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Cycling HRSGS: Jeffrey Phillips

The document summarizes a study on cycling heat recovery steam generators (HRSGs). The study reviewed problems encountered when operating HRSGs in cycling mode and identified best practices to avoid or minimize these issues. The two most important best practices for existing units are to conduct a design review to determine cyclic design conditions and remaining fatigue life, and to implement effective water lay-up procedures, especially using nitrogen. The document provides details on causes of thermal stress during cycling and discusses thermal stress-related problems such as fatigue damage from rapid ramping, with the high pressure steam drum being the most vulnerable component.

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Amir Joon
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77 views19 pages

Cycling HRSGS: Jeffrey Phillips

The document summarizes a study on cycling heat recovery steam generators (HRSGs). The study reviewed problems encountered when operating HRSGs in cycling mode and identified best practices to avoid or minimize these issues. The two most important best practices for existing units are to conduct a design review to determine cyclic design conditions and remaining fatigue life, and to implement effective water lay-up procedures, especially using nitrogen. The document provides details on causes of thermal stress during cycling and discusses thermal stress-related problems such as fatigue damage from rapid ramping, with the high pressure steam drum being the most vulnerable component.

Uploaded by

Amir Joon
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Cycling HRSGs

Jeffrey Phillips [email protected]

CTC2 HRSG Cycling Study


In 2001, Fern conducted a study for the Combustion Turbine Combined Cycle Users Group (CTC2) Issued CTC2 Report HSRG 20-14 On CTC2 best seller list (www.ctc2.org)

Study Goals
Review problems encountered when operating an HRSG in cycling mode Identify best practices that are employed to avoid or minimize these problems Results should be applicable to both existing plants and new units

Major Cycling-Related Problems


Four General Categories
Thermal stress related Water-related Exhaust gas side Other

Will focus on first two categories


Report covers all four

Best Practices for Existing Units


The Two Most Important Actions to Take:
Conduct a design review of the HRSG
Determine cyclic design conditions Assess remaining fatigue life Define ramping limits

Implement effective water lay-up procedures


Wet lay-up should use nitrogen or steam cap Dry lay-up: drain hot & use nitrogen cap

Other Actions
Use slower ramps Gradually reduce superheated steam T at shutdown
Moderates impact of CT purge on SH

Avoid or closely monitor Spin Cooling Add motor-operated drain valves on superheater and automate drain sequence

Other Actions
Keep HP drum P as high as possible during shutdowns
close all valves including blowdown import steam from another unit or aux. Boiler Add a stack damper or inlet garage door

Stack Damper

Garage Door on Inlet

Other Actions
For long-term shutdowns, add and circulate a octadecyl amine (ODA) to BFW
Forms a protective film on metal surfaces Then place unit in dry lay-up Film resists corrosion even if surfaces get wet

Add on-line water quality analyzers


pH of drum and conductivity of condensate

Summary: Remember 2 Things


Know what your HRSG is capable of withstanding!
Conduct a design review (or life cycle analysis for new units)

Implement good water lay-up practices


Hint: buy nitrogen

The rest is details


I.e., read the report!

Background Information
Causes of Thermal Stress During Cycling See notes portion of Powerpoint presentation for narrative

Thermal Stress
All metals expand when heated Amount of expansion is directly proportional to the change in temperature Unconstrained expansion does not generate stress, but
Constrained parts will be stressed Non-uniform temperatures also create stress

Steel Stress-Strain Curve

Yield Strength vs T
25 20

Allowable Stress (ksi)

15

SA-213-T91 SA-213-T22 SA-213-T11 SA-192 SA-178-A


10

0 600

700

800

900 Metal Temperature (deg F)

1000

1100

1200

Cyclic Stresses => Fatigue


Fatigue is damage caused by repeated application of cyclical stresses Fatigue will also cause a material to fail at stress levels below the yield strength The effects of fatigue are cumulative Fatigue is a function of the number of stress cycles and the magnitude of the cyclic stress

Fatigue Curves for Steel

Fatigue-driven Life Expenditure

Thermal Stress-Related Problems


Fatigue damage from rapid ramping
HP Steam Drum is the most vulnerable Ramp downs cause more damage to drum than ramp ups Less of a concern for steam systems <1500 psig (103 barg) Warm and hot starts can be faster due to smaller overall temperature change

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