Hadjret HRSG Operation Training Manual

Heat Recovery Steam Generator
OPERATION TRAINING MANUAL FOR

H AD J RET H RS G
HRSG BU/ POWER PLANT BG

D OOSAN HEAV Y I ND USTRI ES & C ONSTRUC TI ON C O. , LTD .
1
Contents
1. Introduction of Doosan Heavy Industries & Constructions
2. HRSG Main Components
- HRSG Main Design Concept
- Pressure Part
- Nun Pressure Part
- Auxiliary equipment
3. Overview of HRSG System
- HRSG Flow circuit
4. HRSG operation
- HRSG Ready Condition before firing
- Start up
- Shut down
5. HRSG control System
- Main control items
- HRSG protection
2
1. Introduction of Doosan Heavy Industries & Constructions
3
Introduction
1962 : Established
1976 : Fabrication the First HRSG at Domestic Power Plant
1982 : Completed Chang-won Integrated Machinery Plant as
Korea Heavy Industries & Construction (KHIC)
Doosan HRSG
1985 : Fabrication the First HRSG at Overseas Power Plant
1993 : Renamed from KHIC to HANJUNG
2001 : Renamed from HANJUNG to DOOSAN by Privatization
2003 : Entitled No.1 Global HRSG Supplied on McCoy Report
Present : 356 units of Reference in the 35 Countries(Apr. 2008)
4
S h op s a nd F a cil itie s

Seoul

Changwon
Manufacturing Shops Facilities

1. Boiler Main Office
2. NSSS 5. Heavy Fabrication 9. Gas Turbine Dock Facilities
3. T/G 6. Heavy Machinery 10. I&C R&D Center
4. Blade 7. Foundry 11. HRSG NDE and Laboratory
8. Forging Balancing Test
5

D F

/0 56 D
3 21 7: 89 =70 < D G E
23 6 219
3

! $
:C
-. *, 4 ?7 '
@
* 179units were supplied by Doosan utilizing technology

(

%

"
, 9 AB

++ 4- ;) 63

9?
3
%

D

*) 44 *) 7 2? >

+ + @

#
$

Globalized Doosan HRSGs

%
&
6
H R S G G l ob a l M a rk e t S h a re ( 5 y e a rs )
MW, % Market Share (2003-2007)
19,096 14,195 16,152 13,109 23,078 85,630
5.8 8.3 %
15.3 20.1 17.3
30.2 Doosan 17.3
Nooter/Eriksen 15.5
Alstom 13.5
CMI 8.1
NEM
6.8
Others 38.8
2003 2004 2005 2006 2007 Total

Entitled No. 1 Entitled No. 1
Supplier Supplier
Source : McCoy Report 7

Introduction of Doosan Heavy Industries & Constructions
Presentation of Doosan Heavy

DoosanIndustries & Construction Co., Ltd.
Heavy Industries
Doosan Heavy Industries
10 Minutes
Presentation of Doosan HRSG Business Units

HRSG Business Unit
10 Minutes
8
2. Main Components
9
* Support structure
Used to support equipment, stairs,

platforms, ladders and pipes
Easy and safe access using stairs,
platform, ladders to work area
Platform around top steam drum area
Safety cage ladder
Top platform access by two way e.g
stair tower and cage ladder
20
Auxiliary equipment
* Stack Silencer
To release the noise of the HRSG exhaust gas

Installed inside of main stack
Composed of gas baffle lagged by perforated plates
Supported by brackets
21
* Stack Damper
To slow the cooling rate of HRSG

To prevent rainwater into the stack
Adequate sealing to minimize stack heat
loss
minimum pressure loss in the open
position
4-blade assembly design
To self-open without the actuator when
the inlet pressure increase to 125mmWG
22
* Stack Damper (continue)
23
* LP Economizer Recirculation Pump
Delivering the necessary amount of LP

economizer hot water with sufficient head
to overcome piping, valve losses, static
head, etc.
Maintaining enough suction head for
NPSH consideration
Single stage centrifugal type
Using mechanical seal
24
* Safety valve
The purpose of the safety valves are to release the over pressure of the
HRSG caused by blinking the steam turbine
No. Label
1 HP Drum 1
2 HP Drum 2
3 HP S/H
4 IP Drum 1
5 IP Drum 2
6 IP S/H
9 IP Econ
10 LP Drum 1
11 LP Drum 2
12 LP S/H
13 LP Econ
14 Cold RH 1
15 Cold RH 2
16 Hot RH
25
* Safety valve (Continue)
26
* Safety valve Silencer

Silencer
To release the noise of the safety valve

Common steam silencer is provided to the
same system
Noise value is max. 115 dBA at 10m
Safety valve
27
* Safety valve Silencer (Continue)
Pass the steam by this gap
28
* Blowdown tank
To collect the drain water from HRSG and

deliver to blowdown sump
Hot water separating to steam and
condensate in Tank
To deliver flash steam to atmosphere
through silencer
Blowdown
Tank
29
3. Overview of HRSG System
30
HRSG Flow circuit
* Exhaust gas flow
Horizontal flow from GT exhaust

Pass finned tube heat exchanger section
HP S.H 1 => R.H 1 => HP S.H2 => R.H 2 => HP Evap. => HP Econ. 1 =>IP
S.H => LP S.H => HP Econ.2 => IP Evap. => IP Econ. => HP Econ.3 => LP
Evap. => LP Econ.
leave and exit the HRSG through main exhaust stack
31
* P&ID of Exhaust gas system
32
* Steam water flow (High pressure system)
Source of feedwater from HP feedwater pump

Level control valve located at the upstream of HP economizer
Water flow transferred into the HP drum via HP economizer 3/2/1
HP drum / evaporator circuit
Dry steam flow thru HP superheater 2 and 1 to absorb additional heat
Attemperator installed between HP SH 1 and HP SH 2 to control main steam temperature
Safety valves installed to protect over pressure per ASME B&PV code, sec. I
Chemical feed line to feed phosphate into drum
Nitrogen supply line to fill up nitrogen gas during HRSG lay-up period
33
* P&ID of HP System
34
* Steam water flow (Intermediate pressure system)
Source of feedwater from IP feedwater pump

Level control valve located at the downstream of IP economizer
ASME sec.I relief valve installed at IP economizer to protect over pressure
Water flow transferred into the IP drum via IP economizer
Extract hot water to gas fuel heat exchanger at discharge of IP economizer
IP drum / evaporator circuit
Pegging steam to maintain the IP Drum pressure from HP DRUM
Dry steam flow thru IPSH to absorb additional heat
IP steam join into Cold RH steam exhausted from HP steam turbine
35
* P&ID of IP System
36
* Steam water flow (Reheat system)
Exhaust steam from HP steam turbine

Combined Cold RH steam and IPSH steam
Passed via Reheater 2 and 1 tube
Steam transfer to IP steam turbine
Attemperator installed between RH 2 and RH 1 to control Reheat
steam temperature
Safety valves installed to protect over pressure per ASME B&PV
code, sec. I
37
* P&ID of Reheat System
38
* Steam water flow (Low pressure system)
Source of feedwater from condensate pump

Level control valve located at the downstream of LP economizer
ASME sec.I relief valve installed at LP economizer to protect over pressure
A recirculation system to heat up LP Economizer inlet water
Water flow transferred into the LP drum via LP economizer
LP drum & evaporator circuit
Pegging steam to maintain the LP Drum pressure from IP DRUM
Saturated water fed into HP/IP feedwater pump from LP drum
Dry steam flow thru LPSH to absorb additional heat
Safety valves installed to protect over pressure per ASME B&PV code, sec. I
Nitrogen supply line to fill up nitrogen gas during HRSG lay-up period
39
* P&ID of LP System
40
* Steam water flow (Blowdown system)
Receives continuous / stat up blowdown from HP/IP drum

Receives Economizer, Superheater and steam drain around HRSG area
Flashed steam piped into atmosphere via silencer
Condensate piped into waste water system
Cooling water added into the blowdown tank to control outlet water
41
* P&ID of Blowdown System
42
4. HRSG Operation
43
HRSG Ready Condition before firing
Drum water filling to start up level

Valve alignment
Stack Damper Open
One of HP feedwater pump in operation
One of IP feedwater pump in operation
One of Condensate pump in operation
LP Econ. Recirculation pump in operation
No HRSG trip conditions
44
* HRSG initial water filling
45
* LP Drum water filling
Confirm Condensate line stop valve opened

Open Condensate line & LP Econo. Vents valves
(Close it when water overflow)
Open LP drum vent valves (Close it when water fill completed)
Start Condensate Pump
Adjust water water flow about 10% of M.C.R flow by FW control valve
Fill LP drum until Start up water level has been reached
46
* LP Drum water filling (Continue)
47
* IP Drum water filling
Confirm IP FW stop valve opened

Open IP FW line & Econo. Vents valves (Close it when water overflow)
Open IP drum vent valves (Close it when water fill completed)
Start IP feedwater Pump
Fill IP drum until Start up water level has been reached
48
* IP Drum water filling (Continue)
49
* HP Drum water filling
Confirm HP FW stop valve opened

Open IP FW line & Econo. Vents valves (Close it when water overflow)
Open HP drum vent valves (Close it when water fill completed)
Start HP feedwater Pump
Fill HP drum until Start up water level has been reached
50
* HP Drum water filling (Continue)
51
* HRSG Drum Level Setting from Drum Center Line
HP IP LP Action
High/High/High Level 216 mm 254 mm 254 mm

HRSG Trip
High/High 166 mm 175 mm 175 mm Alarm

High Level 129 mm 100 mm 100 mm
Normal Level 0 mm 0 mm 0 mm N.A
Low Level -75 mm - 75 mm -75 mm Alarm
Start up Level - 599 mm - 473 mm -100 mm N.A
HRSG Trip
Low/Low Level - 699 mm - 573 mm - 1486 mm
52
Start up
* HRSG Start up Sequence

Description Section Action
Drum level HP /IP / LP Set the HP, IP and LP drum level at start up water level using start up or
setting Drum intermittent blowoff valves.
•HP Start up blowdown valves (HAD70AA302/251)
•IP Start up blowdown valves (HAD50AA301/251)
•LP intermittent blowdwon valves (HAD20AA003/004)
Valves HP /IP /LP Align HP/IP/LP section valves for Start from cold.
alignment
HRSG Start up All HRSG will be purged and load up following GT start and flue gas entering
by GT start to HRSG
Vent operation HP /IP /LP Vent will be operated for extracting non-condensable from HRSG.
•Open HP start-up vent valve(LBA70AA301) at 0.7 barg and close at 2

barg.
•Open IP start-up vent valve(LBA80AA201) at 0.7 barg and close at 2 barg.
•Open LP start-up vent valve(LBD70AA201) at 0.7 barg and close at 1.3
barg.
53
* HRSG Start up Sequence (Continue)
Drain HP Drain will be operated for removing condensate and extracting non-condensable
operation from HRSG steam path.
*Open HP steam drain valves (HAH70AA301/302, LBA70AA302) when HP
steam pressure above 1.5 barg.
* Close when steam pressure reaches 17 barg with time delay 3min.
Reheater *Reheat steam drain valves

(LBA80AA203,LBC60AA201,HAJ50AA301/302,LBB70AA301) are already
opened from initial start up.
* Close when HP MCV open 20%.
IP *Open IP steam drain valve (HAH50AA201, LBA80AA202) when IP steam
pressure above 1.5 barg.
* Close when IP PCV open 50% with time delay 3min.
LP *Open LP steam drain valve (HAH20AA201) when LP steam pressure above 0.7
barg.
* Close when LP bypass open 20% with time delay 3min.
54
* HRSG Start up Sequence (Continue)
LCV HP / IP /LP Drum level set point should be changed from start up water
set point level into Normal water level when load greater than 25%
change MCR flow.
55
* Plant Start Up Sequence
Plant ready to start

GT rolloff and acceleration to Purge
Purge Gas Path

GT firing and Warmup
GT gas temperature matching
Operation of steam Vents and Drains
Steam is Bypassed to Condenser
Steam is Admitted to the Steam Turbine
Steam Turbine load up
56
* Plant Start Up Sequence (Continue)
Gas Turbine Loaded to Full Load

Reset Drum Level Setpoints to Normal Levels
Steam Production Increases
Steam Pressure Increases
Steam Turbine Reaches Full Load
Duct Burner Operation if required
57
Start up Curve (Typical)
660 120
GT Texh, Deg C
GT Wexh, %
550 100 HP STM FLOW, %
HP STM PRESS, %
HP STM TEMP, %
440 80
* Start initiation at min = 0.

Ready to start conditions satisfied
deg C
(%)
330 60 previously.
220 40 GT Exh. Temp. = 631.7 oC
GT Exh. Flow = 2338898 kg/hr
HP Steam Flow = 304790 kg/hr

110 20
HP Steam Press. = 128 bara
HP Steam Temp. = 567.2 oC
0 0
0 20 40 60 80 100 120 140 160 180 200 220 240
(Minutes)

58
Shut Down
* HRSG Shut Down Sequence
* To maintain the steam cycle pressurized and hot to obtain the fastest
restart the plant.
* HRSG shut down is performed by the GT shutdown
59
* HRSG Shut Down Sequence (Continue)
Duct Burner, if operation, turned off

GT unloading
ST unloading
Steam bypass system open to control the steam pressure
Close all continuous blowdown valve
Stop LP economizer recirculation pump

Close stack damper
60
5. HRSG Control System
61
Main Control Item

* Drum Level Control
•Drum level control maintains drum level setpoint by controlling

the flow of feedwater through control valve
•Matching the steam out flow and in flow of feedwater
•Single element (Drum level) for load lower than 25%
•Three element (Drum level, steam flow, feedwater flow) for load
higher than 25%.
62
* Drum Level Control (Continue)

63
Drum Level Startup Setpoint Action
* Drum Level Control Top

of Drum
(Continue)
SPbias
LA2H
LAH
NWL
Drum Level
SPmax LAL
LAL
SPbias
Drum Level
Setpoint
* SWL = f (startup drum initial pressure)
SWL*
LA2L
Inside Wall
Bottom
of Drum
Initiate IPC and FYH Time

Startup
64
Drum Level
* Drum Level Control

True = 3-Elem. Control
Setpoint NOT
(SPoper)
SP
PV Starting Drum
HP Drum Level (WLcorr)
Level Setpoint
(Continue)
(SPstart)
Track
Variable
PI
3 - ELEM
DRUM LEVEL Track
Switch HP Drum Level SP
CONTROLLER
S (reverse acting) (WLcorr) PV
Track
Variable
PI
drum level SINGLE-ELEM
error correction DRUM LEVEL Track
Switch
CONTROLLER
(reverse acting)
S
HP Steam Flow
calculated flow
setpoint
SP
PV
HP Feedwater Flow
Track
Variable
PI
HP Drum Level Control
FEEDWATER Track Valve Position
CONTROLLER Switch S (ZT____)
(reverse acting)
"1" to energize Solenoid

Valve
|A| to Close Valve
Not Tracking AND
Valve Closed Position
Deviation
Limit Switch (ZSC____)
GT
F
Time Time
Delay Delay
HP Drum Level Control

Valve Control Trouble
Valve Position Command OR
POP
control
T energize LAH
energize de-energize OR
Valve Position (ZT____) LAHH
to close F
HP Feedwater Flow
to the HP Drum
HP Drum
Level/ Flow
Control Valve SIMPLIFIED HP DRUM
LEVEL CONTROL
65
* Final Steam temperature control
•To control HRSG HP Superheater outlet or Reheater outlet

temperature within allowable range
•Installed between heating surface to ensure no water droplet in
main steam line
•Ensure the desuperheater does not spray too much, causing
saturated steam condition at downstream the desuperheater
•Motorized block valve in series with spray control valve for tight
shut off when no demand spray
66
* Final Steam
temperature control
(Continue)
67
* IP Steam Pressure control
•Pressure control valve is installed at IP superheater outlet to

Cold reheater line
•Large, rapid variation in IP drum pressure can cause drum level
swell (drum level rise)
•Prevent rapid pressure fall in IP drum pressure by throttling the
control valve
•Pressure decay rate is controlled
68
* IP Steam Pressure
control (Continue)
69
* IP Drum Pressure pegging control
•Steam from HP drum to IP drum is prepared

•Pegging steam is required when IP steam demand is higher
than the production of IP steam
•Pegging steam control the IP steam pressure above floor
pressure
70
* IP Drum Pressure
control (Continue)
71
* LP drum pressure pegging control
The LP drum pressure is “pegged” by admitting supplementary

steam from a higher pressure/ enthalpy source. Pegging accomplishes
the following:
pegging steam prevents a rapid decay of drum pressure to limit the
generation of steam voids in the drum and BFP suction line water.
Reduced NPSH and/or steam voids entering the BFP can result in
destructive cavitation
To maintain the LP drum pressure high enough above floor pressure
72
* LP drum pressure
pegging control
(continue)
73
* LP Economizer Recirculation control
•To rise the temperature of the condensate entering the LP

economizer
•To avoid flue gas-side corrosion when operation high sulfur
content Gas fuel
•A recirculation control valve modulates the discharge flow of
recirculation pump
•The recirculation run out or min flow is protected by monitoring
the pump outlet flow.
•The control valve opening to be limited if the flow is not
allowable range
74
* LP Economizer Recirculation control (continue)
75
* LP Economizer LP Economizer Recirc Pump Discharge Flow
Recirculation control /L TD A FAL

Low Flow Alarm
FALL
/L TD A Low Low Flow Trip
Trip Recirc Pump
(continue) Fixed Temperature

Setpoint
(SPtemp) /H TD A FAH
High Flow Alarm
FAHH
SP
LP Economizer Inlet Temp PV /H TD A High High Flow Trip
Trip Recirc Pump
Track PI LP ECONOMIZER
Variable
INLET TEMP
CONTROLLER Minimum Flow Setpoint
Track
Switch
(reverse acting) (SPflowmin)
SP
PV
LP ECONOMIZER
Track
Variable
PI RECIRC PUMP MIN
FLOW CONTROLLER
Track
Switch (reverse acting)
Maximum Flow Setpoint

(SPflowmax)
MAX SP
PV
LP ECONOMIZER
Track
Variable
PI RECIRC PUMP MAX
FLOW CONTROLLER
MIN Track
Switch (reverse acting)
From LP Economizer Recirc

Pump Discharge To Inlet of LP Economizer
LP Economizer Recirc
Control Valve
LP ECONOMIZER INLET CONDENSATE

TEMPERATURE CONTROL
76
* LP Economizer 3-way bypass control
•To maintain the subcool margin in condensate temperature before the

LP drum level control valve
•To avoid flashing in the LP drum level control valve
•By modulating 3-way control valve, some cold water bypassed around
the LP economizer to control the LP economizer outlet temperature
•The flow through the LP economizer to the maximum allowable during
periods of high recirculation
•The LP economizer bypass valve is modulated to control the LP economizer
flow so as to achieve a flow within the maximum allowable
77
* LP Economizer 3-way bypass control (continue)

LP Econ
Bypass
TE Control
LCV
LP
Drum TE
TE
DE
Recirc TCV
Pump
78
* LP Economizer 3-way
bypass control
(continue)
79
* Drum startup blowdown control
•Operating during startup of the HRSG

•Functions to limit the rise of drum water level by dumping excess water to a
blowdown tank.
•As the drum is warmed, the level increases due to the steam
formation(swelling).
•The need to dump water occurs during the early stages of a startup while the
drum pressures are relatively low
•The startup blowdown valve opens on a high level and closes after the level is
lowered to normal level to assist the drum level control valve in maintaining
level in the drum
80
* Drum startup blowdown control (Continue)
81
* Drum startup blowdown

control (Continue)
82
HRSG Protection
* HP, IP or LP Drum level > High/High/High
The drum level is protected against impermissible high water level to avoid
water carry over into the superheater and the main steam line.
•Trip ST and GT when High/High/High level

•Protective close the feedwater control valve when High/High level
•Protective close the feedwater control valve after 5 sec time delay when High
level
83
* HP, IP or LP Drum level < Low/Low
The evaporator has to be protected from running dry to avoid local overheating
on evaporator due to missing feed water.
•Trip GT after 5 sec time delay when Low/Low level

•Warning to operator when Low level
84
* HP or Reheat steam temperature > High/High
In case of failure of the HP desuperheater steam temperature control, the

HRSG has to be protected to avoid impermissible high temp.
•GT trip after time delay 20 sec when High/High steam temperature
•GT runback after time delay 300 sec when High steam temperature
85
* HRSG Stack Closure Damper Failure
The protection is required to avoid HRSG duct or HRSG casing wall over
pressure or rupture caused by the stack damper
* GT trip, if the stack damper is not full open during unit operation.
86
Thank you
87

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Available Formats

Heat Recovery Steam Generator

OPERATION TRAINING MANUAL FOR

HRSG BU/ POWER PLANT BG

1993 : Renamed from KHIC to HANJUNG

2001 : Renamed from HANJUNG to DOOSAN by Privatization

2003 : Entitled No.1 Global HRSG Supplied on McCoy Report

2005 : Entitled No.2 Global HRSG Supplied on McCoy Report

2007 : Entitled No.1 Global HRSG Supplied on McCoy Report

Present : 356 units of Reference in the 35 Countries(Apr. 2008)

Manufacturing Shops Facilities

* 179units were supplied by Doosan utilizing technology

2003 2004 2005 2006 2007 Total

Source : McCoy Report 7

Presentation of Doosan Heavy

Doosan Heavy Industries

Presentation of Doosan HRSG Business Units

Used to support equipment, stairs,

To release the noise of the HRSG exhaust gas

To slow the cooling rate of HRSG

* Stack Damper (continue)

* LP Economizer Recirculation Pump

Delivering the necessary amount of LP

* Safety valve (Continue)

* Safety valve Silencer

To release the noise of the safety valve

* Safety valve Silencer (Continue)

Pass the steam by this gap

To collect the drain water from HRSG and

HRSG Flow circuit

* Exhaust gas flow

Horizontal flow from GT exhaust

* P&ID of Exhaust gas system

* Steam water flow (High pressure system)

Source of feedwater from HP feedwater pump

* Steam water flow (Intermediate pressure system)

Source of feedwater from IP feedwater pump

* Steam water flow (Reheat system)

Exhaust steam from HP steam turbine

* P&ID of Reheat System

* Steam water flow (Low pressure system)

Source of feedwater from condensate pump

* Steam water flow (Blowdown system)

Receives continuous / stat up blowdown from HP/IP drum

* P&ID of Blowdown System

HRSG Ready Condition before firing

Drum water filling to start up level

* HRSG initial water filling

* LP Drum water filling

Confirm Condensate line stop valve opened

* LP Drum water filling (Continue)

* IP Drum water filling

Confirm IP FW stop valve opened

* IP Drum water filling (Continue)

* HP Drum water filling

Confirm HP FW stop valve opened

* HP Drum water filling (Continue)

* HRSG Drum Level Setting from Drum Center Line

High/High/High Level 216 mm 254 mm 254 mm

High/High 166 mm 175 mm 175 mm Alarm

Low Level -75 mm - 75 mm -75 mm Alarm

Start up Level - 599 mm - 473 mm -100 mm N.A

* HRSG Start up Sequence

•Open HP start-up vent valve(LBA70AA301) at 0.7 barg and close at 2

* HRSG Start up Sequence (Continue)