
AI PT FT CO TO N2 AND HP
PUMP
ANALYZER FLARE PT FT PI STEAM PURGE
B B
PURGE
LP ESV-016
STEAM HP STEAM
FROM CO2
FV-011
ESV-011 ESV-012
RECOVERY
TO RUN RECIRC
TANKS
PT FT PC PV-014
HPN2 PURGE
FV-008
ESV-014 PREHEAT
BURNER
ESV-013 CONTROL
C PURGE N2 C
TO OTHER HP N2 PDT PT
TRAIN PV-015 TE
HP N2 INJECTOR
PURGE LT CW
TE
HP N2 DRUM DRUM
TE
FT
WCCS
SYNGAS TO
PT RSC STEAM
MAKEUP WCCS
D DRUM AND D
WATER FV-001 RADIANT SCRUBBERS
SYNGAS
COOLER TE PT
GAS
INJECTOR PRESSURE
CW PUMPS FROM RSC
SPRAY
FLOW
CONTROL FT
PROCESS
LV-012 CONDENSATE FOR
ATTEMPERATION
E E
LEGEND
HP Steam
Process Water
LT Coal / Coke Slurry
Gas/vapor
Syngas
Process Condensate
Fossil Consulting Services,
Inc.
Columbia, Maryland
DOE-IGCC
SIMULATOR
F F
GASIFIER SYSTEM
SLAG / COURSE / FV-015
FINES TO GASIFIER FEED AND COOLING
LOCKHOPPER DATE DRAWING NO. REV.
06/17/2008 GAS-FD-004 A
1 2 3 4 5 6 7 8 9 10
68
1 2 3 4 5 6 7 8 9 10
A A
TO STEAM BYPASS VALVE
PC
TE PT
TO HRSG
HP DRUM
FV-016
B FROM HP B
SPARGING
STEAM
NITROGEN FT
TE
SOOTBLOWING
TE FC FT
TE
STEAM HP FEEDWATER
C FV-017 FROM HRSG C
RSC
RSC STEAM
STEAM DRUM LT
SYNGAS COOLER DRUM
CIRC PUMPS
RSC FEED
RADIANT FT
SYNGAS FT
LT COOLER
PT FV-019 TO
BLOWDOWN
TANK
TE PT FT
D D
SPRAY FLOW TO FEED INJECTOR
FT COOLING WATER
CONTROL SYNGAS TO
PRESSURE CONTROL
SCRUBBERS
PROCESS
RECYCLE COND
CONDENSATE
FROM FLASH FV-013
GAS SCRUBBER
QUENCH WATER
REMOVEABLE
FLANGE
LT
E E
FV-011
GASIFIER LEGEND
LEVEL
LH LH CONTROL HP Steam
CIRC RECIRC Process Water
BOILER
Syngas
FEEDWATER
Process Condensate
Recycle Condensate
DIRTY WATER Nitrogen Sootblowing
FV-015
TO SCRUBBER Fossil Consulting Services,
LV-012 Inc.
Columbia, Maryland
SLAG / COURSE / FROM ESS
FINES TO DOE-IGCC
LOCKHOPPER SIMULATOR
F F
RSC
BLOWDOWN GASIFIER SYSTEM
GASIFIER AND RSC SYSTEM
06/17/2008 GAS-FD-005 A
1 2 3 4 5 6 7 8 9 10
69
1 2 3 4 5 6 7 8 9 10
A A
DEA WATER TO BFW COOLING
PRV-110
DEA WATER INLET
B B
VACUUM
CONDENSER SOUR GAS TO EJECTOR
FT
DRAIN
DEPRESSURIZE FROM PT
SLAG LOCKHOPPER FT
FT
FT USS
C C
VACUUM
DIRTY WATER TANK COND. TO GRINDING DRUM
FV-019
FROM SCRUBBER
LT
LT
WBC
FT VACUUM TANK FLASH

D
LEVEL CONTROL WARMUP D
GAS
SCRUBBER
FLARE
COND
LV-017
FLASH GAS
SCRUBBER
EJECTOR LEVEL
COND CONTROL FT
CAUSTIC TO
E CCWS E
GRINDING WATER
COND TO LEGEND
VAC. TANK
LT GASIFIER
CAUSTIC BOTTOMS TO LV-018 Process Water
TANK SLAG SUMP Recycle Condensate
RECYCLE Flash/sour Gas
COND. PUMP Gas/vapor
Caustic
Fossil Consulting Services, Inc.

COND TO ST Columbia, Maryland
GEN K.O. TANK
CCWR DOE-IGCC
SIMULATOR
F F
GASIFIER SYSTEM
VACUUM FLASH SYSTEM
4/08/2008 GAS-FD-002 B
1 2 3 4 5 6 7 8 9 10
70
1 2 3 4 5 6 7 8 9 10
PROCESS REPRESSURIZATION LINE
A CONDENSATE A
SLAG FROM RSC VENT
TO VACUUM
FLASH DRUM
B FV-024 B
FT
FV-020 FV-021
UTILITY WATER SLAG

DEPRESSURIZATION LINE
PRESSURE LOCKHOPPER
PDT FLUSH DRUM
SIGNAL FROM RCS
C C
OVERFLOW WCR
FT
LP
FEEDWATER
FV-022 FV-023 PI FV-027 WCS
FLUSH
SLAG VALVE
D D
LOCKHOPPER
LT
SLAG LOCKHOPPER FT SC
CIRC TO RSC
LOCKHOPPER
PUMP
E E
LEGEND
Slag Holding Tank Recirculation

Process Condensate
FV-025
Flush Water
Vapor/gas
Gasifier Slag & Water

Columbia, Maryland
TO SLAG
CLASSIFICATION AND DOE-IGCC
SIMULATOR
F HANDLING SYSTEM F
GASIFIER SYSTEM
LOCKHOPPER AND FLUSH DRUM
6/02/2008 GAS-FD-003 C
1 2 3 4 5 6 7 8 9 10
71
5. Syngas Scrubbers
There are two Syngas Scrubbers, one for each Gasifier train.
The purpose of the Syngas Scrubber is to:
Clean the syngas of fine solids.

Cool the syngas
Separate the waste stream from the syngas stream
Control the level of chlorides
Collect and recycle quench water used in the quench ring.
Each Syngas Scrubber train is comprised of the following main components:
Syngas Scrubbers (2)

Nozzle Scrubbers (2)
Syngas Scrubber RSC /Quench Pumps (2x100%)
Quench Water Strainers (2x100%)
Start-up Air Ejectors (2)
5.1. Description of Syngas Scrubber Process
Referring to figure SYN-FD-001 at the end of this document:
The purpose of the Syngas Scrubbers is to clean the syngas by separating the solids
and entrained liquids from the syngas. The Syngas Scrubber system also collects and
recycles the quench water used in the gasifier quench ring and dip tube. In addition, it
controls the level of chlorides and other contaminants in the scrubber water system by
bleeding some of the water off to the Vacuum Flash System. The “collection” of
halogens, ammonia, H2S, CO2 etc in the scrubbers is highly influenced by the pH of the
scrubber water.
Syngas Scrubbers
The syngas exiting the RSC/Quench chamber is sent to the Syngas Scrubber. The
syngas also contains entrained solids (flyash and char) and water. Just before entering
the scrubber vessel the syngas passes through a venturi nozzle scrubber where
process condensate is mixed with the gas and wets the entrained solids. The mixture of
syngas, wetted solids and entrained liquid enters the scrubber vessel where the
entrained solids and liquid droplets are removed from the gas flow via centrifugal force.
The raw syngas exits the top of the Syngas Scrubber.
Quench Water System
72
The Quench Water System provides the Quench chamber with quench water that is
recirculated from the Syngas Scrubber.
The Syngas Scrubber (RSC/Quench Water) Pumps pump water and solids from the
bottom of the syngas scrubber vessel a takeoff line of the Syngas Scrubber to the
quench ring in the Quench chamber RSC. The solids from the scrubber settle in the
RSC sump along with the RSC course slag, both are flushed through the lockhopper
system. The solids are processed by the slag handling system where the course and
fine slag is separated and processed. Before flowing through the quench ring the water
passes through the Quench Water Strainers for removal of any entrained solids or pipe
scale. Both pumps and strainers operate simultaneously and the pumps have separate
suction lines and discharge lines (to strainer) to ensure maximum availability of quench
water.
Start-Up Ejector
The Start-up Ejector uses 175 psi steam to generate a sub-atmospheric pressure within
the gasifier during gasifier preheat burner operation and also to pull air through the
system during maintenance activities. The effluent from the ejector is vented to
atmosphere.
73
5.2. Syngas Scrubber Modeling Expectations
It is anticipated that the Syngas Scrubbers will be a functional model that allows the
operator to complete the startup, shutdown and normal monitoring of system equipment.
performance and reliability of the Syngas Scrubbers. Each of these issues will impact
the training effectiveness of the simulator and shall be taken into account when
simulation desired for research and operator training, the simulator model of the Syngas
Scrubbers, the following parameters should be addressed in the model at a minimum:
System compositions, pressures, flows, levels, water pH and temperatures will

respond to changes in system operation.
liquid equilibrium.
The dirty water output to the Vacuum Tank shall be consistent in temperature
and fines content.
The Quench Water Strainers shall have the capacity to clog.
Quench Water temperature shall be modeled to reflect the temperature of the
Gasifier and Gasifier Quench Ring and will also respond to clogging of the
Quench Water Strainers.
Level in each Syngas Scrubber will respond to alterations in the temperature and
pressure of the process condensate by taking into account the change in water
density in addition to the various changes in flowrates of water into and out of the
Scrubber.
Water to the Scrubbers (utility water) is supplied prior to having the Boiler
Feedwater System in operation, and will be supplied from a constant volume of
water at a flowrate that is variable only as an instructor feature from an instructor
station.
All solids entrained into the scrubber are assumed to be removed by the
scrubbing process. No solids are in the raw syngas exiting the scrubber.
No liquid will be entrained out of the scrubber via the scrubbed syngas unless the
liquid level in the scrubber exceeds 100%. Then 10% of the liquid entering with
the syngas will be carried over to the downstream equipment. This carry-over
factor must be adjustable by the trainer.
74
5.3. Syngas Scrubber Controls
model:
Syngas Scrubber A

o Vacuum Tank Pressure Control (PV-028)
o Syngas Scrubber A Level Control (LV-029A/LV-
029B/LV-031)
o Syngas Scrubber A Speed/Flow Control (Cooled Boiler Feedwater Flow
Control) (FV-030)\
o Venturi Nozzle Spray Flow Control (FV-0301)

o Syngas Scrubber A (Quench Water) Pumps
Syngas Scrubber B
Note: Valves and controls for Syngas Scrubber Train B are the same as A. The
difference in numbering is the leading numeral being a “1” vice a “0”. (e.g. PV-128 vice
PV-028)

o Vacuum Tank Pressure Control (PV-128)
o Syngas Scrubber A Level Control (LV-129A/LV-
129B/LV-131)
Control) (FV-130)\
o Venturi Nozzle Spray Flow Control (FV-1301)

75
5.4. Syngas Scrubber Human-Machine Interface (HMI) Screens
associated with the Syngas Scrubbers, one per Syngas Scrubber train.
controls. It is assumed that each HMI screen will contain the Syngas Scrubber controls
and instrumentation,
The two HMI Screens for the Syngas Scrubber process will include the process mimic,
controls and instrumentation shown in SYN-FD-001 and will include:
Syngas Scrubber System A HMI:

o Vacuum Tank A Pressure Control
o Syngas Scrubber A Level Control
Control)
o Venturi Nozzle Spray Flow Control
Syngas Scrubber System B HMI:

o Vacuum Tank B Pressure Control
o Syngas Scrubber B Level Control
o Syngas Scrubber B Speed/Flow Control (Cooled Boiler Feedwater Flow
Control)
o Venturi Nozzle Spray Flow Control
o Syngas Scrubber B (Quench Water) Pumps
76
5.5. Syngas Scrubber System Malfunctions

following malfunctions will be modeled for the Syngas Scrubber:
Failure of Scrubber Pump

Improper Syngas Scrubber Level (High or Low)
Nozzle Scrubber Failure
Improper Nozzle Scrubber Spray
Quench Strainer Plugging
Entrainment of water
Drifting pH of scrubber water
Bad Scrubber function (excess Chlorides in scrubber gas outlet)
5.6. Syngas Scrubber Interconnections
Raw Syngas from the Gasifier

Raw Syngas to Gas Cooling via Water Gas-Shift Reactors
Cooled Boiler Feedwater supply to:
o Quench Water Strainers
o Scrubber Pumps
o Syngas Scrubbers
Process Condensate from the Steam Generator Knockout Drum to Syngas
Scrubber
Dirty water from the Gasifier
Dirty water to Vacuum Tank
175# Steam to Air Ejectors
Utility Water to Cooled Boiler Feedwater Supply Line
Utility / HP Grey Water to Venturi Nozzle Spray
Process Condensate to Gasifier Syngas Spray
Syngas to Scrubber
77
5.7. Syngas Scrubber System References
Hawley, Roger F. (2000). Delaware City Refinery Repowering Project Overview

and Project Status. Paper presented at 2000 Gasification Technologies
Conference. San Francisco, CA. Available Online at
http://www.gasification.org/Docs/2000_Papers/Gtc00170.pdf
Elsevier.
78
1 2 3 4 5 6 7 8 9 10
RAW SYNGAS
PRESSURE CONTROL
A
COND. TO < FC A
GASIFIER SYNGAS FT
SPRAY
RAW SYNGAS TO
TO ATMOS FT < PC GAS COOLING
175# STEAM < FT

PT
LV-029A LV-029B
SYNGAS
B PC B
PV-028 SCRUBBER LV-031
TE TE
SYNGAS TO SCRUBBER
NOZZLE LCH
FC SPRAY
UTILITY / HP GREY WATER PROCESS CONDENSATE
CONTROL
LCL LC
C C
FV-0301
TE
DIRTY WATER FROM GASIFIER
TO FLASH GAS
SCRUBBER INLET
D FT D
SCRUBBER DIRTY WATER TO VAC TANK
PUMPS
PT TE
COOLED B.F.W.
FV-030
QUENCH WATER
TO GASIFIER
E E
LEGEND
VENT VENT
Utility / Grey / Dirty Water
Process Water
Syngas
Steam / AE Vapor
QUENCH Quench Water
Process Condensate
WATER
STRAINERS Inc.
Columbia, Maryland
UTILITY
DOE-IGCC
WATER SIMULATOR
F F
STARTUP
SYNGAS SCRUBBER A
SYNGAS SCRUBBERS
TO SLAG PAD 06/18/2008 SYN-FD-001 C

1 2 3 4 5 6 7 8 9 10
79
6. Shift Reactors
The purpose of the portion of the process is to:
Preheat the syngas prior to entering the first Shift Reactor

Adjust the H2O:CO ratio to 2:1 on a molar basis
Convert the Gasifier product to hydrogen and carbon dioxide rich syngas
Recover the heat of the water-gas shift reaction as medium pressure steam
The IGCC plant has two trains of Shift Reactors, one for each gasifier. Each train of the
portion of the process is comprised of the following main components:
Two Shift Gas Reactors arranged in series

Water Vaporization Heat Exchanger
MP Steam Generation Heat Exchanger
6.1. Description of Process
Referring to figure SGS-FD-001 at the end of this document:
The conversion of CO to CO2 for this plant is achieved by sour gas shift (SGS), where
the water-gas (CO-) shift reaction occurs prior to removal of the acid gas from the
synthesis gas. The shift reactors also serve to hydrolyze COS, which eliminates the
need for a separate COS hydrolysis reactor. They also decompose metal carbonyls,
formic acid, and hydrogen cyanide.
The SGS is placed after the Gasifier and subsequent syngas cooling, but before further
gas cooling in preparation for the de-Sulfurization step of the Acid Gas Removal Unit.
This flow scheme is depicted in the following general process flow diagram.
80
Figure 2 General PFD for IGCC with Sour CO-Shift and CO2 Capture
The CO-Shift reaction is well understood and extensively used commercially in large
ammonia (fertilizer) and hydrogen plants, operating on the basis of both steam
reforming of natural gas and gasification of heavy fossil fuels. The principal catalyst and
technology suppliers for CO-Shift are Johnson-Matthey, Haldor Topsoe, and Sud-
Chemie.
Each train includes two fixed-bed water-gas shift reactors arranged in series to achieve
sufficient conversion to meet the 90 percent CO2 capture target.
The first step in the process is to convert most of the CO in the syngas to CO2 and
hydrogen by reacting the CO with water vapor over a bed of catalyst. The H2O:CO
molar ratio in the shift reaction, shown below, is adjusted to optimally 2:1 by the addition
of steam to the syngas stream (exiting the scrubber and prior to the first SGS reactor),
thus promoting a high conversion of CO. In addition, this molar ratio ensures the
avoidance of CH4 formation and Carbon deposition.
CO + H2O ↔ CO2 + H2
81
The CO-Shift Reaction is an equilibrium reaction, governed by the following relationship:
Figure 3 Equilibrium Constant for the Water-Gas Shift Reaction versus

Temperature
Left-to-right reaction very exothermic (-41 kJ/kg-mol)
Because the CO-Shift reaction is an exothermic equilibrium reaction, 100% conversion

of the CO is not possible. The degree of conversion is usually expressed in terms of the
residual CO in the dry shifted gas, or CO slip. Low reaction temperatures favor low
equilibrium levels of CO, but higher temperatures are required for a high rate of reaction.
CO shift systems are usually multi-staged with the operating temperatures adjusted so
that bulk conversion (<~5%V CO residual) takes place at a higher temperature and
lower temperatures are used for final, trim conversion (<~2%V CO residual). Typically
two beds in series are required and normally used, but for high conversion to less than
1% CO slip a third bed must optionally be added.
The shift reactors require a minimum inlet temperature of >~270°C (520°F) in order to
have acceptable reaction kinetics. Care should also be taken to avoid excessively high
gas temperatures (<480°C (<896°F)) in each reactor to protect the catalyst. Cooling is
provided between the series of reactors to control the exothermic temperature rise and
limit the catalyst temperature. The feed gas to the CO-Shift will already have an
established H2O:CO ratio based upon the upstream Gasification and subsequent
syngas cooling technology, The Water Vaporization Heat Exchanger, located
downstream of the first shift reactor, is used to vaporize water, which is then used to
adjust the syngas H2O:CO molar ratio prior to entering the first shift reactor. If needed,
extraction steam from the HP steam turbine can be used to supplement the steam
requirement for the shift reaction. The MP Steam Generation Heat Exchanger, located
82
downstream of the second shift reactor, is used to generate IP steam, which is mixed
with Cold Reheat steam and then passes through the reheater section of the HRSG.
The warm syngas exiting the second shift reactor is cooled to approximately 232°C
(450°F).
Note that in figure above, a higher H2O:CO ratio reduces the outlet temperature of the
first bed, which can be critical in situations of high CO content and low steam content in
the syngas. It also lowers the outlet CO content from each stage, which might be
important to attain a fixed target of residual CO in the syngas after 2 catalytic stages of
shift. This could particularly have merit as the CO-Shift catalyst ages with time and
experiences decreased activity. However, arbitrarily increasing the H2O: CO ratio needs
to be counterbalanced with the understanding that this ultimately is taking elevated
pressure steam from the Steam Turbine and thus limiting the power output of the IGCC
plant. Thus the H2O:CO ratio is an economical balance between higher CO conversion
and lower power output.
Since the CO-Shift Reaction has 1 mole of each reactant forming 1 mole of each
product, increasing or decreasing pressure has virtually no impact upon the equilibrium.
The catalyst material is Co-Mo (cobalt-molybdenum).
6.2. Modeling Expectations
It is anticipated that the System will be a functional model that allows the operator to
performance and reliability of the System. Each of these issues will impact the training
for research and operator training of the simulator model of the System, the following
System compositions, pressures, flows, levels, and temperatures will respond to

The temperature increase of the synthesis gas across the reactor bed will be
proportional to the heat released by the water-gas shift reaction
The synthesis gas CO, H2, H2O and CO2 composition at the exit of each reactor
will be based on an approach to equilibrium of the water-gas shift reaction
All COS will be assumed to be converted to H2S across the first reactor bed
83
6.3. Controls
Syngas Temperature Control (TCV-001)

st
o Inlet to 1 Reactor Bed via upstream cooling and/or steam injection, with
set point at >~270°C (520°F), and minimum and maximum alarms
o Outlet of 1st Reactor Bed via BFW heating to steam, with maximum
allowable temperature of 480°C (896°F), to prevent thermal damage to
catalyst
o Exit of 2nd Reactor Bed via BFW heating to steam to further downstream
cooling
Steam/Carbon Monoxide Ratio inlet to the 1st Reactor Bed
o 1st source is addition steam from BFW vaporization
o 2nd source if needed is addition of steam from Steam Turbine
o Setpoint is H2O:CO ratio of 2:1 at Start-of-Run, when catalyst is new
o Setpoint will modestly increase as catalyst ages until End-of-Run
I/P Boiler Feedwater to Water Vaporization HX Flow Control (FV-001, FV-002)
o BFW flowrate is not only a function of level control within the HX, but is
also controlled by exit cooling temperature of the syngas from the HX
o The discharge steam from the HX is split, with:
Part or all of the steam being injected into the syngas upstream of
the 1st Reactor Bed to satisfy the H2O:CO ratio requirement
Residual steam sent to the Steam Turbine to produce incremental
power
I/P Boiler Feedwater to MP Steam Generation HX Flow Control (FV-003)
o BFW flowrate may be controlled either by:
Exit temperature of syngas from HX, or
Steam exit temperature (and thus pressure) to satisfy HRSG
temperature/pressure requirement
Water Vaporization HX Level Control
MP Steam Generation HX Level Control
Note: Valves and controls for Shift Reactors Unit Train 2 are the same as 1. The
difference in numbering is the leading numeral being a “1” vice a “0”. (e.g. TCV-101 vice
TCV-001)
Syngas Temperature Control (TCV-101)

st
o Inlet to 1 Reactor Bed via upstream cooling and/or steam injection, with
set point at >~270°C (520°F), and minimum and maximum alarms
o Outlet of 1st Reactor Bed via BFW heating to steam, with maximum
allowable temperature of 480°C (896°F), to prevent thermal damage to
catalyst
o Exit of 2nd Reactor Bed via BFW heating to steam to further downstream
cooling
84
Steam/Carbon Monoxide Ratio inlet to the 1st Reactor Bed

o 1st source is addition steam from BFW vaporization
o 2nd source if needed is addition of steam from Steam Turbine
o Setpoint is H2O:CO ratio of 2:1 at Start-of-Run, when catalyst is new
o Setpoint will modestly increase as catalyst ages until End-of-Run
I/P Boiler Feedwater to Water Vaporization HX Flow Control (FV-101, FV-102)
o BFW flowrate is not only a function of level control within the HX, but is
also controlled by exit cooling temperature of the syngas from the HX
o The discharge steam from the HX is split, with:
Part or all of the steam being injected into the syngas upstream of
the 1st Reactor Bed to satisfy the H2O:CO ratio requirement
Residual steam sent to the Steam Turbine to produce incremental
power
I/P Boiler Feedwater to MP Steam Generation HX Flow Control (FV-103)
o BFW flowrate may be controlled either by:
Exit temperature of syngas from HX, or
Steam exit temperature (and thus pressure) to satisfy HRSG
temperature/pressure requirement
Water Vaporization HX Level Control
MP Steam Generation HX Level Control
6.4. Human-Machine Interface (HMI) Screens
associated with the System.
controls. It is assumed that each HMI screen will contain the System controls and
instrumentation,
The two HMI Screens for the System will include the process mimic, controls and
instrumentation shown in SGS-FD-001 and will include:
System A HMI:

o Syngas Temperature Control
o I/P Boiler Feedwater to Water Vaporization HX Flow Control
o I/P Boiler Feedwater to MP Steam Generation HX Flow Control

o None
85
o H2O – CO Analyzer
o High and Low Temperature Alarms
System B HMI:

o I/P Boiler Feedwater to Water Vaporization HX Flow Control
o I/P Boiler Feedwater to MP Steam Generation HX Flow Control

o None
o H2O – CO Analyzer
o High and Low Temperature Alarms
6.5. System Malfunctions

following malfunctions will be modeled for the Shift Reactors system:
Catalyst Exhaustion
Low Shift Reactor Inlet Temperature
Loss of, or Improper Feedwater Flow to the Shift Gas Reactors
Component Failures., e.g. improper output analyzers, malfunctioning of pumps
Process Control Failures (TBD), valve position indicators, control valve suddenly
on manual
86
6.6. Interconnections
Syngas from Syngas Scrubber

Supplemental Steam Supply from HP Steam Turbine
I/P Boiler Feedwater to Water Vaporization HX
I/P Boiler Feedwater to MP Steam Generation HX
Syngas to Gas Cooling, Boiler Feedwater Heating, and Knockout
I/P Steam (to mix with Cold Reheat Steam) to HRSG
Excess BFW to Water Vaporization HX to Steam Turbine
6.7. System Startup Considerations
During plant startup, the following issues are important and need to be controlled
properly:
Increase in pressure in the Reactors has to be limited to < 3.5 bar (50 psi) per
minute to prevent crushing of the catalyst or undue stress on the catalyst support
system via the downward flow of the gas
The H2O:CO ratio should always exceed 2:1 at all times to avoid Carbon
deposition on the catalyst beds
Reactor Bed operating pressure should be restricted to 30 bar (450 psi) pressure
to avoid capillary condensation of the water vapor in the catalyst pores
The syngas flow should be restricted to a fraction of design flows until the CO-
Shift operation has stabilized and achieved steady state
Full syngas flows should be attained in a stepwise and incremental fashion
6.8. System References
systems described in this Process Description:

Plants Study Volume 1: Bituminous Coal and Natural Gas to Electricity. Available
online at http://www.netl.doe.gov/energyanalyses/
pubs/Bituminous%20Baseline_Final%20Report.pdf.
Systems Analyses of Advanced Brayton Cycles for High Efficiency Zero
Emission Plants, Topical Report, Task 1.3: Baseline IGCC Plant Systems Study,
Update 2, November 2006, Advanced Power and Energy Program, University of
California.
87
1 2 3 4 5 6 7 8 9 10
A A
TO
STEAM
FV-002 TURBINE
TO TRAIN 2
B B
TO HRSG
SUPPLEMENTAL TAH/L TAH/L TAH/L

TT
STEAM FROM GAS
HP ST ANALYZER
TCV-001
C TC TC C
TAH/L TC LC FY TT LC FY TT
FROM
TO GAS COOLING,
SYNGAS
BFW HEATING &
SCRUBBER
KNOCKOUT
WATER FV-001 MP STEAM FV-003
SHIFT GAS VAPORIZATION SHIFT GAS GENERATION
REACTOR HEAT REACTOR HEAT
EXCHANGER EXCHANGER
D FC FC D
I/P BFW I/P BFW
E E
LEGEND
Shift Steam
I/P BFW
Syngas
I/P Steam

Columbia, Maryland
DOE-IGCC
SIMULATOR
F F
NOTES: SHIFT REACTORS
1. WATER VAPORIZATION HX IS A.K.A HTSC #1 RGC SHIFT REACTORS

2. MP STEAM GENERATION HX IS A.K.A. HTSC #2 RGC DRAWING NO. REV.
DATE
06/23/2008 SGS-FD-001 B
1 2 3 4 5 6 7 8 9 10
88
7. Gas Cooling, MP and LP Steam Generation and

Knockout
There are two Gas Cooling, MP and LP Steam Generation and Knockout trains, one for
each Gasifier.
The purpose of the Gas Cooling, MP and LP Steam Generation and Knockout portion of
the process is to:
Cool the syngas before entering the Mercury Removal System.

Preheat MP Feedwater prior to entering the HRSG.
Removes moisture from the syngas and recycles it as sour water.
Each train of the Gas Cooling, MP and LP Steam Generation and Knockout portion of
the process is comprised of the following main components:
A syngas / MP Boiler Feedwater Heat Exchanger with an MP Steam output to an

MP steam header.
A syngas / LP Boiler Feedwater Heat Exchanger with an LP steam output to an
LP steam header.
A Final Syngas Cooler to cool the syngas prior to entering the Mercury Removal
System.
A Low Temperature Syngas Cooling Knockout Drum to flash the syngas and hold
the resulting liquid.
7.1. Description of Gas Cooling, MP and LP Steam Generation, and

Knockout
Referring to figure GCF-FD-001 at the end of this document:
Gas Cooling and MP and LP Steam Generation
Syngas leaves the Water-Gas Shift (WGS) system and passes through a series of gas
coolers which also act to heat boiler feedwater and to produce steam at two pressures.
The syngas coming from the WGS system first enters the syngas / MP Boiler Feedwater
Heat Exchanger. The first stage of syngas cooling lowers the temperature
approximately 70° Fahrenheit as the Medium Pressure Boiler Feedwater passes
through the heat exchanger. The Boiler Feedwater is heated to Medium Pressure
Steam and enters a Medium Pressure steam header.
The syngas leaves the first stage of cooling and enters the second stage where it is
cooled by Low Pressure Boiler Feedwater passing through the heat exchanger. The LP
89
Boiler Feedwater heat exchanger lowers the temperature of the syngas by

approximately 115° Fahrenheit. The Low Pressure Boiler Feedwater is heated to LP
Steam and enters a Low Pressure steam header.
The third stage of syngas cooling takes place as the syngas enters the Final Syngas
Cooler to cool the syngas prior to entering the Mercury Removal System. The Final
Syngas Cooler uses process cooling water to lower the temperature of the syngas to
approximately 100° Fahrenheit on its way to the Knockout Drum and Mercury Removal
Beds.
Under normal operation, liquids should not condense out of the syngas until it reaches
the Final Syngas Cooler. However during start-up, shutdown, part-load and other
transients, condensate may form in the upstream heat exchangers.
Knockout
The syngas enters a Knockout Drum where any liquid in the syngas is collected. The
resulting Process Condensate liquid is pumped to the Syngas Scrubber system.
The level in the Knockout Drum is maintained by a split signal level controller.
7.2. Gas Cooling, MP and LP Steam Generation and Knockout

Modeling Expectations
It is anticipated that the Gas Cooling, MP and LP Steam Generation and Knockout
System will be a first principle model that allows the operator to complete the startup,
shutdown and normal monitoring of system equipment.
performance and reliability of the Gas Cooling, MP and LP Steam Generation and
Knockout System. Each of these issues will impact the training effectiveness of the
simulator and shall be taken into account when developing the model. In order to
address these issues and achieve the fidelity of simulation desired for research and
operator training, the simulator model of the Gas Cooling, MP and LP Steam
Generation and Knockout System, the following parameters should be addressed in the
model at a minimum:

system operation.
liquid equilibrium.
The temperature drop of the gas across the First and Second stage heat
exchangers drops in proportion to the heat duty of the heat exchanger.
The level in the Low Temperature Syngas Cooling Knockout Drum is variable,
and is controlled by a level controller.
90
Spray flow of process condensate to the Final Syngas Cooler is controlled by

varying the position of a control valve to maintain syngas temperature at the inlet
of the Final Syngas Cooler relatively constant.
The inlet flow of boiler feedwater at each of the First and Second Stage Heat
Exchangers is controlled by a flow control valve which prevent the heat
exchangers from running dry if steam production increases or from flooding the
heat exchangers if steam production decreases by adjusting Boiler Feedwater
Inlet flow.
Raw syngas leaving the Final Syngas Cooler shall have a temperature of
approximately 100°F.
Vent Valves and associated piping for the MP and LP Steam Generators shall be
modeled as part of the remote instructor station controls associated with local
operations. Blowdown connections to these steam generators will not be
modeled.

Controls

o Final Syngas Cooler A Spray Flow Control (Temperature Control)
(FV-037)
o MP Steam Generator A Level Control (FV-034/036)
o LP Steam Generator A Level Control (FV-032/033)
o Low Temperature Syngas Cooling Knockout Drum A Level Control
(LV-038/039)

o Process Condensate Pumps A Control
Note: Valves and controls for Gas Cooling, MP and LP Steam Generation, and
Knockout Train B are the same as A. The difference in numbering is the leading
numeral being a “1” vice a “0”. (e.g. LV-137 vice LV-037)

o Final Syngas Cooler B Spray Flow Control (Temperature Control)
(FV-137)
o MP Steam Generator B Level Control (FV-134/136)
o LP Steam Generator B Level Control (FV-132/133)
o Low Temperature Syngas Cooling Knockout Drum B Level Control
(LV-138/139)

o Process Condensate Pumps B Control
91

Human-Machine Interface (HMI) Screens
associated with the Gas Cooling, MP and LP Steam Generation and Knockout Systems,
one per train.
controls. It is assumed that each HMI screen will contain the Gas Cooling, MP and LP
Steam Generation and Knockout controls and instrumentation,
The two HMI Screens for the Gas Cooling, MP and LP Steam Generation and
Knockout Systems will include the process mimic, controls and instrumentation shown
in GCF-FD-001 and will include:
Gas Cooling, MP and LP Steam Generation and Knockout System A HMI:

o Final Cooler A Syngas Spray Flow Control (Temperature Control)
o MP Steam Generator A Level Control
o LP Steam Generator A Level Control
o Low Temperature Syngas Cooling Knockout Drum A Level Control
o Process Condensate Pumps Control
Gas Cooling, MP and LP Steam Generation and Knockout System B HMI:

o Final Cooler B Syngas Spray Flow Control (Temperature Control)
o MP Steam Generator B Pressure Control
o LP Steam Generator B Pressure Control
o Low Temperature Syngas Cooling Knockout Drum B Level Control
o Process Condensate Pumps Control
92

System Malfunctions

following malfunctions will be modeled for the System:
Failure of Process Condensate Pump

Insufficient Feedwater Flow to MP and LP Steam Generators
MP and LP Steam Generators tube leaks
Failure of Low Temp Syngas Cooling Knockout Drum level control

Interconnections
Raw Syngas from the Water-Gas Shift Reactors to the MP and LP Steam
Generators (Gas Cooling).
Raw Syngas to Mercury Removal.
Boiler Feedwater supply to the MP and LP Steam Generators.
Process Condensate to the Final Syngas Cooler Spray.
Process Condensate as Makeup Water to the Low Temperature Syngas Cooling
Knock Out Drum.
Process Condensate to the Syngas Scrubber.
Condensate from the Flash Gas Scrubber to the Low Temperature Syngas
Cooling Knock Out Drum.
Sour Water to the Sour Water Drum
50 psi Steam to the Low Pressure Steam Header
175 psi Steam to the Medium Pressure Steam Header
93

System References
Elsevier.
94
1 2 3 4 5 6 7 8 9 10
50 psi LOW PRESSURE STEAM HDR
A A
175 psi MEDIUM PRESSURE STEAM HDR
FT CONDENSATE
FT FROM FLASH
GAS SCRUBBER
PT PT SPRAY FLOW
CONTROL
FT
MP STEAM LP STEAM
GEN GEN PROCESS
B TE CONDENSATE B
FV-037 GA
SYNGAS FROM
WATER-GAS RAW SYNGAS
SHIFT TO MERCURY
REACTORS TE TT REMOVAL
CONDENSATE
FC LV-038 MAKE-UP WATER
FC FT
CW IN FINAL
FV-036
FV-033
SYNGAS
FT CW OUT
COOLER
C FT TE C
BOILER FEEDWATER TE
LOW TEMP SYNGAS

D COOLING SG KO DRUM D
LT LEVEL
CONTROL
K.O. DRUM
TE
E
PROCESS CONDENSATE E
PUMPS LEGEND
Sour Water
Boiler Feedwater / Makeup Water
TO SYNGAS Syngas
LV-039 MP Steam
SCRUBBER Condensate
LP Steam

Inc.
Columbia, Maryland
DOE-IGCC
SIMULATOR
F F
SOUR WATER
GAS COOLING, BOILER FEEDWATER HEATING, AND
DRIPS TO THE KNOCKOUT
GAS COOLING, BOILER FEEDWATER HEATING, AND
SOUR WATER KNOCKOUT
DRUM DATE DRAWING NO. REV.
06/23/2008 GCF-FD-001 C
1 2 3 4 5 6 7 8 9 10
95
8. Sour Water Strippers

The Sour Water Stripper is common to each of the Gasifier trains.
Remove and reclaim the sour gas from the various process streams for
processing in the Claus Plant
Return process condensate that has been stripped of sour gases to either the
syngas scrubber, coal slurry, and quench water or wastewater treatment
The portion of the process is comprised of the following main components:
Sour Water Knockout Drum

Sour Water Knockout Drum Pump
Sour Water Stripper
Reboiler
Condensate Pot
Process Condensate Pumps
Sour Water Stripper Top Condenser Vessel
Sour Water Stripper Top Condenser Pump
Stripped Condensate Cooler
Sour Water Top Flow Condenser (Air) Cooler
Referring to figure SWS-FD-001 at the end of this document:

The sour water stripper removes H2S, NH3, and other impurities from the syngas
scrubber and other waste streams.
The stripper system consists of a sour drum that accumulates sour water from the
syngas scrubber and condensate from syngas coolers. Sour water from the drum flows
to the sour water stripper, which consists of a packed column with a steam-heated
reboiler. As the sour water flows down the tower, sour gas is stripped from the liquid by
steam. The sour gas and steam rise to the tower cooling section.
The overhead sour gas flows through a top condenser air cooler and from there the
sour gas is sent to the sulfur recovery unit. The condensate is fed back to the stripper.
The stripped water is collected in the tower bottom and is either recycled back to the
process or sent to wastewater treatment. To maintain a minimum required flow through
the stripper, a recycle will be operational when the sour water feed flow to the stripper is
too low. The bottom flow is cooled to meet design specifications for the stripper
condensate.
96
There are several configurations possible for this system, depending on the use of the
stripped water/slurry. In this model, stripped water is used in systems were the
condensate doesn’t have to be solid free so one stripper should be adequate. Also for
training purposes modeling just one stripper is alright.
performance and reliability of the System. Some of the operating parameters that
affect sour water stripper operation are steam rate and tower pressure. Increasing the
steam rate increases the stripping of H2S and NH3. Likewise, lowering the tower
pressure will increase the stripping effectiveness at a constant steam rate, or it will allow
for the decrease in steam rate while achieving the desired stripping effectiveness.
Each of these issues will impact the training effectiveness of the simulator and shall be
taken into account when developing the model. In order to address these issues and
achieve the fidelity of simulation desired for research and operator training of the
simulator model of the System, the following parameters should be addressed in the
model at a minimum:

system operation.
Changes in Stripper operation in response to a loss of steam supply to the
Reboiler.
Changes in Stripper operation based on operational changes in the condensate
recycle, the Air Cooler, or Knockout Drum.
Reboiler Condensate Pot flow to the Sump
If a simplified model will be used, it can be assumed that a constant, small
fraction of sour gas is absorbed by the water. It can also be assumed that all of
the sour gas is stripped out of the water under certain tower pressure and steam
rate conditions.
97
8.3. Controls
Level Control in the Stripper Bottom (LCV-001)

Level Control in Knockout Drum (LCV-002)
Stripped condensate temperature control (TCV-001)
Level control in the stripper top condenser vessel (LCV-003)
Temperature control top condenser discharge (TCV-002)
Recycle minimum flow control (FV-001)
Pressure Control of the Sour Gas exiting the Stripper (PV-001, PV-002)
Flow Control of the Steam to the Reboiler (FV-002)
Level Control of the Reboiler Condensate Pot (LCV-004)

It is anticipated that there will need to be one Human-Machine Interface (HMI) Screens
The HMI Screen shall be in a mimic diagram format with pop-up faceplates for the
instrumentation,
The HMI Screen for the System will include the process mimic, controls and
instrumentation shown in SWS-FD-001 and will include:
o Level Control in the Stripper Bottom
o Stripped Condensate Temperature Control
o Recycle minimum flow control
o Pressure Control of the Sour Gas exiting the Stripper
o Flow Control of the Steam to the Reboiler
o Level Control of the Reboiler Condensate Pot
o Process Condensate Pump Control
o Level Control in Sour Water Knockout Drum
o Level Control in the stripper top condenser vessel
o Temperature Control top condenser discharge
98

following malfunctions will be modeled for the Sour Water Stripper system:
Malfunction of Process Condensate pumps

Failure of top cooler and too much water entering the Claus unit
Failure of acid gas coolers (e.g. no/improper fan speed)
Reboiler failure (e.g. steam pressure to low, level condensate pot to high
Heat Exchanger tube leakage
Failure of measurements
Sour Water from Tail Gas Treatment (from Direct Contact Condenser and Tail
Gas Compressor Intercoolers)
Sour Water from Syngas Scrubber Knockout Drum
Sour Water Drips from LP/MP Steam Gen
Steam to Reboiler
Condensate from Reboiler
Condensate to Sump
Condensate to Process or Wastewater Treatment
Sour Gas to Claus Plant
Sour Gas to Flare Knockout Drum
Sour Water Knockout Drum Vapors to Flare Knockout Drum

99
1 2 3 4 5 6 7 8 9 10
A PV-002 A
TO FLARE
PC
TOP KO DRUM
CONDENSER TC
VESSEL PV-001
SOUR GAS
FROM TGTU TO CLAUS
LC
SOUR WATER
B
DRIPS FROM B
LP/MP STEAM GEN TOP
AIR CONDENSER
COOLER PUMP
SOUR WATER
KNOCKOUT LC
FC
DRUM
C C
SOUR WATER
KNOCKOUT DRUM PUMP
SOUR
WATER
STRIPPER
FC
MIN. FLOW CONTROL
STEAM FLOW
CONTROL
D
FV-001 D
CW LC
FC
REBOILER
PROCESS CONDENSATE TO 65 PSIA STEAM

COAL SLURRY, SYNGAS LCV-001
SCRUBBER AND QUENCH
OR
E STRIPPED CONDENSATE E
WASTEWATER TREATMENT LEGEND
TC CONDENSATE
CONDENSATE FV-002
POT Sour Water/Gas
COOLER LT Condensate
PROCESS
Process Condensate
CONDENSATE Steam
TCV-001 PUMP Cooling Water

Columbia, Maryland
DOE-IGCC
LCV-004 SIMULATOR
F F
SOUR WATER STRIPPING
SOUR WATER STRIPPING

TO SUMP DATE DRAWING NO. REV.
08/01/2008 SWS-FD-001 C
1 2 3 4 5 6 7 8 9 10
100
9. Mercury Removal
There are two Mercury Removal trains, one for each gasification train.
The purpose of the Mercury Removal portion of the process is to:
Remove mercury from the syngas using a packed carbon bed.
Each Mercury Removal train of the process is comprised of the following main
components:
Packed Activated Carbon Mercury Removal Bed (4)

Mercury Removal Preheater (2)
Carbon Bed Regeneration Tanks (2)
Regeneration Separator (1)
Mercury Removal After Cooler (2)\
Mercury Drum (2)
Gas Recycle Blowers (4)
9.1. Description of Mercury Removal Process
Referring to Figure MER-FD-001 at the end of this document
Removal of very low concentrations of Mercury is necessary to meet environmental

regulations. Mercury in Fossil Fuels is vaporized as Elemental Mercury (Hg) during
Gasification, and proceeds with the synthesis gas to the Gas Turbine, where it is
emitted to the atmosphere with the flue gas if unabated. Hg is a heavy metal and an
environmental pollutant, and many States in the USA have already imposed reduction
timetables or are considering stringent legislation regarding emission.
Syngas leaving each of the Final Syngas Coolers in the upstream Gas Cooling System
is cooled to 85-104°F (30 – 40°C), and water is separated from the syngas in a
separator. Therefore the resulting syngas is water saturated. The syngas is then
superheated to a minimum of 5ºF above its water dewpoint in a Mercury Removal
Preheater using MP boiler feedwater. The purpose of the preheating is to prevent
steam condensation on the activated carbon adsorbent, which would lead to serious
mal-performance of the carbon beds. Excessive preheat temperatures will lead to
diminished capacity of the Adsorbent to remove the Hg.
After leaving the preheater, the syngas passes downward through two parallel
Adsorbers which are packed with sulfur-impregnated Activated Carbon Beds that are
designed to remove mercury from the syngas. The Elemental Hg reacts irreversibly and
non-regenerably with the Sulfur to form HgS, and is bound in the Adsorbent pores.
101
Although a chemical reaction (chemi-adsorption) is occurring, the Hg concentration in

the entering syngas is well under 1 ppmv. There is therefore no temperature rise in the
bed during adsorption, and there is no concern whatsoever about a runaway reaction.
Typically the empty vessel design basis gas residence time is approximately
20 seconds. Allowable gas velocities are limited by considerations of particle
entrainment, bed agitation, and pressure drop. One-foot-per-second superficial velocity
is in the middle of the range normally encountered
The syngas exiting the Carbon Bed is optionally cooled in a Mercury Removal
Aftercooler prior to entering the Acid Gas Removal System. This Aftercooler can be
considered redundant, however, since the syngas will be further significantly cooled in
the Feed / Product Heat Exchanger that resides in the downstream Acid Gas Removal
Unit, and all syngas cooling can be handled there.
Adsorbent change out is typically on an 18 to 24 months cycle. Change out may be

required for any of the following reasons:
A buildup in pressure drop

A buildup in water in the bed
A buildup of other contaminants
Mercury breakthrough
The spent activated carbon, now containing bound Hg, must be handled and disposed
of by environmentally acceptable methods and procedures. The spent Adsorbent is
removed from the vessels during scheduled maintenance outages, and would be
characterized for proper disposal.
A Regeneration System is provided to renew the packed activated carbon’s mercury

removal capability. Each Mercury Removal train has a Regeneration Tank to hold the
regenerating chemical, as well as a Mercury Removal Cooler and Drum. The cooler
cools the regeneration gas to a temperature that allows the mercury and water to
condense and drip to the Mercury Removal Drum where the liquid Mercury and water
separate and flow to their respective waste product streams. Gas Recycle Blowers are
provided to preserve the syngas in the volume of the system that is circulated during the
regeneration process. A Regeneration Separator is provided in order to separate the
liquid in the system from the syngas, producing a product slipstream regeneration gas
which is sent back to the main syngas supply line to the Acid Gas Removal System.
102
9.2. Mercury Removal Modeling Expectations
It is anticipated that the Mercury Removal System will be a functional model that allows
the operator to complete the startup, shutdown and normal monitoring of system
equipment.
performance and reliability of the Mercury Removal System. Each of these issues will
simulation desired for research and operator training, the simulator model of the
Mercury Removal System, the following parameters should be addressed in the model
at a minimum:

system operation.
The removal of mercury from the syngas streams will be a constant 95% when
the Mercury Removal System is in operation.
Each of the Packed, Activated Carbon Beds has the capacity to remove up to
95% of the Mercury from its respective syngas stream.
The operator will have the capability to switch syngas flow from one Carbon Bed
to the other.
The operator will have the capability to start and stop each of the Gas Recycle
Blowers.
Liquid Mercury and water flow from the Mercury Drum need not be modeled.
A constant level will be indicated for the Mercury Removal Drum.
The operator will have the ability to bypass the Regeneration Separator.
When in use, the Regeneration Separator will provide liquid/gas separation and a
constant flow of product slipstream regeneration gas to the main syngas supply
line to the Acid Gas Removal System.
The Mercury Removal System shall be designed such that upon startup of the
system:
Increase in pressure in the Adsorbers has to be limited to < 3.5 bar (50 psi)
per minute to prevent crushing of the Adsorbent or undue stress on the
Adsorbent support system via the downward flow of the gas.
Full syngas flows should be attained in a stepwise and incremental fashion to
avoid excessive forces on the Adsorbent or its supports.
103
9.3. Mercury Removal Controls
model:

o None

The outlet temperature of the syngas exiting the Preheater must be
controlled to a minimum of 5ºF above the inlet temperature, and a
maximum of 25ºF, with minimum and maximum alarms.
The outlet temperature of the syngas exiting the Aftercooler must
be controlled to a setpoint, with minimum and maximum alarms.
o Syngas Turndown
When the IGCC Plant is running in turndown mode and the syngas
flow is <60% design flow, then 1 of the 2 parallel beds in each
section will be taken out of service and all the syngas will flow
through the other bed. This can be accomplished manually by the
Operator, or can be automated in the control scheme with the Flow
Controller on the inlet syngas.
o Hg Removal Control
There should be a on-stream analyzer for Hg at the exit of each
Carbon Bed, wth a high-concentration alarm.
o Gas Recycle Blower Control
9.4. Mercury Removal Human-Machine Interface (HMI) Screens
It is anticipated that there will need to be one Human-Machine Interface (HMI) Screen
associated with the Mercury Removal System. Both trains will be controlled from the
same HMI.
controls. It is assumed that the HMI screen will contain the Mercury Removal System
The HMI Screen for the Mercury Removal System will include the process mimic,
controls and instrumentation shown in MER-FD-001 and will include:
Mercury Removal System HMI:

o None
104

o Preheater Start/Stop Controls
o Syngas Turndown
o Hg Concentration in Product Syngas
9.5. Mercury Removal Interconnections
Syngas from the upstream Gas Cooling, Boiler Feedwater Heating, and
Knockout Systems.
Syngas to downstream Acid Gas Removal System.
Closed Cycle Cooling Water to the Mercury Removal Aftercoolers.
Hot MP BFW to Syngas Preheaters
Mercury Removal Aftercooler to Acid Gas Removal
Liquid Mercury to Containment x 2
Liquid Mercury from Containment x 2
Feed Gas from Gasifier Train 2 Gas Cooling Knockout Drum
Feed Gas from Gasifier Train 1 Gas Cooling Knockout Drum
Cooling Water In to Mercury Removal Aftercooler
Cooling Water Out from Mercury Removal Aftercooler
9.6. Mercury Removal References
Corvini, G., Stiltner, J., Clark, K. UOP Paper, Mercury Removal from Natural Gas
and Liquid Streams. Available online at
http://www.uop.com/objects/87MercuryRemoval.pdf
Elsevier.
Western Research Institute, US Department of Energy, National Energy
Technology Laboratory. (2006). Removal of Mercury from Coal-Derived
Synthesis Gas. Available online at
http://www.osti.gov/bridge/servlets/purl/882283-IrdtNX/882283.PDF
105

106
1 2 3 4 5 6 7 8 9 10
BL-3A
GAS RECYCLE
BLOWERS
A
A BL-4A A
TE PT FT TE
FEED GAS FROM
PRE
GASIFIER TRAIN 1 GAS
HEATER
COOLING K.O. DRUM
CW IN
MERCURY
BYPASS REMOVAL COOLER
A CW OUT
B B
TE TE TE TE
CARBON CARBON REGEN

BED BED MERCURY
D/P D/P D/P
DRUM
REGEN 1A 2A A WATER TO
LT
SEPARATOR 1 DRAINS
C
LIQUID MERCURY TO C
MERCURY CONTAINMENT
TE
MERCURY FREE
SYNGAS TO ACID GAS REMOVAL
PRODUCT SLIPSTREAM REGENERATION GAS
D LIQUID MERCURY TO D
MERCURY CONTAINMENT
TE TE TE
MERCURY WATER TO
LT
CARBON CARBON REGEN DRUM DRAINS
BED BED
D/P D/P D/P
2
1B 2B B
TE
E E
CW IN LEGEND
MERCURY
REMOVAL COOLER
Syngas
B Regeneration Slipstream
CW OUT
TE PT FT Regeneration Flow
FEED GAS FROM
PRE Gas Recycle
GASIFIER TRAIN 2 GAS Cooling Water / Water
HEATER
COOLING K.O. DRUM
TE
BL-5B Columbia, Maryland
DOE-IGCC
SIMULATOR
F F
MERCURY REMOVAL SYSTEM

BL-6B
GAS RECYCLE MERCURY REMOVAL SYSTEM
BLOWERS DRAWING NO. REV.
DATE
B
08/01/2008 MER-FD-001 C
1 2 3 4 5 6 7 8 9 10
107
10. Selexol Acid Gas Removal with CO2 Capture

The simulator reference plant includes one two-train, dual stage Selexol (Acid Gas
Removal) Unit which receives the shifted raw syngas flowing out of the Mercury
Removal System from each Gasifier train.
The purpose of the Dual Stage Selexol Unit portion of the process is to:
Remove the Hydrogen Sulfide (H2S) and Carbon Dioxide (CO2) gas from the raw
syngas stream, creating three product streams
o Clean syngas for the combustion turbine, less then TBD ppm H2S
o H2S gas for conversion in the Claus Plant, more then TBD ppm H2S
o CO2 for drying, compression and sequestration, less then TBD % CO2
One train of the two Dual Stage Selexol Unit is shown in flow diagram AGR-FD-2 at the
end of this document. The system is comprised of the following main components:
H2S Absorber 2 x 50%

Rich Solvent Strainer 2 x50%
Lean/Rich Solvent Heat Exchanger 2 x 50%
4 x 50% Lean Solvent Pumps
Lean Solvent Strainer 2 x 50%
Lean Solvent Cooler 2 x 50%
CO2 Absorber 2 x 50%
4 x 50% Loaded Solvent Pumps
Loaded Solvent Cooler 2 x 50%
H2 Recovery Drum 2 x 50%
MP Flash Drum 2 x 50%
LP Flash Drum 2 x 50%
4 x 50% Semi-lean Solvent Pumps
H2 Recovery Compressor 2 x 50%
H2 Recovery Cooler 2 x 50%
H2 Recovery Knock Out Drum 2 x 50%
H2S Concentrator 2 x 50%
Steam Heater 2 x 100%
Stripped Gas Knockout Drum2 x 50%
Stripped Gas Cooler 2 x 50%
Stripped Gas Compressor 2 x 50%
Selexol Stripper 1 x 100%
Reboiler 1 x 100%
Acid Gas Cooler 1 x 100%
Acid Gas Knock Out Drum 1 x 100%
2 x 100% Reflux Pumps
108
10.1. Description of Selexol Acid Gas Removal Process
Referring to AGR-FD-2 at the end of this document is the process description of one
train:
The Selexol Acid Gas Removal Process (AGR) with CO2 Capture removes the
Hydrogen Sulfide (H2S) and Carbon Dioxide (CO2) gas from the shifted raw syngas
Stream, creating three product streams: clean syngas for the combustion turbine, H2S-
rich acid gas for use in the Claus Plant, and CO2 for sequestration. There are three
major vessels in the AGR process, the H2S Absorber, CO2 Absorber and the Stripper.
Both Absorber columns use Selexol for H2S and CO2 capture. Selexol is a physical
solvent which has an affinity to absorb both CO2 and H2S at high partial pressures and
low temperature and will release those gases when the solvent is depressurized and
heated. CO2 stripping is accomplished by flashing the gas off at various pressures.
H2S is stripped from the Selexol through reboiling and recirculation action.
Selexol H2S Absorber
Raw shifted Syngas from the gasification process is fed to the Selexol H2S Absorber.
Here, the cooled syngas is fed into the lower section of the Absorber below the
Absorber mixing trays. The syngas leaves the top of the H2S absorber. “Loaded”
solvent pumped from the bottom of the CO2 Absorber is cooled in the Loaded Solvent
Coolers and fed to the upper section of the H2S Absorber where it flows down across
the mixing trays. At this point, the solvent absorbs H2S in the syngas and becomes
“rich” solvent. This rich solvent flows out of the bottom of the Absorber through the Rich
Solvent Strainer which removes any solids that may be contained in the liquid. The rich
solvent then flows through a Lean/Rich Heat Exchanger where the rich solvent is
heated by lean solvent coming from the Stripper. After this preheating takes place, the
hot, rich solvent flows to the inlet of the H2S Concentrator where it partially flashed via
depressurization.
The stripped gases from the H2S Concentrator (predominantly CO2) are cooled, dried,
compressed and sent back to the raw syngas inlet of the H2S Absorber. The solvent
leaving the bottom of the H2S Concentrator is sent to the Stripper so that the remaining
gases in the rich solvent are liberated.
The clean or “sweet” fuel syngas flows out of the top to the H2S Absorber to the CO2
Absorber vessel.
Selexol Stripper
In the Stripper, rich solvent is heated in order to separate the H2S from the solvent.
Rich solvent from the H2S Concentrator enters the chimney portion of the Stripper at the
top, and the H2S that is easily separated vaporizes and goes off the top the unit,
together with the rest of the stripped steam and a small portion of the entrained Selexol.
109
This acid gas stream is cooled, so the condensed steam and the Selexol will enter the
stripper again as reflux. A small portion of the reflux will be blown off to keep the water
content of the Selexol constant. The solvent in the Selexol stripper is heated in the
Selexol Reboiler. The Reboiler uses low pressure steam (at approximately 50 psig) to
heat the solvent. The stripped steam rises in the column and aids in the separation of
the incoming rich solvent until the H2S exits at the top.
There are two major flows out of the Selexol Stripper, lean solvent that is recirculated
back to the CO2 Absorber from the Stripper bottom, and H2S-rich acid gas that flows out
of the top of the Stripper.
Lean solvent at the bottom of the Stripper is supplied to the inlet of the 2 x 100%
capacity Lean Solvent Pumps. The in-service pump discharges the lean solvent
through a strainer and pumps the lean solvent through the Lean/Rich Heat Exchangers
where the lean solvent is cooled as it preheats the rich solvent flowing to the H2S
Concentrator. The lean solvent then flows through the Lean Solvent Cooler where it is
cooler further prior to entering the chimney of the CO2 Absorber. In the CO2 Absorber,
the solvent cycle begins again by absorbing CO2 in the clean syngas coming from the
H2S Absorber.
The “sour” H2S-rich acid gas that is discharged from the top of the Stripper is routed
through an Acid Gas Cooler, where its temperature is lowered. Steam will condense
and any solvent remaining is removed from the sour gas. The Acid Gas Cooler is air
cooled by multiple speed fans. The exit temperature of the acid is controlled by
modulation of the Acid Gas Cooler Air Vanes. It is desirable to condense all the solvent
while keeping the temperature as high as possible so the H2S gas will not be absorbed
by the solvent. The condensed liquids removed from the acid gas stream are collected
in a Knock Out Drum and pumped back to the Stripper as reflux by either of the 2 x
100% capacity Reflux Pumps, while the acid gas exits from the Knock Out Drum and
leaves the Selexol Unit for processing in the Claus Plant to recover elemental Sulfur
from the H2S gas.
CO2 Absorber and CO2 Capture
The syngas leaving the H2S absorber is fed into the CO2 absorber. The CO2 Absorber
receives the lean solvent in the chimney portion of the structure near the top. The lean
solvent flows down over the upper tray and mixes with the semi-lean solvent from the
LP Flash Drum being fed at the top of the lower tray. This semi-lean solvent is the
resulting solvent flow after the CO2 Absorption and removal takes place. The gas outlet
of the CO2 absorber contains H2S and CO2.
A portion of the loaded solvent flow from the bottom of the CO2 Absorber is processed
for removal of captured H2 and CO2. The remainder flows to the Loaded Solvent
Pumps and eventually is used in the H2S Absorber.
110
The loaded solvent splits off for CO2 and H2 removal and is sent through a series of
three flash drums that operate at descending pressures (the first being the highest
pressure). The three drums involved in the CO2 removal process in order of flow are:
the H2 Recovery Drum operating at approximately 300 psia, the Medium Pressure (MP)
Flash Drum operating at approximately 150 psia and the Low Pressure (LP) Flash Drum
operating at approximately 75 psia.
H2 is recovered in the H2 Recovery Drum by flashing the loaded solvent, and then
compressing and cooling the resulting H2 and returning it to the CO2 Absorber syngas
inlet.
CO2 is recovered in the process as the solvent flashes in the MP and LP Flash Drums.
After the CO2 comes out of solution, it is sent to the CO2 Compression Unit.
Selexol Makeup Flow
Makeup of Selexol is provided from a constant volume (for simulation purposes)

makeup inventory through a Selexol Makeup Pump (SX-P-4). Makeup can be provided
to the system through a connection just upstream of the inlet of the Lean Solvent
Pumps by starting the Selexol Makeup Pump. A separate fill line is also provided at the
inlet of the Lean Solvent Booster Pumps, but is only graphically modeled. To simplify
the simulation, Selexol makeup is provided through only one piping header.
111
10.2. Selexol Acid Gas Removal System Modeling Expectations

It is anticipated that the Selexol Acid Gas Removal System will be a high fidelity model
that allows the operator to complete the startup (cold and hot), shutdown, ramp up and
down at the required rate and normal monitoring of system equipment. Since the AGR
is a two-train system, with its own dynamics, the model should also include this two-
train AGR. Since Selexol is a proprietary solvent, its behavior can be approximated by
using a similar chemical component.
performance and reliability of the Selexol Acid Gas Removal System. Each of these
issues will impact the training effectiveness of the simulator and shall be taken into
account when developing the model. In order to address these issues and achieve the
fidelity of simulation desired for research and operator training, the simulator model of
the Selexol Acid Gas Removal System, the following parameters should be addressed
in the model at a minimum:
System compositions, pressures, flows, levels, and temperatures will respond to
liquid equilibrium.
H2S and CO2 gas concentrations at each of the gas analyzers.
Selexol components will be modeled with a chemical species with the same
molecular weight and similar behavior.
Shifted raw syngas inlet flowrate, and system response to changes in its value,
and composition.
Clean syngas flowrate and composition and its response to changes in system
operation and CT loading.
CO2 outlet gas flowrate response to changes in system operation and loading.
Operational parameters while operating with one side of a cooler or heat
exchanger isolated.
Stripper operation and change in vaporization in response to dynamics in steam
supply to the Reboiler.
Changes in Stripper and Absorber operations based on operational changes in
the Reflux Pumps, the rich solvent steam heater, the Acid Gas Coolers, or Knock
Out Drum.
Changes in CO2 Absorber operations based on changes in the H2 Recovery
portion of the process.
Operation with the Acid Gas Cooler Fans in both slow and fast speed.
Reboiler Condensate Pot flow to the Sump.
Acid Gas flowrate to Claus Plant.
IGCC vendor as validation of the dynamic model at normal operating conditions
Ambient temperature.
112
10.3. Selexol Acid Gas Removal System Controls
At a minimum, the following primary control schemes will be included as part of the
simulator model:
• H2S concentration control (Selexol inlet)

o By forward control the raw syngas absorber inlet flow and sulphur + CO2
concentration are used to control the Selexol inlet flow and the flow is
adjusted by the actual H2S absorber outlet concentration.
• CO2 concentration control (if desired)
o Same principle as the H2S control
• Lean solvent Temperature Control
o Stabilizes the system, not absolutely necessary
• Selexol stripper reflux bleed flow adjustment
• Selexol make up water inlet flow adjustment
• Reboiler steam flow Control
o Forward control of reboiler condensate pot level by inlet Selexol flow.
• H2S concentrator inlet Temperature Control
o When Selexol steam heater is added, then use temperature control with
control valve in condensate outlet of the heater.
H2S Absorber Selexol Inlet Flow Control See above (SX-FV-001/002)
H2S Absorber Column Bottoms Level Control (SX-FV-003)
H2S Concentrator Level Control (SX-FV-004)
CO2 Absorber Level Control CO2 absorber Selexol inlet
valve
H2 Recovery Level Knock Out Drum Level Control (SX-FV-006)
Selexol Stripper Level Control (SX-FV-007)
Reboiler Steam Pressure Control (SX-FV-005)
Reboiler Condensate Pot Level Control see above (SX-LCV-001)
Acid Gas Cooler Cooling Fan Speed Control (Slow/Fast)
Acid Gas Cooler Air Vane Control (85-95F by 0-100%
position)
Acid Gas Cooler Knock Out Drum Level Control (SX-FV-005)
If required flow control in solvent split-off system for CO2 en H2 removal
113
10.4. Selexol Acid Gas Removal System HMI Screens
It is anticipated that there will need to be two Human-Machine Interfaces (HMI) per AGR
train to cover an overall view associated with the Selexol Acid Gas Removal System.
controls. It is assumed that one HMI screen will contain the H2S and CO2 Absorber
controls and instrumentation. The other will contain the Stripper Controls and
Instrumentation. (I think this is to less, also the flash drums, heat exchangers, pumps,
concentrator need some place at the screens),
The HMI Screens for the AGR process will include the process mimic controls and
instrumentation shown in AGR-FD-2, and will include:
H2S and CO2 Absorber A HMI

o Absorber Trays Inlet Flow Control
o H2S Absorber Column Bottoms Level Control
o CO2 Absorber Level Control
o H2 Recovery Level Knock Out Drum Level Control

o Lean Solvent Pump Controls
o Loaded Solvent Pump Controls
o Semi-Lean Solvent Pump Controls
o Gas Analyzers (8)
Selexol Stripper A HMI

o H2S Concentrator Level Control
o Selexol Stripper Level Control
o Reboiler Steam Pressure Control
o Reboiler Condensate Pot Level Control
o Acid Gas Cooler Air Vane Control
o Acid Gas Cooler Knock Out Drum Level Control
114

o Acid Gas Cooler Cooling Fan Speed Control
o Stripped Gas Compressor Control
o Reflux Pump Controls
o Gas Analyzers (3)
H2S and CO2 Absorber B HMI

o Absorber Trays Inlet Flow Control
o H2S Absorber Column Bottoms Level Control
o CO2 Absorber Level Control
o H2 Recovery Level Knock Out Drum Level Control

o Lean Solvent Pump Controls
o Loaded Solvent Pump Controls
o Semi-Lean Solvent Pump Controls
o Gas Analyzers (8)
Selexol Stripper B HMI

o H2S Concentrator Level Control
o Selexol Stripper Level Control
o Reboiler Steam Pressure Control
o Reboiler Condensate Pot Level Control
o Acid Gas Cooler Air Vane Control
o Acid Gas Cooler Knock Out Drum Level Control
115

o Acid Gas Cooler Cooling Fan Speed Control
o Stripped Gas Compressor Control
o Reflux Pump Controls
o Gas Analyzers (3)
10.5. Selexol Acid Gas Removal System Malfunctions

Plugged Filters
Heat Exchanger Fouling
Foaming in the absorbers due to fouled solvent or to high water content
Improper Selexol / Water ratio
Selexol degradation
Process Control Failures, valve position indicators, control valve suddenly on
manual
Running with 1 out of 2 AGR trains
Heat Exchanger Tube Leakage
Failure of acid gas coolers (e.g. no fan speed)
Reboiler failure (e.g. steam pressure to low, level condensate pot to high
116
10.6. Selexol Acid Gas Removal System Interconnections
The Selexol Acid Gas Removal System has the following interconnections with other
plant systems and equipment:
Treated Syngas Supply to the Combustion Turbine(s)

Acid Gas Supply to the Claus Plant
CO2 to Drying and Compression System
Process Condensate Return from the Reboiler Condensate Pot
Process condensate from additional Selexol heater
Selexol Solvent Makeup from a makeup source
Additional anti-foam from a source
Water Makeup from a makeup source
o Lean Solvent Cooler
o Loaded Solvent Cooler
o H2 Recovery Cooler
o Stripped Gas Cooler
50 psia Steam to the Reboiler
Process Condensate Return from Prepurifier Regenerative Heater and Cooler
Shifted syngas from syngas production
117
10.7. Selexol Acid Gas Removal System References
Breckinridge, W., Holiday, A., Ong J., Sharp C. (2000). “Use of Selexol Process
in Coke Gasification to Ammonia Project”. Paper presented at Laurence Reid
Gas Conditioning Conference, Norman, Oklahoma.
Heaven, D., Mak. J., Kubek, D., Clark, M. (2004). Synthesis Gas Purification in
Gasification to Ammonia/Urea Plants. Paper presented at Gasification
Technologies Conference, Washington, D.C. Available online at
http://www.gasification.org/Docs/2004_Papers/26KUBE.pdf.
Elsevier.
HTC Pure Energy. CO2 Capture Process. Available online at
http://www.htcenergy.com/co2info.html
Snyder, W.G., and Depew, C.A. (1986). Coproduction of carbon dioxide (CO/sub
2/) and electricity. EPRI-AP-4827.
UOP. (2008). Gas Processing: Selexol Process. Available online at
http://www.uop.com/objects/Selexol.pdf.
118
1 2 3 4 5 6 7 8 9 10
TO CO2
DRYING AND
TREATED SYNGAS COMPRESSION
PT PT H2 RECOVERY
GAS
A ANALYZER KNOCK OUT DRUM A
RV-104 CO2 , H2S TE TE LT
RV-105
CW IN
3AB 3BB
CW OUT
LC
CW IN
3AA 3BA
CW OUT
CO2 P-5A P-5B
PT PT FV-006
ABSORBER SEMI-LEAN
H2 RECOVERY
B SOLVENT B
COOLER VENT
PDIT TE TE PUMPS
GAS
PT
H2 RECOVERY ANALYZER
COMPRESSOR
TE
H2
CO2 RECOVERY VENT
ABSORBER DRUM
LT
C GAS LEVEL HP FLASH C
ANALYZER CONTROL DRUM
H2S
LP FLASH
LOADED DRUM
P-1A SOLVENT
PUMPS
PT PT
FT P-1B
RV-101 FROM STRIPPED TE TE
RV-102 GAS COMPRESSOR
CW IN
D D
1AB 1BB
PT PT CW OUT
FV-001
TE TE
CW IN
CW IN 1AA 1BA
FT 2AB 2BB CW OUT
SELEXOL H2S CW OUT
ABSORBER PT LEAN PT
PDIT SOLVENT
COOLERS
CW IN TE TE
E
FV-002 2AA 2BA E
FT CW OUT
LEGEND
PT PT FROM LEAN / RICH Rich Solvent
LOADED
RAW HEAT EXCHANGER Lean Solvent
TE SOLVENT Liquid
SYNGAS Vapor
TE COOLERS TE
LT Liquid/Vapor Mixture
Loaded Solvent
CO2 Capture
ABSORBER H2 Recovery Liquid
FT
BOTTOMS LEVEL Condensate/Cooling Water
CONTROL FOSSIL CONSULTING SERVICES, INC.
H2S, COLUMBIA, MARYLAND, USA
QT FT
CO2 TO LEAN / RICH DOE-NETL-IGCC
F HEAT EXCHANGER SIMULATOR F
FV-003 (On AGR-FD-4)
RICH AGR WITH CO2 CAPTURE
H2S SOLVENT
FLOW DIAGRAM
CONTROL STRAINER
F-010 PDIT DATE DRAWING NO. REV.
05/28/2008 AGR-FD-3 0
1 2 3 4 5 6 7 8 9 10
119
1 2 3 4 5 6 7 8 9 10
TO CLAUS
PLANT
TE
AIR VANE
CONTROL
A A
TO H2S AC-1A AC-2A TE

ABSORBER GAS
ANALYZER
ACID GAS
FT COOLERS
STRIPPED GAS ACID GAS
COMPRESSOR TO CLAUS
PLANT
GAS
B FT B
ANALYZER CW IN ACID GAS
CW OUT KNOCK OUT
STRIPPED
LT DRUM MAKEUP
GAS COOLER
WATER
H2S
CONCEN- ACID GAS
TRATOR KNOCK OUT
DRUM LEVEL
PDIT
CONTROL REFLUX
PT PUMPS
STRIPPED GAS
LT KNOCK OUT P-3B P-3A
LC REFLUX
C TE DRUM C
BLEED
LT
FT
FV-005
LC
PT TE
TE FT
FT RV-103
D D
PDIT SELEXOL
STRIPPER
FT
FROM RICH FV-004
SOLVENT
STRAINER REBOILER
(On AGR-FD-3) TEMP PT REBOILER
CONTROL STEAM
PT
CONTROL
TE CONDENSATE
TE CONDENSATE LT POT LEVEL
TE POT
COND. CONTROL
50# STEAM
E E
STEAM FT
TO LEAN
LEAN / RICH HEATER LEGEND
SOLVENT
HEAT EXCHANGER LT Rich Solvent
COOLERS STEAM Lean Solvent
HX - 1A / 1B
LCV-001 Liquid
1C / 1D STRIPPER Vapor
BOTTOMS LEVEL Liquid/Vapor Mixture
Loaded Solvent
C A LEAN SOLVENT CONTROLLER CO2 Capture
STRAINER H2 Recovery Liquid
F-020 Condensate/Cooling Water
P-2A FV-007
FOSSIL CONSULTING SERVICES, INC.
COLUMBIA, MARYLAND, USA
LEAN TO SUMP
DOE-NETL-IGCC
F
SOLVENT SIMULATOR F
FT
D B PUMPS
P-2B AGR WITH CO2 CAPTURE
FROM SELEXOL MAKEUP
AND ANTI FOAM FLOW DIAGRAM
PDIT P-4 DATE DRAWING NO. REV.
05/28/2008 AGR-FD-4 0
1 2 3 4 5 6 7 8 9 10
120
11. CO2 Compression

There are two CO2 Compression trains which receives CO2 from the Selexol Acid Gas
Removal System.
The purpose of the CO2 Compression portion of the process is to:
Compress, and dry the captured CO2 to the plant fence for transport and
sequestration or sale.
Each The CO2 Compression train portion of the process is comprised of the following
main components:
Multiple Stage, Intercooled Centrifugal CO2 Compressor

o Individual Compressor Stages
o Individual Stage Suction Drums
CO2 Aftercooler
Glycol Tower
11.1. Description of CO2 Compression Process
Referring to figure COC-FD-001 at the end of this document:
Each CO2 Compression Train consists of a, five stage, intercooled, centrifugal CO2
Compressor connected to a Glycol dehydration system. Each compressor receives
CO2 at two different pressure levels from the CO2 capture portion of the Selexol Acid
Gas Removal System and raises the CO2 pressure from atmospheric, to about 2200 psi.
As a part of this process, the CO2 undergoes a phase shift from gas to supercritical fluid.
The CO2 from the LP Flash Drum of the Selexol system enters at the CO2 Compression
system at the 1st Stage Suction Drum. The CO2 from the MP Flash Drum of the Selexol
system enters the CO2 Compression system at the discharge of the 1st Stage
Aftercooler.
The pressure of the CO2 is raised as the gas passes from stage to stage. When the
CO2 reaches the end of the fourth stage, it passes to a Glycol Tower where the CO2 is
dried by mixing with Tri-ethylene Glycol, thereby minimizing the possibility of corrosion
in the transport piping due to moisture being present.
121
11.2. CO2 Compression Modeling Expectations
It is anticipated that the CO2 Compression System will be a first principle / high fidelity
model that allows the operator to complete the startup, shutdown and normal operation
and monitoring of system equipment.
performance and reliability of the CO2 Compression System. Each of these issues will
simulation desired for research and operator training, the simulator model of the CO2
Compression System, the following parameters should be addressed in the model at a
minimum:

system operation.
Rigorous equation of state or other thermodynamic systems will be used to
calculate supercritical CO2 properties at high pressures.
Each CO2 Compressor has an Inlet Pressure Control Valve which regulates the
inlet flow of CO2.
Interstage pressure is allowed to float to maintain pressure throughout the
compressors. Recycle valves in between stages allow spillback to maintain CO2
flow and keep the compressors out of surge.
Compressor stages will be cooled by interstage coolers connected to a heat
exchanger model that is based on a cooling fluid.
Each compressor stage is modeled by a typical compressor performance curve.
Glycol Regeneration and Glycol Tower Level Control shall be a simple functional
model. For simulation purposes, the glycol will not require regeneration, but the
operator will see that a regeneration process would normally exist for the process.
The CO2 Compressors are driven by variable speed motors to help control
throughput without energy by spillback recycle operations.
122
11.3. CO2 Compression Controls
model:
CO2 Compression System A HMI:

o LP CO2 Compressor A Inlet Pressure Control (PV-040)
o MP CO2 Compressor A Inlet Pressure Control (PV-048)
o CO2 Discharge Pressure Control (PV-046)
o CO2 Compressor A Anti Surge Controller (PV-049)
o CO2 Compressor A Variable Speed Motor Control

o Glycol Regeneration and Level Control
o CO2 Compressor A Interstage Pressure Control (PV-041 / 042 / 043 / 044 /
045)
o CO2 Compressor A Discharge MOV (MOV-047)
CO2 Compression System B HMI:
Note: Valves and controls for CO2 Compression Train 2 are the same as 1. The
difference in numbering is the leading numeral being a “1” vice a “0”. (e.g. LV-140 vice
LV-040)

o LP CO2 Compressor B Inlet Pressure Control (PV-140)
o MP CO2 Compressor A Inlet Pressure Control (PV-148)
o CO2 Discharge Pressure Control (PV-146)
o CO2 Compressor B Anti Surge Controller (PV-149)
o CO2 Compressor B Variable Speed Motor Control

o CO2 Compressor B Interstage Pressure Control (PV-141 / 142 / 143 / 144 /
145)
o CO2 Compressor B Discharge MOV (MOV-147)
123
11.4. CO2 Compression Human-Machine Interface (HMI) Screens
associated with the CO2 Compression System.
controls. It is assumed that each HMI screen will contain the CO2 Compression System
controls and instrumentation,
The two HMI Screens for the CO2 Compression System will include the process mimic,
controls and instrumentation shown in COC-FD-001 and will include:
CO2 Compression System A HMI:

o LP CO2 Inlet Pressure Control
o MP CO2 Inlet Pressure Control
o CO2 Compressor A Discharge Pressure Control
o CO2 Compressor A Anti Surge Controller
o CO2 Compressor A Variable Speed Motor Control

o CO2 Compressor A Interstage Float Pressure Control
o H2O Dewpoint
CO2 Compression System B HMI:
The HMI for CO2 Compression System B will be exactly the same as CO2 Compression
System A with the following exceptions:
The inlet and discharge cross connections will read, “To Train 1”, and “From
Train 1” respectively.
PV-146 (Compressor A Discharge Pressure Control Valve) will receive an input
from the Combined CO2 Discharge Pressure Controller.
124

o LP CO2 Compressor B Inlet Pressure Control
o MP CO2 Compressor B Inlet Pressure Control
o CO2 Compressor B Discharge Pressure Control
o CO2 Compressor B Anti Surge Controller
o CO2 Compressor B Variable Speed Motor Control

o CO2 Compressor B Interstage Float Pressure Control
o H2O Dewpoint
11.5. CO2 Compression Malfunctions
Variable Speed Motor Trip

Variable Speed Motor Control Malfunction
Compressor Inlet Valve Failure
Compressor Discharge Valve Failure
Interstage recycle valve failure
Intercooler Air Fan Motor Trip
11.6. CO2 Compression Interconnections
LP and MP CO2 from the Selexol Acid Gas Removal System

CO2 to pipeline
CO2 to venting drum
125
11.7. CO2 Compression System References
Elsevier.
HTC Pure Energy. CO2 Compression. Available online at
http://www.htcenergy.com/co2info.html.
In-Salah Gas. The In-Salah CCS Experience, Sonatrach, Algeria. Available
online at http://www.opec.org/home/Press%20Room/EU-
OPEC%20presentations/HaddadjiSonatrach%20Algeria.pdf
126
1 2 3 4 5 6 7 8 9 10
WATER DEW POINT
A A
TE
PV-049
FROM MP CO2 GLYCOL

FLASH DRUM REGENERATION
& LEVEL CONTROL PDIT
CO2 COMPRESSOR COMPRESSOR

B B
A INLET PRESSURE INTERSAGE
CONTROL PRESSURE CONTROL COMPRESSOR
SURGE / SPILLBACK
FROM LP CO2 CONTROL
PV-048
FLASH DRUM
PV-040
PT
VENT TO
ATMOSPHERE
PV-042 PV-043 PV-044 PV-045
PV-041
C C
CO2 DISCHARGE
PRESSURE
CONTROL
PT
D PV-046 MOV-047 D
LT LT LT LT LT
FT
CO2
SUCTION DRUM
PT
AFTER COOLER
PT PT PT TE TO CO2 PIPELINE
TE
TE TE TE
M 1ST STAGE 2ND STAGE 3RD STAGE 4TH STAGE 5TH STAGE
E E
TO DRAIN
LEGEND
Main CO2 Compression

CO2 Interstage / Recycle Flow
TO VENTING Glycol
DRUM
Columbia, Maryland
DOE-NETL-IGCC
SIMULATOR
F F
CO2 COMPRESSION AND DRYING
FLOW DIAGRAM
04/02/2008 COC-FD-001 B
1 2 3 4 5 6 7 8 9 10
127
12. Syngas Reheat and Expansion

There are two sets of Syngas Reheat and Expansion equipment, one set per
Combustion Turbine.
Reheat the syngas prior to the expansion process so that there is no risk of the
expander outlet temperature dropping below the dew point of the gas.
Lower the pressure of syngas while making power prior to sending the fuel to the
combustion turbine
Each train of the portion of the process is comprised of the following main components:
Fuel Gas Reheater

Fuel Gas Expander Turbine-generator (Turbo-expander)
Referring to figure RHE-FD-001 at the end of this document:
Clean syngas from the AGR system is combined with a small amount of clean gas from
the CO2 compression process and heated to 465°F using Cold Reheat steam before
passing through an expansion turbine.
The temperature of the syngas entering the Expander will be controlled by varying the
amount of steam entering the Fuel Gas Reheater. Using the Expander inlet
temperature as the lead control value should also provide better system response. The
condensed steam from the Fuel Gas Reheater will be routed to the condenser. Since
there is a concern with the expander outlet temperature dropping too low, a temperature
alarm on the expander outlet shall be provided.
Pressure control of the Syngas entering the Expander will be based on the Syngas
pressure upstream of the Fuel Gas Heater and pressure relief to flare. Based on this
setup, the combustion turbine will control the Expander backpressure.
The capability to bypass the Fuel Gas Expander will be included in the event of an
Expander trip or during startup. The bypass will include a pressure reducing station that
can accommodate startup conditions as well as a full load Expander trip. Isolation
valves for both the Expander and the pressure reducing station in the bypass line shall
be included.
128
System pressures, flows, levels, temperatures and turbine power output will
respond to changes in system operation.
Ambient temperature.
12.3. Controls
model:
Temperature Control of the Syngas entering the Fuel Gas Expander

(TCV-001)
Pressure Control of the Syngas entering the Fuel Gas Expander
(PV-001, PV-002)
Pressure Control of the Syngas exiting the Acid Gas Removal System
(PV-003) with set pressure about 15 psi above PV-001
Note: Valves and controls for Syngas Reheat and Expansion Unit Train 2 are the same
as 1. The difference in numbering is the leading numeral being a “1” vice a “0”. (e.g.
TCV-101 vice TCV-001)
Temperature Control of the Syngas entering the Fuel Gas Expander

(TCV-101)
Pressure Control of the Syngas entering the Fuel Gas Expander
(PV-101, PV-102)
Pressure Control of the Syngas exiting the Acid Gas Removal System
(PV-103) with set pressure about 15 psi above PV-101
129
instrumentation,
The two HMI Screens for the System will include the process mimic, controls and
instrumentation shown in RHE-FD-001 and will include:
System A HMI:

o Temperature Control of the Syngas entering the Fuel Gas Expander
o Pressure Control of the Syngas exiting the Fuel Gas Expander

o None
Process Instrumentation (with alarms)

System B HMI:

o Temperature Control of the Syngas entering the Fuel Gas Expander
o Pressure Control of the Syngas exiting the Fuel Gas Expander

o None
Process Instrumentation (with alarms)

130

following malfunctions will be modeled for the Syngas Reheat and Expansion system:
Trip of Fuel Gas Expander – Syngas will be bypass the Fuel Gas Expander and
throttled to the appropriate pressure
Slow reaction of transfer to bypass on expander trip –release of gas to flare.
Flare indication/alarm – open (or not closed) position of PV-003 and PV-103 can
be used to signify this event
Slow reaction of transfer to bypass on expander trip – drop of inlet pressure to
gas turbine.
Loss of steam – Low temperature alarm on Expander exit.
Cold Reheat Steam to Fuel Gas Reheater

Clean Syngas from Selexol AGR System
CO2 Vent from CO2 Compressor
Condensate from Fuel Gas Reheater
Syngas to Gas Turbine

Availability Improvement of an IGCC Plant: A Successful Example at API Energia
SPA – Falconara Facility, S. Arienti, C. Boeri, M. Sinisi, P. Ciccarelli.
131
1 2 3 4 5 6 7 8 9 10
A A
B
COLD B
REHEAT
STEAM TCV-001
CO2 VENT
FROM CO2 TC PC
COMPRESSOR FUEL GAS
REHEATER
SYNGAS
TO GAS
FROM AGR
C TURBINE C
SYSTEM PV-001
~
FUEL GAS
EXPANDER
D D
TO TRAIN 2 PV-002
TO CONDENSER
E E
LEGEND
Sweet Syngas
Condensate
Cold Reheat Steam
CO2

Columbia, Maryland
DOE-IGCC
SIMULATOR
F F
SYNGAS REHEAT AND EXPANSION
SYNGAS REHEAT AND EXPANSION
06/25/2008 RHE-FD-001 A1
1 2 3 4 5 6 7 8 9 10
132
13. Claus Plant

There is one Claus plant which receives H2S from the Selexol unit.
Partially oxidize the H2S in the acid gas to elemental sulfur

Produce low pressure steam for the low pressure steam header
The portion of the process is comprised of the following main components:
O2 Heater
Sour Gas Heater
Acid Gas Heater
Claus Furnace
Waste Heat Boiler
Sulfur Condensers (3)
Converter Preheaters (2)
Sulfur Converters (2)
Referring to figure SRU-FD-001 at the end of this document:
There is only one, oxygen-blown Claus Plant that receives acid gas from the AGR
system and sour gas from the sour water stripper. The Claus process converts H2S to
elemental sulfur.
The first reaction shown below is thermal and occurs in the reaction furnace. The
furnace temperature should be high enough to destroy any ammonia in the acid gas.
H2S + 3/2 O2 ↔ H2O + SO2
2H2S + SO2 ↔ 2H2O + 3S
One-third of the H2S is oxidized to SO2. The newly formed SO2 reacts with the
remaining H2S to form elemental sulfur. Since these reactions are highly exothermic, a
waste heat boiler, which recovers this heat to generate high-pressure steam while
cooling the process stream, usually follows the furnace. Sulfur is condensed in a
condenser that follows the high-pressure steam recovery section and is drained through
a seal leg to the sulfur pit. Low-pressure steam is raised in the condenser from further
cooling of the process gas.
133
The tail gas from the first condenser then goes to two catalytic conversion stages,
where the remaining sulfur is recovered via the Claus reaction:
3H2S + 3/2 O2 ↔ 3H2O + 3S
The Claus reaction is catalytic and equilibrium limited. The sulfur in the vapor phase
exists as S2, S6, and S8 molecular species, with the S2 predominant at higher
temperatures, and S8 predominant at lower temperatures.
Each catalytic stage consists of gas preheat (in the Converter Preheater), a catalytic
reactor (Sulfur Converter), and a Sulfur Condenser. Gas preheating is required prior to
entering the catalytic reactor to avoid sulfur condensing in the catalyst bed. In the
catalytic reactor, the Claus reaction takes place over a fixed bed of activated alumina
catalyst in which sulfur is formed. The reacted process gases then flow to the sulfur
condenser and are cooled while condensed sulfur drains to the sulfur pit. After the
second catalytic stage, the tail gas proceeds to the hydrogenation reactor for further
processing.
There are number of commercial Claus Plant configurations available from several
licensors. The selected process is very simple and straight forward. The temperatures
needed to convert NH3 and HCN will only be achieved when the H2S concentration is
high enough; otherwise, additional natural gas will be needed. Insufficient conversion of
NH3 and HCN will lead to the formation of ammonia salts, which will block the liquid
sulfur pipe lines. Also a natural gas (NG) burner is needed to heat the plant to start it up.
This summary describes the “Jacobs” configuration, with NG addition to all the Claus
sections. In case the selected process for the generic model is different, the NG burner
from the first catalytical step can be left out of the model.
In the process flow diagram at the end of this document, the NG burners and their
control are added to the catalytical steps. The temperature control of the steam heaters
has not been taken out of the PFD but can be removed if a Claus model with burners
has been selected.
134

system operation.
liquid equilibrium.
The Claus reaction is equilibrium limited, and sulfur conversion is sensitive to
reaction temperature. The highest sulfur conversion in the thermal zone (non-
catalytic stage) is limited to about 75%, and approximately 65 to 70% of the
sulfur is recovered. Each catalytic stage should be able to recover half to two-
thirds of the incoming sulfur.
Sour gas inlet flowrate and system response to changes in its value, and
composition.
Acid gas inlet flowrate and system response to changes in its value, and
composition. This includes the calculation of the acid gas’ heating value. The
minimum heating value of the acid gas should be determined that is acceptable
to the Claus plant; flame out should occur if the heating value falls below this
minimum value. Please note that when flame temperature is too low, HCN and
NH3 will be converted insufficiently and sulfur blocking ammonia salt will be
formed.
Oxygen inlet flowrate and system response to changes in its value.
I/P boiler feedwater inlet flow rate, and system response to changes in its value
Tail gas conditions to the tail gas treating unit (hydrogenation reactor)
High pressure steam conditions to the tail gas treating unit
Low pressure steam conditions to the low pressure steam header
Sulfur production
Operational parameters while operating with one side of a cooler or heat
exchanger isolated.
The model should respond especially to changes in flow and quality of the sour
gas feed streams. The coal feed and process conditions in the AGR highly
influence the quality of the Claus feed and therefore the operation of the Claus
unit
135
13.3. Controls
model:
Sour Gas Inlet Flow Control (FV-001)

Tail gas H2S-SO2 control
Natural gas to thermal Claus burner control (FV-002)
Air to thermal Claus burner control (FV-003)
Natural gas to 1st catalytic Claus control (FV-004)
Air to 1st catalytic Claus control (FV-005)
Natural gas to 2nd catalytic Claus control (FV-006)
Air to 2nd catalytic Claus control (FV-007)
Sour Gas Inlet Pressure Control (PV-001)
Temperature thermal Claus by NG control (TCV-001)
Temperature outlet 1st catalytic Claus by NG control (TCV-002)
Temperature outlet 2nd thermal Claus by NG control (TCV-003)
Pure Oxygen Flow Control (FV-008)
Acid Gas Inlet Flow Control (FV-009)
Acid Gas Inlet Pressure Control (PV-002)
Waste Heat Boiler Level Control (LCV-001)
Waste Heat Boiler HP Steam Pressure Control (PV-003)
Sulfur Condenser LP Steam Pressure Control (PV-004)
Sulfur Condenser Level Control (LCV-002, LCV-003)
Converter Preheater Temperature Control (TCV-004, TCV-005)
Sulfur Pit Level Control (LCV-004)
(Over) pressure control Sour gas feed (from stripper) (PV-005)
(Over) pressure control Acid gas (PV-006)
136
13.4. Human-Machine Interface (HMI) Screen
It is anticipated that there will need to be one Human-Machine Interface (HMI) Screen
instrumentation,
instrumentation shown in SRU-FD-001 and will include:

o Sour Gas Inlet Pressure Control
o Sour Gas Inlet Flow Control
o Sour Gas Overpressure Control
o Pure Oxygen Inlet Flow Control
o Acid Gas Inlet Pressure Control
o Acid Gas Inlet Flow Control
o Acid Gas Overpressure Control
o Natural Gas to Thermal Claus Burner Flow Control
o Air to Thermal Claus Burner Flow Control
o Temperature Thermal Claus by NG control
o Waste Heat Boiler Level Control
o Waste Heat Boiler HP Steam Pressure Control
o Sulfur Condenser LP Steam Pressure Control
o Sulfur Condenser Level Control
o Converter Preheater Temperature Control
o Natural gas to catalytic Claus control
o Air to catalytic Claus control
o Temperature outlet catalytic Claus by NG control

o Sulfur Pit Level Control
o H2S Analyzer (on Acid Gas line)
o H2S – SO2 Analyzer (on line to Hydrogenation)
137

following malfunctions will be modeled for the Claus Plant system:
Improper Reaction temperature (high and low)
Loss of Waste Heat Boiler (Boiler Trip)
Loss of Natural Gas supply to Claus Furnace
Loss of Air Supply to Claus Furnace
Catalyst Exhaustion
Process Control Failures (TBD), valve position indicators, control valve suddenly
on manual
Sour Gas from Sour Water Stripper
95% Pure O2 from ASU
Acid Gas from Selexol AGR System
Heat Exchangers Condensate to Medium Pressure Flash System
I/P Boiler Feedwater to Sulfur Condenser
HP Steam from WHB to Hydrogenation Reactor Preheater
LP Steam to 65 psia Steam Header
MP Steam to Sulfur Pit Vent Ejector
Sulfur to Storage
Tail gas to Hydrogenation
Sour gas to flare
Acid gas to flare
Natural Gas from distribution
California.
138
1 2 3 4 5 6 7 8 9 10
TO TGTU
SOUR GAS
A
FROM STRIPPER A
TO FLARE TCV-004 TCV-005
CONVERTER CONVERTER
PREHEATER PREHEATER
95% O2 SOUR GAS
FROM ASU HEATER
PV-005 TC TC
CD TO
PC MP FLASH
B HS B
O2 FC FV-006
FV-005 FV-004 AIR FV-007 NG
HEATER AIR NG
PC TC TC
FV-001 PV-003 FC FC
OXYGEN FC FC
CONTROL FC
SULFUR SULFUR
FV-008
CONVERTER CONVERTER TO 65 PSIA
WASTE STEAM HEADER
CLAUS LC
HEAT
C FURNACE C
BOILER
PV-004
FV-009
SULFUR PC SULFUR PC SULFUR H2S-
TC CONDENSER CONDENSER CONDENSER SO2
FC
LCV-001
TO
HS FC LC
LC HYDRO-
D
GENATION D
LCV-002 LCV-003
ECONOMIZED BFW
PC
I/P BFW
PV-006
FV-002 ACID GAS
HEATER TO FLARE
VENT EJECTOR
FV-003
FC FC MP STEAM
H2 S NG AIR
E E
LEGEND
LC
STARTUP ONLY TO SULFUR STORAGE Sour Gas Condensate
I/P BFW Tail Gas
Acid Gas Natural Gas
ACID GAS 95% Pure O2 Air
FROM AGR Steam
Sulfur

SULFUR PUMP
Columbia, Maryland
DOE-IGCC
SIMULATOR
F SULFUR PIT F
H2S – SO2 CONTROL CLAUS PLANT
CLAUS PLANT
06/23/2008 SRU-FD-001 B
1 2 3 4 5 6 7 8 9 10
139
14. Hydrogenation Plant and Gas Cooler

There is one set of Hydrogenation Reaction and Gas Cooling equipment which sends
tail gas back to the AGR (Selexol) system.
Hydrogenate the remaining sulfur compounds in the Claus plant tail gas to H2S
in a catalytic hydrogenation reactor.
Supply tail gas to the Selexol Acid Gas Removal Process
The portions of the process are comprised of the following main components:
Hydrogenation Reactor Preheater

Hydrogenation Reactor
Gas Cooler
Direct Contact Condenser (DCC)
Tail Gas Knockout Drum
Tail Gas Compressor
Recycled Water Cooler
DCC Pump
Caustic Pump
Referring to figure TGT-FD-001 at the end of this document:
The tail gas from the Claus plant usually contains small but varying quantities of COS,
CS2, SO2, and elemental sulfur vapors. Sulfur recovery is increased by converting
these remaining sulfur compounds in the tail gas to H2S and then compressing the tail
gas and returning it to the Selexol AGR process.
The tail gas is first preheated in the Reactor Preheater with HP steam produced from
the Claus Waste Heat Boiler. The inlet temperature to the Hydrogenation Reactor is
controlled by adjusting the HP steam rate. An analyzer on the tail gas measures the H2
content of the stream and, if required, treated fuel gas from the Acid Gas Removal unit
is added to the reactor feed. The heated tail gas is hydrogenated where sulfur
compounds are reduced at elevated temperature. The following hydrogenation and
hydrolysis reactions occur in the hydrogenation reactor:
S + H2 → H2S
SO2 + 3H2 → H2S + 2H2O
140
CS2 + 2H2O → 2H2S + CO2
COS + H2O → H2S + CO2
The reactions are exothermic, and heat is removed from the gas in the Gas Cooler,
which produces LP steam.
The gas is further cooled in a Direct Contact Condenser (or Quench Tower). The gas
enters the condenser below the bottom trays and is contacted with caustic so that any
sulfur dioxide remaining in the gas is captured. The column bottoms is recycled in a
circulating loop and spent caustic is periodically removed from the loop and routed to
the effluent bio-treatment unit. Water from the Direct Contact Condenser is also
recycled with the following controls:
A pH indicator is included in the recycle.

When pH is too low, there is SO2 seep-through of the Hydrogenation reactor,
caused by too low inlet temperature of the reactor or too low H2 level in the feed
of the reactor. There is a risk that the Claus reaction takes place in the reactor
and gets solidified by sulfur.
When pH is too high, there is NH3 seep-through of the Claus reactor caused by
too low operating temperature of the thermal Claus. There is a risk then of
corrosive salt deposits in the DCC.
The scrubbed gas then flows up the condenser for direct quenching with water. The
water is removed from the chimney tray in the middle of the condenser and cooled in an
air cooler followed by a trim cooler with cooling water. If required, sour water is removed
from the system to maintain the water balance (flow rate is varied to control the liquid
level on the chimney tray). A portion of the water from the cooling loop may also be
diverted to the lower section of the condenser to maintain the liquid level in the bottom
of the column.
The contact condenser overhead gas is sent to the Tail Gas Knockout Drum to remove
entrained liquid before entering the Tail Gas Compressor. The compressed tail gas is
recycled back to the Acid Gas Removal unit.
141
There are several hydrogenation process designs available from different licensors. In
this process summary description, the gas is heated by a steam heater. Other viable
designs utilize a furnace in which the gas from the Claus Plant is heated by burning
natural gas sub-stoichiometrically with air and providing a reducing gas that is needed
for the catalytic hydrogenation.

system operation.
The model should convert 100% of the non-H2S sulfur species to H2S across the
Hydrogenation Reactor.
The model can assume that all gas that enters the bottom of the Direct Contact
Condenser will exit at the top of the Condenser. In other words, no gas will be
absorbed by the circulated water streams.
H2 concentration at the gas analyzer
pH indicator responds to changes in Tail Gas (inlet flowrate, value, and
composition)
H2 indicator in tail gas responds to changes in Feed Gas (inlet flowrate, value,
and composition) and hydrogenation reactor performance.
Tail Gas inlet flowrate and system response to changes in its value, and
composition.
Clean Syngas inlet flowrate, and system response to changes in its value, and
composition.
Tail Gas recycle to Selexol AGR System
LP Boiler Feedwater to Gas Cooler
LP Steam conditions from Gas Cooler
142
14.3. Controls
model:
Tail Gas Temperature Control (TCV-001)

Clean Syngas Flow Control (FV-001)
Gas Cooler Level Control (LCV-001)
Direct Contact Condenser Bottoms Level Control (LCV-002)
Direct Contact Condenser Level Control (LCV-003)
Level control tail gas knockout drum (LCV-004)
Pressure control steam outlet gas cooler (PV-001)
Pressure control tail gas outlet of the tail gas compressor (PV-002)
Flow control DCC recycle (FV-002)
Temperature control DCC recycle (TCV-002)
Caustic flow recycle flow control (FV-003)
Caustic flow (manual) control
14.4. Human-Machine Interface (HMI) Screen

It is anticipated that there will need to be one Human-Machine Interface (HMI) Screens
instrumentation,
instrumentation shown in TGT-FD-001 and will include:
o Tail Gas Temperature Control
o Gas Cooler Level Control
o Direct Contact Condenser Bottoms Level Control
o Direct Contact Condenser Level Control
o Tail Gas Knockout Drum Level Control
o Gas Cooler Steam Outlet Pressure Control
o Tail Gas Outlet of Tail Gas Compressor Pressure Control
o Direct Contact Condenser Temperature Control
o Caustic flow recycle flow control
o Clean syngas flow control
143
o Direct Contact Condenser Pump Start/Stop

o Tail Gas Compressor Start/Stop
o Caustic Pump Start/Stop
o H2 Analyzer at inlet of Hydrogenation Reactor
o H2 Analyzer at inlet of Tail Gas Compressor
o pH Analyzer on the DCC recycle water loop

following malfunctions will be modeled for the Hydrogenation Reactor and Gas Cooler
system:
Less steam from distribution, causing low inlet temperature hydrogenation

Malfunction of pumps: caustic, DCC
Claus unit operates at too low temperature resulting in pH increase in DCC
Too low H2 level in feed gas
Failure of measurements
Degradation of hydrogenation catalyst
HP Steam from WHB to Hydrogenation Reactor Preheater

Tail Gas from Claus Sulfur Condenser to Hydrogenation Reactor Preheater
Hydrogenation Reactor Preheater condensate to medium pressure flash system
Clean Syngas from Selexol AGR System to inlet of Hydrogenation Reactor
LP Boiler Feedwater to Gas Cooler
LP Steam from Gas Cooler to LP Steam Header
Tail Gas Recycle to Selexol AGR System
Sour Water from DCC to Sour Water KO Drum
Spent Caustic to effluent bio-treatment
Caustic from distribution
144

California.
Selection Criteria for Claus Tail Gas Treating Processes, M. Rameshni, Worley
Parsons.
145
1 2 3 4 5 6 7 8 9 10
H2
TAIL GAS PC FT
A
COMPRESSOR A
FROM CLAUS TAIL GAS
WASTE HEAT TAIL GAS
KO DRUM RECYCLE
BOILER TCV-001 TO AGR
PV-002
TC SYSTEM
TAIL GAS LC
FROM CLAUS FROM TAIL GAS
SULFUR CONDENSER COMPRESSOR
INTERCOOLERS
HYDROGENATION
B REACTOR B
PREHEATER
CD TO
MP FLASH LCV-004
CLEAN SYNGAS
FC pH
FROM AGR LCV-003
FV-001 TO SOUR WATER
DIRECT
H2 GAS CONTACT KNOCKOUT DRUM
ANALYZER
FV-002 TC
C CONDENSER C
TCV-002
LC COOLING WATER
TI
DCC
RECYCLED
PUMP
WATER
HYDROGENATION LP STEAM COOLER
TI
REACTOR
TI
PV-001
D D
PC LCV-002
GAS COOLER
LC FV-003
LC
FC
E
LCV-001 E
SPENT LEGEND
LP BFW CAUSTIC TO LP Steam Condensate

EFFLUENT LP BFW Tail Gas
CAUSTIC BIO-TREATMENT Sour Water
NaOH
Steam
CAUSTIC
PUMP Columbia, Maryland
DOE-IGCC
SIMULATOR
F F
HYDROGENATION REACTOR
HYDROGENATION REACTOR
06/23/2008 TGT-FD-001 B
1 2 3 4 5 6 7 8 9 10
146
15. Combustion Turbine Units

15.1. Combustion Turbine Units Overview and Descriptions
15.1.1. Component Overview
The simulator shall model two independent combustion turbines (CT’s). Each CT shall
be directly coupled to a 3-phase AC generator driven at 3600 RPM by an extension of
the inlet compressor shaft. Each CT shall be capable of operating on either hydrogen-
rich syngas derived from coal gasification and various gas treatment processes or by
natural gas. CT’s shall be capable of transferring between fuels while maintaining
continuous operation at any load point. Furthermore, these CT’s shall be capable of
operating on any mixture between the two fuels.
Each combustion turbine shall be associated with a Heat Recovery Steam Generator
(HRSG) designed to recover the energy in the hot combustion turbine exhaust gas. The
combustion turbines are not able to operate in simple cycle mode. Under standard
conditions (59 degrees F., 29.92 in. hg.), each combustion turbine/generator assembly
shall be capable of delivering 232 MW on syngas fuel, and 185 MW on natural gas.
Purpose of the Combustion Turbine/Generator Assemblies are to:
• Consume the flow of hydrogen-rich syngas supplied by the gasification island

• Supply approximately 185 to 232 MWe depending on fuel
• Supply a flow of hot exhaust gasses to their respective HRSG
15.1.2. Component Descriptions
Compressor
The compressor shall be an axial flow design with 18 progressive stages housed at the
forward end of the turbine compartment on a common shaft with the power turbine.
Combustion System
The combustion system utilized within each combustion turbine shall be comprised of 14
interconnected combustion chambers (“combustors”). These combustors are housed on
the compressor discharge wrapper aft of the compressor, prior to the power turbine.
Combustion chambers are numbered counterclockwise when viewed looking downstream

and starting from the top left of the machine.
This system also includes the fuel nozzles, a spark plug ignition system, flame detectors,
false start drains, and crossfire tubes.
147
Power Turbine
The three-stage power turbine section is the area in which energy in the form of high
temperature pressurized gas, produced by the compressor and combustion sections, is
converted to mechanical energy. Power turbine hardware includes:
• Turbine rotor
• Turbine casing
• Exhaust frame
• Exhaust diffuser
• Nozzles (stationary blades)
• Shrouds
Exhaust
Downstream of the power turbine is the exhaust duct. The purpose of the exhaust duct
is to provide a flow path through which the gases used to power the turbine wheels are
redirected to a heat recovery steam generator (HRSG). The gas turbine exhaust system
consists of a diffuser duct section that carries the hot exhaust gases from the exhaust
frame diffuser to the exhaust ducting.
15.2. Combustion Turbine Units Modeling Expectations

15.2.1. Simulation Model Architecture
The simulation for each of the two combustion turbine/generator assembly models shall
consist of the following process model areas:
• Air and gas pressure and flow calculations

• Dual fuel combustion process model
• Evaporative cooler model
• Air, gas and metal temperature calculations and turbine speed and power
• Lubricating oil system model
• Hydraulic and pressure-lift oil system model
• Starting system model
• Bearing vibrations and temperatures model
• NOx emission model
• Valve actuators model
• Inlet Guide Vanes (IGVs)
148
15.2.2. Description of Pressure and Flow Calculation Process

This model determines air and gas pressures and flows around the compressor-turbine.
Air enters the compressor through the inlet filters, evaporative cooler and Inlet Guide
Vanes. For purposes of pressure-flow calculations, the filter is considered a flow
admittance that is set constant for normal operation and can be failed low by the
instructor. The evaporative cooler is considered to be a flow boundary that adds some
water vapor to the air. IGV admittance is modulated by demand from the DCS via a
non-linear characteristic.
The compressor is represented by its characteristics1:
Pco T
= ε ( Fcomp ci , N )
Pci Pci
Air after the compressor is passed through the Combustion Chamber and the
combustor bypass valves to the turbine inlet. Some part of the air can be also passed
to the turbine exhaust through bleed valves. A portion of the air from the compressor
discharge and an interstage takeoff is routed to the rotor and turbine wheelspaces for
cooling. Another portion of air after compressor is delivered to the compressor inlet via
Inlet Bleed Heat valve (IHB). Fuel flow is also conveyed to the turbine inlet. The
resulting flow pressure network is shown on Figure 4.
The turbine is represented by its characteristics2:
Pti T
= δ ( Fturb ti , N )
Pto Pti
The characteristics of passive flow elements (valves and pipes) are linear:
Flow = Admittance * (Pressure Drop)
Air and gas pressures are determined from simultaneous solution of all the equations
above and mass conservation equations.
1
Since there is no plant data available for this very important characteristic, the model will utilize generic
compressor curves from textbooks. Generic characteristics may differ from those of the actual plant, as
will the performance of the simulator.
2
Likewise, the model will utilize a generic turbine curve from textbooks.
149
N2 & Syngas
Steam
Air
Evaporative
Cooler Water
IHB
Cooling Air
Bleed
Figure 4 CT Air and Gas Flow Pressure Network
15.2.3. Description of Combustion Process

The model shall determine flame status in the combustor, combustion heat, specific
heats and adiabatic exponents of air and gas. It shall also determine flashback
temperatures.
Compressed air, dilution nitrogen, steam, and syngas and/or natural gas enter the
combustion chamber, where the fuels are combined with dilution nitrogen and steam
and burned, provided the flame is ignited. Although modeled as 14 combustors, the
actual combustion zone will be modeled as a single combustion area, with fuel and air
evenly distributed among combustors. Syngas and natural gas, steam and nitrogen
shall be injected into the combustion zone by separate sets of nozzles.
150
If the fuel/air ratio at combustion area is within flammability limits, the ignition can be
started with either of 14 spark plugs controlled from the DCS. The instructor, with a
particular malfunction, can fail ignition. If the flame is ignited, outputs of four flame
detectors are set true, unless failed by the instructor. If the fuel/air ratio goes beyond
flammability limits, the flame will be lost.
The model shall determine fuel/air ratios after mixing points and finds the location at
which the mixture becomes flammable. The actual flame location will be shifted
downstream from this point by a value proportional to fuel/gas flow through the
combustion chamber.
The composition of each fuel is characterized by its heating value and chemical make-
up. For a given composition, the required amount of air for combustion is calculated
based on the chemical reaction:
CxHyOz + (x-z/2 + y/4)O2 → xCO2 + (y/2)H2O
Any trace amounts of sulfur in the syngas shall be treated in the following manner
during combustion:
H2S + (3/2 O2) → H2O + SO2
Oxides of Nitrogen shall be based on adiabatic flame temperature and available

nitrogen and oxygen using a curve to be supplied to the selected simulation vendor
once under contract.
Air includes moisture, which is calculated from the air humidity external parameter set
by the instructor, the moisture acquired in evaporative cooler, and water injected into
combustors.
Based on the moisture content of the air and the chemical composition of fuel and
combustion products, this model calculates properties of air, fuel and gas such as
molecular weight, specific heat and adiabatic exponent.
15.2.4. Evaporative Cooler Model

Evaporative cooler provides cool and moist air to the compressor inlet. This is achieved
by evaporating water from the cooler media into the air-flow right after the air filters.
Evaporative Cooling
The air is drawn into the evaporative cooler filled with wet media. Water evaporates
from the media and mixes with the air, cooling it. The amount of water evaporated will
depend on the ambient air temperature and humidity, air flow through the cooler and the
amount of water in the cooler media.
151
Cooler Water Pumps

Water is delivered to the cooler media by four pumps. The instructor with a particular
remote function will be able to start/stop each pump separately. When started, the pump
will deliver a constant amount of water to the cooler media. The amount of water there
will be found from the balance of the sum pumps flow and evaporation.
15.2.5. Turbine Temperatures, Speed and Power

The model shall determine the enthalpies and temperatures of air and gases along the
compressor and turbine, CT metal temperatures, power developed by the compressor-
turbine, and CT speed.
Inlet Air Conditions

Inlet air conditions shall be set by the instructor via two external parameters: Ambient
Air Temperature and Ambient Air Humidity. Normally, it will be warm and dry air
entering the plant.
Air Compressor
Compression of air in the compressor can be described as an almost adiabatic
(efficiency ηc < 1.0) process from pressure Pin to pressure Pout:
γ −1
 
P 
γ
= 1 +   out  − 1 ηc
H out
H in   Pin  
 
where H is specific enthalpy and γ - adiabatic exponent. Compressor torque is

γ −1
Fcomp H in   Pout  γ 
Bc =   − 1 ηc

ω   Pin  
 
Compressor efficiency is a function of air-flow Fcomp, CT speed, air inlet temperature and
pressure, multiplied by the instructor-set factor to represent degraded performance.
Turbine
Gas in the turbine expands almost adiabatically (efficiency ηt < 1.0) from pressure Pin to
pressure Pout:
γ −1
  
P 
γ
= 1 − 1 −  out  η
H out
H in   Pin   t
 
152
Where H is specific enthalpy, and γ - adiabatic exponent. Turbine torque is

γ −1
  
P 
γ
Bt = turb in 1 −  out  η

F H
ω   Pin   t
 
Turbine efficiency is a function of gas flow Fg, CT speed, gas inlet temperature and
pressure.
CT Speed and Power Calculation

When the electrical generator is not synchronized to the grid, compressor-turbine speed
is found from torque balance on the shaft:
dω
I = Bt + Bsm − Bc − Bloss
dt
Where ω is speed, I is inertia, Bt - turbine torque, Bsm - starting motor torque, Bc -

compressor torque, and Bloss – loss torque being a function of speed. In this case the
power output is zero. When not driven with gas, nor with the motoring generator, the
turbine will coast down at a rate determined by its inertia. If the turning gear is on, it
limits the turbine speed to 6 RPM, else the turbine coasts down to standstill.
When synchronized, the CT speed is set equal to the grid frequency, and power is
calculated from the equation:
W = ω * (Bt + Bsm - Bc - Bloss)
Air, Gas and Metal Temperatures
Air and gas temperatures shall be calculated at 8 points:
• 9th stage of the compressor

• 13th stage of the compressor
• compressor discharge
• turbine inlet
• turbine 1st wheel aft
• turbine 2nd wheel aft
• turbine 3rd wheel aft
• turbine exhaust
153
Metal temperatures will be calculated at 7 points:
• compressor casing average

• combustor shell
• turbine 1st wheel
• turbine 2nd wheel
• turbine 3rd wheel
• turbine casing inlet
• turbine exhaust frame
Air/gas temperature will be determined from the enthalpy of air/gas:
H = Cp * T
Enthalpies are carried with air/gas flows from point to point and heat is put into the
system due to compressor work and fuel combustion. Heat is removed from the system
due to turbine work and heat transfer to ambient. Heat is transferred between air/gas
and metal. Heat transfer is described by the equation:
Q12 = K * (T1 - T2),
Where coefficient K = const * flow0.8 for gas/air-to-metal and K = const for metal-to-
ambient.
Turbine Cooling Air

Part of the air for rotor cooling is taken from the compressor discharge and 13th stage,
and is delivered to the 1st and 2nd wheelspaces of the turbine. Other sources of cooling
air are from Exhaust Frame Cooling Fans and Bearing Cooling Fans. This air is used to
cool the last stage of the turbine, outer exhaust frame and #2 journal bearing area.
Cooling Air Fans

There are two Exhaust Frame Cooling Fans and two Bearing Cooling Fans. In each pair,
one fan is primary and one is backup. The instructor can control each fan with a
particular remote function (RF) representing a switch with HAND, OFF and AUTO
positions. Setting the RF to OFF stops the fan and setting it to HAND starts the fan. In
AUTO, the fan is controlled with a signal from the DCS. In any mode, the fan will start
and run only if AC power is available.
15.2.6. Lubricating, Seal, and Trip Oil System Model

This model determines the availability and pressures of bearing lubricating oil, generator
seal oil and trip oil and oil temperature.
154
Lube Oil Reservoir

The Lubricating and Seal Oil System is supplied from the lube oil reservoir, containing a
constant amount of oil. Pressure in the reservoir is maintained at –7” H2O by either of
two Mist Eliminators. If neither eliminator is running, the pressure will rise at a rate
proportional to the compressor-turbine speed to 0” H2O. When any eliminator is started,
the pressure is lagged to –7” H2O.
Mist Eliminators
The eliminators are controlled by the instructor with three remote functions: two of them
representing control switches with HAND, OFF and AUTO positions and the third one
representing a selector switch with PUMP1 and PUMP2 positions. The instructor can
start an eliminator at any time by setting the relevant RF to HAND, provided the AC
power is available and lube oil pressure is greater than 6 PSIG, or stop the running
eliminator by setting the RF to OFF. When in AUTO, the eliminator will start
automatically, if it is not selected with the third RF and the reservoir pressure is above –
2” H2O and the power supply is healthy.
AC Lube Oil Pumps

Lubricating oil is normally supplied from either of two AC Lube Oil Pumps at 15 PSIG. If
no pump is running, oil pressure decays to 0 PSIG. When any pump is started, the
pressure is lagged to 15 PSIG. Pumps are controlled by the instructor with three
remote functions: two of them representing control switches with HAND, OFF and
AUTO positions and the third one representing a selector switch with PUMP1 and
PUMP2 positions. The instructor can start a pump at any time by setting the relevant
RF to HAND, provided the AC power is available, or stop the running pump by setting
the RF to OFF. When in AUTO, the pump will start automatically, if it is not selected
with the third RF and the pump is stopped, and the power supply is healthy. It will also
stop automatically when the condition that started it has gone.
Emergency Lube Oil Pump

Lube oil can also be supplied by the Emergency Lube Oil Pump at 12.5 PSIG. The
pump can be started or stopped by the instructor setting the relevant RF to HAND or
OFF. When in AUTO, the pump will start automatically if oil pressure is below 11 PSIG
or none of the AC Lube Oil Pumps are running, or it is requested to start from the DCS.
It will also stop automatically if oil pressure is above 14 PSIG and at least one AC Lube
Oil Pump is running and it is not requested to start from the DCS. DC power for the
pump is always available.
Main Seal Oil Pump

Seal oil to electric generator is normally supplied from Lube Oil Pumps. In case of low
lube oil pressure, the Main Seal Oil Pump will supply oil at 15 PSIG. The pump can be
started or stopped by the instructor setting the relevant RF to HAND or OFF. When set
to AUTO, the pump will be controlled from DCS.
155
DC Seal Oil Pump

Seal oil can also be supplied by the DC Seal Oil Pump at 12.5 PSIG. The pump can be
started or stopped by the instructor setting the relevant RF to HAND or OFF. When in
AUTO, the pump will start automatically if oil pressure is below 11 PSIG or the Main
Seal Oil Pump is not running, or it is requested to start from the DCS. It will also stop
automatically if seal oil pressure is above 14 PSIG and the Main Seal Oil Pump is
running and it is not requested to start from the DCS. DC power for the pump is always
available.
Oil Pressure Malfunctions

The instructor will be able to fail lubricating and seal oil pressure separately to any value
between 0 and 15 PSIG to simulate a leak, by initiating one of the Oil Pressure
malfunctions.
Lube Oil Temperatures

The temperature of lubricating oil in the reservoir is determined from the balance of heat
transferred from bearings, heat from Reservoir Heater and heat removed to ambient.
Heat from bearings is a sum of two terms: one proportional to the compressor-turbine
speed, another – to the turbine load. Heat from the Reservoir Heater is constant zero if
the heater is off, and non-zero if it is on. Heat to ambient is proportional to the difference
between tank temperature and ambient temperature. Oil after pumps flows through heat
exchangers, where it is cooled with service water. The temperature control valve
modulates the coolant flow through the heat exchangers. The oil temperature drops by
a value proportional to the difference between oil temperature and service water
temperature, and if service water is available, to the position of the control valve.
Lube Oil Reservoir Heater

The reservoir Heater can be turned on or off by the instructor setting the relevant RF to
HAND or OFF respectively. When in AUTO, the thermostat will energize the heater at
78° F decreasing and de-energize at 90° F increasing reservoir temperature.
15.2.7. Hydraulic and Lift Oil System Model

This model determines the availability and pressures of hydraulic control oil and oil
temperatures.
Hydraulic Oil Pumps

Hydraulic and lift oil is supplied by either of two Hydraulic Oil Pumps at 1200 PSIG. The
source of the oil is the lubricating oil header. If no pump is running, the hydraulic oil
pressure decays to the lubricating oil pressure. When any pump is started, the pressure
rises to 1200 PSIG over a particular time lag. Pumps are controlled by the instructor
with three remote functions: two of them representing control switches with HAND, OFF
and AUTO positions and the third one representing selector switch with PUMP1 and
PUMP2 positions. The instructor can start a pump at any time by setting the relevant
RF to HAND, provided the AC power is available, or stop the running pump by setting
the RF to OFF. When in AUTO, the pump will start automatically, if it is not selected
156
with the third RF and oil pressure is below 1100 PSIG and power supply is healthy. It
will not stop automatically.
Hydraulic Oil Pressure Malfunction
The instructor will be able to fail lubricating oil pressure to any value between 0 and
1200 PSIG to simulate a leak, by initiating the Hydraulic Oil Pressure malfunction.
15.2.8. Turning Gear and LCI Static Starter

This model determines the status of the turning gear and variable frequency voltage to
the generator which serves as a starting motor during the turbine startup.
Turning Gear
The Turning Gear is controlled by the instructor with a remote function representing
control switch with HAND, OFF and AUTO positions. The instructor can start the gear
at any time by setting the relevant RF to HAND, or stop the running gear by setting the
RF to OFF. When in AUTO, the gear will start automatically if it is requested to start
from DCS. It will also stop automatically when it is no longer requested to start from
DCS. The DC power to the gear is always available.
Static Starter
The DCS configures various generator breakers. During the startup sequence, the field
breaker closes and energizes the exciter. Other breaker connects the generator to the
Load Commutated Inverter which drives the generator with variable frequency voltage
to the 90% of the synchronous speed, after which the control system disconnects the
static starter.
15.2.9. Turbine Supervisory Information

This model determines the compressor-turbine and generator bearing metal and lube oil
temperatures, bearing vibrations and thrust bearing proximitor readings.
Bearing Oil and Metal Temperatures

The bearing metal temperatures are given by the first order time lag of target
temperatures. The target temperature is the bulk oil inlet temperature plus a factor,
which is linearly dependent on the speed from 0 to 3600 rpm, plus a factor linearly
dependent on the turbine load, plus an instructor-set factor to represent a malfunction.
The bearing oil outlet temperatures are normally given by the metal temperature minus
9° F.
157
Turbine Vibrations
Vibrations are monitored at four journal bearings and can be affected by lubricating oil
temperature, critical speeds and instructor-set malfunction. Vibrations will be higher
also, if the turbine was started from standstill (instead of off the turning gear). All
vertical and horizontal proximitors and seismometers for the same bearing will act
proportionally. Thrust bearing proximitors will read values dependent on the turbine
load.
Vibration Monitor
If vibration at any bearing exceeds 5.75 mils, the vibration alarm signal is sent to the
DCS. If vibration at any bearing exceeds 8.5 mils, the vibration trip signal is sent to the
DCS. These signals are maintained until the Monitor receives a reset command from
the DCS. The instructor can fail the monitor with a particular malfunction. In this case
the vibration alarm and trip signals are inhibited and the monitor status alarm is sent.
15.2.10. Compressor Inlet Vanes and Valves

This model transfers hydraulic oil or instrument air status, demands or commands from
the DCS to the IGV and valves control models. Demands and commands are also
affected by instructor-initiated malfunctions where applicable. Valve control circuits and
drives shall be developed which include component-based malfunction features.
15.3. Combustion Turbine Malfunctions

The instructor will be able to initiate malfunctions for the Combustion Turbine as listed in
Table 1-1 and will get responses as described above.
Table 1-1
Tag Description Lo Hi Type
mfCT101 CT A Inlet Filter Clogged (% degradation) 0 100 VR
mfCT102 CT A Ignitors Failure 0 1 DG 0 1
mfCT103 CT A Flame Detectors Failure 0 1 DG 0 1
mfCT104 CT A Lube Oil Pressure Low (header pressure, psig) 0 15 VR
mfCT105 CT A Hydraulic Oil Pressure Low (header pressure, psig) 0 1200 VR
mfCT106A CT A Collector End Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT106B CT A Turbine End Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT106C CT A Inlet End Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT106D CT A Exhaust End Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT107 CT A Thrust Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT108A CT A Collector End Bearing Vibration High (multiplier) 0 10 VR
mfCT108B CT A Turbine End Bearing Vibration High (multiplier) 0 10 VR
mfCT108C CT A Inlet End Bearing Vibration High (multiplier) 0 10 VR
mfCT108D CT A Exhaust End Bearing Vibration High (multiplier) 0 10 VR
mfCT109 CT A Thrust Bearing Proximity Meter Reading High (multiplier) 0 15 VR
158

mfCT110 CT A Vibration Monitor Failure (inhibit alarm and trip) 0 1 DG 0 1
mfCT111 CT A Steam injection failure 0 100 VR
mfCT112 CT A purge air/atomizing air failure 0 100 VR
mfCT201 CT B Inlet Filter Clogged (% degradation) 0 100 VR
mfCT202 CT B Ignitors Failure 0 1 DG 0 1
mfCT203 CT B Flame Detectors Failure 0 1 DG 0 1
mfCT204 CT B Lube Oil Pressure Low (header pressure, psig) 0 15 VR
mfCT205 CT B Hydraulic Oil Pressure Low (header pressure, psig) 0 1200 VR
mfCT206A CT B Collector End Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT206B CT B Turbine End Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT206C CT B Inlet End Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT206D CT B Exhaust End Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT207 CT B Thrust Bearing Oil Temperature High (increase, deg F) 0 100 VR
mfCT208A CT B Collector End Bearing Vibration High (multiplier) 0 10 VR
mfCT208B CT B Turbine End Bearing Vibration High (multiplier) 0 10 VR
mfCT208C CT B Inlet End Bearing Vibration High (multiplier) 0 10 VR
mfCT208D CT B Exhaust End Bearing Vibration High (multiplier) 0 10 VR
mfCT209 CT B Thrust Bearing Proximity Meter Reading High (multiplier) 0 15 VR
mfCT210 CT B Vibration Monitor Failure (inhibit alarm and trip) 0 1 DG 0 1
mfCT211 CT B Steam injection failure 0 100 VR
mfCT212 CT B purge air/atomizing air failure 0 100 VR
15.4. Combustion Turbine Remote Functions

The instructor will be able to operate remote switches and pushbuttons in the
Combustion Turbine system using the Remote Functions listed in Table 1-2
Table 1-2
rfCT101A CT A AC Lube Oil Pump A Control Switch 0 2 DG HAND OFF AUTO
rfCT101B CT A AC Lube Oil Pump B Control Switch 0 2 DG HAND OFF AUTO
rfCT102 CT A AC Lube Oil Pump Selector Switch 0 2 DG PUMP1 PUMP2
rfCT103 CT A Emergency Lube Oil Pump Control Switch 0 2 DG HAND OFF AUTO
rfCT104 CT A Main Seal Oil Pump Control Switch 0 2 DG HAND OFF AUTO
rfCT105 CT A DC Seal Oil Pump Control Switch 0 2 DG HAND OFF AUTO
rfCT106A CT A Mist Eliminator A Control Switch 0 2 DG HAND OFF AUTO
rfCT106B CT A Mist Eliminator B Control Switch 0 2 DG HAND OFF AUTO
rfCT107A CT A Hydraulic Oil Pump A Control Switch 0 2 DG HAND OFF AUTO
rfCT107B CT A Hydraulic Oil Pump B Control Switch 0 2 DG HAND OFF AUTO
rfCT108 CT A Hydraulic Oil Pump Selector Switch 0 2 DG PUMP1 PUMP2
rfCT109 CT A Turning Gear Control Switch 0 2 DG HAND OFF AUTO
rfCT110 CT A Compressor Efficiency Multiplier 0.8 1.1 VR
rfCT111A CT A Exhaust Frame Cooling Fan A Control Switch 0 2 DG HAND OFF AUTO
rfCT111B CT A Exhaust Frame Cooling Fan B Control Switch 0 2 DG HAND OFF AUTO
rfCT112A CT A Bearing Cooling Fan A Control Switch 0 2 DG HAND OFF AUTO
159

rfCT112B CT A Bearing Cooling Fan B Control Switch 0 2 DG HAND OFF AUTO
rfCT201A CT A AC Lube Oil Pump A Control Switch 0 2 DG HAND OFF AUTO
rfCT201B CT B AC Lube Oil Pump B Control Switch 0 2 DG HAND OFF AUTO
rfCT202 CT B AC Lube Oil Pump Selector Switch 0 2 DG PUMP1 PUMP2
rfCT203 CT B Emergency Lube Oil Pump Control Switch 0 2 DG HAND OFF AUTO
rfCT204 CT B Main Seal Oil Pump Control Switch 0 2 DG HAND OFF AUTO
rfCT205 CT B DC Seal Oil Pump Control Switch 0 2 DG HAND OFF AUTO
rfCT206A CT B Mist Eliminator A Control Switch 0 2 DG HAND OFF AUTO
rfCT206B CT B Mist Eliminator B Control Switch 0 2 DG HAND OFF AUTO
rfCT207A CT B Hydraulic Oil Pump A Control Switch 0 2 DG HAND OFF AUTO
rfCT207B CT B Hydraulic Oil Pump B Control Switch 0 2 DG HAND OFF AUTO
rfCT208 CT B Hydraulic Oil Pump Selector Switch 0 2 DG PUMP1 PUMP2
rfCT209 CT B Turning Gear Control Switch 0 2 DG HAND OFF AUTO
rfCT210 CT B Compressor Efficiency Multiplier 0.8 1.1 VR
rfCT211A CT B Exhaust Frame Cooling Fan A Control Switch 0 2 DG HAND OFF AUTO
rfCT211B CT B Exhaust Frame Cooling Fan B Control Switch 0 2 DG HAND OFF AUTO
rfCT212A CT B Bearing Cooling Fan A Control Switch 0 2 DG HAND OFF AUTO
rfCT212B CT B Bearing Cooling Fan B Control Switch 0 2 DG HAND OFF AUTO
15.5. Combustion Turbine External Parameters

The instructor will be able to manipulate the environment in which the combustion
turbines operate by using the External Parameter Functions as listed in Table 1-3.
Table 1-3
Tag Description Lo Hi Initial Value
EP001 Ambient Air Temperature, deg F 14 104 59
EP002 Ambient Air Humidity, % 0 100 60
EP014 Ambient air pressure feet ASL 0 10000 0
EP012 Electrical System Grid Voltage, kV 450 550 500
EP013 Electrical System Grid Frequency, Hz 55 65 60
160
15.6. Combustion Turbine Fuel Systems

The plant can use two kinds of fuel: natural gas from a pipeline source, and syngas
derived from the coal gasification plant. Each combustion turbine will have separate
simulations for both the natural gas and syngas fuel systems. Each combustion turbine
shall be capable of operating on either fuel or any combination thereof independent of
the other. Refer to illustration Figure 2-1.
Figure 5 Combustion Turbine Arrangement
15.6.1. Natural Gas Fuel System

This system determines pressure and flow of fuel gas to the combustion turbine, and
the gas temperature. The system consists of a Natural Gas Pressure Regulating
Station supplying gas to both units and two identical CT Natural Gas fuel systems, one
per each unit.
Natural Gas Supply Pressure Regulating Station

Natural gas is supplied to the plant at conditions specified by the instructor with
pressure and temperature as external parameters. There is a pressure-operated safety
shutoff valve at the inlet. The gas flows through this valve, through the heat exchanger,
161
where it is heated with the feedwater. After the heat exchanger gas passes a set of four
control valves on which its pressure is reduced, and through two parallel filter-
separators. The instructor shall have the capability to clog either filter any variable
amount. The instructor shall also have four remote functions to set levels in the liquid
separators to initiate relevant alarms in the DCS. Filtered natural gas is distributed
among the two units via a shared header.
Dilution steam for NOx control shall be supplied to each combustion turbine as cold
reheat steam by its respective heat recovery steam generators.
Natural Gas Flow / Pressure Control

The natural gas system of each combustion turbine consists of a Stop/Isolation Valve
(NGIV) and a Natural Gas Control Valve (NGCV). The natural gas control valve
receives a demand from DCS to provide correct amount of fuel for desired load/speed.
Pressures and Flows

Based on valve positions, instructor-initiated malfunctions, gas supply pressure and air
pressure after compressor, the model calculates gas pressure before throttle valves and
flows through each valve. Pressure differences across filter, and throttle valves are also
calculated.
15.6.2. Natural Gas System Malfunctions

The instructor will be able to initiate malfunctions for the Natural Gas Fuel Systems as
listed in Table 2-1 and will get responses as described above.
Table 2-1
mfNG001A Natural Gas Fuel Filter #1 Clogged (% degradation) 0 100 VR
mfNG001B Natural Gas Fuel Filter #2 Clogged (% degradation) 0 100 VR
15.6.3. Natural Gas System Remote Functions

The instructor will be able to operate local switches and pushbuttons in the Fuel
Systems using the Remote Functions as listed in Table 2-2.
Table 2-2
rfNG001A BOP Fuel Gas Filter #1 Level 0 100 VR
rfNG001B BOP Fuel Gas Filter #2 Level 0 100 VR
162
15.6.4. Natural Gas System External Parameters

The instructor will be able to manipulate the natural gas supply conditions using the
External Parameter Functions as listed in Table 2-3.
Table 2-3
Tag Description Lo Hi Initial Value
epNG001 Fuel Gas Carbon Content, % weight 0 100 75
epNG002 Fuel Gas Hydrogen Content, % weight 0 100 25
epNG003 Fuel Gas Supply Pressure, psig 0 500 450
epNG004 Fuel Gas Supply Temperature (at FG Htr. Inlet) -100 100 40
epNG005 Fuel Gas Heating Value, BTU/SCF 900 1100 1014
15.6.5. Syngas Fuel System

Normally, operation of the gasification plant model determines the pressure and flow of
syngas to each combustion turbine. The syngas fuel system consists of piping from
each gasification train to its respective combustion turbine. However, the instructor may
elect to have syngas supplied as a boundary condition whereby pressure, temperature,
and flow are controlled by instructor station-based malfunctions, remote functions, and
external parameters.
Dilution steam for NOx control shall be supplied to each combustion turbine as cold
reheat steam by its respective heat recovery steam generators. Additionally, when
operating on syngas a metered amount of dilution N2 shall be supplied from the air
separation unit.
Syngas Flow / Pressure Control

The syngas system of each combustion turbine consists of four Stop/Speed Ratio
Valves (SRV’s) and four Gas Control Valves (GCV’s). All valves are hydraulically
operated and receive demand from DCS to provide correct amount of fuel for desired
load/speed. During operation on syngas, each combustion turbine shall also be
supplied with an appropriate stream of nitrogen from the air separation unit.
The Syngas system of each combustion turbine consists of a Stop/Isolation Valve

(SGIV) and a Syngas Control Valve (SGCV). The syngas gas control valve receives a
demand from DCS to provide correct amount of fuel for desired load/speed.
Pressures and Flows

Based on valve positions, instructor-initiated malfunctions, gas supply pressure and air
pressure after compressor, the model calculates gas pressure before throttle valves and
flows through each valve. Pressure differences across filter, and throttle valves are also
calculated.
163
15.6.6. Syngas System Malfunctions

The instructor will be able to initiate malfunctions for the Syngas Fuel Systems as listed
in Table 2-1 and will get responses as described above.
164
Table 2-1
mfSG201 Loss of syngas supply, Train 1 0 1 DG 0-False, 1-True
mfSG202 Loss of syngas supply, Train 2 0 1 DG 0-False, 1-True
mfSG202 Loss of nitrogen supply, Train 1 0 1 DG 0-False, 1-True
mfSG202 Loss of nitrogen supply, Train 2 0 1 DG 0-False, 1-True
15.6.7. Syngas System Remote Functions

When using syngas supplied from the boundary condition source, the instructor will be
able to manipulate supply pressure, flow, and temperature of the syngas using the
Remote Functions as listed in Table 2-2.
Table 2-2
rfSGxxx None Defined 0 0
15.6.8. Syngas System External Parameters

The instructor will be able to manipulate the syngas supply conditions using the External
Parameter Functions as listed in Table 2-3. Note the syngas composition calculation in
the model shall adjust all other syngas constituents accordingly so as to always
maintain a molar fraction of one.
Table 2-3
epSG01 Boundary Syngas Source Selected Train A 0 1 DG 0-False, 1-True
epSG02 Syngas supply pressure (psi), Train A 0 500 VR
epSG03 Syngas supply temperature (deg F.), Train A 250 750 VR
epSG04 Syngas CO2 Composition (%), Train A 0 100 VR
epSG05 Syngas Hydrogen Content % 0 100 VR
epSG06 Syngas Argon Content % 0 5 VR
epSG07 Syngas Methane Content % 0 50 VR
epSG08 Syngas Carbon Monoxide Content % 0 75 VR
epSG06 Syngas Heating Value, BTU/SCF 700 1000 VR
epSG07 Boundary Syngas Source Selected Train B 0 1 DG 0-False, 1-True
epSG08 Syngas supply pressure (%), Train B 0 110 VR
epSG09 Syngas supply temperature (%), Train B 0 110 VR
epSG010 Syngas CO2 Composition (%), Train A 0 100 VR
epSG011 Syngas Hydrogen Content (%) 0 100 VR
165
15.7. Instrument / Service Air System

15.7.1. Air Systems Model
This limited model determines availability of service/instrument air to the plant primary
and secondary equipment. The system consists of a Balance of Plant (BOP) IA/SA
System and two Unit Instrument Air Systems.
15.7.2. BOP Service Air Compressors

Each of the two BOP SA Compressors receives a control signal to start/stop from the
DCS. The compressor will run if positive a signal from the DCS is present and the AC
power is available, and it is not failed by the instructor. Otherwise the compressor stops.
15.7.3. BOP Instrument/Service Air Pressures

If any compressor is running, the SA pressure will follow a target value of 120 PSIG
over a particular time lag.
Air after each compressor is passed to the Air Dryers with pre-filter and after-filter. The
instructor will be able to clog these filters with a particular malfunction, which will cause
a decrease in the IA pressure after the filters and, delta-P alarms in the DCS. Normally,
this pressure will be 110 PSIG. The instructor will also have malfunctions to initiate a
‘trouble’ alarm for the dryer, IA moisture alarm and high level in air receiver alarms.
15.7.4. IA Pressure
Instrument air for Combustion Turbine equipment may come from any of three sources:
Exhaust Cooling Frame Blowers, Bearing Cooling Air Blowers and discharge of main
compressor. The target value for IA pressure supply will be the maximum of these three,
but not greater than 110 PSIG. Actual IA pressure will follow its target over a particular
time lag.
15.8. Controls and Human-Machine Interface (HMI) Screens for

Combustion Turbine and Generator Assemblies
Each Combustion Turbine / Generator Assembly shall be modeled with a generic
distributed control system and human machine interface. All displays and controls shall
be identical for each train, with the exception of different background colors for the
displays. All “A” train displays will have a light tan background, while all “B” train
displays shall have a light blue background.
Control loops and logic arrays shall be constructed using standard discrete process
control and logic objects. The use of “multi-function” or macro objects shall be avoided.
All objects shall be labeled with both their specific object name and their function. All
inputs, outputs, constants, and coefficients shall be appropriately labeled as to their
function. Additionally, output tags shall bear the name of the parent object in its naming
convention.
166
15.8.1. Control Loops and Logic

Control loops and logic shall be modeled for each CT / Generator Assembly to provide
the following functions:
Control Loops:
Engine Speed and Load Control (Fuel and LCI Starter)
Exhaust Temperature (Inlet Guide Vanes)
Generator Excitation
Logic Arrays:
Engine Start Permissives
Load Limiting and Runbacks
Engine Trips
Generator Protection (Load, Voltage, and Reactive Limits)
Generator Breakers and Synchronization
Four control modes shall be provided:

Coordinated Control
Gasifier Lead
CT Lead
Manual
15.8.2. Human-Machine Interface

It is anticipated that there will need to be three Human-Machine Interface (HMI) Screens
associated with each combustion turbine and generator assembly, for a total of six
displays.
controls. It is assumed that one HMI screen will usually be used for primary CT controls,
generator controls, and critical instrumentation values. The second display shall
normally be used for process trending and/or plant performance information. The third
display shall be dedicated to alarms. Any one of the three HMI displays shall be
capable of displaying any of the HMI graphics, including alarms and trends.
Each combustion turbine DCS shall be configured with the following displays:
Control:
Master Unit Control
Inlet Air Heating / Evap Cooler Control
IGV and EGT Control
Fuel Select / Control
Start Check Permissives
LCI Starter / Turning Gear Control
Lube Oil Temp Control
Generator Breaker Control / Sync
Excitation Voltage / MVAR & PF Control
167
Trips / Reset Control
Data Acquisition:
Wheelspace Temps
Bearing Metal / Drain Oil Temps
Vibration Monitoring
Exhaust Thermocouples
Hydrogen Seal Oil Monitoring
Generator RTD Temps
15.9. Alarms
A text-based alarm display shall be provided to alert the operator of all abnormal
process values or logic states. Alarms shall be prioritized by levels 1 through 4. Priority
1 alarms shall originate from all critical process or logic state values that either indicates
potential equipment damage, an impending trip condition or that a trip condition has
occurred. Priority 1 alarms shall display in red text. Priority 2 alarms shall indicate that
a serious condition exists, either with a process value or a logic state that could result in
equipment damage, equipment trip, runback, or load limiting. Priority 2 alarms shall
display in yellow text. Priority 3 alarms shall display unusual or abnormal process
values or logic states. These could be the result of equipment problems, abnormal
equipment or system line ups. Priority 3 alarms indicate the potential for a more serious
condition to occur is possible (for example, generator disconnects open). Priority 3
alarms shall display in blue text. Priority 4 alarms are shall be status state indications
that likely would not impact plant operation. Priority 4 alarms shall be displayed in white
text.
168
15.10. Generator Cooling

15.10.1. Generator Temperatures Model
This model determines the H2 cooled generator stator winding temperature, and H2 air
inlet and outlet temperatures for generator.
15.10.2. Generator Stator and H2 Temperatures

The Generator is cooled with H2, the inlet temperature of which, Ta is equal to the
hydrogen cooler outlet temperature.
Generator stator temperature (Ts) will be a first order time lag of a linear function of
stator amps:
Ts = Ts + ∆t/Lag * (Ta + A*amps - Ts),
The H2 outlet temperature will be a weighted average of H2 inlet temperature and stator
winding temperature:
To = (1-B)*Ta + B*Ts
At full load steady state (FLSS) with Ta=59° F, the model will produce Ts = 194° F and
To = 167° F.
The instructor can fail the generator cooling with a particular malfunction for each phase
of the generator. In this case the stator winding temperature will rise and outlet H2
temperature will be equal to it, as if there is no cooling H2 flow through the generator:
Ts = Ts + ∆t/lag1 * (C*amps)
To = Ts
15.10.3. Hydrogen Coolers

Hydrogen is circulated through the generator in a closed system. The heat absorbed by
the gas in passing over generator surfaces is removed to the service water in the heat
exchangers. The temperature of hydrogen after heat exchangers will drop by a value
proportional to the difference between temperature of hydrogen before heat exchangers
and service water temperature and the service water flow.
169
15.10.4. Generator Cooling Related Malfunctions

The instructor will be able to initiate malfunctions for the Generator Cooling System as
Table 5-1
mfGC101A CT “A” Generator #1 Phase A Temperature Multiplier 1 10 VR
mfGC101B CT “A” Generator #1 Phase B Temperature Multiplier 1 10 VR
mfGC101C CT “A” Generator #1 Phase C Temperature Multiplier 1 10 VR
mfGC201A CT “B” Generator #2 Phase A Temperature Multiplier 1 10 VR
mfGC201B CT “B” Generator #2 Phase B Temperature Multiplier 1 10 VR
mfGC201C CT “B” Generator #2 Phase C Temperature Multiplier 1 10 VR
15.11. Electrical System

The Electrical system consists of models of the Switchyard, Electrical Generators,
Electrical Distribution, 125VDC Battery Charger and Battery and UPS.
The Electrical Distribution system model will simulate:
• the synchronizing of each generator output breaker

• dynamic voltage response to breaker operation and bus loading
• circuit breaker controls
• monitored parameters included on the DCS
• breaker operation and correct response of connected equipment upon loss or
isolation of the appropriate bus.
• starting of electrical loads on each bus with appropriate breaker trips resulting from
overloading
The scope of simulation models will include the following systems / components:
• Unit, Station Service and Excitation Transformers

• 4160/480 V Transformers
• Lining up and charging the various buses
• Bus loss will trip corresponding supplied equipment
• Bus currents calculated based on simulated loads
• In-plant & Switchyard
The simulated generator models will accurately compute:
• generator load, voltage, frequency, reactive power (vars)

• generator current under different turbine loading and grid conditions
• infinite grid with capability to change system grid voltage and frequency (via
Instructor station)
170
The scope of simulation models will include but not limited to the following systems /
components:
• generators
• voltage regulators
• exciters
• generator transformers
• generator speed matching and synchronization
• generator interlocks and associated equipment protections and trip logic
• high voltage breakers and disconnects
15.11.1. Switchyard
Modeling of the switchyard shall be limited to those components which directly affect the
simulated Combustion Turbine Generators (CTGs), Steam Turbine generator (STG)
and in-house electrical distribution system. Those components shall consist of three 18
kV / 230 kV step-up transformers, two station service transformers and five associated
sets of 230kV circuit breakers and motor operated disconnects.
The model will be simply based on two external parameters, namely grid voltage and
frequency, and the remote functions (RFs) to set the states of disconnects. The grid will
be assumed to be “infinite” with all three phases completely balanced. A malfunction for
loss of off-site power (LOSP), or loss of the grid, will also be provided. Each simulated
CTG and STG will therefore “see” infinite grid voltage and frequency if:
The 230 kV Grid is available (malfunction inactive)
Respective 230 kV Disconnects are closed (RF set to “closed”)
CTG / STG output breakers are closed (synchronized)
Back-feeding or connection to the grid of any simulated TG through the 4160V system
and back through the HV switchyard will not be simulated.
Sudden Pressure Malfunctions will be provided for simulated HV transformers. The

effects will be to trip the applicable 86 lockout relays (LOR) and initiate appropriate trip
and trouble alarms on the DCS. These malfunctions will only occur if initiated by the
instructor.
The effects of simulated malfunctions will be to trip the applicable 86 lockout relays
(LOR) and initiate appropriate trip and trouble alarms on the DCS. These malfunctions
will only occur if initiated by the instructor.
Remote Functions will be provided to reset all simulated 86 Lock Out Relays.
171
15.11.2. Electrical Generators

As stated previously, each combustion turbine shall be directly coupled to a 3-phase
synchronous AC generator. Generators shall be modeled using ordinary differential
equations for determining all transient and subtransient voltages
d-q Axes Voltages Equations are:
Vd = V * sin δ
Vq = V * cos δ
where:
V = module of generator terminal voltage phasor
Vd = direct axis voltage
Vq = quadrature axis voltage
Generator Currents Equations:
Id = (1/x '') *(ω*E''q - Vq)

Iq = ( 1/x'') *( -ω*E''d + Vq)
Transient and Subtransient Voltages Equations are:
dE'q/dt = (1/T'd0) *(Eqe - Id*(xd-x'd)-E'q)

dE''q/dt = (1/T''d0)*(E'q - Id*(x'd-x'')-E''q) + dE'q/dt
dE''d/dt = (1/T''q0)*(E'q - Iq*(x'q-x'')-E''q)
where:
E'q = quadrature axis fictitious transient voltage
E''d,E''q = d-q axes fictitious subtransient voltage
Eqe = induced voltage proportional to exciter wind voltage
xd, xd’, xd’’ = direct axis synchronous, transient and subtransient synchronous
reactance
xq, xq', xq'' = quadrature axis synchronous, transient and subtransient
synchronous reactance
T'd0 = direct axis transient time constant
T''d0, T''q0 = direct and quadrature axis subtransient time constant
x''=0.5*(x''d+x''q) = effective sub-transient reactance
Torque Equations:
Te = E''q*Iq + E''d*Id
P= ω*Te
172
Mechanical Equations:
ds/dt =1/J *((Pt/1+s) - Te)

dδ/dt = s* ωnom
where:
ω = angular velocity in p.u.
ωnom = nominal frequency
Pt = turbine mechanical power
J = moment of inertia of generator's rotating system
s = absolute surge of motor
δ = angle of rotation
As described above, all of the main electrical parameters for each simulated GTG,
including voltage, frequency, current, real- and reactive-power and power factor shall be
calculated using first principles modeling, to interface with the appropriate DCS points.
All three phases will be assumed “balanced”, so there will be no differences in voltages
or currents between different phases.
Synchronization will be accomplished through the DCS. Auto versus manual

synchronizing will be selected via normal DCS control. The auto-synchronizing circuitry
will be fully modeled based upon suitable voltage match, speed differential, and phasing
window.
15.11.3. Excitation System

The generator excitation system for each combustion turbine generator shall model a
static exciter and electronic automatic voltage regulator (AVR) and will provide for both
automatic and manual generator excitation control.
Voltage regulator trip malfunctions will trip the AVRs to manual and drive the
appropriate DCS points. Operators will not be able to restore AVRs to “auto” until these
malfunctions are cleared by the instructor.
The logic for generator field breakers will be fully simulated including all manual and
automatic trip and close operations.
15.11.4. Generator Main & Aux. Transformers

The model will include main and auxiliary transformers for each combustion turbine
generator assembly. Main transformers shall have an 18KV primary and a 230KV
secondary. Auxiliary transformers shall have a 230 KV primary and a 4.16 KV primary.
15.11.5. Generator Output Breakers and Disconnects

The logic for generator output breakers will be fully simulated including all manual and
automatic trip and close (plus synchronization) operations and both DCS and local (via
173
RFs and panel graphics) control and indication. Critical and non-critical alarm
conditions logic will be simulated to drive the appropriate DCS points.
RFs will be provided to control motor operated disconnects. Logic will prevent these
disconnects from operating when the applicable generator is on-line. The main purpose
of these RFs is to provide accurate indications on the DCS when the TGs are off-line.
15.11.6. Generator Protection

Main Generator protection, trip, and lockout relays will be modeled to the extent needed
to provide interface to the simulated DCS. Calculated voltage and current values will
provide inputs to protection and lockout relaying, as will spurious malfunctions for
Generator Fault and breaker failure.
15.11.7. Electrical Distribution

The simulated electrical distribution system shall include both 4160 volt busses feeding
a series of 480 volt busses to provide the appropriate power feed for all electrical
equipment modeled.
15.11.8. Electrical Network Model Theory

The Electrical Network Model consists of all the elements that connect the users of
electric power to the generating equipment. Basically, all the elements consisting of
passive elements and active elements can be lumped together to form a network that
obeys basic Kirchoff current and voltage laws.
The Electrical Network Model is based on solving the simultaneous equations for the
entire network. The simultaneous equations of a (N+1) node network can be written as:
[Y] * [V] = [I]
where:
[Y] = complex quadratic [N*N] matrix of node admittance;
[V] = transposed complex vector of node voltage,
[I] = complex vector of injected current.
Elements of the nodal admittance matrix are defined as:
y[i,j] = -1/Z, if node i is connected to node j

= 0, if not connected
y[i,i] = y[i,1] + y[i,2] +...+y[1,n] + y0[i]
where:
Z= R+jX - complex resistance of the link, connecting nodes i and j
y0[i] = sum of complex admittance to earth
174
Two Winding Transformers with Taps have the following parameters:
Rt = real resistance
Xt = imaginary resistance
Kt = transformer coefficient presented in Electrical network model as :
Yt = (1/Z) /Kt
y0i = Yt*(1 - Kt)/ Kt* Kt
y0j = Yt*( Kt-1)/ Kt
where :
Yt = complex admittance of the transformer, connecting nodes i, j
y0i,y0j = complex shunts on nodes i, j
Similar equations can be written for other passive equipment of electrical system
models.
15.11.9. Station Service Transformers

Station Service transformers primary disconnect switches will be instructor controlled
via RFs, and operation will only be possible when both sides of the applicable
disconnect are de-energized.
Sudden Pressure Malfunctions will be provided for the transformers. The effects will be
to trip the applicable protection relays and breakers and initiate appropriate trip and
trouble alarms on the DCS. These malfunctions will only occur if initiated by the
instructor.
15.11.10. 4160 V AC Distribution

The main 4160 V AC buss will be simulated. This buss will interface with, and provide
power for, all simulated 4160 V loads, primarily the large BOP pumps. Bus protective
relaying will be modeled, and DCS alarms, such as undervoltage, will actuate as
applicable.
Circuit breakers and associated logic will be simulated in sufficient detail to interface
with the simulated DCS and provide all necessary switching. These breakers will be
controlled from the DCS, and may also be tripped by the instructor using standard
component level malfunctions (CMFs) to bring in associated alarms. CMFs may also be
inserted by the instructor to fail these breakers from tripping or closing, to bring in
associated DCS alarms as applicable.
15.11.11. 4160 V / 480V Transformers

Seven 4160V / 480V Transformers will be modeled with nominal 4160 V on the primary
and 480 V on the secondary.
175
Sudden Pressure Malfunctions will be provided for these transformers. The effects will
be to trip the applicable protection relays and breakers and initiate appropriate trip and
trouble alarms on the DCS. These malfunctions will only occur if initiated by the
instructor.
15.11.12. 480V AC Distribution

Fourteen 480V AC busses will be simulated: These busses will interface with, and
provide power for, all simulated 480V loads. Bus protective relaying will be modeled,
and DCS alarms will actuate as applicable.
Circuit breakers and associated logic will be simulated in sufficient detail to interface
with the simulated DCS and provide all necessary switching between 480V load centers.
These breakers will be controlled from the DCS, and may also be tripped by the
instructor using standard component level malfunctions (CMFs) to bring in associated
alarms. CMFs may also be inserted by the instructor to fail these breakers from tripping
or closing, to bring in associated DCS alarms as applicable.
Remote Functions will be provided to locally operate 480V bus breakers that do not
have DCS control.
15.11.13. 125V DC Distribution

A logical model will be provided for the low voltage systems. The status of the DC
Battery will be calculated based on the positions of remote function controlled breakers
from the AC inverter supply, battery charger, UPS, and feeder breakers. Simulation of
the station battery, battery chargers, and UPS are described in their respective sections
below. Remote functions will be provided to operate locally controlled DC breakers.
15.11.14. Battery and Battery Charger

The 125V DC Station battery and chargers will be simulated logically with remote
functions and malfunctions. The instructor can set the battery to “charged” or
“discharged”, or disconnect it with the remote function for battery breaker. The charger
can be faulted via malfunction, initiating breaker trips and applicable DCS alarms, or
disconnected via remote functions.
15.11.15. UPS
The Station UPS will be simulated logically with remote functions and malfunctions.
The instructor can connect or disconnect it with remote functions. The static switch can
be faulted to via malfunction, initiating appropriate DCS alarms.
15.11.16. Electrical System Malfunctions

The instructor will be able to initiate malfunctions for the Electrical System as listed in
Table 6-1 and will get response as described above.
176
Table 6-1
mfEL001 LOSP – Loss of Off-site Power / Grid 0 1 DG 0 1
mfEL002A CT Transformer A Sudden Pressure 0 1 DG 0 1
mfEL002B CT Transformer B Sudden Pressure 0 1 DG 0 1
mfEL002C ST Transformer Sudden Pressure 0 1 DG 0 1
mfEL002D Station Service Transformer Sudden Pressure 0 1 DG 0 1
mfEL002E Reserve Station Service Transformer Sudden Pressure 0 1 DG 0 1
mfEL005A AVR trip to manual CT A 0 1 DG 0 1
mfEL005B AVR trip to manual CT B 0 1 DG 0 1
mfEL005C AVR trip to manual ST 0 1 DG 0 1
mfEL007A CT Generator A Lockout (86G) 0 1 DG 0 1
mfEL007B CT Generator B Lockout (86G) 0 1 DG 0 1
mfEL007C ST Generator Lockout (86G) 0 1 DG 0 1
mfEL011A CT Generator A Local Output Breaker Trip Switch 0 1 DG 0 1
mfEL011B CT Generator B Local Output Breaker Trip Switch 0 1 DG 0 1
mfEL011C ST Generator Local Output Breaker Trip Switch 0 1 DG 0 1
Standard Component Level Malfunctions (CMFs) can be used to fail to trip, fail to close
or trip all DCS controlled breakers. These malfunctions will also trigger associated DCS
alarms, as appropriate.
15.11.17. Electrical System Remote Functions

The instructor will be able to operate remote switches and pushbuttons in the Electrical
System using the Remote Functions as listed in Table 6-2.
Table 6-2
rfEL002A CT Transformer A LOR 86-MT Reset 0 1 DG NORM RESET
rfEL002B CT Transformer B LOR 86-MT Reset 0 1 DG NORM RESET
rfEL002C ST Transformer LOR 86-MT Reset 0 1 DG NORM RESET
rfEL002D SS Transformer LOR 86-MT Reset 0 1 DG NORM RESET
rfEL002E RS Transformer LOR 86-MT Reset 0 1 DG NORM RESET
rfEL014A CT Generator A Lockout Relay 86G Reset 0 1 DG NORM RESET
rfEL014B CT Generator B Lockout Relay 86G Reset 0 1 DG NORM RESET
rfEL014C ST Generator Lockout Relay 86G Reset 0 1 DG NORM RESET
rfEL019A-Z 480V Breaker Local Operation -1 1 DG OPEN NORM CLOSE
mfEL011A CT Generator A Local Output Breaker Trip Switch 0 1 DG NORM TRIP
mfEL011B CT Generator B Local Output Breaker Trip Switch 0 1 DG NORM TRIP
mfEL011C ST Generator Local Output Breaker Trip Switch 0 1 DG NORM TRIP
177
15.12. Combustion Turbine Units Modeling Details
SYSTEM/SUB-SYSTEM SCOPE COMMENTS

MAJOR COMPONENT
1st Prin. Limited
Combustion Turbine & Associated

Systems:
Inlet Air System (Filter and cooler) Malfunction will cause plugging of
X filter degrading performance.
Inlet Guide Vanes
X
Air Compressor
X
Bleed Air/Cooling Air System Compressor surge can occur during
X improper operation.
Natural Gas Fuel System (Fuel Flow Low gas pressure can cause
Control, X flameout.
Ignition, Flame Scanner, Dilution Steam)
Syngas Fuel System (Fuel Flow Control, Low gas pressure can cause
Ignition, Flame Scanner, Dilution Steam X flameout. CT’s respond
and Nitrogen) appropriately to changes in syngas
composition and changes in nitrogen
flow
Rotor, Stator and Nozzles Loss of cooling air leads to high temp
X of turbine parts.
Turning Gear System High vibrations if turning gear is not
X placed in service at start.
Turbine Starting System One hr. cooling reqd. after two
X unsuccessful starts.
Lube Oil System Cold oil causes high vibrations.
X
Control Oil System and Turbine Loss of lube oil directly affects control
Speed/Load Control X oil.
Fuel Delivery Systems
X
Steam Injection System NOx Control
X
Turbine Supervisory
Instrumentation (TSI) System X
178

MAJOR COMPONENT
1st Prin. Limited
Combustion Turbine Generator
Excitation System X
Excitation Control Protection X
(MEL,Volts per Hz, URAL)
Generator Hydrogen Cooling System X Ambient air temperature, load, MVAR,
and excitation level affect the stator and
rotor temperatures.
Generator Synchronizing X
179
16. Heat Recovery Steam Generator (HRSG), Steam Turbine

and BOP
16.1. HRSG Overview
The simulator shall model two independent heat recovery steam generators, one for
each train. Each of these HRSG’s is a triple-pressure natural circulation water tube
steam generator that is designed to utilize exhaust energy available from its attached
combustion turbine. The HRSG design shall include high pressure, intermediate
pressure, and low pressure evaporator sections with superheater, drum, and
economizer for each section. The simulation shall model all of specified heat
exchangers piping, tanks, valves, and volumes specified. Each HRSG shall also be
fitted with a selective catalytic reduction grid with ammonia injection.
Exhaust gas from the combustion turbine is directed to the HRSG by the inlet transition
duct. The “setting” provides CT exhaust gas containment ductwork, encasement of
various heat recovery module units, and the exhaust stack. The HRSG setting includes
ductwork transitions for connection with the CT outlet flange and HRSG module boxes.
Heat transfer is accomplished by a series of components arranged vertically and

perpendicular to the CT exhaust gas flow in a “double-wide” configuration. The heat
transfer surfaces are located in such a manner as to provide for maximum temperature
differential between the declining exhaust gas temperature and the temperature of the
steam and water inside the heat transfer surfaces.
In support of the coal gasification plant, the HRSG shall also be designed to supply an
adequate flow of heated feedwater to the syngas cooler equipment, and in return
receive a commensurate flow of high pressure steam which shall be used to augment
the HRSG’s production of high pressure steam. During times when the combustion
turbine is operating on natural gas, the syngas cooler feedwater supply and high
pressure steam returns shall be isolated.
The HRSG shall be designed with the following operating performance criteria for
operation on either syngas or natural gas, or any blended combination:
180
Comparison Performance – Syngas vs. Natural Gas

Table 1-1
Fuel Type Nat. Gas Syngas
Ambient Temperature – Degrees F. 69 69
Combustion Turbine Load 100% 100%
Combustion Turbine Exhaust Flow – lb/hr 3,420,000 4,219,000
Combustion Turbine Exhaust Temp – Degrees F. 1,150 1,052
Nitrogen Diluent Flow 0 600,260
Combustion Turbine Exhaust Constituents
• N2 73.75 73.15
• CO2 3.85 0.50
• O2 12.30 10.00
• H20 9.25 13.50
• AR .85 .85
High Pressure Steam Flow – lb/hr 745,734

High Pressure Steam Temperature – Degrees F. 1000
High Pressure Steam Pressure - PSIA 1815
Intermediate Pressure Steam Flow – lb/hr 611,029
Intermediate Pressure Steam Temperature – Degrees 1000
F.
Intermediate Pressure Steam Pressure – PSIA 420.4
Intermediate Pressure Feedwater Flow to Natural Gas 45,000
Heater – lb/hr
Low Pressure Turbine Inlet Steam Flow 1,275,097
Low Pressure Turbine Inlet Steam Temperature – 532
Degrees F.
Low Pressure Turbine Inlet Steam Pressure - PSIA 65
Intermediate Pressure Feedwater Temperature to 430
Natural Gas Heater – Degrees F.
Low Pressure – lb/hr 30,000
Low Pressure Steam Temperature 311.2
Low Pressure Steam Pressure 79
16.1.1. Water and Steam Side Flow Paths

After returning from the gasification plant where it is used for cooling, condensate
entering the HRSG first passes through the condensate pre-heater. The condensate
then enters the deaerating section of the low pressure drum where it is now considered
to be feedwater. Stripped of virtually all non-condensable gases, the feedwater mixes
with the water inside the low pressure drum and becomes the suction supply for the
feedwater pumps. An additional flow of water leaves the drum via the downcomers and
enters the low pressure evaporator. Here the water is heated to saturation to produce a
steam/water mixture which exits the evaporator tubes and re-enters the drum through a
series of steam/water separators. Once separated, the saturated steam exits the LP
181
steam drum and, after passing through the low pressure steam superheater, enters the
low pressure steam system.
Acting much like the deaerator storage tank in a conventional steam plant, the LP drum
located on the top deck of the HRSG supplies a reserve of water with adequate net
positive suction head (NPSH) to the suction side of the main feedwater pumps. Each
feedwater pump actually provides two discharge streams of feedwater. High pressure
feedwater is produced at the pump’s main discharge, while intermediate pressure
feedwater is derived from an interstage extraction. High pressure feedwater is then
directed through the high pressure primary and secondary economizers before entering
the high pressure drum. Spray water for the main steam attemperators (sprays) is
supplied from the feedwater pump high pressure discharge, and cooling water for the
gasifier syngas cooler is obtained from the discharge of the high pressure primary
economizer. Intermediate pressure feedwater is directed through the intermediate
pressure feedwater economizer and then to the intermediate pressure drum. An
additional flow of intermediate pressure feedwater is also used to supply the spray
water for the reheat attemperators.
Saturated high pressure steam leaving the high pressure drum is transferred to the
primary and secondary main steam superheaters. The superheated steam then passes
through the main steam attemperator before entering the final main steam superheater.
The attemperators are necessary to ensure the final superheat and reheat temperatures
do not exceed 1,055 degrees F. Superheated steam exiting the final main steam
superheater is collected in the high pressure superheater outlet header where the high
pressure steam from both the “A” and “B” HRSG’s is mixed before being fed to the inlet
of the high pressure steam turbine.
Saturated intermediate pressure steam leaving the intermediate pressure drum is

transferred to the primary intermediate pressure steam superheater. After exiting the
superheater the intermediate pressure steam is mixed with cold reheat steam which has
been exhausted from the high pressure steam turbine. This mixture of intermediate
pressure steam and cold reheat is then passed through the secondary intermediate
pressure steam reheater. The steam is then routed through the reheat attemperation
sprays, through the final intermediate pressure steam superheater and finally to the
reheat (intermediate pressure) steam turbine.
16.1.2. Hot Gas Heat Transfer Flow Path

The combustion turbine exhaust gas is directed into the HRSG through high
temperature ductwork and transfers thermal energy into the steam and water by means
of a series of heat exchangers. The flow path is in the following order beginning at the
HRSG hot gas inlet and ending at the discharge duct to the stack:
1. Main Steam Final Superheater

2. Reheat/Intermediate Steam Final Superheater
3. Main Steam Secondary Superheater
182
4. Reheat/Intermediate Steam Secondary Superheater

5. Main Steam Primary Superheater
6. High Pressure Evaporator
7. High Pressure Secondary Economizer
8. Intermediate Pressure Primary Superheater
9. Intermediate Pressure Evaporator
10. Intermediate Pressure Economizer
11. High Pressure Primary Economizer
12. Low Pressure Evaporator
13. Condensate pre-heater
Figure 6 HRSG Hot Gas Flow Path
16.1.3. Combustion Turbine Exhaust Constituents

Combustion turbine exhaust constituents, particularly the moisture content, are an
important factor in the design and performance of an HRSG. Higher moisture content
increases the gas enthalpy, which results in more heat available for the same
temperature difference. The heat transfer coefficient is higher for the gas with higher
moisture content. The net result is to transfer more heat for the same surface.
In the case of IGCC applications, especially those using shift reactors, the change in
hydrogen content, and thus moisture content in the exhaust gas will vary tremendously
between syngas operation and natural gas operation of the combustion turbines. The
model shall consider these changes in exhaust gas enthalpy based on fuel composition
along with changes in flow and temperature, and realistically model the HRSG’s thermal
performance accordingly.
183
16.1.4. Component Descriptions
Economizer
The HRSG model shall include economizers for the intermediate and high pressure
sections. The economizer’s function is to increase water temperature to an “approach”
temperature near the saturation temperature. The economizers in this HRSG design
are “once through” and “non-steaming” types. Flashing in the economizers is not
desirable at any time. The condensate pre-heater in the low pressure section is not
considered and economizer as it is not designed to heat the water to near saturation
conditions.
Evaporators
Evaporator sections are where the boiling process or steam generation occurs. Natural
circulation design high pressure, intermediate pressure, and low pressure evaporator
sections of the HRSG’s will be modeled.
A five-equation two-phase equilibrium model shall be used to model the steam and
water flow through the appropriate HRSG elements. All valves and non-return valves,
pumps and heat exchanger elements shall be modeled as discrete objects. The volume
of all water-side and steam-side elements shall be additionally modeled. Shrink and
swell effect on the drum levels will be modeled by evaluating the boiling regime present
in the associated evaporator relative to that element’s volume. The following equations
are solved for each node in the network to produce a consistent pressure-flow-energy
network solution:
Mass Conservation
M = M `+ ( ∑ m& in − ∑ m& out )∆t
Where: M - The mass of the fluid in the node
M ` - The mass of fluid in the node at the previous time step
m& - Mass flow
Conservation of momentum
m& = m& `+ ( ∆Pgrad + ∆Padm + ∆Ppump + ∆Pgrav )∆t S
l
Where: m& ` - Mass flow at previous time step
∆Pgrad - Overall pressure difference between two nodes
2
∆Padm - The hydraulic resistance: ∆Padm = ξ total m&
ρ with
ξ total = ξ valves + ξ friction
∆Ppump - Pump head added to flow path (dependent on mass flow, pump
characteristics and speed)
Pgrav - Static head due to node elevation differences
184
Conservation of Energy
H = H `+ ( ∑ m& in hin + ∑ m& out hout + Qexternal )∆t
Where: H - Enthalpy of the node
h - Specific enthalpy
Qexternal - External heat flux to the node from sources like heat exchangers
Superheaters
The superheaters in the HRSG shall be modeled to absorb heat energy from the CT
exhaust gas and transfer it to the steam. The steam superheat energy level is
measured as an increase in steam temperature beyond the steam temperature
achieved in the evaporator section.
Condensate and Feedwater Connection Boundaries

The HRSG low pressure inlet boundary shall connect to the condensate system model
at the condensate pre-heater inlet. Intermediate and high pressure HRSG inlet
boundaries shall connect to the feedwater system model at the inlets to the IP and HP
economizers respectively. The feedwater system additionally supplies the HP and IP
attemperator flow.
Steam Connection Boundaries

There shall also be an inlet boundary of high pressure steam generated by the syngas
cooler.
Outlet boundaries for the HRSG models shall consist of:

• HP steam system at the superheater outlet.
• IP steam system at the cold reheat inlet and hot reheat outlet.
• LP admission steam piping.
• Combustion turbine dilution steam supply piping.
Blowdown piping and valves will be modeled to allow for continuous blowdown from the
HP and IP drums. Intermittent blowdown lines and manual valves will be modeled for all
evaporator elements.
Startup Bypasses
Each HRSG shall be equipped with steam bypasses for controlling temperatures and
flows through the various HRSG elements until sufficient flow is established through the
steam turbine. Although only the “A” train is illustrated, the “B” train steam bypasses
are identical.
Since the low pressure steam is saturated, the low pressure bypass system is used
primarily to control the pressure in the low pressure drum, and permits circulation
through the low pressure evaporator and condensate pre-heater circuits.
185
The intermediate pressure steam bypass routes steam from the hot reheat line, then
reduces both the steam’s pressure and temperature through a regulating valve and
desuperheater, then dumps it into the condenser.
When placed in service, the high pressure steam bypass system provides steam flow
through all of the high pressure superheaters by removing steam from the high pressure
steam outlet, reducing its pressure and temperature through a regulating valve and a
desuperheater, and inserting it into the cold reheat line before it enters the HRSG. To
ensure the proper flow of steam on startup, the intermediate pressure steam bypass
must be placed in service first.
Figure 7 HRSG High Pressure Steam Bypass System
186
Figure 8 HRSG Intermediate and Low Pressure Steam Bypass Systems
Heat Exchanger Models in the HRSG

Convection heat exchange will be modeled in the HRSG. Heat is exchanged between
the CT exhaust gas and the following feedwater/steam elements:
• HP, IP and LP superheaters
• HP, IP and LP evaporators
• HP and IP economizers
• LP condensate pre-heater
• Reheater
Convective heat losses to the environment will be consolidated and modeled at the
following areas:
• HP Drum
• IP Drum
• LP Drum
• Gas Path at the HP section
• Gas Path at the IP section
• Gas Path at the LP section
187
Convective heat exchange calculations will be based on the following basic equation:
Q = K (T − T )
A H L W
Where: Q - The heat flux due to convective heat transfer

A - Heat exchanger surface area.
K H - Calculated heat transfer coefficient based on empirical correlations
with fluid properties and velocity. Mapped regions include free convection,
forced convection, boiling and condensation
TL - The fluid temperature (two-phase water or gas).
TW - The wall temperature.
Radiation heat exchange will be modeled based on the following basic principles:
Q R = Fe Fv σ A (TF − TS )
4 4
Where: Q R - The heat flux due to radiation

Fe - Surface emissivity
Fv - View factor (flame to HRSG element)
σ - Stefan Boltzman constant
A - Flame area (variable)
TF - Flame temperature
TS - HRSG element surface temperature
The heat exchanger wall heat capacitance will be modeled assuming a nearly uniform
internal temperature (lumped capacitance) distribution using the principle:
dT
Qtotal = C p M
dt
Where Qtotal - The total heat flux to the heat exchanger wall
C p - The thermal capacitance of the wall material
M - The wall mass
T - Wall temperature
The heat exchanger wall models will include surface conduction resistances to enable
slagging/fouling effects on both sides.
1
Qsurface = (Tslaglayer − TWall )
Rsurface
Where Rsurface - The surface heat flux resistance
188
Selective Catalytic Reduction (SCR)

The SCR will be modeled as a chemical catalyst element in the HRSG flow path. The
ammonia injection and dilution air flows will be added to the exhaust gas flow path. This
system interfaces to the Chemical Injection System at the ammonia injection grid inlet.
The following chemical reactions occur in the reactor:
NO reduction
4 NO + 4 NH3 + O2 ⇒ 4 N2 + H2O
4 NH3 + 6 NO ⇒ 5 N2 + 6 H2O
NO2 reduction
2 NO2 + 4 NH3 + O2 ⇒ 3 N2 + 6 H2O
6 NH3 + 8 NO2 ⇒ 7 N2 + 12 H2O
The ratio of NO to NO2 is combustion process dependent and determines the required
ammonia to NOx ratio.
The Reactor object model takes into account the following:

• Gas flow characteristics such as velocity, temperature, density and chemical make
up (O2, NH3, NO and NO2 mass fractions)
• Reactor characteristics like catalyst pitch and void fraction
• Catalyst fouling and age
The reactor model calculates the following:

• Reduction reaction rates
• Approximation of undesirable side reactions like ammonia oxidation which reduces
reactor efficiency
• Reactor element pressure drop
• Catalyst depletion rate
• Mass fractions for all the reaction products and ammonia slip
189
Figure 9 HRSG SCR System
16.1.5. HRSG Malfunctions

The instructor will be able to initiate malfunctions for the HRSG as listed in Table 1-1.
Table 1-1

MfSG1 “A” LP Economizer Tube Leak 0 100 VR
MfSG2 “A” IP Economizer Tube Leak 0 100 VR
MfSG3 “A” HP Primary Economizer Tube Leak 0 100 VR
MfSG4 “A” HP Secondary Economizer Tube Leak 0 100 VR
MfSG5 “A” LP Evaporator Tube Leak 0 100 VR
MfSG6 “A” IP Evaporator Tube Leak 0 100 VR
MfSG7 “A” HP Evaporator Economizer Tube Leak 0 100 VR
MfSG8 “A” IP Primary Superheater Fouling 0 100 VR
MfSG9 “A” IP Secondary Superheater Fouling 0 100 VR
MfSG10 “A” IP Final Superheater Fouling 0 100 VR
MfSG11 “A” HP Primary Superheater Fouling 0 100 VR
MfSG12 “A” HP Secondary Superheater Fouling 0 100 VR
MfSG13 “A” HP Final Superheater Fouling 0 100 VR
190

MfSG14 “A” IP Spray Valve Failure 0 100 VR
MfSG15 “A” HP Spray Valve Failure 0 100 VR
MfSG16 “A” HP Bypass Press Regulator Failure 0 100 VR
MfSG17 “A” HP Bypass Temperature Regulator Failure 0 100 VR
MfSG18 “A” SCR catalyst life (0 – new, 100 – depleted) 0 100 VR
MFSG19 “A” SCR reactor fouling 0 100 VR
MfSG20 “A” Air Dilution Fan Trip 0 1 DG
MfSG21 “B” LP Economizer Tube Leak 0 100 VR
MfSG22 “B” IP Economizer Tube Leak 0 100 VR
MfSG23 “B” HP Primary Economizer Tube Leak 0 100 VR
MfSG24 “B” HP Secondary Economizer Tube Leak 0 100 VR
MfSG25 “B” LP Evaporator Tube Leak 0 100 VR
MfSG26 “B” IP Evaporator Tube Leak 0 100 VR
MfSG27 “B” HP Evaporator Economizer Tube Leak 0 100 VR
MfSG28 “B” IP Primary Superheater Fouling 0 100 VR
MfSG29 “B” IP Secondary Superheater Fouling 0 100 VR
MfSG30 “B” IP Final Superheater Fouling 0 100 VR
MfSG31 “B” HP Primary Superheater Fouling 0 100 VR
MfSG32 “B” HP Secondary Superheater Fouling 0 100 VR
MfSG33 “B” HP Final Superheater Fouling 0 100 VR
MfSG34 “B” IP Spray Valve Failure 0 100 VR
MfSG35 “B” HP Spray Valve Failure 0 100 VR
MfSG36 “B” HP Bypass Press Regulator Failure 0 100 VR
MfSG37 “B” HP Bypass Temperature Regulator Failure 0 100 VR
MFSG38 “B” SCR catalyst life (0 – new, 100 – depleted) 0 100 VR
MFSG39 “B” SCR reactor fouling 0 100 VR
MFSG40 “B” Air Dilution Fan Trip 0 1 DG
191
16.1.6. HRSG Remote Functions
The instructor will be able to operate remote switches and pushbuttons in the HRSG
using the Remote Functions as listed in Table 1-2.
Table 1-2

RfSG1 “A” LP intermittent blowdown valve 0 1 VR
RfSG2 “A” IP intermittent blowdown valve 0 1 VR
RfSG3 “A” HP intermittent blowdown valve 0 1 VR
RfSG4 “A” LP continuous blowdown isolation valve 0 1 VR
RfSG5 “A” IP continuous blowdown isolation valve 0 1 VR
RfSG6 “A” HP continuous blowdown isolation valve 0 1 VR
RfSG7 “B” LP intermittent blowdown valve 0 1 VR
RfSG8 “B” IP intermittent blowdown valve 0 1 VR
RfSG9 “B” HP intermittent blowdown valve 0 1 VR
RfSG10 “B” LP continuous blowdown isolation valve 0 1 VR
RfSG11 “B” IP continuous blowdown isolation valve 0 1 VR
RfSG12 “B” HP continuous blowdown isolation valve 0 1 VR
16.2. Condensate System

16.2.1. Condensate System Description
The primary purpose of the condensate system is to provide condensate to the low
pressure deaerator and steam drum for each HRSG train. Major components of the
condensate system include the condenser, two 100% capacity condensate pumps, and
the gland steam condenser. The system provides cooling water for the steam turbine
exhaust hood sprays and receives heating from various heat exchangers associated
with the gasification plant.
The condensate system also includes the make-up piping and valves connected to the
condensate storage tank. Leak flows will be modeled in the high-pressure steam
systems to allow the make-up system to function realistically. Two liquid ring vacuum
pumps provide air evacuation to the condenser and turbines, and provide continuous
removal of non-condensable gases during condenser operation.
The condensate and economizer recirculation pumps will be modeled using standard
commercially available pump curve data. The LP drum/deaerator level is controlled with
the condensate flow control valve at the inlet to each deaerator. The condensate make
up system will be modeled as a condensate tank with a limitless supply from the water
treatment plant. The make–up flow is controlled by the DCS using two parallel make-up
valves. Refer to Figure 1-5.
192
Figure 10 Condensate System
16.2.2. Condensate System Control Methodology

Primary condensate system control shall consist of a three-element scheme to
accurately control low pressure drum level on each HRSG train. The inlet flow element
shall be positioned on the low pressure drum feedwater supply line. Outlet steam flow
shall be measured at the low pressure drum outlet. Outlet feedwater flow shall be
measured on the feed pump suction line and summed with the outlet steam flow.
Redundant level transmitters shall be fitted to the low pressure drum. The calculated
feedwater demand signal is then sent to the low pressure feedwater flow control valve
located at the inlet to the low pressure drum. Variable speed couplings shall be used on
each condensate pump to maintain condensate discharge pressure at an established
set point value. During start up and extremely low load operation, the system will
automatically reject to single element control. The operator shall also have the option to
manually select single element control. Variable speed drives on the condensate
pumps maintain a constant system pressure regardless of varying condensate demand.
Refer to figure 1-6.
193
Figure 11 LP Feedwater Drum Level Control
16.2.3. Condensate thermo-hydraulic network solution

The condensate system shall be modeled using a first principles-based thermo-
hydraulic network solution that properly calculates two-phase flow conditions. Object
models for valves and non-return valves, pumps and heat exchanger elements shall be
included in the network solution in addition to system volume. The condensate piping
system will be discretized using a number of hydraulic tool nodes. Condenser and
GSSC heat exchange to the Circulating water system will be modeled using the
hydraulic heat exchanger objects. The following equations are solved for each node in
the network to produce a consistent pressure-flow-energy network solution:
Mass Conservation
M = M `+ ( ∑ m& in − ∑ m& out )∆t
Where: M - The mass of the fluid in the node
M ` - The mass of fluid in the node at the previous time step
m& - Mass flow
Conservation of momentum
m& = m& `+ ( ∆Pgrad + ∆Padm + ∆Ppump + ∆Pgrav )∆t S
l
Where: m` - Mass flow at previous time step
&
194
∆Pgrad - Overall pressure difference between two nodes

2
∆Padm - The hydraulic resistance: ∆Padm = ξ total m&
ρ with
ξ total = ξ valves + ξ friction
∆Ppump - Pump head added to flow path (dependent on mass flow, pump
characteristics and speed)
Pgrav - Static head due to node elevation differences
Conservation of Energy
H = H `+ ( ∑ m& in hin + ∑ m& out hout + Qexternal )∆t
Where: H - Enthalpy of the node
h - Specific enthalpy
Qexternal - External heat flux to the node from sources like heat exchangers
16.2.4. Condensate System Malfunctions

The instructor will be able to initiate malfunctions within the Condensate System as
listed in Table 2-1.
Table 2-1
MfCD001 “A” Condensate Pump Motor Trip 0 1 DG NORM TRIP
MfCD002 “A” Condensate Pump Efficiency (0-100%) 0 100 VR
MfCD003 “B” Condensate Pump Motor Trip 0 1 DG NORM TRIP
MfCD004 “B” Condensate Pump Efficiency (0-100%) 0 100 VR
MfCD005 “A” Condensate Flow Transmitter Fail Hi/Lo 0 100 VR
MfCD006 “A” Condensate Flow Transmitter Noise 0 100 VR
MfCD007 “B” Condensate Flow Transmitter Fail Hi/Lo 0 100 VR
MfCD008 “B” Condensate Flow Transmitter Noise 0 100 VR
MfCD009 Gland Steam Condenser Tube Leak 0 1 VR
MfCD010 LP Economizer Recirc Pump Trip 0 1 DG NORM TRIP
MfCD011 Condenser tube leak 0 100 VR
MFCD012 Condenser air leak 0 100 VR
MFCD013 Condenser tube sheet fouling 0 100 VR
MFCD014 “A” Vacuum Pump Trip 0 1 DG NORM TRIP
MFCD015 “A” Vacuum Pump Efficiency (0-100%) 0 100 VR
MFCD016 “B” Vacuum Pump Trip 0 1 DG NORM TRIP
MFCD017 “B” Vacuum Pump Efficiency (0-100%) 0 100 VR
195
16.2.5. Condensate System Remote Functions

The instructor will be able to operate remote switches and pushbuttons in the HRSG
using the Remote Functions as listed in Table 2-2.
Table 2-2
RfCD001 Gland steam condenser bypass valve 0 1 VR
RfCD002 Fuel plant condensate heaters bypass 0 1 VR
RfCD003 Exhaust hood spray isolation valve 0 1 VR
RfCD004 Condensate recirc. Bypass valve 0 1 VR
16.3. Feedwater System

16.3.1. Feedwater System Description
Each HRSG Train has its own feedwater system. This system consists of two 100%
capacity feedwater pumps, suction piping from the LP drum and discharge piping to the
IP and HP economizer inlets on each of the two HRSG`s. The minimum flow system for
each feedwater pump discharges to the LP drum. Each pump has a balancing drum
leak-off that drains to the deaerator section of the LP drum. Variable speed motors
(variable frequency controlled) power the feedwater pumps. The feedwater pumps will
be modeled using standard pump curves for this pump application. IP and HP drum
levels are controlled using the variable speed drives on the feedwater pumps. Refer to
Figure 3-1. The following subsystems are supplied from the feedwater system:
Superheater desuperheater (from HP)
Reheater desuperheater (from IP)
Steam bypass HP attemperators
Syngas coolers
196
Figure 12 HP and IP Feedwater Systems
16.3.2. Feedwater System Control Methodology

There are actually two separate feedwater control systems, one for the intermediate
pressure feedwater system, and one for the high pressure feedwater system. In both
systems primary system control shall consist of a three-element scheme to accurately
control the intermediate and high pressure drum levels respectively. For the high
pressure feedwater system, the inlet flow element shall be positioned on the outlet of
the secondary high pressure economizer. The outlet flow shall be measured at the inlet
to the main steam primary superheater. To maintain proper feedwater demand,
supplemental steam returning from the syngas cooler is subtracted from the overall
outlet mass flow entering the high pressure primary superheater. Redundant level
transmitters shall be fitted to the high pressure drum. The calculated feedwater demand
signal is then sent to the high pressure feedwater flow control valve located at the inlet
to the high pressure drum.
The intermediate pressure feedwater control scheme operates in much the same way
as the high pressure feedwater controls. Inlet flow is measured at the outlet of the
intermediate pressure economizer, while outlet flow is measured at the inlet to the
intermediate pressure steam primary superheater. Like the high pressure system,
redundant level transmitters are located on the intermediate pressure drum. The
calculated feedwater demand signal is then sent to the intermediate pressure feedwater
flow control valve located at the inlet to the intermediate pressure drum.
197
Variable speed drives on the feedwater pumps maintain a constant system pressure
regardless of varying feedwater demand. Refer to figure 3-2.
Figure 13 HP and IP Feedwater Control Methodology
16.3.3. Feedwater System Malfunctions

The instructor will be able to initiate malfunctions within the Feedwater System as listed
in Table 3-1.
Table 3-1
MfFW001 “A” Feedwater Pump Motor Trip 0 1 DG NORM TRIP
MfFW002 “A” Feedwater Pump Efficiency (0-100%) 0 100 VR
MfFW003 “B” Feedwater Pump Motor Trip 0 1 DG NORM TRIP
MfFW004 “B” Feedwater Pump Efficiency (0-100%) 0 100 VR
MfFW005 “A” HP Feedwater Flow Transmitter Fail Hi/Lo 0 100 VR
MfFW006 “A” HP Feedwater Flow Transmitter Noise 0 100 VR
MfFW007 “A” HP Drum Level Transmitter #1 Fail Hi/Lo 0 100 VR
MfFW008 “A” HP Drum Level Transmitter #2 Fail Hi/Lo 0 100 VR
MfFW007 “B” HP Feedwater Flow Transmitter Fail Hi/Lo 0 100 VR
MfFW009 “B” HP Feedwater Flow Transmitter Noise 0 100 VR
MfFW010 “B” HP Drum Level Transmitter #1 Fail Hi/Lo 0 100 VR
MfFW011 “B” HP Drum Level Transmitter #2 Fail Hi/Lo 0 100 VR
198

MfFW012 “A” IP Feedwater Flow Transmitter Fail Hi/Lo 0 100 VR
MfFW013 “A” IP Feedwater Flow Transmitter Noise 0 100 VR
MfFW014 “B” IP Feedwater Flow Transmitter Fail Hi/Lo 0 100 VR
MfFW015 “B” IP Feedwater Flow Transmitter Noise 0 100 VR
MfFW016 “A” IP Drum Level Transmitter #1 Fail Hi/Lo 0 100 VR
MfFW017 “A” IP Drum Level Transmitter #2 Fail Hi/Lo 0 100 VR
MfFW018 “B” IP Drum Level Transmitter #1 Fail Hi/Lo 0 100 VR
MfFW019 “B” IP Drum Level Transmitter #2 Fail Hi/Lo 0 100 VR
MfFW020 “A” LP Drum Level Transmitter #1 Fail Hi/Lo 0 100 VR
MfFW021 “A” LP Drum Level Transmitter #2 Fail Hi/Lo 0 100 VR
MfFW022 “B” LP Drum Level Transmitter #1 Fail Hi/Lo 0 100 VR
MfFW023 “B” LP Drum Level Transmitter #2 Fail Hi/Lo 0 100 VR
16.3.4. Feedwater System Remote Functions

The instructor shall be capable of manipulating the following remotely operated devices
for the Feedwater System as shown in table 3-2
Table 3-2
RfFW001 “A” Feedwater to Syngas Clr Man Isolation Valve 0 1 DG OPEN CLOSE
RfFW002 “B” Feedwater to Syngas Clr Man Isolation Valve 0 1 DG OPEN CLOSE
RfFW003 “A” Feedwater to HP Spray Man Isolation Valve 0 1 DG OPEN CLOSE
RfFW004 “B” Feedwater to HP Spray Man Isolation Valve 0 1 DG OPEN CLOSE
RfFW005 “A” Feedwater to IP Spray Man Isolation Valve 0 1 DG OPEN CLOSE
RfFW006 “B” Feedwater to IP Spray Man Isolation Valve 0 1 DG OPEN CLOSE
16.4. Circulating Water System

16.4.1. Circulating Water System Description
The circulating water system removes heat from the condenser, service water loop and
vacuum pump lube oil coolers. Two 50% capacity circulating water pumps draw water
from an infinite heat sink source and pass it through the condenser and other heat
exchangers before returning it to the heat sink.
16.4.2. Circulating Water System Modeling Approach

Simulation modeling of the circulating water system shall include complete and realistic
models of major components including, but not limited to, intake, circulating water
pumps, electrically operated discharge valves, and associated manually operated
valves, piping, and controls.
199
The simulation shall compute the water flow through the condenser and the water outlet
temperature. The inlet temperature of the water shall be an instructor controlled
variable.
16.4.3. Circulating Water System Malfunctions

The instructor will be able to initiate malfunctions within the Circulating Water System as
Table 4-1
MfCW001 “1A” Circulating Water Pump Motor Trip 0 1 DG NORM TRIP
MfCW002 “1A” Circulating Water Pump Efficiency (0-100%) 0 100 VR
MfCW003 “1B” Circulating Water Pump Motor Trip 0 1 DG NORM TRIP
MfCW004 “1B” Circulating Water Pump Efficiency (0-100%) 0 100 VR
16.4.4. Circulating Water System Remote Functions

The instructor shall be capable of manipulating the following remotely operated devices
for the Circulating Water System as shown in table 4-2
Table 4-2
RfCW001 Circulating Water Inlet Temperature (Deg F.) 33 100 VR
RfCW002 Vac. Pump Lube Oil Cooler #1 Isolation Valve 0 1 DG OPEN CLOSE
RfCW003 Vac. Pump Lube Oil Cooler #2 Isolation Valve 0 1 DG OPEN CLOSE
16.5. Service Water System

16.5.1. Service Water System Description
The service water heat exchangers are cooled with the circulating water flow in parallel
with the condenser. The service water heat exchangers are of the plate type. The
service water system operates in a closed loop with a surge/make-up tank. Two 100%
rated service water pumps circulate the water through the system. Make-up is from the
condensate system.
The major service water heat loads are:

• Steam Turbine lube oil coolers (2)
• Steam Turbine Generator hydrogen coolers (4)
• Condenser Vacuum Pump coolers (2)
• CT lube oil coolers (4)
200
• CT Generator coolers (10)

• CT base coolers (2)
• BFP seal oil coolers (8)
• BFP lube oil coolers (4)
• Condensate Recirc Pump seal oil cooler (4)
• LCI cooler (1)
Figure 14 Service Water System
16.5.2. Service Water System Modeling Approach

A simple thermo-hydraulic model will be constructed incorporating the piping, valves,
and heat exchangers of the service water system. Operation of various equipment will
impose appropriate heat loads throughout the system. Heat will be appropriately
rejected to the circulating water system.
16.5.3. Service Water System Malfunctions

The instructor will be able to initiate malfunctions within the Service Water System as
201
Table 5-1
MfSW01 “1A” Service Water Pump Motor Trip 0 1 DG NORM TRIP
MfSW02 “1B” Service Water Pump Motor Trip 0 1 DG NORM TRIP
MfSW03 Stm Turb L.O. Cooler Efficiency (0-100%) 0 100 VR
MfSW04 Stm Turb Gen H2 Cooler Efficiency (0-100%) 0 100 VR
MfSW05 “1A” Cond Vac Pmp Cooler Efficiency (0-100%) 0 100 VR
MfSW06 “1B” Cond Vac Pmp Cooler Efficiency (0-100%) 0 100 VR
MfSW07 “A” Comb Turb L.O. Cooler Efficiency (0-100%) 0 100 VR
MfSW08 “B” Comb Turb L.O. Cooler Efficiency (0-100%) 0 100 VR
MfSW09 “A” Comb Turb Gen H2 Clr Efficiency (0-100%) 0 100 VR
MfSW010 “B” Comb Turb Gen H2 Clr Efficiency (0-100%) 0 100 VR
MfSW011 “A” Comb Turb Base Clr Efficiency (0-100%) 0 100 VR
MfSW012 “B” Comb Turb Base Clr Efficiency (0-100%) 0 100 VR
MfSW013 “A” BFP Seal Oil Cooler Efficiency (0-100%) 0 100 VR
MfSW014 “B” BFP Seal Oil Cooler Efficiency (0-100%) 0 100 VR
MfSW015 “A” BFP Lube Oil Cooler Efficiency (0-100%) 0 100 VR
MfSW016 “B” BFP Lube Oil Cooler Efficiency (0-100%) 0 100 VR
MfSW017 Cond Recirc Seal Oil Cooler Efficiency (0-100%) 0 100 VR
MfSW018 Cond Recirc Seal Oil Cooler Efficiency (0-100%) 0 100 VR
MfSW019 LCI Cooler Efficiency (0-100%) 0 100 VR
MfSW019 “1A” Svc Water Cooler Tube Sheet Fouling 0 100 VR
MfSW020 “1B” Svc Water Cooler Tube Sheet Fouling 0 100 VR
16.5.4. Service Water System Remote Functions
Table 5-2
RfSW001 Service Water Storage Tank Level (Inches) 0 60 VR
202

HRSG’s and Balance of Plant
Each HRSG and its associated balance of plant systems shall be modeled with a
generic distributed control system and human machine interface. All displays and
controls shall be identical for each train, with the exception of different background
colors for the displays. All “A” train displays will have a light tan background, while all
“B” train displays shall have a light blue background.
Control loops and logic arrays shall be constructed using standard discrete process
control and logic objects. The use of “multi-function” or macro objects shall be avoided.
All objects shall be labeled with both their specific object name and their function. All
inputs, outputs, constants, and coefficients shall be appropriately labeled as to their
function. Additionally, output tags shall bear the name of the parent object in its naming
convention.

Control loops and logic shall be modeled for the HRSG’s and associated balance of
plant systems to provide the following functions:
Control Loops:
High Pressure Drum Level Control
Intermediate Pressure Drum Level Control
Low Pressure Drum Level Control
Main Steam Temperature Control
Reheat Steam Temperature Control
Feedwater Pressure Control (Feed Pump Spd)
Condensate Pressure Control (Condensate Pump Spd)
Hotwell Level Control
High Pressure Steam Bypass Pressure/Flow Control
Intermediate Pressure Steam Bypass Pressure/Flow Control
Low Pressure Steam Bypass Pressure/Flow Control
Logic Arrays:
Condensate Pump Start Permissives
Feedwater Pump Start Permissives
SCR System Start Permissives
High Pressure Feedwater Control Three Element/Single Element Transfer
Intermediate Pressure Feedwater Control Three Element/Single Element Transfer
Condensate Control Three Element/Single Element Transfer

associated with each heat recovery steam generator.
203
controls. On each train, it is assumed that one HMI screen will usually be used for
primary system controls, and critical instrumentation values. The second display shall
The DCS for each heat recovery steam generator shall be configured with the following
displays:
Control, Heat Recovery Steam Generator:

HRSG A&B Overview (Common Display)
HRSG Master Control
High Pressure Steam System Control
Intermediate and Reheat Steam Control
Low Pressure Steam Control
High Pressure Steam Bypass
Intermediate & Low Pressure Steam Bypass
SCR Control
Instrument & Service Air Control
Data Acquisition, Heat Recovery Steam Generator:

HRSG Gas & Tube Metal Temperatures
Heat Rate, Thermal Performance
CEMS
16.6.3. Alarms
condition to occur is possible. (For example: generator disconnects open.) Priority 3
alarms shall display in blue text. Priority 4 alarms are shall be status state indications
text.
204
16.7. Steam Turbine

16.7.1. Description of Model
The function of turbine models is to convert the thermodynamic energy of main and
reheat steam into mechanical energy used to drive the generator rotor. LP, IP and HP
turbines are used. The reheat cycle takes HP exhaust steam and cycles it through the
HRSG. Reheat steam is returned to the IP turbine. The combined stop and control
valves regulate main steam flow to the turbine HP turbine. The combined reheat valves
control the admission of reheated steam into the IP turbine. The purpose of the stop,
control and intercept valves is to regulate the turbine speed, load, steam pressure and
to provide emergency protection. The positioning of these valves is performed by
Electro-hydraulic Control (EHC) System, where a combination of analog and digital
electrical signals is transformed by a high-pressure hydraulic fluid system. The Turbine
Supervisory Instrumentation (TSI) System, as implemented in the turbine control DCS,
monitors the following important turbine parameters:
Turbine eccentricity measured as the amount of bow in the turbine rotor at turning
gear speed.
Vibration of rotating shafts of the turbine and generator monitored at each bearing
for the purposes of recording and protective tripping.
Rotor-shell expansion due to differential temperature response of the turbine rotor
and shells.
Turbine temperatures monitored in order to minimize metal stress caused by thermal
gradients. Temperatures are measured at the stop valve, steam chest, HP turbine
first stage inner shell, and the IP turbine reheat bowl.
Water induction into the steam path of the turbine is monitored in order to prevent
serious damage to the high-pressure shells, rotors, buckets and bearings.
The turbine system also includes the turning gear, which rotates the turbine-generator
rotor train at slow speed (3-5 rpm) after the turbine shutdown to prevent the rotor
bowing and bearings overheating. Another use of the turning gear is to assist steam
flow in rolling off the turbine at startup.
The turbine lubricating oil supply provides cleaned and purified oil at regulated pressure
and temperature for lubrication and cooling of the rotor bearings of the turbine,
generator and exciter. Primary closed-loop cooling directly supplies oil to the turbine-
generator bearings.
The turbine hydraulic power supply provides a source of high-pressure fluid to convert
the electrical signals produced in the turbine’s analog and logic control circuits into
power for operating the turbine’s control and stop valves.
205
16.7.2. Turbine Supervisory Information

This model determines the compressor-turbine and generator bearing metal and lube oil
temperatures, bearing vibrations and thrust bearing proximitor readings.
Bearing Oil and Metal Temperatures

The bearing metal temperatures are given by the first order time lag of target
temperatures. The target temperature is the bulk oil inlet temperature plus a factor,
which is linearly dependent on the speed from 0 to 3600 rpm, plus a factor linearly
dependent on the turbine load, plus an instructor-set factor to represent a malfunction.
The bearing oil outlet temperatures are normally given by the metal temperature minus
9° F.
Turbine Vibrations
Vibrations are monitored at five journal bearings and can be affected by lubricating oil
temperature, critical speeds and instructor-set malfunction. Vibrations will be higher
also, if the turbine was started from standstill (instead of off the turning gear). All
vertical and horizontal proximitors and seismometers for the same bearing will act
proportionally. Thrust bearing proximitors will read values dependent on the turbine
load.
Vibration Monitor
If vibration at any bearing exceeds 5.00 mils, the vibration alarm signal is sent to the
DCS. If vibration at any bearing exceeds 10.0 mils, the vibration trip signal is sent to the
DCS. These signals are maintained until the Monitor receives a reset command from
the DCS. The instructor can fail the monitor with a particular malfunction. In this case
the vibration alarm and trip signals are inhibited and the Monitor status alarm is sent
16.7.3. Modeling Approach for the Steam Turbine

The model shall calculate an energy balance for each stage. Total turbine power shall
then be calculated from the result. The base of turbine mechanical energy calculation is
the turbine-generator (pump) rotor torque equation. A basic equation of mass balance
exists for each control volume in the turbine.
The Turbine model is used to obtain positive shaft torque. Steam at high temperature
and pressure are fed to turbine inlet. Steam temperatures and pressures are reduced
at turbine outlet due to their transformation to turbine torque. In the model, the
characteristics of turbine are approximated by arc of ellipse.
206
The model will properly represent turbine startup, operation, and coast down. The main
turbine model will include main stop valves, control valves and combined reheat stop-
intercept valves. Valve configuration for each turbine type shall be modelled. Energy
storage in the rotating inertia of the turbine generator system will be present. Mass
storage in the reheater will be modelled. Turbine windage losses shall be simulated to
represent losses while not synchronized. Turning gear will be simply modelled. Turbine
metal masses will be simply modelled, axial and radial conduction will be modelled.
Inner metal temperatures will be based on heat transfer from incoming steam.
Turbine control is accomplished via stop valves and control valves. The turbine is rolled
on stop valves with control valves wide open. This control mode is referred to as full arc
mode. After the unit is tied online, turbine control is transferred from full arc mode to
partial arc mode. To accomplish partial arc mode, the control valves close to take
control and the stop valves go wide open.
Turbine prewarming is achieved by maintaining steam in the HP section of the turbine at

55-70 psig with the control and combined reheat stop-intercept valves completely
closed. The prewarming time is selected from an S&L chart and will ensure that reheat
inlet bowl temperature has been above 130 °F for one hour.
OR
Warming is accomplished by rolling the turbine to 2100 rpm to 2250 rpm and soak.
Warming time starts when reheat steam temperature reaches 500 °F. Soak time to be
determined by HP first stage metal temperature and reheat inlet bowl temperature. The
turbine must be on turning gear for at least 1 hour prior to rolling to minimize
eccentricity.
The main turbine hood sprays and temperature will be a separate model based on an
algebraic energy solution combining turbine exit flow and energy, windage losses, gland
steam flows, and exhaust hood spray flows.
This system will accurately simulate the following turbine parameters:

• turbine differential and casing temperatures;
• turbine metal and bearing temperatures;
• shaft eccentricities and vibration
• Thermodynamic properties of exhaust steam
• Power transfer to the generator through a common shaft object
• Each control valve will be with a characteristic curve that is a function of control
valve position to provide realistic turbine power production changes.
• Main turbine model will be nodalized to reflect turbine output between each cluster of
stages between extraction points.
• The main turning gear start/stop and engage will be simply modelled. Turbine shaft
speed will be 3 rpm while the turning gear is engaged and the turning gear motor is
running. Turbine eccentricity will be simply modelled, with a roll-out rate that is a
function of shaft temperature.
207
• The main turbine hood sprays and temperature will be a separate model based on
turbine backpressure and spray flow.
• Turbine-generator criticals (extracted from a table) shall be integrated to produce
worsening vibration at critical speeds for each appropriate section of the turbine.
• Turbine-generator vibration will be a function of oil temp and speed.
• Vibrations, eccentricity, wear, temperatures, and other turbine measurements will be
modeled to reflect the operating characteristics of a steam turbine typical of this
design
The simulated turbine system will provide accurate models for:

• Main steam stop valves and actuator
• Governor valves and controls
• Reheat stop valves and intercept valves and controls
• Oil-driven booster pump in oil reservoir
• Main shaft-driven oil pump
• AC motor-driven oil pump
• DC motor-driven lube oil pump and controls
• Servomotor operation/steam valve control
Limited-Scope models will be provided for:

• Lube oil reservoir modeled as instructor-defined level
• Lube oil filters and cooler controls modeled as instructor-initiated malfunctions and
remote functions
• Turning gear motor controls and oil pump modeled as remote functions
• EHC hydraulic system simplified to the pressure in the system and controls
simulated as remote functions
208
16.7.4. Steam Turbine Malfunctions

The instructor will be able to initiate malfunctions with the Steam Turbine as listed in
Table 6-1.
Table 6-1
MfST01 Steam Turbine Trip Block 0 1 DG NORM RESET
MfST02 Steam Turbine Bearing # 1 High Vibration 0 100 VR
MfST03 Steam Turbine Bearing # 1 high Temperature 0 100 VR
MfST012 Steam Turbine Thrust Bearing 0 100 VR
16.7.5. Steam Turbine Remote Functions
Table 6-2
RfST01 Steam Turbine Load Limit Hand Wheel 0 110 VR
16.8. Steam Turbine Generator

16.8.1. Description of Model
The electrical generator converts mechanical power from the prime mover (steam
turbine) into electrical energy for supply to the grid. The generator consists of a wire-
wound rotor that spins inside a wire-wound stator; the rotor windings are energized by a
separate excitation circuit, and create a rotating magnetic and electrical field. This field
passes through the stationary windings of the stator to induce an electrical current and
terminal voltage. This voltage is stepped up to grid voltage by a transformer. Terminal
voltage strength and/or generator reactive power are determined by the field excitation,
transformer step-up ratios, and grid conditions.
16.8.2. Excitation System

The generator excitation system for the steam turbine-generator shall model a static
exciter and electronic automatic voltage regulator (AVR) and will provide for both
automatic and manual generator excitation control.
209
Voltage regulator trip malfunctions will trip the AVRs to manual and drive the
appropriate DCS points. Operators will not be able to restore AVRs to “auto” until these
malfunctions are cleared by the instructor.
The logic for generator field breakers will be fully simulated including all manual and
automatic trip and close operations.
16.8.3. Modeling Approach for the Generator

The generator model shall be based upon first principles and shall consist of two
fundamental components. The first shall consider rotor shaft dynamics and perform
computations that consider shaft acceleration, speed and angular position. These
calculations shall be based on the mechanical power from the turbine, electrical power
delivered by the generator, inertia and various losses (i.e., copper losses, core losses,
and friction losses.) The second component of the simulation shall consider voltage
induction within the machine. Angular speed, magnetic saturation and various
reactances shall be considered in the calculation of the generator Electromotive Force
(EMF) phasor, EMF frequency and saturated synchronous reactance. Generator AND
plant auxiliaries need to respond to changes in grid frequency and reactive.
Generator synchronization will be modelled to include the synchroscope, incoming and

running voltages, and generator breakers. Automatic synchronization will be modelled if
used by Purchaser. Generator trip and interlock logic will be modelled if the logic is
provided by Purchaser in simple block diagram form. There is a reverse power relay,
provided for overspeed protection that will cause generator breakers to trip on a turbine
trip.
16.8.4. Generator Malfunctions

The instructor will be able to initiate malfunctions with the Generator as listed in Table 7-
1.
Table 7-1
MfGS01 ST Generator # 1 Bearing High Vibration 0 100 VR
MfGS02 ST Generator # 1 Bearing High Temperature 0 100 VR
MfGS03 ST Generator # 2 Bearing High Vibration 0 100 VR
MfGS04 ST Generator # 2 Bearing High Temperature 0 100 VR
MfGS05 STG Exciter Reject to Manual 0 1 DG NORM REJECT
MfGS06 STG Main Generator Breaker Trip 0 1 DG NORM TRIP
MfGS07 STG Main Generator Breaker Trip Inhibit 0 1 DG NORM INHIBIT
MfGS08 STG Field Generator Breaker Trip 0 1 DG NORM TRIP
MfGS09 STG Field Generator Breaker Trip Inhibit 0 1 DG NORM INHIBIT
210
16.8.5. Generator Remote Functions
Table 7-2
RfGS01 Turbine HEA Lockout Relay Reset 0 1 DG NORM RESET
16.9. Steam Turbine Generator Cooling

16.9.1. Generator Temperatures Model
This model determines the H2 cooled generator stator winding temperature, and H2 air
inlet and outlet temperatures for generator.
16.9.2. Generator Stator and H2 Temperatures

The Generator is cooled with H2, the inlet temperature of which, Ta is equal to the
hydrogen cooler outlet temperature.
Generator stator temperature (Ts) will be a first order time lag of a linear function of
stator amps:
Ts = Ts + ∆t/Lag * (Ta + A*amps - Ts),
The H2 outlet temperature will be a weighted average of H2 inlet temperature and stator
winding temperature:
To = (1-B)*Ta + B*Ts
At full load steady state (FLSS) with Ta=59° F, the model will produce Ts = 194° F and
To = 167° F.
The instructor can fail the generator cooling with a particular malfunction for each phase
of the generator. In this case the stator winding temperature will rise and outlet H2
temperature will be equal to it, as if there is no cooling H2 flow through the generator:
Ts = Ts + ∆t/lag1 * (C*amps)
To = Ts
16.9.3. Hydrogen Coolers

Hydrogen is circulated through the generator in a closed system. The heat absorbed by
the gas in passing over generator surfaces is removed to the service water in the heat
exchangers. The temperature of hydrogen after heat exchangers will drop by a value
proportional to the difference between temperature of hydrogen before heat exchangers
and service water temperature and the service water flow.
211
16.9.4. Generator Cooling Related Malfunctions

The instructor will be able to initiate malfunctions for the Generator Cooling System as
Table 8-1
MfGS01 ST Generator #1 Phase A Temperature Multiplier 1 10 VR
MfGS02 ST Generator #1 Phase B Temperature Multiplier 1 10 VR
MfGS03 ST Generator #1 Phase C Temperature Multiplier 1 10 VR

Steam Turbine and Generator Assembly
The Steam Turbine / Generator Assembly shall be modeled with a generic distributed
control system and human machine interface. Control loops and logic arrays shall be
constructed using standard discrete process control and logic objects. The use of
“multi-function” or macro objects shall be avoided. All objects shall be labeled with both
their specific object name and their function. All inputs, outputs, constants, and
coefficients shall be appropriately labeled as to their function. Additionally, output tags
shall bear the name of the parent object in its naming convention.

Control loops and logic shall be modeled for the Steam Turbine / Generator Assembly
to provide the following functions:
Control Loops:
Turbine Speed and Load Control
Generator Excitation
Full Arc / Partial Arc Transfer
Lube Oil Temperature Control
Logic Arrays:
Load Limiting and Runbacks
Generator Protection (Load, Voltage, and Reactive Limits)
Generator Breakers and Synchronization
Three control modes shall be provided:

Coordinated Control
Steam Turbine Follow (follows main steam pressure)
Manual
212

associated with the steam turbine and generator assembly.
controls. It is assumed that one HMI screen will usually be used for primary steam
turbine, generator controls, and critical instrumentation values. The second display shall
The DCS for the Steam Turbine-Generator shall be configured with the following
displays:
Control, Steam Turbine-Generator:

Steam Turbine-Generator Control
Start Up
Lube Oil Temperature Control
Turning Gear
Turbine Drains
Misc Aux Equipment Control
Trip/Reset Control
Generator Breaker Control / Sync
Excitation Voltage / MVAR & PF Control
Data Acquisition, Steam Turbine-Generator:

Start Check Permissives
Bearing Metal / Drain Oil Temps
Vibration Monitoring
Hydrogen Seal Oil Monitoring
Generator RTD Temps
16.11. Alarms
condition to occur is possible. (For example: generator disconnects open.) Priority 3
alarms shall display in blue text. Priority 4 alarms are shall be status state indicators
text.
213
16.12. HRSG, Steam Turbine and BOP Modeling Details

MAJOR COMPONENT
1st Prin. Limited
1. HRSG System:
Flue Gas Path X
High Pressure Economizer, Drum, X Excessively high drum level causes water
Evaporator, and Superheater induction in steam turbine.
Reheater with Bypass Reheater bypass selectable by instructor
X
Intermediate Pressure Evaporator,
Drum, and Superheater
Low Pressure Drum, Evaporator and X
Superheater
HP Superheater Attemperator X
Combined Economizer and Bypass X
System
HRSG Vents, Drains and
Blowdown X
Continuous Blowdown Flash Tank
X
Feedwater Flow & Drum Level X Including 3 element and single element
Controls drum level controls. Shrink and Swell
realistic
Aqueous and Anhydrous Ammonia X NOx excursions result from improper
SCR System and Controls operation.
Continuous Emissions Monitoring X Emissions vary with ammonia injection,
(CEM) System and Controls catalyst temperature, steam injection,
combustion and load.
214

MAJOR COMPONENT
1st Prin. Limited
2A. HP Steam System (from
HRSG superheater outlet to
HP turbine main stop valve):
HP Drum Level Controls

X
HP Steam Bypass Flow Control

Valve X
HP Steam Attemperators
X
HP Steam Drains and Blowdowns
X
2B. IP Steam System (from IP
Superheater Outlet to the IP
Turbine Reheat Stop/Intercept Valve):
Cold Reheat, Reheater, and Hot Reheat X
Steam System Components
IP Steam Drum Level Controls

X
IP Steam Bypass Flow Control Valve
X
IP Steam Attemperators X
2C. LP Steam System (from LP

Drum Outlet to the LP
Steam Header):
LP Drum Outlet and LP
Motor Operated Valves. X
LP Steam Bypass Pressure Control
Valve X
LP Pegging Steam to Deaerator
Control Valve X
215

MAJOR COMPONENT
1st Prin. Limited
2D. Steam Turbine Gland Steam Seal
System (including all steam sources
to the glands)
Turbine Glands X
HP Supply Line and Pressure X

Control Valve
Spillover Control Valve X
Turbine LP end Seal Steam X

Desuperheater
Gland Steam Condenser X

MAJOR COMPONENT
1st Prin. Limited
3. Condensate and Feedwater

System:
Main Condenser and Hotwell Level X Condenser tube leak will be
Controls malfunction with instructor set
intensity leading to water quality
excursions.
Condensate Pumps X
Cycle Makeup and Dump Valves X
Gasification Island Condensate Coolers X

Gland Steam Condenser X
Condensate Recirculation Valve X
Condensate Storage Tank X Level set as an external parameter.
Condenser X
Condenser Makeup and X

Dump Valves
Feedwater Pumps X
FP Interstage bleed off to IP X

economizer
FP Discharge MOVs X
HP/IP Flow Control Valves X
216

MAJOR COMPONENT
1st Prin. Limited
5. Circulating Water System:
Circulating Water Pumps and X Simulation to compute water flow

Controls through condenser and cooling water
outlet temperature based on inlet
temperature, load and cleanliness.
Condenser (Tube side) X Effect of tube side fouling will reflect on
condenser differential pressure and
condenser performance.
Travelling Screen System X Screen plugging will restrict the
circulating water flow.

MAJOR COMPONENT
1st Prin. Limited
6. Cooling Water System:
Service Cooling Water Pumps and

Controls X
Service Cooling Water Exchangers High temperature of cooling water
and Controls X affects various plant heat exchangers in
a linear manner.
Steam Turbine Lube Oil Coolers X
Steam Turbine Generator Hydrogen X

Coolers
Condenser Vacuum Pump Coolers X
Combustion Turbine Lube Oil Coolers X
Combustion Turbine Generator X

Hydrogen Coolers
Combustion Turbine Base Coolers X
Feed Pump Seal Oil Coolers X
Feed Pump Lube Oil Coolers X
Condensate Ricirc Pump Seal Oil X

Coolers
LCI Coolers X
217
Figure 15 HRSG Train “A” Arrangement
218

Simulator

Uploaded by

Document Informationclick to expand document information

Document Informationclick to expand document information

Copyright:

Available Formats

Simulator

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Simulator

Uploaded by

Copyright:

Available Formats

DOE/NETL IGCC Dynamic Simulator

Research and Training Center

Volume 2: IGCC Process Descriptions

NETL Collaboratory for Process & Dynamic Systems Research

Volume 2: IGCC Process Descriptions

Michael R. Erbes, Enginomix, LLC

National Energy Technology Laboratory

Revision 1: Summary of Revisions - List of Affected Pages

5.1. Description of Syngas Scrubber Process ............................................................... 72

15. Combustion Turbine Units ............................................................................. 147

15.11.10. 4160 V AC Distribution............................................................................................ 175

16.8.3. Modeling Approach for the Generator..................................................................... 210

1. General IGCC Plant Description

This document provides a conceptual design of the DOE/NETL IGCC Dynamic

1.1. Flowpath Description

1.1.1. Slurry Preparation

1.1.2. Air Separation Unit

Regeneration of the adsorbent in the pre-purifiers is accomplished by passing a hot

cryogenic expander to produce refrigeration to sustain the cryogenic separation process

The Gasifier vessel is a refractory-lined, high-pressure reaction chamber. The coal

1.1.4. Syngas Scrubbers

Quench Water System

1.1.5. Shift Reactors

1.1.6. Gas Cooling, MP and LP Steam Generation, and Knockout

Gas Cooling and MP and LP Steam Generation

1.1.7. Sour Water Stripper

1.1.8. Mercury Removal

Removal of mercury is necessary to prevent corrosion of heat exchangers, and to

1.1.9. Selexol Acid Gas Removal

Selexol H2S Absorber

CO2 Absorber and CO2 Capture

1.1.10. CO2 Compression

1.1.11. Syngas Reheat and Expansion

1.1.12. Claus Plant

H2S + 3/2 O2 ↔ H2O + SO2

2H2S + SO2 ↔ 2H2O + 3S

3H2S + 3/2 O2 ↔ 3H2O + 3S

1.1.13. Hydrogenation Reactor and Gas Cooler

SO2 + 3H2 → H2S + 2H2O

CS2 + 2H2O → 2H2S + CO2

COS + H2O → H2S + CO2

A pH indicator is included in the recycle.

1.1.14. Combustion Turbine-Generator Assemblies

Purpose of the Combustion Turbine/Generator Assemblies are to:

Consume the flow of hydrogen-rich syngas supplied by the gasification island

1.1.15. Heat Recovery Steam Generators and Steam Turbine-Generator

Heat transfer is accomplished by a series of components arranged vertically and

The Generator shall have the following supporting system:

2. Slurry Preparation System

The purpose of the Slurry Preparation System is to:

2.1. Description of Slurry Preparation Process

Referring to SLURRY-FD-1 at the end of this document:

Normal Conveyor interlocks include

2.2. Slurry Preparation System Modeling Expectations

System pressures, flows, levels, and temperatures will respond to changes in

2.3. Slurry Preparation System Controls

Train 1 Grinding Water Flow Control (FV-101)