Download - 0504.05-ES-20.14_Rev. D3

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  • ES-20.14

    WASTE HEAT PTT PUBLIC CO., LTD PAGE 1 OF 10 RECOVERY UNITS ENGINEERING STANDARD REV: 02

    ES-20_14 WHRU(23 Nov 11)

    REVISION REV 01 REV 02 REV 03 REV 04 REV 05 REV 06

    DATE JAN 04 Sept 11

    ORIG.BY PIRIYA Weradech

    APP BY Sunvaris

    SIGNATURE

    CONTENTS

    SECTION SUBJECT

    1.0 SCOPE

    2.0 MAIN COMPONENTS OF THE SYSTEM

    3.0 HOT OIL PUMPS

    4.0 MISCELLANEOUS

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    ES-20_14 WHRU(23 Nov 11)

    1.0 SCOPE

    This standard covers the Waste Heat Recovery Units (hereinafter called Heaters).

    2.0 MAIN COMPONENTS OF THE SYSTEM

    2.1 Burners

    a) Only burners commercially proven in comparable services shall be acceptable.

    b) The burners shall be the Gas burner, Low NOx type

    c) Local control and turndown ratio shall be 20:1.

    d) SAFETY PLC based burner management system (BMS) shall be supplied for the start-up and shutdown of the duct burner (supplementary firing). The BMS

    shall be based on the requirements of NFPA 85.

    e) Each burner shall be capable of firing at 125% of design heat release.

    f) Two UV flame scanners shall be provided for each burner runner. UV flame

    scanners shall be sighted to see pilot as well as main flame. UV flame scanners

    shall not sense to any radioactive source.

    g) One peep hole shall be provided for each burner runner. The sight port ray

    diagram shall be provide to confirm that the operator can properly see the

    flame.

    h) Flame stability shall be maintained.

    i) Burners manufacturer shall be select form the Vendor Lists.

    j) Each burner runner shall be provided with fuel isolation valve (tight shut-off,

    metal seat type ,and shall be operated/powered by 24VDC )

    k) Burner lay-out and the path of flue gas through the heater shall ensure

    symmetrical heat flux loading of heater casing and all convection banks confirm

    with CFD modeling

    Flames shall not impinge on walls or any metal parts during any operating

    condition confirm with CFD modeling.

    Burners and associated equipment shall be capable of withstanding the

    maximum turbine exhaust gas (TEG) temperature when not firing, and

    maximum temperature/back-radiation when firing.

    Burner shall have load variation between 25%-110% of normal heat release

    without changing of burner. The flame shall remain stable and in case a flame

    detector is applied, it shall produce a stable signal over the whole operating

    range of burner.

    When operating at reduce firing rates, shutdown some burners if possible but

    burner material shall not have any affect.

    The burners shall be properly designed to burn the provide fuel from minimum

    load to maximum load without carbon build up and flame impingement.

    2.2 Pilots Igniters

    a) Each burner runner shall be provided with a gas fueled pilot burner.

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    ES-20_14 WHRU(23 Nov 11)

    b) The pilots shall be of the interrupted type with spark igniters.

    c) Each pilot shall have a minimum heat release of approximately 5% of the main

    burner.

    d) Flame stability shall be maintained.

    e) Ease of ignition shall be guaranteed.

    f) Pilot gas header and burner gas header shall furnished with individual pressure

    regulator.

    g) Each pilot burner runner shall be provided with fuel isolation valve (tight shut-

    off, metal seat type, and shall be operated/powered by 24VDC)

    2.3. Refractory/Insulation

    Duct/Heater shall be insulated by internal insulation using high density Insulation Brick. Castable refractory shall be used under PTTs prior approval. Refractory/insulation thickness shall be provided to achieve outside casing temperature of max 70 C in still air

    (0.0 m/s) at an ambient temperature of 40 C. However in areas where the operator can

    get in contact with the casing, the temperature shall not exceed 60 C. Where this is not

    feasible, adequate personal protection shall be provided.

    Main exhaust stacks and bypass stacks shall not be insulated by any internal lining. They

    shall be bare steel stack. However in areas where the operator can get in contact with the

    stack casing and temperature higher than 60 C the external lining or personal protection

    shall be provide.

    Bypass stacks shall be made from stainless steel.

    Ceramic fiber with stainless steel liner may be used instead of Insulation Brick, under PTTs prior approval, However

    - each liner plate shall thermally design to accommodate thermal expansion , anchor

    point and free end of all plates shall be defined on the drawing.

    - Anchor shall be studs and double nuts. Both studs and nuts shall be stainless

    steel. Stud size shall be M12 minimum.

    - Liner thickness minimum of 3.0 mm on floor and Wall and roof may be 2 mm or 3

    mm.

    - The manufacturer/Supplier shall ensure that the steel sheeting is supported firmly

    on both surfaces such as the TEG pressure fluctuations or vibration will not cause

    the sheet move or work loose and compress the underlying ceramic fiber.

    - Particular attention shall be given to the duct floor, which shall be sufficiently strong

    to bear the weight of maintenance personnel and scaffolding. The density of

    insulation brick or other refractory, the thickness of sheet and pitch of anchors shall

    be so chosen to meet this requirement.

    - Manhole, access doors, etc. Shall have their own separate insulation or refractory

    so that they can be opened without damage to the insulation or refractory.

    The selected refractory/insulation layer thickness shall be at least 10% above the

    calculated minimum thickness to achieve the limit on surface temperatures. Surface

    temperature calculations shall be performed for maximum ambient temperature and 0.5

    m/s wind velocity, the design calculation shall be submit. Insulation quality shall be tested

    by infrared scan as parts of guarantee test.

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    ES-20_14 WHRU(23 Nov 11)

    2.4. Access Doors

    Each heater shall have lined access doors, which are structurally rigid, to the

    up/downstream of the radiation section, above the convection section ,upstream of the by-

    pass damper, upstream/downstream of the duct burner, etc. Access doors shall be sized

    of 600mm X 600mm with davit/hinge and shall be explosion proof type.

    2.5. Observation Openings

    Peepholes and/or observation openings shall be provided in sufficient number to permit

    observation of all radiation tubes as well as the flames. 2X100% centrifugal blowers shall

    be provided to supplied cooling air to observation opening, pilot, flame scanner, etc.

    Cooling air pressure monitoring and low alarm shall be provided.

    Observations windows shall be provided on supplementary fires and afford an

    unrestricted view of all burners and flames. The windows shall also allow observation of

    all surfaces liable to flame impingement.

    The glasses shall have external cover to prevent cracking and shall be protected on the

    hot side by pivoting metal plates. It shall be possible to renew the glasses during

    operation using purge air or the above mentioned pivoting metal plates

    2.6. Stacks

    a ) Each gas turbine shall have its own by-pass stack. Each hea te r shall have

    its own main stack. The stack shall be of a self-supporting construction.

    b ) The minimum height of each stack (also the stack of the gas turbine) shall be 25 m above ground level. If the specified environmental impact data cannot be met by a stack height of 25 m, the stack height shall be increased accordingly.

    CONTRACTOR shall confirm stack heights required. According to the Air

    Dispersion Modeling analysis.

    c) Each stack shall be provided with a painter ring and a trolley.

    d) A protection device against rain shall be provided at each the bypass stack and

    WHRU main stack.

    e) Continuous emission monitoring (CEM) for NOx and O2 shall be supplied at each

    stack.

    Additional 4 inch manual sampling nozzle with full bore valve and blind flange and

    platform shall be provided at each stack.

    g) 4 inch low point drain with valve and blind flange shall be provided at each stack.

    h) Sampling nozzle shall locate at the position that can insert sampling detector to

    the middle of WHRU duct.

    2.7. Tubes

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    a) Materials and wall thicknesses shall be in accordance with API recommended

    practice for the calculation of heater tube thickness in petroleum refineries, API

    530.

    b) External piping shall be in accordance with ANSI B31.3.

    c) All tubes shall be in accordance with ASTM specification.

    d) Minimum design pressure for calculation of the tube wall thickness is 10 barg.

    e) Design temperature for calculating the tube wall thickness for required shall be

    28 C above the maximum calculated metal skin temperature for clean tube

    condition.

    f) Minimum corrosion allowance is 3 mm.

    g) Fin-type extended surface tubes may be used in the convection section. Fins

    shall be welded to the tubes. Extended surface dimension shall be complied with

    API 560.

    h) Tube skin temperature monitoring and alarm at CCR shall be provided.

    j) Heater tube shall be horizontal arrangement to allow freely drain of the hot oil

    from the heater.

    k) Total hot oil flow meter to each heater shall be provided. In addition, if split

    flow to different tube section , hot oil flow meter shall be provided for each

    section.

    l) Computerized Fluid Dynamic (CFD) shall be utilized to confirm WHRU duty,

    temperature distribution/zoning, flow distribution all area (including burner and

    SCR module), pressure drop across whole WHRU system for flue gas side and

    hot oil side. The flow distribution over 95 % of duct area may not vary more than

    5% of the average velocity and no location flow should vary by more than 15% of

    average velocity.

    m) CFD shall utilized for all of operating case.

    n) 2 of 3 inch nozzle with valve and blind shall be provide as vent and drain for each

    hot oil header.

    o) Blind and oil filling connection for pressure test according safety legislation by law

    shall be providing.

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    Typical arrangement Inlet/Outlet valve

    2.8 Dampers (Diverter)

    a) Each Gas Turbine shall have its own main damper and its own by-pass damper

    for control purposes. These dampers are mechanically linked.

    Dampers shall be of multi-blade type, pneumatic operate with positioner.

    Damper shaft shall be furnished with spherical bearings, these bearings shall be

    mounted in the cold zone (away from the heater casing).

    Leak rate of each damper shall be Zero when fully closed at all turbine operating

    conditions.

    It shall be possible to lock damper in its close position. The damper blade shall

    not move under the effects of gravity or vibration.

    b) Isolation guillotine with 2X100% seal air fan, shall be provided downstream of

    each main damper. Seal air fan shall be mounted on WHRU foundation.

    Guillotine blade shall be made from high-alloy steel.

    Isolation guillotine shall be supplied with gear operating electric motor and

    bypass with manual turn facility including a hand wheel.

    Manual insertion of guillotine plate shall be done from the top of ducting by

    means of a chain block which shall not normally from part of the supply. The

    chain block shall be supported from suitable overhead beam. Facilities for storing

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    ES-20_14 WHRU(23 Nov 11)

    the spade plate securely while not in use shall be included.

    2.9 Fuel Gas skid

    Fuel Gas skid shall be consist of - adequate strainer with PDI, isolation and by-pass valve

    - Isolation gate valve with spectacle blind shall be provided at inlet.

    - double block and bleed valves systems (with positioner and partial stroke

    test function) shall be provided at fuel gas main header.

    - Pressure regulator at fuel gas main header.

    - Fuel control valve (with positioner).

    - Coriolis type mass flow meter, block and bypass valves.

    - Local Control Panel

    2.10 Selective Catalytic Reduction (SCR) system

    a) SCR shall be ammonia-base SCR system that use 27% Liquid Aqueous Ammonia b) Amonia injection nozzle shall cleanable type. c) Amonia 2x100% filter shall be provide. d) SCR continuous service life shall be 48 months with out maintenance require. e) NOx outlet from SCR system shall be less than 12 ppmv (correct to 7% O2 dry) for

    all along SCR service life (48 months). Vendor shall guarantee emission outlet shall less than limit in any operating case such as GTE mode, non GTE mode, and turndown mode.

    f) Vendor has to confirm emission requirement as below at each WHRU exit - NOx and NO2 : 12 ppmv @7% O2 dry - CO2 : 621 ppmv @7% O2 dry - NH3 slip : 2 ppmv @7% O2 dry

    g) Vender shall provide maintenance area, tools, equipment for catalyst handling. h) Electric control panel for Ammonia heater shall compliance with IEC standard and

    should install on main sub. Contractor shall provide SCR catalyze bed diff pressure transmitter.

    3.0 HOT OIL PUMPS

    3.1 Pumps for hot oil shall be in accordance with API610 8 th edition and API682. Pumps

    for hot oil shall have proven shaft seals the suitability of which shall be certified by the

    VENDOR.

    3.2 If cooling is required, cooling system failure shall be alarmed.

    4.0 MISCELLANEOUS

    4.1 Emissions

    Data given in the Project Specification shall not be exceeded.

    4.2 Heater casing plate thickness shall be 5-mm minimum. Floor and roof plate

    thickness shall be 6-mm minimum. The heater casing shall have a design pressure

    based on the most severe combination of wind pressure/suction and 1.5 times the

    maximum operation pressure in the casing, but not less than 50 mbar.

    4.3 Carbon steel casing of heater (both internal and external) shall be painted in

    accordance with project engineering standard for painting.

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    4.4 Hot oil isolation valves with spectacle blinds shall be provided at hot oil inlet/outlet

    of the heater.

    4.5 In case of WHRU running with No GTE specified in project specification : the 2 x 100%

    Auxiliary fan for combustion air (to achieve 100% duty of the heater during Gas turbine

    shut down) shall be provided. The auxiliary fan shall equipped with flow control damper

    and air inlet filter.

    4.6 Contractor shall provide hot oil PTT HI-TEMP500 to the hot oil system.

    Contractor shall design hot oil system in accordance with PTT HI-TEMP500

    specification (refer to attachment).

    4.7 Platform with ladder/stair shall be provided where necessary for operation and

    maintenance. In general, access to burner runner, flame scanner, peep hole, stair

    ways, vent, drain, sampling point are required.

    4.8 All of the following inspection/approval shall be provided by contractor in

    accordance with Thai regulation.

    - Third party approval of the design

    - Construction permit from local authorities

    - Third party Inspection

    Operational permit from local authorities shall be provided by contractor(on behalf of

    PTT).

    4.9 Vendor list of the sub assembly /sub equipment /part/device shall be in accordance with

    the PTTs project vendor list.

    4.10 Design /Construction/ testing shall also follow PTT/CONSULTANT Engineering

    Standards included but not limit to the list below:

    ES-20.02 Quality Requirement for Pressure Vessel

    ES-20.03 Marking for Vessels and Heat Exchangers.

    ES-30.00 General requirement for machinery

    ES-40.05 Wind and Earthquake Loading.

    ES-40.06 Design Loading for Structures.

    ES-40.07 Structural Steelwork Design.

    ES-60.03 Package Instrument Specification.

    ES-70 Electrical Standard-All chapter

    ES-70.02 Electrical Equipment.

    ES-70.09 Motors.

    ES-91.01 Equipment Noise Specification.

    ES-92.01 Hot Insulation for Piping and Equipment.

    ES-92.02 Cold Insulation for Piping and Equipment.

    ES-92.06 Painting.

    ES-99.05 Spare parts

    ES-99.04 Final document

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    4.11 If necessary turning vane shall be used to maintain flow uniformity for every duct elbow &

    split flow.

    4.12 Total flue gas pressure drop shall be less than 8 in H2O (include pressure from SCR

    catalyst) and 2 barg for Hot oil side.

    4.13 Each burner runner shall be able start and stopped by DCS. And, one runner shutdown shall not cause whole burner trip.

    4.14 The Manufacturer/Supplier shall include his design all measures necessary to ensure

    that no part of heater installation and ducting shall be subject to excessive vibrations

    which are induced by gas flow and which may reduce the design lifetime of any part of

    the heater and ducting, or create equipment noise exceeding the limitation.

    4.15 The Manufacturer/Supplier shall also ensure that, during the switch-over from GTE mode to FD mode, switch-over online fan to standby fan operation and vice versa, oil

    circulation within the coils is maintained at level sufficient to accommodate the heat load

    fluctuation without any mechanical damage.

    4.16 The transition time for switch-over from GTE mode to FD mode must be as short as possible (e.g. approximately 10 minute) without any mechanical damage.

    4.17 The duct system shall be arranged so that only the minimum numbers of changes in

    direction are made. Turning vanes shall be provided at change in direction to assure

    uniform flow distribution Turning vanes shall be designed to avoid resonance and the

    formation of eddies in the TEG stream; hence they shall have a smooth tapered leading

    edge. Attachment to ducting shall be by welding and allowance shall be made for

    differential thermal expansion. Particular attention shall be paid to design of turning

    vanes when applied downstream of combustion chamber in order to avoid thermal

    distortion of vanes

    4.18 Each manhole/access door shall be provided with utility air station and 24 VDC

    receptacles.

    4.19 Duct plate of heater casing shall be designed to limit the deflections to 1/100 of span

    plate between stiffeners. Duct stiffeners shall be designed to limit deflection to 1/240 of

    stiffener or support span under design condition.

    4.20 All stiffeners shall be provided with weep holes so that rainwater cannot accumulate.

    Horizontal (flat) sections of casing shall be designed sloping. It shall be possible to drain

    all ducting.

    4.21 For monitor the filling oil in the WHRU Hot oil tube are full, the sight glass with block

    valve shall provide on the top vent line of the hot oil tube. The type of sight glass shall

    working properly on operating temp.

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    DESCRIPTIONS PTT HITEMP 500, 600 are high quality heat transfer fluids of superior thermal stability, producted from a highly refined paraffinic oils and contain anti-oxidation additives, which provide excellent thermal stability and long service life.

    SPECIAL PROPERTIES - Exhibit excellent thermal and oxidation stability, resist formation of sludge. - Having low volatility, high flash point and good low-temperature flow characteristics. - Non corrosive and non-toxic.

    APPLICATIONS - Recommended bulk fluid temperature 320 C max for closed systems and 200 C max for opened systems. -Can be used in heat transfer systems requiring temperature control such as dye-works, bleaching plants and plastics industries.

    REFERENCE STANDARDS

    TYPICAL VALUES

    PTT HITEMP - Viscosity @ 40 oC, cSt - Viscosity @ 100 oC, cSt - Viscosity @ 150 oC, cSt - Viscosity @ 200 oC, cSt - Viscosity @ 300 oC, cSt - Flash Point, (COC), oC - Fire Point, (COC), oC - Density @ 15 oC, kg/l - Specific Heat @ 200OC, kj/kg.OC

    500 30.42 5.23 2.35 1.35 0.62 212 258

    0.868 2.63

    600 46.21 6.76 3.11 1.98 0.84 220 270

    0.878 2.61

    - SHELL THERMIA OIL B - ESSOTHERM 500, 550 - CASTROL PERFECTO HT - MOBILTHERM For more information, contact Fuels & Lubricants Research department, PTT Research and Technology Institute PTT Public Company Limited. Tel 0-2537-3000 Ext. 2413 and 3248 Fax : 0-2537-3000 Ext. 2236 and 3210 Technical Service Division Tel : 0-2537-2327 , 0-2537-2408 , 0-2537-2412

    Product Data Sheet PTT HITEMP 500, 600 Heat Transfer Oil Product no. ILRD-39-02

    Rev 01-45