Gop Uty 02a (HRSG)

DOCUMENT : GOP-UTY-2 (A)
Heat Recovery REV. NO. : 00

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Steam Generator EFFECTIVE DATE
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ORIG. PREPARED BY : BK/OSW
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Job Qualification Program
GOP-UTY-02
HRSG , B-2201(A)
A/B
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Prepared By: ____________________________________________

Bilal Khan/Owen Wilfred
Reviewed By: ____________________________________________

Unit Manager(Operations/ Training)
_____________________________________________
Approved By: M. Ali Ansari ( Training & Technology Manager )
Change Record
S No. Rev. Date Page Section Description of Change

No. No.
Distribution List
1 LAN
2 Training Manager (Original Copy
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Content
1. Purpose .................................................................................................................................... 6
2. Abbreviation ............................................................................................................................ 6
3. Technical Terms ....................................................................................................................... 6
4. Introduction of VCM Plant………………………………………………………………………………………………….7
5. Introduction to Power Plant………………………………………………………………………………………….…….8
6. Process Diagram…………………………………………………………………………………………………………….9-10
7. Basic Knowledge (Simple term definitions)……………………………………………………………………11-16
i. Temperature
ii. Pressure
iii. Steam
iv. Saturated Steam
v. Super Heated Steam
vi. Thermodynamics
vii. Internal Energy
viii. Entropy
ix. Enthalpy
x. Deaerator
8. Boiler ....................................................................................................................... 17-22
i. Introduction to Boiler
ii. fuel of boiler
iii. Classification Of Boiler
iv. Why water is used in Boiler
v. Boiler Economizer
vi. Boiler Evaporator
9. HRSG…………………………………………………………..……………………………………………………………………23
i. Introduction to HRSG……………………………………………………………………………………………………23
ii. HRSG Structure……………………………………………………………………………………………………..…24-30
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a. HP superheater
b. HP evaporating pipe bank
c. HP Drum
d. HP economizer
e. LP boiler Evaporating pipe bank
f. LP Dearating Boiler drum
g. Boiler frame
h. Boiler Inlet Flue, Main Stack and Relevant Flue Accessories
iii. HRSG Datasheet………………………………………………………………………………………………………..30-31

iv. HRSG Equipment Description…………………………………………………………………………………….31-44
4.1 Exhaust gas system
4.1.2 GT outlet flue
4.1.3 Three way Diverter damper
4.1.4 Expansion joint
4.1.5 Silencer
4.1.6 Bypass stack
4.1.7 Motor Operated valve
4.1.8 Flow control valve
4.1.9 Pressure Safety valve
v. Startup,Trial and normal operation of the system………………………………………………………45-53
5.1 HRSG Exhaust gas system startup
5.2 HRSG Operation Description
5.2.1 General Description
5.2.2 HRSG Trial Operation requirements and points for attention
5.2.3 Boiling out

5.2.4 Flushing and purging of pipe
5.2.5 Safety Valve Adjustment
5.2.6 HRSG Trial operation
5.2.7 HRSG Normal operation
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5.2.8 HRSG operation under dry firing

vi. HRSG Boiler shutdown .......................................................................................................... 54
i. Temperary Shutdown
ii. Complete Shutdown
iii. Emergency Boiler Shutdown
vii. Routine Operational Checks…………………………………………………………………………………………55-56
i. Routine checks for HRSG exhaust gas system
ii. Attention Item during HRSG operation
iii. HRSG short-term checks
viii. HRSG Maintenance…………………………………………………………………………………………………….56-58

i. HRSG medium repair
ii. Boiler Maintenance
iii. Nitrogen or chemical solution preservation
ix. Design condition and normal parameters .............................................................................. 59

i. weather condition
ii. Design operating conditions
x. Boiler Feed water………………………………………………………………………….60-61

xi. Blow down control………………………………………………………………………...61-62
xii.HRSG(flow diagram)………………………………………………………………………….63
xiii.HRSG (Piping & Instruement Diagram)…………………………………………………..64-69
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1. Purpose
The purpose of this document is to give introduction on the basic parts and operations of C-2410
fuel gas compressor, it’s include basic theory of dynamic and Reciprocating compressor,
operations, mechanical parts, Startup and troubleshooting.
2. Abbreviation
JQP Job Qualification Program
QSP Quality Standard Procedure
SOP Standard Operating Procedure
T/A Trade Apprentice
TAE Trainee Assistant Engineer
HRSG Heat Recovery Steam Generator
UM Unit Manager
CI Craft In charge
TM Training Manager
VP Manu. Vice President Manufacturing
3. Technical Terms
UTY Utility Power Plan

FLA Full load Ampere
VFD Variable frequency drive
PSL Pressure switch low
RPM Revolution per minutes
HP Horse Power
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4. Introduction to VCM Plant
VCM plant at this site is relocated plant from Formosa Plastics Corporation, Baton Rogue, LA,
USA. It is world 2nd relocated VCM plant and Pakistan 1st VCM plant. FPC operated this plant till
2002-2003 and then shutdown it due to economic considerations. VCM is raw material of PVC,
which is a growing industry in this region.
EDC plant technology belongs to Stauffer and VCM to BF Goodrich, now both belong to Ineos
Vinyl.
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5. Introduction to Power Plant
A power station (also referred to as a generating station, power plan powerhouse or generating
plant) is an industrial place for the generation of electric power.[1][2][3] At the center of nearly
all power stations is a generator, a rotating machine that converts mechanical power
into electrical power by creating relative motion between a magnetic field and a conductor. The
energy source harnessed to turn the generator varies widely. It depends chiefly on which fuels
are easily available, cheap enough and on the types of technology that the power company has
access to. Most power stations in the world burn fossil fuels such as coal, oil, and natural gas to
generate electricity, and some use nuclear power, but there is an increasing use of cleaner
renewable sources such as solar, wind, wave and hydroelectric. Central power stations
produce AC power, after a brief Battle of Currents in the 19th century demonstrated the
advantages of AC distribution.
In electric power generation a combined cycle is an assembly of heat engines that work in
tandem from the same source of heat, converting it into mechanical energy, which in turn usually
drives electrical generators. The principle is that the exhaust of one heat engine is used as the
heat source for another, thus extracting more useful energy from the heat, increasing the
system's overall efficiency. This works because heat engines are only able to use a portion of the
energy their fuel generates (usually less than 50%). In an ordinary (non combined cycle) heat
engine the remaining heat (e.g., hot exhaust fumes) from combustion is generally wasted.
Combining two or more thermodynamic cycles results in improved overall efficiency, reducing
fuel costs. In stationary power plants, a widely used combination is a gas turbine burning natural
gas or synthesis gas from coal, whose hot exhaust powers a steam power plant .This is called a
Combined Cycle Power Plant (CCPP)
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General Process Description

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6. BASIC KNOWLEDGE
SIMPLE TERMS (DEFINITIONS)
I. TEMPERATURE
II. PRESSURE
III. STEAM
IV. SATURATED STEAM
V. SUPER HEATED STEAM
VI. THERMODYNAMICS
VII. INTERNAL ENERGY
VIII. ENTROPY
IX. ENTHALPY
X. DEAERATOR
TEMPERATURE
Temperature is a physical property of a system that underlies the common notions of hot and
cold; something that is hotter generally has the greater temperature. Specifically, temperature is
a property of matter. Temperature is one of the principal parameters of thermo.
PRESSURE
Pressure (symbol: 'p') is the force per unit area applied to an object in a direction perpendicular
to the surface. Gauge pressure is the pressure relative to the local atmospheric or ambient
pressure.
STEAM
In physical chemistry, and in engineering, steam refers to vaporized water. It is a pure, completely
invisible gas. At standard temperature and pressure, pure steam (unmixed with air, but in
equilibrium with liquid water) occupies about 1,600 times the volume of an equal mass of liquid
water. In the atmosphere, the partial pressure of water is much lower than 1 atm , therefore
gaseous water can exist at temperatures much lower than 100 °C (212 °F)
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In common speech, steam most often refers to the white mist that condenses above boiling
water as the hot vapor ("steam" in the first sense) mixes with the cooler air. This mist is made of
tiny droplets of liquid water, not gaseous water, so it is no longer technically steam.
SATURATED STEAM
Saturated steam is steam at equilibrium with liquid water. It occurs when the steam quality is
100% without going into the super-heated region. It is indicated by the left hand side of the
pressure-enthalpy inverted bell curve.
SUPER HEATED STEAM
Superheated steam is steam at a temperature higher than its saturation temperature. If

saturated steam is heated at constant pressure, its temperature will rise, producing superheated
steam. This will occur if saturated steam is exposed to a surface with a higher temperature The
steam is then described as superheated by the number of temperature degrees through which it
has been heated above saturation temperature. Superheated steam and liquid water cannot
coexist under thermodynamic equilibrium, as any additional heat simply evaporates more water
and the steam will become saturated steam. However, under dynamic conditions some degree of
superheating is often possible.
THERMODYNAMICS
In physics, thermodynamics (from the Greek therme, meaning "heat" and dynamis, meaning
"power") is the study of the transformation of energy into different forms and its relation to
macroscopic variables such as temperature, pressure, and volume
INTERNAL ENERGY
The sum of all microscopic forms of energy of a system. It is related to the molecular structure
and the degree of molecular activity and may be viewed as the sum of kinetic and potential
energies of the molecules; it comprises the following types of energy.
Type Composition of Internal Energy (U)
Sensible energy The portion of the internal energy of a system associated with kinetic energies
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(molecular translation, rotation, and vibration; electron translation and spin;

and nuclear spin) of the molecules.
Latent energy The internal energy associated with the phase of a system.
Chemical energy The internal energy associated with the different kinds of aggregation of
atoms in matter.
Nuclear energy The tremendous amount of energy associated with the strong bonds within
the nucleus of the atom itself.
Energy Those types of energies not stored in the system (e.g. heat transfer, mass
interactions transfer, and work), but which are recognized at the system boundary as they
cross it, which represent gains or losses by a system during a process.
Thermal energy The sum of sensible and latent forms of internal energy.
ENTROPY
In thermodynamics (a branch of physics), entropy, symbolized by S, is a measure of the

unavailability of a system’s energy to do work. The second law of thermodynamics states that
entropy in the combination of a system and its surroundings (or in an isolated system by itself)
increases during all spontaneous chemical and physical processes. Spontaneity in chemistry
means “by itself, or without any outside influence”, and has nothing to do with speed
ENTHALPY
In thermodynamics and molecular chemistry, the enthalpy (denoted as H, h, or rarely as χ) is a

quotient or description of thermodynamic potential of a system, which can be used to calculate
the "useful" work obtainable from a closed thermodynamic system under constant pressure and
entropy.
The term enthalpy was composed of the prefix en-, meaning "to put into" and the Greek word -
thalpein, meaning "to heat", although the original definition is thought to have stemmed from
the word "enthalpos
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INTRODUCTION TO BOILER
BOILER DEFINITION
A boiler is a closed pressure vessel in which a fluid is heated for use external to itself by the direct
application of heat resulting from the combustion of fuel (solid, liquid, or gaseous) or by the use
of electricity or nuclear energy.
BOILER CLASSIFICATIONS
Fire-tube boiler
Here, water partially fills a boiler barrel with a small volume left above to accommodate the
steam (steam space). This is the type of boiler used in nearly all steam locomotives. The heat
source is inside a furnace or firebox that has to be kept permanently surrounded by the water in
order to maintain the temperature of the heating surface below the boiling point. The furnace
can be situated at one end of a fire-tube which lengthens the path of the hot gases, thus
augmenting the heating surface which can be further increased by making the gases reverse
direction through a second parallel tube or a bundle of multiple tubes (two-pass or return flue
boiler); alternatively the gases may be taken along the sides and then beneath the boiler through
flues (3-pass boiler). In the case of a locomotive-type boiler, a boiler barrel extends from the
firebox and the hot gases pass through a bundle of fire tubes inside the barrel which greatly
increase the heating surface compared to a single tube and further improve heat transfer. Fire-
tube boilers usually have a comparatively low rate of steam production, but high steam storage
capacity. Fire-tube boilers mostly burn solid fuels, but are readily adaptable to those of the liquid
or gas variety.
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Water-tube boiler
Tubes connect large drums, the lower ones containing water and the upper ones, steam and
water; in other cases, such as a monotube boiler, water is circulated by a pump through a
succession of coils. In this type, tubes filled with water are arranged inside a furnace in a number
of possible configurations: often the water is type generally gives high steam production rates,
but less storage capacity than the above. Water tube boilers can be designed to exploit any heat
source and are generally preferred in high pressure applications since the high pressure
water/steam is contained within small diameter pipes which can withstand the pressure with a
thinner wall.
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POWER (HIGH PRESSURE) BOILER
A power boiler is a steam or vapor boiler operating above 15 psig (1.05 kg/cm 2); this also includes
hot-water-heating or hot-water-supply boilers operating above 160 psi (11.25 kg/cm2) or 250
degree Fahrenheit (121.1 °C). Power boilers are also called high-pressure boilers.
LOW-PRESSURE BOILER
A low-pressure boiler is defined as a steam boiler that operates below 1.05 kg/cm 2 pressure or a
hot-water boiler that operates below 11.25 kg/cm2 or 121.1 °C.
HOT-WATER-HEATING BOILER
A hot-water-heating boiler is a boiler in which no steam is generated, but from which hot water is
circulated for heating purposes and then returned to the boiler. It operates at a pressure not
exceeding 11.25 kg/cm2 or a water temperature not over 121.1 °C at or near the boiler outlet.
These types of boilers are considered low-pressure heating boiler.
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HOT-WATER-SUPPLY BOILER
A hot-water-supply boiler is completely filled with water and furnished hot water to be used
externally (not returned) at a pressure not exceeding 11.25 kg/cm2 or a water temperature not
exceeding 121.1 °C. These types of boiler are also considered low-pressure boilers. No steam is
used from such boiler.
WASTE-HEAT BOILER
A waste-heat boiler uses by-product heat such as from a blast furnace exhaust in a steel mill or
exhaust from a gas turbine or by-products from a manufacturing process. The waste heat is
passed over heat-exchanger surfaces to produce steam or hot water for conventional use.
The same basic ASME code construction rules apply to waste-heat boilers as are applied to fired
units, and the usual auxiliaries and safety system are provided. Features normally require on a
boiler are also required for a waste-heat unit.
PACKAGED BOILER
A packaged boiler is a completely factory-assembled boiler. It includes boiler firing apparatus,
controls, and boiler safety apparatus. A shop-assembled boiler is less costly than a field erected
unit of equal steaming capacity. While a shop-assembled boiler is not an off-the-shelf item,
generally it can be put together and delivered much faster than a field erected boiler. Installation
and start-up times of package boiler are substantially shorter as compared to other. Shop-
assembled work usually can be better-supervised and done at lower cost. The packaged boiler
can be waste heat or fired type.
SUPERCRITICAL BOILER
A Supercritical boiler operates above the supercritical pressure of 3206.2 psia
(224.4 kg/cm2 G) and 705.4 °F (374.1 °C) saturation temperature. Steam and water have a critical
pressure at 224.4 kg/cm2 G. At this pressure, steam and water are at the same density, which
means that the steam is compressed as tightly as the water. When this mixture is heated above
the corresponding saturation temperature of 374.1 °C for this pressure, dry, superheated steam
is produced to do useful high-pressure work. This dry steam is especially well suited for driving
turbine generators.
STEEL BOILER
Steel boilers can be of the high-pressure or low-pressure type and today are usually of welded
construction. They are subdivided into two classes:
1. In fire-tube boilers, the products of combustion pass through the inside of tubes
with the water surrounding the tubes.
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2. In water tube boilers, the water passes through the tubes, and the products of
combustion pass around the tubes.
NOTE: The boilers may also be classified according to the type of fuel they are
operating. For example,
- Gas fired boiler
- Oil fired boiler
- Dual fired boiler
- Bagasse fired boiler
- Coal fired boiler. etc.
They are so many other types of boiler classification based on the design of
construction. For example, vertical drum boilers, Horizontal drum boilers, bend
tubes boilers, once through boiler etc.
Advantages of Water Tube Boiler:

 High capacity.
 High pressure and temperature.
 Good Efficiency.
Dis-Advantages of Water Tube Boiler:
 High initial cost.
 Operational difficulties.
 High maintenance cost.
QUALITIES OF A GOOD BOILER
1) Strong and simple construction

2) Even distribution of water to all its water areas and circulation is such that its material
remains nearly at same temperature.
3) Big heating surface area.
4) Good combustion chamber for better mixing of fuel and burning.
5) Maximum steam space available.
6) All areas accessible
7) Workman ship & material of highest standard.
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Why water is used in Boiler:
 Water is a cheap medium.

 Available at everywhere.
 Boils at relatively low temperature.
 Non-Toxic, Hazardous or Combustible.
 On boiling it volume increases about 1600 times.
Boiler Economizer:
In boilers, economizers are heat exchange devices that heat fluids, usually water, up to but not
normally beyond the boiling point of that fluid. Economizers are so named because they can
make use of the enthalpy in fluid streams that are hot, but not hot enough to be used in a boiler,
thereby recovering more useful enthalpy and improving the boiler's efficiency. They are a device
fitted to a boiler which saves energy by using the exhaust gases from the boiler to preheat the
cold water used to fill it (the feed water).
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Boiler Evaporator:
The goal of evaporation is to vaporize most of the water .In an evaporator using tubing, after the
water begins to boil, bubbles will rise and cause circulation, facilitating the separation of the
liquid and the vapor at the top of the heating tubes. The amount of evaporation that takes place
depends on the temperature difference between the water and the heat.
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DEAERATOR
A DE aerator is a device that is widely used for the removal of air and other dissolved gases from
the feed water to steam generating boilers. In particular, dissolved oxygen in boiler feed waters
will cause serious corrosion damage in steam systems by attaching to the walls of metal piping
and other metallic equipment and forming oxides (rust). It also combines with any dissolved
carbon dioxide to form carbonic acid that causes further corrosion. Most deaerators are designed
to remove oxygen down to levels of 7 ppb by weight (0.0007 cm³/L) or less. There are two basic
types of deaerators, the tray-type and the spray-type.
 The tray-type (also called the cascade-type) includes a vertical domed deaeration section
mounted on top of a horizontal cylindrical vessel which serves as the deaerated boiler
feed water storage tank.
The spray-type consists only of a horizontal (or vertical) cylindrical vessel which serves as
both the deaeration section and the boiler feed water storage tank
Spray Type Dearator

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TRAY TYPE DEAERATOR
PRINCIPLES OF DEAERATION
The solubility of gases in water decreases with an increase in temperature of liquid. The partial
pressure of vapor increases and consequently decreases the solubility of dissolved gases in the
water.
There is a physical law, which states that the solubility of any gas in a liquid is directly
proportional to the partial pressure of gas above the liquid surface.
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Experience has shown that more rapid and more complete removal of non-condensable gases
from a liquid is obtained when the liquid is vigorously boiled or scrubbed by condensable or
carrier gas bubbles.
Therefore the de aerator must,
 Heat the feed waters to as high a temperature as possible; i.e. to the temperature
corresponding to the steam pressure.
 Vigorously boil and scrub the water with fresh steam which can carry to the liquid surface
any traces of O2 or CO2.
 Maintain the partial pressure of the O2 and CO2 in the steam atmosphere as low as
possible, particularly at the point where the de aerator water separates from the steam.
 Continually withdraw non-condensable gases from the heater at the rate at which they
are being liberated.
 Have an efficient vent condenser to concentrate the non-condensable gas mixture in the
vapor as it leaves the heater in an attempt to avoid wasting steam.
VENT PIPING OF DE AERATOR

The vent piping should be installed with no sharp bends or traps that could obstruct the flow of
gases. The ideal vent pipe rises vertically from the heater to the valve located above the junction
of the vessel in a short length of pipe above the valve. This is normally satisfactory where a slight
amount of steam vapor can be tolerated in the area of the de-aerating heater. Where this is not
possible, and it becomes necessary to pipe the vent line to the outside atmosphere, precautions
must be taken to avoid consistently long lines with a great number of turns. Horizontal runs
should be avoided whenever possible and, where necessary, should have a slight slope toward
the heater and a drip line at the lowest point to permit draining of condensate from the vent line.
VENTING PROCEDURE
The valve should normally be open one or more turns to allow for complete removal of the gases.
To determine the correct amount of piping required, the vent valve should be set approximately
½ stem travel and the effect on the operating temperature noted.
If no appreciable effect on the temperature is noted after a period of one hour, oxygen tests
should then be made to determine the effectiveness of venting; satisfactory reduction of oxygen
is obtained when tested by a recognized sampling and testing procedure.
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Tightening the vent can further decrease the vent setting of the valve can be further decreased
by tightening the vent outlet the temperature of the steam shown in a thermodynamic table, the
indication is that venting is not adequate and that the vent valve must be opened further. In
EAPCL an RO. is installed at d/s of vent valve to control the velocity of steam and adequate
venting of steam. The vent valve must be opened & car sealed.
9. Heat Recovery Steam Generator (HRSG)
i. Introduction to HRSG:
A heat recovery steam generator or HRSG is a heat exchanger that recovers heat from a hot gas
stream. It produces steam that can be used in a process or used to drive a steam turbine. A
common application for an HRSG is in a combined-cycle power station, where hot exhaust from a
gas turbine is fed to an HRSG to generate steam which in turn drives a steam turbine. This
combination produces electricity more efficiently than either the gas turbine or steam turbine
alone. The HRSG is also an important component in cogeneration plants. Cogeneration plants
typically have a higher overall efficiency in comparison to a combined cycle plant. This is due to
the loss of energy associated with the steam turbine
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Exhaust Stack
By Pass Stack
st of three major components. They are the Evaporator, Super heater, and Economizer. The
different components are put together to meet the operating requirements of the unit.HRSGs
can also have diverter valves to regulate in the inlet flow into the HRSG. This allows the gas
turbine to continue to operate when there is no steam demand or if the HRSG needs to be taken
offline
ii. HRSG Structure
HRSG mainly include components such as

a. HP super heater.
b. HP evaporating pipe bank
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c. HP Drum
d. HP economizer
e. LP boiler Evaporating pipe bank
f. LP Dearating Boiler drum
g. Boiler frame
h. Boiler Inlet Flue, Main Stack and Relevant Flue Accessories
LP Dearator
LP Drum MP Drum HP Super heater

Header
View of main component of HRSG

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A Typical HRSG
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HP Super heater
A super heater is a device in a boiler that heats the steam generated by the boiler again,
increasing its thermal energy and decreasing the likelihood that it will condense inside the
engine. Super heaters increase the efficiency of the boiler, and were widely adopted. Steam
which has been superheated is logically known as superheated steam; non-superheated steam is
called saturated steam or wet steam.
The structure of double-header vertical helical finned pipe heating surface piping panel is
employed for the HP super heater. The pipe diameter of both upper and lower header is 219mm.
The helical finned pipes and the headers are welded together into the heating surface piping
panels. The six rows of pipe banks are arranged staggerly and divided into two groups of three
rows each. The communicating pipes are provided b/w two headers and spray water
desuperheater is arranged at the back of the outlet header, moreover, the blow-down valve pipe
seating and drain pipe seating and drain pipe joint are arranged separately on the outlet header
and the connecting pipes.
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HP Superheater
Header
Two steam flow paths along with steam intersects flue gas twice at the flow direction are formed
b/w the heating surface piping panel and its communicating pipe. The saturated steam joint is
used on the super heater inlet header and safety valve, pressure gauge, thermometer, blow-
down valve pipe seating, nitrogen filled pipe joint, emergency blow-down pipe joint and back-
wash pipe joint are on the outer header of super heater
.
a. HP Evaporating Pipe Bank
employed for the HP evaporating pipe bank. The pipe diameter of upper and lower header is
159mm. The helical finned pipes and the headers are welded together into the heating surface
piping panels. The twenty rows of pipe banks are arranged staggerly and divided into two groups
of three rows each. The upper headers of HP boiler evaporating pipe bank and the lower headers
of that are separately connected with the drum and with the connecting header at the bottom of
boiler by communicating piping. The down-comers are arranged b/w the drum and the
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connecting header. The drum, six groups of double-header heating surface piping panels, the
connecting headers, upper and lower communicating pipes and the down-comers constitute
boiler-water natural circulation circuit. The periodic blow-down pipe joint is provided for the
connecting header at the bottom of boiler.
b. HP Drum
HP drum is horizontal type. The inner diameter of drum body is 12mm. The drum body and head
are both made of 20g. Located on the drum are the safety valve, the pressure gauge, the blow-down
valve pipe seating, the primary steam and the secondary steam pipe joints, the water level meter joint,
the feed water joint, the chemical dosing pipe joint, the continuous blow-down joint, emergency drain
pipe joint, the nitrogen-filled pipe joint and the economizer recirculating pipe joint. The saturated steam
sampler is supplied in the primary steam pipe joint.
The primary separating component under-water orifice plate, the secondary separating
component dry screen and the uniform-steam orifice plate steam-water separator as well as the
feed water pipe, the chemical dosing pipe, the continuous blow-down pipe are included in the HP
drum internals
c. HP Economizer
employed for the HP economizer. The pipe diameters of both the upper header and the lower
header are 159mm. The helical finned pipes and the headers are welded together into the
heating surface piping panel. The pipe banks are arranged staggerly and each upper header is
supplied with one piece of horizontal division plate. The ten feed water flow paths along which
feed water intersects flue gas five times at the flow direction are formed in economizer. The drain
pipe joint is used for the lower header of economizer and the feed water joint as well as
recirculating pipe joints are arranged on the inlet of the economizer.
d. LP Boiler Evaporating Pipe Bank

employed for the LP boiler evaporating pipe bank. The pipe diameters of both the upper and
lower headers are 159mm. The helical finned pipe and I the header are welded together into the
heating surface piping panel. The eleven rows of the pipe banks are arranged staggerly and are
divided into four groups. The upper headers of the evaporating pipe banks are connected with LP
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drum by communicating pipes or communicating header, the lower headers are connected with
the connecting header at the bottom of boiler by communicating pipes and down-comers are
arranged between LP drum and the connecting header. LP drum, three groups of double-header
heating surface pipes, the connecting headers, the upper communicating pipes, the lower
communicating pipes and the down-comer constitute natural circulation circuit. The blow-down
pipe joint is provided for the connecting header at the bottom of the boiler.
e. LP Deaerating Boiler Drum
The inner diameter of the LP deaerating boiler drum is 2000mm. The drum body and head are
both of horizontal type and made of 20g. Located on the drum are the safety valve, pressure
gauge, blow-down valve pipe seating, primary steam join, water level meter, feed water joint,
chemical dosing joint, continuous blow-down pipe.
f. Boiler Frame
The integrated frame is adopted for the boiler frame. The beams and the columns are welded
together with boiler outer casing as a whole.
g. Boiler Inlet Flue, Main Stack and Relevant Flue Accessories
Boiler inlet flue which is supplied with flue deflector is used for leading G.T. exhaust gas into
HRSG which can ensure good flow distribution, low flue gas resistance, high sealing quality and
high capability to withstand heat shock.
The flue accessories include the expansion joints at every location and all kinds of connections
which can ensure each section of flue free expansion under the high temperature conditions and
can meet the needs of supervising and controlling connections.
The height of main stack is determined as 30m in consideration of needs of flue gas discharge.
The main stack will be divided into three sections for transportation. Flange connection will be
performed b/w two sections and after this sealing weld would be conducted.
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iii. HRSG DATA SHEET
No. Item Unit Value

1 Ambient Temperature C 25
2 Atmospheric Pressure Mbar 993
3 Relative Humidity % 45
4 G.T fuel - NG
5 G.T Load % 100
G.T Exhaust
6 C 564
Temperature
7 G.T Exhaust flow rate t/h 321.522
Nitrogen Nm3/h 188740
Oxygen Nm3/h 34027
G.T Exhaust
8 CO2 Nm3/h 8592
Composition
Water Nm3/h 20028
Argon Nm3/h 2241
Boiler Rated Steam
9 MPa 3.82
Pressure
Boiler Rated
10 C 450
Temperature
Boiler Rated Steam
11 t/h 47.6
Output
12 Deaerator Pressure MPa 0.065
Deaerator Steam
13 t/h 8.44
Output
14 Boiler Blow-down rate % 1
15 BFW Temperature C 113.9
Condensate
16 C 39
Temperature
17 Feed water flow t/h 27.3
Make up Water
18 C 20
Temperature
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19 Condensate Flow t/h 23.6

Boiler Exhaust
20 C 125.7
Temperature
Heat Recovery
21 % 81.3
Utilization Efficiency
iv. HRSG EQUIPMENT DESCRIPTION
4.1. Exhaust Gas System
The exhaust gas system includes G.T. outlet flue, three way diverter damper, expansion joint,
bypass stack steel frame, transition flue, silencer and bypass stack.
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4.1.2. G.T. Outlet Flue
It assumes an outside reinforced and internal-insulated construction. Its outer shells are made of
carbon steel plates of 6mm in thickness and are welded together. The shape steel is used as
reinforced frame on its outer surfaces. The inner casing of flue gas side is made of alloyed steel
plates of 2mm in thickness. The inner casing is overlapped section by section in order to ensure
free thermal expansion. The insulating layers of 160mm in thickness are laid out b/w two layers
of steel plates. The silicate aluminium fiber felts added up with rock wool felts are selected for
insulating materials. The inner casing and outer casing are connected by insulating pins.
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Types of Damper
All systems require dampers to control or shut off the flow of gases. The degree of effectiveness in which
this is done influences the operation of the complete system.
It is imperative that the dampers are properly designed and engineered so they will effectively complement
other system components and withstand the high temperature, pressure and corrosive gas common in
today’s process systems.
A damper for boiler flue gas service can have three basic functions. Dampers modulate gas flow, divert gas
flow into an alternate duct system, or isolate equipment. There are three basic types of dampers:
• Louver
• Guillotine, or gate type
• Diverter, or flap
Each type, in its basic form, is designed for a certain function. Louvers are primarily intended for modulating
gas flow. Guillotines are for open / close isolation service only. Diverters / Flaps have been successfully
applied as an effective isolator and also to provide modulation along with primary function of flow diversion.
Diverter damper
Although any two dampers can be used to divert flow, Diverter dampers are a common way to
divert a flow of gas from one outlet to another.
Diverter dampers are simple and can withstand high temperatures. The blade is located out of
the gas stream, so erosive particles do not impact directly on the surface. Disadvantages include
the large side of the frame and drive, and flutter of the blade when moving across the flow or
when splitting flow between outlets.
The frame of a diverter damper represents a large piece of ducting with a branch in it. This frame
requires reinforcement to ensure that the seal seats will retain reasonable flatness at
temperatures near 900°F.
The blade itself is built up to give stiffness for tight sealing and flutter resistance. Hinging of the
blade is at the duct top and at the aperture edge farthest from the source of hot gas. This
mounting allows upstream pressure to help seat the blade tightly.
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One type of a seal consists of a tadpole-type gasket or rolled-up Inconel fiber sheet, which is
compressed by the closing blade. The blade strikes a metal bar stop, so the gasket is not
compressed beyond the desired shape. The gasket completely surrounds the exit port, leaving a
clearance along the duct wall, so the blade can swing freely.
Diversion of gas-turbine exhaust is not the only application for the swinging blade damper. In a
straight duct, it can act as a bypass damper, as in flue gas desulfurization work.
Advantages of Diverter Dampers:
• Good isolation
• Low pressure drop across the wide open damper
• Flow modulation may be possible
• Good for high temperature applications
• Blade can be insulated to mitigate condensation
• Seal air requirements lower than with louver type
Disadvantages of Diverter Dampers
• Movement is slow
• a large frame structure required
• Sensitivity of attitude is higher than for the louver damper
• Linkages exposed to flue gas
• not much experience in coal-fired boiler applications
•Generally more costly than either the louver or guillotine on a per unit basis
A Gas Flow Diverting Damper is a three way damper ideally suited for gas flow diversion in bypass
systems and is used for alternate isolation. A diverter replaces two guillotines or louver dampers
and is very cost effective as it utilizes a duct transition piece providing three ports. Only one
actuator system is required, simplifying flow control and making improper isolation impossible.
They are used widely in bypass stacks of gas turbine combined cycle plants. The frame of a
swinging blade damper represents a large piece of ducting with a branch in it. This frame requires
reinforcement to ensure that the seal seats will retain reasonable flatness at elevated
temperatures. The blade itself is built to give stiffness for tight sealing and flutter resistance. The
hinging of the blade is at the top of the duct and at the aperture edge farthest form the source of
hot gas. This mounting allows upstream pressure to help seat the blade tightly.
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4.1.3. Three-way Diverter Damper
It is driven by Electric Motor with single valve plate as well as dual-seal, i.e. flexible metallic hard
seal and air seal. It has following rating,
Design Temperature: 5000C

Design Pressure: 3400Pa
Nominal area of operating course: 8m2
Operating duration of valve plate: 90 second
Working medium: Flue gas
Leakage rate: < 0.5%
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Three-way
Diverter
Damper
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Three way diverter Damper
Dual sealing system is also provided on both sides of valve plates. The flexible metallic sealing
sheets are adopted for the sealing parts. High-pressure air will be fed into the space b/w two
rows of sealing sheets in order to provide a compact and highly efficient seal. Two sealing air fans
(one in operation and the other at standby) are needed for this system.
The three-way diverter dampers are provided with main drive shafts with four-linkage device.
The main drive shaft is arranged on the bypass side so as to guarantee that there is no restraint
for damper action when HRSG is at full-open location, thus, decreasing the pressure loss.
An electrical driven device with worn gear reducer is supplied at the end of the pivot. The torque
output produced by electrical-driven devices is transmitted by ways of main shaft and four-
linkage device to open and close the valve plates. The main drive shaft and four-linkage device
are both made of alloyed steel. The specially fabricated gland packing is used on the ends of shaft
to provide reliable sealing of through-wall holes.
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The self-aligning bearing is used for main bearing. The self-lubricating ball bearing is arranged on
the four-linkage device in order to ensure the flexible hot state operation of transmitting system.
The alloyed steel is selected for valve plate frames on both sides of which two pieces of sealing
plates with insulating layer are arranged. The two pieces of sealing plates are used separately for
flue gas separation on the boiler side and the bypass side. Moreover, the two pieces of sealing
plates both provide a free expansion.
The shell is of self-supporting construction. The bottom foot-plate supports the overall weight. A
positioning support is arranged in the middle of the shell, except which, other parts can slide. The
outer shell is made of steel plates and welded with shape-steel reinforced frames so as to ensure
the integral stiffness. 140mm thickness fiber insulating layers are laid out on the inner side of the
shell. The alloy net sheets are selected for the inner side of the shell to protect inner casing. The
overlapping type is also adopted for the inner casing to provide convenience of free expansion
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4.1.4. Expansion Joint
Expansion Joint
Outside the three flanges of the three-way diverter damper, the expansion joints are provided.
This joint allows free expansion of Boiler setting towards Stack. Its non-metallic and internal-
insulating type ensures good absorbability and expandability.
4.1.5. Silencer
The silencer is absorption type with low-frequency noise. Equipped in the steel-fabricated is the
removable sound-absorbing slice. The frame of sound-absorbing slice is made of alloyed steels
filled with some fiber sound-absorbing materials.
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4.1.6. Bypass Stack
The bypass stack is made of steel plates and equipped with reinforced ring. Because of an
elevation of 30m at the outlet of bypass stack, the bypass stack is divided into several sections
with ease of transportation and erection. Each segment are flanged first and then welded for
sealing.
By pass
stack
4.1.7. Motor Operated Valve
Motor Operated Valve (MOV) is an important item of Plant & Piping system. These valves are
generally of large size and are used for different applications such as Pump discharge etc. Motor
Operated Valves are often called as On-Off valves as the motors serve the purpose of fully
opening or fully closing valves in pipelines. For example, cooling water lines, process pipelines
where controlling of fluid is not required, motor operated valves can be used to fully allow or
fully stop the fluid flow. These valves are not used for throttling purposes as they serve mainly
On-Off service application.
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Motor operated valves can be of various types e.g. Gate/ Ball/ Butterfly etc. with actuator
control. Design of Motors and valves can be different. An electric motor is mounted on the valve
and geared to the valve stem so that when the motor operates the valve will open or close. For
this MOV, motor operated with actuator control from local panel or, from control room is
required. There is a requirement of co-ordination among Piping-Electrical-Instrumentation-
Process engineers and vendor for design and procurement of such motor operated valves.
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4.1.8. Flow Control Valve
A flow control valve regulates the flow or pressure of a fluid. Control valves normally respond to
signals generated by independent devices such as flow meters or temperature gauges.
Control valves are normally fitted with actuators and positioners. Pneumatically-actuated globe
valves and Diaphragm Valves are widely used for control purposes in many industries, although
quarter-turn types such as (modified) ball, gate and butterfly valves are also used.
Control valves can also work with hydraulic actuators (also known as hydraulic pilots). These
types of valves are also known as Automatic Control Valves. The hydraulic actuators will respond
to changes of pressure or flow and will open/close the valve. Automatic Control Valves do not
require an external power source, meaning that the fluid pressure is enough to open and close
the valve. Automatic control valves include: pressure reducing valves, flow control valves, back-
pressure sustaining valves, altitude valves, and relief valves. An altitude valve controls the level of
a tank. The altitude valve will remain open while the tank is not full and it will close when the
tanks reaches its maximum level. The opening and closing of the valve requires no external power
source (electric, pneumatic, or man power), it is done automatically.
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Process plants consist of hundreds, or even thousands, of control loops all networked together to
produce a product to be offered for sale. Each of these control loops is designed to keep some
important process variable such as pressure, flow, level, temperature, etc. within a required
operating range to ensure the quality of the end product. Each of these loops receives and
internally creates disturbances that detrimentally affect the process variable, and interaction
from other loops in the network provides disturbances that influence the process variable. To
reduce the effect of these load disturbances, sensors and transmitters collect information about
the process variable and its relationship to some desired set point. A controller will then process
this information and decides what must be done to get the process variable back to where it
should be after a load disturbance occurs. When all the measuring, comparing, and calculating
are done, some type of final control element must implement the strategy selected by the
controller. The most common final control element in the process control industries is the control
valve. The control valve manipulates a flowing fluid, such as gas, steam, water, or chemical
compounds, to compensate for the load disturbance and keep the regulated process variable as
close as possible to the desired set point
4.1.9. Pressure Safety Valve
A safety valve is a valve mechanism which automatically releases a substance from a boiler,
pressure vessel, or other system, when the pressure or temperature exceeds preset limits.
It is one of a set of pressure safety valves (PSV) or pressure relief valves (PRV), which also includes
relief valves, safety relief valves, pilot-operated relief valves, low pressure safety valves, and
vacuum pressure safety valves.
Safety valves were first used on steam boilers during the Industrial Revolution. Early boilers
operating without them were prone to accidental explosion.
Vacuum safety valves (or combined pressure/vacuum safety valves) are used to prevent a tank
from collapsing while it is being emptied, or when cold rinse water is used after hot CIP (clean-in-
place) or SIP (sterilization-in-place) procedures. When sizing a vacuum safety valve, the
calculation method is not defined in any norm, particularly in the hot CIP / cold water scenario,
but some manufacturers have developed sizing simulations.
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Basic Component of Safety Valve

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Safety Valve at HRSG MP drum
Pressure
Safety valve
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V. Startup, Trial and Normal Operation of the System
5.1 HRSG Exhaust Gas System Startup
Before starting up HRSG exhaust gas system, the following items should be checked strictly:
a) Ensure that no foreign objects are present in all the equipment of exhaust gas system as
well as the connecting seams in good state.
b) Ensure proper and reliable erection of fixed device.
c) Ensure proper space for expansion and free expansion displacement.
d) Make sure that all measuring devices are in proper position
e) check the sealing of each connection
f) After complete erection of three-way diverter damper, cold-state regulations should be
performed.
g) In order to prolong service life of three-way diverter damper plates, the period for valve
plate under regulation conditions should not be too long.
h) The opening of three-way diverter damper plates shall be adjusted along with changes of
HRSG operating conditions.
5.2 HRSG Operation Description
5.2.1 General Description
a) Prior to HRSG boiler start-up and trial operation, a boiler regulation program in
accordance with design and equipment characteristics should be drawn up.
b) Prior to HRSG whole-set trial operation, the item-by-item trial operation and test for every
HRSG system should be finished (including item-by-item trial operations of boiler auxiliary
machines and each auxiliary system, flushing or chemical cleaning of feed water system,
boiler chemical cleaning, purging of super heater and steam pipe system, steam tightness
test, regulations of safe valve as well as thermodynamic measuring system, regulation test
of control system and protecting system and so on.
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c) HRSG unit trial operation can be conducted with general completion of civil work and
erection, with unblocked water intake pipes and drainage pipes, with a removal of all the
barriers as well as with such facilities as lighting, communicating and firefighting
equipment.
5.2.2. HRSG Trial Operation requirements and points for attention
I
a) Prior to HRSG first-time start-up and pressure-rise, the air-tightness hydrostatic test
should be performed once under drum operating pressure. Put stress on inspections of
valves as well as pipes and parts not attending super high pressure hydrostatic test.
Before boiler starts up, boiler feed water should be ensured as qualified chemically
treated water which should meet the water quality standard of GB12145-89 "Water
Quality Standards for Thermal Power Plant and Steam Power Equipment". After
hydrostatic test, the boiler water pressure (not lower than 50 percent of operating
pressure) can be used to flush the sampling pipes, blow-down pipes, drainage pipes and
instrument pipes with guarantee of unblocked pipes.
b) Prior to HRSG start-up and pressure rise, the following requirements should be met:
 The water level meter shall have distinct water level marks, right locations, good
lighting and reliable power resource to make sure that the water level can be read
easily. The drum water level should be able to be supervised reliably in the, control
room.
 All the necessary thermodynamic instruments and their protecting and supervising
system have been checked and adjusted and can be put into use.
 It is essential to assure proper expansion space and unblocked expansion

displacement. The expansion indicator should be erected firmly and accurately and be
adjusted to zone position under cold state conditions.
 The action check test should be performed for emergency lighting system, over-limit
alarm system and all kinds of protecting system.
 The mark of gauge and meter of three-way diverter damper should be examined to
make sure the correctness of damper open-close direction and of meter indication as
well as flexibility of damper operation.
 The man-hole and hand-bole devices should be erected firmly with complete
accessories.
 It is essential to ensure the frame of HRSG in good condition and checking door, in
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tight and normal state.
 The steam pipeline, feed water pipeline, blow-down pipeline should be all fully
equipped and feed water pump can operate normally.
c) During the first-time pressure rise of HRSG, the pressure should be raised slowly and
smoothly, the speed of pressure rise should be controlled within the scope of rise of
saturated temperature equal to or less than 50°C per hour. During the boiler temperature
rise and pressure rise, every part of heating surface should be checked to ensure the
expansion in good condition. In case of any abnormal phenomena, the reasons for it
should be checked out in time and solved the problems at once before pressure continue
rising.
d) When the HP boiler is heated to attain a pressure of 0.3-0.4 MPa and DEOXIDIZE BOILER
to attain a pressure of 0.2 MPa, tightening of bolts shall be performed with respect to
pressure bolt.
e) During HRSG trial operation, the air-tightness of pressure parts and flue, as well as
stressed state and expansion situation of boiler hanging rod and pipe supporting-hanging
frame should be checked frequently, meanwhile, the vibration situation of every part of
boiler should be noted.
f) During trial operation, the steam-water quality should be supervised to make sure that
the steam-water quality is qualified.
g) During trial operation, attentions shall be paid to keeping reasonable water level and
preventing from water shortage and water fullness.
h) During trial operation, before safety valve is in good condition, the pressure of every
pressure part should not exceed operating pressure.
5.2.3 Boiling Out

a) Alkali boiling-out would be performed for the HRSG. 3-5 kilograms of Sodium hydroxide
and trisodium phosphate per cubic meter of water are to be added (based on 100%
concentration). The water volume of HP boiler is about 15 cubic meter of water, so 60
kilograms of both Sodium hydroxide and trisodium phosphate are needed. The water
volume of LP boiler is about 4.3 cubic meter of water, so 17 kilograms of both Sodium
hydroxide and trisodium phosphate are needed.
b) The chemicals shall be prepared to attain a solution of 20% concentration. It is not
allowed to dump solid chemicals directly into the boiler.
c) When the boiler water is lower than underside of upper drum man-hole, chemical liquid
can be fed once for all from the upper drum manhole followed by a closing of the
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manhole and a rising of boiler water level to 100mm below normal water level marked by
upper drum water level meter.
d) After the chemical liquid is added, the pressure of HP boiler shall be raised to about 1.96-
2.45MPa; the steam discharge amount is 10-15 percent of rated output. After 24 hours of
boiling-out, the blow-down and water-exchange would be kept c6nducting until the water
quality is up to trial operation standard. Finally, other ore rations such as boiler shut-
down or pressure rise to conduct steam purging, steam-tightness test and adjustment of
safety valve can be performed.
e) During the alkali boiling-out period, the chemical liquid cannot fed into super heater.
f) After the completion of alkali boiling-out, boiler shut-down and water drainage, the
interior of drum should be checked; all accumulated matter and residue in the drum and
header should be cleared out.
5.2.4. Flushing and Purging of Pipe
a) The feed water pipes, desuperheating water pipes, superheater and its pipes within the
scope of HRSG should be flushed and purged prior to water and steam supply in order to
clean residue and rust in the pipe.
b) When water is used for flushing of pipe, demineralized water or softening water ought to
be used. The flushing water volume should be more than maximum water volume needed
for normal operation. If outlet water and inlet water have almost identical quality, the
flushing of pipes is complete.
c) Generally, for the purging of superheater and its evaporating pipes, the following
requirements should be met: the sectional area of temporary pipe should be more than
or equal to that of purged pipe. The temporary pipe should be as short as possible to
reduce resistance. The control door during purging should be opened fully. When heat
storage method is used to purge, the open period for control door should be less than I
min generally.
d) During the period of steam flushing, the superheater outlet pressure shall be controlled
at the pressure 1.7MPa and steam output at the output about 43t/h.
e) At every period of purging, at least one-time boiler shut-down for cooling should be
performed (shut-down time is more than 12 hour) to cool the superheater and its pipes in
order to raise purging efficiency.
f) The target plate can be arranged in the temporary drainage pipe at the end of purged
pipe (or steam discharge port) and be made of aluminum plate with width of 8 percent of
inner diameter of steam discharge pipe and length more than pipe inner diameter. On the
premise that purging can be guaranteed, the target plate shall be changed twice in
succession to check whether the size of speckle hit on the target plate is not more than
O.8mm and number of speckles is not more than 8. If these two requirements have been
met, the purging shall be proven qualified.
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g) Upon the completion of purging and flushing of pipe, the relevant records should be
sorted out and the certificates be issued.
5.2.5 Safety Valve Adjustment
a) The local pressure gauge would be selected as a standard for pressure of safety valve
adjustment. The pressure gauge should pass the calibration examination and relevant
error records should be kept. If the error is more than 0.5%, it shall be corrected.
b) One safety valve is provided at the outlet of superheater and both HP drum and LP drum
are supplied with two safety valves. The adjustment for start-up pressure shall conform to
following table. The stipulations of detailed start-up pressure are as follows:
Equipment Maximum Allowable Start-up Pressure of safety valve

Operating Pressure
High start-up Lower start-up
pressure pressure
Super heater 3.82 MPa / 3.97 MPa
HP drum 4.12 MPa 4.37 MPa 4.28 MPa
Deoxidizing Drum 0.7 MPa 0.75 MPa 0.73 MPa
c) During every period of trail operation, it is forbidden to make the safety valves separated
or get stuck.
d) Upon the completion of safety valve adjustment, the relevant records should be sorted
out and the certificate be issued.
e) Under the operating pressure the special property tests for feedwater regulating valve
should be performed with the aim of putting the feedwater automatic regulating device
into operation during whole-set trial operation.
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5.2.6. HRSG Trial Operation
a) After the completion of HRSG erection and trail operation of relevant system, 72-hour
whole-set trail operation must be performed in order to examine the qualities of
construction, design as well as equipment manufacture and check whether the rated
output can the attained as well as whether the equipment is up to design requirements.
b) During 72-hour trial operation following requirements should be met:
 All the defects found in the preceding stages have been remedied.
 The trial operation of every auxiliary system can be up to the requirements and meet
the needs of boiler operation with full load.
 All the checks and tests have been completed and every protection system can be put
into use.
 The erection and adjustment for all the thermodynamic, electrical instrument and
control devices used for boiler whole-set trial operation and performance
examination have been completed based on design requirements with proper
indication and good action.
 'The chemical supervision can go on successfully. G.T. and three-way diverter damper
can operate in good condition.
 The departments using the steam have made good preparations for meeting the trial
operation needs.
d) After boiler operating load rises to full load, under full load condition HRSG shall undergo
successive 72-hour trial operation (if for some reasons, boiler load cannot rise to full load,
the maximum load shall be decided by start-up committee). During the 72-hour trial
operation, all the auxiliary equipment shall be put into operation at the same time or one
after another. The boiler proper and auxiliary systems should operate in good condition.
The expansion situation, air-tightness and vibration situation shall meet the technical
requirements and boiler steam parameters can reach design needs on a whole.
e) After 72-hour trial operation and performance examinations, in accordance with relevant
stipulations of "Regulations Governing the Start-up and Acceptance of Thermal Power
Plant Capital Construction Projects" the certificates for whole-set trial operation and
performance examination shall be issued and the formalities for acceptance of the boiler
shall be gone through.
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5.2.7. HRSG Normal Operation
a) After 72 hour trial operation, HRSG can be put into normal operation.
 Cold-state start-up: after 72-hour boiler shutdown, HRSG starts up once again. The
boiler water temperature is lower than 100°C; the start-up period is two hours (for full
load).
 Hot-state start-up: Under pressure-retaining & temperature-retaining banking

conditions, within 8-hour boiler shutdown, HRSG starts up once again. The start-up
period is 50 minutes.
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b) Prior to HRSG normal start-up, purging should be conducted. The purging period for
exhaust gas system shall be not less than 5 minutes and that for HRSG be not less than 7
minutes.
c) When the steam pressure in the boiler approaches the operating pressure and is about to
supply steam to the outside, the boiler water level had better not exceed the normal
water level.
d) During the supply of steam the main steam valve shall be slightly opened to let out a small
amount of steam for the warming-up of downstream system. Meanwhile, drainage valves
on the piping are opened to discharge condensate water. Only when the piping is hot and
the quantity of condensate water in the piping has considerably decreased then the main
steam valve is allowed to be open fully. The valve should be opened slowly. Meanwhile,
close attention should be paid to detect if there are abnormal sounds/water hammering.
In case of such sounds being heard an immediate check is to be conducted. After the main
stop valve is fully open, the hand wheel of the valve should be turned back about half
circle in order to prevent its seizure due to thermal expansion.
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e) After the supply of steam by the HRSG it is necessary to check once again if there are any
steam leakages in accessories as valves, instrumentation, etc.
f) The water level meter must be rinsed and flushed at least once each work-shift. If water
or steam leakage is detected in the sealing packing of glass tube, sealing packing should
be tightened. When only one of the two water level meters is damaged, a repair can be
performed for the damaged one. If both water level meters have been damaged, the
boiler must be shut down. The operation of the boiler can be allowed to continue only
when one of the water level meters has been restored to normal service after repair.
g) In the course of operation if requires the boiler should be periodic blow-down under
lower load condition. Meanwhile the water level should be kept close watch over. The
number of periodic blow-down is to be determined by the quality of the boiler water, and
generally is 1-2 times each work-shift. During the blow-down first open the valves
located far distant from the boiler, and then slowly open the valve near the boiler. Upon
completion of the blow-down first close the valve near the boiler and then close the valve
located far distant from the boiler. The quantity of the continuous blow-down shall be
determined based on the alkalinity of the drum.
h) In the course of operation, steam pressure should be kept as stable as possible with the
steam pressure maintained at a value not exceeding the maximum allowable operating
pressure.
i) The elbows of pressure gauge shall be flushed once each work-shift. To ensure the
precision of the pressure gauge a calibration check should be conducted every six months.
j) The steam discharge test should be conducted periodically to prevent the sticking of
safety valve clack and valve seat.
5.2.8. HRSG Operation under Dry Firing
a) During the period start-up, the heating surface of super heater can operate in the absence
of water (dry firing) at a flue gas temperature lower than 550°C.
b) Every heating surface of whole set of HRSG can operate under dry firing at a flue gas
temperature lower than 400°C for a short time. Under this condition, boiler feed water
system is not allowed to start up.
c) Under dry firing, the boiler temperature must be cooled to lower than 100°C in order to
start boiler feed water system.
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VI. HRSG Boiler Shutdown
By closing the three-way diverter damper or G.T., the HRSG shutdown can be conducted.
Shutdown scenarios:
i. Temporary Shutdown
A temporary shutdown shall be initiated if steam supply is not required in a short period of time.
At this time the boiler can start up quickly without any special treatment. The drum should be
retained at a certain of steam pressure in order to avoid air going into boiler water. The
anticorrosion method such as injecting nitrogen can also be selected.
ii. Complete Shutdown
Prior to conducting such operations as cleaning, inspection and repair the boiler water must first
be thoroughly drained and then a complete shutdown can be conducted.
During the boiler shutdown, close attentions must be paid to safety and proper maintenance of
equipment. Water is drained out only after the boiler has been slowly cooled to a temperature
less than 50'C. During the drainage of water it is necessary to open an air valve. After the boiler
water has been drained, open a manhole and flush out water scale with clean water.
iii.Emergency Boiler Shutdown
In one of the following cases emergency shutdown will be conducted
i. The boiler water level has lowered or risen to stipulate upper or lower limit.
ii. Boiler auxiliary steam-water system, control system fault, which affects boiler
normal operation.
iii. Complete failure of one of the following items: water level meter, pressure
gauge or safety valve.
iv. Boiler pressure components are damaged.
v. Any other abnormal situation which endangers boiler safety operation
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VII. Routine Operational Checks
i. Routine Checks for HRSG Exhaust Gas System
a) Check inner casing and its insulating pin assemblies of exhaust gas system periodically. In
case of damages being detected, repair them in time.
b) Constantly check tightness of exhaust gas system connections. In case of flue gas leakage,
the nuts can be tightened evenly or sealing welds can be conducted.
c) Check operating conditions of flue supporting seating periodically to ensure proper
expansion space and free displacement.
d) Constantly check wall temperature of every part of exhaust flue system shell body to
ensure insulation in good condition.
e) During each-time overhaul or medium repair, maintenance personnel should go into
three-way diverter damper internals to check operating conditions of every part in the
valve. In case of any problem, solve it at once.
f) The lubricants (such as graphite power) shall be painted periodically to main bearing of
three-way diverter damper.
g) Periodically check shaft-end sealing conditions of three-way diverter damper and
operation situations of main shaft and motor-operated device and remove the obstacles
at once.
ii. Attention Items during HRSG Operation
a) Check frequently whether boiler steam pressure, water level, superheated steam output
and temperature are normal.
b) Check frequently whether every boiler system and pipeline accessories are in good
working order.
iii. HRSG Short-term checks
During the period of HRSG operation, every two or three weeks the following checks should
be conducted once:
a) Check dirt deposit situation of heating surfaces and eliminate oily soot and ashy scale in
the heating surfaces.
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b) Make a comprehensive inspection of doors, frames and heating surfaces to determine

whether they are functioning normally.
c) Make a comprehensive check of water level meter, valve, pipe and flanges for evidence of
leakage. If discovered, it should be timely repaired.
d) Make a comprehensive inspection of every system and equipment of HRSG to determine

whether they are in good state.
viii. HRSG Maintenance
i. HRSG Medium Repair
a) When the boiler has operated for 3-6 months, it should be shut down for a comprehensive
upkeep and maintenance. In addition to the items described above it is also necessary to
perform the following maintenance work:
b) Eliminate scale and slime in the boiler drum, heating surface pipes and each header. Wash
all the steam/water ducts in the boiler with clean water.
c) Clear away oily scale and soot on various heating surfaces.
d) Inspect the inside and outside of the boiler and check pressure element welds for cracks
and corrosion damage. Serious defects discovered should be repaired timely. All
suspicious points should be recorded for further checks if they do not affect the present
safe operation of the boiler.
e) The boiler frame, smoke stack and rain-proof shed should be painted once every year.
ii. Boiler Maintenance
Dry Conservation Method and Wet Conservation Method
The dry conservation method will be employed for boiler shutdown lasting more than one month
and wet conservation method for shutdown lasting less than one month.
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Dry conservation method
 After boiler shutdown boiler water is drained with dirt and filth being thoroughly cleared
out and washed clean. Then a pan loaded with quicklime is put into the boiler from a
manhole of the boiler drum. The quicklime quantity is calculated based on a weight of 2-3
kilograms per cubic meter. The proper size of the quicklime is 10-30mm. Some measures
should be taken to avoid the direct contact of the quicklime with boiler metallic walls.
 When the dry conservation method is used for corrosion prevention, close attention
should be paid to boiler air-tightness. Boiler manhole and pipe valves should be all closed.
Every month manholes and hand holes should be opened once for inspection. If the
quicklime has been found broken into powdery pieces it should be timely replaced. The
boiler outer surface should also be checked.
 After boiler shutdown, when boiler temperature is lowered to 100-200℃, drain totally all
of water in the heating surface and then utilize the heat recovery to evaporate left
moisture. Because boiler water has a certain alkaline, after the moisture is dried out, a
layer of protecting film can be formed on the metallic surface. The film can play a certain
protection roles. But because the boiler water alkaline is low, the protecting film is not
reliable, so the maintenance period of validity is generally about one week.
Wet conservation method
After boiler shutdown the boiler water is drained with internal dirt being thoroughly flushed clean
and processed qualified water fed into the boiler. After the boiler is filled with water the latter
should be heated to 100℃ by the heat of gas turbine flue gas or external steam heat so that the
air in the water can be discharged. Thereupon all valves shall be closed.
iii. Nitrogen or Chemical Solution Preservation
 Short-term shutdown (at most three or four days)
Generally no special treatment is needed, and boiler can be started up at any time. Certain
steam pressure must be kept in the boiler in order to avoid the entry of air into boiler water. If
steam pressure can’t be retained in the boiler, nitrogen can be filled in when the boiler begins
to cool so that contiguous slight overpressure of nitrogen of about 100-200g/cm2 can be
continuously kept with the ease of boiler corrosion prevention.
 Middle-term shutdown (at most three or four weeks)
The boiler evaporation pipe bank, economizers and LP boiler should be filled with volatile
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protecting solution which is one kind of uniform solution made up from 200 ppm of hydrazine
(N2H4) and ammonia (PH value more than 10.5) dissolved in 1 kilogram of demineralized
water.
Low nitrogen pressure corrosion prevention method can also be adopted, but water level in
drum must exceed normal water level and the deaerated feedwater should be filled. The
condensate water in superheater should be drained out completely from superheater and no
air should be allowed to enter it.
 Long-term shutdown (more than 4 weeks)
Boiler evaporating pipe bank, economizer and LP boiler should be filled with alkaline
protecting solution, but alkaline protecting solution should be cleaned thoroughly when boiler
is restarted up. The alkaline protecting solution is a kind of uniform solution made up from 4g
of trisodium phosphate (Na3PO4·12H2O) dissolved in 1 kilogram of demineralized water.
In case of shutdown within six weeks, volatile protecting solution can be adopted for
corrosion prevention just like the treatment for middle-term shutdown. The condensate
water in superheater should be drained out completely from superheater and no air should
be allowed to enter it. If possible, slight overpressure nitrogen corrosion prevention method
can be adopted. But if the period of long-term shutdown exceeds 3 months, the superheater
should be filled with volatile protecting solution.
 When wet conservation method is adopted, some frost prevention method should be
adopted in winter in cold area.
 The situations outside of heating surface pipes should be checked frequently to prevent
from corrosion.
 The salinity the saturated steam contains collecting in the superheater may affect safe
operation of superheater, so if needed backwash for superheater should be adopted.
 The operating unit should make a good job of chemical supervision.

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ix. Design Conditions & Normal Parameters
i. Weather Conditions
Many-year average atmosphere pressure : 1007Mbara
Extreme highest atmosphere temperature: 470C
Extreme lowest atmosphere temperature : 3C
Many-year average highest atmosphere temperatures: 42.70C
Many-year average lowest atmosphere temperature: 5.50C
Extreme highest relative humidity: 87%
Max. Wind velocity: 40m/s
All-year wind prevalent direction in winter
 Northeast wind: 50%
 No winder: 50%
All-year wind prevalent direction in summer
 Southwest wind: 35%
 West wind: 65%
ii. Design operating conditions
Ambient temperature: 250C
Atmospheric pressure: 1007 Mbara
Relative humidity: 45%
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x) Boiler Feed water:
Boiler feed water plays a very important role for the trouble-free operation of steam generators.
As they are used 24 hours a day, breakdowns and downtime can be avoided or reduced by
correct boiler feed water treatment. ProMinent provides different systems for boiler feed water
treatment. First salt and gas are removed from the boiler feed water using a thermal process. All
the boiler feed water is vaporized causing high concentrations of substances in the boiler water
that attack the steam boiler material and form deposits. By checking and limiting the buildup of
salt in the boiler water using chemical dosage into the boiler feed water, these problems can be
avoided. ProMinent offers solutions for such applications
BFW pump
View of Boiler feed Water pump (P 2202)
Capacity
Head
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Desalination of the boiler feed water
High cycles of concentration in the boiler feed water can only be achieved if boiler feed water
with a low mineral content is available, providing low conductivity. Reverse osmosis and water
softening systems are used.
Treating the boiler feed water
The boiler feed water treatment is normally done with the following chemicals:
 Hardness stabilizers
 Deflocculating agents
 Corrosion inhibitors
 Oxygen binding agents (e.g. hydrazine)
 pH value regulation (caustic soda, ammonia)
 DE foaming agents
Dosing of these chemicals into the tank of boiler feed water is accomplished using dosing pumps
xi) Blow down control
Increase in salinity in the boiler water is monitored by conductivity. When the maximum value is
reached, blow down occurs. The blow down valve is opened and boiler water is removed from
the boiler. Low-salt boiler feed water compensates for the loss in the boiler and reduces the
boiler water conductivity. Part of the boiler water flow is guided across a cooler before reaching
the conductivity probe, in order to avoid thermal overload of the probe. To reduce sample water
losses, samples can be taken periodically making use of a motorized valve system.
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Blow down vessel
View of Blow down Vessel

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Internal Damages to Boiler Tubes

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Leakage rectification of Tubes of HRSG

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Leakage rectification from Economizer tubes

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Leakage rectification from Economizer tubes

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Internal Arrangements of HRSG

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The following is a partial list of operational guidelines and requirements, which will
provide a safer, more economical operation and extend the operating life of your
boiler.
DON'T
 Operate a boiler which is not constructed the American Society of
Mechanical Engineers (A.S.M.E) Code.
 Operate a boiler unless it is equipped with a safety valve, with sufficient
relieving capacity, set at or below the maximum allowable working
pressure.
 Ever bypass the pressure controls, low water cutout, or any other limit
switch or control.
 Ever restrict the design function of any safety valve, such as by reducing or
plugging the outlet, painting, or removing it.
 Permit unqualified personnel to operate a boiler.
 Ever leave the boiler unattended for long periods of time.
 Operate a boiler without an adequate source of combustion air.
 Operate a boiler without an adequate source of combustion air.
 Operate a boiler without a valid certificate of inspection.
DO
 Respect the boiler. It can be dangerous!
 Have the vessel inspected internally annually, as required by State law.
 Report newly installed boilers to the State Office of Boiler and Pressure
Vessel Safety.
 Test safety controls and devices on a periodic basis (as recommended by
CSD1).
 Ensure boiler operators are adequately trained to assure safe and efficient
operation.
 Inspect the boiler daily for proper operation, and/or adverse conditions.
 Maintain a log of incidents that effect boiler operation, and when safety
controls and devices were tested (i.e., low water cutout, safety valve(s),
combustion controller).
 Allow only authorized ("R" stamp or proper ASME symbol holder) repair
firms to make welded repairs.
 Have you burner serviced immediately, if the burner starts with a puff or
operates in an unusual manner.
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HRSG (Flow Diagram)

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Xiii) HRSG PIPING AND INSTRUMENT DIAGRAM

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Gop Uty 02a (HRSG)

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DOCUMENT : GOP-UTY-2 (A)

Heat Recovery REV. NO. : 00

ORIG. PREPARED BY : BK/OSW

Job Qualification Program

ORIG. PREPARED BY : BK/OSW

Prepared By: ____________________________________________

Reviewed By: ____________________________________________

S No. Rev. Date Page Section Description of Change

ORIG. PREPARED BY : BK/OSW

ORIG. PREPARED BY : BK/OSW

iii. HRSG Datasheet………………………………………………………………………………………………………..30-31

5.2.3 Boiling out

ORIG. PREPARED BY : BK/OSW

5.2.8 HRSG operation under dry firing

viii. HRSG Maintenance…………………………………………………………………………………………………….56-58

ix. Design condition and normal parameters .............................................................................. 59

x. Boiler Feed water………………………………………………………………………….60-61

ORIG. PREPARED BY : BK/OSW

UTY Utility Power Plan

ORIG. PREPARED BY : BK/OSW

4. Introduction to VCM Plant

ORIG. PREPARED BY : BK/OSW

5. Introduction to Power Plant

ORIG. PREPARED BY : BK/OSW

ORIG. PREPARED BY : BK/OSW

General Process Description

ORIG. PREPARED BY : BK/OSW

SIMPLE TERMS (DEFINITIONS)

ORIG. PREPARED BY : BK/OSW

SUPER HEATED STEAM

Superheated steam is steam at a temperature higher than its saturation temperature. If

Type Composition of Internal Energy (U)

ORIG. PREPARED BY : BK/OSW

(molecular translation, rotation, and vibration; electron translation and spin;

In thermodynamics (a branch of physics), entropy, symbolized by S, is a measure of the

In thermodynamics and molecular chemistry, the enthalpy (denoted as H, h, or rarely as χ) is a

ORIG. PREPARED BY : BK/OSW

ORIG. PREPARED BY : BK/OSW

ORIG. PREPARED BY : BK/OSW

POWER (HIGH PRESSURE) BOILER

ORIG. PREPARED BY : BK/OSW

ORIG. PREPARED BY : BK/OSW

Advantages of Water Tube Boiler:

QUALITIES OF A GOOD BOILER

1) Strong and simple construction

ORIG. PREPARED BY : BK/OSW

Why water is used in Boiler:

 Water is a cheap medium.

ORIG. PREPARED BY : BK/OSW

ORIG. PREPARED BY : BK/OSW

Spray Type Dearator

ORIG. PREPARED BY : BK/OSW

TRAY TYPE DEAERATOR

ORIG. PREPARED BY : BK/OSW

Therefore the de aerator must,

VENT PIPING OF DE AERATOR

ORIG. PREPARED BY : BK/OSW

9. Heat Recovery Steam Generator (HRSG)

ORIG. PREPARED BY : BK/OSW

ii. HRSG Structure

HRSG mainly include components such as

ORIG. PREPARED BY : BK/OSW