STEAM / POWER

SYSTEM
 STEAM & POWER

◼ 1. Sources of steam generation & their

optimization
◼ 2. Sources of power generation
◼ 3. Types of steam users
◼ 4. Development of steam balance
◼ 5. Typical requirement of VHP/SHP steam
in GCU/NCU of petrochemical
complexes
◼ 6 Intermittent requirements of steam in
a refinery
 STEAM & POWER

◼ Typical de- aerator calculations

◼ Typical PRDS calculations
◼ Typical design margins used by refiners
◼ Emergency boiler
◼ Boiler feed water System
◼ Condensate Sytem
◆ Problems faced by clients & their solution
 STEAM & POWER

◼ 1 Sources of steam generation & their

optimization
◼ 1.1 sources of steam generation
◼ 1.1.1 Internal generation
◼ In a typical refinery several process units generate
steam at LP, MP& HP levels .
◼ 1.1.1.1 HP Steam
◼ FCCU,H2U & Reforming units generate HP steam.
◼ 1.1.1.2 MP Steam
◼ CDU/VDU, HCU, VBU & SRU generate MP steam.
 STEAM & POWER

◼ 1.1.1.1 LP Steam
◼ CDU/VDU, HCU (or OHCU), SRU etc generate
LP steam.
◼ Generally steam from internal generators or
steam turbines should have sufficient pressure
to connect with respective header.
◼ Typical pressure should be maximum pressure
of steam + pressure drop for connecting to
main header.
 STEAM & POWER

◼ 1.1 Utility boilers

◼ 1.1.1.1 Steam generation
◼ Generate very high pressure steam , send it to steam
turbines to generate power and meet the steam
requirement at lower levels.
◼ 1.1.1.2 Typical reference
◼ • At IOCL Panipat , VHP steam is generated in CPP
boilers . It is then sent to steam turbines to meet
power and steam requirements of the refinery
◼ • MP level steam is sent to process users.
◼ LP steam by let down of MP steam.
 STEAM & POWER

◼ • LP consumption of distance users is met

by taking care of pressure drop as well as
temperature loss in the steam header. At IOCL
Panipat, Sulphur block (SRU, SWSU & ATU) is
about one KM away from process units, LMP
steam is produced in process units to meet LP
steam requirement. of distant users
◼ HP steam requirement (during normal case
generation matches consumption)with let
down of VHP steam
 STEAM & POWER

◼ 1.1 Heat Recovery Steam Generator(HRSG)

◼ 1.1.1 Sources of steam generation
◼ When gas turbine is used as compressor drive or a part
of captive power plant then GT exhaust (480-540 0C) is
used to generate steam.
◼ 1.1.2 Power generation
◼ If power is required then maximum power can be
generated by letting down VHP steam to condensing
level in the steam turbine.
 STEAM & POWER

◼ 1.1.1 Steam / Power generation

◼ If both steam (at two levels or one level) and
power are required then extraction cum
condensing or extraction cum back pressure
steam turbine should be used
 STEAM & POWER

◼ 1.1.1 Steam generation

◼ 1.1.1.1 VHP steam generation
◼ GT exhaust with auxiliary firing from fuel gas are
taken to HRSG. Fuel gas is required to meet VHP steam
temperature
◼ 1.1.1.2 Single user level
◼ Steam can be generated at single user level in HRSG.
Additional fuel gas is used for extra steam than
possible with heat from gas turbine exhaust.
◼ 1.1.1.3 Dual level steam generation
◼ It is possible to generate steam at two user levels
(Take HRSG vendor’s advise on extent of generation) in
HRSG e.g. At HPL 165 T/hr SHP steam with 22 T/hr MP
steam.
 STEAM & POWER

◼ 1.1 TYPICAL STEAM CONDITIONS

◼ STEAM UNITS MIN NOR MAX MECH
DESIGN
◼ SHP/VHP STEAM

◼ PressureKg/cm2A 103 105 107 117

◼ Temp.oC 480 500 510 513
◼ HP STEAM

◼ PressureKg/cm2A 39 41 43 47
◼ Temp.oC 360 370 390 420
 STEAM & POWER

MP STEAM

◼ Pressure Kg/cm2A 13 15 16 19

◼ Temp.Oc 210 290 305 350

◼ LP STEAM

◼ Pressure Kg/cm2A 4 5 6 10

◼ Temp.oC 190 220 235 260

 STEAM & POWER

◼ 1.1 Optimization of steam systems

◼ 1.1.1 Old Power Plants
◼ Process plants normally require large quantity
of low pressure steam to meet the process
heat requirement. In most of existing old
plants this demand is met by generating
steam at low to medium pressure (20-40
kg/cm2g) and used after reducing through let
down valves or through steam turbines driving
some equipment or generator.
 STEAM & POWER

◼ 1.1.1 New Power Plants

◼ High pressure boilers generating steam at 106
kg/cm2g with very high superheat(510 0C)are
ideally suited for passing through extraction
cum back pressure or extraction cum
condensing type turbines.
 STEAM & POWER

◼ 1.1.1 Optimization Methodology

◼ • There is no single solution to the selection of
optimum steam pressure & system. Each case needs to
be worked out and studied separately to derive the
optimum condition of steam. Optimum system can be
selected after preparing techno-economic evaluation of
the various possible schemes
◼ • Heat conservation in the refinery/petrochemical
complex can be achieved by providing optimum heat
insulation, pipe size, efficient steam traps to prevent
leakage of steam.
 STEAM & POWER

◼
◼ 1 Sources of power generation
◼ 1.1 General
◼ • Power can be made available either from
grid network or by captive generation
◼ • Based on economics of grid power Vs
captive generation , decision may be taken to
go for the system to be considered for power
generation.
◼ • Present trend of design is to have
minimum dependence on outside agency.
 STEAM & POWER

◼ 1.1 Grid Power

◼ 1.1.1 Dependability
◼ Grid power is usually considered unreliable
due to varying frequency & difficulty in
meeting varying requirement during shutdown
of any running unit or other operating
problems. Due to this problem, most clients
prefer to go for captive generation.
 STEAM & POWER

◼
◼ 1.1.1 Combination Power
◼ • In few cases where power consumption
was very high grid power will be considered in
parallel with captive generation to meet power
requirement
◼ • In above mentioned cases, due to some
disturbance in grid power, power failure of the
entire complex can not be ruled out. It is
desirable to design steam /power system after
considering total power failure case.
 STEAM & POWER

◼ •
◼ 1.1 Captive power
◼ 1.1.1 Typical system
◼ Captive power is generated with gas turbine or steam
turbine or a combination of both.
◼ 1.1.2 Recent captive power plants Refer
fig. 1
◼ Consist of gas turbines to meet part power requirement
followed by steam generation in HRSG s/boilers and
steam turbine for balance power generation as well as
to meet part requirement of steam(balance from
internal generation) consumption at lower levels.
◼ 1 Types of steam users
◼ 1.1 Superheated steam
◼ When steam turbine is considered to drive
compressor/pump, superheated steam is used.
◼ Degree of superheat in various levels is as follows:
◼ In HP & VHP steam 150-200 0C
◼ In MP steam it is 50-100 oC
◼ In LP steam it is 25 – 50 0C.
◼ Whenever condensing turbine is used then surface
condensate produced is pumped to de aerator for its
further utilization as boiler feed water.
◼ 1.1 Saturated steam-Reboiler in distillation
columns
◼ • Provide saturated steam for optimum utilization of
heat exchange area .
◼ • Area provided for sensible heat is less economical
as compared to area for latent heat transfer.
◼ • De-super-heater is used to provide saturated
steam from super heated steam at that level.
◼ • Condensate (MP/HP steam) produced is flashed at
LP level to generate LP steam. It is then pumped to de-
aerator for its further utilization in producing BFW.
◼ •
◼ 1.1 Superheated Steam-Stripping steam
◼ • It is used in side steam strippers of CDU,
sour water stripper etc.
◼ Condensate generated in these units is either
routed to sour water stripper(sour) or directly
used in desalter of CDU.
◼ 1 Development of Steam Balance
◼ • Steam consumption/generation is finalized in such
a manner that minimum let down with Pressure
Reducing Desuperheating Station(PRDS) is required
from higher to lower levels.
◼ • Surplus steam from process units is routed to
common header, shortfall or intermittent demand is
met from the common header.
◼ • Overall steam balance for consumption /
generation at different levels is done by introducing
steam turbine as drives for letting down of steam.
◼ • Some rational approach like cluster of LP
steam consumers are considered. They are
supplied steam with let down at various
locations in a refinery to ensure supply of
steam at desired conditions.

◼ Preliminary information collected from

licensor/client. If this information is not
available then information of past similar units
is taken & used after clients approval.
◼ • A discussion is held with client to decide the
consumption of steam for fuel oil atomization, tracing
for congealing lines within units as well as in off site
area, storage tank heating, intermittent requirements
like snuffing, decoking, soot blowing, purging etc, air
conditioning for central control rooms & administrative
buildings(vapor absorption type )and other losses etc.

◼ • Design margin is considered to compensate for

uncertainty of data when this information is taken from
study report or Detail Feasibility Report(DFR). Normal
margin considered is 5-10 % for DFR & 10-20 % for
study reports.
◼ •
◼ • The data collected on steam balance
needs to be approved by client before doing
any calculation.
◼ • Calculations are started with heat and
material balance around the de-aerator.
◼ It includes saturated/surface condensate, LP
steam, boiler feed water after considering blow
down(3%), loss from de-aerator(0.5–1.0 t/hr)
and DM water.
◼ • Feed back information on the above mentioned
consumers is taken from past jobs ,vendor(for air
conditioning plants) & climatic conditions of the site are
collected to facilitate the discussion.
◼ • With this, quantity of LP steam & DM water are
calculated.
◼ • Identify LP steam generators & consumers and
then take balance steam from next higher level i.e. MP
steam by let down with PRDS.
◼ • Similarly identify generators & consumers at MP
level & take balance steam by let down from HP level
◼ • Consider generators / consumers at HP level &
take balance by let down of VHP steam.
◼ • Once this balance is completed then a discussion
is held with client to get steam balance approved by
client & further discussion is held on the margin to be
considered for finalizing capacity of boilers/HRSG s.
◼ • Margins (consumption is increased by margin &
generation is reduced) vary from 10- 20 % for different
clients
◼ Add the loss of steam in steam traps etc during the
transfer of steam from CPP to different process units ,
off site storage & flare area by LP, MP & HP headers .
• It varies from 0.5-3% of total steam depending
on climatic conditions of the site.
◼
◼ 1 Typical requirement of VHP/SHP steam in
GCU/NCU of petrochemical complexes
◼ 1.1 Normal & sudden tripping/start up
requirements
◼ • Normal & sudden four furnace tripping steam
requirement in gas cracker are 4.7 & 115 T/HR
respectively. (400,000 TPA of ethylene capacity).
Sudden steam is provided in a very short duration
(with in a minute) to avoid shut down of gas cracker.
◼ Sudden steam is used for drives of Charge gas
compressor, Ethylene & Propylene refrigerant
compressors at minimum (65-70% to avoid surge)
capacity. With this total shut down of GCU/NCU is
avoided.
◼ 1 Intermittent requirements of steam in a
refinery
◼ 1.1 Types of consumption
◼ • Snuffing steam is required to extinguish fire
during sudden shut down in the furnace of any process
unit.
◼ • Requirement of steam for soot blowing to clean
the outside of steam coils in convection zone
◼ • De-coking to remove coke of radiant section of
tubes in burning phase with steam air mixture & then
in a de coking pot for its disposal.
◼ Purging to make the furnace hydrocarbon free during
the shut down of the process unit.
◼ Following typical steam consumption ( client
agreement required):
◼ • Two soot blowers operating at any one time, each
consuming 4.5 T/Hr MP steam.
◼ • One furnace considered to be snuffed at a time. A
peak of 20 T/Hr of LP steam during CDU/VDU
shutdown steam Balance was assumed to be made
available due to shut down of that unit.
◼ • 10 T/Hr of LP steam was considered for other
shutdown units .
◼ Peak purging requirement for the furnaces during the
shut down of CDU /VDU was considered as 9 T/Hr of
MP steam.
◼

◼ • For furnaces in other units, purging

requirement of 4 T/Hr MP steam was
considered.
◼ No provision for de-coking steam was kept. It
was assumed that requirement will be met due
to reduction in the consumption of MP steam
of that particular unit in which furnace is to be
decoked.
 DEAERATOR CALCULATION

◼ 1 Typical De-aerator Calculations Ref fig 2

◼ 1.1 Typical input data
◼ • Surface condensate-45 T/Hr@45 0C,Enthalpy 45
kcal/kg
◼ • saturated condensate-90 T/Hr @95oC,Enthalpy 95
kcal/kg
◼ • BFW-250 T/Hr @ 110oC, Enthalpy 110 kcal/kg
◼ • Assume LP Steam-X T/Hr, Enthalpy 680 kcal/kg
◼ • DM water-Y T/Hr @ 30oC,Enthalpy 30 kcal/kg
◼ Vent from de-aerator say 1 t/hr, Enthalpy 640 kcal/kg
(based on 0.2 kg/cm2g de-aerator pressure)
 DEAERATOR CALCULATION
◼ 1.1 Calculation Procedure
◼ Material balance
◼ IN = OUT
◼ 45+90+X+Y=250+1
◼ X+Y=126
◼ Y=126-X
◼ Enthalpy Balance
◼ 45x45+90x95+(680)X+(126-X)x30=250x110+1x640
◼ X=21.2 T/Hr
◼ Y=126-21.2=104.8 T/Hr
◼ Check
◼ 45x45+90x95+680x21.2+104.8x30=28135
◼ 250x110+640=28140
◼ Hence OK
 Vent 1 T/hr

DM Water Condensate
90 T/hr @ 95oC

Steam
Surface Condensate
45 T/hr @ 45oC

BFW
250 T/hr @ 110oC
 PRDS CALCULATION

◼ 1 Typical PRDS calculations Ref fig 3

◼ 1.1 Typical input data
◼ VHP to HP let down PRDS :
◼ Say 25 T/Hr of HP steam is required ,enthalpy
762 kcal/kg
◼ Assume X T/Hr of VHP steam with enthalpy
811 kcal/kg
◼ BFW Y T/Hr with enthalpy 110 kcal/kg
◼

◼ 1.1 Calculation Procedure

◼ Mass Balance
◼ X+Y=25
◼ Heat Balance
◼ (X) 811+(25-X) 110=25x762
◼ VHP steam BFW HP steam
◼ X (VHP steam)=23.25 T/Hr
◼ BFW=1.75 T/Hr
◼ Similarly other let down (HP to MP & MP to LP)
calculations can be done.
VHP Steam HP Steam
2 o
@ 105kg/cm g and 510 C @ 40kg/cm2g and 400oC

BFW
@ 60kg/cm2g and 110oC
◼ 1 Typical design margins used by
refiners/petrochemical complexes
◼ 1.1 Reasons of keeping margin
◼ • Design margin is provided to take care of
uncertainty in estimate of steam consumption
◼ • Lower temperature @ unit B/L can result in higher
steam consumption in steam turbine due to its lower
enthalpy as compared to design figures.
◼ • Experience of users is that steam consumption is
higher than figures provided by licensor.
◼ GCU, normal requirement of VHP steam (Process
licensor M/S Stone Webster ) is 5T/Hr but most of the
complexes require 40-50 T/Hr.
◼ 1 Typical design margins used by
refiners/petrochemical complexes
◼ 1.1 Reasons of keeping margin
◼ • Design margin is provided to take care of
uncertainty in estimate of steam consumption
◼ • Lower temperature @ unit B/L can result in higher
steam consumption in steam turbine due to its lower
enthalpy as compared to design figures.
◼ • Experience of users is that steam consumption is
higher than figures provided by licensor. •
◼ GCU, normal requirement of VHP steam (Process
licensor M/S Stone Webster ) is 5T/Hr but most of the
complexes require 40-50 T/Hr.
◼ • Reasons of this could be fouling in cracker
furnaces leading to less steam generation from cracked
gases, low temperature steam for compressor drives,
etc.
◼ • VHP steam header is designed for 5/120 T/Hr so
there will be significant loss in temp during normal
operation.
◼ • If GCU is far away from CPP then temp loss in
header will be still higher & any attempt in reducing
temp loss is not possible because pressure drop criteria
is equally important in the design of VHP header.
◼ • For pressure drop calculations, one loop
(4x90degree bends, 2x45degree bends, 10-15m
straight length) is required after every 30m of VHP,
35m of HP, 40m of MP & 45m of LP steam header. This
results in total equivalent length 2-3 times of straight
length.
◼ Temperature drop considers 1.6d for 90 degree bends
& 0.8 d for 45 degree bends of the expansion loop.
◼

◼ 1.1 Typical procedure during power failure

◼ • During power failure, shut off hydrocarbon to all
furnaces. Block in feed control valves and purge lines
with dilution steam, maintain a flow of dilution steam
and inject steam into the pre heat coils on all cracking
furnaces, allowing the flow through the primary
fractionator.
◼ Continue a flow of quench oil for cooling & shut off
heating medium to all towers & exchangers, primary
fractionator and liquid pre heaters.
◼ 1.1 Typical system for emergency boiler
◼ • For emergency boiler, provide one steam
turbine(back pressure type HP to LP let
down)driven BFW pump(hot stand), dual
drive(electric cum steam turbine type)FD fan.
◼ • Auxiliaries of boiler should be connected
to emergency power.
◼ Availability of instrument air (with air receiver)
& condensate/DM water with emergency
power driven pump.
◼
◼ 1 Boiler feed water System
◼ 1.1 Supply of BFW
◼ • Boiler feed water requirement of various process
units is estimated on the basis of their steam
generation quantity after considering blow
down(3%)losses.
◼ • Steam is generated at LP, MP, and HP levels in a
refinery. MP boiler feed water is supplied for low and
medium pressure steam generators. LP level shall use
the same by letting down MP level BFW. HP boiler feed
water is provided for high pressure steam generators.
◼ Typical BFW conditions at B/L of generating and
consumer plant are as follows:
◼ HP Boiler Feed Water
◼ Units Normal Mech.Design
@generating plant B/L
@consumer plant B/L
◼ Pressure Kg/cm2g 60 58 76
◼ Temperature 0C 100-110 100-110 150

◼ MP Boiler Feed Water

◼ Units Normal Mech.Design
@ generating plant B/L
@ consumer plant B/L
◼ Pressure Kg/cm2g 30 28 40
◼ Temperature 0C 100-110 100-110 150
◼ 1.1 Location of De-aerators
◼ • In a typical refinery, De aerator-I is located in the
H2 plant which will cater to the OHCU,H2 plant, CRU &
the S block(SRU,ARU,SWS-I,SWS-II) & BBU
◼ • De-aerator-II shall be located in the FCC unit
which will cater to the FCCU,CDU/VDU,VBU
◼ • In case one of the de aerator is down, BFW
requirement of the complex should be met by the other
de aerator.
◼ • Receipt of condensate at following conditions:
◼ For a typical refinery complex, it was as following:
◼
◆ Units Min. Nor. Max. Mech.Design
◼ PressureKg/cm2g 5.0 8.0 10.0 16.0
◼ Temperature 0C 50 100 150 180
◼

◼ For a typical petrochemical complex, it was as following:

◼ Operating Mech. Design
◼ Pressure 5.5 kg/cm2A 7.5 Kg/cm2A
◼ Temperature 80 0C 100 0C
 CONDENSATE SYSTEM

◼ 1 Condensate System
◼ 1.1 General
◼ • Steam is used in the refinery as process steam,
motive fluid for the steam turbine drives, for heating
etc.
◼ • Condensate results from the condensing steam
turbine drives, steam reboilers and ejector condensers.
◼ Provision shall be kept to dump the condensate in the
event of oil break through. Necessary means to
analyze the characteristic of condensate should be
provided in respective units.
 CONDENSATE SYSTEM

◼ •
◼ • Depending on steam side pressure in
shell and tube exchangers, condensate is
termed clean or suspect. With higher pressure
on steam side, condensate has no possibility
of contamination so termed clean.,with lower
steam side pressure ,possibility of
contamination during tube failure can not be
ruled out. Monitoring of condensate for
suspect cases is always done .
 CONDENSATE SYSTEM
◼ 1.1 Types of Condensate
◼ Condensate being generated in a typical refinery ,
which shall be recovered can be classified under
following headings:
◼ 1.1.1 Condensate from exchangers
◼ • Condensate coming from exchangers may be
consuming HP, MP or LP steam.
◼ • Individual units generating HP or MP level
condensate shall flash it to LP level, pump the
condensate at the condensate header pressure(LP
condensate shall be pumped without flashing).
◼ • A single header shall be routed through the
refinery for collection of this condensate.
◼ • This condensate will then be routed to de aerators
with in FCCU and H2 Unit under header pressure
control and flow control respectively.
 CONDENSATE SYSTEM

◼ 1.1.1 Condensate from FCCU

◼ • Quality of condensate from the steam drives need
to be maintained with polisher if required
◼ • Condensate need to be pumped to the de aerator
located in FCCU
◼ 1.1.2 Condensate from H2 plant
◼ • Condensate through the condensation of
unreacted steam injected for reforming in the process
stream and turbine drives.
◼ • It is routed to the de aerator with in the H2 unit.
◼ Polishing of this condensate if required and pumping to
de aerator is required.
 CONDENSATE SYSTEM

◼ 1.1.1 Condensate from OHCU

◼ Condensate obtained from condensing turbine
with in OHCU will be monitored and if found
acceptable shall be routed to H2 unit de-
aerator.
◼ 1.1.2 Condesate from Sulfur block
◼ It shall be recovered and routed through a
common condensate handling facility with in
the sulfur block.
◼ 1.1 Characteristics of condensate/DM water

◼ pH 6.5-7.0
◼ TDS, ppm 0.1
◼ Silica as SiO2, ppm 0.02
◼ Iron as Fe, ppm 0.005
◼ Copper as Cu, ppm 0.005
◼ Conductivity, mmho/cm@20 0C 0.20 max.
 CONDENSATE SYSTEM

◼
◼ 1.1 Condensate recovery
◼ Total recoverable condensate is not considered
for DM water system design.
◼ It is 90% of total surface condensate
generated and 50% of total process
condensate generated.
◼ Condensate system needs to be designed for
total recoverable condensate. The above
mentioned % recovery is considered for design
of DM water system.
 CONDENSATE SYSTEM
◼ 1.1 Condensate Polishing Unit
◼ 1.1.1 Typical system
◼ It consists of:
◼ • Activated Carbon beds optional-when oil
contamination is expected
◼ • Condensate Polishing beds - to remove lowe ionic
loads & hardness and to adjust pH
◼ • Regeneration Facilities-To regenerate cationic and
anionic beds of mixed bed.
◼ • Effluent treatment facilities-To adjust effluent as
per ETP.
◼ • Feed effluent exchanger- to heat polished
condensate
◼ Feed cooler-cooling feed condensate to suitable temp
for activated bed/polishing mixed bed.
 CONDENSATE SYSTEM

◼ Condensate polisher unit shall consist of

standby chain to take care of maintenance ,
repair etc.
◼ Condensate after polishing should go to
polished condensate tank with a capacity
equivalent to two hours storage.
 OPERATING PROBLEMS

◼ 1 Problems faced by clients & their

solution
◼ 1.1 Excessive temperature drop in steam
header
◼ 1.1.1 Problem
◼ • Refinary was experiencing too much of
temperature loss in MP steam header
◼ • Consumption in steam turbine was much
higher than estimate
◼ • Wastage of steam as condensate in the
header
 OPERATING PROBLEMS
◼ 1.1.1 Reasons of problem
◼ • Steam header was being used @ 30 % of design
capacity
◼ • Temperature loss is fixed for particular values of
header size , length of header & insulation thickness .
◼ • The temperature loss assured is for design flow
rate.
◼ • Lower flow rate will experience higher temp drop
due to fixed heat loss through the header
◼ 1.1.2 Solution
◼ • Use the header close to design value
◼ • If header has to be used for very low capacity
then it should be made clear during the design basis
◼ For dual (high and low consumption for flare system or
GCU)capacity users ,two independent headers are
provided to minimize heat loss.
 OPERATING PROBLEMS
◼ 1.1 Damage of HRSG s tube bundle
◼ 1.1.1 Problem
◼ • Damage of HRSG s tube bundle in super heat zone
◼ • Steam generation in the complex was reduced
◼ • Finding problem to start GCU
◼ 1.1.2 Reasons of problem
◼ • Design of HRSG was based on to use GT exhaust
normally & for a short duration during the tripping of
compressor on external fuel.
◼ • UPPC used it continuously with external fuel (gas)
for several months & due to this both HRSG’s tube
bundles in the superheating zone were damaged
◼ • Design of HRSG with external fuel is
having much higher temperature in the super
heat zone than the one with GT exhaust.
◼ • This design was not suitable for operating
HRSG with external fuel
◼ 1.1.1 Solution
◼ Vendor was asked to change the tube bundle
as per external fuel case.
◼ 1.1 Utility boiler not generating design steam
◼ 1.1.1 Problem
◼ Utility boiler not generating steam as per design
◼ 1.1.2 Reasons of problem
◼ • Due to non availability of HRSG, UPPC used their
boiler @ 110 % of design capacity continuously to
meet their steam requirement.(Boiler vendor
mentioned very clearly that boiler can run @ 110 % of
design capacity for two hours in a day.)
◼ 1.1.3 Solution
◼ • Client must follow vendor s instructions
◼ • Steam shortage could have been taken care by
providing proper design margins in the steam system.
◼ Corrective action was done by boiler vendor.
◼ 1.1 Condensate to De-aerator at very high
temperature
◼ 1.1.1 Problem
◼ condensate generated with in the H2 unit was at a very
high temperature so part quantity was being thrown to
make BFW. in de aerator
◼ 1.1.2 Reasons of problem
◼ • During the design of H2 unit client asked for
provision to export 30 T/Hr of HP steam from this unit
to existing refinery’s power plant.
◼ • The export provision was not used by the client
◼ Heat equivalent to 30 T/Hr of HP steam remained in
the hot streams to be cooled.
◼ Solution
◼ • Generate additional 30 t/hr HP steam