HRSG - Basic Understanding
-
date post
03-Jan-2016 -
Category
Documents
-
view
389 -
download
17
description
Transcript of HRSG - Basic Understanding
GE Energy
Date
HRSG – 101
TPSE – Dave Rogers, Wulang Chriswindarto
What, Where, Why…?
3
GE Internal - For internal distribution only.
Heat Recovery Steam Generator
What is an HRSG?
Wikipedia – energy recovery heat exchanger that recovers heat from a hot gas stream. It produces steam that can be used in a process (cogeneration plant) or used to drive a steam turbine (combined cycle power plant)
It’s A Boiler…!!!
4
GE Internal - For internal distribution only.
HRSG – More Than Just A Box of Tubes
Overview
Converts exhaust energy
from gas turbine into steam
Enables plant efficiency
from 38% to 58%
$20-$25MM Parts
$8-$9 MM Ship
$10 MM Field Assembly
Modular assembly
Operational Challenges on Installed Based
BOP trips driven by HRSG accessories
25% of forced outage hrs
Drum level issues cause
trips preventing fast starts
Tube cracks and failures
are costly … critical path
during outages
Upgrades to GT often
require HRSG analysis …
potential showstopper
5
GE Internal - For internal distribution only.
Differences: HRSG vs Fossil Boiler
HRSG uses exhaust gas (e.g. gas turbine) as a heat source
and typically does not required a dedicated firing system
HRSG do not use fans (draft is from gas turbine exhaust)
HRSG generates steam at multiple pressure levels to
improve heat recovery efficiency
Heat transfer is typically by convection rather than radiation
HRSG do not use membrane water walls
HRSG uses finned tubes to maximize heat transfer
HRSG typically has lower height profile & smaller footprint
Fossil Boiler
6
GE Internal - For internal distribution only.
Basic ComponentsWater/ Steam Side:- Economizer/ Pre-heater (gas to heated water)
- Evaporator & Drum (gas to boiling water to steam)
- Superheater (gas to dry steam)
Gas Side:Inlet Duct, Baffles, Structural Steel, Casing, Insulation & Liner, Stack
Accessories:- Silencers (gas & steam side)
- Stack Damper & Bypass Stack Damper
- Supplemental Fire/ Duct Burner
- Feedwater Pump
- CO Catalyst & SCR System
- Valves & Instruments
Superheater
Evaporator
Economizer
Gas in
Gas out
7
GE Internal - For internal distribution only.
HP Drum
Integral Deaerator
IP Drum
HP SuperheaterReheaterDuct Burner
HP Evaporator SCR / CO Catalyst
IP EconomizerIP EvaporatorIP Superheater
LP EconomizerLP EvaporatorLP Economizer
Height ~ 85’
Stack Height ~ 150 – 200’
Gas in - 1100 F
NOx
CO
Feedwater – 100 F
Gas Out –180 F
NOx & CO reduced 80%
HP & RH Steam Out
–1050 F
3 Pressure Level Reheater HRSG
LP Steam Out –540 FIn and Out
Length- ~ 100’
50’
20’
8
GE Internal - For internal distribution only.
Why HRSG is important?
1. Gas Turbine (GT): Converts Fuel
to Electricity and Waste Heat
3. Steam Turbine (ST):
Converts Steam to
Electricity
2. HRSG:
Converts Waste
Heat to Steam
*Combined Cycle:
A combination of thermodynamic Gas (GT) Cycle and Steam (HRSG & ST) Cycle in an Electrical Generating Power Plant to gain higher power output and efficiency
HRSG is the critical link between gas turbine and steam turbine in a
combined cycle power plant
9
GE Internal - For internal distribution only.
10
GE Internal - For internal distribution only.
11
GE Internal - For internal distribution only.
Combined Cycle T-S Diagram
5 /
Combined Brayton and Rankin Cycle
T
S
Heat Source
Heat Sink
COMPRESSION
EXPANSION
HRSG
GAS TURBINETOPPING CYCLE
BOTTOMING CYCLESTACK
TEMPERATURE
ENTROPY
COMBUSTION
CONDENSER
EXPANSION
12
GE Internal - For internal distribution only.
Typical Energy Utilization Chart
FUEL
(100%)
to Gas Turbine
GT POWER
(35.8%)
ST POWER
(20.9%)
STACK LOSS
(7.1%)
CONDENSER
(32.9%)
EXHAUST HEAT (62.4%) to HRSG
STEAM TURBINE (54.8%)
GT LOSSES
(1.8% ACCESORIES)
HRSG CASING LOSSES
(0.5%)
ST LOSSES
(1% ACCESORIES)
Combined Cycles Systems (with HRSG & ST) Utilize More Fuel EnergCombined Cycles Systems (with HRSG & ST) Utilize More Fuel Energy to y to Produce Useful Work Than GT AloneProduce Useful Work Than GT Alone
Design Philosophy
14
GE Internal - For internal distribution only.
HRSG Design Philosophy
SuperHeater
Evaporator
Economizer
Heat Duty
Temperature
Turbine Exhaust Gas
Pinch
Approach
SH EVAP ECON
Pinch Point
The Difference Between Gas Temperature and Saturation Temperature at the Outlet of the Generating Bank
Approach Temperature
The Difference Between Economizer Discharge Temperature and Saturation Temperature
HRSG design is a precise balance of the utilization of exhaust energy to produce steam energy in an economic way
The smaller the pinch and approach temperatures, the more efficient the HRSG, but also the more expensive the design
15
GE Internal - For internal distribution only.
0
400
800
1200
0% 20% 40% 60% 80%
Percent Exhaust Energy Used
Tem
pera
ture
°F
Steam and Water
HP
IP / ReheatLP
Tem
pera
ture
°F
Percent Exhaust Energy Used
HRSG Pinch Point Plot
HRSG Types
17
GE Internal - For internal distribution only.
HRSG TypesHorizontal
• Horizontal gas flow direction
• Vertical tubes arrangement
• Majority installed
Vertical
• Vertical gas flow direction
• Horizontal tubes arrangement
• Smaller footprint (historically common in Europe or outside US)
Once Through
• Either horizontal or vertical gas flow direction & tubes arrangement
• Once Through eliminates the need of drum
• Phase change from water to steam is free to move throughout the bundle
• Theoretically more agile
Product Features
19
GE Internal - For internal distribution only.
Product FeaturesFinned Tubes
Act as heat transfer/ exchanger medium
Fins increase surface areas
Internal insulation & Liner
Prevent heat losses, Provide outside casing temp of ~80 F
Duct Burner
Supplemental firing to increase heat input for peak load
Gas dP 0.25” w.c expected
Burner Skid & Elements/ Runners
BMS-Burner Management System
Flame Scanner
Ignitor
Gas BafflesTo Prevent Gas bypassing the heat exchanger
SCR Systems
NOx reduction by ~ 86%
Gas dP 2-3” wc expected
Skid, Ammonia Based, Injection Grid, Catalyst
CO catalyst
CO reduction by ~ 80%
Gas dP ~ 1” wc expected
Drum & Internals
Steam & water mixture
Is separated to produce dry steam
Manufacturing
21
GE Internal - For internal distribution only.
Manufacturing – Heat Transfer Section
Headers
Finned TubesERWBare Tuin Coil Slit
Bare Tubes
Fin Coil Slit
Finned Tubes to header fit upFinned Tubes to header weldHarps Assembly
22
GE Internal - For internal distribution only.
Manufacturing – Casing, Insulation & Liner
23
GE Internal - For internal distribution only.
Manufacturing - Drums
Field Assembly
25
GE Internal - For internal distribution only.
HRSG – Typical Field Assembly
PLACE POOBTAIN
MATERIALS1 - 2 Months 2 - 3 Months 7 - 9 Months SHIP COMPONENTS
3 - 4 Months ASSEMBLY COMMISSION7 - 9 Months 1 - 2 Months
Total Cycle Duration: 21 - 29 Months
MANUFACTURE
26
GE Internal - For internal distribution only.
HRSG- Degree of Shop Modularization
1. Harps
2. Modular 4. Full Assembly
3. C-Frame
HRSG Life Cycle Issues & Opportunities
28
GE Internal - For internal distribution only.
Considerations for Cycling Operation
Component fatigue damage
Chemistry control
Attemperation
Drum level control
Sulfur dew point corrosion
Critical Components affected by Cycling
HP Drum
HP Superheaters
RH Superheaters
Factors that impact fatigue damage
GT Ramp Rates
Pressure Management
Heat retention during offline periods
HRSG design & construction
HRSG issues
Flow Accelerated Corrosion
(FAC)
Light and Heavy Ammonium Bisulfate Deposits
GT Exhaust Non Uniform Flow
29
GE Internal - For internal distribution only.
GE technologies applicable to HRSG
Metallurgy & coatingsCreep, oxidationThermal barrierAnticorrosion
Aeromechanics/CFDBent fin tubeCFD modeling
Life modelsPhysics based & empirical lifing models
Sensing and inspectionPulse eddy current, bore scope, high temp ultrasound, digital radiography etc.
Performance improvementGatecycle, eMapAcoustic cleaning
Water chemistryMonitoring, chemicals, chemistry models, laboratory failure analysis etc.
M&D TechnologyRemote M&D24/7 monitoring
30
GE Internal - For internal distribution only.
Thank you.