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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
Seminar exhaust stacks and waste heat recovery
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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
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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
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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
Silencer shown partly
Drawings & photo from Kanfa-Tec
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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
- Detection of hydrocarbon in exhaust?
- Separate the 2 exhaust stream to avoid bellows?
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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
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Duc t l eak ages
l Design changes to reduce vibrations
- avoid fatigue
- Rounded corners
- Minimum temperature gradients
- Avoid lifting ears or other additional
- 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
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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
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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
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Val ve c ompar i son
Louver selected
l Smoother regulation in almost
closed position
- Improved temperature control
l Improved flow distribution
l Lower torque and material stresses
l Pneumatic control system
l Leakage rate is 0.04 %
l Pressure loss is higher not critcal
l More moving parts
Flap (new type used on Grane)
l Improved sealing to avoid
oveheating the oil/cracking
- Leakage rate 0.02 %
l Grane experience is positive
l Hydraulic control is required due to
high torque required
l More expensive
l Higher weight
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2 separ at e ex haust out l et s - i dea
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
l The reduced velocity in case of part
load will have effect on dispersion
Turbine has excess power and
a restriction in the outlet to increase
flow is possible
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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
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