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New Waste Heat Recovery System - Challenges and Solutions: Heimdal New Power Generator Project

This document summarizes the challenges and solutions for a new waste heat recovery system being installed on the Heimdal power generator project. Key points include: - A new cantilevered module will be installed in 2008 to capture waste heat from the gas turbine exhaust and use it to power a hot oil system. - Alternative configurations were evaluated, settling on locating the heat recovery unit in the bypass stream to avoid issues if hot oil leaked into the turbine. - Main challenges involve detecting and addressing potential hot oil leaks, preventing fires, and ensuring structural integrity during operation. - Design changes have been made to ducting, piping and valves to minimize leaks and vibrations at high temperatures. Detection

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Manuel Rosas
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107 views13 pages

New Waste Heat Recovery System - Challenges and Solutions: Heimdal New Power Generator Project

This document summarizes the challenges and solutions for a new waste heat recovery system being installed on the Heimdal power generator project. Key points include: - A new cantilevered module will be installed in 2008 to capture waste heat from the gas turbine exhaust and use it to power a hot oil system. - Alternative configurations were evaluated, settling on locating the heat recovery unit in the bypass stream to avoid issues if hot oil leaked into the turbine. - Main challenges involve detecting and addressing potential hot oil leaks, preventing fires, and ensuring structural integrity during operation. - Design changes have been made to ducting, piping and valves to minimize leaks and vibrations at high temperatures. Detection

Uploaded by

Manuel Rosas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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New Wast e Heat Rec over y Syst em c hal l enges and sol ut i ons

Heimdal New Power Generator Project


Prepared by:
Hydro: Unn Orstein, Project manager
Knuth Jahr, Mechanical Disipline Lead
Reinertsen: Morten Kongelf, Mechanical Discipline Lead
Petroleumstilsynet
Seminar exhaust stacks and waste heat recovery
2007-02-07
Page: 2
I nt r oduc t i on
l New cantilevered module to be installed on Heimdal summer 2008
- Reinertsen AS is engineering and fabrication contractor
l Gas turbine from GE: LM 1600 gas generator with PGT 16 power turbine
and ABB generator
- Iso rating 14 MW, Design case 10 MW
- Exhaust data:
- 40 kg/sec 492 oC (10 MW)
- 33.7 kg/sec 523 oC ( 7 MW) normal operating)
- Max temp: 597 oC (3-4 MW)
l 11 MW hot oil waste heat recovery package (including silencer) - Letter of
Intent to Kanfa-Tec mid January
- Procurement direct to KanfaTec and not via GE as planned
l The system has been improved - ref sgard B fire in the exhaust stack
2005, and other experiences
l The hot oil heat exchanger is located in the bypass to avoid:
- Hot oil leakage into the turbine
- Fire water inside the stack
Page: 3
WHRU - hot oil systems - challenges
l Leakage from tube bundle in traditional vertical exhaust stack
- Accumulates in bellows textile a special problem
- Tube rupture can result in > 3 M3 drainage to the turbine collector
- Fire - due to oxygen in the exhaust, air during rundown of turbine and the
chimney effect
l Detect the hydrocarbon in the exhaust before the fire starts
l Drainage of hot oil
l Fire fighting system
l Damage to turbine and turbine casing due to fire and water
l Leakage from flanges in the hot oil piping hitting warm surfaces
Page: 4
Al t er nat i ve c onf i gur at i ons eval uat ed
l Traditional configuration
with WHRU above the
turbine exhaust outlet
l WHRU in the bypass stream
Silencer not shown
Exhaust
Exhaust
Silencer shown partly
Drawings & photo from Kanfa-Tec
Page: 5
Mai n i ssues i n c ase of hot oi l l eak age
l Sump to collect hot oil leakage
- Separate tank not shown on figure, 3 m3
l Detect liquid in sump
- Drain test valve
- Level indication
l Bellows should avoid:
- small hot oil leakage into the exhaust
stream to collect in the textile and ignite
In case of leakage:
- Close the louver (shut off air flow)
- Nitrogen to inert the volume?
- Drain the bundle to recovery tank
- Fire water monitor on the LQ roof
Ideas:
- Detection of hydrocarbon in exhaust?
- Separate the 2 exhaust stream to avoid bellows?
Page: 6
Mat er i al sel ec t i on
l Ducting: AISI 321
- Max operating temperature is 597 0C at 25 oC ambient
- WHRU Supplier recommend design temperature of 593 oC
- Ambient temperature is normally well below the 25 oC
- Max operating temperature is a transient case and not a normal operating case
- Due to cooling of the outside of the duct
- Duct downstream the bundle is exposed to lower exhaust temperature
- AISI 321 is the standard material for GE Energy LM1600 Exhaust Collector.
l Heatexchanger tube bundle/fins: ASTM A 106 GrB
Page: 7
Duc t l eak ages
l Design changes to reduce vibrations
- avoid fatigue
- Rounded corners
- Minimum temperature gradients
- Avoid lifting ears or other additional
structures
- reduced swirls
- LM 1600 has trippel diffusers in the
Exhaust Collector
l Improved bolt design
- Thermobolt has been specified
- Bolt does not loose pre-tension during
turbine start cycle
- Lover loads on bolts
- Controlled compression loads on gasket
Page: 8
Reduc e pot ent i al f or hot oi l l eak age f r om
WHRU heat ex c hanger
l Improved bundle support
- Avoid U-clamps interfering with the tubes
- Possible tube contacts with screw, bolts etc is avoided
l Inspection of support of tube bundle during assembly
l The deck structure to be designed to reduce WHRU casing deflection
Page: 9
Leak age f r om hot oi l pi pi ng
l The following has been specified:
- The hot oil/supply and return lines shall be welded to the WHRU
l Flanges are minimized and located away from hot surfaces
Page: 10
Val ve c ompar i son
Louver selected
Pro
l Smoother regulation in almost
closed position
- Improved temperature control
l Improved flow distribution
l Lower torque and material stresses
l Pneumatic control system
Con
l Leakage rate is 0.04 %
l Pressure loss is higher not critcal
l More moving parts
Flap (new type used on Grane)
Pro
l Improved sealing to avoid
oveheating the oil/cracking
- Leakage rate 0.02 %
l Grane experience is positive
Con
l Hydraulic control is required due to
high torque required
l More expensive
l Higher weight
Page: 11
2 separ at e ex haust out l et s - i dea
Pro
l Avoid potential small hot oil leakage
into the exhaust to collect in the
textile in the bellow
l Reduce maintenance
- Remove 2 bellows
- Simplify removal of silencer and bundle
l Reduce weight
Con
l The reduced velocity in case of part
load will have effect on dispersion
Note:
Turbine has excess power and
a restriction in the outlet to increase
flow is possible
Page: 12
Ear l y det ec t i on of hydr oc ar bon l eak age - i dea
l Install suction probe downstream
hot oil heatexchanger
l Dual oven gas chromatographs to
detect the hot oil
- Large differance between exhaust and
hot oil fractions
l Plan to be issued for inquiry Februar
2007
Page: 13

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