• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.4
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• pp.150-159
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• 2018

The present research deals with a finite element analysis and fatigue evaluation of a steam separator of a high-pressure evaporator for the Heat Recovery Steam Generator (HRSG). The fatigue during the expected life of the HRSG was evaluated according to the ASME Boiler and Pressure Vessel Code Section VIII Division 2 (ASME Code). First, based on the eight transient operating conditions prescribed for the HRSG, temperature distribution of the steam separator was analyzed by a transient thermal analysis. Results of the thermal analysis were used as a thermal load for the structural analysis and used to determine the mean cycle temperature. Next, a structural analysis for the transient conditions was carried out with the thermal load, steam pressure, and nozzle load. The maximum stress location was found to be the riser nozzle bore, and hence fatigue was evaluated at that location, as per ASME Code. As a result, the cumulative usage factor was calculated as 0.00072 (much less than 1). In conclusion, the steam separator was found to be safe from fatigue failure during the expected life.

• Journal of computational fluids engineering
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• v.16 no.1
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• pp.67-72
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• 2011

HRSG (Heat Recovery Steam Generator) is a boiler to recover heat from the exhaust gas of an engine and to generate steam for more power generation or process. For the HRSG, water-tube type boiler is commonly adopted to accommodate the working pressure or capacity requirement of the system. The water-tube type boiler has a steam drum to separate steam from the water-steam mixture supplied from the evaporator tube (riser). The drum should be sized properly to separate the steam by the gravity and auxiliary internals, such as a demister, which are installed to filter the steam. To size the steam drum and to estimate the filter efficiency of drum internals, the velocity distribution inside the drum needs to be identified. In the present study, a series of CFD has been conducted to find the velocity distributions inside steam drums for conventional HRSGs and water-tube type industrial boilers. The velocity distributions obtained from the simulation have been normalized and a correlation to predict them has been found. The correlation is applied to the steam drum design by determining a proper position of a demister to show proper separation performance.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.24 no.7
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• pp.994-1001
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• 2000

The dynamic behavior of a single-pressure heat recovery steam generator and turbine system for the combined cycle power plant is simulated on the basis of one-dimensional unsteady governing equations. A water level control and a turbine power control are also included in the calculation routine. Transient response of the system to the variation of gas turbine exit condition is simulated and effect of the turbine power control on the system response is examined. In addition, the effect of the treatment of inertia terms(fluid inertia and thermal inertia of heat exchanger metal) on the simulated transient response is investigated.

• 한국연소학회:학술대회논문집
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• 2012.04a
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• pp.3-6
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• 2012

Analysis method for the radiation heat transfer from the duct burner flame to the heat exchanger in a Heat Recovery Steam Generator (HRSG) was presented to supplement the existing thermal design process. Flame on a burner and a heat exchanger were postulated as imaginary planes and flame temperature, surface and emissivity was simplified in a aspect of engineering approach. The calculated local flame radiative heat flux on the heating surface was compared with the heat flux of 3-atomic gas radiation and convection.

• Corrosion Science and Technology
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• v.20 no.2
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• pp.69-76
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• 2021

In this work, we have performed a corrosion failure analysis of a leaking tube connected to an upper header of a condensate pre-heater in a heat recovery steam generator. It was revealed that the leakage position in the tube was the location where the materials were easily vulnerable due to tensile residual stresses induced by the material manufacturing process and welding process. In addition to an imbalance in the module induced by temperature difference during operation of the pre-heater, the weight of the modules and thermal fatigue provoked a type of stress of tensile-tensile fatigue on the tube. Thus, the leakage position of the pre-heater was exposed to the tensile stress on the inner surface of the tube facing the gas, which rendered the unstable oxide layer susceptible to corrosion and the formation of pits on the water side. The cracks propagated along with the degraded microstructure in a transgranular cracking mode under fatigue loading and finally resulted in water leakage.

• Proceedings of the KSME Conference
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• 2001.11b
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• pp.872-877
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• 2001

This study analyzed the design performance of the bottoming system of combined cycle power plants adopting a single-pressure once-through heat recovery steam generator with reheat. A computer program was constructed and parametric analyses were carried out to present the criteria for determining the reheat pressure and the location of the starring point of the reheater in the HRSG. The performance of the bottoming system was presented for the range from high subcritical to supercritical pressures. It was founded that the power of the bottoming system can be as high as that of the present triple-pressure bottoming system even with a higher exhaust gas temperature. A requirement for this high performance is a proper arrangement of the reheater.

• Proceedings of the KSME Conference
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• 2001.11b
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• pp.782-787
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• 2001

An optimum thermal design analysis of the combined cycle power plant with triple pressure heat recovery steam generator was performed by the numerical simulation. The optimum design module used in the paper is DNCONF, a function of IMSL Library, which is widly known as a method to search for the local optimum. The objective function to be minimized is the cost of total power plant including the steam turbine power enhancement premium. The result of this paper shows that the cost reduces if the design point of power plant becomes the local optimum, and many calculations at various initial conditions should be carried out to get the value near the global optimum.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.33 no.6
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• pp.403-410
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• 2009

This paper proposes a new approach to find the optimum ratios between sizes of the heat exchangers of the heat recovery steam generator (HRSG) system with limited size to maximize the efficiency of the steam turbine (bottom) cycle of combined cycle power plants (CCPP), but without performing the bottom cycle analysis. This could be achieved by minimizing the unavailable exergy (the sum of the destroyed and the lost exergies) resulted from the heat transfer process of the HRSG system. The present approach is relatively simple and straightforward because the process of the trial-and-error method, typical in performing the bottom cycle analysis for the system optimization, could be avoided. To demonstrate the usefulness of the present method, a single-stage HRSG system was chosen and the optimum evaporation temperature was obtained corresponding to the condition of the maximum useful work. The results show that the optimum evaporation temperature based on the present exergy analysis appears similar to that based on the bottom cycle analysis. Also shown is the dependency of size (NTU) ratios between the heat exchangers on the inlet gas temperature, which is another important factor in determining the optimum condition once overall size of the heat recovery steam generator is given. The present approach turned out to be a useful tool for optimization of the singlestage HRSG systems and can easily be extended to multi-stage systems.

• Proceedings of the KSME Conference
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• 2008.11b
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• pp.3053-3058
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• 2008

We develop a heat exchanger modules for a multi-burner boiler. The heat exchanger module is kind of a heat recovery steam generator (HRSG). This heat recovery system has 4 heat exchanger modules. The 1st module consists of 27 bare tubes due to high temperature exhaust gas and the others consist of 27 finned tubes. The maximum steam pressure of each module is 1 MPa and tested steam pressure is 0.7 MPa. In order to test these heat exchanger modules, we make a 0.5t/h flue tube boiler (LNG, $40\;Nm^3/h$). We tested the heat exchanger module with changing the position of each heat exchanger module. We measured the inlet and outlet temperature of each heat exchanger module and calculated the heat exchange rate. The results show that if module C is placed at second stage (the 1st stage is always module O, bare tube module), there is no need to attach an additional heat exchanger module. In this case the exit temperature of module C is low enough to enter an economizer which is more effective in heat recovery than a heat exchanger module.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.4
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• pp.23-31
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• 2018

Stress of a steam separator, equipment of the high-pressure (HP) evaporator for a HRSG, was analyzed and evaluated according to ASME Boiler & Pressure Vessel Code Section VIII Division 2. First, from the analysis results of the piping system model of the HP evaporator, reaction forces of the riser tubes connected to the steam separator, i.e., nozzle loads, were derived. Next, a finite element model of the steam separator was constructed and analyzed for the design pressure and the nozzle loads. The results show that the maximum stress occurred at the bore of the riser nozzle. The primary membrane stresses at the shell and nozzle were found to be less than the allowable stress. Next, the steam separator was analyzed for the steady-state operating conditions of operating pressure, operating temperature, and nozzle loads. The maximum stress occurred at the bore of the riser nozzle. The primary plus secondary membrane plus bending stress at the shell and nozzle was found to be less than the allowable stress.