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 GENERATE STEAM WHICH CAN BE USED IN THE PROCESS PLANT 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 FUEL FIRING TO (1) ENSURE FULL GENERATION OF STEAM EVEN WHEN GT IS ON PART LOAD, OR (2) TO ENSURE STEAM GENERATION EVEN WHEN GT IS SHUT DOWN.

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CC

COMP

GAS TURBINE

GUILOTINE DAMPER

S T A C K

H R S G

DIFFUSER

INTERFACE OF GT WITH HRSG SKB

COMBINED CYCLE EFFICIENCY CC

=

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

OPEN CYCLE GT EFFICIENCY IS LOW. WITH HIGH COST OF FUEL, OPEN CYCLE MODE FOR GT OPERATION IS UNACCEPTABLE. GT EXHAUST TEMPERATURE IN ADVANCE CLASS GT SUCH AS FRAME 9FA IS IN EXCESS OF 600C HENCE IS NEVER RUN IN OPEN CYCLE MODE. THIS, PERHAPS, IS THE REASON THAT AT COMBINED CYCLE PLANT SUCH AS AT VEMAGIRI WE DO NOT HAVE BYPASS STACK

HIGH GT EXHAUST TEMPERATURE PUTS VERY SEVERE OPERATING CONDITIONS ON HRSG. OUTAGE OF HRSG THEREFORE FORCES SHUT-DOWN OF THE GT.

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TYPICAL HORIZONTAL CONFIGURATION

PERFORATED PLATE

M A I N S T A C K

INLET DUCT

HPSH

HPEVA HPEC LPSH

LPEV

LPEC

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EVA

SH

TURNING VANES

VERTICAL CONFIGURATION OF HRSG

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INDICATOR OF EFFICIENCY OF STEAM 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 DESIGN TEMPERATURE 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 GAS TEMPERATURES ARE VERY HIGH ( OF THE ORDER OF 600+C) THE INSULATION CAN BE INTERNAL OR EXTERNAL FOR FLUE GAS TEMPERAURE > 570C, USE OF EXTERNAL INSULATION WILL REQUIRE USE OF AUSTENITIC STEELS WHICH ARE QUITE EXPENSIVE AND ALSO DIFFICULT TO WELD. THEY ARE ALSO LIABLE TO STRESS RELIEF CRACKING. ALSO ALLUMINIUM CLADDING IS REQUIRED TO MINIMIZE HEAT LOSS AS WELL AS FOR PROTECTION FROM WEATHER EFFECTS. APPARENTLY EXTERNAL INSULATION IS MORE PROBLEMATIC.

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INSULATION ..
DURING ITS PASSAGE, THE FLUE GAS COOLS DOWN. THUS IN EXTERNALLY INSULATED HRSG, CHEAPER ALLOY STEELS CAN BE USED IN LOW TEMPERATURE ZONE. HOWEVER THIS NECESSIATES USE OF EXPANSION JOINT TO TAKE CARE OF DIFFERENTIAL COEFFICIENTS OF EXPANSION EXPANSION JOINTS PROVIDED FOR ABOVE MENTIONED PURPOSE AT TIMES, IS A SOURCE OF SEVERAL COMPLEX PROBLEMS PERSONALLY RECOMMEND INTERNAL INSULATION ONLY.

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INTERNAL INSULATION

USE OF CHEAPER MATERIAL OF CONSTUCTION OF INLET DUCT AND BOILER CASING NO NECESSITY OF LARGE FLEXIBLE JOINTS IN BOILER CASING AS ARE REQUIRED FOR EXTERNAL INSULATION TUBE LEAKS IN EVAPORATOR CAN CAUSE IMPINGEMENT OF HIGH VELOCITY 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, THE GT EXHAUST CAN BE AT RIGHT ANGLE TO THE DIFFUSER. CONSEQUENTLY FLOW CORRECTORS SUCH AS TURNING VANES ARE REQUIRED TO BE INSTALLED. ANY ERRORS IN DESIGN & ERECTION OF THESE CAN CAUSE SEVERE DISTORTION OF BOILER DUCT. IN CASE IT IS NOT POSSIBLE TO MAKE DIFFUSER AND THE BOILER INLET DUCT CO-LINEAR, FLOW STABILIZERS SUCH AS PERFORATED PLATE OR TURNING VANES MUST BE PROVIDED. A NON-UNIFORM FLOW DISTRIBUTION WILL OFTEN CAUSE STRUCTURAL DEFORMATION AND FAILURES OF BOILER CASING AND ALSO PRESSURE PARTS. THIS GREATLY REDUCES EFFECTIVE LIFE OF HRSG.

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BYEPASS STACK

DAMPER

DIFFUSER

BOILER INLET DUCT

IDEAL LAYOUT

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SKB

BYEPASS STACK

DAMPER Hotter top

BOILER INLET DUCT

DIFFUSER

Cold bottom

OFFSET LAYOUT RESULTS IN DISTORTION OF INLET DUCT

FAILURES OF JOINT HOT TOP SIDE

COLD BOTTOM SIDE

EFFECT OF OFFSET IS TO CAUSE DUCT TO DISTORT AND ALSO MAY CAUSE FAILURE OF THE JOINT

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CASE STUDY : OFFSET BOILER INLET DUCT AND USE OF DIFFERENT MATERIALS FOR BOILER CASING

ALLOY STEEL

EXPANSION JOINT AUSTENITIC STEEL

HOT TOP SIDE

FAILURES OF JOINT

COLD BOTTOM SIDE

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BYEPASS STACK

DAMPER

TURNING VANE

DIFFUSER

BOILER INLET DUCT

OFFSET LAYOUT CORRECTION BY TURNING VANE

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BYEPASS STACK

DAMPER
PERFORATED PLATE

TURNING VANE

DIFFUSER

BOILER INLET DUCT

OFFSET LAYOUT CORRECTION BY PERFORATED PLATE

TURNING VANES

USE OF TURNING VANES TO STREAMLINE THE FLOW

APPROACH DUCT

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HRSG DUCT

THERMO-MECHANICAL FACTORS AFFECTING LIFE

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PRIME CONSIDERATIONS IN LARGE HRSG BEHIND LARGE GT

HIGH EFFICIENCY HIGH RELIABILITY HIGH DURABILITY LOWEST INSTALLED COST LOW LIFE TIME COST

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REQUIREMENT OF HIGH EFFICIENCY HAS RESULTED INTO

HIGHER FIRING TEMPERATURE IN GAS TURBINE VERY LARGE MASS FLOW RATE OF FLUE GASES ENTERING HRSG VERY HIGH TEMPERATURE OF EXHAUST GASES ENTERING HRSG. FOR VEMAGIRI PROJECT, IT IS + 600C.

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COMBINED CYCLE PLANTS ARE REQUIRED TO MEET

VERY AGGRESSIVE START UP DURATION VERY STEEP LOAD RAMP RATES PROMISED BY GT MANUFACTURER VERY RAPID AND LARGE CHANGES IN THE GT EXHAUST TEMPERATURE VERY HIGH RELIABILITY AND AVAILABILITY OF HRSG

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CC

STEAM TO STG

COMP

GAS TURBINE

GUILOTINE DAMPER

422C

S T A C K
155 MIN

H R S G

T E M P E R A T U R E

60C DROP

GT SYNCRONIZED

DIFFUSER

COLD START GT EXHAUST TEMP PROFILE. THE HRSG PARTS WILL EXPERIENCE THIS IN EVERY COLD START
~18 min.

11 min

TIME

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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 TUBES WHICH ARE GETTING HEATED. THE HEADERS BEING VERY HEAVY MASSES WILL NOT ALLOW TUBES TO EXPAND FREELY AND THUS THE TUBES ALSO GET STRESSED. 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 MUCH FASTER WHILE THE HEADER WILL TAKE LONGER TIME TO COOL. THIS WILL CAUSE REVERSAL OF STRESSES. AFTER LONG TIME THESE WILL ALSO GET SMOOTHENED OUT. IT IS CLEAR THAT EACH COLD START IS ASSOCIATED WITH ALTERNATING 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. A LARGE NUMBER OF STARTS IS THEREFORE VERY DAMAGING.

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THE CONSEQUENCES OF SUCH TRANSIENTS ARE

RAPID CONSUMPTION OF LIFE BY THERMAL FATIGUE ADDED TO HIGH TEMPERATURE CREEP LIFE CONSUMPTION IT IS NECESSARY TO KNOW THE ENTIRE MECHANISM OF THESE FAILURE PROCESSES. THIS REQUIRES THAT WE CLEARLY 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 A TREMENDOUS DROP IN THE HEAT RATE OF THE OVERALL PLANT AND GENERATION COST BECOME PROHIBITIVLY HIGH IT IS NECESSARY TO GIVE TOP PRIORITY TO LAY OUT RELATED ISSUES. IN CASE IT IS NOT POSSIBLE TO KEEP GT AND HRSG CO-LINEAR, FLOW STRAIGHTENING DEVICES MUST BE INSTALLED. MAJORITY OF THE PROBLEMS SUCH AS BUCKLING OF DUCT/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 PARAMETERS THAT DECIDE RELIABILITY AND AVAILABILITY OF HRSG

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GT EXH. TEMP TG

SUPPOSE 140000 lb/hr GAS AT TEMP.980F ENTERS HRSG GENERATING STEAM AT 200 psi. FEED WATER TEMP. IS 230 F , BLOW DOWN 5%. ASUME SP.HEAT OF GAS AT EVAPORATOR 0.27 AND AT ECONOMIZER 0.253. LET US SIMULATE THERMAL DESIGN. NORMALLY PINCH POINT AND APPROACH TEMP. IS IN THE RANGE 15-30 F.LET US CHOOSE 20 FOR PINCH AND 15 FOR APPROACH. SATURATION TEMP. =388. THERFORE GAS TEMP LEAVING EVAPORATOR = 388+20=408.TEMP OF WATER ENTERING EVA.=38815=373 F.

PINCH POINT

STACK TEMP T2

SH OUT TSH SAT. TEMP TS ECO OUT t2

APPROACH TEMP.

ASSUMING 1% LOSS, EVAPORATOR DUTY = 140000.0.99.0.27.(980-408) =21.4MMBTU/hr.ENTHALPY ABOSRBED BY STEAM =(1199-345)+0.05.(362-345) =855 BTU/lb. STEAM GENERATED = 21.106/855 = 25000lb/hr. ECONOMIZER DUTY =25000.1.05.(345-198) = 3.84.106BTU/hr. GAS TEMPERATURE DROP = 3840000 / (140000.0.253.0.99) = 109F. TEMPERATURE OF GAS LEAVING THE STACK =408 -109 = 299 F ~ 150C. WE THUS HAVE SIMULATED THE DESIGN. KNOWING THE GAS TEMPERATURE PROFILE AND WATER/ STEAM PARAMETERS, WE CAN JUDGE THE PERFORMANCE OF HRSG.

ECO IN t1

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GT EXH. TEMP TG1

SUPPOSE 140000 lb/hr GAS AT TEMP.980F ENTERS HRSG GENERATING STEAM AT P. FEED WATER TEMP. IS 230 F. ASUME SP.HEAT OF GAS AT EVAPORATOR 0.27 AND AT ECONOMIZER 0.253. LET US EVALUATE THE EXIT GAS TEMPERATURES FOR VARIOUS STEAM PRESSURES. WgCPg(Tg1 Tg3) = WS(hso hw2) IN SH AND EVAPORATOR ZONE. CONSIDERING NOW THE ENTIRE HRSG

Tg3
PINCH POINT

STACK TEMP Tg4

APPROACH TEMP.

WgCPg(Tg1-Tg4) = WS(hso-hw1) FROM THE ABOVE EQUATIONS WE OBTAIN (Tg1-Tg3) / (Tg1-Tg4) = (hso-hw2) / (hso-hw1) = X. WE NOW EVLUATE EFFECT OF INCREASING STEAM PRESSURE FROM 100 TO 600 PSI ON STACK TEMPERAURE. PRESS STEAM T SAT.T X 100 250 400 400 600 600 SAT SAT SAT 600 SAT 750 EXIT T 338 0.904 300 406 0.833 313 448 0.790 353 448 0.800 367 490 0.740 373 490 0.773 398

SH OUT TSH SAT. TEMP TS ECO OUT tw2

ECO IN tw1

THIS SHOWS CLEARLY THE REASON FOR MULTIPLE PRESSURE WHEN MAIN STEAM PRESSURE IS HIGH SO THAT BEST HEAT EXTRACTION FROM FLUE GAS 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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593C 545.5

GAS TEMP.PROFILE IN HRSG

488.3 456

564

DESIGN
ACTUAL
335 282 317 271 174 211 160

T SH 105 ACTUAL 108

T EVA 172 ACTUAL 121 ?? T HPEC 57 ACTUAL 53 T IPEV 49 ACTUAL 11 ?? T HP/IP ECO 51 ACTUAL 97 ??

260

SH1 ATTEMP. DESIGN 1.1 ACTUAL >5.5 TPH

SH1

SH2

HPEV

HPEC

IPEV

HP/IPECO

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194

189

181

207

IPECO HPECO
333 350

HPECO IPECO
307 306

THE TEMPERATURE DISTRIBUTION SHOWS A VERY HIGH BIAS OF FLUE GAS FLOW TOWARDS IPECO SIDE. TEMPERATURE DROP ACROSS IPEV NOT PROPER IPECO CONTINUES TO STEAM HEAT PICK UP IN HPEV IS QUITE LESS AND LESS STEAM IS GENERATED NECESSARY TO INCREASE HP FEED FLOW HEAVY ATTEMPERATION IN SH TO CONTROL SH TEMPERATURE

IPEV
322 292

IPEV
287 354

HPECO
361 352

HPECO HPEVA

328 368

HPEVA
482 452

NA

467

SH1 SH2
560

SH1 SH2
564

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128,115,58.8 / 121,121,71 194 189 181 207

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

IPECO HPECO
333 350

TO HPECO2

HPECO IPECO
307 306

IPEV
322 292

IPEV
287 119,301,57 121,302,71 452 NA 354

29,250,12.2 / 23.5,198,14

HPECO
361 352

HPECO HPEVA

328 368

P ACROSS HPECO = 9 BAR ?? HP/IP FEED TEMP. 115 AGAINST 121. IP STEAM TO PROCESS AT A TEMPARATURE OF 190 AGAINST 200.7C. LOW DEAERATOR PRESSURE WHICH CAN INCREASE HP STEAM PARAMETERS TO ST ARE 72 BAR, 494 C AND 57 TPH AGAINST 98 B, 514 AND 71TPH

HPEVA
482

467

SH1 SH2
560

SH1 SH2
564

PERFORATED PLATE

SUGGESTIONS
INSTALL FLOW STRAIGHTNER INSTALL PERFORATED PLATE INCREASE DEAERATOR PRESS. INVESTIGATE AND CORRECT EXCESSIVE PRESSURE DROP IN HP FEED LINE INCREASE HPEVA AREA (10%)

FLOW STRAIGHTNER

TURNING VANES

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593C 545.5

GAS TEMP.PROFILE IN HRSG

488.3 456

564

DESIGN
ACTUAL

ACHIEVABLE
317

335

282

271 174 211 160

260

SH1

SH2

HPEV

HPEC

IPEV

HP/IPECO

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CASE STUDY

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HRSG BEHIND GE FRAME 9E GT

DELTAK MAKE, UNFIRED, NATURAL CIRCULATION, THREE PRESSURE, HORIZONTAL CONFIGURATION 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 AND CONSEQUENT 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) HP BOILER 3 TRAINS HP ECONOMIZER 2 TRAINS LP SUPER HEATER 1 TRAIN

MODULE 2

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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600

500

400

H/E SH1 SH2 HPB HPE1 LPB HPE2 DAB

300

HIGH HEAT PICK UP IN SH1 LESS IN SH2 VERY LOW HEAT PICK UP IN DA BOILER. VERY LOW T ACROSS LPSH (~1.6C DESIGN). LOW T ACROSS HPE1 AND HPE2

THMBD 11.5 66.8 184 59.2 31.6 20.3 44.2

TACT 63 35 180 35 33 10 20

DIF -54 27 ~ 24 ~ 10 24

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200

100

SH1

SH2

HPB

HPE1

LPSH

LPB

HPE2

DA BOILER

DAB STORAGE TANK

RECOMMENDATIONS
OUTER MOST EXPERIENCES MINIMUM GAS TEMPERATURE. ADDITIONALLY THIS TUBE RECEIVES MAXIMUM WATER FLOW. THE TUBE THERFORE HAS LARGE WATER CONTENT. THIS WATER CAUSES IMPINGEMENT AND THINNING OF THE TUBE BY EROSION. THE LAST ROW CAN BE TOTALLY REMOVED SINCE THE REMINING THREE ROWS ARE SUFFICIENT IT IS BETTER TO REMOVE ABOUT 10% TUBES IN SH1 7-10% INCREASE HPECO2 SURFACE AREA

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5 BURNERS

SCREEN TUBES

FIRED HRSG

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IMPORTANT ISSUES IN FIRED HRSG

LENGTH OF FIRING DUCT IS A VERY CRITICAL FACTOR TO ENSURE PROPER RADIATION AND CONVECTIVE HEAT TRANSFER. THE BURNERS MUST ENSURE OPTIMUM PENETRATION AND DIVERGENCE OF THE FLAMES. THE SCREEN BOILER MUST SEE A UNIFORM HEAT FLUX TO THE EXTENT POSSIBLE. NON-UNIFORM HEAT FLUX DISTRIBUTION MAY CAUSE SEVERE BUCKLING OF SCREEN TUBES ALL THE BURNERS MUST BE TUNED TO GIVE THE SAME FLAME SHAPE AND SIZE. SELECTION OF FIRING ELEVATIONS DO PLAY AN IMPORTANT ROLE IN THE LONG TERM PERFORMANCE OF THE HRSG

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FIRED HRSG CONFIGURATION

REQUIRES AUXILIARY AIR SUPPLY FOR COOLING BURNER TIPS. FORCED DRAFT FANS OR ID FANS. THE LATER IS NOT 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 BLOWING LANES IN FLUE GAS AND HEAT EXCHANGER PATH TO ENSURE CLEANLINESS OF HEAT TRANSFER SURFACES.

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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 LOADING RATES. HRSG DESIGNS FOR THIS PURPOSE ARE REQUIRED TO BE TAILOR MADE SO THAT THE AGGRESSIVE START UPS AS WELL AS LOADING RATES DO NOT CAUSE PREMATURE FAILURES AND LIFE EXPIRY. COMPARED TO CONVENTIONAL BOILER R&M ACTIVITIES FOR HRSG MUST START MUCH EARLIER.WE CAN IDENTIFY THE PROBLEM AREAS IN HRSG BY STUDYING THE PRESENT FLUE GAS TEMPERATURE PROFILE, WATER AND STEAM PARAMETERS WITH REFERENCE TO THE SAME AS GIVEN IN HMBD SUPPLIED BY OEM. STACK TEMPERATURE IS ONE PARAMETER WHICH TO A LARGE EXTENT WOULD INDICATE THE QUALITY OF PERFORMANCE OF THE HRSG

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THANK YOU SKB