Deep cleaning alignment apparatus

Abstract

To provide a system and method for cleaning a heat recovery steam generator system having tubes and fins associated with the heat recovery steam generator system using a deep cleaning alignment device.SOLUTION: The deep-cleaning alignment device mainly includes at least one wedge and at least one wand. The wedge may be an elongated wedge configured to maximize the surface area in contact with the tube and the fin, and thus the wedge minimizes the amount of stress on a particular point of either the tube or the fin. In addition, the wedge may be manufactured from a variety of different materials. The wedge may be releasably secured to the plate to improve the ease with which the wedge can be driven towards the tube and fin. The wedge may also include respective wedge halves that are movable between an expanded position and a collapsed position.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] This application is a continuation-in-part application claiming priority to U.S. patent application Ser. No. 17 / 729,133, entitled "Deep Cleaning Alignment Equipment," filed April 26, 2022, which in turn claims priority to U.S. provisional patent application Ser. No. 62 / 597,179, entitled "Deep Cleaning Alignment Equipment," filed December 11, 2017, which claims priority to U.S. patent application Ser. No. 16 / 204,281, entitled "Deep Cleaning Alignment Equipment," filed November 29, 2018, which issued as U.S. Patent No. 11,313,632 on April 26, 2022, the entire contents of each of which are expressly incorporated herein by reference.

[0002] The present invention relates generally to power plants that produce electricity, including heat recovery steam generators (HRSGs) having boiler tubes therein, and more particularly to apparatus used to improve the ease with which modules that house these boiler tubes can be cleaned. [Background technology]

[0003] Combined-cycle power plants use both gas and steam turbines together to generate up to 50 percent more electricity from the same fuel than conventional simple-cycle plants. Waste heat from the gas turbine is passed through a heat recovery steam generator (HRSG) to a nearby steam turbine, which generates additional power. The boiler tubes in these HRSGs are contained in modules of various sizes, each with a different number of tubes. The modules in an HRSG generally consist of several components: Feedwater 1, Feedwater 2, Low-Pressure (LP) Economizer, Intermediate-Pressure (IP) Economizer, High-Pressure (HP) Economizer, LP Evaporator, IP Evaporator, HP Evaporator, LP Preheater, IP Preheater, HP Preheater, LP Superheater, IP Superheater, HP Superheater, LP Reheater, IP Reheater, and HP Reheater. When these systems become fouled, the heat transfer rate can decrease, which in turn reduces the efficiency of such systems.

[0004] Cleaning the interior of a module can be very difficult. In the past, available methods only allowed for cleaning the first one or two rows of tubes. By creating passageways between the boiler tubes, it is possible to create enough space between the tubes to insert a specialized wand that allows for cleaning all of the boiler tubes in the module. In the past, this space was created by inserting a sharp, wedge-shaped metal lancer between the tubes. Once the passageways are created, the wand is used to spray a liquid or gas, traditionally air, to clean the tubes and associated components. In many cases, these wands simply spray air directly forward. As a result, to clean the entire HRSG, a wand must be inserted into each tube row.

[0005] Traditionally, these wedge-shaped rods have been manufactured from steel. Similarly, the majority of tubes in HRSGs are constructed from carbon steel, stainless steel, T22 steel, or T19 steel. Due to the hard material of the wedges, their use often carries a risk of damage to the tubes or associated fins. Additionally, traditionally, the wedges are sharp lancers of minimal height, which increases the amount of stress caused by the wedge contact with the tubes. Furthermore, these wedges are often heavy and costly to transport. Furthermore, while air is effective at clearing some tube passages, it may be ineffective at clearing hard deposits. Summary of the Invention [Problem to be solved by the invention]

[0006] Therefore, there is a need for a deep cleaning alignment device that can create and widen communication passages in the tubes without damaging the tubes or associated fins. Further, there is a need for a deep cleaning alignment device that is configured to spray various liquids or gases against the tubes and associated fins to clean the HRSG. Further, there is a need for a cleaning wand that can spray liquids or gases at a variety of different angles relative to the tube passages. [Means for solving the problem]

[0007] In summary, the present invention is directed to a deep cleaning alignment apparatus and associated method for use in cleaning a heat recovery steam generator system. The heat recovery steam generator system may include a plurality of metallic tubes. The tubes may be mounted vertically, horizontally, or at various other angles. Each of the tubes may include a base having a plurality of fins extending outwardly from the base.

[0008] According to a first aspect of the present invention, a deep cleaning alignment device may include an elongated wedge. The elongated wedge may include a width, a length, and a height, and may be configured to contact and expand against the tubes and fins to form a passage between the tubes. The elongated wedge is configured to contact the tubes and fins with an expanded surface area, thereby minimizing stress between the wedge and the tubes.

[0009] According to another aspect of the present invention, the wedge may have a height of at least 6 inches. The wedge may further have a height of at least 8 inches. Furthermore, the wedge may have a width of at least ½ inch. Alternatively, the wedge may have a width of 1 inch. Additionally, the wedge may have a length of at least 3.5 feet. Similarly, the wedge may have a length of at least 5 feet.

[0010] According to a first aspect of the present invention, the deep cleaning alignment device may include a composite wedge. The composite may be softer than the metallic material of the tube and associated fins. For example, the composite may be a high-strength carbon nylon. More specifically, the wedge may be made of nylon 12CF. In other embodiments, the wedge may be made of a metallic material or other hard material. In yet other embodiments, the wedge may be made of a metallic material or other hard material, but may be encased in a composite or other softer material. The wedge may or may not have a handle for gripping.

[0011] According to another aspect of the present invention, a deep cleaning alignment device may include a wand. The wand may be configured to spray one of a liquid or a gas into the heat recovery steam generator system. Additionally, the wand may be configured to be removably insertable into the passageway formed by the wedge. The wand may have a first end and a second end opposite the first end. A handle is attached to the wand at the first end. An outlet may be formed at the second end. For example, the outlet may be configured to spray one of the liquid or the gas at approximately 30 degrees, 45 degrees, or another angle relative to the passageway.

[0012] According to another aspect of the present invention, multiple wands may be provided. More specifically, a first wand may be provided and a second wand may be provided. The first wand may be configured to push debris forward. Additionally, the second wand may be configured to spray a liquid or gas. For example, the second wand may be configured to spray dry ice. As noted above, either wand may be configured to spray the liquid or gas at approximately 30 degrees, 45 degrees, or other angles relative to the passageway.

[0013] According to another aspect of the present invention, a method of using a deep cleaning alignment device for cleaning a heat recovery steam generator system is described. The method includes inserting an elongated composite wedge having a width, length, and height between tubes to widen the tubes to form a passageway therebetween. The method may also include inserting a wand into the passageway and spraying a liquid or gas through the wand to clean the tubes and fins. The method further includes inserting a first elongated composite wedge having a first width between the tubes and then inserting a second elongated composite wedge having a second width between the tubes, the first width being narrower than the second width. The method may also include spraying a quantity of dry ice through the wand onto an outlet portion to clean the tubes and fins, the outlet portion being angled approximately 30 degrees, 45 degrees, or any other angle relative to the passageway.

[0014] According to another aspect of the invention, the various components may be made from metallic materials. In other embodiments, the various components may be made from composite or other materials. According to yet another aspect of the invention, the wedge may have a handle at the end. In other embodiments, the wedge may not have a handle.

[0015] In accordance with yet another aspect of the present invention, the wedge may be from about 6 inches to about 9 feet in length, and more preferably between about 3 feet and about 5 feet in length. Additionally, the wedge may have a height of from about 1 / 2 inch to about 2 feet, and more preferably between about 2 inches and about 8 inches in height. Furthermore, the wedge may have a width of between about 1 / 8 inch and about 4 inches, and more preferably between about 1 / 2 inch and about 1.5 inches in width.

[0016] According to yet another aspect of the present invention, the wedge may have at least one, and more preferably multiple, openings formed therein. These openings are configured to allow various devices to be inserted into one or more of the openings to speed and simplify removal of the wedge from the heat recovery steam generator system. For example, a lever, L-bracket, or other device may be inserted into one or more of the openings, where the device may be used as a cantilever to aid in removing the wedge from the heat recovery steam generator system. For example, a user may first use the outermost opening located closest to the end of the wedge that will not be inserted into the heat recovery steam generator system. Once the wedge is removed from the heat recovery steam generator system, a device may be inserted into a second opening that is exposed when the wedge is first moved. The device may then move the wedge further from the heat recovery steam generator system. As many openings as necessary may be included to gradually remove the wedge from the heat recovery steam generator system. Additionally, the device used to engage the apertures and remove the wedge from the heat recovery steam generator system may be a mechanical device that allows the user to forcefully remove the wedge, or it may be a pneumatic device that can be used to simplify and speed removal of the wedge from the heat recovery steam generator system. These holes or apertures may be of any desired size and spacing, for example, no less than about 1 / 16 between consecutive holes and no more than about 3 feet between consecutive holes.

[0017] According to yet another aspect of the present invention, the wedge may be a multi-piece wedge. For example, the wedge may be in two or more pieces, which may potentially allow for cheaper and / or easier transportation of the wedge from one location to another. By way of example, and without limitation, the various pieces of a multi-piece wedge may be secured together using threaded openings, interlocking components, jigsaw-cut connections, etc.

[0018] These and other aspects and objects of the present invention will be better understood and appreciated when considered in conjunction with the following description and the accompanying drawings. It will be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of example and not by way of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the scope thereof, and the invention includes all such modifications.

[0019] The advantages and features constituting the present invention, as well as a clearer understanding of the structure and operation of typical mechanisms in which the invention is provided, will be more readily apparent by reference to the illustrative, and therefore non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, in which like reference numerals designate the same elements in the several views. [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 is an isometric view of a deep cleaning alignment device including a wedge. [Figure 2] 2 is a top or bottom plan view of a deep cleaning alignment device including the wedge of FIG. 1. FIG. [Figure 3] FIG. 2 is a side view of a deep cleaning alignment device including the wedge of FIG. 1. [Figure 4] FIG. 2 is a front view of a deep cleaning alignment device including the elongated wedge of FIG. 1; [Figure 5] FIG. 2 is a rear view of the deep cleaning alignment device including the elongated wedge of FIG. 1. [Figure 6] FIG. 2 is an isometric view of the deep cleaning alignment device of FIG. 1 when a wedge is inserted into the heat recovery steam generator to widen the tubes to create a passage for the cleaning wand. [Figure 7] A top plan view of the deep cleaning alignment device shows the wedge spreading the tubes and the cleaning wand injecting cleaning fluid into the heat recovery steam generator. [Figure 8] A top plan view of the deep cleaning alignment device showing wedges spreading multiple tubes in a twisted tube configuration and a cleaning wand injecting cleaning fluid into a heat recovery steam generator. [Figure 9] FIG. 1 is a perspective view of one embodiment of a wand used in a deep cleaning alignment device. [Figure 10] FIG. 10 is a detailed view of the outlet section of the wand of FIG. 9. [Figure 11] FIG. 10 is another perspective view of the wand including a handle associated with the wand. [Figure 12] A perspective view of one potential nozzle used in the deep cleaning alignment device. [Figure 13] FIG. 1 is a perspective view of the deep cleaning alignment device with wedges driven between the tubes and fins associated with a heat recovery steam generator prior to cleaning. [Figure 14] FIG. 12 is a perspective view of the deep cleaning alignment device with wedges driven between the tubes and fins associated with the heat recovery steam generator after cleaning is completed. [Figure 15] FIG. 10 is an exploded perspective view of an embodiment of a deep cleaning alignment device in which the wedge is a multi-piece wedge. [Figure 16] FIG. 16 is a perspective view of the wedge of FIG. 15 in an assembled state. [Figure 17] FIG. 10 is a side view of an embodiment of a deep cleaning alignment device having multiple openings formed in the wedge. [Figure 18] 18 is a perspective view of the wedge of FIG. 17 with a removable bracket attached to one of the openings. [Figure 19] FIG. 19 is a perspective view of the wedge of FIGS. 17-18 inserted into a heat recovery steam generator system, with a removable bracket inserted into the system to remove the wedge from the heat recovery steam generator system. [Figure 20]FIG. 10 is a perspective view of another embodiment of a wedge in use with a plate. [Figure 21] FIG. 21 is a side view of a wedge in use with the plate of FIG. 20; [Figure 22] FIG. 22 is a front view of a wedge used with the plate of FIGS. 20 and 21; [Figure 23] FIG. 23 is an exploded view of the wedge and plate of FIGS. 20 to 22. [Figure 24] FIG. 10 is a perspective view of another embodiment of a wedge in use with a plate. [Figure 25] FIG. 25 is a top plan view of the wedge and plate of FIG. 24. [Figure 26] FIG. 26 is an exploded view of the wedge and plate of FIGS. 24 and 25. [Figure 27] FIG. 10 is a top plan view of another embodiment of an expandable and collapsible wedge in a first configuration. [Figure 28] FIG. 28 is a top plan view of the wedge of FIG. 27 in a second configuration. [Figure 29] FIG. 29 is a perspective view of the wedge of FIGS. 27 and 28 in a first configuration. [Figure 30] FIG. 30 is a perspective view of the wedge of FIGS. 27 to 29 in a second configuration. [Figure 31] FIG. 10 is a perspective view of another embodiment of an expandable and collapsible wedge in a first configuration. [Figure 32] FIG. 32 is a perspective view of the wedge of FIG. 31 in a second configuration. DETAILED DESCRIPTION OF THE INVENTION

[0021] In describing the preferred embodiment of the present invention as shown in the drawings, specific terminology will be used for ease of understanding. However, the present invention is not intended to be limited to the terminology selected, and it will be understood that each terminology includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. For example, the terms connected, attached, or similar terms are often used, which are not limited to direct relationships, but include relationships via other elements that have such relationships recognized as equivalent by those skilled in the art.

[0022] The invention and its various features and advantageous details will be explained more fully in the following description with reference to non-limiting embodiments which are described in detail.

[0023] A deep cleaning alignment apparatus 20 and system for cleaning a heat recovery steam generator system 22 or other types of heat exchangers and associated tubes 24 is generally shown in the figures. While the apparatus 20 is described with respect to a heat recovery steam generator system 22, it should be noted that the apparatus 20 may similarly be used in many other instances where the exteriors of various tubes need to be widened for cleaning purposes, such as in other heating, ventilation, and air conditioning applications. As seen in FIGS. 6 and 7, the tubes 24 may be configured to be aligned with one another in an "in-line" configuration. Alternatively, as seen in FIG. 8, the tubes 24 may be twisted relative to one another. Of course, other tube 24 configurations may be used as well.

[0024] The deep cleaning alignment apparatus 20 is specifically designed to maximize the efficiency of cleaning the heat recovery steam generator system 22. The heat recovery steam generator system 22 includes a plurality of tubes 24. As shown, the tubes 24 extend vertically relative to the system 22. However, the tubes 24 may also be mounted horizontally or at other angles as desired. Typically, the tubes 24 are fabricated from steel, but may also be fabricated from other materials. While the figures only show exemplary cylindrical tubes 24, it should be noted that the tubes 24 may include a plurality of fins 26 extending outwardly from the tubes 24, as seen in FIGS. 12 and 13. While these fins 26 are not shown in all figures, it should be noted that the deep cleaning alignment apparatus 20 is configured to similarly accommodate any fins 26 or tubes 24 associated with the heat recovery steam generator system 22.

[0025] The deep cleaning alignment device 20 may include a wedge / alignment rod 28 and at least one wand 30, both of which are described further below. The wedge 28 is configured to facilitate outward movement of the various tubes 24 to create a passageway 32 between the tubes 24. Once the passageway 32 is formed, the at least one wand 30 is used to clean any material located against the tubes 24. The wedge 28 may have a handle 56 to provide an easy grip for a user to facilitate use and movement of the wedge 28. However, the inclusion of a handle is not required for the wedge 28.

[0026] Next, the wedge / alignment rod 28, as shown in FIGS. 1 through 5, will be further described. Among other features, the wedge 28 is preferably elongated, having a body 29 extending to a pointed end 31. Accordingly, the wedge 28 may come in several different sizes. For example, a longer and taller wedge 28 may be used than other wedges conventionally used in the field. As a result, when the wedge 28 is used, the surface area of ​​the wedge 28 that contacts the tube 24 may be increased. This, in turn, reduces the amount of stress between the wedge 28 and the steel tube 24 at any particular point. The wedge 28 may be approximately 8 inches deep to spread out stress points around the wedge 28 and the tube 24. This may also allow for a larger opening along the length of the tube 24, allowing for desirable access for the cleaning wand 30. The width and length of the wedge 28 may vary depending on the type of HRSG 22, the width of the module, the type of configuration, the tube spacing specific to the module being cleaned, and any other factors that may affect the functionality of the deep cleaning alignment apparatus 20.

[0027] While several embodiments are described herein, it should be noted that these are exemplary, as many other potential dimensions of the wedges 28 shown may be used. In a first embodiment, the wedges 28 may be between 3.5 feet and 5 feet long. In this embodiment, the wedges 28 may be between approximately 1.5 inches and 1 inch wide. The specific size may vary based on the size of the module. For example, in a boiler module including 12 rows of tubes 24, 3.5-foot wedges 28 may be used. In any module with more than 12 rows of tubes 24, longer 5-foot wedges 28 may be used. For tubes 24 located closely together, narrower 1.5-inch-wide wedges 28 may be used first. After 1 / 2-inch wedges 28 are inserted, 1-inch-wide wedges may be inserted to further space the tubes 24. Alternatively, tubes 24 initially spaced apart may simply be separated using 1-inch-wide wedges 28.

[0028] According to another embodiment, the wedge 28 may be between 2 feet and 6 feet long. In this embodiment, the wedge 28 may be between about 1 / 2 inch and 1.5 inches wide. The wedge 28 may also be between 1 inch and 8 inches tall.

[0029] In yet another embodiment, the wedge 28 may be between 1 / 4 inch and 2 inches wide. Additionally, the wedge 28 may be between 1 / 2 inch and 2 inches wide. The length of the wedge 28 may also vary, for example, between 1 foot and 10 feet long. Furthermore, the height of the wedge 28 may vary between 1 / 2 inch and 12 inches high, and more preferably, between 1 inch and 8 inches high.

[0030] In yet another embodiment, the wedge 28 may be from about 6 inches to about 9 feet in length, and more preferably between about 3 feet and about 5 feet in length. Additionally, the wedge 28 may have a height from about 1 / 2 inch to about 2 feet, and more preferably between about 2 inches and about 8 inches in height. Furthermore, the wedge 28 may have a width between about 1 / 8 inch and about 4 inches, and more preferably between about 1 / 2 inch and about 1.5 inches in width.

[0031] Another feature of the wedge 28 is that it may be fabricated from a composite component. The composite component is preferably constructed of a material softer than the steel tubes 24 and fins 26. As a result, when the wedge 28 is inserted into the HRSG 22 and contacts the tubes 24 and / or fins 26, wear caused by the sliding of the wedge 28 can be absorbed by the composite wedge 28 instead of the tubes 24 or fins 26. For example, the wedge 28 may be fabricated from high-strength carbon fiber nylon. In one embodiment, the wedge 28 is fabricated from nylon 12CF, a lightweight yet durable carbon fiber reinforced thermoplastic. Thus, the wedge 28 is easily transportable due to its weight, yet still durable enough for use in the deep cleaning and alignment apparatus 20. Alternatively, the wedges 28 may be fabricated from any other material that is softer than the tubes 24 and associated fins 26, which are typically fabricated from steel, e.g., various plastic, composite, and nylon materials. Of course, the wedges 28 may be configured to be elongated and fabricated from composite components to minimize potential damage to the tubes 24 and fins 26.

[0032] Additionally, the deep cleaning alignment apparatus 20 may feature at least one cleaning wand 30, as shown in detail in FIGS. 9 through 11. The cleaning wand 30 is configured to spray a liquid or gaseous cleaning fluid 34 against the HRSG 22. More specifically, the cleaning wand 30 may be configured to spray dry ice, which may include high-density dry ice (CO2) pellets. These pellets may be propelled with ultra-high pressure air, ranging from 200 to 350 psi. This may be advantageous because the dry ice may eventually evaporate, allowing for cleaning of the HRSG 22. Of course, other types of spraying media may also be present. For example, the cleaning wand 30 may be similarly configured to spray other liquids or gases, including air, water, cleaning fluids, and any other material capable of cleaning the tubes 24 and fins 26.

[0033] As shown, the cleaning wand 30 may have a first end 36 and a second end 38. At the first end 36, the cleaning wand 30 may include a handle 40 to allow a user to securely fasten the cleaning wand 30 during use. At the second end 38, an outlet port 42 is formed. A supply passage 44 extends through the wand 30 to deliver liquid or gas to the outlet port 42. The outlet port 42 may direct the liquid or gas directly out of the wand 30. Alternatively, the outlet port 42 may direct the liquid or gas out of the wand 30 at various angles. More specifically, although FIGS. 7, 9, and 10 show a wand 30 capable of spraying liquid or gas out of the outlet port at an angle of approximately 45 degrees relative to the wand 30, the wand 30 may similarly be configured to exit at approximately 30 degrees or any other desired angle. The wand 30 may also be capable of front and side blowing to clean the tubes 24 and fins 26. Of course, the wand 30 may similarly blow liquid or gas at any other angle as desired. Additional wands 30 may also be used, such as a first wand to blow air to dislodge the first layer of debris and a second wand to inject liquid or gas into the HRSG 22. Furthermore, the wand 30 may have any number of different nozzle assemblies 46 to vary the path that the liquid or gas is delivered from the wand 30. For example, FIG. 12 shows one potential nozzle 46 configuration.

[0034] Additionally, the wand 30 may be fabricated from steel or composite materials. The use of composite materials may be desirable for the same reasons as the use of composite wedges 28, which reduce potential damage to the tubes 24 and fins 26 when the wand 30 is moved quickly and swiftly against the tubes 24 and fins 26. The wand 30 is moved up and down the wedge-shaped passage 32 to clean the tubes 24 from all directions. Cleaning may occur from each side of the module (both the upstream and downstream faces), overlapping the wedges 28 from each side.

[0035] The operation of the deep cleaning alignment apparatus 20 will now be described. Initially, a wedge 28 is inserted between two adjacent rows of tubes 24. The adjacent rows of tubes 24 are then separated from each other to form a passageway 32. Multiple wedges 28 may be used with adjacent rows of tubes 24 that are spaced closely together. For example, a first wedge having a narrow width may be used to initially separate the tubes 24, followed by a second wedge having a wider width that further separates the tubes 24 to create the passageway 32 via one or more wands 30. Once the passageway 32 is formed, one or more wands 30 may be removably inserted into the passageway 32 to facilitate cleaning of the HRSG 22.

[0036] Additional features of this system will now be described. Initially, in FIGS. 15 and 16 , the elongated wedge 28 may be a multi-piece elongated wedge 28. While these figures show an exemplary multi-piece elongated wedge, other multi-piece wedges having different proportions may be used as well. More specifically, the wedge 28 may have one or more segments 48 that can be releasably connected to one another using various connecting surfaces 50. Such a wedge 28 is desirable because it makes it easier, cheaper, more efficient, etc., to transport the wedge 28 from one location to another. As shown, the wedge 28 has three sections 48 a, 48 b, 48 c that can be releasably connected to one another. The various segments / sections 48 may be releasably connected using any number of different connecting surfaces 50. By way of example, and not limitation, the connecting surfaces 50 may be threaded openings, such that adjacent segments 48 may be rotated relative to one another so that the threaded sections engage. In another embodiment, the connecting surface 50 may be an interlocking section, with portions of adjacent pieces 48 interlocking with each other at the connecting surface. Furthermore, the connecting surface 50 may have a jigsaw-type or other connection. Regardless of what connecting surface 50 is used, the connecting surface 50 allows the various pieces 48 to be quickly and easily releasably secured to each other with sufficient connection to act as a wedge as described herein, after which the pieces 48 can be separated from each other.

[0037] 17-19, additional features related to the wedge 28 are illustrated. Additionally, the embodiments shown in these figures are not drawn to scale, but rather are shown with exaggerated dimensions, sizes, and proportions to demonstrate essential features. More specifically, the embodiments shown in these figures are for a wedge having at least one as shown a plurality of holes or openings 52 formed in the side of the wedge 28. Various devices, such as brackets, L-brackets, removal brackets, clips, rods, or any other device 54 that can be inserted into the openings 52, can be used to engage the wedge 28 to facilitate removal of the wedge 28. As is known in the art, once the wedge 28 is installed, it can be difficult to remove the wedge 28 from the passage of a heat recovery steam generator system or other system. These holes or openings 52 facilitate this removal. As shown in FIG. 19, the wedge 28 is installed in a heat recovery steam generator system with the openings 52 exposed directly adjacent to the handle 56. Additionally, although the wedge 28 does not require a handle, for purposes of describing the location of the openings 52, the handle 56 is used as a point of reference to indicate the end of the wedge 28 that is not inserted into the system. When a user desires to remove the wedge 28 from the system, the device 54 is inserted into the first opening 52. The device 54 is then manually grasped by the user and used as a cantilever or otherwise connected to another device, such as a pneumatic device. The user or the pneumatic or other device then pulls the device 54 away from the system, thereby at least partially removing the wedge 28 from the system. When the wedge 28 is securely hooked to the system, the wedge 28 can only be gradually moved out of the system. Once the second opening 52 is exposed, the device 54 can be inserted into the second opening 52, after which the process may be repeated. A desired number of openings may be included to facilitate the gradual removal of the wedge 28 from the system. The holes or openings 52 may be sized and spaced as desired relative to one another.For example, in one embodiment, the holes are between about 1 / 16 inch from each other and about 3 feet from each other.

[0038] 20-23, additional features of the wedge 28 will be described. More specifically, this embodiment includes the wedge 28 in combination with a plate 58, or smash plate. The smash plate 58 is releasably connectable to the proximal end 60 of the wedge 28. For example, in the embodiment shown, the smash plate 58 may include a plurality of hooks 62, while the wedge 28 may include a plurality of compatible protrusions 64 extending from the proximal end 60 of the wedge 28. As shown, there are four hooks 62 and four protrusions 64. Thus, the protrusions 64 can be positioned over the hooks 62 and held in place by the hooks. This allows the wedge 28 and smash plate 58 to be held together during insertion of the wedge 28 into the passageway 32.

[0039] In another embodiment shown in Figures 24-26, the smash plate 58 may include one or more brackets 66 having apertures 68 formed therein. The wedge 28 may have complimentary apertures 70 that align with the apertures 68 formed in the brackets 66. In this embodiment, a bolt 72 is inserted through the apertures 68, 70 secured to the bolt 72 with a nut 74. This is another method of securing the smash plate 58 to the wedge 28. Of course, other attachment and securing mechanisms, including pins, hinges, joints, keys, etc., may similarly be used to secure the smash plate 58 and wedge 28 together.

[0040] The illustrated smash plate 58 is substantially rectangular or square in shape, but could take on any number of different shapes and sizes. The smash plate 58 provides a contact surface significantly larger than the contact surface of the proximal end 60 of the wedge 28. Depending on the particular configuration of the wedge 28 and the area to be cleaned, a variety of different smash plate 58 sizes may be utilized. For example, in areas with minimal spacing, a 3-inch by 3-inch square smash plate 58 may be used where at least some additional surface area is desired. In areas with more space, a 20-inch by 20-inch square may be used. Furthermore, if more space is available, a 36-inch by 36-inch square may be used. This increased surface area makes it even easier for one or more users to contact the smash plate 58 to drive the wedge 28 further into the passageway 32. Typically, these wedges 28 are driven by a sledgehammer or other object using blunt force contact. Thus, the larger surface area of ​​the smash plate 58 makes it easier to contact the proximal end 60 of the wedge 28 during insertion, which also provides increased safety for the user compared to inserting only the smaller surface area wedge 28 using a sledgehammer or other object of blunt force.

[0041] 27-30, further additional features of the wedge 28 will be described. This illustrated embodiment includes a wedge 28 having multiple segments that can be manipulated relative to one another for improved operating characteristics. As shown, the wedge 28 includes a first wedge half 76 and a second wedge half 78. By way of example and not limitation, each wedge half 76, 78 may be approximately 1 / 4 inch wide, although narrower or wider wedge halves 76, 78 may be used depending on the desired configuration of the wedge 28. The first wedge half 76 and the second wedge half 78 are maneuverable and movable relative to one another about a hinge 77 located at a distal end 79 of the wedge 28. More specifically, the wedge halves 76, 78 may initially be in a folded position in which they are adjacent or substantially adjacent to one another. See FIGS. 27 and 29. In this configuration, the wedge 28 has a minimum width. With the wedge 28 including the 1 / 4 inch wedge halves 76, 78, the thickness of the wedge 28 in the folded configuration is approximately 1 / 2 inch. In this configuration, the wedge 28 can be easily inserted into the passageway 32.

[0042] Once properly positioned, the wedge 28 may be moved to an expanded position, in which the two wedge halves 76, 78 are moved apart from one another about the hinge 77 to their maximum width. For example, in FIGS. 28 and 30 , the wedge 28 includes a rod 80, such as a threaded rod, and a plurality of gates 82 that are movable when the threaded rod 80 is rotated. More specifically, when in the collapsed position, the gates 82 are oriented substantially parallel to the threaded rod 80 or at an angle relative to the threaded rod 80. When the wedge 28 is moved to the expanded position, the gates 82 are substantially perpendicular to the threaded rod 80, such that the wedge halves 76, 78 are maximized from one another. For a wedge 28 including ¼-inch wedge halves 76, 78, the thickness of the wedge 28 in the expanded configuration is approximately 2 inches. Furthermore, the wedge 28 may have a wider or narrower width depending on the desired operating characteristics of the wedge 28 and the passageway.

[0043] The wedge halves 76, 78 may also be moved between the collapsed and expanded positions using other mechanisms including a combination of threaded rods and gates. For example, as shown in FIGS. 31 and 32 , another embodiment of the wedge halves 76, 78, similar to those described above, is shown including an inflatable bladder, bladder, or other device 84 that can be quickly and easily expanded or collapsed. The illustrated bladder 84 can be inflated in a manner similar to an air bag used in a vehicle. More specifically, the bladder 84 can be inflated with an air or other gas supply, or by filling the bladder 84 with water or some other liquid. Either of these gases or liquids may be supplied to the bladder 84 by a hose 86. When inflated, the bladder 84 holds the wedge halves 76, 78 in the expanded configuration, as shown in FIG. 32 . After use is complete, gas, water, or other liquid can be depleted from the bladder 84 via the hose 86, at which point the wedge halves 76, 78 return to their folded configuration relative to the hinge 37, as shown in Figure 31. The wedge 28 can then be quickly and easily removed from the passageway.

[0044] Some general background is now provided regarding the HRSG process and associated components.

[0045] HRSG Function and Design: As stated in Combined Cycle Theory, a combined cycle plant is a combination of a simple-cycle gas turbine (Brayton cycle) and a steam power cycle (Rankine cycle). The Brayton cycle consists of a compressor, combustor, and combustion turbine.

[0046] HRSG Function: The exhaust gases from the combustion turbine provide the heat source for the Rankine cycle portion of the combined cycle. Steam is produced in a heat recovery steam generator (HRSG). The HRSG recovers the waste heat available in the combustion turbine exhaust gases. The recovered heat is used to generate steam at high pressure and temperature, which is then used in a steam turbine / generator to generate electricity.

[0047] HRSGs are essentially heat exchangers made up of a series of preheaters (economizers), evaporators, reheaters, and superheaters. HRSGs also have auxiliary combustion in ducts that raise the gas temperature and mass flow rate.

[0048] This section is intended to provide turbine operators with a basic understanding of the design and operation of a heat recovery steam generator (HRSG). The power generating block of the facility produces electricity on two separate islands. The first island in the combined cycle power block is a combustion turbine (CT) generator set. The second island is the HRSG steam turbine generator set.

[0049] The HRSG absorbs thermal energy from the combustion turbine's exhaust gas stream. The absorbed thermal energy is converted into thermal energy as high-temperature, high-pressure steam. The high-pressure steam is then used in a steam turbine generator set to generate rotational mechanical energy. The steam turbine shaft is then connected to a generator to generate electrical power.

[0050] Waste heat is recovered from the combustion turbine exhaust gas stream via absorption by the HRSG, which is a large mass flow with temperatures up to 1,150°F.

[0051] The largest HRSGs can be classified as auxiliary combustion units of natural circulation design, double width with reburn and triple pressure level, installed behind a natural gas-fired combustion turbine.

[0052] The steam produced by the HRSG is supplied to a steam turbine that drives a generator system.

[0053] HRSG Design: The function of a combined cycle heat recovery steam generator (HRSG) system is to provide a method for extracting sensible heat from the combustion turbine (CT) exhaust gas stream.

[0054] The heat is converted by heat transfer surfaces within the HRSG into usable steam, which is produced at three separate, different pressure levels for use in steam turbine (ST) generator sets and for power augmentation of CTs.

[0055] Pressure levels and their associated components are: High pressure (HP) Intermediate pressure (IP) Low pressure (LP) ·Reheat (RH) -Feedwater preheater (FWPH).

[0056] All produced steam from the HP, RH, and LP systems is fed to the steam turbine, except for some LP steam which is used for degassing. The IP steam is combined with the cold RH return loop before entering the steam turbine.

[0057] A typical heat recovery steam generator circuit has four main components: ·Superheater Evaporator Economizer ·drum

[0058] A triple pressure system may be operated at HP, IP, and LP, so these components may be used at each associated pressure. These components (except the drum) are arranged sequentially in the gas flow path within the HRSG. Essentially, this means that the heat transfer boiler circuits are not parallel to each other with respect to the CT exhaust gas flow. After being used to heat water / steam within the HRSG, the gas is released to the environment through the stack.

[0059] Heat Recovery Steam Generator: Although HRSGs do not have any moving parts, they do have thermal inertia, and rapid heating can result in high thermal stress, which can affect the HRSG's operating life. In HRSGs, the high-pressure drum is most vulnerable to increased thermal stress if heating occurs very rapidly. To eliminate this possibility, the drum is heated in a controlled manner. The magnitude of the stress depends on the temperature difference, which in turn depends on the thickness of the material type, the operating pressure of its components, and the fatigue life cycle.

[0060] Controlling the pressure within the drum can effectively control the temperature differential. If the temperature differential is close to the design limit, it can be controlled at that level by holding the pressure constant until the temperature differential decreases due to increasing temperatures of the components caused by the construction. This is indicated by the constant pressure or saturation temperature line on the drum heating chart.

[0061] Before an HRSG is put into operation, it is filled with water and heat is applied. The cold metal takes some time to heat up, and time is needed to allow the heat to soak into the HRSG. The HRSG begins to produce steam after a soaking period of several minutes. If the steam is not released, the pressure then begins to increase. The amount of steam produced and the increase in pressure depend on the amount of heat supplied. More heat produces more steam, and the pressure increases at a faster rate.

[0062] The pressure in the drum can be controlled either by releasing the steam produced or by controlling the heat input to the boiler.

[0063] Often, a combination of both methods is used to achieve heat control in HRSGs. Steam is released by venting to the atmosphere or by routing the steam to a radiator such as a condenser. Operating the CT at reduced load controls the heat input. A gas-side bypass system, which diverts some of the hot CT gases to the atmosphere, is sometimes used to control the heat input to the boiler. If a bypass system is provided, it is not necessary to operate the CT at reduced load.

[0064] High Pressure Evaporator: In the High Pressure Evaporator (HP EVAP) section, a phase change between water and steam occurs. This phase change occurs through convective heat transfer, or energy exchange, between the CT exhaust gas flow and the water within the HP EVAP module. The HP EVAP module is completely single-pass with no internal baffles in the upper or lower headers. The steam / water mixture flows upward through the tubes and exits into the steam drum via a riser system. Water is supplied to the module through two downcomer supply pipe header assemblies. This is called a natural circulation loop.

[0065] High Pressure Steam Generator: The High Pressure Steam Generator (HPSG) consists of an economizer (HP ECON), an evaporator (HP EVAP), and a high pressure superheater (HP SH). The HPSG flow path is from the economizer to the steam drum / evaporator and finally to the superheater. Its sections are strategically placed in the exhaust gas flow according to the exhaust gas temperature drop and heated feedwater temperature increase, thus providing maximum energy recovery from the CT exhaust gas. The placement of these heat transfer surfaces can be seen in the right-side mounted elevation view.

[0066] The HPSG is equipped with a system of three safety relief valves, typically two mounted vertically on the top of the drum and one mounted vertically on the HP main steam header. All PSVs are closed during normal operation, but in an overpressure situation, the HP superheater PSV will lift first. If the pressure continues to increase, the HP drum PSV will lift (first lowest pressure setting). The three PSVs are designed to release 100% of the total HP steam generating capacity.

[0067] High Pressure Economizer: Each module is multi-pass on the water side and single-pass on the gas side. This is achieved by internal baffles in the upper and lower module headers.

[0068] The high pressure economizer (HPEC) receives water from the feedwater pump (provided elsewhere), absorbs heat from the CT exhaust gas, reduces the CT exhaust gas temperature, and raises the water temperature to near saturation temperature before entering the high pressure steam drum.

[0069] High Pressure Superheater: The steam inside the tubes is received from the high pressure steam drum at saturation temperature and heated to the final steam temperature.

[0070] The HP superheater is equipped with an intermediate desuperheater. The desuperheater control valve and injection nozzle assembly are typically located between the high pressure superheater (HP SHTR) 2 and the HP SHTR 3. The desuperheater is provided for final steam temperature control. The injection attemperation process uses water as the cooling medium. Injection water is fed directly to the desuperheater from the HP feedwater pump discharge line. Final steam temperature control is important for the protection of the superheater and the equipment supplied by the HRSG. The injection attemperation is designed to limit the final steam temperature at the HP superheater outlet to the final design steam temperature.

[0071] Intermediate Pressure Steam Generator: The Intermediate Pressure Steam Generator (IPSG) consists of an economizer (IP ECON), an evaporator (IP EVAP), and a high pressure superheater (IP SH). The IP steam generator economizer typically has two rows of tube bank. The IP EVAP has many rows, while the IP SH typically has only two rows. The IPSG flow path is the flow path from the economizer to the steam drum / evaporator and finally to the superheater. Its sections are strategically placed in the exhaust gas flow according to the exhaust gas temperature drop and heated feedwater temperature increase, thus providing maximum energy recovery from the CT exhaust.

[0072] The IPSG is equipped with a system of three safety relief valves, typically two mounted vertically on the top of the drum and one mounted vertically on the IP main steam header. All PSVs are closed during normal operation, but in an overpressure situation, the IP superheater PSV will lift first. If the pressure continues to increase, the IP drum PSV will lift (first lowest pressure setting). The three PSVs are designed to release 100% of the total IP steam generating capacity.

[0073] Intermediate Pressure Economizer: Each module is multi-pass on the water side and single-pass on the gas side. This is achieved by internal baffles in the upper and lower module headers. The Intermediate Pressure Economizer (IPEC) receives water from the feedwater pump (provided elsewhere), absorbs heat from the CT exhaust gas, reduces the CT exhaust gas temperature, and raises the water temperature to near saturation temperature before entering the steam drum.

[0074] Intermediate Pressure Evaporator: In the Intermediate Pressure Evaporator (IP EVAP) section, a phase change between water and steam occurs. This phase change occurs through convective heat transfer or heat exchange between the CT exhaust gas flow and the water within the IP EVAP module. The IP EVAP module is completely single-pass with no internal baffles in the upper or lower headers. The steam / water mixture flows upward through the tubes and exits to the steam drum via the riser system. Water is supplied to the module through two downcomer supply pipe header assemblies. This is called a natural circulation loop.

[0075] Intermediate Pressure Superheater: The steam inside the tubes is received from the steam drum at saturation temperature and heated to the final steam temperature.

[0076] Reheater: The steam inside the tubes is received from the cold reheat line at the HP steam turbine discharge line. The cold reheat steam is superheated by the reheater to the final hot reheat steam temperature.

[0077] The RH is equipped with an intermediate desuperheater located before the final reheat module. The desuperheater is supplied for final steam temperature control. The injection attemperation process uses water as the cooling medium. Injection water is supplied directly to the desuperheater from the IP feedwater pump discharge line. Final steam temperature control is important for the protection of the reheater and the equipment supplied by the HRSG.

[0078] Low Pressure Steam Generator: The low pressure steam generator includes an evaporator (LP EVAP) and a superheater (LPSH). The two are circuit components and are interspersed sequentially within the HRSG setup. The low pressure steam generator (LPSG) flow path is from the LP ECON to the steam drum / evaporator and finally to the superheater. There are no intervening valves between the steam drum and the superheater surface. The arrangement of these heat transfer surfaces can be seen in the right-hand cross-sectional elevation of Vogt-NEM.

[0079] LPSGs are equipped with a system of three safety relief valves, typically two mounted vertically on the top of the drum and one mounted vertically on the LP main steam header. All PSVs are closed during normal operation, but in an overpressure situation, the LP superheater PSV lifts first. If the pressure continues to increase, the LP drum PSV will lift (first lowest pressure setting). The three PSVs are designed to release 100% of the total LP steam generating capacity, including maximum pegging steam.

[0080] Low Pressure Evaporator: The LP EVAP module is completely single pass with no internal baffles in the upper or lower headers. The module is oriented in this way to allow any vapor bubbles generated to escape through the riser into the vapor drum. Water is supplied to the module from the downcomer supply header assembly. This is called a natural circulation loop.

[0081] In the LP EVAP section, a phase change occurs between water and steam or steam generation, which occurs through convective heat transfer or energy exchange between the gas turbine exhaust gas flow and the water in the LP EVAP tube generated steam.

[0082] Low Pressure Superheater: The steam inside the tubes is received from the steam drum at saturation temperature and heated to the final steam temperature.

[0083] Feedwater Preheater: The module has multiple passes on the water side. This is achieved by internal baffles in the upper and lower headers.

[0084] The FW PHTR receives water from the condensate pump system and absorbs heat from the gas turbine exhaust, lowering the gas temperature and raising the water temperature. The FW PHTR improves the efficiency of the HRSG.

[0085] While the above description provides some potential uses of the deep cleaning alignment apparatus, it should be noted that there are virtually countless uses for the present invention, not all of which need be described in detail here, and all disclosed embodiments can be practiced without undue experimentation.

[0086] While the best mode contemplated by the inventors for carrying out the invention is disclosed above, practice of the invention is not limited thereto. It will be apparent that various additions, modifications, and rearrangements of the features of the invention may be made without departing from the spirit and scope underlying the inventive concept. In addition, the individual components need not be made from the materials disclosed, but may be made from virtually any suitable material.

[0087] Furthermore, the individual components need not be formed in the shapes or assembled in the configurations disclosed, but may be provided in virtually any shape and assembled in virtually any configuration to improve the efficiency with which the deep cleaning and alignment apparatus functions and prevent damage to the HRSG. Furthermore, all disclosed features of each disclosed embodiment may be combined with or substituted for each disclosed feature of any other disclosed embodiment, except where such features are mutually exclusive.

[0088] It is intended that the appended claims cover all such additions, modifications and rearrangements. Suitable embodiments of the invention are distinguished by the appended claims.

Claims

1. 1. A deep cleaning alignment device for use in cleaning a heat recovery steam generator system including a plurality of metallic tubes, each of the plurality of tubes including a base having a plurality of fins extending outwardly therefrom, the deep cleaning alignment device comprising: an elongated wedge having proximal and distal ends spaced a length apart, the wedge configured to contact and spread the plurality of tubes and the plurality of fins to form passages therebetween; a wand configured to direct one of a liquid or a gas onto the heat recovery steam generator system; the elongated wedge contacts the tubes and the fins over an extended surface area to minimize stress between the wedge and the tubes and the fins; A deep cleaning alignment device, wherein the wand is removably insertable into the passageway.

2. The deep cleaning alignment device of claim 1 , further comprising a plate configured to be releasably secured to the proximal end of the elongated wedge.

3. the plate has a first cross-sectional area; the proximal end of the elongated wedge has a second cross-sectional area; The deep cleaning alignment apparatus of claim 2 , wherein the first cross-sectional area is greater than the second cross-sectional area.

4. the plate is substantially rectangular in size; 4. The deep cleaning alignment apparatus of claim 3, wherein the first cross-sectional area is approximately 9 square inches.

5. the plate further comprising at least one hook; the elongated wedge further comprising at least one protrusion extending therefrom; The deep cleaning alignment device of claim 2 , wherein the at least one protrusion is configured to releasably engage the at least one hook.

6. the plate further comprising at least one bracket; the elongated wedge further comprises at least one opening adapted to mate with the at least one bracket; 3. The deep cleaning alignment device of claim 2, wherein one or more bolts, screws, and nuts are configured to secure the plate and the elongated wedge to the at least one bracket and the at least one opening.

7. The elongated wedge further comprises: a first wedge half; a second wedge half; The first wedge half and the second wedge half are a folded configuration having a first width; an expanded configuration having a second width; It is movable between The deep cleaning alignment apparatus of claim 1 , wherein the second width is greater than the first width.

8. Rod and at least one gate attached to the rod in contact with the first wedge half and the second wedge half; The rod is a first position in which the at least one gate is substantially parallel to the rod; a second position in which the at least one gate is substantially perpendicular to the rod; 8. The deep cleaning alignment apparatus of claim 7, wherein the at least one gate is rotatable to move between

9. further comprising an expandable bladder located between the first wedge half and the second wedge half, the expandable bladder comprising: a first configuration in which the expandable bag is substantially deflated; a second configuration in which the expandable bladder is substantially inflated to contact the first wedge half and the second wedge half; 8. The deep cleaning alignment device of claim 7, configured to move between

10. 1. A method of using a deep cleaning alignment device to clean a heat recovery steam generator system including a plurality of metallic tubes, the method comprising: inserting a wedge having a width, a length, and a height between the plurality of tubes to widen the plurality of tubes to form a passage therebetween; inserting a wand into the passage; spraying a liquid or gas through the wand to clean the plurality of tubes; and removing the wedges from the plurality of tubes.

11. releasably securing the wedge to a plate; 11. The method of claim 10, further comprising contacting the plate for driving the wedges between the plurality of tubes to spread the plurality of tubes to form a passage therebetween.

12. The method of claim 11 , further comprising releasably securing one or more protrusions extending from the wedge to one or more hooks extending from the plate.

13. aligning one or more apertures formed in the wedge with one or more apertures formed in a bracket extending from the plate; The method of claim 11 , further comprising inserting fasteners into the one or more openings formed in the wedge and the one or more openings formed in the bracket.

14. inserting the wedge between the plurality of tubes when the wedge is at a first width; 11. The method of claim 10, further comprising: pivoting the first and second wedge halves about a hinge so that the wedge has a second width that is greater than the first width.

15. inserting the wedge between the plurality of tubes when the wedge is at a first width; rotating a rod located between a first wedge half and a second wedge half in a first direction to move one or more gates located between the first wedge half and the second wedge half; The method of claim 10 , further comprising: moving the first wedge half and the second wedge half to a second width that is greater than the first width.

16. rotating the rod located between the first wedge half and the second wedge half in a second direction opposite to the first direction; The method of claim 15 further comprising the step of: removing the wedges from the plurality of tubes.

17. inserting the wedge between the plurality of tubes when the wedge is at a first width; 12. The method of claim 11, further comprising inflating a bladder located between the first wedge half and the second wedge half to expand the first wedge half and the second wedge half to a second width greater than the first width.

18. an elongated wedge configured to contact and spread the plurality of tubes and fins to form passages therebetween, the elongated wedge having a first piece and a second piece releasably secured to the first piece; a wand configured to spray one of a liquid or a gas onto the heat recovery steam generator system; A deep cleaning alignment device, wherein the wand is removably insertable into the passageway.

19. a plate configured to be releasably secured to a proximal end of the elongated wedge; the plate has a first cross-sectional area; the proximal end of the elongated wedge has a second cross-sectional area; 20. The deep cleaning alignment apparatus of claim 18, wherein the first cross-sectional area is greater than the second cross-sectional area.

20. The elongated wedge further comprises: a first wedge half; a second wedge half; The first wedge half and the second wedge half are a folded configuration having a first width; an expanded configuration having a second width; It is movable between 20. The deep cleaning alignment apparatus of claim 18, wherein the second width is greater than the first width.

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