Dynamic behaviour analysis of a heat recovery steam generator during start‐up

This work presents an analysis of the dynamic behaviour of a HRSG (heat recovery steam generator) during start‐up. A calculation program based on a quasi‐steady method is constructed. A typical high‐pressure HRSG is designed conceptually and analysis is performed to examine the influence of the gas inlet condition of the HRSG on its start‐up behaviour. Effects of the gas turbine operation mode and the gas bypass are analysed. In addition, the water level control during start‐up, which is one of the most important facts in the real plant operation, is simulated. Through a parametric calculation, the effect of the control parameters on the start‐up behaviour is analysed and examples of optimum control are demonstrated. Copyright © 2000 John Wiley & Sons, Ltd.     

双压再热余热锅炉蒸汽参数优化与分析

本文对联合循环系统双压再热余热锅炉的蒸汽参数进行了优化研究,计算并总结了最优化的蒸汽压力、蒸汽流量以及回收量随余热锅炉进口燃气参数的变化规律．其结果对联合循环余热锅炉的优化设计县有理论意义和实用价值．     

Transient thermal modelling of heat recovery steam generators in combined cycle power plants

Heat recovery steam generator (HRSG) is a major component of a combined cycle power plant (CCPP). This equipment is particularly subject to severe thermal stress especially during cold start‐up period. Hence, it is important to predict the operational parameters of HRSGs such as temperature of steam, water, hot gas and tube metal of heating elements as well as pressure change in drums during transient and steady‐state operation. These parameters may be used for estimating thermal and mechanical stresses which are important in HRSG design and operation. In this paper, the results of a developed thermal model for predicting the working conditions of HRSG elements during transient and steady‐state operations are reported. The model is capable of analysing arbitrary number of pressure levels and any number of elements such as superheater, evaporator, economizer, deaerator, desuperheater, reheater, as well as duct burners. To assess the correct performance of the developed model two kinds of data verification were performed. In the first kind of data verification, the program output was compared with the measured data collected from a cold start‐up of an HRSG at Tehran CCPP. The variations of gas, water/steam and metal temperatures at various sections of HRSG, and pressure in drums were among the studied parameters. Mean differences of about 3.8% for temperature and about 9.2% for pressure were observed in this data comparison. In the second kind of data verification, the steady‐state numerical output of the model was checked with the output of the well‐known commercial software. An average difference of about 1.5% was found between the two latter groups of data. Copyright © 2007 John Wiley & Sons, Ltd.     

燃气轮机温度匹配功能在热应力控制的汽轮机应用

在燃气-蒸汽联合循环机组中,燃气轮机在不同工况下的排烟温度不同,使得整个燃气轮机联合循环 机组启动过程主蒸汽温度波动频繁,从而引起汽轮机启动过程中各金属部件温差增大,热应力和热变形也随 着增加。GE公司的6503燃气轮机的温度匹配功能和汽轮机热应力计算监控模块相结合,可以通过实时控 制主蒸汽温度实现对汽轮机转子热应力的有效监视和控制,减少设备损坏。     

Thermodynamic analysis of a tri-generation system based on micro-gas turbine with a steam ejector refrigeration system

In the present work, performance of new configuration of Micro-gas turbine cogeneration and tri-generation systems, with a steam ejector refrigeration system and Heat recovery Steam Generator (HRSG) are studied. A micro-gas turbine cycle produces 200 KW power and exhaust gases of this micro-gas turbine are recovered in an HRSG. The main part of saturated steam in HRSG is used through a steam ejector refrigeration system to produce cooling in summer. In winter, this part of saturated steam is used to produce heating. In the first part of this paper, performance evaluation of this system with respect to Energy Utilization Factor (EUF), Fuel Energy Saving Ratio (FESR), thermal efficiency, pinch point temperature difference, net power to evaporator cooling load and power to heat ratio is carried out. It has been shown that by using the present cogeneration system, one can save fuel consumption from about 23% in summer up to 33% in winter in comparison with separate generation of heating, cooling and electricity.     

Thermo‐Economic Analysis and Multiobjective Optimization of Dual Pressure Combined Cycle Power Plant with Supplementary Firing

The heat recovery steam generator (HRSG) and duct burner are parts of a combined cycle which have considerable effect on the steam generation. The effect of the gas turbine, duct burner and HRSG on power generation is investigated to reduce exergy destruction and power loss in the gas turbine. The results show that with an increase in duct burner flow rate, pressure loss in the recovery boiler increases, steam generation increases on the HP side while it decreases on the LP side. With a reduction in the HP pinch point, thermal recovery increases while the LP pinch point does not have a significant effect. Then, power loss due to pressure drop in the gas turbine and the electricity cost are considered as two objective functions for optimization. Finally, the sensitivity analysis on ambient temperature, compressor pressure ratio, fuel lower heating value, duct burner fuel rate, condenser pressure and main pressure are performed and results are reported. It is concluded that with an increment in compressor pressure ratio, the duct burner flow rate and consequently steam generation increases while electricity cost decrease.     

Optimal thermodynamic and economic volume of a heat recovery steam generator by constructal design

The ratios of gas flow to steam flow are huge in heat recovery steam generators (HRSGs) compared to other steam generators. So the volume which is occupied by components of the HRSG such as economizer, evaporator and superheater is important factor when the HRSG is applied in structures including buildings and ships. The optimum volume of a HRSG is deduced through optimization of entropy generation and cost evaluation. By increasing volume, second law of thermodynamics is improved, but this improvement may not be economical. In this work, the best dimensions and arrangements of flows in HRSG are obtained by constructal design and the optimization method is algorithm genetic. In this case, super heater temperature, pinch point, water/steam flow rate and gas pressure drop are derived from configuration which designed by constructal theory for HRSG. The effects of gas flow rate and inlet gas temperature are examined on the values of optimum volume.     

Influence of the heat recovery steam generator design parameters on the thermoeconomic performances of combined cycle gas turbine power plants

This paper proposes a methodology to identify the most relevant design parameters that impact on the thermal efficiency and the economic results of combined cycle gas turbine power plants. The analysis focuses on the heat recovery steam generator (HRSG) design and more specifically on those operating parameters that have a direct influence on the economic results of the power plant. These results are obtained both at full and part load conditions using a dedicated code capable of simulating a wide number of different plant configurations. Two different thermoeconomic models aimed to select the best design point are proposed and compared: the first one analyzes the generating cost of the energy while the second one analyzes the annual cash flow of the plant. Their objective is to determine whether an increase in the investment in order to improve the thermal efficiency is worth from an economic point of view. Both models and the different HRSG configurations analysed are compared in the results section. Some parametric analysis show how the design parameters might be varied in order to improve the power plant efficiency or the economic results. Copyright © 2004 John Wiley & Sons, Ltd.     

余热锅炉快速启动的影响因素及实现措施分析

根据余热锅炉的运行及研究现状,阐述余热锅炉快速启动的意义及余热锅炉的启动方式,分析余热锅炉快速启动的影响因素,对实现余热锅炉安全、快速启动的措施进行了论述。     

A performance analysis of integrated solid oxide fuel cell and heat recovery steam generator for IGFC system

Solid oxide fuel cell (SOFC) is a promising technology for electricity generation. Sulfur-free syngas from a gas-cleaning unit serves as fuel for SOFC in integrated gasification fuel cell (IGFC) power plants. It converts the chemical energy of fuel gas directly into electric energy, thus high efficiencies can be achieved. The outputs from SOFC can be utilized by heat recovery steam generator (HRSG), which drives the steam turbine for electricity production. The SOFC stack model was developed using the process flow sheet simulator Aspen Plus, which is of the equilibrium type. Various ranges of syngas properties gathered from different literature were used for the simulation. The results indicate a trade-off efficiency and power with respect to a variety of SOFC inputs. The HRSG located after SOFC was included in the current simulation study with various operating parameters. This paper describes IGFC power plants, particularly the optimization of HRSG to improve the efficiency of the heat recovery from the SOFC exhaust gas and to maximize the power production in the steam cycle in the IGFC system. HRSG output from different pressure levels varies depending on the SOFC output. The steam turbine efficiency was calculated for measuring the total power plant output. The aim of this paper is to provide a simulation model for the optimal selection of the operative parameters of HRSG and SOFC for the IGFC system by comparing it with other models. The simulation model should be flexible enough for use in future development and capable of predicting system performance under various operating conditions.     

A performance analysis of integrated solid oxide fuel cell and heat recovery steam generator for IGFC system

Solid oxide fuel cell (SOFC) is a promising technology for electricity generation. Sulfur-free syngas from a gas-cleaning unit serves as fuel for SOFC in integrated gasification fuel cell (IGFC) power plants. It converts the chemical energy of fuel gas directly into electric energy, thus high efficiencies can be achieved. The outputs from SOFC can be utilized by heat recovery steam generator (HRSG), which drives the steam turbine for electricity production. The SOFC stack model was developed using the process flow sheet simulator Aspen Plus, which is of the equilibrium type. Various ranges of syngas properties gathered from different literature were used for the simulation. The results indicate a trade-off efficiency and power with respect to a variety of SOFC inputs. The HRSG located after SOFC was included in the current simulation study with various operating parameters. This paper describes IGFC power plants, particularly the optimization of HRSG to improve the efficiency of the heat recovery from the SOFC exhaust gas and to maximize the power production in the steam cycle in the IGFC system. HRSG output from different pressure levels varies depending on the SOFC output. The steam turbine efficiency was calculated for measuring the total power plant output. The aim of this paper is to provide a simulation model for the optimal selection of the operative parameters of HRSG and SOFC for the IGFC system by comparing it with other models. The simulation model should be flexible enough for use in future development and capable of predicting system performance under various operating conditions.     

燃气-蒸汽联合循环热效率关于耦合参数的关系式

在考虑实际影响因素的前提下,推导出燃气轮机热效率关于耦合参数的关系式。以三压有再热余热锅炉的燃气-蒸汽联合循环为例,推导出非补式余热锅炉型蒸汽轮机热效率关于耦合参数的关系式,在此基础上得到了燃气-蒸汽联合循环热效率关于耦合参数的关系式。为研究燃气-蒸汽关于耦合参数的优化研究提供理论依据。     

联合循环机组"炉跳机"事故原因分析及技术改造

采用“二拖一”运行方式的联合循环机组,当一台余热锅炉出现故障而跳炉时,如不及时处理会引起汽轮机误跳,进而使另一台余热锅炉跳炉。这几年,镇海联合循环机组此类事故频发,影响了机组的稳定运行。本文介绍该厂针对此类汽轮机误跳现象,在确保主设备安全的前提下,对锅炉部分保护逻辑进行了修改,以减少汽轮机误跳几率,确保汽轮机稳定运行。     

Availability analysis of heat recovery steam generators used in thermal power plants

The combined-cycle gas and steam turbine power plant presents three main pieces of equipment: gas turbines, steam turbines and heat recovery steam generator (HRSG). In case of HRSG failure the steam cycle is shut down, reducing the power plant output. Considering that the technology for design, construction and operation of high capacity HRSGs is quite recent its availability should be carefully evaluated in order to foresee the performance of the power plant.This study presents a method for reliability and availability evaluation of HRSGs installed in combined-cycle power plant. The method’s first step consists in the elaboration of the steam generator functional tree and development of failure mode and effects analysis. The next step involves a reliability and availability analysis based on the time to failure and time to repair data recorded during the steam generator operation. The third step, aiming at availability improvement, recommends the fault-tree analysis development to identify components the failure (or combination of failures) of which can cause the HRSG shutdown. Those components maintenance policy can be improved through the use of reliability centered maintenance (RCM) concepts. The method is applied on the analysis of two HRSGs installed in a 500 MW combined-cycle power plant.     

基于有限元的汽轮机调节级温度场研究

针对汽轮机在启停以及变负荷运行等非稳定工况时,主要部件温度梯度较大,导致机组寿命损耗.利用ANSYS有限元分析软件,通过对汽轮机调节级温度场进行仿真,为其他各级进行建模仿真以及整个汽轮机转子的温度分布和热应力分析提供了理论基础,并为机组的启动优化提供了参考.     

燃气-蒸汽联合循环余热锅炉技术研究现状

燃气-蒸汽联合循环技术发展迅速，余热锅炉处于燃气轮机和蒸汽轮机之间，是燃气-蒸汽联合循环电站的三大主要设备之一。论述了国内外关于余热锅炉在受热面布置、烟气流动特性、热力参数优化、快速启停和变工况运行等方面的研宛现状，并指出了其中的不足。对联合循环余热锅炉的研宛开发和优化谩计有一定的参考意义。     

Exergy based performance analysis of a solid oxide fuel cell and steam injected gas turbine hybrid power system

This paper presents exergy analysis of a hybrid solid oxide fuel cell and gas turbine (SOFC/GT) system in comparison with retrofitted system with steam injection. It is proposed to use hot gas turbine exhaust gases heat in a heat recovery steam generator to produce steam and inject it into gas turbine. Based on a steady-state model of the processes, exergy flow rates are calculated for all components and a detailed exergy analysis is performed. The components with the highest proportion of irreversibility in the hybrid systems are identified and compared. It is shown that steam injection decreases the wasted exergy from the system exhaust and boosts the exergetic efficiency by 12.11%. Also, 17.87% and 12.31% increase in exergy output and the thermal efficiency, respectively, is demonstrated. A parametric study is also performed for different values of compression pressure ratio, current density and pinch point temperature difference.     

余热锅炉带辅助蒸汽加热的高压下降管集箱优化设计

在余热锅炉高压蒸发器系统中的集箱部位加装一套辅助蒸汽加热管系,对高压锅筒进行预热,能很好地降低启动时高压锅筒的热应力,加快机组的启动速度。针对原有集箱蒸汽加热系统汽、水混合不均匀,热胀差大的设计结构缺陷,进行了相应的结构优化设计。通过跟踪实际项目的运行情况发现,优化后的集箱加热管系能够有效减小余热锅炉冷态启动到满负荷启炉运行时间,从原来的6 h降到4 h,经济效益明显。     

Exergy and Energy Analysis of Combined Cycle systems with Different Bottoming Cycle Configurations

The paper deals with thermodynamic analysis of cooled gas turbine‐based gas‐steam combined cycle with single, dual, or triple pressure bottoming cycle configuration. The cooled gas turbine analyzed here uses air as blade coolant. Component‐wise non‐dimensionalized exergy destruction of the bottoming cycle has been quantified with the objective to identify the major sources of exergy destruction. The mass of steam generated in different configurations of heat recovery steam generator (HRSG) depends upon the number of steam pressure drums, desired pressure level, and steam temperature. For the selected set of operating parameters, maximum steam has been observed to be generated in the case of triple pressure HRSG = 19 kg/kg and minimum in single pressure HRSG = 17.25 kg/kg. Plant‐efficiency and plant‐specific works are both highest for triple‐pressure bottoming cycle combined cycle. Non‐dimensionalized exergy destruction in HRSG is least at 0.9% for B3P, whereas 1.23% for B2P, and highest at 3.2% for B1P illustrating that process irreversibility is least in the case of B3P and highest in B1P. Copyright © 2012 John Wiley & Sons, Ltd.     

Performance Improvement of Combined Cycle Power Plant Based on the Optimization of the Bottom Cycle and Heat Recuperation

Many F class gas turbine combined cycle(GTCC)power plants are built in China at present because of less emis-sion and high efficiency.It is of great interest to investigate the efficiency improvement of GTCC plant.A com-bined cycle with three-pressure reheat heat recovery steam generator(HRSG)is selected for study in this paper.In order to maximize the GTCC efficiency,the optimization of the HRSG operating parameters is performed.Theoperating parameters are determined by means of a thermodynamic analysis,i.e.the minimization of exergylosses.The influence of HRSG inlet gas temperature on the steam bottoming cycle efficiency is discussed.Theresult shows that increasing the HRSG inlet temperature has less improvement to steam cycle efficiency when itis over 590℃.Partial gas to gas recuperation in the topping cycle is studied.Joining HRSG optimization with theuse of gas to gas heat recuperation,the combined plant efficiency can rise up to 59.05% at base load.In addition,the part load performance of the GTCC power plant gets much better.The efficiency is increased by 2.11% at75% load and by 4.17% at 50% load.