GE VERNOVA YANBU - FIRING SYSTEM TRAINING OIL FIRING PDF

YANBU - FIRING SYSTEM TRAINING OIL FIRING Bill Miller / Rich Donais May 27, 2024 © 2024 GE Vernova and/or its affiliates. All rights reserved. LEGAL NOTICE: Yanbu – FIRING SYSTEMS TRAINING © 2024 GE Vernova and/or its affiliates. All rights reserved Page 2  Presenters...

YANBU - FIRING SYSTEM TRAINING OIL FIRING Bill Miller / Rich Donais May 27, 2024 © 2024 GE Vernova and/or its affiliates. All rights reserved. LEGAL NOTICE: Yanbu – FIRING SYSTEMS TRAINING © 2024 GE Vernova and/or its affiliates. All rights reserved Page 2  Presenters Rich Donais Bill Miller Lead Engineer - Process Chief Consulting Engineer Engineering (burners) (In person) (remote) © 2024 GE Vernova and/or its affiliates. All rights reserved. 3 © 2024 GE Vernova and/or its affiliates. All rights reserved. 4 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports Open the Handout on your tablet: C - Yanbu Boiler Training - Student 3 Materials Tips Windbox - Nozzle 8 - Firing Systems (DO Vol 5 Part 6 Sec 1)– Single Fireball Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 5 Tangential Firing: CE –> ABB –> ABB/Alstom –> Alstom -> GE (typical) Rƽ ⇒ Maȍữaɱ ⇒P © 2024 GE Vernova and/or its affiliates. All rights reserved. 6 Yanbu – Iso View Adobe Acrobat Document © 2024 GE Vernova and/or its affiliates. All rights reserved. 7  Yanbu – Side Elev View © 2024 GE Vernova and/or its affiliates. All rights reserved. 8 Yanbu – Plan View 1 2 L 4 3 5 6 8 7 © 2024 GE Vernova and/or its affiliates. All rights reserved. 9 Yanbu – SA Duct to WB Adobe Acrobat Document typical © 2024 GE Vernova and/or its affiliates. All rights reserved. 10 Yanbu – GR Duct to WB Adobe Acrobat Document © 2024 GE Vernova and/or its affiliates. All rights reserved. 11  1 Corner Firing – WB Arrangement 6o © 2024 GE Vernova and/or its affiliates. All rights reserved. 12  1 Key Plan – Main WB Twin Fireball Arrangement Key Features Twin Counter Rotating Fireballs Air & Fuel Streams – Corner Distributed Vertically Stacked Fuel / Air Distribution © 2024 GE Vernova and/or its affiliates. All rights reserved. 13  1 Twin Fireball Arrangement 6o 6o Fữƽɱ ⇒aȍḕ⇒ Ajṩ Fữƽɱ ⇒aȍḕ⇒ Ajṩ Yanbu – Oil Pg 31 © 2024 GE Vernova and/or its affiliates. All rights reserved. 15 Typical Refinery Fuel Properties Classification and Description Heat Content Temperature at pumping Temperature at atomization Viscosity at atomization Specific Gravity American Petroleum Institute (API) Gravity for classification. Sulfur Percent Sediment Percent Ash Percent Carbon Residue Percent Ultimate Analysis (N, H, S, M, C). © 2024 GE Vernova and/or its affiliates. All rights reserved. 16 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports 3 Windbox - Nozzle Tips 8 Fireball – Single Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 17  1-9 Elevation View - Main WB Corner Arrangement Tangential Firing – Key Features Lower Furnace is the Burner Bulk Air Staging – SOFA + CC-OFA Air & Fuel – Vertically Layered Injection Directing Fuel & Air – Tangent to Firing Circle Flame Stabilizing Turbulence at Nozzle Tip Long Diffusion Mixing Flames Distributing & Balancing Heat Release Rates Main WB – 100% Fuel and 70% to 90% TCA Ref Manual P1, P9, P3 18 © 2024 GE Vernova and/or its affiliates. All rights reserved.  1-9 Elevation View - Main WB Corner Arrangement Yanbu - Key Features Main WB Twin Fireball - Eight (8) Main WB Assemblies – Vertically Stacked Nozzles with +/- 30° Tilt Range Future NG Elevation - Top End Air 4 Spinner Vane Stabilized Oil Elevations / HEA & Flame Scanner 3 NG Elevations / Twin Ignitor & Flame Scanner Auto Tilt System +/- 30° CC-OFA thru UFA CC-OFA +/- 20° Yaw Top / BTM End Air UFA Elevation FGR Elevations +/- 30° Manual Tilt © 2024 GE Vernova and/or its affiliates. All rights reserved. 19  Corner Firing – Twin Fireball / One Burner - Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 20 Key Plan – SOFA & Main WB - Twin Fireball Arrangement Twin Counter-Rotating Fireballs A Furnace B Furnace 6° Firing Angles – Off Diagonal Tangent to Firing Circles A Furnace: Main WB & SOFA Corners 1 – 4 B Furnace: Main WB & SOFA Corners 5-8 © 2024 GE Vernova and/or its affiliates. All rights reserved. 21  Twin Fireball Arrangement 6o 6o Fuel and Air Fuel and Air  7-9 Yanbu - Main WB Corner – Compartment Designations Main WB – Compartment Designations pg 5-7 & 9 19 Compartments Tall – Partition Plate Flow Separated to Damper Box 16 Damper Actuators - Each w/Integral I/P and Position Feedback 128 Total – Main WB Pneumatic Damper Actuators 4 HFO Elevations 3 NG Elevations with Future NG Elevation at Top End Air Top / Bottom End Air Elevation Under Fire Air Elevation 2 FGR Elevations © 2024 GE Vernova and/or its affiliates. All rights reserved. 23  7-9 Yanbu – SOFA Box – Compartment Designations SOFA – Compartment Designations SOFA – Separated OFA Three (3) Elev / SOFA Box Eight (8) SOFA Boxes – Located Directly Above Main WB Flow Directed Tangent to Main WB Firing Circles CC-OFA – Close Couple OFA 1 Elevation – CC-OFA. Top of Each Main WB 3 SOFA + 1 CC-OFA Damper Actuators per Corner 32 Total – Pneumatic Damper Actuators for OFA Each w/Integral I/P and Position Feedback © 2024 GE Vernova and/or its affiliates. All rights reserved. 24 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports 3 Windbox - Nozzle Tips 8 Fireball – Single Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 25  6-9 Yanbu – SOFA Nozzle Tip – Replacement P/N’s Crn 1-8 © 2024 GE Vernova and/or its affiliates. All rights reserved. 26  6-9 Yanbu – Main WB Nozzle Tip – Replacement P/N’s Crn 1-4 © 2024 GE Vernova and/or its affiliates. All rights reserved. 27  6-9 Yanbu – Main WB Nozzle Tip – Replacement P/N’s Crn 5-8 © 2024 GE Vernova and/or its affiliates. All rights reserved. 28  6-9 SOFA Compartment Nozzle Tip 2 Piece +/- 25° Yaw Replaceable Nose Section w/ 309 SS Fasteners © 2024 GE Vernova and/or its affiliates. All rights reserved. 29  6-9 CC-OFA Compartment Nozzle Tip 2 Piece +/- 25° Yaw Replaceable Nose Section w/ 309 SS Fasteners © 2024 GE Vernova and/or its affiliates. All rights reserved. 30  6-9 Top End Air Nozzle Tips Top End Air Compartment Nozzle Tip Design - Twin Guide Pipes Future NG Spud and Pipe Ignitor © 2024 GE Vernova and/or its affiliates. All rights reserved. 31  6-9 Oil Nozzle Tip © 2024 GE Vernova and/or its affiliates. All rights reserved. 32  6-9 Center Aux Air / NG Ignitor Compartment Twin 12 MBTU/hr Pipe Ignitor Diverging Flame Center Flame Scanner © 2024 GE Vernova and/or its affiliates. All rights reserved. 33  6-9 Outboard U/L Main Gas Tips © 2024 GE Vernova and/or its affiliates. All rights reserved. 34  6-9 Bottom End Air & UFA Nozzle Tips - 2 Piece Bottom End / UFA Tip 2 Piece – Replaceable Nose Section Replacement Nose Sect – Incl 309 SS Fasteners © 2024 GE Vernova and/or its affiliates. All rights reserved. 35  6-9 FGR Nozzle Tips FGR – B Elevation New Reduced Flow Nozzle Tip © 2024 GE Vernova and/or its affiliates. All rights reserved. 36  6-9 FGR Nozzle Tips FGR – A Elevation © 2024 GE Vernova and/or its affiliates. All rights reserved. 37  6-9 TPT Compartment - Dust Shields Partial Arc – Repair Style Full Arc - Replacement TPT Cover © 2024 GE Vernova and/or its affiliates. All rights reserved. 38 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports 3 Windbox - Nozzle Tips 8 Fireball – Single Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 39  31 - 32 Yanbu – Oil Specification Pg 31 © 2024 GE Vernova and/or its affiliates. All rights reserved. 40  29 Oil Gun – Flow Rate Selection (typical) BMCR Selection Basis: HFO 380 with 30 of 32 Oil Guns 1 Oil Gun – OOS per Furnace Cell BMCR – Total Fuel Heat Input 5790 MBTU/hr 1,697 MWt Heat input per oil Gun 193 MBTU/hr 56.56 MWt Heat Content 18487 BTU/lb 43 MJ/kg HF 380: Min oil Temp 240 F 116 C For firing viscosity 100 SSU 20 cst Heat Content 140312 BTU/gal 39.15 MJ/L Required oil Flow per oil Gun 1376 gallon/hur 86.8 L/min Atomizer: Predicted Required il Pressure at Stationary Union 160 psig 11 barg © 2024 GE Vernova and/or its affiliates. All rights reserved. 41  31 - 32 Oil – Viscosity & Pre-Heat Temperature (typical) Target Atomizing - Viscosity & Temp Viscosity Range – 15 to 21 cSt / 75-100 SSU HFO – 380 MAX - 21 cSt / 100 SSU -> 115°C / 240°F MIN – 15 cSt / 75 SSU -> 130°C / 266°F HFO – 180 MAX - 21 cSt / 100 SSU -> 100°C / 212°F MIN – 15 cSt / 75 SSU -> 111°C / 235°F © 2024 GE Vernova and/or its affiliates. All rights reserved. 42  29 – 36 Elevation View - Main WB - Fuel Compartments © 2024 GE Vernova and/or its affiliates. All rights reserved. 43 Oil Gun Guide Pipe & Seal Tube Assembly – Air Cooled 29 – 36 Pg 35 © 2024 GE Vernova and/or its affiliates. All rights reserved. 44 Yanbu – First Fires April 2018 © 2024 GE Vernova and/or its affiliates. All rights reserved. 45  29 – 36 Oil Gun Guide Pipe & Seal Tube Assembly – Air Cooled Guide Pipe Assembly Equipped w/13” Dia Vane Diffuser Flex Section – Alignment Hinge Design Slip Fit – Sliding Joint Construction Scanner Cooling Air - 3” Connection Stationary Union Mount Pg 35 © 2024 GE Vernova and/or its affiliates. All rights reserved. 46  29 – 36 Oil Gun - Stationary Union Assembly Pg 36-37 © 2024 GE Vernova and/or its affiliates. All rights reserved. 47  33 Oil Gun Assembly – Air Cooled via Scanner Air System Pg 33 © 2024 GE Vernova and/or its affiliates. All rights reserved. 48  TM EVER-KOOL Oil Guns (typical) 33  33 Oil Gun Assembly – Air Cooled Pg 34 © 2024 GE Vernova and/or its affiliates. All rights reserved. 50  34 Oil Gun Assembly – Air Cooled Pg 33 © 2024 GE Vernova and/or its affiliates. All rights reserved. 51  Pg 33 31 – 32 Yanbu – Spray Plate & Back Plate External Mix Spray Plate GE P/N 1G-6496-JX-38-30% Special: 12 Hole – JX-38 – 70° Spray Plate External Mix – with 30% Higher Steam Flow Heat Treated CPM Tool Steel Thermal Barrier Coating Back Plate GE P/N 1G-5120-JX Heat Treated CPM Tool Steel Surface A - 4 micro inch / 0.10 micron – flat, mirror surface finish required for effective contact seal. Each oil gun cleaning – inspect all 3 faces - spray plate and back plate for imperfections, including chipped edges and deep scratches. Before oil gun re-assembly - Hand Lap Surface A - back to original flat, mirror finish. Wet Surface A – and using light to moderate hand pressure run Surface A - thru figure 8 patterns. Over lapping stone, or 800 grit / finer - wet or dry silicon carbide paper, taped to clean, flat glass surface. If Surface A can not be fully restored to mirror finish with local bench hand lapping – grind and lap face at machine shop. © 2024 GE Vernova and/or its affiliates. All rights reserved. 52  30 – 32 Oil Gun Assembly – Air Cooled Cap Nut Pg 38 © 2024 GE Vernova and/or its affiliates. All rights reserved. 53 Atomizer Tip Wear Operation with worn tips leads to: Poor Atomization (larger than antipacted droplets) Longer Burnout time. Difficulties meeting emissions for NOx / CO Additional risk of slagging Nozzle Tip Condition must be assessed and as necessary the tip replaced. Atomizer Tip Wear and replacement The purpose of classifying atomizer tips in groups, based on wear, is to define a maximum allowable degree of wear, and to prevent simultaneous use of tips that exhibit differing ranges of wear. All tips on the unit must be the same classification. Use of tips beyond classification C will risk high unburnt, excessive fouling and buildup on the furnace floor. A 10% flow increase defines the maximum allowable degree of wear. Discard tips exhibiting this level of wear or greater. Wear Classification Effective Flow Increase A 3 to 5% B 5 to 7% C 7 to 10% (replace or emergency use) D > 10% (replace) Always Replace Atomizer Tips that exceed 10% Combustion Performance Issues will result  29 - 30 Oil Gun Assembly – STYLE K Air-Cooled Cap Nut Pg 38 © 2024 GE Vernova and/or its affiliates. All rights reserved. 56  29 - 30 Oil Gun Assembly – Air Cooled Cap Nut (typical) Pg 38 © 2024 GE Vernova and/or its affiliates. All rights reserved. 57  29 - 30 Oil Gun Assembly – Air Cooled via Scanner Air System Dwg: E2B-000109-1E4410 2 x 100% Scanner Air Fans Consumers – Design Flow: 55 SCFM/Flame Scanner 150 SCFM / Oil Gun 15 SCFM / Oil Gun HEA 100 SCFM / NG Pipe Ignitor Selection Margins: +20% Flow + 40% Head Pg 38 © 2024 GE Vernova and/or its affiliates. All rights reserved.  29 - 30 Proper Air Distribution via Scanner Air System INSERT GP DUST PLUGS: Ignitor + Flame Scanner + Oil Gun Ensure Adequate Cooling Airflow – Manifold Distribution Pg 38 © 2024 GE Vernova and/or its affiliates. All rights reserved.  31 - 32 Yanbu – HFO Firing Spray Plate Flow Characteristic JX – 38 Spray Plate 6.5 Bar – Constant Steam Pressure Yanbu - JX 38 HFO – Oil Flow Characteristic 125.0 100.0 Oil Gun / Spray Plate – HFO Flow Characteristic Design Operating Range Oil Flow (L/min) 25 - 175 psig 75.0 1.75 - 12.03 kg/cm2 50.0 Predicted Oil Flow Characteristic 25.0 with CURRENT 6.5 bar(g) Atomizing Steam Pressure 0.0 0 2 4 6 8 10 12 14 16 Oil Pressure at Oil Gun Union (kg/cm2) Atomizing Steam – Min 28°C / 50°F SH Required Yanbu - Jx 38 HFO - Steam Flow Characteristic 1200.0 1100.0 Design Operating Range Steam Flow (kg/hr) 25 - 175 psig 1000.0 900.0 800.0 700.0 Pg 31 600.0 0 2 4 6 8 10 12 14 16 2 Oil Pressure at Oil Gun Union (kg/cm ) © 2024 GE Vernova and/or its affiliates. All rights reserved. 60  31 - 32 Yanbu – LDO Firing Spray Plate Flow Characteristic Oil Gun / Spray Plate – LDO Flow Characteristic Predicted Oil Flow Characteristic at 5.2 bar(g) Atomizing AIR Pressure Pg 32 © 2024 GE Vernova and/or its affiliates. All rights reserved. 61 HFO & Atomizing Steam Supply – P&ID © 2024 GE Vernova and/or its affiliates. All rights reserved. 62 LDO & Atomizing Air Supply – P&ID © 2024 GE Vernova and/or its affiliates. All rights reserved. 63 Oil Compartment – P&ID © 2024 GE Vernova and/or its affiliates. All rights reserved. 64 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports 3 Windbox - Nozzle Tips 8 Fireball – Single Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 65 NFPA 85 Igniter Types (typical) NFPA-85-2015 Igniter Definition Yanbu III Yanbu III Oil Gas Class 1 Igniter. An igniter that is applied to ignite the fuel input through the burner and X to support ignition under any burner light-off or operating conditions. Its location and capacity are such that it will provide sufficient ignition energy, generally in excess of 10 percent of full load burner input, at its associated burner to raise any credible combination of burner inputs of both fuel and air above the minimum ignition temperature. Class 2 Igniter. An igniter that is applied to ignite the fuel input through the burner under prescribed lightoff conditions. It is also used to support ignition under low load or certain adverse operating conditions. The range of capacity of such igniters is generally 4 percent to 10 percent of full load burner fuel input. Class 3 Igniter. A small igniter applied particularly to fuel gas and fuel oil burners to ignite the fuel input to the burner under prescribed light-off conditions. The capacity of such igniters generally does not exceed 4 percent of the full load burner fuel input. Class 3 Special Igniter. A special Class 3 high energy electrical igniter capable of directly X igniting the main burner fuel. © 2024 GE Vernova and/or its affiliates. All rights reserved. 66  38 HIGH ENERGY ARC (HEA) RETRACTABLE IGNITOR (typical) Defined as a class 3 special electric ignitor – NFPA 85 Capable of lighting off main fuel directly without a separate pilot ignitor Standard GE practice for lightoff of oil guns since the 1980’s 8” Stroke – Pneumatic Cylinder Solenoid (Retracts on Loss Of Power) Advance and Retract Limit Switches © 2024 GE Vernova and/or its affiliates. All rights reserved Page 67  38 HIGH ENERGY ARC (HEA) ROD ASSEMBLY (typical) HEA Rod Assembly Guide Tube HEA Spark Rod Champion © 2024 GE Vernova and/or its affiliates. All rights reserved Page 68  38 HEA INSERTION TARGET – Wet Spray (typical) 8” stroke – insert 7” into spray © 2024 GE Vernova and/or its affiliates. All rights reserved Page 69 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports 3 Windbox - Nozzle Tips 8 Fireball – Single Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 70  10 Yanbu - Main WB Corner – Compartment Designations Main WB – Compartment Damper & Tilt Drives pg 5-7 19 Compartments Tall – Partition Plate Flow Separated to Damper Box 16 Damper Actuators - Each w/Integral I/P and Position Feedback 128 Total – 2 ½” x 5” Pneumatic Damper Actuators AB U/L, B/C U/L, CD U/L Damper Elevations Linked. 1 Actuator / Pair 1 Tilt Actuator / Main WB 8 Total 8” bore by 14” Stroke – Pneumatic Tilt Actuators © 2024 GE Vernova and/or its affiliates. All rights reserved. 71  10 Yanbu – SOFA Box – Compartment Designations Adobe Acrobat Document SOFA – Compartments pg 7-9 3 Compartments Tall – Partition Plate Flow Separation to Damper Box 3 Damper Actuators / Box– Each w/Integral I/P and Position Transmitter 24 Total – SOFA Pneumatic Damper Actuators. 2 ½” dia x 5” stroke 1 Pneumatic Tilt Actuator / SOFA Box. 8” dia x 14” stroke 8 Total – SOFA Box Tilt Positioners. +/- 30° tilt range © 2024 GE Vernova and/or its affiliates. All rights reserved. 72  10 Elevation View - SOFA Corner Arrangement SOFA Features pg 7-9 Remaining 10% to 30% TCA +/- 30° Tilt Range SOFA Tilt Generally Follows Main WB Tilt Position +/- 25° Horizontal Yaw Range Yaw - Manually Positioned Set During Commissioning – based on NOx & CO emissions © 2024 GE Vernova and/or its affiliates. All rights reserved. 73  10 Yanbu - Tilts Main WB Tilts Main WB Injection – Tilt positioned to control FOT / Finishing RH Steam Temp All Main WB nozzle tips tilt together – except for Manual tilt FGR compartments. Positioned at minus 10° tilt. Physical Tilt Range +/- 30° DCS Control Limited to +/- 20° SOFA Tilts All SOFA tips per corner tilt together Physical Tilt Range +/- 30° Generally - follow Main WB tilt position to maintain flow separation Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 74  10 Yanbu – SOFA Tilt Arrangement Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 75  10 Yanbu – SOFA Tilt Tilt Drive System Compartment Drives - Linked Together via External Flat Bar Compartment Drive Lever – Equipped with cam Bolts for +/- 7° nozzle tip – independent tilt adjustment Main Drive – Equipped w/Shear Pin and Maintenance Locking Pin Tilt Main Drive – Connected via Turnbuckle Pipe for Field Adjustment w/ Pneumatic Actuator – 8” Dia x 14” Stock Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 76  10 Yanbu – Main WB Tilt Arrangement Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 77  10 Yanbu – SOFA and Main WB Tilt - Pneumatic Actuator 16 - Pneumatic Tilt Actuators 8” Bore x 14” Stroke Cylinder Each with: Integral – I/P Inlet Filter/Regulator with Auto Drain Inlet Pressure Gauge Siemens Positioner - Self Calibrating 4-20 mA Position Feedback Signal Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 78  10 Yanbu – FGR Compartment – Manual Tilt 16 – Manual Lever Tilt Drives +/- 30° Tilt Range 5° Increments Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 79  8 Elevation View - SOFA Yaw Arrangement Range Limited Yaw +/- 20° bolt-on Stop Plates © 2024 GE Vernova and/or its affiliates. All rights reserved. 80 SOFA & Main WB - Seal Box / WW Flange Connection Spiral WW Evaporator – Passes Thru WB Compartments TPT – Tube Pass Thru Compartments WW Tubing at TPT – No Fins / Not Seal Welded Full Seal Box Construction – WW Tube Panel Frame / WB Mount SOFA and Main WB – Center Bolt Fastened to WW Mount Frame – Driving Travel with WW Cubical Expansion Slotted Bolt Flange Connection – Above / Below the Center Holding Bolts – Allow for Differential Exp – between WW and WB Air Duct Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 81  5 Yanbu – SOFA & Main WB Support – Constant Load Spring Hanger Spiral WW Evaporator – Minimize WW Loading SOLUTION: Constant Load Spring Hanger Supports BOTH Main WB & SOFA Approx 5% Design Loading – Actuate Hanger Travel SOFA and Main WB – Center Bolt Fastened to WW Mount Frame – Driving Travel Slotted Bolt Connection – Both sides of Fixed Center for Differential Exp Full Seal Box Construction – WW Tube Panel Frame / WB Mount Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 82  11 Yanbu – Damper Box Arrangement Compartment Damper - Simple Construction Off-Center / Imbalanced Blade Design Airflow “Opens” Blade Compartment Height – Sets 1 vs 2 Damper Blade Compartment Opposed Blade – Arrangement Provides Better Throttled Airflow Distribution 2 blade compartment – Actuator driven shaft and slave shaft. Slave shaft driven via blade linkage U / L Main Gas Comp’t – Single Damper Actuator. Linkage spans center comp’t Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 83  11 Yanbu – Windbox Damper Arrangement 15° Off Vertical - Full Closed on Stop Closed Damper – has design cooling leakage built in = 10% of Nozzle Tip / Comp’t Flow Area. 75° - Blade Rotation to Full Open Shaft Wrench Flats – Mirror Blade Airflow “Opens” - Off Center Blade Opposed Blade Arrangement: Centers Throttled Airflow Actuator driven shaft – equipped w/ Spherical Graphite Bearing. Slave Shaft - Driven via blade linkage Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 84  11 Yanbu – SOFA Damper – Operations Arrangement 152 - Pneumatic Damper Actuators / Unit 3 – per SOFA Box 24 Total – SOFA Arrangement – Shown w/ Closed Dampers 75° Blade Rotation – Closed to Open Imbalanced Blade - Design Cylinder Rod Retracts w/loss of 4-20 mA Signal or Drive Air B & C SOFA Dampers – Fail Closed A - SOFA Dampers – Fail Open Elev Basis >50% Fail Closed. Top > Down Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 85  11 Yanbu – Main WB Damper Actuator Arrangement 152 - Pneumatic Damper Actuators / Unit 16 – Per Corner – Main WB 128 – Total for Main WB Arrangement – Shows Closed Dampers Extended Actuator Rod – Closed 75° Blade Rotation – Closed to Open Imbalanced Blade - Design Cylinder Rod Retracts w/loss of 4-20 mA Signal or Drive Air All Main WB Dampers – Fail Open Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 86  11 Yanbu – Damper Actuator 152 - Pneumatic Damper Actuators 2 ½” Bore x 5” Stroke Cylinder Each with: Integral – I/P Inlet Filter/Regulator with Auto Drain Inlet Pressure Gauge Siemens Positioner - Self Calibrating 4-20 mA Position Feedback Signal Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 87 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports 3 Windbox - Nozzle Tips 8 Fireball – Single Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 88  5 Yanbu – Constant Load Spring Hangers Seonghwa: Constant Load Hangers Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 89  5 Yanbu – SOFA – Constant Load Spring Hanger Seonghwa: Constant Load Hangers SOFA Box: Design Load – 62 kN MAX Travel – 220 mm Down Design Travel – 167 mm Down Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 90  5 Yanbu – Main WB – Constant Load Spring Hanger Seonghwa: Constant Load Hangers Main WB Arrangement: Hanger Pair Design Load – 110 kN Each MAX Travel – 280 mm Down Design Travel – 215 mm Down Pg 10 © 2024 GE Vernova and/or its affiliates. All rights reserved. 91 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports 3 Windbox - Nozzle Tips 8 Fireball – Single Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 92 Fireball – One Burner Control (typical)  At Start: Individual Burner Control: Elevation Start. Corner Basis Light-off of Individual Oil Guns or NG Burners.  Individual Oil Guns – Remain In-service following HEA light-off. OIL FLAME PROVEN: When compartment discriminating flame scanner indicates flame.  (Individual Corner NG Burner Valves Remain Open – following start sequence. MAIN GAS PROVEN: When both compartment Ignitor IFM flame rods indicate flame OR the associated compartment scanner proves flame.)  Fireball Condition: Exists when 3oo4 fuel compartments / cell in service AND Elevation Firing Rate exceeds 30%.  Fireball Monitoring: Yanbu units - 2 furnace cells. Each cell operates and is monitored independently. Effectively – 2 Fireballs / 1 Fireball each Furnace Cell  Fireball - Flame PROVEN: Exists when elevation firing rate exceeds 30% AND 2oo4 associated elevation flame scanners / furnace cell OR 3oo4 NG ignitor pairs in- service / furnace cell – proven via IFM flame rods. Low Fireball Conditions, the associated elevation NG ignitors can now be shut down.  Generally, NG ignitors should remain in-service until the elevation loading > 40% firing rate.  Placing additional elevations into service – merely enlarges the fireball  Unit Flame Failure - MFT Initiated with Loss of Sufficient Fireball Flame Votes on Elevation in either furnace cell. © 2024 GE Vernova and/or its affiliates. All rights reserved. 94 Review of transition to Fireball conditions (typical) © 2024 GE Vernova and/or its affiliates. All rights reserved. 95 Corner Firing – Single Fireball / One Burner - Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 96  Corner Firing – Twin Fireball / One Burner - Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 97  Oil & NG Compartments - Flame Scanner & Ignitor Locations © 2024 GE Vernova and/or its affiliates. All rights reserved. 98 Topics 1 Yanbu firing system 6 Tilt Drives & Damper orientation control 2 Windbox assembly 7 Windbox supports 3 Windbox - Nozzle Tips 8 Fireball – Single Burner Control 4 Oil Compartment 9 WindBox – Air Flow Control and Distribution 5 HEA Ignitor - Oil 10 Gas Firing (multiple topics) © 2024 GE Vernova and/or its affiliates. All rights reserved. 99  11 - 28 Yanbu – WB Airflow Control - Components FD Fan – Controls Total Airflow to Furnace WB Pneumatic Dampers - Elevation Control via Secondary Air Damper Control System Fuel Air Dampers – Modulate per Fuel Header Pressure when Elevation In-Service.  Opening Fuel Air or Decreasing Aux Air – INCREASES Air to Fuel Compartment  Closing Fuel Air or Increasing Aux Air – DECREASES Air to Fuel Compartment Auxiliary Dampers – Modulate to Control Windbox to Furnace Differential Pressure CC-OFA Dampers – Positioned as a Function of Unit Air Flow SOFA Dampers – Modulate to Control Main Burner Zone Stoichiometry © 2024 GE Vernova and/or its affiliates. All rights reserved Page 100  11 - 28 Yanbu – WB Airflow Control  Oil Fuel Air Compartments - Elevations A, B, C, & D  Main Gas Fuel Air Compartments - Elevations AB, BC, & CD  1 Damper Actuator / U-L Main Gas Spud Pair – Physically Located at Upper Comp’t  Auxiliary Air Compartments - Elevations AA, AB, BC, CD & DD.  Oil Firing – Adjacent Auxiliary Air Elevations AA, AB, BC, CD & DD Modulate for dp Control.  Fuel Air Elevations – Oil Header Pressure Control  NG Firing – Adjacent Oil Fuel Air Comp’t Dampers – A, B, C & D Now Auxiliary Air Elevations.  Center Gas / Aux Air Elevations: AB, BC, CD – on WB/furn dp Control when not firing ignitor gas at the elevation, AND firing either Main Gas at the elevation OR Oil in the Adjacent Elevation. NOTE – Co-firing Oil WB/furn dp Set Point f(X) dominates.  Main Gas Elevations: AB U-L, BC U-L, CD U-L follow NG Header Pressure when firing G at the elevation. © 2024 GE Vernova and/or its affiliates. All rights reserved Page 101  19 Yanbu – Aux Elevation Airflow Control CURRENT WINDBOX TO FURN DP SETPOINT Aux Air Control – WB/furn dpFunction Curve f4(X) DRAWING -1D8676 20.00 Aux Air Dampers – When adjacent to an Active 18.00 Fuel Elevation Modulate Open - Based on Unit WINDBOX/FURNACE dP (mbar) 16.00 Airflow Controlling WB/Furn DP. 14.00 12.00  Higher dp Set Point Fuel Prevails 10.00 HFO - Current 8.00 LDO - Current During Start-up and Low Load 30% Unit Load Yanbu WB - Oil Firing Auto, No Firing Load Load Load Load Load Load Boiler Purge Boiler Purge Modulate As Function AUX AIR CONTROL Modulate As Function Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of CC OFA OPEN of Unit Airflow of Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow TO AUTO Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn D D - E N D AIR OPEN OPEN OS - Closed WB/Furn dp dp dp WB/Furn dp dp dp dp T PT I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header D - LEX OIL OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) T PT CD - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp Linked Damper CD - AU X AIR Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn OPEN OPEN OS - Closed N G P ipe Ignitors WB/Furn dp dp dp WB/Furn dp dp dp dp CD - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp T PT I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header C - LEX OIL OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) T PT BC - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed Linked Damper BC - AU X AIR Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn OPEN OPEN N G P ipe Ignitors WB/Furn dp dp dp WB/Furn dp WB/Furn dp dp dp dp BC - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed T PT I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header B - LEX OIL OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) T PT AB - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed Linked Damper AB - AU X AIR Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn OPEN OPEN OS - Closed N G P ipe Ignitors WB/Furn dp dp dp WB/Furn dp WB/Furn dp dp dp AB - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed T PT I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header A - LEX OIL OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed Pressure f(X) Pressure f(X) Pressure f(X) Pressure T PT Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control Modulate - Control Modulate - Control WB/Furn AA - EN D AIR OPEN OPEN OS - Closed OS - Closed WB/Furn dp dp dp WB/Furn dp WB/Furn dp dp Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r AAA U FA OPEN OPEN OS - Closed OS - Closed OS - Closed OS - Closed Ramp Ramp Ramp Ramp T PT Modulate - GR WB to Furn Modulate - GR WB to Furn Modulate - GR WB to Furn Modulate - GR WB to Furn Modulate - GR WB to Furn B - FGR Closed CLOSED / OPEN Closed Closed Closed Characteristic Curve Characteristic Curve Characteristic Curve Characteristic Curve Characteristic Curve T PT Modulate - GR WB to Furn Modulate - GR WB to Furn Modulate - GR WB to Furn Modulate - GR WB to Furn Modulate - GR WB to Furn A - FGR Closed CLOSED / OPEN Closed Closed Closed Characteristic Curve Characteristic Curve Characteristic Curve Characteristic Curve Characteristic Curve 116 Yanbu – Windbox Damper Operation – Oil 14 - 15 Oil Firing Operation - BMCR to Min Load SADCS - WB Damper Operating Characteristics BMCR-K TMCR-A 95% TMCR-D 75% TMCR-E 70% TMCR-3 60% TMCR-2 50% TMCR-F 30% TL 35% B1 20% TL 3.75% HFO 3.75% HFO 3.75% HFO 3.75% HFO 3.75% HFO 3.75% HFO 3.75% HFO 3.75% HFO 3.75% HFO 3.75% HFO Yanbu WB - Oil Firing Top 4 of 4 Top 4 of 4 Top 4 of 4 Top 4 of 4 Top 4 of 4 Top 4 of 4 Top 3 of 4 Top 2 of 4 BTM 2 of 4 BTM Oil Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of Modulate As Function of CC OFA Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn D D - EN D AIR OS - Dmp'r Ramp OS - Dmp'r Ramp WB/Furn dp dp dp dp dp dp dp dp T PT I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header D - LE X OIL OS - Dmp'r Ramp OS - Dmp'r Ramp Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) T PT CD - N AT GAS OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp Linked Damper CD - AU X AIR Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn OS - Dmp'r Ramp OS - Dmp'r Ramp N G Pipe Ignitors WB/Furn dp dp dp dp dp dp dp dp CD - N AT GAS OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp T PT I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Use Oil Header C - LEX OIL OOS Damper Ramp Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure Ramp Function T PT BC - N AT GAS OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp Linked Damper BC - AU X AIR Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn OS - Dmp'r Ramp N G Pipe Ignitors WB/Furn dp dp dp dp dp dp dp dp dp BC - N AT GAS OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp T PT I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header B - LEX OIL OOS Damper Ramp OS - Dmp'r Ramp Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) T PT AB - N AT GAS OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp Linked Damper AB - AU X AIR Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn OS - Dmp'r Ramp N G Pipe Ignitors WB/Furn dp dp dp dp dp dp dp dp dp AB - N AT GAS OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp T PT I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header I/S - Oil Header A - LEX OIL OS - Dmp'r Ramp OS - Dmp'r Ramp Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) Pressure f(X) T PT Modulate - Control Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - Control WB/Furn Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r AA - E N D AIR OS - Dmp'r Ramp OS - Dmp'r Ramp WB/Furn dp dp dp dp dp dp Ramp Ramp Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r Modulate - to UFA Dmp'r AAA U FA Ramp OS - Dmp'r Ramp OS - Dmp'r Ramp Ramp Ramp Ramp