BOILER:

A boiler is a closed vessel in which water or other fluid is heated under pressure. The fluid is then circulated out of the boiler for use in various processes or heating applications.

6.1 Heat Recovery Steam Generator (HRSG):

The gas turbine exhaust gases first flow horizontally through the exhaust gas diffuser and the diverter damper at the base of the bypass stack and then enter the boiler inlet ducting. After being deflected at the boiler inlet, the exhaust gases flow upwards through the vertical part of the heat recovery steam generator (HRSG). The steam generator heating surfaces are dividing into following sections in the direction of the exhaust gas flow:

HP super-heater (Area 5693 m) HP evaporator (Area 34578m) HP economizer (Area 33909m) LP evaporator (Area 9914m )

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Dearator

From Condensate Pumps

Feed Water Storage Tank

LP Fw Pump LP Drum HP Feed water Pump

LP Evaporator

HP Economizer HP Drum
M

HP Evaporator

Super heater Flue Gases Inlet ~540 C

To Steam Turbine Desuperheater

Fig.6.1 HRSG-1 Simplified Diagram The heating surface construction consists of finned of bare horizontal tubes welded together to form heating surface packages. Support plates, by which the tubes are fixed and supported, are located at regular intervals within the heating surface packages. The heating surface packages with surrounding walls, headers and piping are suspended in the boiler frame and can expended freely downward. Pipes elbows are located inside the exhaust gas flow so that bypassing of the tubes bundles by the exhaust gas is prevented. The headers are located outside the gastight boiler enclosure. After it leaves the LP evaporator, the cooled down exhaust gas flows through the boiler silencer and is discharged through the stack to atmosphere. During simple cycle gas turbine operation, the exhaust gas duct is closed to the boiler by the diverter damper. The gas turbine exhaust gases are deflected upwards in the diverter damper, flow through the bypass stack silencer and then through the bypass stack to atmosphere. The diverter damper is hydraulically operated. The diverter is equipped with a seal air system for the damper and shaft to ensure full gas-tightness. The sealing air system is equipped with 2 x 100% sealing air fans, one of which is always on stand by. Downward of the diverter-box in direction to HRSG a blanking plate is incorporated to enable safe maintenance of the boiler during simple cycle operation. In combine cycle operation, the diverter dampers close the bypass duct. The exhaust gas duct is opened to the boiler. The exhaust gas then flow through the boiler and stack.

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Each sootblower is equipped with one sealing air fan preventing penetration of the gas through the boiler walls. Fabric type expansion joints are incorporated in the exhaust gas system to absorb the thermal expansion of the ducting. The diverter-box and gas ducting up to the blanking plate before the boiler inlet will made out of carbon steel and provided with internal insulation covered by stainless steel lining. The GT diffuser, the silencer housing including transition ducts, the bypass stack, boiler inlet ducting and the first part of the boiler casing will be made out of stainless steel and will be provided with external insulation covered with aluminium cladding. The connection with the carbon steel diverter is made by means of expansion joint of fabric type.

6.1.1 Overview:
In the simple cycle mode of operation, the temperature of the exhaust gas leaving a gas turbine can be as high as 540C, and a huge mass flow (On HRSG mass flow of steam is 64 Kg/sec on Gas and 57 Kg/sec on FO). This high temperature gas represents a source of heat energy, which can be recovered if the means to do so are available. By recovering this waste heat, not only can the output of a power plant be increased but also its overall efficiency will be greatly enhanced. The means to recover some of the energy in the gas turbine exhaust gas is provided in a combined cycle power plant. By installing a Heat Recovery Steam Generator (HRSG) at the exhaust of the gas turbine, part of the heat energy available in the exhaust gas can be utilized to produce steam, which can then be used to drive a steam turbine to produce electricity. For the transformation of Fuel energy resources into electric energy the water steam cycle has proved to be the most economical solution in high output plant. Thermal energy is transformed into mechanical energy by means of turbines and into electrical energy by means of generators. The entire cycle consists of various components, as well as main auxiliary and additional systems. They allow for transforming energy with an optimum energy exploitation from the economic and the technological point of view.

6.1.2 Objective of the System:

The exhaust gas system comprises the uncooled, gastight, welded components of the exhaust gas path with gas turbine diffuser, exhaust gas ducts, diverter damper, boiler housing, boiler outlet ducting, silencer and exhaust gas stack. A bypass stack with silencer is provided for simple cycle operation of the gas turbine without heat recovery steam generator (HRSG). The exhaust gas system also includes the boiler framework, stiffening, silencers and instrumentation. The HP system of the boiler is producing the HP steam of the HRSG. For this purpose it has to be supplied with the right amount of feedwater at any time

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during its operation; e.g. during start up, load variation etc. Additional it has to produce steam of specific quality, which means of correct pressure and temperature, which varies again with different operation modes and load conditions. The high-pressure system HA10 generates HP steam at 60 bar/530C from the thermal energy contained in the GT exhaust gas. The LP system of the boiler is producing the LP steam of the HRSG. For this purpose it has to be supplied with the right amount of feedwater at any time during its operation, e.g. during start up, load variation etc. The LP steam is used for condensate heating and for the feedwater deaeration in the deaerator. The low pressure system generates saturated LP steam at 3-10 bar and corresponding boiling temperature from the thermal energy contained in the GT exhaust gas and ensures a low boiler exhaust temperature.

6.1.3 Gas Side Flow-path:

Steam temperature from any particular section of the HRSG can never be higher than the gas temperature entering that section. This is because transfer of heat requires a temperature differential in the direction of heat transfer. The hottest gases flow across the HP section of the HRSG. Once through the HP section, the gases are still at relatively high temperatures and can be used to generate more steam, although at a lower pressure. This is done in another section of the HRSG, which operates at a lower pressure. The resultant LP steam is injected in feedwater storage tank to control the feedwater temperature according to the fuel burning in GT which is in operation. The LP steam from LP drum controls the temperature of feedwater tank.

6.1.4 Configuration of the Pressure System:

a) High Pressure (HP) System:
The high pressure system is subdivided into the following sections, listed in the order in which exhaust gas flows through them: HP super-heater HP evaporator HP economizer The HP superheater and the HP economizer are counterflow heat exchangers and the evaporator flow is parallel to the exhaust gas flow. The HP evaporator is of a forced circulation design.The high pressure system is located between the exhaust gas inlet and low pressure system in the lower portion of the heat recovery steam generator. The heating surfaces are fabricated from finned tubes or plain tubes (HP superheater).

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The feedwater is pumped from the feedwater tank by HP feedwater pumps to the HP economizer where it is heated up to preheat temperature and then delivered to the HP drum. Two feedwater control valves are located between HP economizer and HP drum inlet. The 100% main feedwater regulating control valve is suitable for 30-100% and the 30% low load feedwater regulating valve is suitable for 030%. Both valves are fitted with upstream and downstream isolating valves. A non-return valve is provided downstream of each control valve. The HP economizer is prevented from flashing in the part load range by maintaining a pressure above boiling pressure by means of HP feedwater valve and not regulated feedwater pumps. In case of heavy fuel (FO) firing the HP economizer inlet temperarure is controled by forced recirculation of boiler drum water to the economizer inlet. Two 100% recirculation pumps are connected in parallel, one being standby and cut in only on loss of the other. Each pump is equipped with a suction-side and a discharge-side isolation valve, a non return valve on the discharge side and a strainer on the suction side to protect the pump. The two recirculation pumps discharge into a single pipe where a control valve regulates the recirculation flow. An orifice to measure the flow is located between this valve and economizer inlet. The spray water line to the HP spray desuperheater branches off the feedwater line before the HP economizer recirculation. Water is fed from the HP drum through standpipes to the circulation pumps (2x100%) . The HP circulation pumps are connected in parallel, one being on standby and cut in only on loss of other. Each pump is equipped with a suction side and a discharge side isolation valve, a non return valve on the discharge side and a strainer on the suction side to protect the pump. The two circulation pumps discharge into a single pipe from which water flows to the inlet header of the HP evaporator. An orifice to measure the flow is located between the circulation pumps and the evaporator. A portion of water fed into the HP evaporator evaporates and the water/steam mixture is fed from the outlet header back to the HP drum. The connecting piping between the outlet header and drum are distributed uniformly over the length of the drum. Water and steam are separated in the drum. The HP main steam line, in which a spray desuperheater is provided for HP temperature control, is connected to the outlet header. Starup and blowdown lines connected to the atmospheric flash tank are also connected to drum.

b) Low Pressure (LP) System:

The LP system is LP evaporator of a forced circulation design and is connected to the exhaust end of the HP system. The heating surfaces are fabricated from finned tubes. The feedwater is pumped from the feedwater tank by LP feedwater pumps to the LP drum. The feedwater control valve is located between the LP feedwater pumps and LP drum inlet and is fitted with upstream and downstream gate valves. A non-return valve and an additional isolation valve is provided downstream of the control valve. An

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orifice to measure the feedwater flow is located between this valve and the feedwater pumps. Water is fed from the LP drum through down comers to the LP circulation pumps (2x100%). The LP circulation pumps are connected parallel, one being on stand-by and cut only on loss of the other. Each pump is equipped with suction side and a discharge side isolation valve, a non-return valve on the discharge side and a strainer on the suction side to protect the pump. The two circulation pumps discharge into a single pipe from which water flows to the inlet header of the LP evaporator. An orifice to measure the circulation flow is located between the circulation pumps and the evaporator. A portion of the water is fed into the LP evaporator evaporates and the water/steam mixture is fed from the outlet header back to the LP drum. The connecting piping between the outlet header and drum are distributed uniformly over the length of the drum. Water and steam are separated in the drum. Saturated steam flows from the LP drum through connecting piping to the feedwater tank. A control valve is arranged in the saturated steam piping to regulate the pressure in the LP evaporator and thus also the inlet temperatures and output. This arrangement permits both connected boiler to be operated with different inlet temperatures at the LP evaporator but the same de-aeration temperature in the feed-water tank. This is necessary when one gas turbine is operated with natural gas and other with heavy fuel oil.The control valve is equipped with suction and a discharge side isolation valve. An orifice between the LP drum outlet and the LP steam control valve is used to measure the LP steam mass flow. Startup and blow-down lines connected to the atmospheric flash tank are also connected to the drum. An additional blow-down line from drum outlet header to the atmospheric flash tank is used to discharge excess LP steam not required for feedwater heating during part load operation. For this purpose this line is equipped with a straight way valve as well as stop valve.

6.1.5 HRSG Protection Criteria:

If an HRSG protection signal is initiated the diverter damper has to be closed to the HRSG in case of a trip or load rejection of the gas turbine in order to protect the steam generator and the steam turbine (temperature decrease) and if the pressure in the exhaust gas duct rises to 45 mbar, the bypass duct is opened, the GT must then trip simultaneously without any delay. Further the gas turbine must be shut down whenever the diverter or its hydraulic drive fails to operate properly.

6.2 Main Components:

a) Soot Blower System / Scavenging Air:

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The soot blower system is provided for periodic cleaning of the tube bundles (exhaust gas side), and operates with steam from the high pressure steam system. Soot blower penetrations are sealed with scavenging air from seal air fans. Individual seal air fans are provided at Block 1,3 and one main seal air fan is provided at Block 2.

b)

By Pass Stack and Damper:

In KAPCO combined cycle arrangements, a bypass stack and damper are provided at the outlet of the gas turbine, prior to the HRSG. At some facilities, the damper can be modulated to allow a portion of the turbine exhaust to pass through the HRSG for warm-up purposes. The installation of a bypass damper has several advantages including the ability to run the gas turbine in open cycle mode, and to allow the gas turbine to be brought up to load independently and faster than the HRSG or steam turbine. By allowing the gas turbine to be operated in the open cycle mode, it becomes possible to increase the availability of the gas turbine, even if the steam cycle is out of service for maintenance.

c)

By Pass and Boiler Inlet Dampers :

At Block 1 & 2 Dampers are installed at bypass stack of the gas turbine and at boiler inlet which makes it possible to send the exhaust gas directly to the atmosphere, by means of a bypass stack or allow the flue gases entering in gas path of the boiler. This system is operated by hydraulic power pack. This system is specially designed to isolate the boiler or the bypass. In any case, it is impossible to close simultaneously the boiler and the bypass.

d)

Diverter Damper and Seal Air Fans:

On Block-3, at outlet of the gas turbine, upstream the boiler, diverter damper is provided which makes it possible to send the exhaust gas directly to the atmosphere, by means of a bypass stack. In any case, it is impossible to close simultaneously the boiler and the bypass. The diverter damper is provided with hydraulic actuators. The actuators have been sized to permit intermittent operation of the damper to a predetermined position, but not regulated control. The close position is with the blade closed to HRSG and the open to bypass stack. The open position is with the blade open to HRSG and the close to bypass stack.

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The diverter damper seal air fans provide sealing air to the shaft seals of the diverter damper to ensure full gas tightness. This system is equipped with 2x100% sealing air fans, one of which is always on standby.

6.3 Accessories Of HRSG:

6.3.1 Feed water storage and deaeration tank: Description :
The feed water storage and deaeration system is designed for base load operation but it can also with stand transient load condations. The steam flow from the main LP steam system is controlled reduced by means of a pressure control valve. The main condensate is given via a control system to the storage tank.this control system is depending on the level in the feed water storage tank. Over flow condensate and the drain out of the storage tank is led controlled into the condensate storage tank.

Design features :
The feed water storage tank is of the horizontal straight cylindrical type made of fabricated welded carbon steel plates and has a corrosion allowance of 3mm. The feed water storage tank is equipped with necessary connection and distribution facilities for direct contact heating by steam and for the reception of return flow from the minimum flow device of the boiler feed pumps. The deaeretor and feed water storage tanks are designed to withstand a vacuum, however, a vacuum breaker is provided. The deaeretor is of the atomizing type. The arrangement of the spary nozzels of atomizing the deaerator system on the top of the boiler feed water tank is accepted. The feed water storage tank is equipped with all necessary valves, like safety valves, level alarm switch, water level indicators for complete of water level, pressure and temperature controlled devices(local & remote etc). Connections for steam, condensate feed water(minimum flow and suction pipe), safety valves connections and tank drains are provided as minimum.

6.3.2 Circulation Pumps:

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LP Circulation pump:

Two 100% LP evaporator circulation pumps will be provided for the LP evaporator section, with respect to the possibility that each of the gas turbine may be operated with different fuel at different loads, the control of feed water shall be individually achieved by forced recirculation of boiler drum water to evaporator. The pumps are of the single stage centrifugal type with overhang impeller and driven by an electric motor.

HP Circulation Pump:
The waste heat boiler each be provide with two 100% forced circulating pumps for the HP evaporator section and two 100% circulation pumps for the HP economizer in case of heavy fuel oil firing, the HP economizer inlet temperature is controlled by forced recirculation of boiler drum water to the economizer inlet. The pumps are of the single stage centrifugal type with overheating impeller and driven by an electric motor. The pump shaft of each pump is made of forged stainless steel and the impeller on cast stainless steel in order to minimize corrosion of the pump during service.

HP and LP Drums: The purposes of the drum are multiple

Ensure a good mixing of feed water and boiler water. Constitute water receives, required for controlled circulation system. Allow water expansion during start up. Ensure the water and steam separation.

The steam/water separation will be occurred by means of steam/water separators of the cyclone type, which is arranged in the boiler drum. In addition to the cyclone separators, the drum will be provided with all required steam purifiers and steam defecting baffles. Internal fighting is provided for the extraction of the continuous blowdown over the whole length of the drums. One start-up blow-down will be provided for each drum. The drum will be provided with a manhole in each end, the man door being

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arranged to swing inward on a hinge attached to the inside of the drum. The design of the drum internal fitting allows quick and easy removal and replacement of all parts for inspection purpose.

6.4 HRSG Drum Level Control:

Maintaining proper steam drum level is a critical function and can not be over stressed. An excessively high drum level will flood the moisture separators located within the steam drum, resulting in moisture carry over to the super heater and a steam turbine trip. An excessively low drum level will result in decreased steam output, overheating of the economizer, evaporator, and super heater tubes and a gas turbine trip. Drum pressure is a result of drum level combined with the generation of steam in the evaporator tubes. The drum pressure will fluctuate with changes of load demands on the steam system. During a sudden steam load increase, drum pressure will decrease. This will result in a false high level condition known as "swell." During a sudden decrease of steam demand, steam drum pressure will increase and result in a false low level condition known as "shrink." In some situations, the tuning of the steam drum level control loop may not respond quick enough to maintain proper drum level during such abnormal conditions.

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