Examples of modeling efforts are discussed with basic configuration of boiler. A heat recovery steam generator hrsg is one of the major pieces of equipment in a gas turbine combined cycle power plant that boasts a high thermal efficiency and produces minimal co 2 emissions. See table 1 for an example of cyclic operation for an hp steam drum. In more complex cases, spreadsheet balances or specialist flow sheet simulation software. Design methodology of heat recovery steam generator in. For a hrsg steam drum, does asme section i, mandate vacuum design check. The present research is focused on the design of a hrsg, including a dualpressure steam generator cycle that is intended for use in a typical gas turbine unit having a power output of 60 mw. Coal fired boilers, bagasse boilers, rice husk boilers, husk boilers, wood boiler,other biomass boilers, lignite boiler and other industrial steam generators.
Ganapathy 2003, problems such as corrosion are a main concern in keeping and maintaining the boilers and steam. Benson technology power plant solutions siemens global. This results in enhanced availability for our customers with boiler reliability as high as 94%. The only limitations of the program are that the hrsg design be of convective typemost hrsgs are and that the gas stream be clean. The arrangement of the evaporator is such that the wet steam collects in the steam drum by the natural law of mass transfer. Hrsg simulation theory and examples boiler and hrsg. Tab 1 typical desing hybrid design difference high pressure. During the development of this software, special care has been given to the study of the influence of the vaporizer pressure drop on the temperature and pressure gradient at the inlet of the drum, where critical thermal and mechanical stresses might appear. Hrsg heat recovery steam generator is a boiler to recover heat from the exhaust gas of an engine and to generate steam for more power generation or process. Learn the basics of hrsg inspection welcome to combined. Access 2001 summer specifications for access access 2002 winter hrsg inspection access.
Therefore, heat recovery steam generators hrsg are important components of many power plants. Difference between heat recovery steam generators hrsg. Modeling and design of the heat transfer between the gas and steam side of a heat exchanger. Comparing between hrsg and boiler in parameters, design and operation. Remote steam drums for higher steam capacities or shipping restrictions. The steam generated by the hrsg is supplied to the steam turbine that drives the electrical generator system. Modeling, simulation, and control of steam generation processes. Assists in proper and economical design for the expected operational conditions. Failure mode effect analysis fmea on heat recovery steam. Nootereriksen heat recovery steam generators are customdesigned to meet your projectspecific needs. The circulation pump specifications have been taken into account.
Heat recovery steam generators 10 u thermal performance modeling u to identify causes of performance shortfalls u to evaluate benefit of design improvements u modeling is done using amec foster wheelers expert performance design software which is continually updated and validated with field data. Solid fuel fired steam generators upto 200,000 kghr and 550 degc can be designed. Most large hrsgs can be classified as a doublewide, triplepressure level with reheat, supplementary fired unit of natural circulation design, installed behind a natural gas fired combustion turbine. The heat is converted into usable steam by the heat transfer surfaces within the hrsg. Hrsg simulation is a valuable tool that may be used to evaluate the performance of hrsgs in various modes of operation to determine if the hrsg design can be optimized. The superheated steam from each pressure level is duplicated to simulate the second hrsg and fed to steam turbine slices connected to a generator bottom right. Design methodology of heat recovery steam generator in electric. Design considerations for advanced combined cycle plant using.
Dehai boiler is a manufacturer for aclass boiler power plant boiler, industrial boiler, hrsg, wastetoenergy boiler, biomass boiler etc. The heat recovery steam generator hrsg is composed of numerous mechanical heating surface components superheaters, evaporators and economizers and steam drums. Heat recovery steam generator hrsg fundamentals euci. Model of a heat recovery steam generator hrsg process and. The flow of gas is horizontal while the water is heated in verticallyarranged evaporator tubes, producing a natural, costeffective circulation effect. An excellent primer for power plant professionals who have to wear many hats and need a practical explanation of the design and basic operation of conventional steam generating boilers and hrsgs without having to wade through technical material. Steam production from steam tables we can see that the total heat of steam does not vary a great deal as the boiler pressure increase the boiling point b. Hrsg design the function of the combined cycle heat recovery steam generator hrsg system is to provide a method to extract sensible heat from the combustion turbine ct exhaust gas stream. Hrsg parts heat recovery steam generator components ge power. In other words, is it correct to say that all hrsg boiler steam drums are required to be designed for full vacuum by asme section i.
Reduction in drum size will lead to faster start up times control system conventional controls known by all operators. It is a gastowater heat exchanger that extracts energy. Steam drums for heat recovery steam generator hrsg, water tube boilers, and waste heat boilers engineered and manufactured in south korea, our horizontal steam drums are used in multiple projects globally for steam generation and power plants. Design boiler have developed software that is able to simulate the dynamic response of a boiler control system to rapid changes in boiler load. Design of dual pressure heat recovery steam generator for. Preparation of 3d model of boiler pressure and nonpressure parts using catia software. Heat recovery steam generators for large combined cycle. Modern heat recovery steam generator hrsg design must balance operating response with the reduction in life of components caused by daily cycling and fast starts. Dynamic constraints on hrsg drum design turbo expo. Im working on a project where the vendor of an existing hrsg bpvc section 1 will not provide stated nozzle allowables for their steam drum connections. The steam drum is the primary interface between water and steam.
Provides transfer of flue gases through the hrsg path installation of an auxiliary burner is possible here superheater. Tracing back over 5 years, vogt is credited with producing the very first hrsg, the first threepressurelevel hrsg, the first reheat hrsg and others. The fluid in the evaporator undergoes forced circulation by pump for both pressure levels. I hrsg designed for superior performance and advanced operations. In its basic form these are bundles of water or steam carrying tubes paced in the hot gas flow path. Options for improving the efficiency of heat recovery steam. Adaptable modeling approach accor ding to the required level of detail. This course on hrsg fundamentals is intended for those that want to know a little bit more about the hrsg and its use in combined cycle and cogeneration plants. It produces steam that can be used in a process cogeneration or used to drive a steam turbine combined cycle.
In combinedcycle operations, a heat recovery steam generator hrsg serves the same purpose as a boiler. Topics to be covered include types of hrsgs, heat exchangers, boiler circulation systems, components, heat management, controls, water chemistry, emission controls, associated equipment. Hp, ip, and lp drum level measurement is an example of this. The following design features can be used for the hp drum to reduce shell thickness. However, approaching these new challenges with a positive mindset can yield significant benefits. The main contribution of this paper is the development of a numerical. Today, operators of more than 600 hrsgs in over 40 countries consider vogt their onestop source for excellenceinheatrecovery. The term hrsg refers to the waste heat boiler in a combined cycle power plant. Nextgeneration hrsgs designed to start faster, cycle.
Our special software for boiler thermal design, hrsg solution, provides customers with a wide range of calculations required for boiler thermal calculations as. Static thermal programs that predict steam flows, pressures and. Its difficult to believe that you will be asked to do more with a smaller budget, but you will. Hrsg description the dual pressure heat recovery steam generator is. Ganapathy, abco industries g as turbines with heat recovery steam.
Using thermohydraulic simulations to assess hrsg performance. Heat transfer technology nem power plant solutions. The hrsg manufacturer takes the number and severity of the cycles into consideration when choosing the details used in the design of the hrsg. Boiler group khi design and technical service, inc. Hrsg heat recovery steam generators cain industries. The first combined cycle power plant with a benson heatrecovery steam generator hrsg the 390mw cottam cdc, located in great britain was successfully commissioned in 1999. As an oem with a global workshop network, ge can offer standard and tailormade parts for all types of heat recovery equipment. Hrsgs for next generation combined cycle plants power. Hrsg heat recovery steam generator overview animation for nooter eriksen 3 drum hrsg with ammonia injection and duct burners. Our waterwall hrsg shares many design features with our industryleading direct fired packaged boilers.
Those variables are usually analyzed with design predicted performance of real. A number of design features can be applied to minimize the impact of cycling on the longevity of hrsg components. Steam is an essential element in the energy supply system. Sect i is intended for positive pressure above 15 psi. The correlation is applied to the steam drum design by determining a proper position of a demister to show proper separation performance. There are a variety of hrsg configurations and operating pressures. The level of detail and type of analysis will drive. We supply boiler design, fabrication, installation, repair and maintenance. Heat recovery steam generators 2 drum boilers keystone package steam generators vl boilers travagrate stokerssolid fuels experts in boiler startup.
The global economic downturn will impose new challenges on plant operations. A successful hrsg is comprised of the following components. Heat recovery steam generators hrsgs are important components for. This feedwater system removes any impurities in the condensate, which is steam converted back to water, preheats and pressurizes it then returns it to the power boiler steam drum. Supplying complete solutions for hrsg units requires largescale facilities and extensive epc experience. The steam turbine or a downstream process uses the steam. The first step in doing a simulation of hrsg operation is to build a software model using the mechanical design data for the unit in question. Modelling and practical studying of heat recovery steam generator. They substantially increase a plants overall efficiency, and help to minimize the costs of fuel. Hrsg heat recovery steam generators additional benefits you can expect from a horizon series.
Books,software on boilers,hrsgs,steam plant calculations by v. Nextgeneration hrsgs designed to start faster, cycle posted on september 9, 20 by team ccj the shuttering of nuclear and coalfired generation in the name of the environment has encouraged manufacturers of gas turbines and heatrecovery steam generators to push the designs of their equipment to limits unexpected a decade ago. Vogt power internationaldesigns for all your hrsg needs. The slant series of natural circulation heat recovery steam generators features the traditional slant model and the vc vertical drum cross flow model, both tailored for applications with gas side inlet temperatures less than. At the end all the water need not necessarily convert into steam. It produces steam that can be used in a process cogeneration or used.
The flow of gas is horizontal while the water is heated in verticallyarranged. In water tube boilers water goes through the tube and it gets converted to steam. Heat recovery steam generator hrsg solutions emerson. Unit birwelco ccgt hrsg high pressure steam drum repair and upgrade duration. For the hrsg, watertube type boiler is commonly adopted to accommodate the working pressure or capacity requirement of the system. Our gas fired plant training courses not only fully explain the heat recovery steam generator hrsg, including 2 drum hrsg and 3 drum hrsg, gas turbine and steam turbine flowpaths of a combined cycle site, they also cover balance of plant or bop equipment such as the condensate system. Heat recovery steam generators hrsg boilers product.
Each hrsg solution is customengineered to meet your desired operating flexibility and performance requirements. Faststart hrsg lifecycle optimization modern heat recovery steam generator hrsg design must balance operating response with the reduction in life of components caused by daily cycling and fast. The heating surface elements are bare and finned tubes integrated with collector headers and interconnecting piping systems. All boiler water eventually passes through one or more steam drums in a triplepressure unit, so a great deal can be learned from a proper inspection. What is the purpose of the steam drum on a water tube boiler. See table 1 for an example of cyclic operation for. 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.
For the purposes of this document two configurations have been considered. A heat recovery steam generator hrsg is a type of heat exchanger between. Horizontal drum hrsg units are the most popular type of steam generator. In a coalfired plant, boiler feedwater passes through the economizer and into the drum where the steam separates from the feedwater and is drawn off to the superheater.
Our primary offering is a natural circulation design with horizontal exhaust flow and vertical tube design with internally insulated casing and structure. Drum design design utilizes steam drum for storage volume and steam water separation. A leader in the supply of drum type boilers for gts rated up to 60 mw is rentech boiler systems of abilene, texas. Storage volume is normally sized for swell and hold up time. The first combined cycle power plant with a benson heatrecovery steam generator hrsg the 390 mw cottam development center, located in great britain was successfully commissioned in 1999. Ttp has created or is completing 14 different simple cycle and combined cycle plant courses. Also the place of the duct burner between the bundles has to be optimised to have a minimum reheater spray water flow see pic 7 comparing typical hrsg design vs. Pdf hrsg heat recovery steam generator is a boiler to recover heat from the exhaust gas of an engine and to generate steam for more. An hrsg is a kind of heat exchanger that recovers heat from the exhaust gases of a gas turbine to an. Will utilize ibd or start up drain for swell control.
Heat recovery steam generator hrsg in utility gebeng. More than 100 benson heatrecovery steam generators have been commissioned to date or are currently under construction. Modeling of the complete system, including superheaters, economizers, evaporators, pumps, turbines, etc. Higher temperatures and pressures along with the flows presented challenges for hrsg design. A heat recovery steam generator hrsg is an energy recovery heat exchanger that recovers heat from a hot gas stream, such as a combustion turbine or other waste gas stream. Selecting the correct heat recovery steam generator hrsg for engine cogeneration chp and other industrial waste heat systems involves much consideration. Heat recovery steam generator hrsg 2 drum hrsg 3 drum. Heat recovery steam generator wiki odesie by tech transfer. Instead theyve provided the nozzle fabrication details nozzleshell materials, thickneses, repads, etc for us to perform our own calculations. The protrax model is a mathematical representation of the entire combinedcycle plant and includes the hrsg heat transfer surfaces and drums, feedwater recirculation systems, and the gas and steam. Heat recovery steam generators hrsg the heat recovery steam generator hrsg provides the thermodynamic link between the gas turbines and steam turbines in a combinedcycle power plant. High pressure steam drum soak time remains a limiting factor in the startup ramp rate of hrsgs. Steam drums are used in hrsg to separate the water and steam from the evaporator. For an advanced gt hrsgs design temperatures for the heating.
Superheater outlet combined cycle utility hrsg modular design multiple pressures. Heat recovery steam generators hrsgs are waste heat boilers. Heat recovery steam generators for engines, incinerators, thermal oxidizers and catalytic converters. The small hrsg market is served by several firms offering conventional drum type and oncethrough steam generators otsgs. Horizontal steam drum for heat recovery steam generator. To this day, more than 100 benson heat recovery steam generators have either been commissioned or are currently being built. Collection of 21 programs ranging from boiler duty,efficiency calculations,steam.
You also benefit from greater flexibility when operating at part load during load changes or by simply utilizing one of our diverter bypass stack systems. Software designed to model and simulate hrsg operations can provide valuable information about corrosion and other operational problems. Contact ge power to learn more about boilers for steam power plants. Siemens offers steam generation based on benson oncethrough technology or drumtype heat recovery steam generators. What is the purpose of the steam drum on a water tube.
Hrsgs must be designed for cycling power engineering. If you are interested in reading one of our past articles, please contact us to request it. The results show that the maximum heat transfer occurs in the evaporator section for highpressure levels, and in the economizer section for lowpressure levels. It also helps to arrive at the gas steam temperature profiles in a hrsg, which is basic to understanding and improving the hrsg performance. Our experienced based design enables to burn a wide range of fuels, while avoiding or mitigating the impact of slagging, fouling, corrosion and erosion in the furnace. Steam drums provide the only nonintrusive access to the watersteam side of an fclass hrsg. One design feature includes the configuration of tube and headers in platens.
Steam drum w integral deaerator 1 distribution grid 3 observation port 7 injection grid 8 s. Due to the higher steam flow rates and temperatures caused by the. One such design is the industrial boilers in heat recovery steam generators hrsg, a complex design of a system which utilizes the generation of steam to provide a work output on certain machines. Section 152590 heat recovery steam generator hrsg lp evaporator replacement.
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