Optimizing Duct Burner Reliability

2002 HRSG Operations and Maintenance Seminar
Optimizing Duct Burner Reliability and Performance

through Regular Maintenance and Inspection
Harold F. Honath Jr., P.E.

Manager, Project Engineering, Burlingame Division
Coen Company, Inc.
Contents
TYPICAL DUCT BURNER ARRANGEMENT ..................................................1
Burner Elements........................................................................................................................ 1
Flow Baffles.............................................................................................................................. 2
Structural Supports.................................................................................................................... 2
Duct Burner Design Evolution.................................................................................................. 3
TYPICAL OPERATING CONDITIONS .............................................................4

Its Hot In There! ...................................................................................................................... 4
When Steel Gets Hot, It Expands ............................................................................................. 4
Its Not Just the Heat, Its the Humidity ................................................................................... 4
Gale Force Winds ..................................................................................................................... 5
BURNER TROUBLESHOOTING AND MAINTENANCE...............................5

Starting Sequence...................................................................................................................... 5
Master Fuel Trip Device Maintenance ..................................................................................... 6
Flame Scanner Maintenance ..................................................................................................... 6
Safety Shutoff Valve Maintenance ........................................................................................... 6
Light Off Position Switch on Flow Control Valve ................................................................... 6
Igniter Maintenance .................................................................................................................. 7
Fuel Supply ............................................................................................................................... 7
Main Burner Component Maintenance..................................................................................... 7
SUMMARY ..............................................................................................................8
Maintenance & Inspection ........................................................................................................ 8
Burner Longevity ...................................................................................................................... 8
Optimizing Duct Burner Reliability and Performance through Regular Maintenance and Inspection
TYPICAL DUCT BURNER ARRANGEMENT

Burner Elements
Most new duct burners have horizontal natural gas elements or runners that span the duct width.
Figure 1
Horizontal Natural Gas Fired Duct Burner Element
Other configurations are also used:
Vertical gas runners (Shown in Figure 2 with in line oil atomizers for dual fuel
capability)
Horizontal oil runners
Side fired oil burners, using atomizers in wind boxes that take a slip stream of CT
exhaust, along with horizontal gas runners. Another type of dual fuel burner. See Fig. 3.
Various alternate fuels process off gases, hydrogen, biogas, landfill gas, blast furnace
gas
Figure 2
Vertical Natural Gas Fired Elements
with in line oil atomizers
Figure 3
Side Fired Oil Burners with in line
Horizontal Natural Gas Fired Elements
Page 1
Flow Baffles
Flow baffles may be required between the burner elements to increase the CT (combustion
turbine) exhaust gas velocity to 4,000 to 6,000 feet per minute across the burner for optimum
combustion and emission performance.
Structural Supports
Any duct over 10 feet wide will require some kind of support structure to keep burner elements
from sagging under their own weight. These are usually vertical supports from the flow baffles,
or some sort of truss attached to the HRSG casing.
Figure 4
Horizontal Natural Gas Fired Element with
simple vertical support
Figure 5
Sectional view of a Horizontal Natural
Gas Element Supported by Flow Baffles
Page 2
Duct Burner Design Evolution

Heat Recovery Steam Generators (HRSGs) have gotten bigger, with wider, taller ducts and more
heat input. More efficient turbines are firing to higher exhaust gas temperatures with lower
oxygen and higher water content. Steam injection for power augmentation and NOx control
further reduces oxygen levels and raises water content. Duct burner designs have had to improve
to keep meeting lower emissions requirements under these more difficult firing conditions.
Figure 6
Large HRSG under construction showing Horizontal Duct Burner Elements and Flow Baffles
Page 3
Typical Operating Conditions

Its Hot In There!
Typically CT exhaust temperatures are 750F to 1100F.
Downstream firing temperatures are 1200F to 1800F.
Materials used to accommodate this are:
304SST for parts cooled by incoming CT exhaust
309/310SST for parts under high radiant heat load of burner flame.
Higher-grade alloys can be used when a corrosive atmosphere or extremely high
temperatures are present.
When Steel Gets Hot, It Expands

Thermal expansion of stainless steel components is approximately 1 inch of growth over 10 feet
of length for every 1000F temperature increase. Burner elements, baffles, supports, liner plates,
etc., must be free to move or grow unconstrained.
Some parts may grow more than others. For example, both flow baffles and burner elements
typically span the duct width. Both will grow equally as the CT comes on line and hot exhaust
flows through the duct. As the duct burner is brought on line, fuel gas (at ambient temperature)
flows into the gas runners and cools them. The elements then shrink relative to flow baffles.
The elements need to be designed to expand thermally with the baffles, then shrink back to some
degree when operating.
Its Not Just the Heat, Its the Humidity

Moisture content of CT exhaust gas can range from 5% to 24%.
When the duct burner is not operating, CT exhaust enters burners, pilots, and associated piping,
cools and water vapor condenses. Over time, water can accumulate in piping and burner and
pilot components and corrosion can occur. If no isolation valves are present, the fuel piping to
the pilots and burners needs to be regularly drained at low point drains during periods of nonoperation of the burner and operation of the CT.
Water accumulation can be minimized or prevented when there are automated isolation valves
on pilots and main gas lines. These are supplied when pilots and elements have individual light
off and shut down capability.
In some cases manual valves may be present that can be closed to isolate fuel to pilots and
elements when the burner will be down for an extended period.
Pilots may also have check valves or be air purged which will prevent water from CT exhaust
from entering the fuel piping.
Page 4
Gale Force Winds

CT exhaust gas velocities are 3000 feet per minute or 30-40 miles per hour. At the burner, this
is increased by 25% to 100%. Its breezy in there! The straightness of the flow and uniformity
of the flow are very important. For optimum results, the velocity profile should be 25% of
average free stream velocity, with velocity vectors perpendicular to the burner plane. Eddies and
localized areas of high or low flow can cause flames to impinge on burner parts or sidewalls.
Distribution grids and flow straightening vanes are used in expanding ducts to achieve the
required profile. Localized areas of poor exhaust gas flow can sometimes be addressed by
reducing fuel input to those portions of the burner by pinning or plugging burner orifices.
Figure 7
Isometric view of Duct Burner with Combination CT Exhaust Flow Straightening /Fresh Air
Distribution Vanes
BURNER TROUBLESHOOTING AND MAINTENANCE

Starting Sequence
The six main steps in the Duct Burner Start Sequence are:
1. Establish Safety Permissives, including master fuel trip conditions, safety shutoff valves
proved closed no flame detected and system stop not activated.
2. Duct burner purge
3. Prove fuel flow control valve is in the light off position.
4. Pilot trial for ignition.
5. Main burner trial for ignition.
6. Release of burner to modulate.
Page 5

The basis of these steps is NFPA 85 - Boiler & Combustion Systems Hazards Code. Chapter 1
(Fundamentals of Boiler Combustion Systems) and Chapter 5 (Heat Recovery Steam Generators)
apply to duct burners. NFPA 85 establishes minimum requirements for design, installation,
operation, training and maintenance, as they relate to the safety of combustion systems. As such
it is an important and invaluable reference and tool.
Master Fuel Trip Device Maintenance

Safety Permissives include all master fuel trip (MFT) signals (see NFPA 85 Section 5.10.4.3 or
your job specific sequence of operations). These trip signals can come from pressure switches,
transmitters, control system contacts and valve position switches. These devices should be
checked at least semiannually for proper generation of trip signals at the required set point and
for resetting to normal condition within proper deadband. For critical service, if operations allow
more frequent inspection, monthly inspections may be prudent.
Flame Scanner Maintenance

Flame scanners must prove no flame is present in order to proceed beyond steps 1 to 3, and must
prove flame is present for steps 4, 5 and 6. These devices must be properly sighted to pick up a
strong signal when flame is present. They are typically mounted on an adjustable swivel ball
mount. These should be sighted by a qualified start up technician during commissioning and
should only require re-sighting if the swivel mount is accidentally directionally altered.
Vibrations, or being used as a step are possible culprits for a scanner becoming misaligned.
Most scanners have quartz lenses that can pick up dust and dirt over time. This foreign material
can absorb UV radiation and cause loss of flame signal strength. A schedule should be set based
on experience to clean these lenses regularly using a clean soft cloth. Precautions need to be
taken when removing a scanner head while the duct is hot.
Scanners can be tested with an open flame from a lighter. This can also verify the integrity of
wiring back to the DCS.
Inspection of scanners should include verification that conduit connections are tight to prevent
water intrusion.
Safety Shutoff Valve Maintenance

All fuel safety shutoff valves must be proven closed in order for steps 1 to 3 to proceed. These
redundant valves are of critical importance to ensure that fuel is not entering the unit when the
burner is shutdown. These valves fail closed and require power to open. If they are kept clean
internally by strainers upstream in the fuel line, they will require little maintenance. Proper
operation and switch settings should be checked semiannually. Leak testing should be
performed monthly. Coen provides a leak test valve downstream of each safety shutoff valve to
facilitate leak testing with the shutoff valve pressured upstream and blocked in downstream.
Light Off Position Switch on Flow Control Valve

The fuel flow control valve must be proven at the proper position, usually 25% to 35% open in
order for purge to proceed. This set point is determined during initial commissioning. The
Page 6

control system will position the valve upon prompting by the burner management system. This
switch setting should be checked semiannually.
Igniter Maintenance
Igniters (or Pilots) have a somewhat checkered past as a source of problems. Improved
electrodes and premixing air with fuel have much improved the reliability of pilots, even in
difficult applications.
For a pilot to work, you need fuel (and oxygen of course) and a spark. The pilot fuel regulator
must be properly set so a constant regulated pressure is available. Fuel lines must be kept clear
of condensate by valves or by draining during non-operation. Pilots have small orifices and
passages on the fuel side that can become plugged with debris if strainers are not properly
maintained in the fuel lines.
If air is premixed with the fuel, it too must be available at the flow and pressure specified by the
manufacturer. In addition, spare electrodes should be kept on hand, and scanners must be
properly sighted and maintained as described earlier.
Fuel Supply
Fuel Supplied to the duct burner piping train must be at a constant regulated pressure.
Regulators must be sized properly to be able to keep up with changes in fuel demand to the
burner. Having a sufficient volume of gas between the last regulator and the safety shutoff
valves is important to cushion the large increase in flow on a burner start without tripping the
unit on low fuel supply pressure.
Strainers need to be present and properly maintained to prevent debris from fouling shutoff and
flow control valve seats and seals and burner orifices. For natural gas service we recommend
100 mesh stainless steel strainer baskets.
Main Burner Component Maintenance

For the most part, duct burner elements, especially horizontal gas elements contain no moving or
adjustable parts and require no maintenance other than inspecting during shutdowns to make sure
parts are secure and in good condition. Internal inspections should be done at least semiannually
to check that elements, baffles, support structures and liners are intact and free to expand
thermally as described earlier. Baffles and burner wings that direct CT exhaust flow and pilot
covers that shield pilots need to be reasonably intact. Some minor distortion of parts, and some
oxidation of surface metal can be expected and tolerated without affecting performance.
Page 7
Summary
Maintenance & Inspection
The unique characteristics of each operating environment as well as unit availability demands
require that each site setup a regular inspection and maintenance schedule based on plant
experience. A conservative starting point might be NFPA 85, Section A.1.7.1.1:
A.1.7.1.1 An example of an inspection and maintenance schedule is a follows:
a) Daily. Flame failure detection system, low water level cutout, and alarm
b) Weekly. Igniter and burner operation
c) Monthly. Fan and airflow interlocks, fuel safety shutoff valves for leakage, high steam
pressure interlock, fuel pressure and temperature interlocks for oil, high and low fuel
pressure interlocks, and gas strainer and drip leg for gas
d) Semiannually. Burner components, flame failure system components, piping, wiring, and
connections of all interlocks and shutoff valves, calibration of instrumentation and
combustion control system.
Semiannual inspections of internal components are important for components subject to thermal
expansion. Maintenance of shutoff valves, limit switches, interlocks, scanners and pilots will
ensure reliable light offs and burner operation.
Burner Longevity
The life of duct burner components will be most affected by:
Proper design and installation that allows unconstrained thermal expansion of burner
elements, baffles, supports and liners.
How straight the CT exhaust gas flow is.
How uniform the CT exhaust gas flow is.
Not firing the burner beyond its rated capacity.
Page 8

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2002 HRSG Operations and Maintenance Seminar