Report H10245 - HP Evaporator Analysis

HRSG Evaporator Analysis

Pluspetrol International

HRST Ref. No.: H10245
Report Date: November 8, 2010

Report H10245 Pluspetrol International
November 8, 2010

Contents
Background ................................................................................................................................................... 3
Mission ....................................................................................................... Error! Bookmark not defined.
Executive Summary ....................................................................................................................................... 4
Failure Sequence ....................................................................................................................................... 4
Recommended Solution ............................................................................................................................ 4
Discussion ..................................................................................................................................................... 5
Failure Characteristics ............................................................................................................................... 5
Analysis Performed ................................................................................................................................... 7
Findings ..................................................................................................................................................... 8
Conclusions ................................................................................................................................................. 11

Analysis Summary Data ................................................................................................................ Appendix A

2
300 Scarlet Blvd Phone: 813‐855‐4688
Oldsmar, FL 34677 Fax: 813‐354‐4533
www.hrstinc.com Email: bcraig@hrstinc.com

November 8, 2010

Background

HRST was hired by Pluspetrol International to analyze the effects of exhaust gas bypass on the
HP evaporators of two horizontal tube (vertical gas flow) HRSGs located in Tucuman, Argentina.
The scope of supply of this study includes the following:
1. Generate a computer performance model of the HP evaporator section of this HRSG.
2. Model the effect of exhaust gas bypass on steam exit quality and flow regime in tubes
located along sidewalls, compared to those within the tube bundle.
3. Prepare a report explaining the analysis performed, and making baffle modification
recommendations based on the analysis.
4. Report will also include recommendations for tube replacement, and additional
inspection / NDE to be performed to ensure the existing tubes are suitable for future
service.

These are forced circulation evaporators, meaning that they require a circulation pump to force
water through the heat transfer tube bundles. These evaporators have 20 rows of tubes, with
four rows flowing in parallel to one another. I.E. the steam/water flow makes five passes across
the exhaust gas stream.

Pass 5
Pass 4
Pass 3
Pass 2
Pass 1

20‐Row, 5‐Pass Evaporator

Multiple tube failures have occurred in the HP evaporators of these HRSGs over a period of
several years. HRST understands that all tube failures to date have occurred in tubes that are
adjacent to the sidewalls.
3
Oldsmar, FL 34677 Fax: 813‐354‐4533

November 8, 2010

Executive Summary
Failure Sequence
1. The evaporator, as designed, has a marginal (low) water flow, leaving little margin for
side‐to‐side variance.
2. High gas flow along the walls drives high heat absorption by the tubes adjacent to the
wall.
3. The tubes adjacent to the wall generate more steam than the center tubes thereby
reducing the water flow to the sidewall tubes.
4. The combination of increased heat absorption and reduced water flow results in
localized dry‐out near the outlet of the sidewall tubes.
5. Deposits collect in the dry zones.
6. The deposits restrict the tubes and further reduce the water flow.
7. Low flow in the water inlet side of the tubes causes flow stratification failures in the
water inlet area of the tubes.

Recommended Solution
1. Eliminate the possibility of any partially plugged or damaged tubes either through
boroscope inspection or replacement.
2. Install no less than three intermediate side‐wall baffles besides restoring the top and
bottom baffle.
3. Upgrade the circulation pumps with a goal of 50% flow increase, if possible. Any flow
increase would be beneficial.

4
Oldsmar, FL 34677 Fax: 813‐354‐4533

November 8, 2010

Discussion
Failure Characteristics
HRST was provided tube samples comprised of sections of failed tubes from this site. Two
different failure modes are apparent. The photos below were taken of the samples.

Figure 1. High deposit loading indicates dryout. This is most likely to occur in tubes near the
outlet of the tube bundle (i.e. passes 4 and 5) where the heat flux is higher and the water flow
is lower than intended by the designers.

Figure 2. Thinning characteristics indicate stratified flow in tube. This is most likely to occur
near the inlet to the tube bundle if the flow in the tube is lower than intended by the designers.
5
Oldsmar, FL 34677 Fax: 813‐354‐4533

November 8, 2010

HRST believes the root cause of the failures is high heat flux due to exhaust gas bypass. The
sketch below illustrates how a lack of intermediate sidewall baffles can result in bypass and
high heat flux in tubes adjacent to the sidewalls. Because this is a very deep coil, the front and
back baffles do not sufficiently reduce bypass.

6
Oldsmar, FL 34677 Fax: 813‐354‐4533

November 8, 2010

Analysis Performed
A thermal‐hydraulic model of the HP evaporator was created for the purpose of doing this
analysis. HRST’s model includes proven performance correlations that are routinely used for
designing and rating heat transfer equipment. Heat flux calculations and the effects of exhaust
gas bypass are part of this analysis. It is based on the specific tube and fin geometry of the
Tucuman HRSGs.

The results of this were then used to check for dryout and flow stratification. Flow regime
analysis was done using a proprietary method of horizontal two‐phase flow regime analysis.

Analysis was performed for the following cases:

Case 1A: Full cycle (2 on 1) operation with duct firing, unit A
Case 1B: Full cycle (2 on 1) operation with duct firing, unit B
Case 2B: Half cycle (1 on 1) operation with no duct firing, unit B

Since there are four rows of tubes flowing in parallel throughout the evaporator (each making 5
passes across the exhaust gas path), the analysis was also done on a circuit by circuit basis.
Circuits were labeled A, B, C, and D, as follows:

Circuit A: Rows 1, 8, 9, 16, 17
Circuit B: Rows 2, 7, 10, 15, 18
Circuit C: Rows 3, 6, 11, 14, 19
Circuit D: Rows 4, 5, 12, 13, 20
7
Oldsmar, FL 34677 Fax: 813‐354‐4533

November 8, 2010

Findings
The tables below summarize the thermal modeling results for Case 2B, which was found to be
the worst case of the operating cases modeled. Data summaries for all three cases are included
in the appendix of this report.

1 on 1 operation, base load with
Case 2B duct firing, HRSG B
Exh Gas Mass Flow 3265000 lb/hr
Exh Gas Inlet Temp 828 deg F
Exh Gas Outlet Temp 525 deg F
Steam Flow 370,206 lb/hr
Steam Outlet
Pressure 674 psig
Gas flow fraction to sidewall
Gas Flow Fraction 0.0511 tubes.
Overall Circ Ratio 2.64
Non- Sidewall
sidewall tubes
Gas dP 3.25 3.25 in w.g.
Stm/Wtr dP 2.45 2.44 psi
Circ Ratio 2.7 1.46
Stm Prod/Circuit 1426 2072 lb/hr
Water Flow/Circuit 3850 3025 lb/hr
Outlet Steam Quality, Circuit by Circuit Basis:

Average Circuit A Circuit B Circuit C Circuit D
Sidewall Tubes 0.68 0.81 0.75 0.62 0.60
Non-Sidewall Tubes 0.37 0.43 0.38 0.35 0.33

This summary is based on the current configuration, with sidewall baffles at the inlet and outlet
only. The significant finding in these results is that the outlet steam quality (the mass fraction
that is steam), is very high in the sidewall tubes. By definition, complete dryout occurs when
steam quality reaches 1.0. However, local dryout can occur at steam qualities less than 1.0, if
the heat flux is not uniform around the tube’s circumference. In this situation with exhaust gas
bypass causing high heat flux, we expect the heat flux on the side of the tube close to the
sidewall to be much higher than on the other side of the same tube. Therefore, HRST believes
dryout is likely to occur under these operating conditions.

8
Oldsmar, FL 34677 Fax: 813‐354‐4533

November 8, 2010

It should be noted that the average steam quality exiting this evaporator is 0.38. Average exit
quality is simply a function of the mass flow of steam produced and the mass flow of the
circulating water flow:

An average exit quality of 0.38 is high in HRST’s opinion. HRST’s internal design guidelines
require steam quality not to exceed 0.25 in HP evaporators. While this is somewhat
conservative, we would not recommend operating with exit quality exceeding 0.50 in any
tubes, particularly in sidewall tubes where non‐uniform heat flux occurs. In the above
summary, the exit quality ranges up to 0.81 in the tubes adjacent to the sidewalls.

The above analysis was performed for several alternate configurations with additional baffles
installed. The significant results are summarized below.

Case 2B: One on one operation, unit B
Sidewall tubes Non‐sidewall tubes
Average Average
Exit Max Exit Exit Max Exit
Mod Description of Modification Quality Quality Quality Quality
Current, as‐is with baffles at inlet
-- and outlet 0.68 0.81 0.37 0.44
Mod1 Add one baffle, at center 0.56 0.68 0.37 0.43
Mod2 Add two baffles, at rows 6 & 14 0.48 0.56 0.38 0.43
Mod3 Add three baffles 0.42 0.48 0.38 0.43
Mod4 Add four baffles 0.38 0.44 0.38 0.44

This analysis was also performed for Cases 1A and 1B. The results were similar to Case 2B, but
as already noted, Case 2B was found to be the worst case.

Flow regime analysis did not indicate flow stratification in any tubes at any operating point.
HRST believes stratification has occurred however, based on the appearance of the tube in
figure 2. This would require a lower water flow rate than predicted by the above analysis. This
can be explained as follows: Once dryout occurs and deposits form in these tubes, the flow
resistance increases. Increased flow resistance reduces the water inflow to the sidewall tubes.

9
Oldsmar, FL 34677 Fax: 813‐354‐4533

November 8, 2010

The effect of deposits on flow resistance and flow rate can be dramatic. It cannot be analyzed
precisely, because we have no way to determine the exact quantity of and shape of the
deposits in the tubes, which affect the pressure drop characteristics. However, we can do some
approximate analysis:

• In the figure 1 photo, the effective internal diameter of the tube is reduced to
approximately 70% of the clean tube diameter. Therefore the flow area is reduced to
approximately 50% that of a clean tube.
 This increases pressure drop 4X due to reduced flow area (in affected area)
• L/D ratio (length/diameter) also affects pressure drop. When internal diameter is
reduced, this ratio increases.
 Additional 1.4X delta‐P in affected area
• The deposits have a very rough texture compared to that of a clean tube. Relative
roughness is on the order of 0.1.
 Additional 3.6X delta‐P due to increased friction factor relative to clean tubes
• Net Effect of Deposits
 Pressure drop in affected area is 20X that of a clean tube
 If an entire flow circuit was affected by flow restriction, we would expect a 78%
reduction in flow rate to affected circuit.
 If 20% of the length of a flow circuit is affected by flow restriction, we would
expect a 59% reduction in flow rate to the affected circuit.

The bullet points above provide a rough summary of the effect of deposits on flow rate through
the tubes. If we assume one full tube length (I.E. one of five passes, or 20% of total circuit
length) is fouled with deposits similar to those shown in figure 1, then the flow regime analysis
does predict stratification.

10
Oldsmar, FL 34677 Fax: 813‐354‐4533

November 8, 2010

Conclusions

The root cause of the HP evaporator tube failures in the Pluspetrol HRSG’s is exhaust gas bypass
combined with a relatively low circulating water flow rate. This analysis indicates the problem
can be corrected by replacing all tubes that currently have deposits in them, and installing three
or more intermediate sidewall baffles, in addition to the baffles already located at the inlet and
outlet of the tube bundle. Upgrading the circulation pump capacity would provide increased
safety margin.

HRST will provide drawings of an engineered baffle design which is suitable for retrofit.

REPORT BY:

Bryan F. Craig, PE

_________________________________
Robert Krowech, PE
President

REPORT DATE: November 8, 2010

11
Oldsmar, FL 34677 Fax: 813‐354‐4533

APPENDIX

Analysis Summary Data

Analysis Summary 1A:
Case 1A duct firing, HRSG A
Steam Outlet
Pressure 1151 psig
Non- Sidewall
sidewall tubes
Gas dP 3.77 3.77 in w.g.
Circ Ratio 2.74 1.48

Sidewall Tubes 0.6756757 0.7979128 0.733181 0.607931 0.587464

Effect of Adding Baffles, Case 1A:
Average Average
-- and outlet 0.68 0.80 0.36 0.43

Analysis Summary 1B:
Case 1B duct firing, HRSG B
Steam Outlet
Pressure 1145 psig
Non- Sidewall
sidewall tubes
Gas dP 3.53 3.53 in w.g.
Circ Ratio 2.89 1.58

Sidewall Tubes 0.6329114 0.7438094 0.685741 0.570897 0.552277

Effect of Adding Baffles, Case 1B:
Average Average
-- and outlet 0.63 0.74 0.35 0.40

Analysis Summary 2B:
1 on 1 operation, base load
Case 2B without duct firing, HRSG B
Steam Outlet
Pressure 674 psig
Non- Sidewall
sidewall tubes
Gas dP 3.25 3.25 in w.g.
Stm/Wtr dP 2.45 2.44 Psi
Circ Ratio 2.7 1.46

Sidewall Tubes 0.68 0.81 0.75 0.62 0.60

Effect of Adding Baffles, Case 2B:
Average Average
-- and outlet 0.68 0.81 0.37 0.44

Report H10245 - HP Evaporator Analysis

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Report H10245 - HP Evaporator Analysis

Uploaded by

Copyright:

Available Formats

Outlet Steam Quality, Circuit by Circuit Basis:

Outlet Steam Quality, Circuit by Circuit Basis:

Outlet Steam Quality, Circuit by Circuit Basis:

Outlet Steam Quality, Circuit by Circuit Basis:

You might also like