Professional Documents
Culture Documents
INTRODUCTION
The procedures included in this section are of basic nature, intended to serve as a guide in following proper
sequence and precautions during initial stages of operation. Since the Heat Recovery Steam generator is only a
part of the overall plant which must operate in unison, specific and detailed values are to be incorporated to
refine the procedure after sufficient experience is gained and the opportunity to fine tune the controlled to
confirm with actual operating requirements and characteristics.
Reference should be made to respective Manufacturers instructions regarding pre-operational and operational
procedures for auxiliary equipment.
PREOPERATING PROCEDURES
Clean up :
Before initial startup with the admission of GT exhaust gas and prior to each subsequent cold start up , after
maintenance has been done on the unit , it should be inspected and cleaned both internally and externally. All
foreign material should be removed from pressure parts. Any grating ,pipe lines, electric conduit etc. that
might restrict normal expansion of the unit, should be cleared. All personnel should be cleared from the hot
gas path inside the HRSG and Access doors closed.
Chemical cleaning :
Specific procedures for alkali boil out are given separately.
Blowing steam lines :
Prior to starting up a new unit or restarting an older unit following major pressure parts repairs, the main
steam line should be steam blown to remove scale and foreign matter. This should be done after chemical
cleaning and prior to setting safety valves. Detailed procedures for steam line blowing is given separately.
Setting of safety valves :
Setting of safety valves is carried out next.
Cold start up
Preparation for service :
Ensure that the unit has been chemically cleaned, that the steam lines have been blown, that the safety valves
have been set and that the unit has been filled to the start-up level with properly treated feed water.
Ensure that all instruments are calibrated and all instrumentation, control systems and interlocks have been
checked and are available for service.
Ensure that all-mechanical equipment have been checked and are available for service.
Ensure that the feed water system, equipment have been checked and is available fore operation. It is
recommended that during start-up , the feed water be controlled remote manually until sufficient flow is
established. Ensure that feed water quality is as per the recommendation .
Ensure that the GT exhaust system has been checked and is available for service. Ensure proper operation of
GTG , its compressor cleanness, IGV opening, its steam water injection , divertor opening , to deliver the
required GTE gas flow at specified gas temperature and composition. Deviation if any shall be informed to
BHEL for review of further course of action.
It is assumed that smooth manual and remote operation of guillotine gate and divertor damper at HRSG inlet
has been checked and is available for service.
Ensure that SF system of HRSG has been checked as per Burner O & M and is available for service.
If the HRSG has been recently filled up with feed water or stored as per recommended preservation
procedures, the following steps ( 1 to 4 ) can be skipped and step 5 to be followed directly.
1. Open the entire vent and drain valves of economizers, evaporators and the drum.
2. Slowly fill the economizers and evaporators using the cold boiler feed water up to start-up level.
If cold boiler feed water is not available and hot boiler is to be used. The temperature difference
of metal and water should not be more than 30 deg C.
3. Close all the drain valves except SH drain valves after 5 minutes.
4. When the water level in drum reaches the start-up level, vent valves of economizer are to be
closed after ensuring that there is no air in the system.
5. Water level in drum can be adjusted to start-up level with the help of respective emergency drain
(intermittent blow drain valves).
Purge the HRSG as per NFPA requirements.
Now the HRSG is ready for receiving the GT exhaust gases. HRSG can be taken into service, in cold start-up
in the following mode.
Caution :
The procedure should ensure that no damage to the HRSG and its components is caused during start-ups. THE
HEATING RATE DURING START-UP AND THE COOLING RATE DURING SHUTDOWN IS ONE
MAJOR ASPECT TO BE TAKEN CARE OF. Variation in temperature during start-up or shutdown causes
stresses in the boiler components, particularly in the drum and can cause damage to the drum if the rate of
temperature rise / pressure rise is very high. During the initial start up of new unit, it is recommended that a
relatively slow rate of pressure increase be allowed in order to allow sufficient time for checking expansion
movements and to permit the operators to become familiar with the characteristics of the unit and its
auxiliaries.
Start up procedure ;
DIVERTER DAMPER OPENING :
1.
2.
3.
4.
5.
6.
SETTING
0.05 Kg/Cm2
1.8 Kg/Cm2
HRSG trip on scanner air pressure very low 2/3. Only supplementary
firing trip is provided. Divertor will trip with both scanner air fans not
available.
7%
95 %
3 Kg/Cm2
60 %
The flue gas temperature after the duct burner and the superheated metal temp. shall be periodically,
particularly when load on HRSG is raised. In case the flue gas temperature exceeds 875 deg C or the
superheated metal temp. exceeds 490 deg C the firing rate control shall become stayput and control changed
over to manual.
Reasons for increase in gas / metal temperature shall be checked before putting back the firing system on auto.
In case firing rate shall be restricted such that the gas / metal temp. is within acceptable limit specified above.
GT load may be reduced to the required level ( but in any case not less than 25 % load) after reaching the
reqd. steam generation at full load but not exceeding MCR steam generation with GTE temp. Always above
steam outlet temp. During this period of GT load reduction , supplementary firing shall be constant and shall
be increased , even if the steam output decreases. Firing rate may be increased gradually to meet steam
demand ( but not exceeding MCR steam generation) ensuring the gas temp. and metal temp. do not exceed
the above values. Sufficient care shall be taken to ensure steam generation not less than 50 tph at any point of
SF mode operation.
HOT STARTUP IN GT MODE : ( AFTER 4 HOURS OF SHUTDOWN)
Open the divertor damper and guillotine gate at HRSG inlet.
Purge the HRSG as per NFPA requirements.
Reduce the GT load such that the GT exhaust temp. is less than 400 deg C
Adjust divertor damper position as per startup curve matching residual drain pressure with cold startup curve.
After ensuring continuous steam flow through superheated, GT load shall be increased gradually to reach
33.89 MW. Divertor damper shall be fully open towards HRSG. Ensure that the rate of increase of steam
generation, steam pressure and temperature are within limits.
Introduce SF system to increase the steam generation. For introducing the SF system, inststructions /
operations specified under startup procedure shall be strictly adhered to.
Shutting down :
The following procedure is for normal; shutdown. This is based on the assumption that the unit is operating
and it is intended to reduce the pressure to zero and cool the unit completely.
Stop supplementary firing. Slowly close deviator damper towards HRSG. This reduces the gas flow thorough
HRSG. Allow the pressure to drop with reduction in load to accelerate cooling. The load reduction should be
slow enough to ensure that the HRSG cooling rate is not more than 100 deg C per hour. Once the pressure
drops by 2 kg / cm2 below the normal operating pressure close the main steam stop valve and the divertor.
Emergency procedures :
Low water level:
If the water level falls out of sight in the water level gauge, due to failure of feed water supply or some other
fault, except in the case of momentary fluctuations that might occur with extraordinary changes in load,
appropriate action should be taken at once to stop supplementary firing, if SF system is in service and also to
close the divertor damper towards HRSG . In case of
Difficulties in closing the divertor damper within the normal closing time, GT shall be tripped.
If someone in the authority, who is familiar with the circumstances and guide to the emergency and positively
certain that the water level can be restored immediately without damaging the unit is available, he can take the
decision to keep the divertor damper in an intermediate position so that only a limited gas flow passes
through the HRSG after ensuring that SF system is not in service.
If feed water has become available, gradually re-establish the level in the drum. If feed water is not available
fast close divertor damper towards the HRSG, if HRSG is in GT mode, seal air fan and scanner air fan shall be
kept in operation.
If tube failure is suspected reduce the steam pressure gradually by opening the main steam line drain. Open
the drum vent when the pressure drops below 1.5 kg/cm2 and drain the unit following normal draining
procedure once pressure drops to atmospheric pressure. Determine the cause of low water level and examine
the unit for the effects of possible overheating such as leaks and distortion of pressure parts.
Repair any leaks.
After the repairs, hydrostatically test the unit at working pressure before putting the unit back in service.
After the unit is cooled enough to permit a man to enter it, make a thorough inspection of pressure parts for
any indication of damage resulting from loss of water level. Report the tube failure and operated data to
BHEL in the format enclosed elsewhere in the O & M. after necessary reports have been made apply a
hydrostatic test and obtain the approval of proper authorities before putting the unit back in service.
Evaporator tubes :
In case of a leak or tube failure, which does not involve a serious drain on the feed water supply, the water
level should be maintained, and the unit taken out in normal manner. If the tube failure results in a loss of
steam as great that water level cannot be maintained with the feed water supply available, use the method
outlined below :
Economizer :
An economizer tube leak can be detected by sound and increased feed water requirements. The leak should be
investigated at the earliest possible time and the unit shut down in a normal manner. Water leaks in
economizer can cause considerable corrosion damage to adjacent tubes. Any decision to continue operation
with known leaks should be made with this in mind.
The following are some of the items that an operator should be looking for :
1.
2.
3.
4.
Look foe any unusual traces of water on the floor or leaking from casing joints.
Look for valve and valve packing leaks.
Be on the look-out for any unusual condition (discoloration, hot spots etc. ) on boiler casing.
Check for unusual noises, overheating of bearings and for adequate lubrication of all motors and
driven equipment.
The following are the some specific items that should be observed at least once a day:
1.
2.
3.
4.
The following more extensive checking should be done at least once a week :
2. Check spring hangers on boiler support and on steam lines for proper functioning.
TYPE
SERRATED & SOLID
SPIRAL FINNED
PLAIN & SERRATED
FINNED TUBE
SERRATED FINNED
SERRATED FINNED
TUBE SIZE
51.0 X 3.6
AREA ( SQ. M)
1000
51.0 X 3.6
7065
38.1 X 3.6
38.1 X 3.6
1165
1640
SAFETY VALVES
LOCATION
MAKE
STEAM DRUM
VALVE 1
STEAM DRUM
VALVE II
STEAM DRUM
VALVE III
STEAM DRUM
VALVE I
STEAM DRUM
VALVE II
BHEL
SET PRESSURE
KG/SQCM (G)
OPEN
CLOSE
30.0
28.5
BHEL
30.6
29.1
BHEL
30.9
29.4
BHEL
25.6
29.4
BHEL
26.3
25.0
LOCATION
MAKE
TYPE
MUH
BHEL
SETPRESSURE
KG/SQCM (G)
25.0
BHEL
YARWAY
USA
YARWAY
USA
LEVCON
1910 -K
VISIBILITY
(MM)
686
NUMBERS
MODEL
TWO
ONE
953
ONE
762
ONE
AQUARIAN
3000
-
Headers
Outside diameter
Thickness
Material
Top
219.1
25.0
SA 335 P12
Riser tubes
1. Pipe size
2. Number of risers
3. Material
159 x 10
four
SA 106 GrB
Individual feeders
1. Pipe size
2. Number of feeders
3. Material
159 X 12.5
Two
SA 106 GrB
Bottom
219.1
14.2
Tubes in a module :
SH II
SH I
51.0
3.6
10000
51.0
3.6
10000
Fin specification
Type :
Density
Height
Thickness
Solid
110
12.5
1.25
Serrated
200
12.5
1.25
Tube material
Fin material
SA213T22
SA240 TP 409
SA213T22
Top headers
1. Outside diameter x thick
2. Material
219.1 x 32.0
SA335 P22
219.1x32.0
SA335 P22
Bottom headers
1. Outside diameter x thick
2. Material
219.1 x 12.7
SA 335 P22
219.1 x 12.7
SA 335 P 22
fins / m
mm
mm
Drum to SH link
1. Pipe size
2. Number of pipes
3. Material
Connecting links
1. Pipe size
2. Number of pipes
3. Material
DESH links
1. Pipe size
2. Number of pipes
3. Material
159 x 10.0 mm
Six
SA 106 GR. B
159 x 12.5 mm
six
SA 335 P22
406. X 22.2 mm
one
SA 335 P 22
1828.8 ( 72) mm
38 mm (min)
SA 515 Gr. 70
Baffle Screen and centrifugal seperators
Carbon Steel
Inner diameter
Thickness
Material
Internals
Internals material
Tubes in a module:
1.
Tube Outer Diameter 51.0 mm
2.
Tube Thickness
3.6 mm
3.
Fin specification
Module no
Type
Density fins / m
Height mm
Thickness mm
03 to 05
Serrated fins
120
12.5
1.25
Tube material
Fin Material
SA 210 Gr A1
IS 513 Gr. EDD
06 to 14
200
12.5
1.25
219.1 x 14.2
SA 106 Gr B
Down comer
1.
2.
3.
4.
Pipe size
Number of downcomer
Material
Type
406.4 x 32
TWO
SA 106 Gr C
Plain, gas touched
Common feeders
1.
2.
3.
4.
Pipe size
Number of downcomer
Material
Type
406.4 x 32
TWO
SA 106 Gr C
Plain, gas touched
1. Outside Diameter mm
2. Thickness mm
3. Material
Tubes in a module
1. Tube Outer Diameter
2. Tube Thickness
3. Fin specification :
Top
219.1
22.23
SA 106 Gr. B
38.1
3.6
Module No.
No. of tubes per module
Type
Density, Fins /m
Height, mm
Thickness, mm
01 to 02
68
Serrated tube
180
12.5
1.25
Tube material
Fin material
SA 210 Gr. A1
IS 513 Gr. EDD
Connecting Links
From
To
Pipe size mm
Material
Bottom
219.1
14.20
SA 106 Gr. B
inlet
feed pump
economizer
159 x 10, 1 no
SA 106 Gr.B
outlet
economizer
drum
159 x 10, 1 no
SA 106 Gr.B
Pipe size
Number of downcomer
Material
159 x 10.0
ONE per module
SA 106 Gr C
MUH is the fifth heat transfer surface arranged in the direction of the gas flow. The MUH is constructed of
modules , consisting of spiral finned tubes welded to the top and bottom headers, two rows per modules.
The MUH is designed for single pass flow on the gas side and multipass flow on the tube side.
The MUH modules are equipped with high point 1 vents and low point 1
drain for a fully drainable design.
The modules shall be interconnected with multiple 180 degrease bent tubes of similar material as headers.
1. Outside Diameter mm
2. Thickness mm
3. Material
Tubes in a module
1. Tube Outer Diameter
2. Tube Thickness
4. Fin specification :
Top
219.1
22.23
SA 312 P 316
38.1
3.6
Module No.
No. of tubes per module
Type
Density, Fins /m
Height, mm
Thickness, mm
01 to 02
68
Serrated tube
130
15.9
1.25
Tube material
Fin material
SA 213 TP 316
SA 240 TP 316
Connecting Links
From
To
Pipe size mm
Material
Bottom
219.1
12.70
SA 312 P 316
inlet
feed pump
economizer
159 x 10, 1 no
SA 213 TP 316
outlet
economizer
drum
159 x 10, 1 no
SA 240 TP 316
Pipe size
Number of downcomer
159 x 10.0
ONE per module
ATTEMPERATOR
Spray attemperator is utilized to control the final steam temperature to 385 deg C . for this application an
attemperator is used after the superheater. The attemperator piping is furnished and is designed with an
internal sleeve for the first 3 m down stream of the spray nozzle to protect against thermal shock.
EXPANSION JOINTS
One expansion joint at HRSG inlet and one more expansion joint at chimney inlet are provided as shown in
companys GA drg. to take care of the expansions.
SUPPLEMENTARY FIRING SYSTEMS
A supplementary firing system capable of firing Refinery gas and Bombay high associated gas as fuels heats
up the GT. Exhaust to the required temperature whenever reqd. the duct burners are located at the inlet of the
HRSG. The supplementary firing system is supplied by M/S BHEL. Constructional details of burner system
may be seen in burner area enclosed in the O & M manual.
CHIMNEY
The GT exhaust gases, after passing through all the heat transfer surfaces are discharged into the atmosphere
at the safe height through a 60 m high steel chimney of dia 3.5 m . The chimney externally insulated to a safe
height for personnel protection.
SAFETY PRECAUTIONS
Safety is everyones business. While at BHEL boilers have been operating safely over decades, this sections
purpose is to draw the operators attention of the necessary precautions to be taken for the safe operation and
maintenance of HRSG. By observing these simple precautions one can have safe and happy operations of the
HRSG throughout the life period.
NOTE: THIS SECTION IS SUGGESTIVE AND SHALL NOT BE CONSIDERED AS A SAFETY
OR PROCEDURE. THE SECTION INCLUDES MINIMUM REQUIREMENTS BUT IS NOT
ALL-INCLUSIVE.
Proper installations, operation and maintenance are essential for safe and reliable HRSG operation.
Precautions taken should consist of but not limited to , hearing protection, eye protection, protective
clothing(i.e. gloves, hard hat) as reqd for the task being preformed. Due to the various circumstances and
conditions in which plant personnel may be working and the consequences of each, BHEL cannot possibly
evaluate all conditions that may injure personnel or equipment. Nevertheless, BHEL is offering the following
safety precautions for plant personnel as matter of information only.
When replacing instrumentation, always isolate the instrument with root valves and release the pressure with
the instrument vent or the blow off line.
CAUTION : DO NOT TRY TO REPAIR AN INSTRUMENT WHEN UNDER PRESSURE.
It is reqd. to ensure that all control systems and safety interlocks have been checked and are available for
service. Loss of control power should be alarmed and its availability to be ensured. If any interlock is
bypassed or removed from service for testing or repair, other means need to be substituted to supervise this
interlock manually and caution should be made in the log book as per NFPA requirement.
HRSG ACCESS:
When entering ductwork or boiler casing through the access doors during outage for routine maintenance or
inspections, operators should ensure that the environment has been checked for man safe conditions. When
entering the cavity. Look around to be sure there are no loose liner pads or other boiler components overhead.
Extended outages for major HRSG upgrades or maintenance require the installation of blank-off plates. The
blank-off plates provide a positive gas flow interruption between the divertor damper outlet and the HRSG
inlet duct flange. This provides a means for simple cycle GT operation and operators safety during extended
HRSG outages.
After safe entry has been gained, ensure proper lighting and ventilation have been installed to perform the
task.
When entering steam drums, operators should mechanically ensure that drum access doors can not be
inadvertently closed trapping personnel inside.
Operators should be alert for grating not properly fastened down. Loose grating can result in tripping hazards.
When HRSG are in operation, never touch an exposed piece of process pipe or tubing without first testing for
temperature.
Do not touch the HRSG casing while in operation without making sure that the temperature of the surface is
tolerable to the human skin.
WARNING: DISCOLOURED CASING AREA IS INDICTIVE OF HOT SPOTS CAUSED BY
INSULATION SYSTEM FAILURE OR GAS LEAK.
VALVES:
Never repack or perform maintenance while the valves are under pressure unless a special procedure exists.(
i.e. setting of safety valves) and qualified personnel are performing the task.
Always be sure that all safety relief valves are in working order to start-up.
CAUTION: HRSG OPERATION WITH SAFETY RELIEF VALVES IN NON- OPERATIONAL
CONDITION COULD CAUSE SERIOUS INJURY AND EXCESSIVE DAMAGE TO HRSG PRESSURE
PARTS. MOTOR OPERATED VALVE SETTING (ACTAUTOR) ARE TO BE DONE AS PER O & M
AND SHALL NOT BE CHANGED DO NOT EXCEED THE TORQUE LIMITS WHILE CLOSING.
HRSG DUCTING
The ducting is a gas tight system and any hot gas leakage or gaps in insulation will cause hot spots and
discoloring in the duct. It needs to be attended.
WARNING: DISCOLOURED CASING AREA IS INDICTIVE OF HOT SPOTS CAUSED BY
INSULATION SYSTEM FAILURE OR GAS LEAK.
INSULATION:
Repair damaged insulation and lagging as soon as possible, particularly in areas where personnel could be
injured (i.e. near aisles, areas easily reached from platforms, ladders, stairs, etc.). The insulation specified is
non-asbestos bearing ceramic fibers.
CAUTION: DO NOT WALK ON CLADDING SHEET INSIDE THE DUCT. USE LONG WOODEN
PLATE OVER THE PIN FOR STANDING OR WALKING.
Follow guidelines as described in vendor manuals found in the HRSG operation and maintenance instruction
manual.
When examining high-pressure steam lines for leaks, extreme care should be taken particularly if the leak is
heard but not seen.
DIVERTOR DAMPER IN BY-PASS STACK :
Divertor damper is to be kept fully open towards HRSG during supplementary firing. No modification is
permitted during the operation.
DIVERTOR : Closing of divertor damper towards by-pass stack when guillotine gate at HRSG inlet is not
opened will cause major problem in GT.
CAUTION : DO NOT CLOSE DIVERTOR ON BY-PASS STACK SIDE WHEN GUILLOTINE GATE AT
HRSG INLET IS NOT OPENED.
GAS TURBINES :
Also the reduction in GT exhaust gas flow through HRSG with divertor damper modulation at any GT
operating point in SF mode can damage HRSG. Ensure divertor damper full open towards HRSG during SF
mode of operation.
CAUTION : DO NOT OPERATE HRSG IN SF MODE WHEN EXHAUST GAS FLOWS FROM GT IS
REDUCED WITH DIVERTOR DAMPER MODULATION.
DEARATOR: If the dearator is not proper, it will reduce its outlet temperature and increased oxygen content
in feed water. It is not desirable for proper HRSG operation. If need to be checked during operation and the
design values are to be maintained particularly when GT or SF system is fired with fuel oil to avoid back end
corrosion.
DOSING SYSTEM:
The dosing system including blow down C.B.D. and I.B.D. system should be available for service prior to
start up procedure.
DOs
PREPARATION OF HRSG FOR STARTUP
DOS
Familiarize with the operation and maintenance manual of duct burner.
Ensure readiness of selected fuel systems.
Check the igniters and scanners for the corresponding fuel.
Ensure all interlocks and protections to be in operation, to trip or stay put / decrease firing corresponding to
SH metal temp. gas temp and fuel pressure as per the control scheme.
Reduce the load in step of 2.5% per minute for load down to 50 % MCR. Reduce supplementary firing
accordingly.
Check and take the controls on manual at a point where better control can be obtained manually.
Check the normal drum level and maintain. When the pressure is 2kg/cm2 open all vents.
Stop scanner air fan when gas temperature after duct burner reaches 60deg.C. Open SH & DESH drain valves
and evaporator and economizer vent valves. Do not open evaporator, economizer & MUH valves.
DONTS
UNFIRED MODE :
Do not continue HRSG operation if the drum water level is near low low condition.
Do not purge HRSG with gas temperature above NFPA /GT supplier recommendation.
Till HRSG startup parameters reaching the nominal shown in startup curve. Exhaust gas temp. should not be
increased beyond 400 deg.C.
Do not increase the rate of steam pressure and temperature than recommended value as per startup curve.
Feed water temperature not below 138 deg.C.
SUPPLEMENTARY FIRING MODE :
Showing no flame.
Main gas pressure is not very low and not very high.
Scanner air pressure is not very low and any scanner air fan running feedback.
Once all the above conditions are satisfied, select LOCAL or REMOTE (selector switch in the
hardware console) in the control room and accordingly, press START PURGE PB in local BMS
panel or in the control room.
GT should be running.
UNIT FLAME FAILURE TRIP conditions :All burners unsuccessful start or trip.
Once pilot MTV open feedback is received, PLC will give command for opening BTV within 10
secs.
Main gas pressure not very low and not very high.