The function of steam boiler is to transfer heat produced by burning of fuel, to the

water and thus to produce steam.

Requirement of steam

CSU
Min Max
Low pressure steam T/Hr 8.6 12.4
Medium pressure steam T/Hr 81.6 96.8
MP steam pr Kg/cm2g 12 7.5

Temp 200 167

LP steam 2.5 2.5

Temp 175 138

Each waste heat boiler (Steam Generator) HRSG is designed to generate 75t/hr
of saturated steam at 13.5 ata at main steam stop valve with inlet feed water at
1200C, and when 388 800 Kg/hr of GT Exhaust gases flow through the boiler
continuously with a temperature of 5750C at Evaporator inlet. The GT exhaust
gases are heated from 5120C to 5750C using a supplementary firing system with
natural gas as fuel.

Each waste heat boiler is also provided with one FD fan as stand by, in case of
GT shut down to enable the boiler to generate 30 t/hr of saturate steam at 13.5 ata,
when used along with supplementary firing system. The supplementary firing
heats up the fresh air from FD fan to 5750C at the inlet of the evaporator.

Salient Features
Each waste heat boiler consists of the following main components.
(a) Evaporator
(b) Economiser
(c) MU Heater
(d) Chimney
(e) Supplementary firing system
(f) FD fan
(g) Dampers
(h) Toggle sections and expansion Joints
 100% FD Fan
GT Load 100% with SF*
with SF* GT Load
without SF*
1. Gas Flow to SHB hg/hr 389500 388500 188000
3. Gas temperature 0C
a. Entering SF system 512 512 40
b. Leaving SF system 575 512 575
c. Entering Evaporator 575 512 575
d. Entering Eco 214 210 204
e. Entering MU Heater 173 170 161
f. Leaving MU Heater 165 161 146

Steam Flow Kg/hr 75000 64000 30000

Steam Pressure ata 13.5 13.5 13.5
Team Temp 194 194 194

Water and Steam Circuit

Make up water is heated in the MU Heater and from there it goes
to deaerator.
Feed water, being forced by the feed pump, enters the Economiser,
gets heated up too near saturation temperature and flows to the
steam drum. The saturated feed water is distributed uniformly
inside the steam drum by means of a feed header. The saturated
water flows to the mud drum through unheated down-comers and
from there it enters the bank tubes. Steam water mixture is formed
in the bank tubes and it rises to the steam drum. Steam and water
are effectively separated in the drum and separated water is
recirculated in the circuit through downcomers, mud drum and
Bank tubes. Saturated steam is taken through baffle type screens,
for drying of the steam and is available at main steam stop valve
for process use.

There are three modes of operation for the waste heat boiler.
1. Operation with gas turbine exhaust only, without supplementary firing.
2. Operation with supplementary firing without gas turbine exhaust.
3. Operation with gas turbine exhaust and supplementary firing.
Waste heat boiler will have cold start with modes (1) and (2) only. Under
operating mode (3) waste heat boiler will have cold start with gas turbine exhaust
to begin with and the supplementary firing will be introduced only after boiler has
stabilized with gas turbine exhaust.

DESCRIPTION & OPERATIONS OF THERMAX BOILER

It is designed to generate 60 T/HR saturated steam with a pressure .of
12.5 Kg/Sq. c.m.

The boiler has pressurized furnace Air from FD fan enters the furnace for
combustion through air registers (dampers) mounted on front wall

Operating Instruction for HRSG-III

HRSG can be operated in three modes of operation.

MODE STEAM GENERATION
GT (Unfired Mode) -Cogen Mode-GT MODE 60 TPH
GT + Supplementary Firing 90 TPH
FD Fan Mode 90 TPH

3.1.2 System Introduction

Feed water from Boiler feed pump enters the economizer and gets heated up the
near saturator temperature. The heated feed water then goes to drum through the
Eco link to drum. The boiler water from drum flows to the evaporator. The
heated water absorbs latent heat in the evaporator and gets converted in to steam
water mixture which flows back to the drum through riser tube. The saturated
steam is separated by the centrifugal separators final scrubbers placed inside the
drum. The separated boiler water is incubated through down comer evaporator
tubes and risers. The saturated steam is available to main steam line stop valve.

5.2 Condensate System

General
Condensate equivalent to almost 90% of normal MP steam requirement is returned
to boiler house for .recovery of LP steam and re-use as boiler feed water.

System Description
Condensate is returned from Process units to boiler house B/L via line 10" CL
normally. However condensate from light ends column reboiler can be routed via
4" CL line to V-306 from where it can be disposed off to sewer and flashed steam
vented to atmosphere. The latter is provided to accommodate the low pressure
condition existing at the reboiler condensate side when running the column on low
loads. V-306 is also provided with a level gauge and a utility connection.
Normally, the condensate from light end fractionator reboiler will return through
10" header.
10" CL condensate line is led to LP Flash drum V-308 where the condensate is
flashed and steam recovered is connected to LP steam header. LP Flash drum V-
308 is provided with the following instruments:

In deareator oxygen is removed by

1. Mechanical deaeration by heating water with a steam at temp of 105 OC.
2. By chemical scavenging by using sodium sulphite or Hydrazinc
Oxygen is the main cause of corrosion in hotwell tanks, feedlines, feedpumps and boilers

Recommended Lab Analysis

PH
8.5- 9.5
Dissolved O2
0.02 PPM (max.)
Sodium Sulphite (Na2 SO3) 20 - 40 PPM

In deareator oxygen is removed by

1. Mechanical deaeration by heating water with a steam at temp of 105 OC.
2. By chemical scavenging by using sodium sulphite or Hydrazinc
There are two types of deaerators
a) Spray type
b) Tray type In our scope we have spray and tray type deaerator.
Spray deaerator rely on steam nozzles to provide good
steam/water contact that is necessary for good 02 removal. Tray
de aerator use to, provide surface area that enhance steam/water
contact for good 02 removal.

In deaerator M.D. water and steam condensate from the plant are mixing and
spraying on top of deaerator and steam is passing through counter current and
oxygen is venting through vent line provided on top of the deareator.

Boiler feed water is pumping from Deaerator (after scavenging dissolved Oxygen)
through high pressure centrifugal pump to the steam drum through economizer as
to increase the feed water temperature from 105 OC to 110 OC

IBD SYSTEM
Intermittent blow down is taken from the bottom of mud drum, water and headers
or lowest point of the Hr circulation system. The blow off valve is opened
manually and accumulated sludge to be removed every 8 hrs.
CBD SYSTEM
Continuous blow down automatically keeps the boiler water within desired limits.
Continuously removing small stream of boiler water keeps the concentration of
chemicals relatively constant.

FW before economiser 125*c

Temp

FW after economiser 180*c

Temp

MW before heater temp. 32*c

MW after heater temp. 80*c

Condensate return temp (at 150*c

5 kg/cm2)