Yanbu Boiler Training - Firing Systems - Gas PDF

YANBU - FIRING SYSTEM TRAINING NATURAL GAS 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 Topics – Gas Firing 1...

YANBU - FIRING SYSTEM TRAINING NATURAL GAS 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 Topics – Gas Firing 1 Yanbu firing system 6 Air Flow Control and orientation - gas Distribution 2 Natural Gas - Nozzle Tips 3 NG Compartment 4 Limelight TM NG Pipe ignitor 5 Fireball – Single Burner Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 3 Tangential Firing: CE –> ABB –> ABB/Alstom –> Alstom -> GE © 2024 GE Vernova and/or its affiliates. All rights reserved. 4 Yanbu – Iso View Adobe Acrobat Document © 2024 GE Vernova and/or its affiliates. All rights reserved. 5  Yanbu – Side Elev View © 2024 GE Vernova and/or its affiliates. All rights reserved. 6 Yanbu – Plan View Adobe Acrobat Document © 2024 GE Vernova and/or its affiliates. All rights reserved. 7 Yanbu – SA Duct to WB Adobe Acrobat Document © 2024 GE Vernova and/or its affiliates. All rights reserved. 8 Yanbu – GR Duct to WB Adobe Acrobat Document © 2024 GE Vernova and/or its affiliates. All rights reserved. 9 Corner Firing – WB Arrangement 6o © 2024 GE Vernova and/or its affiliates. All rights reserved. 10 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 (for lower than agreed CV fuel) 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. 11 Key Plan – SOFA & Main WB - Twin Fireball Arrangement Twin Counter-Rotating Fireballs 6° Firing Angles – Off Diagonal A Furnace B Furnace Tangent to Firing Circles Air & Fuel Streams – Corner Distributed Vertically Stacked Fuel / Air Distribution 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. 12  Twin Fireball Arrangement 6o 6o Fuel and Air Fuel and Air 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 Top / Bottom End Air Elevation Under Fire Air Elevation 2 FGR Elevations © 2024 GE Vernova and/or its affiliates. All rights reserved. 14 Main WB – NG Compartment © 2024 GE Vernova and/or its affiliates. All rights reserved. Refer to high resolution PIDs in file: E - Yanbu Boiler Training - Controls Student Manual 15 Attachment 4 Boiler PIDs 5-16-24 Corner Firing – WB Arrangement 6o © 2024 GE Vernova and/or its affiliates. All rights reserved. 16 Topics – Gas Firing 1 Yanbu firing system 6 Air Flow Control and orientation - gas Distribution 2 Natural Gas - Nozzle Tips 3 NG Compartment 4 Limelight TM NG Pipe ignitor 5 Fireball – Single Burner Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 17 Yanbu – Main WB Nozzle Tip – Replacement P/N’s Crn 5-8 © 2024 GE Vernova and/or its affiliates. All rights reserved. 18 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. 19 Center NG Compartment Twin 12 MBTU/hr Pipe Ignitor Diverging Flame Center Flame Scanner © 2024 GE Vernova and/or its affiliates. All rights reserved. 20 Outboard U/L Main Gas Tips © 2024 GE Vernova and/or its affiliates. All rights reserved. 21 Topics – Gas Firing 1 Yanbu firing system 6 Air Flow Control and orientation - gas Distribution 2 Natural Gas - Nozzle Tips 3 NG Compartment 4 Limelight TM NG Pipe ignitor 5 Fireball – Single Burner Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 22 Main WB – NG Compartments 2 Main Gas Spuds – Outboard + Center Tip w/Twin-Ignitors & Scanner © 2024 GE Vernova and/or its affiliates. All rights reserved. 23  Elevation View - Main WB - Fuel Compartments © 2024 GE Vernova and/or its affiliates. All rights reserved. 24  Oil & NG Compartments - Flame Scanner & Ignitor Locations © 2024 GE Vernova and/or its affiliates. All rights reserved. 25 Main WB – NG Compartment © 2024 GE Vernova and/or its affiliates. All rights reserved. Refer to high resolution PIDs in file: E - Yanbu Boiler Training - Controls Student Manual 26 Attachment 4 Boiler PIDs 5-16-24 Main WB – NG Compartment Typical NG Piping to U/L Main Gas Spuds © 2024 GE Vernova and/or its affiliates. All rights reserved. 27 Main WB Compartment – NG Piping and Spud Typical NG Piping to U/L Main Gas Spuds Spud Drillings © 2024 GE Vernova and/or its affiliates. All rights reserved. 28 Main WB – NG Compartments © 2024 GE Vernova and/or its affiliates. All rights reserved. 29 Yanbu – Contract Addendum - NG Fuel Analysis © 2024 GE Vernova and/or its affiliates. All rights reserved. 30 Yanbu – NG Performance Fuel BMCR – NG Heat Input 6,087 MBTU/hr Selection Basis: 3 Elev - 24 Compartments / 48 Spuds Heat Input / Comp’t: 254 MBTU/hr Heat Input / NG Spud: 127 MBTU/hr Spud Drillings – for fuel range Typical Min Control Pressure – 1 psig Expected Turndown – with All 3 Elev Inservice: 1030 BTU/SCF Perf Design NG = 4.4 : 1 © 2024 GE Vernova and/or its affiliates. All rights reserved. 31 Yanbu – REVISED NG Performance Fuel © 2024 GE Vernova and/or its affiliates. All rights reserved. 32 Yanbu – REVISED NG Performance Fuel Custome r SW CC Pla nt Yanbu D a te 1-Dec-2022 Fue l N atural Gas "Customer Spec - GAS AN ALYSIS" DRY AIR R EQ'ED F/ COMBU ST ION H 20 IN PRODU CT S CO2 IN PR OD UCT S N2 IN PR ODU CT S H IGH ER H EAT ING VALU E PERCENT MOL W T MOL W T % BY W EIGH T # / # of COMP. # / # of GAS # / # of COMP. # / # of GAS # / # of COMP. # / # of GAS # / # of COMP. # / # of GAS BT U/ # COMP BT U / # GAS GAS COMPOSIT ION BY VOLU ME Of COMPONENT Of GAS HYDROGEN H2 0.000% | 2.016 0.000 0.000 34.340 0.000 | 8.940 0.000 | 0.000 0.000 | 26.407 0.000 | 60990.000 0.000 CARBON MONOXIDE CO 0.000% | 28.010 0.000 0.000 2.470 0.000 | 0.000 | 1.571 0.000 | 1.900 0.000 | 4323.000 0.000 METHANE CH4 88.000% | 16.041 14.116 80.401 17.270 13.885 | 2.250 1.809 | 2.744 2.206 | 13.275 10.673 | 23900.000 19215.739 ETHANE C2H6 2.500% | 30.067 0.752 4.281 16.120 0.690 | 1.800 0.077 | 2.927 0.125 | 12.394 0.531 | 22280.000 953.873 PROPANE C3H8 0.080% | 44.092 0.035 0.201 15.700 0.032 | 1.630 0.003 | 2.994 0.006 | 12.074 0.024 | 21520.000 43.235 n-BUTANE C4H10 0.050% | 58.118 0.029 0.166 15.490 0.026 | 1.550 0.003 | 3.029 0.005 | 11.908 0.020 | 21440.000 35.485 ISOBUTANE C4H10 0.000% | 58.118 0.000 0.000 15.490 0.000 | 1.550 0.000 | 3.029 0.000 | 11.908 0.000 | 21260.000 0.000 n-PENTANE C5H12 0.000% | 72.144 0.000 0.000 15.350 0.000 | 1.500 0.000 | 3.050 0.000 | 11.805 0.000 | 22060.000 0.000 ISOPENTANE C5H12 0.000% | 72.144 0.000 0.000 15.350 0.000 | 1.500 0.000 | 3.050 0.000 | 11.805 0.000 | 21050.000 0.000 HEXANES C6H14 0.000% | 86.169 0.000 0.000 15.270 0.000 | 1.460 0.000 | 3.064 0.000 | 11.738 0.000 | 20940.000 0.000 ETHYLENE C2H4 0.000% | 28.051 0.000 0.000 14.810 0.000 | 1.290 0.000 | 3.138 0.000 | 11.385 0.000 | 21650.000 0.000 PROPYLENE C3H6 0.000% | 42.077 0.000 0.000 14.810 0.000 | 1.290 0.000 | 3.138 0.000 | 11.385 0.000 | 21460.000 0.000 BUTYLENE C4H8 0.000% | 56.102 0.000 0.000 14.810 0.000 | 1.290 0.000 | 3.138 0.000 | 11.385 0.000 | 21550.000 0.000 PENTANE C5H10 0.000% | 70.128 0.000 0.000 14.810 0.000 | 1.290 0.000 | 3.138 0.000 | 11.385 0.000 | 21600.000 0.000 HYDROGEN SULFIDE H2S 0.000% | 34.076 0.000 0.000 6.100 0.000 | 0.530 0.000 | 1.880 0.000 | 4.688 0.000 | 7710.000 0.000 NITROGEN N2 (atmos) 9.370% | 28.016 2.625 14.952 | | 0.000 0.000 | 0.000 0.150 | OXYGEN O2 (atmos) 0.000% | 32.000 0.000 0.000 0.000 | | 0.000 0.000 | 0.000 0.000 | CARBON DIOXIDE CO2 0.000% | 44.010 0.000 0.000 | | 0.000 0.000 | 0.000 0.000 | WATER VAPOR H2O 0.000% | 18.016 0.000 0.000 | | 0.000 0.000 | 0.000 0.000 | H20 FROM AIR 0.195 TOTAL 100.000% 17.557 100.000 14.633 2.087 2.343 11.397 20,248 BT U/ lb 45,275 kJ/ kg 3 HH V, BT U/ SCF = BT U / LB H HV * DENSIT Y LB/ CU FT 937 BT U/ SCF 33,561 kJ/ m HHV, BTU/ ACF = BTU/ LB HHV * DENSITY LB/ CU FT * Elev Corr Factor 937 DESIGN HUMIDITY RATIO ; 60% HUMIDITY/ 80 DEG F 0.013 WET ATMOSPHERIC THEORETICAL AIR lb/ MMBTU 732.264 DRY THEORETICAL AIR REQ'ED FOR COMBUSTION LB/ LB FUEL 14.633 MOISTURE FORMED DURING COMBUSTION lb/ MMBTU 103.047 DRY THEORETICAL PRODUCTS OF COMBUSTION LB/ LB FUEL 13.740 WET THEORETICAL PRODUCTS OF COMBUSTION LB/ LB FUEL 15.826 © 2024 GE Vernova and/or its affiliates. All rights reserved. 33 Yanbu – Nov 2022 Aramco NG Specification BMCR – NG Heat Input 6,087 MBTU/hr Selection Basis: 3 Elev - 24 Compartments / 48 Spuds Heat Input / Comp’t: 254 MBTU/hr Heat Input / NG Spud: 127 MBTU/hr Typical Min Control Pressure – 1 psig Expected Turndown – with All 3 Elev Inservice: 937 BTU/SCF Performance Fuel = 4.6 : 1 © 2024 GE Vernova and/or its affiliates. All rights reserved. 34 Yanbu – NG Operation with Performance Fuel © 2024 GE Vernova and/or its affiliates. All rights reserved. 35 Yanbu – NG System Process Flow Diagram 8532 Refer to high resolution PIDs in file: E - Yanbu Boiler Training - Controls Student Manual © 2024 GE Vernova and/or its affiliates. All rights reserved. Attachment 4 Boiler PIDs 5-16-24 36 Yanbu – NG System Process Flow Diagram 8531 Refer to high resolution PIDs in file: E - Yanbu Boiler Training - Controls Student Manual © 2024 GE Vernova and/or its affiliates. All rights reserved. Attachment 4 Boiler PIDs 5-16-24 37 Main WB – NG Compartment Refer to high resolution PIDs in file: E - Yanbu Boiler Training - Controls © 2024 GE Vernova and/or its affiliates. All rights reserved. Student Manual Attachment 4 Boiler PIDs 5-16-24 38 Yanbu – NG Piping on Boiler Island © 2024 GE Vernova and/or its affiliates. All rights reserved. 39 Main WB – NG Compartments 2 Main Gas Spuds – Outboard and Twin-Center Ignitors © 2024 GE Vernova and/or its affiliates. All rights reserved. 40 Main Gas Firing – NG Compartments © 2024 GE Vernova and/or its affiliates. All rights reserved. 41 Main WB – NG Compartments © 2024 GE Vernova and/or its affiliates. All rights reserved. 42 Topics – Gas Firing 1 Yanbu firing system 6 Air Flow Control and orientation - gas Distribution 2 Natural Gas - Nozzle Tips 3 NG Compartment 4 Limelight TM NG Pipe ignitor 5 Fireball – Single Burner Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 43 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. 44 Elevation View - Main WB Corner Arrangement Key Features 4 Oil Elevations / Each Comp’t with HEA & Flame Scanner 3 NG Elevations / Each Comp’t with Twin Ignitor & Flame Scanner 7 Flame Scanner Elevations 45 © 2024 GE Vernova and/or its affiliates. All rights reserved. Main WB – NG Compartment Twin Ignitors – each 12 MBTU/Hr © 2024 GE Vernova and/or its affiliates. All rights reserved. 46 Introduction & Overview Purpose of Ignitors Ignitions systems are installed to provide a dependable source of heat input for the purpose of: Support ignition during light-off of main fuel Stabilization of the main fuel at NG low firing rates Flame proving – less than 30% load with 2 NG elevating in- service. In some applications, the ignition system may also be sized to provide sufficient heat input for warming of the unit NG Compartment – Pipe Ignitor NFPA Class 1 Ignitor An ignitor that is applied to ignite the fuel input through the burner and 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% 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. 48 NG Pipe Ignitor – 2 x 12 MBTU/Hr Class I Ignitor – 10% Heat Input  6,087 MBTU/Hr BMCR – NG Total Fuel Heat Input o 2,029 MBTU/Hr – per Elev o 1,015 MBTU/Hr – per Furnace Cell / 253 MBTU/Hr - Compartment o 24 MBTU/Hr Ignitor Firing Rate o Class I - 10% Comp’t Heat Input o Twin 3-inch NG Pipe 12 MBTU/Hr Ignitors = 24 MBTU/Hr Ignitor / NG Compartment o Compartment Ignitor Proven Vote - Must Prove Both Ignitors in Compartment are Inservice via IFM Flame Rod o Main Gas Operation – Requires 3 of 4 Compartment Ignitor Votes at Elevation - per Furnace Cell o 24 MBTU/Hr = 10% Compartment Heat Input - Main Gas Heat Input with 3 or 4 corner ignitors proven = [1,015 - (24 * 3)]/4 = 235 MBTU/Hr © 2024 GE Vernova and/or its affiliates. All rights reserved. 49 Yanbu – LIMELIGHTTM 3” NG Pipe Ignitors Components Air Inlet Ignitor Assembly © 2024 GE Vernova and/or its affiliates. All rights reserved. 50 Yanbu – Ignitor Guide Pipe Guide Pipe Assembly 3” Air Inlet ¼” NPT Combustion Air Pressure Tap Material Spec: Carbon Steel 15” 309 SS - fireside end Camlock Coupling LIMELIGHT™ Gas Bluff Body Pipe Ignitor Components – Ignitor Assembly Flame Rod Dust Cap Wiring Harness Bluff Body ¼” NPT Gas Pipe Tip Gas Pressure Tap Material Spec: SS 309 (Removable) Gas Supply – Quick Disconnect LIMELIGHT™ Gas Bluff Body Pipe Ignitor Bluff Body Combustion Zone Initial fuel ignition Superior flame stability at root of the flame LIMELIGHT™ Gas Bluff Body Pipe Ignitor Bluff Body Principals The BB Creates a pressure drop inside the guide pipe and it’s round shape results in uniform air flow around bluff body Turbulence occurs on downstream side of diffuser Gas Weep Holes (3) Diffuser Combustion Air Gas Flow Bluff Body Flame Stabilizer Gas weep holes for initial combustion Adjacent to ignition spark source LIMELIGHT™ Gas Bluff Body Pipe Ignitor Ignition Point Spark occurs between the Kanthal keeper disk on spark rod and Gas Pipe Tip. 10,000 VAC spark jumps across gap (about 1/8 inch) Located about 1-1/4 inch in front of diffuser (bluff Body) and gas weep holes LIMELIGHT™ Gas Bluff Body Pipe Ignitor Components LIMELIGHTTM Bluff Body Gas Pipe Ignitor Bluff Body Pipe Ignitor Connections Swivel Connections DFI Connection Spark Connection The DFI Probe and the Spark Probe are identical and can be swapped. Quick Disconnect Gas Connection LIMELIGHT™ Gas Bluff Body Pipe Ignitor Components – Ignitor Assembly Spark Wiring DFI Wiring Connection Connection Air Inlet Dust Cap Camlock Coupling ¼” NPT Gas Pressure Tap Gas Supply Quick Disconnect Yanbu – 3” NG Pipe Ignitors © 2024 GE Vernova and/or its affiliates. All rights reserved. 60 3” NG Pipe Ignitors – Set-Up / Test Kit © 2024 GE Vernova and/or its affiliates. All rights reserved. 61 Yanbu – 3” NG Pipe Ignitors Set-Up – Adjust NG & Combustion Air Pressures NG Supply Pressure – 2.8 psig for 12 BTU/hr Air Pressure – 3 in wc dp with lower furnace static press Use 0-15 psi Supplied Digital Test Gauge @ ¼” NPT Test Port Use 0-10 inch wc Supplied Digital Test Manometer @ ¼” NPT Test Adjust NG Pressure via Valve Train Manual Globe Valve Port Adjust Air Pressure via Butterfly Valve © 2024 GE Vernova and/or its affiliates. All rights reserved. 62 Main WB – NG Pipe Ignitor Commissioning Set-Up: NG & Airflow Pressures © 2024 GE Vernova and/or its affiliates. All rights reserved. 63  YANBU SPSC - BOILER CONTROLS TRAINING Scanner Cooling Air/Ignitor Air to Furnace Diff. Pressure Control (Reference Drawing No. -1D8718) To Maintain a constant differential pressure between the Scanner Cooling/Ignitor Air Header and the Furnace, a pressure control damper is provided. Control damper is positioned by a single PI controller that responds to the error between measured differential pressure between the Scanner Cooling/Ignitor Air Header and the Furnace as compared to a predetermined setpoint. Due to the stack effect of the boiler when operating, the differential pressure between the upper furnace and the windbox area deviates as a function of load. As the boiler firing rate increases, the static pressure in the lower furnace is reduced. To account for the change in pressure, a load dependent offset is provided to maintain the pressure at the desired setpoint. Limited operator biasing capability is provided to increase or decrease the fixed setpoint. © 2024 GE Vernova and/or its affiliates. All rights reserved Page 64 Yanbu – 3” NG Pipe Ignitors Set-Up – Adjust NG & Combustion Air Pressures NG Supply Pressure: 2.8 psig for 12 MBTU/hr Air Pressure: 3 in wc dp with lower furnace static press Use 0-15 psi Supplied Test Gauge @ ¼” NPT Test Port Use 0-10 inch wc Supplied Test Gauge @ ¼” NPT Test Port Adjust NG Pressure via Valve Train Manual Globe Valve Adjust Air Pressure via Butterfly Valve © 2024 GE Vernova and/or its affiliates. All rights reserved. 65 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. Scanner Cooling Air System – P&ID 2 x 100% Scanner Air Fans Consumers: Flame Scanner: Cooling– 7 Elev Oil Gun: Cooling – 4 Elev HEA: GP Seal Air – 4 Elev NG Pipe Ignitor: Combustion Air – 3 Elev © 2024 GE Vernova and/or its affiliates. All rights reserved. 67 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. 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. Yanbu – 3” NG Pipe Ignitors Typical Operation - Firing Thru Same Flame Spreading Center Nozzle Tip Clip Includes Light-off Diverging Pipe Ignitor Flame Crosses Main Gas - Ensure Light-off © 2024 GE Vernova and/or its affiliates. All rights reserved. 70 Topics – Gas Firing 1 Yanbu firing system 6 Air Flow Control and orientation - gas Distribution 2 Natural Gas - Nozzle Tips 3 NG Compartment 4 Limelight TM NG Pipe ignitor 5 Fireball – Single Burner Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 71 COMBUSTION ENGINEERING FIREBALL – SINGLE BURNER CONTROL © 2024 GE Vernova and/or its affiliates. All rights reserved. 72 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. 74 Corner Firing – Single Fireball / One Burner - Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 75  Corner Firing – Twin Fireball / One Burner - Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 76  Oil & NG Compartments - Flame Scanner & Ignitor Locations © 2024 GE Vernova and/or its affiliates. All rights reserved. 77 Topics – Gas Firing 1 Yanbu firing system 6 Air Flow Control and orientation - gas Distribution 2 Natural Gas - Nozzle Tips 3 NG Compartment 4 Limelight TM NG Pipe ignitor 5 Fireball – Single Burner Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 78 Yanbu – WB Airflow Control 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 79  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.  Ojɱ ⇒Fjṩjȍi – Adjacent Auxiliary Air Elevations AA, AB, BC, CD & DD Modulate for dp Control.  Fuel Air Elevations – Oil Header Pressure Control  NG⇒ Fjṩjȍi – 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 80 Elevation View - Main WB Corner Arrangement Key Features pg 3-4 CC-OFA Elevation with +/- 25° Horizontal Yaw 4 Oil Elevations / Each Comp’t with HEA & Flame Scanner 3 NG Elevations / Each Comp’t with Twin Ignitor & Flame Scanner 7 Flame Scanner Elevations BTM End Air / UFA Elevations FGR Elevations Auto Tilt System – CC-OFA thru UFA Fixed +/- 15° Manual Tilts for FGR Elevation © 2024 GE Vernova and/or its affiliates. All rights reserved. 81 Topics – Gas Firing 1 Yanbu firing system 6 Air Flow Control and orientation - gas Distribution 2 Natural Gas - Nozzle Tips 3 NG Compartment 4 Limelight TM NG Pipe ignitor 5 Fireball – Single Burner Control © 2024 GE Vernova and/or its affiliates. All rights reserved. 82 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 – Adjacent to Active Fuel 18.00 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% - Preferably >40% - Ignitors are OF⇒ Ajṩ⇒ removed from Service and Center Compartment Released to dp Control 40 ⁌ ⇒ Ii ȍjʉớṩ⇒ 20 U/L Compartment – Elevation dampers positioned per Main Gas Header Pressure when In Service. When OOS / Not firing Gas at this elevation – U/L Main Gas NG⇒ 0 Compartment Dampers follow the OOS damper ramps for these Main Gas 0 0.2 0.4 0.6 0.8 1 Compartments NG⇒Ii ȍjʉớṩ⇒ Hƽaḕƽṩ⇒ Pṩƽṯ ṯ ữṩƽ⇒ ⁌dzaṩ⁍ © 2024 GE Vernova and/or its affiliates. All rights reserved. 84 Yanbu – Center & U/L Main Gas - OOS Airflow Control OOS CENTER NG DAMPER OPENING f(X) DRAWING -1D8676 OOS Aux Air – Function Curve 100 90 OOS DAMPER POSITION 80 Aux Air Elevs – AB / BC / CD Released to Out (% OF RANGE) 70 of Service (OOS) Function Curve – when not 60 Rev9 50 adjacent to in-service fuel elevation 40 30 20 10 Aux Air Elevs – U/L - AB / BC / CD Released to 0 0 20 40 60 80 100 Out of Service (OOS) Function Curve – when TOTAL MEASURED AIRFLOW (% BMCR) not adjacent to in-service fuel elevation, and not firing NG the elevation AB U/L COMPARTMENT DAMPER OPENING fxx (X) DRAWING -1D8676 Located Between BOTH an Active and Idle Oil 100 AB U/L DAMPER OPENING 90 Elevation – AB / BC / CD Aux Air Elevation 80 (% OF RANGE) Remains In-Service. Actively Controlling 70 60 WB/Furn DP for Fuel Dependent f(X) Function 50 Rev9 Curve 40 30 20 10 0 0 20 40 60 80 100 TOTAL MEASURED AIRFLOW (% BMCR) © 2024 GE Vernova and/or its affiliates. All rights reserved. 85 Yanbu – Aux Elevation OOS Airflow Control OOS DAMPER OPENING OOS Aux Air – Function Curve f10(X) DRAWING -1D8676 20 Aux Air Elev - Released to Out of Service 18 (OOS) Function Curve – when not adjacent to OOS DAMPER POSITION 16 in-service fuel elevation 14 (% OF RANGE) 12 10 8 Unit Airflow Dependent - Positioned to As Much 6 As 18% Open for Additional Cooling Rev 7 - Current Setting 4 2 0 Located Between BOTH an Active and Idle 0 20 40 60 80 100 120 TOTAL MEASURED AIRFLOW (% BMCR) Fuel Elevation - Aux Air Elevation Remains In- Service. Actively Controlling WB/Furn DP for Fuel Dependent f(X) Function Curve Pg 22-23 © 2024 GE Vernova and/or its affiliates. All rights reserved. 86 Yanbu – UFA Elevation Airflow Control UNDERFIRE AIR DAMPER OPENING f11(X) DRAWING -1D8676 100 UFA Air Control – Function Curve UNDERFIRE AIR DAMPER OPENING 90 80 Pg 22 70 (% OF RANGE) 60 50 UFA Elevation – Active When A Oil Elevation 40 or AB NG Elevation Placed In-Service 30 Position Dependent on Elevation Firing Rate Rev 8 - Current Setting 20 10 0 0 20 40 60 80 100 TOTAL MEASURED AIRFLOW (% BMCR) © 2024 GE Vernova and/or its affiliates. All rights reserved. 87  23 - 24 Yanbu CC-OFA Airflow Control CCOFA DAMPER OPENING f6(X) -DRAWING -1D8677 100 90 CCOFA DAMPER POSITION 80 CC-OFA Elevation – Function Curve 70 (% OF RANGE) 60 50 Unit airflow Dependent - Positioned per 40 Function Ramp 30 Rev 9 - Current 20 10 0 0 20 40 60 80 100 TOTAL MEASURED AIRFLOW (% BMCR) Pg 23-24 © 2024 GE Vernova and/or its affiliates. All rights reserved. 88  23 - 28 Yanbu – OFA Airflow Control Pg 23-24 SOFA Airflow Demand: Actively Controlled via Main Burner Zone Stoichiometry f(X) Function Curve PURPOSE: Control NOx Emissions Independent of Boiler Load, and Excess Air  Maintaining O2 & Optimum Low NOx Conditions over the Boiler Load Range. Annubar Airflow Measurement - 4 Locations. Front Wall / Rear Wall Duct - To SOFA Connecting Duct. SOFA Airflow Demand: MBZ Stoich Set Point vs Total Measured SOFA Flow, Unit Airflow, Fuel Flow, Steam Flow & Outlet O2 SOFA Damper Position – A, B & C Elevations Cascade Ramped as % of Total SOFA Demand SOFA Demand Modulated / Controlled - Comparing Flow Measurement vs Demand Set Point © 2024 GE Vernova and/or its affiliates. All rights reserved. 89  23 - 28 Yanbu – OFA Airflow Control Pitot Tube Grid Array – Located in 4 Ducts to SOFA Connecting Duct © 2024 GE Vernova and/or its affiliates. All rights reserved. 90 Yanbu – NG Firing Unit O2 Set-Point Yanbu - NG Firing - % O2 Setpoint f(x) The O2 controller controls the 8.00% appropriate amount of excess 7.00% air for the combustion process. NG Firing - % Oxygen - Set Point O2 is measured in the 6.00% Economizer outlet duct. 5.00% air. 4.00% 3.00% 2.00% 1.00% 0.00% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% TOTAL CORRECTED FUEL FLOW (% BMCR) © 2024 GE Vernova and/or its affiliates. All rights reserved Page 91 Low NOx Firing Does Low NOx Firing Impact Air Toxic Emissions ? CO / VOC / UBC NOx Furnace Stoichiometry Increasing (Global / Local) © 2024 GE Vernova and/or its affiliates. All rights reserved. 92 Yanbu – NG Firing MBZ Stoichiometry Set-Point N.G. FIRING MBZ STIOCH SETPOINT f2(X) DRAWING -1D8694 BZS – Set Point Function Curve N.G. FIRING MBZ STOICH SETPOINT (5) 1.50 1.40 1.30 Establishes NG Firing SOFA Demand 1.20 1.10 1.00 0.90 0.80 0.70 0.00 20.00 40.00 60.00 80.00 100.00 TOTAL AIRFLOW DEMAND (% BMCR) Pg 26-27 © 2024 GE Vernova and/or its affiliates. All rights reserved. 93  25 - 26 Yanbu SOFA Airflow Control SOFA Elevation Damper Position - Stagger Ramped with % Total SOFA Demand Pg 24-26 SOFA⇒ - A⇒ DAMPER⇒POSITION SOFA⇒ - B⇒ DAMPER⇒POSITION SOFA⇒ - C⇒ DAMPER⇒POSITION $3 ⁌X⁍⇒DRAWING⇒ - (D) % 0 1 $1 ⁌X⁍⇒DRAWING⇒ - (D) % 0 1 $/ ⁌X⁍⇒DRAWING⇒ - (D) % 0 1 POSITOIN⇒ 120 120 POSITOIN 120 POSITOIN Rev 7 - Current Setting Rev 7 - Current… Rev 7 - Current… 100 100 100 RANGE⁍ RANGE⁍ DAMPER⇒ DAMPER⇒ RANGE⁍ 80 80 80 DAMPER⇒ OF⇒ OF⇒ 60 60 60 OF⇒ ⁌ ⇒ - A⇒ ⇒ ⁌ ⇒ - B⇒ ⁌ ⇒ 40 - C⇒ 40 40 SOFA⇒ SOFA SOFA⇒ 20 20 20 0 0 0 0 20 40 60 80 100 0 20 40 60 80 100 0 50 100 A⇒ SOFA⇒ Oś ƽȍjȍi ⇒ Dƽô aȍḕ⇒ ⁌ ⇒ OF⇒ RANGE⁍ B⇒ SOFA⇒ Oś ƽȍjȍi ⇒ Dƽô aȍḕ⇒⁌ ⇒ OF⇒RANGE⁍ C⇒ SOFA⇒ Oś ƽȍjȍi ⇒ Dƽô aȍḕ⇒ ⁌ ⇒ OF⇒ RANGE⁍ © 2024 GE Vernova and/or its affiliates. All rights reserved. 94 Main WB SA Distribution – Cell Operation © 2024 GE Vernova and/or its affiliates. All rights reserved. 95  Elevation Firing Question Plan View of furnace cells Each in service Firing Elevation: Damper at the firing elevation is controlled by fuel pressure has air admitted adzớуƽ and dzƽɱ ớӳ controlled on windbox to furnace dP Side view of one of eight fuel admission assemblies Yanbu Firing Arrangement B Windbox Plan A Boiler Elevation Single Windbox 8D - Yanbu Burner Tips Coating Delamination and Elevation 97 FGR Burnback -rev 2 Yanbu – Windbox Damper Operation – Gas SADCS - WB Damper Operating Characteristics NG Firing Operation designed to be automated on the plant and this chart 30-40% Airflow 30-40% Airflow BM CR - N G Post Purge, DP in BTM ELEV 30% Unit Post MFT Pre-Firing BTM 2 < 30% Unit Load BTM 2 > 30% Unit Load 3 of 3 N G E le v TOP 2 > 30% Unit Load TOP 2 < 30% Unit Load Windbox examples only. These configurations are Yanbu WB Boiler Purge Boiler Purge Auto, No Firing Load Load Modulate As AUX AIR 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 OPEN Function of Unit CONTROL Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Unit Airflow Airflow TO AUTO Not for operation. For Information on Typical Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control D D - E N D AIR OPEN OPEN OS - Closed OS - Closed WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp can be used for system understanding only TPT Modulate - Control Modulate - Control Modulate - Control D - LEX OIL OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed WB/Furn dp WB/Furn dp WB/Furn dp TPT CD - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure Linked Damper Pipe Ignitor Pair Pipe Ignitor Pair Pipe Ignitor Pair CD - AU X AIR Modulate - Control Modulate - Control Modulate - Control OPEN OPEN OS - Closed OS - Closed Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp N G Pipe Ignitors WB/Furn dp WB/Furn dp WB/Furn dp Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l CD - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure TPT Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control C - LEX OIL OPEN OS - Closed OS - Closed OS - Closed OS - Closed WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp TPT BC - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure Linked Damper Pipe Ignitor Pair Pipe Ignitor Pair Pipe Ignitor Pair Pipe Ignitor Pair Pipe Ignitor Pair BC - AU X AIR Modulate - Control Modulate - Control OPEN OPEN OS - Closed Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp N G Pipe Ignitors WB/Furn dp WB/Furn dp Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l BC - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure TPT Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control B - LEX OIL OPEN OS - Closed OS - Closed WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp TPT AB - N AT GAS OPEN OS - Closed OS - Closed I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure OS - Closed OS - Closed Linked Damper Pipe Ignitor Pair Pipe Ignitor Pair Pipe Ignitor Pair Pipe Ignitor Pair Pipe Ignitor Pair AB - AU X AIR Modulate - Control Modulate - Control OPEN OPEN Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp Ignitor I/S - Ignitor f(X) Ramp OS - Closed N G Pipe Ignitors WB/Furn dp WB/Furn dp Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l Adj Fuel Ignitor OOS - dp cnt'l Adj Fuel AB - N AT GAS OPEN OS - Closed OS - Closed I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure I/S - Gas Header Pressure OS - Closed OS - Closed TPT Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control A - LEX OIL OPEN OS - Closed OS - Closed OS - Closed OS - Closed WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp TPT Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control Modulate - Control AA - EN D AIR OPEN OPEN OS - Closed WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp WB/Furn dp Modulate - UFA Dmp'r Modulate - UFA Dmp'r Modulate - UFA Dmp'r Modulate - UFA Dmp'r Modulate - UFA Dmp'r AAA U FA OPEN OPEN OS - Closed Ramp only when A Oil or Ramp only when A Oil or Ramp only when A Oil or Ramp only when A Oil or Ramp only when A Oil or OS - Closed OS - Closed AB Nat Gas Elev - I/S AB Nat Gas Elev - I/S AB Nat Gas Elev - I/S AB Nat Gas Elev - I/S AB Nat Gas Elev - I/S TPT B - FGR Closed Closed/Open Closed Closed Closed Closed Closed Closed Closed Closed TPT A - FGR Closed Closed/Open Closed Closed Closed Closed Closed Closed Closed 98 Closed © 2024 GE Vernova and/or its affiliates. All rights reserved.  Yanbu – Windbox Damper Operation – Gas / Oil Firing Swap Over (typical) These configurations are designed to be automated on the plant and this SADCS - WB Damper Operating Characteristics Co-Firing - All Compt's on dp Control - Follow higher WB/furn dp - Oil Firing f(x) fuels must be done strictly according to the fuel changeover procedure – 30-40% Airflow 30-40% Airflow Post Purge, DP in A OIL & AB GAS ELEV A OIL & AB GAS ELEV A,B OIL & BC GAS >30% A,B OIL & BC & CD GAS AB GAS & B,C, OIL AB GAS & C,D , OIL AB GAS & B, C,D , OIL Post MFT Pre-Firing ALL IN SERVICE chart can be used only for system understanding. Transitions between Yanbu WB - Oil Firing Auto, No Firing 30% Unit Load Unit Load >30% Unit Load >30% Unit Load >30% Unit Load >30% Unit Load Boiler Purge Boiler Purge Not for operation. For Information on Typical Windbox examples only. MOD As Function AUX AIR MODULATE As MODULATE As Function MODULATE As Function MODULATE As Function MODULATE As Function MODULATE As Function MODULATE As Function MODULATE As Function MODULATE As Function CC OFA OPEN of Unit Airflow CONTROL Function of Unit Airflow of Unit Airflow of Unit Airflow of Unit Airflow of Unit Airflow of Unit Airflow of Unit Airflow of Unit Airflow of Unit Airflow TO AUTO MODULATE - Control MODULATE - Control MODULATE - Control Oil MODULATE - Control Oil MODULATE - Control Oil D D - EN D AIR OPEN OPEN OS - Closed OS - Closed OS - Closed OS - Closed WB/Furn dp WB/Furn dp f(X) WB/Furn dp f(X) WB/Furn dp f(X) WB/Furn dp T PT MOD - Control WB/Furn I/S - Oil Header Pressure D - LE X OIL OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed I/S - Oil Header Pressure I/S - Oil Header Pressure Boiler is not designed for continuous dual fuel operation. dp OS - Closed T PT CD - N AT GAS OPEN OS - Closed OS - Closed OS - Closed OS - Closed OS - Closed I/S - Gas Header Pressure OS - Closed OS - Closed OS - Closed I/S - Gas Header Pressure Linked Damper Ignitor I/S or OOS Ignitor I/S or OOS ref: YNS GE/SEP/C05495: Y3-SEP-GE-L-00907. CD - AU X AIR MODULATE - Con