Professional Documents
Culture Documents
HRSG 101
TPSE Dave Rogers, Wulang Chriswindarto
Date
What is an HRSG?
Heat Recovery Steam Generator
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)
Its A Boiler!!!
3 GE Internal - For internal distribution only.
Tube cracks and failures are costly critical path during outages
Modular assembly
Fossil Boiler
5 GE Internal - For internal distribution only.
Basic Components
Water/ Steam Side:
- Economizer/ Pre-heater (gas to heated water) - Evaporator & Drum (gas to boiling water to steam) - Superheater (gas to dry steam)
Gas out
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
Gas in
In and Out
HP & RH Steam Out 1050 F
HP Drum
Height ~ 85
50
HP Evaporator
SCR / CO Catalyst
Length- ~ 100
7
*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
COMBUSTION
N EXPANSIO
TEMPERATURE
ON
HRSG
COMPRESSI
STACK
BOTTOMING CYCLE
CONDENSER Heat Sink
ENTROPY
S
5/
CONDENSER (32.9%)
Combined Cycles Systems (with HRSG & ST) Utilize More Fuel Energy to Produce Useful Work Than GT Alone
12 GE Internal - For internal distribution only.
Design Philosophy
Temperature
Tur
Super Heater
bin
e Ex
hau st
HRSG design is a precise balance of the utilization of exhaust energy to produce steam energy in an economic way
Gas
Evaporator Economizer
Heat Duty
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
SH EVAP ECON
The smaller the pinch and approach temperatures, the more efficient the HRSG, but also the more expensive the design
14 GE Internal - For internal distribution only.
1200
Temperature F Temperature F
IP LP
/ Reheat
HRSG Types
HRSG Types
Horizontal
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
Product Features
Internal insulation & Liner
Prevent heat losses, Provide outside casing temp of ~80 F
Gas Baffles
To Prevent Gas bypassing the heat exchanger
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
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
Manufacturing
Bare Tubes
ERW
Finned Tubes
Harps Assembly
Manufacturing - Drums
Field Assembly
PLACE PO 1 - 2 Months
MANUFACTURE 7 - 9 Months SHIP COMPONENTS 3 - 4 Months ASSEMBLY 7 - 9 Months Total Cycle Duration: 21 - 29 M onths
COMMISSION 1 - 2 Months
1. Harps
3. C-Frame
2. Modular
4. Full Assembly
26 GE Internal - For internal distribution only.
HRSG issues
Considerations for Cycling Operation
Component fatigue damage Chemistry control Attemperation Drum level control Sulfur dew point corrosion
GT Exhaust Non Uniform Flow
Sensing and inspection Pulse eddy current, bore scope, high temp ultrasound, digital radiography etc.
M&D Technology Water chemistry Remote M&D Monitoring, chemicals, 24/7 monitoring chemistry models, laboratory failure analysis etc.
29
Thank you.