2.3 Feedwater, Boiler Water and Steam System

Asiakirjan nimi - Name of Document Tunniste - Identification Rev.
PROCESS DESCRIPTION CFBT-582-1 1

2.3 FEEDWATER, BOILER WATER
AND STEAM
Osasto - Department Kohde - Subject Sivu - Page
Power Generation RAPP PB3 PROJECT 1 (71)

Systems CFB MULTIFUEL BOILER
TABLE OF CONTENTS
2. PROCESS DESCRIPTION............................................................................ 3
2.3 Feedwater, Boiler Water and Steam System ............................................. 3
2.3.1 Purpose of the system ................................................................................ 4
2.3.2 General description of the system............................................................. 6
2.3.3 Design criteria.............................................................................................. 8
2.3.3.1 Feed water System........................................................................................ 8

2.3.3.2 Boiler Water and Steam System.................................................................. 14
2.3.4 Equipment specification ........................................................................... 30
2.3.4.1 Deaerator .................................................................................................... 30

2.3.4.2 Feedwater Storage Tank ............................................................................. 31
2.3.4.3 Chemical dosing units ................................................................................. 34
2.3.4.4 Steam coil primary air preheater condensate tank ...................................... 36
2.3.4.5 Condensate pump ....................................................................................... 37
2.3.4.6 Feedwater pumps (not in scope) ................................................................. 38
2.3.4.7 Economizers................................................................................................ 39
2.3.4.8 Steam drum ................................................................................................. 42
2.3.4.9 Furnace ....................................................................................................... 44
2.3.4.10 Cyclones and Loop Seals ............................................................................ 47
1 2005 - 08 - 30 T. Anttonen
0 2005 - 02 - 11 T. Anttonen
Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
KLY-1 1997-05 P:\582-RAPP-PB3\int\Kayttoonotto\koulutus\Training Manuals\Folder 1\2.3 Feedwater, boiler water and s

This document is the exclusive intellectual property of Kvaerner Power Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other
project or purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Power Oy.
© Kvaerner Power Oy, Tampere, Finland 2005


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2.3.4.11 Superheaters ............................................................................................... 52

2.3.4.12 Continuous blowdown tank.......................................................................... 64
2.3.4.13 Blowdown Tank ........................................................................................... 66
2.3.4.14 Sample station............................................................................................. 68


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2. PROCESS DESCRIPTION
2.3 Feedwater, Boiler Water and Steam System


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Flowsheets: T582-00007 Feedwater tank

T582-00008 Feedwater pumps
T582-00009 Economizers
T582-00010 Drum and furnace walls
T582-00011 Second pass walls, primary and
secondary superheaters
T582-00012 Tertiary superheater and main
steam pipe
T582-00014 Blowdown system
T582-00015 Chemical station
T582-00016 Sample station
T582-00020 Steam coil air preheater
2.3.1 Purpose of the system
The purpose of the feed water system is to

• transfer condensate and make-up water to the feed water
tank
• heat and store the amount of feed water needed for the boiler
• transfer the feed water to the boiler while it is in operation.
The thermal removal of oxygen and the feed of volatile chemical

for binding O2 are carried out in the feed water tank. Steam and
water alkalizing chemicals are added after the feed water tank.


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The purpose of the equipment in the water circulation of the

boiler is to:
• heat and vaporize water on the heat surfaces of the boiler at
required capacity
• operate in the water-steam circulation of the boiler as a
separator between the steam generator and the superheater
(drum)
• recover the residual heat of flue gas in the economizer
The purpose of the boiler steam circuit is to

• produce the required amount of superheated steam so that
the steam temperature and pressure correspond to the set
values
The purpose of the sampling system is to

• cool water and steam samples before analyzing
• analyze and control the quality of water and steam in the
boiler circulation.


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2.3.2 General description of the system
The feed water system consists of:

• deaerator (283T001)
• feed water tank with accessories (283T001)
• air preheater condensate tank (283T010) including transfer
pump (283P010)
• feed water pumps with accessories (not in scope) (283P001,
283P002, 283P003, 283P018)
• piping with valves of the above mentioned equipment up to
the economizer (283E002, 283E003, 283E004) of the boiler
• chemical dosing tanks (283T007, 283T008, 283T009) and
dosing pumps (283P004, 283P005, 283P006, 283P007,
283P008, 283P009)
The water and steam system of the boiler consists of:

• economizers (283E002, 283E003, 283E004)
• drum (283T002) with cyclones and droplet separators in order
to separate water and steam
• steam generator (furnace (283E065) and cyclone separators
(283E066, 283E067, 283E068))
• downcomers and circulating pipes
• vent and drain pipes with accessories
• blowdown tank (283T005)
• continuous blow down tank (283T004)
• primary superheater (283E006)
• secondary superheater (283E009)
• tertiary superheater (283E012)
• steam attemperators (283E007, 283E008, 283E010,
283E011)


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• connecting pipes
• safety valves for the superheater and drum
• sampling station for feed water, boiler water and steam
analyzing


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2.3.3 Design criteria
2.3.3.1 Feed water System
Condensate water from the mill processes and turbine is

introduced to the condensate collecting tank (not in scope).
From the condensate tank water is pumped to the deaerator.


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Make-up water from the demineralization plant and the

condensated water from the primary air steam preheater
condensate tank (283T010) are also led to the deaerator. From
the upper part of the condensate tank, expansion steam is led to
open air.
In the dearator most of oxygen dissolved in condensate and

make-up water is removed. Feed water tank serves as feed
water storage having about 15 minutes storing capacity when
boiler is operated at MCR load.
The deaerator is integrated to the feed water tank (283T001) so

that the water is first sprayed in a part of the steam space(pre-
deaeration) and then in the second stage the steam is injected
to the water (final deaeration). During start-up water is heated to
the temperature of about 130 oC by leading low pressure steam
below the water level of the feed water tank through a perforated
pipe and by distributing the steam evenly over the whole length
of the feed water tank.
From the feed water tank (283T001) water is pumped by direct

drive feed water pumps (283P001, 283P002, 283P003,
283P018) (not in scope) to the boiler. These feed water pumps
raise the feed water to the required pressure level. Normally
three parallel feed water pumps are in operation while the fourth
one is stand-by.


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Chemical dosing
Chemical dosing stations includes own tanks for:
• oxygen scavenger (283T007)

• pH control chemical (amine) (283T009)
• phosphate (283T008)
The dosing tanks are used for preparation of chemical solutions

and all tank connections are of gas tight design. In preparation of
dosing solutions make-up water is used. System is equipped
with necessary ejectors (283K001) for solution preparation and
venting fan, which removes harmful vent gases to safe location.
Each tank is furnished with two parallel dosing pumps of which

one is in operation and the other ones are stand-by. Pumps
used for oxygen scavenger (283P004, 283P005) and pH control
chemical dosing (283P008, 283P009) are diaphragm type
pumps and pumps for phosphate dosing (283P006, 283P007)
piston type pumps.
Note: Pay special attention to occupational safety when

working with dosing chemicals and follow
separate instructions of the chemical supplier /
manufacturer.


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Feedwater quality
Since steam temperature control is carried out by direct

feedwater spraying to steam, feedwater quality need to be high
to maintain steam purity.
Required feedwater quality is as follows:

pH-25 8,8-9,2
Oxygen, max mg/kg 0,01
Hardness, max ppb 3
Total iron, max mg/kg 0,02
Copper, max mg/kg 0,003
Silica, max mg/kg 0,02
Na+K,max mg/kg 0,01
Oil + sludge + foaming substances mg/kg 0,0
Cation conductivity at 25 ºC, max µS/cm 0,2
Proper demineralized water and condensate treatment plant is

the basis to meet feedwater quality requirement. Additional
feedwater processing is carried out by degasification in the
deaerator (283T001) and by chemical dosing.
In the deaerator the water is divided into droplets by means of a

sprayer, which is regulated according to the volume of water to
be sprayed. The droplet size remains constant at different
throughputs. The droplets are passed through the steam
compartment of the sprayer at high velocity and then impinge on
the slash plates of this compartment, which causes the droplets
to break up into even smaller droplets. The residence time of the
water in the compartment is a few tenths of a second.


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Picture 1. Principal picture of deaeration
As the droplets travel through the hotter steam, condensation

occurs at the surface of the droplet, as a result of which the
water is warmed up. This heating process proceeds very rapidly
owing to the favourable ratio of contact surface to water volume.


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Constant replacement of the steam ensures that the partial gas

pressure remains very low with respect to the gas content of the
water. This low partial pressure and the reduced solubility owing
to the temperature rise compel the gas to leave the water.
The gas that has remained behind is driven off by conducting

steam through the water by means of a steam charcing device.
Also oxygen scavenger is dosed to the deaerator to decrease

O2-level to required level. This chemical removes the residual
oxygen by reacting with it.
Volatile alkali is dosed into the feedwater tank (283T001) to

control the alkalinity of the steam.
Phosphate (di- or trisodiumphosphate or corresponding

ammonium phosphates) is dosed automatically into the
feedwater line to the boiler after feed water control valve group.
The function of the phosphates in the boiler water is twofold:
• As an unvolatile alkali, phosphate alkalizes the boiler water.

• Phosphate reacts with residual hardness, i.e. Mg++ and Ca++
salts, flocculating magnesium and calcium phosphates, which
are removed by continuous blowdown.


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2.3.3.2 Boiler Water and Steam System
The purpose has been to create a water-steam system with

reliable operating water circulation.
Boiler design basis data:

• maximum continuous rating of the boiler with 650 t/h
design coal firing
• main steam data after the superheaters
- temperature 540 °C
- pressure 142 bar(a)
• feed water temperature in feedwater tank 130 °C
General operation description of the equipment in the water

circulation:
Economizer (283E002 (1), 283E003 (2), 283E004 (3))
The purpose of the economizer is to recover the thermal energy

of flue gas by the means of counter flow principle.
The economizer sections are located in the 2nd (section 3) and in

the 3rd (sections 1 and 2) pass. Economizer sections 1
(283E002) and 2 (283E003) are manufactured of finned tubes
and section 3 (283E004) is made of plain tubes. The advantage
of the finned tube construction is the effective heat transfer ability
and space utilization. In economizer sections the water rises
upwards, i.e. counterflow to the flue gas, and the economizers
are connected in series so that the feedwater enters the lowest
economizer section (eco 1) and comes out from the highest
section (eco 3).


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Picture 2. The structure of the finned tube economizer

(283E004)
From the economizers the feedwater is introduced to the drum

(283T002) of the boiler.
Drum (283T002)
The purpose of the drum is to operate in the natural circulation

boiler as a separator in the water-steam circulation of the boiler
between the steam generator and the superheater.
The internal accessories of the drum consist for instance of the

feedwater distribution pipe, the steam drying equipment including
cyclones and lamella droplet separators.


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Feedwater enters the drum from the both ends of the vessel and
distribution pipe is located in the lower section of the drum. The
cyclones stand in two lines on opposite walls of the drum. The
droplet separators are in the upper section of the drum.
In boilers with natural circulation the circulation of water and

steam/water mixture is based on the change of specific density,
i.e. the heavier steamless water column in the downcomers
presses the lighter steam/water mixture from the steam
generating pipes to the drum.
The feedwater is fed through its own cyclones to the bottom of

the drum where it is distributed by the means of a perforated
distribution pipe at the bottom through the whole length of the
drum. In the drum the feedwater is mixed with the boiler water.
Through the downcomers originating from the bottom of the

drum the boiler water is introduced to the steam generators
(furnace and cyclone separators). The furnace (283E065) and
the cyclones (283E066, 283E067, 283E068) have separate
downcomers and circulation pipes and thus they form separate
circulation loops. The steam/water mixture coming from steam
generating sections is introduced through upper circulation tubes
back to the drum. In the drum the mixture is introduced to the
cyclones where the steam is separated from the water. Above
each cyclone there is a droplet separator so that the upwards
rising steam has to go through it, at the same time being cleaned
from residual drops. In the cyclones the water is separated to the
perimeter and falls down through the bottom back to the
circulating water.


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The steam coming out from the drum flows still through the so-
called lamella droplet separator so when saturated steam gets
into the steam pipes it is dry and clean.
Furnace (283E065)
The size of the furnace is determined by the design fuels and the
required evaporation capability. The heat released in the furnace
is transferred effectively by the means of radiation heat transfer
and particle convection to the furnace wall tubes.
Picture 3. The structure of the lower circulation pipes
Proper water circulation in the furnace walls is ensured by using

a sufficient amount of downcomers, circulating pipes and supply
and collection headers. The water circulation in the steam
generator is carried out by natural circulation.


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By downcomers (5 pcs) originating from the drum (283T002),

the water is introduced to the level of the lower section of the
furnace. Distribution headers of the furnace are fed through
supply pipes originating from lower part of the downcomers. The
furnace bottom forms a fluidized combustion grate which is also
fully water cooled since it is used to provide water to the rear
wall distribution header.
The furnace wall pipes form a so-called generating section where

part of the water is evaporated. Furnace walls are made of gas
tight membrane construction.
Picture 4. The structure of the upper circulation pipes


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Picture 5. The pressure vessel side view
From the collection headers of each wall section the water/steam

mixture is introduced by the upper circulation pipes (raiser pipes)
back to the drum (283T002).


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The furnace is equipped with tight inspection doors in order to

monitor the burners (from 283E059 to 283E064), grate and
furnace. For the maintenance and repair of the furnace and heat
transfer surfaces the boiler is equipped with tightly closed access
doors.
Picture 6. The pressure vessel top view


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Cyclone separators (283E066, 283E067, 283E068) and loop

seals (283E079, 283E080, 283E081)
The size of the cyclones is determined by produced flue gas

amount and the required dust separation efficiency. The heat
released in the cyclones and loop seals is transferred by particle
convection to the refractory layer protecting wall tubes. Gas tight
cyclone and loop seal walls are same type of membrane
construction as furnace walls.
By downcomers (2 pcs) originating from the drum (283T002), the

water is introduced through supply pipes to distribution headers
of the loop seals. After flowing through loop seal tubes
water/steam mixture enters to wall tubes of the cyclones. In
upper parts of the cyclones water/steam mixture is collected to
round shaped collection headers and then led through upper
circulating pipes (risers) back to the steam drum.
Since cyclones and loop seals are totally refractory covered only
little heat is transferred to those evaporation surfaces. Most of
evaporation takes place in the furnace wall tubes.
Superheaters (283E006 prim, 283E009 sec, 283E012 tert)
The purpose of the superheater section is to achieve a steam

temperature of 540 °C after the superheaters.


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Picture 7. The structure of the secondary superheater

(283E009)
The superheater has been divided into three stages. The first
stage (primary superheater) is a convective type superheater
(located in the 2nd pass), the second stage (secondary
superheater) is a radiant type superheater (located inside the
furnace) and the third stage (tertiary superheater) again a
convective type superheater (located in upper part of the 2nd
pass).


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From the drum the saturated steam is introduced by connection

pipes (saturated steam pipes) to the 2nd pass front wall
distribution header. Second pass walls, roof and load carrying
tubes (supporting tubes for heat transfer bundles in the 2nd
pass) are the first part of the primary superheater. Steam flows
first downwards in front wall tubes and is then divided to side
wall tubes and to first row of load carrying tubes. Steam which
has flown upwards through side walls is collected to upper
headers of the side walls and then led through connection pipes
to 2nd pass roof distribution header. Steam then flows
downwards through second pass roof and rear wall tubes to rear
wall collection header. To this same header is collected steam
from load carrying tubes after it has flown the second row of
carrying tubes. From the second pass rear wall collection header
steam flows through connection pipes to the actual primary
superheater sections.
The actual primary superheater sections (2 pcs) are located in

the middle part of the 2nd pass. In the superheater tubes the
steam flows counterflow to the flue gas. The primary
superheater sections are supported from the above mentioned
load carrying tubes.
From the collection header of the primary superheater the steam

is introduced to two parallel steam attemperators (283E007,
283E008). Attemperator is divided to parallel units because then
it is easier to control temperature across the wide superheater.
The purpose of the first stage steam attemperators is to keep
steam temperature after the secondary superheater on the
required level.


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The steam attemperators (283E007, 283E008) are so-called

spraying attemperator where the feedwater is injected into the
steam. While being vaporized and superheated it binds the heat
whereupon the temperature of the steam leaving the
attemperators falls. The spraying attemperator consists of a
spraying chamber, a spraying nozzle and an internal venturi
tube.
The vertical secondary superheater is located in the upper part

of the furnace (283E065), near the furnace front wall. It is a
radiant type superheater that operates on a so called parallel-
flow principle, where steam is led to superheater lower part
header and steam then flows upwards to collection headers of
the superheater elements located above the furnace roof.
From the collection header of the secondary superheater the

steam is introduced to the second attemperator stage (283E010,
283E011). Also this attemperator is divided into two parallel
spray chambers located on both sides of the boiler and in these
units steam temperature is controlled to correspond required
temperature after the tertiary superheater section.
From the second stage attemperators (283E010, 283E011)

steam flows to the tertiary superheater sections located in the
upper part of the second pass. Tertiary superheater consists of
two sections and is convective type superheater where steam
flows counterflow to flue gas flow. From the final superheater
collection header steam is lead to the steam turbine.


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Continuous blow down
Since small amounts of unvolatile matters (salts) enter the boiler

continuously with feedwater, these are enriched in water and the
quality of boilerwater and steam becomes poor. To eliminate this
problem, continuous blowdown from the drum (283T002) is taken
out all the time (normally about 0.5 – 1,0 % of the steam output).


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The blowdown water is introduced to the continuous blowdown

tank (283T004) where part of water evaporates due to lower
pressure. Flash steam (or expansion steam) generated in
continuous blowdown tank is led to feedwater tank (283T001)
and condensate flows to blowdown tank (283T005) where it is
cooled and finally led to sewer.
The flashed water vapor from the blowdown tank (283T005) is

vented to atmosphere via vent steam pipe to roof and water is
lead to sewer.
Boiler water and steam quality
Blowing continuously small amount of water out and dosing

chemicals to feedwater the quality of boiler water can be kept
within correct limits and prevent also unnecessary foaming in the
drum. Proper boiler water quality is the key factor to keep the
inner surfaces of the superheater tubes and steam turbine
blades clean. Deposits inside the superheter tubes form a heat
insulating layer, which can lead to tube material overheating and
even to tube failure.
The quality of water in the boiler circulation is controlled by

samples taken from the continuous blow down line or from a
downcomer. Steam quality is monitored by taking samples from
the saturated steam and from the main steam.
Required boiler water quality depends mainly on the boiler

operation pressure, since in higher pressures some of the
harmful impurities are partly dissolved to steam. This leads to
stricter boiler water requirement in high pressure boilers.


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Boiler water quality to meet steam purity shall be as follows:

pH-25 9,2 – 9,7
Iron, max mg/kg 0,5
o
Conductivity at 25 C (after neutralization) µS/cm < 40
(Na+K) mg/kg <8
SiO2 content mg/kg < 0,35
PO4 content mg/kg 2 -– 6
TDS mg/kg < 0,2
Purity of superheated steam shall be:

Na + K mg/kg < 0,01
SiO2 mg/kg < 0,02
Fe mg/kg < 0,02
Cu mg/kg < 0,003
Drain and vent system
Vents are supplied for the purpose of venting the boiler during
start-up and shutdown. High pressure part vents are piped to the
common collection funnel (283T003) to where vent valves are
also gathered.
Air and vent steam are then led to the blowdown tank (283T005)
vent pipe. Also water coming to funnel with vents is drained to
that same vent pipe. All high pressure part vent and drain lines
are equipped with two sequential shut off valves.


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Drains are used for the drainage of the boiler during start-up and
shutdown. The drains from the economizer, furnace, cyclones,
superheaters and sootblowing system are piped to a common
drainage header and further to the blowdown tank (283T005).
Drains from low pressure parts are introduced to the blowdown
tank through own drainage header.
One furnace drain, which can be used for limiting drum high
water level, and feedwater tank (283T001) overflow pipe are
connected directly to blowdown tank (283T005).
In the blowdown tank hot drains are cooled down and then led to
the sewer.
Sampling System
The sampling system consists of:
• sample probes
• sample piping with valves
• sample coolers (from 283E050 to 283E058)
Sample tapping probes are installed in the condensate pipe

before deaerator, feedwater tank, feedwater pipe, continuous
blow-down pipe, downcomer, saturated and superheated steam
pipes. The water or steam is led into the sample cooler, where it
is condensed and cooled. Condensated and cooled sample is
then analyzed in laboratory or in on-line analyzers.


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With continuous pH-monitoring are equipped the following

samples:
• condensate water
• feedwater
• boiler water
With continuous conductivity monitoring are equipped the

following samples:
• condensate water
• feedwater from the feedwater tank and from feedwater
line
• boiler water
• saturated steam
• superheated steam
In addition to those continuous O2-monitoring is provided for

feedwater line sample and continuous silica monitoring for boiler
water sample.
The adjustments to the continuous blow-down flow and to dosing

chemical feeding will be done based on the indications from the
samples. There are no actual control loops and the adjustments
will be done by the operator.


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2.3.4 Equipment specification
2.3.4.1 Deaerator
PI-diagram T582-00007
Feedwater tank 283T001
Manufacturer Stork Thermeq B.V.
Layout integrated to the feedwater tank

Material SA-516 Gr. 70
Design pressure barg 6,5 / vacuum
Design temperature °C 250
Design
Water in 32 °C 179,1 kg/s
LP-steam in 2,7 bar(a) 33,6 kg/s
Vent steam out 130 °C 0,2 kg/s
Feed water out 130 °C 212,5 kg/s
Equipment:
• 1pc off steam charging device (consisting of 1 pc pipe
NS1000, 2 pcs pipe NS450 and 34 pcs spray pipes)
• 1 pc off-tunnel
• 1 pc off baffle ring around the sprayer
• 2 pcs off small baffle plates
• 1 pc off large baffle plate
• 1 pc shell plate (to close the gap of the deaerator tower)


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2.3.4.2 Feedwater Storage Tank
Feedwater tank 283T001
Manufacturer Taiwan End-Plate Co. Ltd (Kvaerner

design)
Layout horizontal
Volume (gross) m3 270
Dimensions mm φ 5000 x 15750
Material SA-516 Gr. 70
Design pressure barg 6,5 / vacuum
Corrosion allowance mm 1,5
Connections and equipment:

Manhole opening DN500
LP-steam connection DN1000/800
Balance line (connected to the old deaerator DN100
connection)
Overflow pipe connection DN150
Connection from continuous blowdown tank DN200
(connected to the old deaerator connection)
Safety valve connection DN200
Feedwater pump suction line connections 4 x DN250


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Drain pipe connection DN100

FW pump minimum flow pipe connections 4 x DN80
FW pump balance water pipe connections 4 x DN50
Level measurement connections 4 x DN80
Pressure measurement connections 2 x DN15
Temperature measurements 2 x Φ55
Spare connection (old feedwater pump suction line DN250
connection)
Make-up water, condensate and condensate from
airpreheater condensate tank connection DN300
Chemical dosing connections (2 pcs) DN15
Sample connection (connected to one of the old DN15
feedwater pump suction line connection)
Start-up vent line DN100
Vent nozzle connections 4 x DN25
Heating line connection DN250


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Picture 8. Feed water tank and deaerator


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2.3.4.3 Chemical dosing units
Chemical station
Manufacturer Prominent Finland Oy / Milton Roy

Number of units pcs 3
Oxygen scavenger dosing unit

Tank size m3 1
Tank material AISI 304
Equipment
• propeller mixer (283A001), material PVDF, motor 0,25 kW
• measuring tank (283T007) with dosing gauge
• ejector (283K001)
• dosing pumps (283P004 and 283P005)
− material SS 316 L
− diaphragm type (Dosapro Milton Roy GMHX25S4N9)
− 0 … 25 l/h, 12 bar
− 0,25 kW
• filters before the pumps
- opening size 0,5 mm
• safety valves 2 pcs
• valves, pipes and measurements


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Amine dosing unit

Tank size m3 1
Equipment:
− material SST
− diaphragm type (Dosapro Milton Roy GM25SST)
− 0 … 25 l/h, 12 bar
− 0,25 kW
• filters before the pumps, (0,5 mm)
Phosphate dosing unit

Tank size m3 1
Equipment:
− material AISI 316 L
− piston type (Dosapro Milton Roy Milroyal B)
− 0 … 13 l/h, 200 bar
− 0,75 kW
• filters before the pumps, (0,5 mm)


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2.3.4.4 Steam coil primary air preheater condensate tank
Condensate tank 283T010
Manufacturer Mimet Oy
Layout horizontal
Volume m3 2,0
Material Carbon steel
Design pressure barg 5
Corrosion allowance mm 1

Access door DN500
Steam coil preheater condensate connection 2 x DN150
Condensate pump suction line connection DN80
Condensate pump minimum flow connection DN25
Vent steam connection DN50
Water level gauge connection 2 x DN80
Water level control measurement connection 2 x DN15


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2.3.4.5 Condensate pump
Condensate pump 283P010
Manufacturer Sulzer
Number of pumps pcs 1
Type APP22-32
Casing material ASTM A890 3A
Impeller material ASTM A890 3A
Impeller type Closed
Seal Double mechanical
Motor size kW 15
Design values
Flow kg/s 4,55
Temperature °C 100
Discharge pressure barg 6,38
Speed (constant) rpm 2910
NPSH required m 2,1


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2.3.4.6 Feedwater pumps (not in scope)
Feed water pumps 283P001, 283P002, 283P003 and
283P018
Manufacturer KSB
Number of pumps pcs 4
Pump control Direct drive


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2.3.4.7 Economizers
Fin tube economizers (economizer sections 1 and 2)
Economizer 1 and 2 283E002 and 283E003
Manufacturer Kraps
ECO 1 ECO 2
Tube type H2 Finned tube H2 Finned tube
Flow type Counter flow Counter flow
Tube diameter mm 38,0 38,0
Minimum wall
thickness mm 5,0 5,0
Tube material SA-210 A-1 SA-210 A-1
Tubes / group pcs 3 3
Elements pcs 80 80
Tube rows pcs 21 21
Element spacing mm 75 75
Tube spacing mm 75 75
Fin material Carbon steel Carbon steel
Fin pitch mm 25 25
Fin size mm 70 x 145 x 2.0 70 x 145 x 2.0
Heat transfer surface m2 11579,4 11579,4
Design temperature °C 371 371
Design pressure barg 171 171


AND STEAM

ECO 1 ECO 2
Distribution header
Material SA-106 Gr. C -
Diameter mm 355,6 -
Wall thickness mm 40 -
Design temperature °C 351 -
Design pressure barg 171 -
Collection header
Material - SA-106 Gr. C
Diameter mm - 355,6
Wall thickness mm - 40
Design temperature °C - 351
Design pressure barg - 171
Bare tube economizer (economizer section 3 )
Economizer 3 283E004
Manufacturer Kvaerner Power Oy
ECO 3
Tube type Bare tube
Flow type Counter flow
Tube diameter mm 44,5
Minimum wall
thickness mm 5,4
Tube material SA-210 A-1
Tubes / group pcs 1


AND STEAM

Elements pcs 139

Tube rows pcs 14
Element spacing mm 114,3
Tube spacing mm 101,6
Heat transfer surface m2 1605
Distribution header
Material SA-106 Gr. C
Diameter mm 355,6
Wall thickness mm 36
Collection header
Material SA-106 Gr. C
Diameter mm 355,6
Interconnecting pipes
Pipe pcs Pipe size Material
Feed water pipe to economizer 1 2 355,6 x 36 SA-106 C
Feed water pipe from eco 2 to eco 3 2 355,6 x 32 SA-106 C
Feed water pipe from eco 3 to drum 2 355,6 x 32 SA-106 C


AND STEAM

2.3.4.8 Steam drum
Steam drum 283T002
Manufacturer Stabo
Inner diameter mm 1600
Shell length mm 18000
Total length mm 19400
Wall thickness, shell mm 118 min
Wall thickness, heads 96
Material SA - 302B
Design pressure bar(g) 166
Drum Internals:
Cyclone steam separators
- Type Kvaerner
- Number (furnace and
cyclones) pcs 74
Steam droplet separators

- Type Kvaerner, type C
- Number pcs 60
- Width x length x height mm 179 x 458 x 354
Feed water distribution pipes 2 x DN250

- number of holes pcs 420
- hole size mm 15


AND STEAM

Pipe connections
Feed water pipes mm 2 pcs 355,6 x 32
Furnace downcomers mm 5 pcs 457 x 36
Cyclone downcomers mm 2 pcs 406 x 36
Safety valves: mm 1 pc 180 x 36
mm 1 pc 152,4 x 35
Saturated steam pipes 5 pcs 219,1 x 20
Furnace riser pipes 42 pcs 193,7 x 17,5
Cyclone riser pipes 21 pcs 168,3 x 16
Continuous blowdown pipe 1 x DN50
Water level measurement columns 4 x DN80
Pressure measurement 2 x DN25
Nitrogen line connection 1 x DN25
Instruments
Pressure gauge pcs 1
Pressure transmitter pcs 1
Material temperature
measurements pcs 2x3
Water level gauge pcs 2
Water level switch pcs 1
Water level measurements pcs 3


AND STEAM

2.3.4.9 Furnace
Furnace 283E065
Width mm 21080
Depth (freeboard) mm 8330
Depth (grate area) mm 4998
Total height (furn. bottom –> roof) mm 40000
Lower part tapered height mm 5530
Volume, total m3 6630
Lower part refractory height mm 5930
Fluegas side design pressure
− 0 ... 1,2 m kPa +15 / -5
− 1,2 ... 5,0 m kPa +10 / -5
− 5,0 m --> kPa +6 / -5
Wall and roof tubes

Material SA-210 A-1
Diameter mm 60,3
Minimum wall thickness mm 8
Tube spacing mm 85
Number of tubes
− side walls pcs 98
− front / rear wall pcs 247
Fin material 16Mo3 (s=6 mm)


AND STEAM

Furnace division walls

Material SA-210 A-1
Diameter mm 63,5
Number of tubes pcs 2 x 55
Fin material 16Mo3 (s=6 mm)
Bottom tubes
Material SA-210 A-1
Diameter mm 88,9
Minimum wall thickness mm 10,5
Furnace headers
Material SA-106 C
Size
− distribution headers mm 273 x 40
− collection headers mm 273 x 40
− division wall headers mm 273 x 50


AND STEAM

Furnace downcomers
Main downcomers
− material SA-106 C
− diameter mm 457,0
− wall thickness mm 36
− number pcs 5
Supply pipes (Furnace and division walls)

Material SA-106 C
Diameter mm 193,7
Wall thickness mm 17,5
Number
− front wall / bottom pcs 22
− side walls pcs 5+5
− division walls pcs 5+5
Riser pipes
Material SA-106 C
Diameter mm 193,7
Wall thickness mm 17,5
Number
− rear wall pcs 11
− side walls pcs 5+5
− front wall / roof pcs 11
− division walls pcs 5+5


AND STEAM

2.3.4.10 Cyclones and Loop Seals
Cyclones
Cyclone 1 (left) 283E066
Cyclone 2 (middle) 283E067
Cyclone 3 (right) 283E068
Number pcs 3
Wall construction Totally refractory covered
membrane walls, which are part
of evaporation circulation
Diameter of cylindrical part (c-c) mm 7224
Height of cylindrical part mm 7600
Number of tubes in cylindrical
part / cyclone pcs 140
Tube spacing in cylindrical part mm 162
Tube material in cylindrical part SA-210 A-1
Fins in cylindrical part 16Mo3 (s=6 mm)
Fluegas side design pressure kPa ±5


AND STEAM

Diameter of conical part mm 7224 --> 3356

Height of conical part mm 6400
Number of tubes in conical part /
cyclone pcs 140
Tube spacing in conical part mm 162 -->75
Tube material in conical part SA-210 A-1
Fins in conical part 16Mo3 (s=6 mm)
Fluegas side design pressure kPa +30 / -5
Diameter of adaptor part mm 3356 --> 1644 x 1644

Height of adaptor part mm 3200
Number of tubes in adaptor part /
cyclone pcs 84
Tube material in adaptor part SA-210 A-1
Fins in adaptor part 16Mo3 (s=6 mm)


AND STEAM

Diameter of return duct upper part mm 3356

Size of return duct lower part mm 1644 x 1644
Height of return duct mm 12000
Number of tubes in return duct / pcs 84
cyclone
Tube spacing in return duct mm 76,2
Tube material in return duct SA-210 A-1
Fins in return duct 16Mo3 (s=6 mm)
F.g. side design press. upper part kPa ±5
F.g. side design press. lower part kPa +30 / -5
Loop Seals
Fluo seal 1 (left) 283E079
Fluo seal 2 (middle) 283E080
Fluo seal 3 (right) 283E081
Number pcs 3
Wall construction Totally refractory covered
membrane walls, which are part
of evaporation circulation
Number of tubes / loop seal pcs 84


AND STEAM

Tube spacing in loop seal mm varies depending on

location
Tube material in loop seal SA-210 A-1
Fins in loop seal 16Mo3 (s=6 mm)
Cyclone and loop seal headers

Loop seal distribution headers
− size mm 273 x 45
− material mm SA-106 C
− design temperature °C 351
− design pressure barg 166
Cyclone intermediate header

− size mm 139,7 x 28
Cyclone collection header

− size mm 273 x 40


AND STEAM

Cyclone downcomers
Main downcomers
− diameter mm 406
− wall thickness mm 36
− number pcs 2
Supply pipes
Material SA-106 C
Diameter mm 168,3
Number / cyclone pcs 4
Riser pipes
Material SA-106 C
Diameter mm 168,3
Number / cyclone pcs 7


AND STEAM

2.3.4.11 Superheaters
Second Pass Walls and Roof

Second pass walls and roof are the first part of primary
superheater.
Wall construction Steam cooled membrane walls

Width of the second pass mm 16080
Depth of the second pass mm 5943
nd
Heat transfer area of 2 pass walls
and roof (projected area) m2 740
Number of tubes in front and rear wall pcs 140 + 140
Number of tubes in side walls pcs 52 + 52
Tube material SA-209 T1
Fins 16Mo3 (s=6 mm)
Headers of second pass walls
Front wall distribution header

− size mm 355,6 x 40


AND STEAM

Front wall collection header

− size mm 406,4 x 55
Distribution headers of side walls

− size mm 355,6 x 55
Headers of load carrying tubes
Distribution header Same as 2nd pass front wall

collection header
Intermediate headers
− size mm 219,1 x 32
Collection header Same as 2nd pass rear wall

collection header
Distribution header of roof/rear wall

− size mm 355,6 x 55


AND STEAM

Collection header of roof/rear wall

− size mm 355,6 x 55
Load Carrying Tubes in Second Pass

Load carrying tubes are used to support heat transfer surfaces inside
the second pass. These tubes are part of primary superheater.
Number of pcs 70 + 70
Tube material SA-209 T1
Heat transfer surface m2 335
Support plates 10CrMo910 (s=10 mm)


AND STEAM

Primary Superheater
Primary superheater 283E006
SH section 1 SH section 2
Tube type Bare tube Bare tube
Minim. wall thickness mm 5,4 6,5
Tube material SA-209 T1 SA-213 T12
Elements pcs 139 139
Tube rows pcs 18 18
Element spacing mm 114,3 114,3
Tube spacing mm 90 / 112 90 / 112
Heat transfer surface m2 1966 1966
Distribution header
Material SA-106 C -
Size mm 355,6 x 50 -
Collection header
Material - SA-335 P12
Size mm - 406,4 x 55


AND STEAM

Secondary Superheater
Secondary superheater 283E009
Tube type Membrane type heat

surface
Minim. wall thickness mm 5,6 (upper parts)/
6,3 (lower parts)
Tube material SA-213 T91 (upper parts)/
SA-213 T22 (lower parts)
Tubes / element pcs 24
Elements pcs 18
Element spacing mm 1105
Tube spacing mm 50
Element width mm 1150
Element height
− total mm 21600
− inside furnace without refract. mm 18800
− refractory covered mm 1700
Fins
− material 10CrMo910
− thickness mm 6
Effective heat transfer
surface (projected area) m2 819
Design temperature °C 505 (lower part)/
570 (upper part)


AND STEAM

Lower part of superheater elements is protected by refractory
Distribution headers
Main distribution header
− Material SA-335 P12
− Diameter mm 355,6
− Wall thickness mm 45
− Design temperature °C 480
− Design pressure barg 166
Element headers (18 pcs)
Collection headers
Main collection header
Element headers (18 pcs)


AND STEAM

Steam pipe connections to secondary superheater headers:


AND STEAM

Tertiary Superheater
Tertiary superheater 283E012
SH section 1 SH section 2
Tube type Bare tube Bare tube
Minim. wall thickness mm 5,6 6,3
Tube material SA-213 T91 SA-213 T91
Elements pcs 69 69
Tube rows pcs 15 15
Element spacing mm 228,6 228,6
Tube spacing mm 90 / 134 90 / 134
Heat transfer surface m2 854 854
Distribution header
Material SA-335 P91 -
Size mm 355,6 x 36 -


AND STEAM

Collection header
Material - SA-335 P91
Size mm - 406,4 x 50
Steam pipe connections to tertiary superheater headers:


AND STEAM

Spray attemperators
Spray attemperator 1 283E007
Spray attemperator 1 and 2

Number pcs 2
Spray chamber
− Length mm 2800
Venturi tube
− Material 16Mo3/13CrMo44
− Wall thickness mm 10,0
− Length mm 2661
− Throat inner diameter mm 109
Spray water nozzle
− Material SA-182 F12
− Diameter mm 60
− Nozzle opening diam. mm 20


AND STEAM

Spray attemperator 3 and 4

Number pcs 2
Spray chamber
− Length mm 3000
Venturi tube
− Material 10CrMo910
− Wall thickness mm 10,0
− Length mm 2855
− Throat inner diameter mm 114
Spray water nozzle
− Material SA-182 F22
− Diameter mm 50
− Nozzle opening diam. mm 14,5


AND STEAM

Interconnecting pipes
pcs Pipe size Material
Saturated steam pipes 5 219,1 x 20 SA-106 C
Connection pipes between headers of

load carrying tubes 7 114,3 x 13,5 SA-106 C
Balance pipes between second pass

lower and upper headers 6+6 168,3 x 20 SA-335 P12
Connection pipes between headers of 2nd

pass side wall upper header and roof 1+1 355,6 x 40 SA-106C
Connection pipes from 2nd pass rear wall

header to prim SH1 header 1+1 355,6 x 40 SA-106C
Connection pipe from primary

superheater to spray chamber 1 and 2 2 355,6 x 45 SA-335 P12
Connection pipe from spray chamber 1

and 2 to secondary SH main distribution
header 2 355,6 x 45 SA-335 P12
Connection pipe from sec. SH main distr.

header to element header 18 139,7 x 20 SA-335 P12
Connection pipe from sec. SH element

header to main collection header 18 139,7 x 22,2 SA-335 P22
Connection pipe from sec. SH main coll.

header to spray chamber 3 and 4 2 355,6 x 36 SA-335 P91
Connection pipe from spray chamber 3

and 4 to tertiary SH distribution header 2 355,6 x 36 SA-335 P91
Connection pipe from tertiary SH

collection header to T-piece 2 355,6 x 40 SA-335 P91
T-piece 1 DN 350/550 SA-335 P91


AND STEAM

2.3.4.12 Continuous blowdown tank
Continuous blowdown tank 283T004


AND STEAM

Manufacturer Mimet Oy (Kvaerner design)

Layout vertical
Volume (gross) m3 2
Material H II
Corrosion allowance mm 1,5

Continuous blowdown valve connection φ 76,1
Vent steam pipe connection DN200
Condensate drain pipe connection DN40
Safety valve connection DN150
Level gauge connection 2 x DN15
Level control measurement connection 2 x DN15
Pressure measurement connection DN15


AND STEAM

2.3.4.13 Blowdown Tank
Blowdown tank 283T005
Manufacturer Mimet Oy (Kvaerner design)

Layout vertical
Volume (gross) m3 7
Material Carbon steel


AND STEAM



Vent steam pipe connection DN300
Overflow pipe DN500
Feedwater tank overflow pipe connection DN150
Cooling water pipe connection DN150
Drain header for superheater drains DN200
Drain header for feed water and boiler water drains DN200
Continuous blowdown tank drain connection DN40
Blowdown tank drain pipe connection DN50
Furnace downcomer drain pipe connection DN50
Temperature measurement connection φ 18


AND STEAM

2.3.4.14 Sample station
Manufacturer Kontram Oy (Finland)
Cooling water inlet and outlet headers

− material stainless steel
− size DN50
Sample cooler for superheated steam

− equipment numbers 283E050 (1) and
283E051 (2)
− number of coolers pcs 1+1
− shell material SS2343
− sample coil material SS2343
− sample coil pipe size mm 6x1
− sample coil pipe length m 6 + 12
− needle valves stainless steel
− conductivity analyzer
− temperature switch
Sample cooler for saturated steam

− equipment number 283E052 (3)
− number of coolers pcs 1
− sample coil pipe length m 12


AND STEAM

Sample cooler for boiler water

− pH analyzer
− silica analyzer
Sample cooler for feedwater from feedwater line

− pH analyzer
− oxygen analyzer


AND STEAM

Sample cooler for feedwater from feedwater tank

Sample cooler for condensate

− pH-analyzer
Sample cooler for reserve



AND STEAM

Sample cooler for reserve


2.3 Feedwater, Boiler Water and Steam System

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2.3 Feedwater, Boiler Water and Steam System

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PROCESS DESCRIPTION CFBT-582-1 1

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Power Generation RAPP PB3 PROJECT 1 (71)