Cc Power Plants

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    COMBINED CYCLE POWER

    PLANTS

    IMPORATANT ASPECTS

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    COMBINED CYCLE POWER

    PLANTS

    IMPORATANT ASPECTS

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    HEAT RECOVERY STEAM

    GENERATORS (HRSG) ARE BOILERS WHICH USE THE HEAT ENERGY OF

    EXHAUST GAS OF GAS TURBINE TO GENERATESTEAM WHICH CAN BE USED IN THE PROCESSPLANT OR STEAM TURBINE PLANT TO GENERATE

    ADDITIONAL POWER. GAS TURBINE COUPLED WITH HRSG FOR STEAM

    GENERATION IS CALLED CO-GENERATION PLANT.

    THEY CAN HAVE FACILITY FOR AUXILIARY FUELFIRING TO (1) ENSURE FULL GENERATION OFSTEAM EVEN WHEN GT IS ON PART LOAD, OR (2)TO ENSURE STEAM GENERATION EVEN WHEN GTIS SHUT DOWN.

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    GASTURBINECOMP

    CC

    DIFFUSER

    ST

    ACK

    HR

    SG

    INTERFACE OF GT WITH HRSG

    GUILOTINE DAMPER

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    COMBINED CYCLE EFFICIENCY CC

    = (NET GT WORK + NET ST WORK) / (HEAT INPUT IN GT)

    OPEN CYCLE GT EFFICIENCY IS LOW. WITH HIGH COSTOF FUEL, OPEN CYCLE MODE FOR GT OPERATION ISUNACCEPTABLE.

    GT EXHAUST TEMPERATURE IN ADVANCE CLASS GTSUCH AS FRAME 9FA IS IN EXCESS OF 600C HENCE ISNEVER RUN IN OPEN CYCLE MODE. THIS, PERHAPS, IS THEREASON THAT AT COMBINED CYCLE PLANT SUCH AS AT

    VEMAGIRI WE DO NOT HAVE BYPASS STACK HIGH GT EXHAUST TEMPERATURE PUTS VERY SEVEREOPERATING CONDITIONS ON HRSG. OUTAGE OF HRSGTHEREFORE FORCES SHUT-DOWN OF THE GT.

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    M

    AIN

    STACK

    HPSH HPEVA HPEC LPSH LPEV LPEC

    TYPICAL HORIZONTAL

    CONFIGURATION

    INLET DUCT

    PERFORATED PLATE

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    TURNINGVANES

    SH

    EVA

    VERTICAL CONFIGURATION OF HRSG

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    INDICATOR OF EFFICIENCY OFSTEAM GENERATION

    STACK TEMPERATURE

    FOR SULFUR BEARING FUELS DESIGN STACK

    TEMPERATURE IS 140-160 C DEPENDING UP ON SULFUR

    CONTENT AND ACID DEW POINT TEMPERATURE (100 120

    C)

    FOR LOW SULFUR FUELS DESIGN STACK TEMPERATURE

    CAN BE 120 130 C AND FOR VERY CLEAN FUELS SUCH AS

    NATURAL GAS, IT CAN BE AS LOW AS 100 110 C.

    ACTUAL STACK TEMPERATURE VERY NEAR DESIGNTEMPERATURE INDICATES VERY STRONG POSSIBLITY OF

    EXCELLENT HEAT TRANSFER IN THE HEAT EXCHANGER

    TRAINS IN THE FLUE GAS PATH.

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    IMPORTANT CONSTRUCTIONAL

    ISSUES FROM LONGETIVITY POINT

    OF VIEW

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    INSULATION BOTH INLET DUCT AS WELL AS BOILER CASING

    REQUIRES INSULATION AS THE GASTEMPERATURES ARE VERY HIGH ( OF THE ORDEROF 600+C)

    THE INSULATION CAN BE INTERNAL OREXTERNAL

    FOR FLUE GAS TEMPERAURE > 570C, USE OFEXTERNAL INSULATION WILL REQUIRE USE OFAUSTENITIC STEELS WHICH ARE QUITEEXPENSIVE AND ALSO DIFFICULT TO WELD. THEYARE ALSO LIABLE TO STRESS RELIEF CRACKING.

    ALSO ALLUMINIUM CLADDING IS REQUIRED TOMINIMIZE HEAT LOSS AS WELL AS FORPROTECTION FROM WEATHER EFFECTS.APPARENTLY EXTERNAL INSULATION IS MOREPROBLEMATIC.

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    INSULATION .. DURING ITS PASSAGE, THE FLUE GAS

    COOLS DOWN. THUS IN EXTERNALLYINSULATED HRSG, CHEAPER ALLOYSTEELS CAN BE USED IN LOWTEMPERATURE ZONE. HOWEVER THISNECESSIATES USE OF EXPANSION JOINT

    TO TAKE CARE OF DIFFERENTIALCOEFFICIENTS OF EXPANSION EXPANSION JOINTS PROVIDED FOR ABOVE

    MENTIONED PURPOSE AT TIMES, IS ASOURCE OF SEVERAL COMPLEX

    PROBLEMS PERSONALLY RECOMMEND INTERNAL

    INSULATION ONLY.

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    INTERNAL INSULATION

    USE OF CHEAPER MATERIAL OF CONSTUCTION OF INLET DUCT ANDBOILER CASING

    NO NECESSITY OF LARGE FLEXIBLE JOINTS IN BOILER CASING AS AREREQUIRED FOR EXTERNAL INSULATION

    TUBE LEAKS IN EVAPORATOR CAN CAUSE IMPINGEMENT OF HIGHVELOCITY JETS ON ROOF INSULATION.

    GAPS IN INSULATION CAN CAUSE HOT SPOTS AND DISTORTIONS

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    LAYOUT PLAYS A VERY IMPORTANT ROLE FROM FLOW

    DISTRIBUTION POINT OF VIEW.

    IN CASE OF CONSTRAINTS IN THE PLOT SIZE, THEGT EXHAUST CAN BE AT RIGHT ANGLE TO THEDIFFUSER. CONSEQUENTLY FLOW CORRECTORSSUCH AS TURNING VANES ARE REQUIRED TO BEINSTALLED. ANY ERRORS IN DESIGN & ERECTION

    OF THESE CAN CAUSE SEVERE DISTORTION OFBOILER DUCT.

    IN CASE IT IS NOT POSSIBLE TO MAKE DIFFUSERAND THE BOILER INLET DUCT CO-LINEAR, FLOWSTABILIZERS SUCH AS PERFORATED PLATE OR

    TURNING VANES MUST BE PROVIDED. A NON-UNIFORM FLOW DISTRIBUTION WILL OFTEN

    CAUSE STRUCTURAL DEFORMATION ANDFAILURES OF BOILER CASING AND ALSOPRESSURE PARTS. THIS GREATLY REDUCESEFFECTIVE LIFE OF HRSG.

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    IDEAL LAYOUT

    DIFFUSER

    BOILERINLETDUCT

    DAMPER

    BYEPASS STACK

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    OFFSET LAYOUT RESULTS IN DISTORTION OF INLET DUCT

    DIFFUSER

    BOILERINLETDUCT

    DAMPER

    BYEPASS STACK

    Hotter top

    Cold bottom

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    HOT TOP SIDE

    COLD BOTTOM SIDE

    FAILURES OF JOINT

    EFFECT OF OFFSET IS TO CAUSE DUCT TODISTORT AND ALSO MAY CAUSE FAILURE OF THEJOINT

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    HOT TOP SIDE

    COLD BOTTOM SIDE

    FAILURES OF JOINT

    AUSTENITICSTEEL

    ALLOY STEEL

    EXPANSIONJOINT

    CASE STUDY : OFFSETBOILER INLET DUCTAND USE OF

    DIFFERENT MATERIALSFOR BOILER CASING

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    OFFSET LAYOUT CORRECTION BY TURNING VANE

    DIFFUSER

    BOILERINLETDUCT

    DAMPER

    BYEPASS STACK

    TURNING VANE

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    OFFSET LAYOUT CORRECTION BY PERFORATED PLATE

    DIFFUSERBOILER

    INLETDUCT

    DAMPER

    BYEPASS STACK

    TURNING VANE

    PERFORATEDPLATE

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    USE OF TURNING VANESTO STREAMLINE THEFLOW

    HRSG DUCT

    TURNING VANES

    APPROACHDUCT

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    THERMO-MECHANICALFACTORS AFFECTING LIFE

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    PRIME CONSIDERATIONS IN LARGEHRSG BEHIND LARGE GT

    HIGH EFFICIENCY

    HIGH RELIABILITY

    HIGH DURABILITY

    LOWEST INSTALLED COST

    LOW LIFE TIME COST

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    REQUIREMENT OF HIGHEFFICIENCY HAS RESULTED INTO

    HIGHER FIRING TEMPERATURE IN GASTURBINE

    VERY LARGE MASS FLOW RATE OF FLUE

    GASES ENTERING HRSG VERY HIGH TEMPERATURE OF EXHAUST

    GASES ENTERING HRSG. FOR VEMAGIRIPROJECT, IT IS + 600C.

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    COMBINED CYCLE PLANTS AREREQUIRED TO MEET

    VERY AGGRESSIVE START UPDURATION

    VERY STEEP LOAD RAMP RATESPROMISED BY GT MANUFACTURER

    VERY RAPID AND LARGE CHANGES INTHE GT EXHAUST TEMPERATURE

    VERY HIGH RELIABILITY ANDAVAILABILITY OF HRSG

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    GASTURBINECOMP

    CC

    DIFFUSER

    ST

    ACK

    HR

    SG

    GUILOTINE DAMPER

    STEAM TO STG

    TIME

    TEMPERATURE

    ~18 min.11 min

    422C

    60C DROP 155 MIN

    GT SYNCRONIZED

    COLD START GT EXHAUST TEMP PROFILE. THE HRSGPARTS WILL EXPERIENCE THIS IN EVERY COLD START

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    DURING THIS TRANSIENT TUBES IN THE FLOW PATH GET HEATED UP AT VERY HIGH RATE.

    THE HEADERS BEING OF VERY HEAVY CROSS-SECTION WILL BE AT

    MUCH LOWER TEMPERTURE AND WILL GET STRESSED BY TUBESWHICH ARE GETTING HEATED.

    THE HEADERS BEING VERY HEAVY MASSES WILL NOT ALLOWTUBES TO EXPAND FREELY AND THUS THE TUBES ALSO GETSTRESSED.

    AS TIME PROGRESSES, THE TEMPERATURE WILL BECOME MORE

    UNIFORM AND HENCE THERMAL STRESSES WILL REDUCE. TILL NEXT TRIP OF THE SET, THE STRESS LEVELS WILL REMAIN

    UNIFORM. WHEN THE SET TRIPS, TUBES WILL GET COOLED MUCHFASTER WHILE THE HEADER WILL TAKE LONGER TIME TO COOL.THIS WILL CAUSE REVERSAL OF STRESSES. AFTER LONG TIMETHESE WILL ALSO GET SMOOTHENED OUT.

    IT IS CLEAR THAT EACH COLD START IS ASSOCIATED WITHALTERNATING STRESSES DURING START UP AND SHUT DOWN.THIS CAUSES WHAT IS CALLED LOW CYCLE FATIGUE.

    SIMILAR EFFECTS ARE SEEN IN BOTH WARM AND HOT START. ALARGE NUMBER OF STARTS IS THEREFORE VERY DAMAGING.

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    THE CONSEQUENCES OFSUCH TRANSIENTS ARE

    RAPID CONSUMPTION OF LIFE BYTHERMAL FATIGUE ADDED TO HIGHTEMPERATURE CREEP LIFE CONSUMPTION

    IT IS NECESSARY TO KNOW THE ENTIREMECHANISM OF THESE FAILUREPROCESSES. THIS REQUIRES THAT WECLEARLY UNDERSTAND HEAT TRANSFER

    PROCESS IN HRSG

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    CONCLUSIONS HRSG IS A CRITICAL CONSTITUENT OF COMBINED CYCLE

    POWER PLANTS SINCE ITS OUTAGE MEANS ATREMENDOUS DROP IN THE HEAT RATE OF THE OVERALLPLANT AND GENERATION COST BECOME PROHIBITIVLYHIGH

    IT IS NECESSARY TO GIVE TOP PRIORITY TO LAY OUTRELATED ISSUES. IN CASE IT IS NOT POSSIBLE TO KEEP GT

    AND HRSG CO-LINEAR, FLOW STRAIGHTENING DEVICESMUST BE INSTALLED.

    MAJORITY OF THE PROBLEMS SUCH AS BUCKLING OFDUCT/BOILER CASING ARE DUE TO FLOW IMBALANCES.DEVICES SUCH AS TURNING VANES, PERFORATED PLATES

    MUST BE USED TO REMOVE THESE IMBALANCES. HEAT TRANSFER AND TEMPERATURE DISTRIBUTION IN THE

    FLUE GAS PATH ARE THE MOST IMPORTANT PARAMETERSTHAT DECIDE RELIABILITY AND AVAILABILITY OF HRSG

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    GT EXH. TEMPTG

    STACKTEMP T2

    ECO IN t1

    ECO OUT t2SAT. TEMP TS

    SH OUT TSHPINCH POINT

    APPROACH TEMP.

    SUPPOSE 140000 lb/hr GAS AT TEMP.980F ENTERS HRSG GENERATINGSTEAM AT 200 psi. FEED WATER TEMP. IS 230 F , BLOW DOWN 5%.ASUME SP.HEAT OF GAS AT EVAPORATOR 0.27 AND AT ECONOMIZER0.253. LET US SIMULATE THERMAL DESIGN.

    NORMALLY PINCH POINT AND APPROACH TEMP. IS IN THE RANGE15-30 F.LET US CHOOSE 20 FOR PINCH AND 15 FOR APPROACH.SATURATION TEMP. =388. THERFORE GAS TEMP LEAVINGEVAPORATOR = 388+20=408.TEMP OF WATER ENTERING EVA.=388-15=373 F.

    ASSUMING 1% LOSS, EVAPORATORDUTY = 140000.0.99.0.27.(980-408)=21.4MMBTU/hr.ENTHALPY ABOSRBEDBY STEAM =(1199-345)+0.05.(362-345)

    =855 BTU/lb. STEAM GENERATED =21.106/855 = 25000lb/hr. ECONOMIZERDUTY =25000.1.05.(345-198) =3.84.106BTU/hr.

    GAS TEMPERATURE DROP = 3840000 /(140000.0.253.0.99) = 109F.TEMPERATURE OF GAS LEAVING THESTACK =408 -109 = 299 F ~ 150C.

    WE THUS HAVE SIMULATED THEDESIGN.

    KNOWING THE GAS TEMPERATUREPROFILE AND WATER/ STEAMPARAMETERS, WE CAN JUDGE THEPERFORMANCE OF HRSG.

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    GT EXH. TEMPTG1

    STACKTEMP Tg4

    ECO IN tw1

    ECO OUT tw2SAT. TEMP TS

    SH OUT TSHPINCH POINT

    APPROACH TEMP.

    SUPPOSE 140000 lb/hr GAS AT TEMP.980F ENTERS HRSG GENERATINGSTEAM AT P. FEED WATER TEMP. IS 230 F. ASUME SP.HEAT OF GASAT EVAPORATOR 0.27 AND AT ECONOMIZER 0.253. LET US EVALUATETHE EXIT GAS TEMPERATURES FOR VARIOUS STEAM PRESSURES.

    WgCPg(Tg1 Tg3) = WS(hsohw2) IN SH AND

    EVAPORATOR ZONE. CONSIDERING NOW THEENTIRE HRSG

    Tg3WgCPg(Tg1-Tg4) = WS(hso-hw1)

    FROM THE ABOVE EQUATIONS WEOBTAIN (Tg1-Tg3) / (Tg1-Tg4) =

    (hso-hw2) / (hso-hw1) = X. WE NOWEVLUATE EFFECT OF INCREASING

    STEAM PRESSURE FROM 100 TO 600PSI ON STACK TEMPERAURE.

    PRESS STEAM T SAT.T X EXIT T

    100 SAT 338 0.904 300

    250 SAT 406 0.833 313

    400 SAT 448 0.790 353

    400 600 448 0.800 367

    600 SAT 490 0.740 373

    600 750 490 0.773 398

    THIS SHOWS CLEARLY THE REASONFOR MULTIPLE PRESSURE WHEN MAINSTEAM PRESSURE IS HIGH SO THATBEST HEAT EXTRACTION FROM FLUEGAS IS POSSIBLE

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    A CASE STUDY

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    HRSG BEHIND GE FRAME 6 GT

    DESIGN EXHAUST TEMPERATURE 593C 136.5 KG/HR AIR

    DESIGN STACK TEMPERATURE 160C

    HP STEAM 97.6 BAR, 514C, 70.2 TPH

    IP STEAM 15.8 BAR, 200.7C, 14 TPH

    FORCED CIRCULATION RATED STEAM FLOW NOT AVAILABLE,

    VERY HIGH ATTEMPERATION IN SH > 5.5 AGAINST 1.1 TPH

    STEAMING IN IPECO DESPITE INCREASING IP FEED PRSSURE

    HEAVY BUCKLING OF BOILER CASING ACTUAL STACK TEMPERATURE > 190C

    PERFORMANCE DETERIORATING WITH PASSAGE OF TIME

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    593CGAS TEMP PROFILE IN HRSG

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    SH1 SH2 HPEV HPEC IPEV HP/IPECO

    545.5

    488.3

    317

    260

    211

    160

    564

    456

    335

    282271

    174

    GAS TEMP.PROFILE IN HRSG

    DESIGN

    ACTUALT SH 105ACTUAL 108

    T EVA 172ACTUAL 121 ??

    T HPEC 57ACTUAL 53

    T IPEV 49ACTUAL 11 ??T HP/IP ECO 51ACTUAL 97??

    SH1 ATTEMP. DESIGN 1.1ACTUAL >5.5 TPH

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    THE TEMPERATURE

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    SH2 SH2

    SH1 SH1

    HPEVA HPEVA

    HPECO HPECO

    IPEV IPEV

    IPECO IPECOHPECOHPECO

    194 189 181 207

    333 350

    322 292

    361 352

    482 452

    560 564

    467NA

    368354

    306

    328287

    307

    THE TEMPERATUREDISTRIBUTION SHOWS AVERY HIGH BIAS OF FLUEGAS FLOW TOWARDSIPECO SIDE.

    TEMPERATURE DROPACROSS IPEV NOTPROPER

    IPECO CONTINUES TOSTEAM

    HEAT PICK UP IN HPEVIS QUITE LESS ANDLESS STEAM ISGENERATED

    NECESSARY TOINCREASE HP FEED FLOW

    HEAVY ATTEMPERATIONIN SH TO CONTROL SHTEMPERATURE

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    128,115,58.8 / 121,121,71SKB

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    SH2 SH2

    SH1 SH1

    HPEVA HPEVA

    HPECO HPECO

    IPEV IPEV

    IPECO IPECOHPECOHPECO

    194 189 181 207

    333 350

    322 292

    361 352

    482 452

    560 564

    467NA

    368354

    306

    328287

    307

    30 B,115C,13.3 / 23.5,121,14

    29,250,12.2 /23.5,198,14

    119,301,57

    121,302,71

    P ACROSS HPECO =9 BAR ??

    HP/IP FEED TEMP.115 AGAINST 121. IP

    STEAM TO PROCESSAT A TEMPARATUREOF 190 AGAINST200.7C. LOWDEAERATOR PRESSUREWHICH CAN INCREASE

    HP STEAMPARAMETERS TO STARE 72 BAR, 494 CAND 57 TPH AGAINST98 B, 514 AND 71TPH

    TO HPECO2

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    SUGGESTIONS

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    PERFORATED PLATE

    FLOW

    STRAIGHTNER

    TURNING VANES

    INSTALL FLOW STRAIGHTNER

    INSTALLPERFORATED PLATE

    INCREASE DEAERATOR PRESS.

    INVESTIGATE AND CORRECTEXCESSIVE PRESSURE DROP INHP FEED LINE

    INCREASE HPEVA AREA (10%)

    SUGGESTIONS

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    593CGAS TEMP PROFILE IN HRS

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    SH1 SH2 HPEV HPEC IPEV HP/IPECO

    545.5

    488.3

    317

    260

    211

    160

    564

    456

    335

    282271

    174

    GAS TEMP.PROFILE IN HRS

    DESIGNACTUAL

    ACHIEVABLE

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    CASE STUDY

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    HRSG BEHIND GE FRAME 9E GT

    DELTAK MAKE, UNFIRED, NATURAL CIRCULATION,THREE PRESSURE, HORIZONTALCONFIGURATION

    HP STEAM 188 TPH, 59 BAR, 512 C

    LP STEAM 21 TPH, 7.5 BAR, 223C

    DEAERATOR BOILER 50 PSI

    DA BOILER TUBE FAILURE

    REDUCTION IN STEAM GENERATION ANDCONSEQUENT REDUCTION IN STG POWER

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    HEAT EXCHANGER TRAIN

    MODULE 1 SUPER HEATER 1

    SUPER HEATER 2A (ROWS 1 TO 3)

    SUPER HEATER 2B (ROWS 4 TO 6)

    MODULE 2 HP BOILER 3 TRAINS HP ECONOMIZER 2 TRAINS

    LP SUPER HEATER 1 TRAIN

    MODULE 3 LP BOILER 2 TRAINS

    HP ECONOMIZER 1 TRAIN DA BOILERS 4 TRAINS

    FAILURES AT TOP BENDS IN THE LAST TRAIN OF DA BOILER

    HIGH STACK TEMPERATURE

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    DAB STORAGE TANK

    OUTER MOST EXPERIENCESMINIMUM GAS TEMPERATURE.ADDITIONALLY THIS TUBERECEIVES MAXIMUM WATERFLOW. THE TUBE THERFORE HASLARGE WATER CONTENT. THIS

    WATER CAUSES IMPINGEMENTAND THINNING OF THE TUBE BYEROSION. THE LAST ROW CANBE TOTALLY REMOVED SINCETHE REMINING THREE ROWSARE SUFFICIENT

    IT IS BETTER TO REMOVEABOUT 10% TUBES IN SH1

    7-10% INCREASE HPECO2SURFACE AREA

    RECOMMENDATIONS

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    FIRED HRSG

    5 BURNERS SCREEN TUBES

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    IMPORTANT ISSUES IN FIRED HRSG

    LENGTH OF FIRING DUCT IS A VERY CRITICAL FACTORTO ENSURE PROPER RADIATION AND CONVECTIVE HEATTRANSFER.

    THE BURNERS MUST ENSURE OPTIMUM PENETRATIONAND DIVERGENCE OF THE FLAMES. THE SCREEN BOILERMUST SEE A UNIFORM HEAT FLUX TO THE EXTENTPOSSIBLE. NON-UNIFORM HEAT FLUX DISTRIBUTIONMAY CAUSE SEVERE BUCKLING OF SCREEN TUBES

    ALL THE BURNERS MUST BE TUNED TO GIVE THE SAMEFLAME SHAPE AND SIZE.

    SELECTION OF FIRING ELEVATIONS DO PLAY ANIMPORTANT ROLE IN THE LONG TERM PERFORMANCE OFTHE HRSG

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    FIRED HRSG CONFIGURATION

    REQUIRES AUXILIARY AIR SUPPLY FOR COOLINGBURNER TIPS.

    FORCED DRAFT FANS OR ID FANS. THE LATER ISNOT A POPULAR OPTION. RELIABILITY AND

    AVAILABILITY OF FANS IS A CRITICAL ISSUE. DEPENDING UP ON THE CLEANLINESS OF FUEL,

    IT IS ADVISABLE TO PROVIDE SOOT BLOWINGLANES IN FLUE GAS AND HEAT EXCHANGER

    PATH TO ENSURE CLEANLINESS OF HEATTRANSFER SURFACES.

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    CONCLUSIONS

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    CONCLUSIONS COMPARED TO CONVENTIONAL COAL FIRED BOILER LIFE

    EXPENDITURE IN HRSG IS VERY FAST DUE TO FACTORS

    SUCH AS RAPID START UP AND VERY HIGH LOADINGRATES. HRSG DESIGNS FOR THIS PURPOSE ARE REQUIRED TO

    BE TAILOR MADE SO THAT THE AGGRESSIVE START UPSAS WELL AS LOADING RATES DO NOT CAUSEPREMATURE FAILURES AND LIFE EXPIRY.

    COMPARED TO CONVENTIONAL BOILER R&M ACTIVITIESFOR HRSG MUST START MUCH EARLIER.WE CANIDENTIFY THE PROBLEM AREAS IN HRSG BY STUDYINGTHE PRESENT FLUE GAS TEMPERATURE PROFILE, WATERAND STEAM PARAMETERS WITH REFERENCE TO THESAME AS GIVEN IN HMBD SUPPLIED BY OEM.

    STACK TEMPERATURE IS ONE PARAMETER WHICH TO ALARGE EXTENT WOULD INDICATE THE QUALITY OFPERFORMANCE OF THE HRSG

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    THANK

    YOU