POWER AND INDUSTRIAL PLANTS

Industrial boilers Package & Site erected steam

Under licence from Foster Wheeler

S.p.A.

LOOKING TO THE FUTURE

S.p.A.

Jebel Ali Power Plant - UAE

STEAM GENERATORS
STF supplies a full line of Package and Site Erected SD Boilers designed to meet the most demanding requirements in terms of capacity, performances, emissions, operating exibility, long term reliability and low maintenance costs.

PACKAGE type furnace design

SD type vertical ow path

ADDITIONAL FEATURES
MAIN TECHNICAL FEATURES
L  arge oversized furnace T  wo drums design O  versized steam drums with high efficiency internals M  ONO-WALL fin tube construction Convective or radiant super-heater F  ully drainable super-heater M  inimum refractory L  ow NOx burners, flue gas recirculation F  uels: natural gas, light oil, heavy oil, refinery gas, low heating value gases.

OPERATIONAL FLEXIBILITY
H  igh turndown Extended low load operation Warm/hot stand by Fast ramping for cogeneration back up Large load swings Fuel complex combination firing Multiple operation conditions One button start-up Critical service availability

INTEGRATED DESIGN
M  ass & thermal balances N  oise & vibration analysis C  abling, conduit & tubing I nstrumentation, BCS, BMS P  iping and valves C  abling, cable trays & conduit R  acks and structural steel

OPTIMIZED PERFORMANCES
T  hermal efficiency Auxiliary power consumption Emissions control & abatement

PACKAGE boilers
Steam capacity range from 50 to 200 tons/h
Steam generation today asks for strict adherence to emission regulations, utilization of alternative fuels, and minimization of operating and maintenance costs. In this complex scenario, STF is able to provide a complete solution to your steam generation needs. Our experience diversification of products and commitments to engineering integrity, ensure STF quality, resulting in maximum equipment availability and reliable source of steam for your process, power or heating requirements. At STF, our focus is on total system integration and optimization. Total System integration and optimization are our goals. By utilizing state-of-the-art automation tools, STF can apply technical and cost factors in a combined value-added analysis satisfying our customers unique needs. This provides our engineers the necessary degree of freedom to design the best system for each customer by balancing capital and operational costs. Corporate experts in specialized fields such as combustion, circulation, noise, vibration, metallurgy and global procurement are drawn upon as required to effectively address the most complex project requirements. Our product focus is supported by the manufacturing and financial resources of the entire STF organization.

5000 Series Package Boiler

STF pre-engineered boiler models include five series: 5000, 5100, 5200, 5300, 5400. Each series comprises multiple models of boilers, up to reaching a total number of 21 boiler models, in accordance to an overall size envelope settled for each model (L X H X W), whilst model signifies the boiler capacity (kilo-pound per hour). Each boiler model contains pre-engineered options like: t  hree upper steam drum size options, to minimize cost and optimize performance exibility, combined to utility quality of drum internals; t  hree boiler bank templates; t  wo boiler bank longitudinal pitches; t  hree super-heater templates x 2 tube ODs. A wide range steam production is covered to suit the clients requirements, from 50 tons/hour (110 kp/h) to 200 tons/hour (440 kp/h), with pressures spanning from 10 barg (150 psig) to 110 barg (1,600 psig), SH/PH steam temperatures up to 500 C (930 F). The weight of the boilers may vary from 40 tons with a furnace volume of 32 m3 (1,120 ft3) up to 245 tons with a furnace volume of 362 m3 (12,782 ft3). Each furnace size is capable to granting Conservative Volumetric Liberation Rates and Cross-sectional Heat Flow Rate less than 2.5 mbtu/ft2/hour. Steam drums can be sized for each boiler model to minimize the costs and optimize performance flexibility.

5100 Series Package Boiler

Super-heater sections are convective and drainable, with conservative metallurgical design well over operating range and an advanced antivibration design. Three convective banks are provided for each boiler model in order to minimize the auxiliary load and maximize the performance. Package Boilers are capable of burning the majority of Gaseous and Liquid Fuels, either natural or by-products of refinery process. Gaseous Fuels include Natural Gas, Refinery Process Gases (high hydrogen, tail gas, alcohols), Landfill Gas, CO & Blast Furnace Gas, Coke Gas, Waste Gases. Liquid Fuels include Oils (No. 2, No. 6 & Bunker C, Diesel, Cracker Bottom, Pitch), Alcohols (Methanol, Ethanol), Waste Liquids.

5200 5300 5400 Series Package Boiler

DESIGN AND TECHNICAL FEATURES

MONO-WALL MEMBRANE CONSTRUCTION and FURNACE DESIGN
Boiler wall are designed as mono wall finned tubes, with a high utility grade construction and fins suitably sized (1 or 1 width) to ensure the thermal integrity and gas tight of the furnace. Utilization of refractory materials is minimized, with a great advantage in terms of boiler reliability, outage planning, maintenance activities. In addition a complete fuel combustion is assured as flue gases cannot bypass the boiler convective sections.

PREFABRICATION DETAILS

Steam capacity range from 120 to 455 tons/h

The SD pre-engineered steam generator has proven itself over the years, reliably meeting the rigorous demands of industrial steam producers. The most common users of this equipment are utilities and petroleum, chemical, paper and metal industries. Numerous applications have been made for power generation in a wide range of sizes with capacities up to and in excess of 65 MW. STF Standard Design Field Erected Boilers present a constant cross of the furnace and boiler bank, whilst setting of the boiler width defines the boiler production in accordance to the design output required by the Client. The boiler design can be also optimized by pre-engineering design flexibilities and allowance for granting special modifications to standard models. Standard for the selection of a SD Standard Design Field Erected Boiler capable to suit the Client requirements, are based on the boiler performance program, the maximum heat volumetric liberation rate allowed, furnace width, maximum ue gas ow, maximum ue gas temperature at the boiler outlet. Nine Series of Boiler Models define Nine Size Classes: SD-31, SD-32, SD-33, SD-34, SD-35, SD-36, 3D1, 3D2, 3D3. Series SD-31, SD-32, SD-33 incorporate 4 (four) burners; Series SD-34, SD-35, SD-36 incorporate 6 (six) burners; Series 3D1, 3D2, 3D3 incorporate 8 (eight) burners. Burners are fuel exible, being capable of burning the majority of Gaseous and Liquid Fuels, either natural or by-products of refinery process. Gaseous Fuels include Natural Gas, Refinery Process Gases (high hydrogen, tail gas, refinery fuel gas), Landfill Gas, CO & Blast Furnace Gas, Coke Gas, Waste Gases. Liquid Fuels include Oils (normal fuel oil, light fuel oil, diesel), Waste Liquids. Firing systems are designed and engineered to achieve for all fuels the required combustion parameters with safety, ease of control, reliability, granting that the emissions are within the required limits, with a minimum of maintenance.

SERIES SD

Circulation in this type of boilers is provided by the difference in specific gravity of the fluid in the heated circuits (water-steam mixture) and in the downcomer tubes (water only). Boiler furnaces are generously sized to ensure a complete combustion The Width of STF Standard Design Field Erected Boilers can span from 5 meters to 12 meters and as a consequence the Furnace Volume can range from 268 m3 to 690 m3. Remaining boiler dimensions are kept almost fixed, to an overall height of about 15 meters. Steam production can vary from 120 tons/hour to 455 tons/hour with superheated steam temperature of 540 C at the operating pressure of 110 barg, granting the best available technology for the emission using a wide variety of gaseous and liquid fuels.

Series SD

Field Erected Boilers may be used in the following applications:

Chemical Plants, Gas Plants & Petroleum Refineries Power and Cogeneration Plants & Combined Cycles Manufacturing Industries & Districts Heating Sugar Cane & Paper Industries Desalination Plants.

FIELD ERECTED BOILERS

STF SD Field Erected Boilers are bottom supported, with complete water cooled furnace walls, two drums (water and steam) D-style design, with furnace walls and boiler bank tubes rolled expanded to the drums. This design facilitates a controlled expansion of the boiler pressure parts while allowing for the inclusion of a hopper bottom for an easy removal of the ashes. Gas ow is perpendicular to the steam drum providing uniform heat all cross the drum width, resulting in a steady configuration of the drum level. Suitable manholes and access doors are installed in water drum (lower) and steam drum (upper) as well as in furnace walls to assure an easy access for inspection and maintenance. Steam drums are generously sized in diameter allowing an excellent water/steam separation performance, enhanced by the high grade of the drum internals like the Primary Horizontal Cyclones and Integral Chevron Dryers, easy to be installed and removed providing dry steam to the super-heater sections and steam free water to the down-comer system. Boiler Retention Capacity at MCR and Load Swing Capability are also increased, facilitating an improved response to process demand. The furnace is designed to assure a Low Volumetric Heat Release Rate combined with an optimized cross section and length, resulting ideally suited for burners Low NOx application. Large furnace cross section eliminates ame impingement on boiler tubes enhancing furnace longevity, whilst a Conservative Heat Release Rate facilitates low maintenance and long-life tube integrity.

Large oversized drum

Tube to Drum connections details

DRUMS < 63.5 mm < 2 inches

DRUMS > 63.5 mm > 2 inches

APPLICATIONS

Site view

DESIGN AND TECHNICAL FEATURES

Boiler walls are designed as tubular membranes, mono wall finned tubes, with a high utility grade construction. Fins are suitably sized to ensure the thermal integrity of the boiler. This arrangement, equally effective with pressurized or balanced draft operation, contributes to high levels of boiler efficiency by reducing using of refractory materials, with a great advantage in terms of reliability, maintenance activities, outage planning, minimizing as well casing corrosion and/or gas leakage throughout the life of the steam generator. Observation and access doors, properly designed, (fixed, pressure tight, air aspirating design) are provided in suitable positions to allow a complete control of the operating conditions of the boiler, an easy access for inspection and maintenance. Tubes are bent around all openings (no bifurcation of steam flow), eliminating the risk of possible localized circulation patterns that may cause panel hot-zones leading to tube failure. The furnace walls are made up of shop-prefabricated panels assembled through a continuous welding of adjacent tubes, with or without fins, carried out with single or multiple head submerged arc automatic welding machines. These panels are matched together during the erection to form a sturdy metal casing that completely encloses the steam generator section, performing a dual function of heat transfer surface and sealing against ue gas leakage. The gas tight enclosure prevents the flue gas by-passing the furnace to the convection bank, which would lead to a high emission of CO reducing thermal efficiency, maintaining boiler integrity. Boiler super-heaters may be non drainable or fully drainable, located inside the furnace or in a convective area of the boiler. Non drainable super-heaters are located inside the boiler furnace, protected from radiation by the tubes of the furnace nose, supported of furnace wall headers, provided with stainless steel side-to-side spacers to guide the thermal expansion of the coil piping. Typical Drainable Super-heater Construction

Typical Non-Drainable Super-heater Construction

SD Boiler with Non-Drainable Super-heater and Standard Furnace

Fully drainable super-heaters are located in a convective area between the furnace rear wall and convection bank front wall, are properly supported on furnace rear wall and convection bank front wall, provided with support spacers between the coil piping. Headers are located outside the ue gas path. Temperature of superheated steam is controlled, when required, by a spray type desuperheater, installed in the intermediate temperature zone to assure a uniform mixing and a quick complete evaporation of the water injected into the steam ow. Stringent uid and vibration design criteria promote boiler life by ensuring a uniform flow distribution and minimizing flow induced vibrations. An optimized Boiler Bank consists of a finely tuned convective surface that balances good heat transfer with reduced draft losses. SD Boiler with Drainable Super-heater and Enlarged Furnace

SHOP PREFABRICATION
STF SD Field Erected Boilers can be shipped to site in different configurations: d  isassembled components, loose tubes and panels; b  oiler bank completely assembled, loose tubes and parts; c  ompletely assembled. Major boiler components may be delivered at site as follows: Steam Drums (water and steam drums): supplied as single pieces, internal details (cyclones and chevron dryers) installed. Super-heater headers are supplied as single pieces, stubs welded, whilst super-heater coils are delivered fully prefabricated, ready to be welded to the header stubs. Furnace Right and Left Side Walls, Front Wall, Rear Wall, Roof and Floor Walls: supplied in complete panels of tubes, ready to be assembled and welded at site to form the boiler furnace. Tubes are ready to be expanded into the steam/water drums and/or welded to the adjacent walls panels. Upper and lower headers of furnace side panels, provided with nozzles to be welded to risers and down-comers, are already welded to the panels. Riser Tubes: supplied as single spools, bent, cut and bevelled for welding to the steam drum and/or side wall header nozzles. Boiler Bank Front Wall, Intermediate Wall, Rear Wall, Internal Tubes: to be supplied at site by longitudinal welding to form the complete boiler bank. Tubes ends are already to be expanded into water/steam drums. Typical and Complete Sequence Assembly

TRANSPORT TO SITE and ERECTION

Jebel Ali Power Plant - UAE

Jebel Ali Power Plant - UAE

CERTIFIED QUALITY

STF S.p.A. Via Robecco, 20 20013 Magenta (MI) Italia Tel: +39 02 972091 Fax: +39 02 9794977 www.stf.it e-mail: stf@stf.it

BWE Burmeister & Wain Energy A/S Lundtoftegrdsvej 93A DK-2800 Kgs. Lyngby - Denmark Tel: +45 39 45 20 00 Fax: +45 39 45 20 05 www.bwe.dk e-mail: info@bwe.dk

BWE Energy India Pvt. Ltd No. 43, KB Dasan Road Teynampet Chennai - 600 018 TamilNadu, India Tel: +91 44 24 32 8101/2 Fax: +91 44 24 32 8103 e-mail: info@bweenergy.in