A custom design allows theoretical flexibility to satisfy thermal and hydraulic process requirements. Both theory and practical applications are covered, giving engineers the proper guidance needed to design and operate hrsg power plants. F igu r1 sh ow tf m expected for the case of a onestage hrsg producing a single stream of saturated steam at 300 psig. It should, however, be remembered that the closer the pinch, or approach, the less reliable the results will be. Design methodology of heat recovery steam generator in electric. Therefore, in the paper we want to consider a triplepressure hrsg which is particularly patterned on the rafakos production 22, nem energy 8. However, since hrsgs in general are of the convective type, one can easily simulate their offdesign performance without actually designing the hrsg in terms of tube sizes, dimensions, surface areas, etc.
Model of a heat recovery steam generator hrsg process and. Pdf heat recovery steam generator design for a graz. After deciding on the evaporator type to be used for the unit, the next important step in the design of an hrsg unit is to decide the arrangement of the various coils in the unit. Ger3574g ge combinedcycle product line and performance. This section is intended to provide turbine operators with a basic understanding of heat recovery steam generator hrsg design and operation. The steam turbine is designed for steam inlet conditions of. Hrsg heat recovery steam generators design and operations. At off design conditions the inlet guide vanes igv are used to regulate the air so as to maintain a high temperature to the hrsg. Heat recovery steam generator hrsg fundamentals euci. The hrsg in eor service is a major component in the combined cycle power scheme with energy supplied by a gas turbine generator gtg set. Advanced technology combustion turbines in combined. In this chapter the reader will be taken through the various methods of heat recovery steam generator hrsg construction.
Department of energy under contract deac0500or22725. Auxiliary steam generating system steam from auxiliary boilers may be used for brief periods at startup, used to maintain vacuum during longer outages or used for sparging of the hrsg. Ganapathy is filled with over 225 boiler hrsg operation and design problems, industrial boilers and heat recovery steam generators ebook covers steam generators and related systems used in process plants, refineries, chemical plants. Pdf design considerations for combined cycle plants for the. Heat recovery steam generators hrsg various types and designs shell and tube exchanger. General design considerations gas turbine plants come in many sizes and flavors simple cycle hrsg combined cycle with without catalyst with without tempering air with without duct burner footprint site arrangement performance optimization involves careful balance of competing goals power steam. Offfice of industrial technologiesinformation clearinghouse8008622086cosponsored by. Nowadays designs need to incorporate many more features to ensure optimum efficiency 18. The guidebook on design, operation, and maintenance of heatrecovery steam generators hrsg was published to mark 10th anniversary of hrsg users group. With the obvious consideration being larger combustion turbines and the additional power generated, there are other power block and balanceofplant bop design impacts. Coverage ranges from market surveys, heat balances and mechanical design to operation of hrsgs. In addition, special hrsg design considerations are discussed for altering the steam production by operating the diverter in a fixed intermediate position, where only part of the ct exhaust gas is admitted into the.
The heat recovery steam generators shall consist of the following scope of supply. To order additional copies ofthis sourcebook, please call. Materials selection considerations for thermal process. Controlling steam production in hrsgs for combined cycle a. Thermal design and optimization of heat recovery steam. Design considerations for cycling in the design phase the most important requirement is to make sure that all the factors which affect the life of hrsg have been accounted for. Thermodynamic design aspects are discussed, and useful screening tables are presented for.
Considerations in the capacity uprating of an eor hrsg. Considerations boiler pressure, design pretreatment plant type feedwater quality hot well, deaerator type. General design considerations gas turbine plants come in many sizes and flavors simple cycle hrsg combined cycle with without catalyst with without tempering air with without duct burner footprint site arrangement performance optimization involves careful balance of competing goals power steam output emissions pressure drop. Readily installed in the hrsg inlet duct, difficult to install within the boiler surface area hrsg enclosureboiler house free standing, self supporting enclosure attached to and supported by the hrsg structure, light enclosure natural circulation state of the art special design considerations, though state of the art. This paper provides the main characteristics of a modeling and simulation tool to analyze the steady state and transient operation of a hrsg heat recovery steam generator when they are subject to load changes. And as a practice, a 30 f pinch design for these hrsgs should be considered. This means that either the design features must be modified to mitigate the effect of damaging factor or the damaging factor must be eliminated. A simplified diagram of this cycle is shown in figure 4. Design considerations for combined cycle plants for. Hrsg construction varies widely in levels of modularization and order of assembly of the components. One is driven by design considerations, another by manufacturing reasons. Heat recovery steam generators handbook for cogeneration and.
Besides continuous development in design and performance of gas turbines for power generation, tremendous progress is being made in hrsg technology 22,8,9,10. The hrsg represents an evolution in design of a conventional heat exchanger for which hrsg steam generation rates have become comparable to a fired steam generator unit sgu in either power generation. Increasing sizes, exhaust gas turbines t600 oc and mass. Design considerations for advanced combined cycle plant using. Hence, predicting hrsg performance under different conditions is a must for consultants, plant engineers and hrsg designers. Gas turbine exhaust systems have unique design characteristics. Understand the basics by understanding how gasturbine heatrecovery steam generators differ from conventional steam generators, engineers can design and operate hrsg systems that produce steam efficiently. Design and modification of hrsgs for cycling operations pg. Design allowable stresses are often based on asme design codes. Ge combinedcycle product line and performance ge power systems ger3574g 4 gt16402a figure 3. Executive director, hrsg users group po box 1054 bozeman, mt 59771 usa tel. The survey revealed some minor deviations in design considerations, yet it showed. Heat recovery steam generators primer an introductory.
This pdf guidebook provides an introduction for all aspects of heat recovery steam generators hrsg engineering. Readily installed in the hrsg inlet duct, difficult to install within the boiler surface area hrsg enclosureboiler house free standing, self supporting enclosure attached to and supported by the hrsg structure, light enclosure natural circulation state of the art. Description and functions of a heat recovery steam generator hrsg types and configurations of hrsgs. Steam generation range an optional case of hrsg steam generation was also a nlyz ed. Unlike in a conventional steam generator, where the steam demand drives the design case, in a hrsg. Heat recovery steam generator wiki odesie by tech transfer. Materials selection considerations for thermal process equipment. Hrsg generating more lowpressure steam than high pressure steam, then a larger pinch and approach may be used.
Based on actual and existing hrsg in most combined cycle power plants, a water tube hrsg including two superheaters, one evaporator and one economizer is considered in the optimization. Paper ac experience in hrsg design developments ac boilers. Key features include heat transfer, surface arrangements, design operating considerations, and integration with combined cycles and cogeneration equipment. Gas turbineheat recovery steam generation phone 502. Steam production when heat is added to water, its temperature rises at a rate of 0. Uniperge announce he upgrade project with enfield as the lead engine. Ger3582e steam turbines for stag combinedcycle power systems. Well explore what is important, considerations for specific jobsites, and design influences.
Efficiency of hrsg within a combined cycle with gasification. Pdf heat recovery steam generator design for a graz cycle. Pdf exergetic optimization of design parameters for heat recovery. Key features include heat transfer, surface arrangements, designoperating considerations, and integration with combined cycles and cogeneration equipment. These considerations will be discussed later on in this document. Above about 1,000f 540c, creep or rupture is the basis for setting design stresses. Combined cycle systems typically are an optimized system of high technology power generating equipment, software, and services that are integrated into the utilities ancillary equipment to create an economical and stable power generating facility. Recent trends in hrsg design include multiplepressure units for maximum. Heat recovery steam generators hrsgs are important components for industrial waste heat. Ganapathy, abco industries g as turbines with heat recovery steam.
Feasibility study by uniper considering full plant. Design for mechanical integrity of the pressure parts to withstand specified number of startup cycles and number of hours at elevated temperatures usually a life cycle analysis is done using asme api or en code procedures these analyses are inadequate because. The hrsg also has supplemental firing in the duct that raises gas temperature and mass flow. Thermodynamic design aspects are discussed, and useful screening tables are presented for steam turbine selection.
Vogt approach to fast start hrsg design traditional approach. Council of industrial boiler ownerscouncil of industrial boiler operators6035 burke centre parkway, suite 360 improvingburke, va 22015 steam systemnational insulation association99 canal center plaza, suite 222. Performance optimization of dual pressure heat recovery. Guide to combined heat and power systems for boiler owners. Council of industrial boiler ownerscouncil of industrial boiler operators6035 burke centre parkway, suite 360 improvingburke, va 22015 steam systemnational insulation association99 canal center plaza, suite 222 performancealexandria, va. In other words, it would be easy to calculate the steam generated in a unit at a 5 f pinch, but the probability of achieving this result with the. For most thermal processing equipment, design stress is either onehalf of the 10,000hour rupture strength, or onehalf of the stress to cause a minimum creep rate of 1% in 10,000 hours.
Department of energy industrial technologies program prepared by oak ridge national laboratory oak ridge, tennessee 37831 managed by utbattelle, llc for the u. The hrsg heating surface is arranged into coil bundles comprised of rows of finned tubes connected to headers andor return bends at the top and bottom of each tube as seen in fig. Description and functions of a heat recovery steam generator hrsg types and configurations of hrsgs how an hrsg produces steam components of an hrsg design considerations fabrication considerations very knowledgeable. Ganapathy is filled with over 225 boilerhrsg operation and design problems, industrial boilers and heat recovery steam generators ebook covers steam generators and related systems used in process plants, refineries, chemical plants. Furthermore, the operational limits of the various components and of possible component upgrades will be assessed to determine whether hsrg performance can be improved beyond the design operating capacity. Design considerations for advanced combined cycle plant. The hrsg generates steam utilizing the energy in the exhaust. Of course, if only an evaporator is present, this may consist of a very simple schematic, but if. Proceedings of the asme 2016 pressure vessels and piping conference. Two distinctly different approaches to the physical design of an economizer exist in todays heat recovery steam generator hrsg business.
The addition of the h technology to the stag combined cycle systems is described. Singlepressure nonreheat cycle diagram gt1640b figure 4. About international journal of lowcarbon technologies editorial board author guidelines facebook twitter. Combined cycle systems encompass a large range of capabilities for both 50 and 60 hz operation. The ge design for the 3x3x1 power island at the hsin tao power plant in taiwan and several other steam turbine generator vendor designs have overcome the startup problem of hp exhaust overheating. Imia working group paper 91 15 imia annual conference 2015, merida yucatan, mexico. Decisions made during the design and construction phase of the hrsg can have a tremendous impact on the chemistry control that can be used to prevent corrosion. Pdf initial aerothermal design considerations for an oxy. Industrial boilers and heat recovery steam generators. However, since hrsgs in general are of the convective type, one can easily simulate their off design performance without actually designing the hrsg in terms of tube sizes, dimensions, surface areas, etc.
The power generation block of the facility produces electrical power in two separate islands. Hrsg and directing this feedwater to a tubeandshell heat exchanger. Standards for the design, construction, maintenance. Guide to combined heat and power systems for boiler. The design includes two 2 ge 7fa combustion turbines running in cogeneration mode with two vogt power international vpi hrsgs.
The thermal design and the optimization of an hrsg are important. Consensus on operating practices for control of water. Gryphon is a canadian multidiscipline, fullservice engineering design firm specializing in cogeneration, combinedcycle and thermal power plants and related equipment and systems, including level i, ii and iii feasibility studies, conceptualschematic design, project development. Recent trends in hrsg design include multiplepressure. Design considerations for combined cycle plants for the deregulated. Answered any questions asked and was very detailed on responses. Model of a heat recovery steam generator hrsg process. A fatigue analysis has been carried out in order to optimise startup time in consideration of. For design purposes these rows of tubes and connecting headers are arranged into coils that serve a specific purpose, such as an evaporator or an economizer. Proper steam bypass system design avoids steam turbine. Following design and economic considerations are based on ras laffan hrsg case, where a double post firing, described in paragraph 2. Ger3582e steam turbines for stag combinedcycle power. Heat recovery steam generator technology sciencedirect.
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