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

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

    Uploaded by

    Manuel Rosas
    58 views13 pages
    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

    Original Description:

    Manual de usuario

    Original Title

    Hydro

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    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

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    58 views13 pages

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

    Uploaded by

    Manuel Rosas
    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

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 13

    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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