mp steam boiler package familiarisation - attachment 1

PETROFAC - GS JV

RUWAIS 4TH NGL TRAIN

RUWAIS, UAE

Doc No.

Rev.

1015-C-310

2

Gallarate - Italy

Basic Engineering DEPT

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Date 05/12/2011

BOILER DATA SHEET

Boiler type: TITAN M - Bidrum - Bottom supported - TAG 7V-454 A/B/C/D/E

Circulation:

Arrangement:

Number of burners:

Burners type:

Fuels:

Firing: HRSG type:

Recovery:

Desuperheater type:

2 Pressure parts materials:

Natural circulation

Horizontal

3

Macchi Low NOx burners - MHM type

Fuel Gas

Lean Gas/Deo Gas

Single Firing

Not Applicable

External economizer finned type

Interstage - Injection type

U.N.I. E.N. A.S.T.M.

A.S.M.E.

D.I.N. N.F.E.

Calculation code:

Performance test code:

ASME Without Stamp ASME With Stamp ISPESL

AFNOR T.R.D. P.E.D.

ASME PTC 4-2000 ASME PTC 4.1(Abbreviated Test) ASME PTC 4

ASME PTC 4.4 D.I.N. 1942

MAIN DESIGN DATA

Steam capacity at MCR [1] : 180000 kg/h Boiler heating surface : 1886 m2

Superheated steam temp. at B/L : 355(+5°/-0°) °C

Total heating surf. (including SH + ECO) : 4517 m2

Steam pressure at B/L [2] : 30 barg Total water volume : 74,8 m3

Boiler feed water temperature [3] : 110/149 °C Water volume at normal level : 62,0 m3

Boiler efficiency on LHV at MCR [4] : 90 % Volume of final superheater : 1,8 m3

Steam temperature control range : 25÷110 % MCR Volume of primary superheater : 1,7 m3

Boiler automatic control range : 25÷110 % MCR Volume of economizer : 2,6 m3

Boiler design pressure

Superheater design pressure

Economizer design pressure

: 41 barg

: 41 barg

: 41 barg

E.P.R.S. geometrical

Furnace volume

Drums centerline

: 264,4 m2

: 342,00 m3

: 8000 mm

Start-Up vent capacity design 25%MCR : 45000 kg/h Boiler feedwater pressure [5] : 46,0 barg

Load variation

Blow down flow @1%

: 15 % / min

: 1800 kg/h

Blow down design flow @ 5% : 9000 kg/h

COILS HEATING SURFACE

Indicated quantities are for 1 ( one ) boiler

SECTION Tubes

Tubes Tubes Pitch [mm] Out. Diam. thk

Exchang. Fins Fins/m Fins [mm] Surface

per row deep in parall. tr. long. [mm] [mm] Length [m] type h thk [m2]

Final Superheater 10 10 60 103 101 50,8 3,6 5,85 - - - - 180

Primary Superheater 9

Boiler Bank #1 17

Boiler Bank #2 17

10 54

34 578

33 561

103 101

120 100

120 100

50,8

63,5

63,5

3,6

3,6

3,6

5,85

6,53

6,53

- - - -

- - - -

- - - -

162

752

730

Economizer 26 10 260 100 102 50,8 3,6 6,00 solid 157

Sheet

19 1,25

2 of

2289

13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

BOILER TUBES - MEMBRANED WALLS


FURNACE [6]

Depth 10443 mm Width 4513,5 mm Avg. height 7130 mm Outlet width 1593 mm

Volume 342 m3 E.P.R.S. 264,4 m2 Heat transf. Surf. 280,8 m2 Outlet height 7175 mm

Design pressure 889 mmH2O Test pressure 508 mmH2O

Description

Pitch

[mm]

Avg.

length

[mm] [7]

Outside

diam.

[mm]

Thick.

[mm]

Corrosion

allowance

[mm]

Number

of tubes

Material

Design

pressure

[barg]

Design

temp.

[°C] [8]

TUBES

"D" wall 88,5 16500 63,5 3,6 1,0 117 SA 210 Gr. A1 41,0 385

Side wall 88,5 7765 63,5 3,6 1,0 98 SA 210 Gr. A1 41,0 385

Front wall 88,5 8050 63,5 3,6 1,0 43 SA 210 Gr. A1 41,0 385

Rear wall 88,5 8050 63,5 3,6 1,0 51 SA 210 Gr. A1 41,0 385

HEADERS [11]

Front wall header 4625 219,1 18,26 3,2 2 SA 106 Gr. B 41,0 276

Rear wall header 4625 219,1 18,26 3,2 2 SA 106 Gr. B 41,0 276

RISERS AND FEEDERS [9]

Risers 4350 76,1 4 1,0 26 SA 210 Gr. A1 41 276

Feeders 4000 76,1 4 1,0 20 SA 210 Gr. A1 41 276

BOILER BANK SIDE WALLS

Depth 10443 mm Width 2160 mm Avg. height 6525 mm

Volume 147 m3 E.P.R.S. 140 m2 Heat transf. Surf. 147,1 m2

Description

Pitch

[mm]

Avg.

length

[mm]

Outside

diam.

[mm]

Thick.

[mm]

Corrosion

allowance

[mm]

Number

of tubes

Material

Design

pressure

[barg]

Design

temp.

[°C]

TUBES

Side wall 88,5 8050 63,5 3,6 1,0 111 SA 210 Gr. A1 41 385

Double side wall SH [10] 100 7667 76,1 4 1,0 26 SA 210 Gr. A1 41 385

Front Wall 120 7000 76,1 4 1,0 17 SA 210 Gr. A1 41 385

Screen 354/100 7500 63,5 3,6 1 6 SA 210 Gr. A1 41 385

Sheet 3 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

BOILER TUBES - SUPERHEATER


FINAL SUPERHEATER

Arrangement In line Staggered Flow Parallel Counter Cross

Tubes per row 10 Number of rows 10 Tubes in parallel 60 Avg. exchanging height 5850 mm

Description

Pitch

tr. long

[mm]

Avg.

length

[mm] [7]

Outside

diam.

[mm]

Thick.

[mm]

Corrosion

allowance

[mm]

Number

of tubes

Material

Design

pressure

[barg]

Design

temp.

[°C] [8]

TUBES

SH tubes 103 96 9400 50,8 3,6 1,3 120 SA 213 Gr. T22 41 490

HEADERS / NOZZLES / JUMPERS [11]

Inlet header 1061,5 355,6 23,83 3,2 1 SA 335 Gr. P11 41 352

Outlet header 1061,5 355,6 23,83 3,2 1 SA 335 Gr. P11 41 385

1 Inlet Nozzle 400 355,6 27,79 3,2 1 SA 335 Gr. P11 41 352

1 Outlet Nozzle 300 355,6 27,79 3,2 1 SA 335 Gr. P11 41 385

INLET HEADER

Saturated Superheated steam steam from DSH

diaphragm

Superheated

steam to DSH Superheated steam outlet to BL

OUTLET HEADER refractory

INLET

HEADER

OUTLET

HEADER Tubes to be

protected

Sheet 4 of 13

PETROFAC - GS JV


RUWAIS, UAE

Doc No.

Rev.

1015-C-310

2

Gallarate - Italy


N° 5 TITAN M

180 t/h, 30 barg, 355°C

Date 05/12/11

BOILER DATA SHEET

BOILER TUBES - SUPERHEATER


PRIMARY SUPERHEATER Arrangement In line Staggered Flow Parallel Counter Cross

Tubes per row 9 Number of rows 10 Tubes in parallel 54 Avg. exchanging height 5850 mm

Pitch Avg. Outside Thick. Corrosion Number Design Design

Description tr. long length diam. allowance of tubes Material pressure temp.

[mm] [mm] [7] [mm] [mm] [mm] [barg] [°C] [8]

TUBES SH tubes 103 96 9400 50,8 3,6 1,3 108 SA 213 Gr. T22 41 465


Inlet header 1010 355,6 23,83 3,2 1 SA 335 Gr. P11 41 352

Outlet header 1010 355,6 23,83 3,2 1 SA 335 Gr. P11 41 385

1 Inlet Nozzle 400 355,6 27,79 3,2 1 SA 335 Gr. P11 41 352

1 Outlet Nozzle 750 355,6 27,79 3,2 1 SA 335 Gr. P11 41 385

FURNACE

PRIMARY

SUPERHEATER

FINAL

SUPERHEATER

BOILER BANK #1

Sheet 5 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

BOILER TUBES - EVAPORATOR


BOILER BANK #1

Arrangement In line Staggered

1 Tubes per row 17 Number of rows 34 Tubes in parallel 578 Avg. exchanging length 6525 mm

Description

Pitch

tr. long

[mm]

Avg.

length

[mm] [7]

Outside

diam.

[mm]

Thick.

[mm]

Corrosion

allowance

[mm]

Number

of tubes

Material

Design

pressure

[barg]

Design

temp.

[°C] [8]

TUBES

Tubes 120 100 7000 63,5 3,6 1,0 578 SA 210 Gr. A1 41 385

BOILER BANK #2

Arrangement In line Staggered

1 Tubes per row 17 Number of rows 33 Tubes in parallel 561 Avg. exchanging length 6525 mm

Description

Pitch

tr. long

[mm]

Avg.

length

[mm]

Outside

diam.

[mm]

Thick.

[mm]

Corrosion

allowance

[mm]

Number

of tubes

Material

Design

pressure

[barg]

Design

temp.

[°C] [8]

TUBES

Tubes 120 100 7000 63,5 3,6 1,0 561 SA 210 Gr. A1 41 385

Sheet 6 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

BOILER TUBES - ECONOMIZER


ECONOMIZER

Arrangement In line Staggered Flow Parallel Counter Cross

Tubes per row 26 Number of rows 10 Tubes in parallel 26 Avg. exchanging length 5997 mm

Description

Pitch

tr. long

[mm]

Avg.

length

[mm] [7]

Outside

diam.

[mm]

Thick.

[mm]

Corrosion

allowance

[mm]

Number

of tubes

Material

Design

pressure

[barg]

Design

temp.

[°C] [8]

TUBES

Tubes 100 102 6150 50,8 3,6 1,0 260 SA 210 Gr. A1 41 385


Inlet header 2950 219,1 15,09 3,2 1 SA 106 Gr. B 41 276

Outlet header 2950 219,1 15,09 3,2 1 SA 106 Gr. B 41 276

FINS

Description

Type

Finned

length

[mm]

Fins x

meter

[fins/m]

Height

[mm]

Thick.

[mm]

Segment

[mm]

Material

[23]

Max Fin

Temperature

[°C]

Tubes solid 5997 157 19 1,25 - EN 10130 DC04 454

Sheet 7 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

PRESSURE PARTS


STEAM DRUM [12]

Outside diameter 1800 mm Heads type Spherical Manhole [13] 20"x24" inch

Shell thickness 60 mm Heads outside diam. 1800 mm Design pressure 41 barg

Cylindrical length 11000 mm Heads thickness 55 mm Design temperature 253+25 °C

Corr. allowance 3,2 mm Heads corr. allow. 3,2 mm

Shell material SA 516 Gr. 70 Heads material SA 516 Gr. 70

Levels from centerline Water volumes Hold up

Full of water 25,63 m3 From HL to HHL 31,2 sec

High-High level 200 mm High-High level 16,7 m3 From NL to HL 31,8 sec

High level 100 mm High level 14,8 m3 From NL to LL 47,5 sec

Normal level 0 mm Normal level 12,8 m3 From LL to LLL [14] 46 sec

Low level [14] -150 mm Low level 9,9 m3 From NL to HHL 63 sec

Low-Low level -300 mm Low-Low level 7,1 m3 Form NL to LLL 93,3 sec

Internal details

Cyclones number 42 Dryers number 30 Dryers type 6 Dryers dimensions HxLxW 257x762x313 mm

WATER DRUM

Outside diameter 1150 mm Heads type Spherical Manhole [13] 16"x20" inch

Shell thickness 45 mm Heads outside diam. 1150 mm Design pressure 41 barg

Cylindrical length 11000 mm Heads thickness 35 mm Design temperature 253+25 °C

Corr. allowance 3,2 mm Heads corr. allow. 3,2 mm

Shell material SA 516 Gr. 70 Heads material SA 516 Gr. 70

SAFETY VALVES

Description

Number

Set

pressure

[barg]

Over

pressure

[%]

Blow down

pressure

[%]

Type

Capacity

[t/h] [%]

Superheater 1 34,5 3 4 Spring Loaded 52,00 25

Steam drum 1 41,0 3 4 Spring Loaded 78,00 37,5

Steam drum 1 42,0 3 4 Spring Loaded 78,00 37,5

Total [15] 208,0 100

Sheet 8 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

BURNERS


FUELS: Fuel Gas/Lean Gas/Deo Gas

Burners duty at 100 %MCR 147,1 MW (126450000 Kcal/h)




Burners turn-down 1 : 5 with all fuel gas

Single Burner Design 56 MW ( 48150000 Kcal/h)

MECHANICAL DATA

dp

average height

h2

depth

h1

ds-bottom

width

Furnace average height 7130 mm

Furnace depth 10443,0 mm

Furnace width 4513,5 mm

Number of burners 3

ds-bottom 1405,0 mm

h1 2050 mm

h2 2050 mm

dp 2179,75 mm

Furnace peephole 6"

Sheet 9 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

PIPING AND DUCTs

Indicated quantities are for 1 ( one ) boiler MAIN PIPEWORK WITHIN ASME JURISDICTION

Line description Outside

diam.

[mm]

Thick.

[mm]

Corrosion

allowance

[mm]

Number

of tubes

Material

Rating

Design

pressure

[barg]

Design

temp.

[°C]

Boiler feed water line (from check to eco) 168,3 10,97 1,6 1 SA 106 Gr. B 600 51,25 276

Economizer - steam drum line (from eco) 168,3 10,97 1,6 1 SA 106 Gr. B 600 41 276

Saturated steam drum nozzle 273,0 12,7 3,2 3 SA 106 Gr. B 600 41 276

Steam drum - primary superheater line 323,9 9,52 1,6 1 SA 106 Gr. B 600 41 276

Primary superheater - desuperheater line 355,6 9,52 1,6 1 SA 106 Gr. B 600 41 352

Desuperheater - final superheater line 355,6 9,52 1,6 1 SA 106 Gr. B 600 41 352

Main steam line 355,6 19,05 1,6 1 SA 106 Gr. B 600 41 385

AIR AND GAS DUCTS

Duct description

Max Velocity

[17]

[m/s]

Cross

Area

[m2]

Design

Temp.

[°C] [16]

Design

pressure

[mmH2O]

Min.Thick.

[mm]

Material

Air duct single fan 11 2,50 111 1470 5 S275 JR [21]

Air duct delivery 11 4,80 111 1470 5 S275 JR [21]

Windbox 7 7,60 111 1470 5 S275 JR [21]

Gas duct from boiler to economizer [18] 15 8,00 427 200 6 S275 JR [21]

Gas duct from economizer to stack [18] 12 7,25 270 ±50 6 S275 JR [21]

MAIN STACK [19] [20]

Base diameter 2600 mm Base thickness 20 mm Top diameter 2600 mm Top thickness 8 mm

Height 40 m Material S275 JR [21]

Insulation type Internal lining Thickness 60 mm Material refractory with anchor

Design pressure ±50 mmH2O Design temperature : 270 °C

Corrosion allowance 3 mm

Sheet 10 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

INTERNAL INSULATION


INTERNAL TYPE INSULATION

GAS DUCT FROM BOILER TO ECONOMIZER

INTERNAL LINING Layer 2 Casing Material refractory Material HES cement [22] Material S275 JR [21] Thickness 50 mm Thickness 1 mm Thickness 6 mm type Insulating castable Design pressure 200 mmH2O density ≥1340 kg/m

3 Design temperature 427 °C

GAS DUCT FROM ECONOMIZER TO STACK

INTERNAL LINING Layer 2 Casing

Material refractory Material HES cement [22] Material S275 JR [21] Thickness 50 mm Thickness 1 mm Thickness 6 mm type Insulating castable Design pressure ±50 mmH2O density ≥1340 kg/m

3 Design temperature 270 °C

Sheet 11 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

CASING AND EXTERNAL INSULATION


EXTERNAL TYPE INSULATION

AIR DUCT -ACOUSTIC INSULATION

Hot wall Insulation 1 Insulation 2 Cladding

1 Material S275 JR [21] Material Mineral Wool Material N.A. Material Alluminium 3003-H14

Thickness 5 mm Density 100 kg/m3 Density N.A. kg/m3 2 Design pressure 1470 mmH2O Thickness 75 mm Thickness N.A. mm Design temperature 111 °C

WINDBOX-ACOUSTIC INSULATION

Hot wall Insulation 1 Insualtion 2 Cladding


Thickness 5 mm Density 100 kg/m3 Density N.A. kg/m3 2 Design pressure 1470 mmH2O Thickness 75 mm Thickness N.A. mm Design temperature 111 °C

BOILER

Boiler wall Insulation 1 Insulation 2 Cladding

1 Material SA 210 Gr. A1 / A696 Material Mineral Wool Material N.A. Material Alluminium 3003-H14

Design pressure 889 mmH2O Density 100 kg/m3 Density N.A. kg/m3 Thickness 150 mm Thickness N.A. mm

GAS DUCT FROM BOILER TO ECONOMIZER

Casing Insulation 1 Insualtion 2 Cladding


Thickness 6 mm Density 100 kg/m3 Density N.A. kg/m3 Design pressure 200 mmH2O Thickness 150 mm Thickness N.A. mm Design temperature 427 °C

GAS DUCT FROM ECONOMIZER TO STACK

Casing Insulation 1 Insualtion 2 Cladding


Thickness 6 mm Density 100 kg/m3 Density N.A. kg/m3 Design pressure ±50 mmH2O Thickness 100 mm Thickness N.A. mm Design temperature 270 °C

Sheet 12 of 13

Gallarate - Italy


PETROFAC - GS JV


RUWAIS, UAE

N° 5 TITAN M

180 t/h, 30 barg, 355°C

Doc No. 1015-C-310

Rev. 2

Date 05/12/2011

BOILER DATA SHEET

NOTES

[1] Peak load 110%MCR only 2hrs/24hrs.

Normal steam demand is 81%MCR.

[2] Void

[3] Design Temperature: 183°C

[4] Based on design ambient condition 25°C/60%RH @ MCR with all fuel gas and T BFW equal to 110°C.During

Molecular sieve regeneration efficiency is 89%@MCR on design ambient condition 25°C/60%RH with all fue l

gas and T BFW equal to 149°C.

[5] Minimum BFW pressure @ BL. Boiler feedwater is variable pressure.

[6] Access door 600x600mm for Furnace, Superheater and Economizer

[7] Approximate lenght.

[8] Design temperature according DGS-0000-020, par.4.1 and Macchi Standard.

Headers:

Design Temperature = maximum ( Tsat @ Pdesign; T @ maximum continuous operating + 30°C)

Superheater tubes:

Design Temperature = Maximum(Metal Temperature at MCR + 30°C; Metal temperature in unbalanced

condition)

Design temperature of Boiler tubes is 385°C instea d of 371°C according DIP sec.3 (Company Comments,

mail 23/12/09)

[9] External to flue gas path

[10] Membraned wall.

[11] Headers shall be seamless, of the same material as connecting tubes, and shall have flanged 6" inch

diameter handholes to permit inspection of internal surfaces (DGS 0150 001,par.10.7.19). [12] The minimum size for all steam drum connection is 2" inches.

[13] Two Manholes for each drum

[14] According DGS 0150-001 rev.1 par. 10.7.5

[15] Based on 5% margin on peak load (110%MCR)

[16] Design temperature for duct:

Air duct: Maximum operating temperature + 56°C

Flue Gas duct: The calculated metal temperature + 56°C based on the maximum flue gas temperature

[17] Maximum velocity according DGS 0150 001 rev.1, par.10.18.2 and 10.18.3

1 [18] The flue gas ducts shall be refractory-lined and externally insulated.

1 [19] The stack shall be refractory-lined. No external insulation only personnel protection.

[20] Stack mechanical and structural design shall be compatible with 45m height.

1 [21] Equivalent to ASTM A36

1 [22] Acid proof high strength cement.

[23] Material Equivalent to ASTM 1008 DDS

Sheet 13 of 13

mp steam boiler package familiarisation - attachment 1

Documents