ECUADOR 192MW PPS

WASTE HEAT RECOVERY SYSTEM

PROJECT CLIENT :

FOR FINAL

2010.11.19

40,WOUNGNAM-DONG,CHANGWON CITY, KOREA

TEL: +82-55-269-7700(REP.)
FAX:+82-55-269-7798/9(PRODUCTION DIVISION)
E-MAIL : tech1@kangrim.com
VENDOR NAME :

VENDOR PRINT
ECUADOR 192MW PPS

CLIENT :

CONTACTOR : HYUNDAI HEAVY INDUSTRIES CO., LTD.

ENGINE TYPE : HYUNDAI HIMSEN 9H21/32

 ▶INDEX

* TECHNICAL SPECIFICATION

* DRAWING

* SPARE & SPECIAL TOOLS

* ERECTION PROCEDURE & GUIDE LINES FOR W.H.R.S.

* W.H.R.B. COMMISSIONING PROCEDURE

* FLOW CHART & OPERATING

PLAN HISTORY
4
3
2
1
0 2010.11.19 FOR FINAL S.W.KIM H.C.KWAK H.S.JUNG
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
 S. Page T. Page

TECHNICAL SPECIFICATION

PROJECT NAME : ECUADOR 192MW PPS

PLANT OWNER : EQUITATIS S.A.

ENGINE TYPE : HYUNDAI HIMSEN 9H21/32

TITLE : EXHAUST GAS BOILER

( 26 SHEETS WITH COVER)

DRAWN DESIGN CHECK APRD DESCRIPTION R

J.C.LEE J.C.LEE Y.T.SEOK S.W.SHON

FIRST ISSUE 0
2010-11-19 2010-11-19 2010-11-19 2010-11-19

DOC NO.

ENGINE & MACHINERY DIVISION ECR1-TEC-M08

HSEF-K210-C014(R0) ENGINE & MACHINERY DIVISION A4(210mm×297mm)
 ECUADOR 192MW
PLANT :
PPS

▶ INDEX
No. Description Rev. Remark

1 SPECIFICATION 0

1-1 EXH. GAS BOILER SPECIFICATION 0

1-2 HOT WELL TANK SPECIFICATION 0

1-3 BLOW DOWN TANK SPECIFICATION 0

2 CALCULATION 0

2-1 EXH. GAS BOILER CALCULATION 0

2-2 BLOW DOWN TANK CALCULATION 0

3 SETTING LIST 0

3-1.1 Boiler safty setting list 0

3-1.2 Boiler water level setting 0

3-1.3 Boiler steam pressure setting 0

3-2.1 Water level setting(Hot well tank) 0

3-2.1 Hot well tank setting list 0

4 PAINT SPECIFICATION 0
1. SPECIFICATION
 ECUADOR 192MW
PLANT :
PPS

▶ EXH. GAS BOILER SPECIFICATION

1. DESIGN CONDITION

1) Normal working pressure : 7.0 Bar G

2) Sat. steam evaporation required : 1200 Kg/hr
3) Sat. steam pressure : 7.0 Bar G
4) Exhaust gas amount : 53200 Kg/hr
5) Exhaust Gas Inlet Temperature : 295 ℃
6) Feed water temperature : 70 ℃
7) Design pressure : 10 Bar G
8) Design code : ASME 2007Ed. + 2009 ADD
9) Stamp : NONE
10) QUANTITY : 1 Set

2. PERFORMANCE OF E.G.B

1) Sat. steam evaporation : 1200 Kg/hr @ 295℃

2) Sat. steam temperature : 169 ℃
3) Exhaust gas outlet temperature : 242 ℃
4) Total draft loss at design Capacity : 96.9 mmAq
 ECUADOR 192MW
PLANT :
PPS

3. PARTICULARS OF E.G.B

1) Arrangement
The unit consists of 309 tubes, 2674mm effective length, two end, gas flows upwards.

2) Heating surface
- Steam generator section : 186.1 m2

3) Safety valve setting pressure : 9 Bar G

4) Dimensions of overall casings

- Diameter : 2200 mm
- Height (Exclude In/Out chamber) : 1936 mm

5) E.G.B weight (Dry) : Abt.8 Ton

6) E.G.B weight (Operating) : Abt.11.8 Ton

 ECUADOR 192MW
PLANT :
PPS

4. STRUCTURE AND MATERIALS OF E.G.B

1) Materials
- Heatings tubes : Carbon steel boiler tubes
- Headers : Carbon steel
- Body : Carbon steel / Gal'v sheet
- Frame : Carbon steel

2) Paint
- First : Zinc primer
- Final : Heat resistant silver
 ECUADOR 192MW
PLANT :
PPS

▶ HOT WELL TANK SPECIFICATION

Technical data

Number of cond. Storage tank : 1 set

3
Capacity : 6.0 m
Working pressure : ATM
Working pressure : ATM
: ATM
Hydro. Test pressure : FULL OF WATER
Operating temperature : 70 ℃
Design temperaature : 100 ℃
Material (body) : SUS304

Dimension & Weight

Dimension(O.DxL)- excl. of insulation : O.D1750x2800 mm

Insulation : 25 mm
Dry weight : 1.5 ton
Operating weight : 7.5 ton
 ECUADOR 192MW
PLANT :
PPS

▶ BLOW DOWN TANK SPECIFICATION

Technical data

Number of blow down tank : 1 set

Capacity : 0.14 m3
Working pressure : ATM bar g
Working pressure : ATM bar g
: ATM bar g
Hydro. Test pressure : FULL OF WATER
Design temperature : 100 ℃
Operation temperature : 60 ℃

Dimension

In diameter excl. of insulation : 406.4 mm

Height incl. of vent : 1628 mm
Weight of boiler (dry) approx : 150 kg
Weight of boiler (operation) approx : 290 kg
2. CALCULATION
 Strength calculation of Exh. Gas Boiler

1. Spec. of Aux. Boiler

1) Class = ASME 2007ED

+2009 ADD
2) Working pressure = 7 kg/cm2

2
3) Design pressure(W) = 10 kg/cm

4) Design temperature = 300 °C

5) Allowable stress of material

For ASME SA516 - 70(Shell Plate & Tube Sheet, = 14.07 kgf/mm2
Furnace Plate) (ASME Sec. Ⅱ Table 1A)
For A106-B (Nozzle Pipes) = 7.95 kgf/mm2

2
For A192(Boiler Tube & Stay Tube) = 7.34 kgf/mm

For SF440(Flange) = 11.21 kgf/mm2

2
For A182-F304(Flange) = 12.13 kgf/mm

For SS400 = 10.19 kgf/mm2

2
For SUS304 TP(PIPE) = 8.25 kgf/mm

For SUS304 (PLATE) = 9.78 kgf/mm2

6) Steam capacity = 1,200 kg/hr

2
7) Heating surface = 186.1 m

8) Diameter excl. of insulation = 2,200 mm

9) Height excl. of mountings, incl. uptake = 1,936 mm

10) Water volume at normal water level = 3.7 m3

11) Insulation(RockWool,RW #80) = 75 mm

12) Weight of boiler incl. insulation, = 8 TON

Burner and fitting excl. water approx
2. Shellplate of boiler (PG-27.2.2)

PxD
t = ------------------- + C = 8.80 mm
2SE + 2yP

P = maximum allowable working pressure(see PG-21) = 10 kg/cm2

D = outside diameter of cylinder = 2200 mm
2
S =Allowable stress PG-23 ( see PG-27.4,Note 2) = 14.07 kgf/mm
E = efficiency (see PG-27.4,Note 1) = 1
y = temperature coefficient (see PG-27.4, Note 6) = 0.4
C = minimum allowance (see PG-27.4, Note 3) = 1

* Actual th'k of shellplate(PFT-9.1) = 12 mm

(OK!)
3. Tubesheet of boiler (PFT-31.2)(PFT-9.2.1)

P
T=p --------- = 15.07 mm
C

2
P = DESIGN PRESSURE = 10 kg/cm
p = Pitch measured between the centers of tube in row = 221.6 mm
C = Factor = 2160
* Actual th'k of tubesheet(PFT-9.2) = 18 mm
(OK!)
4. Boiler gusset stay

2F
h= ----------------- = 159.13 mm2
b f sinV
b = Thickness of the gusset stay = 18 mm
e2 < b < 1.7e2
b > 0.7 e1
e1 = The end plate thickness = 18 mm
e2 = The shell plate thickness = 12 mm
f = Allowable stress(Table1A of SectionII,Part D) = 14.07 kgf/mm2
F = Force exerted by press on the plate = 15436.441 kg
in the zone assumed to be supported by gusset
V = Angle from endlate to gusset stay = 50 deg.
A = Plate area supported by gusset stay = 115885 mm2

* Actual gusset stay bar b = 18 mm

h = 268 mm
 5. Required thickness of smoke tube for internal pressure (PG-27.2)
(see PG-27.4, Notes 2,4,8 and 10.)

PD
t = ------------ + 0.005D + e = 1.598 mm
2S + P

P = maximum allowable working pressure = 10 kg/cm2

D = outside diameter of cylinder = 50.8 mm
e = thickness factor for expanded tube ends = 1
S =Allowable stress = 7.34 kgf/mm2

* Actual thickness of water tube = 2.9 mm

(OK!)
6. Required thickness of smoke tube for external pressure (PFT-51)

L
--------- = 37.40157
Do
○L / Do > 50 ------> L / Do = 50
○L / Do < 0.05 ------> L / Do = 0.05

Do
--------- = 17.51724
t
Do = outside diameter of tube = 50.8 mm
L = lengh of tube between tubesheet = 1900 mm
t = minium required thickness of tube = 2.9 mm

Do / t = 17.51724 ------------------------------------------------> USE SHEET (A)

(a) Cylinder having Do / t > 10 (SHEET A)

○ 0.00016 < A < 0.02 (USE!)

4xB
2
Pa = ------------- = 58.21213 kg/cm
3(Do / t)

○ 0.00016 > A > 0.02 (NOT USE!)

2xAxE
Pa = ------------- = 0 kg/cm2
3(Do / t)

A = factor determined from Sec.II, part D, Fig.G = 0.004000

B = factor determined from the applicable material = 75.0 Mpa
chart if Sec.II, part D
Do = outside diameter of tube = 50.8 mm
E = modulus of elasticity of material at design temp. = 0 Mpa
P = externam design pressure = 10 kg/cm2
Pa = calculated value of allowable external press. = 53.95 kg/cm2
t = minium required thickness of tube = 2.9 mm

Pa( 53.95 ) > P( 10 ) OK!

(b) Cylinder having Do / t <= 10 (SHEET B)

Do / t = 17.51724 ------------------------------------------------> NOT CALCULATE (A)

1.1
A = -------------- = 0.003585
2
(Do / t)
○A > 0.1 ------> A = 0.1

2.167
Pa1 = ----------- -0.0833 B = 0 kg/cm2
Do / t

2Sb 1
2
Pa2 = ----------- 1 - ---------- = 0 kg/cm
Do / t Do / t

A = factor determined from Sec.II, part D, Fig.G = 0.000000

B = for a given temperature curve, determine the B = 0.0 Mpa
value that corresponds to the right hand side
termination point of the curve
Sb = the lesser of 2 * maximum allowable stress values = 0.0 Mpa
at design metal temperature or 0.9 * yield strength
of the material at design metal temperature
Pa1 = calculated value of allowable external press. = 0 kg/cm2
2
Pa2 = calculated value of allowable external press. = 0 kg/cm

Pa = smaller of Pa1 calculated or Pa2 calculated = 0 kg/cm2

Pa( 0 ) > P( 10 ) NOT OK!

7. Required thickness of stay tube(PFT-23)

P x A2
A1= ----------------- = 321.75 mm2
S
P = Pressure corresponding to the strength of the stay = 10 kg/cm2
A2 = Maximum area supported by stay tube = 45270 mm2
S = Allowable stress = 14.07 kgf/mm2
A1 = Required area of stay tube = 321.7484 mm2

Actual area of one stay tube

= (63.5^2-53.5^2) x PI / 4 = 719.4247 mm2

* Actual dia. of boiler stay tube = 50.8 x 5 mm

(OK!)
8. Manhole of boiler shellplate (PG-33 FIG. PG-33.1)

trn = Required thickness of a manhole nozzle wall

PxD
= ------------------- + C = 2.27 mm
2SE + 2yP

P = maximum allowable working pressure(see PG-21) = 10 kg/cm2

D = outside diameter of cylinder = 430 mm
2
S =Allowable stress PG-23 ( see PG-27.4,Note 2) = 14.07 kgf/mm
E = efficiency (see PG-27.4,Note 1) = 1
y = temperature coefficient (see PG-27.4, Note 6) = 0.4
C = minimum allowance (see PG-27.4, Note 3) = 0.75 mm
Actual Used Thickness = 25 mm

A = Request area
= (d + 2tn)trF = 3782.23 mm2

2
A1 = ( d - 2tn ) ( t - Ftr ) = 1057.36 mm
A2 = 2( tn - trn )( 2 1/2 t fr1) = 770.46 mm2
A3 = 2tn fr1 h = 1186.5672 mm2
2
A41 = (WL1)^2 fr2 = 81.364606 mm
2
A42 = (WL2)^2 fr3 = 36.162047 mm
A43 = (WL3)^2 fr1 = 36.162047 mm2
A5 = ( Dp - d - 2tn) te fr3 = 678.03838 mm2

2
A0 = A1+A2+A3+A41+A42+A43+A5 = 3846.11 mm

d = Dia. of manhole = 380 mm

tr = Theoretically min thickness (ref. 2) = 8.80 mm
t = thickness of shellplate = 12 mm
F = Correction factor which compensates for the variation= 1
in pressure stresses on different planes with respect to
the axes of a vessel.
A value of 1.00 shall be used for all configurations.
fr = 1.0 for nozzle wall abutting the vessel wall = 1
fr1 = allowable stress in nozzle / allowable stress in vessel = 0.565032
fr2 = allowable stress in nozzle / allowable stress in vessel = 0.565032
fr3 = allowable stress in nozzle / allowable stress in vessle = 0.565032
E = efficiency (see PG-27.4,Note 1) = 1
tn = Thickness of nozzle wall = 25 mm
h = The smaller than 2.5t or 2.5tn = 42 mm
te = Thickness of reinforcing element = 12 mm
Dp = length of reinforcing element = 530 mm
WL1 = Length of reinforcing element = 12 mm
WL2 = Length of reinforcing element = 8 mm
WL3 = Length of reinforcing element = 8 mm

A( 3782.23 mm2 ) < A0 ( 3846.11 mm2 ) (OK!)

9. Main steam nozzle of boiler (PG-33 FIG. PG-33.1)

trn = Required thickness of a nozzle wall

PD
------------ + 0.005D + e = 1.75 mm
2S + P

P = maximum allowable working pressure(see PG-21) = 10 kg/cm2

D = outside diameter of cylinder = 89.1 mm
2
S =Allowable stress PG-23 ( see PG-27.4,Note 2) = 7.95 kgf/mm
E = efficiency (see PG-27.4,Note 1) = 1
y = temperature coefficient (see PG-27.4, Note 6) = 0.4
C = minimum allowance (see PG-27.4, Note 3) = 0.75 mm
Actual Used Thickness = 5.46 mm

A = Request area
= (d + 2tn)trF = 783.71 mm2

A1 = ( d - 2tn ) ( t - Ftr ) = 215.51 mm2

A2 = 2( tn - trn )( 2 1/2 t fr1) = 125.67 mm2
2
A3 = 2tn fr1 h = 158.57284 mm
2
A41 = (WL1)^2 fr2 = 9.0405117 mm
A42 = (WL2)^2 fr3 = 27.686567 mm2
2
A43 = (WL3)^2 fr1 = 9.0405117 mm
2
A5 = ( Dp - d - 2tn) te fr3 = 684.14072 mm

2
A0 = A1+A2+A3+A41+A42+A43+A5 = 1229.66 mm

d = Dia. of nozzle = 78.18 mm

tr = Theoretically min thickness (ref. 3) = 8.80 mm
t = thickness of shell = 12 mm
F = Correction factor which compensates for the variation= 1
in pressure stresses on different planes with respect to
the axes of a vessel.
A value of 1.00 shall be used for all configurations.
fr = 1.0 for nozzle wall abutting the vessel wall = 1
fr1 = allowable stress in nozzle / allowable stress in vessel = 0.565032
fr2 = allowable stress in nozzle / allowable stress in vessel = 0.565032
fr3 = allowable stress in nozzle / allowable stress in vessle = 0.565032
E = efficiency (see PG-27.4,Note 1) = 1
tn = Thickness of nozzle wall = 5.46 mm
h = The smaller than 2.5t or 2.5tn = 25.7 mm
te = Thickness of reinforcing element = 12 mm
Dp = length of reinforcing element = 190 mm
WL1 = Length of reinforcing element = 4 mm
WL2 = Length of reinforcing element = 7 mm
WL3 = Length of reinforcing element = 4 mm

A( 783.71 mm2 ) < A0 ( 1229.66 mm2 ) (OK!)

10. Pipe of Steam header (UG-27)

(1) CIRCUMFERENTIAL STRESS(LONGITUDINAL JOINT)

PR
t = ------------------- + C = 3.28 mm
SE - 0.6P

P dose not exceed 0.385SE = (OK!)

(2) LONGITUDINAL STRESS(CIRCUMFERENTIAL JOINT)

PR
t = ------------------- + C = 2.13
2SE + 0.4P

P dose not exceed 1.25SE = (OK!)

2
P = internal design pressuer(see UG-21) = 10 kg/cm
R = inside diameter of shell = 158.4 mm
S = maximum allowable stress (UG-23 and UG-24) = 8.25 kgf/mm2
E = efficiency (see UW-12) = 0.85
C = corrosion allowance = 1 mm

* Minimum th'k of Pipe = 3.28 mm

* Actual th'k of Pipe = 7.1 mm

(OK!)
11. Endplate of Steam header (UG-34)

cP
t=d ------- +C = 9.77 mm
SE

d = diameter = 158.4 mm
c = a factor depending upon the method of attachment = 0.3
of head
2
P = internal design pressure = 10 kgf/cm
S = maximum allowable stress (UG-23 and UG-24) = 9.78 kgf/mm2
E = efficiency (see UW-12) = 1
C = corrosion allowance = 1 mm

* Actual th'k of Pipe = 20 mm

(OK!)
12. Pipe of Return header (UG-27)

(1) CIRCUMFERENTIAL STRESS(LONGITUDINAL JOINT)

PR
t = ------------------- + C = 4.64 mm
SE - 0.6P

P dose not exceed 0.385SE = (OK!)

(2) LONGITUDINAL STRESS(CIRCUMFERENTIAL JOINT)

PR
t = ------------------- + C = 2.80
2SE + 0.4P

P dose not exceed 1.25SE = (OK!)

2
P = internal design pressuer(see UG-21) = 10 kg/cm
R = inside diameter of shell = 253.4 mm
S = maximum allowable stress (UG-23 and UG-24) = 8.25 kgf/mm2
E = efficiency (see UW-12) = 0.85
C = corrosion allowance = 1 mm

* Minimum th'k of Pipe = 4.64 mm

* Actual th'k of Pipe = 6.5 mm

(OK!)
13. Endplate of Return header (UG-34)

cP
t=d ------- +C = 15.72 mm
SE

d = diameter = 253.4 mm
c = a factor depending upon the method of attachment = 0.33
of head
2
P = internal design pressure = 10 kgf/cm
S = maximum allowable stress (UG-23 and UG-24) = 9.78 kgf/mm2
E = efficiency (see UW-12) = 1
C = corrosion allowance = 1 mm

* Actual th'k of Pipe = 20 mm

(OK!)
 ECUADOR 192MW
PLANT :
PPS

▶ BLOW DOWN TANK CALCULATION

1. DESIGN DATA

1) MAIN
DesignENGINE
capacityCONDITION
: 5% of intermittent blow down rate

2) Steam velocity : 0.3 m/s

2. CALCULATION

1) MAIN
Blow down
ENGINE
water
CONDITION
Q = 1200 x 0.05 = 60.0 kg/h

2) Flashed steam
176.8 - 100
G = 60 x = 8.2 kg/h
662.7 - 100

3) Tank required area

8.2 x 1.100
A = = 0.008 m2
3600 x 0.3

4) Tank diameter
0.008 x 4
D =( )1/2 = 0.103 m
π

Approx. diameter = 0.4 m

5) Tank height (not include tank head)

Seal height = 0.833 m
Vent height = 0.267 m
Total height = 1.1 m

6) Service water quiantity (X kg/h)

Service water temp. : 25
Outlet temp. : 60

60 x 176.8 = ( 8.2 x 663 ) + ( 60 - 25 )xX

X = 148 kg/h
3. SETTING LIST
4. PAINT SPECIFICATION
 PAINT SPECIFICATION (HHI PPS PJT.-SMOKE TUBE TYPE BOILER)

Specipication

Unit Name Part Name Material SIDE Dry Film Insulation Remark
Surface
1'st 2'nd 3'rd Thickness
Preparation
(㎛)

Water soluble
Exh.Gas Boiler Carbon steel IN - SD3020
corrosion inhibitor
Body
IZ180 QT 606 Insulation 75t
Carbon steel OUT SP-10 100
(75㎛) (25㎛) Al Sheet 0.8t

IZ180 QT 606 Tube sheet gas zone

IN SP-10 100
(75㎛) (25㎛) 포함
IN/OUT Chamber Carbon steel
IZ180 QT 606 Insulation 75t
OUT SP-10 100
(75㎛) (25㎛) Al Sheet 0.8t

Phosphale QT 606
IN (Outside to 300mm) 25
Coating (25㎛)
Tube Carbon steel
Phosphale Water soluble
OUT SD3020
Coating corrosion inhibitor

Valves SUS304 OUT Maker Standard Insulation Mat

Safety valve SUS304 OUT Maker Standard

Bolt/Nut SUS304 OUT Maker Standard

IN Phosphale Coating
Pipes Carbon steel
OUT Phosphale Coating

Gauge board SUS304 OUT Maker Standard

Steam Header IN Pickling pasivity

Header SUS304
Insulation 75t
OUT Pickling pasivity
Al Sheet 0.8t
 Specipication

Unit Name Part Name Material SIDE Dry Film Insulation Remark
Surface
1'st 2'nd 3'rd Thickness
Preparation
(㎛)

Leg, Gauge Board seat SUS304 OUT Pickling pasivity

Gauge Board SUS304 OUT Maker Standard

IN Pickling pasivity
Pipes SUS304
OUT Pickling pasivity

Bolt/Nut SUS304 OUT Maker Standard

Valves SUS304 OUT Maker Standard Insulation Mat

Hot Well Tank

IN Pickling pasivity
& Pump Unit
Hot Well Tank SUS304
Insulation 25t
OUT Pickling pasivity
Al Sheet 0.8t

Ladder Carbon steel OUT HOT DIP GALVANIZING

IN Pickling pasivity
Pipes SUS304
OUT Pickling pasivity

Bolt/Nut SUS304 OUT Maker Standard

Gauge Board Seat SUS304 OUT Pickling pasivity

Level gauge SUS Maker Standard

Feed Water Pump - OUT Maker Standard

Motor base of Feed Water

Carbon steel OUT HOT DIP GALVANIZING
Pump