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

High Pressure Circuits

The main parts of the high-pressure circuits are. The feedwater circuit from boiler area inlet. The HP economizer. The drum. The HP evaporator with associated circulation system. The HP superheater with associated by pass circuit and the live steam circuit. The boiler flash tank. The blow down tank.

1.1 The Feedwater Circuit from Boiler Area Inlet

This circuit includes mainly: One automatic shutoff valve (UV 001) to isolate the boiler during shut down and avoid the filling of the drum by the level control valve tightness and its bypass with automatic valve (UV 002) to prevent water hammer at main valve opening. One non-return valve (YV 001) designed to maintain pressure in the boiler when the boiler is not in operation and the feedwater system out of operation. One nipple for acid cleaning. One drain line with one hand isolating valve (HV 564). One special line for filling the boiler with hand isolating valve. (see elementary systems SER and APH). One special line designed to limit over pressure due to the water thermal expansion inside the economizer during starting up. This line is connected to the separator and is equipped with a pressure valve (PV 039). One vent at economizer inlet with two hand shut off valves (HV 701, HV 702). This vent is used for air evacuation during the filling of the economizer.

1.2 The HP Economizer

The HP economizer includes: Several rows of finned tubes. One inlet header connected to the feedwater circuit. One outlet header connected to the drum. One drain line on the outlet header to drain the economizer. This drain line is connected to the blow down tank with two hand isolating valves (HV 401, HV 402). One pressure safety valve (PSV 004), to protect the economizer. Two 100 % feedwater control valves (LCV 050 A, LCV 050 B) in parallel with for each control valve one motorized shut off valve (UV 050 A, UV 050 B) upstream to choose the control valve in operation and one hand shut off valve downstream (HV 310, HV 320), for maintenance. One of these feedwater control valves is for normal operation and the second is in stand by.

The outlet pipe connected to the drum is equipped with: -

1.3 The HP Boiler Drum (001 BA)

The HP drum is a shrouded type drum so as to obtain a satisfactory thermal stresses repartition in the shell during transient periods. The water steam mixture coming from the HP vaporizer and HP economizer is maintained all around the drum shell inside the shrouded zone. The corrugated plate assembly at the upper part of the drum provides an efficient separation of water by removing moisture from steam. The drum is equipped with: One down comer to the HP vaporizer circulating pumps (100 PO, 200 PO). One continuous blow down circuit to avoid over concentration of salts in the water. This circuit includes one hand-isolating valve (HV 404) and one step by step remotely controlled valve (UV 035) and is connected to the flash tank. Between the two valves is connected one water sample line to control water quality. This line includes one isolating valve (HV 602). One vent circuit with two hands shut off valves (HV 705, HV 706). This vent is used for air evacuation during the filling for pressure test. Two pressure safety valves (PSV 006, PSV 007) for drum protection. One chemical injection circuit to maintain water quality. This circuit includes one non-return valve (YV 604) and one hand shut-off valve (HV 603). Four pipes to the superheater, which connect into two lines, then one line. Nozzles for pressure, temperature and level measurements. One nozzle for pipe coming from the HP economizer. Six nozzles for pipes coming from the HP vaporizer.

1.4 The HP Evaporator

This system includes mainly: The circulation system through the vaporizer, realised by a pumping set with two similar lines, one for normal operation and one in stand by, each one including:
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One hand (isolating) valve at pump inlet (HV 101 or HV 201) for maintenance. One pump (100 PO or 200 PO) with associated motor (100 MO or 200 MO) and cooling system. One common warming circuit of the stand by pump with one hand isolating valve (HV 052). One non return valve (YV 102 or YV 202) to protect the stand by pump. One hand shut-off valve at pump outlet (HV 103 or HV 203), for maintenance. One nipple for acid cleaning.

One emergency blow down circuit with one hand isolating valve (HV 403) and one motorized shut off valve (LV 050) at the pumping set discharge. This emergency blow down circuit is designed to limit the over level in the drum. The evaporator is equipped with:
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One inlet header connected to the pumping set. Several rows of finned tubes. One outlet header connected to the drum through six lines.

1.5 The HP Superheater

This system includes: The connecting pipe between the drum and the superheater is equipped with:
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One vent circuit with two hand isolating valves (HV 703, HV 704). This vent is used during filling periods for air evacuation and during pressure test. One steam sample line with two hand isolating valves (HV 605, HV 606). One saturated steam outlet line to supply steam to warm condensate in the deaerator, with one non return valve (YV 051) and one automatic isolating valve (UV 053). One inlet header. Several rows of finned tubes. One outlet header. One superheater drain with one hand shut off valve (HV 405) and one motorized isolating valve (LV 034). Between these two valves a line for filling of superheater during the long duration stoppage, equipped with one handisolating valve (HV 412). The superheater by-pass line designed to control temperature at superheater outlet and equipped with one temperature control valve (TCV 051) and two hands isolate valves (HV 015, HV 016) upstream and downstream for maintenance. One steam supply line for the soot blowing system (see FRM system). One safety valve (PSV 033) connected to the associated silencer. One no return valve (YV 010). One vent line with two hand isolating valves (HV 707, HV 708). One live steam hand isolating valve (HV 002) with its by-pass hand valve (HV 003).

The superheater is equipped with:

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The live steam line is equipped with:

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1.6 The Boiler Flash Tank (003 BA)

The flash tank is designed to recover water from the continuous blowdown. It is equipped with: One nozzle for the continuous blow down circuit supply. One line to LP separator, to recover steam. One drain connected to the blow down tank through the level control valve (LCV 053), with upstream and downstream two hand isolating valves (HV 409, HV 410) for maintenance and one hand by pass valve (HV 411).

1.7 Boiler Blowdown Tank (002 BA)

The blow down tank is designed to collect all boiler drains and the water coming from the flash tank (continuous blow down). This blow down tank is equipped with: One vent duct to atmosphere. One cooling water circuit including one motorized isolating valve (TV 038), one hand isolating valve (HV 013) and one by-pass hand valve (HV 012) with orifice plate (DI 011). One discharge line to sewer and one drain line with one hand isolating valve (HV 407).

Necessary nozzles for all drains from the HP economizer, the LP evaporator, the boiler flash tank, the superheater and the emergency blow down. Nozzle for condensate from sootblowing system. One line with hand isolating valve (HV 014) for filling the water siphon of the boiler drain.

1.8 The Motor Pump Cooling System

The motor pump cooling system is designed to control the temperature of the mechanical seal cooling circuit, the mechanical seal housing and the bearing housing, An emergency cooling is provided by mean of an automatic valve (UV 163). This system includes: a) For the set of two circulating pumps of a boiler b) An inlet line (main inlet line) of demineralized cooling water from the demineralized cooling water system (SRI system). An outlet line (main normal outlet line) of demineralized cooling water to the demineralized cooling system (SRI system). An outlet line (main emergency outlet line) of demineralized cooling water to the sewer, for emergency cooling of pump. An individual inlet line from the main emergency outlet line. An individual normal outlet line to the main normal outlet line. An individual emergency outlet line to the main emergency outlet line. A heat exchanger between the high pressure (HP) water cooling circuit of mechanical seal and the demineralized cooling water. A connecting line of hot HP water from the mechanical seal to the heat exchanger. A connecting line of cold HP water from the heat exchanger to the mechanical seal, with a magnetic filter, its bypass and a vent line. An inlet line of demineralized cooling water from the individual inlet line to the heat exchanger with a vent line. An outlet line of demineralized cooling water from the heat exchanger to the individual normal outlet line, with a drain line. An inlet line of demineralized cooling water from the individual inlet line to the mechanical seal housing. An intermediate line of demineralized cooling water from the mechanical seal housing to the bearing housing. An outlet line of demineralized cooling water from the bearing housing to the individual emergency outlet line. A connecting line between the outlet line from the bearing housing and the outlet line from heat exchanger.

For each pump -

The system is equipped with: 1) For the set of two circulating pumps of a boiler An isolating hand valve on the inlet line from SRI system. A hand valve on the drain line. An isolating hand valve on the outlet line to SRI system. An isolating hand valve on the outlet line to sewer. An electric valve on the outlet line to sewer.

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On the main emergency outlet line, one hydraulic valve with its associated circuit of control including one solenoid valve. One hand-isolating valve on individual inlet line. One hand-isolating valve on individual normal outlet line. One hand-isolating valve on individual emergency outlet line. One orifice plate on individual emergency outlet line. One hand-isolating valve on inlet line of demineralized cooling water to mechanical seal housing. One hand-isolating valve on inlet line of demineralized cooling water to the heat exchanger. One non-return valve on the connecting line between the outlet line from the bearing housing and the outlet line from heat exchanger.

For each pump -

2.

Low Pressure Circuit

The water is supplied from the feedwater tank and is sent through the LP evaporator by a pumping set. The inlet line includes: One automatic isolating valve (UV 042) for maintenance and during outage. One non return valve (YV 552). One drain line with hand isolating valve (HV 562). A vent circuit with one hand shut-off valve (HV 565). This vent is used for air evacuation during pressure test and is adequately located in the higher point of the circuit. One pressure safety valve (PSV 036) designed to protect the circuit.

2.1 The Feedwater Circuit

The outlet line (two pipes then one) includes.

2.2 Low Pressure Evaporator

The low pressure evaporator includes: Several rows of finned tubes. One inlet header connected to the LP evaporator pumping set outlet. One outlet header connected to the separator.

2.3 The Separator

The water steam mixture coming from LP evaporator and boiler flash tank arrives in the separator. The steam goes to the de-aerator 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 an hand isolating valve (HV 553) locked open. The water outlet line is equipped with an hand isolating valve (HV 554).