DUCT BURNER SYSTEM

(HRSG SUPPLEMENTARY FIRING)

Burner

Natural Gas path

Atomizing Air path

Oil Gun

Gas Main Nozzles (30 holes)

- 6 groups w/ 5 outlet nozzles each

Gas Pilot Flame (6 holes)

Deflectors
 Burner Installation

Atomizing Air/Oil Feed Line

S/heater II
modules
Gas Turbine
Diffuser

Gas Feed Line

TEG Duct
& Mesh
(not yet
Ignition Feed Line Installed)

Supports

Burner
Throat

Burner Frontplate
 General Layout

Main Valve Rack

Auxiliary Fans

Comp. Skid

BMS Cubicle Burner Numbering

Burner Angle of Deflection

(Degrees)

12.5’
8 7
Main
11’
6 5 Valve
10’ Rack
4 3 Side
9‘
2 1
Burner Set-up

 Each HRSG has eight burners

 Four on each side
 Each burner has the ff:
Igniter & transformer
UV scanner (gas)
IR scanner (oil)
Oil feed line
Gas feed line
Ignition gas line
Steam purge line
Sight glass
Cooling/sealing air
lines
Flame Detectors

Flame scanners
- 1 IR flame scanner (oil)
- 1 UV flame scanner (gas)

Transformer for igniter

- Primary voltage (230VAC)
- Secondary voltage (7500V)

Sight glass with ball valve

Igniter (with flame rod for

flame supervision)
Gas/Oil Feedlines

Atomizing air line

Gas feed line

Oil feed line

Limit switch
(signals if oil gun is
coupled)

Cooling/sealing lines
Sub Valve Rack
Steam purge line

Steam purge solenoid valve

Oil supply solenoid valve

Ignition gas line

Ignition gas solenoid valve

Gas supply solenoid valve

Oil supply flexible line

Oil supply pressure CV

Instrument supply valves

Main Valve Rack
Fire deluge system

Gas line

Gas inlet press switches

Gas control valve

Instrument air press switches

Ignition line (natural gas)

Oil control valve

Oil inlet press switches

Oil line

Oil suction strainer

Main Valve Rack
Terminal boxes

Gas burner press switches

- HH (2X3) prot. logic
Steam purge line

Gas manual valve

Manual 3-way valve

(for ignition gas – NG or
propane bottle)

Steam purge press switch

BMS cubicle and CO2 rooms

BMS local control room

- power supply (XXBFF00GS001)

Compressor skid
- 2 compressors (piston type)

CO2 room
- (1 bottle)

Fire Protection System

(inside BMS control room)
- 4 smoke detectors
(2X4) prot. logic
2 ionization
2 optical
- CO2 discharge
Auxiliary Fans/Pressure Switches Rack
Three Auxiliary Fans
1 fan - in gas operation
2 fans - in oil operation
Air Flow
During gas firing - 2.0 kg/s
During oil firing - 3.6 kg/s

Power Installed - 45 kW
Voltage - 400V,
3PH
Pressure Switches Rack
Oil operation:
USAGE OF AUXILIARY AIR:
PSL - Start of 1 fan
-Stabilization air for gas burners PSLL - DB trip (2 of 3)
-Atomizing/stabilization air for oil burners
-Combustion/cooling air for igniters
Gas Operation:
-Cooling/sealing for flame scanners, sight glasses PSL - Start of 1 fan
-Sealing air for burner bushings PSLL - DB trip (2 of 3)
Instrument Air Compressor

Compressed air tank press switch

- responsible for start-up of compressors
- setting 7.5 / 8.8 bars for ON and OFF
- c/o of compressor (every 1 running hr)
- clocklike switch inside the panel

Press switch of each compressor

- if compressors are selected
individually
- compressor 1 setting:
7.8/9.9 bars
- compressor 2 settings:
7.5/9.2 bars
 BMS Touch Screen Panel

Touch screen panel

Silence
Buzzer Start
Gas Oil Alarm
Reset Stop
Acknowledge

Lamp test
Emergency Selector Switch
Pushbutton BMS or DCS
Auxiliary Fan Panel / Burner Selector Switches

Auxiliary fan status

indication

Stand-by
Failure Back-up Running
Off Auto Manual

Individual Burner ON/OFF

switches

( 8 selector switches)
 Changeover of Auxiliary Fans
GAS OPERATION

Status Switching (O,A,M) / mode (run, backup, standby)

(Change DCS to BMS first) Fan 1 Fan 2 Fan 3

Fan 1 in operation "AUTO"/run "AUTO"/backup "AUTO"'/standby

Start fan 3 AUTO"/run "AUTO''/backup "MANUAL''/run

Disable fan 1 & 2 "'OFF''/off "'OFF''/off "MANUAL''/run

Fan switch 3 on "AUTO" "'OFF''/off "'OFF''/off "AUTO"/run

Select fan 1 backup mode "AUTO"/backup "'OFF''/off "AUTO"/run

Select fan 1 standby mode "AUTO"/backup "AUTO"'/standby "AUTO"/run

 AUXILIARY AIR FANS / INSTRUMENT AIR COMPRESSORS

Oil Pressure Switches

Air Flow : Rack
Gas firing = 2 kg/s Oil Operation :
Oil firing = 3.6 kg/s operating value = 110 mbar
Voltage = 400V, 50Hz,3ph start of one fan = 98 mbar (L)
Power = 45 KW trip of DB (2X3) = 87.7 mbar (LL)
Auxiliary Fans Gas
Gas Operation: (DP)
operating value = 47 mbar
start of one fan = 30 mbar (L)
trip of DB (2X3) = 25 mbar (L)

Butterfly valve

Pressure Switch LL
(2 X 3) - DB Trip
(Setting = 6.5 bars)

Instrument Air
Compressors

Design
Design press
press= =10
10bars
bars
Effective
Effective pressure
press – 9.8
= 7.5= –7.59.8 barsbars
Air flow
Voltage = =400V,50Hz,3ph
2 kg/s
Power = 4 KW
 AUXILIARY AIR & INSTRUMENT AIR SUPPLY

Atomizing/stabilizing air for oil

Stabilizing air for gas

Cooling/sealing air on flame scanners

and sight glass

Combustion/cooling air on igniters

Sealing air for pipe bushings

(gas and oil pipelines)
Sealing air for

Auxiliary Air Line

Instrument Air Line
 GAS SUPPLY LINE (Gas Train)

Three way valve for ignition gas

(Gas/Propane)

Eff. Press = 0.6 bars

Flow = 0.0175 Nm3/s
Propane bottle
for ignition gas
Eff. Press = 1 bar
Flow = 0.04 Nm3/s
Extraction from gas train
(For ignition gas)

Pressure Switch HH
Pressure Switch (2 X 3) – DB Trip
LL (2 X 3) – DB Trip (Setting = 8 bars)
(Setting = 7 bars)

Gas Supply

Supply press
= 25 bars
Net Heating Value Pressure reducing station Main gas vent valve Control Valve
= 31.67 – 38.8 (Maintains = 9 bars) (Vented gas seal) (Press range = 0.25–7 bars)
MJ/Nm3
Max gas flow
= 4.3 Nm3/s
 GAS FEED LINE
Gas feed line
Burner
Solenoid vent valves
(one on each side)

Igniter

Individual block
solenoid valves Ignition gas feed line

Ignition gas line

Main gas header

 OIL SUPPLY LINE (Oil Train)

Pressure switch L
(Setting = 0.3 bar)
(stops steam purge)
Supply press = 2.5 – 5 bars
D/strm CV = 1 bar
Temp. = 180 deg C
Flow = 0.01 kg/s

Steam purge line

Pressure switch LL Pressure switch HH

(2 X 3) - DB Trip (2 X 3 ) - DB Trip
Solenoid valve (Setting = 9 bars) (Setting = 6 bars)

Fuel oil line

Supply press = 10 – 12 bars

Net Heating Value = 42.7 MJ/kg
Max flow = 3.5 kg/s
Viscosity = 4.9 cSt at 40% Control Valve
(Press range = 0.13-4 bars)
 OIL FEED LINE

Oil feed line Manual vent valves

(one on each side)
Burner

Steam purge line

Main oil header

BURNER FEED LINES
Burner Throat

Oil Gun Limit Switch Sight Glass

IR UV
Igniter
Flame Scanners
 PRESSURE SWITCHES RACK

PSL - start of one fan . PSLL (2of 3) - trip of DB

Auxiliary Air Pressure Switches

(Gas Operation)

Auxiliary Air Pressure Switches

(Oil Operation)

PSL - start of one fan PSLL ( 2 of 3)

- trip of DB

Pressure switch rack drain valves

 Protection Matrix
Duct Burner Pressure Switches
Setpoints
Operating Protection
KKS Description Value Alarm Trip Logic/Interlocks Consequences
XXQFA50
CP010 Aux. air press low (oil) 110 mbar 98 mbar Start of back up fan Alarm
XXQFA50
CP020/03
0/040 Aux. air press low-low (oil) 110 mbar 87.7 mbar 2V3 Burner trip

XXQFA50
CP050 Aux. air press low (gas) 47 mbar 30 mbar Start of back up fan Alarm
XXQFA50
CP060/07
0/080 Aux. air press low-low (gas) 47 mbar 25 mbar? 2V3 Burner trip
XXEKG10
CP141/14
2/143 Gas supply press low-low 9 bar 7 bar 2V3 Burner trip
XXEKG10
CP145/14
6/147 Burner gas press high-high 0.25 – 7 bar 8 bar 2V3 Burner trip
XXEKD10
CP141/14
2/143 Oil supply press low-low 12 bar 9 bar 2V3 Burner trip
XXEKD10
CP145/14
6/147 Burner oil press high-high 0.13 – 4 bar 6 bar 2V3 Burner trip
XXQHA50
CP180 Purge steam press low 0.7 bar 0.3 bar Stop the oil gun purge Alarm
XXQFA10
CP170 Comp. 1 press low/high 8 bar 7.8? / 9.9 bar? Start/stop of comp. 1
XXQFA10
CP180 Comp sel. switch low/high 8 bar 7.5 / 8.8 bar Interval start of comp.
XXQFA10
CP160 Comp. 2 press low/high 8 bar 7.5? / 9.2 bar? Start/stop of comp. 2
XXQFA10 Standby compressor will
CP130/14 start ( certain time delay)
0/150 Instrument air press low-low 8 bar 6.5 bar 2V3 Burner trip
 OM SCREEN

HRSG Protection
42 mbars
Indicates green if Remote is HBK10 - Warning
selected at BMS local panel. CP001 48 mbars
-DD close (11 & 12)
- GT Trip (21,22,23)
Indicates green if aux air press > min, no flame, fuel
valves close prior to GT Start-up. GT start permissive.

Indicates green if all burners were ignited.

Release for control to increase load. HRSG Alarms
700 deg.C – Too High
Red indication if DB trip was caused by 650 deg. C - High
protection/fault of the system.
HBK10
Red indication if burner trips due CT011/012 HBK10 SF Prot OFF
to GT trip/DD close/HRSG high /013/014 CT901 (3 X 4) prot. logic
temp protection. (CT001/002/003/004) >857 deg. C
Time delay=180 secs
Duct
Control setpoint to Burners
increase thermal load.

SF Prot OFF
XXLBA10CT001/002/003
HP STM T S/HTR OUTL > MAX3
T > 580 deg. C (2X3)
Time Delay=180 secs Auxiliary
Fans
 HRSG Parameters with Duct Burners
Based on Design Data
Parameters Unfired condition Fired condition

Steam pressure in 79 82.7

Bar (g) (3.7 diff)

Steam temp. in 541.7 562.8

°C (21.1 diff)

Steam flow in TPH 332.24 476.4

(144.16 diff)

(kg/s) 92.2 132.2

(40 diff)
 Burner Start-up
 Two different ways to start:

- Thru pushbutton at BMS local panel.

- And thru DCS command from CCR.

• Start can only take place if at least 7 burners are selected and ready
for operation (not under maintenance).
• Successful operation only takes place if at least 7 burners were ignited
within 3 minutes. If not, burners will trip.
• Burners will start sequentially starting from burner 1 – 8. If one burner
will trip, it will continue to start other burners. If two, all burners will trip.

• Conditions for operating the burners;

-GT load @ 25MW and DD open to HRSG
-furnace purge must be complete (boiler and burner)
-fuel must be selected (gas and oil) – start of fans
-gas and oil supply conditions are present
-burner switches at panel selected to “1”
 Oil and Gas Start-up Sequence
 Oil start sequence:
a. Shortly after oil start is initiated, main oil CV is energized
b. The ignition burner and transformer starts simultaneously
c. Main oil CV is sent to min position (30MJ/s) after 5 sec.
d. If after 10 seconds, main flame is established - burner is on
e. Ignition burner is then switched off
f. Next burner will follow the same steps until all burners are fired

 Gas start sequence:

a. Shortly after gas start is initiated, main gas CV is energized and main
gas vent valve is closed.
b. The ignition burner and transformer starts simultaneously, then the
central gas vent valve is closed.
c. Main gas CV is sent to min position (14MJ/s) after 5 sec.
d. If after 5 seconds, main flame is established – burner is on
e. Ignition burner is then switched off
f. Next burner will follow the same steps until all burners are fired
 Fuel Changeover (Gas to Oil)
 Fuel changeover from gas to oil
Can be initiated thru:
Pushbutton at local panel – fuel oil selected.
Selection of fuel oil at DCS OM screen.

Once initiated the sequence is as follows:

Second auxiliary fan will start

Ignition burner will start
Main oil valve opens at minimum firing (32MJ/s)
Gas control valve is sent to minimum (14.4MJ/s)
Oil burner will start/ignite
After fifteen (15 seconds) ignition burner will stop
Oil burner can be loaded up
 Fuel Changeover (Oil to Gas)
 Fuel changeover from oil to gas
Can be done thru:
- Pushbutton at local panel – fuel gas selected.
- Selection of fuel gas at DCS OM screen
Once initiated the sequence is as follows:
Ignition burner will start
Oil burner CV goes to minimum firing (32MJ/s)
Gas burner CV opens to minimum firing (14.4MJ/s)
Gas burner will start/ignite
Oil burner CV closes
After changeover, oil gun steam purge follows
If completed, one auxiliary fan and ignition burner will stop
Can be loaded up to maximum load
* Any failed changeover, sequence is terminated and goes back to
original fuel.
 Oil Gun Purge
 After oil burners are taken out, oil guns are steam purged
automatically to eliminate oil accumulation on the line.
Steam purge is initiated after:
Fuel complete changeover from oil to gas
Five (5) minutes after the stop of an individual oil burner

Steam purge sequence:

Ignition burner starts
Oil gun purge valve opens
Purging duration will be for 60 seconds
Purge valve then closes after time had lapsed
After 5 seconds, ignition burner will stop

* Two auxiliary fans for oil are operated during purging. After steam
purge and steam valve is closed, one fan is switched off.
 Manual Oil Gun Purge
• After a GT/HRSG trip, oil gun steam purge is interlocked
(solenoid valve closed). The oil guns for each burner
should be purged manually.

• Procedure for manual oil gun purging/draining:

a. Disconnect flexible oil supply hose at valve rack
connection
b. Put the unscrewed flexible end in a bucket
c. Drain the oil gun in the bucket
d. After draining, the oil gun shall be retracted from
burner
e. The gun then shall be held in sloping position to
remove oil
f. Re-install and re-connect back the burner oil gun
 Furnace Purge
 Furnace purge is a necessary action before s/up or after burner stop to
remove explosive mixture from the furnace.

Two separate purge sequences are required prior to start-up:

1. Boiler purge - only performed when GT is started
- 5 minutes to HRSG.
2. Burner purge - is executed prior to every burner start
after a burner trip and described as furnace purge.

Furnace purge (by GT exhaust gas) before start-up or after a trip :

- starts counting automatically when burners are reset
- fuel valves are closed
- no flames are detected
- furnace purge lasts for 300 seconds ( 5 minutes)
Equivalent % Load to MJ/s (MW)
% Load MJ/s (gas) MJ/s (oil)
 10% - 14.4 - 13.4
 20% - 28.8 - 26.9
 30% - 43.2 - 40.4
 40% - 57.6 - 53.8
 50% - 72 - 67.3
 60% - 86.4 - 80.8
 70% - 100.8 - 94.2
 80% - 115.2 - 107.7
 90% - 129.6 - 121.1
 100% - 144 - 134.6
 Scheduled Weekly Inspection
 Weekly Inspection:
1. Lamp test
2. Water drain pressure switch rack
Procedure for draining:
1. Open valve X1.50
2. Wait five (5) seconds
3. Remove plug below valve X1.51
4. Close valve X1.50
5. Open valve X1.51 till water stops draining
6. Close valve X1.51
7. Repeat sequence 4 to 6 until no water
8. Fit plug back below valve X1.51

* Adjust interval of this procedure according to site requirements.

 Scheduled Inspection
 Six weeks inspection:
- Flame scanners
- Block valves
 Six months inspection:
- Functional check of safeguarding system
Total closing time of block valves in case of flame failure
Timer functions
Purge time
Safety conditions
- Leak testing of the block valves
- Leak test on in-line equipments
- Checking of limit switch and pressure switch settings
 Yearly inspection:
- Check all analogue field components
- Cleaning of strainers, igniters, flame detectors
- Components with a limited lifetime must be replaced
End of Presentation

Thank You

Levy