Hrsg heat recovery steam generators cain industries. They substantially increase a plants overall efficiency, and help to minimize the costs of fuel. The circulation pump specifications have been taken into account. 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. A successful hrsg is comprised of the following components. The only limitations of the program are that the hrsg design be of convective typemost hrsgs are and that the gas stream be clean. Nootereriksen heat recovery steam generators are customdesigned to meet your projectspecific needs. Failure mode effect analysis fmea on heat recovery steam. Remote steam drums for higher steam capacities or shipping restrictions. It also helps to arrive at the gas steam temperature profiles in a hrsg, which is basic to understanding and improving the hrsg performance. In more complex cases, spreadsheet balances or specialist flow sheet simulation software. The arrangement of the evaporator is such that the wet steam collects in the steam drum by the natural law of mass transfer.
Supplying complete solutions for hrsg units requires largescale facilities and extensive epc experience. Heat recovery steam generators hrsgs are important components for. Access 2001 summer specifications for access access 2002 winter hrsg inspection access. Heat recovery steam generator hrsg fundamentals euci. Heat recovery steam generators for large combined cycle. Model of a heat recovery steam generator hrsg process and. 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. See table 1 for an example of cyclic operation for an hp steam drum. 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 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.
For the hrsg, watertube type boiler is commonly adopted to accommodate the working pressure or capacity requirement of the system. Heat recovery steam generator hrsg solutions emerson. The steam drum is the primary interface between water and steam. It produces steam that can be used in a process cogeneration or used to drive a steam turbine combined cycle. In water tube boilers water goes through the tube and it gets converted to steam. Heat recovery steam generator hrsg in utility gebeng.
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. Learn the basics of hrsg inspection welcome to combined. Drum design design utilizes steam drum for storage volume and steam water separation. The fluid in the evaporator undergoes forced circulation by pump for both pressure levels. Today, operators of more than 600 hrsgs in over 40 countries consider vogt their onestop source for excellenceinheatrecovery. Superheater outlet combined cycle utility hrsg modular design multiple pressures. Instead theyve provided the nozzle fabrication details nozzleshell materials, thickneses, repads, etc for us to perform our own calculations. This results in enhanced availability for our customers with boiler reliability as high as 94%. Modeling of the complete system, including superheaters, economizers, evaporators, pumps, turbines, etc. Modeling, simulation, and control of steam generation processes. The following design features can be used for the hp drum to reduce shell thickness. 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. 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. Modeling and design of the heat transfer between the gas and steam side of a heat exchanger.
Our primary offering is a natural circulation design with horizontal exhaust flow and vertical tube design with internally insulated casing and structure. 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. Heat recovery steam generators hrsgs are waste heat boilers. Hp, ip, and lp drum level measurement is an example of this. A heat recovery steam generator hrsg is a type of heat exchanger between. 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.
Design boiler have developed software that is able to simulate the dynamic response of a boiler control system to rapid changes in boiler load. Siemens offers steam generation based on benson oncethrough technology or drumtype heat recovery steam generators. Storage volume is normally sized for swell and hold up time. Its difficult to believe that you will be asked to do more with a smaller budget, but you will. 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. 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.
Hrsg description the dual pressure heat recovery steam generator is. Will utilize ibd or start up drain for swell control. Higher temperatures and pressures along with the flows presented challenges for hrsg design. Hrsg heat recovery steam generator overview animation for nooter eriksen 3 drum hrsg with ammonia injection and duct burners. Design methodology of heat recovery steam generator in. Unit birwelco ccgt hrsg high pressure steam drum repair and upgrade duration.
Steam drum w integral deaerator 1 distribution grid 3 observation port 7 injection grid 8 s. Benson technology power plant solutions siemens global. The small hrsg market is served by several firms offering conventional drum type and oncethrough steam generators otsgs. The hrsg manufacturer takes the number and severity of the cycles into consideration when choosing the details used in the design of the hrsg. High pressure steam drum soak time remains a limiting factor in the startup ramp rate of hrsgs. Collection of 21 programs ranging from boiler duty,efficiency calculations,steam. The heat recovery steam generator hrsg is composed of numerous mechanical heating surface components superheaters, evaporators and economizers and steam drums. 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. Contact ge power to learn more about boilers for steam power plants.
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. For an advanced gt hrsgs design temperatures for the heating. Software designed to model and simulate hrsg operations can provide valuable information about corrosion and other operational problems. Steam is an essential element in the energy supply system. Heat recovery steam generators hrsg boilers product. 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. 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. Dynamic constraints on hrsg drum design turbo expo.
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. Difference between heat recovery steam generators hrsg. Each hrsg solution is customengineered to meet your desired operating flexibility and performance requirements. Vogt power internationaldesigns for all your hrsg needs. In its basic form these are bundles of water or steam carrying tubes paced in the hot gas flow path. Preparation of 3d model of boiler pressure and nonpressure parts using catia software. Tracing back over 5 years, vogt is credited with producing the very first hrsg, the first threepressurelevel hrsg, the first reheat hrsg and others. Hrsg parts heat recovery steam generator components ge power. What is the purpose of the steam drum on a water tube boiler. As an oem with a global workshop network, ge can offer standard and tailormade parts for all types of heat recovery equipment.
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. Modelling and practical studying of heat recovery steam generator. Nextgeneration hrsgs designed to start faster, cycle. 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. Hrsgs must be designed for cycling power engineering.
We supply boiler design, fabrication, installation, repair and maintenance. Hrsgs for next generation combined cycle plants power. 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. Hrsg simulation theory and examples boiler and hrsg. The main contribution of this paper is the development of a numerical. For a hrsg steam drum, does asme section i, mandate vacuum design check. The flow of gas is horizontal while the water is heated in verticallyarranged evaporator tubes, producing a natural, costeffective circulation effect. The heating surface elements are bare and finned tubes integrated with collector headers and interconnecting piping systems. Heat recovery steam generators for engines, incinerators, thermal oxidizers and catalytic converters. Topics to be covered include types of hrsgs, heat exchangers, boiler circulation systems, components, heat management, controls, water chemistry, emission controls, associated equipment.
Power plant staff need reliable information on process. 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. An hrsg is a kind of heat exchanger that recovers heat from the exhaust gases of a gas turbine to an. The steam generated by the hrsg is supplied to the steam turbine that drives the electrical generator system. One design feature includes the configuration of tube and headers in platens. Heat recovery steam generator hrsg 2 drum hrsg 3 drum. A leader in the supply of drum type boilers for gts rated up to 60 mw is rentech boiler systems of abilene, texas. Heat recovery steam generators 2 drum boilers keystone package steam generators vl boilers travagrate stokerssolid fuels experts in boiler startup. Ganapathy, abco industries g as turbines with heat recovery steam. If you are interested in reading one of our past articles, please contact us to request it. Adaptable modeling approach accor ding to the required level of detail. Asme section 1 steam drum nozzle analysis via nozzlepro.
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. Assists in proper and economical design for the expected operational conditions. Ganapathy 2003, problems such as corrosion are a main concern in keeping and maintaining the boilers and steam. 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. 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. Boiler group khi design and technical service, inc.
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. Coal fired boilers, bagasse boilers, rice husk boilers, husk boilers, wood boiler,other biomass boilers, lignite boiler and other industrial steam generators. Therefore, heat recovery steam generators hrsg are important components of many power plants. I hrsg designed for superior performance and advanced operations. Options for improving the efficiency of heat recovery steam. The heat is converted into usable steam by the heat transfer surfaces within the hrsg. 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. Dehai boiler is a manufacturer for aclass boiler power plant boiler, industrial boiler, hrsg, wastetoenergy boiler, biomass boiler etc. Design of dual pressure heat recovery steam generator for. Solid fuel fired steam generators upto 200,000 kghr and 550 degc can be designed. Design methodology of heat recovery steam generator in electric. Heat recovery steam generator wiki odesie by tech transfer.
Design considerations for advanced combined cycle plant using. The term hrsg refers to the waste heat boiler in a combined cycle power plant. Provides transfer of flue gases through the hrsg path installation of an auxiliary burner is possible here superheater. Sect i is intended for positive pressure above 15 psi. There are a variety of hrsg configurations and operating pressures. At the end all the water need not necessarily convert into steam. A number of design features can be applied to minimize the impact of cycling on the longevity of hrsg components. Reduction in drum size will lead to faster start up times control system conventional controls known by all operators. The level of detail and type of analysis will drive. 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. Due to the higher steam flow rates and temperatures caused by the.
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. What is the purpose of the steam drum on a water tube. Our special software for boiler thermal design, hrsg solution, provides customers with a wide range of calculations required for boiler thermal calculations as. Steam drums are used in hrsg to separate the water and steam from the evaporator. 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. Comparing between hrsg and boiler in parameters, design and operation. Heat transfer technology nem power plant solutions. Using thermohydraulic simulations to assess hrsg performance. Section 152590 heat recovery steam generator hrsg lp evaporator replacement. Our waterwall hrsg shares many design features with our industryleading direct fired packaged boilers. Tab 1 typical desing hybrid design difference high pressure. 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. For the purposes of this document two configurations have been considered.
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. Horizontal steam drum for heat recovery steam generator. In combinedcycle operations, a heat recovery steam generator hrsg serves the same purpose as a boiler. The steam turbine or a downstream process uses the steam. It produces steam that can be used in a process cogeneration or used. The results show that the maximum heat transfer occurs in the evaporator section for highpressure levels, and in the economizer section for lowpressure levels. Static thermal programs that predict steam flows, pressures and. Those variables are usually analyzed with design predicted performance of real. 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. Horizontal drum hrsg units are the most popular type of steam generator.
Steam drums provide the only nonintrusive access to the watersteam side of an fclass hrsg. Selecting the correct heat recovery steam generator hrsg for engine cogeneration chp and other industrial waste heat systems involves much consideration. The global economic downturn will impose new challenges on plant operations. 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. To this day, more than 100 benson heat recovery steam generators have either been commissioned or are currently being built. However, approaching these new challenges with a positive mindset can yield significant benefits. It is a gastowater heat exchanger that extracts energy. Books,software on boilers,hrsgs,steam plant calculations by v. 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.