This document provides an overview of equipment for HRSG training in Beni Suef, Burullus & New Capital power plants. It describes the key flue gas and water/steam side equipment, including: 1) diverter dampers and stack dampers that control gas flow; 2) drums that separate water and steam; 3) blowdown and attemperation systems that control water quality and temperature; and 4) silencers that reduce noise levels. The document focuses on the purpose, operation, and maintenance of this core HRSG equipment.

1. EQUIPMENT
HRSG TRAINING
BENI SUEF, BURULLUS & NEW CAPITAL
WILLEM JAN DOMENIE & MARTIJN VAN GAMEREN
NEM ENERGY BV
21050/51/52

2. CONTENT OPERATION
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1. Flue gas side equipment
• Diverter damper
• Stack damper
• Flue gas silencer
• Expansion joints
2. Water & steam side equipment
• Drums
• Blowdown system
• Attemperator
• Steam silencers

3. FLUEGAS SIDE EQUIPMENT

4. DIVERTER SYSTEM (BYPASS)
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Diverter damper and bypass stack
Diverter dampers isolate the
HRSG from the GT
Allow GT operation when HRSG is
off.

5. OPERATION OF DIVERTER DAMPER (MOVIE)
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6. STACK DAMPER
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Saving energy
HRSG cooling time
•Stack damper open: 1-2 days
•Stack damper closed: 3-4 days
Rain protection
Actuator for open and close

7. STACK DAMPER
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Open position
Closed position

8. STACK DAMPER
Normal
For start of GT the stack damper must be
open (back pressure)
DCS  Actuator  turns shaft
Limit switches open  GT gets clearance
from stack damper  GT can start
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Limit switches Animation open/close stack damper

9. STACK DAMPER
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Safety for GT
Problem: if limit switches say “open” but damper is actually closed 
Too much back pressure: GT will trip
Solution: Damper blades also open Mechanically
Based on balance of blades

10. STACK DAMPER MAINTENANCE
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Safety for you
• The blade can open when you stand on it
• If you do not want to fall down during
maintenance or inspection place locking pins
in position 1
• Inform control room (boiler cannot start)
Locking pin position 2, blade can move
Locking pin position 1, blade can NOT move
and boiler can NOT start

11. FLUEGAS SILENCER
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Reduction of the noise produced by the GT
Location:
• For Beni Suef, Burullus & New Capital Outlet duct

12. Equipment - You are not allowed to copy, alter or use this information without permission from NEM Energy BV - P. Honcoop / A. Cabrerizo
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FLUEGAS SILENCER

13. NOISE LEVELS: EXAMPLES
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dB
140 Gunshot / fireworks
120 Plane taking off
110 Rock concert
100 Head phones full volume
90 Hairdryer
85 Busy City Traffic
60 Normal conversation
40 Whisper
20 Leaves rustling

14. EXPANSION JOINT
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Provide flexibility:
absorb the thermal expansion of flue gas duct
For Beni Suef, Burullus & New Capital

15. EXPANSION JOINT
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Typical Expansion Joint
Configuration for Egypt projects
Outside Air
Flue Gas Side
Internal
insulation
Casing Casing
Sheeting

16. WATER/STEAM SIDE EQUIPMENT

17. DRUMS
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IP
LP

18. DRUMS
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Functions:
•Separate water - steam
•Hold-up volume
•Accommodate load changes
•Concentrate dissolved salts
for blow down (chemistry)
Water level
Evaporator
Downcomer
Feed water
Continuous
Blow Down
(CBD)

19. DRUMS INTERNALS
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Primary Separator
Secondary
Separator
Feed water
distribution pipe
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Guided Wave
Radar
Downcomer
Inlet

20. DRUMS
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Manhole Level gauge

21. BLOW DOWN SYSTEM
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Function:
Safely collect water from drums,
HP separator, drains and vents
Water partly flashes* to steam
o Approximately 25 % becomes steam
o Steam to atmosphere
o Water to sewer (after additional cooling)
*Flashing:
Water from liquid state to steam state due to pressure change
Steam to atmosphere
Entrance
of water
Water to Service Cooling Water System

22. BLOW DOWN SYSTEM
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Consists of piping, valves and
the blowdown tank (HRSG Drains Flash Tank)
Operates at atmospheric pressure
Each HRSG has its own blow down system

23. BLOW DOWN SYSTEM
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Operation:
Continuous Blow Down Control Water Quality
Intermittent Blow Down Level Control
HP Separator Collect excess water
during start up and
level mode
Drip legs of superheater Removal of condensate
and reheater

24. BLOW DOWN SYSTEM
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Shut down:
Almost all drains and vents are routed to the blow down
system for draining the boiler (when cold)
NOTE:
• Do not operate “cold” vents and drains when
boiler is hot.
(valves will be damaged, due to flashing)

25. ATTEMPERATORS
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Lowering the temperature of steam by injecting water droplets
Evaporation of droplets takes energy from steam, cooling it
BOILER STEAM TURBINE

26. ATTEMPERATORS OPERATION
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Points of attention:
Ensure minimum flow through attemperator to get proper spraying
Plugging of water inlet holes with dirt

27. ATTEMPERATORS
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Clean water -> proper spaying Dirty water -> NO proper spaying

28. STEAM SILENCER
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Reduces noise level generated during blowing of the safety valves to
a safe, but not quiet, level (Egypt projects 125 dB(A))

29. STEAM SILENCER
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30. THE END
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