Index
Note: Page numbers followed by “f” and “t” refer to figures and tables, respectively.
A
Acid phosphate corrosion (APC),
325,
334
Acoustic resonance,
63,
63
casing radiated noise,
259
stack radiated noise,
259
Air Pollution Control Act,
147,
148
Air-cooled condensers (ACCs),
321
flow-accelerated corrosion in,
328–331
All-volatile treatment
American Boiler Manufacturers Association (ABMA),
248–249
American Institute of Steel Construction (AISC),
200
American Society for Testing and Materials (ASTM),
226
American Society of Civil Engineering (ASCE),
200,
200
American Society of Mechanical Engineers (ASME),
200
Ammonia injection grid (AIG),
157,
368
Ammonia salt buildup on finned tubes,
370f
exhaust gas path components,
253–260
combustion turbine exhaust characteristics,
253–254,
254f
inlet duct configuration and mechanical design requirements,
254
outlet duct and stack configuration and mechanical design requirements,
256–257
water/steam side components,
260–261
ANSI B31.1 and B31.3,
144
Atomic absorption (AA),
194t
Automatic pressure control/control valve bypass,
317–318,
318f
Automatic recirculation (ARC) valve,
260
Automatic relief valve(s),
317
Automatic startup, general comments for,
299
B
Baffle type separator,
73
vs fast startup and/or high cycling,
109–110
Bowed/distorted tubes,
367f
Brayton cycle and Rankine cycle, combining,
18–21
Bundle support types,
104
C
Carbon monoxide catalyst systems,
285
Carbon monoxide oxidizers,
173
determining the catalyst volume,
186–187
catalyst deactivation mechanisms,
191–193
initial commissioning,
188
putting it all together,
182
oxidation catalyst fundamentals,
174–179
catalytic reaction pathway,
176–177
effect of the rate limiting step,
177–179
Carbon monoxide–volatile organics oxidation (CO/VOC) catalyst,
157
Carbon steel grade SA-516 Gr. 70,
78
Casing radiated noise,
259,
259
Catalyst and tunnel analogy,
175f
Catalyst characterization tools,
194t
Catalyst materials and construction,
150–153
Caustic treatment (CT),
326
Challenging the status quo,
339
Circulating boiler, use of,
6
Circulation ratio,
68,
68
Clean Air Act Amendments of 1990 (CAAA),
149
Clean Air Act in 1963,
147
Clean Air Act of 1970,
147
Coal-fired power plants,
40
Coil bundle modularization,
266–276
goalpost-style modularization,
272–273
modular or bundle construction,
268–271
O-frame (shop modular) construction,
275,
275f
super modules and offsite erection,
275–276
Coils in the low-temperature region of the HRSG,
368–369
Cold inspection and maintenance,
359–373
coils in the low-temperature region of the HRSG,
368–369
emissions control equipment,
368
heating surfaces/HRSG coils,
365–366
HP superheater and reheater coils,
366–367
internal steam drum inspection,
369–372
decisions affecting heat recovery,
31–34
Combined cycle cogeneration plant,
35–36
with three pressure HRSG and condensing steam turbine,
37f
with two pressure HRSG and backpressure steam turbine,
37f
Combined cycle plants,
1,
3f,
22f
Combustion air and turbine exhaust gas,
122–127
equipment configuration and TEG/combustion airflow straightening,
126–127
temperature and composition,
122
turbine power augmentation,
122–123
Combustion air blower inlet preheaters,
117
Combustion turbine exhaust characteristics,
253–254,
254f
Computational fluid dynamic (CFD) modeling,
127–131,
256
Condensate and feedwater cycle chemistry treatments,
323–324
all-volatile treatment
film forming products (FFP),
324
oxygenated treatment (OT),
324
Condensate detection,
308f
Condensate detection/removal,
307–308
Condensate management,
215
Condensate pump discharge (CPD),
328–329
Conductivity after cation exchange (CACE),
322
Congruent phosphate treatment (CPT),
325
coil bundle modularization,
266–276
goalpost-style modularization,
272–273
modular or bundle construction,
268–271
O-frame (shop modular) construction,
275,
275f
super modules and offsite erection,
275–276
construction considerations for valves and instrumentation,
284–285
platforms and secondary structures,
284
Consumption of energy,
17
and intermittent blowoff systems,
76
Continuous emission monitoring (CEM),
153,
256
Continuous online cycle chemistry instrumentation,
339
condensate detection/removal,
307–308
deaerator inlet temperature,
314,
315f
intermittent blowoff (IBO),
316
single-element control (SEC),
301–302
three-element control,
303
feedwater preheater inlet temperature,
308–311
automatic relief valve(s),
317
interstage attemperator,
306
Custom designed economizer,
81
full-circuit arrangement,
82f
half-circuit arrangement,
83f
Cycle chemistry-influenced damage/failure mechanisms,
326–336
allowing repeat cycle chemistry situations,
345
combined cycle/HRSG steam purity limits,
333
cycle chemistry guidelines and manual for the combined cycle plant,
345
deposition of corrosion products in the HP evaporator,
344
ensure the combined cycle plant has the required instrumentation,
345
failure/damage mechanisms in HRSGs,
334
flow-accelerated corrosion
in combined cycle/HRSG plants,
327
HRSG HP evaporators, deposition in,
334–336
steam turbine phase transition zone failure/damage,
331–333
transport of corrosion products,
344
unit shutdown limits,
334
Cyclone type separator,
73
D
Daily walkdown of equipment,
359
Damaged liner system due to overheating,
364f
Damper seal air systems,
258
integral floating pressure deaerator,
79
Density wave instability,
60–61
Deposition in HRSG HP evaporators,
334–336
Deposits in conventional boilers/evaporators,
338
Dew point monitoring,
93–94
Diesel particulate filter (DPF),
151
Distributed control system (DCS),
292
Distribution grid fixed support,
362f
Distribution grid floor guide,
362f
Distribution grid sidewall restraints,
363f
Drainability and automation,
110
intermittent blowoff (IBO),
316
secondary separator,
74–75
single-element control (SEC),
301–302
three-element control,
303
Drum water levels and volumes,
72–73
high high water level (HHWL),
72
high water level (HWL),
72
low low water level (LLWL) trip,
72–73
low water level (LWL),
72
normal water level (NWL),
72
combustion air and turbine exhaust gas,
122–127
equipment configuration and TEG/combustion airflow straightening,
126–127
temperature and composition,
122
turbine power augmentation,
122–123
design guidelines and codes,
143–144
ANSI B31.1 and B31.3,
144
Underwriters’ Laboratories,
143–144
distorted lower burner runners,
364f
drilled pipe duct burner,
130f
CO, UBHC, SO
x, and particulates,
134–138
in-duct or inline configuration,
118
E
dew point monitoring,
93–94
mechanical details,
86–88
Electron microprobe analysis (EPMA),
194t
Emission reduction catalysts,
382
Emission regulations,
149
unburned hydrocarbons (UHCs),
135–136
Emissions control equipment,
368
Engineering, procurement, and construction (EPC) contractor,
201,
299
Engineering, procurement, and construction (EPC) firm,
264–265
Enhanced oil recovery HRSGs,
388–393
Environmental Protection Agency (EPA),
147–148
Environmental regulations,
174
Equilibrium phosphate treatment (EPT),
325
flow accelerated corrosion (FAC),
68–71
heat transfer/heat flux,
66–67
natural circulation and circulation ratio,
68
Exhaust flow control dampers and diverters,
257–258
damper seal air systems,
258
Exhaust gas path components,
253–260
casing radiated noise,
259
stack radiated noise,
259
exhaust flow control dampers and diverters,
257–258
damper seal air systems,
258
HRSG inlet duct design and combustion turbine exhaust flow conditioning,
253–256
combustion turbine exhaust characteristics,
253–254,
254f
inlet duct configuration and mechanical design requirements,
254
outlet duct and stack configuration and mechanical design requirements,
256–257
Exposed insulation at liner system,
360,
361f
External access, of equipment,
261
External heat exchanger,
90–91
F
Failure/damage mechanisms in HRSGs,
334
Fast start cycles, multiple drum designs for,
78
Fast-start and transient operation,
231
components most affected,
233
construction details,
243
scope items for cycling,
249
miscellaneous cycling considerations,
250–252
National Fire Protection Association (NFPA),
250
Feedwater control valve,
87–88
Feedwater flow distribution,
85
alternative external heat exchanger,
92f
basic feedwater heater,
89,
90f
external heat exchanger,
90–91
high-efficiency feedwater heater,
92–93,
93f
water recirculation,
89–90
dew point monitoring,
93–94
Feedwater preheater inlet temperature,
308–311
recirculation pumps (with bypass),
309
Feedwater recirculation,
215
Feedwater velocities,
83–84
Field erection and constructability,
228
Film forming amine product,
322–323
ammonia salt buildup on,
370f
Firetube heat recovery boiler,
4
Flame impingement, liner damage from,
365f
Flow velocity (turbulence),
70
in combined cycle/HRSG plants,
327
Fluidized bed boilers,
117
Fluidized bed startup duct burner,
117f
Fuel-bound nitrogen NO
x,
133
Full load exhaust gas temperatures, evolution of,
24f
G
Gas flow HRSGs
Gas turbine–based power plants,
1–4,
4
Goalpost-style modularization,
272–273
H
Hazardous air pollutant (HAP),
184
Heat exchanger design,
54–61
evaporation and circulation,
58–59
Heat recovery steam generator (HRSG),
1,
2–3,
4–14
enhanced oil recovery design,
11–12
horizontal gas flow, vertical tube, natural circulation design,
7,
7f
large once-through design,
11,
12f
vertical gas flow, horizontal tube, forced circulation design,
7–8,
8f
vertical gas flow, horizontal tube, natural circulation design,
8–10,
9f
Heat Transfer Research, Inc. (HTRI),
391
Heat transfer/heat flux,
66–67
Heating surfaces/HRSG coils,
365–366
High-energy piping and support system,
358–359
High-pressure superheaters and reheaters,
97,
112–113
Horizontal gas flow HRSGs,
382,
382
Horizontal tube economizers,
86,
87
high-energy piping and support system,
358–359
HP superheater and reheater coils,
32,
366–367
Hybrid power augmentation (PAG) cycle,
39–40,
40f
I
Independent power producers (IPPs),
2–3,
3
Inductively coupled plasma electron spectrometry (ICP),
194t
Inlet chillers/foggers,
291
Insertion type desuperheater,
106f
Inspection and maintenance, of HRSG,
353–373
cold inspection and maintenance,
359–373
coils in the low-temperature region of the HRSG,
368–369
emissions control equipment,
368
heating surfaces/HRSG coils,
365–366
HP superheater and reheater coils,
366–367
internal steam drum inspection,
369–372
daily walkdown of equipment,
359
high-energy piping and support system,
358–359
Integral drum style evaporator,
69f
Integral floating pressure deaerator,
79
Intermittent blowoff (IBO),
76,
314,
316
Internal access, of equipment,
261
Internal steam drum inspection,
369–372
International Association for the Properties of Water and Steam (IAPWS),
324,
335f,
348
Interstage attemperator,
306
J
K
Kyoto Protocol of 1998,
147
L
cycling, scope items for,
249
Ligament reduction factor variables,
206f
damaged liner system due to overheating,
364f
Long-chain hydrocarbons,
135
Longitudinal force-resisting system,
221,
224
Lower heating value (LHV),
23
Low-pressure economizer,
34
Low-pressure evaporator,
79
Low-pressure steam drum,
371
Low-pressure steam turbine,
332
M
Main steam temperature control,
304,
307f
carbon steel material,
70–71
higher-strength materials,
78
code of design
field erection and constructability,
228
owner’s specifications and regulatory body/organizational review,
201–202
piping and support solutions,
226–227
mechanical component geometries and arrangements,
203–204
pressure parts design flexibility,
209–215
condensate management,
215
feedwater recirculation,
215
preventing quenching,
214
longitudinal force-resisting system,
224
tube vibration and acoustic resonance,
62–63
Mechanical details,
86–88
Medium-pressure (MP) process steam header,
36,
38
secondary separator with,
372f
Modular or bundle construction,
268–271
Modularization, coil bundle,
266–276
goalpost-style modularization,
272–273
modular or bundle construction,
268–271
O-frame (shop modular) construction,
275,
275f
super modules and offsite erection,
275–276
Multiple drum evaporator designs for fast start cycles,
78
Multiple pressure systems,
53
N
National Ambient Air Quality Standards (NAAQS),
149,
184
National Board Inspection Code (NBIC),
373
National Emissions Standards for Hazardous Air Pollutants (NESHAP),
184
National Fire Protection Association (NFPA),
250
Natural and assisted circulation,
379
Natural circulation and circulation ratio,
68
Natural circulation evaporator designs,
65–66
Natural circulation HRSGs,
58
refinery/chemical plant fuels,
121
Nitric oxide
ammonia oxidation to,
158
Nitrogen oxides
formation mechanisms in gas turbines,
152–153
NO to NO
2 conversion,
186
Nonreheat steam turbine configurations,
27f
O
Octadecylamine (ODA),
324
O-frame (shop modular) construction,
275,
275f
Oklahoma Gas & Electric’s Belle Isle Station,
22
Oleylpropylendiamine (OLDA),
324
serpentine coil OTSG,
383
Open cycle gas turbine generator,
19f
balance of plant operating pressure,
290
combustion turbine load,
290
CT fuel (natural gas or fuel oil),
291
inlet chillers/foggers,
291
general comments for automatic startup,
299
steam temperature (interstage/final),
296–297
superheater/reheater drain(s),
295–296
Operator-defined power load,
292
Optimum cycle chemistry, developing,
319
damage/failure in PTZ of steam turbine in combined cycle/HRSG plants,
341–342
under-deposit corrosion—hydrogen damage,
342–343
understanding deposits in HRSG HP evaporators,
343
for combined cycle/HRSG plants,
343–345
allowing repeat cycle chemistry situations,
345
cycle chemistry guidelines and manual for combined cycle plant,
345
deposition of corrosion products in the HP evaporator,
344
ensuring the combined cycle plant has the required instrumentation,
345
transport of corrosion products,
344
condensate and feedwater cycle chemistry treatments,
323–324
all-volatile treatment (oxidizing),
323
all-volatile treatment (reducing),
323
film forming products (FFP),
324
oxygenated treatment (OT),
324
cycle chemistry-influenced damage/failure mechanisms,
326–336
combined cycle/HRSG steam purity limits,
333
failure/damage mechanisms in HRSGs,
334
flow-accelerated corrosion in air-cooled condensers,
328–331
flow-accelerated corrosion in combined cycle/HRSG plants,
327
flow-accelerated corrosion in combined cycle/HRSGs,
327–328
HRSG HP evaporators, deposition in,
334–336
steam turbine phase transition zone failure/damage,
331–333
unit shutdown limits,
334
HRSG evaporator cycle chemistry treatments,
325–326
caustic treatment (CT),
326
repeat cycle chemistry situations (RCCS), development of,
337–339,
339–340
challenging the status quo,
339
continuous online cycle chemistry instrumentation,
339
conventional boiler/evaporator deposits,
338
shutdown/layup protection,
339
Outlet duct and stack configuration and mechanical design requirements,
256–257
Overheating
damaged liner system due to,
364f
damaged vibration supports due to,
365f
Overstrength factors,
220
catalytic reaction pathway,
176–177
effect of the rate limiting step,
177–179
putting it all together,
182
representative performance of,
185f
Oxygenated treatment (OT),
324
P
PACE (Power at Combined Efficiency),
2
Partial water side bypass,
88,
88f
Photovoltaic (PV) power,
41–42
less-than-desirable pipe routings,
226–227
Platforms and secondary structures,
284
Platinum and chromium (III) oxide based catalysts,
150
Power cycle variations that use HRSGs,
34–43
integrated gasification combined cycle,
40–41
steam power augmentation,
38–40
Preoperational acid cleaning,
67
Pressure
balance of plant operating pressure,
290
high-pressure evaporator,
104
integral floating pressure deaerator,
79
intermediate-pressure superheaters,
109
multiple pressure systems,
53
single pressure level,
26
sliding/floating pressure operation,
102
three-pressure nonreheat cycle,
27,
27,
27–29
two-pressure nonreheat cycle,
27
automatic relief valve(s),
317
condensate management,
215
feedwater recirculation,
215
preventing quenching,
214
mechanical component geometries and arrangements,
203–204
Proportional integral derivative (PID) controller,
301,
312
Public Utility Regulatory Policies Act (PURPA),
2–3,
35
Q
Qualifying facility (QF),
35
Quenching, preventing,
214
R
combining Brayton cycle and,
21
Reciprocating engines,
116
Recirculation pumps (with bypass),
309
Refinery/chemical plant fuels,
121
Remote drum style evaporator,
69f
casing or liner failures,
375
flow-accelerated corrosion (FAC),
374
under-deposit corrosion,
375
challenging the status quo,
339
continuous online cycle chemistry instrumentation,
339
conventional boiler/evaporator deposits,
338
shutdown/layup protection,
339
Ring type desuperheater,
106f
S
Scanning electron microscopy (SEM),
194t
Selective catalytic reduction (SCR) technology,
145,
174,
285,
285
catalyst materials and construction,
150–153
catalyst performance vs temperature graph,
155f
advancements in multifunction catalyst,
167–170
enhanced reliability and lower pressure loss,
165–166
impact on HRSG design and performance,
153–164
SCR location within the HRSG,
153–156
Separated (or slip) flow,
66
Separated flow condition,
57
Serpentine coil OTSG,
383
Shipping bundle versus individual coil,
98f
Shutdown and trips, of HRSG,
247
Shutdown/layup protection,
339
Siemens Benson OTSG technology,
384
Silica-based carriers,
180
Single-row harp isometric,
267f
Sliding/floating pressure operation,
102
Solar hybrid cycle,
34–35
Specialty steam drums,
77–79
fast start cycles, multiple drum designs for,
78
water source vs steam purity,
107
Spring can with indicator in proper location,
358f
Stack radiated noise,
259
Starting up a power/process plant,
293–299
automatic startup, general comments for,
299
steam temperature (interstage/final),
296–297
superheater/reheater drain(s),
295–296
secondary separator,
74–75
drum water levels and volumes,
72–73
high high water level (HHWL),
72
high water level (HWL),
72
low low water level (LLWL) trip,
72–73
low water level (LWL),
72
normal water level (NWL),
72
Steam drum operation,
75–77
continuous blowdown and intermittent blowoff systems,
76
drum level control,
76–77
single-element control,
76–77
three-element control,
77
Steam power augmentation,
38–40
Steam purity
combined cycle/HRSG limits,
333
vs various applications,
97
Steam side flow distribution,
110–111
interstage attemperator,
306
Steam turbine phase transition zone failure/damage,
331–333
Steam/water injection,
389
Steaming in economizer,
87–88
Stress due to change in temperature,
234–240
Stress–strain curve for a metal,
207f
Sulfur buildup on finned tubes,
370f
Super modules and offsite erection,
275–276
Supercritical steam cycles,
387–388
Superheater and reheater,
95
base load vs fast startup and/or high cycling,
109–110
design types and considerations,
97–105
bundle support types,
104
countercurrent/cocurrent/crossflow,
98–99
headers/jumpers vs upper returns,
99–100
sliding/floating pressure operation,
102
tube-to-header connections,
105
unfired/supplemental fired,
103–104
drainability and automation,
110
general description of superheaters,
96–97
power plant steam turbine,
97
steam purity vs various applications,
97
outlet temperature control,
105–109
mixing requirements for each,
109
Superheater/reheater drain(s),
295–296
burner in inlet duct,
103
at combustion gas turbine part load,
104
impact downstream of the high-pressure evaporator,
104
split superheater/reheater,
103
Surface area sequencing,
32
Surface of the superheaters (SHTR),
289
Sweetwater condenser desuperheater,
107
T
Taitel & Dunkler chart,
391
Technical Guidance Document (TGD),
331
Terminal point spraywater desuperheater,
106–107
Thermal deactivation of catalyst,
191,
192f
heat exchanger design,
54–61
evaporation and circulation,
58–59
multiple pressure systems,
53
supplemental firing,
50–51
Thermogravimetric analysis (TGA/DTA),
194t
Three-element control,
66,
303
Titania-based carriers,
180
Top-supported modular style bundle,
271f
Total dissolved solids (TDS),
389
Tripping a power plant/process plant,
288
Trisodium phosphate (TSP),
325
TSP (total suspended particulate),
136
Turbine exhaust gas distribution,
111–112
Turbine power augmentation,
122–123
Two-phase flow heat transfer,
66
U
Ultimate tensile strength,
208
Unburned hydrocarbons (UHCs),
135–136
Underwriters’ Laboratories (UL),
143–144
Unit shutdown limits,
334
US Energy Information Administration projects,
3–4
V
horizontal HRSG, comparison to,
379–382
natural and assisted circulation,
379
Vertical tube economizer,
87,
381
Vertical tube natural circulation evaporators,
65
evaporator design fundamentals,
66–71
flow accelerated corrosion (FAC),
68–71
heat transfer/heat flux,
66–67
natural circulation and circulation ratio,
68
specialty steam drums,
77–79
fast start cycles, multiple drum designs for,
78
drum water levels and volumes,
72–73
steam drum operation,
75–77
continuous blowdown and intermittent blowoff systems,
76
drum level control,
76–77
W
Water/steam flow mixture,
381
Water/steam side components,
260–261
Watertube heat recovery boilers,
4
X
X-ray diffraction (XRD),
194t
X-ray fluorescence (XRF),
194t
X-ray photoelectron spectroscopy (XPS),
194t
Y