Beruflich Dokumente
Kultur Dokumente
09-Sep-11 DATE
B.H.Park CHKD.
C.R.Kim CERT.
J.S.Kim APPD.
CONVERSION OF QURAYYAH OPEN CYCLE POWER PLANT TO COMBINED CYCLE POWER PLANT PROJECT C
Client
Consultant
Contractor
Document Title
THIS DOCUMENT IS NOT TO BE USED FOR CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL CERTIFIED AND DATED
SAUDI ARABIA
1-0923053.01
JOB NO. PROJECT SUBDIVISION DOCUMENT TYPE CODE DOCUMENT NUMBER REV. NO.
30621127
000
3DT
00019
000
1.0
GENERAL
Chapter 1.0
General
Introduction The triple pressure heat recovery steam generator (HRSG) with reheater based on the natural circulation principle is located downstream of combustion gas turbine for use in a combined cycle power plant which is installed in the Qurayyah on Combined Cycle Power Plant 30 & 40, Saudi Arabia. Add-
The Qurayyah plant consists of five (5) blocks and each block consists of three(3) gas turbine generator units(GT Model GE 7FA), three(3) unfired HRSGs utilizing the exhaust heat of the gas turbine and one(1) steam turbine generator unit (STG).
The gas turbines and associated components have been installed as part of previous Qurayyah open cycle project. Exhaust gas diverter dampers is provided and able to divert flow to either the bypass stack for open cycle operation, or to the HRSG for combined cycle operation.
Each HRSG operates independently with its own gas turbine and produced steam to be fed into a common steam header to drive the steam turbine.
The HRSG is unfired, reheat, three (3) pressure levels of high pressure (HP), intermediate pressure (IP) and low pressure (LP), natural circulation and vertical gas flow design. The low pressure drum is provided with feedwater storage function. The integrated deaerator is mounted on the LP drum.
Chapter 1.0
General
[ ]
[ ]
- Safety valves information of HP system; Description HP S.H ERV HP S.H SV HP Drum 1st SV HP Drum 2nd SV HP Economizer SV Tag. No. LBA-90-AA-191 LBA-90-AA-192 HAD-90-AA-191 HAD-90-AA-192 HAC-90-AA-191 Set Pressure (barg) 145.5 146 153 157.6 210 Capacity (kg/s) 9 14.9 22.4 22.4 19.1
The system fulfils the following object: Delivers feedwater to the high pressure drum during start-up, shut-down and power operation of the combined-cycle unit. Shuts off feedwater supply during feedwater control malfunction in order to prevent overfeeding of the HRSG. Supplies HP steam produced by the HRSG to the HP main steam system during normal operation. Supplies HP feedwater to the HRSG HP desuperheating system. Maintains and safeguards the HP superheated steam temperature within the allowable main steam system limit during part load operation at high ambient temperatures.
2.0 General Description Doc.No :xxxxx Rev. -
[ ]
HP Feedwater System The HP feedwater line is equipped with a check valve to prevent back-streaming from the HRSG into the feed water pumps. The line can be isolated by a motorized stop valve. The HP feedwater control valve station is located downstream of the HP economizer to prevent steaming of feedwater in the economizer. A relief valve is installed downstream of economizer to prevent overpressure in the economizer if the HP feedwater control valve is closed and HRSG in operation. From the HP feedwater line, the spray water line to the HP desuperheating spray system branch off. The HP desuperheating spray system delivers water into the HP interstage desuperheater located between HP superheater heating surfaces. It can limit the HP steam temperature within the design value during part load or normal operation at high ambient temperature. The Max. spray flow is approximately 8% of the steam flow. HP Steam Generation The high pressure system is located downstream the exhaust gas inlet of the HRSG. The heating surfaces are fabricated mainly from finned tubes. The high pressure system is subdivided into the following sections, listed in the order in which exhaust gas flows through them; HP Superheater 3/2/1 HP Evaporator HP Economizer 2/1 The HP economizer recovers the remaining heat contained in the exhaust gas at the HP evaporator outlet. The HP evaporator generates steam through a natural circulation loop from and to the HP drum. The HP superheater heats the saturated steam from HP drum temperature to superheated steam. The HP superheater and the HP economizer are cross counter flow heat exchangers and the HP evaporator flow is cross to the exhaust gas flow. The HRSG is of vertical design. The feedwater is fed by the HP/IP feedwater pumps from the LP drum to the HP economizers, where it is heated up to economizer outlet temperature and then delivered to the HP drum. Water is fed from the HP drum through downcomers to the inlet header of the HP evaporator. Water partly evaporates in the HP evaporator and the water/steam mixture is fed via natural convection in the tube risers from the outlet header back to the HP drum. The connection piping between the outlet header and drum is distributed uniformly over the length of the drum.
2.0 General Description Doc.No :xxxxx Rev. -
[ ]
The HP drum has the following functions: ensure good mixing of feedwater and HP Drum water reserve a water required for the circulation system allow water expansion during start-up ensure a thorough water and steam separation Deliver saturated steam of specified purity (<0.1% carry over) The HP drum capacity is selected to ensure safe and stable operation under all normal operating conditions. The HP drum is installed outside of the casing thus is not heated by exhaust gas. The separation of water and steam is achieved by means of water/steam separation system (Two stage separation system, baffle assisted separator as a primary and chevron type of dryer as a secondary separator), which restricts carryover of water to the superheater within the limits. Two safety valves are installed on the HP drum to protect the system against over pressure. The vent piping from the drum safety valves is routed into the silencer to limit noise level. Sampling connections are provided in the system for sampling of HP drum water (taken off from the continuous blowdown line) and saturated steam (taken off from the saturated steam piping) from the HP drum during operation. Connection for chemical dosing is installed at the HP drum. The intermittent blowdown line from the HP drum to the HRSG blowdown system is equipped with a motorized valve. The continuous blowdown line from the HP drum to the HRSG blowdown system is equipped with a motorized stop valve and a manual blowdown valve. Saturated steam flows from the HP drum through connecting piping to the HP superheater. The HP superheater is divided into three parts. A desuperheater is located between the HP superheater2 &3 heating surfaces to maintain the HP steam temperature within the design value during part load operation at high ambient temperature. (For the detail of set point, refer to the item no.8 in Clause 5.) HP Main steam Piping system The HP main steam piping system receives HP steam from the HRSG and transfers it to the HP steam header.
[ ]
Drain station is provided in the system to allow system drainage and warm-up particularly during start-up. A motorized start up venting system is provided in the piping to remove the noncondensable gas like an air during start-up. A safety valve is installed to protect the system against over pressure. In addition, electrically assisted relief valve (ERV) is provided in the HP main steam piping. The vent piping from the steam line safety valve, ERV and start up vent valve is routed into the silencer to limit noise level. Sampling connection is provided in the system for HP steam sampling during operation.
The HP steam line is equipped with a check valve to prevent back-streaming from another HRSG. The line equipped with motorized main and small stop valve, which is used to isolate or connect to the common steam header.
[ ]
Cold Reheat 1st SV Cold Reheat 2nd SV IP S.H SV IP Drum 1st SV IP Drum 2nd SV IP Economizer SV
The system fulfils the following object: Delivers feedwater to the intermediate pressure drum during start-up, shut-down and power operation of the combined-cycle unit. Feeds superheated IP steam from the HRSG to the cold reheat system Supplies IP feedwater to the HRSG RH desuperheating system. Maintains and safeguards the hot reheat steam temperature within the allowable hot reheat steam system limit during part load operation at high ambient temperatures. Shuts off feedwater supply during feedwater control malfunction in order to prevent overfeeding of the HRSG. Passes the exhaust steam of the HP turbine and the steam from the IP superheater via the reheater section of the HRSG to the hot reheat steam header. IP Feedwater System The IP feedwater line is equipped with a check valve to prevent back-streaming from the HRSG into the feed water pumps. The line can be isolated by a motorized stop valve. The IP feedwater control valve station is located downstream of the IP economizer to prevent steaming of feedwater in the economizer. A relief valve is installed downstream of IP economizer to prevent overpressure in the economizer if the IP feedwater control valve is closed and HRSG in operation. From the IP feedwater line, the spray water line to the RH desuperheating spray system branch off. The RH desuperheating spray system delivers water into the RH interstage desuperheater located between Reheater heating surfaces. It can limit the hot reheat steam temperature within the design value during part load or normal operation at high ambient temperature. The Max. spray flow is approximately 5% of the steam flow. IP Steam Generation The intermediate pressure system is located downstream the exhaust gas inlet of the HRSG behind the HP part. The heating surfaces are fabricated mainly from finned tubes. The
2.0 General Description Doc.No :xxxxx Rev. -
[ ]
intermediate pressure system is subdivided into the following sections, listed in the order in which exhaust gas flows through them; IP Superheater IP Evaporator IP Economizer The IP economizer recovers the remaining heat contained in the exhaust gas at the IP evaporator outlet. The IP evaporator generates steam through a natural circulation loop from and to the IP drum. The IP superheater heats the saturated steam from IP drum temperature to superheated steam. The IP superheater and the IP economizer are cross counter flow heat exchangers and the IP evaporator flow is cross to the exhaust gas flow. The HRSG is of vertical design. The feedwater is fed by the HP/IP feedwater pumps from the LP drum to the IP economizers, where it is heated up to economizer outlet temperature and then delivered to the IP drum. Water is fed from the IP drum through downcomers to the inlet header of the IP evaporator. Water partly evaporates in the IP evaporator and the water/steam mixture is fed via natural convection in the tube risers from the outlet header back to the IP drum. The connection piping between the outlet header and drum is distributed uniformly over the length of the drum. The IP drum has the following functions: ensure good mixing of feedwater and IP Drum water reserve a water required for the circulation system allow water expansion during start-up ensure a thorough water and steam separation Deliver saturated steam of specified purity (<0.1% carry over) The IP drum capacity is selected to ensure safe and stable operation under all normal operating conditions. The IP drum is installed outside of the casing thus is not heated by exhaust gas. The separation of water and steam is achieved by means of water/steam separation system (Two stage separation system, baffle assisted separator as a primary and chevron type of dryer as a secondary separator), which restricts carryover of water to the superheater within the limits. Two safety valves are installed on the IP drum to protect the system against over pressure. The vent piping from the drum safety valves is routed into the silencer to limit noise level. Sampling connections are provided in the system for sampling of IP drum water (taken off from the
2.0 General Description Doc.No :xxxxx Rev. -
[ ]
continuous blowdown line) and saturated steam (taken off from the saturated steam piping) from the IP drum during operation. Connection for chemical dosing is installed at the IP drum. The intermittent blowdown line from the IP drum to the HRSG blowdown system is equipped with a motorized valve. The continuous blowdown line from the IP drum to the HRSG blowdown system is equipped with a motorized stop valve and a manual blowdown valve. Saturated steam flows from the IP drum through connecting piping to the IP superheater. IP steam Piping system The IP main steam piping system receives IP steam from the HRSG and transfers it to the Cold reheater piping system. Drain station is provided in the system to allow system drainage and warm-up particularly during start-up. A motorized vent valve is provided in the piping to remove the non-condensable gas like an air during initial start-up. A safety valve is installed to protect the system against over pressure. The vent piping from the steam line safety valve and start up vent valve is routed into the silencer to limit noise level. Sampling connection is provided in the system for IP steam sampling during operation. A pressure control valve is installed in the IP steam piping and used to control the IP system pressure within allowable range during start up and shut down period. The IP steam piping can be isolated by motorized stop valve. A check valve is provided to prevent back streaming from the cold reheat piping system. Reheater system The reheater, which is divided into two parts, is located in high temperature gas zone. During normal plant operation the exhaust steam from the HP turbine section is routed via the reheater of the HRSG to the IP turbine inlet. Before entering the reheat section the HP turbine exhaust steam is mixed with superheated IP steam coming from the IP superheater. The line from the HP-steam bypass is routed to the cold reheat line during bypass operation. Reheater desuperheating spray system deliver water into the reheater desuperehater located between the divided reheater heating surfaces. It limits the steam temperature to the allowable range during part load operation at high ambient temperatures. (For the detail of set point, refer to the item no.12 in Clause 5.)
2.0 General Description Doc.No :xxxxx Rev. -
[ ]
Two safety valves are installed upstream and one safety valve downstream of the reheater to protect the system against overpressure. A sampling connection is provided in the downstream of the reheater system for steam sampling during operation. Drain station is provided in the system to allow system drainage and warm-up particularly during start-up. A motorized stop valve and pneumatic control valve in series is provided in start up venting system in the Hot reheat piping to control the steam pressure during start-up. The vent piping from the steam line safety valve and start up vent valve is routed into the separate silencer to limit noise level.
- Safety valves information of LP system; Description LP S.H SV LP Drum 1st SV LP Drum 2nd SV C.P.H SV Tag. No. LBD-90-AA-191 HAD-97-AA-191 HAD-97-AA-192 LCA-91-AA-191 Set Pressure (barg) 9 10 10.3 40 Capacity (kg/s) 1.9 2.82 2.82 15.3
The low pressure steam generation system generates LP steam of specific quality, which means of correct pressure and temperature, from the thermal energy contained in the GT exhaust gas. The steam is produced in the HRSG, supplied to heat the condensate in the deaerator system and fed to the LP steam system. Condensate through the condensate preheater is fed to the
[ ]
deaerator where it is heated and deaerated with steam from the LP evaporator. The deaerator is integrated at the top of the LP drum for the deaeration of condensate. The system fulfils the following object: Delivers condensate to the deaerator and LP drum during start-up, shut-down and power operation of the combined-cycle unit. Shuts off condensate supply during feedwater control malfunction in order to prevent overfeeding of the HRSG. Supplies LP steam produced by the HRSG to the LP steam system during normal operation. Reserves and Supplies feedawater to the feedwater pumps Supplies saturated steam from the LP drum to the deaerator for deaeration. Remove non condensable gases like CO2 and oxygen from the condensate during operation of the plant. Control the temperature of the condensate entering the condensate preheater. Condensate System The condensate line is equipped with a check valve to prevent back-streaming from the HRSG into the condensate extraction pump. The line can be isolated by a motorized stop valve. The LP drum level control valve is located downstream of the condensate preheater to prevent steaming of condensate in the condensater preheater. A relief valve is installed downstream of condensate preheater to prevent overpressure in the condensate preheater if the LP drum level control valve is closed and HRSG in operation. LP Steam Generation The low pressure system is located downstream the exhaust gas inlet of the HRSG behind the IP part. The heating surfaces are fabricated mainly from finned tubes. The low pressure system is subdivided into the following sections, listed in the order in which exhaust gas flows through them; LP Superheater LP Evaporator Condensate preheater The condensate preheater recovers the remaining heat contained in the exhaust gas at the LP evaporator outlet. The LP evaporator generates steam through a natural circulation loop from and to the LP drum. The LP superheater heats the saturated steam from the LP drum temperature to superheated steam.
2.0 General Description Doc.No :xxxxx Rev. -
[ ]
The LP superheater and the condensate preheater are cross counter flow heat exchangers and the LP evaporator flow is cross to the exhaust gas flow. The HRSG is of vertical design. The condensate is fed by the condensate extraction pumps to the condensate preheater, where it is heated up to condensate preheater outlet temperature and then delivered to the deaerator. The condensate preheater system is equipped with recirculation system which is used to control the condensate preheater inlet temperature. The condensate preheater recirculation pump recirculates water from the outlet of the condensate preheater to the inlet of the condensate preheater. The temperature control valve, which is located in the recirculation pump discharge line, controls the recirculation flow to maintain the condensate preheater inlet temperature. To prevent less flow operation, below minimum flow of the recirculation pump, the recirculation system control must limit the closure of the temperature control valve when the recirculation pump flow approaches actual min. flow. The condensate preheater system is also equipped with a condensate bypass system. The three-way valve sends condensate water flow to the condensate preheater and/or bypass around the condensate preheater. The three-way valve can be positioned to ; 1. direct all condensate flow to the condensate preheater, 2. direct all condensate flow through the condensate preheater bypass, 3. direct any portion of the flow to either the preheater or the bypass around the condensate preheater. When the recirculation pumps are all failure, the three-way valve is positioned in the fully-closed position, resulting in all the condensate flow bypassing the condensate preheater so that the HRSG can be continuously operation without shut down. The three-way valve is positioned to route a portion of the condensate flow to the condensate preheater bypass as required to hold a minimum subcooling before entering the deaerator to ensure an optimum deaeration process. At the top of the LP drum, a direct contact spray-tray-type deaerator vessel is provided. A spring loaded spray nozzle is provided for guaranteed operation of deaerating. All condensate through the condensate preheater is fed to the deaerator where it is deaerated and heated by the saturated steam from the LP drum and the resulting air is expelled through the vent line to
2.0 General Description Doc.No :xxxxx Rev. -
[ ]
atmosphere. The deaerated condensate falls down through the deaerator downcomer and collected in the LP drum. Water is fed from the LP drum through downcomers to the inlet header of the LP evaporator. Water partly evaporates in the LP evaporator and the water/steam mixture is fed via natural convection in the tube risers from the outlet header back to the LP drum. The connection piping between the outlet header and LP drum is distributed uniformly over the length of the LP drum. The LP drum has the following functions: ensure good mixing of feedwater and LP Drum water reserve a water required for the circulation system and providing feedwater to the feedwater pumps allow water expansion during start-up ensure a thorough water and steam separation Deliver saturated steam of specified purity (<0.1% carry over) The LP drum capacity is selected to ensure safe and stable operation under all normal operating conditions. The LP drum is installed outside of the casing thus is not heated by exhaust gas. The separation of water and steam is achieved by means of water/steam separation system (Two stage separation system, baffle assisted separator as a primary and chevron type of dryer as a secondary separator, which restricts carryover of water to the superheater within the limits. The steam for the heating of the deaerator/LP drum is supplied by various sources. The main source of steam is the LP evaporator. Additionally, the pegging steam is supplied from the IP superheater outlet steam line. This pegging steam operation is required when the LP drum pressure cannot be maintained above floor pressure or drops quickly. Two safety valves are installed on the LP drum to protect the system against over pressure. The vent piping from the drum safety valves is routed into the silencer to limit noise level. Sampling connections are provided in the system for sampling of LP drum water (taken off from the BFP suction line) and saturated steam (taken off from the saturated steam piping) from the LP drum during operation. The suction line is provided from the LP drum to provide feedwater into the feedwater pumps.
[ ]
Connections for the min. recirculation and leak off lines from the feedwater pumps are provided on the LP drum. The intermittent blowdown line from the LP drum to the HRSG blowdown system is equipped with a motorized valve. Saturated steam flows from the LP drum through connecting piping to the LP superheater. LP steam Piping system The LP steam piping system receives LP steam from the HRSG and transfers it to the steam header. Drain station is provided in the system to allow system drainage and warm-up particularly during start-up. A safety valve is installed to protect the system against over pressure. A motorized stop valve and pneumatic control valve in series is provided in start up venting system in the LP steam piping to control the steam pressure during start-up. The vent piping from the steam line safety valve and start up vent valve is routed into the separate silencer to limit noise level. Sampling connection is provided in the system for LP steam sampling during operation. The LP steam line is equipped with a check valve to prevent back-streaming from another HRSG. The line equipped with motorized main and small stop valve, which is used to isolate or connect to the common steam header.
The system fulfils the following requirements; Rooting the exhaust gas from the outlet of the GT exhaust gas system through the HRSG to the HRSG exhaust gas stack during the combined cycle operation.
2.0 General Description Doc.No :xxxxx Rev. -
[ ]
The gas turbine exhaust gas flows through the HRSG exhaust gas inlet ducting and the HRSG before being routed to atmosphere via the HRSG exhaust gas stack. The HRSG heating surfaces are divided into the following sections in the direction of the exhaust flow; HP superheater 3 Reheater 2 HP superheater 2 Rehater 1 HP superheater 1 HP evaporator IP superheater HP economizer 2 IP evaporator LP superheater HP economizer 1 / IP economizer LP evaporator Condensate preheater
The heating surface mainly consist of horizontal finned tubes joined together to form heating surface packages. The tube banks are suspended in the HRSG frame and walls. The HRSG is of vertical design. The cooled exhaust gas, after it leaves the last heating surface (Condensate Preheater), flows through the HRSG exhaust gas stack. A stack damper is provided to reserve a heat in the HRSG casing during shut down period. A stack silencer is provided to limit noise within allowable value.
[ ]
[ ]
The blowdown system is designed to collect the process water from drains, continuous and intermittent blowdown. The main purpose of the blowdown system is to receive the discharge of blowdown water in order to control boiler water quality and decrease drum levels. The continuous blowdown is used to control the water quality. The purpose of the intermittent blowdown is lowering drum water levels. - Blowdown Tank Design and Operating Condition; * Design Condition; 3.5 barg, 390 deg.C * Operating Condition; Atmosphere, 100 deg.C The system fulfils the following requirements; To collect and discharge excess water from the HRSG drums in a controlled manner during start-up. To collect continuous blowdown from the HRSG HP and IP drums during normal operation. To collect steam/water from the drain of main steam, feedwater systems located in the HRSG area. To discharge excess water through the intermittent blowdown line. To deliver the vapor in the blowdown tank to the atmosphere through the vent line. To discharge the collected drain water after cooling down to blowdown sump. The blowdown tank is vertical, cylindrical tank in which drain headers enter tank tangentially above water level. The tank water level is maintained by an internal loop seal of overflow line. A drain line is supplied at the bottom of tank to allow complete drain. A silencer is supplied at exhaust vent line to limit noise level.
3.0
DESCRIPTION OF COMPONENT 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 General Description Steam Drums for HP, IP and LP System HP Superheaters Reheaters HP Evaporator HP Economizers IP Superheater IP Evaporator IP Economizer LP Superheater LP Evaporator Condensate Preheater Safety Valve Vent Silencer Duct and Casing Expansion Joints Insulation and Lagging Access Door Gas Bypass Baffle Stack Stack Silencer Support Structures Stairs, Platform and Ladders Instrumentation and Controls Piping Attemperator Blowdown Tank
3.0
Description of Component
- The assembled HRSG consists of fourteen (14) different heat exchanger sections from the inlet transition duct to the exit of HRSG. - Each heating surface is composed of multiple layers tube bank of finned tubes. - All finned tubes are attached with serrated or solid fin, which is helical wound onto the tube under tension. - The very low penetration of attachment weld minimizes any effects on the physical or chemical characteristics of the tube and/or the fin.