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
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
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
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
Gas-Engines and Producer-Gas Plants
A Practice Treatise Setting Forth the Principles of Gas-Engines and Producer Design, the Selection and Installation of an Engine, Conditions of Perfect Operation, Producer-Gas Engines and Their Possibilities, the Care of Gas-Engines and Producer-Gas Plants, with a Chapter on Volatile Hydrocarbon and Oil Engines