Chapter 4 HRSG

CHAPTER 4
HEAT RECOVERY STEAM GENERATOR

SECTION 1. HRSG FUNCTION
1. GENERAL
This section describes operating procedures and control philosophy of the Heat Recovery Steam
Generator (HRSG) for NORTE II Combined Cycle Power Plant as a guide, which is mainly intended
to be used during engineering stage and initial stage of the operation. They include the proper
operating sequences for the HRSG and auxiliary equipment furnished. Please refer to the relevant
Piping and Instrumentation Diagram.
2. COMPONENT DESCRIPTION
2.1 INTRODUCTION
Two (2) triple pressures HRSGs with reheater supply steam to one (1) Steam turbine. The HRSGs
are natural circulation type with horizontal gas turbine exhaust gas flow through vertical tube heat
transfer sections. The heat transfer sections are configured in the direction of exhaust gas flow to
obtain optimum exhaust gas energy utilization based on thermo-economic considerations. The basic
heat transfer section configuration is shown on the HRSG P&ID (DWG No. 28S-HG-PI-
2001~2009).
The heat transfer in the HRSG is accomplished through convection in the banks of externally finned
tubes. Spiral finning is attached to the tubes by continuous welding..
Feedwater flow through each economizer is counter to the exhaust gas flow, from the inlet to the
outlet header through the multi-pass arrangement of finned tubes. The economizers are design to
heat the feedwater from supply temperature to a temperature slightly less than the saturation
temperature corresponding to the steam drum pressure.
The subcooled economizer outlet temperature reduces the possibility that the economizer steaming
limit is exceeded during low load and startup operation. The economizer outlet flow is discharged
directly to the steam drum (For HP and IP system). The feedwater flow is supplied to the LP steam
drum through the Condensate Preheater section.
Feedwater enters the steam drum from the economizer and is distributed along the length of the
steam drum by a distribution manifold. The water flows from the bottom of the steam drum to the
evaporator section through downcomer piping via the natural circulation process. The saturated
water enters the evaporator bottom header and flows upward through evaporator tubes where
evaporation occurs. The evaporator section operates essentially at constant temperature absorbing
heat from the exhaust gas in the amount equal to the latent heat of vaporization for the steam drum
operation pressure. The steam/water mixture leaves the evaporator top header through short pipe
connections to the steam drum and is directed to a primary separator where the first stage of
steam/water separation occurs. The primary separator of HP and IP drum is applied as cyclone type.
However, the primary separator of LP drum is applied as channel type instead of the cyclone. The
water discharges downward while the steam rises to a second moisture separator (Chevron Dryer)
where final steam purity is reached before leaving the drum.
The steam drum is designed to provide high purity steam to the superheater and to accommodate
evaporator surge during startup and operating transients.
Saturated steam is piped from the steam drum to the superheater inlet header and then flows through
a single-pass (IP and LP Superheater) or multi-pass (HP Superheater) arrangement of finned tubes to
the outlet header. The flow of steam is countered to the exhaust gas flow. The superheater section
raises the steam temperature from saturation to a superheated temperature consistent with the gas
turbine exhaust conditions and requirement of the steam turbine.
An interstage attemperator utilizing feedwater is provided for temperature control of the high
pressure superheater outlet steam temperature and Reheater outlet steam temperature.
The superheated steam from the intermediate pressure superheter is combined with the steam
returning from the high pressure steam turbine exhaust. This combined steam flow is piped to the
reheater section where the steam is heated to the reheater temperature stated in the heat balance.
The Condensate preheater is integrated in the HRSG and located downstream of the LP evaporator
section. The heating surfaces are also fabricated from finned tubes. This arrangement enables higher
efficiencies of the combined cycle power plant, by using the exhaust gas energy to preheat the
condensate water. A recirculation system is furnished for the condensated preheater to protect the
HRSG from cold end corrosion. The recirculation system consists of one(1) x 100% capacity motor
driven recirculation pump which discharge through a modulating recirculation flow control valve to
control the condensated preheater water inlet temperature to a preset value(60 deg C), to maintain
above the water dew point of the exiting flue gas. The pump is protected by a minimum flow limit
on the flow control valve. Also, The Condensate Preheater is equipped with a preheater bypass
system. Three-way control valve send condensated water flow to the condensated preheater and/or to
a bypass around the condensated preheater. Three-way control valve position is automatically
controlled by the DCS, in order to maintain stack temperature above acid dew point, if necessary.
2.2 FEEDWATER SUPPLY
Feedwater for each HRSG is supplied from HRSG LP drum. HP/IP Feedwater for each HRSG
are supplied from two(2) x 100% nominal capacity HRSG F.W pumps.
2.3 HIGH PRESSURE WATER/STEAM FLOW PATH
After passing through the Flow Control Valves(LCV-5101) and the Motorized HP FW Inlet Stop
Valve(MOV-5101), the HP feedwater flow path is as below:
HP economizer 1 -> HP economizer 2 -> HP economizer 3 -> HP economizer 4 ->

HP economizer 5 -> HP economizer 6 -> HP evaporator -> HP superheater 1 -> HP
superheater 2 -> Interstage Attemperator -> HP superheater 3 -> HP main steam header
2.4 INTERMEDIATE PRESSURE WATER/STEAM FLOW PATH
After passing through the Motorized IP FW Inlet Stop Valve (MOV-5121), the IP feedwater flow path
is as below:
IP economizer -> Flow Control Valve (LCV-2321) -> IP evaporator -> IP superheater -> Cold
reheater -> Interstage Attemperator -> Hot reheater -> Hot reheater main steam header
2.5 LOW PRESSURE WATER/STEAM FLOW PATH
After passing through the Condensate preheater and the Flow Control Valve (LCV-3601), the LP
feedwater flow path is as below:
Deaerator -> LP superheater -> LP main steam header
2.6 CONDENSATE PREHEATER FLOW PATH
After passing through the Motorized Inlet Isolation Valve (MOV-3601) and the three-way control
valve(FCV-3601), the condensated water enter condensate preheater. Condensate preheater
recirculation system is used to control the condensate preheater inlet temperature above water dew
point (60 deg C) during operation. Also, Condensate preheater bypass system is applied to maintain a
minimum stack temperature, if necessary.
2.7 EXHAUST GAS PATH:
The exhaust gas that enters the HRSG will pass by the heat transfer sections of the HRSG, heating the
steam or water inside the tubes. The exhaust gas will pass across the pressure sections in the
following order:
HP Superheater3 -> Hot Reheater -> Duct burner -> HP Superheater2 -> Cold Reheater-> HP
Superheater1 -> HP Evaporator ->IP Superheater -> HP Economizer6 -> HP Economizer5 -> LP
Superheater -> HP Economizer4 -> IP Evaporator -> HP Economizer3 -> HP Economizer2, IP
Economizer -> HP Economizer1 -> LP Evaporator-> Condensate Preheater
2.8 HRSG INLET/OUTLET DUCT AND STACK
The HRSG inlet duct delivers the gas turbine exhaust gas from the outlet of the gas turbine to the
HRSG inlet and includes all supports, expansion joints and horizontal ducting. The duct is
designed to minimize pressure drop and to distribute the exhaust gas to the HRSG tube banks
uniformly.
The HRSG outlet duct, expansion joint and stack are provided to deliver the gas turbine exhaust gas
from the exit of the HRSG to the atmosphere. The outlet transition duct and stack are provided with
personnel protection (expanded metal) at ladders, platforms and test ports. Stand-offs are provided
for attachment of the expanded metal. Sampling ports are provided in the stack for emission testing.
2.9 HRSG STACK DAMPER
A stack damper is provided in the stack for isolation and to keep the HRSG warm after shutdown as
well as providing weather protection. This damper is operated by an electric drive. The configuration
will also allow the damper blades to open independently of actuator position if the damper
differential pressure is greater than 125 mm of water column.
2.10 HRSG BLOWDOWN TANK AND TRANSFER SYSTEM
One(1) blowdown tank, associated piping, valves and instrumentations are provided with the HRSG
to receive blowdown and water/steam drains.
The continuous blowdown lines are used to control the steam drum water chemistry during normal
operation in conjunction with the chemical feed system. During the continuous blowdown operation,
water is blown down directly into the blowdown tank. This is a water/steam flashing mixture when
it enters the blowdown tank.
The intermittent blowdown is used for two kinds of purpose. One is to assist in controlling water
level in the drums during startup, if necessary. The other is to reduce the solids that collect in the
drums or lower headers. It is operated intermittently, usually shortly after the HRSG is shutdown
and still pressurized. During the intermittent blowdown operation, water is also blown down directly
into the blowdown tank. This also is a water/steam flashing mixture when it enters the blowdown
tank. The flashed steam is vented off the top of the tank and the discharged water is cooled by the
blowdown heat exchanger and then is sent to HRSG blowdown sump. During start up operation, all
SH drains also are blown down directly into the blowdown tank.
2.11 METHOD OF STARTING THE HRSG
Starting of the HRSG can be implemented in several ways as follows:
1) Cold Startup: Both GT and HRSG are initially in shutdown and in cold condition. The pressure
in the HP drum is lower than 10 bara.
2) Warm or Hot Startup: Both GT and HRSG are shutdown in warm or hot condition.
HP drum pressure is higher than 10 bara and below 70 bara for Warm startup, and HP
drum pressure is higher than 70 bara for Hot startup.
3. DESCRIPTIONS OF OPERATION
3.1 GENERAL
The operating sequence recommended ensuring a safe and proper start-up is given below.
Modifications may be necessary as subsequent operating experience dictate. Follow the
manufacturer’s instructions for operating auxiliary equipment.
3.2 PREPARATION PRIOR TO START UP
Make sure that test gags and hydroplug are removed from all safety valves. Check
availability of utility service, power, and suitable treated feedwater. Check operation
of chemical feed pumps and piping system
Close all access doors and observation ports after it is ascertained that no one is
inside the unit. New gaskets should be used on all man way.
Check that all control valves have been stroked and tested.
Check that all temperature indicating and/or recording equipment are functional.
Check that all the scaffolding, temporary brackets, lights, tools etc, have been
removed. Place the valves in the unit to the required open or closed position
3.2 INITIAL FILLING
Fill the HP unit by admitting water from the Condensate Extraction pumps to the HP economizer.
Ensure that prior to filling, the drum vent and all economizer vent valves are open to vent air.
Feedwater flow may be regulated by HP FW Flow startup CV (LCV-5102).
Bring the water level in the HP drum up to start up level (-600mm from drum centerline). The start
up level shall be adjusted according to the HP drum pressure.
Fill the IP and LP system following similar procedure to those outlined for the HP system.
3.3 HRSG Purge
A. General
The purging concept involves that the HRSG will be purged prior to every GT start based on GT
operating manual.
The related purging automatic is completely realized within the GT control.
B. HRSG PURGING
The purging of the HRSG has to be done by spinning of the GT at purging speed and must be
realized without active GT combustion.
The purging time starts with “purge speed reached”.
The purging time is reached if the purging conditions had been maintained as long as the specified
times above.
3.4 CONTROL OF DRUM LEVELS
Drum water level set points should be set to Start-up Set points to accept swelling of the water
contained in evaporators transferred to the drums as the steam generation in the evaporator starts.
A. SINGLE ELEMENT CONTROL
The median value of the drum level is compensated for HP drum pressure. The compensated
output is selected for load less than 30%. The measured level is compared with the set value and
the error is applied to the controller for positioning the low load control valve (LCV-5102). The
HP drum start up level shall be decided as a linear function of initial HP drum pressure.
According to the HP drum pressure, the start up level have two set points namely high start up
level(-20mm from centerline) and low start level(-600mm from centerline) according to the drum
pressure condition as below.
If HP drum pressure is less than 70 bara: low start up level (-600mm from centerline).
If HP drum pressure is above 70 bara: high start up level (-20mm from centerline).
IP and LP drum start up level also have two set points namely high start up level and low start
level according to the drum pressure condition as below.
If IP drum pressure is less than 16 bara: low start up level (-360mm from centerline).
If IP drum pressure is above 16 bara: high start up level (-150mm from centerline).
If LP drum pressure is less than 2.5bara: low start up level (-450mm from centerline).
If LP drum pressure is above 2.5 bara: high start up level (+100mm from centerline).
B. THREE ELEMENT CONTROL
This control is used for load greater than 30%. It is based on three parameters namely drum
level, steam flow and feed water flow.
The steam flow is applied as a feed forward signal to the drum level controller and the output
of the controller is given as the set point for the feed water flow controller.
C. SINGLE ELEMENT / THREE ELEMENT TRANSFER
Changeover from single element to three element control and vice versa is carried out by an
automatic transfer circuit consisting of a maximum and minimum selector. When load is less
than 30% the minimum selector provides zero bias to the single element control and the
maximum selector provides a positive bias to three element control to keep the full load control
valve in closed position. Hence during this condition the single element level error positions the
low load control valve.
As the load increases beyond 30% the bias signal provided by the maximum selector becomes
zero and the three element error signal then positions the full load control valve. During this
condition (load >30%) the bias provided by the minimum selector to the single element
controller starts closing the low load control valve, while the full load control valve starts
opening correspondingly. This process continues until the low load control valve is fully closed.
Then the full load control valve controls the feed water flow depending on the three element
level error. The reverse process occurs for decreasing load. Suitable bias and gain constant are
provided to adjust the opening and closing rates.
D. HP DRUM LEVEL
If HP Drum level was below Startup NWL, the level should be topped-up from the HRSG Feed
Water Pump or the Condensate Extraction pump. The HP FW Flow startup CV (LCV-5102) is
capable of satisfactorily controlling the low flow rate with high pressure differential from
constant speed HRSG Feed Water pump.
Before any hot exhaust gas from GT is admitted to HRSG, the automated sequence of
operation should be followed as below:
y Before the HRSG Feed Water pump is started, HP FW Inlet Motorized Stop Valve (MOV-
5101) is shut.
y After HP BFP start, the HP FW Inlet Motorized Stop Valve (MOV-5101) and HP FW
startup CV(LCV-5102) will open to “top up” the water to the start-up water level in the HP
Drum. When there is a demand for FW to fill the drum, the HP FW startup CV(LCV-5102)
will be commanded open to preset set point (about 30%) a set time prior to the HP FW
Inlet Stop Valve open command. When drum level reaches set point the FW Inlet Stop valve
(MOV-5101) will close first, then the HP FW startup CV (LCV-5102) will close. This mode
will continue until steam flow reaches set point (10%)
y When steam flow reaches set point (10%), two actions will be initiated. 1) HP Drum level
set point will switch from startup to Normal level. 2) HP FW startup CV will switch from
preset opening set point (about 30%) to modulating control.
y When steam flow reaches set point (30%) the drum level control
a. Switch from single element to three element controls.
b. Switch from HP FW startup CV (LCV-5102) to HP FW main CV (LCV-5101).
The HP valves controlling the water feed to the HP drum are in a 2-valves arrangement consisting
of a 30% valve (LCV-5102) for low flow control and one 100% valve(LCV-5101). The 30% valve
(LCV-5102) and 100% valve (LCV-5101) will respond to the level controller output as per the
graph below. A controller output of 0 to 30% will be scaled to correspond to 0 to 100% open of
the 30% valve.
100
90
80
70
Valve Position of 100% Valve, %
60
%
on
iti
Po 50
se
lv
a
V
40
30
100% Valve
20
10
30% Valve
10 20 30 40 50 60 70 80 90 100
Controller Output %
The 30% valve (LCV-5102) will be controlled up to 25% of the controller range having a flat
spot at this value as the 100% duty valve (LCV-5101) begins to open to allow for errors in setting
up the valve positioner as the valves start to operate together. Between 30 and 40% of the
controller output the 30% valve (LCV-5102) will close as the 100% valve (LCV-5101) opens
maintaining a linear controller characteristic between the two until the 100% valve (LCV-5101)
assumes full control at 40% controller output.
If the HP Drum was initially overfilled, water level may be adjusted to the Startup Level by
manually opening a HP Evaporator Blowoff [MOV] (MOV-3003). For manual operation this
valve is provided with open/stop/close control and position feedback.
When drum level set point starts to ramp from Startup set point to NWL set point, the blowoff
valve(MOV-3003) will open automatically, if drum level reaches 100mm above the ramp set
point, and will close when level falls to the ramp set point.
E. IP AND LP DRUM LEVELS
If either IP or LP Drum level is below Startup level, the levels will be topped up as similar
procedure to those outlined for the HP section.
Before any hot exhaust gas from GT is admitted to HRSG, the automated sequence of
operation should be followed as below:
y Before the IP HRSG Feed Water is started, IP FW Inlet Stop Valve (MOV-5121) is shut.
y Before the Condensate Extraction Pump is started, LP FW Inlet Stop Valve (MOV-3601) is hut.
y After HRSG Feed Water and Condensate Extraction Pump start, the IP and LP FW Inlet Stop
Valves (MOV-5121, MOV-3601) and IP and LP FW CV (LCV-2321, LCV-3601) will open to
“top up” the water to the start-up water level in the IP and LP Drum. When there is a demand
for FW to fill the drum, the IP and LP FW CV (LCV-2321, LCV-3601) will be commanded
open prior to the IP and LP FW Inlet Stop Valve open command (MOV-5121, MOV-3601).
When drum level reaches set point, the IP and LP FW Inlet Stop valve(MOV-5121, MOV-
3601) will close first, then the IP and LP FW startup CV(LCV-2321, LCV-3601) will close.
This mode will continue until steam flow reaches set point (10%).
y When steam flow reaches set point (10%), IP and LP Drum level set point will switch from
startup to Normal level and initiate modulating control.
If the IP and LP Drum were initially overfilled, water level may be adjusted to the Startup Level
by manually opening a IP and LP Evaporator Blowoff [MOV] (MOV-3023, MOV-3132). For
manual operation these valves are provided with open/stop/close control and position feedback.
When drum level set point starts to ramp from Startup set point to NWL set point, the blowoff
valves (MOV-3023, MOV-3132) will open automatically, if drum level reaches 100mm above the
ramp set point, and will close when level falls to the ramp set point.
F. HP Drum Level Set point
Drum level will be corrected by the drum pressure.
y Normal Level : (85mm above Centerline)
The drum level controls will regulate the rate of feed water flow to maintain a proper
drum level throughout the operation range of the HRSG.
To get the maximum benefit from a three-element system, feed water flow should be
proportional to steam flow with reset action on drum level. This means that the mass of
feed water entering should always equal the mass of steam leaving, with continuous
corrections made for deviations from level set points. The best drum level control is
achieved through the mass flow balance.
y HLT Level: (480mm above centerline)
If the HP/IP steam isolation valve is not closed, trip of the steam turbine.
Feedwater control and stop valves remain closed.
y HLA level: (300mm above centerline)
Sound the alarm.
Open the start-up blowdown Valve (MOV-3003).
y LLA level: (200mm below centerline)
Sound the alarm.
Close continuous blowdown valve (MOV-3002)
y LLT Level: (760mm below centerline)
Close of HP steam isolation valve (MOV-2501)
G. IP Drum Level Set point
y Normal Level: (0mm below centerline)
The drum level controls will regulate the rate of feed water flow to maintain a proper
drum level throughout the operation range of the HRSG.
proportional to steam flow with reset action on drum level. This means that the mass of feed
water entering should always equal the mass of steam leaving, with continuous corrections
made for deviations from level set points. The best drum level control is achieved through the
mass flow balance.
If the IP steam isolation valve is not closed, trip of the steam turbine.

Sound the alarm.
y LLA level: (125mm below centerline)
Sound the alarm.
Close continuous blowdown valve (MOV-3022)
Close of IP steam isolation valve.(MOV-2801)
H. LP Drum Level Set point
y Normal Level: (340mm below centerline)
The drum level controls will regulate the rate of condensate water flow to maintain a
proper drum level throughout the operation range of the HRSG.
proportional to steam flow with reset action on drum level. This means that the mass of feed
water entering should always equal the mass of LP steam leaving and HP&IP feed water, with
continuous corrections made for deviations from level set points. The best drum level control
is achieved through the mass flow balance.
If the LP steam isolation valve is not closed, trip of the steam turbine.
Sound the alarm.
y LLA level: (0mm BELOW centerline)
Sound the alarm.
Close of IP steam isolation valve.(MOV-2901)
3.5 CONTROL OF SUPERHEATER AND STEAM LINE DRAINS
The purpose of the drain valves are to remove any accumulated condensate from the steam lines and
provide a flow path for steam to heat the piping during start up.
HP Superheater 3 Drain [MOV] MOV-3102
HP Main Steam Line Drain [MOV] MOV-3101
IP Superheater Drain [MOV] MOV-3122
IP Main Steam Drain [MOV] MOV-3121
Cold Reheater Drain [MOV] MOV-3112
Hot Reheater Drain [MOV] MOV-3111
LP Superheater Drain [MOV] MOV-3131
These drain valves should be proven open for about 2 minutes before introducing hot GT exhaust gas to
HRSG.
A. HP Superheater drain (MOV-3103, MOV-3102) and HP Main steam drain (MOV-3101) shall be
opened with following steps below.
y Fully open if HP Drum pressure < 10 bara
y Intermediate open if 10 bara < HP Drum pressure (PIT-2001C/2001B/2001A)
y After 2 minutes open then these drain valves are closed and placed into auto operation.
y During the auto operation, these valves are activated by monitoring the drain pot temperature
and comparing it with the saturated temperature at corresponding drum pressure.
y Fully open:
If drain pot temperature < Saturated temp. + 30 deg C at HP Drum pressure
And HP Drum Pressure < 10 bara
y Intermediate open:
If drain pot temperature < Saturated temp. + 30 deg C at HP Drum pressure
And HP Drum Pressure > 10 bara
y Close:
If drain pot temperature > Saturated temp. + 30 deg C at HP Drum pressure
B. Reheater Drain (MOV-3112, MOV-3111) shall be opened with following steps below.
y Open:
If drain pot temperature < Saturated temp. + 30 deg C at Hot Reheater pressure (PIT-2701)
And Hot Reheater Pressure < 5 bara
y Close:
If drain pot temperature > Saturated temp. + 30 deg C at Hot Reheater pressure (PIT-2701)
And Hot Reheater Pressure > 5 bara
C. Cold Reheater Drain (MOV-3112) and IP Superheater Drain (MOV-3122, MOV-3121) shall be
opened with following steps below.
y Open:
If drain pot temperature < Saturated temp. + 30 deg C at IP Drum pressure (PIT-2021A, PIT-2021B,
PIT-2021C)
And IP Drum Pressure < 5 bara
y Close:
If drain pot < Saturated temp. + 30 deg C at IP Drum pressure (PIT-2021A, PIT-2021B, PIT-
2021C)
And IP Drum Pressure > 5 bara
D. LP Main steam Drain (MOV-3131) shall be opened with following steps below.
y Open:
If drain pot < Saturated temp. + 30 deg C at LP Drum pressure (PIT-2031A, PIT-2031B, PIT-
2031C)
And LP Drum Pressure < 3 bara
y Close:
If drain pot < Saturated temp. + 30 deg C at LP Drum pressure (PIT-2031A, PIT-2031B, PIT-
2031C))
And LP Drum Pressure > 3 bara
3.6 HP AND RH STEAM TEMPERATURE CONTROL
The HP and RH attemperator function to control HRSG superheater and reheater outlet steam
temperature by injection feedwater spray into the steam flow. The temperature (TT-2501A, 2501B,
2501C) measured in the HP main steam line is compared with fixed temperature set point 567.7 deg C.
Also the temperature (TT-2701, 2701B, 2701C) measured in the RH steam line is compared with
fixed temperature set point 566.8 deg C. The difference is the input signal for the controller of
attemperator. During start up the steam temperature will be controlled start up temperature set point as
requested by Steam turbine supplier. Note1)
As a feed forward signal, the temperature measurements (TT-2102A, TT-2102B for HP and TT-
2402A,TT-2402B for RH) downstream of the attemperator are added with a correction factor. A
motorized isolation valves(MOV-3103 for HP and MOV-5111 for RH) are placed in the pray water
line in series with a spray control valves (TCV-2101 for HP and 2401 for RH). The isolation valves
are automatically closed whenever the attemperator control is not enable and is automatically
opened when enable.
It is recommended that the minimum position of spray control valve will be not less than typically
5%, to prevent excessive wear on the valve trim.
Note1) During the cold start up condition, the Gas Turbine exhaust gas temperature may be limited
according to steam temperature requirement from steam turbine. That is, the steam temperature at
the discharge of the inter-stage attemperator should have a minimum of 30 deg C superheater at any
operating condition. So, in case of high exhaust gas temperature operation, the steam temperature
control ability shall be limited due to the 30 deg C of residual temperature requirement at the
discharge of the attemperator.
3.7 HP, IP AND LP MAIN STEAM STARTUP VENTS
HP Main Steam Start up Vent, Inching [MOV] MOV-3001
IP Main Steam Start up Vent, Inching [MOV] MOV-3021
LP Main Steam Start up Vent, Inching [MOV] MOV-3031
The function of these valves is to provide release of any noncondensable from

superheaters.
Open:
If HP Drum pressure < 2.0 bara
Close:
If HP Drum pressure > 3.0 bara
Open:
If IP Drum pressure < 1.5 bara
Close:
If IP Drum pressure > 2.0 bara
Open:
If LP Drum pressure < 1.5 bara
Close:
If LP Drum pressure > 2.0 bara
3.8 HP/IP/LP DRUM CONTINUOUS BLOWDOWN
HP Drum Continuous Blowdown, Inching [MOV] MOV-3002

IP Drum Continuous Blowdown, Inching [MOV] MOV-3022
Continuous blowdown is to control the steam drum water chemistry (Conductivity) during normal
operation in conjunction with the chemical feed system. Blowdown flow will be controlled
automatically based on the feed back of drum and steam quality.
HP/IP Drum Continuous Blowdown Valves should be shut when associated Drum Levels fall below
Low Alarm level.
3.9 HP/IP/LP EVAPORATOR INTERMITTENT BLOWDOWN
HP Evaporator Intermittent Blowdown MOV, Inching [MOV] MOV-3003
IP Evaporator Intermittent Blowdown, MOV, Inching [MOV] MOV-3023
LP Evaporator Intermittent Blowdown, MOV, Inching [MOV] MOV-3132
The intermittent blowdown is used for two kinds of purpose. One is to assist in controlling water
level in the drums during startup, if necessary. The other is to reduce the solids that collect in the
drums or lower headers.
y Opening set point:
During start up (below 30% MCR); If each Drum level > Ramp set point + 100mm
During Normal operation (above 30% MCR); If each Drum level > HLA level
y Opening limit (for HP only):
Fully open; If HP Drum Pressure < 10 bara
Intermediate open; If HP Drum Pressure > 10 bara
3.10 CONDENSATED PREHEATER RECIRCULATNG TEMPERATUE CONTROL
Condensated Preheater Recirculation Temp. Control [Control] TCV-3601
A temperature control valve, which is located in the recirculation pump discharge line, controls
the recirculation flow to maintain the Condensated Preheater inlet temperature to a preset
value(60 deg C), to maintain above the water dew point of the exiting flue gas.
The opening position of the temperature control valve shall be limited to maintain the pump
minimum flow (Approximately 30%). Also the opening position may be limited when required to
avoid pump run-out.
3.11 CONDENSATED PREHEATER BYPASS CONTROL
Condensated Preheater Three-way Control valve [Control] FCV-3601

The Three-way Control valve on condensated preheater system can be used to maintain stack
temperature which is necessary to prevent low temperature corrosion in HRSG stack, if necessary.
The bypass system of Condensated Preheter may be operated in conjunction with the recirculation
system to increase the Condensated inlet temperature, if necessary. Partially bypass of the condensate
preheater while maintaining a fixed recirculation flow increases the condensated preheater inlet
temperature.
3.12 Shutdown of HRSG
This description is to provide automatic shutdown sequences for individual HRSGs, where
shutdown of one HRSG as lead is requested but the other HRSG as lag currently in service and the
steam turbine should remain in service.
The shutdown operation is conducted to minimize life expenditure for the normal daily startup and
shutdown cycle.
1) Gas Turbine load should be lowered to the predetermined minimum load where HRSG can
easily be bottled up and shutdown.
2) Enable LP bypass line and close LP steam Shut-off Valve
3) Enable IP bypass line and close LP steam Shut-off Valve
4) Enable HP bypass line and close HP steam Shut-off Valve.
5) Stop Gas Turbine
6) Close IP steam Shut-off Valve
7) After ensuring shut down of Gas Turbine, close all IP/LP bypass valves in sequence to
bottle-up the pressure of each drum in their proper pressure if required.
8) Stop Condensate preheater recirculation pump
9) Close all feed water supplying isolation MOVs
10) Close spray water supplying MOVs for attemperator
11) Close stack damper for heat preservation, if required

4. Design and Operating Data
Item Design and Operating Data
Design Pressure 136.0 barg
Operating Pressure 126.6 barg
Design Temperature 335.0 ℃
Operating Temperature 329.4 ℃
Drum Storage Time 3 min. 0 sec.

High Pressure From Lo-Lo To Low 1 min. 51 sec.
Steam Drum
From Low To Normal 1 min. 9 sec.
Hi-Hi Water Level +315 ㎜
High Water Level +185 ㎜
Normal Water Level +85 ㎜
Low Water Level -200 ㎜
Lo-Lo Water Level -760 ㎜
Operating Pressure 26.3 barg
Design Temperature 238.0 ℃

From Lo-Lo To Low 6 min 46 sec.
Intermediate From Low To Normal 2 min 46 sec.
Pressure
Steam Drum
Normal Water Level +0.0 ㎜
Low Water Level -125 ㎜
Low Pressure Operating Pressure 3.7 barg
Steam Drum
(LP Drum/ Design Temperature 165.0 ℃
Deaerator
Storage Tank)
From Lo-Lo To Low 1 min 53 sec

From Low To Normal 4 min 12 sec
Hi-Hi Water Level +570 ㎜
Normal Water Level +340 ㎜
Low Water Level +0.0 ㎜
Inlet Pressure 24.6 barg
Pressure Drop 0.2 bar
Reheater Design Temperature(Tubing) 591.0℃
(High Temperature)
Inlet Temperature 510.6℃
Outlet Temperature 566.8℃
Flow 225,700 kg/s

Inlet Pressure 25.2brg

Reheater
Design Temperature(Tubing) 593.0℃
(Low Temperature)
Flow 220,598 kg/s

Inlet Pressure 124.4 brg
High Pressure Pressure Drop 0.4 bar

Superheater Design Temperature(Tubing) 604.0℃
(High Temperature) Inlet Temperature 521.8℃
Flow 202,900 kg/s

High Pressure
(Inter. Temperature) Inlet Temperature 414.7℃
Flow 197,148 kg/s

High Pressure
(Low Temperature) Inlet Temperature 329.1℃
Flow 197,148 kg/s


HP Evaporator
Flow 197,148 kg/s

HP Economizer
(High Temperature) Design Temperature(Tubing) 340.0℃

Flow 197,148 kg/s
HP Economizer Design Temperature(Tubing) 340.0℃
(Inter. Temperature)
Inlet Temperature 205..4℃
Flow 197,148 kg/s

HP Economizer
(Low Temperature)
Flow 197,148 kg/s
IP Superheater Design Temperature(Tubing) 336.0℃
Flow 19,866 kg/s

IP Evaporator

Flow 19,866 kg/s
IP Economizer Design Temperature(Tubing) 287.0℃
Flow 35,926 kg/s
LP Superheater Design Temperature(Tubing) 149.2℃
Flow 14,500 kg/s

Design Pressure 8 barg
LP Evaporator Design Temperature(Tubing) 175.0℃
Flow 14,500 kg/s

Preheater

Flow 255,790 kg/s
SECTION 2
HRSG OPERATIONS
1. INTRODUCTION
This section describes start up and shut down procedure of the Heat Recovery Steam Generator
(HRSG) for NORTE Ⅱ Combined Cycle Power Plant project as a guide which is mainly intended to be
used during engineering stage and initial stage of the operation.
2. COMPLETION OF MAINTENANCE PRIOR TO OPERATION
Check the HRSG to make sure that all maintenance work has been completed, all tools and debris have
been removed, the handhole plates and manhole covers have been installed and secured, and all access
doors have been installed and secured.
Check the safety valves to see that the gags have been removed, the lifting levers have been replaced,
and the valves are not fouled or hung up.
3. INITIAL FILLING
3.1 INITIAL FILLING
This section describes the recommended procedure for filling an empty HRSG with water. If the unit is
hot, filling with cold water should be done slowly to avoid severe temperature strains. Also, since deposits
of solids in superheater & reheater can cause corrosion or inhibit heat transfer, introduction of solids by
carryover of boiler water from the drum during filling, hydrostatic test, or chemical cleaning must be
avoided. Initial water filling is done by using Condensate Extraction pump.
Stage Description Section Action
1 Stage Precautions All 1. All instruments should be lined up for service.
2. All power operated valves should be lined up.
3. All equipment should be lined up.
4. All drain valves should be closed.

2 Stage Ready for CPH Open and prepare the following valves for filling.
Initial filling 1. Condensate line stop valve (MOV-3601)
2. CPH 3-way bypass valve (TCV-3602) open to CPH
direction
3. CPH recirculation control valve and isolation valve
(TCV-360)
4. CPH recirculation pumps isolation valves
5. CPH vent valves
Close it after finishing water fill.
3 Stage Ready for LP Open and prepare the following valves for filling.
LP drum 1.LP FW control valve (LCV-3601)

filling
2.LP FW control valve isolation valves
3.LP Drum vent valve
4 Stage Ready for IP Open and prepare the following valves for filling.
IP drum 1. IP Initial filling line stop valve

filling
2. IP FW control valve (LCV-2321)
3. IP FW control valve isolation valves
4. IP Drum vent valve

5 Stage Ready for HP Open and prepare the following valves for filling.
HP drum 1. HP Initial filling line stop valve

filling
2. HP FW low load control valve (LCV-5102, 30%)
3. HP FW control valve isolation valves
4. HP Economizer Vent valves
Close it when water overflow.
5. HP Drum vent valves
6 Stage LP Drum LP 1. Start the Condensate Extraction pump.
filling 2. Adjust the water flow during filling stage about 10% of
MCR flow by operating feed water flow control valve.
(LCV-3601)
3. Fill all LP section until Start up level (-450mm from drum

centerline) alarm has been cleared.
7 Stage IP Drum IP 1. Start the Condensate Extraction pump.
MCR flow by operating feed water flow control valve.
(LCV-2321)
3. Fill all IP section until Start up level (-360mm from drum

8 Stage HP drum HP 1. Start the Condensate Extraction pump.
MCR flow by operating low load feed water flow control
valve. (LCV-5102)
3. Fill HP section until Start up level (-600mm from drum

HRSG is now ready to be started for “START-UP FROM A COLD CONDITION”.
3.2 WATER FILLING AND DRUM LEVEL ADJUSTMENT
In case of start up after normal shut down, drum level can be adjusted by same as above procedure.
4. START UP
4.1 HRSG START UP IN CONJUNCTION WITH GT START UP
GT load maybe increased to partial load to reduce the exhaust gas temperature for a smooth start up of the
HRSG.. During start up, the steam pressure shall be controlled by HP/IP/LP bypass system.
4.2 OVERALL START UP OPERATION SEQUENCE
1) HRSG start-up preparation
2) GT start by turning motor
3) HRSG Purge
4) GT ignition and rotation raise up
5) Drain HRSG SH section to certain period according to the resident pressure before GT star-up
6) GT Full Speed No Load
7) GT synchronization
8) HRSG drum pressure reaches to set pressure and HP/IP/LP bypass valve control the steam pressure
9) HRSG steam stop valve open, HRSG steam introduction to ST
10) GT load increase to desired load in conjunction with ST condition
4.3 START–UP SEQUENCE FOR STEAM / WATER SIDE FROM COLD CONDITION
1 Stage Drum level HP / IP/ Set the HP / IP / LP drum level at start up water level using
setting LP Drum start-up & intermittent blowdown valves.
1. HP blowdown valve (MOV-3003)
2. IP blowdown valve (MOV-3023)
3. LP blowdown valve (MOV-3132)

2 Stage Valves HP / IP / Align HP/IP/LP section valves as shown on the column

alignment LP labeled “START FROM COLD” listed in the table 1, 2 and
3as attached.
3 Stage Drain HP Confirm all condensate is drained within SH heating surface

and steam line. Open and close drain valves.
4 Stage CPH LP When CPH outlet temperature reach over 90℃, Condensate
recirculation
recirculation pump is running and CPH inlet temperature
pumps
control is in auto.
5 Stage HRSG start- HP / IP / HRSG will be load-up following GT running and flue gas
up by ignition LP entering to HRSG.
of GT
1. Check the condensate extraction pump is running
2. Check the HP/IP feedwater pump is running
6 Stage Drain HP Drain will be operated for extracting non-condensable and

operation condensate from HRSG.
Open HP SH drain valve (MOV-3101/3102/3103)
Hold open for 2 minutes with following below steps.
1 [barg] ≤ Drum pressure< 9 [barg] ; full open.
9 [barg] ≤ Drum pressure ; intermediate open.
After 2 minutes, closed and placed into auto operation.
RH/IP Open CRH drain valve (MOV-3112) and HRH steam line
drain valve (MOV-3112)
Open IP SH drain valve (MOV-3121/3122)
LP Open LP SH drain valve (MOV-3131)

7 Stage Vent HP Open HP start up vent (MOV-3001) when HP drum pressure
Operation below 1 [barg]
Close HP drum vent when drum pressure above 2 [barg]
IP Open IP start up vent (MOV-3021) when IP drum pressure
below 0.5 [barg]
Close IP drum vent when drum pressure above 1 [barg]
LP Open LP start up vent (MOV-3031) when LP drum pressure

below 0.5 [barg]
Close LP drum vent when drum pressure above 1 [barg]
8 Stage LCV HP Drum level set point should be changed start up water level
into normal water level when load greater than 20% MCR
4.4 START–UP FROM WARM/HOT CONDITION
1 Stage Drum level HP / IP/ Set the HP / IP / LP drum level at start up water level using
setting LP Drum start-up & intermittent blowdown valves.
1. HP blowdown valve (MOV-3003)
2. IP blowdown valve (MOV-3023)
3. LP blowdown valve (MOV-3132)
2 Stage Valves HP / IP / Align HP/IP/LP section valves as shown on the column

alignment LP labeled “START FROM COLD” listed in the table 1, 2 and
3as attached.
3 Stage Drain HP Confirm all condensate is drained within SH heating surface

and steam line. Open and close drain valves.
4 Stage CPH LP When CPH outlet temperature reach over 90℃, Condensate
recirculation
recirculation pump is running and CPH inlet temperature
pumps
control is in auto.
5 Stage HRSG start- HP / IP / HRSG will be load-up following GT running and flue gas
up by ignition LP entering to HRSG.
of GT
1. Check the condensate extraction pump is running
2. Check the HP/IP feedwater pump is running
6 Stage Drain HP Drain will be operated for extracting non-condensable and

operation condensate from HRSG.
Open HP SH drain valve (MOV-3101/3102/3103)
Hold open for 2 minutes with following below steps.
1 [barg] ≤ Drum pressure< 9 [barg] ; full open.
9 [barg] ≤ Drum pressure ; intermediate open.
RH/IP Open CRH drain valve (MOV-3112) and HRH steam line
drain valve (MOV-3112)
Open IP SH drain valve (MOV-3121/3122)
LP Open LP SH drain valve (MOV-3131)

5. HRSG SHUT DOWN
5.1 HRSG SHUT DOWN CONCEPT
HRSGs in normal operation are connected to HP, IP and LP steam header and supply steam to it. When
shutting down the HRSG, the sequential action is as follows:
1) GT load decrease to No Load Operation
2) GT shut down
3) TBN bypass valve open
4) Steam outlet valve close
5) TBN bypass valve gradually closes as steam pressure decreases
6) Feed water control valve closes
7) Boiler feed water pump maintain minimum flow operation
8) Boiler feed water pump shut down
9) Close stack damper for heat preservation, if required.
5.2 SECURE TO A WARM/HOT CONDITION
This section describes the recommended procedure for securing the HRSG to a warm/hot lay–up
condition. Warm / Hot lay up reserves heat in HRSG for the next start –up.
1) GT load decrease to NO Load Operation.
2) Align all HRSG valves as shown under the column labeled “SECURE TO WARM” on Tables 1, 2 and 3.
3) If the HP Drum pressure falls below 1 [barg], open the motor operated HP start-up vent valve
(MOV-3001).
4) If the IP Drum pressure falls below 0.5 [barg], open the motor operated IP start-up vent valve (MOV-
3021)
5) If the LP Drum pressure falls below 0.5 [barg], open the motor operated LP start-up vent valve (MOV-
3031).
5.3 SECURE TO DRAIN
This section describes the recommended procedure for securing the HRSG in order to drain the unit
prior to performing maintenance.
GT load decrease to NO Load
Operation.
Align all HRSG valves as shown under the column labeled “SECURE TO DRAIN" on
Tables 1, 2
and 3.
Open the motor operated HP start-up vent valve (MOV-3001) when the HP drum pressure
falls to 1 [barg]. Open the motor operated IP start-up vent valve (MOV-3021) when the LP
drum pressure falls to 0.5 [barg]. Open the motor operated LP start-up vent
valve (MOV-3031) when the LP drum pressure falls to 0.5 [barg]. These valves must be
opened before the drum pressures fall any lower to prevent a vacuum from developing that
may cause leakage of the drum manway gaskets.
Open all of the motor operated superheater drain valves when their respective drum
pressures have dropped to1 [barg].
The HRSG can be drained when it is completely cooled (By checking the each drum water
temp and pressure)
Open the vent and drain valves for one pressure level at a time to avoid overloading the
drain discharge system downstream of the HRSG if required.
6. TRIP
The HRSG trip will result in fast shut down of the GT.
Table 1 –Valve Alignment: High Pressure Section
Table 2 –Valve Alignment: Intermediate Pressure Section
Table 3 –Valve Alignment: Low Pressure Section
SECTION 3
HYDRAULIC TESTS
[Attach the 28M-HG-MN-2201,
Hydro Test Procedure at Site Manual]
SECTION4
RESERVATION
1. DRY STORAGE
The steam generator should be drained and dried as thoroughly as possible. The two desiccants
most commonly used are Silica-Gel and Quick-lime. Silica-Gel is the better of the two
because it can be dried or regenerated by heating and therefore used over and over again. Also,
it is not caustic and therefore it is safer to handle. In the case of Quick-lime shallow
metal trays should be used to contain the powdered lime within the drum, whereas Silica-Gel
which is available in bags should be suspended within the drums.
Quick-lime requirements are 3-4 kg per 1000 kg/hr steam generator rating, while Silica-Gel
requirements are 2 kg per 3 cubic meters of internal volume. After placing Quick-lime or
Silica-Gel in the drums, all openings should be tightly closed. Quick-lime or Silica-Gel should
be rechecked every 3 months for replacement or regeneration.
Dry storage can also be accomplished in starting with a clean, dry Unit, then purge all the
oxygen from the steam generator by introducing nitrogen through the lower header and
drum blowdown valves. Nitrogen replaces oxygen that if remains in the tubes may cause
corrosion of metallic surfaces.
An oxygen analyzer is used to check that all oxygen has been eliminated and that only nitrogen
remains inside the steam generator.
The nitrogen gas for the preservation of the HRSG will be supplied from high pressure
nitrogen tube trailers and connectors are located at each HRSG. It is necessary to verify there
are no leaks on the valves. A manometer installed for this purpose will control pressure.
If the steam generator stops without having been drained, the areas located above the water
level of the drum may be protected with the nitrogen gas supplied from high pressure nitrogen
tube trailers, if necessary.
2. WET STORAGE
The steam generator will be completely filled with a condensate contain 10 [ppm] of ammonia
and 200 [ppm] of hydrazine.
First, the Drums are filled and then superheaters are filled until the water is drained from the
vent valves.
All valves shall be closed for protecting the air inflow.
It must be put special care in avoiding the freezing of water during this period.

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CHAPTER 4

HEAT RECOVERY STEAM GENERATOR

2.2 FEEDWATER SUPPLY

2.3 HIGH PRESSURE WATER/STEAM FLOW PATH

HP economizer 1 -> HP economizer 2 -> HP economizer 3 -> HP economizer 4 ->

2.4 INTERMEDIATE PRESSURE WATER/STEAM FLOW PATH

2.5 LOW PRESSURE WATER/STEAM FLOW PATH

Deaerator -> LP superheater -> LP main steam header

2.6 CONDENSATE PREHEATER FLOW PATH

2.7 EXHAUST GAS PATH:

2.8 HRSG INLET/OUTLET DUCT AND STACK

2.9 HRSG STACK DAMPER

2.10 HRSG BLOWDOWN TANK AND TRANSFER SYSTEM

2.11 METHOD OF STARTING THE HRSG

Starting of the HRSG can be implemented in several ways as follows:

3.2 INITIAL FILLING

3.3 HRSG Purge

The related purging automatic is completely realized within the GT control.

The purging time starts with “purge speed reached”.

3.4 CONTROL OF DRUM LEVELS

A. SINGLE ELEMENT CONTROL

B. THREE ELEMENT CONTROL

C. SINGLE ELEMENT / THREE ELEMENT TRANSFER

a. Switch from single element to three element controls.

b. Switch from HP FW startup CV (LCV-5102) to HP FW main CV (LCV-5101).

E. IP AND LP DRUM LEVELS

F. HP Drum Level Set point

Drum level will be corrected by the drum pressure.

y Normal Level : (85mm above Centerline)

y HLT Level: (480mm above centerline)

y HLA level: (300mm above centerline)

Sound the alarm.

Open the start-up blowdown Valve (MOV-3003).

y LLA level: (200mm below centerline)

Sound the alarm.

Close continuous blowdown valve (MOV-3002)

y LLT Level: (760mm below centerline)

Close of HP steam isolation valve (MOV-2501)

G. IP Drum Level Set point

Drum level will be corrected by the drum pressure.

y Normal Level: (0mm below centerline)

y HLT Level: (250mm above centerline)

y HLA level: (125mm above centerline)

Open the start-up blowdown Valve (MOV-3023).

y LLA level: (125mm below centerline)

Sound the alarm.

Close continuous blowdown valve (MOV-3022)

y LLT Level: (460mm below centerline)

Close of IP steam isolation valve.(MOV-2801)

H. LP Drum Level Set point

Drum level will be corrected by the drum pressure.

y Normal Level: (340mm below centerline)

y HLT Level: (650mm above centerline)

y HLA level: (450mm above centerline)

Sound the alarm.

Open the start-up blowdown Valve (MOV-3132).

y LLA level: (0mm BELOW centerline)

Sound the alarm.

y LLT Level: (860mm below centerline)

Close of IP steam isolation valve.(MOV-2901)

3.5 CONTROL OF SUPERHEATER AND STEAM LINE DRAINS

HP Main Steam Line Drain [MOV] MOV-3101

IP Superheater Drain [MOV] MOV-3122

IP Main Steam Drain [MOV] MOV-3121