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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