POWER

AND
INDUSTRIAL
PLANTS
Industrial boilers
Package &
Site erected steam
Under licence from Foster Wheeler
S.p.A.
S.p.A.
LOOKI NG TO THE FUTURE
Jebel Ali Power Plant - UAE
STF supplies a full line of Package and Site Erected
SD Boilers designed to meet the most demanding
requirements in terms of capacity, performances,
emissions, operating exibility, long term reliability
and low maintenance costs.
STEAM GENERATORS
SD type vertical ow path
PACKAGE type furnace design
ADDI TI ONAL FEATURES
MAIN TECHNICAL FEATURES
Large oversized furnace
Two drums design
Oversized steam drums with high effciency internals
MONO-WALL fn tube construction
Convective or radiant super-heater
Fully drainable super-heater
Minimum refractory
Low NOx burners, fue gas recirculation
Fuels: natural gas, light oil, heavy oil, refnery gas,
low heating value gases.
OPERATIONAL FLEXIBILITY
High turndown
Extended low load operation
Warm/hot stand by
Fast ramping for cogeneration back up
Large load swings
Fuel complex combination fring
Multiple operation conditions
One button start-up
Critical service availability
OPTIMIZED PERFORMANCES
Thermal effciency
Auxiliary power consumption
Emissions control & abatement
INTEGRATED DESIGN
Mass & thermal balances
Noise & vibration analysis
Cabling, conduit & tubing
Instrumentation, BCS, BMS
Piping and valves
Cabling, cable trays & conduit
Racks and structural steel
PACKAGE boi l ers
Steam capacity range from 50 to 200 tons/h
Steam generation today asks for strict adherence to emission
regulations, utilization of alternative fuels, and minimization of
operating and maintenance costs.
In this complex scenario, STF is able to provide a complete
solution to your steam generation needs.
Our experience diversifcation of products and commitments to
engineering integrity, ensure STF quality, resulting in maximum
equipment availability and reliable source of steam for your
process, power or heating requirements.
At STF, our focus is on total system integration and
optimization.
Total System integration and optimization are our goals.
By utilizing state-of-the-art automation tools, STF can apply
technical and cost factors in a combined value-added analysis
satisfying our customers unique needs.
This provides our engineers the necessary degree of freedom
to design the best system for each customer by balancing
capital and operational costs.
Corporate experts in specialized felds such as combustion,
circulation, noise, vibration, metallurgy and global procurement
are drawn upon as required to effectively address the most
complex project requirements.
Our product focus is supported by the manufacturing and
fnancial resources of the entire STF organization.
5000 Series Package Boiler
5200 5300 5400 Series Package Boiler
5100 Series Package Boiler STF pre-engineered boiler models include fve series: 5000, 5100, 5200,
5300, 5400.
Each series comprises multiple models of boilers, up to reaching a total
number of 21 boiler models, in accordance to an overall size envelope
settled for each model (L X H X W), whilst model signifes the boiler capacity
(kilo-pound per hour).
Each boiler model contains pre-engineered options like:
three upper steam drum size options, to minimize cost and optimize
performance exibility, combined to utility quality of drum internals;
three boiler bank templates;
two boiler bank longitudinal pitches;
three super-heater templates x 2 tube ODs.
A wide range steam production is covered to suit the clients requirements,
from 50 tons/hour (110 kp/h) to 200 tons/hour (440 kp/h), with pressures
spanning from 10 barg (150 psig) to 110 barg (1,600 psig), SH/PH steam
temperatures up to 500 C (930 F).
The weight of the boilers may vary from 40 tons with a furnace volume of
32 m
3
(1,120 ft
3
) up to 245 tons with a furnace volume of 362 m
3
(12,782
ft
3
).
Each furnace size is capable to granting Conservative Volumetric Liberation
Rates and Cross-sectional Heat Flow Rate less than 2.5 mbtu/ft2/hour.
Steam drums can be sized for each boiler model to minimize the costs and
optimize performance fexibility.
Super-heater sections are convective and drainable, with conservative
metallurgical design well over operating range and an advanced anti-
vibration design.
Three convective banks are provided for each boiler model in order to
minimize the auxiliary load and maximize the performance.
Package Boilers are capable of burning the majority of Gaseous and Liquid
Fuels, either natural or by-products of refnery process.
Gaseous Fuels include Natural Gas, Refnery Process Gases (high hydrogen,
tail gas, alcohols), Landfll Gas, CO & Blast Furnace Gas, Coke Gas, Waste
Gases.
Liquid Fuels include Oils (No. 2, No. 6 & Bunker C, Diesel, Cracker Bottom,
Pitch), Alcohols (Methanol, Ethanol), Waste Liquids.
DESI GN AND TECHNI CAL FEATURES
MONO-WALL MEMBRANE CONSTRUCTION and FURNACE DESIGN
Boiler wall are designed as mono wall fnned tubes, with a high utility grade
construction and fns suitably sized (1 or 1 width) to ensure the thermal
integrity and gas tight of the furnace.
Utilization of refractory materials is minimized, with a great advantage in
terms of boiler reliability, outage planning, maintenance activities.
In addition a complete fuel combustion is assured as fue gases cannot by-
pass the boiler convective sections.
PREFABRI CATI ON DETAI LS
Steam capacity range from 120 to 455 tons/h
The SD pre-engineered steam generator has proven itself over the years,
reliably meeting the rigorous demands of industrial steam producers.
The most common users of this equipment are utilities and petroleum,
chemical, paper and metal industries.
Numerous applications have been made for power generation in a wide
range of sizes with capacities up to and in excess of 65 MW.
STF Standard Design Field Erected Boilers present a constant cross of the
furnace and boiler bank, whilst setting of the boiler width defnes the boiler
production in accordance to the design output required by the Client.
The boiler design can be also optimized by pre-engineering design
fexibilities and allowance for granting special modifcations to standard
models.
Standard for the selection of a SD Standard Design Field Erected Boiler
capable to suit the Client requirements, are based on the boiler performance
program, the maximum heat volumetric liberation rate allowed, furnace
width, maximum ue gas ow, maximum ue gas temperature at the boiler
outlet.
Nine Series of Boiler Models defne Nine Size Classes:
SD-31, SD-32, SD-33, SD-34, SD-35, SD-36, 3D1, 3D2, 3D3.
Series SD-31, SD-32, SD-33 incorporate 4 (four) burners; Series SD-34,
SD-35, SD-36 incorporate 6 (six) burners; Series 3D1, 3D2, 3D3 incorporate
8 (eight) burners.
Burners are fuel exible, being capable of burning the majority of Gaseous
and Liquid Fuels, either natural or by-products of refnery process.
Gaseous Fuels include Natural Gas, Refnery Process Gases (high hydrogen,
tail gas, refnery fuel gas), Landfll Gas, CO & Blast Furnace Gas, Coke Gas,
Waste Gases. Liquid Fuels include Oils (normal fuel oil, light fuel oil, diesel),
Waste Liquids.
Firing systems are designed and engineered to achieve for all fuels the
required combustion parameters with safety, ease of control, reliability,
granting that the emissions are within the required limits, with a minimum
of maintenance.
Circulation in this type of boilers is provided by the difference in specifc
gravity of the fuid in the heated circuits (water-steam mixture) and in the
downcomer tubes (water only).
Boiler furnaces are generously sized to ensure a complete combustion
The Width of STF Standard Design Field Erected Boilers can span from 5
meters to 12 meters and as a consequence the Furnace Volume can range
from 268 m
3
to 690 m
3
.
Remaining boiler dimensions are kept almost fxed, to an overall height of
about 15 meters.
Steam production can vary from 120 tons/hour to 455 tons/hour with
superheated steam temperature of 540 C at the operating pressure of 110
barg, granting the best available technology for the emission using a wide
variety of gaseous and liquid fuels.
SERI ES SD
Series SD
Field Erected Boilers may be used in the
following applications:
Chemical Plants, Gas Plants & Petroleum Refneries
Power and Cogeneration Plants & Combined Cycles
Manufacturing Industries & Districts Heating
Sugar Cane & Paper Industries
Desalination Plants.
STF SD Field Erected Boilers are bottom supported, with
complete water cooled furnace walls, two drums (water and
steam) D-style design, with furnace walls and boiler bank tubes
rolled expanded to the drums.
This design facilitates a controlled expansion of the boiler
pressure parts while allowing for the inclusion of a hopper
bottom for an easy removal of the ashes.
Gas ow is perpendicular to the steam drum providing uniform
heat all cross the drum width, resulting in a steady confguration
of the drum level.
Suitable manholes and access doors are installed in water drum
(lower) and steam drum (upper) as well as in furnace walls to
assure an easy access for inspection and maintenance.
Steam drums are generously sized in diameter allowing an
excellent water/steam separation performance, enhanced by
the high grade of the drum internals like the Primary Horizontal
Cyclones and Integral Chevron Dryers, easy to be installed and
removed providing dry steam to the super-heater sections and
steam free water to the down-comer system.
Boiler Retention Capacity at MCR and Load Swing Capability
are also increased, facilitating an improved response to process
demand.
The furnace is designed to assure a Low Volumetric Heat Release
Rate combined with an optimized cross section and length,
resulting ideally suited for burners Low NOx application.
Large furnace cross section eliminates ame impingement on
boiler tubes enhancing furnace longevity, whilst a Conservative
Heat Release Rate facilitates low maintenance and long-life
tube integrity.
FI ELD ERECTED BOI LERS
Large oversized drum
Tube to Drum
connections details
DRUMS
< 63.5 mm < 2 inches
DRUMS
> 63.5 mm > 2 inches
APPLI CATI ONS
Site view
DESI GN AND TECHNI CAL FEATURES
Boiler walls are designed as tubular membranes, mono wall fnned tubes,
with a high utility grade construction.
Fins are suitably sized to ensure the thermal integrity of the boiler.
This arrangement, equally effective with pressurized or balanced draft
operation, contributes to high levels of boiler effciency by reducing
using of refractory materials, with a great advantage in terms of reliability,
maintenance activities, outage planning, minimizing as well casing corrosion
and/or gas leakage throughout the life of the steam generator.
Observation and access doors, properly designed, (fxed, pressure tight,
air aspirating design) are provided in suitable positions to allow a complete
control of the operating conditions of the boiler, an easy access for
inspection and maintenance.
Tubes are bent around all openings (no bifurcation of steam fow),
eliminating the risk of possible localized circulation patterns that may cause
panel hot-zones leading to tube failure. The furnace walls are made up
of shop-prefabricated panels assembled through a continuous welding of
adjacent tubes, with or without fns, carried out with single or multiple head
submerged arc automatic welding machines.
These panels are matched together during the erection to form a sturdy
metal casing that completely encloses the steam generator section,
performing a dual function of heat transfer surface and sealing against ue
gas leakage.
The gas tight enclosure prevents the fue gas by-passing the furnace to
the convection bank, which would lead to a high emission of CO reducing
thermal effciency, maintaining boiler integrity.
Boiler super-heaters may be non drainable or fully drainable, located inside
the furnace or in a convective area of the boiler.
Non drainable super-heaters are located inside the boiler furnace, protected
from radiation by the tubes of the furnace nose, supported of furnace wall
headers, provided with stainless steel side-to-side spacers to guide the
thermal expansion of the coil piping.
Typical Drainable Super-heater Construction
Typical Non-Drainable Super-heater Construction
Fully drainable super-heaters are located in a convective area between the
furnace rear wall and convection bank front wall, are properly supported
on furnace rear wall and convection bank front wall, provided with support
spacers between the coil piping.
Headers are located outside the ue gas path.
Temperature of superheated steam is controlled, when required, by a
spray type desuperheater, installed in the intermediate temperature zone
to assure a uniform mixing and a quick complete evaporation of the water
injected into the steam ow.
Stringent uid and vibration design criteria promote boiler life by ensuring
a uniform fow distribution and minimizing fow induced vibrations.
An optimized Boiler Bank consists of a fnely tuned convective surface that
balances good heat transfer with reduced draft losses.
SD Boiler with Non-Drainable Super-heater and Standard Furnace
SD Boiler with Drainable Super-heater and Enlarged Furnace
SHOP PREFABRI CATI ON
STF SD Field Erected Boilers can be shipped to
site in different confgurations:
disassembled components, loose tubes and
panels;
boiler bank completely assembled, loose tubes
and parts;
completely assembled.
Major boiler components may be delivered at site
as follows:
Steam Drums (water and steam drums): supplied
as single pieces, internal details (cyclones and
chevron dryers) installed.
Super-heater headers are supplied as single
pieces, stubs welded, whilst super-heater coils are
delivered fully prefabricated, ready to be welded
to the header stubs.
Furnace Right and Left Side Walls, Front Wall, Rear Wall, Roof and Floor Walls:
supplied in complete panels of tubes, ready to be assembled and welded at site to form the boiler
furnace.
Tubes are ready to be expanded into the steam/water drums and/or welded to the adjacent walls
panels. Upper and lower headers of furnace side panels, provided with nozzles to be welded to risers
and down-comers, are already welded to the panels.
Riser Tubes: supplied as single spools, bent, cut and bevelled for welding to the steam drum and/or
side wall header nozzles.
Boiler Bank Front Wall, Intermediate Wall, Rear Wall, Internal Tubes:
to be supplied at site by longitudinal welding to form the complete boiler bank. Tubes ends are already
to be expanded into water/steam drums.
Typical and Complete Sequence Assembly
TRANSPORT TO SI TE and ERECTI ON
Jebel Ali Power Plant - UAE
Jebel Ali Power Plant - UAE
CERTI FI ED QUALI TY
STF S.p.A.
Via Robecco, 20
20013 Magenta (MI) Italia
Tel: +39 02 972091
Fax: +39 02 9794977
www.stf.it
e-mail: stf@stf.it
BWE
Burmeister & Wain Energy A/S
Lundtoftegrdsvej 93A
DK-2800 Kgs. Lyngby - Denmark
Tel: +45 39 45 20 00
Fax: +45 39 45 20 05
www.bwe.dk
e-mail: info@bwe.dk
BWE Energy India Pvt. Ltd
No. 43, KB Dasan Road
Teynampet
Chennai - 600 018
TamilNadu, India
Tel: +91 44 24 32 8101/2
Fax: +91 44 24 32 8103
e-mail: info@bweenergy.in