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I TABLE OF CONTENTS

I TABLE OF CONTENTS ..................................................................................................................2


II REFERENCE DOCUMENTS ...........................................................................................................3
III ATTACHMENTS...............................................................................................................................3
IV ABBREVIATIONS.............................................................................................................................4
1. INTRODUCTION .............................................................................................................................5
1.1 Plant data .....................................................................................................................................5
2. OPERATION AND DESIGN CRITERIA ..........................................................................................6
2.1 Regulations and Design Codes ....................................................................................................6
2.2 Supervision...................................................................................................................................6
2.3 Operation......................................................................................................................................6
2.4 Dynamic Characteristics...............................................................................................................7
2.5 Degree of Automation...................................................................................................................8
2.6 Protection Concept .......................................................................................................................9
2.7 Control System Requirements......................................................................................................9
2.8 Environmental Conditions.............................................................................................................9
2.9 HRSG performance Guarantees ..................................................................................................9
2.10 Water and Steam quality ............................................................................................................10
3. CONFIGURATION OF THE SYSTEM...........................................................................................12
3.1 Water and steam system ...............................................................................................................12
3.1.1 LP-Feedwater system ....................................................................................................................12
3.1.2 LP-boiler system .........................................................................................................................13
3.1.3 LP-Steam system .......................................................................................................................14
3.1.4 HP-Feedwater system ................................................................................................................15
3.1.5 HP-boiler system ........................................................................................................................15
3.1.6 HP-steam system .......................................................................................................................16
3.1.7 Drain and blow down system......................................................................................................17
3.2 Flue gas system .............................................................................................................................18
3.2.1 Description of the flue gas system .............................................................................................18
4. DESCRIPTION OF COMPONENTS..............................................................................................18
4.1 Steel structure ................................................................................................................................18
4.2 Ducting Steel..................................................................................................................................19
4.3 Internal insulation ...........................................................................................................................19
4.4 Ducting / Casing.............................................................................................................................19
4.5 Pressure Parts ...............................................................................................................................20
4.6 Bumpers.........................................................................................................................................20
4.7 Bottom- and top box.......................................................................................................................20
4.8 Inspection facilities .........................................................................................................................20
4.9 Piping .............................................................................................................................................21
4.10 Expansion joints pipe penetrations ................................................................................................21
4.11 Safety valves ..................................................................................................................................21
4.12 Desuperheater (attemperator) .......................................................................................................21
4.13 Steam silencers..............................................................................................................................21
4.14 Level indicators ..............................................................................................................................22
4.15 Valves ............................................................................................................................................22
4.16 Expansion joints (ducting) ..............................................................................................................22
4.17 Aircraft warning lights.....................................................................................................................22
4.18 Stack (closure)damper...................................................................................................................22
4.19 Hanger and pipe supports..............................................................................................................23
4.20 Field instrumentation......................................................................................................................23

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II REFERENCE DOCUMENTS

Description NEM doc. no.


Site conditions & Utility data 22033-100-02

General arrangement Right and rear view 22033-100-05-001


General arrangement Left and front view 22033-100-05-002
General arrangement Top view 22033-100-05-003
General arrangement Isometric view 22033-100-05-004

Purge calculation 22033-103-45


Process flow diagram 22033-104-01

P&ID HRSG, Legend, Symbols and Abbreviations 22033-105-01


P&ID HRSG, Legend, Symbols and Abbreviations 22033-105-02
P&ID HRSG, Legend, Symbols and Abbreviations 22033-105-03
P&ID LP- Economizer preheater System 22033-105-11
P&ID HP- Feed water System 22033-105-13
P&ID LP- Boiler System 22033-105-21
P&ID HP- Boiler System 22033-105-23
P&ID LP- Steam System 22033-105-31
P&ID HP- Steam System 22033-105-33

P&ID HRSG Drains & Vents 22033-105-40


P&ID Blow down System 22033-105-41
P&ID Fluegas System 22033-105-61
P&ID Instrument air system 22033-105-70

Piping List 22033-400-01


Valve List 22033-530-02

Functional control diagrams DCS/ESD 22033-641-20


Calibration and Setting List ( I/O List ) 22033-643-10
Instrument List 22033-643-30
Functional control description DCS/ESD 22033-647-01
Start-up & Shut down procedures HRSG 22033-647-11

Operation & Maintenance Manual 22033-790-01


Water Chemistry Specification 22033-790-21

III ATTACHMENTS

Not applicable.

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IV ABBREVIATIONS

ASME Design Code for Pressure Parts


CCR Central Control Room
CEMS Continuous Emission Monitoring System
DCS Distributed Control System
DSH De-superheater
ECO Economizer
ESD Emergency Shut Down System
EVA Evaporator
GT Gas turbine (Combustion Turbine)
FW Feedwater
FWCV Feedwater control valve
FWP Feedwater pump
H High
HH Too high
HHH Extreme high
HP High pressure
HRSG Heat recovery steam generator
L Low
LL Too low
LLL Extreme low
LP Low pressure
MCR Maximum continuous rating
NWL Normal water level
P&ID Piping and instrumentation diagram
S.. Setting value
SH Superheater
SL Start level (related to NWL)
ST Steam turbine
TEG Turbine exhaust gas

Text Revised content is Shaded

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1. INTRODUCTION

This document describes the heat recovery steam generators (HRSGs) of the TANJUNG UNCANG
CCPP project. It should be read in conjunction with the piping and instrumentation diagrams (P&IDs
mentioned in chapter II Reference documents.

The HRSGs form an integral part of a Combined Cycle Power Plant. The plant consists of two identical
HRSGs, each operating independently with its own Gas Turbine and producing steam for the generation
of electrical power in one full condensing steam turbine generator. In general, the description is
applicable for one HRSG.

A turbine exhaust gas (TEG) bypass system is installed to enable operating of the gas turbine in simple
cycle when the HRSG is not in operation. The HRSG is designed to operate in sliding pressure mode as
well as operating at part load conditions of the gas turbine. Natural gas will be used as the primary fuel
for the gas turbines.

The HRSGs operate at dual pressure with natural circulation in the evaporators, HP-Steam drum and
LP-integrated deaerator. The exhaust gas flow is horizontal; the tubes of all heat transfer sections are
vertical.

In this document reference can be made to equipment that is not in NEMs scope of supply, for a
detailed overview of NEMs scope of supply reference is made to the P&IDs mentioned in chapter II
Reference documents.

Coding of equipment, instruments, valves, piping etc. is according the KKS coding system. On all
drawings and documents the KKS code of HRSG 01 is used. For the KKS code of HRSG 02 the unit
number is 02.
e.g.
HRSG#1 KKS code: 01HAN20AA001
HRSG#2 KKS code: 02HAN20AA001

1.1 Plant data

Type of plant... : Combined Cycle Power Plant

Number of boilers.. : Two (2)

Location of boilers : Tropical coastal environment with high salinity

Plant location. : Tanjung Uncang villages, Batam Disctrik, Kepulauan Riau


Province, Indonesia

Owner plant : Tanjung Uncang CCPP

Project name : TANJUNG UNCANG CCPP 120 MW

NEM Project number : 22033

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2. OPERATION AND DESIGN CRITERIA

2.1 Regulations and Design Codes

The following codes and standards have been applied for the design of the HRSG and its components:

HRSG: ASME I edition 2010, addenda 2011, incl. applicable code cases.
Pressure vessels: ASME VIII div. 1 edition 2010, addenda 2011, incl. applicable code cases
Piping: ASME I edition 2010, addenda 2011, incl. applicable code cases, ASME B31.1, incl. applicable
code cases

Valves ASME B16.34, API 608


Stack ASME STS 1-2006
Pumps ANSI B73.1

Steel structure AISC


Platforms and ladders OSHA
Steel structure materials BS/EN/JIS/ASTM
Paint EN-ISO 12944

Electrical IEC
Aircraft warning lights ICAO, FAA

Steam properties tables IAPWS-IF97


Water and steam quality VGB
Flue gas properties NASA RP 2002-211556:09-2002
Flue gas ducting purge NFPA 85

Each HRSG and all components and systems thereof, unless otherwise specified, complies with
mentioned codes and standards in effect at the date of order.

The components which are not mentioned above shall be according to NEM and International
Standards.

2.2 Supervision

The system is designed for continuous supervision from a (Central-) Control Room in the vicinity of the
HRSGs. Important pressures, temperatures and levels can be read out locally from local gauges.
Further reference is made to the Functional control descriptions, NEM doc. 22033-647-01.

2.3 Operation

The HRSGs are designed for continuous operation with a design lifetime of 240,000 hours for creep
sensitive parts. The following number of start-ups is expected per year:

Type of cycle HP-drum Number/year


Pressure
Hot start >30 barg 24
Warm start >5 barg , <30 barg 16
Cold start <5 barg 4
Total number of starts 44

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2.4 Dynamic Characteristics

The HRSGs are designed to cope with the gas turbine load fluctuations during normal operation. The
HRSG is designed for sliding pressure operation of the steam turbine within the load range between
50% and 100%, down to a minimum of 37 barg (ON HOLD- to be verified by steam turbine supplier
regarding the floor pressure)at NEM terminal point TP3301 at the outlet of the HP-superheater.

During start-up the GT load is limited by the HRSGs allowable start-up pressure and temperature
gradients. During normal operation the GT ramp up and down rate is limited by the HRSGs allowable
temperature gradient.

The HRSG can be started-up according the following methods:

HRSG start-up from GT simple cycle mode


GT is in simple cycle operation over the TEG bypass stack.
Prior to opening of the TEG bypass damper to HRSG, the GT load is limited, depending on cold or warm
start. During start-up the TEG bypass damper has two intermediate positions, which are reached
gradually, and depend on the HP-Steam pressure:
- TEG bypass damper is held at the first intermediate position if HP-Steam drum pressure <S1,
- TEG bypass damper is held at the second intermediate position if HP-Steam drum pressure >S1 and
<S2.
Once the HP-Steam drum pressure is >S2 the TEG bypass damper is opened fully to the HRSG. After
completion of the HRSG soaking period the GT is released to be loaded according the normal GT start-
up program.

HP and LP steam systems


During start-up the HP and LP steam turbine bypass valves are opened and control the allowable
pressure gradient of the HP and LP steam drum. The produced steam by the HRSG during start-up will
make sure that the superheaters are sufficiently cooled. The steam turbine bypass valves will dump
steam into the condenser until the steam conditions are reached to allow HP and LP steam to the steam
turbine.

Shutdown of the HRSG


The GT is gradually reduced in load, limited by the HRSGs allowable temperature gradient. The main
steam isolation valves will close after close command or as soon as steam temperature drops below the
allowable limit. The TEG bypass damper will be closed to HRSG and the GT will be running through the
TEG bypass stack.

Further reference is made to Start-up & Shut down procedures HRSG, 22033-647-11.

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HRSG purge

Purge of the HRSG is performed as defined by NFPA 85.

The following purge procedure is based on a HRSG without supplementary firing. The by-pass stack and
the HRSG shall be purged prior to the ignition of the GT. Purging of HRSG and /or bypass stack shall be
done according to the following scheme:

After Bypass stack HRSG purge


purge required required
GT normal Yes No (1)
shutdown
HRSG trip or No No (1)
shutdown
GT trip TEG bypass damper Yes No (1)
closed to HRSG
GT trip TEG bypass damper Yes Yes
partly open to HRSG
GT trip TEG bypass damper No Yes
fully opened to HRSG

(1) It is supposed that the diverter damper is closed to HRSG and is opened to by-pass before
stopping the GT. It means that HRSG is in purged condition after normal operation and shutdown.

Purge prior to the light-off of the combustion turbine shall be accomplished by at least five volume
changes and for a duration of not less than 5 minutes.
This volume shall be calculated based on the following:
(1) The combustion turbine operating at full load
(2) The volume from the combustion turbine inlet to the portion of the HRSG or other combustion turbine
exhaust systems where the combustion turbine exhaust gas temperature is reduced to at least 56C
(100F) below the lowest auto-ignition temperature of the fuel(s) for which the system has been
designed.

Similar to the HRSG, the TEG bypass stack needs to be purged prior to start of the GT. For combustion
turbine exhaust systems without heat recovery (simple cycle mode), the purge volume shall extent to the
stack exit.

The purge flow rate shall not be less than 8 percent of full-load mass airflow is provided through the
HRSG or other combustion turbine exhaust systems, regardless of damper leakage or degradation in
the HRSG enclosure. The purge volume is determined in document 22033-103-45 Purge calculation
HRSG system.

Further reference is made to Start-up & Shut down procedures HRSG, 22033-647-11.

2.5 Degree of Automation

The HRSGs are designed for semi-automatic start-up and shutdown and for fully automatic continuous
operation.
Further reference is made to the Functional control descriptions, NEM doc. 22033-647-01.
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2.6 Protection Concept

Dangerous situations shall be avoided by interlocking of process control system (DCS), by Trip of the
safety oriented Emergency Shut-Down system (ESD) and safety relieve valves as final mechanical
protection against overpressure.
Further reference is made to the Functional control descriptions, NEM doc. 22033-647-01.

2.7 Control System Requirements

The controls of the HRSGs shall be realized with a control system, which is commonly used in power
plants. The control system shall be capable of handling the dynamics of the system without limiting the
performance.
Further reference is made to the Functional control description, NEM doc. 22033-647-01.

2.8 Environmental Conditions

The HRSGs are located outdoors in a tropical, coastal and corrosive area.
Further reference is made to the Site conditions & Utility data, NEM doc. 22033-100-02.

2.9 HRSG performance Guarantees

The guarantee case: Case 1 Unit / Remarks


GT load 100% full load -
GT fuel Natural Gas -
GT flue gas temperature 571.23 C
GT flue gas flow 124.2 Kg/s
GT flues gas composition:
- N2 (Nitrogen) 72.84 vol%
- O2 (Oxygen) 12.67 vol%
- Ar (Argon) 0.87 vol%
- CO2 (Carbon Dioxide) 3.66 vol%
- H2O (Water) 9.96 vol%
Ambient temperature 30.0 C
Ambient pressure 1.013 bara
Relative Humidity 83% -
HRSG supplementary firing No -

The following performance will be guaranteed:


The output flow of the HP steam (per Two HRSG's) will not 34.00 kg/s
be less than
HP steam temperature at the discharge of the HP 530.0 C, +3C / -3C
superheater will be
The total steam energy output from the HP steam and LP 127.7 MW
steam (per Two HRSG's) will not be less than *
The static pressure loss from the HRSG inlet flange to 254.9 mm W.C.
HRSG stack discharge will be less than

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Note: The guaranteed total steam energy output is based on guaranteed HP steam flow
of 34.00 kg/s, and expected LP steam flow of 6.04 kg/s for two HRSG's.

IAPWS-IF97
The steam properties used in the performance guarantee Industrial formulation
are according to/derived from:

* The total steam energy output is calculated as follows:


Total steam energy output = Number of HRSG * [ (HP discharge flow x HP discharge enthalpy) + (LP
discharge flow x LP discharge enthalpy) - (FW flow (into HRSG) x BFW discharge enthalpy) -
HPBFW pump enthalpy rise ]

HP discharge enthalpy (kJ/kg) 3473.11 kJ/kg, @ 80 bara/530C


LP discharge enthalpy (kJ/kg) 3001.45 kJ/kg, @ 6.8 bara/272.1C
BFW discharge enthalpy (kJ/kg) 202.9 kJ/kg, @ 13.25 bara/48.2C
HPBFW pump enthalpy rise (kJ/kg) 12
kJ/kg, assumed @ pump 75% efficiency

Further reference is made to Process flow diagram, NEM doc. 22033-104-01.

2.10 Water and Steam quality

The HRSG design is based on the water and steam quality according:
VGB Guidelines for feed water, boiler water and steam quality for power plants/industrial plants.

Steam conditions

Parameter Quality
Silica (SiO2) < 0.020 ppm
Sodium (Na) < 0.020 ppm
Iron (Fe) < 0.020 ppm
Conductivity < 0.200 S/cm

The steam quality can be guaranteed, in the design case, when the feed water quantities comply with the
VGB guidelines.

Feedwater requirements

Parameter Quality normal operating


(VGB-S-010-T-00; 2011-2012, Table 10)
1)
pH 9.2 9.5
Acid conductivity (at 25C) < 0.1
2)
S/cm
Oxygen (O2) 5 - 20 g/kg
Silica (SiO2) <5 g/kg
Iron (Fe) < 10 g/kg
3)
Dissolved Organic Carbon (DOC) < 0.1 mg/l

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1) Actual operating value pH 9.6 9.8 due to LP integrated deaerator loss of ammonia through vent and
feedwater extraction for HP boiler.
2) Cation conductivity measurements values exclude carbon dioxide.
3) TOC shall be as low as practically possible.

(1 mg/l = 1 mg/kg = 1 ppm = 1000 ppb = 1000 g/kg)

pH control:
LP-Condensate - / feed water system, LP-Boiler system: Volatile treatment with ammonia (NH3) dosing
in condensate feed water supply to HRSG.
HP-Boiler system: Phosphate treatment with Tri-sodium phosphate (Na3PO4) dosing in HP-feed water
line between the HP-economizer and the HP-steam drum.

Oxygen control:
LP-Condensate - / feed water system: Oxygen scavenger dosing downstream condenser (upstream
NEM battery limit).
LP-Boiler system and HP-Boiler system: Physical deaeration by LP integral deaerator.

Water and Steam purity control:


LP-Boiler system:
- Extraction of HP boiler feedwater.
-Physical separation by LP steam drum internal primary and secondary separator.

HP-Boiler system:
-Continuous blow down.
-Physical separation by HP steam drum internal primary and secondary separator.
-Tri-sodium phosphate dosing, reacts with the hardness salts and will be removed by blow down.

Further reference with regard to water and steam quality of the HRSG is made to the Water chemistry
Specification, NEM doc. 22033-790-21

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3. CONFIGURATION OF THE SYSTEM

This chapter describes the configuration of the feed water system, HP- and LP-boiler, blowdown/drain
and flue gas systems.

3.1 Water and steam system

3.1.1 LP-Feedwater system


See P&I DIAGRAMS 22033-105-11 and 22033-105-21

The LP-feedwater system consists of LP-Economizer pre-heater heat transfer section with recirculation
and bypass system.

Condensate feedwater is fed to the HRSG LP-Economizer pre-heater system where it is heated up close
to saturation temperature.

The condensate feedwater flow is measured by a flow element with dP-transmitters 01LAB20CF001&2
and controlled by the feed water control valve (FWCV) 01HAC20AA002 located between the LP-
Economizer pre-heater and the LP-integrated deaerator 01HAD20BB001. In this way the LP-Economizer
pre-heater pressure is maintained at a higher level than in the LP-integrated deaerator to avoid steaming
of the LP-Economizer pre-heater.
Due to the position of the FWCV the LP- Economizer pre-heater can be shut off from the boiler. For this
reason a safety relieve valve 01HAC20AA191 is located downstream the LP-Economizer pre-heater,
which will open at 51barg.
To avoid flue gas side corrosion the condensate feed water temperature to the LP-Economizer pre-
heater is controlled at a minimum temperature of 60C, which is above the water dewpoint of the flue
gas; by recirculation pump 01HAC20AP001 and temperature control valve 01HAC20AA001.
Temperature control valve 01HAC20AA001 has a minimum opening set-point to assure a minimum flow
for recirculation pump 01HAC20AP001.

LP-economizer preheater bypass control valves 01HAC20AA003 and 01HAC20AA004 maintain the
approach temperature minimum 8 below the steam saturation temperature of the LP-integrated
deaerator so as to avoid flashing in LP-integrated deaerator level control valve 01HAC20AA002. It
accomplishes this by partly bypassing the LP-economizer preheater and mix the (cooler) bypassed water
with the water from the LP-economizer preheater.

For maintaining the correct boiler water pH, (diluted) ammonia (NH3) is dosed in the condensate feed
water line at dosing point 01LAB20BN001 before it enters the LP-economizer pre-heater. Ammonia dosing
is controlled by a pH controller and a dosing pump.
LP-Boiler water sample for pH measurement is extracted from the LP-integrated deaerator through the
HP feedwater extraction line.

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3.1.2 LP-boiler system


See P&I DIAGRAMS 22033-105-11, 22033-105-21 and 22033-105-31

The LP-boiler system consists of a LP steam drum with evaporator heat transfer sections and integrated
deaerator.

After the LP-integrated deaerator level control valve 01HAC20AA002, LP-feed water is entering the LP-
integrated deaerator 01HAD20BB001 where it will be deaerated and evaporated to saturated steam.
LP-integrated deaerator serves as a feedwater storage tank for the HRSG LP and HP section, it
contains a hold-up volume of water (between normal water level and LLL-water level GT trip) to produce
steam for ten (10) minutes during failure of feed water supply.

In the LP integrated deaerator water is deaerated to 7 ppb dissolved oxygen remaining in the water with
a temperature difference of 8 between the deaeration steam and the preheated condensate.
The LP integrated deaerator is of the spray tray type with counter flow, steam flows up and water is
flowing down in the deaerator dome.

Water from the LP economizer pre-heater is sprayed into the deaerator dome where steam from the LP
integrated deaerator heats the water close to the steam saturation temperature. Because the solubility of
oxygen is very low under these conditions the oxygen is mainly released to the steam and is purged from
the system through vent line 01HAD20BR501. Although the remaining oxygen is not soluble under
equilibrium conditions, it is not completely released to steam. In order to maximize the oxygen removal,
intense contact between the steam and water is required prior to the water exiting the deaerator. This is
achieved by water cascading down over trays where it is in close contact with the steam flowing up.

Pegging steam from the HP-steam drum can feed the LP integrated deaerator by pegging steam control
valve 01HAD10AA001 to maintain a minimum pressure in LP-integrated deaerator in order to protect the
HP-feed water pumps against cavitation and to heat up the LP boiler system during start-up. Latter is
released when the HP steam flow is above LL to ensure sufficient cooling of the HP superheaters.

LP-feed water leaves the drum through the downcomer to the LP-evaporator. The steam/water mixture
coming from the LP-evaporator enters the drum in the primary steam separator, in the shape of an
internal box covered with a slotted plate where water and steam are separated. Before leaving the LP-
integrated deaerator the steam passes the secondary separator (steam dryer), which consist of
wiremesh packs, and leaves the LP-integrated deaerator via the saturated steam lines. The combination
of above separators results in a maximum carry-over of 0,1 wt.%.

The volume of the steam bubbles produced in the LP-evaporator is much larger than the volume of the
water before evaporation. During a HRSG start the LP-integrated deaerator level may rise quickly when
more water is pushed to the LP-integrated deaerator (by the steam bubbles) than leaves the LP-
integrated deaerator through the downcomer. This phenomenon is known as swell.
The LP-integrated deaerator is able to absorb the swell of the water volume of the LP-evaporator during
start-up, when the (lower than normal) start level is taken into account and the normal start-up gradient
is applied, refer to the Start-up & shut-down Procedure HRSGs, NEM doc. 22033-647-11.

During normal operation the LP-integrated deaerator water level is maintained at normal water level
(NWL) by a three element control configuration; a mass balance of incoming water and outgoing steam
and water level. This is measured by flow element with dP-transmitters 01LAB20CF001&2 for LP
feedwater flow and by flow element with dP-transmitters 01HAH20CF001&2 for LP steam flow and the
level is measured by three dP-transmitters 01HAD20CL001&2&3.
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During start-up the LP-integrated deaerator water level is controlled by one element control (level) from a
(lower) start-up level to accommodate the swell of the water, as soon as there is sufficient pressure built-
up and steam flow the control system will switch over to three element control.
Prior to start-up the start-up level can be reached by LP-intermittent blow down valve 01HAD20AA020.
During start-up and normal operation LP-intermittent blow down valve will open if the actual water level is
too much higher than the water level set point.

For LP-integrated deaerator protection against extreme low level, LLL (HRSG trip) three level dP-
transmitters 01HAD20CL001&2&3 are applied. When 2 out of 3 level transmitters detect extreme low
water level (LLL), the HRSG is in emergency shut-down and as a result the TEG-diverter damper closes
to the HRSG. If the TEG-diverter damper is not (yet) closed to the HRSG after the TEG-damper time to
allow a full stroke is expired the gas turbine will be in emergency shut-down.
When 2 out of 3 level transmitters detect extreme (HHH) high water level, the steam turbine looses its
start/run permissive and produced steam will be led to steam turbine bypass station.

To prevent the pressure in the LP-integrated deaerator from exceeding above the design pressure, it is
equipped with a safety relieve valve 01HAD20AA191 which will open at 11barg.
Prior to reaching this pressure however the HRSG is emergency shut-down by LP-integrated deaerator
pressure transmitters 01HAD20CP001&2&3, in a 2 out of 3 configuration.

For maintaining the correct boiler water quality boiler water can is drained continuously via the HP
feedwater extraction line. LP-Boiler water sample for conductivity measurement is extracted from the HP
feedwater extraction line.

The LP-Economizer pre-heater, LP-integrated deaerator and LP-evaporator can be drained completely
via blow down vessel 01HAN10AC001.

3.1.3 LP-Steam system


See P&I DIAGRAMS 22033-105-21 and 22033-105-31

The LP-steam system consists of LP-superheater heat transfer sections and LP main steam line.

In the LP-Steam system saturated steam from the LP-integrated deaerator is superheated to supply
steam to the LP section of the steam turbine.

The LP-Steam system consists of one LP-superheater section and is located in between of the HP-
economizer section 2&1. There is no desuperheater to control the steam temperature.

The LP-steam flow is measured by a flow element with dp-transmitters 01HAH20CF001&2.

To prevent pressure in the LP-steam system from exceeding above the design pressure, it is equipped
with a safety relieve valve 01HAH20AA191 with a set pressure of 9 barg.

During start-up sufficient cooling of the LP-superheater is assured by opening the LP steam turbine
bypass station block valve 01LBH20AA053, produced LP-steam is led to the steam turbine bypass
station until the LP-steam conditions are reached to supply steam to the steam turbine.

The LP-steam line and LP-superheater are automatic drained if the steam is not sufficiently
superheated, by means of motor operated drain valves 01HAH20AA061&62.

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The HRSGs can be isolated from the LP-main steam systems by means of motor operated main steam
isolating valve 01LBA20AA051, provided with a motor operated bypass valve for cracking (heating up
the down stream piping and equalizing the pressure over the main steam valve), 01LBA20AA052.

3.1.4 HP-Feedwater system


See P&I DIAGRAMS 22033-105-13, 22033-105-21 and 22033-105-23

The HP-feedwater system consists of HP-Economizer heat transfer sections with bypass system.

HP-feed water is extracted from the LP-integrated deaerator, which operates at a temperature of approx.
150.5 C. The HP-feed water pumps increase the pressure of the feed water to a value, sufficient to feed
the HP-boiler at all operating conditions. The HP-feed water pumps supply boiler feedwater to the HP-
economizer where it is heated up close to saturation temperature.
The HP-feed water flow is measured by a flow element with dP-transmitters 01LAB10CF001&2
upstream the HP-economizer. Downstream this element the HP-injection water is extracted, which is
used for HP-Steam temperature control.
The HP-feed water control station, consisting of start-up control valve 01LAB10AA002 and main
feedwater control valve 01LAB10AA001, upstream the HP-economizer controls the HP-feedwater flow to
the HP steam drum 01HAD10BB001.

HP-Economizer bypass control valves 01HAC10AA003 and 01HAC10AA004 maintains the approach
temperature some degrees below the saturation temperature of the HP-steam drum so as to avoid
steaming of the HP-economizer during part loads.

3.1.5 HP-boiler system


See P&I DIAGRAMS 22033-105-13, 22033-105-23, 22033-105-33 and 22033-105-40.

The HP-boiler system consists of a HP-steam drum with evaporator heat transfer sections.

HP-feed water is led via HP-economizers to the HP-steam drum 01HAD10BB001 and evaporators
where it is evaporated to saturated steam.

Feedwater coming from the HP-economizer is evenly distributed in the HP-steam drum by the feed
water distribution pipe. Boiler water leaves the drum through the downcomer to the HP-evaporator. The
steam/water mixture coming from the HP-evaporator enters the HP-steam drum in the primary steam
separator, in the shape of an internal box covered with a slotted plate where water and steam are
separated. Before leaving the HP-steam drum the steam passes the secondary separator (steam dryer),
which consist of wire mesh packs, and leaves the drum via the HP-saturated steam lines. The
combination of above separators results in a maximum carry-over of 0,1 wt.%.
The HP-steam drum contains a hold-up volume of water (between NWL and low-water trip level) to
produce steam for three (3) minutes during failure of feed water supply.

The volume of the steam bubbles produced in the HP-evaporator is much larger than the volume of the
water before evaporation. During a HRSG start the HP-steam drum level may rise quickly when more
water is pushed to the HP-steam drum (by the steam bubbles) than leaves the HP-steam drum through
the downcomer. This phenomenon is known as swell.
The HP-steam drum is able to absorb the swell of the water volume of the evaporator during start-up,
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when the (lower than normal) start level is taken into account and the start-up gradient is applied, refer to
the Start-up & shut-down Procedure HRSGs, NEM doc. 22033-647-11.

During normal operation the HP-steam drum water level is maintained at normal water level (NWL) by a
three element control configuration; a mass balance of incoming water and outgoing steam and water
level. This is measured by flow element with dP-transmitters 01LAB10CF001&2 for HP feedwater flow
and by flow element with dP-transmitters 01HAH10CF001&2 for HP steam flow and the level is
measured by three dP-transmitters 01HAD10CL001&2&3.
During start-up the HP-steam drum water level is controlled by one element control (level) from a (lower)
start-up level to accommodate the swell of the water, as soon as there is sufficient pressure built-up and
steam flow the control system will switch over to three element control.
Prior to start-up, the start-up level can be reached by HP-intermittent blow down valve 01HAD10AA020.
During start-up and normal operation HP-intermittent blow down valve will open if the actual water level
is too much higher than the water level set point.

For HP-steam drum protection against extreme low level, LLL (HRSG trip) three level dP-transmitters
01HAD10CL001&2&3 are applied. When 2 out of 3 level transmitters detect extreme (LLL) low water
level, the HRSG is emergency shut-down and the TEG-diverter damper closes to the HRSG. If the TEG-
diverter damper is not (yet) closed to the HRSG after the TEG-damper time to allow a full stroke is
expired also the gas turbine will be emergency shut-down.
When 2 out of 3 level transmitters detect extreme (HHH) high water level, the steam turbine looses its
start/run permissive and produced steam will be led to steam turbine bypass station.

To prevent the pressure in the HP-steam drum from exceeding above the design pressure, it is
equipped with a safety relieve valve 01HAD10AA191 which will open at 93 barg.
Prior to reaching this pressure however the HRSG is emergency shut-down by HP-steam drum pressure
transmitters 01HAD10CP001&2&3, in 2 out of 3 configuration.

For maintaining the correct boiler water pH, diluted tri-sodium phosphate (Na3PO4) is dosed into the HP-
feed water line between the HP-economizer and the HP-steam drum, via connection 01HAD10BN001.
Diluted tri-sodium phosphate is distributed in the HP steam drum with HP feedwater distribution pipe. Tri-
sodium phosphate dosing is controlled by a pH controller and a dosing pump.

For maintaining the correct boiler water conductivity boiler water can be drained continuously via the
continuous blow-down connection to the HP-steam drum via line 01HAD10BR420&422. Continuous
blow-down is controlled by a conductivity controller and control valve 01HAD10AA010.
HP-Boiler water sample for pH and conductivity measurement is extracted from the continuous blow-
down line.

The HP-Economizer, HP-steam drum and HP-evaporator can be drained completely via blow down
vessel 01HAN10AC001.

3.1.6 HP-steam system


See P&I DIAGRAMS 22033-105-23 & 22033-105-33

The HP-steam system consists of HP-superheater heat transfer sections, HP-steam desuperheater and
HP-main steam line.

In the HP-steam system saturated steam from the HP-steam drum is superheated to supply steam to
the HP section of the steam turbine.
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The HP-superheater is divided into two main sections.


Steam from the HP-steam drum passes superheater 1&2&3 and then via desuperheater line
01HAH10BR020&21 with desuperheater control valve 01LAD10AA001 to superheater 4. The
desuperheater sprays HP-feed water into the superheated steam to control the steam temperature at the
HP-main steam line. Looking at the flue-gas side of the HRSG, superheater 1&2&3 is located
downstream of superheater 4.

The HP-steam flow is measured by flow-nozzle with dp-transmitters 01HAH10CF001&2.

To prevent pressure in the HP-steam system from exceeding above the design pressure, it is equipped
with a safety relieve valve 01HAH10AA191 with a set pressure of 88 barg.

During start-up sufficient cooling of the HP-superheater is assured by opening the HP steam turbine
bypass station block valve 01LBH10AA053, produced HP-steam is led to the steam turbine bypass
station until the HP-steam conditions are reached to supply steam to the steam turbine.

The HP-main steam line and HP-superheaters are automatic drained if the steam is not sufficiently
superheated, by means of motor operated drain valves 01HAH10AA061&62&63&64.

The HRSGs can be isolated from the HP-main steam systems by means of motor operated main steam
isolating valve 01LBA10AA051, provided with a motor operated bypass valve for cracking (heating up
the down stream piping and equalizing the pressure over the main steam valve), 01LBA10AA052.

3.1.7 Drain and blow down system


See P&I DIAGRAMS 22033-105-41 (22033-105-11, -13, -21, -23, -31, -33 , -40)

The main purpose of this system is to collect all blow down water, drain water and start-up drain water &
steam of the HRSG in a safe way and to dispose flash steam to atmosphere and water to the sewer.
The HP- intermittent blow down valve, 01HAD10AA020 and LP-intermittent blow down valve,
01HAD20AA020 as well as the HP-continuous blow down control valve, 01HAD10AA010 are connected
directly to the steam side of the blow down vessel. Each of these blow downs has its own connection to
the blow down vessel.

The start-up drains of the HP-superheaters, 01HAH10AA061&062&063&64, as well as the start-up drain
of the LP-superheater, 01HAH20AA061&62 are controlled by the DCS-system during start-up of the
HRSG and are motor operated as a consequence. Start-up drain water/steam mixture is collected with a
separate start-up drain header 01HAN10BR401, which is connected to the steam space of the blow
down vessel. Steam trap 01HAN10AA801 will prevent a water blockade in the start-up drain header by
draining water to the sewer.

The drains from the HP- and LP-safety valves, as well as the blow-off of the LP-economizer safety
relieve valve are connected to the blow down vessel.

All drains of pressure parts are led to the common drain header, which is connected to the water-side of
the blow down vessel.
To avoid steam entering the sewer system, the blow down vessel is equipped with a water-lock.
Prior to common draining of the HRSG, in principle the HRSG should be cooled down first to < 150 C
(<5 barg), then the drains are allowed to be opened to the common drain system.
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All open drains with tundishes at instrument drain level and process drain and vent level are routed the
blow down vessel via the tundishes drains collector.

The blow down vessel water is drained after it is cooled down to 60C by means of cooling water, which
is supplied through temperature control valve 01PUN10AA001 and mixed with the blow-down tank drain
water.

3.2 Flue gas system

3.2.1 Description of the flue gas system


See P&I DIAGRAMS 22033-105-61

The flue gas system guides the exhaust gas from the gas turbine outlet through the HRSG via the stack
to the atmosphere.
The main components are HRSG bypass system with the TEG-diverter damper (not in NEMs scope of
supply), HRSG inlet duct, HRSG casing, HRSG outlet duct and HRSG stack.

Between the outlet of gas turbine and the inlet of the HRSG a bypass stack with diverter is installed (not
in NEMs scope of supply). This system allows the gas turbine to operate in simple cycle in case the HRSG
is not in operation.
The damper is a single flap damper, which can close to the HRSG or to the by-pass stack. A blanking plate
can be installed at the outlet of the diverter box to the HRSG to avoid any TEG leakages to the HRSG and
thus to allow maintenance activities in the HRSG while the gas turbine is in operation via the bypass stack
(simple cycle).

An expansion joint is positioned between the outlet of the diverter box and the inlet duct of the HRSG (not
in NEMs scope of supply). The expansion joint must absorb the thermal expansion of both the diverter box
and the HRSG inlet ducting to avoid unacceptable stress on the ducting.

During normal condition the flue gas system guides the exhaust gas from the gas turbine outlet through
the HRSG and via the stack to atmosphere. The HRSG inlet duct connects the turbine outlet duct with
the HRSG casing. This inlet duct distributes the flue gas to the heat transfer sections.
The HRSG casing contains the heat transfer sections.
The HRSG outlet duct connects the HRSG casing with the HRSG stack. An expansion joint absorbs the
thermal expansions of boiler outlet duct and the stack.
The stack discharges the flue gas to the atmosphere. It is equipped with connections for temperature
measurement and sampling the exhaust gas for the CEMS and for manual sampling.

In between pressure part module 1 and 2 a dummy duct is installed.

4. DESCRIPTION OF COMPONENTS

4.1 Steel structure

The HRSG steel structure is designed to support the HRSG under various load conditions, including
environmental and seismic conditions as specified in the contract.
The steel structure consists of primary steel, which is all steel that is required to keep the installation

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standing safely upright, and of secondary steel, which is all steel that is required to attach platforms and
equipment to the HRSG.
The HRSG casing is welded to the steel structure.
The steam drums are supported by top beams of the main steel structure.
The steam drums are supported by saddles that allow movement in longitudinal direction. The tube
racks are hanging on the steel structure with a suspension.
Maximum permissible load on the grating: 5 kN/m2
Warning: Dismantling of any structural component is not permitted without NEMs prior written approval.

4.2 Ducting Steel

The HRSG casing is an integral part of the steel structure. The casing plates are gastight welded to the
goal posts of the steel structure and are reinforced with welded stiffeners. At the outlet of the GT, a
diverter damper with connecting ducting is installed.
The inlet duct connects the diverter damper outlet duct to the HRSG casing and the outlet duct connects
the HRSG casing with the stack.

4.3 Internal insulation

The HRSG inlet duct, spool piece duct, outlet duct (upstream expansion joint) and module casing are
internally insulated to limit the outer wall temperature and the heat losses. Due to the internal insulation,
the thermal stresses and thermal expansion of the casing and ducting can be neglected.

4.4 Ducting / Casing

Ducting and casing is required to obtain a gas tight containment and is, in general designed as cold
casing.
The duct is capable of withstanding transient pressure peaks as they may occur during start-up and
turndown of the plant. Basically, carbon steel plate is used for the construction, while structural integrity
is achieved by profiles welded on the outside of the plates. These profiles are seal welded to the casing
plates to avoid corrosion between the members and the casing. The minimal wall thickness of the casing
is 8mm.

Internal insulation will be installed to provide the specified casing surface temperature. Selected small-
localized areas can be expected to exceed the design skin temperature requirement. These areas would
include casing test or instrumentation connections, support attachment points for flow distribution
devices and similar areas. The design will minimize on a practical basis the skin temperature excursion.
The insulation material is confined between the casing plate and lagging material and the insulation and
liner panel are attached to the outside casing plates by means of retaining studs.
The stud spacing is a square pitch design for the non-critical areas of the ductwork and casing, and a
staggered stud pitch for the critical areas of the inlet duct.

HSRG casing
The HRSG casing is an integral part of the steel structure. The casing plates are gastight welded to the
goal posts of the steel structure and are reinforced with welded stiffeners. The insulation concept does
allow for manual cleaning of the heat transfer surfaces and ducting areas.

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Ducting
The inlet ducting is designed to withstand the high flue gas velocities and rapid temperature gradients
during start-up. Gas turbine cleaning fluid is drained by means of openings at the lowest position.
The inlet duct connects the diverter damper outlet duct to the HRSG casing and the outlet duct connects
the HRSG casing with the stack. Between modules 1 and 2 a dummy duct is installed.

4.5 Pressure Parts

Boiler design and manufacturing are according to ASME section I, edition 2010, Addenda 2011.
In the HRSG pipe racks are placed behind each other. A pipe rack is defined as a bottom header and a
top header with in between the (finned) tubes. The steam or water flow in or out a pipe rack can be
through the top or bottom header.
The headers are placed against each other in order to avoid the by pass flow of exhaust gases to
outside the gaspath.
The steam drums are supported by saddles, which allow movements in longitudinal direction. Inside
each drum equipment is installed to improve the operation of the drum. A primary and a secondary
water/ steam separator are installed. The primary separator is placed above the riser outlets. A
secondary water/ steam separator of the wire mesh type is installed upstream the steam outlet line.
The drums are equipped with a feedwater distribution pipes. The distribution pipe is located below water
level and provided with perforations to distribute the feed water. Additionally the LP integrated deaerator
is equipped to remove oxygen from the water.

4.6 Bumpers

In the direction of the gas flow, the module racks are supported against deflection by bumpers. The
bumpers at the bottom headers of the modules are part of the bottom of the gaspath and the bumpers at
the top headers of the modules are part of the ceiling of the gaspath.

4.7 Bottom- and top box

The bottom and top of the HRSG gaspath is formed by bumpers and headers, they create a separate
space between the gaspath and outside of the casing. These spaces, also referred to as dead spaces,
contain the piping from the downcomer to the different headers of the evaporators, economizer and
superheater crossover piping. Provisions are made to get access to the adjacent dead space.

4.8 Inspection facilities

All drawings of inspection facilities can be found in the Operation & Maintenance manual.
External access doors are located at:
Location Drawing:

Inlet duct, one side 22033-100-05-001


Spool piece duct between module 1&2, one side 22033-100-05-001
Stack inlet duct 22033-100-05-001

At both heads of HP-steam drum 22033-100-05-003


At both heads of LP-integrated deaerator and at dome 22033-100-05-003

Blow down vessel 22033-100-05-002


The gas-tight casing is foreseen with drains at the bottom, closed by a blind flange.

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4.9 Piping

All piping systems have been designed, manufactured and pressure tested in accordance with the
ASME regulations section B31.1 and ASME I. Routing and supporting of the pipe lines have been
determined based on stress and process calculations.
Warning: It is not allowed to change the pipe line routing or adjust pipe hangers, without NEMs prior
written approval.

4.10 Expansion joints pipe penetrations

At several locations piping penetrates the casing wall. These passages are provided with fabric
expansion joints to retain the pressure tight integrity of the casing while allowing movement of the piping
relative to it.

4.11 Safety valves

The purpose of a safety or relieve valve is protection of personnel, plant and production. It is a pressure-
relieving device for any installation requiring pressure protection; that is, it protects a pressure vessel (or
pressure parts) against a pressure in excess of its design strength.
The safety or relieve valves relieve the pressure by discharging steam or water when the set pressure is
exceeded.
Safety valves are installed on the steam drums, the main steam lines and LP-economizer pre-heater,
namely:

Tag number Safety valve location Set pressure (barg)


01HAC20AA191 LP-economizer pre-heater outlet 51
01HAD20AA191 LP-integrated deaerator 11
01HAH20AA191 LP-superheater 9
01HAD10AA191 HP-steam drum 93
01HAH10AA191 HP-superheater 88

4.12 Desuperheater (attemperator)

The purpose of the desuperheater (01LAD10AA001) is cooling the steam, for control of the steam
temperature. Each HRSG comprises one desuperheater in the high-pressure section. Water is sprayed
in small droplets into the steam flow. By absorbing heat of the steam for evaporation of the water, the
steam temperature is controlled. To protect the pipe line where the de-superheater is installed from
thermal shocks, an internal protective pipe sleeve is installed.
The desuperheater is located in between two superheater sections, which has advantages over
desuperheating after the last superheater:
All water droplets will surely evaporate, no water droplet will reach the steam turbine,
Lower tube wall temperatures in the hottest section of the superheaters.

4.13 Steam silencers

Steam silencers are installed on top of the exhaust stack of the steam blow off safety valves. The noise
level produced by the blowing safety valves is decreased to 115 dB(A) at 1 meter distance. Inspections
of the silencers should only be carried out when the boiler is not in operation.

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4.14 Level indicators

The HP-steam drum and LP-integrated deaerator both have two level indicators of different type.

A local transparent level gauge, at this level gauge the actual water level in the drum can be seen. Each
level gauge is provided with gauge glass lighting and with self-closing ball valves for automatic shutoff in
case of glass breakage.

A level indicator of the electronic level probe array type, the measurement is based upon the difference
in conductivity of water and steam, with indirect level indication on a LED-display mounted near the drum
and another in the CCR.

4.15 Valves

Shut-off valves are designed in order to answer the process, ASME code and operational requirements.
The nominal diameter of the valve may differ from the accompanying pipeline system provided that the
process requirements are guaranteed. Due to the automatic operation of the plant, some valves have
been equipped with an electric or pneumatic actuator. The valve will then be made suitable for the higher
weight of the actuator by more rigid installation bridges and adequate actuator mounting flanges.
Valve internals will be standard of chrome alloy steel, and if required by the process hard facing will be
applied.
Further reference is made to the Valves and Fittings List, NEM doc. 22033-530-02.

Control valves will be designed in order to answer the process and operational requirements with a
control characteristic suitable for stable process operation.
The control valves will be equipped with a positioner and position transmitter. Body dimensions and
material selection will follow the philosophy presented for shut-off valves. Internals will be basically of
stainless steel, and if process requirements demand, with hard facing.

4.16 Expansion joints (ducting)

Any movement of the ductwork because of thermal expansion is extracted into account by the two HRSG
fabric expansion joints, one between diverter damper outlet and inlet of the HRSG and one between HRSG
outlet duct and stack.

4.17 Aircraft warning lights

On the top section of the main stack an aircraft warning lights system is installed. The system consists
of:
Three low intensity continuous red lights (min 10 cd)

4.18 Stack (closure)damper

A stack damper is installed in the main stack. The control of the stack damper is based on a passage of
the 100% gas turbine flue-gas. To prevent cooling down of the HRSG, the flue-gas stack damper is
closed when the gas turbine is stopped or is switched to open cycle operation.
Nevertheless, the design provides that, in case of a pressure higher than 100 mmH2O inside the boiler
due to an incorrect operation, the prevailing gas pressure will open the damper and act as pressure
relieving device.
For this purpose, the damper is provided with a welded frame built with materials suitable for the range
of operating temperatures. The whole frame has been reinforced in order to support the normal working
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stresses for this kind of machine.


The damper has two symmetrical blades with interior stiffeners; each blade pivots on an actuator /
connection shaft and an opposite shaft.

4.19 Hanger and pipe supports

For the support of the piping different sorts of hangers and supports are applied. All hangers and
supports are standard design. The operational position of the moving parts (hangers and supports) can
be read directly off a travel scale. Hangers and supports can be blocked in any travel position.

4.20 Field instrumentation

Adequate field instrumentation is provided to enable remote start-up, operation and shut-down,
automatic control and remote supervision and monitoring.
Important pressures, temperatures and levels can be read out locally from local gauges.
Further reference is made to the Functional control descriptions, NEM doc. 22033-647-01 and the
Instrument List, NEM doc. 22033-643-30.

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