9.

Heat Recovery Steam Generator

9.1 Introduction
The Heat Recovery Steam Generator (HRSG) is specifically designed to match the operating
characteristics of the GE gas turbine and provide optimum performance for the total power plant cycle.
The HRSG is designed to be fully integrated into the combined-cycle system and includes required
inlet/outlet ductwork, structural supports, piping and accessories.
Significant features of the HRSG are:
• Fast startup and shutdown capability
• Operational flexibility
• High reliability and availability
• Fuel flexibility
• Environmental compatibility

9.2 General Description

The HRSG is a three-pressure level with reheat, unfired, once through, natural circulation type
configured for horizontal exhaust flow through vertical tube heat transfer sections. The heat transfer
sections are positioned in the exhaust gas flow to achieve optimum exhaust energy utilization based on
thermo-economic considerations.
The HRSG will be supplied by one of the leading HRSG vendors who have been reviewed and approved
by GE. Subsystems including valves, instruments, manufacturing, etc. will be procured by the HRSG
vendors based on the GE approved vendor lists and will not be restricted to the Customer’s approved
vendor lists.
The combined-cycle water, steam and exhaust gas circuits are shown on the Heat Balance Diagram
contained in the “Plant Performance” Tab4 of this document. The HRSG water, steam and exhaust gas
flow arrangements and the control and instrumentation devices which are provided are shown on the
HRSG Flow Diagram of this document. The exact configuration may vary in the final design from that
shown.
Feedwater flows through the heat transfer sections counter to the exhaust gas flow and is progressively
heated, vaporized, then super-heated. The steam leaving the intermediate pressure superheater is
combined with steam returning from the high pressure steam turbine exhaust and reaches final steam
temperature in the reheater section prior to being returned to the steam turbine.
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 a continuous high frequency resistance welding process.
The tube and fin geometry and tube pitch has been selected to match the fuel specification and to
optimize the performance. Alloy tubes are seamless and carbon steel tubes are seamless as well.
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The HRSG pressure part train is an all welded construction from the economizer inlet to the superheater
outlet in the high, intermediate and low pressure sections and reheater section. Direct tube-to-steam
drum joints are eliminated by using a series of headers with interconnecting welded piping connections.
This approach provides a gradual change in pressure part wall thickness which allows the HRSG to
accommodate the temperature changes associated with the transient operation of the gas turbine
(startup, load increases/decreases, shutdown, etc.).
The HRSG casing and ductwork is also an all welded construction, gas tight and stiffened to withstand
internal gas pressure and external loads. The casing and ductwork are internally insulated and lined to
minimize heat loss and provide personnel protection. The outlet duct and stack are externally insulated
and lagged as necessary. The insulation and liner system is selected to meet the environmental design
criteria and the operating parameters of the gas turbine. Localized hot spots in the casing and ductwork
that cannot be avoided will be properly treated with personnel protection as needed by location. The
steam drum and HRSG piping systems are externally insulated and lagged externally in accordance with
the HRSG system design requirements. All insulation, lagging and cladding are provided with the HRSG.
All valves, instruments and accessories necessary for the startup and operation of the HRSG are
provided. In addition, steam/water sample and chemical injection connections are also included with
the system.
A system of platforms, stairways and ladders is provided for inspection and maintenance access to
valves, instrumentation and access doors. Permanent access is provided for components that require
normal and routine access. Access lanes are provided within the HRSG for inspection of the heat
transfer sections and internal piping. Cable openings in the roof of the HRSG are provided to facilitate
inspection and access along the elevation of the heat exchangers.
The HRSG equipment is designed and fabricated in sections consistent with shipping limitations and site
installation requirements.

9.3 Codes and Regulations

The HRSG proper will be designed and fabricated in accordance with the requirements of Section I
(Power Boilers) of the ASME Boiler and Pressure Vessel Code.
The piping systems will be designed and fabricated in accordance with the requirements of ANSI/ASME
B31.1, Power Piping, and ASME, Section I or the Boiler and Pressure Vessel Code.
All valves, instruments and pumps will be designed in accordance with the applicable ANSI/ASME codes.
For purposes of establishing a base, the editions of ASME and ANSI/ASME Codes in effect as of the
original date of this Scope of Work shall be utilized. Where actual design of the equipment to the
requirements of codes and standards mandated by the date of contract award or thereafter result in a
change in the cost of the equipment and/or services provided, the contract price shall be adjusted
accordingly.

9.4 Heat Recovery Steam Generator Major Components

9.4.1 Economizer Sections
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 designed to heat the
feedwater from supply temperature to a temperature slightly less than the saturation temperature
corresponding to the steam drum pressure. The sub-cooled economizer outlet temperature reduces the
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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.
The intermediate pressure economizer outlet also supplies hot water to the fuel gas heater. Fuel gas
heater discharge water is piped to the condenser.

9.4.2 Low Pressure Economizer Recirculation System

A recirculation system is furnished for the low pressure economizer to maintain an inlet feedwater
temperature to protect the HRSG from cold end corrosion based on the fuel specification defined in this
document. The recirculation system consists of two (2) 100% capacity motor driven recirculation pumps
which discharge through a single flow control valve to control the low pressure economizer water inlet
temperature to a preset value. The pump is protected by a minimum flow limit on the flow control valve.

9.4.3 Evaporator Systems

9.4.3.1 Evaporator Systems (Steam Drum and Evaporator Section for IP and LP
Systems)
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 finned 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 operating pressure. The steam/water mixture leaves the evaporator top headers through
pipe connections to the steam drum and is directed to a primary separator where the steam/water
separation occurs. The water discharges downward while the steam rises to a second moisture
separator where final steam purity is reached before leaving the drum.
The steam drum is sized to provide high purity steam to the superheater and to accommodate
evaporator surge during startup and operating transients. Access is provided into the steam drum for
inspection and maintenance at both ends thru doors provided in the drum heads.

9.4.3.2 HP Once Through System

HP system applies once through evaporator system in lieu of steam drum for the steam generation. The
main components in the once through system are a once through heat exchanger and a separator.
The sub cooled water from the economizer tubes is collected at feed water once through manifold and it
is then distributed to the once though tubes by a distribution control system. The once through section
exchanges the sub cooled water into superheated steam. The separator is installed at the downstream
of the once through section to ensure water that may be produced during start up and low plant load
operating conditions not passing through into superheater sections. The collected water in the
separator is recirculated back into the water/steam system or discharged into the blowdown system

9.4.4 Superheater Section(s)

Saturated steam is piped from the steam drum to the superheater inlet header and then flows through a
multi-pass arrangement of finned tubes to the outlet header. The flow of steam is counter to the
exhaust gas flow. The superheater section raises the steam temperature from saturation to a superheat

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temperature consistent with the gas turbine exhaust gas conditions and requirements of the steam
turbine.
A high pressure superheater interstage attemperator, utilizing high pressure feedwater, is provided for
temperature control of the high pressure superheater final steam temperature. Steam temperature in
the IP and LP circuits is uncontrolled.

9.4.5 Reheater Section

Superheated steam from the intermediate pressure superheater is combined with the steam returning
from the high pressure steam turbine exhaust. This combined steam flow is piped to the reheater inlet
header and then flows through a multi-pass arrangement of finned tubes to the outlet header. The flow
of steam is counter to the exhaust gas flow. The reheater section raises the steam temperature to a
superheat temperature consistent with the gas turbine exhaust gas conditions and requirements of the
steam turbine.
A reheater interstage attemperator, utilizing intermediate pressure feedwater, is provided for
temperature control of the reheater final steam temperature.

9.4.6 Ductwork
9.4.6.1 HRSG Inlet Ductwork
The HRSG inlet ductwork is provided to direct the gas turbine exhaust gas from the outlet of the gas
turbine to the HRSG inlet and includes all supports, casing plates, internal insulation and liners and
access doors.

9.4.6.2 HRSG Outlet Ductwork and Stack

HRSG outlet ductwork, expansion joint and stack are provided to direct the gas turbine exhaust gas from
the exit of the HRSG to the atmosphere. The outlet transition duct and stack are uninsulated but will be
provided with personnel protection where necessary at ladders, platforms and test ports. Sampling
ports are provided in the stack for emission testing.
Silencer panels will be installed in the stack as needed to meet the noise levels as defined in this
proposal.
The HRSG Stack height is approximately 60 m from grade.

9.4.7 HRSG Stack Closure

A stack closure damper is provided in the stack for isolation of the gas path to keep the HRSG warm after
shutdown and to provide weather protection. This damper is operated by an electric drive and is
interlocked into the control system for safe operation. The configuration of the damper is failsafe which
will allow the damper blades to open independently of actuator position if the damper differential
pressure is greater than 125 mm (5 in.) of water column.

9.4.8 Blowdown System

One (1) blowdown tank including piping and valves is provided with the HRSG to receive evaporator
section blowdown and water/steam drains from various locations in the HRSG system.
There are three (3) types of blowdown; startup, intermittent and continuous. The startup blowdown is
used to assist in controlling water level in the drums during startup. An intermittent blowdown is used
to reduce the solids that collect in the drums or lower headers if/when larger corrections are needed to

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adjust the water chemistry. The continuous blowdown connection is located just below the low water
level in the high pressure and intermediate pressure steam drums. This blowdown is used during
normal operation in conjunction with the chemical feed system to control the steam drum water
chemistry and final drum steam purity levels.
During blowdown operation, water is blown down into the blowdown tank. This is a water/steam
flashing mixture when it enters the blowdown tank. The steam is vented off the top of the tank. The
discharge water is directly pumped to Plant's sump pit.

9.4.9 Support Structure, Stairways, Ladders and Platforms

The HRSG heat transfer sections, steam drum, inlet/outlet ductwork systems and interconnecting piping
are supported by a support structure designed in accordance with the equipment data, the site
conditions and the applicable structural codes and standards. GE considers that the HRSG support steel
is part of the equipment and not a building structure. The structural steel design considers the
applicable wind and seismic loads, but damage/serviceability limitation requirements, such as
displacement limitations, are not considered to be applicable to the steel design.
Stairways, ladders and platforms are provided for operation and maintenance access to valves,
instrumentation, steam drums, access doors and emission test ports. All stairways and platforms are
provided with handrails and kick plates. Platform grating and stair treads are open style.
Access to the gas path of the HRSG is via access doors located at the lower level of the HRSG.

9.4.10 Piping
HRSG interconnecting piping is provided to transfer the water and steam between the heat transfer
sections and the steam drums. The piping is supported as much as possible from the HRSG support
structure.
In addition, small bore piping is provided to allow for the venting and draining of the various sections
within the HRSG.

9.4.11 Accessories
Instrumentation and valves are provided in accordance with the HRSG Flow Diagram of this document.
In general, automated valves in the HP and Reheat sections will be electrically operated and automated
valves in the IP and LP sections will be pneumatically operated as shown on the HRSG Flow Diagram.
Drum Level Control Valves will be pneumatically operated.
Vents, drains and instrument connections in the HP, Reheater and IP sections will be provided with
double valve isolation. Vents, drains and instrument connections in the LP and Blowdown Tank
systems will be provided with single valve isolation as shown on the HRSG Flow Diagram.
Safety valve and startup vents will be equipped with silencers as needed to meet the noise levels as
defined in this proposal.

9.4.12 Surface Preparation and Coating

The structural steel, casing, and ductwork are provided with a single coat of inorganic zinc rich primer on
the exterior surfaces.
Externally insulated drums and piping are provided unpainted and will be finished with a galvanized or
embossed aluminum exterior lagging system over the insulation during field construction.
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Platform grating and handrails, stairways and ladders are provided galvanized.
Individual valves, instruments and pumps will be supplied finish painted per the individual
manufacturers’ standard.

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