HEAT RECOVERY STEAM GENERATORS (HRSG 11 A-B & 12 A-B) 1.

PURPOSE OF THE SYSTEM

KOT ADDU POWER STATION UNITS 11&12 convert the four open cycle gas turbine units (GT 5 to 8) in two combined cycle blocks. Each block consists of; Two gas turbine generator units, Two heat recovery steam generators (HRSG's), One steam turbine generator.

The gas turbines are of the 9001 E type; they operate on natural gas or on BFO. The gas turbine exhaust is fitted with two duplex flap isolators, one at the inlet of the by-pass stack and one on the inlet of the HRSG. Each gas turbine exhausts into its own HRSG. The heat recovery steam generators are single pressure type. The water circulation in the boiler vaporizer is ensured by HP circulating pumps. The advantage of forced circulation boilers is their start-up speed. With this type of boiler, circulation is ensured before start-up of the gas turbines, allowing the tubes to cool down and following advantages. No problem of water hammer No flow unbalance in the tubes Small diameter tubes, thus low thermal inertia, Fast start-up.

To maintain the very high availability of the HRSG, two HP circulating pumps are installed on normal/stand by operation, with automatic start-up of the second pump if there is an incident on the first. The HRSG's are provided with soot-blowers for the blowing of exchanger's tubes.

2.
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PLANT DESIGN DATA

Type of Fuel in gas turbine Atmosphere Pressure Ambient temperature Relative Humidity Wind speed Exhaust gas flow GT Exhaust temperature boiler inlet Gas temperature at the boiler (chimney outlet) Gas turbine load mbar C % m/s t/h C C % t/h C bar abs C Natural Gas 996 30 60 44 max. 1345 538 156 100 173.2 512 42 130 BFO 996 15 60 44 max 1342 499 170 100 151.3 476 35.8 150

10- HP steam outlet 11- HP Steam temperature at superheater outlet 12- HP Steam pressure at superheater outlet 13- HP feedwater temperature

3.

PLANT DESCRIPTION

The boiler is a vertical duct in which the various heat exchanger tube banks are arranged horizontally. The gas turbine exhaust flue gas successively passes through. The HP superheater, The HP evaporator, The HP economizer, The LP evaporator.

The HP circulating pump takes suction from the HP drum and feeds the HP evaporator. The HP drum is fed by three HP feedwater pumps, two on duty, the other on stand-by. At the top of each HRSG, a LP evaporator feeds the feedwater tank with LP steam. The LP evaporator pumps take suction from the feedwater tank and feed the LP evaporator. The LP evaporators are fed by three evaporator pumps, two on duty, the other on stand-by. The LP steam produced by the LP evaporators is discharged in the feedwater tank for heating and deaerating of the feedwater. A LP separator tank is installed between evaporator outlet and deaerator. From the deaerator water is returned to the HP drum by up to 3 50 % HP boiler feed pumps. The feedwater tank also supplies 3 50 % LP evaporator pumps, which deliver water to the LP evaporator. From the condenser, condensate is delivered to a single deaerator by either of 2 100 % condensate extraction pumps.

4.

STEAM DRUMS

The drum volumes are determined in accordance with the volume of tube banks in order to monitor the water level during start-ups or rapid load swings without undue blowdown. An inside plate concentric to the shell is fitted in the drum to guarantee good temperature uniformity in the outside housing, taking into account the temperature rises and very rapid load swings. The steel and the drum thickness are chosen as to obtain an acceptable temperature gradient in the wall thickness for a very high number of cycles. The drums incorporate steam dryers to the form of corrugated plate assemblies. The drums are put on the boiler structural steel above the tube banks in order to avoid accidental drainage of the economizer into the drum.

5.

HP CIRCULATING PUMP

Pump assisted circulation successfully manage fast start-up, transient operation, reliable operation and high availability. To maintain the very high availability of the HRSG, two pumps (2 100%) are installed on normal/stand by operation with automatic start-up of the second pump if there is an incident of the first.

6.

FLUE GAS DUCT

Ducts are provided to direct the turbine exhaust gases from bypass stack to the boiler and from the boiler to the top stack. A flexible expansion below allows free expansion of ducts and boiler blocks. Ducts are bottoms supported on two lubricating piles. A stack is located downstream of the boiler, at its summit. This self-supporting stack is fixed into the upper part of the boiler by means of transformation pieces. Deflectors are installed in the stack to avoid rainfalls into the boiler.

7.

SOOTBLOWERS

Sixteen rake sootblowers with a translation stroke are provided per boiler as furnace oil is burnt in the gas turbine. One sequence each 8 hours is enough when GT is continuously operating with furnace oil. Necessary steam used by the sootblowers is taken at the superheater outlet. But the sootblowers can be used to waterwash the exchangers during shutdown. Sootblowers are electrically driven units.

8.

ATMOSPHERE DRAINS AND BLOWDOWN EQUIPMENT

The flash is designed to recover:

8.1 FLASH TANK

Water from continuous blowdown HP drum. Steam from LP separator.

8.2 BLOWDOWN TANK

The blowdown tank is design to collect all boiler drains and the water coming from the flash tank. This blowdown is equipped with:

One vent duct to atmosphere. One cooling water circuit. One discharge to sewer. One condensate from sootblowing system. All drain from the HP economizer, the LP evaporator, the boiler flash tank, the superheater and the emergency blowdown.

9.

LP-SEPARATOR TANK FSR004ZE

The water steam mixture coming from LP separator arrives in the separator. The steam goes to the deaerator and the water to feedwater tank. The separator is equipped with a steam dryer of corrugated plate type. The steam outlet line is equipped with a manual-isolating valve. The water outlet line is equipped with a manual-isolating valve.

10. SAFETY VALVES

A) ON HP CIRCUIT
Downstream of the superheater, a relief safety valve (about 30% nominal flow) avoids too many accidental blows off on drum safety valves. All drum safety valves are designed to about 70% nominal flow.

B) -

ON LP CIRCUIT
Downstream of the LP evaporator a relief safety valve is installed to protect the evaporator against over pressure.

OPERATION PROCEDURE
This part describes the different operations, which are

1.

NORMAL OPERATION CONFIGURATION

Basic conditions Load changing

1.1 BASIC CONFIGURATION

Exhaust gases from associated gas turbine goes through the boiler and: One HP vaporizer circulating pump (FSR100 PO or 200 PO) is in operation. One LP vaporizer-feeding pump is in operation (APB101PO or 201PO) and common discharge line motorized shut off valve (UV 042) is open. The selected feedwater control valve (LCV 050 A or LCV 050 B) controls the level in boiler drum and associated motorized shut-off valve (UV 050 A or UV 050 B) is open. The general feed water shut off valve (UV 001) is open. The drain valves (LV 050 and LV 034) at circulating pump and superheater outlets are closed. The continuous blowdown (UV 035) is open at the good position. The superheater by-pass control valve (TCV 051) controls the steam temperature at superheater outlet. The boiler flash tank level control valve (LCV 053) controls the level in the flash tank. The boiler blowdown tank is cooled by water injection (HV 012 is open). One boiler is said to be in operation when exhaust gases go through the boiler i.e. when the associated boiler damper is not closed.

NOTE :

1.2 LOAD CHANGING

A load change can be requested by the operator or caused by a grid frequency variation.

LOAD INCREASE
The HP by-pass valve may eventually open according to the loading rates to limit the positive pressure gradient at 4-bar/mm maxi.

LOAD DECREASE
Only normal load decreases (between 0 and 10 %) are considered here. In this case, the steam turbine valves may operate in limitation mode in order to limit the HP steam negative pressure gradient or to prevent the HP steam pressure from falling below 20-bar abs. (4 bar /mm maxi). The HP steam by-pass remains closed.

2.

COMBINED CYCLE BLOCK START-UP

The combined cycle block start-up is automatic when the plant is ready to start. On boilers, "plant ready to start" means that all circuits must be filled, the drums levels adjusted, all circulating pumps ready to start and flop isolators ready. This preparation for start-up must be done before the combined cycle start-up.

2.1 FIRST FILLING OF BOILER

FIRST FILLING OF HP AND LP EVAPORATOR The boiler filling is made before any other start-up operation. The first filling is made at atmospheric pressure with water from system SER (APH) in MANUAL OPERATION.

At boiler inlet, motorized and manual shut-off valves are open. At drum inlet, the level control valve is OPENED (LCV 050). At steam outlet, the condensate pot-draining valve is OPENED. Be sure that following are in service:

Pressure transmitters, Level switches on drain pots, Level indicators on drum, Level transmitters on drum and boiler flash tank. The indications of level transmitters on HP drum are correct only if the connection pipes between transmitter and drum are filled up with cold water. It is necessary to fill them before the first filling of boilers.

NOTE :

Fill the boiler up to reach the filling level into the drum Check the indications of drum level Complete the filling of economizer by opening manual vent valves inlet economizer, close then when air free water passes through Adjust (if necessary by acting on intermittent blowdown) the level at the filling level

2.2 CIRCULATION PUMP PREPARATION BEFORE STARTING

LOCALLY: Check lubrication on bearings Open the cooling circuit:

Mechanical seal housing (HV 161 and HV 261) Pump body and bearing box (HV 181 and HV 281) Cooler of mechanical seal (HV 156, 155 and HV 256, 255) FSR HV 162 and HV 262 FSR HV 175, 176 and HV 275, 276

Check there is no air in the circuit, brief opening of following:

2.3 COLD START-UP

2.3.1 Before GT start-up (on the first boiler to be started) The boiler inlet damper is closed, by-pass blast stack full open. HP circulating pump is started-up.

2.3.2

HP Drum level adjusted below the swelling level and the low level. One HP feedwater pump is in operation. One condensate extraction pump is started and the level in the condenser is kept constant by the control valve. One LP evaporator pump is in operation. Piping drains closed. START-UP OF FIRST GT

At the start-up order The boiler inlet is fully open, the by-pass blast stack is also fully open (about 30% of the gas turbine rated low is discharged in the HRSG in order to limit the boiler thermal stresses). The isolating valves are open: 2.3.3 The steam isolating valves on the HP header is open, if the isolating valve associated with the other boiler is closed. To supply steam to the steam turbine gland sealing system and the piping heating up to the steam turbine. The piping drain valves open as soon as the boiler inlet damper starts to open. The HP drum pressure increases naturally and when the HP drum level reaches the swelling level, the HP feedwater control valve is put under automatic control. The LP evaporator begins to produce steam and feed the deaerator. At 12-bar abs of HP steam pressure, the steam turbine gland seal system is put in operation. As soon as the condenser vacuum is < 0.35 bar abs, the HP by pass is available. The HP by-pass controls the boiler pressure gradient < 4 bar/min. At 15 % steam turbine load, the HRSG load increases by closing step by step of the by-pass flap. At 20 % steam turbine load, the ST drain valves receive a closing order. SECOND HRSG START-UP The second GT and HRSG can be started at any time. The start-up of the second HRSG is the same than the first one but with the condenser already under vacuum. The HP by-pass limits the HRSG pressure gradient and then stabilizes the HP steam pressure at the sliding pressure set point. When the pressure at the second HRSG is slightly higher than the other, and when there is no more saturation detection, there is an automatic opening of the HP steam header value. As soon as both HP steam-isolating valves are open, both HP by-pass receivers the same sliding pressure set point values depending on the total steam flow. When both HP by-pass valves are closed, the unit operates in sliding pressure made with HP control valve fully open if the steam flow is sufficient or at minimum pressure of 20 bar abs controlled by the turbine HP control valves. The HP steam pressure follows the natural sliding pressure curve. The HP bypasses receive a set point value, which is slightly higher than the sliding pressure curve.

3.

COMBINED CYCLE BLOCK AUTOMATIC SHUTDOWN

The combined cycle block automatic system ensures complete shutdown of the steam plant. As for start-up sequence, the operator may decide to stop all or part of the plant. The normal shutdown of a combined cycle block is scheduled to maintain the boiler. Steam turbine plant in the hottest possible conditions and is as follows; The steam turbine load is reduced to a minimum value.

During this load reduction sequence, the HP by-pass follows the sliding pressure curve. As far as the boiler inlet damper is kept open during the ST load reduction, the steam flow remains at its initial value so that the sliding pressure set point is maintained at its higher value. The turbine drains open when ST load < 20 %. Then, the by-pass blast stack is open and the boiler inlet damper is closed. The HRSG's are maintained at the steam pressure existing before the shutdown and isolated on the same side (drains and vents are closed). The HRSG's and common feedwater plant auxiliaries are shutdown where applicable. The gas turbines are shutdown.

The steam turbine and its auxiliaries are tripped.

4.

OPERATION FOLLOWING INCIDENTS Loss of a heat recovery steam generator.

This failure causes the opening of the by-pass stack and the closing of the HRSG inlet damper. The gas turbine continues operating in the open cycle mode. The boiler is isolated on its steam side. The HP steam by-pass holds the pressure, which was present when the fault appeared. If the steam turbine was operating with both boilers, the valves close to 50%. If the other HRSG is not in operation, steam turbine trips.