HEAT RECOVERY STEAM GENERATOR. 1. INTRODUCTION The purpose of this manual is to provide guidance in the operation and maintenance of the Heat Recovery Steam Generator and associated Auxiliary Equipment furnished by the Westing- house Electric Corporation. A thorough under- standing of the equipment furnished is essential to successful performance and full use of protec- tive devices is mandatory to prevent damage to the equipment. It is not intended to define every aspect of operation including emergency situa- tions. ‘The Purchaser is required to act in accordance with the requirements of his Insurance Company and/or other legal authority having power in this area. The Purchaser should notify the Westing- house Electric Corporation of any conflicts that may arise between the requirements of the Insurance Company and/or the legal authority and the instructions contained in this manual. The Purchaser should discuss instructions con- tained in this manual with his Insurance Company inspector and his suggestions should be given serious consideration. It would be desirable that the Insurance Company inspector be present during startup and be given the freedom of inspecting whatever equipment he deemed neces- sary. The responsibility of the Westinghouse Electric Corporation is defined in the purchase order. Publication of this manual or furnishing an engineer for the purpose of instruction does not increase the responsibility of the Westinghouse Electric Corporation over that contained in the purchase order, 2. FUNCTIONAL DESCRIPTION Figure 1 shows a sectional view of the heat recovery steam generator. The exhaust gas leaves the gas turbine axially and passes first through a connecting duct and then through a bumer section. In the burner section the gas is heated to the temperature required to maintain the desired steam production. After leaving the burmers the heated gas flows through a diffuser duct which terminates in a Y-shaped section splitting the gas flow into two parallel paths. A tuning vane module then turns the gas flow upwards. After the bend, the gas flows in turn over the tubes of the superheater, high pressure evaporator, econo- mizer, and low pressure evaporator before passing through the exhaust transition section, stack cover and exhaust stack extension. The stack cover can be closed when the system is either not in use or in a hot standby mode of operation. The split into the two parallel gas paths mentioned above is dictated by the tube modules which are shop fabricated and have to be split into two widths in order to make them rail shippable. Figure 2 shows the unit broken up into modules and also shows the high pressure steam drum 19, the low pressure storage tank 20, and the deaera- tor 21 All sections have a stiffened outer carbon steel casing with internal calcium silicate block or fibre glass insulation, The insulation is protected from the erosive forces of the exhaust gases by metal lagging. ‘The purpose of the turning vanes is to provide 2 uniform distribution of flow and also minimize the bend loss. A maldistribution of flow would have a negligible effect on performance, but it ‘might cause high temperatures in some super- heater tubes. This effect is minimized by the careful sizing, shaping, and spacing of the vanes. A third and very important advantage of using turning vanes is fo produce an arrangement where the superheater tubes absorb almost no heat by radiation. As shown in Figure | the first row of superheater tubes is not in a direct line of sight of the burner flame because of the 90° bend and the shielding produced by the vanes. Since there is virtually no radiant heating, superheater perform- ance and tube metal temperatures can be more accurately predicted. This results in superheater tubes which are less likely to fail from unexpect- edly high metal temperatures, Figure 3 is a flow schematic of the HRSG system used in the PACE plant. The gas flow is vertical and the tubes are horizontal with serpen- tine designs being used in all sections except the low pressure evaporator which is made up of only LLL. 1385-006HEAT RECOVERY STEAM GENERATOR Gas TURENE FLANGE STACK COVER & EXTENSION (NoT SHOWN) exnaust TRANSITION ‘TURNING VANE | \ ~ WODULE | | *S oireuseR | uct BURNER SECTION Ssiwver ouct Figure | a single row of tubes instead of the two rows shown in Figure 3. Downflow is used in the supetheater and economizer in order to take full advantage of the log mean temperature difference through a counterflow design. A forced circula- tion design is utilized for the evaporator. Since the process of evaporation is isothermal, the log mean temperature difference is the same for either a counterflow or parallel flow design. The parallel flow design was chosen chiefly to permit operation at part loads under natural circulation should there be a circulating pump failure. Care~ ful consideration has been given to the external LLL. 1385-006 piping and the steam drum to impart this capabil: ity to the system, vane ‘The elgifnts are arrSiged with the superheater being exposed to the hot gases from the burner first followed by the high pressure evaporator and then the economizer. Additional heat recovery is obtained by locating a low pressure evaporator after the economizer. Condensate from the con- denser is pumped to a deaerating feedwater heater where the temperature is raised to 250 F. The water then enters a low pressure storage tank from which it is pumped by a boiler feed pump toRehr HEAT RECOVERY STEAM GENERATOR eo cael Figure 3 the economizer. As the water flows through the economizer it is heated to within approximately 5 F of the saturation temperature. The water then flows to the steam drum where it mixes with recirculated water and then leaves the drum at the bottom. It then passes through the high pressure circulating pump and then through the high pressure evaporator where a steam-water mixture is generated. The high pressure evaporator shown in Figure 3 is a split serpentine design containing two rows of tubes in parallel in order to reduce the pressure drop and also reduce the steam and water velocities at the exit. Reducing the pressure drop helps to assure hydrodynamic stability. The steum-water mixture flows to the steam drum where separation of steam and water takes place. Saturated steam leaves the top of the drum and flows to the superheater where additional heating takes place to produce superheated steam at the required temperature and pressure. Steam temper ature control is obtained by using a superheater bypass. In the low pressure circuit, water at 250 F is taken from the storage tank and pumped to the LLL. 1385-006 Jow pressure evaporator where a steam-water mixture is generated for heating the condensate in the deaerator. Extraction steam from the steam turbine is also introduced into the deaerator for heating the condensate, High pressure water from the economizer is also introduced into the deaera- tor for heating the condensate through a recircu- lation line as shown in Figure 3. The flow through the economizer is maintained constant over the full load range to prevent steaming at part loads. ‘The excess flow leaving the economizer flows through the recirculation line to the deaerator. The high pressure evaporator has inlet flow restrictors located in each evaporator tube in order to assire hydrodynamic stability. The restrictors ure located just after the inlet header in the end space outside of the gas stream in order to ensure that there is no boiling and that the restrictors are in fact located in the single phase region. The inlet flow restrictors are designed using an eccentric shape in order to make them fully drainable and to prevent an accumulation of suspended solids at the inlet end which would cause plugging.HEAT RECOVERY STEAM GENERATOR 3.1 GENERAL DATA 3. ENGINEERING DATA ASME Boiler And Pressure Equipment Vessel Code Low Pressure Evaporator Section | Economizer Section I High Pressure Evaporator Section I Superheater Section I High Pressure Steam Drum Section I Low Pressure Storage Tank Section VIII Deaerator Section VIII Interconnecting Piping Section I Blowdown Tank Section VIII PLACE OF WESTINGHOUSE EQUIPMENT MANUFACTURE SERIAL NO. Lower Tube Module | Sauder Industries 727927 (Superheater & High | — Ine., Emporia, Kansas 727230 Pressure Evaporator) | Tube Fab, Ine. 1395-20 Tulsa, Okla 1395-48 Upper Tube Module | Sauder Industries 727226 (Economizer & Low | Inc. 727331 Pressure Evaporator) | Emporia, Kansas 727234 727235 High Pressure Steam | Westinghouse 18A-2880B Drum Electric Corp. 18A-2888B Orange, Cal. Deaerator ASC Mig. Co., Inc. 0-73.29. 0-73-299-6 Low Pressure Behm Company 0-73-2993 Storage Tunk Inc. 0-73-299-4 Paterson, NJ. Blowdown Tank Westinghouse Elec. Corp.|_18A-2880-C&D Orange, Cal, PACE #2 - DOS BOCAS Ref: Plant #2880 LLL. 1385-006HEAT RECOVERY STEAM GENERATOR PLACE OF WESTINGHOUSE, MANUFACTURER'S EQUIPMENT MANUFACTURE SERIAL NO. SERIAL NO. Lower Tube Module | Tube Fab, Inc. 1395-24 (Superheater & High | Tulsa, Okla. 1395-28 Pressure Evaporator) | Sauder Industries 1395-20 Ine., Emporia, Kansas B28 Upper Tube Module | Sauder Industries 737223 (Economizer & Low — | Ine. 737224 Pressure Evaporator) | Emporia, Kansas 737225 737232 High Pressure Steam | Westinghouse Drum Electric Corp. Orange, Cal. Deaerator fg. Co., Ine. rato ASC Mig. Co., pe 0-73-2993 Low Pressure Behm Company 299 Storage Tank Inc. ea Paterson, NJ. eee Blowdown Tank Westinghouse Elec. Corp| 18A-2888-C&D Orange, Cal. PACE #3 - DOS BOCAS — Ref: Plant #2888 3.2 DESIGN INFORMATION Design Design Hydrostatic Test Pressure ‘Temperature Pressure Equipment PSIG F PSIG Low Pressure Evaporator 200 600 300 Low Pressure Storage Tank 200 650 300 Deaerator 200 650 300 Economizer 1550 600 2325 High Pressure Evaporator 1440 600 2160 Superheater 1440 oe 2160 High Pressure Steam Drum 1440 600 2160 Blowdown Tank 360 600 540 3.3 PERFORMANCE 1277 PSIA steam at the outlet of the superheaters and at site conditions of 59 F ambient and sea ‘A. Guarantee for Two (2) HRSGs level. ‘The steam temperature will be 952 F with a variation of plus or minus 10 F. The low pressure 1. The Guarantee net high pressure steam pro- water production is 1,008,918 pounds per hour at duction is 886,954 pounds per hour of 250 F with 0.005 cc per liter or less of dissolved LL. 1385.006 7HEAT RECOVERY STI !AM GENERATOR oxygen at the inlet to the boiler feed pumps and the low pressure circulating pumps. We guarantee the solids in the steam entering the superheater will be maintained at a low level and will permit trouble-free operation without the need for clean- ing for a period of at least 8000 hours of operation providing that the solids in the drum do not exceed 500 ppm. Preferably, the solids in the drum should be maintained in the range of 50-100 ppm. When operating with drum solids not exceeding 500 ppm, we predict that the solids in the steam will not exceed 0.05 ppm. The heat input to the duct bumers at the ‘guarantee condition is 286 x 106 BTU/HR (LHV) ‘on natural gas and 292 x 106 BTU/HR (LHV) on #2 fuel oil. The back pressure on the GT exhaust flange for each HRSG system will not exceed 12" of water. ‘The above guarantees are based upon the following; feedwater, condensate, extraction steam, drum water, exhaust gas and fuel specifica tions for each HRSG which include 0.5% blow- down from the high pressure steam drum. Fig- ture 4 shows the flows, pressures and temperatures in the various parts of the system. The flows here are bases on 0.5% blowdown. Feedwater to Economizer ‘A. Pressure - PSIA ~ 1424 B, Temperature - °F - 250.0 ©. Flow, Lbs./hr- °F - 489105.0 D. Maximum Dissolved Oxygen, evjliter - 0.005 E, pH at 25°C- 8.5 minimum 9.5 (preferred) F. Hardness - fess than 0.1 PPM Condensate to Deaerator A. Pressure, PSIA - 35.0 B, Temperature, °F - 108.7 C. Flow, Lbs./hr- 407,620 D. pHat 25°C- 8.5 minimum, 9.5 (preferred) Extraction Steam to Deaerator A. Pressure, PSIA - 32.8 B. Temperature OF - Saturated C. Enthalpy, BTU/LB - 1157.3 D, Flow, Lbs./hr- 40085 Drum Water A. Total Dissolved Solids, Max. PPM-500 B. Blowdown, % of flow entering the high pressure drum - 0.5 C. Suspended Solids, Maximum PPM-2 Exhaust Gas at Inlet to HRSG System A. Flow, Lbs./hr - 2,550,000 B. Temperature,°F - 988.0 C. Maximum Deviation from a Uniform Gas ‘Temperature Profile °F #25 D. Velocity over 85% of the incoming duct area to be within 25% of the average velocity. No velocity to vary by more than 40% of the average velocity. E. Gas Composition Composition : Constituent % By Weight 0 15.94 C07 4.67 HO 4.22 Ng 73.85 A 1.32 802 Nil 803 Nil Sodium Nil Vanadium Nil LL. 1385-006HEAT RECOVERY STEAM GENERATOR yp amnaiy LL. 1385-006HEAT RECOVERY STEAM GENERATOR Fuel at Inlet to Duct Burners A. Natural Gas 1) Pressure, PSIG - 100 (before control valve) 2) Analysis, Constituent % By Volume (Gi) Methane 90.0 (u) Ethane 5.0 (w) Na 5.0 3) Higher Heating Valve, BTU/CU. Ft. Dry - 1000 4) Specific Gravity - 0.60 5) Ratio HHV/LHY = 1.11 B. #2 Fuel Oil 1) Fuel Pressure, PSIG - 400 psig (before control valve) 2) Atomizing Air Pressure, PSIG - 8 psig 3) Atomizing Air Flow, SCFM - 2000 4) Analysis Constituent By Weight (@ Sulfur 0.0 (uw) Hydrogen 14.0 (ui) Carbon 86.0 Giv) Nitrogen Nil () Ash Nil 5) Gravity 1) Deg. API-32 2) Lbs. per gallon - 7.21 6) Pour Point, °F - (-5.0) 10 7) Visocosity, centistrokes @ 110 F - 2.4 8) Water‘and Sediment, Volume % - Nil 9) Heat Valtie, BTU/Lb. Gross - 19300.0 10) Ratio, HHV/LHY - 1.06 2. Bach HRSG system is capable of dry operation for 6000 hours per life without damage if the exhaust gas, specification entering the HRSG system is same in Item I except the gas tempera- ture is reduced from 988 F to 900 F. B, Operating Condition 1. Each HRSG system is to produce a minimum of 1250 pounds per hour of 300 PSIA steam by electric heating elements during standby condi- tion at site, conditions as specified in CCM3-C dated 1/8/71. 2. The superheater is designed to handle a gas side flow of 800 Ibs/sec at - 15 degrees F ambient. This results in approx. 20 percent excess surface on a normal ambient day for which a bypass system is furnished in order to obtain superheater temperature control. 3.4 SAFETY VALVE SETTINGS All safety valves are Dresser Valves with a raised face inlet flange and a 150 1b. raised face outlet flange. 3.5 WATER VOLUMES (Includes low pressure evaporator, economizer high pressure evaporator, superheater, deaerator, ow pressure storage tank, high pressure steam drum, and interconnecting piping where each of these are applicable.) Volume for Hydrostatic Test 20,426 gal. Volume for Chemical Cleaning 24,000 gal, Volume for Operation 11,330 gal. LL. 1385-006HEAT RECOVERY STEAM GENERATOR™ 1éqote Ohathios! Size Inlet x —L set Orticex’ | tne Ftnge | [ Pewuve/ Location Tag Style Outlet Rating LB} | PSIG? High Pressure | PSV-1A 17374, 21/2x3x6 1500 1440. Steam Drum. | High Pressure] PSV-1B 17578 3x5x6 1500 | 1493 Steam Drum Economizer PSV-IC 17574 3x5x6 1500 1550 Inlet Superieeater PSV-3 1737 W1/2x3x6 1500 1360 Outlet Low Pressure, | PSV-2A IgiPA | 4xPx6 > 300 80 Storage ae | Deserator PSV-2B 1811QA | 6xQxB- 300 85 | Low Pressure | PSV-2C 18IFA | ~F/4xFxit/2| 300 | Evaporator 1 Outlet sr } Low Pressure | PSV-2D IFA | 11/4xF x2 300 | Evaporator Outlet J 4. PHYSICAL DESCRIPTION 4.1 LOWER AND UPPER TUBE MODULES The lower tube module contains the super heater and high pressure evaporator while the upper tube module contains the economizer and low pressure evaporator. All of the tubes are arranged in horizontal serpentines with an/offset tube pitch jand are supported in interlocking tube supports. These supports are punched and bent out of carbon steel in the upper tube module and 11% chromium stainless steel in the higher tem- perature lower tube module. The tube supports are suspended from U shaped hangers by means of rollers, The hangers are welded to the under- side of T beams. One set of I beams is used to support the low pressure evaporator and econo- mizer and another set is used to support the high pressure evaporator and superheater. Six steel 1 beams are used at the top of each module. These beams protrude through the module walls and are bolted to vertical columns during field erections. LL. 1385-006 All of the headers in the economizer, high pressure evaporator, and superheater are located at the high pressure steam drum end. The outlet, end of the low pressure evaporator is also located at the steam drum end. All of the headers are fixed to the 3/4” casing forming the walls of the modules, except for the superheater inlet and low pressure evaporator inlet headers which are flexi- bly mounted. The tubes are free to expand in a direction away from the headers. The tubes do not slide in the tube supports as thermal expan- sion takes place, instead the tube supports move with the tubes and cause a circular bar to roll in the U shaped hanger. Welded construction is used throughout, with no rolled joints and with pressure parts all designed to satisfy the requirements of Section 1 of the ASME Boiler and Pressure Vessel Code. Socket welds are not used for tube connections to the headers. Nipples are used for tube connection WWHEAT RECOVERY STEAM GENERATOR, and this joint is stress-relieved in accordance with the requirements of Section I. All of the pressure parts within the casing are relatively small in diameter and light wall permitting rapid startup without any danger of failure due to thermal stress or differential expansion. All of the elements in this design are fully drainable, an important consideration for acid cleaning and corrosion protection during fabrica- tion and preparation for dry layups. ‘The walls of the modules are made up of a stiffened 3/4” thick carbon steel casing insulated on the inside with calcium silicate block insula- tion. The insulation is protected from the erosive forces of the exhaust gases by metal lagging. The entire heat recovery steam generator is designed to withstand loadings specified for Zone 3 by the Uniform Building Code. These ‘include seismic loads which will result in a safe design even in the worse earthquake areas and wind loads of 50 pounds per square foot which correspond to a velocity of approximately 140 miles per hour. ENGINEERING DATA FOR LOWER AND UPPER TUBE MODULES There are two lower and two upper tube modules for each heat recovery steam generator. Superheater ST =4.50" 6 rows of 2.00" O.D. tubes ia 6 "i Kat teas Flow OFFSET 26 tubes per row for each module. Effective tube length - 39 ft. 4 in, Heating surface - 36,036 sq. ft. per module All fins are made of 1196 Cr stainless steel. All fins are serrated fins with a segment width of 0.156” except for the fins in rows I and 2 which are solid fins. E Inlet 6" sch. 120 SA-106 GR B Outlet 6” double extra strong SA-335 P11 with Discharge outlet 8" - Schedule 160 High Pressure Evaporator ST=4.50" SL= 4.5" except 6.5” between - ‘Tube Wall Fin Fin. Tube Thickness | Height | Thickness | No.of | SL Row Material | Min, Wall,In. | In. In. Fins/Inch | In. 6(top) | SA2i3TI | 0.120 1 0.0478 6 45 5 saaisril | 0.203 1 0.0478 6 45 4 sazsT2 | 0.340 1 0.0478 6 4.75 3 sa2i3sT22 | 0340 0.75 0.0478 6 5.06 2 sa2i3T22 | 0.340 0.188 0.030 3 is LeBort.) |_sa213T22 | 0340 0.188 0.050 oa LLL. 1385-006HEAT RECOVERY STEAM GENERATOR. 12 rows of 2.00" 0.0. tubes 26 tubes per row for each module Effective tube length - 39 ft. 4 in, Heating surface - 107,150 sq. ft. per module Minimum tube wall thickness - 0.110" Tube material - SA-178 GR C Fins are 1” high carbon steel serrated with a 0.156" segment width, 0.0478” thick, 6 fins) Headers Inlet 8” sch. 120 SA-106 GR B Outlet 8" sch. 140 SA-106 GRC Economizer € Cov OD. tubes —— 4x, E Pukey 32 tubes per row for each module Ke ekabo.o Effective tube length - 39 ft. 4 in. ‘Heating surface - 151,046 sq. ft. per module Minimum tube wall thickriess - 0.110" ‘Tube material SA-178 GR A Fiii‘are 1" high carbon steel serftted with a 0.156" segment width, 0.0478” thick, 6 fins/ inch Headers Inlet and outlet 6 sch. 120 SA-106 GR B Low Pressure Evaporator ‘Same as economizer except only 1 row of tubes Heating surface - 6869 sq. ft. per module. Headers Inlet and outlet 4” sch. 80 SA-106 GR B LLL. 1385-006 4.2 SOOT BLOWER PROVISIONS Provisions have been made for adding soot blowers. These provisions include 1. Cavities between the heat transfer sections to allow space for fixed position rotary soot blowers. A total of 24 soot blowers can be added to one lower and one upper tube module. Six would be located between the superheater and high pressure evaporator, six between the high pressure evaporator and economizer, six in the center of the economizer and six located above the low pressure evaporator. There would be a total of 48 soot blowers for each heat recovery steam generator. 2, Bearings and bearing supports for supporting the soot blower elements 3. Wallbox extensions, flanges, and cover assem- blies to’ permit mounting of the blowers elimina ing the need for expensive cutting operations in the field. 4.3 HIGH PRESSURE STEAM DRUM ‘The high pressure steam drum used is shown in, Figure 5. It consists of two stages of separation, a primary centrifugal stage plus a secondary chev- ron stage. The steam-water mixture from the evaporator enters the ‘drum through two nozzles and is directed upward into the stationary centrif- ugal swirl vane contained in a cylinder called the riser where a vortex motion is imparted. A swirling doughnut-shaped vortex is formed at the top of the riser and is contained by a cylinder called the swirl vane downcomer surrounding the riser, and a flat plate called the deck plate which separates the primary and seconday stage. Most of the water in this vortex is discharged through two tangential nozzles located at the top of the swirl vane downcomer. A small amount of entrained steam discharged from the tangential nozzles flows to the second stage of separation through an annular opening between the deck plate and drum shell. Some of the water also flows. down through an annulus formed by the swirl vane downcomer and the riser. Steam with entrained moisture leaves the primary separator through an otifice located in the center of the deck plate and flows through the second stage of separation 13