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UA=Q/ T
In the off-design case,we know the new gas flow & temperature.It is desired to obtain the temperature profiles and steam flows. Calculation is tedious as surface area is indirectly known. Correct (UA) for effects of gas flow,temperature and analysis and solve for: Q=(UA)c T In typical design,we compute U and then A for each surface.In simulation we compute (UA) and hence there is no need to physically the HRSG in terms of tube size,fin density etc.Hence anyone familiar with heat balances can perform these studies. Consultants,plant engineers,project planners can use this method to evaluate HRSG performance without even knowing its size!They need not also contact a HRSG supplier!
approach point,F
130-150 80-130
30-60 10-30
40-70 10-40
Facts Pinch about Pinch and Approach Points and Approach points are selected in unfired mode at
Design gas flow,exhaust gas temperature.These are called design pinch and approach points Once selected,they fall in place in other cases of gas flow/inlet gas temperature/steam conditions,whether unfired or fired. Pinch/approach points increase with inlet gas temperature They cannot be arbitrarily selected
-temperature cross can occur -low pinch point may not be physically feasible unless extended surfaces are used -affected by inlet gas temperature -economizer steaming is a concern ;suggest minimum approach at coldest ambient HRSG conditions -steam temperature can be achieved in fired conditions if it is achieved in unfired conditions HRSG surfaces are determined once design pinch/approach points are selected
Dividing (1) by (3) and neglecting effect of variations in Cpg with temperature,we have: (tg1-tg3)/ (tg1-tg4)= (hso-hw2)/ (hso-hw1)=K For steam generation to occur and for a thermodynamically feasible temperature profile,two conditions must be met: If pinch and approach points are arbitrarily selected,one of these may not be met. Psig 100 150 250 400 400 600 600 (3) stm temp,F sat sat sat sat 600 sat 750 sat temp,F 338 366 406 448 450 490 492 K .904 .8704 .8337 .7895 .8063 .7400 .7728 exit gas,F 300 313 332 353 367 373 398
Temperature calculations
Example 1: Determine HRSG exit gas temperature when inlet gas temperature=900 F,steam press=100 psig.use 20 F pinch and 15 F approach points. Solution:K=0.904 sat temp=338 F.hence tg3=358F.tw2=323 F.(900-358)/(900-tg4)=0.904 or tg4=300 F Example 2: what is tg4 when steam press=600 psig and temp=750 F? Solution:K=0.7728.sat temp=492 F.tw2=477F.tg3=512 F.(900-512)/(900-tg4)=0.7728 or tg4=398 F.So 300 F stack temperature is not feasible! Example 3:Why cant we obtain 300 F at 600 psig,750 F steam? Solution:K=0.7728 Let us compute tg3 from:(900-tg3)/(900-300)=0.7728 or tg3=436 F.This is called temperature cross! Example 4:What should be done to get 300 F stack temperature? Solution:Increase tg1 by firing.say tg1=1600 F.(1600-tg3)/(1600-300)=0.7728 or tg3=595 F and pinch=103 F. Example 5:If tg1=800F,what is tg4 at 100 psig sat? Solution:(800-358)/(800-tg4)=0.904 or tg4=312 vs 300 F when tg1 was 900F. Example 6:With 1600 F gas inlet,can we use 20 F pinch? Solution:(1600-512)/(1600-tg4)=0.7728 or tg4=192 F,which is below 230 F.Not feasible! Thats why pinch & approach points should not be selected in the fired mode!We have no idea in what range they can fall.
Off-design Performance
Simulate the HRSG performance with a 165,000 lb/h of gas flow at 880 F.Steam pressure =150 psig. Using the model for evaporators discussed elsewhere,ln[(980-388)/(408388)]=Kx140000-0.4 or K=387.6 Under new conditions: ln[(880-366)/(Tg366)]=387x165000-0.4 =3.1724 or Tg=388 F.Evaporator duty=165000x.99x.27x(880388)=21.7 MM Btu/h In order to determine the steam flow,the feed water temperature to evaporator must be known.Try 360 F.Then steam flow=21.7x106/[1195.7-332)+.05x(338.5332)]=25,110 lb/h. Economizer duty(assumed) Qa=25110x1.05x(332-198.5)=3.52MM Btu/h.Compute (US)d=Q/T for economizer based on design conditions. Q=3.84x106 T =[(408-373)-(299-230)]/ln[(69/35)]=50 F.(US)d=3840000/50=76800. Correct this for off-design case. (US)p=(US)dx(165000/140000).65=85200.The effect of variations in gas temperature is minor and not considered. The energy transferred =(US)p xT. Based on 360F water exit temperature,the economizer duty=3.52MM Btu/h and gas temperature drop=3520000/(165000x.99x.253)=85 F or exit gas =388-85=303 F.T=[(303-230)-(388-350)]/ln[(73/28)]=47 F or transferred duty=85200x47=4.00 Mm Btu/h.As this does not match the assumed value of 360F and duty ,another iteration is required. It can be shown at 366 F,the balance is obtained.
Superheater performance
Performance of a superheater is obtained from: Q=(US)pT T=[(Tg1-ts2)-(Tg2ts2)]/ln[(Tg1-ts2)/(Tg2-ts2)] (US)p is obtained from design (US) values as follows: (US)p=Wg0.65FgK1(Ws/Wsd)0.15 where K1=a constant obtained from design case = Q1/(T Wg0.65Fg) where Fg = (Cp0.33k0.67/m0.32).Basically we are correcting for the effects of: 1.Gas flow 2. gas analysis, gas temperature and hence gas properties, which is significant if the superheater operates say in unfired and fired modes. Similar constants K2,K3 may be evaluated for evaporator and economizer. Example:In design mode, gas flow=150,000 lb/h.Gas in=900F and leaving SH=842F. steam flow=18510 lb/h.steam pressure=450 psig. steam in=460F,out=650F.duty=2.34 MM Btu/h Cp=.273,m=.0826 ,k=.029. Fg=.2730.33x.0290.67/.08260.32=0.135.T=[(842460)-(900-650)]/ln[(842-460)/(900-650)] = 311F.Hence K1=2.34x106/(311x.135x1500000.65) =24.1 Off-design:steam flow=18050 lb/h,gas flow=165000,gas in=840F.steam pressure=450 psig.Let exit steam temp=640F.Duty=18050x(1325-1204.4)=2.177MM Btu/h. Exit gas=840-2177000/165000/.99/.271=791F. Since gas temperatures are close, Use same Fg=0.135. (US)p=1650000.65x0.135x24.1x(18050/18510)0.15=7974. T=[(840-640)(791-460)]/ln[(840-640)-(791-460)]=260F. Hence Qt=7974x260=2.074MM Btu/h. This is close to the assumed value, else another iteration would be required. The NTU method may also be used here by using the new US term.
Gas flow=550,000 lb/h pinch=20 F approach=20F,make up=60 F,cond pr=2.5 in hg,steam at 620 psig,650F
temperature profiles,duty and steam flows.In the design case,solve for:UA=Q/ T.In the off-design case knowing the new gas parameters,use the NTU method to establish performance using Q=(UA)T.Correct for UA using new gas parameters. We do not have to compute U. Hence there is no need to know the tube size,fin details,HRSG mechanical data;anyone can perform such calculations and evaluate HRSG performance in unfired,fired modes,evaluate burner duty,optimize temperature profiles,predict part load performance,review performance different gas turbines...
HRSG performance at 40 % load. Note steaming in economizer and also the high exit gas temperature.
HRSG performance is evaluated at different gas flow,exhaust temperature conditions to see if the performance is reasonable.
Design basis
Note:Actual steam flow is 68,700 lb/h and exit gas temperature is 380 F,while it should have been about 364 F.Hence further evaluations are necessary to check if HRSG design is adequate. The gas flow was estimated based on steam duty and inlet/exit gas temperatures.
We are trying to see if a 2 pressure HRSG is required. Customer wants about 40,000 kg/h,30 kg/cm2 steam and 3000 kg/h steam at 6 kg/cm2 in fired mode and about 3500 kg/h LP steam in unfired mode,which is taken off the drum and pressure reduced..
HRSG makes 40,000 kg/h HP steam at 400 C and 30 kg/cm2 and 3000 kg/h steam is taken off the drum for process and pressure reduced to 6 kg/cm2
It may be seen that as long as the HRSG operates in the fired mode,the single pressure system has the same performance as the dual pressure unit when process LP steam is at 6 kg/cm2a,thus saving lot of expenditure, field costs,operational costs etc. A pressure reducing station replaces a complete LP evaporator,which could cost several hundred thousand dollars.If the LP steam pressure were different,then the outcome will be different.When process steam is at 3 kg/cm2a,then dual pressure looks attractive as seen in columns 5 and 6.HP steam is at 30 kg/cm2a.So there is an optimum LP pressure below which multiple pressure is justified. We cannot simply go for dual pressure without doing this analysis. If the HRSG runs more often in unfired mode,then a dual pressure may be warranted even at 6 kg/cm2
ABOVE: TYPICAL EXHAUST GAS. BELOW: WITH STEAM INJECTION. Note the difference in steam generation
Q 2:Repeat the calculation at 10 kg/cm2a for saturated as well as superheated steam and discuss the findings. If pinch and approach increase by 5 C, 10 C, how much duty we lose and also the steam generation for Q 1 above? Table shows enthalpy in btu/lb vs temperature.
Temp,F enthalpy
200 34.98
400 86.19
600 138.7
800 192.48
1000 247.56
If gas flow changes to 80,000 kg/h and steam pressure to 45 kg/cm2a in operation, what is the HRSG performance, duty, steam temperature and ASME efficiency? ASME efficiency=energy absorbed by steam/water/fluids or duty/(gas flow x enthalpy+fuel input on LHV basis)
What are the effects of part load operation of gas turbine on HRSG and effect of supplementary firing? Discuss.
Module 1
10
ACTUAL DESIGN
Mod 7 feeds 4. mod 8 feeds 7. mod 10 feeds 8 and 9 mod 5 fed by mod 9. mod 13 feeds 11 and 12