Four Years of Successful Operation at Mercer Generating Station Following Feedwater Heater Tube Repair: An Alternative to Replacement

2003 ◽  
Author(s):  
Bruce W. Schafer ◽  
Daniel B. Patten ◽  
Charles R. McCall
Keyword(s):  
High Pressure ◽  
Heat Exchangers ◽  
Close Contact ◽  
Good Condition ◽  
Life Assessment ◽  
Operating Life ◽  
Successful Operation ◽  
Repair Work ◽  
Parent Tube ◽  
Heater Tube

In the late 1990’s, two of the high-pressure feedwater heaters at PSEG Power LLC’s Mercer Generating Station began to experience tube leaks after almost 40 years of operation. Prior to the repair, these leaks were occurring at least once per month. Based on eddy current and video probe inspections, the area of tube degradation appeared to be isolated to the desuperheater region of the bundle. PSEG Power LLC performed a life assessment of the feedwater heaters and, based on the good condition of the remainder of the heaters, determined that repair of the desuperheater region could improve the reliability and significantly extend the operating life of the heat exchangers. The heater condition, coupled with a repair vs. replace economic model, led to the decision to sleeve the feedwater heaters. During the April 1999 maintenance outage, Framatome ANP performed repair work on the two high pressure feedwater heaters. This repair consisted of installing an 11 foot-2 inch (3404 mm) sleeve in all outlet tube ends, spanning the desuperheating region. The sleeving method used consisted of a three step process. After the sleeve was installed, its lower end was roll expanded within the tubesheet. Next, the entire length of the sleeve in the desuperheater section was expanded into close contact with the parent tube. The final installation step was upper hydraulic expansions, above the desuperheating zone end plate, in nondefective portions of the tube. This installed sleeve became the pressure boundary in the desuperheater section of the feedwater heater. After more than 4 years of operation, no tube leaks have been noted and the need to replace the components has been eliminated for the foreseeable future.

Development Status of Coal-Fired Gas Heaters for Brayton-Cycle Cogeneration Systems

1983 ◽  
Author(s):  
S. V. Gunn ◽  
J. R. McCarthy
Keyword(s):  
High Pressure ◽  
Heat Exchangers ◽  
Coal Combustion ◽  
Operating Experience ◽  
Department Of Energy ◽  
Test Facility ◽  
Brayton Cycle ◽  
Pulverized Coal Combustion ◽  
Development Status ◽  
Near Term

Under contract from the Department of Energy, Rocketdyne is developing the technology of coal-fired gas heaters for utilization in Brayton-cycle cogeneration systems. The program encompasses both atmospheric fluidized bed and pulverized coal combustion systems; and it is directed toward the development of gas heater systems capable of delivering high pressure air or helium at 1550 F, when employing metallic heat exchangers, and 1750 F, when employing ceramic heat exchangers. This paper reports on the development status of the program, with discussions of the completed “screening” corrosion/erosion tests of candidate heat exchanger materials, a description and summary of the operating experience with the 6- by 6-foot AFB test facility and a projection of the potential for relatively near term commercialization of such heater systems.

Risk Based Optimization of the Life Assessment for Fossil Power Plant

2006 ◽  
Vol 321-323 ◽  
pp. 1572-1575
Author(s):  
Bum Shin Kim ◽  
Jung Soo Ha ◽  
Gee Wook Song ◽  
Jung Seob Hyun ◽  
Woo Sung Choi
Keyword(s):  
Risk Assessment ◽  
High Pressure ◽  
Power Plant ◽  
Power Plants ◽  
Life Assessment ◽  
Assessment Procedure ◽  
Operation Condition ◽  
High Pressure And Temperature ◽  
Fossil Power Plant

As a number of aged fossil power plants recently increased, the precise life assessment of critical equipments gets to be important more than ever. Despite of infrequent likelihood of failure, the equipments in high pressure and temperature operation condition have traditionally been considered as critical because of huge consequence of the equipments and hence life assessment of fossil power plant has been focused on all of the severe operated equipments for past decades. Nowadays, with Risk-Based Inspection technology being developed rapidly, most of the power plant utilities get a chance to reduce the scope of the inspection and test and to extend the interval for the life assessment. This paper provides methodology based on Risk-Based Inspection technology to optimize the life assessment work scope and interval and also demonstrates the enhanced life assessment procedure including risk assessment of equipments.

The ALSTOM GT13E2 Medium BTU Gas Turbine

2002 ◽  
Author(s):  
Frank Reiss ◽  
Timothy Griffin ◽  
Karl Reyser
Keyword(s):  
Gas Turbine ◽  
Fuel Injection ◽  
Pressure Ratio ◽  
Good Condition ◽  
Residual Oil ◽  
Safe Operation ◽  
Successful Operation ◽  
Heating Value ◽  
Gasification Process ◽  
High Flexibility

ALSTOM Power’s GT13E2 gas turbine has been successfully commissioned in a refinery residual oil gasification process (api Energia, Italy) operating on Medium Btu gas (GT13E2-MBtu). The modification of the standard GT13E2 to operate with MBtu fuel has resulted in an improvement in the performance of the GT13E2 to exceed 192 MW and 38% efficiency (simple cycle) at ISO conditions. The GT compressor has been upgraded to incorporate an extra-end stage to boost the pressure ratio to 17:1 and improve performance. Syngas from residual oil gasification has a typical volumetric composition of 45% H2, 48% CO and 7% CO2 and a lower heating value of 13.9 MJ/kg. This syngas has been diluted with N2 to reduce the heating value to 7 MJ/kg lowering reactivity and allowing partially premixed operation. In order to operate with syngas a redesign of the standard EV burners was necessary to deal with the associated high flame velocities and volume fluxes. The fuel injection for syngas operation was placed at the burner end and the gas injected radially inward to obtain inherently safe operation. The gas turbine demonstrated successful operation with both syngas and oil No. 2 fuels. At the standard dilution of 7MJ/kg NOx emissions are in the 20–25 vppm range and the CO emissions are below 5 vppm independent of load. The modified burners demonstrated safe operation on syngas with and without dilution of nitrogen in a tested LHV range from 6.8 to 14 MJ/kg. This behavior allows high flexibility of the entire power plant. Changeover from oil no. 2 to syngas and vice versa can be done between 50 and 100% load. The gas turbine components have been inspected several times during the commissioning period and shown to be in good condition.

scholarly journals Optimization of Design of High Pressure Compact and Light-Weight Liquid Heat Exchangers

1998 ◽  
Author(s):  
P. Avran ◽  
A. Soudarev ◽  
B. Soudarev ◽  
V. Soudarev
Keyword(s):  
Experimental Study ◽  
High Pressure ◽  
Heat Exchange ◽  
Heat Exchangers ◽  
Three Dimensional ◽  
Fuel Oil ◽  
Heat Output ◽  
Light Weight ◽  
Combined Approach ◽  
Liquid Heat

Results of an experimental study with a support of DRET (France) of two designs of liquid heat exchangers made of multi-channel aluminium tubes are presented with the objective to develop a fuel-oil recuperator, compact and light (less than 3 Kg). It was demonstrated that the application of a combined approach to heat exchange enhancements using three-dimensional turbulators as semi-spherical craters and bulges on channel walls of internal paths allows to increase the specific heat output of the heat exchanger from 10.5 to 13.3 kW/kg.

Continued Study on the Effect of Mean Stress on Ground Storage Vessels for Hydrogen Fueling

2020 ◽  
Author(s):  
Daniel T. Peters ◽  
Myles Parr
Keyword(s):  
High Pressure ◽  
Pressure Vessels ◽  
Life Assessment ◽  
Gaseous Fuels ◽  
Division 1 ◽  
Section Viii ◽  
Pressure Storage ◽  
Cyclic Service ◽  
The Impact ◽  
Division 2

Abstract The use of high pressure vessels for the purpose of storing gaseous fuels for land based transportation application is becoming common. Fuels such as natural gas and hydrogen are currently being stored at high pressure for use in fueling stations. This paper will investigate the use of various levels of autofrettage in high pressure storage cylinders and its effects on the life of a vessel used for hydrogen storage. Unlike many high-pressure vessels, the life is controlled by fatigue when cycled between a high pressure near the design pressure and a lower pressure due to the emptying of the content of the vessels. There are many misunderstandings regarding the need for cyclic life assessment in storage vessels and the impact that hydrogen has on that life. Some manufacturers are currently producing vessels using ASME Section VIII Division 1 to avoid the requirements for evaluation of cylinders in cyclic service. There are currently rules being considered in all of ASME Section VIII Division 1 and Division 2, and even potentially for Appendix 8 of ASME Section X. Recommendations on updating the ASME codes will be considered in this report.

A Study of Pressure Homogeneity in the Hexahedral Anvil High-Pressure Apparatus

1964 ◽  
Vol 86 (4) ◽  
pp. 729-735 ◽  
Author(s):  
G. A. Samara ◽  
A. Henius ◽  
A. A. Giardini
Keyword(s):  
High Pressure ◽  
Stress Distribution ◽  
Material Flow ◽  
Applied Load ◽  
Pressure Gradients ◽  
Operational Characteristics ◽  
Large Pressure ◽  
Heater Tube ◽  
High Pressure Apparatus ◽  
Increased Pressure

A study of operational characteristics and stress distribution in a large volume hexahedral apparatus has been made. Pyrophyllite containers with integral preformed gaskets were found to be superior to plain blocks. Pregasketing reduced material flow and sample deformation, increased by over 100 percent the central region of the container over which little or no deformation occurs, and greatly increased anvil life. Even so, large pressure gradients still existed within the container. These gradients become more severe the higher the pressure. Pressure efficiency and distribution were appreciably changed by varying the length and thickness of preformed gaskets. Built-in metal intensifiers increased pressure efficiency by up to 30 percent. The inclusion of a metal heater tube had no measurable influence on pressure gradients. Cycling decreased the applied load required to reach a given pressure only if the load was not allowed to fall below a certain minimum. This is attributed to the ability of pyrophyllite to remain static while supporting large stress gradients.

Performance Analysis and Optimal Design of Heat Exchangers Used in a High Temperature and High Pressure System

2008 ◽  
Author(s):  
Byoung Ik Choi ◽  
Kui Soon Kim ◽  
Man Yeong Ha ◽  
Ji Hwan Jeong ◽  
Jong Rae Cho ◽  
...  
Keyword(s):  
High Pressure ◽  
High Temperature ◽  
Heat Exchanger ◽  
Optimal Design ◽  
Heat Exchangers ◽  
Pressure Loss ◽  
Pressure System ◽  
High Pressure System ◽  
Flow Type ◽  
Design Variables

A computational study for the optimal design of heat exchangers used in a high temperature and high pressure system is presented. Two types of air to air heat exchangers are considered in this study. One is a single-pass cross-flow type with straight plain tubes and the other is a two-pass cross-counter flow type with plain U-tubes. These two types of heat exchangers have the staggered arrangement of tubes. The design models are formulated using the number of transfer units (ε-NTU method) and optimized using a genetic algorithm. In order to design compact light weight heat exchangers with the minimum pressure loss and the maximum heat exchange rate, the weight of heat exchanger core is chosen as the object function. Dimensions and tube pitch ratio of a heat exchanger are used as design variables. Demanded performance such as the pressure loss (ΔP) and the temperature drop (ΔP) are used as constraints. The performance of heat exchangers is discussed and their optimal designs are presented with an investigation of the effect of design variables and constraints.

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