Shuaiba North HRSG Manual

Heat Recovery Steam Generator (HRSG)
Training Manual
TechComm Simulation
Module Purpose
The aim of this course is to provide participants with the
knowledge and skills required for the operation and maintenance
of a typical HRSG. The program is structured so as to provide
operating staff with an overview of the plant, familiarity with
plant locations, and a knowledge of unit operations and plant
maintenance requirements.
Module Content
By the end of this training, competent participants, shall be able
to:
• Locate OEM operating procedures
• Interpret OEM operating procedures
• Describe the major steps in performing a cold start
• Describe the major steps in performing a hot start
• Describe the procedure recommended for altering load
• Describe the major steps in shutting down the unit
• Describe the procedures recommended for HRSG storage.
• Understand the reasons and methods for chemical control.
• Locate and interpret OEM procedures for responding to
critical incidents
Disclaimer
While every care will be taken to ensure the accuracy and
adequacy of information, concepts, advice and instructions
conveyed to participants in the Course, no responsibility or
liability is accepted by either TechComm Simulation, the course
leaders or their associates, for any errors or omissions which
may arise through no fault of the parties, and which may be
attributed to errors or omissions in the information, advice or
instructions given to the parties by the Client or others. Nor is
any responsibility or liability accepted for any consequent errors,
omissions or acts of the participants or others.
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Table of Contents
1. Co-Generation Concepts 6
1.1 System Overview 9
1.2 HRSG Design Considerations 11
1.2.1 GT Exhaust Gas Design Data 13
1.3 Heat Energy Transfer 14
1.3.1 Radiation 14
1.3.2 Conduction 14
1.3.3 Convection 15
1.4 Properties of Steam 17
1.4.1 Wet Steam 17
1.4.2 Dry Saturated Steam 17
1.4.3 Superheated Steam 18
1.4.4 Reason for Superheating Steam 18
1.5 Water/Steam Characteristics 19
1.5.1 Evaporation 19
1.5.2 Shrink & Swell 19
1.5.3 Natural Circulation 20
1.6 Feedwater and Boiler Water Treatment 20
1.6.1 Water Treatment Aims 21
2. Impacts on Pressure Parts Remnant Life 23
2.1 Creep 23
2.2 Fatigue 23
2.3 Creep-Fatigue 24
3. HRSG Construction 25
3.1 Internal Insulation and Liner 25
3.2 Support and Structural Details 25
3.3 Tube Sections Construction 26
4. Major Components of the HRSG 27
4.1 HRSG Economisers 27
4.1.1 Detailed Description 27
4.1.2 Operation & Control 28
4.2 HRSG Drums 29
4.2.2.1 Drum Level Control 31
4.2.3 Technical Data 34
4.3 HRSG Evaporators 35
4.4 HRSG Superheaters 37

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5. Control of Main HRSG Equipment 41
5.1 HP Steam Temperature Control 42
5.2 ST Bypass System 42
6. Component Alarms 43
7. Start-Up the HRSG 48
7.1 First Boiler Filling 48
7.2 Cold Start of GT + HRSG + STG 48
7.3 Start of Warm HRSG 48
7.4 Start of Hot HRSG 48
7.5 Operational Outline 48
7.6 SYSTEM START-UP 49
7.6.1 Pre-Start Operational Instructions 49
7.6.2 Prerequisites 49
7.6.3 Extra Considerations and Precautions 49
7.6.4 Pre-Start Checklist 52
7.6.5 Instrument Air 55
7.6.6 Remote Operating Valves Function: 55
7.6.7 Closed Cycle Cooling Water System: 57
7.6.8 Check the Valve Open and Close Position for each section: 57
7.6.9 Check the Selection Mode of Controllers and Selection Switch 60
7.6.10 Confirm the Completion: 60
8. System Start-Up Instructions 61
8.1 Procedure for Preliminary water filling and Flushing 61
8.1.1 Start-Up procedure for HRSG 63
9. System Normal Operation 65
9.1 Routine Plant Checks 65
10. System Shutdown Instructions 70
10.1 Normal Shutdown Requirements 70
10.2 Scheduled Shutdown Procedure for Boxing up HRSG 70
11. Emergency Shutdown Procedure 71
11.1 Emergency Shutdown Requirements 71
12. Alarm Responses 72
12.1 Summary of Alarms 72
12.1.1 Alarm Response # 1 72

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12.2 Actions on Non Alarm Faults 77
12.2.1 Gas Leaking from Ducts or HRSG Casing 77
12.2.2 Water and Steam Leaks 77
13. Steam Line Blowing 78
13.1 Introduction 78
13.2 Safety 78
13.3 Steam Blowing Precautions 78
13.4 Steam Blowing Methods 79
13.5 Operating Procedures 80
14. Pre-Operational Chemical Cleaning Procedures 82
14.2 Pre-Operational Boilout 82
14.2.1 Preliminary to Boilout 82
14.3 Boil-out Procedures 83
14.4 Post Boil-out Lay-up 86
14.5 Preparations for Putting the HRSG into Service Following Boil-out 86
14.5.1 Prior to Initial HRSG Operation: 86
14.6 Operational Acid Cleaning 87
14.6.1 Introduction 87
14.6.2 Acid Cleaning Procedures 88
15. Valves 89
15.2 Pneumatic valves 89
15.2.1 General 89
15.2.2 Blowoff Valves 89
15.2.3 Start Up Vent Valves 89
15.2.4 Drain valves 89
16. Table of Figures 90
17. Table of Tables 91

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1. Co-Generation Concepts
Typical applications for steam raising in the HRSG, like the
intermediate pressure steam, may be used either to supply the
anti-Nox steam system at the gas turbine burners or used to
provide process steam, if required. Similarly with the low
pressure system, this can provide an additional source of
process steam and commonly is also employed to provide
deaeration of the feedwater entering the boiler.
The amount of heat which can be transferred from the gas to the
water and steam in the HRSG is dependent on two factors:
• The quantity of exhaust gas (mass flow)
• The temperature of the exhaust gas
It is important to note that the steam temperature from any
particular section can never be higher than the gas temperature
entering that section. Clearly in order to promote a transfer of
heat, a temperature differential must exist between the gas and
steam. For a typical example, the gas condition entering the high
temperature section of the HRSG is at 640ºC at rate of 392kg/s
while the HP steam outlet conditions are 568ºC at 102.2 bar and
flow rate is 69.84kg/s.
These conditions only apply when the unit is running at rated
load. At lower load in a conventional arrangement, the gas flow
rate from the gas turbine remains constant, but its temperature
falls. As less fuel is mixed with the same quantity of air, the
temperature of the gas at both the turbine inlet and exhaust will
decrease. For example if the load is decreased by 50%, the
exhaust gas temperature only falls by approximately 70ºC.
The steam temperature at the high pressure section has reduced
by approximately 80ºC. Moreover the amount of heat available
for transfer is less and hence the quantity of steam produced
also decreases. A similar reduction in steam temperature and
flow rate would occur in the intermediate and low pressure
sections. Of course, we should expect the steam flow rate to
decrease at lower turbine loads, because there is less heat
available in the exhaust gas. But it is the decrease in steam
temperature which is more of a concern.
We know that the efficiency of the steam turbine is very much
dependent upon maintaining rated steam temperature, so a
decrease in efficiency would obviously occur at lower
temperature. However a more serious problem, caused by the
low steam temperature, may be partial condensation within the
turbine with resultant damage to blades.
The relative size of the steam turbine/generator compared with
the gas turbine actually depends upon what other energy
demands exist. For example a large demand for process steam
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would reduce the quantity available for power generation.

However, in most power generation applications the steam
turbine generator output will be say 40 – 50% of that of the gas
turbine generator.
In such an arrangement it is quite common to operate the steam
turbine with the control valves wide open, so that it pulls as
much steam as is available from the HRSG.

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Fuel
Compressor Turbine Turbine

exhaust
Generator
Air
Combustion
chamber
HRSG
Stack
Steam
Turbine
Generator
Cooling Condenser
Water
Feed
Pump
Condensate
Figure 1: Elementary Diagram of a Combined Cycle Plant

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In Figure 2 an intermediate section and low pressure section

have been added so as to extract more heat from the exhaust gas.
An economiser is sometimes installed and this raises the
temperature of the incoming feedwater.
HRSG
Turbine HP IP LP
exhaust
Gas
Turbine Stack
HP IP LP
Steam Steam Steam
Figure 2: HSRG Fitted with HP, IP and LP Steam Sections
1.1 System Overview

The HRSG is a dual-pressure level, natural circulation, water
tube steam generator. The HRSG is designed to utilise the
exhaust heat energy from the gas turbines installed at Power
Station.
The function of the Heat Recovery Steam Generator is to convert
pressurised water into superheated steam utilising the sensible
heat of the gas turbine exhaust gas.
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Exhaust gas from the GT is directed to the HRSG by the inlet

transition duct.
The HRSG generates steam in the two-pressure levels, High
Pressure (HP) and Low Pressure (LP). The steam generated in a
HRSG is used to drive the Steam Turbine (ST) for power
generation. The HP and LP superheated steam enters the HP
cylinder and LP cylinder of the steam turbine.
The boiler metal components are exposed to high pressure and
temperatures. All boiler components are designed for a target life,
typically 22 years, while taking into consideration the material
properties, expected operating conditions and amount of
acceptable degradation.
The theoretical steam produced in The CCCP for two (2) GTs
operating at base load and fired with natural gas is about
174360 kg/hr in the HP System; and 38595 kg/hr in the LP
System.
The steam operating pressure at the outlet of HP Superheater is
85.4 barg and in the LP Superheater outlet is 8.8 barg. The
steam temperatures at the outlet of the Superheaters in HP /LP
systems are 532°C and 219°C respectively.
The HRSG has been designed for the following operating
conditions:
1. GT generally operates at base load.
2. GT can be fired both by Natural Gas and Distillate Oil.
3. Both the GTs can be operated simultaneously at base load
and with Steam Turbine Bypass in operation.
4. The average yearly ambient design basis is 32°C.
5. Twenty two (22) years of Economic Service Life.

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Figure 3: GT Exhaust inlet and HRSG Exhaust outlet
1.2 HRSG Design Considerations

The 2 stage HRSG circuits have three (3) major components.
These components are the superheaters, evaporators, and
economisers. The typical layout for a 3 stage HRSG is shown
below.

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Heat from
Final Waste
Gas to
Heat in Hot Gas transferred to Water in Atmosphere
HRSG creating IP and HP Steam Supply
HP IP
Steam Steam
Hot Gas from Gas

Turbine Exhaust
Temperature
Temperature Gradient across HRSG
Figure 4: Typical HRSG Arrangement

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1.2.1 GT Exhaust Gas Design Data
Ambient Temperature oC 32 32
GT Fuel Type Natural Gas Distillate Oil
Temperature of Exhaust oC 558 559
Exhaust Gas flow tonne/hr 1369 1373.4
Gas Composition
N2 72.85 73.61
CO2 3.11 4.20
O2 13.37 13.49
H2O 9.81 7.84
Ar 0.86 0.86
SO2 Not Reported
SO3 Not Reported
The HRSG is designed for "Zero Leakage" or gas tight enclosure

to contain the heat and duct the GT exhaust gas through the
HRSG heat transfer surfaces to the atmosphere. The gas is
released to the atmosphere through a stack. The design of the
stack is based on design and environmental licence
requirements.
The CCPP, the pressure parts components are arranged in series
in the gas flow path within the HRSG heating chamber. The
boiler circuit is interspersed within the chamber in such a way
as to optimize the HRSG thermal conversion performance. Hence
the HP Steam evaporative and superheater sections are in the
hottest part of the heating chamber.
The high pressure system includes two banks of superheater,
drum, evaporator, and two banks of high pressure economisers.
The low pressure system includes a superheater, drum,
evaporator, and a bank of low pressure economiser.
Pressure part materials are based on the expected operating
metal temperatures and pressures, and restricted to those
materials listed in the Boiler or Piping Codes. Typical pressure
parts are superheater tubes and headers, evaporator tubes and
headers, drums, economiser tubes and headers, downcomers
and interconnecting piping.
The HRSG casings and ductwork are internally insulated to keep
the outer carbon steel casing cool. The internal insulation
system consists of ceramic fiber or mineral wool insulation
layers covered by a metal liner. The metal liner protects the
internal insulation from the high velocity gas stream. The liner is
also designed to accommodate the necessary thermal expansion
as the HRSG is brought on line.
The liner is anchored to the casing with studs and is composed
of a series of panels or plates to minimise the thermal growth of

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the panels. These liner panel attachment studs are welded to the
casing. The stud size and spacing pattern is selected according
to the velocity, turbulence, and operating temperature of the
exhaust gas stream.
1.3 Heat Energy Transfer

Heat Transfer is the exchange of heat energy from one media to
another. In an HRSG this energy transfer is between GT
exhaust gas and HRSG water/steam. This occurs because the
GT Gas is at a higher energy level than the water's energy
level. The difference in energy level is measured as a
temperature differential. The greater the temperature
differential the more energy transfer occurs.
Three heat transfer methods or modes have been used to
describe this energy exchange. These methods are Radiation,
Conduction, and Convection. These terms will be explained
in the following paragraphs.
1.3.1 Radiation
Radiation energy is transmitted from the flame of a hot source
to colder surface without any actual contact being made.
The principal is best illustrated by the light given off by the

Sun or a light bulb. When the heat radiation strikes a surface,
some of the radiant energy may be reflected or reradiated, some
of it may be transmitted through the body, and the remainder
will be absorbed. This mode of energy exchange is similar to a
line of sight electromagnetic wave phenomenon. As there is
no actual naked flame in the GT Exhaust Gas, radiation
energy transfer is negligible within an HRSG
1.3.2 Conduction
Is a transfer of heat from one part of a substance to another
without permanent displacement of the molecules. For example
when one end of a metal rod is heated, heat will transfer along
the rod making the other end warmer; this is shown below. The
ability of a substance to transfer heat by conduction is known as

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its thermal conductivity. Metals are very good conductors of heat,

while substances (such as glass) with poor thermal conductivity
are known as thermal insulators.
Heat transfers
Figure 5: Conduction of heat along metal rod
There is some remnant conduction heat transfer taking place

between each of the tubes in an HRSG, but this is largely
considered as negligible.
1.3.3 Convection
Energy exchange occurs between a stationary surface and a hot
fluid or gas moving over the surface. This energy exchange is
referred to as Convection. Two regimes of convective heat
transfer have been identified, free convection and forced
convection. Free Convection is defined as the movement of a
fluid or gas over a surface caused solely by the difference in
fluid/gas density due to temperature differences. Forced
convection requires fluid/gas movement produced by
mechanical devices such as fans or a GT. The exchange or
transfer rates for Radiation and Conduction can not be changed
by increasing the velocity of the fluid/gas. Convective heat
transfer rates are enhanced however by increases in fluid/gas
velocity
The main source of heat transfer in the HRSG is through
forced convection. Convective heat transfer is governed by gas
temperature, gas velocity, final steam temperature, initial
steam temperature, operating pressure, and surface area. Gas
temperature and velocity are dictated by GT operations.
Steam temperatures and pressure are set by Steam Turbine
Design Parameters. Surface area is established during the
HRSG Design phase to maximise the required Final Steam
Conditions.
Convective heat transfer is further enhanced through the use of
extended surface areas of the metal in the HRSG and
superficial gas velocity approaching a maximum of 100 feet
per second (fps). Gas velocities beyond 100 fps (30.5 meter per
second) run a risk of tube wall erosion and excessive GT
exhaust gas back pressure or HRSG pressure drop. The
maximum pressure drop for these HRSGs is about 25 inches

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(635mm) of water column. The extended surface used in the

HRSG is produced through the use of finned tubes. Fins are
ribbon of steel spirally wrapped around the outside of the tube.
Fins may be serrated or solid configuration and are resistance
welded to the tube wall.
Fin
Water tube wall
Boiler casing
Figure 6: Typical Finned Water Tube Arrangement

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1.4 Properties of Steam

The temperature at which a liquid boils depends on the type of
liquid and the surrounding pressure. An increase in pressure
raises the temperature at which a liquid will boil and conversely
a decrease in pressure reduces the boiling temperature.
The boiling temperature of a liquid is the saturation temperature.
The corresponding pressure is the saturation pressure.
Water at standard atmospheric pressure of 101.3 kPa (absolute)
will boil at a saturation temperature of 1000C
Steam is water in its gaseous state and tends to behave in the
same manner as a gas.
Within the power plant cycle, steam may exist as wet, dry
saturated or superheated steam.
1.4.1 Wet Steam

Is a mixture of dry saturated steam and water vapour or water
particles in suspension. Wet steam is usually present during the
conversion of water to steam due to the agitation of the water
surface, ejecting water particles into the steam space above. It is
also present during the condensation of dry saturated steam
back to water. Due to the presence of the water particles, wet
steam is visible and is shown in Figure 7.
Wet steam
cloud
Figure 7: Wet Steam
1.4.2 Dry Saturated Steam

Is steam at its saturation temperature (or boiling point) and
which contains exactly the amount of latent heat to convert all
the water into steam. Due to the absence of water particles, dry
saturated steam is invisible. Refer to diagram below:

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Wet steam
cloud
Stream of invisible dry

saturated steam
at exit of kettle spout
Figure 8: Dry Saturated Steam
Next time you boil water for a cup of coffee or tea; have a careful
look at the steam stream coming from the kettle spout. You will
be able to observe that immediately adjacent the kettle spout the
stream is invisible (dry saturated steam) but as it travels further
out it begins to cool and returns to wet steam.
1.4.3 Superheated Steam

Superheated steam is at a temperature in excess of the
saturation temperature and is produced when heat is absorbed
by dry saturated steam. It is a dry invisible gas with the potential
to harm or kill if a person was to enter its stream.
1.4.4 Reason for Superheating Steam

When steam is supplied to a turbine it gives up heat as it travels
through the blade system. As it gives up heat, work occurs on
the turbine blades. If the steam was dry saturated steam only, it
would immediately begin to become wet steam as it flowed
through the turbine. In the early stage of the turbine the steam
would drive the blades but as the moisture in the steam
increased the blades would drive the steam. Also the impact of
the water droplets on the blades would cause erosion along with
a reduction in turbine efficiency.
By superheating the steam, most of the work is done by the
steam before it begins to become wet steam as only sensible heat
an approximately 12% of the latent heat is able to produce work
within the turbine.

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1.5 Water/Steam Characteristics

1.5.1 Evaporation
Evaporation or boiling is the process that occurs in the
different stages of a typical steam generator circuit. This
process changes the state of water from liquid to vapour or
steam. The steam is generated at the saturation temperature
associated with the operating pressure.
Steam results from adding sufficient heat to water to cause it to
vaporize or boil. Boiling occurs in two steps. In Step 1, enough
heat is added to the water to raise its temperature close to the
boiling point. This occurs in the Economiser. In Step 2, more
heat is added to change the state of the water from liquid to
steam, known as latent heat of vaporization. This occurs in the
Evaporator. The 3rd step is when superheat is added to the dry
saturated steam. This occurs in the Superheater.
When water is heated at average sea level atmospheric pressure,
each pound of water increases in temperature about 1°F for
each Btu added until 212°F (100°C) is reached. Additional heat
does not cause the steam temperature to rise in an evaporator
section. When water is heated in an evaporator section and
steam is generated, an increase in evaporator section pressure
occurs. As the pressure increases, the temperature of the boiler
water rises. It has been determined experimentally that during
the phase change from liquid to steam at constant pressure,
the steam in contact with the liquid will remain at constant
temperature until boiler vaporization has been completed.
Thus, the temperature at which boiling occurs for any given
pressure is constant and is called the saturation temperature.
This temperature is the same for the water as it is for the steam.
1.5.2 Shrink & Swell

The steam bubbles that form within the hot water cause it to
expand. "Shrink" and "Swell" are two terms associated with
steam and water specific volume characteristics. Shrink is the
decrease in the drum water volume that occurs when boiling
stops, while swell is the increase in drum level due to increased
boiling resulting from an increase in heat absorption. The
impact of swell is most noticeable when heat is initially
introduced into the HRSG.

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1.5.3 Natural Circulation

This refers to the flow of water and steam particles in a closed
loop system as shown in the figure below.
This flow takes place because one side of the loop is outside the
heat chamber whilst the other is inside the heat chamber,
resulting in uneven heating in the loop. As steam bubbles are
produced on the heat chamber side, the density reduces. The
higher density, cooler water on the outside then flows toward the
less dense side, is heated in turn and produces steam bubbles.
So the circulation cycle continues.
Feed water Steam

replacing
evaporated
water lost to
atmosphere
in form of Steam
bubbles
Water not
Cold water turned to
descending steam
i l ti
Hot
water/steam
rising
Source of
heat
Figure 9: Simple Diagram of Natural Circulation
1.6 Feedwater and Boiler Water Treatment

The successful and reliable operation of steam generating plant
depends upon maintaining close control of water chemistry. To
control deposits, scale formation and corrosion, not only in the

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boiler but also in the feed lines, feed heaters, economisers,

superheaters and prime movers, it is necessary to maintain
favourable chemical conditions in the boiler water. This is done
by injecting treatment chemicals into the steam drum, and by
treatment of the feedwater before it enters the system.
There are a number of experienced water treatment consultants
and companies that specialise in the supply of water treatment
chemical services. It is recommended that the care and control of
water conditions be put in the hands of such specialists unless
the plant has adequate analytical facilities and personnel skilled
to do it.
Modern steam turbines require a very high standard of steam
purity and it is often this requirement that determines the level
of salts in the boiler water.
Note: Deviation from industry normal practice can lead to
serious problems.
1.6.1 Water Treatment Aims

With all its complexity, water treatment has only these simple
aims:
To minimise the accumulation of corrosion products from
the pre-boiler piping system, such as the oxides of iron,
copper, or nickel (these heavy metal oxides invariably plate
out on heat transfer surfaces and must be periodically
removed by acid cleaning).
To chemically control the normal impurities contained in
makeup water, such as calcium, magnesium, and silica. The
objectives are to manufacture a soft, porous sludge or to
keep the impurities in a solution so that they can be
removed by either bottom blowdown or continuous
blowdown. (Hard, adherent scales must be avoided because
they prevent tube metal cooling by boiler water, generally
resulting in tube failures.)
To prevent the carry-over of boiler solids into superheaters or
down-stream users, such as turbines or process. (This is
usually easily accomplished by limiting total boiler water
solids, but occasionally special water problems require the
use of anti-foaming agents.)
The following general rules and procedures should be adhered to
no matter what type of program is followed:
1. Use care in obtaining samples. Reliable results are
dependent upon representative samples. Data must be
accurately recorded and analysed. If feedwater or boiler

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water limits are exceeded, the problem should be

discussed and the proper course of action decided upon
and taken.
2. Oxygen removal should be monitored by periodic testing of
the deaerator (without chemical addition). The indigo
carmine test for oxygen is widely used for this purpose.
3. Consideration should be given to using multi-test field kits,
which contain simple spectrophotometers for performing
routine feedwater tests, including iron and copper.
4. Coordinated phosphate treatment relies on precise pH and
phosphate measurements requiring greater precision than
possible with colour comparators.
5. Protection of the boiler against corrosion should not be
limited to when the unit is in operation. Rigid water
conditioning standards must also be maintained during
lay-up periods.
6. Boiler water silica content should be limited for the
particular operating pressure involved. Refer to standard
silica vaporisation curves.

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2. Impacts on Pressure Parts Remnant Life

The boiler components are exposed to high pressure and
temperatures. All boiler components are designed for a target
life, typically 22 years, while taking into consideration the
material properties, expected operating conditions and amount
of acceptable degradation. The "design life" can be maintained
or extended by operating and monitoring the units within the
guidelines recommended by the designer.
The operation of a unit involves start-up, shutdown, load
increase, decrease, steady load operation and emergency
conditions resulting in abrupt load changes. If the unit is
operated in the failure causing environment, then the design
life would be reduced resulting in forced outage or premature
retirement.
The failure or damage phenomena in high temperature/thicker
components such as SH tubes, SH headers, drums and large
bore steam pipelines include high temperature creep fatigue,
creep fatigue, embrittlement, hydrogen attack and hot corrosion.
For HRSG, which unlike a conventional boiler operate in lower
gas temperatures, the hydrogen attack and hot corrosion are of
less concern.
2.1 Creep
Creep is defined as the deformation of material under stress at
an elevated temperature. In a metal tube inside the HRSG the
resulting deformation may result in unacceptable dimensional
changes and distortion to the extent that even though the tube
does not fail heat transfer will be greatly diminished. An example
of such deformation is the bowing out of tubes due to expansion.
The tubes may be functional but the performance may not be as
desired. The creep can also result in failure due to stress-
rupture. Creep occurs when a component is either overheated
for a short term or kept at temperature above its nominal design
limits for a long term.
2.2 Fatigue
A component subjected to a repetitive or fluctuating stress will
fail at a much lower load than the load applied constantly. This
failure is termed as the "Fatigue Failure." Fatigue can be
developed by cyclic loading due to temperature alterations and
resultant pressure fluctuations which can be experienced
during periods of plant trips.

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2.3 Creep-Fatigue
This occurs when the conditions associated with both Creep and
Fatigue combine. The reasons for this impact are as follows:
1. the extent and rate of temperature change
2. the surface heat transfer coefficient
3. the diameter or thickness of the pressure part
4. thermal concentration factors in high stress region
5. thermal properties of the material
The problem with creep-fatigue is that it is not necessarily
apparent until there is a failure. Usually early warning can only
be detected by removing samples of tubes in known problem
areas and subjecting them to X-ray testing to identify any
cracking on the surface.

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3. HRSG Construction
3.1 Internal Insulation and Liner
The HRSG casings and ductwork are internally insulated to
keep the outer carbon steel casing cool. The internal
insulation system consists of ceramic fibre or mineral wool
insulation layers covered by a metal liner. The metal liner
protects the internal insulation from the high velocity of GT
Exhaust Gas stream. The liner is also designed to accommodate
the necessary thermal expansion as the HRSG is brought to its
hot operating service conditions. The liner is anchored to the
casing with studs. The liner is composed of a series of panels or
plates to minimize the thermal growth of the panels. These
liner panel attachment studs are welded to the casing. The stud
size and spacing pattern is selected according to the velocity,
turbulence, and operating temperature of the GT exhaust gas
stream.
Insulation and liner deterioration can rapidly lead to severe
operating problems. This deterioration may result in thermal
expansion problems, higher heat losses to the environment,
and hazardous conditions for operators.
3.2 Support and Structural Details

The all pressure part sections of HRSGs supplied to the CCCP
are suspended from the top, free to expand downward during
the operation. The drums are located on top of the roof
structure beams. The pressure parts are in eight (8) module
boxes per HRSG and have vent and drain lines.
The top support system for sections is achieved through
hanging these parts by rods from top support beams outside the
top casing. Seismic and wind loads are restrained through the
structural members to the foundation.
All superheaters steam outlet delivery headers are located on
the top of the HRSG. This placement, in conjunction with top
support, minimizes the thermal movement of the steam outlet
terminal points. Minimizing bottom placement of the steam
headers clears the area directly below the HRSG of all large
bore piping obstructions and minimizes the bottom casing
penetrations
The HRSG bottom is approximately 2.55m above the floor.
This clearance below the bottom casing, elimination of heat
bleed paths, and the minimizing of bottom casing penetrations
increases the bottom casing cooling.

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The steam drums (high pressure and low pressure systems) are
located on top of the HRSG and supported from its bottom.
Each drum weight is carried by two saddles and saddle beams;
and then transferred to the top transverse beam of the HRSG
beneath it. The weight is ultimately transferred by the vertical
columns to the HRSG foundation. The saddles slide over saddle
beams to accommodate thermal expansion. By this design, the
downcomers and evaporator tubes/headers do not carry the
drum weight.
3.3 Tube Sections Construction

The different heating sections of the HRSG are constructed of
finned tubes welded to top and bottom headers in single and
three rows per section. Each section has either single pass or
multi-pass steam/water flow arrangements. The multi-pass
arrangement is on the steam/water side while the gas side is
single pass only. Interconnection of tube sections is achieved
by multiple 180° return bends made of tubing or pipe. The
return bends are of similar material to the modules and are
welded to the nozzles on the module headers. This arrangement
is referred to as a ‘Platen’

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4. Major Components of the HRSG

4.1 HRSG Economisers
An economizer’s function is to increase water temperature close
to the Saturation Temperature, known as Approach Temperature.
Approach Temperature is designed to ensure maximum heat
energy absorption efficiency and operational flexibility.
Economizers are "Once Thru" heat exchangers, such that each
bank of tubes is in series with the next. Economisers can be
designed for "Steaming" or Non-Steaming". The selection of
steaming versus non-steaming economizers is based on
operational consideration, water quality, heat absorption
optimisation, and boiler life. Economizers incorporated in the
CCCP HRSG are of the non-steaming type.
Figure 10: Section of HRSG Showing External Area of Economiser
4.1.1 Detailed Description

Economiser sections are composed of extended or finned tube
surface banks. Each economiser section bank is a multipass two
or four row module with drains and vents. These modules are
arranged in a Series/Parallel configuration to reach the desired
final water temperature and capacity.

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Figure 11: Economiser Drains
The HP ECON tube sections are located in the exhaust gas

stream according to the dictates of the declining temperature of
the exhaust gas and the increasing temperatures of the heated
feed water thus providing maximum energy recovery from the GT
exhaust. The HP ECON consists of twenty four (24) rows of tubes
arranged in eight (8) modules.
4.1.2 Operation & Control

The HP feedwater, entering the HP ECON, is discharged from the
high pressure stages of the boiler feed pumps. A motorised HP
ECON vent valve is located in the HP economiser vent collection
header for sliding pressure and partial load operating conditions,.
This control valve is operated to allow the release of any trapped
steam within this system, particularly at partial load operating
conditions (low pressure operation) and thus prevent vapor
binding or flashing steam in the HP economiser.
A check valve is located just prior to the FW entering the HP
ECON. The check valve is used to allow flow into the HP ECON
and to prevent flow in the reverse direction if the FW pumps trip.
As the Economiser holds a large amount of water, which is
situated high above the FW pumps, reverse flows would cause
damage to the FW pipe work and components. The HP ECON
section contains vents and drains. These HP ECON vents are
used during start up or priming of the system to vent trapped air
from the upper headers into the high pressure drum. The HP

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ECON drains are used primarily to drain the sections and flush
the economiser section free of sediment during filling of boiler.
No. Description Design Design

Pressure temperature
1 HP Economiser 1 140.3 BARG 298.9 o C
2 HP Economiser 2 140.3 BARG 176.7 o C
3 LP Economiser 24.1 BARG 176.7 o C
Table 1: Typical Economiser Pressures & Temperatures
4.2 HRSG Drums

The CCCP HRSG is equipped with High Pressure and Low
Pressure Steam Drums. The steam drums are steam/water
separators and storage tanks as well as the provision of chemical
injection for steam/water purity requirements.
Level Drum
Column
Figure 12: HRSG HP Drum
Figure 13: LP Drum

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Apart from the function of steam/water separation required for
the LPSH, the LP Drum also serves as a water storage tank for
the LP Feedwater Systems. There is a take-off line with
regulating valve after the LP Economiser which provides
Deaerator hot water heating and responds to Deaerator low/low
levels. The water level ranges have been selected to provide an
adequate margin for safe and reliable pump operation.
The LP steam drum is 1.4 m inside diameter, with a minimum of
17.7mm thick wall with 2: 1 semi ellipsoidal end. The LP steam
drum is equipped with two (2) pressure relief safety valves (PSV)
mounted vertically on top of the drum. One (1) PSV is set at 10.1
kg/cm2 g to relieve 18390 kg/hr. of saturated steam, and the
other PSV is set at 10.4 kg/cm2 psig to relieve 18587 kg/hr. of
saturated steam. Both safety valves are closed during normal
operation; however, in an over-pressure situation, the PSV’s pop
or lift, relieving excess steam pressure.
Figure 14: Drum Safety Valves
The HP steam drum is 1.8 m inside diameter with a minimum of

171.7mm thick wall with full hemispherical end. The high
pressure steam drum is equipped with two (2) pressure relief
valves (PSV’s) mounted vertically on top of the drum. One (1)
PSV is set at 99.0 kg/cm2 to relieve max. 74234 kg/hr of
saturated steam and the other PSV is set at 102.1 kg/cm2 to
relieve max.74847 kg/hr of saturated steam. Both PSV’s are

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closed during normal operation; however, in an over-pressure

situation, the HPSH PSV will lift or pop first, relieving excess
steam. If the pressure continues to build, the HP drum PSV’s will
lift.

Drum boilers operate in the area on or under the saturation
curve. The HP steam drum receives the hot HP ECON outlet
feedwater and distributes/mixes it with the existing drum water.
The water is then fed to the HP evaporator through the
downcomers, feeder headers, and feeder tubes. Steam bubbles
are created and as a result of the variation in density in the
evaporator loop, the steam and water rises to the HP steam
drum via the riser tubes or riser collection header, thus
completing the natural circulation loop.
The Steam/Water mixture entering the drum from the riser
tubes is usually 5% to 30% steam, depending on the boiler load
and pressure. Staying at low quality levels protects the tubes
from overheat failures due to the nature of the boiling process.
In the steam drum, saturated steam is separated from the
steam/water mixture. The separated steam rises up through the
drum as feedwater enters the drum from the economiser. The
separated water from the steam/water mixture is then
recirculated together with the feedwater to the heat absorbing
evaporator tubes through the circulation loop. The steam/water
separation is done through a combination of gravity and
mechanical components.
4.2.2.1 Drum Level Control

Drum steam/water separation is reliant on maintaining the
water level in the drum at approximately the ½ way level of the
gauge glass. This water level is referred to as the Normal Water
Level (NWL). Maintaining NWL ensures a free controlled surface
for steam/water mixture separation and proper operation of the
primary separation equipment. High drum level will increase
carryover to downstream equipment. In extreme cases, the steam
lines can become flooded. Carryover can result in superheater
tube contamination due to even slight amounts of chemicals and
impurities in the boiler water. Low drum level can cause circulation
problems by restricting flow to the downcomers which, in turn,
supply the evaporator circuits. This ultimately results in evaporator
tube overheating and failure. Excessive low water level (LLWL) in
the HP/LP drums will cause a trip of HRSG.

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Figure 15: Drum Level Control Valves
The drum level is controlled by a single element control (during

start up) or three element control (during normal operation). The
input for the single element controller is drum level only.
However once steam pressure is established and feeding forward
to the turbine is possible, drum level on it’s own is not enough to
give an accurate level indication.
The inputs for the three element controller are steam flow, feed
water flow and drum level. It also incorporates a drum pressure
compensation signal. There are three inputs per each signal for
back up. The control system will take an average of two signals
out of three, or if one fails will take the lowest reading. At the
high water level (HWL) alarm the drum level control valve will be
closed and the intermittent blowdown valve will be opened to blow
down the level in the drum from high level to normal level.
In the CCCP HRSG drums, the separation of steam from the
steam/water mixture generated usually takes place in two steps.
Primary separation removes nearly all of the water from the
mixture, so that in effect, no steam is recirculated to the boiler
water. However, the steam may still contain some water and
solid contaminants which must be removed or reduced in
amount before the steam is sufficiently pure for use. This step is
called secondary separation or steam scrubbing.
Primary steam separation is accomplished with cyclone steam
separators (for the HP steam drums) or an impact plate (for the
LP steam drum).
Further steam scrubbing of any trace amounts of water or
contaminants in the steam is achieved by the secondary
scrubbers. Located at the top of the steam drum, these
corrugated plates provide a large surface which intercepts water
particles as the steam weaves through the closely fitted plates.
Steam velocity through the corrugated plate assembly is very low,
so that re-entrainment of water is avoided. The collected water is

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drained from the bottom of the scrubber assembly to the water

below.
Figure 16: Cyclone Separator Internals
Figure 17: Steam Drum Internal

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The drum is also designed to act as a storage tank or reservoir,

allowing the boiler to accommodate upsets in feed pump
operation and to “smooth out” transient drums level excursions
during load swings. The steam drum acts as a contact vessel for
internal boiler water treatment by chemicals. Continuous
blowdown for reduction of solids concentration in the boiler
water is an integral part of the chemical water treatment process.
Figure 18: HRSG Drum Blowdown Vessel
4.2.3 Technical Data

HRSG process function is to extract sensible heat energy from
the GT exhaust and produce steam. Based on various operating
conditions, the maximum steam parameters in each pressure
system for Natural Gas fired are given below:
System Description Rated condition Unit

High Pressure System Flow 348720 Kg/hr.
Pressure 83.4 bar(a)
o
Temperature 530 C
Low pressure system Flow 77190 Kg/hr.
Pressure 7.8 bar(a)
o
Temperature 218 C

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4.3 HRSG Evaporators

In the evaporation circuit the water is heated to as close to
saturation temperature as is possible. This process changes the
water from liquid to vapour or steam. It should be understood
that the water in the HRSG is under pressure. Therefore this
liquid to vapour state can only be achieved at extremely high
temperatures. A comparison table between saturation
temperature and pressure is in Table 2. Note that as the
pressure increases the amount of heat energy required to raise
the water temperature to saturation increases also.
Absolute Saturation Heat Energy

pressure temperature kJ/kg
0
(kPa) C
5 33 138
8.5 36.7 154
101.3 100 420
1000 180 763
3000 234 1008
4000 250 1087
6400 280 1233
10000 311 1399
16000 346 1645
22120 347.2 2107.4
Table 2: Steam Table Example
The LP EVAP section consists of twelve (12) rows of tubes,

arranged in four (4) banks. The banks are all single pass, with
flow from bottom to top and with no internal baffles in upper
and lower headers. The tubes are oriented in this direction to
allow steam bubbles generated to rise via the riser tubes to the
steam drum. Water is fed to the tubes from the downcomer
feeder header assemblies. This is referred to as a natural
circulation loop.
The HP EVAP section consists of eighteen (18) rows of tubes
located in six (6) sections. The HP EVAP is split or separated into

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two (2) subsections. Subsection 1 (referencing the gas flow)

located at the back of box 2 contains nine(9) rows of tubes in
three (3) sections, subsection 2 located at the front of box 3
contains again nine (9) rows of tubes in three (3) sections.
Figure 19: HP Drum Showing Downcomer Pipes

Evaporator sections are where the boiling process or steam
generation occurs. As heat energy is absorbed by water from the
gas stream, the water temperature increases. When water
reaches the boiling point or saturation temperature, some of the
water evaporates or vaporises to steam.
The CCCP evaporator sections are typically single pass two and
three row sections. The single pass is on the water side and is
vertically upward. The system feed a steam/water mixture to the
riser tubes. The downcomers are fed with water from the
downcomers/feeder header assembly to replace the water exiting
as a steam/water mixture.
In the LP NAP section, the water phase change between liquid
and steam occurs. This phase change occurs due to the
convective heat transfer or energy exchange between the GT
exhaust gas stream and the water in the LP NAP tubes. The LP
NAP tubes are components in the Natural Circulation Loop.
The lower downcomer crossover header located at the bottom of
the system contains intermittent blowdown (IBD) connection.
The Low Pressure Evaporator intermittent blowdown (IBD) is
designed to remove any sludge or contaminates formed in the
LPSG evaporator water and to maintain boiler water chemistry
within limits. The IBD can be used to lower the drum level
during start up to avoid unnecessary high drum level trips.

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In the HP EVAP section, the phase change between water and

steam occurs. This phase change occurs due to the convective
heat transfer or energy exchange between the CT exhaust gas
stream and the water in the HP EVAP tubes. The HP NAP tubes
are a component in the Natural Circulation Loop. The lower
downcomer crossover headers located at the bottom of the
system contain startup/intermittent blow-off connections. These
are designed to remove any sludge or contaminates formed in
the HPSG evaporator water and to maintain boiler water
chemistry within limits. The IBD can be used to lower the drum
level during start up to avoid unnecessary high drum level trips.
This header is also equipped with connections for chemical
cleaning, sparging steam, and start-up drain.

Pressure temperature
1 HP Evaporator 99.1 BARG 310 o C
2 LP Evaporator 12.4 BARG 185 o C
Table 3: Typical Evaporator Pressure & Temperatures
4.4 HRSG Superheaters

The major function of superheater is to increase the pressurized
water temperature above the steam saturation temperature for
use in the steam turbine. Saturated steam is considered as “dry”
steam. Steam below saturation temperature would still contain
water droplets, which can cause damage to a steam turbine.
The Superheater absorbs heat energy from the GT exhaust gas
and transfers this energy to the steam. The steam superheat
energy level is measured as an increase in steam temperature
beyond the steam temperature achieved in the evaporator
section. Superheater sections typically have the highest metal
temperatures in the HRSG.
Superheater sections are composed of extended or finned tube
surface modules. The CCCP High and Low pressure modules are
one steam pass modules. These sections are arranged in a
Series-Parallel configurations to reach the desired final steam
temperature and capacity.
The LPSH consists of two (2) rows of tubes in two (2) modules i.e.
one row per module. The modules have one (1) pass on steam

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side with the steam entering the top header and exits from the
bottom header. Steam on the inside of the tubes is received from
the low pressure steam drum and is heated from saturation to
219°C (maximum). The LPSH is not equipped with a final steam
temperature control system for attemperation. Steam leaving the
LPSH is fed to the low pressure cylinder of the steam turbine.
The HPSH consists of eighteen (18) rows of tubes arranged in six
(6) modules. Steam on the inside of the tubes is received from
the high pressure steam drum at saturated temperature. The
maximum steam temperature at the inlet of Main Stop Valve is
535°C. These modules are top supported to minimise thermal
expansion considerations for the outlet header piping. These
modules are constructed of chrome-molly alloyed carbon steel
(SA 335 P 22) material designed for high temperature operation.
HPSH subsection 1 (referencing the gas flow) contains two (2)
modules with six (6) tube rows providing a single steam side
pass from bottom to top. HPSH subsection 2 contains four (4)
modules with twelve (12) tube rows providing a single pass from
top to bottom. The steam flow from the top headers of HPSH
subsection 2 to HPSH sub-section 1 passes through an
attemperator loop.

Drainable superheaters are employed in the HRSG design to
ensure that any liquid water accumulated in the lower headers
are removed during start up. The water may be there as a result
of the filling process or condensate formed during the purge of a
"Hot' or 'Warm" Start. Drainable superheaters allow the CCCP
HRSG to startup following the GT Exhaust Gas flow ramp.
The LP Superheater is fitted with a one (1) PSV, set to lift at 9.8
kg/cm2 to relieve a max of 9064 kg/hr of steam at 219°C. The
PSV is mounted on the LP main steam outlet. The PSV is closed
during normal operation; however, in an over-pressure situation,
the safety valve pops, or lifts, relieving the excess steam pressure
until the system pressure is reduced to the desired level. The
LPSH PSV and the LP drum PSVs provide 100% relieving
capacity as required by Boiler Code, Section I for personnel and
equipment protection.
The LPSH modules are designed as drainable superheaters. This
enables the superheater modules to be completely drained prior
to startup. The LP superheater drains are used for the removal of
condensate formed during the purge portion of HOT or WARM
start ups, draining of hydro water and draining / flushing
during chemical cleaning. The LPSH is equipped with vents to
eliminate non-condensable gasses at startup and to release any

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air pockets to LP drum, during boiler commissioning. The LPSH

vent is included with a silencer to control noise.
The HP superheater outlet is equipped with a pressure relief
valve (PSV) set at 96.5 kg/ cm2g to relieve max 37882 kg/hr of
superheated steam at a final steam temperature of 535°C. The
PSV is closed during normal operation; however, in an over-
pressure situation, the safety valve pops, or lifts, relieving the
excess steam pressure until the system pressure is reduced to
the desired level. If the system pressure continues to increase,
the PSVs on the HP drum will open.
The HP Superheater is equipped with an interstage attemperator
manufactured by the Nippon Keystone Corporation. The
attemperator is a self contained control valve and spray nozzle
assembly and located in the pipeline connecting HPSH
subsection 2 and subsection 1. The attemperator is supplied for
final steam temperature control. The spray attemperation
process uses water as the cooling media. The spray water is
directly fed to the attemperator from the HP Economiser 2 outlet
line. Final steam temperature control is important for protection
of the superheater and equipment served by the HRSG. The
attemperation is designed to limit final steam temperature at HP
superheater outlet to max 535oC (final rated temperature).
Figure 20: Typical Direct Spray Attemperator
Steam temperature sensing elements are located in the HP

superheater outlet header. The HPSH modules are designed as
drainable superheaters. This enables the superheater modules
to be completely drained prior to startup. The HP superheater
drains are used for the removal of condensate formed during the
purge portion of HOT or WARM startups, draining of hydro water
and draining /flushing during chemical cleaning. The HPSH

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modules and outlet header are equipped with vent valves to vent
non-condensables at startup and to release any air pockets
during boiler commissioning.

Pressure Temperature
1 HP Superheater 97.2 BARG 560 o C
2 LP Superheater 12.4 BARG 185 o C
Table 4: Typical Evaporator Pressure & Temperatures

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5. Control of Main HRSG Equipment

The HRSG has several critical control devices. These devices
control steam temperature and water level in the drums. The drum
level controls were discussed in detail earlier. Steam temperature is a
function of heat energy input and steam pressure. The steam
pressure in the HRSG is a function of FW pressure and ST loading
requirements. Before optimal steam pressure can be reached
however, it is important that the steam temperature is raised in such
a way as to maximise plant and material life. The most accurate
method of determining the optimal temperature rise is to measure
heat input versus steam pressure.
The graph of GT load and Steam Pressure is shown in Figure 21
below for the HRSG.
Figure 21: GT load and Steam Pressure

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5.1 HP Steam Temperature Control

This was discussed earlier.
5.2 ST Bypass System

The ST bypass system can accept 2 x 100% HRSG steam
production and is operated when the steam turbine is tripped.
The HRSG HP/LP steam pressure is controlled by HP/LP ST
bypass. The temperature is reduced by HP/LP steam attemperator

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6. Component Alarms
Alarm Title Alarm Level Set Point

HRGS1 LP DRUM CONT BLOW V :LOCK LOW ----
HRGS1 LP DRUM CONT BLOW V :FAULT HIGH ----
HRGS1 LP DRUM CONT BLOW V :LOCAL LOW ----
HRGS1 LP DRUM DRN VLV :LOCK LOW ----
HRGS1 LP DRUM DRN VLV :FAULT HIGH ----
HRGS1 LP DRUM DRN VLV :LOCAL LOW ----
HRGS1 HP DRUM CONT BLOW V :LOCK LOW ----
HRGS1 HP DRUM CONT BLOW V :FAULT HIGH ----
HRGS1 HP DRUM CONT BLOW V :LOCAL LOW ----
HRGS1 HP DRUM DRN VLV :LOCK LOW ----
HRGS1 HP DRUM DRN VLV :FAULT HIGH ----
HRGS1 HP DRUM DRN VLV :LOCAL LOW ----
HRGS1 HP SH1 DRNVLV :LOCK LOW ----
HRGS1 HP SH1 DRNVLV :FAULT HIGH ----
HRGS1 HP SH1 DRNVLV :LOCAL LOW ----
HRGS1 LP ECO AIRVENT VLV :LOCK LOW ----
HRGS1 LP ECO AIRVENT VLV :FAULT HIGH ----
HRGS1 LP ECO AIRVENT VLV :LOCAL LOW ----
HRGS1 HP FWT STPVLV :LOCK LOW ----
HRGS1 HP FWT STPVLV :FAULT HIGH ----
HRGS1 HP FWT STPVLV :LOCAL LOW ----
HRGS1 HP ECO AIRVENT VLV :LOCK LOW ----
HRGS1 HP ECO AIRVENT VLV :FAULT HIGH ----
HRGS1 HP ECO AIRVENT VLV :LOCAL LOW ----
HRGS1 LP ECO STARTUPVENT VLV :LOCK LOW ----
HRGS1 LP ECO STARTUPAIRVENT VLV :FAULT HIGH ----
HRGS1 LP ECO STARTUPAIRVENT VLV :LOCAL LOW ----
HRGS1 LP STM STPVLV :LOCK LOW ----
HRGS1 LP STM STPVLV :FAULT HIGH ----
HRGS1 LP STM STPVLV :LOCAL LOW ----
HRGS1 LP STM STBYP VLV :LOCK LOW ----
HRGS1 LP STM STBYP VLV :FAULT HIGH ----
HRGS1 LP STM STBYP VLV :LOCAL LOW ----
HRGS1 LP STM DRNVLV :LOCK LOW ----
HRGS1 LP STM DRNVLV :FAULT HIGH ----
HRGS1 LP STM DRNVLV :LOCAL LOW ----
HRGS1 HP STARTUPVENT VLV :LOCK LOW ----
HRGS1 HP STARTUPVENT VLV :FAULT HIGH ----
HRGS1 HP STARTUPVENT VLV :LOCAL LOW ----
HRGS1 HP STM STPVLV :LOCK LOW ----
HRGS1 HP STM STPVLV :FAULT HIGH ----
HRGS1 HP STM STPVLV :LOCAL LOW ----
HRGS1 HP STM STPBYP V :LOCK LOW ----
HRGS1 HP STM STPBYP V :FAULT HIGH ----
HRGS1 HP STM STPBYP V :LOCAL LOW ----
HRGS1 HP STM DRNVLV :LOCK LOW ----
HRGS1 HP STM DRNVLV :FAULT HIGH ----

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HRGS1 HP STM DRNVLV :LOCAL LOW ----
HRGS1 BWS STP VLV1 :LOCK LOW ----
HRGS1 BWS STP VLV1 :FAULT HIGH ----
HRGS1 BWS STP VLV1 :LOCAL LOW ----
HRGS1 LP DRUM LVL INTERLOCK :BYPASS LOW
HRGS1 LP DRUM LVL-1 :L-LOW CRITICAL -500mm
HRGS1 LP DRUM LVL :L-LOW CRITICAL -500mm
HRGS1 LP DRUM LEVEL :LOW LOW -100mm
HRGS1 LP DRUM LEVEL :HIGH LOW 100mm
HRGS1 LP DRUM LVL-1 :HI-HI CRITICAL 250mm
HRGS1 LP DRUM LVL :HI-HI CRITICAL 250mm
HRGS1 LP DRUM LVL-1 :TROUBLE LOW ----
HRGS1 LP STM DRUM PRESS :HIGH LOW 9.4barG
HRGS1 LP STM DRUM PRESS :HI-HI HIGH 9.9barG
HRGS1 LP STM DRUM LVL DIFF 1-2 :H LOW +/-50mm
HRGS1 HP DRUM LVL-1 :L-LOW CRITICAL -750mm
HRGS1 HP DRUM LVL :L-LOW CRITICAL -750mm
HRGS1 HP DRUM LVL :HI LOW 100mm
HRGS1 HP DRUM LVL :LOW LOW -100mm
HRGS1 HP DRUM LVL-1 :HI-HI CRITICAL 150mm
HRGS1 HP DRUM LVL :HI-HI CRITICAL 150mm
HRGS1 HP DRUM LVL-2 :TROUBLE LOW ----
HRGS1 HP STM DRUM PRESS :HIGH LOW 94.5barG
HRGS1 HP STM DRUM PRESS :HI-HI CRITICAL 97.0barG
HRGS1 HP STM DRUM LVL DIFF 1-2 :H LOW +/-50mm
HRGS1 LP DRUM LVL CV-1 FAULT LOW ----
HRGS1 LP DRUM LVL CV-2 FAULT LOW ----
HRGS1 HP DRUM LVL CV-1 FAULT LOW ----
HRGS1 HP DRUM LVL CV-2 FAULT LOW ----
B1 HP STM DSH CV-1 FAULT :FAULT LOW ----
B1 HP STM DSH CV-2 FAULT :FAULT LOW ----
HRGS1 LP SH OUTL STM PRESS :HIGH LOW 9.6barG
HRGS1 LP SH OUTL STM TEMP :LOW LOW 170ºC

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P DIFF HRGS1/MAIN LP S :HIGH LOW 0.5barG
P DIFF HRGS1/MAIN LP S :LOW LOW -1.0barG
HRGS1 HP SH OUTL STM FLOW :HI-HI HIGH 208.0 T/H
HRGS1 HP SH OUTL STM PRESS :HIGH LOW 94.6barG
HRGS1 HP SH OUTL STM TEMP :LOW LOW 350ºC
HRGS1 HP SH OUTL STM TEMP :HIGH LOW 544ºC
HRGS1 HP SH OUTL STM TEMP :HI-HI HIGH 558ºC
HRGS1 LP SAT. STM CONDCT :HIGH LOW 0.3µS/cm
HRGS1 HP STM DRUM PRESS :LOW LOW 43.1barG
HRGS2 HP SH OUTL STM PRESS :HIGH LOW 94.6barG
HRGS2 LP DRUM CONT BLOW V :LOCK LOW ----
HRGS2 LP DRUM CONT BLOW V :FAULT HIGH ----
HRGS2 LP DRUM CONT BLOW V :LOCAL LOW ----
HRGS2 LP DRUM DRN VLV :LOCK LOW ----
HRGS2 LP DRUM DRN VLV :FAULT HIGH ----
HRGS2 LP DRUM DRN VLV :LOCAL LOW ----
HRGS2 HP DRUM CONT BLOW V :LOCK LOW ----
HRGS2 HP DRUM CONT BLOW V :FAULT HIGH ----
HRGS2 HP DRUM CONT BLOW V :LOCAL LOW ----
HRGS2 HP DRUM DRN VLV :LOCK LOW ----
HRGS2 HP DRUM DRN VLV :FAULT HIGH ----
HRGS2 HP DRUM DRN VLV :LOCAL LOW ----
HRGS2 HP SH1 DRNVLV :LOCK LOW ----
HRGS2 HP SH1 DRNVLV :FAULT HIGH ----
HRGS2 HP SH1 DRNVLV :LOCAL LOW ----
HRGS2 LP FWT STPVLV :LOCK LOW ----
HRGS2 LP FWT STPVLV :FAULT HIGH ----
HRGS2 LP FWT STPVLV :LOCAL LOW ----
HRGS2 DEAER HW STP VLV :LOCK LOW ----
HRGS2 DEAER HW STP VLV :FAULT HIGH ----
HRGS2 DEAER HW STP VLV :LOCAL LOW ----
HRGS2 LP ECO AIRVENT VLV :LOCK LOW ----
HRGS2 LP ECO AIRVENT VLV :FAULT HIGH ----
HRGS2 LP ECO AIRVENT VLV :LOCAL LOW ----
HRGS2 HP FWT STPVLV :LOCK LOW ----
HRGS2 HP FWT STPVLV :FAULT HIGH ----
HRGS2 HP FWT STPVLV :LOCAL LOW ----
HRGS2 HP ECO AIRVENT VLV :LOCK LOW ----
HRGS2 HP ECO AIRVENT VLV :FAULT HIGH ----
HRGS2 LH ECO AIRVENT VLV :LOCAL LOW ----
HRGS2 LP STARTUPVENT VLV :LOCK LOW ----
HRGS2 LP STARTUPVENT VLV :FAULT HIGH ----
HRGS2 LP STARTUPVENT VLV :LOCAL LOW ----
HRGS2 LP STM STPVLV :LOCK LOW ----
HRGS2 LP STM STPVLV :FAULT HIGH ----
HRGS2 LP STM STPVLV :LOCAL LOW ----
HRGS2 LP STM STPBYP VLV :LOCK LOW ----
HRGS2 LP STM STPBYP VLV :FAULT HIGH ----
HRGS2 LP STM STPBYP VLV :LOCAL LOW ----
HRGS2 LP STM DRNVLV :LOCK LOW ----
HRGS2 LP STM DRNVLV :FAULT HIGH ----

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HRGS2 LP STM DRNVLV :LOCAL LOW ----
HRGS2 HP STARTUPVENT VLV :LOCK LOW ----
HRGS2 HP STARTUPVENT VLV :FAULT HIGH ----
HRGS2 HP STARTUPVENT VLV :LOCAL LOW ----
HRGS2 HP ST STP VLV :LOCK LOW ----
HRGS2 HP ST STP VLV :FAULT HIGH ----
HRGS2 HP ST STP VLV :LOCAL LOW ----
HRGS2 HP STM STPBYP V :LOCK LOW ----
HRGS2 HP STM STPBYP V :FAULT HIGH ----
HRGS2 HP STM STPBYP V :LOCAL LOW ----
HRGS2 HP ST DRN VLV :LOCK LOW ----
HRGS2 HP ST DRN VLV :FAULT HIGH ----
HRGS2 HP ST DRN VLV :LOCAL LOW ----
HRGS2 LP DRUM LVL INTERLOCK :BYPASS LOW
HRGS2 LP DRUM LVL :L-LOW CRITICAL -500mm
HRGS2 LP DRUM LEVEL :LOW LOW -100mm
HRGS2 LP DRUM LEVEL :HIGH LOW 100mm
HRGS2 LP DRUM LVL :HI-HI CRITICAL 250mm
HRGS2 LP STM DRUM PRESS :HIGH LOW 9.4barG
HRGS2 LP STM DRUM PRESS :HI-HI HIGH 9.9barG
HRGS2 HP DRUM LVL NTERLOCK :BYPASS LOW
HRGS2 HP DRUM LVL :L-LOW CRITICAL -750mm
HRGS2 HP DRUM LVL :HI LOW 100mm
HRGS2 HP DRUM LVL :LOW LOW -100mm
HRGS2 HP STM DRUM PRESS :HIGH LOW 94.5barG

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HRGS2 HP STM DRUM PRESS :HI-HI CRITICAL 97.0barG

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7. Start-Up the HRSG

The following procedures are to be carried out to start-up the
HRSG:
7.1 First Boiler Filling

Prior to starting the plant, the HRSG tubes shall be filled with
feed water to the normal start up level as indicated in the HP
and LP drums.
This is carried out by pumping water from Demineralised Water
Tank. In order to avoid thermal shocks or water hammering with
flashing off of steam, the boiler must be cold (including the heat
exchangers, piping, drums) prior to admitting water to the boiler.
7.2 Cold Start of GT + HRSG + STG

The GT, HRSG and ST can be automatically started through the
Automatic Plant Start-up Program.
The initial conditions of each part of the plant must be met prior
to initiating an AUTO START.
7.3 Start of Warm HRSG

Refer to the CCPP start-up procedure and warm start up curves.
7.4 Start of Hot HRSG

Refer to the CCPP start-up procedure and hot start up curves.
7.5 Operational Outline

HRSG is started as part of the Combined Cycle Power Plant
(CCPP) start-up operating procedure. The CCPP is started in
Automatic sequence after pre-start preparations are completed.
The automatic sequence starts the following systems:
1. Service air system

2. Instrument air system
3. Fire Hydrant and Auto Sprinkler Systems Ready
4. CO2 Fire Protection Systems Ready
5. Demineralised water system.

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6. Make –up water system

7. Closed Cycle Cooling Water system
8. Steam Turbine Auxiliaries.
9. Condensate Water system
10. High Pressure BFP System.
11. Low Pressure BFP System.
12. Initial water filling for HRSG HP drum
13. Initial water filling for HRSG LP drum
14. Gland steam system
15. Vacuum Raising & ACC system
16. CCPP system
7.6 SYSTEM START-UP

7.6.1 Pre-Start Operational Instructions
In this section the following items are described.
1. HRSG Start-up Preparation Procedure
2. HRSG Preliminary Water Filling and Flushing Procedures
7.6.2 Prerequisites
If the HRSG was shut down for maintenance, prior to re-starting
the plant must be returned to operations personnel control and
all safety permits to work must be cleared.
Prior to handing the plant back, Maintenance must ensure that
the equipment is serviceable and cleared of all debris both
internally and externally.
Once the permits have been cleared the Operators are to return
the plant to operational-ready condition.
7.6.3 Extra Considerations and Precautions
1. Ensure all trip relays have been reset.

2. The plant can be started to achieve closed cycle mode
provided the HRSG is purged. This is done during run-up
of the gas turbine shaft prior to ignition and for usually for
a period corresponding to 5 volume charges of the HRSG

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3. While the HRSG is in the process of heating up, frequent

checks should be made to the thermal expansion of the
boiler and gas duct.
4. As soon as the heat is introduced into the HRSG chamber,
the water level in the drum gauge glass will rise due to the
expansion of the water.
5. Care must be taken that the water level is maintained at
the levels specified values by operation of the intermittent
blowdown valves.
6. Prior to starting any pumps they should be adequately
primed and have a proper discharge head of pressure to
avoid damage to the pump and associated pipe work as a
result of fluid hammer and stress. If this is not possible
the pump should not be started except with discharge
valves closed.
7. Be careful not to reduce pump flow to less than the
minimum flow described in the data sheet at any time.
Otherwise it may cause the fluid temperature to rise inside
the pump resulting in vapor pockets forming and
cavitations or in the case of a chemical solution could
accelerate internal corrosion.
8. If the drum water levels are observed to be increasing
during steady-state operation, the boiler feed water control
valve(s) may require to be exercised as they may be subject
to sticking spindles.
9. The most important rule in the safe operation of a natural
circulation boiler is to keep the water as near the normal
water level as conditions will permit.
10. During normal operation more frequent intermittent
blowdown may be necessary when trouble is experienced
with boiler chemical imbalance, foaming, priming and
other feed water troubles. However experience may
indicate that less frequent intermittent blowdowns are
desirable. The frequency of intermittent blowdowns should
be determined by regular checks of the water chemistry
and the control of the water levels.
11. When on continuous operation the boiler water should be
blown down once a month. This is achieved by opening the
HP/LP intermittent manual blow down valves. Blowdown
should be maintained until a maximum water level
decrease in the Drum of 50 mm is achieved.
The amount of blow down valve opening is usually
determined by the following formula and Cv curves.

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Cv=1.17X * F/(ρ * ΔP)^0.5
Cv: Flow coefficient of blowdown valve

X: Rate of blowdown (Usually determined by Chemist when plant is
on-line)
F: Feed water flow (t/h)
ρ: Specific gravity of boiler water (t/m3)
ΔP: Differential pressure of valve (bar)
12. Gauge glass lights should be maintained and the glasses

kept clean. Steam or water should not be allowed to leak
from the gauge glass connections, as this will cause the
gauge glasses to show a false level.
13. Each drum and boiler safety valve should be checked
periodically to ensure that it is open and free to operate. It
is recommended that a specialist from the original valve
manufacturer be used for checking safety valves. The valve
manufacturer will normally be able to provide the tools and
a technician to check the operating pressure and assist in
restoring the valves to the optimum performance level.
14. Perform all boiler water and boiler feed water tests as
directed by the Chemical Engineer. Adjust dosages etc
accordingly.
15. Except for control valves, all other valves must be either
fully open or fully closed and must not be left partially
open. Non-control valves will wear the seat of the valve
section rapidly when only partially open. If difficulty is
experienced in closing a valve due to an obstruction
between the valve and its seat, do not try to close the valve
forcibly but open and close the valve several times to flush
away the obstruction by the pressure of transferred liquid
and then close the valve.
16. Initial opening of drains and vents allows condensate to
escape and warm air or steam also to be driven out of the
pipework.
17. By limiting the rate of pressure rise within the evaporator
elements and the steam water drum, the rate of rise of the
drum and evaporator metal temperatures are also limited
18. When a positive pressure (2 barg for the HP and 1bar for
the LP) is present in the steam/water drums it can be
assumed that steam is being generated and the steam
space is free of oxygen (air). The drum vents can then be
closed

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19. Following the closure of the drum vents steam begins to

flow from the drum to the superheater.
20. On closure of the intermediate or interstage drains on the
superheater the steam flows out from the superheater into
the steam mains and either to atmosphere through the
Vents or to the Blowdown Tank via the Steam Line Drains.
21. The vents are normally opened fully, initially, and then
progressively closed to allow a pressure rise according to
the design rate. The vents should remain partially open
until such time as a continual steam flow is established
through the superheater by the passage of steam to the
steam turbine or through the bypass to condenser.
The valves are lined up for cold start-up, HRSG pressure raising
and HRSG water filling as per list given below:
No System Description Status Check

3. List of main stop valves to be Refer to table 2 in Closed Confirm
closed. this document
Setting of remote operated Refer to Table 3 in Defined in Confirm
valves. this document table 3 setting.
Valve openings at initial setting Refer to Table 7 in Defined in Confirm
for cold start. this document. table 7. valve
position.
7.6.4 Pre-Start Checklist

If not previously completed, inspect the entire unit, consisting of
gas ducts, access lanes between tube blocks, stack base and
each manhole and maintenance opening to be sure that all boiler
manholes and maintenance holes are tight and ready for start-
up.
Remove all tools and foreign matter from the gas side of the unit.
This is particularly important with regard to any combustible
debris around the superheater and boiler inlet.
The following preparation procedures are to be carried out with
reference to their appropriate tables:
Procedure Description Refer to

No. Table No.
4. Confirm that HRSG pre-start check points are completed. 1
Check that all main stop valves are closed. 2
Switch on electrical power supplies 3
Feed instrument air. 4
Check the function of remote operation valves. 5
Feed the cooling water 6

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Procedure Description Refer to

No. Table No.
Check the valve open-and-close position for each line. 7
Check the selection mode of controller. 8
Confirm the completion of ready for start-up of boiler feed 9
water supply equipment, chemical dosing equipment and
sampling system.
Table 1- Preparation and Checklist
No. Check Point Confirmation and Notes

5. Internal check
1) Steam drum Cleaned (without debris)
2) Steam drum internals Correctly installed
3) Gas side of boiler proper Cleaned (without debris)
4) Gas duct and stack Cleaned (without debris)
5) Blow down tank Cleaned (without debris)
External check
1) Flange connected parts Gasket are adequately tightened
Manholes and inspection holes Closed tightly
1) Manhole door of steam drum
2) Manhole door of boiler proper
3) Manhole door of gas duct & stack
4) Manhole door of blow down tank
Strainers Cleaned (without debris)
Local gauge Confirm that indication each
gauge is correct
Lubricant oil initially filled / confirmation
Level transmitters are in service

All trip relays Reset

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Table 2- List of Valves to be closed
No. Plant Item Valve No. Checked

6. Boiler feed water line
- HP feed water stop valve
- LP feed water stop valve
7. Make up water line
- HP make-up water stop valve inlet valve
- LP make-up water stop valve inlet valve
8. Steam line
- HP steam stop valve (Boiler outlet valve)
- LP steam stop valve (Boiler outlet valve)
- HP-SH drain valves
- LP-SH drain valves
9. Desuperheating line
- HP DSH injection water stop valve
10. Blowdown line
- HP drum continuous blowdown valve
- LP drum continuous blowdown valve
-HP drum intermittent blowdown valve
-LP drum intermittent blowdown valve
11. Chemical dosing line
-HP drum chemical feed stop valve
(Phosphate)
-LP drum chemical feed stop valve
(Phosphate)
- Ammonia feed stop valve
- Hydrazine feed stop valve
12. Sampling line
- HP drum water sampling stop valve
- LP drum water sampling stop valve
- HP saturated steam sampling stop valve
- LP saturated steam sampling stop valve
- Condensate Pump outlet water sampling
stop v/v
- DEA outlet water sampling stop valve
13. N2 supply line
- HP drum nitrogen supply stop valve
- LP drum nitrogen supply stop valve

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Table 3- Electric Power Supply Items
No. Check Point Equipment No. /

Notes
14. HP BFW pumps
LP BFW pumps
Condensate pumps
Make-up water pumps
Motor operated valves Refer Table 5 below
Chemical dosing equipment (Local control panel) N/A
Sampling unit (Local panel) N/A
HP & LP drum level indicators
Gas analyzer
7.6.5 Instrument Air

The compressed air for instrumentation is used to actuate flow
control valves and on-off valves. The procedure to supply
instrument air is shown in Table 4.
Table 4: Instrument Air Supply Procedure
No. Check Point Notes

15. Confirm that inlet valve of each branch line and drain
valve are opened.
Gradually open stop valve, until fully open.
Confirm supply pressure by observing pressure
gauge.
Close drain valve after ensuring that all residual
water has been completely evacuated.
7.6.6 Remote Operating Valves Function:

The function of various valves such as motor-operated valves
and control valves should be checked in accordance with Table 5
at the control panel and local panel (where applicable) preferably
when the plant is shutdown. Selector switches for remote
operation valves should be selected to Remote or Auto after
checking the functions.

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Table 5: Confirmation of Remote Operated Valves Function
Valve No. Valve Description Check For Initial

Pressure
Raising
Motor Operated Valves
HP ECO vent valve Open-Close Open
LP ECO vent valve Open-Close Open
HP drum continuous blowdown valve Open-Close Part Open
LP drum continuous blowdown valve Open-Close Part Open
HP drum intermittent blowdown valve Open-Close Closed
LP drum intermittent blowdown valve Open-Close Closed
HP-SH1 drain valve Open-Close Closed
HP steam drain valve Open-Close Closed
LP steam drain valve Open-Close Closed
HP start-up vent valve Open-Close Open
LP start-up vent valve Open-Close Open
HP steam stop valve Open-Close Closed
LP steam stop valve Open-Close Closed
HP steam stop valve bypass valve Open-Close Open
LP steam stop valve bypass valve Open-Close Open
HP feed water stop valve Open-Close Open
LP feed water stop valve Open-Close Open
Duty pump
HP BFW pump outlet stop valves Open-Close Open
Duty pump
LP BFW pump outlet stop valves Open-Close Open
Deaerator hot water stop valve Open-Close Open

Deaerator steam stop valve Open-Close Open
Control Valve
HP drum level control Level Auto
control
LP drum level control Level Auto
control
HP steam temperature control Temp. Auto
control
Deaerator level control Level Auto
control
Deaerator steam flow control Level Auto
control
Deaerator hot water pressure control Pressure Auto
control
Condensate recirculation flow control Flow control Auto
Condensate tank level control (Spill Level Auto
over) control

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7.6.7 Closed Cycle Cooling Water System:

Comprises of pumps, CCCW coolers, pipes and valves. The
system must be checked and primed prior to starting the CCCW
pumps.
Table 6: Closed Cycle Cooling Water Feed Procedure
No. Check Point Equipment

No.
16. Confirm the operation of closed cycle cooling water system
Check that cooling water is supplied to the following equipment.
- HP boiler feed water pumps
- LP boiler feed water pumps
- Condensate pumps
- Boiler Water Chemical Sampling cooler
- ST condenser vacuum pump
- STG air cooler
Outlet flow shall be checked through the flow sight glass
provided for each equipment
7.6.8 Check the Valve Open and Close Position for each section:
Table 7: Valve Openings at Initial setting for Cold Start-Up, HRSG pressure
raising and water filling
C: CLOSED O: OPEN S.O: SPECIFIED OPEN POSITION
Function
No. Line Valve number Water From Initial
Filling Setting for
only HRSG
press.
rising
17. Condensate line
Condensate pump suction C->O->C C->O
stop valves
Condensate pump discharge C->O->C C->O
stop valves
Gland steam condenser inlet C->O->C C->O
stop valve
Gland steam condenser C->O->C C->O
outlet stop valve
DEA level C/V inlet stop C->O->C C->O
valves
DEA level C/V outlet stop C->O->C C->O
valve
DEA hot water stop valve C C->O

TechComm Simulation
Function
Filling Setting for
only HRSG
press.
rising
DEA steam stop valve C C->O
Boiler feed water line
HP BFW pump suction stop C->O->C C->O
valves
LP BFW pump suction stop C->O->C C->O
valves
HP BFW pump discharge C->O->C C->O
stop valves
LP BFW pump discharge C->O->C C->O
stop valves
HP boiler water filling stop C->O->C C
valve
LP boiler water filling stop C->O->C C
valve
HP feed water stop valve C->O->C C->O
LP feed water stop valve C->O->C C->O
HP FW C/V inlet stop valve C->O->C C->O
LP FW C/V inlet stop valve C->O->C C->O
H P feed water C/V C->O->C C
LP feed water C/V C->O->C C
HP FW C/V outlet stop valve C->O->C C->O
LP FW C/V outlet stop valve C->O->C C->O
HP DSH injection water stop C C->O
v/v
HP DSH valves C C
Steam drum attachment
HP drum continuous C C->O
blowdown stop valve
LP drum continuous C C->O
blowdown stop valve
HP continuous blowdown C C->S.O
valve
LP continuous blowdown C C->S.O
valve
HP drum intermittent C C->O
blowdown stop valve
LP drum intermittent C C->O

blowdown stop valve
HP drum intermittent C C->O/C
blowdown reg valve
LP drum intermittent C C->O/C
blowdown reg valve
HP drum level gauge drain S.O->C C
valves
LP drum level gauge drain S.O->C C

TechComm Simulation
Function
Filling Setting for
only HRSG
press.
rising
valves
HP drum level gauge vents S.O->C C
LP drum level gauge vents S.O->C C
HP chemical feed stop valve C->O->C C->O
LP chemical feed stop valve C->O->C C->O
H P drum vent valves C->O->C O->C
LP drum vent valves C->O->C O->C
HP drum water sampling C C->O
stop valves
LP drum water sampling C C->O
stop valve
HP steam sampling valves C C->O
LP steam sampling valve C C->O
HP/LP economizer
HP ECO-2 vent valves C->S.O- O->C
>C
H P ECO-1 vent valves C->S.O- O->C
>C
O O->C
LP ECO vent valves C->S.O- C
>C
O O->C
HP ECO-2 & ECO-1 drain C C
valves
LP ECO drain valves C C
HP/LP evaporator
HP EVAP drain valves C C
LP EVA P drain valves C C
HP/LP superheater
HP SH vent valve C C->O->C
HP SH drain valves C C->O->C
LP SH drain valves C C->O->C
HP/LP steam lines
HP steam stop valves C C->O
LP steam stop valves C C->O

TechComm Simulation
7.6.9 Check the Selection Mode of Controllers and Selection Switch
Table 8: Selection Mode of Controllers for Start-Up Operation
No. Item Tag No. selection

18. All motor operated valves Refer to Table 5. Auto
All control valves Refer to Table 5. Auto
7.6.10 Confirm the Completion:

of Ready for Start-Up of Boiler Feed Water Supply Equipment,
Chemical Dosing Equipment and Sampling System.
Table 9: Ready for Start-Up Checks
No. Item Tag No. Status

19. Boiler feed water supply equipment
Condensate tank NWL
Deaerator NWL
HP boiler feed water pumps Ready to Start
LP boiler feed water pumps Ready to Start

Condensate pumps Ready to Start
Chemical dosing equipment Chemical mixing
tanks filled.
Pumps ready to
start
Sampling system Available

TechComm Simulation
8. System Start-Up Instructions

8.1 Procedure for Preliminary water filling and Flushing
This procedure shown in Table 10 will provide a guide to
flushing dirt, grit or other contaminants from HRSG upon initial
HRSG fill. It also may be used as a guideline for refilling HRSG
during maintenance outages or repairs.
SYSTEM HRSG PROCEDURE No 1

PLANT ITEM HRSG and Auxiliaries REVISION: 0
JOB HRSG Preliminary water filling and flushing
STATE OF PLANT Empty and Cold
No ACTION/Description Valve Tag No.

/Verification
20. Confirm the completion of preparation for HRSG start-up
described in Section 7.6
Confirm that all valve openings are set in accordance with
the initial setting of water filling stage of Table 7 of Section
7.6.8
Check the water quality is within acceptable limits Confirm OK with
Chemist
Start make-up pump. (See Note 1)
Open HP/LP water filling stop valves.

Gradually open HP/LP level control valves and increase
boiler feed water flow rate
Close air vent valves for upper headers of condensate pre-
heater and LP and HP economizers when water overflow
from vent valves is confirmed.
If a minimum of 7 barg water pressure is available, flush

the condensate pre-heater and, LP and HP economizers
by opening drain valves until the water runs clear.
Repeat as often as required to clear headers and valves of

construction dirt (Note 2)
Flush HP/LP boiler until water runs clear from the
blowdown valves.
The use of an open drain will permit the boiler operator to

check the water for clarity and also provide a visible
indication that the blowdown valves are completely shut
off.
Continue to fill the boiler until water flows from the drum
vent.
Close the drum vent when no additional air flows from this
line.

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No ACTION/Description Valve Tag No.

/Verification
Flush through HP and LP superheater drain valves in a
similar manner to the HP and LP economizers.
Use caution, if introducing hot condensate in boiler, as the

hot water will flash and may also cause water hammer in
the piping.
Purge the air from the HP and LP superheater through the

vent lines as provided.
Flush the gauge glass and water column valves until each
runs clear and is free of air.
Flush out all pressure gauge and other instrument lines. Instrument
Technician
Drop the HP/LP Drum level to NWL and proceed to
alkaline clean (boiling out) the HP/LP boiler, or drop the
NWL to start-up level.
Stop make-up water pump.
Confirm that the condensate pre-heater inlet and outlet
valves and the HP and LP feed water filing stop valves are
fully closed
Notes:
1) If cold water is not available the boiler feed water may be
used to use hot condensate. However, extra care must be
taken so as not to thermally shock the pipework with hot
water or cause water to flash off into steam. The maximum
temperature differential should be 800C between the water
and the metal of HP/LP drum. This not only prevents
damage to piping, but also maintains acceptable
differential temperature limits across each of the drums
and prevents hogging.
2) Flushing the pipework and valves should not be attempted
unless 7 barg for HP and 3.5 barg for LP are available. The
higher pressure is required to ensure that any dirt trapped
under a drain valve seat to blow clear completely to ensure
the valve will properly reseat.
3) When cold water is used, the complete pressure parts
must be full before significant pressure builds in the
system. Remember that at a head pressure of 20 meter the
indicated pressure at the lower drains without steam or air
pressure is about 2.0 barg.

TechComm Simulation
8.1.1 Start-Up procedure for HRSG

Two start-up situations of HRSG need to be considered. One is
cold start after long term shutdown; the other is hot start after
short term shutdown. Both start-up procedures are basically the
same, except that for a hot start-up the steam vent valves, steam
drain valves and drum vent valves are closed. The cold start
routine is as follows:
1. Confirm the completion of manual preparation prior to

HRSG start-up as stated in Section 2.1.3.
2. Confirm that all valve openings are set in accordance with
the initial setting for HRSG pressure raising stage as
stated in Table 7.
3. Confirm that the cooling water and instrument air systems
are in operation.
SYSTEM HRSG PROCEDURE No

PLANT ITEM HRSG and Auxiliaries REVISION: 0
JOB Start-up procedure
STATE OF PLANT Cold/Hot
Step Action/ Description Tag No./ Checked

Verification
Condensate System
21. Select either Condensate pump 1 or 2 and
open it’s respective suction stop valve
Start selected Condensate pump

Slowly open Condensate pump discharge
stop valve
Open Gland steam condenser inlet stop
valve
Open Gland steam condenser outlet stop
valve
Open DEA level C/V inlet stop valves
Select Condensate tank level control valve to
Auto mode.
Select Condensate recirculation flow control

valve to Auto mode
Select DEA level C/V to Auto mode
Open DEA level C/V outlet stop valve
Select DEA steam pressure control valve to
Auto mode.
Select DEA hot water pressure control valve
to Auto mode
Boiler Feed water system
Open HP BFW pump suction stop valves
Open LP BFW pump suction stop valves

TechComm Simulation
Step Action/ Description Tag No./ Checked

Verification
Start selected HP BFW pump
Start selected LP BFW pump
Open selected HP BFW pump discharge
stop valve
Open selected LP BFW pump discharge stop
valve
Close HP boiler water filling stop valve
Close LP boiler water filling stop valve
Open HP feed water stop valve
Open LP feed water stop valve
Open H P FW C/V inlet stop valve
Open LP FW C/V inlet stop valve
Select HP feed water C/V to Auto mode
Select LP feed water C/V to Auto mode
Open HP FW C/V outlet stop valve
Open LP FW C/V outlet stop valve
Open HP DSH injection water stop valve
Select HP DSH valve to Auto mode
HP & LP Steam drum
Open HP drum continuous blowdown stop
valve
Open LP drum continuous blowdown stop
valve
Select HP continuous blowdown valve to
Auto mode
Select LP continuous blowdown valve to
Auto mode
Open HP drum intermittent blowdown stop
valve
Open LP drum intermittent blowdown stop
valve
Select HP drum intermittent blowdown valve
to Auto mode
Select LP drum intermittent blowdown valve
to Auto mode

TechComm Simulation
9. System Normal Operation

The following sections give the procedures for normal operation
and the precautions to be observed.
Normal operation of the HRSG is conducted in conjunction with
the Gas Turbine and Steam Turbine operating procedures.
The operating philosophy of the GPS HRSG is such that the
HRSG steam output follows the gas turbine. The HRSG has been
designed for the following conditions:
• Continuous operation at maximum steam generating
capability
• Operation in constant pressure mode
In general, HRSGs are much more responsive than conventional
utility boilers, especially during start-up. Being more responsive,
the HRSGs operation must be integrated with the GTG, STG,
and other plant and equipment and their associated operating
limits.
The rapid changes in the HRSG parameters require operators to
be more responsive. They should keep in mind the following
boiler operating criteria.
• Drums being operated at the specified NWL’s.
• HP final steam temperature limits are not exceeded
• Instrumentation, alarms and trips are accurate and level
control is in good working order
• Water Chemistry remains within limits
• Deaerator system is operated at a steady pressure.
Under normal conditions HRSG operation is usually completely
automatic; however individual systems can or may have to be
operated manually.
9.1 Routine Plant Checks

In order to ascertain the current operating condition of HRSG for
any corrective action that may be required it is recommended
that the following items be checked:
1. As a minimum requirement all Control screens associated
with the HRSG should be scanned regularly and any alarm
attended to immediately.
2. Operators must patrol the area related to GTG, HRSG, STG
and ACC at regular intervals to ensure that each
component is operating correctly. Prompt corrective action
must be taken if any abnormality is found.

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3. A record of measured values not ready by the DCS

historian must be taken at regular intervals not only for
the control room instruments but for all other
instruments.
4. These manually prepared records should be maintained for
future reference.
5. All instruments should be regularly checked to ascertain if
they are indicating correctly or not, and adjusted if
necessary (as per manufacturer’s recommendations).
6. Functional tests of standby plant should be conducted
periodically during unit operation to determine the true
standby plant status and availability.
7. Control equipment and protection safety devices shall be
regularly checked as per equipment supplier or ISA
recommendations dictate.
8. Drum water level gauges must be checked for operation
once a day by carrying out a gauge glass blowdown
routine. This involves shutting off the steam and water
supply valves and opening the drain then blowing through
the gauge glass in turn with steam and water before
restoring the level gauges to normal.
9. Each gauge must be watched carefully when load is varied
or low load operation is performed. It is important to take
corrective action promptly in the case of any abnormality.
10. Selection mode of controller and selection switch for
normal operation is shown in Table below:
Table 12: Selection of MOV and Control Valves
No. Item Tag No. Selection

1. All motor operated valves shown in Table Refer to Table 5. Auto
5
All control valves shown in Table 5 Refer to Table 5. Auto
Table 13 is provided as a basic guide for recording routine

measurements at local monitoring points. However, depending
on operating conditions of the HRSG it may be considered
necessary to increase the frequency of monitoring and the
number of points monitored. Each value measured locally
should be compared with the Control Room Control System
measurement.

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Table 13: Measurements to Take During Routine Walkdowns of HRSG Plant
No. Description Tag No. Interval

1. Local Pressure Gauges
Condensate tank Once a shift
Deaerator Once a shift
HP BFP FW outlet Once a shift
LP BFP FW outlet Once a shift
HP Drum Once a shift
LP Drum Once a shift
HP Steam Once a shift
LP Steam Once a shift
2. Local Temperature Gauges
H P steam Once a shift
LP steam Once a shift
Local Level Indicators
Deaerator Once a shift
HP drum gauge – compare immediately Once a shift
with Control Room
LP drum – compare immediately with Once a shift
Control Room
Chemical tanks – confirm details with Once a shift
Chemist
Cooling water flow & temperature for
pumps, sampling system and ST system
to be checked in accordance with each
O&M manual.
11. Early detection of abnormal conditions or problems, and

prompt remedial actions are essential in HRSG operation.
From this point of view, it is essential to carry out
adequate periodical checks on relevant plant and
equipment during HRSG operation as stated in Table 14.
Depending on operating conditions of HRSG, it may be
considered necessary to increase the frequency of the
checks and to carry out checks on more items.

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Table 14: Items to Check During Routine HRSG Walkdowns
No. Item Frequency Notes

2. Boiler proper
1.1 Mass balance of HRSG. Check the Once a day Check with
energy input to energy output balance Performance
considering flow rate of steam, feed Engineer
water, blowdown, etc.
1.2 Drum manholes Leakage Once a shift
1.3 Casing & gas duct hot spots and leakage Once a shift Use a thermal
camera to check
any suspicious
areas
1.4 HRSG framework and supports Once a month
2 Pressure piping
a. Leakage Once a shift
b. Water hammering Once a shift Check for noise
c. Vibration Once a shift
d. Pipe hangers and supports Once a month
3 Safety valve As per
a. Relieving and closing pressure maintenance
b. Leakage schedules
c. Deformation of exhaust piping Once a shift
Once a shift
4 Water level gauge
a. Correct indication Once a day Compare with
b. Leakage Once a shift CCR
c. Transparency of gauge glasses Once a shift
d. Gauge lights working Once a shift
5 Pressure gauges
a. Correct indication Once a shift Compare with
6 Thermometers
a. Correct indication Once a shift Compare with
7 Valves
a. Leakage through gland packing, Once a shift
bonnet or flanges.
b. Passing valves Once a shift Check drain lines
c. Vibration or abnormal sound Once a shift
8 Drain Traps Steam leakage Once a week
9 Control valve
a. Leakage through gland packing, Once a shift
bonnet or flange.
b. Vibration or hammering Once a shift
c. Operating condition Once a shift Freedom of
d. Correct operation Once a month movement
e. Instrument air pressure Once a shift

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No. Item Frequency Notes

10 Local transmitters
a. Leakage through flange or connector at Once a shift Report all
impulse pipe. defects to
b. Leakage through flange or plug Once a shift Instrument
c. Correct function Once a shift Engineer
11 Thermocouples Report all
a. Tightness of flange of terminal box Once a month defects to
cover Once a month Instrument
b. Tightness of terminal Engineer
12 Level switches
a. Tightness of terminal box cover Once a month Report all
b. Tightness of terminal Once a month defects to
c. Correct function Once a month Instrument
Engineer

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10. System Shutdown Instructions

It is assumed that under scheduled shut down conditions that
the STG will be shutdown at the same time, or at least its load
reduced proportional to one HRSG being taken out of service.
The associated GTG would be shutdown accordingly in parallel
with the HRSG.
10.1 Normal Shutdown Requirements

The shutdown of the steam cycle can be initiated through the
following:
• Scheduled Shutdown or Trip of HRSG
• Scheduled Shutdown or Trip of GTG (s)
• Scheduled Shutdown or Trip of Steam Cycle (Steam
turbine or HRSG)
• Shutdown Trip/Failure of the Main Cooling System
• Shutdown Trip/Failure of other Equipment.
Shutdowns can also be scheduled for short periods (a few
hours), for weekends or for long periods.
10.2 Scheduled Shutdown Procedure for Boxing up HRSG

STEP ACTION Tag No. Condition
3. Switch Drum level control from When the feed water
Three element control to single flow ≤ 25% of design
element control flow rate
Stop Chemical dosing pumps Inform Chemist
Select to manual and close HP/LP
steam stop valves
Open HP/LP superheated When HP drum press
steam drain valves ≤ 2barg
When LP drum press

≤ 1barg
continuous blowdown valves.
intermittent blowdown valves.
Close HP/LP boiler feed water
stop valves
Stop HP/LP BFW pumps
It is desirable to maintain HP and Do not ‘top-up’ drum
LP Drum levels at NWL until boiler level if differential
water temperature is ~1000C at < temp is > 800C
1barg

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11. Emergency Shutdown Procedure

In the event that the critical failures develop, operators must
urgently decide either to shut down or decrease GT load by
carrying out the emergency shutdown procedure immediately.
After cooling down of HRSG, confirm the cause of the failure and
repair if necessary.
11.1 Emergency Shutdown Requirements

In order to maintain personnel safety, plant integrity and
minimise plant damage it is vital that all operations personnel
are familiar with the Emergency Shutdown Procedures of the
plant. Any critical incident will require correct and urgent
response. In the event that the critical develop, operators must
urgently decide either to shut down or decrease GT load by
carrying out the emergency shutdown procedure immediately. It
is important that operators are trained to be prepared for such
abnormal conditions.
STEP ACTION Tag No. Condition

4. HRSG trip order ON In the event of critical
(and GT trip order ON) failures
Switch Drum level control from When feed water flow

three element control to single ≤ 25% of design flow
element control. rate
Stop Chemical dosing pumps Inform Chemist
Select to manual and close
HP/LP steam stop valve
Open HP/LP superheated When HP drum press
steam drain valve ≤ 2barg
When LP drum press

≤ 1barg
HP/LP continuous blowdown
valves.
HP/LP intermittent blowdown
valve.
Close HP/LP boiler feed water
stop valves
Stop HP/LP BFW pump

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12. Alarm Responses

Please Note; These are typical alarms for a HRSG and may not
reflect the readings at the Power Station. These readings will
need to be cross-referenced with local plant data.
System Monitored Parameters (Alarm Conditions) Summary.
No Tag No. Description Status Check

5. HP drum water level LL= -750 mm
LP drum water level LL=-500 mm
HP drum pressure HH=97 barg
HP steam temperature H=544 deg C
L=350 deg C
Deaerator Pressure H=3.6 barg
Flue gas temperature at boiler inlet High
Flue gas Pressure at boiler inlet H=+40 mbarG
12.1 Summary of Alarms

12.1.1 Alarm Response # 1
Alarm Title HP/LP Drum Level (high)

Initiating Device Level transmitter/ Level switches.
Set Point H= +100 mm from NWL for HP & LP
Possible Causes 1 Problem with drum level control valve
2 Problem with level transmitter

3 Sudden Increase of load
Consequences 1 High Drum level trip if level is not controlled.
Immediate Action 1 Continue operation, paying attention to the water

level and flow rate indications
2 Open the intermittent blowdown valves
3 Re-adjust the control device, if above 1) and 2)

are not successful
Follow-up Action 1 Check level gauges and compare with remote

indications (to be coincident with above 3))

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Alarm Title HP/LP Drum Level (Low)

Initiating Device Level transmitter/ Level switches.
Set Point L= - 100 mm from NWL for HP & LP
Possible Causes 1 Problem with drum level control valve
2 Problem with level transmitter

3 Sudden decrease of load
4 Feed water line leakage.
Consequences 1 Low Drum level trip if level is not controlled.
Immediate Action 1 Continue operation, paying attention to the water

level and flow rate indications
2 Never rapidly increase the feed water flow but

slowly and steadily.
3 Re-adjust the control device, if above 1) and 2)

are not successful
Follow-up Action 1 Check level gauges and compare with remote

indications
(to be coincident with above 3)
2 Check boiler feed water lines for leakage.
Alarm Title Abnormal HP & LP Drum Pressure (HIGH)

Initiating Device Pressure transmitters
Set Point H = 94.5 barg for HP drum
H=9.4 barg for LP drum.
Possible Causes 1 Problem with steam pressure control device

2 Sudden increase of GTG load or decrease of STG
load.
Consequences 1 High HP/LP drum level trip.
Immediate Action 1 Continue operation paying attention to the steam

pressure.
2 Re-adjust the control device.
Follow-up Action 1 Check local indication and compare with remote

indication

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Alarm Title Abnormal Quality of HP & LP Drum Water
Initiating Device Chemical measurements
Set Point pH less than "L" and more than "H"
(L =9.0, H =10.5) for HP drum
(L = 9.8, H = 10.8) for LP drum
Conductivity more than "H"
HP/LP : (H =I50 μ s/cm)
Possible Causes 1 Incorrect application of Boiler water treatment

2 Insufficient quantity of Continuous Blow Down
HP Blowdown valve: HAD90AA202
LP Blowdown valve: HAD20AA202
Consequences 1 Boiler water pH or conductivity abnormal.
Immediate Action 1 Continue operation paying attention to the boiler

water quality.
2 Check chemical dosing equipment and feed water
quality.
3 Adequate regulation of continuous blow down
Follow-up Action 1 Consult with Chemical Laboratory Staff

Alarm Title Abnormal Low Level of Chemical Tank Solution
Initiating Device Tank level switches low alarm.
Set Point Low level.
Possible Causes 1 Insufficient chemical solution preparation

2 Chemical solution feed line or tank leaking
Consequences 1 Chemicals not available for treatment.
Immediate Action 1 Recharge chemical solution.
Follow-up Action 1 Inspect the chemical solution tank, feed piping and
each valve.

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Alarm Title Abnormal Temperature of HP steam DSH Outlet
Initiating Device Temperature transmitter
Set Point HP steam temperature more than H (H = 544 degC)
HP steam temperature less than L (L =350 degC)
Possible Causes 1 Problem with desuperheater spray water control

device LAE80AA004/05
2 Problem with steam temperature detection device
LBA80CT002
Consequences 1 Steam temp high/low trip.
Immediate Action 1 Continue operation paying attention to the

superheater outlet steam temperature, or deload
the GT
2 Check desuperheater spray water control device

and steam temperature detecting device
Follow-up Action 1 Inspect the desuperheater system.

Alarm Title Abnormal Pressure of Deaerator
Initiating Device Pressure transmitter
Set Point Deaerator pressure more than H
H=3.6 barg
Possible Causes 1 Problem with pressure control device

39LAB01 AA011/021
39LBA20AA003
2 Problem with pressure detection device

39LAA10CP001
Consequences 1 Steam temp high/low trip.
Immediate Action 1 Continue operation paying attention to the

Deaerator pressure and level
Follow-up Action 1 Check pressure control device and pressure

detection device.

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Alarm Title Abnormal Flue Gas Temperature of Boiler Inlet
Initiating Device Temperature Device
Set Point Boiler inlet flue gas temperature more than
design temperature
Possible Causes 1 Problem with Gas Turbine equipment
Consequences 1 Flue gas temp high.
Immediate Action 1 Continue operation paying attention to

superheater inlet gas temperature, or de-load Gas
Turbine
Follow-up Action 1 Check Gas turbine exhaust controls.

Alarm Title Abnormal Pressure of Boiler Inlet Flue Gas
Initiating Device Pressure Transmitter
Set Point Boiler inlet flue gas pressure more than H
(H = +40 mbarG)
Possible Causes 1 Problem with Gas Turbine equipment

2 Problem with stack isolation damper
Consequences 1 Flue gas pressure high.
Immediate Action 1 Continue operation paying attention to Gas

Turbine exhaust gas pressure, or deload Gas
Turbine
Follow-up Action 1 Check Gas turbine equipment and stack dampers.

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12.2 Actions on Non Alarm Faults

12.2.1 Gas Leaking from Ducts or HRSG Casing
This can be caused by metal distortion due to ‘hot’ spot
temperatures, or through natural expansion and contraction of
the metal parts over a number of operating cycles.
Actions:
• Identify source of leakage and conduct repairs as soon as
plant is safely shutdown
• Minimise sudden changes in the GT loads to reduce large
temperature excursions.
12.2.2 Water and Steam Leaks

Leaks can occur at valve spindles, pipe joints, pump body and
flanges located throughout the plant. HP Steam leaks can be of
particular concern as the steam can be invisible. If a leak is
heard but not seen, it will usually be compressed air or HP
Steam. Spindle and flange leaks will deteriorate exponentially as
once the spindle packing or flange gasket is passing, the leak
will continue to get worse. Early detection and repair is preferred
to avoid damage to valve or flange.
Actions:
• For safety, plant should be shutdown to effect repairs
• Protect electrical equipment within the vicinity of any leak
• Place safety barricades around any suspected steam leak
to keep personnel away from the affected area.

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13. Steam Line Blowing

13.1 Introduction
New construction steam line blowing is performed prior to
admitting steam to a turbine consumer and is intended to-clean
the steam line(s) of any loose or foreign materials that would
cause significant damage to the machinery.
Steam blowing should be considered following all major HRSG
pressure parts repairs.
13.2 Safety
It is the responsibility of the persons performing the steam
blowing procedure to ensure that all Safety Procedures, such as
Job Hazard Analysis, are properly followed.
13.3 Steam Blowing Precautions

Prevention of damage to the steam turbine is of primary concern
to the turbine manufacturer and the purchaser. The
responsibility for determining cleanliness criteria and the
effectiveness of the steam blows rests with the steam turbine
manufacturer and/or the purchaser.
After hydrostatic testing and prior to steam line blowing,
manufacturer's representative(s) for safety and safety relief
valves should be contacted for on-site assistance in completing
the installation and de-blocking of the valves.
All HRSG safety systems and functions should be tested and
verified prior to steam line blowing. While steam line blowing is
in progress, all HRSG safety systems are to be operational. No
safety systems are to be bypassed or suppressed.
CAUTION: When steam line blowing is being performed, the
HRSG experiences full operational thermal loads.
Care must be exercised to insure that all pressure
parts are expanding properly.
Care should be exercised in the design, fabrication and
installation of all temporary piping used in the steam blow
procedure. Protective measures should be used to insure that
pressure and temperature operating limits for this piping are not
exceeded.
Since all steam generated in the steam line blowing procedure is
released to the atmosphere, substantial quantities of treated
demineralised water is required. Care should be exercised to

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ensure that sufficient stocks of this water, and all other

necessary chemicals, are readily available.
It is difficult to avoid carry over from the steam drums to the
super-heaters during the steam line blowing operations.
Therefore, boiler water should not be treated with non volatile
chemicals during this process to avoid deposits of solid materials
into the superheaters.
Waterside blow down of the HRSG, at the conclusion of each
day's steam line blowing activities, is required throughout the
steam line blowing procedure. Adhering to this schedule will
greatly reduce water quality problems that can occur on new
boiler installations.
Gas turbine flow must be discontinued during all steam line
blows.
13.4 Steam Blowing Methods

Multiple pressure HRSG's require simultaneous operation of the
boiler sections throughout the steam blows. Personnel are
required to monitor and operate each of the boiler sections.
Temporary piping and silencers are also required for each
section to be operated independently of the others.
There are two basic methods currently in use for performing
steam blows, the pulse method and the continuous method.
The pulse method is performed by running the combustion
turbine at its minimum MW rating and raising the pressure in
the HRSG while the steam outlet valve is closed. When the
pressure reaches approximately 50% of full HRSG operating
pressure, the steam valve is opened, releasing steam to the new
steam lines. As the pressure decays, the steam outlet valve is
closed, raising the HRSG operating pressure. These pressure
pulses should be repeated until the steam lines are determined
to be clean as indicated by target impact testing. The pulse
method is difficult to perform on an HRSG that is not fitted with
a diverter damper. This method can also be detrimental to the
combustion turbine due to erratic drum levels, which can cause
combustion turbine trips as HRSG safety interlocks are
activated.
The continuous method is based upon using high steam
velocities that are attained by operating at the highest allowable
steam temperature, at the lowest attainable steam pressure.
When the unit is stabilised at these operating conditions, the
control desuperheaters are operated to produce rapid steam
temperature fluctuations. With all steam outlet valves in the
wide-open position, the combustion turbine is started. With the

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steam outlet valves open to atmospheric pressure, pressure in

the HRSG will rise to approximately 10% of the normal operating
pressure.
13.5 Operating Procedures

The steam generator is started in the normal manner. All normal
recommendations and limitations with respect to gas turbine
operation, fuel firing equipment, drains and vents, etc. should be
followed, as if the unit was being started for normal operation.
As for any new unit, the steam blowing operation is the first
occasion that it is fired at any significant rate. Consequently, the
start-up as well as the steam line blowing must be conducted
with great care. The unit must be brought up much slower than
normal (one half the normal start-up rate) to allow checking of
all equipment and monitoring of expansion movements. Do not
use the duct burners (if so equipped). The same general
precautions taken on any new unit for this period of operation
apply equally here.
The drum level in the steam drums will be subject to extreme
fluctuations during the blows. As the temporary blow off valve is
opened, the drum level will rise rapidly and may go out of sight
in the gauge glass. As the blow progresses, the drum water level
will reappear and may drop out of sight. Therefore it is important
that the drum level is established at or slightly above normal
operating level before the start of each blow. A small amount of
feedwater flow should be established before the start of each
blow and the feedwater flow should be increased as soon as the
water level drops back in sight, in order to prevent an excessive
low water level.
When the drum pressure reaches the value calculated to
produce the desired blowing flow rate, the blowing process can
be started:
1. Discontinue gas turbine flow and firing of duct burners (if
so equipped). Gradually open the temporary blow off valve,
to blow through the superheaters, main steam line and out
the temporary blow off piping.
CAUTION: The first blow should always be done at
reduced pressure, in order to check out the
temporary piping system, its supports end
anchors.
2. When the drum pressure has dropped to the value
corresponding with a 100øF (56øC) saturated steam
temperature decrease (see Figure 1), close the temporary
blow off valve and re-fire the unit to re-establish blowing
conditions.

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Repeat the above cycle until it is considered that cleaning is

satisfactory as indicated by inspection of impact specimens
during the final blows.
Figure 22: Steam Line Blowing Curve

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14. Pre-Operational Chemical Cleaning Procedures

14.1 Introduction
Immediately before a new HRSG is put into service, the internal
surfaces should be cleaned to remove oil and grease by means of
an alkaline boil-out. For new installations, acid cleaning is not
recommended as a method of cleaning internal surfaces.
If acid cleaning is selected as the method for initial HRSG
cleaning, it should be undertaken only by experienced,
competent personnel. It is strongly recommended that a reliable
chemical cleaning company be contracted for this purpose. In
addition to cleaning the boiler surfaces, the pre-boiler system
must be flushed with a hot alkaline solution to remove oils and
siliceous material.
CAUTION: Do not boil out or acid clean the high pressure
(HP)superheater or the intermediate pressure (JP)
superheater. During either operation, the HP and IP
superheaters should be back filled with
demineralised water.
There are several methods of boiling out a HRSG. The
recommended procedure outlined in this section has been
proven to be successful.
14.2 Pre-Operational Boilout
14.2.1 Preliminary to Boilout

1. To minimise the amount of foreign matter that can be
introduced into the HRSG from the pre-boiler system
following start-up, the pre-boiler system should be alkaline
flushed prior to boil-out.
2. It is good practice, though not a requirement, to remove all
drum internals before boil-out. If drum internals are
removed, inspect and steam clean prior to reinstallation, if
necessary.
3. Mechanically remove as much oil and grease as possible
from the drums before boil-out.
4. All HRSG instrumentation leads exposed to the cleaning
solution should be isolated during the cleaning process.
5. Provisions should be made to utilise demineralised water.
6. The HP and IP superheaters shall be back filled with
demineralised water and are not to be subjected to the
boil-out solution.

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7. Install a temporary gauge glass on each steam drum.

8. Special lines are required from a truck location or remote
chemical pumping station. Provisions should be made for:
a) A DN 80 mm or larger fill line to the acid fill
connections on the HRSG.
b) Drain lines of adequate size to empty the HRSG rapidly,
preferably within 1 hour. The method of disposal must
also be considered.
c) Necessary atmospheric vents.
d) Blowdown valves should be used for sampling
connections and should be appropriately tagged. All
HRSG sections should be sampled independently
utilising the blowdown valves supplied. This is required
to ensure that::
(1) All sections of the HRSG are being properly
cleaned.
(2) All sections of the HRSG are being properly flushed
and neutralised.
9. All pressure parts must be carefully inspected for
obstructions and the necessary hydrostatic tests made.
Internal chemical feed lines should be checked to be
certain that they are free and clear.
10. It is important that the operators on duty during the boil-
out operation are familiar with normal operating
procedures and precautions. The normal HRSG trip
interlocks should be in operation and functioning properly.
The HRSG auxiliaries and the special cleaning equipment
should be in good operating condition.
11. Before introducing the cleaning solution into the HRSG,
particular care should be taken to eliminate possible leaks,
and adequate precautions should be taken to protect
personnel in the event of leaks occurring.
14.3 Boil-out Procedures

1. A boil-out is normally performed to remove oil or
preservatives, and requires the use of a fairly strong
caustic solution. The HRSG should be filled to normal
operating level with the boil-out solution. The
recommended boil-out solution is:
4.00 kg of sodium carbonate (Na2CO3) per 1000 kg (1 m3)
of water
and

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4.00 kg of Trisodium Phosphate (Na3PO4) per 1000 kg (1

m3) of water
and
detergent (0.05 to 0.1% by volume)
CAUTION: Use of most commercial detergents at

concentrations in excess of 0.1% by volume
during boil-out may cause foaming and carry-
over of alkaline solution to the superheaters.
Since commercial detergents vary in strength
(i.e. water diluted) check with the
manufacturer if recommended use strengths
arc-higher then 0.1%.
Other formulations and combinations of chemicals can be
satisfactorily employed for boil-out, and in cases where
pollution control requirements dictate, changes in
formulation can be made. Changes should, however, be
reviewed by ABB Power Generation for suitability prior to
use.
2. The solution is added to the HRSG via the steam drum
manholes (LP, IP and HP sections). Fill the drum to
approximately the bottom edge of the drum door. Dissolve
the chemicals in a suitable container with hot water and
then slowly transfer the solution to the drum. Proceed
slowly to allow time for dispersion. Chemicals should be
added at both ends of the drum if practical.
3. After the boil-out solution has been added, close the drum
doors (with temporary gaskets). Continue filling the boiler
and confirm the drum level in the temporary water gauge
glass. Prepare for start-up (refer to Unit Operating
Procedures section of this manual). Apply heat slowly,
bringing the pressure in the HP section of the HRSG to
between 700 and 1400 kPa within 8 hours. The IP and LP
sections will balance out at approximately 200 to 350kPa.
Hold the pressure for 4 hours. The water level in the steam
drums will rise during this period, however, blowdown
should be restricted only to what is necessary to keep the
water level from going out of sight in the temporary gauge
glasses. A high water level should be maintained during
the boil-out process. The gas turbine, controls, vents,
drains, etc, should be operated as during normal start-up.
4. After 4 hours, secure the heat source and allow the HRSG
pressure to decrease. After the pressure in the HP
superheater has dropped noticeably, at least 500 kPa,
restore the water level to normal operating level by means

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of blowdown. Blowdown the HRSG using the blowdown

valves supplied, operating them in sequence. Do not allow
the water level to go out of sight in the gauge glasses.
5. Reapply heat, raise the pressure to between 700 to 1400
kPa in the HP section and hold for 4 hours. At the end of
the 4-hour period, repeat step 4.
6. Repeat step 5 two more times.
7. A boil-out solution sample should be obtained periodically
and should be analysed for alkalinity, phosphate, and the
presence of oil. All HRSG sections should be sampled
independently to ensure that all sections are being
properly cleaned. If the water alkalinity and phosphate
concentrations have dropped to 1/2 the original values,
additional boil-out chemical should be added to restore the
original concentrations. Although quantitative de-
terminations are preferable, qualitative checks for the
presence of oil will be highly satisfactory for monitoring
and control purposes.
8. When analysis of the samples show that alkalinity,
phosphate and dissolved silica have reached equilibrium
levels and oil is no longer detected in samples, the heat
source should be shutdown.
9. When the steam pressure drops to 175 kPa, the drum
vents and superheater header drains should be opened
wide. This will occur for the HP, IP and LP (without
superheater drains) sections.
10. Following the complete draining of the boil-out solution,
the HRSG should be filled to the top of the gauge glasses
with clear rinse water heated to 80øC. While the HRSG is
being filled for the boil-out rinse, back fill the HP and IP
superheaters through the outlet headers with
demineralised water until water spills over into the steam
drums. Leave the rinse water in the HRSG until it has
sufficiently cooled to allow internal inspection. Drain the
HRSG.
CAUTION: The use of fill water treated with solid chemicals
should be avoided. Deposits of solid materials
in superheaters can be detrimental from heat
transfer and corrosion standpoints. Fill water
quality should be verified immediately prior to
its introductions into the superheater circuits.
A demineralised water supply is recommended.
11. If the internal inspection of the HRSG indicates
unsatisfactory cleaning, the boil-out procedure should be
repeated.

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12. If immediate operation of the HRSG is not anticipated

upon completion of the boil-out, the HRSG should be laid
up using the procedure given below.
14.4 Post Boil-out Lay-up

If the operation of the HRSG is delayed for more than 1 or 2 days
after boil-out, lay-up can be accomplished by the following
method:
1. Through normal filling connections, fill the HRSG with
demineralised water containing approximately 200 ppm of
hydrazine (N2H4) and sufficient ammonia (NH3)
(approximately 10 ppm) to raise the pH to 10.
2. The HP and IP superheaters should be filled through their
outlets with demineralised water containing the same
solution as the rest of the HRSG. When the demineralised
water solution overflows from the superheaters into the
steam drums, the filling of the superheaters can be
secured.
3. Introduce nitrogen through the superheater drains.
Maintain a total pressure of 35 kPa with nitrogen.
14.5 Preparations for Putting the HRSG into Service Following Boil-
out
14.5.1 Prior to Initial HRSG Operation:
1. Refill the superheaters with demineralised water. Drain
and test each superheater header individually to ensure
that no chemicals have been inadvertently left in the
superheaters. If required, flush the superheaters until
satisfactory test results are achieved.
2. Inspect the steam drums.
a) Blow out the internal gauge glass connections and
instrument leads. Remove temporary gauge glasses and
install permanent gauge glasses.
b) Blow out chemical feed and continuous blowdown
piping.
c) Flush out any loose sediment from drum surfaces and
steam separators. Flush with clear water from the
drums, draining through the blowdown connections at
the bottom of the HRSG.

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3. When all internal surfaces are clean, reinstall drum

internals if they were removed. Inspect and clean steam
drum internals if required prior to installation.
4. Remove all temporary piping and/or valves used for the
boil-out process.
5. When all work is completed, a thorough inspection should
be made to ensure that no foreign material has been left in
the drums.
6. Fill the HRSG. Apply a hydrostatic test at normal operating
pressure. Refer to Hydrostatic Testing Procedures provided
elsewhere in this manual. If the HRSG is not to be placed
into operation, refer to recommended HRSG lay up
procedures. If the HRSG is to be placed into operation
continue with step 7.
7. Reduce the water level in the steam drums to the
suggested operating level.
8. Drain the superheaters.
The HRSG is now ready for operation.
14.6 Operational Acid Cleaning

14.6.1 Introduction
Periodically during the operating life of any steam generator,
chemical cleaning is recommended for the removal of iron oxide,
copper, water formed and other deposits that may have
accumulated on steam generating surfaces. The frequency of
operational cleaning is dependent upon a number of operating
conditions. However, cleaning every 3 years appears to be a
common and suitable period. This schedule should be altered
for units that are subjected to intermittent operation or in cases
of system upsets, such as condenser leakage, when feedwater
contamination is greater than normal. In cases of tube failures
caused by excessive deposits, chemical cleaning is one of the
steps to be taken to return the unit to a sound operating
condition.
Additives included in the acid cleaning solution facilitate the
removal of specific materials, such as copper and silica, which
may be present in the deposit. The choice of additives should be
based on the materials contained in deposits, and these should
be determined prior to cleaning. If unusual or difficult to remove
deposits are encountered, it may be necessary to use multi-step
cleaning with special solvents to completely remove scale. It is
recommended that one of the reliable chemical cleaning
contractors be contacted for operational cleaning. These

TechComm Simulation
companies have the experience and technical know-how to

properly formulate a cleaning mixture to re-move undesired
materials.
14.6.2 Acid Cleaning Procedures

CAUTIONS:
Acid cleaning should only be performed by experienced
personnel who will provide the appropriate procedures.
The initial clean out should be accomplished by means of a boil-
out.

TechComm Simulation
15. Valves
15.1 Introduction
Commissioning procedures particular to the Island Co-
generation Project are provided in this chapter. Detailed
procedures are also provided for hydrostatic testing and steam
line blowing as separate chapters due to the complexity of these
items.
15.2 Pneumatic valves

15.2.1 General
Pneumatically actuated valves are provided in the intermittent
blow-off, start up vents and drain systems. Commissioning is
required to set the opening time of each valve as given below.
Adjust the speed controller and lock in position (locknut or
thread adhesive). Observe the operation of the valves during hot
commissioning to verify acceptable action.
15.2.2 Blowoff Valves

The intermittent blowoff system consists of a manual `y`-globe
valve and actuated angle valve at the HP, IP and LP evaporators.
The intermittent blowoff actuated valves require an opening time
of 10 to 20seconds.
15.2.3 Start Up Vent Valves

Start up vents are provided at the HP and IP superheater outlet
pipes and the LP saturated steam line and consist of a manual
globe valve and an actuated ball valve. The actuated start up
vent valves require an opening time of 5 to 10 seconds.
15.2.4 Drain valves

Pneumatically actuated drains are provided at the HP steam pipe
HP superheaters, HP evaporator, IP steam pipe IP evaporator
and LP evaporator The drains require an opening time of 5 to 10
seconds.

TechComm Simulation
16. Table of Figures

Figure 1: Elementary Diagram of a Combined Cycle Plant.......................................................... 8
Figure 2: HSRG Fitted with HP, IP and LP Steam Sections ........................................................ 9
Figure 3: GT Exhaust inlet and HRSG Exhaust outlet ............................................................... 11
Figure 4: Typical HRSG Arrangement........................................................................................ 12
Figure 5: Conduction of heat along metal rod ............................................................................ 15
Figure 6: Typical Finned Water Tube Arrangement ................................................................... 16
Figure 7: Wet Steam .................................................................................................................. 17
Figure 8: Dry Saturated Steam................................................................................................... 18
Figure 9: Simple Diagram of Natural Circulation ........................................................................ 20
Figure 10: Section of HRSG Showing External Area of Economiser ......................................... 27
Figure 11: Economiser Drains.................................................................................................... 28
Figure 12: HRSG HP Drum ........................................................................................................ 29
Figure 13: LP Drum .................................................................................................................... 29
Figure 14: Drum Safety Valves .................................................................................................. 30
Figure 15: Drum Level Control Valves ....................................................................................... 32
Figure 16: Cyclone Separator Internals...................................................................................... 33
Figure 17: Steam Drum Internal ................................................................................................. 33
Figure 18: HRSG Drum Blowdown Vessel................................................................................. 34
Figure 19: HP Drum showing downcomer pipes ........................................................................ 36
Figure 20: Typical Direct Spray Attemperator ............................................................................ 39
Figure 21: GT load and Steam Pressure.................................................................................... 41

TechComm Simulation
17. Table of Tables

Table 1: Typical Economiser Pressures & Temperatures .......................................................... 29
Table 2: Steam Table Example .................................................................................................. 35
Table 3: Typical Evaporator Pressure & Temperatures ............................................................. 37
Table 4: Typical Evaporator Pressure & Temperatures ............................................................. 40

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What is the purpose of the HRSG training manual?

What is the purpose of the HRSG training manual?

What are the major components of an HRSG?

What are the major components of an HRSG?

Heat Recovery Steam Generator (HRSG)

HRSG Manual Version (1) February 2009 Page 2 of 91

HRSG Manual Version (1) February 2009 Page 3 of 91

4.4.1 Detailed Description 37

HRSG Manual Version (1) February 2009 Page 4 of 91

12.1.7 Alarm Response # 7 75

HRSG Manual Version (1) February 2009 Page 5 of 91

would reduce the quantity available for power generation.

HRSG Manual Version (1) February 2009 Page 7 of 91

Compressor Turbine Turbine

Figure 1: Elementary Diagram of a Combined Cycle Plant

In Figure 2 an intermediate section and low pressure section

Figure 2: HSRG Fitted with HP, IP and LP Steam Sections

1.1 System Overview

HRSG Manual Version (1) June 2008 Page 9 of 91

Exhaust gas from the GT is directed to the HRSG by the inlet

HRSG Manual Version (1) June 2008 Page 10 of 91

Figure 3: GT Exhaust inlet and HRSG Exhaust outlet

1.2 HRSG Design Considerations

HRSG Manual Version (1) June 2008 Page 11 of 91

Hot Gas from Gas

Temperature Gradient across HRSG

Figure 4: Typical HRSG Arrangement

HRSG Manual Version (1) June 2008 Page 12 of 91

1.2.1 GT Exhaust Gas Design Data

The HRSG is designed for "Zero Leakage" or gas tight enclosure

HRSG Manual Version (1) June 2008 Page 13 of 91

1.3 Heat Energy Transfer

The principal is best illustrated by the light given off by the

HRSG Manual Version (1) June 2008 Page 14 of 91

its thermal conductivity. Metals are very good conductors of heat,

Figure 5: Conduction of heat along metal rod

There is some remnant conduction heat transfer taking place

HRSG Manual Version (1) June 2008 Page 15 of 91

(635mm) of water column. The extended surface used in the

Water tube wall

Figure 6: Typical Finned Water Tube Arrangement

HRSG Manual Version (1) June 2008 Page 16 of 91

1.4 Properties of Steam

1.4.1 Wet Steam

Figure 7: Wet Steam

1.4.2 Dry Saturated Steam

HRSG Manual Version (1) June 2008 Page 17 of 91

Stream of invisible dry

Figure 8: Dry Saturated Steam

1.4.3 Superheated Steam

1.4.4 Reason for Superheating Steam

HRSG Manual Version (1) June 2008 Page 18 of 91

1.5 Water/Steam Characteristics

1.5.2 Shrink & Swell

HRSG Manual Version (1) June 2008 Page 19 of 91

1.5.3 Natural Circulation

Feed water Steam

Figure 9: Simple Diagram of Natural Circulation

1.6 Feedwater and Boiler Water Treatment