Heat Recovery Steam Generator

I&C Training Program

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LPG TRAIN-4 PROJECT _ AT MINA AL-AHMADI REFINERY - HRSG

 TOPICS

• Main reference documents

• Process Description and P&ID
• Involved systems
• Operating modes
• Instruments
• Control & Automation
• HRSG Protections
• HRSG Status definition, Ramp rate, Sequences
 Main Reference Documents

The presentation refers to the following documents:

1) Piping and Instrumentation Diagrams
• HP SH System
• Exhaust Gas System
• Fresh Air Fan System
• Duct Burner System
• Sampling System
• Service System
2) HRSG Control and Automation Narrative and Diagrams
3) HRSG Protection and Operating Mode Narrative and Diagrams
 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
Process Description – HRSG mail parts
Exhaust Gas Circuit
1. Inlet duct (GT
connection)
2. By-pass System
3. Transition duct &
Duct Burner
4. Horizontal Duct with
5 H.E.
5. Exhaust gas stack
8 Water/Steam Circuit
6. Economizer
7. Evaporator
7 8. Boiler drum
6 9 9. Superheater 1&2
1 Main Equipments
4 3 10. Fresh Air Fan
2
11. Sampling skid
10 12. DB skid
12 13
11 13. Sealing sys.
 P&ID – Exhaust gas system

By-Pass
Stack HP Drum

SH-EVA-ECO coils
TEG

Multi
Louver Burner Main
Dampers Stack
 P&ID – HP EVA system
Sat. Steam HP Drum

BFW

BFW control valve

EVA ECO
 P&ID – HP SH system
DSH Control Valve
DSH
Start Up Vent Water
Control Valve

HP SH Steam Sat. Steam

DSH nozzle SH2 SH1

P&ID – Fresh Air (FA) System
 P&ID – FA Fan Steam Turbine

LP steam

Steam Turbine

ST Trip Valve
ST Governor Vlv

MP steam

ST Bearings oil
circuit
 P&ID – Duct Burner system

NG Burner control &

protection skid To Burner
Elements
Local control
panel To Pilots
P&ID – Duct Burner Elements

Pilot
Flame scanners
Main burner

Burner
elements/runners (7)
 P&ID – Sampling System
Feed Boiler SH Sat.
water water steam steam

9,5 pH; 9,5 pH;

0-1 50-100
µS/cm µS/cm 0-1 µS/cm 0-1 µS/cm
 P&ID – Service System

Nitrogen

Cooling water for ST

and sampling

Instrument air
Process Flow Diagram
Boiler Safety Valves
Boiler Safety Valves
 Involved Systems
The following control & protection systems are involved during
HRSG operation:

• Distributed Control System (DCS)

• Gas Turbine Safeguarding System (GTS)
• Emergency ShutDown System (ESD)
• Burner Management system (BMS)

Systems Not supplied by NE

 DCS Functions
The DCS performs the following functions:

• Supervises HRSG start up/shut down

• Measures or detects process conditions
• Displays the status information from ESD, BMS and GTS
• Automatically computes required adjustments, based on the
deviations between the process conditions and the relevant set
points and records/trends of the process conditions
• Outputs references to control elements in order to control the
process.
• Supervises, controls and managements Burner elements
• Transfers status information to the BMS and ESD
 GTS Functions

The GTS performs the following:

• Supervises GT operation and control

• Protects the GT
• Transfers status information to the DCS, BMS and ESD
• Purge sequence (GT+By-pass Stack)
 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. MP Steam turbine header LP Steam
pressure > min Header
2. MP Steam turbine header
temperature > min
3. LP Steam turbine header
pressure > min Woodward
4. LP Steam turbine header Governor
temperature > min Peak 150
5. FA fan damper close (231-
ZSL-6644A) (If FA fan is not MP Steam
running by means of the Header
electric motor)
6. Turbine exhaust steam side
open (HV-403A manual
isolation valve open)
7. Check oil level in the
reservoir (H-231-001A-V2)
(fill if necessary) 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. Turbine Oil pump start up (either by
local or remote command from DCS)
2. Reset trip from ESD. Depress local
emergency trip reset button to
energized solenoid valve. Then reset
emergency trip lever (steam turbine
trip valve 231-HV-6650A opened)
3. Check MP steam line steam trap in
operation and MP steam pipe to Local Start
Trip Reset
turbine free of condensate
4. Since all process and other
permissive to start conditions are Reset valve trip lever
met, depress local start button; the
Governor Valve
governor valve (SCV-6651A) goes MP steam
wide open Main vlv
5. Open MP steam to turbine system
manual bypass isolation valve (HV- MP drain
MP steam by- ST drains
401A) and slowly open MP steam to
pass valve
turbine system main manual isolation
valve (HV-400A), so that the inrush
of steam starts the rotor spinning Oil Pump
6. Check steam turbine drains steam
traps in operation
 MODES OF OPERATION
HRSG in FA mode (GT in OPEN CYCLE)
7. Since the governor senses the
speed, it closes the governor
valve (SCV-6651A) and adjust the
steam flow so to ramp up the
speed up to the programmed
rated speed
8. Fully open MP steam to turbine
system main manual isolation Woodward
valve (HV-400A) then back one- Governor
quarter turn to prevent the valve Peak 150
from sticking in open position and Governor Valve
close relevant bypass valve (HV-
401A)
9. Adjust the speed set point to the ST by-pass and main
desired operation point by Steam valves
depressing speed raise or lower
buttons onto the ST governor
 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
isn’t 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.
 MODES OF OPERATION – CHANGE OVER

HRSG Sequences into DCS will allow manual change over

(initiated by operator) between the two HRSG operating
modes: HRSG on in FA mode and HRSG in CC mode with
supplementary firing on.
 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
manufacturer’s 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 air-
flow.
 PURGE REQUIREMENT
(GT+HRSG)
Two different phases compose this purging sequence:
1. phase 1, the GT purge sequence purges the GT and the By-
pass 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 manufacturer’s 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.
 DUCT BURNER PURGE REQUIREMENT

The duct burner purge (BMS) shall accomplish eight volumes

change of the HRSG volume with a fresh air flow not less than
25% of full-load mass flow rate or the minimum flow necessary
for operation of the duct burner, whichever is greater.
The duct burner purge takes 5 minutes.
 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: By-pass stack close and HRSG inlet open

• System close: By-pass stack open and HRSG inlet close

Intermediate positions are not allowed.

 INSTRUMENT– General Notes

• Instruments are conventional type, 4-20 mA signal, I.S., Smart

Hart protocol.
• Instruments related to the safety functions are in voting 2 o o 3
or 2 o o 2 and are connected to the safety systems (ESD or
BMS)
• Instruments related to control and monitoring functions are in
voting 1 o o 1 and are connected to the DCS
Control & Automation
 Main Control Loop

HRSG main control loops and automations are:

• HP Drum Level Control

• HP Drum Continuous Blow Down Control
• HP Steam vent control
• HP Steam temperature control
• Duct Burner Load Control and elements managements
• Condensate drain valves automation
 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.
 HP DRUM LEVEL CONTROL
The purpose of the control is to maintain a constant water level
inside the HP steam drum during any load condition (during start-
up and in the transient states due to load changing) by modulation
of the boiler feed water control valve.
 HP DRUM LEVEL CONTROL

• Operation below Low-Low level in any of the drums could cause

overheating of the tubes and headers, and must initiate a HRSG trip.
• Low level alarms the operator to allow corrective action to be taken
before Low-Low level is reached.

• Operation above High-High level in any of the drums could cause

water droplets carryover and subsequent fouling of superheater
tubes or other downstream equipment. High- High level initiates
automatic action to immediately reduce water level.
• High level alarms the operator to allow corrective action to be taken
before High-High level is reached.
HP DRUM LEVEL CONTROL
 HP DRUM LEVEL CONTROL

P compensated

Involved process variable

 HP DRUM LEVEL CONTROL

Involved process
variable

P, T compensated
HP DRUM LEVEL CONTROL

T compensated

Involved
process
variable
 HP DRUM LEVEL CONTROL

• During startup, when water starts to boil, a drum level swelling takes
place due to the sudden formation of steam bubbles in the evaporator

• This swelling can cause a high-high drum level trip

• To prevent this problem, level setpoint during startup is lowered and goes
back to normal value as drum pressure reaches operating levels
 HP Drum Set Point Generation

1000
950
900
850
800
750
700
NWL (640 mm)
H P D ru m L e v e l (m m )

650
600
550
500
450
400
350
300 NWL
250 Start-up Set Point
200 To be adjusted during
150 Commissioning
Set Point
100
50
0
0 10 20 30 40 50 60 70 80 90 100
HP Drum Pressure [%]

100% Boiler pressure is 64 barg [Case 10 Fired FAF]

 HP DRUM LEVEL CONTROL
Control philosophy could be single or three elements base on operating
condition.
The control philosophy will be:
• SINGLE ELEMENT TYPE during the start-up or during normal operation
when the steam flow is less than 30%
• THREE ELEMENTS TYPE for higher steam flow (>30%).
An automatic switch between single element and three element [in both
direction] is foreseen by the status of a threshold [about 30% - 27 t/h] on the
compensated steam flow.
Single element control is automatically selected in case of a discrepancy
between HP Feedwater total ingoing compensated flow (see after) and
compensated superheated steam higher than 10%. Return to three element
control is manually done by the operator.
The operator can, however, choose single element control even at steam
flows more than 30% by selection.
Suitable tracking logic is required for the single and three element
controllers to ensure a bumpless transfer between the control modes.
 HP DRUM LEVEL CONTROL
• Single-element control is
based on the action of a
PID controller which acts
according to the level PV
and SP. Single element
control

• 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, Three elements control
generating the SP with
which the PI controller
acts according to the HP
FW flow.
 HP DRUM LEVEL CONTROL

St eam Flo w

DCS LT
Boiler Drum

ECO
LCV
M

Bo iler feed
water

General typical control loop, not related to the plant

 HP DRUM LEVEL CONTROL

St eam Flo w

DCS LT
Boiler Drum
PT

ECO
LCV LEVEL COMPESATION
M

Bo iler Feed
water

General typical control loop, not related to the plant

 HP DRUM LEVEL CONTROL

FT
St eam Flo w

DCS
LT Boiler Drum
PT

ECO
LCV
FT M FLOW BALANCE:
FT steam- FT water
Bo iler feed
water

General typical control loop, not related to the plant

HP DRUM LEVEL CONTROL

SP function generator – start up

 One element

FF/Bias

Three element

HP DRUM LEVEL CONTROL

 HP DRUM CONTINUOUS BLOWDOWN
CONTROL
The purpose is to maintain a water chemistry inside the drum to correct
value by modulation of the blowdown valve .
Operator fixes
continuous
blowdown flow
SP, about 1% of
HRSG steam
flow.
The FIC
compares the SP
with the PV. The
error is
processed by a
PI algorithm.
Involved process variable The FIC output is
the valve
opening/closing
request.
HP DRUM CONTINUOUS BLOWDOWN
CONTROL
 HP STEAM VENT CONTROL
The purpose of the HP Steam vent control valve is to control the rate of
water temperature (pressure in drum, water saturated condition) into the
HP drum during start up phase, by modulation of the HP steam vent
control valve. More over at the end of the start up phase the controller SP
is set in guard of pressure, in order to prevent the opening of PSV.
HP STEAM VENT CONTROL
Drum Pressure

Involved
process
variable
Control element
 HP STEAM VENT CONTROL

During start-up, the HRSG has to follow the HRSG temperature ramp rate (HP
drum temperature gradient), in accordance to the HRSG temperature rise
gradient indicated by the HRSG Manufacturer Instruction book.

Because drum temperature is related to the drum pressure (saturation

condition) and pressure measure is more easy and reliable to be read,
temperature gradient is calculated starting from HP Drum pressure.

Temperature gradient set-point is generated in accordance to boiler start-up

curves (8,5°C/min).

During startup phase, the controller TIC compares the set point (SP) with
actual boiler gradient temperature [d/dt of saturated temperature] and
processes the error by means of a PID algorithm.
The TIC controller is activated only when the GT is ON and the HP drum
pressure reaches 1 barg.
 HP STEAM VENT CONTROL
Once a pre-defined operating pressure is achieved (boiler drum
pressure: 64 barg [Case 10 Fired FAF GT shutdown]), the vent TIC
control will switch to a PIC control, in order to maintain the reached
steam pressure. Set Point for PIC control is the operating HP SH
pressure achieved (i.e. 62,1 barg) and his measured variable is the
SH steam pressure.
The resulting signal (coming from TIC/PIC) is sent as output signal to
the start-up vent valve through a common Auto/Manual station.

At “GT Flame ON” the vent will be positioned according to the actual
HP Drum pressure as per the following table (to be tuned during
commissioning) [step function]: HP Drum pressure Vent opening
[barg] [%]

<1 50
>=1 40
>=40 10
>=64 0
 HP STEAM VENT CONTROL
In order to ensure a minimum steam flow through the heat
exchangers, during the start-up phase a vent valve minimum opening
of 10% is foreseen.
The same minimum opening is applied, during the normal operation,
if the main steam MOV is detected closed.
This minimum opening has to be applied also in manual mode.

When boiler drum pressure is equal or higher than 64 barg [end of

start-up phase] AND the main steam valve is detected not closed,
then the PIC set point will switch from 62,1 to 68 barg (HP SH
pressure).
By this way the vent will be driven to the closed position and will stay
in guard of pressure, in order to prevent the opening of PSV (PSV
Set Point = 69 barg).
When GT is OFF the vent is driven to closed position.
 Vent valve positioning during start up

HP STEAM VENT CONTROL

 start up ramp rate control
Vent valve positioning and guard of
pressure after start up

HP STEAM VENT CONTROL

HP STEAM VENT CONTROL
 HP STEAM TEMPERATURE CONTROL
The purpose of the
control is to
maintain constant
the temperature of
the high pressure
steam by means of
the desuperheater
situated between Control element
the HP SH1 and
HP SH2, on the
basis of the final
HP steam
temperature.
Involved
process
variable
 HP STEAM TEMPERATURE CONTROL
During normal operation the HP main steam temperature set point value
is fixed by process design at 441°C, operator can apply a bias (+/- 5°C).
This set point is compared with the HP main steam temperature and
elaborated by a TIC controller [master-direct]. The output of this controller
is passed as a Remote Set Point to the temperature controller TIC [slave-
reverse] to position the desuperheater valve to maintain a temperature
downstream the desuperheater.
The Remote Set Point to slave controller is scaled and limited to the
operating range of the desuperheater. Even if between the operating
range, the Remote Set Point to slave controller is also limited to a value
that is at least 30°C above the steam saturated temperature [calculated
from HP drum pressure].
Suitable tracking logic is to be provided for the master controller
whenever the slave controllers are limited or forced to the closed position.
 HP STEAM TEMPERATURE CONTROL

The output of the slave TIC is by-passed completely and the relevant
desuperheater valve forced to close in the following cases:

1. When compensated HP steam flow is less than 25%.

2. To prevent excessive opening of the desuperheater valve, when the
difference between the HP steam temperature downstream of the
desuperheater and the saturated steam temperature is less than 20°C.
Saturated steam temperature is calculated starting from the HP drum
pressure.
3. When the final steam temperature is 10°C below set point.
HP STEAM TEMPERATURE CONTROL

Control
TV system
Attemperating water

TT

Vapore A.P.

HP drum
SH-1 SH-2
 HP STEAM TEMPERATURE CONTROL

Control
TV system
Attemperating water

TT TT

Vapore A.P.

HP drum
SH-1 SH-2
 Cascade Control

Master Controller

Slave Controller

HP STEAM TEMPERATURE CONTROL

 DUCT BURNER LOAD CONTROL
The purpose of this control loop is to control the duct burner firing by
modulating the fuel valve on the basis of the plant load control.

Control element

Involved
process
variable
 DUCT BURNER LOAD CONTROL

Set Point definition:

• Set point [Nmc/h] is calculated as a function of the remote set point
[MW] (from Balance Of Plant load demand).
• A set point limitation is foreseen depending on the CC/FA operating
mode: in case of FA operating mode the maximum allowed set point
is 44 MW, in case of CC operating mode is 32.3 MW with (GT
>=60% load, 0 MW with GT at reduced loads).
• Set Point is also limited if any of the 7 rows of the burner is out of
service to avoid either loss of the flame or too long flame
• During Start-up phase the duct burner gas control valve is
positioned in the “Start-up” position
 DUCT BURNER LOAD CONTROL

HRSG limits are provided by DCS in order to limit the Duct burner gas
control valve maximum opening:
• HP Main Steam volumetric flow, to avoid too high steam velocity in
the steam pipe
• HP Main Steam pressure, to avoid too high steam pressure in the
steam pipe.
• HP SH2 Outlet temperature, to avoid too high steam temperature in
the steam pipe.
 HRSG limits

Burner limits

DUCT BURNER LOAD CONTROL

DUCT BURNER LOAD CONTROL
DUCT BURNER ELEMENTS MANAGEMENT
 Drain Pot Condensate Removal
The unit have been supplied with condensate pots downstream of the
desuperheating stations and at the bottom of the SH banks.

The purpose of these pots is protection against quenching of tubes from

over spraying (incomplete evaporation of water) or steam condenses,
improving the life time of the components as well as avoid the water
hammering in the steam lines during GT start-up.
The pots are fit with temperature detectors to automatically operate the
pneumatico on-off valves in the case that excessive water builds up in the
pots.
During the commissioning of the boiler, the frequency of operation (for DSH
drain pot) should be noted by plant personnel.
If any significant change to this frequency occurs, plant operators are
responsible for diagnosing and correcting the root cause of the over spraying
of water.
It is advised that an alarm signal be generated upon the opening of the drip
leg condensate pot.
Drain pot condensate removal

Drain
Pots

Temperature
elements

Pneumatic on-off
vlv
 Drain pot condensate removal

The valve can be opened/closed either:

1. manually by the operator from DCS interface or

2. in automatic mode when required by process conditions.

The valve working mode (automatic or manual) will be selected by the

operator.
The valve is open/close type, and will travel full stroke when the open/close
signal is initiated.
 Drain pot condensate removal
OPEN PERMISSIVE
(temperature in drain pot is lower than saturation temperature at HP Drum
pressure + 20°C) OR (HP Drum Pressure is lower or equal to 0,4 barg)

OPEN REQUEST
By the operator in manual mode or in auto mode if:
(temperature in drain pot is lower than saturation temperature at HP Drum
pressure + 20°C AND [GT in Crank Mode OR GT Running OR FA fan
running]) OR (HP Drum Pressure is lower or equal to 0,4 barg).

CLOSE PERMISSIVE
Always present

CLOSE REQUEST
By the operator in manual mode or in auto mode if:
(Temperature in drain pot is 30°C higher than saturation temperature at HP
Drum pressure OR [GT NOT Running AND FA fan not running AND GT
start-up sequence NOT initiated]) AND (HP drum pressure higher than 0,4
barg).
Drain pot condensate removal
HRSG & DUCT BURNER
PROTECTION
 HRSG Protection (ESD)
HRSG shutdown will be initiated by one the following initiators:

1. plant shut-down
2. HP Boiler drum high-high level
3. HP Boiler drum low-low level
4. Cooling air to flame detector low low pressure, delayed to enable
cooling air fan change-over
5. Sealing air to FA duct damper low low pressure, delayed to enable
fan change-over of FA operation change over
6. SH steam HH temperature, 90 sec delayed (duct burner trip 60 sec.
Delayed)
7. HRSG stack damper not open
8. HRSG instrument air low-low pressure
9. HRSG emergency trip (push button in Control Room)
10. 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)
 HRSG Protection (ESD)

11. HRSG change over from CC mode to FA mode initiated and time
expired
12. HRSG change over from FA mode to CC mode initiated and time
expired
13. GT trip; GT trip initiator shall be masked in case of HRSG in FA
mode operation
14. Diverter damper system discrepancy (diverter damper system NOT
closed & NOT open – signal delayed to enable the CC/FA mode
change over)
15. BFW pumps trip
 HRSG Protection (ESD)
EFFECT
1. Emergency close diverter system (*)
2. Duct Burner Shutdown request

(*) Close HRSG damper and open By-pass stack damper (de-energizing
the ESD solenoid valve of the diverter dampers system). In the mean
time the ESD will start a timer of 12 seconds (shall be defined during
design and commissioning) to check correct by-pass stack damper
opening and HRSG damper closing. If the time expires and the HRSG
inlet damper is not closed OR the by-pass stack damper is not open, a
signal of “GT shutdown for HRSG shutdown and diverter system failure
to close” will be transmitted hardwired to GTS.

When the above trip initiators have been restored and HRSG trip
condition are reset from ESD, the diverter system will be released to be
operate from DCS (in manual mode by the operator or in auto mode by
logics) for the purge sequence (logic from GTS, BMS and ESD) and
operation in CC or FA mode.
 Duct Burner trip request from ESD
Duct Burner Shutdown from ESD will be initiated by one of the following
initiators:

1. HRSG shutdown
2. SH steam HH temperature (60 sec. delayed)
3. HRSG flue gas (right or left side) high-high temperature (60 sec
delayed)
4. HRSG-HP EVA differential pressure < min
This initiator is masked during either CC to FA or FA to CC
changeover
5. Duct Burner emergency trip (push button in Control Room)
 Duct Burner trip request from ESD

EFFECT
Duct Burner Shutdown request (Hardwired signals to BMS)

Moreover, the DCS shall track the gas control valve (231-FCV-6756A)
at the light-off position and shall force the relevant controller in manual
mode.
The DCS track shall be removed when the duct burner is confirmed IN
OPERATION

The BMS shall provide the closing of the pilot/burner valves and the
main pilot/burner double block & vent valve (vent will be open), and the
opening of pilot/burner header vent valves (for further details please
refer to the Duct Burner - BMS Function Specification). Moreover, the
“DUCT Burner purged” condition shall be reset.
 Duct Burner Protection (BMS)
The duct burner shutdown will be initiated by the BMS by one of the
following initiators:
• Duct burner Shutdown from ESD
• Emergency trip from BMS local push button
• Others duct burner trip initiators from duct burner skid or runners
(Pressure, Flame, valves position, etc) see doc - Duct Burner - BMS
Function Specification

EFFECT:
BMS:
• The BMS shall provide the closing of the pilot/burner valves and the
main pilot/burner double block & vent valve (vent will be open), and
the opening of pilot/burner header vent valves
• Moreover, the “DUCT Burner purged” condition shall be reset.
• The HRSG can remain in service as simple recovery (if, before the
duct burner trip, HRSG were in CC mode).
 Duct Burner Protection (BMS)

DCS:
• The DCS shall track the gas control valve (231-FCV-6756A) at the
light-off position and shall force the relevant controller in manual
mode. The DCS track shall be removed when the duct burner is
confirmed IN OPERATION.

NOTE
• The “Duct Burner Purge completed” condition is reset through
intervention of one of the above initiators.
• When all the trip initiators have been removed, then it will be
possible to perform the duct purge and the duct burner light-off.
 Fresh Air Fan Protection (ESD)
FA Fan shutdown will be initiated by ESD by one of the following
initiators:
• Fixed bearing MDE high high temperature
• Floating bearing STDE high high temperature
• Fixed bearing MDE high high vibration
• Natural Draft

EFFECT
• FA Fan motor drive emergency stop
• FA Fan Steam turbine emergency stop
 Fresh Air Fan Protection (ESD)
Motor drive shutdown will be initiated by ESD by one of the following
initiators:
• Motor drive bearing NDE high high temperature
• Motor drive bearing DE high high temperature
• FA Fan shutdown

EFFECT
• FA Fan motor emergency stop signal to MCC
 Fresh Air Fan Protection (ESD)
Steam Turbine shutdown will be initiated by ESD by one the following
initiators:
• Bearing NDE high high temperature
• Bearing DE high high temperature
• FA Fan steam turbine emergency trip
• FA Fan Fan shutdown
EFFECT
Emergency close Steam turbine trip valve, by means of ESD SOV (de-
energize 231-HV-6650A)
Emergency shutdown Steam turbine signal to pick 150 local panel (ST
governor, for logic alignment purpose only).
NOTE:
In case of steam turbine over speed, the local speed governor control
unit will close the relevant steam inlet control valve 231-SCV-6651A, as
well as the steam turbine built-in over speed protection system will
force to close (emergency closure) the turbine trip valve 231-HV-
6650A.
 Natural Draft (ESD)
During FA operation with Duct burner in operation, in case of Duct
burner trip caused by the loss of fresh Air (FA fan not running OR FA
downstream damper not open) the condition “natural draft” shall be set
by ESD and the following trip actions shall be kept for 15 minutes:
• Burner trip shall be request from ESD
• FA duct damper, HRSG stack damper and the FA fan damper shall
be locked-out open
• FA fan motor shall be locked-out stopped
• Diverter dampers system shall be locked-out in close position
• Steam turbine shall be tripped via valve 231-HV-6550A

After 15 minutes, the “natural draft” condition will be reset by the ESD
and the trip actions will be removed.
The Duct burner trip has to be reset also by operator before of the
restart in FA mode operation with the FA purge and duct burner
operation.
HRSG STATUS DEFINITION
START- UP & SHUT-DOWN
SEQUENCES
 HRSG status definition, ramp rate
Actual HP drum operating temperature compared with normal base load
operating temperature define the HRSG status [Hot/Warm/Cold].
Following situations are possible :
HRSG Cold Status
HP drum temperature up to 110°C (pressure up to 0.4 barg)
HRSG Warm Status
HP drum temperature between 110°C and 230°C (0.4<pressure<27
barg)
HRSG Hot Status
HP drum temperature higher than 230°C (pressure>27 barg)

During start-up HP drum water temperature gradient shall be

maintained below 8.5°C/min during boiler start-up/shutdown.
The thermal gradient in the drum is controlled by the HRSG start-up
vent.
 HRSG START-UP SEQUENCE
This sequence prepares the HRSG to be purged and to receive the
exhaust gas from GT or, in alternative, to be purged and started in FA
mode.
It is activated on operator request. Manual start-up of the boiler is also
possible.

Sequence steps shall be integrated, customized and harmonized to

plant procedures and standard.
 HRSG START-UP SEQUENCE
Step 1
• Verify no trip initiators present and sequence start req. by operator.
Step 2
• This step checks that all equipments [not only the ones involved in
the sequence] are available and in auto mode.
• If some equipment is not in auto mode, operator shall be requested
to put in auto mode or, alternatively, the sequence may put the
equipments in auto mode (according to the general plant
philosophy).
• Only the equipments that require a manual startup by operator could
be left in manual mode.
Step 3
Following actions are required:
• HP Desup. Interc. Valve Close
HP Interm. Blow-down Interc. Valve Close
HP Cont. Blow-down Interc. Valve Close
HP Main steam Stop. Valve Close
HP Drum Water Isolation Valve Close
 HRSG START-UP SEQUENCE
Step 4
Once previous step is finished, sequence will start the sealing air
blowers.
• Main sealing air blower Start
Step 5
Once previous step is finished the operator is required to put in service
Feed Water system (not in NE supply scope)
• FW system: HP FW pumps and valves in service
Step 6
Once previous step is finished, sequence will open the stack damper.
• Stack Damper Open
Step 7
Once previous step is finished, sequence will start the cooling air
blowers.
• Main cooling air blower Start
 HRSG START-UP SEQUENCE
Step 8
Once previous step is finished the operator is required to reset the
HRSG trip condition and drum start-up level shall be checked.
• Start-up level is a function of the actual drum pressure and it is
considered acceptable if it is +/- 50 mm from actual set-point [refer
to drum level start up SP curve].
HP Drum manual refilling
• If water level is too low, the HP Drum control valve [231-LCV-6601A]
and HP Drum water isolation Valve [231-MOV-6610A] will be
opened by operator to fill in required amount of water. If water level
is too high the intermittent blow down intercept valve [231-MOV-
6605A] shall be opened by operator to reduce the level.
Step 9
When level is acceptable and the level control valve 231-LCV-6601A is
closed.
• 231-LCV-6601A HP drum level control will be put in AUTO mode.

Operator can proceed with the unit purge and start up.
 HRSG SHUT-DOWN SEQUENCE
This sequence is activated on operator request. Manual shut-down of
the boiler is also possible. Sequence steps shall be integrated,
customized and harmonized to plant procedures and standard.

Sequence can be started only if the GT and the Duct Burner are both
off.
Step 10
• This step checks that all equipments [not only the ones involved in
the sequence] are in available and in auto mode.
• If some equipment is not in auto mode, operator shall be requested
to put in auto mode or, alternatively, the sequence may put the
equipments in auto mode (according to the general plant
philosophy). Only the equipments that require a manual startup by
operator could be left in manual mode.
 HRSG SHUT-DOWN SEQUENCE
Step 11
Once previous step is finished following actions are required:
• HP Drum water Interc. valve Close
Step 12
Once previous step is finished, following actions are required :
• HP System:
HP Desup. Interc. Valve Close
HP Interm. Blow-down Interc. Valve Close
HP Cont. Blow-down Interc. Valve Close
HP Main steam Interc. Valve Close
Step 13
• Once previous step is finished, and GT is OFF AND Duct Burner is
OFF AND [HRSG HRSG flue gas temp. left side right side <100°C]
the duct burner air Blowers can be switched OFF
• Stack Damper Close
END