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Heat Recovery Steam Generator (HRSG)

Introduction:
The function of the Heat Recovery Steam Generating System is to transfer heat from the
combustion turbine exhaust gases over the heat recovery steam generator (HRSG)
heating surfaces to the water or steam piped through those surfaces to produce
superheated steam. This heat transfer process produces the main steam, intermediate
pressure steam; reheat steam, and low-pressure steam at the pressures and
temperatures required by the steam turbine. In principle, function and component wise,
HRSG is nothing but a steam generator, using exhaust heat to produce steam and
therefore a detail understanding of steam generator is required before we discuss the
specific aspects of HRSG.

Steam Generator:
The Steam Generator is a plant for energy conversion. In a combustion process,
chemical bond energy is converted into the thermal energy of the flue gases. Via the
heat exchanging surfaces in the steam generator, the flue gases in turn convey the
energy as thermally usable energy to the water steam, which serves as a driving
medium for the turbine.
Technically, there are two types of steam generators:

Fire Tube Boilers Water Tube Boilers

In this type of boilers, the hot flue gas In this type the water and steam flo
carried by tubes which transfer the he through tubes which receives heat fro
into a water volume and heat the water. the surrounding hot flue gas

The fire tube boiler is very sluggish in terms of control characteristics (large water
volume) and the attainable pressure is very limited. Therefore, this boiler type is today
only used in plants with a lower output.
Modern power plants in the intermediate and upper ranges of output use exclusively
water tube steam generators.
Independent of its type, the steam generator's output is always indicated by:
ƒ The maximum super heated steam flow at the outlet, expressed in T/h
ƒ The thermo-dynamical condition of steam at the outlet, denoted by the steam
pressure (in kg/ cm2 or bar) and its temperature (in degree centigrade)
The major components of water tube steam generators:

furnace flue gas

to smoke
stack

evaporator superheater reheater economizer

air heater

radiation part connection heating surfaces

A. Evaporator – Heat exchanger; the specific heat demand for evaporation of water is
much higher than the one for increasing steam temperature. This is one reason why the
evaporator is arranged at the place where the heat offer is at its highest.
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B. Steam drum – Feed Water enters and steam leaves the evaporator for further
heating. Steam drum is fitted with internals to keep the water droplets going into the
steam space. These are baffle plates, cyclone separators and scrubbers.

C. Super heater – Dry Saturated steam is further heated to attain the superheated
temperature. The following super heater design types are differentiated:
• Radiation super heater – receives heat mainly by radiation; located in the radiation
chamber of the steam generator
• Convection Super heater – receives heat mainly by convection; located in the
convection zone of the steam generator
• Platen-Type Super heater – receives heat by both radiation and convection; the
platen-type super heater consists of tube walls with a pitch of 800 - 1000 mm,
which are suspended beneath the boiler roof in the radiation chamber.

The convection super heater has a rising temperature characteristic curve over the boiler
load, that is, with increasing load the higher flue gas quantity entails an increase in flue
gas velocity and thereby in heat transmission so that higher heat absorption takes place
in the super heater.
Whereas the radiation super heater has a falling temperature characteristic curve over
the load. The flame radiation changes only little at a higher furnace output. However,
since a higher steam flow passes through the super heater with increasing load, the heat
absorption percentage in the radiation super heater must consequently drop if the heat
supply remains the same.
The platen-type super heater absorbs both radiation heat and convection heat. Its
characteristic curve is influenced proportionally more or less, depending on its position in
the steam generator.

Characteristics of radiant and convection super heater with boiler load

Usually the platen-type super heater has a characteristic curve with a slightly rising
tendency at increasing steam generator output.
Super heaters are further classified by the mode of heat transfer, they are:
ƒ Parallel Flow - the flue gas and the steam flow in the same direction in this
configuration
ƒ Counter flow - the steam flows in the reverse direction of the flue gas; the
improved heat transfer allows thus smaller heating surfaces.

D. Re-heater - In some of the large steam turbines, steam after doing work through a
few stages, substantially looses its pressure and temperature and the enthalpy thus gets
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reduced. Cycle efficiency can be improved, if the steam is extracted out from the high-
pressure cylinder and again taken to the steam generator, where by addition of heat,
the steam temperature is increased. The Re heater comprises a set of coils of tubes,
located in boiler furnace where the steam is reheated. Re heaters are located ahead of
final Super heater in the direction of flue gases and in the convection zone.

E. Attemperator - The attemperator is basically a heat exchanger in which the

superheated steam is cooled either by a direct heat exchange with cold condensate
sprayed into the flow of the superheated steam (SPRAY-TYPE) or indirect heat exchange
with feed water in tube-and-shell type heat exchanger (SURFACE-TYPE).

Normally only feed water is used for attemperation of superheat steam temperature
control. Feed water is tapped of just before the feed control valve and the water
injection is done in two or three stages. The first stage injection is done just after the
primary super heater and second after the radiant super heater.

F. Economizer – The feed water is heated near to its saturation temperature by the
residual heat of the hot gas leaving the major heat transfer components. Economizer is
similar to feed water heater but it is called Economizer, since, by its function; it helps to
improve upon efficiency of the boiler and saves on fuel consumption. The economizer is
located, along the flue gas path, before the last two stages of Air heaters and following
the primary Superheater or Reheater. Counter flow arrangement is normally selected so
that heating surface requirement is kept at minimum for the same temperature drop in
the flue gas. Water flow is from bottom to top so that steam, if any formed during the
heat transfer can move along with water and prevent the lock up of steam, which will
cause overheating and failure of economizer tube. The temperature of water should be
always kept below the saturation temperature to avoid Economizer Steaming.

G. Air heater - The air heater serves for preheating the combustion air while
simultaneously reducing the exit gas temperature. The use of the waste heat in the flue
gas for increasing the temperature of the combustion air increases among others the
efficiency of the combustion process.
The preheated combustion air furthers the ignitability of the fuel and is used for mill
drying (in coal fired boilers) if required.
The air heaters are classified as per following:
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• Recuperative air heaters - In case of recuperative air heating, flue gas and air are
steadily admitted to the air heater heating surface (tube air heater, plate-type air
heater etc.).
• Regenerative air heaters - In case of regenerative air heating, flue gas and air are
alternatingly admitted to the air heater heating surface (rotary air heaters).

H. Stack – A necessary component of the steam generating plant through which

exhaust flue gas is released in the atmosphere.

The water tube steam generators can be categorized by the mode of circulation of water
(or water and steam) inside the tubes. There are three types:
ƒ Natural circulation steam generator,
ƒ Forced circulation steam generator, and
ƒ Once through force flow steam generator

In Natural circulation type of boilers, circulation of water in the boiler takes place due
to natural convection currents produced by the application of heat. Saturated water
flows down the unheated down comer and receives heat in the riser whereupon a part of
it gets converted into steam. The difference in densities of saturated water in the down
comer and the steam-water mixer in the riser brings about natural circulation. It is
applicable to all those boilers, which are operating at a pressure less than critical
pressure.
live cold reheated
steam steam
live
steam

feedwater economizer super- reheater

pump heater

down- evaporator
comer

riser

Natural circulation steam generator

In a Forced circulation, the working fluid is forced through the boiler circuits by an
external pump (Re-circulating Pump).
In a natural circulation steam generator, the density difference between the water-
steam mixture in the riser tubes and the water in the unheated down comers is ever
decreasing with rising pressures. The limit for the maximum possible pressure stage for
a natural circulation steam generator is 175 bar. Moreover, the arrangement of the
down comers and risers in a natural circulation steam generator must be clearly
structured in their geometry in order to guarantee circulation. This condition cannot
always be met in practice
The re-circulating pump works at a pressure of about 2 - 4 bar in order to overcome the
pressure losses in the boiler system and forces the water circulation in the steam
generator independently of the tube geometry of the down comers and the risers.
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cold reheated
live steam steam

drum

feedwater economizer superheater reheater

pump

evaporator

recirculating
pump

Forced Circulation Steam Generator

Advantages of Forced circulation over natural circulation:

1. Steam generation rate is higher for same physical dimensions and weight,
2. Greater capacity to meet load variation,
3. Quicker start-up from cold,
4. Lower scaling problem due to high circulation velocity,
5. More uniform heating of all parts reduces the danger of overheating and thermal
stresses,
6. Smaller tube diameter and hence lighter tubes and
7. Greater freedom in arrangement of furnace, boiler component and tube layout.

Circulation ratio:
It is the ratio of the mass flow rate of circulating water Gfw (t/hr) to the rate of steam
generation Gs (t/h); thus Circulation Ratio = Gfw / Gs
It usually ranges from 4 to 30 for Natural Circulation and 3 to 10 for Forced Circulation
boilers.

The once-through forced flow steam generator design does not include a drum and
consists of tube runs which form the economizer, evaporator and super heater. The
water is forced through the steam generator in one flow once through by feed pump
pressure and, in the course of this, is transformed into hot steam.
steam generator
HP-turbine
feed-
water
reheater
pump economizer evaporator superheater
to the IP-
turbine
live steam

Once-through forced flow steam generator

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Heat Recovery Steam Generator in Power Plant: The HRSG [Heat Recovery Steam
Generator] is a system that generates steam from a primary source of heat, like gas
turbine exhaust, or the waste Incinerators etc.
The main function of the HRSG is to serve as the link between two different
thermodynamic cycles. These are:
ƒ The gas turbine cycle (Brayton) and
ƒ The water steam cycle (Rankine).
These two cycles conform what is called a combined cycle.
To efficiently mate the Rankine steam cycle with high-temperature gas turbines, HRSGs
are developed to operate at substantially higher flue-gas temperatures. New HRSG
designs also are required to match each incremental jump in gas-turbine size as
combined cycle units grow larger and larger. Perhaps the most important development
in HRSG design is the move from single to dual-pressure steam production. This change,
which enabled lower stack temperatures and thus greater recovery of thermal energy
from the gas turbine exhaust, increased thermal efficiency of a combined-cycle plant by
nearly four percentage points. Later designs has gone one step further, from dual to
triple-pressure steam production, and yielded approximately one more percentage point
gain for the overall cycle. Today, most of the HRSGs for large combined cycle power
plants are designed for triple pressure reheat steam systems to maximized efficiency.

Importance of Pinch Point and Approach Point in HRSG

Unlike conventional steam generators, where the inlet gas temperatures are very high
namely adiabatic combustion temperatures of the fuel fired (1600-1800oC), the gas
turbine exhaust inlet gas temperature to the HRSGs is very low, on the order of 500 -
580 oC. This creates a problem. We cannot arbitrarily assume an exit gas temperature to
determine the steam flow. There are a few reasons for this, such as the low ratio of
gas/steam and capacity of heat sink in the form of economizer. A lot of energy is
transferred to the steam before the flue gases enter the economizer, while in HRSGs, it
could be very small due to the low inlet gas temperature. This in turn affects the energy
absorbed in economizer and hence the HRSG exit gas temperature. Hence gas/steam
profiles cannot be easily predicted.

The pinch point is the difference between the gas temperature leaving the evaporator
and the saturation temperature, while approach point is the difference between the
water temperature leaving the economizer and saturation temperature.
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Approach point is used in the sizing of the Economizer. A good approach point is
between 10°C-15°C. This temperature will guarantee that no steaming will occur in the
economizer section.
Pinch is used in sizing the heat transfer surface area of the HRSG. It is desirable to
make the pinch point as small as possible with out making the cost of the HRSG too
high.
Pinch and approach points are to a great extent dependent on the inlet gas temperature
and whether the evaporator is bare or finned.
With single pressure or even multiple pressure HRSGs, an option to improve energy
recovery is to use lower pinch and approach points.
A Typical exhaust gas/steam cycle temperature profile "Q-T diagram" for three-pressure
system is given below indicating Gas turbine exhaust gas temperature, the highest
pressure level, superheated steam temperature, minimum temperature difference (pinch
point), approach temperature difference, stack gas temperature, reheat steam
temperature, etc.

Heat Transfer and Tube Finning

The temperature differential between the flue gas, steam and water, especially around
the back end of the evaporators, is very poor. The situation is compounded by the poor
heat transfer coefficient on the flue gas side. Water side and steam side coefficients are
much better as will seen in the Table below.
Typical HRSG Heat Transfer Coefficients
Section of HRSG Flue Gas Water Water HP Steam
Economiser Evaporator
Heat Transf 50 500 2500-10000 1000
Coefficient (W.
2
.K-1)

It follows from this that tube wall temperatures tend to run quite close to the water and
steam side temperatures. Even when temperature differentials are at their highest, the
heat transfer rates are very modest. For example with a 100ºC difference the flue gas,
as at the beginning of an HP evaporator, the actual heat transfer rate will not be much
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more than 5-10 kW.m-2. This compares with peak heat transfer rates in pulverized
boilers which can be well over 200 kW.m-2.

Given such poor flue gas side heat transfer rates, tubes must be of small diameter, with
tight spacings and be of the finned type to provide sufficient heat transfer area. The only
section of the HRSG which might not use finned tubes is the HP superheater where there
might be a possibility of oxidation of the finning.
High efficiency finning is desirable as this reduces the size of the HRSG. Fin material
with a high conductivity is needed.
Fin shape and pitch are also critical due to the need to prevent excessive pressure drops
through the system, otherwise gas turbine output will suffer. The overall pressure drop
across the whole HRSG should not be much more than 25 mbar. A potential problem
with finning, where different types of materials are employed, is expansion differences
leading to thermal fatigue.

Classification of HRSG
There are a few variants to the basic design of the HRSG. These variants define the type
of HRSG and the variant is determined by a specific aspect of the HRSG operation. These
are as below:
• Horizontal or Vertical design
• Circulation - Natural, Forced, assisted Circulation or once through
• Supplementary fired, and Auxiliary fired.
• Single, Dual or Triple pressure levels

Horizontal or Vertical design

The vertical or the Horizontal design is basically the particular manufacturer's design
feature. In the Horizontal design the exhaust hot gases from the primary heat source
flow in a horizontal direction over the exchanger tubes. In a vertical design the gases
flow in a vertical direction [bottom to top] over the exchanger tubes. Though both
designs work equally effectively, certain countries have preference for one over the
above.
Vertical designs, which have originally been developed in Europe, offer a smaller
footprint and are less vulnerable to thermal cycling problems than the horizontal designs
commonly applied and originated in North America.
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Horizontal vs Vertical HRSG (some of the important comparisons)

Horizontal HRSG Vertical HRSG

Surface Area for equal Similar, except the re-heat Base
Output and super heater section
which might require slightly
more heating surface area
mainly due to less
advantageous flue gas flow
distribution with regard to
temperatures and mass flo
Plot Plan Area for equal Up to 30% more, mainly d Base
Output to the opening angle of the
inlet duct and the stack, an
if supplementary firing
systems, SCR’s, CO
Catalysts, etc. are required
Emission control Requires more HRSG lengt Requires more HRSG heigh
cleaning of downstream
fouled surfaces has to be
carried out carefully, not to
poison the catalyst.
Supplementary Firing Readily installed in the HRS Readily installed in the HRS
inlet duct or within the boil inlet duct, difficult to instal
surface area within the boiler surface ar
HRSG enclosure/Boiler hou Free standing, self Attached to and supported
supporting enclosure by the HRSG structure, ligh
enclosure
Regular Inspections Headers and surfaces not Header and surface
easy to access inspection carried out
accessing through manhole
with-out requirement for
additional auxiliaries

Circulation
As the HRSG exchanger tubes are constantly exposed to the hot gases from the primary
heat source, the tubes cannot be dry at anytime. Hence there is need to keep the water
circulating all the time through the various exchangers. This can be Natural, Forced,
Assisted or Once through flow. In the vertical HRSG design where the exchanger tubes
are horizontal, often forced circulation is deployed. These days there are vertical HRSGs
with natural circulation also.
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On the other hand, the horizontal HRSGs with vertical exchanger tubes deploy natural
circulation as the norm.
Natural Circulation:

Natural Circulation
ƒ The circulation arises from the density difference between water and steam.
ƒ It normally includes a drum.

Forced Circulation:

Forced Circulation

ƒ The circulation arises from the work done by a water circulation pump.
ƒ It normally includes a drum.

The Assisted Circulation

Similar to forced circulation
ƒ The circulation arises from the work done by a water circulation pump that is only
in service during the start-up of the HRSB.
ƒ Applies normally for vertical HRSB types.
ƒ It normally includes a drum.
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The Once Through Flow

ƒ The circulation arises from the weight force of the water entering the boiler at a
very high point.
ƒ It normally has no drum.
ƒ There is no recirculation taking place in the evaporator.

Supplementary-fired, and Auxilliary fired

If the heat from the primary source is not adequate to meet the specific plant
requirements, then supplementary firing is required in the HRSG using some burner
system. In the supplementary fired HRSG heat from the primary source and from the
burner are always available. Auxiliary firing will be required if the HRSG is to produce
steam for the plant even when the primary heat source is not available.
Per ASME Power Test Code 4.4, the HRSG efficiency is defined as:
E= (energy to steam/water/fluids)/[exhaust gas flow x enthalpy + fuel
input on LHV basis]
Compared to an unfired HRSG, the fired unit should be more efficient for the following
reasons:
ƒ Addition of auxiliary fuel reduces the effective excess air in the exhaust gases, as no
air is added. The fuel utilizes only the excess oxygen in the turbine exhaust. This is
opposite to what happens in a steam generator, where with increase in excess air,
the heat losses are more and thus efficiency is reduced.
ƒ With increased steam generation, usually the exhaust gas temperature decreases in
a single pressure system. This is due to the increased ratio of steam/gas. In a
conventional steam generator, the gas/steam ratio is nearly constant, while in a
HRSG, exhaust gas flow remains the same, while the steam generation increases due
to auxiliary firing. The increased water flow through the economizer (with gas flow
remaining same) can pull the gas temperature further down due to the increased
duty.
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But in practice, it has been found that the heat rate increases with auxiliary
firing. Radiation heat pick up in the HRSG designed to utilize low grade heat is poor and
thus contributes to the decrease of the overall efficiency of the power plant. It is
therefore prudent to use duct firing as Supplementary firing instead of auxiliary firing
only to augment power generation at the time of need.

Single, Dual or Triple pressure levels

HRSGs, may have single or multiple pressure levels, to suit a specific plant requirement.
The pressure and flow values are dictated by the downstream equipment's requirement.
There are obvious differences in HRSGs from a coal fired or oil fired steam plant. The
HRSG does not have a furnace and all the heat coming from a Gas Turbine exhaust.
Where in conventional boiler, the superheater is located after the evaporator, in an
HRSG, the evaporators are located at downstream of superheater and reheater. In a
triple pressure HRSG, there are actually three sets of evaporators, an HP set, an IP and
an LP set. There are also separate sets of HP, IP and LP economizers. In an conventional
fired boiler, although there are HP, IP and LP steam turbines, all the evaporation takes
place at just one very high pressure. These differences can be traced back to heat
transfer consideration, which dominates the HRSG design.
The temperature in the furnace of a conventional coal or oil fired steam plant is around
2000oC, and in the superheater and reheater region, temperatures run between 800 to
1400oC.
It is a truism for both gas and steam turbines, that to attain the highest practicable
efficiencies, the turbine entry temperature needs to be as high as possible. Steam
temperatures of most HRSG units lie in the range of 480 to 530oC, to make use of a
steam temperature of the order of 500oC or more, the steam must be expanded through
an adequate pressure ratio. Since the pressure in condenser is more or less fixed, this
requires an adequate steam pressure into the turbine. For an HRSG equipped with a
superheater and a reheater these days, the pressure is more than 120 bar.
Generating steam at this pressure has a huge impact on HRSG design, basically because
much of the heat uptake happens at the evaporator due to the higher requirement of
latent heat. Since the saturation temperature increases with the increase of pressure,
the water side has to be raised to a very high temperature – to the extent of 300 –
320oC. Given that the flue gas entering an HRSG is around 600ºC, and the bulk of the
heat uptake occurs at around the boiling point, this would mean that the temperature of
the flue gas going up the stack would be just over 300ºC. In other words, about half of
the available heat in the flue gas would be lost up the stack, in a HRSG that produced
steam at just one very high pressure, as in a pulverized fuel boiler.
This problem is overcome by installing a further set of evaporators, economizers and
superheaters in the HRSG, down stream of the high pressure steam. This additional set
produces steam at a much lower pressure, somewhere between 4 and 10 bar, the actual
value being that which corresponds to the exit pressure from the HP turbine, or if the
plant is fitted with a reheater, the IP turbine. As the boiling point of water at this sort of
pressure is in the range of 140ºC-180ºC low temperature heat in the flue gases can be
picked up quite easily. In addition some superheating of the LP steam is done with the
aim of matching the temperature of the “cold” steam from the HP or IP turbine. It is
then possible to merge the steam from these two different systems and put them to the
LP turbine.
Steam, for deaeration, at an even lower pressure, can also be raised using the last
vestige of heat in the flue gases. To summarise in a modern HRSG steam would be
raised at three different pressures with separate evaporator and pumping circuits for
each. This is in complete contrast to a pulverized fuel steam plant, where all the
evaporation takes place at one very high pressure. Another difference is that
feedheaters, of the type used on conventional pulverized fuel plant, using steam
extracted from the turbines are not used on HRSG systems. This would simply raise the
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water temperature at the inlet to the economizers, and would reduce the amount of
heat, which could be transferred from the flue gases.

HRSG at Vemagiri Power Plant

HRSG Overview

The vertical HRSG at VPGL is of the 3 pressure level (HP, IP and LP); reheat type
including a condensate pre-heater. The boiler feed steam to a steam turbine.
The input comes to the HRSG from a GE 9 FA gas turbine, which is fuelled with natural
gas. There is no gas by-pass stack and diverter damper given at the input side of HRSG.
Therefore, the HRSG runs in line with the gas turbine. Supplementary firing system is
installed in the inlet duct.
The heat recovery steam generator includes horizontal heat exchangers, boiler casing,
boiler inlet and outlet ducts, circulating pumps, feedwater pump, blow down tank, boiler
drums, expansion joint, burner, dosing, sampling, stack analyzer, piping, valves and
Instrumentation.
Each exchanger is inserted in the vertical gas flow and a casing is constructed around
them to form a sealed unit.
The casing is manufactured from steel sheets, without any concrete or water tubes and
is externally insulated. The super-heater/re-heater module is internally insulated.
All exchangers with the casing are separately hung to horizontal box beams which are
supported by the main boiler steel structure to allow a free expansion downward and
laterally.
The water circulation through the evaporator is natural type in case of IP system. In HP
and LP systems the water circulation through the evaporator is through circulation
pumps.
In re-heater circuits an attemperator is installed in the inlet of cold reheat steam line to
the boiler.
In HP circuits it is installed between the 2 super-heaters.
Three different circuits produce the steam flows at three different required pressures
and temperatures.
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The re-heater installed in the HRSG reheats the medium pressure steam coming from
the HP steam turbine exhaust and the medium pressure steam from the IP superheater,
up to the required superheated temperature.
A preheater is installed to heat water coming from the condenser and going to the
deaerator, which is also getting re-circulated with hot water in order to reach 60 °C at
its inlet.
The feedwater control valves are installed downstream the economizers on IP and HP
circuits. Thus, the pressure in the economizer is near to the feedwater pump pressure
and therefore is always greater than the pressure inside the drum (saturation pressure).
Consequently, the risk of steaming is avoided.

Some of the specific features of this HRSG:

The HRSG gets the input from a Frame 9 FA Gas turbine, which produces 2231 TPH
exhaust gas at 616.7oC temperature, when running with base load. The large thermal
input calls for some special features to be incorporated in the HRSG design.
1. Absence of Diverter Damper and by-pass stack – this is one of the most notable
features which differentiate this HRSG from others. The loading of HRSG is carried
out in tandem with the GT Load. The gas turbine is equipped with a special
temperature matching facility to adjust the exit flue gas temperature by IGV control
during cold start-up (during 10 – 50% load) so that the steam temperature can be
controlled. 100% cascading HP/ IP and LP Bypass is also provided in this HRSG.
2. Reheat Cycle – Along with a three pressure system and condensate pre-heating, the
HRSG also has a reheat cycle from the HP exhaust steam to utilize the large thermal
load available from the GT and therefore no HP start-up vent to ensure coolant in the
reheater elements during start-up.
3. Fuel Gas heating – Frame 9FA machine requires fuel gas heating for which the
heating media has been taken from the IP Economizer out let.

System Description
Flue Gas Circuit:
The flue gas path conveys the gas turbine exhaust gas through supplementary duct
firing, the different heat exchangers and then to the atmosphere. While flowing across
each heat exchanger, the flue gas loses part of its thermal energy; the different heat
exchangers are thus arranged in regards to the local gas temperature in order to recover
the maximum of the heat contained in the gas turbine exhaust gas.
The flue gas path is equipped with the following accessories (from the inlet flange to the
outlet stack):
- expansion joint
- duct supplementary firing
- drain connection at the lowest point
- pressure transmitter
- temperature transmitters underneath the first tube bundle
- weather damper with 8 position switches (3 in opened position & 1 in closed
position per blade)
- emission monitoring (CEMS) including Co, NOx, 02, SO2 and particulates
measurement.
The chimney is also equipped with aircraft warning (aviation) light.

Condensate Preheater Circuit:

The condensate preheater is installed at the cold end of the HRSG to heat the
condensates up to a temperature close to the deaerator operating temperature
recovering the maximum heat contained in the gasses.
A pump assisted recirculation line sends condensate coming from the preheater outlet to
its inlet in order to increase the condensate inlet temperature above the flue gas dew
point of 60oC.
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A by-pass line allows a partial or a total bypassing of the preheater.

The preheater circuit is equipped with the following accessories:
- condensate flow element
- preheater inlet/by-pass distributor control valves
- preheater inlet non-return valve
- nitrogen connection with non-return valve
- preheater pressure relief valve
- 2 X 100% recirculation pumps with strainers, isolation valves and non-return
valves
- recirculation flow element
- recirculation control valves with its minimum flow orifice
- all necessary local and remote instrumentation
- all necessary vents and drains

HP Circuit:

The high pressure circuit produces HP superheated steam for injection into the HP stage
of the steam turbine. The feed water is supplied by a combined HP/ IP feed water pump.
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The economisers heat the feedwater up to a temperature close to the drum

temperature.
The evaporator generates steam by forced circulation.
The superheater heats the saturated steam from the drum temperature up to the
required value. A desuperheater, kept between the two superheaters, controls the
superheated steam temperature.
The high pressure circuit is equipped with the following accessories:
- inlet feedwater flow element
- branch line to the steam de-superheater with non-return valve, flow element
- pneumatically operated isolation valve, filter and flow control valve
- economizer inlet non return valve
- 2 x l 00 % feedwater control valve and 1x30 % feedwater control valve both
equipped with their inlet motorized isolation valves, outlet isolating valve.
- economizer N2 connection with non-return valve
- drum with phosphate injection, sampling line
- continuous and intermittent blow down, motorized start-up vent.
- 2 drum safety valves with silencers
- 2 circulation pumps with strainer, isolation valves and non-return valves
- circulating water flow element
- 1 interstage steam desuperheater
- 1 superheater outlet safety valve with silencer
- 1 superheated steam flow element
- 1 superheater outlet isolation valve
- 1 superheated steam sampling line
- all necessary local and remote instrumentation
- all necessary vents, drain .

Out put Parameters at 100% load without duct firing:

284.42 TPH steam at 112 bar and 540.2oC superheated temperature

IP Circuit:

The intermediate pressure circuit produces steam at intermediate pressure level for
injection into the IP stage of the steam turbine. The feed water is supplied from the
intermediate stage of a combined HP/ IP feed water pump. The economisers heat the
feedwater up to a temperature close to the drum temperature.
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The evaporator generates steam by natural circulation. The superheater heats the
saturated steam before mixing with the cold reheat steam.
The reheater heats the mixed steam up to the required temperature. The desuperheater
located at the inlet controls the final reheated steam temperature as required.
The intermediate pressure circuit is equipped with the following accessories:
- economizer inlet non-return valve
- motorized feedwater inlet isolation valve with motorized by-pass valve.
- economizer pressure relief valve.
- economizer N2 connection with non-return valve.
- branch line to the steam desuperheater with non-return valve, flow element
- pneumatically operated isolation valve, filter and flow control valve. (Cooling
- water is tap –off from the IP feed water inlet )
- economiser outlet flow element
- fuel heater extraction line equipped with flow element and isolating valves.
- 2 x l 00 % feedwater control valve and 1x30 % feedwater control valve both
equipped with their inlet motorized isolation valves, outlet isolating valve.
- drum with phosphate injection, sampling line , continuous and intermittent blow
down, motorized vent valve.
- drum safety valves with silencers
- saturated steam sampling line
- superheater outlet flow element
- non-return valve
- reheater inlet safety valves with silencers
- inlet steam desuperheater
- reheater outlet safety valve with silencer
- reheater outlet motorized start-up vent valve with silencer
- reheated steam flow element
- reheated steam sampling line
- all necessary local and remote instrumentation.
- all necessary vents, drains and water trap

Out put Parameters at 100% load without duct firing:

326.69 TPH steam at 23.1 bar and 536.2oC superheated temperature

LP Circuit:
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The low pressure circuit produces LP superheated steam turbine for injection into the LP
stage of the steam turbine.
The drum receives water from the deaerator through a separate LP Boiler Feed Pump.
The evaporator generates steam by forced circulation system.
The superheater heats the saturated steam at the required temperature.
The low pressure circuit is equipped with the following accessories:
- control valve with its inlet isolating motorized valves, outlet manual isolating
valves.
- motorized valve installed in the water inlet line
- drum with phosphate injection, intermittent blow down, continuous blow down,
- motorized vent valve
- drum safety valves
- circulating water flow element
- superheater inlet drain line
- superheater outlet safety valve
- superheated steam flow element
- superheater outlet start- up vent valve .
- superheater steam sampling line
- all necessary local and remote instrumentation.
- all necessary vents and drains

Out put Parameters at 100% load without duct firing:

32.52 TPH steam at 4.6 bar and 259oC superheated temperature

Boiler drum:
All three circuits (HP, IP and LP) have steam drums, which ensure the steam/water
separation. The purposes of the boiler drums are:
• to insure a good mixing of feedwater and boiler water;
• to constitute a water reserve, required for the circulation system;
• to allow water/steam expansion mainly during start-up, when the first steam
produced in the evaporator repels back to the drum the water contained in the
evaporator tubes (swelling effect);
• to insure the water and steam separation .
The steam and water separation is achieved by means of mesh type separator installed
in the upper part of the drum.
Each steam drum is equipped with:
1. Mesh steam dryers;
2. Steam distribution header;
3. Feedwater distribution header;
4. Water outlet to evaporator with anti-vortex;
5. Steam inlet nozzle (from the evaporator);
6. Steam outlet nozzle (to the super-heater).

Blow Down System:

The Continuous Blow Down tank collects drains from the HP steam drum and IP steam
drum and from the HP superheater and reheater drain lines.
The flashed steam from the blow down tank is discharged to the deaerator. A safety
valve is also mounted on the CBD tank. The condensate is sent to the intermittent blow
down tank through a control valve which maintains the required level in the CBD tank.
The Intermittent Blow Down Tank collects all the drains from the HRSG and also from
the continuous blow down tank.
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The flashed steam from the blowdown tank is discharged to the atmosphere by means of
a vertical exhaust pipe. The drain water is sent to the HRSG pit after quenching by
service water.
The circuit is equipped with the following accessories:
- LP drum intermittent blow down motorized valve.
- IP drum intermittent blow down motorized valve.
- HP drum intermittent blow down motorized valve.
- Deaerator over flow motorized valves.
- pneumatically actuated quenching water flow On–Off valve with isolation valve

Duct Burner

The supplementary firing has been kept only for augmenting power generation at the
time of peak demand and operation without gas turbine and with combustion air fan
running is not envisaged. With duct firing, power generation gets augmented by only
22.06 MW, whereas the heat rate increases from 1680 to 1730 kcal/ kWh.
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The burner design consists of a burner frame suitable for mounting in the ductwork
between the gas turbine and waste heat HRSG, with special heat resistant cast steel
frame stabilizers. The design ensures a stable flame with good combustion results within
the burner turn down range with gas turbine load at 100 % load.
There are total four elements at the duct cross section and each element is provided
with a gas electric ignition burner and two self checking UV scanner.
The burners are designed for natural gas firing only.
The UV scanners require cooling air to protect them from overheating, due to convection
and radiation to the scanners from the TEG and burner flames.
The burner operation is controlled by BMS (Burner Management System).
Start / Stop sequence of the system can be executed either from the Local Panel (In the
field) or from the BMS Panel in Control Room or from the DCS console depending upon
the selection of the mode (LOCAL MODE / REMOTE MODE / DCS MODE). All the control
logic such as combustion control will be executed from the DCS. Start / Stop sequence
of any drive has not been provided on the Local Panel.

Boiler chimney
A complete boiler chimney is provided and supported on the outlet duct.
The boiler chimney is constructed as follows:
• carbon steel sheets which withstand all stresses due to chimney weight, wind and
seismic loads.
• outside this shell, heat insulation covers the chimney. The thickness of this heat
insulation is designed for personal protection and to avoid reaching the acid dew
point on steel plates.
• to cover the heat insulation, aluminum cladding is provided.

Expansion joints
The joints are designed to compensate both longitudinal and lateral movements of the
ducts and boiler casing, due to thermal expansion.

Two expansion joints are provided and the locations are as follows.
• Expansion joint between Module 5 and Module 4
• Expansion joint at the HRSG outlet duct.

One impervious layer of SS laminated glass fabric included in multi-layer expansion joint
design of KE- BURMAN’s design ensures gas tightness.
The joint is also protected from gas turbulence by a bolster made of ceramic fiber and
stainless steel wire mesh.
Joint composition: Multi-layer composition is intended to assure general flexibility and to
increase the thermal insulation effect. External part of joint produces the tightening and
resistance to the stress due to internal gas pressure.
The internal part of the joint, called BOLSTER, fills the space under the external part and
protects it against gas swirls while providing thermal insulation.

Anti-vibration baffles
Anti-vibration baffles are inserted in the heat exchangers. These are steel plates,
installed vertically, parallel to the tubes.
The purpose of these baffles is to divide the gas path into different sections of such
dimensions that any flow-induced vibration condition is avoided.
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Chemical injection system

In accordance with the HRSG requirements, the water quality in the HRSG must be
continuously checked with injection of chemicals as required.
The chemicals are injected by dosing pumps which allow adjustment of the chemicals
flow rate. Dosing pumps are mounted on storage tanks, suitable for chemical
preparation. One stand-by pump is provided on each tank.
For HRSG group, injection into the HP / IP / LP drums (phosphate or equivalent) are
provided.
The tanks are made from SS 304 with chemical addition removable type basket , level
gauge connection, flanges for dosing pumps and agitator. A drain connection is
provided.
A DM water connection is provided (for chemical .preparation).
On each tank, an electric agitator is provided in order to prepare and mix liquids up to
the required viscosity. The dosing pump is adjusted by modification of the membrane
stroke.
The pumps are protected by two level switches per tank stopping the unit in case of low
low level.

Sampling system
Sample coolers and fittings are mounted on a rack.
Sample coolers are provided with safety relief valves on cooling water side. All pressure
reducers, isolating valves are provided on a fixed rack.
Sampling points:
• IP drum water
• LP drum water
• HP drum water
• LP superheater
• Hot reheat .
• HP live steam
• IP saturated steam
• LP saturated steam
• HP saturated steam
• HP/IP/ LP feedwater
• Deaerator
• LP BFP Suction