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Nigeria Olorunsogo Combined Cycle Power Station Phase II

Training on HRSG

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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

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 Typical HRSG construction.


 Function of an Economizer, Evaporator, Desuperheater and Superheater.
 Function of HP & LP Drums
 Steam fundamentals, saturation, wet and superheated steam.
 HRSG drains and vents.
 Steam temperature control, desuperheater.
 Function of Safety Valves
 Dampers arrangements, Weather & Diverter.
 Condensate, Make-up Water.
 Preheater
 Deaeration, Feedwater pumps.
 HRSG trips - causes and effects.
 Drum - level; three-element control.
 Preventive maintenance.

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Combined Cycle Power Plant


• 4 GE Frame 9E Gas Turbines x 125MW
• 4 Wuxi Boiler HRSG’s (Heat Recovery Steam Generator)
• 2 Harbin Steam Turbines X 125MW

BLOCK 1 BLOCK 2
125MW GT 1 GT 2 GT 3 GT 4

HRSG1 HRSG2 HRSG3 HRSG4

ST1 ST2
125MW

• Total Plant Output = 750MW

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What is an HRSG?

HEAT RECOVERY STEAM GENERATOR

An Heat Recovery Steam Generator also known as a Boiler is the process


of generating steam by recovering heat energy from a Gas Turbines exhaust
to heat up de-oxidized water.

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HRSG Specifications

Manufacturer – Wuxi Huaguang Boiler Co. LTD


Year – 2009
Model – UG-PG9171E-R
Steam Temp (℃) – High Pressure (523), Low Pressure (257.5)
Steam Pressure (Mpa) –High Pressure (7.3), Low Pressure (0.75)
Gas Inlet Temperature (℃) – 541.1
Mass Flow Rate (t/h) – High Pressure (179.11), Low Pressure (39.5)
Build – Gas Inlet Horizontal to Vertical, HRSG Modules are arranged
Horizontally
Drums – High Pressure , Low Pressure & Deaerator

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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.

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HRSG
Water System
The main components of an HRSG in regards to Water system are:

•Water Source – Iro River & Borehole


•Preheater - Preheater recirculation pumps and T-junction.
•Drums - Deaerator, High Pressure Drum and Low Pressure Drum.
•Feed Water System - 3 High Pressure & 3 Low Pressure Feedwater Pumps.

•HRSG Modules - HP Economizer, HP Evaporator and LP Evaporator.

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Water Source
• Iro River
• Fire Fighting Tank
• Cooling Towers
• Raw Water Tank
• Demineralized Water Tank
• Condensate Storage Tank
• Service Water
• Borehole
• Portable Water Tank
The water in the raw water tank is Demineralized using cations, anions, resins
etc.. To prevent corrosion

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Preheater
Preheater – This is the process of heating condensate to the required
temperature to aide deaeration.

Preheater Recirculation Pump A & B


• The Recirculation loop of a preheater is set at the preheater outlet, one in
service and one standby.

• Its function is to recirculate the condensate to the required temperature to


aide deaeration.

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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.

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12 Preheater feed water system

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Deaerator
Deaerator
•The Deaerator is a device used for the removal of oxygen and other dissolved gases
from the Feedwater to steam generating boilers or HRSG. It is also known as de-
oxidization.

•Dissolved oxygen in Feedwater will cause serious corrosion damage in the steam
systems by attaching to the walls of metal piping forming oxides (Rust)

•Tray Type Deaerator


•Domed Deaeration Section
•Air Vent
•Internal Steam Distributor Piping
•Perforated Trays
•Low Pressure Steam

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Deaerator

•Horizontal Feedwater Storage Vessel


•Internal Steam Distributor Piping
•Low Pressure Steam

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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Deaerator Design Parameters

• Design pressure (Mpa) 0.97


• Working pressure (Mpa) 0.36
• Design temperature (℃) 140
• Working temperature (℃) 177
• Drum center elevation (m) 30.19
• Straight length (mm) 7780
• External diameter (mm) 3040
• Wall thickness (mm) 20
• Specification Φ3040×20

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Deaerator

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HP & LP DRUMS

• High Pressure Drum - A water reservoir and a separator of saturated


steam and water at high pressure

• Low Pressure Drum - A water reservoir and a separator of saturated


steam and water at low pressure

• The design of the Steam turbine requires high and low pressure superheated
steam (Dry Steam)

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HP Design Parameters

• Design pressure (Mpa) 7.2


• Design temperature (℃) 321
• Working temperature (℃) 313
• Drum center elevation (m) 30
• Straight length (mm) 6380
• External diameter (mm) Φ2480mm
• Wall thickness (mm) 90
• Specification Φ2480×90

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LP Design Parameters

• Design pressure (Mpa) 0.83


• Working pressure (Mpa) 0.35
• Design temperature (℃) 235
• Working temperature (℃) 223
• Drum center elevation (m) 29.6
• Straight length (mm) 6700
• External diameter (mm) 2040mm
• Wall thickness (mm) 20
• Specification Φ1250×20

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HRSG Modules Water System

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.

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HRSG Modules Water System

Economizer - This is used to preheat de-oxidized water from the Deaerator/


HP Feed water pump.
Evaporator –This is used to change liquid form into its gaseous form while
absorbing heat in the process.

•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.

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HRSG Modules Water System

• 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.

• As shown in picture below.

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HRSG Modules Water System

• 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.

• The flow : LP Feedwater (Water Inlet) – LP Drum – Downcomer(Water) -


Evaporator– Upcomer(Steam + Water) – LP Drum (Steam and water
separation) – Steam Outlet / Downcomer (Water) .

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LP Drum Structure

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END OF WATER SYSTEM

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HRSG
Chapter 2 Steam System
• HRSG Modules
• HP
• Evaporator
• HP Superheater 1 & 2
• LP
• Evaporator
• Superheater
• Steam Drums
• High Pressure Drum
• Low Pressure Drum (Deaerator)

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STEAM DRUMS (HP & LP)


High Pressure & Low Pressure Steam Drum.
The Steam Drum is key component HRSG system.

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

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Steam Drum Principle


Feedwater from the HP economizer/ LP Feedwater pumps enters the steam
drum via sparger nozzles, it is directed towards the bottom of the drum and
then via downcomers to the LP/HP Evaporator modules.

It operates via natural circulation.

Water and steam in the drum travel in opposite direction


• Water leaves the bottom to Evaporators
• Steam exits the top to the Superheaters.

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Steam Drum Separation


• It is based on the density difference of water and steam

• The Separation are carried out in stages;


• Primary Separation
• Secondary Separation

The primary separator


These are cyclones. It enables the rising steam/water mixture to swirl, causing the
heavier water to drop out of the cyclones to the bottom of the drum and thus let the
lighter steam rise above and out of the cyclones.

The secondary separator


The steam which is virtually free of moisture at this point, continues through the
secondary separator, called demisters.

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Demister are bundles of screens that consist of many layers of tightly


bundled wire mesh. It removes and capture any remaining droplets that
may have passed through the cyclones.

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High Pressure Steam System
• High Pressure (HP) comprises of HP Drum, HP Evaporator, HP Superheater
and the HP Desuperheater.

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

•The feedwater is tapped from the HP FWP via the Deaerator.

•The steam temperature alarm value for desuperheating water is 470℃


(approx.), HP main steam temperature value is 523 ℃, desuperheating water
out of service temperature is 420 ℃(approx.).

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Low Pressure

• Low Pressure (LP) comprises of LP Drum, LP Evaporator and LP Superheater.

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..

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• The HRSG is designed in modules which is for good
transportation and easy installation.

• The HRSG modules are composed of pipeline bundles which


connect to upper and lower headers. These pipeline bundles
are heating surfaces and water/steam inside is heated up.

• 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.

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Steam Parameters
High-pressure section
• High-pressure section maximum continuous rating179.11 t/h
• High-pressure section rated steam outlet pressure 7.3 MPa
• High-pressure section rated steam outlet temperature 523℃
Deaerator
• Temperature 177 ℃
• Flow 240 t/h
Low-pressure section
• Low-pressure section maximum continuous rating 39.5 t/h
• Low-pressure section rated steam outlet pressure 0.75 MPa
• Low-pressure section rated steam outlet temperature 257.5 ℃

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END OF STEAM SYSTEM

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HRSG
Chapter 3 Flue Gas System
• Flue Gas – This is the output of the Gas Turbines combustion.
• Flue Gas Composition (V%)
• N2 – 74.87
• CO2 – 3.33
• H2O – 7.19
• O2 - 13.72
• SO2 – 0.00 (Trace)
• Ar – 0.89

• Flue Gas Temperature


• HRSG Inlet Duct – 541.1 ℃
• HRSG Outlet Duct – 113 ℃

• Flue Gas Flow


• 1495000kg/h
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Flue Gas System
• Flue Gas System Main Components
 Bypass Inlet Flue
 Chimney Bypass or Bypass Stack
 Bypass Gas Silencer
 Three-way Diverter Damper
 Seal Fans
 Blank Flange /Expansion Joint
 Bypass Outlet Flue
 HRSG Inlet Flue
ST ND RD
 HRSG Modules (1 , 2 &3 Layer)
 HRSG Outlet Flue
 HRSG Chimney
 Weather Damper

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Flue gas system emission process


•In combined cycle, the GT exhaust is called Flue Gas. The Flue gas is
channeled into the HRSG, flushes the modules ( third-layer module, second-
layer module and first-layer) in turns, and finally flows out through the HRSG
chimney.

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

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Flue Gas Temperature Inlet & Outlet
Third Layer
HP Superheater 2 541.1
HP Superheater 1 521.6
Second Layer
HP Evaporator 465.2
HP Economizer 3 304
LP Superheater 292.4
HP Economizer 2 287.5
First Layer
LP Evaporator 244
HP Economizer 1 187.4
Preheater 173.9
Chimney 105.3
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Flue Gas System Main Components Summary

Bypass Inlet Flue


•The function of Bypass Inlet flue is to connect the GT Outlet diffuser with
HRSG bypass system.

Chimney Bypass or Bypass Stack


•When simple cycle is adopted, the flue gas is channeled to the atmosphere
through chimney bypass. The chimney adopts interior thermal insulation
structure, its enclosure is carbon steel plate. Ladder stand and a platform are
also provided for the convenience of repair.

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Bypass gas silencer


• The bypass gas silencer is made of punched stainless steel with acoustical
material inside and it lowers the noise that is generated from gas emission
of combustion engine in simple cycle.

Three-way diverter damper


• The function of three-way diverter damper is to divert the flue gas to the
chimney bypass or HRSG. The Three-way diverter damper can seal the
chimney bypass, the bypass outlet flue and lastly be regulated at several
angles.

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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.

Bypass Outlet Flue


This connects the bypass system and HRSG inlet flue. The flue adopts interior
thermal insulation structure.

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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.

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HRSG Inlet Flue


• This connects the bypass outlet flue with HRSG and distribute flue gas
onto each heating surface evenly.

HRSG Outlet Flue


• The function of HRSG outlet flue is to connect the HRSG flue with HRSG
chimney.

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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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Structure Description of HRSG Flue


•The HRSG adopts all-sealed structure. The HRSG inlet flue, vertical flue and
outlet flue are frame cover structures made up of steel and steel plates. The
frame cover is connected with HRSG steel structure which seals the HRSG
and also increases the rigidity of HRSG.

•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.

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END OF FLUE GAS SYSTEM

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HRSG
Chapter 4 DCS Operation System

DCS – Distributed Control Systems are controllers that performs


control functions, provides readings of the status processes,
maintain databases and advanced man-machine-interface.

It includes the startup and shutdown of HRSG, monitoring and


controlling valves, pumps, drum water level, pressure,
temperature and flow rate of water/steam

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Most of the control actions on the HRSG are performed


automatically, but the operator must be aware of the current
status and be prepared to take manual action, if this becomes
necessary.

•Start Up & Shutdown


•HRSG Trip
•Three Elements Control
•Maintenance and Protection – Sampling, Conductivity & Dozing

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Start Up & Shutdown


During start-up and shutdown of a unit, there will be thermal
stress, faster temperature rising which will impact on service life
of an equipment.

The following factors limit the temperature rising rate;


1.The GT exhaust temperature needs to be controlled.
2. The three – way diverter damper degree should be controlled
according to the drums temperatures.
3. The water level in the drums should be controlled within
certain range.
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Types of HRSG Start-Ups

Cold start-up: The water temperature inside the Drum is below 100℃

Warm start-up: The temperature inside the Drum is above 100℃ ‘

Hot start-up: The temperature inside the Drum is above 464.4℃

•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

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Types of HRSG Shutdowns
Normal Shutdown
• HRSG common maintenance
• HRSG long time shutdown
• HRSG shutdown without maintenance
Example of HRSG Normal Shutdown

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 :

a) The GT exhaust will be bypassed via the chimney bypass.

b) The TWDD will be fully closed, so as to isolate the HRSG from the source
of heat.

c) HP / LP main steam valves will be closed.

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An HRSG trip will normally be triggered by:

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.

5) A gas turbine trip.


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• During an HRSG trip, the condensate and Feedwater pumps continue to


operate, supplying water as necessary. When the condensate and feed flow
reduces close to certain amount, the respective recirculation valves open.

• 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

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Three Element Control

Maintenance of correct temperature is very important.

Low Steam Temperature - Steam turbine efficiency decrease


Higher Steam Temperature - Internal turbine damage will eventually take
place.

Control of water level in each HRSG drum utilizes three element control
 Feedwater Flow
 Drum Water Level
 Steam Flow

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• 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.

• This is important, because the two may need to operate in opposition at


times.

Example.

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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.

However, this is exactly what it shouldn't’t do under these conditions.


As soon as the steam flow ceases, the water level in the drum falls
rapidly.

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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Maintenance and Protection

Control of the HRSG water chemical condition is extremely important. The


following items must be monitored and controlled:

a) Solids content.
b) Dissolved oxygen content.
c) pH value.
d) Content of specific constituents such as silica, iron...

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Solids Content
It is inevitable, that some minute quantity of solids enter with the HRSG
Feedwater. These solids usually include
Calcium, Magnesium, Silica and Sodium

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.

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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

The concentration can be reduced by draining off a portion of water through


the continuous blow-down , to be replaced by incoming Feedwater with an
extremely low concentration of solids.

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Sampling & Dozing
The chemical condition of the HRSG water and Feedwater must be controlled,
based upon regular analysis. The analysis may be performed manually, on a
regular basis (once per day). In many installations, a continuous sampling
system is installed, to provide continuous automatic analysis.

Dissolved oxygen content


Oxygen in Feedwater causes corrosion both to the pipework and the boiler
tubes.
Solution
Hydrazine; acts as an oxygen scavenger by absorbing dissolved oxygen in the
Feedwater.

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pH value

The pH value of the HRSG water must be maintained within a very


narrow range, 8.5 to 9.2
Lower pH – Corrosion may occur in the HRSG modules.
High pH - The water level fluctuates wildly, and may carry over with the
steam, thereby reducing the steam temperature.

Solution

Phosphate; injected into the boiler drum to control pH.

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80

Content of specific constituents such as silica, iron..

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

Amines; injected into the condensate system, so as to inhibit corrosion of the


steel pipework.

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81

END OF HRSG

THANK YOU !!!

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