Heat Recovery Steam Generator Operation Manual

MIRANT- KENDALL
REPOWERING PROJECT
Cambridge. MA
OPERATING MANUAL
HEAT RECOVERY STEAM GENERATOR
Section 13.1

Table of Contents
1.0 Simplified Diagram......................................................................3

2.0 System Purpose..........................................................................4
3.0 System Components...................................................................4
3.1 Control Loop Narratives......................................................10
4.0 System Description...................................................................15
4.1 Primary System Flow Path..................................................16
4.2 Normal Operating Parameters............................................17
4.3 Secondary Systems.............................................................17
5.0 System Startup .........................................................................18
5.1 Precautions..........................................................................20
5.2 Prerequisites........................................................................23
5.3 Startup.................................................................................26
6.0 Normal Operation......................................................................28
6.1 Valve Alignment...................................................................28
7.0 Normal Shutdown......................................................................35
7.1 Precautions..........................................................................35
7.2 Shutdown.............................................................................36
Date of Issue: 12/20/01

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8.0 Abnormal Shutdown..................................................................39

8.1 Power Failure......................................................................39
8.2 Instrument Air Failure..........................................................39
8.3 Steam Turbine Generator Trip.............................................40
9.0 Alarm Summary and Response................................................40
10.0 References..............................................................................44
10.1 Drawings............................................................................44
10.2 Vendors..............................................................................45
1.0
SIMPLIFIED DIAGRAM

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2.0

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IP
Steam
Out
SYSTEM PURPOSE
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TAH
HP
Steam
Drum
PAH
CO Reducer / SCR
HP Evaporator
HP Superheater #1
HP/IP Boiler
Feedwater Pumps
LALL
LAL
LAH
LC
HP Economizer #3
LV-10013
YV-10131
YV-10031
LAL
LAH
LC
LALL
LV-10113
IP
Steam
Drum
PAH
CT Trip
HP Economizer #1
Heat Recovery
Steam Generator
Burner
Management
System
Duct Burner
TAHH
LALL
LAL
LAH
LAHH
LC
PAHH
Pegging Steam
IP Evaporator
Fuel Gas
TAH
TAHH
HP Superheater #3
Duct Burner Trip
YV-10041
YV-10141
Chemical
Feed Pumps
HP Economizer #2
CT Trip
PAL
PAHH
YV-10141
Duct Burner Runback
HP Steam Out
STG Trip
YV-10140
Deaerator
LV-10213
LP
Steam
Drum
Feedwater Heater
TC
YV-10232
TV-10203
YV-10231
Stack
Silencer
YV-10233
CEMS
Ports
LP Circulation Pumps
PAH
Startup
Silencers
FIC
Condensate
Makeup
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OPERATING MANUAL
LP Evaporator
IP Economizer
IP Superheater
HP Superheater #2
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OPERATING MANUAL
The purpose of the heat recovery steam generator is to pre-heat boiler

feedwater and generate two pressure levels of steam by the circulation of
this water through superheat steam tubes that cross pattern the gas
turbine's hot exhaust.
3.0
SYSTEM COMPONENTS
The heat recovery steam generator (HRSG) is a fabricated, horizontal,
metal duct that connects to the combustion turbine exhaust and directs
the hot exhaust gas through a series of metal tubes to the exhaust stack.
Inside the metal tubes, feedwater is circulated and heated to produce
steam in the steam drums. Steam produced in the two steam drums
supplies the HP and LP steam systems.
Heat Recovery Steam Generator
Mfg:
Foster Wheeler
HP steam:
Flow rate 500-900 kpph
Pressure
1360-1370 psia
Temperature 895-905F
IP steam:
Flow rate - 28 50 kpph
Pressure - 195-235 psia
Temperature
500-550F
The HRSG is comprised of several major sections and components,
which collectively produce steam for delivery to the Kendall Station
steam.

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The major sections of the HRSG from the exhaust gas inlet looking toward
the stack are as follows:
Expansion joint
HRSG casing
Duct Burner
HP superheater #3
HP superheater #2
HP superheater #1
HP evaporator
CO, SCR, and Ammonia injection grid
IP superheater
IP evaporator
HP economizer 2
HP economizer 3
IP Economizer / HP economizer 1
LP evaporator
Feedwater heater
Exhaust stack
HRSG Casing
A carbon steel casing encloses the heat transfer sections. The casing is
lined with stainless steel from the HRSG inlet through the HP Evaporator
section, then a carbon steel liner to the main exhaust stack. The gas path
is completely gas tight to prevent leakage.
A carbon monoxide (CO) catalyst section and selective catalytic reduction
(SCR) System is located downstream from the HP evaporator section of
the HRSG.

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Steam Drums
Steam drums are provided in each section of the HRSG to maintain an
interface between the water and the steam. The drums have internals
that separate the water from the steam and provide for a storage volume
of water. Water level is maintained in the drums by means of level control
valves controlled by the DCS based on information from steam flow and
feedwater flow elements and drum level transmitters. The HP and IP
drums are designed with 3 minutes of retention time from normal water
level to low-level trip water level based on maximum steam production
with no duct firing. The LP drum is designed with 5 minutes of retention
time from normal water level to low-level trip water level based on
maximum steam production with no duct firing.
Each drum is provided with internal distributors, baffles, shields,
separators and internal piping. The separators maintain steam quality
and prevent the carry-over of water into tube sections that contain steam.
The drums also have provisions for chemical feed, sampling, and
continuous blowdown.
Heat Transfer Surfaces
Heat transfer surfaces consist of vertical banks of tubes. The tube
material varies in order to be compatible with the pressure and
temperature of steam and with the temperature of the exhaust gas that
comes in contact with the tubes. The gas temperature is highest at the
HRSG inlet and decreases through successive sections of the HRSG as
heat is transferred to the water. The coolest gas is at the exit of the
HRSG. The coolest water (condensate) is introduced at the exhaust gas
exit end of the HRSG. This arrangement is referred to as a countercurrent
flow path.
The various sections of the HRSG include the condensate preheater,
economizer, evaporator and superheater sections. The economizer is the
first section in the water flow path and contains no steam. There are
several evaporator sections where steam generation takes place.
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The evaporator sections of each HRSG consist of a steam drum,

downcomers, feeder tubes, modules, and riser tubes to create a natural
circulation effect. Natural circulation ensures that water is continuously
moving within the HRSG tubes to remove and replace the steam
produced due to the difference in density between the water and steam.
Water is supplied from the drum to the bottom of the unit through the
downcomer. As the gas turbine exhaust gas, supplemented with the duct
burner, heats the evaporator tubes, a steam/water mixture is formed in the
tubes that is less dense than the water in the downcomers; thus, the
mixture rises up to the steam drum and ultimately is sent to the
superheater as saturated vapor. The circulation process continues with a
steam/water mixture generated in the tubes and replaced with heavier
water from the downcomers. As more heat is added to the HRSG tubes,
the steam quality of the fluid increases. Up to a point, circulation will
naturally increase with increased heat input and provide more flow to
keep the HRSG tubes cooled as more steam is generated. Beyond a
certain level, friction in the tubes overcomes the difference in density and
circulation is reduced with additional heat input.
The saturated steam from the drum enters the superheater sections
before leaving the HRSG as either HP Steam or IP Steam. LP steam from
the LP drum goes directly to the deaerator and is not superheated.
Continuous Blowdown System
The system is a continuous cascading system from the HP steam drum to
the IP steam drum and from the IP drum to a continuous blowdown tank.
Flash steam from the continuous blowdown tank is vented to the LP
Drum.
Desuperheaters
HP desuperheater provides temperature control for the HP steam. The
desuperheater is spray type and uses feedwater to cool the steam to
achieve the desired outlet temperature. The HP desuperheater is located
between the second and third stage of HP superheater. All controls for
the desuperheater are furnished with the HRSG and are controlled
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through the DCS. The controls include control valves, automatic block
valves, temperature sensing elements and transducers.
Condensate Preheater
Condensate from the existing plants condenser, together with
demineralized water make-up from the water treatment system, enters the
HRSGs condensate preheater prior to entering the deaerator and LP
evaporator section. The preheater is constructed of stainless steel tubes.
Two condensate recirculation water pumps draw a portion of heated
condensate from the discharge of the condensate preheater and return it
to the preheater inlet to maintain the condensate at a minimum of 120F
to prevent exhaust gas from condensing on the outside of the tubes.
Insulation
The inlet ductwork, inlet transition section, and the HRSG are internally
insulated to minimize heat loss and for personnel protection. The
insulation is attached to the internal wall surfaces and is protected by an
internal stainless steel liner. The outlet transition duct and stack are
provided with thermal insulation barriers for personnel protection.
Insulation materials are asbestos free and non-corrosive.
Piping
equipment operating between 140F and 500F are insulated with heavy
density fiberglass. All piping operating at temperatures above 500F is
insulated with high temperature mineral wool or calcium silicate. Calcium
silicate is also installed where piping and equipment, operating below 500
F, is subject to mechanical damage or people walking, leaning, sitting,
etc. on it.

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Support Steel, Stairs and Platforms

Stair towers, caged ladders, platforms and walkways are provided for
access to the HRSG trim.
Ducts, Silencers and Stack
The 18 foot diameter stack extends to a height of 250 feet above grade. A
caged ladder is provided to access the 360-degree platform that serves
the continuous emission monitoring (CEM) ports and sample test ports
and the platform that serves the FAA lighting. Expansion joints are
provided in the ducts at the HRSG inlet and outlet.
Duct Burners
The duct burner system is designed to provide supplemental heat to the
combustion turbine exhaust gas in order to increase steam production in
the HRSG. The duct burner system is designed to burn natural gas and
is located upstream of the HP superheater sections in the HRSG gas
path. The duct burner system consists of the following components and is
discussed further in Section 13.2.
Duct burners
Natural gas fuel train
Burner management system
Ignitor system
Scanner system
Selective Catalytic Reduction System

The selective catalytic reduction (SCR) system is used to chemically react
the NOx emissions from the combustion turbine exhaust and HRSG duct
burner with injected ammonia to produce environmentally neutral nitrogen
and water, thereby reducing the NOx emissions to the environment. The
SCR system is composed of a set of ammonia injection nozzles; a catalyst
bed and an in-line air heater used vaporize ammonia provided by the
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ammonia storage and supply system. The SCR catalyst is designed for a
5-year catalyst life and can be replaced when required. The SCR and
ammonia injection system are discussed in Section 13.3.
CO Reduction System
The CO catalyst system is an emission control device designed to oxidize
carbon monoxide (CO) from the combustion turbine exhaust and HRSG
duct burner into carbon dioxide. The catalyst is supplied in modules that
can be replaced when required. The carbon monoxide reduction system is
are discussed in Section 13.3
3.1
Control Loop Narratives

PCV-10227 LP Pegging Steam Control Valve
Operation:
The LP Steam Drum Pegging Steam Pressure Control Valve

is controlled and monitored remotely at the DCS.
LP Steam Drum Pegging Steam Pressure Control Valve
regulates flow of pegging steam to the low-pressure steam
drum. LP Steam Drum Pegging Steam Pressure Control
Valve is controlled as follows:
The control valve is equipped with a typical AUTO/MANUAL
station at the DCS. Once the HRSG LP Drum is placed in
service, the valve is placed in the AUTO mode.
When in AUTO the valve modulates to maintain LP Steam Drum
pressure at the setpoint. As the pressure decreases the valve
opens to allow more steam to the steam drum.
Upon loss of compressed air the valve fails in the closed
position.
The DCS will indicate the following about the LP Steam
Drum Pegging Steam Pressure Control Valve:

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AUTO/MANUAL operation
% OPEN
LCV-10013 HP Steam Drum Level Control

Note:
This description also applies in principle to IP and LP control

valves LV-10131 and LV-10213 respectively.
Operation:
The level indicating controller is preset to maintain HP

steam drum level. The controller provides a signal to the
boiler feedwater single and three element control loops to
open and close LV-10013 on the supply side of HP
economizer 1.
The HP Steam Drum Level Control Valve is controlled and
monitored remotely at the DCS.
HP Steam Drum Level Control Valve regulates flow of water
from the HP Feedwater system to the HP Steam drum, to
maintain HP Steam Drum water level. The HP Steam Drum
Level Control Valve is controlled as follows:
The control valve is equipped with a typical AUTO/MANUAL
station at the DCS.
The operator at the DCS selects SINGLE or 3-ELEMENT
control.
During unit startup and low load conditions, drum level is
controlled by single element control; based on drum level
only. The process variable used during single element
control is solely from Level Transmitter.

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During three-element control, the level controller uses the

computed value (summary) of the following input signals as
the process variable.
Drum Level
Feedwater Flow
Steam Flow (pressure and temperature compensated)
During normal operation, the valve is in AUTO, 3-ELEMENT

operation.
Upon loss of compressed air the valve fails in the closed
position.
The DCS will indicate the following about the HP Steam
Drum Level Control Valve:
AUTO/MANUAL operation
% OPEN
SINGLE or 3-ELEMENT Level Control
LP Feedwater Economizer Bypass Block Valve

Operation:
The HRSG LP Economizer Bypass Valve is controlled and

monitored remotely from the DCS. The valve operates
based on signals generated from the DCS. The signals are
OPEN and CLOSE.
The valve can be placed in AUTO or MANUAL at the DCS.
During normal operation the valve is placed in AUTO and
OPENS/CLOSES based on the following conditions:

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Valve will automatically CLOSE, when valve is in AUTO,

if the CT FIRING ON GAS signal is activated.
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Valve will automatically OPEN, when valve is in AUTO, if

the CT FIRING ON OIL signal is activated.
When changes in system occur, the DCS will indicate either

HRSG ECONOMIZER REQUIRED or HRSG ECON
BYPASS REQUIRED.
The following can change in the MANUAL valve position:
Valve will CLOSE when the LP economizer is placed in

service from the DCS.
Valve will OPEN when the LP economizer bypass is

activated from the DCS.
If valve does not meet open or closed limits in a specified

time period there will be a VALVE TRAVEL FAILURE at the
DCS.
The DCS will indicate the following for the HRSG LP
Economizer No. 1 Block Valve:
AUTO/MANUAL
CLOSED
OPEN
Gas Turbine Trip

The Gas Turbine should trip on any of the following:
HP Drum level low-low (LSLL-10014) @ NWL 52.5

IP Drum level low-low (LSLL-10114) @ NWL 9
LP Drum level low-low (LSLL-10214) @ NWL 63
HP Drum steam pressure high-high (PT-10011) @ 1585 psig (2nd safety
valve)

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IP Drum steam pressure high-high (PT-10111) @ 345 psig (2 nd safety

valve)
Pre-alarms as follows:
HP Drum level low (LSL-10014) @ NWL 25.5
IP Drum level low (LSL-10114) @ NWL 5
LP Drum level low (LSL-10214) @ NWL 59
High Steam Temperature
If the HP Superheater outlet steam temperature becomes high (TE-10022
@ 920 deg F) the duct burners should be run back to minimum load.
The Gas Turbine should be run back to minimum load and the duct
burners tripped if this temperature reaches 930 deg F.
Gas Turbine loading rate must not allow an increase in any HP drum
metal temperatures (TE-11002A-D) to exceed 600 deg F per hour.
The Gas Turbine should not be started, re-started after a trip, or re-loaded
after a runback, unless all drum levels and pressures, and HP steam
temperature, are within their normal operating range (i.e. all alarms and
trips have been reset). The re-start or re-load should be an operator
action.
Process Alarm
In addition to those listed in the preceding sections, the following process
conditions will be alarmed:
LP Drum level low (LSL-10214) @ NWL 59
LP Drum steam pressure high (DCS alarm from PT-10211) @ 56 psig
IP Drum steam pressure high (DCS alarm from PT-10111) @ 307 psig
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HP Drum steam pressure high (DCS alarm from PT-10011) @ 1546

psig
LP Drum level high (LSH-10214) @ NWL +6
IP Drum level high (LSH-10114) @ NWL +10
HP Drum level high (LSH-10114) @ NWL +4.5
Steam Turbine
The Steam Turbine HP admission valve should trip on HP Drum level
high-high (LSHH-10014 @ NWL +10.5). There should be a pre-alarm at
HP Drum level high (LSH-10014 @ NWL +4.5).
Re-loading of the steam turbine will follow operating procedures for the
ST.
4.0
SYSTEM DESCRIPTION
This section provides a general understanding of the Heat Recovery
Steam Generator (HRSG) by tracing flow paths, identifying and describing
major components, and locating and describing the system
instrumentation and controls.
The HRSG utilizes the exhaust gases from the combustion turbine (CT) to
produce HP and IP steam for use in the existing plants steam turbines.
IP steam produced is combined with extraction steam from the steam
turbines to export to various customers. The HRSG is a natural
circulation water tube, three pressure level unit. Heat transfer is
accomplished by convection through banks of finned tubes. Duct burners
that use natural gas provide supplemental firing.

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4.1
Primary System Flow Path

The HRSG has three sections: a high pressure (HP) section, an
intermediate pressure (IP) section, and a low pressure (LP) section. LP
steam is not exported, but is used to deaerate the incoming condensate
makeup to the LP steam drum or boiler feedwater storage tank. HP steam
may also be used for deaeration when LP steam quantities are not
sufficient. Steam is produced when the combustion turbine generator
(CTG) exhaust gas enters the HRSG and flows through each section of
the HRSG. The feedwater to the HRSG is supplied from the condensate
system and circulated by the boiler feedwater system. The exhaust gas
discharges to atmosphere through the stack at the low temperature end of
the HRSG.
High Pressure (HP) Steam: High-pressure boiler feedwater is supplied to
the economizers of the HRSGs HP sections. The water is heated, and
then passed through the evaporators and superheaters.
The
superheated HP steam exits HP superheater #3 at approximately 1365
psia and 960 F.
Intermediate Pressure (IP) Steam: IP steam is produced in the same
manner as the HP steam, except utilizing IP boiler feedwater in the IP
sections of the HRSG. IP steam exits the IP superheater at approximately
255 psia and 524 F.

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4.2
Normal Operating Parameters

HP Normal Operating Parameters
Tag No.
FE-02001
Description
HP steam flow
TE-02001
PT-02001
HP steam temperature
HP steam pressure
TE-02010A/B
CT power augmentation steam

temperature
CT power augmentation steam
pressure
PT-02003
Parameter
500-900
kpph
895-905F
1360-1370
psia
700F
405 psia
IP Normal Operating Parameters

Tag No.
TE-03001
FE-03002
TE-03002
PT-03002
4.3
Description
IP Steam Temperature from HRSG
IP Steam Flow
IP Steam Temperature to tie-in
IP Steam Pressure to tie-in
Parameter
528F
28 50 kpph
500 550 F
195-235 psia
Secondary systems
The following systems interface with the HRSG during normal operation:

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Boiler Feedwater System

HP Steam System
IP Steam System
Condensate System
Chemical Feed System
Combustion Turbine
Fuel Gas System
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5.0
Aqueous Ammonia System

Continuous Emissions Monitoring System (CEMS)
Boiler Blowdown System
SYSTEM STARTUP
Note: Startup time depends on the length of shutdown of each HRSG
and steam turbine generator. There are three different starting
conditions:
Hot Start - The steam turbine generator has been shut down for
a short period of time, the first stage metal temperature is 900
F or greater, and the steam turbine generator is on turning
gear with steam to the steam seals.
Warm Start - The steam turbine generator has been shut down
for more than a day, and the first-stage metal temperature is
between 400 F and 900 F.
Cold Start - The steam turbine generator has been shut down
for several days, and the first-stage metal temperature is less
than 400 F.
Startup procedures for the three different starting conditions are

similar except for the warm-up times required for the piping and
steam turbine generator, which increase as the steam turbine
generator first-stage metal temperature decreases. Steam line
warm-up from a cold start is accomplished with steam from the
existing boilers.
Before starting the combustion turbine generator, the HP, IP, and
LP HRSG steam drums are set at a low level (just above the lowlow level) to account for the drum water expansion that occurs
during initial startup. The vent valve on each drum is open until
steam is established in the HP, IP, and LP steam lines. These vent
valves are then closed when the drum pressure typically reaches
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3.45 bara (50 psia) (HP and IP) and 2.07 bara (30 psia) (LP). The
HP, IP, and LP evaporator intermittent blowdown valves are closed.
These blowdown valves are operated for immediate blowdown in
the event of a high level in the HP and IP steam drums. The HP,
IP, and LP superheater drain valves are open to discharge any
condensate into the HRSG blowdown flash tank. The HP and IP
steam line drain valves are all open.
The combustion turbine generator is started, synchronized, and
loaded at a controlled rate until a predetermined load is reached,
which provides the HP steam temperature acceptable for steam
turbine generator admission. This predetermined load on the
combustion turbine generator is selected by the operator before
startup. Typically, the gas turbine generator is started and loaded
to the spinning reserve mode (5 percent load). The gas turbine
generator load ramp rate is limited to approximately 8 percent per
minute up to 40 percent steam flow (HRSG in startup). At this load,
the HP steam pressure will increase to the steam turbine generator
floor pressure. When sufficient pressure is reached, the HRSG HP
steam atmospheric vent valve (HP sky valve) opens to maintain
this pressure.
The warm-up rate for the HP steam drum is approximately 25
minutes; 15 minutes for warming the water inventory from ambient
to 212 F and then approximately 10 minutes to ramp to a soak
temperature of 482 F. This ramp rate precludes the HP steam
drum maximum allowable thermal fatigue stress from being
exceeded. Fatigue stresses on the IP and LP steam drums during
startup are not a concern.

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5.1
Precautions
WARNING: VERIFY ALL MAINTENANCE PERSONNEL HAVE EXITED
THE BOILER AND THAT ALL INSPECTION PORTS AND
MANWAYS ARE SECURELY FASTENED.
WARNING: VERIFY THAT
MAINTENANCE ACTIVITIES ARE
COMPLETE BEFORE SAFETY TAGS AND LOCKING
DEVICES ARE REMOVED.
WARNING: DO NOT ATTEMPT TO OPERATE THE HRSG AND
STEAM
SYSTEMS
WITHOUT
THOROUGH
FAMILIARIZATION OF OPERATIONAL INSTRUCTIONS.
CAUTION:
DO NOT ALLOW STEAM PRESSURE TO BUILD IN

"DEAD LEGS" AND/OR SECTIONS OF PIPE THAT
CANNOT BE DRAINED.
THIS IS TO PREVENT
HYDRAULIC HAMMER FROM CONDENSATE BUILDUP IN
STEAM PRESSURE ENVIRONMENT.
CAUTION:
ONCE THE COMBUSTION TURBINE HAS BEEN

STARTED AND TEMPERATURES IN THE HRSG BEGIN
RISING, STEAM PRODUCTION IN THE DRUMS WILL
QUICKLY FOLLOW. IT IS AT THIS CRITICAL POINT
THAT THE OPERATOR MUST BE ACUTELY AWARE OF
ALL OPERATING PARAMETERS, AS THE CONTROL OF
THE SYSTEM SHOULD BE IN THE MANUAL MODE.
CAUTION:
ON STARTUP OF THE BOILER IT IS CRITICAL TO

MAINTAIN
STEAM
FLOW
THROUGH
THE
SUPERHEATERS TO PREVENT TUBE DAMAGE.
CAUTION:
DURING A COLD START, THE STARTUP VENTS

SHOULD BE OPENED PRIOR TO FIRING THE
COMBUSTION TURBINE AND CLOSED ONCE ALL
DANGER OF EXCEEDING THE STARTUP RAMP RATE
HAS PASSED.

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THESE CONTROL VALVES SHOULD NOT BE OPERATED

AT LESS THAN 10% OPEN TO AVOID EROSION OF THE
SEATS.
General Notes:
Maintaining proper steam drum level is critical during startup and
operation of the HRSG. An excessively high water level can cause water
carryover into the superheater and result in an automatic trip of the steam
turbine. A low-low water level can result in thermal damage to the
evaporator tubes and will result in an automatic trip of the combustion
turbine.
Thermal stresses are induced in the HRSG during startup and shutdown.
The greater the rate of change during these periods, the greater the
stress. If ignored, these stresses can cause fatigue and premature
mechanical problems.
During startup, failure to expel a continuous purge of steam from the
steam drums will result in stagnation of natural circulation within the
circuit. Therefore, it is necessary to vent steam through the superheater
vent valves until the unit goes online supplying steam to the respective
header through the non-return valves.
Never operate the HRSG without all of the safety valves in place,
calibrated, and in good working condition.
The economizers should be periodically vented during HRSG operation to
prevent the accumulation of air in the high points of the tube bundles.

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The steam drum water column isolation valves should be open at all
times. Closing the valves can bypass the protective functions of the drum
level switches by holding a false level in the column.
The reliability of the steam drum level transmitters should be periodically
checked against the actual level using the corresponding gauge glass.
The steam drum gauge glass must be periodically blown down to prevent
the accumulation of contaminates and sludge.
The heat input to the HRSG should be controlled by monitoring the rate at
which the saturation temperature rises in the steam drums. The rate of
temperature increase should be limited by releasing steam through the
startup vents and/or controlling the rate at which heat enters the HRSG by
limiting combustion turbine loading.
Proper boiler water chemistry must be maintained at all times. Improper
chemistry can lead to fouling or corrosion of internal surfaces, reduced
unit efficiency, and possible damage and/or failure of the boiler tubes.
If solids carryover is being caused by excessive boiler water solids
concentration, adjustment of the continuous blowdown valve may be
required.
1_____
VERIFY proper communications are established between

floor Operators and the Control Room.
2_____
VERIFY operations personnel are rehearsed with the startup

procedures and are prepared with emergency response
actions.
3_____
VERIFY that all personnel involved with the operation of this

system are familiar with the equipment manufacturers
startup and operating procedures.
4_____
VERIFY safety tags and locking devices have been removed

as required.

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MIRANT- KENDALL
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Cambridge. MA
OPERATING MANUAL
5.2
5_____
WARNING: VERIFY THAT MAINTENANCE ACTIVITIES

ARE COMPLETE BEFORE SAFETY TAGS AND LOCKING
DEVICES ARE REMOVED.
6_____
REVIEW operations logbook for any condition prohibiting safe

startup or need for resetting of controls or instrumentation.
7_____
VERIFY all applicable safety practices and procedures are

in place.
Prerequisites
1_____
VERIFY 125VDC control voltage is available to system

instrumentation.
2_____
VERIFY 24VDC control voltage is available to system

instrumentation.
3_____
VERIFY the associated DCS control functions and interlocks

are ready for service.
4_____
VERIFY the instrument air system is in service.
5_____
VERIFY the raw water system is in service.
6_____
VERIFY the fire protection system is in service and local

portable extinguishers are fully charged.
7_____
INSPECT boiler lagging and insulation for damage or loose

sections. Notify maintenance of necessary repairs.
8_____
VERIFY that the blowdown system mechanically operable

and ready for service.

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Page 23 of 45
MIRANT- KENDALL
REPOWERING PROJECT
Cambridge. MA
OPERATING MANUAL
9_____
VERIFY that the boiler feedwater system is mechanically

operable and ready for service.
10_____
VERIFY that the HRSG chemical feed

mechanically operable and ready for service.
system
is
11_____
VERIFY that the demineralized water

mechanically operable and ready for service.
system
is
12_____
VERIFY that HP BFW system block valves are aligned to

establish flow from the HP BFW pumps to the #1 HP
economizer and to the HP steam drum.
13_____
VERIFY LP BFW system block valves are aligned to

establish flow from the LP BFW pumps to the IP economizer
and IP steam drum.
14_____
VERIFY HP steam drum level control valve LV-10013 is in

MANUAL mode and CLOSED.
15_____
VERIFY IP steam drum level control valve LV-10113 is in

MANUAL mode and CLOSED.
16_____
VERIFY HP BFW isolation MOV YV-10031 is CLOSED.
17_____
VERIFY IP BFW isolation MOV YV-10131 is CLOSED.
18_____
VERIFY the HP and IP desuperheater spray water control

valves are in AUTO.
19_____
VERIFY the desuperheater spray control valve isolation

valves are CLOSED.
20_____
VERIFY all boiler feedwater pump HOA control switches in

AUTO.

Revision: 0
Page 24 of 45
MIRANT- KENDALL
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OPERATING MANUAL
21_____
START one BFW pump with recirculation OPEN to the LP

steam drum, in accordance with the guidelines in Section
9.0, Boiler Feedwater System.
22_____
START one condensate pump and one condensate header

booster pump with makeup to the system in accordance with
the guidelines in Section 14, Condensate System.
23_____
PARTIALLY OPEN HP steam drum level control valve to fill

the HP steam drum to just above the LO level alarm
setpoint.
Note: As temperature and pressure within the boiler and
steam drums increase, water level will rise.
Therefore, allow for this expansion in setting the
working levels. If the level rises above the working
level it may be necessary to blow down some water
in order to maintain the level.
5.3
24_____
COMPARE local sight glass and level indicating to DCS

level indicator.
25_____
As the HP drum level reaches the desired level, PLACE the

level control valve in single element AUTO control and
monitor feedwater flow shutoff on the associated BFW flow
indicator.
26_____
From the DCS, OPEN IP BFW level control valve and repeat
the process.
27_____
CHECK the boiler feedwater chemistry for proper quality.
Startup

Revision: 0
Page 25 of 45
MIRANT- KENDALL
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OPERATING MANUAL
Note:
It is recommended that start-up of the boiler be manually

controlled; however controllers should be placed in
automatic position as soon as possible.
Note:
The normal shutdown condition of the boiler is a wet lay-up

with minimal operator involvement returning it to full
operation.
1_____
START the combustion turbine in accordance with

guidelines in Section 12.0, Combustion Turbine Generator
2_____
MONITOR the level in the HP, IP and LP steam drums.
3_____
CLOSE LP steam drum vent valves when drum pressure

reaches 25-30 psig.
4_____
CLOSE HP and IP steam drum vent valves when drum

pressure reaches 50 psig.
5_____
Once steam drum pressures have reached 50 psig, the

Operator may place the boiler feedwater control system in
AUTO single element control mode.
Note: Verify that boiler feedwater supply and steam flows
are stabilized and correspond before placing in three
element control.
6_____
OPEN HP and LP intermittent blowdown valves on the

steam drums to prevent high drum levels, if necessary.
Note: It may be necessary to first drain down the blowdown
tank prior to opening the intermittent blowdown
drains.

Revision: 0
Page 26 of 45
MIRANT- KENDALL
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OPERATING MANUAL
7_____
ADJUST combustion turbine heat output to the boiler or

regulate superheater startup vent valving to produce
8%/minute maximum temperature increase during start-up.
8_____
PARTIALLY OPEN the existing steam isolation valve and

begin warming the HP steam system.
9_____
PARTIALLY OPEN the existing steam isolation valve and

begin warming the IP steam system.
10_____
VERIFY HP and IP desuperheaters are in service.
11_____
ENSURE that low point drains on steam headers remain

OPEN during low-pressure warm-up only.
12_____
ADJUST the continuous blowdown rate from the steam

drums to the minimum acceptable level to maintain boiler
water quality.
CAUTION:
DO NOT START THE DUCT BURNER UNTIL STEAM

PRESSURE AND TEMPERATURE HAVE STABILIZED
AND THE COMBUSTION TURBINE GENERATOR IS AT
BASE LOAD.
13_____
OPERATE the intermittent blowdown at 1/2-hour intervals

for three blows to rid the system of any residual silt or
sludge collected during shutdown.
14_____
OPEN the economizer vents for 2 minutes to ensure that all

air is out of the economizers.

Revision: 0
Page 27 of 45
MIRANT- KENDALL
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OPERATING MANUAL
6.0
NORMAL OPERATION
During normal operation, the main steam system operates at various
loads dictated by ambient conditions and the steam turbine generator and
combustion turbine generators electrical demand. As the electrical
demand changes, the HRSG high pressure steam pressure is kept
constant by varying duct burner firing, which in turn maintains steady HP
steam pressure to the steam turbine generator.
6.1
Valve Alignment
HP Steam System
Valve Tag
YV-10040
YV-10041
TIC-10019
PCV-10227
YV-02013
YV-02002
PV-02003
YV-02004
YV-02009
YV-02014
YV-10039
YV-10037
YV-10036

Revision: 0
Description
Startup vent
HP steam outlet valve
HP desuperheater BFW control
Pegging
steam
pressure
control
Existing STG steam supply
CT steam injection supply MOV
CT steam injection pressure
control
HP steam line drip leg drain
HP 1 superheater drain
HP 2/3 superheater drain
Page 28 of 45
Position
Closed
Open
Variable
Variable
Open
Open
Variable
Closed/Auto
Closed/Auto
Closed/Auto
Closed/Auto
Closed/Auto
Closed/Auto
MIRANT- KENDALL
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OPERATING MANUAL
IP Steam System
Valve Tag
YV-10140
YV-10141
TY-10119
YV-03101
YV-03102
YV-03007
YV-03009
YV-03010
Description
Startup vent
IP steam outlet valve
IP desuperheater BFW control
CT injection steam control valve
CT steam injection stop valve
IP steam line drip leg drain
Position
Closed
Open
Variable
Variable
Open
Closed/Auto
Closed/Auto
Closed/Auto
WARNING: EXERCISE EXTREME CAUTION WHEN WORKING ON

OR NEAR EQUIPMENT THAT GENERATES STEAM WITH
HIGH PRESSURE AND TEMPERATURE.
CAUTION:
NEVER DEPEND ENTIRELY UPON AUTOMATIC ALARMS

OR FEEDWATER INSTRUMENTATION FOR CONTROL
OF BOILER LEVELS. PERIODICALLY INSPECT LOCAL
PRESSURE, TEMPERATURE, AND LEVEL INDICATORS
FOR COMPARATIVE READINGS ON THE DCS.
Note:
The following checks and inspections

accomplished at least once per shift.
Note:
During normal operation, Operators should periodically visit

the HRSG to check local instrument readings. During these
walk-downs, the operator should look for potential
equipment problems. If a problem is observed, it should be
quickly evaluated for its severity and a corrective plan be
developed.
1_____
INSPECT boiler equipment, valves and piping for steam,

water and hot air leaks.

Revision: 0
Page 29 of 45
should
be
MIRANT- KENDALL
REPOWERING PROJECT
Cambridge. MA
OPERATING MANUAL
2_____
RECORD system parameters. INVESTIGATE all abnormal

readings.
Note: DCS trends of operating parameters indicate
problems such as fouling or turbine degradation. A
review of this data should be made regularly, looking
for any changes in unit performance
3_____
Periodically BLOW DOWN steam pressure gages, level

columns and gages periodically to ensure proper flushing.
4_____
CHECK the overall condition of the HRSG. Steam or water

leaks from any source should be investigated and repaired
as soon as possible.
Note: Gas side leaks should be noted and scheduled for
repair. In particular, casing penetrations at inlet and
outlet headers and drain lines should be checked for
leaks.
Note: The bottom of the HRSG casing is equipped with
drain valves. A rupture or leak within the steam/water
circuits of the HRSG will be indicated by the presence
of water at the drain connections.
5_____
CHECK the HP and IP superheater vent valves for steam

leakage. Due to their service, these valves may require
more frequent attention than others.
6_____
INSPECT expansion joints for discoloration of fabric belt due

to leak or high heat waves
Note: Expansion joints may have heat waves due to hot
flange connections to CTG flange and diffuser duct.
7_____
Revision: 0
Inspect casing for paint discoloration or peeling hot spots.
Page 30 of 45
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OPERATING MANUAL
8_____
INSPECT casing for water leakage (particularly at the rear

of the HRSG.
9_____
INSPECT casing for smoke or plume due to casing leak

heat waves
10_____
CHECK for signs of manway cover leakage.
11_____
LISTEN to piping for water hammer.
12_____
INSPECT platforms for loose grating or bolting on handrails.
13_____
MONITOR vent stack for excessive steam plume.
14_____
INSPECT safety valves for "sizzling" valve due to poor

seating.
15_____
CHECK for steam plume from vent stacks when valve

should be closed.
16_____
LISTEN to deaerator for signs of rumbling.
17_____
MONITOR carryover (steam purity) from steam drum to

superheater.
18_____
ANALYZE total solids concentration and silica values.

Intermittent blowoff shall be used to reduce boiler water TDS
in order to improve steam purity.
19_____
MONITOR oxygen content of the boiler.
20_____
MONITOR DCS for indications of abnormal conditions.
21_____
MONITOR tube metal surface temperature to verify

temperature is within design limits.

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Page 31 of 45
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OPERATING MANUAL
Note: If the temperature limit is exceeded, it must be

immediately
investigated
for
problems
like
steam/water flow, localized hot gas temperature, etc.
22_____
MONITOR gas side pressure drop across HRSG. Increased

pressure drop may indicate fouling possibility.
23_____
LISTEN for unusual noises coming from HRSG inlet duct.
24_____
On a periodic schedule, manually BLOW DOWN the HP

steam system line drip legs and gage glasses.
25_____
MONITOR steam drum level gages for operating water

levels.
Note: it may be necessary for the operator to blow down
the water column and gage drains. More frequent
blowdown may be necessary when trouble is
experienced with boiler compounds, foaming, priming,
and other feedwater problems.
Make provisions to by-pass any low water cutouts
while blowing down the gage glasses and water
columns. Experience may indicate that less frequent
blowdown is desirable. This should be coordinated
with the boiler operator, and water treatment
consultant.
26_____

Revision: 0
MONITOR boiler feedwater pumps for excessive noise,

vibration, or heat buildup.
Page 32 of 45
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OPERATING MANUAL
27_____
BLOW DOWN the boiler drums as required, by OPENING

the bottom, or intermittent blowdown valves.
Note: Better cleaning is obtained with multiple short blows
than one long blow. The valve farthest from the boiler
should be completely opened before the valve
closest to the drum is opened.
Open the second valve fully and quickly, leaving it
open for only a few seconds. If possible, watch the
flow of water coming from the bottom of the drum. If
there are solids in the water, perform a second
bottom blow and repeat this process until the water is
clear.
The frequency of performing this procedure should be
between once per shift and once per week, depending on
the quality of the feedwater. To ensure the valves work
when needed, always bottom blow at least once per week.
28_____
MONITOR boiler feedwater chemistry by periodically taking

water samples from the grab sample outlets and comparing
to water/steam analyzers.
29_____
COMPARE DCS indicating controllers with local readings.
30_____
REVIEW HP boiler conditions on three-element control by

RECALLING the HISTORICAL TREND feature on the DCS.
31_____
REVIEW LP boiler conditions on three-element control by

RECALLING the HISTORICAL TREND feature on the DCS.
32_____
MONITOR HRSG skin temperatures for possible "hot spots".

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OPERATING MANUAL
33_____
MONITOR DCS for indications of abnormal conditions.
34_____
MONITOR HP steam drum level gages and EYE-HYES for

operating water levels.
35_____
MONITOR DCS for indications of abnormal

temperature, pressure and flow conditions.
36_____
MONITOR steam parameters by RECALLING the historical

trends from the DCS.
37_____
VERIFY HP steam pressure to Kendall Station is between

1360 and 1370 psia
38_____
VERIFY HP steam temperature to Kendall Station is

between 895 and 905F.
39_____
VERIFY that HP steam flow is 500 to 900 kpph.
40_____
VERIFY HP steam pressure to CT steam injection is

approximately 405 psia
41_____
VERIFY HP steam temperature to CT steam injection is

approximately 700F.
42_____
VERIFY HP steam blowdown temperature to the HRSG

intermittent blowdown drum is normal.
43_____
MONITOR IP steam drum level gages and EYE-HYES for

operating water levels.
44_____
VERIFY IP steam flow at FI-03002 is 28 50 kpph.
45_____
VERIFY IP steam pressure at PI-03002 is approximately 255

psia.
46_____
VERIFY IP steam temperature at TI-03002 is normal.

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Page 34 of 45
steam
MIRANT- KENDALL
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OPERATING MANUAL
7.0
NORMAL SHUTDOWN
7.1
Precautions
WARNING: HP
STEAM
HEADER
COMPONENTS
BECOME
EXTREMELY HOT DURING OPERATION. SOME AREAS
MAY RETAIN RESIDUAL HEAT FOR LONG PERIODS
AFTER SHUTDOWN. WEAR PROTECTIVE APPAREL TO
PREVENT SERIOUS BURNS TO EXPOSED SKIN.
MANY LINES AND FITTINGS ON THE BOILER CONTAIN
STEAM AND HOT FLUIDS UNDER HIGH PRESSURE.
USE EXTREME CAUTION WHEN LOOSENING PIPING
AND FITTINGS.
WEAR SAFETY GOGGLES AND
GLOVES WHEN PERFORMING MAINTENANCE TO
PREVENT EYE INJURY OR BURNED SKIN.
WARNING: FOLLOW
LOCKOUT
PROCEDURES
WORKING ON THIS EQUIPMENT.
PRIOR
TO
WARNING: EXTREME CAUTION SHOULD BE EXERCISED BEFORE

ENTERING THE STEAM DRUMS AS THEY MAY CONTAIN
OXYGENLESS GASSES THAT CAN CAUSE SEVERE
ILLNESS OR DEATH IF INHALED.
ENSURE THE APPROPRIATE CONFINED SPACE ENTRY
PERMIT IS FILLED WITH THE DESIGNATED SAFETY
OFFICER.
Note:

Revision: 0
During unit operation, feedwater sludge and other matter

are kept in suspension by circulation of the boiler water.
When the circulation stops due to shutdown, solids will tend
to settle and adhere to internal surfaces. This can inhibit
heat transfer and promote corrosion. To avoid these
Page 35 of 45
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OPERATING MANUAL
problems, perform the following several hours or more prior

to unit shutdown:
7.2
Increase continuous blowdown by 10% and double the

frequency of bottom blowdown.
Increase the boiler water alkalinity treatment based on

the guidelines of the plants Boiler Water Treatment
Program.
1_____
COORDINATE stopping the boiler feedwater pumps and

steam systems with the Control Room Operator, as
shutdown of the boiler requires a prior orderly shutdown of
the duct burner and combustion turbine.
2_____
Prior to shutdown, CHECK drum chemistry to ensure that

pH, the oxygen scavenger and phosphate inhibitor residuals
are at the proper level.
Shutdown
1_____
If the duct burner is operating, TURN DOWN the burner

control by lowering the setting on the DCS gradually until
the controls are at the minimum fire position.
2_____
SHUTDOWN the duct burner from the DCS, following the

Forney operating procedures.
3_____
Following GE operating procedures, SLOWLY REDUCE

combustion turbine to minimum load before shutdown.
4_____
At the DCS, PLACE HP steam controllers and valves in the

MANUAL mode.
5_____
REMOVE the HP and IP desuperheaters from service by

CLOSING the associated temperature control valve.

Revision: 0
Page 36 of 45
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OPERATING MANUAL
6_____
MAINTAIN load at minimum level for an additional 15

minutes if conditions permit. TRIP the turbine.
7_____
MONITOR steam drum levels. Add boiler feedwater as

needed to maintain levels between the LO level setpoint and
normal operating level.
8_____
CLOSE HP and IP steam drum continuous blowdown.
9_____
STOP HRSG chemical injection into the steam drums.
10_____
At the DCS, CLOSE combustion turbine HP steam injection

isolation MOV valve.
11_____
Once steam pressure in the HP steam line diminishes,

CLOSE HP steam header isolation MOV.
Note: If the boiler is to be shutdown, isolate the HP steam
header when line pressure decreases to
approximately 15 psig.
12_____
OPEN HP steam header startup vent.

Note: Opening the startup vent is not required if the HRSG
is to be bottled up for temporary shutdown.
13_____
OPEN HP and IP steam header vents when drum pressure

decreases to less than 25 psig to avoid drawing a vacuum
on the system.
14_____
OPEN HP steam header low point drains.
15_____
CLOSE boiler feedwater level control valves when no further

makeup water is required.
Note: If the HRSG is to be shut down for a period of less
than 24 hours, the unit can be bottled up by closing

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Page 37 of 45
MIRANT- KENDALL
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OPERATING MANUAL
the steam header isolation valves, boiler feedwater

supply valves and the continuous blowdown valves.
16_____
DETERMINE
accordingly.
lay-up
considerations
and
prepare
Note: Depending on ambient conditions, the HRSG will

remain warm for up to 24 hours after unit shutdown.
If the combustion turbine is scheduled for restart
within that period of time, the system can be left as is,
ready for an immediate return to service.
If the unit is to remain idle for a week or more, a wet
lay-up must be performed in accordance with the
manufacturers procedures and recommendations.
If the boiler is to be placed in wet storage open all
boiler feedwater pump circuit breakers.
Fill the steam drums completely full to the top by
opening the makeup valve bypass with the block
valves closed. This action will minimize the corrosion
attack in the unit and prevent the presence of oxygen
within the system.
When water has reached the uppermost position as
evidenced by seepage from the vent valves, close the
makeup by-pass valve.
For longer outage periods it is recommended that a
"nitrogen blanket" be applied to each steam drum
through the nitrogen fill and bleed valves fitted on
each drum.
17_____

Revision: 0
ISOLATE any equipment requiring maintenance.
Page 38 of 45
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OPERATING MANUAL
8.0
18_____
ENSURE necessary work permits have been issued prior to

beginning maintenance on the system.
19_____
PERFORM all pre-start inspections before placing the

system back in service.
ABNORMAL SHUTDOWN
8.1
Power Failure
Other than instrumentation 24VDC control voltage and 125VDC control
valve voltage, the HRSG does not require electrical power to operate.
8.2
Instrument Air Failure

Loss of instrument air to the control valves would prevent automatic
control of the steam system pressure and temperature and shutdown the
combustion turbine and all steam production.
Manual regulation of
steam by a qualified Operator can maintain steam production and boiler
feedwater supply by monitoring pressure, flow and temperature. The
system can function until instrument air is restored to the affected
component(s) or an orderly shutdown can be accomplished.
All control valves would go to their design fail position.

Revision: 0
Page 39 of 45
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OPERATING MANUAL
8.3
Steam Turbine Generator Trip

In the event of a steam turbine generator trip, the following devices are
actuated closed by either the DCS or the steam turbine generator control
system:
Main steam stop and control valves
HRSG HP steam isolation valves (only in the event all STGs tripped).
A single turbine trip would only require a runback to minimum turbine
load.
9.0
ALARM SUMMARY AND RESPONSE

The following chart is provided to assist an experienced Operator in
identifying and resolving abnormal conditions associated with the Heat
Recovery Steam Generators. It is not intended as a substitute for a
thorough understanding of the system equipment, common sense, and
safe operating practices and techniques.
Alarm
LAH-xxxx
Steam drum HI
level alarm
Probable Cause
Feedwater valve
malfunction
Response Action
Remove water from the drum through
the intermittent blowdown valves.
Feedwater valve setpoint

incorrect
Verify the level control valve

feedwater pump is in AUTO.
Feedwater valve
operation incorrect
Check control valve for possible

binding; i.e., stuck in the open position.
Use manual bypass valve if necessary.
Drum level instrument

failure
or
Check the drum level controller for

failure. If the controller fails to operate
in AUTO, place in MANUAL and
control level as necessary.
Check level transmitter signal quality.

Revision: 0
Page 40 of 45
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OPERATING MANUAL
Compare remote level indications

against the local sight glass.
Swelling of water during startup
Level control loop malfunction or incorrect
setpoint.
LAHH-xxxx
Steam drum HI HI
level alarm
Feedwater valve
malfunction
incorrect
Feedwater valve
operation incorrect
failure
Check for HI level alarm LAH-xxxx

Check steam drum level gage
Check DCS level control setpoint
Check if HP boiler feedwater level
control valve stuck open
Check for possible sudden pressure
loss on HP steam system or vent
opening
Check that feedwater and steam outlet
flow correspond - switch to single
element control in the event they vary
noticeably
Note:
HI HI Steam drum alarm results in
an automatic trip of the steam turbine and
duct burner.
As appropriate, restore steam turbine
operation when drum level is restored.
LAL-xxxx
Steam drum LO
level alarm
Feedwater valve
malfunction
incorrect
Feedwater valve
operation incorrect
failure

Revision: 0
Verify the level control valve

feedwater pump is in AUTO.
or
Check control valve for possible

binding; i.e., stuck in the closed
position. Use manual bypass valve if
necessary.
Check the drum level controller for
failure. If the controller fails to operate
in AUTO, place in MANUAL and
Page 41 of 45
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OPERATING MANUAL
control level as necessary.

Check level transmitter signal quality.
Compare remote level indications
against the local sight glass.
Add makeup to bring level to normal
operation level.
LALL-xxxx
Steam drum LO LO
level alarm
Feedwater valve
malfunction
incorrect
Feedwater valve
operation incorrect
failure
Check for LO level alarm

Check steam drum level gage
Check DCS level control setpoint
Check if the gas turbine tripped
Check if duct burner tripped to the low
fire position
Check if boiler feedwater level control
valve is stuck closed
Check for sudden pressure increase in
steam system
NOTE: Alarm results in an automatic
TRIP of the combustion turbine.
Address the unit trip. Perform all functions
associated with a unit shutdown.
Make repairs or adjustments to the system
as required.
Restore drum level.
Restore unit operation.
PAH-xxxx
Steam drum HI
pressure alarm
Revision: 0
Gas turbine load to high
Check pressure gage

Check the pressure setpoint in DCS
Duct burner firing rate too

high
Open steam drum vent
Page 42 of 45
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OPERATING MANUAL
Pressure relief valve

failure
Decrease duct burner firing

temperature
Decrease gas turbine load
Pressure instrument
failure
Check for sudden decrease in HP

steam flow
Steam drum vent

misalignment
TAH-xxxx
Steam drum HI
temperature alarm
Gas turbine load to high
Check DCS temperature indicator

Check alarm setpoint
Duct burner firing rate too

high
Temperature instrument
failure
Check HI temperature switch

operation and setpoint
Reduce duct burner firing temperature
Check for abnormally high steam
drum pressure
Duct firing rate too low

TAL-xxxx
LO temperature
alarm for steam
exiting the steam
drum
Check DCS pressure indicator

Turbine load minimum
Instrument failure
Increase duct burner firing

temperature
Temperature setpoint
Check for abnormally low steam drum

pressure
incorrect
TAH-xxxx
Steam desuperheater
HI temperature
alarm for the HP
flow control valve

Revision: 0
malfunction
Check DCS pressure indicator

10019
TI-
Compare to temperature indicating
Page 43 of 45
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OPERATING MANUAL
steam header from

the desuperheater
transmitter TIC-10019
Low feedwater flow to
attemporator
Temperature controller

Check if temperature control valve is
stuck closed
setpoint incorrect
Check DCS temperature controller

setpoint
Instrument failure
Check desuperheater operation

Check duct burner firing temperatures
10.0 REFERENCES
10.1
Piping and Instrument Diagrams

Revision: 0
20-078-1-PS-050 Condensate
20-078-1-PS-060 Boiler Feedwater
20-078-1-PS-090 Blowdown, Traps, and Drains
20-078-1-PS-500, 501, 502 - Sampling
20-078-1-PS-520 Chemical Feed Steam Cycle
20-078-1-PS-650 Fuel Gas
20-078-1-PS-780 Aqueous Ammonia Storage and Supply
3595-0201 Low Pressure (Foster Wheeler)
3595-0202 Intermediate Pressure (Foster Wheeler)
3595-0203 High Pressure (Foster Wheeler)
3595-0204 Gas Flow (Foster Wheeler)
Page 44 of 45
MIRANT- KENDALL
REPOWERING PROJECT
Cambridge. MA
OPERATING MANUAL
10.2
61-7723-5-6101 Selective Catalytic Reduction (Foster Wheeler)

400851-01 Multiple Gas Element Duct Burner (Forney)
Vendor Manuals

Revision: 0
Foster Wheeler HRSG

Forney
Page 45 of 45

Heat Recovery Steam Generator Operation Manual

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Heat Recovery Steam Generator Operation Manual

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MIRANT- KENDALL

HEAT RECOVERY STEAM GENERATOR

1.0 Simplified Diagram......................................................................3

Date of Issue: 12/20/01

8.0 Abnormal Shutdown..................................................................39

Date of Issue: 12/20/01

Date of Issue: 12/20/01

Duct Burner Trip

Duct Burner Runback

HEAT RECOVERY STEAM GENERATOR

The purpose of the heat recovery steam generator is to pre-heat boiler

Date of Issue: 12/20/01

Date of Issue: 12/20/01

The evaporator sections of each HRSG consist of a steam drum,

Date of Issue: 12/20/01

Support Steel, Stairs and Platforms

Selective Catalytic Reduction System

Control Loop Narratives

The LP Steam Drum Pegging Steam Pressure Control Valve

Date of Issue: 12/20/01

LCV-10013 HP Steam Drum Level Control

This description also applies in principle to IP and LP control

The level indicating controller is preset to maintain HP

Date of Issue: 12/20/01

During three-element control, the level controller uses the

During normal operation, the valve is in AUTO, 3-ELEMENT

LP Feedwater Economizer Bypass Block Valve

The HRSG LP Economizer Bypass Valve is controlled and

Date of Issue: 12/20/01

Valve will automatically CLOSE, when valve is in AUTO,

Valve will automatically OPEN, when valve is in AUTO, if

When changes in system occur, the DCS will indicate either

Valve will CLOSE when the LP economizer is placed in

Valve will OPEN when the LP economizer bypass is

If valve does not meet open or closed limits in a specified

Gas Turbine Trip

HP Drum level low-low (LSLL-10014) @ NWL 52.5

Date of Issue: 12/20/01

IP Drum steam pressure high-high (PT-10111) @ 345 psig (2 nd safety

HP Drum steam pressure high (DCS alarm from PT-10011) @ 1546

Date of Issue: 12/20/01

Primary System Flow Path

Date of Issue: 12/20/01

Normal Operating Parameters

CT power augmentation steam

IP Normal Operating Parameters

Date of Issue: 12/20/01

Boiler Feedwater System

Aqueous Ammonia System

Startup procedures for the three different starting conditions are

Date of Issue: 12/20/01

DO NOT ALLOW STEAM PRESSURE TO BUILD IN

ONCE THE COMBUSTION TURBINE HAS BEEN

ON STARTUP OF THE BOILER IT IS CRITICAL TO

DURING A COLD START, THE STARTUP VENTS

Date of Issue: 12/20/01

THESE CONTROL VALVES SHOULD NOT BE OPERATED

Date of Issue: 12/20/01

VERIFY proper communications are established between

VERIFY operations personnel are rehearsed with the startup

VERIFY that all personnel involved with the operation of this

VERIFY safety tags and locking devices have been removed

Date of Issue: 12/20/01

WARNING: VERIFY THAT MAINTENANCE ACTIVITIES