Professional Documents
Culture Documents
NOOTER/ERIKSEN s.r.l.
Giuseppe Battaglia
TOPICS
Process Description
The Steam Generator characteristics are:
1. Drum type, Natural circulation & vertical tube
2. One pressure level
3. Horizontal gas flow
4. Heat Recovery Boiler for use with Gas Turbine
5. Duct Burner for supplementary firing
6. Fresh Air firing facility for Steam Generation without Gas
Turbine
7. T-box / by-pass Stack to connect GT
Heat Recovery Steam Generator supplies HP superheated
steam into the steam headers for process use.
Process Description
HRSG, Drum type,
Natural circulation &
vertical tube
Process Description
1.
2.
3.
4.
5
5.
8
Water/Steam Circuit
6.
7.
8.
9.
7
6
9
4
11
12
2
10
13
Economizer
Evaporator
Boiler drum
Superheater 1&2
Main Equipments
10.
11.
12.
13.
HP Drum
SH-EVA-ECO coils
TEG
Multi
Louver
Dampers
Burner
Main
Stack
Sat. Steam
BFW
ECO
P&ID HP SH system
DSH Control Valve
DSH
Water
Start Up Vent
Control Valve
Sat. Steam
HP SH Steam
DSH nozzle
SH2
SH1
ST Bearings oil
circuit
NG
Local control
panel
To Burner
Elements
To Pilots
Pilot
Flame scanners
Main burner
Burner
elements/runners (7)
9,5 pH;
0-1
S/cm
Boiler
water
9,5 pH;
50-100
S/cm
SH
steam
0-1 S/cm
Sat.
steam
0-1 S/cm
Instrument air
Involved Systems
The following control & protection systems are involved during
HRSG operation:
DCS Functions
The DCS performs the following functions:
GTS Functions
The GTS performs the following:
ESD Functions
The ESD performs the following:
Supervises HRSG protection, automatically by-pass the TEG or
trips the GT (via GTS) or trip the Duct burners (via BMS) in
emergency situation
Detects process conditions (trip initiators)
Transfers status information to the DCS, BMS and GTS
Purge sequence (HRSG Duct)
BMS Functions
The BMS performs the following:
Supervises Duct Burner operation and performs relevant
burner elements light off / shut down sequences
Detects process conditions (duct burner trip initiators)
and protects the Duct Burner
Transfers status information to the DCS and ESD
HRSG/Duct Burner Purge
MODES OF OPERATION
HRSG in FA mode (GT in OPEN CYCLE)
In this operating mode the Turbine Exhaust Gases (TEG)
produced by gas turbine (GT) are directly discharged to the
atmosphere by means of the by-pass stack.
HRSG operation is allowed in fresh air (FA) operation with duct
burner only (the HRSG stack damper is open ).
In FA mode the duct burner purge and light-off logics will be
inhibited by BMS until the HRSG trip causes (monitored by
ESD system) and the duct burner trip causes (monitored by
BMS and ESD systems) are removed.
When the HRSG and duct burner safe condition has been
restored it is possible to purge and start the HRSG and duct
burner in fresh air operation and then change over in combined
cycle mode operation (GT+HRSG) when required by Operator.
MODES OF OPERATION
HRSG in FA mode (GT in OPEN CYCLE)
FA fan is provided by two drives:
1. main drive is an electric motor
2. stand-by drive is a steam turbine.
The drives changeover from electric motor
to steam turbine is manually performed by
local operator, whereas from steam turbine
to electric motor can be in auto mode from
DCS.
Electric motor has local/remote start-up
and shut down facilities. Steam turbine has
local start-up facilities only as well as local
shut down and remote ESD command.
During the HRSG FA mode operation it is
recommended to change over from electric
motor to steam turbine, in order to avoid
an HRSG trip due to electric motor failure.
FA fan clutches automatically couple the
actual driving machine (Steam turbine or
electric motor)
MODES OF OPERATION
HRSG in FA mode (GT in OPEN CYCLE)
MODES OF OPERATION
HRSG in FA mode (GT in OPEN CYCLE)
STEAM TURBINE LOCAL (MANUAL) START UP PROCEDURE
Prior to start-up (locally) the Steam Turbine, all the following conditions has to be
checked:
HV-403A
1.
2.
3.
4.
5.
6.
7.
LP Steam
Header
Woodward
Governor
Peak 150
MP Steam
Header
Oil tank
MODES OF OPERATION
HRSG in FA mode (GT in OPEN CYCLE)
With the above permissive, the Steam Turbine Manual start up procedure consists of:
1.
2.
3.
4.
5.
6.
Local Start
Trip Reset
Oil Pump
Governor Valve
ST drains
MODES OF OPERATION
HRSG in FA mode (GT in OPEN CYCLE)
7.
8.
9.
Woodward
Governor
Peak 150
Governor Valve
MODES OF OPERATION
COMBINED CYCLE MODE
(GT+HRSG)
After the GT+HRSG purge, in this operating mode the TEG are
directly sent to the HRSG. The by-pass stack damper is closed;
the HRSG damper is open as well as HRSG stack damper. There
isnt provision for diverter dampers system in intermediate
position.
The combined cycle operation includes:
simple recovery
recovery with supplementary-firing
In the first mode the HRSG receives enough TEG to produce the
required steam.
When the GT has reached the 60% of the load it is possible to
light-off the HRSG supplementary firing (duct burner) in order to
increase the steam production and satisfy the steam demand.
PURGE REQUIREMENT
(GT+HRSG)
A cold purge of both the HRSG enclosure and GT+By-Pass
system shall be completed prior to the light-off of the GT and
prior to the admission of combustion turbine exhaust gas into
the HRSG.
The purge sequence shall be in accordance to the GT
manufacturers requirements and NFPA 85 code, considering
HRSG volumes to be purged.
Purge shall be accomplished by at least five volume changes
and for a duration of not less than 5 minutes. During the purge,
the flow rate shall be not less than 8% of GT full-load mass airflow.
PURGE REQUIREMENT
(GT+HRSG)
Two different phases compose this purging sequence:
1. phase 1, the GT purge sequence purges the GT and the Bypass stack
2. phase 2, after the above phase the ESD monitors the purge
of the HRSG duct using the Unfired GT airflow
As alternative and during purge phase 1, the phase 2 (HRSG
purge) could be performed by BMS (HRSG/Duct Burner purge)
using fresh air from FA fan and then from DCS the operator can
change over the HRSG from FA mode to CC mode (with GT still
not firing and in purging condition).
After the HRSG purge and during combined cycle mode, the GT
load ramp has to respect the permissive for the HRSG warming
up, following the temperature ramp rate (Start up curves)
indicated in the HRSG manufacturers manual.
PURGE REQUIREMENT
(GT+HRSG)
During the combined cycle operation, and following the
GT+HRSG purge operations as above indicated, the GT is
permitted to switch back in open cycle mode (by closing the
diverter dampers system by DCS) and to purge and operate the
GT in open cycle through the by-pass stack.
When the GT is operating in open cycle through the by-pass
stack, then the HRSG Purge completed condition (Purging
phase 2) is reset by ESD. In this case the TEG is not permitted
to re-enter the HRSG at a later time without HRSG re-purging
(the opening of the diverter system dampers is not allowed by
DCS and ESD).
PURGE REQUIREMENT
(GT+HRSG)
When the GT is running in open cycle mode through the by-pass
stack, in order to include the HRSG and operate in CC mode the
following steps shall be necessarily performed:
1. HRSG duct shall be purged in FA mode (by means of the FA
duct burner purge sequence, managed by BMS logic).
2. In FA mode it shall be possible to light-off the duct burner and
start up the HRSG (following the FA start up curve/ramp
rate).
3. Then the TEG shall be permitted to re-enter the HRSG at a
later time (by activating the manual change over sequence
from FA mode to CC mode) without lowering the GT load.
4. TEG shall not be permitted to re-enter the HRSG (logic by
ESD) until the HRSG is in service, pressurized and in hot
status (i.e. the Boiler drum pressure is higher than 27 barg).
As alternative GT shall be shut down and an integrate
(GT+HRSG) cold purge shall be performed.
HRSG
By-Pass System
By-pass system is realized by means of two dampers (multi louver
type), one to isolate the by-pass stack and another to isolate the
HRSG inlet. The system includes sealing air also, in order to
guarantee multi louvers tightness of 100 % when in close position.
The two dampers have a single pneumatic actuator and are
mechanical linked in order to have the following two
configurations:
System open:
System close:
General Notes
The controller function blocks within the DCS provide auto/manual facilities
on the outputs to the final control devices.
Auto/Manual selection is indicated to the operator.
The bump-less switching is provided during the Automatic to Manual control
and tracking functions.
Flow signals from the field transmitters are linearized in the DCS (square
root inside DCS).
Controllers actions: the error between a set point (SP) and the measure of
the same variable (PV) is calculated as: SP PV, thus positive if set point
is bigger than measure; this error is the input of the controllers in the control
loops logic.
The PID controllers is considered direct if a positive error in input,
generates an increment of the PID output, reverse if generates a reduction
of the PID output.
Final Tuning of controllers and threshold settings will be done during the
commissioning.
P compensated
Involved process
variable
P, T compensated
T compensated
Involved
process
variable
During startup, when water starts to boil, a drum level swelling takes
place due to the sudden formation of steam bubbles in the evaporator
To prevent this problem, level setpoint during startup is lowered and goes
back to normal value as drum pressure reaches operating levels
H P D ru m L e v e l (m m )
700
650
600
550
500
450
400
350
NWL
300
250
200
150
Set Point
100
50
0
10
20
30
40
50
60
HP Drum Pressure [%]
70
80
90
100
Single-element control is
based on the action of a
PID controller which acts
according to the level PV
and SP.
Three-elements control is
based on the action of a
PID controller which acts
according to the level PV
and SP; the output is
scaled and added to the
HP main steam flow,
generating the SP with
which the PI controller
acts according to the HP
FW flow.
Single element
control
St eam Flo w
DCS
LT
Boiler Drum
ECO
LCV
M
Bo iler feed
water
St eam Flo w
DCS
LT
Boiler Drum
ECO
LCV
PT
LEVEL COMPESATION
M
Bo iler Feed
water
DCS
LT
Boiler Drum
ECO
LCV
FT
FLOW BALANCE:
FT steam- FT water
Bo iler feed
water
PT
One element
FF/Bias
Three element
Involved
process
variable
Control element
[%]
<1
>=1
>=40
>=64
50
40
10
0
Control element
Involved
process
variable
TV
Control
system
Attemperating water
TT
Vapore A.P.
HP drum
SH-1
SH-2
Control
system
TV
Attemperating water
TT
TT
Vapore A.P.
HP drum
SH-1
SH-2
Cascade Control
Master Controller
Slave Controller
Control element
Involved
process
variable
HRSG limits
Burner limits
Drain
Pots
Temperature
elements
Pneumatic on-off
vlv
plant shut-down
HP Boiler drum high-high level
HP Boiler drum low-low level
Cooling air to flame detector low low pressure, delayed to enable
cooling air fan change-over
Sealing air to FA duct damper low low pressure, delayed to enable
fan change-over of FA operation change over
SH steam HH temperature, 90 sec delayed (duct burner trip 60 sec.
Delayed)
HRSG stack damper not open
HRSG instrument air low-low pressure
HRSG emergency trip (push button in Control Room)
Diverter damper system open & GT running & FA duct damper not
closed, (with time delay 15 sec to enable the change-over from CC
to FA mode)
END