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Training on HRSG
HRSG
AIM
To gain theoretical and practical knowledge of an Heat Recovery Steam Generator.
OBJECTIVE
To present the main features of the Heat Recovery Steam Generator, as employed for
"Power Generation”:
•Water System
•Steam System
•Flue Gas System
•DCS Operations
BLOCK 1 BLOCK 2
125MW GT 1 GT 2 GT 3 GT 4
ST1 ST2
125MW
What is an HRSG?
HRSG Specifications
HRSG
Brief Description
• Non-additional combustion, self-contained forced-circulation.
• All tubes on heating surfaces are arranged horizontally, the flue gas flows
vertically
• The flue gas enters from inlet duct, flows from horizontal to vertical from
bottom to top, flushes the heating surfaces (HRSG Modules) at all levels
one by one, and finally expelled via the outlet duct and chimney.
Preheater
Preheater – This is the process of heating condensate to the required
temperature to aide deaeration.
Preheater
T-Junction
•T-junction regulating valve controls the condensate temperature entering the
Deaerator so as to ensure its temperature is within 105℃.
Nitrogen Fill
•Nitrogen Fill – The presence of water and oxygen causes corrosion to occur in
the stream lines. Wet & Dry Nitrogen are used to prevent corrosion.
•Dissolved oxygen in Feedwater will cause serious corrosion damage in the steam
systems by attaching to the walls of metal piping forming oxides (Rust)
The steam strips the dissolved gas from the Feedwater and exits via the vent valve
(air vent) at the top of the domed section.
The Deaerator and its auxiliaries includes the deaeration head, water tank,
preheater, the steam supply (LP Drum) and make up steam circuits, the
recirculation circuits for filling water, the steel frame, platform, walkway, stairs,
the local pressure gauges (including the valves for the instrument and accessories),
a set of contact water level gauges are arranged for the Deaerator (for the camera
and TV). Etc.
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• The design of the Steam turbine requires high and low pressure superheated
steam (Dry Steam)
The HRSG modules are composed of pipeline bundles which connect to upper
and lower headers. These pipeline bundles are heating surfaces with fin tubes
welded outside to enlarge the heat transfer area.
For more effective heat absorption, fin tubes are welded outside of the pipeline
to enlarge the heat transfer area as shown in the following picture.
•Upcomer and downcomer – This is the Flow of water/ saturated steam in the
HRSG modules via pipeline bundles in an upward and downward flow
respectively.
•Upcomer includes many pipelines and it is connected to an upper header and
a lower header.
•The Upcomer, drums and downcomer are looped.
• During Evaporation water and saturated steam rises via the upper header to
the upcomers then into the drums.
• Separation occurs in the drums, water flows down via the downcomer to
the lower header then as saturated steam via upcomer to upper header into
the drums repeatedly, forming the circulating process.
• The picture below shows the drum structure. Inside the drums, the drum
separates saturated steam and water, ensures the water circulating loop
(Downcomer – Upcomer and vice versa)
• The saturated steam inside the upcomer enters the drum which is then
separated inside the drum. The saturated steam goes out from upper outlet
of the drum and the water flows through the downcomer.
Main Functions
• Supply circulating water to the evaporator through downcomers
• Receive water/steam mixture from risers or upcomers
• Separate Water & Steam
• Removes Impurities
• Controls Water Chemical Balance by chemical feed & continuous blow down
• Supplies Saturated Steam
• Serves as a storage tank
• Act as a reference point for feedwater control
The de-oxidized water flows down via 2 downcomers, through the HP Evaporator
where evaporation takes place and HP saturated steam is created. The HP saturated
steam rises to the HP Drum via 4 upcomers, HP saturated steam and water
separation takes place in the HP Drum. The water separated in the drum flows down
via the downcomers and this circulation process continues, generating more
saturated steam.
The saturated steam is extracted through 2 steam outlets (downcomers located at the top
of the HRSG) and flows through HP Superheater1 and Superheater 2 respectively
for further dryness, which produces HP Superheated Steam or Dry Steam for the
steam engine HP cylinder.
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High Pressure Steam System
•Desuperheater – A steam temperature control system that uses feedwater as
spray water in order to attain the required HP Superheated Steam Temperature
523℃
•An injector sprays feedwater in the steam line and thus reduce the temperature
of the superheated steam. The injectors are located between the superheater
stages. Also known as attemperator
Low Pressure
The de-oxidized water flows down via a downcomer through the LP Evaporator where
evaporation takes place and saturated steam is created. The saturated steam rises to
the LP Drum via 3 upcomers, saturated steam and water separation takes place in the
LP Drum. The water separated in the drum flows down via a downcomer and this
circulation process continues, generating more saturated steam.
The saturated steam is extracted through steam outlets (located at the top of the HRSG)
via 2 downcomer and flows through a LP Superheater for further dryness, which
produces Superheated Steam or Dry Steam for the steam engine LP cylinder..
Modules Layers
•First Layer – Preheater, HP Economizer 1, LP Evaporator
•Second Layer – HP Economizer 2, LP Superheater, HP Economizer 3, HP
Evaporator
•Third Layer – HP Superheater 1 & HP Superheater 2
Seal Fan
•Its an air seal system that seals and cools the three-way diverter damper.
3
Flow 6762m /h , Full pressure 5180 Pa, Power of motor 18.5kw×2
• HRSG side air – Cools and seals the TWDD during simple cycle operation
• Bypass Side air – Cools and seals the TWDD during combined cycle
operation.
Blank flange
• This is used to isolate the HRSG during installation to prevent foreign
bodies into the HRSG.
Expansion Joint
• A non-metallic flexible expansion joint is set at the end of bypass outlet
flue, right below the hung blank flange to absorb the displacement
generated from hot & cold operation.
HRSG Chimney
•The function of HRSG chimney is to discharge the HRSG waste gas to the
atmosphere. The HRSG chimney is provided with measuring point in order to
sample the waste gas composition and monitor it.
•HRSG chimney is steel chimney, its internal diameter is Φ5000mm and it is
made up of δ16mm~δ10mm steel plate.
Weather Damper:
•It is mounted within the HRSG chimney. It is closed during shutdown of the
HRSG to keep the temperature of HRSG as long as possible and also serves as
a rain-proof. During HRSG operation the weather damper is opened. It
consists of two blades and an electric motor.
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•Discharge outlet is set on the bottom frame cover of HRSG Inlet flue and it
can be used to inspect the leakage of HRSG pressure when the HRSG is shut
down.
•Expansion joint is set in the position where the header goes through the frame
cover to maintain the tightness and whole performance of frame cover. It
allows the header to have certain expansion displacement to the frame cover.
Cold start-up: The water temperature inside the Drum is below 100℃
•Each type of start-up on HRSG will shorten the unit start-up time differently,
protecting the system from damage due to heat stress
•Example of HRSG Cold Start-up
Emergency Shutdown
• HRSG Urgent maintenance.
• ST, GT or HRSG Trip
Note: Cooling down HRSG within short time will lead to thermal stress on
HRSG, so it is advisable to avoid emergency shutdown.
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HRSG Trip
Like all equipment, the HRSG will be tripped out of service, if hazardous
conditions arise. Typically, automatic functions come into play :
b) The TWDD will be fully closed, so as to isolate the HRSG from the source
of heat.
1) High steam temperature, which could damage the steam turbine internals.
2) Low water level in the drum, which could lead to overheating of the tubes
in the evaporator section.
3) High water level in the drum, which may lead to carry over and consequent
damage of the steam turbine internals.
4) A steam turbine trip with the consequent fall in steam demand to zero.
• Also during an HRSG trip, the desuperheater inlet valve is also tripped
closed to prevent the possibility of water entering into the superheater, and
entering the turbine along with the steam when HRSG is placed back in
operation
Control of water level in each HRSG drum utilizes three element control
Feedwater Flow
Drum Water Level
Steam Flow
• In normal stable operation the Feedwater flow-in = Steam flow out, with a
correction for any small amount of blow-down.
• The control system adjusts the Feedwater control valve, so as to keep the
two flows in balance, but at the same time allowing the control to be
trimmed by the actual drum level.
Example.
ST suddenly trips due to an electrical fault. As the steam flow from the
H.P. superheater, suddenly falls to zero, the Feedwater controller
would try to close the Feedwater control valve, so as to reduce the
Feedwater flow into the H.P. section to match steam flow.
This is due to the collapse of the steam bubbles which are now in
circulation in the water. This is called "shrink". As the water level falls,
the drum level monitor will override the flow elements and open the
Feedwater control valve, so as to admit more water.
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a) Solids content.
b) Dissolved oxygen content.
c) pH value.
d) Content of specific constituents such as silica, iron...
When this water is evaporated into steam, the solids remain in the HRSG water
and eventually concentrate
A high concentration of solids can result in two problems for the boiler.
a) Deposits of hard scale occur inside the HRSG modules, with resultant lack
of heat transfer, and consequent overheating and damage to the tubes.
b) Violent fluctuations in water level with the possibility of some water
passing over with the steam thereby reducing the steam temperature.
Solution
Conductivity - Limits are set on the permissible solids content of the HRSG
water. Conductivity is used to measure the amount of solids. Typically
conductivity is between 10 and 15 micromhos. The higher the solids content,
the greater the conductivity
pH value
Solution
A small amount of silica can cause considerable build-up of hard scale on the
turbine blades, so reducing output and efficiency of the turbine.
Solution
END OF HRSG