APIN STEAM GENERATOR SPECIFICATION

Transcription

1 Imagination, hope & will Ave. Bolivia Lima 01, PERU Off. (511) Plant (511) APIN STEAM GENERATOR SPECIFICATION 0.0 GENERAL 0.1 The conditioned APIN steam generator will be designed and fabricated in full accordance with the ASME Power Boiler Code, Section I. 0.2 The unit will be trailer-mounted. 0.3 The APIN steam generator will be of the modularized design in order to move around the field. 0.4 The APIN unit is capable of 24 hour per day operation. The only downtime required is for inspections and maintenance. The unit can be operated in the manual or automatic control mode. The operating parameters are set in the control logic. 0.5 The APIN steam generator is designed for continuous service Design Steam Pressure 2500 psi Steam Rate at 80% Quality 25,000 #/hr. Steam Quality at Boiler 80% Thermal Efficiency 90% Natural Gas or Heavy Oil Excess Air 20% Flue gas Exit Temperature 350 Deg. F Heating Surface: Radiant 1000 sq.ft. Convection 5942 sq.ft. Pressure Drop thru Heater 240 psig Safety Valves Set At 2500 psig & 2550 psig Pump Motor 100 HP, TEFC High Eff. Pipe Size 3 Sch. 160

2 0.6 Fuel Characteristics - The APIN steam generator will be capable of burning natural gas or Light or heavy oil. Natural Gas Characteristics: Constituent Composition: Component Mole Percent Fuel/Gas Mol % CH4 78.8% C3H8 0.3% C4J12 0.4% N2 3.0% C2H6 6.2% C4H10 2.3% CO2 5.2% O2 1.1% 0.15 Generator Feedwater The customer supplied feedwater will be treated to the following specifications: Total Hardness Less than or equal to 0.2 mg/l as CaCO3 Fe Less than or equal to 0.5 mg/l Dissolved O2 Less than or equal to 0.01 mg/l ph Value 8 9 Inlet Temp.Design Normal 70 Deg.F Minimum 60 Deg.F Maximum 70 Deg.F FEEDWATER REQUIREMENTS The following is a summary of feedwater conditions recommended for oilfield APIN steam generators: FACTOR OR COMPONENT Hardness (CaCO3) LEVEL REQUIRED 1 ppm or less (recommended Equipment design capable of ½ ppm or less)

3 Total Dissolved Solids (TDS as CaCO3 equiv.) ph Control (against carbon dioxide) Free Oxygen 12,000 ppm or less 7.5 min. adequate to 8.3 max. effective Eliminate (to negligible level Achievable by O2 scavenging) Notes: 1.0 TRAILER (1) The steam generator can handle up to 12,000 TDS routinely. Runs up to 24,000 pm have been made with good success. It is believed that even higher values could be handled. Above 12,000 ppm, a detailed water analysis has to be made. (2) In reference to SiO2, existing literature recommends values much lower than 100 ppm. However, the steam generator has run successfully at levels of 250 ppm. 1.1 Wide flange beams are to be used for full bearing of radiant and convection. 1.2 Appropriate marking of piping and electrical connection is provided. 2.0 RADIANT SECTION 2.1 A quick release light weight door is to be provided for entry and inspection in the radiant section. The door to be refractory lined, and equipped with a davit for ease of handling. 2.2 Radiant tube to be supported at intermediate positions with full circle, free-slip type cast stainless steel hangers. The hangers to be pinned in place and of a length such that at least ½ project occurs on either side of the hanger assembly. 2.3 The tube return bends are to be inside the combustion chamber. 2.4 All radiant tubes are removable without dismantling the economizer or burner and components.

4 2.5 The radiant section steam discharge tube wall temperature is to be monitored by a type J thermocouple on the discharge tube. The thermocouple is shielded. 2.6 An air cooled site port is to be provided in the combustion chamber at burner end. 2.7 The radiant tubes are to be spaced for maximum heat absorption fro both direct and reflected heat. 2.8 A side-mounted Meriam Series 100, U type Model 10AA25WM manometer is installed for measurement of combustion chamber pressure, and has direct reading in millimeters of H2O. 2.9 The radiant chamber is supported by cross members located as required to provide integral structure with the wide flange skid The radiant chamber is provided with drain connection The radiant chamber is to be fully refractory lined as follows: a) Radiant Chamber Manufacturer RHI Type Ceramic Fiber 6# Density Thickness 6 b) Burner End and Target Wall Manufacturer RHI Type Ceramic Fiber 8# Density Thickness CONVECTION SECTION 3.1 The convection section is to be equipped with a quick opening door. Door is secured with assemblies of pin and wedges. 3.2 The construction is of plate steel, refractory lined, and with interior sloped for full drainage during wash down operation. 3.3 The tube sheets are to be refractory lined and coated between refractory and steel with asphaltic cutback to prevent H2SO4 corrosion. Door gasket flanges and joints are designed to prevent leakage under pressure. 3.4 Inlet and Outlet piping is flanged for quick assembly and disassembly.

5 3.5 Water circuit design is single pass design for uniform flow. 3.6 The convection section is to be of the box girder type design with interior refractory insulation on all exposed areas. (a) Refractory Specification: Manufacturer: RHI Type: Kast-O-Lite 22 Tube Sheets 3.7 Flue gas flow is to be across the convection tubes in cross flow in order to provide the most efficient heat transfer. 3.8 The convection section is provided with three (3) rows of bare tubes at the point of flue gas entrance. The bare tubes will serve as shock tubes to shield the extended surface tubes from direct radiation. The extended surface tubes will be provided with fins.750 high x thick x 5 fins per inch. 3.9 The design provides for a maximum fin tip temperature of 850 deg.f Sample connection for stack gas analysis is provided. The stack temperature and gas sample connections are located in a position that will indicate the average condition in the sample expected over the entire stack. The stack gas analysis sample connection consists of stainless steel tubing terminating above ground level at a convenient location The convection section, in a new condition, designed to provide a flue gas temperature of 350 deg. F with 20% excess air. 4.0 WATER SYSTEM 4.1 The APIN steam generator is supplied complete with a plunger type feedwater pump. The pump is designed for the specified steam generator outlet pressure, plus the friction loss through the steam generator package. The pump is driven by an electric motor delivering the horsepower as required.

6 4.2 The feedwater pumps will be Wheatley or equal. Type: Quintuplex Model: HP-125M Fluid Ends: Aluminum Bronze Plunger Mat l: Steel with Ceramic Overspray Packing: Utex 241 Rate: 55 gpm Motor: 100 HP, TEFC, high efficiency 4.3 Each feedwater pump will be provided with an inlet and outlet pulsation dampener. 4.4 All inlet and outlet lines on the pumps will be provided with flanges and/or union piping connections for ease of pump maintenance. 4.5 The feedwater pump is provided with a relief valve. 4.6 The bypass system feedwater pump discharge line is provided with inline orifice meter run for flow control utilizing a D/P cell, orifice plate. 4.7 Local readout pressure and temperature gauges will be provided before feedwater enters convection section, and radiant section. 4.8 A DP transmitter will be provided. 4.9 Feedwater pump, inlet and outlet dampeners, bypass valve will be skid mounted. 5.9 Feedwater preheater is provided to raise temperature of feedwater from 50 deg.f to 140 deg.f prior to entering the convection section. 5.0 STEAM DISCHARGE PIPING 5.1 The steam generator is provided with a Crosby, or equal, safety relief valve, mounted at a convenient height for access and maintenance. All valves will be provided with manual lifting levers. 5.2 An ANSI stop valve and check valve are installed on the discharge line. 5.3 The discharge piping and valves will be sized for minimum pressure drop.

7 The scrubber is 6 diameter schedule 80 to assure low enough velocities so the samples will be of the water phase of the mixture only. The scrubber does not contain mesh, but is provided with impingement baffles with appropriate sink. A sample cooling coil is provided with piping, valves, and drain. Drain piping for cooler includes a look-box where streams may be observed and sampled. Cooling water piping from the feedwater line is included. 5.4 Discharge pressure and temperature is displayed on the screen located in the control panel. Local temperature and pressure connections are furnished for calibrating the control instruments. Pressure connections will have isolation valves. Thermometer wells are installed for temperature points. 6.0 FUEL GAS SYSTEM 6.1 Full pressure regulation and dual shutoff valving will be provided with major components flanged for ease of maintenance and repair. Regulation valving will be by Fisher, or equal, and shutoff valving will be by Maxon or equal. 6.2 Electrical actuated valve for safety shutdown and venting will be provided, and will be fully interlocked with control system. 6.3 Fuel gas manifolding with burner control valve will be provided. Manual condensate blow off valve and piping is also provided. 6.4 Fuel gas metering facilities are included. 8.1 FUEL OIL SYSTEM 8.1 The fuel oil system will include both a low watt density, electric heating system for startup and a steam-oil heat exchanger for running condition. The electric heater will be thermostatically controlled to maintain a constant fuel oil temperature at the burner. Both heaters will be insulated and piped in series with the steam heater preceding the electric heater. 8.2 A throttling valve will be included on the steam/oil exchanger for automatic, oil temperature control. 8.3 A fuel oil bypass system will be provided. 8.4 All fuel lines will be insulated, or electric heating tape will be provided where insulation is not used.

8 8.5 A dual basket, fuel oil strainer will be provided on the fuel oil inlet to the generator. Fuel oil strainer and drain block valves will be provided and drain lines connected to the unit drain system. 8.6 The fuel oil will be metered through a steel case meter mounted as close to the burner as possible. A pneumatic, three-way valve will be mounted downstream of the meter. In addition, a full size manual bypass around the meter will be provided. 8.7 An atomizing steam scrubber complete with flow control pressure reducing valve, block valves, etc., will be included. 8.8 Weatherproof, electrical housing will be provided on the electrical oil heater. 9.0 CONTROL SYSTEM 9.1 The control system will be electric with full modulating control. 9.2 The generator s electrical system will comply with the latest edition of the U.S. National Electrical Code. 9.3 All power to the generator must be 460 volt, 3 phase, 60 cycle. Threephase electrical circuit breakers will be used for the main power. Motor circuit protectors (MCP;s) will be used in all combination motor starters, size 0 and larger. A fused disconnect switch will be provided before all control power transformers. A transformer will be provided to reduce the voltage to 120 volts for use with the electrical instruments and controls. 9.4 The control console will be a free standing, rain-tight, dust-tight enclosure with all electrical controls mounted for ease of monitoring pressures, temperatures, and control functions in a single location. The cabinet will house the main circuit breaker, all combination motor starters, transformers, fused switches, etc. 9.5 The control console will have dead-front construction. All air vents to the control console will be equipped with dust filter pads to prevent dust entrance. 9.6 A positive single-indicating first out alarm system will be provided. 9.7 The APIN steam generator is designed for automatic operation and maximum safety of equipment and personnel.

9 9.8 The alarm system has a positive, internal component, self-checking feature. Should a component fail, which could result in unsafe firing, the system will prevent unit startup. Generator will not restart automatically upon power restoration after power failure; however, the post purge cycle will begin automatically when the power is restored. 9.9 The unit has a selector switch for start and stop (on-off) and a single point pushbutton reset of alarms A built-in pushbutton alarm test timer for functional test of all alarms is designed to be non-defeatable. Alarms will reenter the circuit at end of test interval automatically if reset to run condition A set of single pole, double throw relay contacts is provided for connection to a remote alarm system to signal a generator automatic shutdown condition. Also, the control power on-off switch will be equipped with a single pole, double throw auxiliary contacts to be used in this remote alarm circuit. Wiring to the relay contacts and switch auxiliary contacts will be terminated on a pull-apart terminal block near the generator s main power disconnect in the control console All motor feeder conduits from the control console to the motors are installed in a conduit raceway at floor level The feedwater system transmitter will be by d/p cell Control and Display Solid state thermocouple type; rack mounted in control console. (a) High steam temperature, adjustable set points to 800 deg.f maximum, and low steam temperature adjustable set point. (b) High tube temperature, adjustable set points to 800 deg.f maximum. (c) High stack temperature control and alarm adjustable set points The feedwater rate and fire rate control system include as a minimum, but not limited to, the following: a controller which sends a 4 to 20 milliamp signal to the bypass feedwater valve. The process control signal (steam discharge pressure) will be sensed by the steam discharge line on the downstream side of the radiant section A 110 volt weatherproof receptacle with ground fault protection will be provided adjacent to control console for maintenance and hand tool operation.

10 10.0 MISCELLANEOUS PAINTING: 10.1 All major steel items will be sandblasted, primed, and finish coated with tank enamel. Paints are capable of withstanding maximum expected temperatures. INSULATION: 10.2 Where practical, insulation will be installed on exposed hot lines and surfaces so that the maximum surface temperature will not exceed 140 deg.f. Where appropriate, hot areas exceeding 140 deg. F will be provided with personnel protection. Items, such as the feedwater preheater, lines to and from the convection and radiant sections, steam discharge piping etc., will be insulated. APIN Enhanced Oil Steam Generator 25MMBtuHr Trailer mounted