Heat recovery steam generators |
HRSG design, installation, and O&M: lessons learned
Adoption of best practices based on in-depth experience of HRSG project challenges can yield significant benefits, including higher efficiency, less emissions and reduced maintenance requirements
Kevin Slepicka Vice President of Heat Recovery Boilers, Rentech Boiler Systems
Many facilities have switched from ageing boilers to modern combined heat and power systems (CHP) or combined cycle power generation systems that utilise gas turbines, steam turbines and heat recovery steam generators (HRSGs). Other facilities are planning to switch as they see the advantage of onsite power generation and being able to control their own power costs.
Whether the project is in the planning stages, is ready to be installed, or is now operating, here are some lessons learned in addressing challenges in both new builds and retrofits when an HRSG is involved.
Space
When retrofitting an HRSG into an existing facility, space is almost always an issue. The existing boiler is generally going to have a smaller footprint than a combustion turbine and HRSG package. Combustion turbines are generally pre-engineered as part of a standard package. That leaves only a certain amount of space to integrate the HRSG into the building or site layout. Before anything is designed or built, therefore, it is vital to scope out the layout of the facility, how much room will be consumed by the combustion turbine package and what room is left for the HRSGs. That gives you enough data to
14 | March 2024|
www.modernpowersystems.com
either tailor the design to the available space or to figure out plant modifications needed to allow for the addition of HRSGs.
When it comes to space, it is also important to pay attention to how the HRSGs are going to be delivered to the facility. There may be tight angles for trucks to negotiate, headway restrictions and other factors that make it challenging to get the HRSG into the facility. Decisions should be made in advance as to the maximum size of HRSG parts that can be brought in, where they can be staged and how they are to be assembled. All of this takes careful planning and co-ordination with plant personnel.
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