STEAM GENERATION SYSTEM

For HP and LP Boiler System

OVERVIEW
Steam
The vaporized state of water which contains heat energy intended for transfer into a variety of processes from air heating to vaporizing liquids in the refining process. Steam is created from the boiling of water.

Sensible Heat Heat required to change the water temperature from 32F to 212F. Latent Heat Heat required to change the state of water at its boiling temperature, into steam. It involves no change in the temperature of the steam/water mixture, and all the energy is used to change the state from liquid (water) to vapour (saturated steam).

OVERVIEW
Boiler

LP Boilers

HP Boiler

A closed vessel in which water under pressure is transformed into steam by the application of heat. In the boiler furnace, the chemical energy in the fuel is converted into heat, and it is the function of the boiler to transfer this heat to the contained water in the most efficient manner. It is designed to absorb the maximum amount of heat released in the process of combustion. This heat is transferred to the boiler water through radiation, conduction and convection. The relative percentage of each is dependent upon the type of boiler, the designed heat transfer surface and the fuels.

OVERVIEW

Fire And Smoke-Tube Boiler

Firetube boilers are often characterized by their number of passes, referring to the number of times the combustion (or flue) gases flow the length of the pressure vessel as they transfer heat to the water. Each pass sends the flue gases through the tubes in the opposite direction. The number of passes the boiler contains affects the boiler efficiency, and its first cost to manufacturer. The more heat transfer surfaces the boiler has, the more efficient it can be.

PROCESS

Condensate from Process

Process Flow of Steam Generation System

PROCESS

Steam Generation System Plant

OPERATION
Description
Steam Generating Capacity Design Pressure Operating Pressure Design Temperature Operating Temperature Efficiency Boiler Heating Surface Boiler Water Capacity Boiler Steam Capacity Type

Parameter
8,000 kg/hr (Saturated Steam) 6 bars 3.5 bars 165C 148C 91% 161 m2 11.9 m3 (approximate) 3.9 m3 (approximate) 3-pass combined fire & smoke-tube evaporator w/ external & cooled irradiation chamber Large water space, double fire tube in 3-pass construction cooled over a length of 5,040 mm. 1 fire tube; 1,150 mm 80 smoke tubes; 70 mm x 3.2 m 51 pipes; 70 mm x 3.2 m

Low Pressure Boiler

Evaporator Description

Low pressure steam is used for the heatingup of the jacketed vessels and pipelines in the process area.
1st Pass

Also, it is used for heating up the boiler feed water in the feed water deaerator up to 105OC.

2nd Pass 3rd Pass

OPERATION
Description
Steam Generating Capacity Design Pressure Operating Pressure Design Temperature Operating Temperature Efficiency Boiler Heating Surface Boiler Water Capacity Boiler Steam Capacity Type

Parameter
900 kg/hr (Saturated Steam) 60 bars 55 bars 276C 271C 90% 12.5 m2 2.0 m3 (approx) 0.8 m3 (approx) 3-pass combined fire & smoke-tube evaporator w/ external & cooled irradiation chamber Large water space, one fire tube in 3-pass construction cooled over a length of 3,000 mm 1 external & cooled irradiation chamber 16 smoke tubes; 57 mm x 3.2 m 10 pipes; 57 mm x 3.2 m

High Pressure Boiler

Evaporator Description

High pressure steam is used for heating-up the barrels of the extruder and the purification columns in the purification section.

1st Pass 2nd Pass 3rd Pass

OPERATION

HP/LP Distribution Steam System

OPERATION
Economizer Description
Max. Allowable Pressure Operating Pressure Design Temperature (In/Out) Exchange Surface Area Heat Output Capacity 13 Li

Parameter
Water Side 60 bars 55 bars 105 / 159 C Flue Gas Side 394 / 200 C 25 m2 58 kW -

Feed Water Deaerator Tank Feed Water Deaerator Tank

Capacity

Description
Operating Temperature Design Temperature

Parameter
10 m3 105C 150C 0.2 0.3 bar -1/+2 bar 14 tons/hr 50% (approximate) 50% (approximate) 1,250 kg/hr (approximate)

Removes oxygen, carbon dioxide and other noncondensable gases from feed water Heat-up the incoming makeup water and return condensate to an optimum temperature for Minimizing solubility of the undesirable gases Providing the highest temperature water for injection to the boiler

Operating Pressure Design Pressure Pipeline Throughput Fresh Water Percentage Condensate Percentage Steam Consumption

OPERATION
Condensate Tank Description
Capacity Operating Temperature Design Temperature Operating Pressure Design Pressure

Parameter
7 m3 100C 150C 0.2 0.3 bar 0.5 bar

Condensate Tank

Collects condensate resulting from the process area. Steam supplied to the process area condenses after heat is given off. The steam pressure drives the condensate back to the condensate tank. An exhaust to the atmosphere maintains the tank pressure. Recycling the condensate will reduce the cost of heating feed water to the boiler and the boiler water chemicals.

OPERATION

Condensate Loop

OPERATION

Float Trap

OPERATION
HP/LP Boiler Instrument and Controls
A dedicated PLC panel cabinets for each boiler controls the operation of these steam generators.

LP Boiler Controls Safety Feature PZAH 11 (safety manostat) PZAL 33 (manostat) PZAH 33 (manostat) PZAL 31 (safety manostat) Setting Causes a malfunction shutdown of LP1 at 5 barg. Auto restart is not possible. Shuts down burner at fuel oil pressure of 2.3 barg Shuts down burner at fuel oil pressure of 2.7 barg Shuts down burner if fuel gas pressure 225 mbar or 275 mbar Safety Feature PZAH 2 (safety manostat)

HP Boiler Controls Setting Causes a malfunction shutdown of LP2 at 58 barg. Auto restart is not possible. Shuts down burner at fuel oil pressure > 1 barg.

PZAH 43 (manostat)

OPERATION
Deaerator Feed Water Instrument and Controls
The following solenoid switches and level indicators control the deaerator level: - optical level display by means of the individual magnetic flaps - holding the preset water level constant a) When switch contact for LSL 25 is actuated fresh demin supply pump cuts in b) When switch contact for LSH 24 is actuated fresh demin supply pump cuts out c) When switch contact for LSL 26 is actuated fresh condensate supply pump cuts in d) When switch contact for LSH 27 is actuated fresh condensate supply pump cuts out - Shuts off the boiler feed water pumps when the water level in the deaerator falls below low level Level Indicator

OPERATION
HP/LP Boiler Instrument and Controls

OPERATION
Fuel System

Propylene

LPG

Diesel

LP Burner

Diesel
HP Burner

OPERATION

Boiler Burner

OPERATION

OPERATION
Fuel System

Diesel Tank Section

LPG

OPERATION
LP Boiler Operation

HP Boiler Operation

OPERATION
Blowdown Systems
It is the purge from a system of a small portion of the concentrated boiler water in order to maintain the acceptable level of dissolved and suspended solids in the system.

Continuous Surface Blowdown

Aims to maintain control of dissolved solids (TDS) and prevents large variations in critical boiler water chemical balances.

Bottom Blowdown
Removes the suspended solids from the drum, where sludge accumulates.

Manual (Bottom) Blowdown

Usually remains necessary to control the sludge concentration in the boiler.

B/D valve

OPERATION

OPERATION
Flash Drum
Separates flash vapor from condensate in the boiler lye. This vessel has a holding capacity of 0.024 m3 at a designed parameters of 1 bar at 280OC.

Blowdown Cooler
Collects the boiler lye periodically from the LP-steam boiler and HP-steam boiler. Condensate will separate from the lye. Exhaust vapor will be vented to the atmosphere and the collected lye should be drained periodically to the sewage.

OPERATION
Standby Protection / Preservation Wet Preservation
This technique is implemented during S/Ds lasting for a month or less. The boiler is flooded with deaerated water due to the following: 1. To eliminate the liquid-vapor interface that can cause a water line corrosion 2. To prevent the condensation of acidic dropletes caused by CO2 absorption 3. To eliminate any dissolved oxygen that can cause corrosion The chemical dosing for both oxygen scavenger and corrosion inhibitor uses twice the treatment volume than the normal usage to eliminate the dissolved oxygen and maintain the pH quality of 9.511.0. Nitrogen blanketing can also be employed to displace air from the boiler.

Dry Preservation
This technique is implemented for a prolonged S/Ds for more than a month. The boiler water is drained completely. Dessicants is then added to absorb any water vapor and thus control the relative humidity in the boiler.

WATER TREATMENT
Boiler Problems Caused By Water

Scale

Scale forms mainly with hardness components or silica on the heating surface and the drum. Sometimes leads it leads to embrittlement and explosion of evaporation tube Cause of Problem Poor water quality and fouled ion exchange resin Incomplete control of boiler water (blow down shortage, etc) Corrosion product brought into boiler from feed and condensate lines Insufficient chemical injection

WATER TREATMENT
Boiler Problems Caused By Water

Corrosion

Corrosion at heating surface and feed and condensate lines is due to dissolved gasses (O2, CO2) and to accumulation of metal oxides and hydrates on heating surfaces. Cause of Problem Corrosion product brought into boiler from feed and condensate lines Insufficient pH control and oxygen scavenging Insufficient boiler water control on pH and P-alkalinity Corrosion occurrence at shutdown or idling period

WATER TREATMENT
External Boiler Water Treatment
External treatment, as the term is applied to water prepared for use as boiler feed water, usually refers to the chemical and mechanical treatment of the water source. The goal is to improve the quality of this source prior to its use as boiler feed water, external to the operating boiler itself. Such external treatment normally includes: 1. 2. 3. 4. 5. 6. 7. Clarification Filtration Softening Dealkalization Demineralization Deaeration Heating

Feed Water Deaerator Tank

WATER TREATMENT
Utilizes the fundamental principle: The solubility of a gas in a liquid decreases with increasing liquid temperature. Incoming water is sprayed into a steam atmosphere, where it is heated to within a few degrees of the saturation temperature of the steam. Most of the noncondensable gases (principally oxygen and free carbon dioxide) are released to the steam as the water is sprayed into the unit.

Deaerating Heater

Water cascades from tray to tray, breaking into fine droplets or films which intimately contact the incoming steam which removes all but the very last traces of oxygen.

Deaerated water falls to the storage space below, where a steam blanket protects it from recontamination.

WATER TREATMENT
Internal Boiler Water Treatment

Oxygen Scavenger Tank This a chemical compound that removes dissolved oxygen in water by reduction reaction and thereby inhibits the corrosion caused by the oxygen. Its chemical potentiality is high enough to reduce oxygen The reaction product of the scavenger and oxygen does not have an aggressive effects on the boiler or on the steams and condensate lines

Antiscalant Solution Tank This type of boiler compounds prevents the scale formation and adjusts the pH of boiler water to inhibit corrosion. The phosphate-base type of antiscalant, Reacts with hardness components (Ca2+, Mg2+) in water and converting them into suspendible substance. Keeps silica substances water soluble.

WATER TREATMENT
Typical Water Quality Control Parameters

WATER TREATMENT
Raw Water (Typical Values)
Description pH @ 25OC Conductivity Silica Phosphate (Unfiltered) Phosphate (Filtered) Chloride Total Iron Total Alkalinity P Alkalinity Total Hardness Parameter 7.0 (estimated) max. 265 s/cm 150 ppm SiO2 14 ppm PO4-3 3.8 ppm PO4-3 10 ppm Cl 0.1 ppm Fe 125 ppm CaCO3 0 ppm CaCO3 105 ppm CaCO3 pH Conductivity Silica Total Iron Total Hardness

Demin Water Quality

Description Parameter < 7.0 < 3.0 S/cm < 0.05 ppm 0 ppm Fe 0 ppm CaCO3

The raw water is considered as a ground water type of water.

WATER TREATMENT
Boiler Feed water quality
Description CO2 Combined O2 Oil pH at 25C (LP/HP) Iron Copper Silica (SiO2) Hardness Conductivity Parameter < 25 ppm < 0.02 ppm < 0.5 ppm 8.5 9.5 * < 0.02 ppm < 0.003 ppm < 0.2 ppm 0 < 2000 S/cm

LP water quality
Description pH at 25C Conductivity Phosphate (PO4-3) Silica (SiO2) Hydrate Alkalinity Dissolved O2 Parameter 10.4 11.4 < 500 S/cm 20 - 30 ppm < 40 ppm 100 300 ppm 0 ppm

HP water quality
Description Conductivity Phosphate (PO4-3) Silica (SiO2) Dissolved O2 Hydrate Alkalinity Parameter < 300 S/cm 10 - 20 ppm < 20 ppm 0 ppm 0 ppm

* Depends on the water treatment program.

Lessons Learned

1. Installation of platform at the boiler stacks.

A platform was installed for sampling accessibility of flue gas. This was requested by DENR representatives in lieu of stack emission testing and permit to operate (Boilers).

2. Installation of sampling area for condensate tank and boiler feed water (direct to Deaerating tank).
The need to set up a new sampling points for both condensate and boiler feed water tank was for the adjustment of chemical dosing treatment and monitoring of dissolved oxygen at the boiler water lines. For the feed water, sampling is done at the bleed port of the feed water pump.

Lessons Learned
3. Installation of a double pipe heat exchanger before the feed water pump.
A heat exchanger was installed to minimize the delta T of boiler feed water from the feed water tank to feed water pumps which can prevent the cavitation of the feed water pumps.

4. A provision for nitrogen line should be included on the design for boiler preservation.